Wd600-3 Sebd022902.pdf

SEBM022902

MACHINE MODEL

SERIAL NO.

WD600-3

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.

•

WD600-3 mounts the SAA6D170E-3 engine. For details of the engine, see the 6D170-3 Series Engine Shop Manual.

© 2003 1 All Rights Reserved Printed in Japan 03-03(02)

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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

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

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

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

WD600-3

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WD600-3

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.

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To prevent injury to workers, the symbol 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:

W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) 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

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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

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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.

Oil, water

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

Drain

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

s

4 3 2 5 6

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING

¤ •

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. 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

¤ ¤

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. 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 tan k. Fo r d e tails , se e TES TIN G AN D 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.

Q'ty

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

LT-2

09940-00030

50 g

Polyethylene container

LT-3

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

Adhesive: 1 kg Hardenin g agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

Three bond 1735

790-129-9140

50 g

Polyethylene container

2g

Polyethylene container

Adhesives

Aron-alpha 201

790-129-9130

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

LG-1

790-129-9010

200 g

Tube

LG-5

790-129-9070

1 kg

Can

Main applications, featuresr •

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, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.

• •

Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.

•

Used as adhesive or sealant for metal, glass and plastic.

•

Used as sealant for machined holes.

•

Used as heat-resisting sealant for repairing engine.

• • •

Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.

• •

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.

• • •

Resistance to heat, chemicals Used at joint portions subject to high temperatures.

•

Used as adhesive or sealant for gaskets and packing of power train case, etc.

•

Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

•

Gasket sealant • LG-6

790-129-9020

200 g

Tube

• •

00-10

Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.

FOREWORD

Category

COATING MATERIALS

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr •

LG-7

790-129-9070

1g

Tube

Three bond 1211

790-129-9090

100 g

Tube

LM-G

09940-00051

60 g

Can

•

Adhesives

Molybdenum disulphide lubricant

LM-P

09940-00040

200 g

•

Used as heat-resisting sealant for repairing engine.

•

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.

Tube •

G2-LI

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

G2-CA

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

Various

Various

Molybdenum disulphide lubricant

SYG2-400M

400 g (10 per case)

Belows type

Grease

Various

Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

•

General purpose type

•

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

•

Used for places with heavy load

Various

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. Thread diameter of bolt

Width across flats

mm

mm

6 8 10 12 14

10 13 17 19 22

16 18 20 22 24

24 27 30 32 36

27 30 33 36 39

41 46 50 55 60

Thread diameter of bolt

Width across flats

mm

mm

Nm

6 8 10 12

10 13 14 27

7.85 1.95 18.6 4.9 40.2 5.9 82.35 7.85

Nm

kgm

0 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35

0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340

1.35 3.2 6.7 11.5 18

13.2 31 66 113 177

kgm

0 0 0 0

0.8 1.9 4.1 8.4

0 0.2 0 0.5 0 0.6 0 0.8

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

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

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

65.7 6.8 112 9.8 279 29

0 0 0

6.7 0.7 11.5 1 28.5 3

0

0 0

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

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

14 20 24 33 42

Varies depending on type of connector.

34.3 4.9 93.1 9.8 142.1 19.6 421.4 58.8 877.1 132.3

Norminal No.

02 03, 04 05, 06 10, 12 14

kgm

0 0 0 0 0

0 0.5 01 02 06 0 13.5

3.5 9.5 14.5 43 89.5

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

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

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

14 17 19 22 24 27 30 32 32 n 36 n n

7.35 1.47 11.27 1.47 17.64 1.96 22.54 1.96 29.4 4.9 39.2 4.9 49 4.9 68.6 9.8 107.8 14.7 127.4 19.6 151.9 24.5 210.7 29.4 323.4 44.1

0 0 0 0 0 0 0 0 0 0 0 0 0

0.75 0.15 1.15 0.15 1.8 0.2 2.3 0.2 3 0.5 4 0.5 5 0.5 7 1 11 1.5 13 2 15.5 2.5 21.5 3 33 4.5

Norminal No.

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

0 0 0 0 0 0 0 0 0 0 0 0 0

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

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

Tightening torque

mm

Nm

6 8 10 12

10 2 24 4 43 6 77 12

kgm

0 0 0 0

1.02 2.45 4.38 7.85

0 0.20 0 0.41 0 0.61 0 1.22

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

Tightening torque

mm

Nm

6 8 10 12 14

8 2 10 2 12 2 24 4 36 5

kgm

0 0 0 0 0

0.81 1.02 1.22 2.45 3.67

0 0.20 0 0.20 0 0.20 0 0.41 0 0.51

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

Tightening torque

inch

Nm

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

kgm

0 0 0 0 0 0 0

0.31 0.81 1.22 1.53 2.45 3.67 6.12

0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 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

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

Range

Target

19

35 - 63 {3.5 - 6.5}

44 {4.5}

14

9 – - 18UNF 16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

–

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

20.7

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 – - 12UNF 16

30.3

(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

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 (mm 2)

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

3 Color White & Black Code 4

Auxiliary

WL

Color White & Blue Code

WG

5 Color White & Green Code 6 Color

n n

n n n n n n n n n n

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

RB

YB

GR

LR

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

RY

Black & Red Red & Yellow

n n n n

RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

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

YW

GL

Red & Blue Yellow & White Green & Blue

n n 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 , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point 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.

A B

C

C

A

B

B Millimeters to inches 1 mm = 0.03937 in

A

00-16

0

1

2

3

4

5

6

7

8

9

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

0.197 0.591 0.984 1.378 1.772

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

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

2.165 2.559 2.953 3.346 3.740

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

C

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

}.

01 GENERAL

General assembly drawing ............................ 01-2 Specifications ................................................. 01-3 Weight table .................................................... 01-6 List of lubricant and water ............................. 01-7

WD600-3

01-1

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

Item

Unit

WD600-3

A

Overall length

mm

9,285

B

Overall height

mm

4,250

C

Blade clearance

mm

1,500

D

Max. drop below ground

mm

450

E

Max. tilt adjustment

mm

1,430

F

Blade width

mm

5,100

G

Overall width

mm

3,570

H

Front overhung

mm

2,210

I

Wheel base

mm

4,100

–

Blade size (width x height)

mm

5,100 x 1,470

01-2

WD600-3

GENERAL

SPECIFICATIONS

Weight

SPECIFICATIONS Machine model

WD600-3

Serial Number

50001 and up

Operating weight

kg

42,900

Front wheel load

kg

20,400

Rear wheel load

kg

22,500

km/h

6.5

FORWARD 2nd speed

km/h

11.4

FORWARD 3rd speed

km/h

20.0

FORWARD 4th speed

km/h

34.3

REVERSE 1st speed

km/h

7.2

REVERSE 2nd speed

km/h

12.6

REVERSE 3rd speed

km/h

22.1

REVERSE 4th speed

km/h

37.7

Max. rimpull

kN {kg}

419.7{42,800}

Gradeability

deg

25

Performance

Travel speed FORWARD 1st speed

Min. turning radius

Center of outside wheel Outer end of blade

Overall length

8,500 mm

9,285

(Outside of wheel)

mm

3,570

(Blade)

mm

5,100

Overall height (Upper end of ROPS)

mm

4,250

(Top of exhaust pipe)

mm

4,125

Wheelbase

mm

4,100

Tread

mm

2,650

Min. ground clearance

mm

495

Overall width Dimension

6,980 mm

WD600-3

01-3

GENERAL

SPECIFICATIONS

Machine model

WD600-3

Serial No.

50001 and up

Model

SAA6D170E-3 4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger, and after-cooler

No. of cylinders - bore x stroke

mm

6 – 170 x 170

Piston displacement

¬ {cc}

23.15 {23,150}

Flywheel horsepower

kW/rpm {HP/rpm}

362/2,000 {485/2,000}

Maximum torque

Nm/rpm {kgm/rpm}

2,390/1,400 {244/1,400}

Fuel consumption ratio

g/kW•h {g/HP•h}

231 {172}

Performance

Engine

Type

High idling speed rpm

2,175

Low idling speed rpm

700 24V, 7.5kW x 2

Starting motor

24V, 50A

Alternator

(12V, 200Ah) x 2

Battery Torque converter

3-element, 1-stage,

Axle, wheel

Power train

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

Transmission

Spiral bevel gear, splash lubrication

Reduction gear Differential

Straight bevel gear

Final drive

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

Brakes

Main brake

Parking brake

01-4

kPa {kg/cm2} 2

kPa {kg/cm }

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

WD600-3

Hydraulic system

Steering system

GENERAL

SPECIFICATIONS

Machine model

WD600-3

Serial Number

50001 and up

Type

Articulated steering

Structure

Delivery of hydraulic pump

Control valve

Cylinder

Hydraulic power steering Work equipment pump

152 (Gear pump: SAL (3)-80)

Switch pump

204 (Gear pump: SAL (4)-100)

Steering pump PPC pump

246 (Gear pump: SAL (4)-125) ¬ /min

Transmission and PTO lubrication pump For work equipment, set pressure

247 (Gear pump: SAL (3)-125)

2-spool type

20.6 {210}

For steering system, set pressure

Orbit roll + spool valve type

20.6 {210}

Lift cylinder No. - bore x stroke

Double acting piston type

1 – 160 x 1,080

Double acting piston type

2 – 180 x 236.5

Double acting piston type

2 – 140 x 495

Pitch and tilt cylinder No. - bore x stroke

MPa {kg/cm2}

mm

Steering cylinder No. - bore x stroke

Dozer system

63 (Gear pump: SAL (1)- 32)

Blade width

mm

5,100

Blade height

mm

1,470

Max. lifting height

mm

1,500

Max. tilting distance

mm

1,430

Pitch angle

deg

23

Max. digging depth

mm

450

WD600-3

01-5

GENERAL

WEIGHT TABLE

WEIGHT TABLE Unit: kg

Unit: kg

Machine model

WD600-3

Machine model

WD600-3

Serial Number

50001 and up

Serial Number

50001 and up

Engine assembly

2,900

Lift cylinder

205 184

Radiator assembly

630

Pitch and tilt cylinder

Torque converter assembly

340

Front frame

3,905

1,465

Rear frame

3,645

Transmission assembly Upper drive shaft

27

Blade assembly

2,776

Center drive shaft

57

End bit (1 piece)

35

Front drive shaft

57

Edge (1 piece)

67

Rear drive shaft

49

H linkage

486

Center support

46

Y linkage

549

Front axle assembly

3,065

Rear bumper

410

Rear axle assembly

2,965

Fuel tank

405

Front differential assembly

499

Battery (1 piece)

59

Rear differential assembly

508

Cab

456

Planetary carrier assembly (1 piece)

115

ROPS

822

Wheel (1 piece)

453

Operator seat

35

Front axle support

126

Floor frame

184

Rear axle support

153

Counterweight (1 piece)

600

Bulk head

182

Tire (1 piece)

1,027

Steering valve

48

Engine hood

80

Steering cylinder (1 piece)

84

Side hood (1 piece)

38

Hydraulic tank assembly

362

Radiator guard

270

Steering + switch pumps

39

Side floor (beside cab) (1 piece)

71

Transmission + PPC pumps

24

Side floor (beside hood) (1 piece)

11

Step (beside hood) (1 piece)

38

Work equipment pump

12.2

Work equipment valve

71

★ This table describes mass of assemblies requiring teamwork or lifting tool for hauling.

01-6

WD600-3

GENERAL

LIST OF LUBRICANT AND WATER

LIST OF LUBRICANT AND WATER RESERVOIR

AMBIENT TEMPERATURE

KIND OF FLUID –22

–4 –20

–30

14 –10

32 0

50 10

68 20

86 30

CAPACITY 104 40

122°F 50°C

Specified

Refill

62 ¶

47 ¶

120 ¶

110 ¶

SAE 30 SAE 10W Engine oil pan

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

Transmission case

SAE 10W

Hydraulic system

SAE 10W

330 ¶

215 ¶

Axle (Front and rear) (each)

See Note 1

124 ¶

124 ¶

–

–

670 ¶

–

160 ¶

–

Pins

Grease

Fuel tank

Diesel fuel

Cooling system

Water

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. Meker

Description

SHELL

DONAX TD

5W-30

MOBIL

MOBILFLUID

424

WD600-3

01-7

GENERAL

LIST OF LUBRICANT AND WATER

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

01-8

WD600-3

10 STRUCTURE AND FUNCTION

Cooling system ............................................. 10- 2 General .......................................................... 10- 4 Power train system ...................................... 10- 6 Torque converter and transmission piping .. 10- 8 Torque converter .......................................... 10-10 Torque converter regulator valve ................ 10-14 Lock-up valve ................................................ 10-16 Lock-up solenoid valve ................................ 10-20 Torque converter relief valve ....................... 10-21 Transmission ................................................ 10-23 Transmission control valve ......................... 10-28 Lubrication bypass valve ............................. 10-38 Transmission solenoid valve ....................... 10-39 Emergency manual spool ............................ 10-41 Transfer ......................................................... 10-42 Drive shaft ..................................................... 10-43 Center support .............................................. 10-44 Axle ................................................................ 10-45 Differential .................................................... 10-47 Final drive ..................................................... 10-55 Axle and center hinge pin ............................ 10-56 Steering piping ............................................. 10-57 Steering column ........................................... 10-58 Steering unit (orbit-roll valve) ..................... 10-59 Steering valve ............................................... 10-62 Two-way restriction valve ............................ 10-73 Stop valve ..................................................... 10-74 Emergency steering piping ......................... 10-75 Diverter valve (for emergency steering) ..... 10-76

WD600-3

Brake piping .................................................. 10-79 Brake valve .................................................... 10-80 Charge valve ................................................. 10-85 Accumulator (for brake) ............................... 10-89 Slack adjuster ............................................... 10-90 Brake .............................................................. 10-93 Parking brake ................................................ 10-95 Spring cylinder ............................................. 10-97 Parking brake solenoid valve ...................... 10-98 Hydraulic piping ........................................... 10-99 Work equipment lever linkage .................. 10-100 Hydraulic tank ............................................. 10-101 Accumulator (for PPC valve) ..................... 10-104 PPC valve .................................................... 10-105 PPC relief valve ........................................... 10-110 Work equipment valve ............................... 10-112 DECO valve ................................................. 10-123 Air conditioner ............................................ 10-134 Machine monitor system ........................... 10-137 Main monitor .............................................. 10-138 Maintenance monitor ................................. 10-142 Engine starting circuit ................................ 10-144 Engine stop circuit ...................................... 10-145 Pre-heating circuit ...................................... 10-146 Electric transmission control ..................... 10-147 Kick-down, hold switch .............................. 10-150 Transmission and joystick steering system ... 10-151 Throttle control system .............................. 10-170

10-1

STRUCTURE AND FUNCTION

COOLING SYSTEM

COOLING SYSTEM

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

After cooler Water 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 Cooling water inlet port Hydraulic oil cooler inlet port Hydraulic oil cooler outlet port Cooling water outlet port

10-2

SPECIFICATIONS Radiator • Core model: PF2-7 • Total heat dissipating area: 166.80 m2 • Cross-sectional area of water flow: 233.43 cm2 Hydraulic oil cooler Oil cooler 7A

Oil cooler 7B

Core type

PTO-OL

PTO-OL

Heat dissipating area

1.829 m2

1.829 m2

After cooler • Core type: CF40-1 • Total heat dissipating area: 6.45 m2

WD600-3

STRUCTURE AND FUNCTION

WD600-3

COOLING SYSTEM

10-3

STRUCTURE AND FUNCTION

GENERAL

GENERAL •

LOCATION OF COMPONENTS

OUTLINE • The motive force from engine (1) is transmitted from the flywheel through the ring gear to torque converter (2).The torque converter uses oil as a medium to convert the transmitted torque to match the variation in the load. It transmits this motive force to the input shaft of transmission (4). • In addition, the motive power of the engine passes through the pump drive gear and is sent to the two double pumps, and drives each of the pumps. • In transmission (4), solenoid valves are used to operate the direction spool and speed spool of the transmission valve. In this way, the six hydraulically operated clutches are actuated to select FORWARD and REVERSE speeds. The speed selection is carried out manually.

10-4

•

•

•

The output shaft of transmission (4) transmits the motive force through the gear of transfer (5) to the output shaft of the transfer. At the front, the motive force is transmitted through center drive shaft (6), center support (7), and front drive shaft (8) to front differential (9). At the rear, the motive force is transmitted from rear drive shaft (10) to rear differential (11). The motive force transmitted to front differential (9) and rear differential (11) is transmitted to the sun gear shaft (axle shaft) of final drives. The motive force of the sun gear is reduced by a planetary mechanism, and passes through the planetary hub to front wheel and rear wheel. WD600-3

STRUCTURE AND FUNCTION

POWER TRAIN SYSTEM

POWER TRAIN SYSTEM

10-6

WD600-3

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Engine Torque converter PTO Steering + Switch pump (SAL(4)125 + (4)100) Torque converter charging + PPC pump (SAL(3)125 + (1)32) Work equipment pump (SAL(3)80) Upper drive shaft Transmission Transfer Emergency steering pump (If equipped) Center drive shaft Center support Front drive shaft Parking brake Front differential Front axle Front brake Front final drive Front wheel Rear drive shaft Rear differential Rear axle Rear brake Rear final drive Rear wheel

WD600-3

POWER TRAIN SYSTEM

OUTLINE •

The motive force from engine (1) is transmitted from the flywheel through the ring gear to torque converter (2). The torque converter uses oil as a medium to convert the transmitted torque to match the variation in the load. It transmits this motive force to the input shaft of transmission (8).

•

In addition, the motive power of the engine passes through the pump drive gear and is sent to the pumps (4), (5) and (6), and drives each of the pumps.

•

In transmission (8), solenoid valves are used to operate the direction spools and speed spools of the transmission valve. In this way, the six hydraulically operated clutches are actuated to select FORWARD and REVERSE speeds. The speed selection is carried out manually.

•

The output shaft of transmission (8) transmits the motive force through the gear of transfer (9) to the output shaft of the transfer. At the front, the motive force is transmitted through center drive shaft (11), center support (12), and front drive shaft (13) to front differential (15). At the rear, the motive force is transmitted from rear drive shaft (20) to rear differential (21).

•

The motive force transmitted to front differential (15) and rear differential (21) is transmitted to the sun gear shaft (axle shaft) of final drives (18) and (24).

•

The motive force of the sun gear is reduced by a planetary mechanism, and passes through the planetary hub to front wheel (19) and rear wheel (25).

10-7

STRUCTURE AND FUNCTION

TORQUE CONVERTER AND TRANSMISSION PIPING

TORQUE CONVERTER AND TRANSMISSION PIPING

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

Transmission Transmission control valve Torque converter Oil cooler Oil filter Torque converter charging and PPC pump

A. Oil inlet B. Oil outlet

10-8

WD600-3

STRUCTURE AND FUNCTION

TORQUE CONVERTER

TORQUE CONVERTER

10-10

WD600-3

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

TORQUE CONVERTER

Regulator valve Coupling Housing Torque converter inlet pressure pick-up (PT 1/8) Torque converter outlet oil temperature pick-up Torque converter outlet pressure pick-up (PT 1/8) Stator Turbine Drive case Pump Shaft Lock-up valve Lock-up clutch One-way clutch Mounting part of torque converter charge pump and PPC pump Mounting part of work equipment pumps Mounting part of steering pump and switching pump Mounting part of drain piping

A. Inlet port Inlet B. Outlet port Specifications Type: 3-element, single stage, single phase

WD600-3

10-11

STRUCTURE AND FUNCTION

TORQUE CONVERTER

Path of power transmission Flow of power Lock-up clutch disengaged • When the lock-up clutch is disengaged, the connection of drive case (3) and turbine (4) is disconnected, and the torque converter functions as normal. The power generated by the engine is transmitted from flywheel (1) to clutch housing (2), and rotates drive case (3) and pump (6) as one unit. The power from pump (6) uses oil as a medium to rotate turbine (4) and transmits the power from turbine (4) to transmission input shaft (14).

10-12

Lock-up clutch engaged • When the lock-up clutch is engaged, drive case (3) and turbine (4) are connected and form one unit. Stator (11) is rotated by the rotation of pump (6) and turbine (4). The power generated by the engine is transmitted from flywheel (1) to clutch housing (2), and rotates drive case (3) and pump (6) as one unit. In addition, drive case (3) and turbine (4) are connected by the clutch, so the power is transmitted directly from turbine (4) to transmission input shaft (14) without using oil as a medium.

WD600-3

STRUCTURE AND FUNCTION

TORQUE CONVERTER

Flow of oil • The oil passes through the main relief valve and its pressure is adjusted by the torque converter relief valve so that it is less than the set pressure. It then enters inlet port A, passes through the passage in stator shaft (8) and case (9), and flows to pump (6). The oil is given centrifugal force by pump (6). It then enters turbine (4) and transmits the energy of the oil to turbine (4). • The oil from turbine (4) is sent to stator (11), and enters pump (6) again. However, part of the oil passes between turbine (4) and stator shaft (8), and is sent through outlet port B to the cooler.

WD600-3

10-13

STRUCTURE AND FUNCTION

TORQUE CONVERTER REGULATOR VALVE

TORQUE CONVERTER REGULATOR VALVE

1. Torque converter inlet pressure pick-up (PT 1/8) 2. Torque converter outlet pressure pick-up (PT 1/8) 3. Torque converter outlet oil temperature pick-up 4. Regulator spool 5. Spring 6. Valve body 7. Poppet

10-14

A. Torque converter inlet port B. Torque converter outlet port

WD600-3

STRUCTURE AND FUNCTION

TORQUE CONVERTER REGULATOR VALVE

FUNCTION • The torque converter regulator valve is installed in the output circuit of torque converter to regulate the hydraulic pressure inside the torque converter to the specified pressure.

OPERATION • The oil from the torque converter flows from port A to port B. However, the hydraulic pressure at port B is lower than the tension of spring (5), so spool (4) does not move.

•

When the hydraulic pressure at port B becomes higher than the tension of spring (5),it pushes spool (4) in the direction of the arrow, and the oil at port A flows to port C.

WD600-3

10-15

STRUCTURE AND FUNCTION

LOCK-UP VALVE

LOCK-UP VALVE

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

Spring (Small) Piston Piston Piston Spring Body Spring (Large)

10-16

A: B: C: T: Dr: P: P3: P4:

To lock-up clutch Rod piston oil pressure Pilot oil pressure Drain Drain From pump Lock-up clutch oil pressure Main oil pressure

WD600-3

STRUCTURE AND FUNCTION

LOCK-UP VALVE

FUNCTION This valve sets the specified pressure for the lockup clutch hydraulic pressure, and also switches the lockup clutch. It has a modulation valve, which engages the lock up clutch smoothly, and reduces the shock when shifting gear. Furthermore, it prevents the generation of peak torque in the power train. As a result, the machine gives a good ride, and the durability of the power train is greatly increased.

OPERATION Driving in torque converter range • When the machine is driving in the torque converter range, solenoid valve (5) is switched OFF by an electrical signal, and valve (5a) is pushed to the right in the direction of the arrow by the tension of spring (5b), so port B and port P of solenoid valve (5) are opened. The oil from pump enters port A of lockup valve (6), passes through port B and port P of solenoid valve (5), and goes to port D. Piston (8) is pushed to the left in the direction of the arrow because of the hydraulic pressure applied to port D. This force pushes lockup valve (6), compresses spring (4), and closes port A and port E. The oil at port E and port H is drained, and the lockup clutch is disengaged.

WD600-3

10-17

STRUCTURE AND FUNCTION

LOCK-UP VALVE

Driving in direct range (torque converter range → direct range) 1) When the machine travels in the direct range (lockup), solenoid valve (5) is switched ON by the electrical signal, and valve (5a) is pushed to the left in the direction of the arrow, so port B is closed, and port P and port C are opened. As a result, the oil port D flows from port P of solenoid valve (5), passes through port C and is drained. Lockup valve (6) and piston (8) are pushed to the right by spring (4), and port A and port E are opened.

2) When port A and port E are opened, the oil from the pump is sent to the lockup clutch. In addition, the oil at port E flows to port F and applies back pressure to load piston (2).

3) As the hydraulic pressure of the lockup clutch rises, the pressure of the passing through orifice a and entering port G also rises, and pushes piston (7). Because of the reaction force, lockup valve (6) compresses spring (4) and pushes it to the left in the direction of the arrow to throttle port A and port E.

10-18

WD600-3

STRUCTURE AND FUNCTION

LOCK-UP VALVE

4) The oil from port E to port F applies pressure to load piston (2), and pushes piston (2) to the right in the direction of the arrow to compress spring (4). Compressed spring (4) pushes lock up valve (6) to the right in the direction of the arrow, and opens port A and port E. When this happens, the increase in hydraulic pressure to the lockup clutch starts again.

5) By repeating the actions in Steps 3) and 4), the load on spring (4) is increased, and the hydraulic pressure gradually rises. Finally, when load piston (2) contacts stopper (3), the rise in hydraulic pressure stops. The pressure at this point is the set pressure of the lockup valve. • Set pressure: 1.86 MPa {19 kg/cm2}

WD600-3

10-19

STRUCTURE AND FUNCTION

LOCK-UP SOLENOID VALVE

LOCK-UP SOLENOID VALVE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Cover Coil Spring Plunger Valve seat holder Valve seat Spring Valve seat Cap Cable Connector

10-20

A: From pump B: To piston C: To drain

WD600-3

STRUCTURE AND FUNCTION

TORQUE CONVERTER RELIEF VALVE

TORQUE CONVERTER RELIEF VALVE FUNCTION • The torque converter relief valve acts to maintain the pressure of the oil entering the torque converter at a constant pressure. It drains the oil if it goes above the specified pressure.

OPERATION • The oil from the pump passes through main relief valve (1). It than enters port A and flows to the torque converter.

•

If the oil at port A goes above the specified pressure, it passes through orifice "a" of torque converter relief valve (2) and enters port B. It then moves torque converter relief valve (2) to the left. As a result, the oil from A is drained, and oil flowing to the torque converter is maintained at the specified pressure.

WD600-3

10-21

STRUCTURE AND FUNCTION

TRANSMISSION

TRANSMISSION

1. 2. 3. 4. 5.

Coupling Lubrication bypass valve Transmission Transfer Coupling

WD600-3

6. 7. 8. 9. 10.

Transmission control valve Oil filter Drain plug Strainer Breather

10-23

STRUCTURE AND FUNCTION

10-24

TRANSMISSION

WD600-3

STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

TRANSMISSION

Input shaft Sun gear (Teeth: 32) Planetary gear (Teeth: 29) Reverse clutch Ring gear (Teeth: 112) Ring gear (Teeth: 90) Sun gear (Teeth: 45) Forward clutch Ring gear (Teeth: 95) Planetary gear (Teeth: 25) Planetary gear (Teeth: 25) Sun gear (Teeth: 45) 4th clutch Ring gear (Teeth: 95) 2nd clutch Hub 3rd clutch Ring gear (Teeth: 95) Planetary gear (Teeth: 21) Sun gear (Teeth: 53) 1st clutch Ring gear (Teeth: 95) Planetary gear (Teeth: 21) Sun gear (Teeth: 53) Output shaft Carrier Carrier Carrier Carrier

WD600-3

10-25

STRUCTURE AND FUNCTION

OUTLINE • The transmission consists of a 4-FORWARD, 4-REVERSE speed planetary gear transmission, transfer, and transmission control valve. • In the transmission, the motive force of the input shaft is changed by the combination of Forward or Reverse clutch with 1st, 2nd, 3rd or 4th clutch to give FORWARD 1 – 4 or REVERSE 1 – 4 speed, and is transmitted to the output shaft.

TRANSMISSION

Speed range

Clutch combination

F1

No. 2, No. 6

F2

No. 2, No. 4

F3

No. 2, No. 5

F4

No. 2, No. 3

R1

No. 1, No. 6

R2

No. 1, No. 4

R3

No. 1, No. 5

R4

No. 1, No. 3

OPERATION OF CLUTCH •

Engaged The oil sent from the transmission control valve passes through the oil passage inside the transmission. When it reaches the back of piston (2), it moves the piston (2). When the piston (2) moves, disc (4) and plate (5) are pressed together. Ring gear (6) is meshed with disc (4), so its rotation is stopped.

•

Disengages When the supply of oil from the transmission control valve is shut off, the pressure of the oil acting on the rear of piston (2) is reduced. The piston is then pushed back to the right by return spring (3), and disc (4) and plate (5) are separated. Ring gear (6) then rotates freely, and no motive force is transmitted.

10-26

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION

FORWARD 1ST

•

•

•

In 1st FORWARD, Forward clutch (17) and 1st clutch (30) are engaged. The motive force transmitted from the torque converter by input shaft (10) is transmitted to output shaft (34). Forward clutch (17) is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (18) in position. 1st clutch (30) is actuated by the hydraulic pressure applied to the clutch piston and holds gear (31) in position. The motive force from the torque converter is transmitted to the input shaft (10). The rotation of the input shaft (10) is transmitted to planetary gear (19) through sun gear (16).

WD600-3

•

Ring gear (18) is held in position by Forward clutch so the rotation of planetary gear (19) rotates carries (36), which is on the inside of ring gear (18). This carrier (36) rotates carrier (37) through ring gear (23). Ring gear (31) is held by 1st clutch (30) so the rotation of sun gear (33) is transmitted to carrier (38) through planetary gear (31) and rotate output shaft (34).

10-27

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE

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

Pilot reducing pick-up Lower valve Upper valve Main relief valve Pilot oil filter Torque converter relief pressure pick-up Transmission lubricating pressure pick-up

10-28

8. 9. 10. 11. 12. 13. 14.

Main relief pressure pick-up Priority pressure pick-up Reducing valve pressure pick-up Modulating pressure pick-up Transmission solenoid valve Emergency manual spool Connector

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

UPPER VALVE

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

OUTLINE • The oil from the torque converter charging pump enters port A of main relief valve, and passes through the priority valve (7) via by main relief valve (3). It is then divided into three lines; there are; to the clutch pistons, to the pilot reducing valve (4) and main relief valve. The priority valve (7) acts to control the three lines so that the pilot reducing valve (4) is the priority circuit. • The oil flowing to the pilot reducing valve (4) controls the pilot pressure used to actuate the directional and speed spools. The oil regulated by the pilot reducing valve (4) presses through the orifice in each spool and fills the spool. WD600-3

•

•

Piston Torque converter relief valve Main relief valve Pilot reducing valve Quick return valve Modulating valve Priority valve Housing

The other oil line flows to the modulating valve (6) and quick return valve (5). The action of the modulating valve (6) and quick return valve (5) raises the clutch pressure smoothly. This reduces the shock when actuating the FORWARD, REVERSE and 1st, 2nd, 3rd, and 4th speed clutches to change gear. The lubrication valve (15) controls the lubrication oil inside the transmission.

10-29

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

LOWER VALVE

9. 10. 11. 12. 13.

1st spool 2nd spool Spacer Pilot filter FORWARD spool

10-30

14. 15. 16. 17. 18.

Reducing valve Lubrication valve REVERSE spool 4th spool 3rd spool

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

MAIN RELIEF VALVE FUNCTION • The main relief valve acts to supply the necessary oil to the clutch when shifting gear. When the gears are not being shifted, it sends all of the oil directly to the torque converter.

OPERATION • The oil from the pump passes through the oil filter and enters port A of main relief valve (1). • Until the specified pressure is reached, the oil flows to the priority valve.

•

When the pressure goes above the specified level, oil passes through the orifice in relief valve (1), pushes poppet (2), and moves relief valve (1) to the left. The oil is relieved to the torque converter, so the specified pressure is maintained. fl Specified pressure: 33.3 MPa {34 kg/cm2}

WD600-3

10-31

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

PRIORITY VALVE FUNCTION • The priority valve (1) controls the minimum pressure of the pilot reducing valve (2). In addition, the priority valve (1) gives the oil flow to the pilot reducing valve (2) priority over the other circuit. OPERATION • The oil from the pump flows to port A of priority valve (1) and port B of pilot reducing valve (2).

•

The oil entering port A flows from orifice "a" of priority valve (1) to port D. The hydraulic pressure and force of poppet spring (3) push back spring (4) and move priority valve (1) to the right. When this happens, port A and port C are connected, and the oil flows from port C to the clutch spool.

10-32

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

MODULATING VALVE AND QUICK RETURN VALVE FUNCTION • The modulating valve and quick return valve act together to raise the transmission clutch pressure slowly. In this way, they reduce the shock when shifting gear, and prevent the generation of peak torque in the power train. As a result, operator fatigue is reduced, and at the same time, operator comfort and the durability of the power train are increased.

1) Immediately after shifting gear (Point A)

•

The oil sent from the pump flows from priority valve (1) through port A, passes through modulating valve (2), and enters port B of quick return valve (3). The oil passes through orifice "a" of quick return valve (3) and flows to the clutch piston, which has been actuated. However when it passes through orifice "a" it

WD600-3

creates a difference in pressure between port B and port C. The quick return valve moves to the right and the oil flows to clutch (5). In addition, when quick return valve (3) moves to the right, drain port D is opened, and the pressurized oil at the rear of piston (4) flows to the drain circuit.

10-33

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

2) Clutch pressure rising (Point B)

•

As the pressure at the clutch piston rises, the pressure at port C also rises. Quick return valve (3) is pushed back to the left and drain port D is closed. The oil from the pump flows from port C to the clutch piston and at the same time it flows from orifice "b" through quick return valve (3) and enters port E. The oil at port E acts on the modulating piston (4). It pushes back spring (6) and moves piston (4) to the right. At the same time, pressurized oil also passes through the orifice and enters poppet (7) of modulating valve (2). It moves modulating valve (2) to the left and some of the oil at port A flows to port G.

10-34

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

3) Completion of rise in clutch pressure (Point C)

•

The oil entering port E continues to push piston (4). When the piston reaches the end of its stroke, the rise in pressure stops. When this happens, the pressure reaches the set pressure of the modulating valve. In addition, port F and port G are closed by piston (4).

WD600-3

10-35

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

REDUCING VALVE FUNCTION • The reducing valve is in the circuit between the quick return valve and the 2nd spool. It reduces the pressure applied to the 2nd clutch. The maximum pressure in the main circuit is kept to the specified level by the main relief pressure.

OPERATION • The oil from the quick return valve enters port A and then flows from port B to 2nd spool (2).

•

When the circuit to the 2nd clutch is filled with oil and the hydraulic pressure rises, the oil from port B which flows through orifice a to port C pushes poppet (3). The reaction to this compresses spring (4) and moves reducing spool (1) to the left. As a result, port A and port B are closed, and the oil stops flowing. The hydraulic pressure at this point is 1.96 MPa {20 kg/cm2}.

10-36

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION CONTROL VALVE

PILOT REDUCING VALVE FUNCTION • The pilot reducing valve acts to control the pressure needed to actuate the transmission spools. OPERATION • The oil from the pump passes through the pilot filter and enters port A of pilot reducing valve (1). The oil passes through port B and enters through the orifice of transmission spool (2) to fill the inside of port C.

•

When the pressure inside port C rises, pressurized oil flows from orifice "a" of pilot reducing valve (1) and goes to port D. As a result, pilot reducing valve (1) moves to the right, and port A and B are shut off, so the pressurized oil at port C is maintained at the same pressure.

WD600-3

10-37

STRUCTURE AND FUNCTION

LUBRICATION BYPASS VALVE

LUBRICATION BYPASS VALVE FUNCTION • When traveling in 4th gear, the transmission gears are rotating at high speed. Because of this, the churning resistance of the transmission lubrication oil increases. To reduce this power loss, only enough oil to lubricate the gears at 4th speed is kept. All the rest of the oil is bypassed to the transmission case. OPERATION • 4th clutch not being operated When the 4th clutch is not being operated, there is no hydraulic pressure at port a of spool (1). As a result, spool (1) is pushed to the left by the spring. The oil from the torque converter is stopped by spool (1), so all the oil is used for lubricating the transmission.

•

4th clutch being operated When oil flows to the 4th clutch, pressure oil flows from 4th spool (2) to port a of spool (1). When pressure oil enters port a, it pushed back the spring and moves spool (1) to the right. The oil from the torque converter flows to the transmission lubrication system and drain port b.

10-38

WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION SOLENOID VALVE

TRANSMISSION SOLENOID VALVE

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

1st solenoid valve 2nd solenoid valve 3rd solenoid valve 4th solenoid valve FORWARD solenoid valve REVERSE solenoid valve Body Emergency manual spool Connector

Actuation table for solenoid valve and clutch F F1 F2 F3 F4

R1

•

R2

WD600-3

fi fi fi fi

1

2

3

4

fi fi fi fi

N

STRUCTURE The transmission solenoid valve is installed to the transmission together with the transmission valve. When the directional lever or speed control lever are operated, the solenoid valve is actuated and moves the spool inside the transmission valve.

R

R3 R4

fi fi fi fi

fi fi fi fi

10-39

STRUCTURE AND FUNCTION

TRANSMISSION SOLENOID VALVE

FUNCTION • There is one solenoid valve installed for each directional and speed spool in the transmission valve. When the directional lever and speed control levers in the operator's compartment are operated, the solenoid valve is actuated, and oil is drained to actuate the directional and speed spools.

OPERATION 1) Solenoid valve OFF The oil of spool (2) enters port A. However, solenoid valve (1) shuts off the oil, so directional and speed spool (2) does not move.

2) Solenoid valve ON When the directional and gear shift lever are operated, the solenoid valve (1) is pulled up. The oil from directional and speed spool (2) enters port A and flows from port B to the drain circuit. Therefore, port A becomes the low pressure circuit, and directional and speed spool (2) is actuated.

10-40

WD600-3

STRUCTURE AND FUNCTION

EMERGENCY MANUAL SPOOL

EMERGENCY MANUAL SPOOL FUNCTION • If there is any failure in the electrical circuit of the transmission control system, and the solenoid valve does not work, the emergency manual spool is used. This spool is attached to each directional and speed spool and is used to operate the transmission valve mechanically. (It is used to drive the machine to a place where it can be repaired.) fl Particular attention must be paid for when using this spool.

OPERATION 1. When solenoid valve is normal: (Emergency manual spool is at normal position) When the solenoid valve is working normally, the spool is maintained in this position. Oil from directional and speed spool (1) enters port A, but it is shut off by solenoid valve (2).

2. When solenoid valve is abnormal: a. Clutch in disengaged position (Emergency manual spool is pushed to the left) Emergency manual spool (3) is pushed to the left, and the oil at port A is shut off regardless of the action of solenoid valve (2). The oil cannot flow to port B, so the clutch is not actuated.

b. Clutch in engaged position (Emergency manual spool is pulled to the right) When emergency manual spool (3) is pulled to the right, the oil at port A is drained to port B regardless of the operation of solenoid valve (2). As a result, the clutch is actuated.

WD600-3

10-41

STRUCTURE AND FUNCTION

TRANSFER

TRANSFER OUTLINE • The transfer is installed to the output end of the transmission, and is secured to the transmission case by bolts. TRANSMISSION PATH • Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output gear (8) through idler gear (3) and output shaft (5). Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft.

10-42

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

Transmission output shaft Transfer input gear (teeth 46) Transfer idler gear (teeth 39) Idler gear (teeth 40) Output shaft Rear coupling Strainer Output gear (teeth 41) Front coupling

WD600-3

STRUCTURE AND FUNCTION

DRIVE SHAFT

DRIVE SHAFT

1. Front drive shaft 2. Center support 3. Center drive shaft

OUTLINE • The motive force from the engine passes through the torque converter, upper drive shaft (5), transmission and transfer. Part of this motive force passes through rear drive shaft (4) and goes to the rear axle; the rest of the motive force passes through center drive shaft (3), center support (2) and front drive shaft (1) and is sent to the front axle. In addition to transmitting the motive force, the drive shafts have the following purposes.

WD600-3

4. Rear drive shaft 5. Upper drive shaft

•

When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during operations, the axle in front and behind the engine and transmission change position. To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in angle and length.

10-43

STRUCTURE AND FUNCTION

CENTER SUPPORT

CENTER SUPPORT

1. 2. 3. 4.

Front coupling Case Grease nipple Rear coupling

10-44

FUNCTION • The center support is installed to the front frame between the center drive shaft and the front drive shaft. • With the articulating frame, this part is constantly twisting from side to side, so there is liable to be large stress on the drive shaft. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and in this way improve the durability of the drive shafts.

WD600-3

STRUCTURE AND FUNCTION

AXLE

AXLE FRONT AXLE

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

Axle housing Final drive Brake Differential Parking brake Spring cylinder

WD600-3

10-45

STRUCTURE AND FUNCTION

AXLE

REAR AXLE

1. 2. 3. 4.

Axle housing Final drive Brake Differential

A. Axle support retainer (Front) B. Axle support retainer (Rear)

10-46

WD600-3

STRUCTURE AND FUNCTION

DIFFERENTIAL

DIFFERENTIAL FRONT DIFFERENTIAL

1. 2. 3. 4. 5.

Pinion (Teeth: 15) Bevel pinion (Teeth: 8) Shaft Side gear (Teeth: 22) Bevel gear (Teeth: 43)

WD600-3

10-47

STRUCTURE AND FUNCTION

DIFFERENTIAL

REAR DIFFERENTIAL

1. 2. 3. 4. 5.

Bevel gear (Teeth: 43) Bevel pinion (Teeth: 8) Shaft Pinion (Teeth: 15) Side gear (Teeth: 22)

10-48

WD600-3

STRUCTURE AND FUNCTION

DIFFERENTIAL

OUTLINE • The power from the engine passes through the torque converter, transmission, and drive shafts, and is transmitted to the front and rear axles. • The motive force from the drive shaft passes through bevel pinion (1) and is transmitted to bevel gear (5). The bevel gear changes the direction of the motive force by 90°, and at the same time reduces the speed. It then transmits the motive force through pinion gear (4) to axle shaft (2). • The power of the axle shaft is further reduced by the planetary gear type final drive, and is transmitted to the wheels.

When driving straight forward • When the machine is driven straight forward, the rotating speed of the left and right wheels is the same, so pinion gear (4) inside carrier (6) is sent through pinion gear (4) and side gear (3) and is transmitted equally to the left and right axle shafts (2).

When turning • When turning, the rotating speed of the left and right wheels is different, so pinion gear (4) and side gear (3) inside the differential assembly rotate in accordance with the difference between the rotating speed of the left and right wheels. The motive force of carrier (6) is then transmitted to axle shafts (2).

WD600-3

10-49

STRUCTURE AND FUNCTION

DIFFERENTIAL

REAR DIFFERENTIAL (NON-SPIN DIFFERENTIAL)

1. Bevel gear (Number of teeth: 43) 2. Non-spin differential assembly 3. Bevel pinion (Number of teeth: 8)

10-50

WD600-3

STRUCTURE AND FUNCTION

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

DIFFERENTIAL

Spider Center cam Snap ring Driven clutch Holdout ring Spring Side gear

STRUCTURE • The non-spin differential consists of the spider (1), center cam (2), and snap ring (3). • On both sides of the spider (1), the clutch teeth are arranged in the radius direction. On its outer periphery, four trunnions are mounted and on its inner periphery, a key is mounted to limit rotation of the center cam (2) and holdout ring (5). • Grooves are provided on the outer periphery of center support. The key of the spider (1) is fitted in the narrow groove and the protrusion of the holdout WD600-3

•

ring (5) is fitted in the wide groove. The center cam (2) has cams as many as the clutch teeth and the cam surface is tilting. The center cam (2) and the spider (1) are supported by the snap ring (3). Though the key of the spider (1) can slightly rotate in the groove of the center cam (2), it is not thrown out in the axial direction structurally.

10-51

STRUCTURE AND FUNCTION

DIFFERENTIAL

FUNCTION • When the machine is traveling forward or reverse, the clutch teeth of the spider (1) and the right and left clutch teeth of the driven clutch (4) are completely engaged each other. In addition, they are engaged in the cam teeth of the center cam (2) inserted in the spider. It means that it is in the condition same as the case without using the differential. The contacting face of the clutch teeth differs according to whether the engine is driving the machine or the engine brake is applied. When the machine is driven forward by the engine to swing clockwise • In case that the machine swings, the outer wheels travel faster than the inner wheels, namely, the machine turns. For this reason, a differential is required. • In case of an ordinary bevel gear type differential, the inner wheels rotate slower than the ring gear and the outer wheels rotate faster than it. • When the machine with a non-spin differential is driven by the engine, the clutch teeth are engaged, disabling both side wheels to rotate slower than the ring gear. • When the machine swings clockwise during forward traveling, the right side (inner side) driven clutch (4) is completely engaged to the clutch teeth of the spider (1) to transmit a torque. In this condition, the rpm same as the ring gear's rpm is transmitted to the right side (inner side) to make the machine travel forward. On the left side (outer side), however, friction torque on the road surface causes the driven clutch (4) to rise from the spider on the inclined surface of the center cam. This disengages the clutch teeth, allowing the left side (outer side) to rotate faster than the right side (inner side) to cause the machine to swing. • The left holdout ring (5) is disengaged from the clutch teeth to contact the key of the spider (1). At the same time, the protrusion rises from the groove of the center cam (2) to be positioned. During rotation of the driven clutch (4) faster than the spider (1), therefore, the driven clutch (4) is never engaged. • When the differential is not required after completing the swing, the differential returns to the forward condition of the machine.

10-52

WD600-3

STRUCTURE AND FUNCTION

DIFFERENTIAL

When the machine travels forward with the engine brake applied and swings clockwise • Since friction occurs on the road surface in this case, the direction of the torque applied to the ring gear is opposite to that when the engine drives the machine. • Application of the engine brake to the machine with a non-spin differential engages the clutch teeth, not allowing both side wheels to rotate faster than the ring gear. • In case that the machine swings clockwise during forward traveling, the left side (outer side) driven clutch (4) is completely engaged to the clutch teeth of the spider (1) to transmit the torque. • In this condition, the left side (outer side) wheels rotate at the rpm same as the ring gear's rpm. The rpm of the right side (inner side) wheels, however, is decreased by the friction torque on the road surface, causing the driven clutch (4) to rise from the spider on the inclined surface of the center cam. This disengages the clutch teeth, causing the right side (inner side) wheels to rotate slower than the left side (outer side) wheels to make the machine swing. • The holdout ring (5) operates in the same manner as when the machine is driven by the engine to swing clockwise. When the machine swings counterclockwise during forward traveling • The differential operates in the same manner as when the machine swings clockwise while the engine is driving the machine or serving as a brake. When the machine swings during reverse traveling • The differential operates in the same manner as when the machine is traveling forward to swing both clockwise and counterclockwise while the engine is driving the machine or serving as a brake.

WD600-3

10-53

STRUCTURE AND FUNCTION

DIFFERENTIAL

When the machine travels on a rough terrain or rugged road and requires continuous differential rotation • If a wheel at one side floats from the road surface when a machine with an ordinary differential travels on a rough terrain or rugged road, no load is applied to the wheel, and therefore, it rotates (spins) faster than the wheels contacting the road surface. • If the spinning wheel contacts the road surface, an impact torque is applied to the power train, causing damage on the machine or a fishtail skid. The non-spin differential enables a quick changeover between full differential lock and ordinary differential operation. It means, even if a wheel at one side floats from the road surface, that wheel rotates at the rpm same as when it is contacting the road surface. Accordingly, the wheel does not spin. As a result, the machine makes safety travel without a fishtail skid and also reduces damage due to an impact torque. When a wheel at one side is on the ice and the wheels on the other side are on dry road surface • If a wheel at one side on the ice slips in case of a machine with an ordinary differential, no drive torque is transmitted to the wheels at the other side on dry road surface. Accordingly, the machine cannot travel. If a non-spin differential is mounted on the machine, all torques are transmitted to the wheels on the dry road surface even if the above condition occurs, allowing the machine to travel using the friction on the road surface completely. In this condition, the both wheels rotate at the rpm of the ring gear regardless of the travel and swing directions of the machine.

10-54

WD600-3

STRUCTURE AND FUNCTION

FINAL DRIVE

FINAL DRIVE

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

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

OUTLINE • The final drive obtains a large driving force by reducing the rpm with the planet gear mechanism to transmit it to the wheels.

OPERATION • The power transmitted from the differential to the sun gear (5) through the axle shaft (1) is transmitted to the planetary gear (2). The planet gear rotates inside the secured ring gear (3) to transmit the reduced rpm to the wheel (6) mounted to the planetary carrier (4).

WD600-3

10-55

STRUCTURE AND FUNCTION

AXLE AND CENTER HINGE PIN

AXLE AND CENTER HINGE PIN

1. 2. 3. 4.

Front frame Rear frame Rear axle support Rear axle

OUTLINE • Since the front axle (6) directly receives force of work, it is secured to the front frame (1) with the axle mount bolt. • The rear axle (4) is mounted to the rear frame (2) with the axle supports (3) and (5) so that each tire may contact the ground even during traveling on soft ground and the rear axle can sway at the center of the rear axle.

10-56

5. 6. 7. 8.

Rear axle support Front axle Upper hinge pin Lower hinge pin

•

The front frame (1) and rear frame (2) are connected with the hinge pins (7) and (8) through the bearing. The steering cylinder connects the right and left front frames and rear frames to adjust the bending angle of the frame, i.e., turning radius, based on the cylinder movement.

WD600-3

STRUCTURE AND FUNCTION

STEERING PIPING

STEERING PIPING

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

Steering cylinder (Right) Stop valve (Right) Steering and switching pump Stop valve (Left) Steering cylinder (Left) Charging valve Steering valve Orbit-roll valve Hydraulic tank

WD600-3

10-57

STRUCTURE AND FUNCTION

STEERING COLUMN

STEERING COLUMN

1. 2. 3. 4.

Steering wheel Steering column Joint Orbit-roll valve

10-58

WD600-3

STRUCTURE AND FUNCTION

STEERING UNIT (ORBIT-ROLL VALVE)

STEERING UNIT (ORBIT-ROLL VALVE)

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

Neutral position spring Valve body Check valve Spool Sleeve Gear rim Gear Cover Drive shaft Center pin

WD600-3

a: b: c: d:

To hydraulic tank To steering valve port Pb To steering valve port Pa From PPC pump

10-59

STRUCTURE AND FUNCTION

STEERING UNIT (ORBIT-ROLL VALVE)

OUTLINE • The steering unit is directly connected to the shaft of the steering wheel. The oil from the PPC pump passes through the steering valve, and is switched to the left and right steering cylinders to determine the direction of travel of the machine. • The steering unit can be broadly divided into the following: spool (4) and sleeve (5), which have a rotor type direction selection function, and the gear set (combination of gear (7) and gear rim (6)), which acts as a hydraulic motor when the steering is operated.

STRUCTURE • Spool (4) is interconnected with the drive shaft of the steering wheel and is connected to sleeve (5) by neutral position spring (1) and center pin (10) (when the steering wheel is at neutral, it does not contact the spool). • The top of drive shaft (9) is meshed with center pin (10) and forms one unit with sleeve (5). The bottom is meshed with the spline of gear (7) of the gear set. • Valve body (2) has four ports. These are connected respectively to the pump circuit, tank circuit, and pilot circuit of the steering demand valve. In addition, the port at the pump end and the port at the tank end are connected by check valve (3) inside the housing. If there is any failure in the PPC pump, oil is sucked in directly from the tank end by the check valve.

10-60

WD600-3

STRUCTURE AND FUNCTION

STEERING UNIT (ORBIT-ROLL VALVE)

OPERATION When turning

•

When the steering wheel is turned, spool (4) overcomes neutral position spring (1) and turns slightly in relation to sleeve (5). Because of this rotation, the ports of sleeve (5) and spool (4) overlap, so a passage is formed for the oil to flow, and the oil flows to gear (7).

•

When the steering wheel is turned, the oil inside gear (7) flows, passes inside sleeve (5) and spool (4), operates the spool of the steering demand valve, and actuates the steering cylinders.

•

When the non-reaction type steering valve is at the neutral position, the steering cylinder and spool (4) and sleeve (5) are blocked, so the reaction from the machine is not transmitted to the steering wheel.

At neutral

•

When the turning of the steering wheel is stopped (the rotation of the spool is stopped), the return force of neutral position spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and the oil stops flowing.

WD600-3

10-61

STRUCTURE AND FUNCTION

STEERING VALVE

STEERING VALVE

1. 2. 3. 4.

Overload relief valve Steering spool Demand spool Main relief valve

10-62

A: To steering cylinder B: To steering cylinder P1: From steering pump P2: From switch pump PB: To main control valve T: To hydraulic tank Pa: From steering unit Pb: From steering unit WD600-3

STRUCTURE AND FUNCTION

STEERING VALVE

OVERLOAD RELIEF VALVE

1. 2. 3. 4. 5.

Poppet Relief valve poppet Check valve poppet Pilot poppet Spring

FUNCTION • The overload relief valve is installed in the cylinder circuit of the steering demand valve. When the demand valve is at neutral and any impact is applied to the steering cylinder and abnormal pressure is generated, this valve functions as a safety valve to relieve the circuit to prevent breakage of the cylinder or hydraulic piping. It also functions to prevent any vacuum if any negative pressure is generated at the cylinder end.

OPERATION 1. Operation of relief valve • Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The oil passes through the hole in poppet (1) and acts on the area of diameters d1 and d2. Check valve poppet (3) and relief valve poppet (2) are securely seated.

•

When the pressure at port A reaches the set pressure of the relief valve, pilot poppet (4) opens and the oil goes around pilot poppet (4) and flows to port B.

WD600-3

10-63

STRUCTURE AND FUNCTION

•

When pilot poppet (4) opens, the pressure at the rear of poppet (1) drops, poppet (1) moves to the right, and it is seated with pilot poppet (4).

•

Compared with the pressure at port A, the pressure on the inside is low, so relief valve poppet (2) opens and the oil flows from port A to port B to prevent any abnormal pressure.

STEERING VALVE

2. Operation of suction valve • Negative pressure is generated at port A, the difference in the area of diameters d3 and d4 opens check valve poppet (3), and the oil flows from port B to port A to prevent a vacuum from forming in the circuit.

10-64

WD600-3

STRUCTURE AND FUNCTION

STEERING VALVE

MAIN RELIEF VALVE

1. 2. 3. 4. 5.

Adjustment screw Spring Plug Pilot poppet Valve seat

FUNCTION • The main relief valve of the steering demand valve is inside the valve and sets the maximum pressure in the steering circuit when it is operated. In other words, when the valve is being operated and the steering circuit goes above the set pressure of this valve, it relieves the oil and actuates the flow control spool of the demand valve to drain the oil to the steering circuit.

WD600-3

10-65

STRUCTURE AND FUNCTION

STEERING VALVE

OPERATION OF STEERING RELIEF VALVE

•

•

When the pressure in the circuit rises and reaches the pressure set by spring (2) and adjustment screw (1), pilot poppet (3) opens and drains the oil. When this happens, the balance of the pressure in pressure receiving chamber (I) and pressure receiving chamber (II) is lost, and demand spool (4) moves to the left.

10-66

•

When demand spool (4) moves, the oil from the steering pump is drained and the oil from the switch pump is relieved to the main control valve, so the steering circuit pressure is prevented from going above the set value.

WD600-3

STRUCTURE AND FUNCTION

STEERING VALVE

OPERATION OF DEMAND VALVE WHEN STEERING SPOOL IS AT NEUTRAL

•

•

•

The oil from the steering pump enters port A and the oil from the switch pump enters port B. When steering spool (2) is at the neutral position, pressure receiving pressure chamber (II) is connected to the drain circuit through orifice b, and notch c is closed. Notch c is closed, so the pressure of the oil at port A and port B rises. This pressure passes through orifice a, goes to pressure receiving chamber (I) and moves demand spool (1) to the left.

WD600-3

•

When the pressure in pressure receiving chamber (I) reaches a certain value (set by spring (3)), notch f opens and the oil from the steering pump goes to the drain circuit. Notch g is closed, so the oil from the switch pump all flows to the main control valve.

10-67

STRUCTURE AND FUNCTION

STEERING VALVE

WHEN STEERING SPOOL IS OPERATED Engine running at low speed

•

•

•

When the steering is operated, oil flows from the Orbit-Roll to steering spool (2) and pushes steering spool (2) to the right. The circuit between pressure receiving chamber (II) and the drain circuit is shut off, and at the same time, notch c opens. As a result, the pressure in pressure receiving chamber (II) rises, and demand spool (1) moves to the right until notch h closes. The passage from port B to the main control valve is shut off, so the oil from the switch pump pushes up pump merge-divider check valve (4) and merges with the oil from the steering pump at port A.

10-68

•

•

The merged oil passes through notches c and d, pushes load check valve (5), and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. When this happens, the pressure before passing through notch c is sent to pressure receiving chamber (I) and the pressure after passing through notch c is sent to pressure receiving chamber (II). Demand spool (1) is actuated so that the difference in pressure on both sides of notch c is kept constant. Therefore, an oil flow corresponding to the opening of notch c is supplied to the cylinder port. These pressure differences (control pressure) are set by spring (3). WD600-3

STRUCTURE AND FUNCTION

STEERING VALVE

Engine running at high speed

•

•

There is no need for supply of extra oil from the switch pump, so the steering pump pressure rises until notch g closes and shuts off the merge passage from port B. The pressure difference on both sides of notch c is controlled only by notch f, and the excess oil from the steering pump is drained from notch f to the drain circuit. (At this point, notch g is completely closed.)

WD600-3

•

•

The oil from the steering pump passes through notches c and d, pushes load check valve (5), and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the switch pump all flows from port B and is sent to the main control valve.

10-69

STRUCTURE AND FUNCTION

STEERING VALVE

OPERATION OF STEERING VALVE Neutral

• •

The steering wheel is not being operated, so steering spool (2) does not move. The oil from the steering pump enters port A. The oil from the switch pump enters port B.

10-70

•

When the pressure at ports A and B rises, demand spool (1) moves to the left, so the oil from the steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and all flows to the main control valve.

WD600-3

STRUCTURE AND FUNCTION

STEERING VALVE

Turning right

•

When the steering wheel is turned to the right, the Orbit-roll valve is operated and steering spool (2) moves to the left. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (1). The oil pushes open load check valve (6) of the spool, and flows to the bottom end of the left cylinder and the rod end of the right cylinder to turn the machine to the right. The oil from the left and right cyl-

WD600-3

inders passes through load check valve (5) of the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (1), pushes open check valve (4), and is merged with the oil from the steering pump.

10-71

STRUCTURE AND FUNCTION

STEERING VALVE

Turning left

•

When the steering wheel is turned to the left, the Orbit-roll valve is operated and steering spool (2) moves to the left. The oil from the steering pump enters port A, then flows to steering spool (2) through demand spool (1). The oil pushes open load check valve (5) of the spool, and flows to the rod end of the left cylinder and the bottom end of the right cylinder to turn the machine to the left. The oil from the left and right cylinders passes through load check valve (6) of

10-72

the steering spool and is drained. The oil from the switch pump enters port B, goes through demand spool (1), pushes open check valve (4), and is merged with the oil from the steering pump.

WD600-3

STRUCTURE AND FUNCTION

WO-WAY RESTRICTION VALVE

TWO-WAY RESTRICTION VALVE

1. Poppet 2. Spring 3. Body

FUNCTION • To reduce the shock caused by the inertia of the machine when the steering is operated, an orifice is installed in the oil line of the return circuit from the cylinder. This applies pressure to the returning oil, and regulates the movement of the cylinder piston. OPERATION • When the oil is flowing to arrow ➞, it pushes spring (2) and flows through the orifice, and between poppet (1) and the poppet seat.

When the oil is flowing to arrow , the oil flows only from orifice a inside poppet (1), so the flow is controlled.

WD600-3

➞

•

10-73

STRUCTURE AND FUNCTION

STOP VALVE

STOP VALVE

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

Boot Wiper Seal Poppet Spring Spool Spring

10-74

A: From orbit-roll B: To steering valve DR: To drain

WD600-3

STRUCTURE AND FUNCTION

EMERGENCY STEERING PIPING

EMERGENCY STEERING PIPING

1. 2. 3. 4. 5.

Hydraulic tank Transmission Steering and switch pump Diverter valve Emergency steering pump

WD600-3

10-75

STRUCTURE AND FUNCTION

DIVERTER VALVE

DIVERTER VALVE (for emergency steering)

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

Check valve Check valve Check valve Check valve Spool Valve body

10-76

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

To emergency pump Sensor mounting port To hydraulic oil tank To steering valve From hydraulic tank From steering circuit

FUNCTION • The diverter valve is a selector valve which senses the pilot pressure from the steering pump and if there is no abnormality in the steering circuit, it drains the oil from the emergency pump to the tank. If no pilot pressure from the steering pump reaches the diverter valve, the oil from the emergency pump is switched to the steering circuit and flows to enable the machine to be steered. WD600-3

STRUCTURE AND FUNCTION

DIVERTER VALVE

OPERATION Pump and engine are working normally.

•

When the steering pump and engine are working normally, the hydraulic pump, steering pump, and switch pump are rotated by the engine. Therefore, oil is sent to the steering valve, and the machine can be steered. In addition, the emergency steering pump is rotated by the transmission, so oil from port A of the diverter valve (1) pushes open check valve (2) and enters port B. Pressure oil from the steering pump is flowing to port D, so it pushes spool (3) in the direction of the arrow. As a result, the oil from port B flows to port C and is drained to the hydraulic tank.

WD600-3

To steering cylinder Safety valve (with suction)

Diverter valve Emergency pump

Steering spool

T/M

Demand spool

Hydraulic tank S/T S/W

Oil cooler

To main control valve

•

SLW01242

10-77

STRUCTURE AND FUNCTION

DIVERTER VALVE

Failure in pump or engine when machine is traveling.

If there is a failure in the pump or engine when the machine is traveling, the rotation of the wheels is transmitted through the transfer to rotate the emergency steering pump. The steering pump is not rotating, so no pressure oil is formed at port D. As a result, spool (3) is pushed in the direction of the arrow by spring (4). The oil from the emergency steering pump passes from port A through port B and flows to the steering valve to make steering possible. fl The emergency steering pump is designed so that it can rotate both directions.

10-78

WD600-3

STRUCTURE AND FUNCTION

BRAKE PIPING

BRAKE PIPING

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

Front brake (Right) Slack adjuster (Front) Brake valve (Right) Rear brake (Right) Slack adjuster (Rear) Rear brake (Left) Torque converter charging and PPC (used as brake, too) pump

WD600-3

8. 9. 10. 11. 12. 13. 14.

Accumulator Brake valve (Left) Parking brake Front brake (Left) Strainer Charging valve Parking brake valve

10-79

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKE VALVE BRAKE VALVE (RIGHT)

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

Brake pedal Rod Pilot piston Spool Upper cylinder Plunger Spool Lower cylinder

10-80

A. B. C. D. E.

Pilot port (From brake valve (Left)) Brake port (To rear brake) Brake port (To front brake) Drain port P port (From accumulator)

WD600-3

STRUCTURE AND FUNCTION

BRAKE VALVE

BRAKE VALVE (LEFT)

1. 2. 3. 4. 5.

Brake pedal Rod Spool Cylinder Plunger

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.

WD600-3

A. Drain port B. Brake port (To brake valve (Right)) C. P port (From accumulator)

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.

10-81

STRUCTURE AND FUNCTION

BRAKE VALVE

OPERATION Brake applied (right brake valve) Upper portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders.

1 2

3 Drain

Lower portion • When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed down by plunger (6). When this happens, drain port b is closed, and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders.

Brake applied (left brake pedal) • When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring (9), and drain port c is closed. The oil from the pump and the accumulator flows from port E to port F. • Port F of the left brake valve and port PP of the right brake valve are connected by a hose, so the oil flowing to port F flows to pilot port PP of the right brake valve. • The oil entering pilot port PP enters port G from orifice d, and pushes pilot piston (11). The spring pushes spool (3) down, so the operation is the same as when the right brake valve is depressed.

4

a

C

Accumulator

A To rear brake cylinder

From pump Accumulator

b 5

6 To front brake cylinder

From pump

D

B

SED00109

7 Left brake valve

8 9 C

10

F E

Right brake valve

d G

PP 11 To rear brake cylinder

From pump

3 From pump To front brake cylinder SEW00110

10-82

WD600-3

STRUCTURE AND FUNCTION

BRAKE VALVE

Applying brake when upper valve fails (right brake valve) • Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated.

1

Applying brake when lower valve fails (right brake valve) • Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.

When actuation is balanced Upper portion • When oil fills the rear brake cylinder and the pressure between port A and port C becomes high, the oil entering port H from orifice e of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil entering the brake cylinder is held and the brake remains applied. Lower portion • When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D. Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. • The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.

WD600-3

From pump

To fear brake cylinder

From pump

To front brake cylinder

5

From pump

3 e A f

From pump

B

SEW00111

4 a H

To rear brake

C cylinder 5 b To front brake Dcylinder J

SEW00112

10-83

STRUCTURE AND FUNCTION

BRAKE VALVE

Brake released (right brake valve) Upper portion • When pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the rear brake. Lower portion • When the pedal is released, spool (3) in the upper portion moves up. At the same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the front brake.

10-84

1

3 a From pump

From pump

From rear brake cylinder

b From front brake 5 cylinder SEW00113

WD600-3

STRUCTURE AND FUNCTION

CHARGE VALVE

CHARGE VALVE

A: To PPC valve ACC:To brake valve PP: To brake valve P: From pump T: Drain

WD600-3

FUNCTION • The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. • When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load on the pump.

10-85

STRUCTURE AND FUNCTION

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

CHARGE VALVE

Valve body Main relief valve (R3) Relief valve (R1) PPC relief valve (R2) Relief valve (H1) Filter

10-86

WD600-3

STRUCTURE AND FUNCTION

OPERATION 1. When no oil is being supplied to accumulator (cut-out condition) • The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14), and flows from port A to the PPC valve. At the same time, it also passes through orifices (17), (18), and (16), and flows to the tank.

CHARGE VALVE

T

C T

R3

R1 6 8 Front accumulator pilot pressure

B 16 To front, rear accumulator 18

A To PPC valve

R2

H1 14 17

P

15 SDW00116

2. When oil is supplied to accumulator 1) Cut-in condition • When the pressure at port B is lower than the set pressure of the relief valve (R1), piston (8) is pushed back down by spring (5). Valve seat (7) and poppet (6) are brought into tight contact, and port C and port T are shut off. • The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way. • When the pressure at port P goes above the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed, and the remaining oil flows to port A.

T

C T R1

R3

5 6 7 8 Front accumulator pilot pressure

B 16 To front, rear accumulator 18

A To PPC valve

R2

H1 14 P

17

15 SDW00117

WD600-3

10-87

STRUCTURE AND FUNCTION

2) When cut-out pressure is reached • When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. • When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited. • The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the tank pressure. • The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port B is stopped.

CHARGE VALVE

T

C T

R3

R1 6 7 8 Front accumulator pilot pressure

B 16 To front, rear accumulator 18

A To PPC valve

R2

H1 14 17

P

15 SDW00118

3. Safety relief valve (R3) • If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the tank circuit, so this sets the maximum pressure in the brake circuit and protects the circuit.

3

R3

R1

11

Front accumulator pilot pressure

To front, rear accumulator To PPC valve

R2

H1

P SDW00119

10-88

WD600-3

STRUCTURE AND FUNCTION

ACCUMULATOR

ACCUMULATOR (FOR BRAKE)

1 2

1. 2. 3. 4.

Valve Top cover Cylinder Piston

3

4

SEW00120

FUNCTION • The accumulator is installed between the charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.

WD600-3

SPECIFICATIONS Gas used: Nitrogen gas Charge amount: 6,000 cc Charging pressure: 3.4 MPa {35 kg/cm2} (at 50°C)

10-89

STRUCTURE AND FUNCTION

SLACK ADJUSTER

SLACK ADJUSTER

1

2

5

1. 2. 3. 4. 5.

Bleeder Cylinder Check valve Piston Spring

A: Inlet port B: Outlet port

10-90

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}

WD600-3

STRUCTURE AND FUNCTION

SLACK ADJUSTER

OPERATION 1. When brake pedal is depressed • Before the brake is depressed, piston (4) is returned by the distance of stoke S (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to left and right cylinders (2), where it moves piston (4) by stroke S to the left and right.

•

When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston (7) and disc is to 0, the greater the braking force becomes.

•

If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above the set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.

WD600-3

10-91

STRUCTURE AND FUNCTION

SLACK ADJUSTER

2. When brake pedal is released • When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc.

10-92

WD600-3

STRUCTURE AND FUNCTION

BRAKE

BRAKE

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

Guide pin Return spring Cylinder Brake piston Outer gear (Teeth: 164) Hub gear (Teeth: 112) Plate Disc

WD600-3

10-93

STRUCTURE AND FUNCTION

BRAKE

FUNCTION • Main brakes are wet-type multiple-disc brakes and are installed to all four wheels. OPERATION • When the brake pedal is depressed, the pressure oil from the brake valve moves brake piston (4) to the right in the direction of the arrow. This brings disc (8) and plate (7) into contact, and friction is generated between the disc and plate. The wheel is rotating together with the disc, so the machine speed is reduced and the machine is stopped by this friction.

•

When the brake pedal is released, the pressure at the back face of brake piston (4) is released, so the piston is moved to the left in the direction of the arrow by the force of return spring (2), and the brake is released.

10-94

WD600-3

STRUCTURE AND FUNCTION

PARKING BRAKE

PARKING BRAKE

1. Parking brake disc 2. Spring cylinder 3. Caliper return spring

WD600-3

OUTLINE • The parking brake is a disc type and is installed on the front axle. • The force of the spring inside the spring cylinder (2) is used to apply the brake mechanically; it is released by oil pressure. • The parking brake caliper is fixed to the front differential case. The disc is installed to the differential yoke and rotates together with the coupling.

10-95

STRUCTURE AND FUNCTION

PARKING BRAKE

PARKING BRAKE CALIPER

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

Caliper Pad Piston Piston shaft Lever Adjustment bolt

OUTLINE • Caliper (1) is fitted with a piston guide. Piston (3) and piston shaft (4) are fitted inside, and the rotation of the piston shaft moves the piston in the axial direction to compress pad (2). • Lever (5) is connected by a spline to the spline side of the piston shaft. Pad (2) is fitted and held in position together with caliper (1) in the caliper mounting plate.

10-96

•

The caliper body follows the wear of pad (2) and slides in the axial direction on the plate. Adjustment bolt (6) of lever (5) is used to adjust the clearance between the pad and the disc. Hold the lever and turn the adjustment bolt to adjust the clearance as follows. To INCREASE, turn COUNTERCLOCKWISE. To DECREASE, turn CLOCKWISE.

WD600-3

STRUCTURE AND FUNCTION

SPRING CYLINDER

SPRING CYLINDER

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

Outer spring Inner spring Piston Cylinder Boot Rod

WD600-3

OUTLINE • The oil pressure from the parking brake solenoid valve pushes the spring and releases the parking brake. When the engine is stopped, the parking brake is applied by spring (1), so the machine is prevented from moving.

10-97

STRUCTURE AND FUNCTION

PARKING BRAKE SOLENOID VALVE

PARKING BRAKE SOLENOID VALVE

1. Solenoid valve assembly 2. Block B: Outlet port B1: Port for parking brake pilot lamp switch P: Inlet port T: Drain port

10-98

FUNCTION • The parking brake solenoid valve is installed to the inside left of the front frame. When the parking brake switch is turned ON/OFF, the solenoid valve is energized or deenergized, so the brake oil pressure is taken to the brake cylinder or removed from the brake cylinder to set the parking brake at the PARKED position or TRAVEL position. • Parking brake solenoid valve Energized: TRAVEL Deenergized: PARKED WD600-3

STRUCTURE AND FUNCTION

HYDRAULIC PIPING

HYDRAULIC PIPING

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

Lift cylinder Work equipment valve Steering valve Steering + switching pump Torque converter charging + PPC pump PPC valve Accumulator charging valve

WD600-3

8. Hydraulic tank 9. Work equipment pump 10. Accumulator A. To pitch cylinder (Right) B. To pitch and tilt cylinder (Left)

10-99

STRUCTURE AND FUNCTION

WORK EQUIPMENT LEVER LINKAGE

WORK EQUIPMENT LEVER LINKAGE

1. Work equipment control lever 2. PPC valve 3. Safety lever

10-100

WD600-3

STRUCTURE AND FUNCTION

HYDRAULIC TANK

HYDRAULIC TANK

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

Filter bypass valve Oil filter Breather Oil filler Oil level sight gauge Hydraulic tank Drain valve

WD600-3

A. Brake return port B. Stop valve, charge valve, PPC, orbit-roll return port C. Hydraulic oil cooler return port D. Main return port E. Main suction port F. Emergency steering suction port G. Emergency steering return port

10-101

STRUCTURE AND FUNCTION

HYDRAULIC TANK

OPERATION OF OIL FILTER BYPASS VALVE When the filter is clogged. Bypass valve (1) opens and the oil returns directly to the tank without passing through the filter. Bypass valve set pressure: 125 kPa {1.27 kg/cm2}

When negative pressure is formed in the return circuit. Valve (2) moves up and acts a check valve. Check valve set pressure: 25.5 kPa {0.26 kg/cm2}

10-102

WD600-3

STRUCTURE AND FUNCTION

HYDRAULIC TANK

BREATHER

1. 2. 3. 4.

Body Filter element Poppet Sleeve

FUNCTION Preventing negative pressure inside the tank The tank is a pressurized, sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens the poppet (3), and air from the outside is let into the tank to prevent negative pressure. Preventing rise in pressure inside the tank When the hydraulic cylinder are being used, the oil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above the set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.

WD600-3

10-103

STRUCTURE AND FUNCTION

ACCUMULATOR (FOR PPC VALVE)

ACCUMULATOR (FOR PPC VALVE)

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

Gas plug Shell Poppet Holder Bladder Oil port

SPECIFICATIONS Type of gas: Nitrogen gas Gas amount: 500 cc Max. actuation pressure: 3.4 MPa {35 kg/cm2} Min. actuation pressure: 1.2 MPa {12 kg/cm2}

FUNCTION • The accumulator is installed between the accumulator charge valve and the PPC valve. Even if the engine stops when the blade is raised, it is possible to lower the blade under their own weight by using the pressure of the nitrogen gas compressed inside the accumulator to send the pilot oil pressure to the work equipment valve to actuate it.

OPERATION • After the engine stops, if the PPC valve is at hold, chamber A inside the bladder is compressed by the oil pressure in chamber B. • When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa {30 kg/cm2}. When this happens, the bladder is expanded by the pressure of the nitrogen gas in chamber A, and the oil inside chamber B is used as the pilot pressure to actuate the work equipment valve.

10-104

WD600-3

STRUCTURE AND FUNCTION

PPC VALVE

PPC VALVE

P: From PPC pump P1: To work equipment valve tilt spool (Left tilt, rear pitch) P2: To work equipment valve lift spool (Lower) P3: To work equipment valve lift spool (Raise) P4: To work equipment valve tilt spool (Right tilt, forward pitch) T: Drain

WD600-3

10-105

STRUCTURE AND FUNCTION

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

PPC VALVE

Bolt Piston Plate Collar Retainer Centering spring Metering spring Valve Body

10-106

WD600-3

STRUCTURE AND FUNCTION

PPC VALVE

OPERATION OF PPC VALVE [At neutral]

•

The oil from the PPC pump enters port P of the PPC valve, but the circuit is closed by spool (8), so the oil is drained from relief valve (1). At the same time, the oil at port P1B of the main control valve is drained from port f of spool (8). In addition, the oil at port P1A is drained from port g of spool (10).

WD600-3

10-107

STRUCTURE AND FUNCTION

PPC VALVE

FUNCTION OF PPC VALVE The PPC valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. This pressure oil actuates the spool. OPERATION 1. Control lever at “hold” (Fig. 1) Ports P1B, P4, P1A and P1 are connected to drain chamber D through fine control hole (f) in valve (8). 2. Control lever operated slightly (fine control) (Fig. 2): When piston (2) starts to be pushed by plate (10), retainer (5) is pushed. Valve (8) is also pushed by spring (7) and moves down. When this happens, fine control hole (f) is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pilot pressure of the control valve is sent through fine control hole (f) to port P4. When the pressure at port P4 rises, valve (8) is pushed back. Fine control hole (f) is shut off from pump pressure chamber PP. At almost the same time it is connected to drain chamber D, so the pressure at port P4 escapes to drain chamber D. Valve (8) moves up and down until the force of spring (7) is balanced with the pressure of port P4. The position of valve (8) and body (9) (when fine control hold (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (8) contacts the bottom of piston (2). Therefore, spring (7) is compressed in proportion to the travel of the control lever, so the pressure at port P4 also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port P1B (same as pressure at port P4) and the force of the return spring of the control valve are balanced.

10-108

WD600-3

STRUCTURE AND FUNCTION

PPC VALVE

3. Control lever moved back from slightly operated position to hold (Fine control) (Fig. 3): When plate (10) starts to be pushed back, piston (2) is pushed up by a force corresponding to the force of centering spring (6) and the pressure at port P4. At the same time, fine control hole (f) of valve (8) is connected to drain chamber D, so the oil at port P4 escapes. If the pressure at port P4 drops too far, valve (8) is pushed down by spring (7). Fine control hole (f) is shut off from drain chamber D, and at almost the same time it is connected to pump pressure chamber PP. The pump pressure is supplied until the pressure at port P1B returns to a pressure equivalent to the position of the lever. When the spool of the control valve returns, the oil in drain chamber D flows in from fine control hole (f’) of the valve which has not moved. The extra oil then flows through port P1 to chamber P1A.

4. Control lever operated to end of travel (Fig. 4): Plate (10) pushes piston (2) down, and piston (2) forcibly pushes in valve (8). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port P4 to chamber P1B to push the spool of the control valve. The oil returning from chamber P1A flows from port P1 through fine control hole (f’) to drain chamber D.

WD600-3

10-109

STRUCTURE AND FUNCTION

PPC RELIEV VALVE

PPC RELIEF VALVE

R2

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

1

2

3

4

5

Main valve Spring Valve seat Pilot poppet Spring Screw

6 SDW00149

FUNCTION • The PPC relief valve is between the PPC, brake pump and the PPC valve. When the PPC pump is not being actuated, or when any abnormal pressure is generated, the oil sent from the pump is relieved from this valve to prevent any damage to the pump or circuit. OPERATION • The relief valve is installed to the charge valve. Port A is connected to the pump circuit and port C is connected to the drain circuit. The oil passes through the orifice in main valve (1) and fills port B. In addition, pilot poppet (4) is seated in valve seat (3). • When the pressure at port A and port B reaches the set pressure, pilot poppet (4) opens and the oil pressure at port B escapes from port D to port C to lower the pressure at port B. • When the pressure at port B goes down, a difference in pressure is generated at ports A and B by the orifice of main valve (1). Main valve (1) is opened by the pressure at port A and the oil at port A is drained to port C to relieve the circuit.

A

1

C

B

3

4

R2 To PPC valve

D

SDW00150

A

C

1

B

R2 To PPC valve

SDW00151

10-110

WD600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

WORK EQUIPMENT VALVE

P1A. From PPC valve P1 P2A. From PPC valve P3 P1B. From PPC valve P4 P2B. From PPC valve P2 P1. From pump P2. (Blind plug)

10-112

A1. A2. B1. B2. T.

To pitch and tilt cylinder bottom side To lift cylinder bottom side To pitch and tilt cylinder head side To lift cylinder head side Drain port

WD600-3

STRUCTURE AND FUNCTION

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

WORK EQUIPMENT VALVE

Tilt spool return spring Lift spool return spring Lift spool Tilt spool Body Suction valve Safety valve with suction Main relief valve

WD600-3

10-113

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

MAIN RELIEF VALVE 1. 2. 3. 4. 5.

Main valve Valve seat Pilot poppet Spring Adjustment screw

FUNCTION • The main relief valve mounted at the inlet part of the work equipment valve drains the oil to the tank when it exceeds the specified pressure. This specifies the maximum pressure of the work equipment circuit to protect the circuit. OPERATION • The port A connects to the pump circuit and the port C connects to the drain circuit. The oil goes through the orifice of the main valve (1) to fill the port B. The pilot poppet (3) is seated at the valve seat (2). • When the hydraulic pressures at the ports A and B reach the set pressure of the pilot poppet spring (4), the pilot poppet (3) opens to relieve the hydraulic pressure at the port B through the port D to the port C, eventually lowering the pressure at the port B. • As the pressure at the port B lowers, the orifice of the main valve (1) generates pressure difference at the ports A and B, pushing the main valve open. Then, the oil at the port A goes through the port C to the drain circuit to relieve abnormal pressure. • The set pressure can be changed by changing tension of the pilot poppet spring (4). To change the set pressure, remove the cap nut, loosen the lock nut, and adjust the adjustment screw (5); screw it in to raise the set pressure and loosen it to lower it.

10-114

WD600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

SAFETY VALVE (WITH SUCTION) 1

2

3

4

5

6

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

Suction valve Main valve Main valve spring Pilot piston Suction valve spring Valve body

SEW00166

FUNCTION • The safety valve is mounted in the tilt cylinder circuit in the work equipment valve. If abnormal pressure is generated due to impact to the cylinder with the work equipment valve in the neutral position, the safety valve relieves it to prevent damage on the cylinder. OPERATION Operation as a safety valve • The port A connects to the cylinder circuit and the port B connects the drain circuit. The hydraulic pressure at the port A is led to the port D through the hole of the pilot piston (4) and further to the port C through the orifice consisting of the main valve (2) and the pilot piston (4). The pilot piston (4) is secured to the safety valve and the relation of the cross-section diameter (cross-sectional area) of its each part is d2>d1>d3>d4. • If abnormal pressure is generated at the port A, the suction valve (1) does not operate due to the relation d2>d1. The main valve (2), however, receives hydraulic pressure by difference in the areas of d3 and d4 due to the relation d3>d4 of the port A and port C. When the hydraulic pressure reaches the main valve spring (3) force (set pressure), the main valve (2) operates to flow the oil of the port A to the port B.

A

B

C

2

4

d1 d3 d4

A

B 1

d2

2

D

SEW00167

3

D

SEW00168

WD600-3

10-115

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

OPERATION AS A SUCTION VALVE • If negative pressure is generated at the port A, the pressure at the port D also becomes negative since the port D is led to the port A. To the port E, the tank pressure at the port B is applied. Due to this tank pressure at the port E, the safety valve receives the hydraulic pressure a generated by area differences in d2 and d1. Therefore, the hydraulic pressure e moves in direction to open the valve and the hydraulic pressure a moves in direction to close the suction valve (1). If the pressure at the port A lowers (approaches negative pressure) below the hydraulic pressure e and eventually reaches the level, hydraulic pressure e > hydraulic pressure a + valve spring (5) force, the suction valve (1) opens to flow the oil from the port B to port A to prevent negative pressure generation at the port A.

SUCTION VALVE 1

2

3

1. Main poppet 2. Sleeve 3. Spring FUNCTION • The suction valve prevents negative pressure generation in the circuit. SEW00170

OPERATION • If negative pressure is generated at the port A (lift cylinder rod side) (if pressure lower than the port B in the tank circuit is generated), the area differences in d1 and d2 open the main poppet (1) to flow the oil from the port B in the tank side to the port A in the cylinder port side.

10-116

WD600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

LIFT AND TILT SPOOL HOLD POSITION

FUNCTION • The oil flows from the pump to the port A and the relief valve (11) specifies its maximum pressure. • Since the bypass circuit is opened to protect tilt spool (1), the oil in port A flows around the spool into port B. • Since the lift spool (2) is in the HOLD position, the bypass circuit is open. The oil at the port B goes around the spool to enter the port C in the drain circuit and further goes through the filter back to the tank. WD600-3

•

The oil from the PPC pump goes through the check valve (13) to enter the port L of the PPC valve. Since the work equipment control lever is in the HOLD position, however, the oil returns from the PPC relief valve (12) to the hydraulic tank.

10-117

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

LIFT SPOOL RAISE POSITION

OPERATION • Placing the work equipment control lever (3) at the RAISE position flows the oil from the port L of the PPC valve to the port N and port T. The oil at the port S goes through the port M to the drain circuit. The pressure oil at the port T pushes the lift spool (2) to the RAISE position. • The oil from the pump flows through the bypass circuit of the tilt spool to the bypass

10-118

•

circuit of the lift spool (2). Since the bypass circuit is closed by the spool, the oil pushes the check valve (10) open. The oil flows through the port J and the port K to the cylinder rod side. The oil at the cylinder bottom side goes through the port I to the drain port C to return to the tank. Accordingly, the blade rises.

WD600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

LIFT SPOOL LOWER POSITION

OPERATION • Placing the work equipment control lever (3) at the LOWER position flows the oil from the port L of the PPC valve to the port M and port S. The oil at the port T flows to the drain circuit. The pressure oil at the port S pushes the lift spool (2) to the LOWER position. • The oil from the pump flows through the bypass circuit of the tilt spool to the bypass circuit of the lift spool (2). Since the bypass WD600-3

•

circuit is closed by the spool, the oil pushes the check valve (10) open. The oil flows through the port H and the port I to the cylinder bottom side. The oil at the cylinder rod side goes through the port K to the drain port C to return to the tank. Accordingly, the blade lowers.

10-119

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

LIFT SPOOL FLOAT POSITION

OPERATION • Placing the work equipment control lever (3) at the FLOAT position moves the spool of the PPC valve beyond the LOWER position to the FLOAT position. The pressure oil at the port L flows to the port M and port S. The pressure oil at the port T flows to the port N. • The pressure oil at the port S pushes the lift spool (2) to the FLOAT position.

10-120

•

The oil at the cylinder bottom side goes through the port H and the port C to the drain circuit, and the oil at the cylinder rod side goes through the port K and the port C to the drain circuit. Accordingly, the blade floats.

WD600-3

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

TILT SPOOL AT RIGHT TILT POSITION

OPERATION • If the work equipment control lever (3) is set in the RIGHT TILT position, the hydraulic oil in port L of the PPC valve flows through port Q to port V and the oil in port R flows in the drain circuit. The hydraulic oil in port V sets tilt spool (1) in the RIGHT TILT position. • Since the bypass circuit is closed by tilt spool (1), the oil from port A pushes check valve (9) open. The oil from check valve (9) flows through ports F and G to the bottom side of the pitch and tilt cylinder (Left side). WD600-3

•

The oil on the cylinder rod side flows through port D to drain port C and returns to the tank. The circuit to the pitch cylinder (Right side) is closed by the deco valve. Accordingly, the blade is tilted to the right.

10-121

STRUCTURE AND FUNCTION

WORK EQUIPMENT VALVE

TILT SPOOL AT LEFT TILT POSITION

OPERATION • If the work equipment control lever (3) is set in the LEFT TILT position, the hydraulic oil in port L of the PPC valve flows through port P to port R and the oil in port V flows in the drain circuit. The hydraulic oil in port R sets tilt spool (1) in the LEFT TILT position. • Since the bypass circuit is closed by tilt spool (1), the oil from port A pushes check valve (9) open. The oil from check valve (9) flows through ports D and E to the head side of the pitch and tilt cylinder (Left side).

10-122

•

The oil on the cylinder bottom side flows through port G to drain port C and returns to the tank. The circuit to the pitch cylinder (Right side) is closed by the deco valve. Accordingly, the blade is tilted to the left.

WD600-3

STRUCTURE AND FUNCTION

DECO VALVE

DECO VALVE

1. Solenoid valve (sol. a) 2. Merge/divider valve 3. Solenoid valve (sol. b) A. From work equipment valve port A1 B. From work equipment valve port B1 C. To bottom side of pitch and tilt cylinder (Left side) D. To rod side of pitch and tilt cylinder (Left side) E. To bottom side of pitch cylinder (Right side) F. To rod side of pitch cylinder (Right side) T. To hydraulic tank PL. Pilot port

WD600-3

FUNCTION • The deco valve is installed to the circuit between the work equipment valve and pitch and tilt cylinder and used to select the pitching or tilting operation of the blade. • When the tilting operation is performed, the 2 solenoid valves are turned off and the hydraulic oil from the work equipment valve flows to the left cylinder. The circuit to the right cylinder is closed. As a result, the blade is tilted. • When the pitching operation is performed, the 2 solenoid valves are turned on and the hydraulic oil from the work equipment valve flows to the both cylinders simultaneously. As a result, the blade is pitched.

10-123

STRUCTURE AND FUNCTION

DECO VALVE

SOLENOID VALVE (SOL a)

a. b. c. d. e. f.

Port X Port A Port B Port Y Port P Port T

10-124

WD600-3

STRUCTURE AND FUNCTION

DECO VALVE

OPERATION OF SOLENOID VALVE (a) When no electricity is flowing • The pressure oil entering from port PL passes through solenoid valve port A and enters chamber AS. It than moves the spool to the right and closes the passages between ports P and A and ports B and T of the spool. Chamber BS is also connected to port T the solenoid valve and is opened.

When electricity is flowing • The pressure oil entering from port PL passes through solenoid valve port B and enters chamber BS. It then moves the spool to the left and opens the passages between ports P and A and ports B and T of the spool. • The oil flows from port P to port A, and sends oil to the cylinder head. The oil returning from the cylinder bottom flows from port B to port T. This actuates the cylinder.

WD600-3

10-125

STRUCTURE AND FUNCTION

DECO VALVE

SOLENOID VALVE (SOL b)

a. b. c. d. e. f. g.

Port Ta Port Tb Port Y Port B Port P Port A Port X

10-126

WD600-3

STRUCTURE AND FUNCTION

DECO VALVE

OPERATION OF SOLENOID VALVE (b) When no electricity is flowing • The pressure oil entering from port PL passes through solenoid valve port A and enters chamber AS. It then moves the spool to the left and opens the passages between ports A and P and port T and B of the spool. Chamber BS is also connected to port T of the solenoid valve and is opened. Oil flows is from ports T and A, merges with the oil from ports B and P, and flows to the cylinder.

When electricity is flowing • When the solenoid valve is actuated, the pressure oil entering from port PL passes through solenoid valve port B and enters chamber BS. It then moves the spool to the right and opens the passages between ports P and B and ports A and T of the spool. Chamber AS is also connected to port T of the solenoid valve and is opened. When ports A and T and ports P and B are connected, the oil stops flowing.

WD600-3

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STRUCTURE AND FUNCTION

DECO VALVE

MERGE/DIVIDER VALVE

1. 2. 3. 4. 5. a. b. c.

Spring Cover Sub-spool Spool Body Port A Port B Port P

10-128

FUNCTION Regardless of pressure difference fluctuation between A and B ports, oil in-flow is divided equally or merged.

WD600-3

STRUCTURE AND FUNCTION

DECO VALVE

OPERATION MERGE/DIVIDER VALVE • When the flow is divided, the oil flowing in from port P moves sub-spools 3A and 3B at both port A and port B sides to push them open. The oil passes through the throttle in the sub-spool and through the passages in spools C and D, and then flows out to ports A and B. When there is a differential pressure generated between ports A and B, the oil passages in spools C and D move to the left of right in accordance with the differential pressure. This regulates the width of the oil passages connected to port A and B and allows the same amount of oil flow.

•

When the flow is merged the oil flowing into port A and B moves the sub-spools to the inside. The oil then passes from ports A and B through the throttle in the sub-spools and through the passages in the spools, and is merged equally at port P. When there is differential pressure generated between ports A and B, the spools move in the same way as when the flow is divided and adjust the flow to merge the oil equally.

WD600-3

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STRUCTURE AND FUNCTION

DECO VALVE

1. Operation of right tilt

10-130

WD600-3

STRUCTURE AND FUNCTION

•

•

•

The pressure oil supplied from work equipment valve port A1 flows from port A and enters the merge/divider valve. Part of the pressure oil which is divided passes through port G and flows to port C. The other flows of pressure oil passes through port H, and if solenoid valve (a) is not actuated, pilot spool (1) is also not actuated, so the pressure oil does not flow to port J, but flows to port L and M. Solenoid valve (b) is not actuated, so pilot spool (2) is also not actuated. As a result, the pressure oil passes through ports N and P, merges at port C, and flows to the bottom end of left tilt/pitch cylinder (3). At the same time, the oil at the rod end of left tilt/pitch cylinder (3) flows from port D to port B, and return to the tank. The pressure oil at ports E and F does not flow, so right pitch cylinder (4) does not move. Therefore, the work equipment tilts to the right.

WD600-3

DECO VALVE

2. Operation of left tilt • The pressure oil supplied from work equipment valve port B1 passes through port B. Solenoid valve as is not actuated, so pilot spool (1) is also not actuated. As a result, the pressure oil does not flow to port K, but flows to port D. It then flows to the rod end of left tilt/pitch cylinder (3). • At the same time, the oil at the bottom end of left tilt/pitch cylinder (3) is divided from port C. Some of the oil flows to port G, and the rest flows to port N and P. • Solenoid valve (b) is not actuated, so pilot spool (2) is also not actuated. As a result, the pressure oil passes through ports L and M, flows to port H, is merged at the merge/divider valve, passes through port A and returns to the tank. • The pressure oil at port E and F does not flows, so right pitch cylinder (4) does not move. Therefore, the work equipment tilts to the left.

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STRUCTURE AND FUNCTION

DECO VALVE

3. Operation of forward pitch

10-132

WD600-3

STRUCTURE AND FUNCTION

•

•

The pressure oil supplied from work equipment valve port A1 flows from port A and enters the merge/divider valve. Part of the pressure oil which is divided passes through port G, flows to port C, and then flows to the bottom end of left tilt/pitch cylinder (3). The other flows of pressure oil passes through port H. Solenoid valve a is actuated, so pilot spool (1) is also actuated, and the pressure oil flows to port J. From port J, it passes through port M and E and flows to the bottom end of right pitch cylinder (4). When this happens, the solenoid valve is actuated so pilot spool (2) is actuated and the passages between ports N and P and ports Q and R are opened. At the same time, the oil at the rod end of left tilt/pitch cylinder (3) flows from port D to port B, while the oil at the rod end of right pitch cylinder (4) flows from port F through solenoid valve (a). It is then merged, passes through port B and returns to the tank. Therefore, the work equipment is pitched forward.

WD600-3

DECO VALVE

4. Operation of rear pitch • The pressure oil supplied from work equipment valve port B1 flows from port B. Some of the pressure oil flows to port D, and then flows to the rod end of left tilt/pitch cylinder (3). With the other flows of pressure oil, solenoid valve (a) is actuated, so pilot spool (1) is also actuated, and the oil flows to port L. It when flows from port L, passes through ports K and F and flows to the rod end of right pitch cylinder (4). • At the same time, the oil at the bottom end of left tilt/pitch cylinder (3) flows from port C to port G, while the oil at the bottom end of right pitch cylinder (4) flows from port E to port H. It is then merged at the merge/divider valve, passes through port A and returns to the tank. When this happens, solenoid valve (b) is actuated so pilot spool (2) is actuated and the passages between ports N and P and Q and R are opened. Therefore, the work equipment is pitched to the rear.

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STRUCTURE AND FUNCTION

AIR CONDITIONER

AIR CONDITIONER AIR CONDITIONER PIPING

1. 2. 3. 4. 5.

Vent Window defroster Vent Dry receiver Air conditioner condenser

10-134

6. 7. 8. 9.

Comperssor Hot water inlet port Hot water outlet port Air conditioner unit

WD600-3

STRUCTURE AND FUNCTION

AIR CONDITIONER

CONDENSER 1. 2. 3. 4.

Refrigerant gas inlet port Fan Connector Refrigerant gas outlet port

1. 2. 3. 4.

Refrigerant outlet port Refrigerant inlet port Relief valve Clutch

COMPRESSOR

SPECIFICATIONS Type: Piston pump type Refrigerant used: R134a

WD600-3

10-135

STRUCTURE AND FUNCTION

AIR CONDITIONER

DRY RECEIVER 1. Body 2. Dryer

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WD600-3

STRUCTURE AND FUNCTION

MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM

OUTLINE • The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine. • The machine monitor system consists of the main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and power source. • The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine where an alarm is given) and normal conditions which are always displayed on the instrument panel (pilot lamps and readings for the gauges, speedometer, and service meter). WD600-3

•

There are also various switches built into the monitor panel which function to operate the machine.

ª

The main monitor uses the network wiring to send signals to the controller, and functions to display the following information. 1) Shift indicator: 1st - 4th, N, F, R (F, R are optional) (When auto shift, joystick steering are installed) 2) HOLD (When auto shift is installed) 3) Failure action code, failure code, time elapsed since failure (failure data display mode)

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STRUCTURE AND FUNCTION

MAIN MONITOR

MAIN MONITOR

1. Check lamp 2. Caution lamp 3. Caution items 3A. Emergency steering actuated 4. Pilot items 4A. Turn signal (left) 4B. Turn signal (right) 4C. High beam 4D. Shift indicator

4E. Speedometer 5. Switches 4F. Shift hold 5A. Working lamp (front) 4G. Parking brake switch 4H. Emergency steering 5B. Working lamp (rear) normal switch 4I. Monitor pilot lamp 5C. Transmission cut-off (preheating, afterheating) switch 4J. Failure action code 5D. Auto shift, manual selector switch

OUTLINE • The main motor has a display function for the speedometer and other gauges and a switching function to control the electric components and controllers. • There is one CPU (Central Processing Unit)

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•

installed internally, and this processes the signals from the sensors and outputs the display. A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches. WD600-3

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

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

CHECK

Caution CAUTION

Pilot

WD600-3

Caution

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STRUCTURE AND FUNCTION

MAIN MONITOR

MAIN MONITOR SWITCH FUNCTION Item

Function Front working lamp lights up or goes out each time switch is pressed when side lamps are lighted up

Lights up

Front working lamp lights up

Working lamp (front)

Goes out

Front working lamp goes out

Rear working lamp lights up or goes out each time switch is pressed when side lamps are lighted up

Lights up

Rear working lamp lights up

Goes out

Rear working lamp goes out

Lights up

Cut-off function actuated

Goes out

Cut-off function stopped

Lights up

Manual mode

Goes out

Auto shift mode

Working lamp (rear)

Transmission cut-off

Manual

10-140

Transmission cut-off function is actuated or stopped each time switch is pressed

Auto shift mode switches to manual mode when switch is pressed

Display

Actuation

WD600-3

STRUCTURE AND FUNCTION

MAIN MONITOR

TROUBLE DATA DISPLAY MODE Item

Switch operation

Method of switching to trouble data display mode

With engine stopped and starting switch turned ON, press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds.

ON

SDW00241

Method of sending failure code

Press working lamp (front) switch

Actuation All switch displays (LEDs) go out, and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. (1) Failure code is a two-digit display given in numbers or letters. The display for the failure now occurring flashes and the display for past failures lights up. If there is no failure, CC is displayed (000 is displayed for time elapsed since failure) (2) The time elapsed since failure is displayed as a three-digit number to show how long ago the failure occurred (the oldest failure time is displayed. Any time greater than 999H is displayed as 999H). (3) A maximum of 9 items are stored in memory for the failure code. Failure code and time elapsed since failure change to next item.

ON

Failure code

SPEED x 100 RPM km/h MPH

Time elapsed since failure

SDW01254

SDW00242

Clearing failure code

Press working lamp (rear) switch for at least 2 seconds ON

Failure code and time elapsed since failure being displayed are cleared. Failure code for problem now occurring (flashing display) cannot be cleared.

SDW00243

Resetting from travel data display mode

WD600-3

Press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds, or start the engine.

Changes to normal display

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STRUCTURE AND FUNCTION

MAINTENANCE MONITOR

MAINTENANCE MONITOR

1. Check items (Checks before starting) 1A. Engine water level 1B. Engine oil level 2. Caution items (warning items) 2A. Engine oil pressure 2B. Brake oil pressure 2C. Battery charge 2D. Air cleaner

3. Gauge items 3A. Fuel level 3B. Engine water temperature 3C. Torque converter oil temperature

OUTLINE • The maintenance monitor has a display function for the caution items and gauges, and switch functions to control the work equipment controller. • The maintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms.

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•

•

4. Service meter 4A. Service meter numeric display 4B. Service meter RUN pilot lamp 5. Monitor module 6. Switch module

The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the display and output. A liquid crystal display and LEDs are used for the display portions.

WD600-3

STRUCTURE AND FUNCTION

MAINTENANCE MONITOR

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

Actuated when charge is normal Advances 1 for every hour

Service meter indicator

Lights up when service meter is running

Fuel level EMPTY

FULL

1 2 3 4 5 6 7

E Red

F Green

Engine water temperature Gauges

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

67 80 90 97 102 105˚C

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

1 2 3 4 5 6 7

C

White Green

Torque converter oil temperature

Red

H

50 70 90 110 120 130˚C

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

1 2 3 4 5 6 7

C

WD600-3

Green

Red

H

10-143

STRUCTURE AND FUNCTION

ENGINE STARTING CIRCUIT

ENGINE STARTING CIRCUIT

Function • The neutral safety circuit is employed so that the engine will be started safely, that is, the engine cannot start when the forward-reverse lever is not in the N (Neutral) position. • If the starting switch is turned to the OFF position, supply of the fuel is stopped to stop the engine. • Operation • If the forward-reverse lever is set in the N (Neutral) position, the neutral contacts of the forward-reverse lever are “closed”. If the starting switch is turned to the ON position, the neutral relay operates to “close” terminals 3 - 5. Then the current flows from starting switch terminal BR through the battery relay coil to the ground to “close” the battery relay.

10-144

•

If the starting switch is turned to the START position, the current flows circuit [1] from the positive (+) terminal of the battery through starting switch terminals B and C, neutral relay terminals 5 – 3, starting motor terminal C, and starting motor terminal E to the ground. The ECM controller controls the fuel injection rate and injection timing according to various signals. The circuit from the battery through battery relay to starting motor terminal B is formed to start the engine. If the forward-reverse lever is not in the N (Neutral) position, circuit [1] is not formed and the engine does not start.

WD600-3

STRUCTURE AND FUNCTION

ENGINE STOP CIRCUIT

ENGINE STOP CIRCUIT

Operation • If the starting switch is turned to the OFF position, starting switch terminals B and BR and ACC are “opened”. • The ECM controller outputs a signal to shut off the fuel, then supply of the fuel is stopped to stop the engine.

WD600-3

10-145

STRUCTURE AND FUNCTION

PRE-HEATING CIRCUIT

PRE-HEATING CIRCUIT AUTOMATIC PRE-HEATING SYSTEM

Outline • The automatic preheating system is installed so that the engine will start easily in a cold district. This system shortens the preheating time and sets the preheating time automatically according to the engine coolant temperature when then starting switch is operated. • If the starting switch is turned to the ON position, a current flows in the ribbon heater to preheat the sucked air. The ECM controller determines the preheating time according to the coolant temperature measured by the engine coolant temperature sensor. • During preheating, the preheating pilot lamp of the main monitor keeps lighting up. When preheating is finished, the preheating pilot lamp goes off.

10-146

Operation • If the starting switch is turned to the ON position, the preheating relay operates to “close” the contacts according to the signal from the ECM controller. Then, a current flows through preheating relay terminal [5] to the heater relay to “close” the contacts of the heater relay • The current flows from the battery through the battery relay and heater relay to the ribbon heater to preheat the sucked air. • When preheating is finished, the current from the ECM controller to the preheating relay is cut out and the heater relay contacts are “opened”. • During preheating, the current also flows from preheating relay terminal [5] to the main monitor to turn on the preheating pilot lamp.

WD600-3

STRUCTURE AND FUNCTION

ELECTRIC TRANSMISSION CONTROL

ELECTRIC TRANSMISSION CONTROL

1. 2. 3. 4. 5.

Transmission cut-off selector switch Parking brake switch Directional lever Speed lever Work equipment control leveer 5a. Kick-down switch 5b. Hold switch 6. Maintenance monitor 7. Relays

8. Fuse boxes 9. Transmission controller (with auto shift transmission) 10. Transmission control valve 11. Speed sensor 12. Transmission cut-off switch 13. Brake valve (left) 14. Brake valve (right)

Function 1

Selection of F, R, and N positions

Using directional lever

2

Selection of speed range

3

Kick-down switch

Using speed lever When traveling in F2, it is possible to shift down to 1st using this switch without using the speed lever. If directional lever is operated to R or N, speed range automatically returned to 2nd.

4

Transmission cut-off function

5

Transmission cut-off selector function

6

Neutralizer

7

Neutral safety function

8

Warning function

WD600-3

Transmission is shifted to neutral when left brake is operated It is possible to select whether to actuate or not actuate the transmission cut-off function. To prevent seizure of the parking brake when traveling with the parking brake applied, the transmission is shifted to neutral when the parking brake is applied. If the directional lever is not at the N position, the engine will not start when the starting switch is turned. This prevents the machine from starting suddenly. (For details, see STARTING CIRCUIT.) When traveling in reverse, the backup lamp lights up and the backup horn sounds to warn people in the area.

10-147

STRUCTURE AND FUNCTION

ELECTRIC TRANSMISSION CONTROL

COMBINATION SWITCH

2

7

8

1

3

9

10

4

5

6

SDW00301

OUTLINE • The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is secured to the

body by three screws. When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric current to flow to that circuit only.

General locations, function 1

Directional lever switch

Switches between F, R, and N

2

Speed lever switch

Selects speed range

3

Speed lever stopper

Stopper used to prevent speed lever from entering 3rd or 4th during operations

4

Turn signal indicators

Direction indicator lamps used when turning left or right

5

Self cancel

Turn signal indicator lever automatically returns to central position after machines turns left or right

6

Lamp switch

Switches on clearance lamp, head lamp, parking lamp, etc.

7

Dimmer switch

Selects high beam for travel and low beam for passing

8

Hazard switch

Makes both left and right turn signal indicator lamps flash at the same time

9

Emergency flashing pilot lamp

Flashes at the same time as the emergency flashing lamp flashes

Parking brake switch

Applies or releases parking brake

10

10-148

WD600-3

STRUCTURE AND FUNCTION

OPERATION • Directional lever (1) and shaft (2) of the speed lever of the combination switch form one unit with magnet (3), and magnet (3) also moves together with lever (1). • Control switch (5) with built-in hole IC (4) is installed at the bottom of magnet (3), and hole IC (4) is positioned on the board to match each position. • When directional lever (1) is operated to the F position, magnet (3) is immediately above hole IC (4) for the F position of the control switch. The magnetism from magnet (3) passes through the gap and case (6), and magnetism is applied to hole IC (4). • When this happens, hole IC (4) is inside a magnetism detection circuit, so it detects the magnetism of magnet (3) and sends the F position signal to the electric current amplification circuit. In the electric current amplification circuit, a signal is output to actuate the transmission.

WD600-3

ELECTRIC TRANSMISSION CONTROL

F

N R

2

1

3 4

6

5 SEW00302

10-149

STRUCTURE AND FUNCTION

KICK-DOWN, HOLD SWITCH

KICK-DOWN, HOLD SWITCH

1. 2. 3. 4. 5.

Work equipment control lever Hold switch Kick-down switch Tilt or pitch switch Switch

KICK-DOWN SWITCH

HOLD SWITCH

OPERATION • The kick-down (shifting down from 2nd → 1st) is actuated only when traveling in F2. • When traveling in F2, if it is desired to shift down to 1st without operating the speed lever, operate the kick-down switch on the boom lever to ON to shift down to F1. • After this, even if the kick-down switch is pressed, the transmission is kept at F1.

With auto shift transmission • The hold switch is installed to the work equipment control lever, and when the hold switch is pressed, the speed range displayed on the main monitor transmission indicator is held. • Press the hold switch again to cancel.

CANCELLATION (or not actuated) • When directional lever is at N • When directional lever is at R • When speed lever is not at 2nd • When starting switch is OFF

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WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION AND JOYSTICK STEERING SYSTEM

TRANSMISSION AND JOYSTICK STEERING SYSTEM Outline of system Automatic shift Hold function Kickdown function Safety function Manual shift Kickdown function Engine selecting function (Komatsu/Cummins) Joystick steering control Self-diagnosis function Indication of condition (Output, failure code) Troubleshooting (System trouble, wire breakage in system, detection of short circuit) Communicating function

•

The Automatic shift transmission system consists of a transmission controller, directional/ gear shift lever, engine revolution sensor, travel speed sensor, and solenoid valve for all gear speeds.

•

The transmission controller shifts the transmission to a proper gear speed according to the gear shift lever and travel speed signals.

•

The safety function prevents the vehicle from moving when the engine is started and the transmission protecting function protects the clutch when the directional lever is operated, thus the durability of the vehicle is improved.

WD600-3

•

The self-diagnosis function constantly monitors the input and output conditions and indicates the output condition on the two “7-segment LED” of the transmission controller. The fault detecting function detects a fault and indicates it by an failure code. Then, the main monitor indicates the “failure code” and flashes the caution lamp according to the seriousness of the fault to ensure safety.

•

The transmission controller has a communicating function. It sends the gear speed (N, 1st – 4th) data to the main monitor, then the main monitor indicates the received gear speed. In the joystick mode, the main monitor indicates the travel directions “F”, “N” and “R”, too.

10-151

STRUCTURE AND FUNCTION

TRANSMISSION AND JOYSTICK STEERING SYSTEM

System configuration D

Lock-up switch Lock-up solenoid valve

D

D

Directional switch

F. solenoid valve

D

D

Range switch

R. solenoid valve

D

D

Transmission cut-off switch

1st. solenoid valve

D

D

Kickdown switch (ª1)

2nd. solenoid valve

D

P

Engine speed

3rd. solenoid valve

D

P

Travel speed

4th. solenoid valve

D

D

Neutralizer relay signal

Kickdown signal

D

D

Hold switch (ª2)

D

Manual switch

D

Engine selection

D

Automatic shift transmission signal

D

Transmission controller

Model selection signal

Indication

Failure code

S-Net

Indication

Shift indicator

S-Net

Indication

Trouble indicating buzzer output

S-Net

Indication

Indication

Joystick steering signal Indication

Main monitor F, N, R

S-Net

Hold pilot lamp

S-Net

Engine speed

D

Manual indicator lamp

(ª3) S-Net

D

Joystick steering ON-OFF

Backup lamp relay

D

Joystick lever F.N.R switch

Steering LEFT proportional solenoid valve A

A

Steering lever angle potentiometer

Steering RIGHT proportional solenoid valve A

D

Steering neutral detection switch

Steering solenoid valve cutting relay D

D

Shift-up switch (ª2)

Caution relay (Steering)

D

D

Shift-down switch (ª1)

Engine speed

P

Neutral safety output

D

Indication

A : Analog signal D : Digital signal P : Pulse signal

Steering N LED

D

Steering F LED

D

Steering R LED

D

Lock-up pilot lamp

S-Net

Engine speed control signal

S-Net

:Signal for joystick steering ª1 :Kickdown switch : [Shift-down switch] ª2 :Hold switch : [Shift-up switch] ª3 :Output of the manual indicator lamp is judged by the main monitor.

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WD600-3

STRUCTURE AND FUNCTION

Outline 1. Automatic shift function Shift-up and shift-down operations of the transmission are controlled with the signals from the directional lever, gear shift lever, and travel speed sensor according to the “Automatic shift change points table” (Table 1) stored in the memory of the transmission controller when the engine speed is 1,450rpm or higher. 1) Gear shift lever (1st – 4th) The gear shift lever limits the highest gear speed (gear shifting range) for Automatic shift operation. Examples: Gear shift lever at 4th: 2nd – 4th speed Gear shift lever at 2nd: Fixed to 2nd speed Gear shift lever at 1st: Fixed to 1st speed 2) Directional lever at “N” position If the directional lever is at the neutral position, only the gear speed clutch of the transmission is operated. 3) Directional lever at “F” position If the directional lever is shifted from N position to F position, the F solenoid valve and 2nd speed solenoid valve are turned “ON” (F2). Automatic start at 2nd speed. a) Shifting up When gear shift lever is at “4th”. If the accelerator pedal is pressed and the engine speed rises and the travel speed reaches about 9.3km/h, the 3rd speed solenoid valve is turned “ON” and the 2nd speed solenoid valve is turned “OFF”. The gear is shifted to F3. If the travel speed reaches about 17.6km/h, the 4th speed solenoid valve is turned “ON” and the 3rd speed solenoid valve is turned “OFF”. The gear is shifted to F4. b) Shifting down When the gear shift lever is at “4th”. While the vehicle is traveling at the 4th speed, if the accelerator pedal is released and the travel speed drops to about 15.6km/h, the 3rd speed solenoid valve is turned “ON” and the 4th speed solenoid valve is turned “OFF”. The gear is shifted to F3. If the accelerator pedal is released and the travel speed lowers to about 9.8km/h, the 2nd speed solenoid valve is turned “ON” and the 3rd speed solenoid valve is turned “OFF”. The gear is shifted to F2. WD600-3

TRANSMISSION AND JOYSTICK STEERING SYSTEM

4) Directional lever at “R” position The gear is shifted automatically in a range from 2nd to 4th speed according to the travel speed, just like to the operation at the “F” position. 5) Skip shift While the vehicle is coasting at speed below 8km/h with the transmission at the 3rd or 4th speed, if the accelerator pedal is pressed, the gear is shifted to the 2nd speed position immediately so that the vehicle can be accelerated easily. If the travel speed is 8km/h or higher, the gear speed is not changed. After the engine speed rises to 1,450rpm, the transmission is set to a gear speed matched to the travel speed. 6) Gear-shift inhibition time Once the transmission is set to a gear speed, it is kept at that gear speed for a certain time to prevent shift hunting. The time during which the gear cannot be shifted depends on the gear shifting pattern. See Table 1 “Automatic shift change points table”. 2. Hold function If the hold switch is pressed, the current gear speed is held as the optimum gear speed, and it is not shifted down even if the travel speed lowers. When the travel direction is changed, however, the gear is usually shifted down to the 2nd position according to the current travel speed, then shifted up again to the held position according to the gear shifting condition. This function prevents unnecessary shift-down operation while traveling on a finished ground or down a slope. 3. Kickdown function When the operator turns “ON” the kickdown switch, if the conditions (gear speed, travel speed) in Table 1 “Automatic shift change points table - 5. Kickdown” are satisfied, the gear is shifted to the 1st position forcedly, regardless of setting of the Automatic shift function. This function is reset and the gear is shifted to the 2nd position when the travel speed rises or the travel direction is changed. This function is effective even if the gear speed is fixed while the hold function is turned on or the vehicle is in the engine revolution OFF mode.

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4. Travel modes 1) Manual mode The Automatic shift mode or manual shift mode can be selected. In the manual mode, the gear is shifted according to the operation of the gear shift lever. While the vehicle is traveling in the F 2nd speed in this mode, the kickdown function is available. 2) Joystick control function a) If the joystick function is installed to the vehicle, the operator can select the steering wheel mode or joystick steering mode freely. b) When changing the steering wheel mode and joystick steering mode to each other, be sure to stop the vehicle and set the gear shift lever to the N (Neutral position). At this time, the neutral interlock is applied to the transmission controller to prevent the vehicle from moving abruptly. fl For details, see “List of travel modes and functions of transmission controller”. 5. Safety function 1) Neutral safety When the engine is started, if the directional lever is not at the N position, the transmission controller holds the transmission to the neutral position and does not start the vehicle. This condition is reset when the first N signal is input after the engine is started. 2) Neutral interlock . When the steering wheel mode is changed to the joystick steering mode, the transmission is always set to the neutral position. . When the joystick steering mode is changed to the steering wheel mode, the vehicle cannot be started until the first N signal is input.

TRANSMISSION AND JOYSTICK STEERING SYSTEM

4) Transmission protect While the vehicle is traveling in 3rd or 4th speed, if the directional lever is operated, the gear speed is controlled and the alarm buzzer is turned on to protect the transmission. a) Gear speed control When the engine speed and travel speed are in “Range I”, the gear is shifted down to the 2nd position. When the engine speed and travel speed are in “Range II”, the gear is not shifted immediately, but shifted down to the 2nd position as the travel speed lowers. See “Fig. 1 F-R change and gear-shift pattern” and “Table 1 Automatic shift change points table - 7. Changeover of F and R to each other”. b) Warning with alarm buzzer When the engine speed and travel speed are in “Range III”, the alarm buzzer sounds for warning (when the engine speed is above 1,600rpm and travel speed is above 13km/h or when the travel speed is above 14km/h). 5) Transmission protection in joystick manual mode Since change of the travel direction and shift-down of the gear are facilitated, the gear is shifted up from 1st or 2nd position to 3rd or 4th position in the joystick manual mode, depending on the travel speed and engine speed, to protect the transmission. At this time, the alarm buzzer sounds. 6) Manual shift If the travel speed cannot be detected because of a travel speed sensor, the vehicle is set to the manual shift mode.

3) Gear shift lever priority The gear can be shifted down with the gear shift lever at any time so that the engine brake can be utilized while traveling down a slope.

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6. Torque converter lock-up control function 1) The lock-up operation is performed automatically by turning ON and OFF the torque converter lock-up switch. Even if the manual gearshift mode is selected, the lock-up is turned ON and OFF automatically, if the torque converter lock-up switch is turned ON. The gear speeds of the lock-up specification are as follows. Gear speed of lock-up specification (Lock-up: Travel mode

F1

F2

F3

ª

ª

F4

R1

)

R2

R3

ª

ª

R4

Manual shift Automatic shift

ª

When the gearshift lever is in the 4th position and the actual gear speed is 2nd or 3rd in the automatic shift mode, the torque converter is not locked up. When the gearshift lever is in the 3rd position and the actual gear speed is 3rd, the torque converter is locked.

2) Lock-up gear speed For the gear speed at which the lock-up is turned on and off, see “Automatic shift points list”. Even if the manual gearshift is selected, the lock-up is turned ON and OFF at the same travel speed as in the automatic shift mode. The lock-up is reset automatically for safety if the travel speed exceeds 41.5 km/h. If the travel speed lowers below 41.5 km/h again, the lock-up is turned ON again. 3) Lock-up protection function The lock-up is turned ON only when the travel direction of the machine is the same as the lever position. Judgment of travel direction of machine a. When the travel speed is equal to or higher than 6 km/h, the current travel direction of the machine is determined by the lever position. b. If the travel speed is kept equal to or higher than 6 km/h, the travel direction judged by “a” above is applied. c. If the travel speed is kept below 6 km/h for 1 second continuously, the travel direction judged by “a” above is cancelled and it is assumed that there are no data. d. If there are no data of F and R travel directions or when the travel direction is not the same as the lever position, the lock-up function is not turned ON. 4) Lock-up indicator function The lock-up indicator lights up when the lock-up solenoid output is turned ON. If the lock-up solenoid is abnormal, the lock-up indicator flashes to notify the operator that the lock-up solenoid is abnormal.

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7. Engine overrun prevention function If the operator shifts down the gear while traveling downhill at high speed and pressing the accelerator pedal, the engine may overrun because of the drive force of the tires. To prevent the overrun in this case, the transmission controller limits the shift-down operation according to the engine speed and transmission output shaft speed (= travel speed). 1) The protection application condition: If the gear is shifted down while the protection application condition [A or (B and C)] is satisfied, the shift-down signal is not output but the alarm is turned ON. 2) Protection reset condition: If the protection reset condition [D and (E or F)] is satisfied, the alarm is turned OFF and the shift-down signal is output. Application condition [A or (B and C)] Gear speed shifted down To 3rd gear speed

Condition A Transmission output shaft speed None

Reset condition [D and (E or F)]

Condition B Condition C Transmission output shaft Engine speed speed 2,100 rpm or higher

2,100 rpm or higher

Condition D Transmission output shaft speed None

Condition E Condition F Transmission output shaft Engine speed speed Below 1,900 rpm

Below 1,900 rpm

To 2nd gear speed

2,100 rpm or 1,500 rpm or higher higher

2,100 rpm or Below 1,900 higher rpm

Below 1,300 rpm

Below 1,900 rpm

To 1st gear speed

1,500 rpm or 1,000 rpm or higher higher

2,100 rpm or Below 1,300 higher rpm

Below 800 rpm

Below 1,900 rpm

3) Protect alarm reset condition: The protect alarm output is turned OFF and the normal control is started again in the following cases. a. When the input command and output command become the same after operation of the gearshift lever (gearshift switch) b. When the gear speed of the output command or a higher one is selected by operation of the gearshift lever (gearshift switch) 4) Control in shift-down protection control mode: The holding and kickdown operations are ineffective while the shift-down protection control is turned ON. Transmission output shaft speed and travel speed (Reference) Transmission output shaft speed (rpm) Converted travel speed (km/h) 2,100 34.6 1,900 31.3 1,500 24.7 1,300 – 21.4 1,000 16.5 800 13.2 8. Engine speed control function Signals to control the engine speed are output to the throttle controller through the network to stabilize the engine speed when the travel direction is changed, if necessary. Table 1 Automatic shift change points table Item 1. Basic shift change

Gear speed

Travel speed (km/ h)

Gear-shift inhibition time (sec)

1→2

5.6 (5.8) or higher

2

2→Lock-up at 2

8.0 or higher

0

9.3 (9.8) or higher

2

2→3 3→Lock-up at 3 3→4 4→Lock-up at 4

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Forward : 14.2 or higher Reverse : 15.7 or higher

17.6 or higher Forward : 24.9 or higher Reverse : 27.6 or higher

0 1 0

4→3

Below 15.6

1

3→2

Below 9.8 (9.3)

2

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STRUCTURE AND FUNCTION

Item

TRANSMISSION AND JOYSTICK STEERING SYSTEM

Gear speed

Travel speed (km/ h)

Gear-shift inhibition time (sec)

Lock-up at 4→4

Forward : Below 7.1 Reverse : Below 7.9 Forward : Below 12.6 Reverse : Below 14.0 Forward : Below 22.2 Reverse : Below 24.5

4→2

Below 1.0

0

3→2

Below 1.0

0

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

4→2

Below 8.0

2

3→2

Below 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

Below 12.7

5

4→1

Below 12.7

5

2. Engine speed (Below 1,450rpm)

Lock-up at 2→2 Lock-up at 3→3

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

0 0 0

Note 1)

3→2

2

1→2 7. Changeover of F and R to each other (Range II in Fig. 1) (F→)N→R

Note 2) →4

17.6 or higher

→3

Below 9.3 – 17.6

→4

17.6 or higher

F→N→F

→3

Below 9.3 – 17.6

R→N→R

→2

Below 9.3

(R→)N→F 8. Changeover of F and R to each other

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.

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9. List of travel modes and functions of transmission controller Steering wheel

←

Auto mode

Available functions: Automatic shift, kickdown switch, hold, transmission protect Set the highest using gear speed according to the position of the transmission shift lever.

Position of transmission shift lever F N R

F

Solenoid valve output Gear speed before R setting to N

Transmission protect function for changing over F and R to each other is installed. Solenoid valve output Position of transmission 1 2 3 4 shift lever 1 2 3 4

(*)

(*) Initial output value of gear speed solenoid valve When transmission shift lever is at “1”: 1st gear When transmission shift lever is not at “1”: 2nd gear

Range where kickdown switch is available (Shift-down to 1st gear)

Conditions to reset kickdown function (Kickdown function is available in both F and R) (1) Directional lever: F → N, R → N, or F ↔ R (2) Rise of travel speed: As per Automatic shift change points table (3) Power source: OFF Conditions to reset hold function (1) Hold switch: ON (GND) Press switch again. (2) Manual switch: ON (GND) When set to manual mode. (3) Power source: OFF Joystick steering

←

Auto mode

Available functions: Automatic shift, kickdown switch, hold, transmission protect Set the highest using gear speed according to the position of the transmission shift lever.

Position of transmission shift lever F N R

F

Solenoid valve output Gear speed before R setting to N (*)

(*) Initial output value of gear speed solenoid valve When transmission shift lever is at “1”: 1st gear When transmission shift lever is not at “1”: 2nd gear

Transmission protect function for changing over F and R to each other is installed. Solenoid valve output Position of transmission 1 2 3 4 shift lever 1 2 3 4 Range where kickdown switch is available (Shift-down to 1st gear)

Conditions to reset kickdown function (Kickdown function is available in both F and R) (1) Joystick knob switch: F → N, R → N, or F ↔ R (2) Rise of travel speed: As per Automatic shift change points table (3) Power source: OFF Conditions to reset hold function (1) Hold switch: ON (GND) Press switch again. (2) Manual switch: ON (GND) When set to manual mode. (3) Power source: OFF

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→

Manual mode

Available functions: Manual shift, kickdown switch

Position of transmission shift lever

F

F N R

Solenoid valve output Gear speed before R setting to N

Position of transmission shift lever

Solenoid valve output 1

3

4

1 2 3 4

(*)

(*) Initial output value of gear speed solenoid valve Same gear speed as transmission shift lever

Range where kickdown switch is available (Only in F position)

Conditions to reset kickdown function (Kickdown function is available only in F2) (1) Directional lever: F → N, F → R (2) Gear shift lever: * Shift to position other than 2nd gear. (3) Power source: OFF * When shifted to the first gear: 1st gear (Kickdown function is reset)

→

2

In the steering wheel manual mode, change the gear speed with the transmission shift lever.

Manual mode

Available functions: Shift-up/down function, transmission protect Set the highest using gear speed according to the position of the transmission shift lever.

Position of joystick knob switch F N R

F

Solenoid valve output Gear speed before R setting to N (*)

(*) Initial output value of gear speed solenoid valve When transmission shift lever is at “1”: 1st gear When transmission shift lever is not at “1”: 2nd gear

Position of transmission shift lever

Solenoid valve output 1

1 2 3 4

2 ––––––– ––––––– –––––––

3

––––––– –––––––

4

–––––––

In the joystick manual mode, change the gear speed by one position with the shift-up/down switch.

(Note) When the gear shift lever is at “2” or higher position, if F and R are changed over to each other at 1st speed, the gear is shifted to 2nd speed.

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10. Change of travel mode of transmission controller 1) Specifications for change over “steering wheel and joystick” modes to each other and over “auto and manual” modes to each other a) Neutral interlock function When the mode is changed, the neutral condition is held until the “N” signal is received normally. b) Gear speed The output of the gear speed changes according to change of the mode. Table 2 Output gear speed at change of mode Condition after change of mode Steering wheel Auto

Condition before change of mode

Auto

Joystick

Manual

Auto

Position of range lever (*2 (1))

2nd speed (*1) (Changed at N)

Manual

Steering wheel Manual

2nd speed (*2(2))

Gear speed is held. (Changed at N)

Auto

2nd speed (*1) (Changed at N)

Previous gear speed is held. (*2 (2))

Joystick Manual

Position of range lever (Changed at N)

2nd speed (*2 (3))

(*1)Usually, the steering wheel mode and joystick mode are change over to each other while the vehicle is stopped and the transmission is at the neutral, the gear is shifted to 2nd speed. If the vehicle is traveling, the “restart data” of the Automatic shift function is used and the gear speed matched to the current travel speed is set. If the gear shift lever is at “1”, 1st speed is set. (*2)Auto and manual can be changed to each other in the same mode, even while the vehicle is traveling. (1) Steering wheel mode: When auto is changed to manual, the gear speed of the position of the gear shift lever is set. (2) Joystick mode: When auto is changed to manual, the gear speed is not changed. (3) When manual is changed to auto, the gear speed matched to the current travel speed is set according to the data of “Table 1 Automatic shift change points table - 8. Changeover of F and R to each other”. If the gear shift lever is at “1”, however, 1st speed is set.

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TRANSMISSION AND JOYSTICK STEERING SYSTEM

11. Self-diagnosis function The transmission controller constantly monitors the input and output signals of the Automatic shift transmission system and makes self-diagnosis and indicates the result with the LED on itself. It also transmits the following data to the main monitor. 1) Ordinary indication: The transmission controller indicates the output gear speed with the LED on itself. 2) Indication of failure code: If the transmission controller detects any fault, it indicates the fault by the code. For the failure codes, see Table 3 Failure codes table. Table 3. Failure codes table • Transmission control 1) Auto/Manual transmission control system Main monitor

System Item

Code 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Lock-up solenoid valve None F solenoid valve R solenoid valve 1st speed solenoid valve 2nd speed solenoid valve 3rd speed solenoid valve 4th speed solenoid valve None Joystick directional switch Directional switch signal Gear shift switch signal Travel speed sensor Engine revolution sensor

Short circuit

Disconnection

—

—

—

—

× ×

Failure code

Remarks

No codes — CALL CALL CALL CALL CALL CALL — E00 CALL No codes E00 E00

—

—

2) Joystick control system Main monitor Code

Item

56 57 58 59 60 61 62

Joystick caution relay output Steering R (Right) solenoid valve (Detected when output) Steering L (Left) solenoid valve (Detected when output) Steering R (Right) solenoid valve shorted on HOT side Steering L (Left) solenoid valve shorted on HOT side Steering solenoid valve cut relay output Joystick neutral switch trouble (For detecting range, see separate sheet.) Joystick potentiometer trouble (Out of range from 0.5 to 4.5V)

63

Short circuit

Disconnection

× × ×

Failure code

Remarks

No codes E00 E00 E00 E00 E00 E00 E00

fl E59 and E60 cannot be distinguished from each other, and they can be output simultaneously. fl Since E56 is an output normally turned ON, disconnection cannot be detected.

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12. Communicating function The transmission controller constantly communicates with the main monitor by using communicating function based on the “Snet”. If any fault occurs, the transmission controller indicates the failure code on the main monitor to notify the operator according to the seriousness of the fault to secure the safety. The failure codes stored in the main monitor can be checked in the fault condition mode. For the operating method of the main monitor, see the section of the main monitor. 13. Power source for transmission controller While the starting key is at the “ON” position and the source voltage is 20V or higher and +20V or higher voltage is applied to the transmission controller solenoid valve, each solenoid valve can be controlled. If the source voltage lowers below 19V, all output is turned “OFF” and each solenoid valve cannot be controlled (the vehicle cannot travel). 14. Input signals 1) Directional lever (F, N, R) signal This signal is a digital signal of +24V/ OPEN. Normally, one of F, N, and R signals (+24V) is input.

TRANSMISSION AND JOYSTICK STEERING SYSTEM

5) Neutralizer relay signal This signal is a digital signal of +24V/ OPEN. If the parking brake is released, +24V is input and the vehicle can travel. If the signal is OPEN, the transmission controller holds the neutral state. 24V: Parking brake is released. OPEN: Parking brake is applied. 6) Transmission cut-off signal This signal is a digital signal of GND/ OPEN, which is kept OPEN while the transmission cut-off switch is operated (while the left brake is used). If the transmission cut-off switch is operated, the transmission controller is set to the neutral state. If the former is reset, the latter sets a gear speed matched to the current travel speed. 7) Manual mode signal This signal is a digital signal of GND/ OPEN. When the manual mode switch is turned ON, GND is input. 8) Lock-up switch signal This signal is a digital signal of GND/ OPEN. When the lock-up switch is turned ON, GND is input.

2) Gear shift lever (1st – 4th) signal This signal is a digital signal of +24V/ OPEN. A +24V signal of the position of the lever is input. 3) Kickdown switch/Shift-down switch This signal is a digital signal of +24V/ OPEN. If the kickdown switch installed to the work equipment control lever is pressed, +24V is input. Operation of the switch is judged by the rise signal from OPEN to +24V at this time. In the joystick manual mode, the kickdown switch is used as the shift-down switch. 4) Hold switch/Shift-up switch This signal is a digital signal of +24V/ OPEN. If the hold switch installed to the work equipment control lever is pressed, +24V is input. Operation of the switch is judged by the rise signal from OPEN to +24V at this time. In the joystick manual mode, the hold switch is used as the shiftup switch.

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15. Function selecting signal This signal is a digital signal of GND/OPEN. When the engine is started, each function is judged with this signal. 1) Selection of model Table 4. Model selecting signals table Model

CN3B-2

CN3B-10

CN3B-3

WD600-3

OPEN

OPEN

GND

Komatsu

Cummins

OPEN

GND

2) Selection of engine used Table 5. Engine selection table Selected engine Signal and data Engine select (CN3A-10)

3) Selection of optional function Table 6. Option (Function) selection table Input signal name

State of signal

Automatic shift transmission (CN3A-20)

OPEN

GND

OPEN

GND

Joystick steering (CN3B-1)

OPEN

OPEN

GND

GND

Objective model

WD600-3

Function Transmission auto/manual Transmission and No setting (*1) auto/manual No setting (*1) joystick auto/ manual

(*1) If the state of no setting is detected, all outputs of the controller are turned OFF and the vehicle cannot travel. fl The LED indicates the part No. of the program, then indicates “0. 0.”.

16. Engine revolution sensor signal This signal is a pulse signal. It is made by converting the number pulses from the electromagnetic pickup sensor into the number of revolution for control. The condition that the engine speed is 1,450rpm or higher is called the engine revolution ON mode, and the condition that the engine speed is below 1,450rpm is called the engine revolution OFF mode. 17. Travel speed sensor signal This signal is a pulse signal. It is made by converting the number pulses from the electromagnetic pickup sensor into the number of revolution. 18. Communication signal (S-net) The code of each detected fault is sent to the main monitor.

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19. Output signals 1) Transmission solenoid valve signal Table 7. Combination of gear speeds and solenoid valves : ON Solenoid valve F

R 1st 2nd 3rd 4th

Gear speed F1 F2 F3 F4 N R1 R2 R3 R4

2) Backup lamp relay This signal is an S-NET output. When the forward-reverse lever is in the R position, a signal is output to the throttle controller. 3) Engine revolution signal (Open collector) A signal having the same period as the engine revolution sensor signal, which is input to the transmission controller, is output. 4) Communication signal (Data indicated on main monitor) For the indicating position and operation of the main monitor, see the section of the main monitor. a) Indication of gear speed 1st speed output: “1” 2nd speed output: “2” 3rd speed output: “3” 4th speed output: “4” Neutral: “N” b) Indication of F and R In the joystick steering mode, F and R are indicated. c) Indication of hold When the hold function is turned ON, is pilot lamp is indicated on the main monitor. 5) Lock-up solenoid signal When the lock-up is turned ON, a +24 V ON/OFF signal is output.

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20. Indication with LED When the engine is started, the LED is set in 1. “Program part No. indication mode”, then in 2. “Output gear speed indication mode”. If any trouble is detected, however, the LED is set in the “Troubleshooting indication mode” immediately. 1) Program part No. indication mode When the power is turned on, the following are changed at the interval of one second. –°–° 7°8° 2°3° 1°6° A°1° 0°2° → To Indication mode 2 |→|→|→|→|→|→| 2) Output gear speed indication mode Indication with LED: X° Y.. (Both dots are turned off.) X: Condition of direction solenoid valve Forward “F”: ‘F’, Reverse “R”: ‘A’, Neutral: ‘0’ Y: Condition of gear speed solenoid valve 1–4 → <Example> Indication

Contents

‘0° 2°’

Neutral, 2nd speed

‘F° 1°’

Forward, 1st speed

‘A° 2°’

Reverse, 2nd speed

‘F° F°’

Neutral safety state

If any error is detected, indication mode 3 is turned on.

– – 7 8 ° ° ° ° |→|→| N Gear shifting (F2 speed is indicated continuously.)

3) Troubleshooting indication mode (Currently detected error) “E (2 seconds)” and “Code (2 seconds)” are repeated as one routine. a) When one error is detected <Example> E°–° 2 ° 3 ° → Repeated |→|→| b) When two errors are detected <Example> E°–° 2°3° E°–° 1 ° 8 ° → Repeated |→|→|→|→|

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21. Combination of joystick steering and transmission controller function : Function is installed. Boom lever switch

Steering wheel Auto

Joystick

Manual

Auto

Kickdown function

Manual —

—

Hold function Up/Down function

—

—

—

CN C5-5 input signal

Kickdown

Kickdown

Kickdown

Shift-down

CN C5-13 input signal

Hold

—

Hold

Shift-up

22. Controller input signals • Signal common to kickdown/shift-down switches (CN C5-5 terminal) • Signal common to hold/shift-up switches (CN C5-13 terminal) The above signals are judged by changing with the joystick select signal and manual signal. 23. Up/Down shift switch function • Shift-up switch: If signal is input, normal shift-up signal is output. • Shift-down switch: If signal is input, normal shift-down signal is output. • Input of the switch is judged by change of ON/OFF of the signal. (The signal is turned ON when the switch is pressed.) The latest signal is taken in constantly to judge shift-up and shift-down. • The highest using gear speed is with the transmission lever. Position of range lever

Using gear speed

4

4–1

3

3–1

2

2, 1

1

1

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4. Indicating position of main monitor

5. Indicating position of F, N, and R on console

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CONTROLLER

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WD600-3

STRUCTURE AND FUNCTION

TRANSMISSION AND JOYSTICK STEERING SYSTEM

Connector signals CN1 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13

CN3A Signal name

Steering solenoid valve cut relay Transmission F solenoid valve Transmission 1st gear speed solenoid valve Engine revolution output Transmission 3rd speed solenoid valve GND Power source (+24V) Lock-up solenoid valve Transmission R solenoid valve Transmission 2nd speed solenoid valve Transmission 4th speed solenoid valve GND Power source (+24V)

Input/ Output Output Output Output Output Output Input Input Output Output Output Output Input Input

CN2 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Signal name Solenoid valve power source (+24V) Steering (Right) solenoid valve (+) Steering (Left) solenoid valve (+) F LED (Steering) R LED (Steering) NC N LED (Steering) Neutral safety output (+) Caution relay (Steering) (+) Caution relay (Monitor) (+) PGND Solenoid valve power source (+24V) Steering (Right) solenoid valve (–) Steering (Left) solenoid valve (–) NC NC NC NC Caution relay (Steering) (–) NC PNGD

Input/ Output Input Output Output Output Output — Output Output Output Output Input Input Output Output — — — — Output — Input

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

CN4

Input/ Output NC — NC — Steering lever potentiometer Input NC — NC — Pressure sensor power source (+24V) Output Potentiometer power source (+5V) Output — NC — NC Input Engine selection — NC — NC — NC — NC Signal name

NC Pressure sensor GND Potentiometer GND NC Neutralizer relay Automatic shift transmission

— Output Output — Input Input

CN3B Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Input/ Output Joystick steering Input Model selection 1 Input Model selection (EVEN relay) Input S-NET + Input Direction F Input Direction R Input Gear shift switch 1 Input Gear shift switch 3 Input NC — Model selection 2 Input NC — S-NET + Input Direction N Input Joystick steering ON/OFF switch Input Gear shift switch 2 Input Gear shift switch 4 Input Signal name

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12

Signal name NC Engine revolution sensor (+) RS232C TXD RS232C RXD NC NC NC Flush write switch Engine revolution sensor (-) RS232C GND NC NC

Input/ Output — Input Input Input — — — Input Output Input — —

CN5 Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Signal name Pulse GND Speed sensor (+) GND GND Kickdown/Shift-down switch Transmission cut-off switch Joystick N (NC) Joystick F (NC) Joystick R (NC) Pulse GND Steering lever N switch Lock-up switch Hold/Shift-up switch Neutral switch Joystick N (NO) Joystick F (NO) Joystick R (NO)

Input/ Output Output Input Output Output Input Input Input Input Input Output Input Input Input Input Input Input Input

Joystick selection Pin

OFF

CN3B-1 OPEN GND: Connected to CN2-9

ON GND

Model selection Model WD600-3 Pin CN3B-2 OPEN CN3B-10 OPEN CN3B-3 GND GND: Connected to CN2-9

WD600-3

Automatic shift transmission selection

Model selection

OFF Pin CN3A-20 OPEN GND: Connected to CN2-9

Engine KOMATSU CUMMINS Pin CN3A-10 OPEN GND GND: Connected to CN2-9

ON GND

10-169

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

THROTTLE CONTROL SYSTEM OUTLINE OF SYSTEM Throttle lock function Engine speed setting function Resuming function Acceleration function Deceleration function Lock-up indicator output function Backup buzzer relay output function Engine speed control function

•

The throttle control system consists of the throttle controller, throttle lock switches (ON/ OFF switch, Set/Accelerate switch, and Resume/Decelerate switch), brake pedal operation sensor switch, throttle lock indicator lamp, accelerator pedal, etc.

•

The throttle controller is installed between the accelerator pedal (acceleration potentiometer and low idling switch) and engine controller and used to control the engine speed with the throttle lock function, etc.

10-170

WD600-3

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

SYSTEM CONFIGURATION

D Throttle lock ON/OFF switch

Accelerator pedal signal

A

Low idling switch relay

D

Throttle lock indicator lamp

D

Lock-up indicator lamp

D

Backup buzzer relay

D

D Throttle lock Set/Accelerate switch

D Brake pedal operation sensor switch D Accelerator pedal low idling switch A Accelerator pedal signal

S-Net

Lock-up ON signal

S-Net

Backup buzzer output signal

S-Net

Engine speed control signal

Throttle controller

D Throttle lock Resume/Decelerate switch

A: Analog signal D: Digital signal

WD600-3

10-171

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

OUTLINE 1. Throttle lock function • If the throttle lock ON/OFF switch is set in the ON position and the accelerator pedal is pressed to increase the engine speed to a desired level and the throttle lock Set/Accelerate switch is pressed, the engine speed is set. • If the accelerator pedal is pressed further after the engine speed reaches the set level, the engine speed is increased according to the pressing distance of the accelerator pedal. (The signal of the higher engine speed is taken first.) • If the right or left brake pedal is pressed, the throttle lock function is reset temporarily and the engine speed changes according to the pressing distance of the accelerator pedal. • If the brake pedal is pressed to reset the throttle lock function temporarily and then the throttle lock Resume/Decelerate switch is pressed, the engine speed returns to the set level. • The set engine speed is cleared under either of the following conditions. (1) Set the throttle lock ON/OFF switch in the OFF position. (2) Set the starting switch in the OFF position. • If the throttle lock Set/Accelerate switch or throttle lock Resume/Decelerate switch is pressed and held, they start working as an accelerator switch and a decelerator switch. Then, the operator can increase or decrease the set engine speed finely with these switches. • While the throttle lock is controlled, the output of the low idling switch relay is kept turned ON. Brake pedal operation sensor switch Switch configuraAlternate seesaw Momentary tion switch proximity switch Switch logic ON (GND) Brake operated OFF (OPEN) (GND) Brake not operated (OPEN) When switch is ON, Engine speed Resuming function: If brake pedal is throttle function is setting function: While throttle lock pressed, throttle effective. Accelerator pedal function is reset by lock function is input voltage when operating right reset temporarily. switch is ON is brake pedal, if this saved and engine switch is pressed, speed is controlled throttle lock with fall of signal. function is resumed. Throttle lock function is Function controlled with fall of signal. Acceleration Deceleration function: If this function: If this switch is kept switch is kept pressed, set engine pressed, set engine speed is increased speed is decreased at rate. at rate. Behavior of Cannot lock Cannot set throttle Cannot resume. Cannot reset machine in throttle. lock. Cannot decelerate. throttle lock by abnormal state operating brake pedal. Detection of Impossible Impossible Impossible Impossible abnormality Behavior of Cannot reset Increases engine Decreases engine Cannot lock machine in throttle lock. speed with speed with throttle. deceleration abnormal state acceleration function. function. Detection of Impossible Continuous Continuous Impossible abnormality operation (ON state) operation (ON state) for 30 seconds or for 30 seconds or more is judged more is judged abnormal. (*) abnormal. (*) Recovery from — Detection of OFF Detection of OFF — (OPEN) (OPEN) abnormality Short circuit

Disconnection

Throttle lock ON/ OFF switch

Throttle lock Resume/Decelerate switch Momentary seesaw switch ON (GND) OFF (OPEN)

Throttle lock Set/ Accelerate switch

Throttle lock indicator lamp Lamp ON (24-V output)

While throttle lock ON/OFF switch is in ON position, output is turned ON.

If any switch is abnormal and throttle lock ON/ OFF switch is in ON position, lamp flashes. Does not light up.

Impossible Keeps lighting up.

Impossible

—

(*) Remedy taken when abnormality is detected: Flashes throttle lock indicator lamp (ON for 0.8 seconds and OFF for 0.8 seconds). Stops throttle control even when throttle lock is ON.

10-172

WD600-3

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

2. Lock-up indicator output function Upon receiving the lock-up ON signal from the transmission controller, the throttle control system lights up the lock-up indicator lamp. 3. Backup buzzer relay output function Upon receiving the backup buzzer ON signal from the transmission controller, the throttle control system outputs it to the backup buzzer relay. 4. Engine speed control function Upon receiving the engine speed control signal from the transmission controller, the throttle control system changes the accelerator pedal signal and output it to the engine controller.

WD600-3

10-173

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

THROTTLE CONTROLLER

10-174

WD600-3

STRUCTURE AND FUNCTION

THROTTLE CONTROL SYSTEM

Connector signals CN1 (CN C6) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Signal name NC NC NC Signal GND NC NC NC NC Accelerator pedal signal Signal GND NC NC NC NC NC NC NC NC NC NC Analog GND Potentiometer power source (+5 V) NC NC

WD600-3

CN2 (CN C7) Input/ Output — — — — — — — — Input — — — — — — — — — — — — Output — —

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Signal name NC NC NC 232C_RXD NC NC NC NC NC NC Accelerator pedal signal NC NC NC NC NC NC NC NC NC

21 S-NET (+) 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

NC NC NC NC NC NC NC Pulse GND NC S-NET (GND) NC NC NC NC NC NC NC NC NC

CN3 (CN C8) Input/ Output — — — Input — — — — — — Output — — — — — — — — — Input/ Output — — — — — — — — — — — — — — — — — — —

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Signal name Controller PWR Solenoid PWR Solenoid common GND NC NC NC Backup buzzer relay Throttle lock indicator lamp Low idling switch (Li) Throttle lock ON/OFF switch Controller PWR Solenoid PWR Solenoid common GND Starting switch BR NC NC Low idling switch relay Lock-up indicator lamp Throttle lock Set/Accelerate switch Low idling switch (Acc) Controller GND Solenoid PWR Solenoid common GND Starting switch BR NC NC NC NC NC Throttle lock Resume/Decelerate switch Controller GND Controller GND Controller GND NC NC NC NC NC NC Brake pedal operation sensor switch

Input/ Output Input Input Input — — — Output Output Input Input Input Input Input Input — — Output Output Input Input Input Input Input Input — — — — — Input Input Input Input — — — — — — Input

10-175

20 TESTING AND ADJUSTING

Standard value table Standard value table for engine .................................. Standard value table for chassis ................................. Standard value table for electrical parts ..................... Testing and adjusting ........................................................ Troubleshooting ................................................................

20- 2 20- 3 20- 9 20-101 20-201

fl Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. 2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. 3. These standard values are not the standards used in dealing with claims.

¤

When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving.

¤

When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.

¤

When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.

¤

Be careful not to get caught in the fan, fan belt or other rotating parts.

WD600-3

20-1 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Category

Item

Machine model

WD600-3

Engine

SAA6D170E-3

Measurement conditions

Standard value for new machine

Service limit value

700 ± 25

700 ± 25

2,190

2,190

2,000

—

˚C

650

700

kPa {mmHg}

Min. 113 {850}

100 {750}

Max. 5.0

7.0

Max. 2.0

3.0

0.32

—

0.62

—

Unit

Low idling Engine speed

High idling

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)

(Water temperature: Green range) kPa {mmH2O} At high idling

Max. 3.9 {400}

7.9 {800}

mm Exhaust valve

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

0.21 {2.1}

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

0.18 {1.8}

Oil pressure MPa {kg/cm2}

Min. 0.12 {1.2}

Max. 0.07 {0.7}

At low idling (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

20-2 (1)

At low idling (SAE30)

WD600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS Machine model

Speed control lever

Directional lever

Category

Item Operating effort

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

Travel

N – FORWARD, REVERSE

Travel

+0.5 N {kg} 5.88 +4.9 – 2.94 {0.6 – 0.3 }

Operating effort

16.7 {1.7}

16.7 {1.7}

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

16.7 {1.7}

3rd – 4th

5.88 +4.9 {0.6 +0.5 } – 2.94 – 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}

Max. 14.7 {1.5}

22.6 {2.3}

Max. 23.5 {2.4}

35.3 {3.6}

Max. 23.5 {2.4}

35.3 {3.6}

• Engine speed: Low idling • Hydraulic oil temperature: HOLD→LOWER 45 – 55°C

67 ±␣ 15

67 ±␣ 30

53 ±␣ 15

53 ±␣ 30

HOLD→FLOAT

67 ±␣ 15

67 ±␣ 30

60 ±␣ 15

60 ±␣ 30

60 ±␣ 15

60 ±␣ 30

mm

Max. 40

50 –␣ 100

2nd – 3rd

• Engine stopped • Measure at center of lever knob

N {kg}

mm

2nd – 3rd

RAISE→HOLD

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

LOWER→FLOAT N {kg} FLOAT→HOLD HOLD→ RIGHT TILT (REAR PITCH) Pitch & tilt HOLD→ LEFT TILT (FORWARD PITCH) HOLD→RAISE

Travel

Lift

HOLD→ RIGHT TILT (REAR PITCH)

mm

Pitch & tilt HOLD→ LEFT TILT (FORWARD PITCH)

Steering wheel

Service limit value

+0.5 5.88 +4.9 – 2.94 {0.6 – 0.3 }

mm

3rd – 4th

Lift

Standard value for new machine

35 ±␣ 10

1st – 2nd Operating effort

Unit

35 ±␣ 10

HOLD→RAISE

Work equipment control lever

Measurement conditions

WD600-3

Play

• Engine stopped • Machine facing straight to front

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 idling • Left lock - right lock

Turns

3.9 ±␣ 0.4

4.5

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

Max. 5.8

6.5

sec. Max. 4.1

5.0

Operating time

WD600-3

Low idling High idling

20-3 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Item

Measurement conditions

Operating angle

STD model

Accelerator pedal

• Engine speed: Low idling 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

—

15 +10

—

5 ±␣ 0.5

—

Max. 2.5

—

Max. 4.0

—

2 – 15

—

1,750 ± 100

1,750 ± 200

2,140 ± 100

2,140 ± 200

1,510 ± 100

1,510 ± 300

deg. Max. (α 2)

• If high idling 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

WD600-3

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

Neutral (α 1) deg. Max. (α 2)

mm

Play

A

• Tire inflation pressure: Specified pressure

Tire

Fitting of wheel lock ring B

Clearance of wheel lock ring

Engine speed

Torque converter stall

20-4 (1)

Hydraulic stall

Torque converter stall + hydraulic stall

mm

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

rpm

WD600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Standard value for new machine

Service limit value

0.96 – 1.16 {9.8 – 11.8}

0.96 – 1.16 {9.8 – 11.8}

3.19 – 3.48 {32.5 – 35.5}

3.19 – 3.48 {32.5 – 35.5}

3.38 – 3.68 {34.5 – 37.5}

3.38 – 3.68 {34.5 – 37.5}

1.77 – 1.96 {18 – 20}

1.77 – 1.96 {18 – 20}

1.86 – 2.06 {19 – 21}

1.86 – 2.06 {19 – 21}

Torque converter inlet pressure

0.69 – 0.88 {7 – 9}

0.69 – 0.88 {7 – 9}

Lubrication pressure

0.20 – 0.39 {2 – 4}

0.20 – 0.39 {2 – 4}

Torque converter outlet pressure

0.34 – 0.42 {3.5 – 4.3}

0.34 – 0.42 {3.5 – 4.3}

1.77 – 1.96 {18.0 – 20.0}

1.77 – 1.96 {18.0 – 20.0}

+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

6.5 ± 0.3

6.5 ± 0.3

2nd

11.4 ± 0.6

11.4 ± 0.6

3rd

20.0 ± 1.0

20.0 ± 1.0

34.3 ± 1.6

34.3 ± 1.6

1st

7.2 ± 0.4

7.2 ± 0.4

2nd

12.6 ± 0.7

12.6 ± 0.7

3rd

22.1 ± 1.1

22.1 ± 1.1

4th

37.7 ± 1.7

37.7 ± 1.7

Item Pilot reducing pressure

Transmission, torque converter

WD600-3

Medulating pressure (except F2, R2)

Measurement conditions

Unit

• Torque converter oil temperature: 60 – 80°C • Coolant temAt low idling perature: Inside oprating range At high idling At low idling

Reducing valve oil pressure (for F2, R2)

At high idling

MPa {kg/cm2}

Accumulator

Steering

Lock-up pressure

Steering relief pressure

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

MPa {kg/cm2}

Orbit-roll output pressure

Charge cut-in pressure

Charge cut-out pressure

• Engine speed: Low idling • 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 Travel speed

km/h

REVERSE

WD600-3

20-5 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model

Wheel brake

Category

Item

Measurement conditions

WD600-3 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 }

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 idling

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 mm Total of each end

PPC valve source pressure (Orbit-roll source pressure)

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

PPC valve output pressure

• Hydraulic oil temperature: MPa 45 – 55°C {kg/cm2} • Engine speed: High idling • Work equipment control lever: Operated fully

PPC

Clearance

20-6 (1)

WD600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model Category

Item Work equipment relief pressure

Measurement conditions • Hydraulic oil temperature: 45 – 55°C • Engine speed: High idling

WD600-3 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 }

2.0 ± 0.3

3.0

1.3 ±␣ 0.3

2.0

2.1 ±␣ 0.3

3.0

1.6 ±␣ 0.3

2.0

1.1 ± 0.3

3.0

0.8 ± 0.3

2.0

• Hydraulic oil temperature: 45 – 55°C • Engine speed: High idling • No load Blade RAISE

sec.

Work equipment speed

Work equipment

Blade LOWER

Blade FORWARD PITCH

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

sec.

Blade REAR PITCH

Blade RIGHT TILT

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

sec.

Blade LEFT TILT

WD600-3

20-7 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Machine model

Work equipment

Category

Item

Unit

Standard value for new machine

Service limit value

mm

Max. 100

100

• Hydraulic oil temperature: 45 – 55°C • Leave for 5 minutes after stopping engine then measure for next 15 minutes • Blade empty, blade raise fully. Hydraulic drift

20-8 (1)

Measurement conditions

WD600-3

WD600-3

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Solenoid (1st)

Solenoid (2nd)

Solenoid (3rd)

Solenoid (4th)

Solenoid (F)

WD600-3

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 (1) – (3) Turn parking brake 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.

20-9 (1)

TESTING AND ADJUSTING

Speed

20-10 (1)

Measure resistance Measure resistance Measure voltage

T05 (male)

—

C3B

Measure resistance

—

Adjust

Min. 1 MΩ

C4

Speed control lever (2nd)

Speed control lever (4th)

Between (C), (A) – chassis

Measure in AC range

E06 (male)

Speed control lever (1st)

Speed control lever (3rd)

50 – 70 Ω

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

Adjust

Speed

Controller

Transmission & Joystick steering control

Engine speed

Between (C) – (A)

Between (1) – (2) Between (1), (2) – chassis

Between (2) – (9)

500 – 1000 Ω Min. 1 MΩ

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

—

Measure voltage

Engine speed

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. 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

Controller

Engine speed sensor

T01 (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 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

Solenoid (R)

Connector Inspection No. method

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

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.

WD600-3

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

TESTING AND ADJUSTING

Connector Inspection No. method

Joystick L.H. solenoid

Joystick neutral (N) switch

L27 (male)

L26 (male)

JS5 (male)

Measure voltage

Joystick R.H. solenoid

Measure voltage

System cut-off switch

JS3 (male) JS4 (female)

Measure voltage

Transmission & Joystick steering control

Directional lever (N)

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 Between 20 – 30 V at N (13) – Directional lever chassis Max. 1 V not at N

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

Measure resistance

C3B

If the condition is as shown in the table below, it is normal. Directional lever Between 20 – 30 V at R (6) – Directional lever chassis Max. 1 V not at R

If the condition is as shown in the table below, it is normal. System cut-off Between Max. 1 Ω switch ON JS3(1) – System cut-off JS4(1) Min. 1 MΩ switch OFF

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

Measure resistance

Directional lever (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.

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

Measure resistance

Controller

Directional lever (F)

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

Between (1) – (2)

10 – 20 Ω

Between (1), (2) – chassis

Min. 1 MΩ

Between (1) – (2)

10 – 20 Ω

Between (1), (2) – chassis

Min. 1 MΩ

If the condition is as shown in the table below, it is normal. Between (1) – (3) of joystick N switch Not at N

WD600-3

Measure resistance

JS2 (male)

Max. 1 Ω

At N Between (1) – chassis

Joystick potentiometer

Measurement conditions

Judgement table If the condition is as shown in the table below, it is normal. Directional lever Between 20 – 30 V at F (5) – Directional lever chassis Max. 1 V not at F

Measure resistance

Name of component

System

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

Min. 1 MΩ

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

0 – 2 kΩ ± 20%

Between (2) – (3)

2 kΩ ± 20%

Between (3) – (1)

0 – 2 kΩ ± 20%

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

20-11 (1)

TESTING AND ADJUSTING

Name of component

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector Inspection No. method

Measurement conditions

Judgement table

Joystick lever neutral (N) switch

C5

Measure voltage

If the condition is as shown in the table below, it is normal. Continue pushing N switch

Not to push N switch

Between (7) – (3)

20 – 30 V

Between (15) – (3)

Max. 1 V

Between (7) – (3)

Max. 1 V

Between (15) – (3)

20 – 30 V

Between (8) – (3)

20 – 30 V

Between (16) – (3)

Max. 1 V

Between (8) – (3)

Max. 1 V

Between (16) – (3)

20 – 30 V

Joystick lever R switch

C5

Measure voltage

If the condition is as shown in the table below, it is normal. Continue pushing R switch

L15 (male)

Measure voltage

C3B

Measure resistance

Kick-down switch & shiftdown switch

C3A

Measure voltage

Not to push R switch

System network (S-NET) (Between T/M controller and main monitor)

(1)

Continue pushing F switch

Not to push F switch

Neutralizer relay

20-12

C5

Controller

Transmission & Joystick steering control

Joystick lever F switch

Measure voltage

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

Between (9) – (3)

20 – 30 V

Between (17) – (3)

Max. 1 V

Between (9) – (3)

Max. 1 V

Between (17) – (3)

20 – 30 V

1) Turn starting switch OFF. 2) Set joystick column to joystick position. 3) Turn joystick ON/OFF switch ON. 4) Insert Tadapter. 5) Turn starting switch ON. 1) Turn starting switch OFF. 2) Set joystick column to joystick position. 3) Turn joystick ON/OFF switch ON. 4) Insert Tadapter. 5) Turn starting switch ON. 1) Turn starting switch OFF. 2) Set joystick column to joystick position. 3) Turn joystick ON/OFF switch ON. 4) Insert Tadapter. 5) Turn starting switch ON.

If the condition is as shown in the table below, it is normal. Parking brake is 20 – 30 V released Between Parking brake is (19) – (17) Max. 1 V applied

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

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

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

Between (4), (12) – chassis

4–8V

If the condition is as shown in the table below, it is normal. Kick-down switch Max. 1 Ω at ON Between (1) – (2) Kick-down switch Min. 1 MΩ at OFF

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

WD600-3

TESTING AND ADJUSTING

Solenoid (Lock-up)

Lock-up ON/OFF switch

WD600-3

C5

T06 (male)

C10 (male)

Measure resistance Measure resistance

L12 (male)

Measure voltage

Manual switch

L15 (male)

Measure resistance

Transmission cut-off switch

Controller

Transmission & Joystick steering control

Shift-up switch

Connector Inspection No. method

Measure resistance

Name of component

System

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Measurement conditions

Judgement table If the condition is as shown in the table below, it is normal. Shift-up switch Max. 1 Ω at ON Between Shift-up switch (3) – (4) Min. 1 MΩ at OFF

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

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

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

Normal condition L.H. brake pedal is depressed

Between (1) – (2)

Max. 1 Ω Min. 1 MΩ

If the condition is as shown in the table below, it is normal. Manual switch Between Max. 1 V at ON (14) – Manual switch chassis 20 – 30 V at OFF

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.

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

Between (1) – (2)

50 – 70 Ω

Between (1), (2) – chassis

Min. 1 MΩ

If the condition is as shown in the table below, it is normal. Lock-up ON/OFF Max. 1 Ω switch ON Between (3) – (4) Lock-up ON/OFF Min. 1 MΩ switch OFF

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

20-13 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Preheating ON signal

Starting switch terminal BR

L05

L05

L07

Measure voltage Measure voltage Measure voltage

Starting switch terminal C

L05

Measure voltage

Main monitor

Directional switch (N)

L05

Measure voltage

Battery charge (alternator)

L05

Measure voltage

Power supply

Measure voltage

SysConnector Inpsection Name of component tem No. 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)

20-14 (1)

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 Starting switch OFF (10) – (12) Max. 1 V

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.

WD600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

SysConnector Inpsection Name of component tem No. method

Measurement conditions

Judgement table

Power supply

L18

Measure voltage

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

20 – 30 V

Battery charge (alternator)

L18

Measure voltage

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) – (3), (14) Max. 1 V Starting switch ON

Float raised to stopper

Measure resistance

Maintenance monitor

R07 (male)

Float lowered to stopper

Approx. 4 Ω

WD600-3

R17

Measure resistance Measure voltage

Engine oil pressure switch

G01 (male)

Water level normal Between Max. 1 Ω (1) – (2) Min. 1 MΩ Water level low

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} (Starting switch ON)

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

Approx. 85 Ω

If the condition is as shown in the table below, it is normal Radiator water level switch

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.

Between 20 – 30 V sensor – Chassis Max. 1V

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.

20-15 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

SysConnector Inpsection Name of component tem No. method

Measurement conditions

Judgement table

Engine oil lever switch

Dust indicator

20-16 (1)

E07 (male)

E10

E13 (male) E14 (male)

Measure resistance Measure resistance

Torque converter oil temperature sensor

E04 (male)

Measure resistance

Maintenance monitor

Engine water 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 2 {45 ± 5 kg/cm }

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 or engine stopped

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.

WD600-3

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

Measurement conditions Engine stopped, starting switch ON Engine stopped, starting switch ON Engine running Engine running

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

Engine running

Display

Sensor signal

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

Table 2 Display level according to sensor resistance

Maintenance monitor

Gauge display (Starting switch ON)

E Red

Flash-  ing ←→  67



WD600-3

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 Red →  Flashing Max. White 9.29 – ON ←→  (kΩ)  (1 place) (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 water 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.

20-17 (1)

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Throttle control system

S-NET

Throttle lock ON/OFF switch

Throttle lock set/ resume switch

C7

C11 (male)

C12 (male)

Measure voltage Measure voltage

C8

Measure voltage

Power supply

HEAT

Measure resistance

Pre-heat power

Measure resistance

Pre-heat system

SysConnector Inpsection Name of component tem No. method

Measurement conditions

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

20 – 30 V

ª When water temperature is maintained at lower than 0ºC for more than 30 seconds. If the condition is as shown in the table below, it is normal. Between (1) – (31) Between (2) – (31)

20 – 30 V

20-18 (1)

Measure voltage

C6

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

Between (14) – (31)

If the condition is as shown in the table below, it is normal Between (21) –␣ (31)

4.8 V

If the condition is as shown in the table below, it is normal. Throttle lock ON/ Max. 1 Ω OFF switch ON Between Throttle lock ON/ (3) – (4) Min. 1 MΩ OFF switch OFF

If the condition is as shown in the table below, it is normal. Set switch ON Set switch OFF Resume switch ON Resume switch OFF

Between Max. 1 Ω (1) – (2) Min. 1 MΩ Between (2) – (3)

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

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

Max. 1 Ω Min. 1 MΩ

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

Accelerator pedal signal

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

Between (21) – (22)

4.75 – 5.25 V

Between (9) – (21)

0.5 – 4.75 V

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

Between (9) – (21) 0.5 – 1.6 V (at low idling) Between (9) – (21) (Low-idling voltage (at high idling) + 3V – 4.75V)

WD600-3

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

—

Judgement table

Measurement conditions

Above table shows standard voltage of accelerator potentiometer at which throttle controller can recognize accelerator potentiometer. When readjusting potentiometer, set its voltage in range from 1.3 V to 1.6 V at low idling to secure margin of error judgment range.

—

Low-idling switch signal

Right brake pedal signal

C8

C8

Measure voltage

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

Measure voltage

Throttle control system

Accelerator pedal signal

Adjust

SysConnector Inpsection Name of component tem No. method

Between (9) – chassis (at low idling) Between (9) – chassis (not at low idling) Between (20) – chassis (at low idling) Between (20) – chassis (not at low idling)

Max, 1 V

17 – 30 V

Max. 1 V

If the condition is as shown in the table below, it is normal. Between (40) – chassis (Depress right brake pedal) Max, 1 V Between (40) – chassis (Release right brake pedal) 17 – 30 V

Parking brake solenoid (Emergency brake solenoid)

WD600-3

F14 (male)

Measure resistance

Others

C01 (male) C02 (male)

Measure resistance

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

Emergency brake switch

Accumlator pressure: Min. 3.92 ± 0.49 MPa Between Max. 1 Ω {40 ± 5 kg/cm2} C01 (1) – C01 (2) Depress brake pedal & and lower accumlator C02 (1) – pressure to below C02 (2) Min. 1 MΩ 3.63 ± 0.49 MPa {37 ± 5 kg/cm2}

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

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

19 – 23 Ω Min. 1 MΩ

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

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

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

20-19 (1)

TESTING AND ADJUSTING Table of tools for testing, adjusting, and troubleshooting ................................................................... 20-102 Measuring engine speed ........................................................................................................................ 20-104 Measuring exhaust gas color ................................................................................................................. 20-106 Adjusting valve clearance ....................................................................................................................... 20-107 Testing and adjusting injector lift ........................................................................................................... 20-108 Measuring compression pressure ......................................................................................................... 20-110 Measuring blow-by pressure ................................................................................................................. 20-112 Measuring engine oil pressure .............................................................................................................. 20-113 Replacing fan belt adjusting auto-tensioner ......................................................................................... 20-114 Testing and adjusting alternator belt tension ....................................................................................... 20-115 Testing and adjusting belt tension for air conditioner compressor .................................................... 20-116 Handling equipment in fuel circuit ........................................................................................................ 20-117 Measuring fuel pump outlet port pressure ........................................................................................... 20-117 Bleeding air from fuel circuit .................................................................................................................. 20-118 Measuring exhaust temperature (Overall engine) ............................................................................... 20-120 Measuring exhaust gas temperature (Each cylinder) .......................................................................... 20-121 Measuring air supply pressure (Boost pressure) ................................................................................. 20-122 Adjusting speed sensor .......................................................................................................................... 20-123 Measuring oil pressure of torque converter and transmission ........................................................... 20-124 Method for operation of emergency manual spool ............................................................................. 20-127 Testing and adjusting steering oil pressure .......................................................................................... 20-129 Testing and adjusting steering stop valve ............................................................................................. 20-131 Testing brake oil pressure ....................................................................................................................... 20-132 Measuring wear of brake disc ................................................................................................................ 20-133 Measuring brake performance ............................................................................................................... 20-134 Testing and adjusting parking brake ...................................................................................................... 20-135 Testing and adjusting accumulator charge cut-in and cut-out pressure ............................................ 20-137 Testing and adjusting PPC oil pressure ................................................................................................. 20-138 Testing and adjusting work equipment hydraulic pressure ................................................................ 20-140 Adjusting work equipment lever linkage .............................................................................................. 20-141 Adjusting main monitor (Speedometer module) ................................................................................. 20-143 Bleeding air .............................................................................................................................................. 20-144 Releasing remaining pressure in hydraulic circuit ............................................................................... 20-145

WD600-3

20-101 (1)

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING Test, measurement item Symbol

Part Name

• 799-203-8240

Nut

7/8 –␣ 18 NS

1

799-101-1502

2

—

Digital temperature gauge Heat gun (surface temperature gauge)

2

Pressure gauge:

790-261-1203

Digital hydraulic tester

Pressure gauge: 68.6 MPa {700 kg/cm2}

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

1

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

799-201-9000

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

D

F

G

H

I

79A-264-0090

Kit part No. : 799-101-5002

0 – 490.3N {0 – 50 kg} Scale

M N

79A-264-0211

K

Work equipment speed

L

(1)

Discoloration 0 – 70 % (with standard color) • (Discoloration x 1/10 = • Bosch index) –101.3 to + 199.9 kPa {–760 to + 1,500 mmHg}

0 – 294.2N {0 – 30 kg}

Commercially available Commercially available Commercially available

Stroke, hydraulic drift

20-102

0 – 98 kPa {0 – 1,000 mmH2O}

Push-pull scale

J 2

Measuring brake disc wear Measuring voltage, resistance value

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

E

Air supply pressure (boost pressure)

Brake oil pressure

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

Analog hydraulic tester

3

Blow-by pressure

–99.9 to + 1,299°C

799-101-5002

790-261-1311

Compression pressure

L : 60 – 2,000 rpm

H : 60 – 19,999 prm Kit part No. : 799-203-9000

B

C

Digital display

Multi-tachometer

1 Oil pressure

Remarks

799-203-8001 A

Engine speed

Water, oil, exhaust temperatures

Part No.

Stopwatch

—

Caliper gauge

—

Tester

—

WD600-3

TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

TESTING AND ADJUSTING

Test, measurement item Symbol

Troubleshooting of wiring harness, sensors

Part No.

1

799-601-7400

2

799-601-3460

3

799-601-7360

4

799-601-7370

5

795-799-5460

6

795-799-5470

7

795-799-5480

8

795-799-5520

9

795-799-5530

10

795-799-5540

Part Name

Remarks —

T-adapter assembly MS 10P Adapter

Relay 5P Relay 6P

Q Cable

For engine

WD600-3

Addapter

20-103 (1)

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

MEASURING ENGINE SPEED ¤ ¤

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 idling and high idling) 1) Stick the reflective tape of multi-tachometer A to a rotating part like a fan and set the tachometer. 2) Start the engine and measure the engine speed at high idling and low idling.

2.

Measuring torque converter stall speed 1) Stick the reflective tape of multi-tachometer A to a rotating part like a fan and set the tachometer. 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 idling, 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 (1)

WD600-3

TESTING AND ADJUSTING

3.

Measuring hydraulic stall speed 1) Stick the reflective tape of multi-tachometer A to a rotating part like a fan and set the tachometer. 2) Start the engine and run at high idling. 3) Retract the lift cylinder or tilt and pitch cylinder and measure the engine speed when the circuit is relieved.

4.

Measuring torque converter stall + hydraulic stall (full stall) speed 1) Stick the reflective tape of multi-tachometer A to a rotating part like a fan and set the tachometer. 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 idling and stall the torque converter, and at the same time, retract the lift cylinder or tilt and pitch cylinder and measure the engine speed when the circuit is relieved.

WD600-3

MEASURING ENGINE SPEED

20-105 (1)

TESTING AND ADJUSTING

MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR •

When measuring in the field when there is no air or power supply, use smoker checker G1; when recording official data, use smoke meter G2. fl Raise the coolant temperature to the green range before measuring.

¤

When removing or installing the measuring equipment, be careful not to touch any high temperature part.

1.

Measuring with handy smoke checker G1 1) Fit filter paper in tool G1. 2) Insert the exhaust gas intake port into the exhaust pipe, accelerate the engine suddenly, and at the same time operate the handle of tool G1 to catch the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale provided to judge the condition.

2.

Measuring with smoke meter G2 1) Insert probe of tool G2 into the outlet port of exhaust pipe, then tighten the clip to secure it to the exhaust pipe. 2) Connect the probe hose, accelerator switch plug, and air hose to tool G2. fl The pressure of the air supply should be less than 1.5 MPa {15 kg/cm2}. 3) Connect the power cord to the AC outlet. fl When connecting the port, check first that the power switch of tool G2 is OFF. 4) Loosen the cap nut of the suction pump, then fit the filter paper. fl Fit the filter paper securely so that the exhaust gas does not leak. 5) Turn the power switch of tool G2 ON. 6) Accelerate the engine suddenly, and at the same time, depress the accelerator pedal of tool G2 and catch the exhaust gas color on the filter paper. 7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (10 sheets or more) inside the filter paper holder, and read the indicated value.

20-106 (1)

WD600-3

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE 1. Remove the cover of the flywheel housing, then install barring device F1.

5. Tighten locknut (4) to hold adjustment screw (3) in position. 3 Locknut : 57.8 – 77.4 Nm {5.9 – 7.9 kgm} After tightening the locknut, check the clearance again.

2. Remove the cylinder head cover. 3. Using barring device F1, rotate the crankshaft in the normal direction to set No. 1 cylinder at compression top dead center, and align pointer b with the [1.6TOP] line a on the crankshaft pulley. fl At compression top dead center, the valve rocker arm can be moved by hand by the amount of the valve clearance. If the rocker arm does not move, the crankshaft is not at compression dead center, so rotate it one more turn.

6. Turn the crankshaft 120º each time in the normal direction and repeat the procedure in Steps 3 to 5 to adjust the valves of each cylinder according to the firing order. fl Firing order : 1 – 5 – 3 – 6 – 2 – 4 7. After completing the measurement, set to the original condition. 3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1 ± 0.1 kgm}

5. To adjust the valve clearance, insert feeler gauge F2 into clearance c between rocker arm (1) and crosshead (2), and adjust the valve clearance with adjustment screw (3). fl Insert the feeler gauge and turn the adjustment screw until the clearance is a sliding fit. fl Valve clearance Intake valve: 0.32 mm Exhaust valve: 0.62 mm

WD600-3

20-107 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING INJECTOR LIFT

TESTING AND ADJUSTING INJECTOR LIFT

fl Max. lift c: 20.00 mm

Inspection 1. Remove the cover of the flywheel housing, then install barring device F1.

2. Remove the cylinder head cover. 3. Using barring device F1, rotate the crankshaft in the normal direction to set No. 1 cylinder at compression top dead center, and align pointer b with the [1.6TOP] line a on the crankshaft pulley. fl Watch the movement of the rocker arm and check that the No. 1 cylinder is at the compression stroke. (If the rocker arms for both the intake and exhaust sides move only the amount of the valve clearance, the cylinder is at the compression stroke.) fl The cylinder where at compression top is different from the cylinder where the injector is being checked, so check the table below when carrying out the operation. fl Cylinder at compression top and cylinder for inspection of injector: Compression top

1

5

3

6

2

4

Injector to inspect

2

4

1

5

3

6

4. Set dial gauge [1] to the head of the plunger of the injector to be inspected. fl Use a dial gauge with a stroke of at least 30 mm. 5. Crank the crankshaft and measure the lift of the plunger at the point where the deviation of the dial gauge is the maximum.

20-108 (1)

Adjusting fl If the lift is not correct, adjust as follows. 1. Use the inspection procedure to set the cylinder at the compression top position so that the injector can be adjusted. fl The cylinder where at compression top is different from the cylinder where the injector is being checked, so check the table below when carrying out the operation. fl Cylinder at compression top and cylinder for inspection of injector: Compression top

1

5

3

6

2

4

Injector to inspect

2

4

1

5

3

6

2. Fully loosen adjustment screw (1) of the injector to be adjusted, then tighten it by hand. fl Check that the socket at the tip of the rocker arm and the ball of the push rod are both fitted securely into the injector and push rod, respectively.

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING INJECTOR LIFT

3. Tighten adjustment screw (1), repeat the loosening operation, then tighten finally. 3 Adjustment screw: 1st time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 2nd time : Loosen fully 3rd time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 4th time : Loosen fully 5th time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm} 4. Hold adjustment screw (1) in position, then tighten locknut (2). 3 Locknut: 205.8 – 245 Nm {21 – 25 kgm} fl After completing the adjustment, carry out the inspection procedure to check the lift again.

5. After completing the inspection and adjustment, set to the original position. 3 Cylinder head mounting bolt : 9.8 ± 1.0 Nm {1 ± 0.1 kgm}

WD600-3

20-109 (1)

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE ¤

When measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get caught in rotating parts. fl Measure the compression pressure with the engine warmed up. (Oil temperature: 40°C – 60ºC) 1. Remove the cylinder head cover. 2. Remove rocker arm assembly (1). 5. Install rocker arm assembly (1), then adjust the valve clearance. 2 Mounting bolt thread, seat: Engine oil (E030CD) 3 Mounting bolt: 235.2 – 254.8 Nm {24 – 26 kgm} fl For details, see ADJUSTING VALVE CLEARANCE.

3. Remove injector push rod (2) and injector (3).

4. Fit adapter [1] of compression gauge D1, then connect to the compression gauge. fl Hold the adapter in position with an injector holder. 3 Mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

20-110 (1)

6. Disconnect 2 large-sized intermediate connectors (4) of the engine. fl This sets so that no fuel is supplied from the fuel pump to the injector.

7. Measure the compression pressure when the engine is cranked with the starting motor. fl Measure the compression pressure when the gauge indicator is stable.

WD600-3

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

8. After completing the measurement, remove the measurement equipment and set to the original condition. fl Check the length under the head of the mounting bolt of the injector holder. If it is more than 80 mm, replace the bolt with a new part. 2 Injector mounting bolt thread, seat: Engine oil (E030CD) 3 Injector mounting bolt: 1st time : 24.5 – 34.3 Nm (2.5 – 3.5 kgm) 2nd time : Tighten 90º – 120º 2 Rocker arm mounting bolt thread, seat: Engine oil (E030CD) 3 Rocker arm assembly mounting bolt: 235.2 – 254.8 Nm {24 – 26 kgm} fl Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. fl Adjust the injector. For details, see TESTING AND ADJUSTING INJECTOR LIFT. 3 Cylinder head cover mounting bolt: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

WD600-3

20-111 (1)

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE fl Raise the coolant temperature to the operating range before measuring. 1. Install blow-by checker E1 to the end of engine breather hose, then connect gauge E2. 2. Run the engine at near rated output, and measure the blow-by pressure.

¤

When measuring, be careful not to touch any hot parts or rotating parts.

Note: fl Blow-by varies greatly according to the condition of the engine. Therefore, if the blowby value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

20-112 (1)

WD600-3

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE fl Measure the engine oil pressure under the following conditions. • Coolant temperature: Within operating range 1. Remove oil pressure measurement plug (1). 2. Fit the nipple of pressure test kit C, then connect to the pressure test kit. 3. Start the engine and measure the oil pressure when the engine is running at low idling and high idling. 4. After completing the measurement, remove the measuring equipment and set to the original condition.

WD600-3

20-113 (1)

TESTING AND ADJUSTING

REPLACING FAN BELT ADJUSTING AUTO-TENSIONER

REPLACING FAN BELT ADJUSTING AUTO-TENSIONER Replacing 1. Loosen locknut (1), then screw adjustment bolt (2) back as far as bracket (3). 2. Insert bar [1] (length: approx. 50 cm) into the oblong hole in tension pulley lever (4), then pull strongly and hold in position. 3. The spring will extend and the tension pulley will move to the inside. Remove the oil belts and replace it with new bolts. Adjusting 1. Tighten adjustment bolt (2) to bring the tip of adjustment bolt (2) into contact with tension pulley lever (4), then tighten a further twoturns and secure in position with locknut (1). 3 Locknut: 245 – 309 Nm {25 – 31.5 kgm} fl If a clearance is formed between the tip of adjustment bolt (2) and tension pulley lever (4) during operations, use the same procedure as above to adjust. fl If the fan belt screeches, adjust in the same way.

20-114 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ALTERNATOR BELT TENSION 1.

Testing • Measure deflection a of the belt when it is pushed with a finger force of approx. 58.8 N {approx. 6 kg} at a point midway between the alternator pulley and the drive pulley. fl Deflection a of V-belt (standard value): 10 – 15 mm

2.

Adjusting 1) Loosen the alternator mount bolt (1). 2) Loosen locknut (2), then turn adjustment nut (3) to adjust the tension of belt. 3) After adjusting the belt tension to the standard value, tighten locknut (2), then tighten alternator mount bolt (1).

WD600-3

20-115 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 1.

Testing • Measure deflection b of the belt when it is pushed with a finger force of approx. 58.8 N {approx. 6 kg} at a point midway between the compressor pulley and the engine drive pulley. fl Deflection b of V-belt (standard value): 10 –␣ 15 mm

2. Adjusting 1) Loosen air compressor mounting bolts (1) and (2), nut (3) and adjusting bolt lock nut (4) and adjusting bolt (5). 2) Adjust the tension of fan belt (7) by shifting the position of compressor (6). 3) After adjusting the fan belt tension to the specified value, tighten adjusting bolt lock nut (4), mounting bolts (1) and (2), and nut (3). 3 Nut (3) tightening torque: 98 – 123 Nm {10.0 – 12.5 kgm}

20-116 (1)

WD600-3

TESTING AND ADJUSTING

HANDLING EQUIPMENT IN FUEL CIRCUIT MEASURING FUEL PUMP OUTLET PORT PRESSURE

HANDLING EQUIPMENT IN FUEL CIRCUIT

MEASURING FUEL PUMP OUTLET PORT PRESSURE

fl Precautions when carrying out inspection and maintenance of fuel system. With the HPI type fuel injection system, more precise equipment is used than on the conventional fuel injection pump and nozzle. Problems may occur if dirt or dust get in, so always be careful of the following points. When carrying out inspection or maintenance of the fuel line, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely. fl Precautions when replacing fuel filter cartridge Always use a genuine Komatsu part for the fuel filter cartridge. With the HPI type fuel injection system, more precise equipment is used than on the conventional fuel injection pump and nozzle. Problems may occur if dirt or dust get in, so a special filter with highly efficient filtering performance is used. For this reason, do not use imitation filters. If they are used, there is danger of problems occurring in the fuel line.

fl Measure the outlet port pressure of the fuel pump with the signal voltage of the fuel pump pressure sensor. 1. Insert a T-adapter into the connector of fuel pump pressure sensor (1), then connect to Tadapter box Q.

2. Start the engine and measure the power source voltage of the fuel pump pressure sensor. fl Check that the power source voltage is within the following range. fl Sensor power source voltage (between (A) and (B)): 4.75 – 5.25 V 3. Run the engine at each speed and measure the signal voltage of the fuel pump pressure sensor. fl Check that the power source voltage is within the following range. fl Sensor power source voltage (between (C) and (B)): Engine speed (rpm)

Signal voltage (V)

600

1.78±0.21

700

1.94±0.21

800

2.10±0.21

900

2.26±0.21

1,000

2.42±0.21

1,100

2.59±0.21

1,200

2.76±0.21

Fuel pump outlet port pressure (reference) (MPa{kg/cm2}) 0.83±0.14 {8.45±1.41} 0.93±0.1 {9.50±1.41} 1.03±0.14 {10.53±1.41} 1.14±0.14 {11.60±1.41} 1.25±0.14 {12.70±1.41} 1.34±0.14 {13.70±1.41} 1.46±0.14 {14.90±1.41}

4. After completing the measurement, remove the measuring equipment and set to the original condition.

WD600-3

20-117 (1)

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT

fl Bleed the air from the fuel circuit as follows if the engine does not start or is difficult to start after the following operations. • When starting the engine for the first time • When the fuel filter has been replaced • When the fuel tank has been cleaned • When fuel has been added after the engine stopped

fl Fill with fuel through the 8 inlet port portions a of the filter. Portion b is the outlet port (clean side) after filtering, so fuel must not be added from here.

1. Open the valves at the supply side and return side of the fuel tank. fl At the same time, check that there is ample fuel in the tank. 2.

Fill the fuel filter with fuel. fl Do this only after the fuel filter has been replaced. fl If the fuel filter has not been replaced, there is danger of dirt or dust getting in, so do not remove the fuel filter.

20-118 (1)

WD600-3

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT

fl There is no problem with starting if a small amount of air gets in, so if fuel flows out, the operation is completed. 3. Crank the engine with the starting motor, push air bleed valve (2) at the discharge side, and bleed the air from the discharge circuit. fl There is no problem with starting if a small amount of air gets in, so if fuel flows out, the operation is completed. 4. Start the engine and run at low idling. fl The injector forms an open circuit, so when the engine is operated, the air remaining in the circuit escapes from the injector to the inside of the cylinder or the fuel tank. fl After starting the engine, there is a small amount of variation in the engine speed until the air is completely removed, so continue to run the engine at low idling until the speed becomes stable.

WD600-3

20-119 (1)

TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE)

MEASURING EXHAUST TEMPERATURE (OVERALL ENGINE) ¤

Wait for the exhaust manifold temperature to go down before removing or installing the measuring equipment. 1. Remove exhaust temperature measurement plug (1). 2. Fit the sensor of digital temperature gauge B, then connect to the digital temperature gauge. 3. Start the engine and measure the exhaust temperature when the engine is running at rated horsepower. fl When measuring with the engine mounted on the machine, measure according to the conditions given in the shop manual for the machine. 4. After completing the measurement, remove the measurement equipment and set to the original condition.

20-120 (1)

WD600-3

TESTING AND ADJUSTING

MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER)

MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER) fl If the engine output has dropped or any other problem has occurred, and there is a possibility that it is caused by defective combustion due to defective injection by the injector, use the following procedure to measure the exhaust gas temperature of each cylinder and determine the cylinder with the defective injection (defective combustion). 1. Stop the engine and wait for it to cool down. fl A guideline for judging if the engine has cooled down is that the temperature of the exhaust manifold is less than 20ºC above the ambient temperature. 2. Start the engine and run at low idling for at least 10 minutes. fl Run for at least 10 minutes to stabilize the exhaust gas temperature. 3. Using heat gun R, measure the temperature at the exhaust manifold outlet port of each cylinder. fl Measure the exhaust gas temperature of each cylinder at the same place at the top of the outlet port of the manifold.

fl Method of judgement After compensating, add up the values for the exhaust gas temperature and calculate the average value. Any cylinder that is more than 20ºC lower than the average value can be considered abnormal. fl Measurement and judgement example 1 Unit:ºC Cylinder

No. 1 No. 2

No. 3 No. 4 No. 5 No. 6

Measured value

85

62

79

112

89

82

Compensated value

105

67

79

112

94

102

Average value

93

No. 2 cylinder is more than 20ºC lower than the average value, so judge it as abnormal. fl Measurement and judgement example 2 Unit:ºC Cylinder

No. 1

No. 2

No. 3

Measured value

86

96

73

91

94

103

Compensated value

106

101

79

91

99

123

Average value

No. 4 No. 5 No. 6

99

No. 3 cylinder is more than 20ºC lower than the average value, so judge it as abnormal. fl Measurement and judgement example 3 Unit:ºC Cylinder

4. Compensate the measured value for each cylinder and judge if there is any cylinder with a problem. fl Compensation value Unit:ºC Cylinder Compensation value

WD600-3

No. 1 No. 2 +20

+5

No. 3 No. 4 0

0

No. 5 No. 6 +5

No. 1 No. 2

No. 3 No. 4 No. 5 No. 6

Measured value

70

88

88

93

86

7ºC

Compensated value

90

93

88

93

91

92

Average value

91

No cylinder is more than 20ºC lower than the average value, so judge all cylinders as normal,

+20

20-121 (1)

TESTING AND ADJUSTING

MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) ¤

Be careful not to touch any hot or rotating parts when measuring or when removing or installing the measuring tools.

1. Open the engine side cover (top right), remove air supply pressure measurement plug (1) (PT 1/ 8), and install the coupler (contained in oil pressure kit C1). 2. Connect the oil pressure measurement hose to the coupler and pressure gauge H (–101.3 to + 199.9 kPa {–760 to + 1,500 mmHg}). Note: Operate the engine at midrange speed or above, and use the self-seal portion of the gauge to bleed the oil inside the hose. • Insert the gauge about half way, repeat the action to open the self-seal portion, and bleed the oil. fl If there is oil inside the hose, the gauge will not work, so always bleed the oil. 3. Carry out the torque converter stall operation at high idling and read the gauge indicator. fl The air supply pressure (boost pressure) should be measured with the engine running at rated ouput. However, when measuring in the field, a similar value can be obtained by operating at torque converter stall.

20-122 (1)

WD600-3

TESTING AND ADJUSTING

ADJUSTING SPEED SENSOR

ADJUSTING SPEED SENSOR 1.

Transmission output shaft speed sensor 1) Screw in until the tip of sensor (1) contacts gear (2). 2) When sensor (1) contacts gear (2), turn back 1/2 – 1 turn. 3) Tighten locknut (3). 3 Locknut: 49 ± 4.9 Nm {5.0 ± 0.5 kgm} fl Be particularly careful when handling the sensor wiring to ensure that no excessive force is brought to bear on the wiring. fl Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to it.

2.

Engine speed sensor

fl If the engine speed sensor or flywheel has been removed or replaced, adjust as follows. 1) Screw in sensor (1) until the tip contacts the tip of the tooth of flywheel ring gear (2). 2 Thread: Loctite gasket (Hydraulic sealant No. 21028) 2) After the sensor contacts the tip of the tooth, turn it back 1/2 – 3/4 turns. fl This makes a clearance of 1.25 mm between the tip of the sensor and the tip of the gear tooth. 3) Hold sensor (1) in position, then tighten locknut (3). 3 Locknut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}

WD600-3

20-123 (1)

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

TESTING AND ADJUSTING

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION fl Measurement conditions • Torque converter oil temperature: 60 – 80˚C

¤

Put blocks securely under the tires.

Preparatory work fl The preparatory work given below is preparatory work needed for all measurements of the oil pressure. • Open cover (1) at the rear of the cab (transmission oil pressure) and cover (3) (torque converter oil pressure). • Turn transmission cut-off selector switch (2) OFF and use the left brake. (Check that the pilot lamp is OFF.) • Remove the plug from the measuring port of the transmission valve. • Install hydraulic tester A to the measuring port, pull the gauge to the operator's compartment, then start the engine and measure the pressure. fl When assembling the oil pressure measurement plug again, coat the plug with sealant. 2 Plug: Sealant (LG-5) fl Check that there is no leakage of oil from any joints.

Unit: MPa {kg/cm2} Item Pilot reducing pressure

Standarad value

Permissible value

9.8 – 11.8

9.8 – 11.8

At low idling: 3.19 – 3.48 {32.5 – 35.5} At high idling 3.38 – 3.68 {34.5 – 37.5}

At low diling: 3.19 – 3.48 {32.5 – 35.5} At high idling 3.38 – 3.68 {34.5 – 37.5}

Torque converter relief pressure

0.69 – 0.88 {7.0 – 9.0}

0.69 – 0.88 {7.0 – 9.0}

Lubrication oil pressure

0.20 – 0.39 {2.0 – 4.0}

0.20 – 0.39 {2.0 – 4.0}

At low idling: 1.77 – 1.96 {18.0 – 20.0} At high idling 1.86 –2.06 {19.0 – 21.0}

At low idling: 1.77 – 1.96 {18.0 – 20.0} At high idling 1.86 –2.06 {19.0 – 21.0}

0.34 – 0.42 {3.5 – 4.3}

0.34 – 0.42 {3.5 – 4.3}

1.77 – 1.96 {18.0 – 20.0}

1.77 – 1.96 {18.0 – 20.0}

Modulating pressure (except F2, R2)

Reducing valve oil pressure (for F2, R2)

Torque converter outlet pressure Lock-up pressure

20-124 (1)

WD600-3

TESTING AND ADJUSTING

1.

Measuring pilot reducing pressure 1) Measuring port (P5). 2) Put the direcetional lever in neutral, and measure the pressure when the speed control lever is operated.

2.

Measuring modulating pressure 1) Measuring port (P1). 2) Put the directional lever in neutral, and measure the pressure when the speed control lever is operated. fl Measure pressure except F2 and R2.

3.

Torque converter relief pressure 1) Measuring port (P8). 2) Start the engine and measure the pressure at high idling.

4.

Measuring lubrication valve pressure 1) Measuring port (P9). 2) Start the engine and measure the pressure at high idling.

5.

Measuring reducing valve pressure 1) Measuring port (P3). 2) Start the engine and measure the pressure at high idling.

6.

Torque converter outlet pressure 1) Measuring port (P2). 2) Start the engine and measure the pressure at high idling and low idling.

WD600-3

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

20-125 (1)

TESTING AND ADJUSTING

7.

MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION

Lock-up valve (L/C) oil pressure 1) Measuring port (P3). 2) Run the engine at full throttle and measure the lock-up oil pressure. Note) Measure the oil pressure while the machine is traveling.

20-126 (1)

WD600-3

TESTING AND ADJUSTING

METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL

METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL fl If the machine cannot be moved because of a failure in any part of the transmission valve system (electrical system, solenoid valves, spools, etc.), it is possible to move the machine by operating the emergency manual spool.

¤

¤ ¤

¤

The emergency manual spool is only for emergency use when there has been a failure and it is necessary to move the machine from a dangerous working area to a safe place for repairs. Do not operate the spool except in emergencies. When carrying out this operation, keep strictly to the procedure and pay careful attention to safety when moving the machine . To prevent the machine from moving, lower the work equipment completely to the ground, apply the parking brake, and put blocks securely under the tires. Carry out the operation with the engine stopped.

1. Remove inspection cover (1) at the rear of the cab. 2. Remove lock plate (2) of the emergency manual spool of the transmission valve. fl Simply loosen the mounting bolts to remove the lock plate. 3. Decide the direction to move the machine (forward or in reverse) then move the emergency manual spool to the operating position. FORWARD: Rotate FORWARD clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the operating position. REVERSE: Rotate REVERSE clutch spool and 1st spool counterclockwise, and pull out approx. 10 mm to the operating position.

WD600-3

20-127 (1)

TESTING AND ADJUSTING

METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL

4. Check that the area around the machine is safe, remove the blocks from under the wheels. 5. Sit in the operator's seet, amd depress the left brake pedal fully. 6. Start the engine, release the parking brake, then release the brake pedal gradually to start the machine.

¤

When the engine is started, the transmission is engaged and the machine will start. Therefore, before starting the engine, always check that the direction of travel is safe, and always keep the brake pedal depressed. If the machine does not start, turn the 2nd spool, 3rd spool, and 4th spool clockwise, and screw in approx. 10 mm to the OFF position.

7. After moving the machine, stop the engine, apply the parking brake, and blocks the wheels. 8. Return the emergency manual spool to the neutral position, and install the lock plate.

20-128 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING STEERING OIL PRESSURE

TESTING AND ADJUSTING STEERING OIL PRESSURE fl Hydraulic oil temperature: 45°C – 55°C MEASURING 1. Measuring steering relief pressure

¤

Loose the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping.

¤

Install the safety bar to the frame. 1) Remove oil pressure measurement plug (PT1/ 8) (1) from the elbow at the right steering cylinder head end, then install oil pressure gauge C1 (39 MPa {400 kg/cm2}). 2) Start the engine, run the engine at high idling, then turn the steering wheel to the right and measure the pressure when the relief valve is actuated. fl When removing the oil pressure measurement plug on the left steering cylinder, turn the steering wheel to the left.

2.

¤

Measuring steering pilot pressure Install the safety bar to the frame. 1) Disconnect pilot hose (2) or (3) from steering valve (1). 2) Install adapter C3 (M18 x 1.5) to the elbow at the valve end, then assemble the hose again. 3) Install oil pressure gauge C1 (5.9 MPa {60 kg/ cm2}) to adapter C3. 4) Start the engine and measure the oil pressure when the steering wheel is turned with the engine running at high idling. fl Hose (2): Turn steering to right Hose (3): Turn steering to left

WD600-3

20-129 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING STEERING OIL PRESSURE

Adjusting

¤

Always stop the engine before adjusting the pressure.

1. Adjusting steering relief valve Loosen locknut (2) of steering relief valve (1), then turn adjustment nut (3) to adjust. fl Turn the adjustment screw to adjust the set pressure as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Pressure adjustment for one turn of adjustment screw: Approx. 14.2 MPa {145 kg/cm2} 3 Lock nut: 29.4 ± 2.0 Nm {3 ± 0.2 kgm}

20-130 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING STEERING STOP VALVE

TESTING AND ADJUSTING STEERING STOP VALVE TESTING 1. Set the front frame and rear frame facing straight. 2. Check that locknut (2) of stopper bolt (1) is not loose. 3. Start the engine, and check that there is a clearance between the front frame stopper and rear frame stopper when the steering is turned to the right or left.

¤

Measure the clearance with the engine stopped. fl Measure the clearance between the front frame and rear frame when steering stop valve contact surface (3) and stopper bolt (1) coming into contact and the turning stops. • Standard clearance a: 30– 02 mm

Adjusting fl If the clearance between the front frame and rear frame is not within the standard value, adjust as follows.

¤

When turning, be extremely careful not to get your arm or any other part of your body caught between the front frame and rear frame.

1. Loosen locknut (2), tighten stopper bolt (1), and make sure that there is no contact with the steering stop valve. 2. Start the engine, run at low idling, then turn the steering wheel slowly to bring the front frame and rear frame into contact. 3. From the condition in Item 2, turn the steering wheel back and align the clearance between the front frame and rear frame to the stand ard value. 4. Stop the engine, loosen stopper bolt (1), put in contact with contact surface (3) of the steering stop valve, then loosen st opper bolt (1) a further 1.5 turns and tighten locknut (2). fl Carry out the procedure in Steps 1 – 4 to adjust both the left and right sides. 5. Start the engine, turn the machine, and check that clearance a between the front frame and rear frame is within the standard value for both the left and right and that the steering stopper valve and stopper bolt come into contact and the steering is stopped.

WD600-3

20-131 (1)

TESTING AND ADJUSTING

TESTING BRAKE OIL PRESSURE

TESTING BRAKE OIL PRESSURE ¤

Put blocks securely under the tires.

1.

Inspecting brake oil pressure 1) Remove bleeder screw (1), then install oil pressure gauge tool I (19.6 MPa {200 kg/cm2}), the elbow, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR. 3) Depress the left brake and measure the brake oil pressure.

2.

Measuring drop in brake piston pressure 1) Remove bleeder screw (1), then install oil pressure gauge tool I (19.6 MPa {200 kg/cm2}), the elbow, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR. 3) Stop the engine, depress the left brake pedal, leave for 5 minutes with the oil pressure at 4.9 MPa {50 kg/cm2}, and measure the drop in pressure. fl Be careful not to move the brake pedal for 5 minutes. fl After completing the operation, bleed the air from the brake circuit again.

20-132 (1)

WD600-3

TESTING AND ADJUSTING

MEASURING WEAR OF BRAKE DISC

MEASURING WEAR OF BRAKE DISC fl Brake oil pressure: 4.9 ± 0.49 MPa {50 ± 5 kg/cm2}

¤

Park the machine on horizontal ground and put blocks securely under the tires.

Measurement method 1. Remove plug (1). 2. Depress the brake pedal fully. 3. Use caliper gauge M to measure depth a from the end face of the housing to the spring guide. fl When measuring, keep the brake pedal depressed. 4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain the brake oil. fl After draining the brake oil, check that the brake piston has returned to the end of its stroke. 5. Measure depth b from the end face of the housing to the spring guide. Calculating piston stroke • S=a–b S : Max. 13.4 (mm)

WD600-3

20-133 (1)

TESTING AND ADJUSTING

MEASURING BRAKE PERFORMANCE

MEASURING BRAKE PERFORMANCE fl • • • •

Measurement conditions Road surface: Flat, horizontal, dry paved surface Travel speed: 20 km/h when brakes are applied Delay in applying brakes: 0.1 sec. Tire inflation pressure: Specified pressure

Measurement method 1. Start the engine and move the machine. 2. Set the speed lever to the highest speed position and drive the machine. 3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force. fl Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point. fl Switch the transmission cut-off switch ON when carrying out this operation. 4. Measure the distance from the point where the brakes were applied to the point where the machine stopped. fl Repeat this measurement three times and take the average.

20-134 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING PARKING BRAKE

TESTING AND ADJUSTING PARKING BRAKE ¤

Put blocks securely under the tires.

Measuring pad 1. Turn the starting switch ON, then turn the parking brake switch OFF to release the brake. 2. Remove pad (1) from caliper (2) and measure the thickness of the pad. fl If the starting switch is turned OFF , the parking brake is actuated, so be extremely careful not to turn the starting switch OFF . fl For details of removing and replacing the pad, see DISASSEMBLY AND ASSEMBLY. fl Measure the two pads. fl If the measurement is not within the standard value, replace the two pads as one set.

Measuring clearance 1. Turn the parking brake switch OFF to release the brake. 2. Insert feeler gauge F between pad (1) and disc (3), and measure the clearance. fl The clearance is the total value (a + b) of the measurements at both sides.

WD600-3

20-135 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING PARKING BRAKE

Adjusting fl If the measurement is not within the standard value, adjust as follows. 1. Turn the starting switch ON, then turn the parking brake switch OFF to release the brake. fl If the starting switch is turned OFF, the parking brake is actuated, so be extremely careful not to turn the starting switch OFF. 2. Turn adjustment bolt (4) at the caliper lever counterclockwise until pad (1) and disc (3) are brought into tight contact and resistance is felt when turning the bolt. 3

From the above position, turn adjustment bolt (4) 180˚ ± 30˚ (3 notches) back in the clockwise direction. This adjusts the total clearance on the left a and right b between pad (1) and disc (3) to the standard value of 1.06 ± 0.18 mm.

fl After completing the above adjustment, measure the performance of the parking brake to check that it is the standard value.

20-136 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE

TESTING AND ADJUSTING ACCUMULATOR CHARGE CUTIN AND CUT-OUT PRESSURE Measuring flHydraulic oil temperature: 45 – 55°C

¤ ¤

Put blocks securely under the tires. Depress the brake pedal at least 100 times with the engine stopped to release the pressure inside the accumulat or circuit.

1. Remove the cover and disconnect accumulator inlet hose (1). 2. Install the adapter (M18 x 1.5) to elbow (2) at the charge valve end, then assemble hose (1) again. 3. Install oil pressure gauge C1 (39 MPa {400 kg/cm2}) to adapter C3. 4. Measure the accumulator charge cut-in pressure. Start the engine, run the engine at low idling, and measure the oil pressure when the accumulator pressure warning” pilot lampon the maintenance meter goes out. 5. Measure the accumulator charge cut-out pressure. After the accumulator charge cut-in is actuated, measure the oil pressure when the indicator of the oil pressure gauge has risen and suddenly starts to drop. Adjusting fl When the accumulator charge cut-out pressure is adjusted, the cut-in pressure also changes in proportion to the ratio of the valve area. For this reason, there is no adjustment nut for the cut-in pressure. 1. Loosen locknut (4) of accumulator charge cut-out valve (3), then turn adjustment screw (5) to adjust. fl Turn the adjustment screw to adjust the pressure as follows. • To RAISE pressure, turn CLOCKWISE • To LOWER pressure, turn COUNTERCLOCKWISE fl Pressure adjustment for 1 turn of adjustment screw: 5.59 MPa {57 kg/cm2} 3 Locknut : 9.8 – 11.8 Nm {1 – 1.2 kgm} fl After completion of adjustment, repeat the measurement procedure given above to check the accumulator cut-in pressure and cut-out pressure again.

WD600-3

20-137 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING PPC OIL PRESSURE

TESTING AND ADJUSTING PPC OIL PRESSURE fl Hydraulic oil temperature: 45 – 55°C

¤ ¤

Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Operate the control levers several times to release the pressure in the PPC accumulator circuit.

Measuring 1. Measuring PPC valve source pressure (orbit-roll source pressure) 1) Remove oil pressure measurement plug (PT1/ 8) (1), then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Start the engine, run the engine at high idling, then operate the work equipment control lever and measure the oil pressure.

2.

Measuring PPC valve output pressure 1) Remove the main control valve cover. 2) Remove oil pressure detection plug (PT1/8) (1) of the circuit to be measured, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). fl Plug A: Blade LOWER, FLOAT Plug B: Blade RAISE Plug C: RIGHT TILT Plug D: LEFT TILT 3) Start the engine, run the engine at high idling, then operate the work equipment control lever and measure the oil pressure.

20-138 (1)

WD600-3

TESTING AND ADJUSTING

TESTING AND ADJUSTING PPC OIL PRESSURE

Adjusting 1. Adjusting PPC relief valve Loosen locknut (3) of PPC relief valve (2), then turn adjustment screw (4) to adjust. fl Turn the adjustment screw to adjust as follows. • To INCREASE the pressure, turn CLOCKWISE. • To DECREASE the pressure, turn COUNTERCLOCKWISE. fl Amount of adjustment for one turn of adjustment screw: 1.79 MPa {18.3 kg/cm2} 3 Locknut : 78.5 –␣ 88.3 Nm {8 – 9 kgm} fl After completion of the adjustment, re-check the accumulator charge cut-in pressure and cut-out pressure again referring to the section “Testing and Adjusting Accumulator charge pressure”.

WD600-3

20-139 (1)

TESTING AND ADJUSTING

TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE

TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE fl Hydraulic oil temperature: 45 – 55°C 1.

Measuring blade relief pressure 1) Lower the blade to the ground and stop the engine. fl After stopping the engine, operate the blade lever several times to release the remaining pressure in the hydraulic piping. fl If there is no pressure in the accumulator, run the engine for approx. 10 sec. to charge the accumulator. 2) Remove oil pressure measurement plug (PT1/ 8) (1) or (2), then install oil pressure gauge C1 (39 MPa {400 kg/cm2}). • (1) : For blade RAISE circuit • (2) : For blade LOWER circuit 3) Start the engine, run it at high idling, then operate the blade to the end of the RAISE or LOWER stroke, and measure the pressure when the relief is actuated.

¤

2.

After completing measurement, release the pressure remaining in the circuit in the same way as when installing the hydraulic gauge, then remove the gauge.

Adjusting blade relief valve Loosen locknut (4) of blade relief valve (3), then turn adjustment screw (5) to adjust. fl Turn the adjustment screw to adjust the pressure as follows. • To INCREASE pressure, turn CLOCKWISE • To DECREASE pressure, turn COUNTERCLOCKWISE fl Pressure adjustment for one turn of adjustment screw: Approx. 5.18 MPa {Approx. 52.9 kg/cm2} 3 Locknut : 34.3 - 44.1 Nm {3.5 - 4.5kgm} fl After completion of the adjustment, use the procedure given above to measure the blade relief pressure again.

20-140 (1)

WD600-3

TESTING AND ADJUSTING

ADJUSTING WORK EQUIPMENT LEVER LINKAGE

ADJUSTING WORK EQUIPMENT LEVER LINKAGE

fl If the operating effort or travel of the work equipment lever is not within the standard value, or the work equipment lever or PPC valve have been removed, adjust as follows. fl Carry out the adjustment with the engine stopped. fl Check that the operating effort of the work equipment lever is within the standard value. fl Remove the side cover at the bottom of the work equipment lever.

WD600-3

20-141 (1)

TESTING AND ADJUSTING

1.

ADJUSTING WORK EQUIPMENT LEVER LINKAGE

Adjusting PPC valve linkage 1) Install 2 sets of joint (1) to the PPC valve spool. 2) Install trunnion (2) to the center bolt of the PPC valve, then use 2 nuts (3) to adjust dimension a from the center of trunnion (2) to the top surface of the floor. • Dimension a (target value): 54 mm 3) Install levers (4), (5) to trunnion (2) and secure with nut (6). 3 Bushing portion: Grease (G2-LI)

2.

Adjusting rod 1) Connect rod (7). 2) Operate work equipment lever (8) to the LOWER position and adjust the length of rod (7) so that cam follower (9) enters the detent of cam (10) without any play at the detent. • Clearance b: 0 - 1 mm

3. Adjusting lock lever 1) Set work equipment lever (8) to the HOLD position. 2) Adjust the position of bracket (12) so that work equipment lever (8) is locked when lock lever (11) is operated to the LOCK position. 4. Adjusting release effort for work equipment lever 1) Temporarily assemble spring (13) to the 2nd hole from the top, then operate work equipment lever (8) to the FLOAT position. 2) Measure the effort needed to release work equipment lever (8) from the FLOAT position, and adjust the mounting hole of spring (13) so that it is the standard value. fl Measure the release effort with push-pull scale J1. • Standard release effort: 19.6 N {2 kg} fl Standard spring mounting hole: 2nd hole from top

20-142 (1)

WD600-3

ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)

TESTING AND ADJUSTING

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.

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. Switch Adjustment position

DIPSW4

1

ON

2

ON

3

ON

4

OFF

Function of switch (reference)

Prohibition of monitor switch function

4) After completing the adjustment, fit the rubber caps securely and install the main monitor.

Reference Amount of correction for switch (2) Switch position Amount of correction (%)

WD600-3

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

20-143 (1)

TESTING AND ADJUSTING

BLEEDING AIR

BLEEDING AIR 1.

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Bleeding air from brake system Put blocks securely under the tires. 1) After charging the accumulator, stop the engine, insert vinyl hose (2) into bleeder screw (1), and put the other end in a container. 2) Depress the brake pedal, then loosen bleeder screw (2) and bleed the air. Tighten bleeder screw (1), then slowly release the brake pedal. fl When depressing the brake pedal, use the left pedal. 3) Repeat the above operation, and when no more bubbles come out with the fluid from vinyl hose (2), depress the pedal fully and tighten bleede rscrew (1) while the oil is still flowing. 4) Repeat the procedure to bleed the air from each brake cylinder. fl To bleed the air completely, start with the brake cylinder that is farthest from the brake pedal. fl If the accumulator pressure goes down, start the engine and charge the accumulator again. fl Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level in the oil tank and add more oil if necessary.

2.

Bleeding air from hydraulic cylinders 1) Start the engine and run at idling for approx. 5 minutes. 2) Run the engine at low idling, then raise and lower the boom 4 – 5 times in succession. fl Operate the piston rod to a point approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from the pitch & tilt and steering cylinder. fl When the cylinder has been replaced, bleed the air before connecting the piston rod.

20-144 (1)

WD600-3

TESTING AND ADJUSTING

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 1.

Releasing remaining pressure between each hydraulic cylinder and control valve. fl If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. 1) Stop the engine. 2) Loosen the oil filler cap slowly to release the pressure inside the tank. 3) Operate the control levers. fl When the levers are operated 2 – 3 times, the pressure stored in the PPC accumulator is removed. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. fl Repeat the above operation 2 – 3 times to release all the remaining pressure.

2.

Releasing remaining pressure in brake accumulator circuit fl If the piping between the brake accumulator and parking brake solenoid valve, between the accumulator and accumulator check valve, or between the accumulator and brake valve was disconnected, release the remaining pressure from the circuit as follows. 1) Stop the engine. 2) Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit.

3.

Releasing remaining pressure in PPC accumulator circuit fl If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from the circuit as follows. • Operate the control levers 2 – 3 times to release the remaining pressure in the circuit.

WD600-3

20-145 (1)

TROUBLESHOOTING Points to remember when troubleshooting .......................................................................................... 20-202 Sequence of events in troubleshooting ................................................................................................ 20-203 Points to remember when carrying out maintenance ......................................................................... 20-204 Checks before troubleshooting .............................................................................................................. 20-212 Connector types and mounting locations ............................................................................................. 20-213 Connector arrangement diagram .......................................................................................................... 20-218 Connection table for connector pin numbers ....................................................................................... 20-222 Method of using troubleshooting charts ............................................................................................... 20-239 Method of using matrix troubleshooting tables ................................................................................... 20-241 Troubleshooting of engine system (S mode)........................................................................................ 20-301 Troubleshooting of engine controller system (EA mode) .................................................................... 20-351 Troubleshooting of mainmonitor system (M mode) ............................................................................ 20-451 Troubleshooting of maintenance monitor system (K mode)............................................................... 20-501 Troubleshooting of electrical system (E mode) .................................................................................... 20-601 Troubleshooting of hydraulic and mechanical system (H mode) ....................................................... 20-701 Troubleshooting of transmission control system (T mode) (Only for machine with joystick and automatic shift control) ......................................... 20-801 Troubleshooting of joystick steering system (J mode) (Only for machine with joystick and automatic shift control) ......................................... 20-901 Troubleshooting of throttle control system (TH mode) ....................................................................... 20-951

WD600-3

20-201 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING ¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. ¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.

¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.

¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.

2.

3.

When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for symptoms of any abnormality in the machine. 2) Check the CHECKS BEFORE STARTING items.

20-202 (1)

3) 4)

4.

5.

6.

Other inspection items. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. fl When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. fl The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

WD600-3

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING Office, shop

Jobsite

Step 1 Examination, confirmation of symptoms 1) When a request for repairs is received, first ask the following points. • Name of customer • Type, serial number of machine • Details of jobsite, etc. 2) Ask questions to gain an outline of the problem. • Condition of failure • Work being carried out at the time of the failure • Operating environment • Past history, details of maintenance, etc.

Step 2 Determining probable location of cause 1) Look at the troubleshooting section of the shop manual to find locations of possible causes.

Step 3 Preparation of troubleshooting tools 1) Look at the table of troubleshooting tools in the shop manual and prepare the necessary tools. • T-adapter • Hydraulic pressure gauge kit, etc. 2) Look in the parts book and prepare the necessary replacement parts.

Step 7 • Pinpoint locations of failure (carry out troubleshooting) • Decide action to take 1) Before starting troubleshooting, locate and repair simple failures. • Check before starting items • Other check items 2) See the Troubleshooting Section of the shop manual, select a troubleshooting flowchart that matches the symptoms, and carry out troubleshooting.

Step 6 Re-enacting failure •

Step 4 Go to jobsite

Step 5 Ask operator questions to confirm details of failure. • • •

WD600-3

Drive and operate the machine to confirm the condition and judge if there is really a failure.

Was there anything strange about the machine before the failure occurred? Did the failure occur suddenly? Had any repairs been carried out before the failure?

20-203 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1. POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.

Main failures occurring in wiring harness 1 Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

2 Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-204 (1)

WD600-3

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3 Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

4 High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. fl When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. fl If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

WD600-3

20-205 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors and wiring harnesses ‡

Disconnecting connectors 1 Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. fl Never pull with one hand. 2 When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. fl If the connector is twisted up and down or to the left or right, the housing may break.

3 Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. fl If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

20-206 (1)

WD600-3

TROUBLESHOOTING

‡

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors 1 Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. fl If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. fl If there is any damage or breakage, replace the connector. 2 Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. 3 Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. fl If the connector cannot be corrected easily, remove the clamp and adjust the position. 4 If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

WD600-3

20-207 (1)

TROUBLESHOOTING

‡

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1 Disconnect the connector and wipe off the water with a dry cloth. fl If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.

2 Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. fl Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

3 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. fl After completely drying the connector, blow it with contact restorer and reassemble.

20-208 (1)

WD600-3

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box 1 The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. 2 Do not open the cover of the control box unless necessary.

3 Do not place objects on top of the control box. 4 Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5 During rainy weather, do not leave the control box in a place where it is exposed to rain.

6 Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 7 Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connect connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. fl If there is any change, there is probably defective contact in that circuit.

WD600-3

20-209 (1)

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. 3) Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.

4) Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-210 (1)

WD600-3

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6) Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7) Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

WD600-3

20-211 (1)

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, cooling water

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 (1)

WD600-3

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS 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

Place of use

Address

Connector No.

Type

No. of pins

Place of use

Address

1939

HD

9

Connector for connecting J1939 equipment

W7

C01

X

2

Low pressure switch (emergency)

H1

A02

Connector

1

Battery relay (BR)

L3

C01

M

6

Front wiper motor

B7

A03

Terminal

1

Battery relay (E)

L3

C02

X

2

Low pressure switch (emergency)

H1

A04

Connector

1

Battery relay (BR)

L4

C02

PA

9

Cassette stereo

B7

A4

X

2

Air conditioner air servo motor

P6

C03

X

2

Low pressure switch (brake)

G1

A05

Terminal

1

Battery relay (E)

L4

C03

M

2

Front working lamp (R.H.)

D8

A5

M

2

Air conditioner thermistor

R5

C04

X

2

Low pressure switch (brake)

G1

A6

SWP

6

Air conditioner air mixing motor

R5

C04

M

2

Front working lamp (L.H.)

D8

4

Beacon lamp switch (OP)

D8

A7

M

6

Air conditioner blower motor, resistor R4

C05

KYOURITSU ES

A8A

S

10

Intermediate connector (air conditioner) R4

C06

KES 1

2

Room lamp

E9

A8B

S

8

Intermediate connector (air conditioner) R4

C07

M

4

Rear wiper motor

H9

A9

Yazaki

4

Air conditioner blower relay (M)

R2

C08

Connector

1

Cigar lighter

B7

A10

Yazaki

4

Air conditioner blower relay (Hi)

Q1

C09

Terminal

1

C7

A11

Yazaki

4

Air conditioner blower relay (M2)

R2

C1

MIC

13

A12

Yazaki

4

Air conditioner condenser relay

Q1

C1A

MIC

13

A13

Yazaki

4

Air conditioner blower relay (M1)

R2

C2

MIC

21

A14

X

2

Air conditioner switch

R5

C3A

AMP040 20

A14

Yazaki

4

Air conditioner condenser relay

Q2

C3B

AMP040 16

A15

Yazaki

2

Air conditioner switch

R5

C4

AMP040 12

A15

Yazaki

4

Air conditioner condenser relay

Q2

C5

MIC

17

A16

Yazaki

4

Air conditioner compressor relay

Q2

C5A

MIC

17

Cigar lighter Intermediate connector (Transmission & joystick steering controller) Transmission & joystick steering controller Transmission & joystick steering controller Transmission & joystick steering controller Transmission & joystick steering controller Transmission & joystick steering controller Intermediate connector (Transmission & joystick steering controller) Transmission & joystick steering controller

A16

AMP

12

Air conditioner controller

P1

C6

DRC

24

Throttle controller

Q8

A17

AMP

16

Air conditioner controller

O1

C7

DRC

40

Throttle controller

Q8

A18

SWP

8

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

C8

DRC

40

Throttle controller

Q8

A19

SWP

8

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

C9

—

5

Low idling limit switch relay

M9

AAPR Connector

3

Air pressure sensor

V5

C10

DT-T

6

Lock-up ON/OFF switch

M5

ASS

X

2

Air suspension

R5

C11

Terminal

1

Door switch (R.H.)

E11

B01

X

1

Air conditioner condenser

I2

C11

DT-T

6

Throttle lock acceleration/ deceleration switch

M5

B02

X

2

Air conditioner condenser

J2

C12

Terminal

1

Door switch (L.H.)

G9 M4 G9

P8 P8 P9 P8 P8 P8 P9 P8

B03

X

1

Air conditioner condenser

L6

C12

DT-T

6

Throttle lock acceleration/ deceleration switch

B04

X

2

Air conditioner condenser

L5

C13

KES 0

2

B05

KES 1

2

Diode (window washer)

I9

C13

SWP

6

Speaker switch (L.H.) Intermediate connector (Brake pedal proximity switch)

M2

B06

KES 1

2

Diode (window washer)

I9

C13A

SWP

6

Left brake pedal proximity switch

N1

B07

KES 1

2

Window washer (front)

H9

C14

KES 0

2

Speaker switch (R.H.)

F9

B08

KES 1

2

Window washer (rear)

H9

C14

SWP

6

Right brake pedal proximity switch N1

BR1

SWP

6

Intermediate connector (bulk head) J2

C15

Connector

1

Beacon lamp (OP)

WD600-3

D8

20-213 (1)

CONNECTOR TYPES AND MOUNTING LOCATIONS

TROUBLESHOOTING

Connector No.

Type

No. of pins

Address

Connector No.

Type

C16

M

2

Side working lamp (L.H.)

G9

E31

Terminal

1

Slow blow fuse

W2

C17

M

2

Side working lamp (R.H.)

E8

E32

Terminal

1

Slow blow fuse

V1

CAN

Terminal

3

CAN connector

W6

E33

Terminal

1

Heater relay

W9

Intermediate connector (Deco valve) Intermediate connector (Deco valve solenoid relay)

D8

ECMA

DRC26

40

Engine controller

T5

Q6

ECMB

DRC26

40

Engine controller

V9

Intermediate connector (cab harness) M7

ECB2

DT

2

CH1

L

2

CH2

M

2

CL1

S (blue) 12

Place of use

No. of pins

Address

Place of use

—

S6

CL2

S

10

Intermediate connector (air conditioner) M7

ER1

SWP

14

Intermediate connector (engine harness) V1

CL3

M

6

Intermediate connector (air conditioner) M7

ER2

SWP

14

Intermediate connector (engine harness) V1

CL4

M

6

Intermediate connector (power window) M7

ER3

X

3

Intermediate connector

CL18 Connector

1

Power window regulator (L.H.)

E1

F01

M

3

Intermediate connector (head lamp R.H.) A4

CL19 Connector

1

Power window regulator (L.H.)

E1

F02

M

3

A4

CL20 Connector

1

Power window regulator (R.H.)

C7

F03

M

3

CL21 Connector

1

Power window regulator (R.H.)

C7

F04

M

3

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

CLTP Connector

2

Engine cooling water temperature sensor

T8

F07

Connector

1

Horn (L.H.)

A3

CR1

X

4

Low pressure switch (brake)

I1

F08

Connector

1

Horn (R.H.)

A5

E01

Terminal

1

Slow blow fuse (80A)

W2

F09

Connector

1

Horn (R.H.)

A4

E04

X

2

Water temperature sensor

X4

F10

Connector

1

Horn (L.H.)

A2

E06

X

2

Engine speed sensor

T2

F13

Terminal

1

GND (front frame)

A6

T2

F14

X

2

Parking brake solenoid

D1

V1

A2 A2

E07

X

2

Torque converter temperature sensor (monitor)

E08

X

2

Starting motor

U1

F15

X

2

Parking caution (monitor)

C1

E09

X

2

Starting motor

T1

FD1

Connector

2

Deco valve

A3

E10

X

1

Engine oil level switch

T5

FD2

Terminal

1

GND (front frame)

B6

1-Pin Connector

1

Intermediate connector (Pitch)

O3

2

Fuel temperature sensor

U9

Intermediate connector (front lamp)

F9

E12

X

1

Air conditioner compressor switch

U9

FH3

E13

Connector

1

Dust indicator

T3

FLTP Connector

E14

Connector

1

Dust indicator

T3

FR1

S

10

E15

Terminal

1

Alternator (B)

S7

FR2

SWP

6

E16

Terminal

1

Alternator (R)

S6

FSO- Terminal

1

Fuel shutoff valve (-)

S7

E17

Terminal

1

Alternator (E)

S7

FSO+ Terminal

1

Fuel shutoff valve (+)

S8

E18

Terminal

1

GND

L3

FS1

2

Fuse I

Q6

E19

KES 1

2

Diode (starting motor)

X3

FS2

S (blue) 12

Fuse I

Q6

E20

KES 1

2

Diode (starting motor)

X3

FS3

M

6

Fuse I

Q6

E21

KES 1

2

Diode (starting motor)

T1

FS4

L

2

Fuse II

Q6

E22

KES 1

2

Diode (starting motor)

T1

FS5

M

6

Fuse II

P6

E23

Connector

2

Diode (air conditioner compressor)

U9

FS6

M

4

Fuse II

P6

E24

Terminal

1

Heater relay

V9

G01

X

2

Radiator water level switch

K9

E25

Terminal

1

Heater relay

W9

G02

M

2

Working lamp (R.H.)

J9

E26

Terminal

1

Heater relay

U9

G03

M

2

Working lamp (L.H.)

L8

E27

Terminal

1

Heater relay

W9

G04

M

6

Rear combination lamp

L8

20-214 (1)

L

F1

WD600-3

TROUBLESHOOTING

Connector No.

Type

G05

M

No. of pins

CONNECTOR TYPES AND MOUNTING LOCATIONS

Place of use

Address

Connector No.

Type

L6

L14A

DT-T

6

Rear combination lamp

L7

L15

No. of pins

Place of use

Address

3

Accelerator limit switch

N2

4

Intermediate connector (Kick-down & hold switch)

N6

GR1

SWP

6

Intermediate connector (radiator harness)

GRE

SWP

6

Auto-grease (OP)

R3

L18

AMP040 16

Maintenance monitor (sub motor) N5

GND Terminal

1

GND (OP)

M7

L19

AMP040

8

Maintenance monitor (sub motor) M5

GND Terminal

1

Engine block GND

M6

L21

KES 1

2

Maintenance monitor (sub motor) N6

GND Terminal

1

GND

S6

L22

KES 1

2

Maintenance monitor (sub motor) O6

GND Terminal

1

GND

S7

L28

Connector

1

LED

O8

W9

L29

Connector

1

LED

R8

M

HEAT

DT

2

Intermediate connector (electronically governor)

IL11

—

5

Joystick indicator relay

N9

L30

Connector

1

LED

R8

IMPR Connector

3

Suction air pressure sensor

T8

L31

Connector

1

LED

R8

IMTP Connector

2

Suction air temperature sensor

T9

L32

Connector

1

LED

R8

JC01

DT

6

Joint connector

W6

L33

Connector

1

LED

Q8

JC02

DT

8

Joint connector

V6

L34

Terminal

1

Selector switch

R9

JC03

DT

8

Joint connector

V5

L35

Terminal

1

Selector switch

R9

JC04

DT

8

Joint connector

U5

L36

Terminal

1

Selector switch

R8

JC11

DT

6

Joint connector

U5

L37

Terminal

1

Diagnosis switch

Q9

JC12

DT

6

Joint connector

U5

L38

Terminal

1

Diagnosis switch

Q9

JC13

DT

8

Joint connector

V5

L40

Yazaki

7

Power window switch (R.H.)

M5

JC14

DT

8

Joint connector

V6

L41

Yazaki

7

Power window switch (L.H.)

M5

JC15

DT

6

W6

L42

Connector

1

Caution buzzer

O6

JL1

S

8

P1

L43

Connector

1

Caution buzzer

O6

JL2

S

8

R5

L44

KES 0

6

Wiper relay

O6

JL2A

S

8

R4

L46

KES 1

4

Flasher unit

O8

JS14

S

8

Joint connector Intermediate connector (Joystick steering) Intermediate connector (Joystick steering) Intermediate connector (Joystick steering) Work equipment control lever (Tilt pitch, kick-down & hold switch)

N5

L51

—

6

Side working lamp relay

O9

L01

SWP

6

Parking brake switch

M3

L52

—

5

Hazzard relay

M8

L02

SWP

6

Light & dimmer switch

M2

L53

—

5

Stop lamp relay

M8

L03

SWP

6

Turn signal switch

M3

L55

—

5

Horn relay

O8

L04

SWP

14

Transmission switch

M2

L57

—

5

Neutral relay

M8

L05

AMP040 20

Main monitor

M4

L58

—

5

Neutralizer relay

M9

L06

AMP040 16

Main monitor

M4

L59

—

5

Parking brake safety relay

M9

L07

AMP040 12

Main monitor

M4

L60

—

6

Front working lamp relay

N9

L08

AMP040

8

Main monitor

M4

L61

—

6

Rear working lamp relay

O9

L09

M

6

Starting switch

M3

L62

—

5

Pre-heating relay

M9

L10

S

10

Wiper switch

M2

L63

Connector

8

Horn switch

O1

L12

X

2

Transmission cut off switch

P1

L64

—

5

Engine oil pressure switch relay

M8

L13

DT-T

3

Intermediate connector (Accelerator potentiometer)

N1

L65

—

5

Joy stick caution relay

O8

L13A

DT-T

3

Accelerator potentiometer

N1

L66

—

5

Joy stick switch relay

O8

3

Intermediate connector (Accelerator limit switch)

N1

L67

—

6

Joy stick solenoid relay

O8

L14

DT-T

WD600-3

20-215 (1)

TROUBLESHOOTING

Connector No.

Type

Address

Connector No.

Type

L76

—

5

Backup lamp relay

N8

R12

Terminal

1

Battery relay (B)

L5

L80

—

5

Dust indicator relay

M9

R13

Terminal

1

Back buzzer

L6

L81

X

2

Stop lamp switch

O1

R14

Terminal

1

L6

L91

—

5

Power window relay (left rise)

O9

R16

HD-24

31

W8

L92

—

5

Power window relay (left lower)

O8

R17

HD-24

21

Back buzzer Intermediate connector (electronically governor) Intermediate connector (electronically governor)

L93

—

5

Power window relay (right rise)

N9

RA1

X

2

Intermediate connector (battery relay)

L5

L94

—

5

Power window relay (right lower)

O9

RAIL Connector

3

Fuel rail actuator

S5

L95

—

5

Steering neutral interlock relay

O9

RPR

Connector

3

W5

LINK

DT

6

Data link crossover

W7

SIG

HD-24

31

Fuel rail pressure sensor Intermediate connector (engine wiring harness)

LR1

No. of pins

CONNECTOR TYPES AND MOUNTING LOCATIONS

S (blue) 12

Place of use

No. of pins

Address

Place of use

W8

X8

Intermediate connector (lamp, horn)

R4

SP1

Connector

2

Engine revolution sensor (master) X9

R3

SP2

Connector

2

Engine revolution sensor (backup) X9

1

Connector for connection

N6

Transmission control valve

E8

LR2

SWP

14

Intermediate connector (air conditioner, washer)

LR3

SWP

12

Intermediate connector (engine)

R3

SWL Connector

LR4

SWP

14

Intermediate connector (engine)

R3

T01

MS

10

LR5

X

4

Intermediate connector (GND)

R3

T02

KES 1

2

Diode (transmission control valve) F9

LR6

L

2

Intermediate connector (power supply) R3

T03

KES 1

2

Diode (transmission control valve) F1

LR7

SWP

6

Intermediate connector

R4

T04

KES 1

2

Diode (transmission control valve) F9

2

Intermediate connector (Lock-up solenoid)

F1

T05

X

2

Speed sensor

C7

3

Engine oil pressure sensor

S6

T06

DT-T

2

T2

T08

DT-T

2

Lock-up solenoid Intermediate connector (lock-up solenoid)

V1

—

1

Tachograph (OP)

N7

LR9

DT-T

OLPR Connector OP1

Connector

1

Connector for connecting windR7 shield heater (OP)

OP1

Connector

1

Intermediate connector

N6

TAC

OP2

Connector

1

Intermediate connector

R7

TIMG Connector

3

Timing rail actuator

V9

OP3

Connector

1

Intermediate connector

R7

TL1

SWP

2

Intermediate connector

R2

OP4

Connector

1

Intermediate connector

R7

TPR

Connector

3

Timing rail pressure sensor

W6

OP5

Connector

1

Connector for connection

R7

OP5

Connector

1

Intermediate connector

N6

PMPR Connector

3

POW

HD-24

21

IMO pump pressure sensor

T5

Intermediate connector (engine wiring harness)

X8

PUMP Connector

3

Pump actuator

S5

R01

X

2

Emergency steering switch

H1

R03

KES 1

2

Diode (battery relay)

K2

R04

KES 1

2

Diode (battery relay)

K3

R05

KES 1

2

Fuel level sensor

J2

R06

Terminal

1

Slow blow fuse (30A)

X2

R07

Terminal

1

Slow blow fuse (30A)

W2

R08

Terminal

1

Slow blow fuse (80A)

W2

R09

Terminal

1

Slow blow fuse (80A)

W2

R10

Terminal

1

GND

K3

R11

Terminal

1

Battery relay (M)

L4

20-216 (1)

WD600-3

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DIAGRAM

CONNECTOR ARRANGEMENT DIAGRAM

20-218 (1)

WD600-3

TROUBLESHOOTING

WD600-3

CONNECTOR ARRANGEMENT DIAGRAM

20-219 (1)

TROUBLESHOOTING

20-220 (1)

CONNECTOR ARRANGEMENT DIAGRAM

WD600-3

TROUBLESHOOTING

WD600-3

CONNECTOR ARRANGEMENT DIAGRAM

20-221 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS fl The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. No. of pins

X type connector Male (female housing)

Female (male housing)

1

1

1

2 2

2 TEW00221

1

3

TEW00222

3

1

3

2

2

TEW00224

TEW00223

1

3

3

1

4

2

4

2

4 TEW00225

20-222 (1)

TEW00226

WD600-3

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector Male (female housing)

Female (male housing)

1

4

3

6

4

1

6

3

6

TEW00235

1

5

5

1

4

8

8

4

BLP00033

8

TEW00238

TEW00237

4

1

8

5

12

9

12

1

4

5

8

9

12 BLP00035

BLP00034

1 4

8

11

8

4

1

14 10

7

3

11

14

3

7 10 14

TEW00240

TEW00239

4 8

1

1

4

5

5

8

9

12

16 12

9 16

13 BLP00036

WD600-3

13

16

BLP00037

20-223 (1)

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector Male (female housing)

Female (male housing) 2

2

2

1

2

1

BLP00038

BLP00039

3

3

1

1

2

3

TEW00243

1

3

2

4

TEW00244

3

1

4

2

4

TEW00245

1

4

3

6

TEW00246

4

1

6

3

6

4

TEW00247

1

1

TEW00248

4

8

8

5 BLP00040

20-224 (1)

5

8

BLP00041

WD600-3

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector Male (female housing)

Female (male housing)

1

5

4

8

5

1

8

4

8

1

6

5

10

TEW00249

6

1

10

5

TEW00250

10

TEW00251

1

6

5

12

6

1

12

5

8

1

16

7

BLP00042

12

BLP00043

1

8

TEW00254

16

7

WD600-3

16 BLP00044

TEW00256

20-225 (1)

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector Male (female housing) 4

Female (male housing) 8

8

4

8

1

5 BLP00053

12

6

5

1

BLP00054

12

6

7

1

12

7

1

BLP00055

8

BLP00056

16

16

8

9

1

16

1

9 BLP00057

10

TEW00232

20

20

10

11

1

20

1

20-226 (1)

11

BLP00058

TEW00234

WD600-3

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Automobile connector Male (female housing)

Female (male housing)

1

2

2

2

1

1

BLP00063

BLP00064

3

4

3

1

1

3

6

4

6

WD600-3

4

BLP00069

6 BLP00070

20-227 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No. of pins

Male (female housing)

5

Female (male housing)

3

3

1

1 4

5

5

4

BLP00046

BLP00045

9

1

5

5

1

6

9

9

6

BLP00048

BLP00047

1

8

7

7

1

13

13

8

13

BLP00050

BLP00049

1

9

10

17

9

1

17

10

17

BLP00051

1

12

11

TEW00259

(1)

11

1

21

12

21

21

20-228

BLP00052

TEW00260

WD600-3

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector Male (female housing)

Female (male housing)

1

1

2

2

2

TEW00257

No. of pins

TEW00258

PA type connector Male (female housing)

Female (male housing)

7

No. of pins

Bendix type connector Male (female housing)

Female (male housing)

10

WD600-3

20-229 (1)

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Relay connector (socket) Female

Relay (male pins)

2

2

5

1

5

1

3

5

6

6

3

BLP00074

BLP00073

6

4

3

6

5

6

4

5

2

(1)

1

2

1

BLP00075

20-230

3

BLP00076

WD600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(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

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206

Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106

Pin (female terminal)

Pin (male terminal)

799-601-9210

Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206

Part No.: 08191-13101, 08191-13102, 08191-13105, 01891-13106

Pin (male terminal)

Pin (female terminal)

799-601-9220

18-14 (2)

Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206

Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106

Pin (female terminal)

Pin (male terminal)

799-601-9220

Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206

WD600-3

Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106

20-231 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(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

799-601-9230

18-20 (3)

Part No.: 08191-31201, 08191-31202

Part No.: 08191-34101, 08191-34102

Pin (female terminal)

Pin (male terminal)

799-601-9230

Part No.: 08191-32201, 08191-32202

Part No.: 08191-33101, 08191-33102

Pin (male terminal)

Pin (female terminal)

799-601-9240

18-21 (4)

Part No.: 08191-41201, 08191-42202

Part No.: 08191-44101, 08191-44102

Pin (female terminal)

Pin (male terminal)

799-601-9240

Part No.: 08191-42201, 08191-42202

20-232 (1)

Part No.: 08191-43101, 08191-43102

WD600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(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

799-601-9250

24-9 (5)

Part No.: 08191-51201, 08191-51202

Part No.: 08191-54101, 08191-54102

Pin (female terminal)

Pin (male terminal)

799-601-9250

Part No.: 08191-52201, 08191-52202

Part No.: 08191-53101, 08191-53102

Pin (male terminal)

Pin (female terminal)

799-601-9260

24-16 (6)

Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206

Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106

Pin (female terminal)

Pin (male terminal)

799-601-9260

Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206

WD600-3

Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106

20-233 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(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

24-22 (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

20-234 (1)

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

WD600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

(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

799-601-9290

24-31 (9)

Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206

Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106

Pin (female terminal)

Pin (male terminal)

799-601-9290

Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206

WD600-3

Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106

20-235 (1)

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

Type (Shell size code)

DT series connector Body (Plug)

Body (Receptacle)

2

799-601-9020

Part No.: 08192-12200 (Normal type) 08192-22200 (Fine wire type)

Part No.: 08192-12100 (Normal type) 08192-22100 (Fine wire type)

3

799-601-9030

Part No.: 08192-13200 (Normal type) 08192-23200 (Fine wire type)

Part No.: 08192-13100 (Normal type) 08192-23100 (Fine wire type)

4

799-601-9040

Part No.: 08192-14200 (Normal type) 08192-24200 (Fine wire type)

Part No.: 08192-14100 (Normal type) 08192-24100 (Fine wire type)

6

799-601-9050

Part No.: 08192-16200 (Normal type) 08192-26200 (Fine wire type)

20-236 (1)

Part No. of T-adapter

Part No.: 08192-16100 (Normal type) 08192-26100 (Fine wire type)

WD600-3

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

Type (Shell size code)

DT series connector 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

10

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

WD600-3

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

20-237 (1)

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.: 08192-31200 (Contact size #12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)

20-238 (1)

Part No. of T-adapter

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

WD600-3

METHOD OF USING TROUBLESHOOTING CHARTS

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number Troubleshooting Code No

Component

S-cc

Troubleshooting of engine system

EA-cc

Troubleshooting of engine controller system

M-cc

Troubleshooting of main monitor system

K-cc

Troubleshooting of maintenance monitor system

E-cc

Troubleshooting of electrical systems

H-cc

Troubleshooting of hydraulic, mechanical system

T-cc

Troubleshooting of transmission control system

J-cc

Troubleshooting of joystick steering system

TH-cc

Troubleshooting of throttle control system

2. Method of using troubleshooting table 1) Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. 2) Distinguishing conditions Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. 3) General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with fl. , but must always be followed when carrying The precautions marked fl are not given in the out the check inside the . 4) Method of following troubleshooting chart YES

•

Check or measure the item inside , and according to the answer follow either the NO . (Note: The number written at the top right YES line or the NO line to go to the next corner of the is an index number; it does not indicate the order to follow.) • Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. • Below the there are the methods for inspection or measurement, and the judgement values. If the judgement values below the are correct or the answer to the question inside the is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. • Below the is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1). 5) Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. 6) Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart.

WD600-3

20-239 (1)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

<Example> 1 M-15

Abnormality in buzzer

2 a) Buzzer does not sound for 3 second during self-check when starting switch is turned ON b) Buzzer always sounds 3 Cause

Defective contact or disconnection in wiring harness Repair or between L06 (female) (8) replace and L43 (male) (1)

YES 1 Does buzzer sound?

2 YES

Is voltage between • Turn starting switch L42 (female) and ON. NO chassis ground • Contact L43 (female) normal?

to chassis ground.

Remedy

• 20 – 30 V NO • Turn starting switch ON.

Defective buzzer

Replace

Defective contact or disconnection in wiring harness Repair or between L42 (female) (1) replace and FS2 (female) (9)

M-15 Related electric circuit diagram

20-240 (1)

WD600-3

TROUBLESHOOTING

METHOD OF USING MATRIX TROUBLESHOOTHING TABLES

METHOD OF USING MATRIX TROUBLESHOOTHING TABLES The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to lecate the problems accutately and swiftly. Step 1. Questioning the operator The questions to ask the opetator are given below the failure symptom. If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3 to grasp the true cause.

1. Steering does not work ← Symprom [Example]

Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks before Starting items, and check for oil leakage and loose bolts. These checks may avoid time wasted on unnecessary troubleshooting. The items given under Checks before Srarting are items which must be considerd particularly for that symptom before starting troubleshooting.

Checks before staring [Example]

Ask the operator about the following points. • Did the steering suddenly stop working? → Breakage in steering equipment • Had the steering gradually been becoming heavy? → Internal wear of steering equipment, defective seal

• Is the oil level in the hydraulic tank correct? Is the type of oil correct? • Is there any leakage of oil from the steering valve or Orbit-roll? • Has the safety bar been removed from the frame?

[Example 1]

2) Find the appropriate cause from the cause column. If the symptom appears, the c marks on that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or e.) If there is only one c: Carry out the other troubleshooting items (where the same cause is marked with c), check if the symptom appears, then repair. If there are two c: Go on to Step 3) to narrow down the possible causes.

No. 1

Remedy

Problems

2

Steeing does not work to the left or right. Same as Item 1, but abnormality in actuation of work equipment.

3

Steering can only be operated to one side.

4

Steering wheel is heavy and cannot be turned.

[Example 2] Cau ses

Step 3. Using cross-reference table 1) Operate the machine to carry out the checks in the troubleshooting item column. Mark the items where the results match the symptom. fl It is not necessary to follow the troubleshooting checks in order; follow an order which is easiest to carry out troubleshooting.

Remedy Problems

a

×

b c C

×

d e A

×

1 2 3 4 5

WD600-3

20-241 (1)

6) Repeat the operations in Steps 3), 4) and 5) until one cause (one common cause) remains. fl If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible. 7) Remedy If the causes are narrowed down to one common cause, take the action given in the remedy column. The symbols given in the remedy column indicate the follwing: ×: Replace, t: repair, A: Adjust, C: Clean

20-242 (1)

×

b c C

d e A

×

×

1 2 3 4 5 Applicable troubleshooting item located in Step 3). Applicable troubleshooting item located in Step 1).

Ignore these causes

ses

5) Narrow down the possible causes. There is one common cause among the causes located in Steps 2) and 4). (One cause marked c appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1) and 3). fl The causes which are not common to both troubleshooting items (items which are not marked c for both symptoms) are unlikely causes, so ignore them. (In the example given on the right, the causes for Troubleshooting Item 2 are c or e, and the cause for Troubleshooting Item 5 are b or e, so cause e is common to both.)

Problems

Cau

4) Find the appropriate cause from the cause column. In the same way as in Step 2), if the symptom appears, the c marks on that line indicate the possible causes. (For item No. 5 in the table on the right, the possible causes are b or e.)

Remedy

a

Remedy

a

×

Problems

b c C

×

d e A

Common causes

×

1 2 3 4 5

ses

3) Operate the machine and check the troubleshooting items other than those in 1). Operate the machine and check the items in the same way as in 1), and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5).

Cau ses

METHOD OF USING MATRIX TROUBLESHOOTHING TABLES

Cau

TROUBLESHOOTING

Remedy Problems

a

×

b c C

×

d e A

×

Action to take

1 2 3 4 5

WD600-3

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 ...................................................................................................................... 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 cooling water, or water spurts back, or water 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 Water temperature becomes too high (overheating) ................................................................ 20-322 S-15 Abnormal noise is made .............................................................................................................. 20-323 S-16 Vibration is excessive ................................................................................................................... 20-324

WD600-3

20-301 (1)

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHART This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under C in the chart on the right correspond to this. The serviceman narrows down the causes from information A that he has obtained from the user and the results of C that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

Causes

A

Questions

(1) (2) (3)

(a)

w w

(b) w

(c) (d)

c c

B

Troubleshooting

C

Check items

(e)

20-302 (1)

i ii iii

b b b

WD600-3

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

ed t urbo cha Clog rger ged , int air c erfe lean Wor renc er e n pi e lem ston e n ring Clog t , cyl ged inde , sei r zed Imp inje rope ctio r inj n no e ctio Defe zzle n tim ctiv e in ing ject ion pum p (e xces sive

inje ctio n)

Causes

Seiz

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with c, and of these, causes that have a high probability are marked with w. Check each of the [Questions] and [Check items] in turn, and marked the c or w in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ª1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with t to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. ª2. Use the t in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

ª1

Confirm recent repair history

ª2

Degree of use

Operatred for long period

w

WD600-3

20-303 (1)

TROUBLESHOOTING

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Air cleaner clogging caution lamp is flashing]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel

Legend : Possible causes (judging 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 to confirm the cause.

ed t Clog urboch arge ged r, in air Wor terfe n pis cleaner elem rence ton Clog ring ent ged , cyli , se nde Imp r rope ized inje r c tion inje Defe ctio ctiv n tim nozzle e in ing Imp rope jection pum r va Cru lve p (e she c xces le d, c aran sive logg Lea ce inje kag e d ctio muf e of n) fler Defe air b ctiv etw e e e con n tu Deff t a r ectiv boc ct o harg f va e in lve, er a ject valv ion nd h e se pum ead at p (ra ck, p lung er s eize d

)

Causes

Seiz

•

METHOD OF USING TROUBLESHOOTING CHARTS

Confirm recent repair history Degree of use

Operated for long period

Questions

Suddenly became black Color of exhaust gas

Gradually became black Blue under light load

Engine oil must be added more frequently Power was lost

Suddenly Gradually

Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged

Troubleshooting

When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal

20-304 (1)

Replace

Repair

Replace

Adjust

Replace

Adjust

Adjust

Replace

Replace

Clean

Remedy

Replace

When control rack is pushed, it is found to be heavy or does not return

WD600-3

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.

Three symptoms

Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and head: (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder: Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

WD600-3

20-305 (1)

TROUBLESHOOTING

S-1

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

Ambient temperature

Charging rate

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

20°C 0°C –10°C •

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.

•

uck)

Causes

Wor np Defe iston ri ng ctive cont , cylind Clog er act o ged f val air c Clog ve, v lean ged alve er e fuel lem seat Clog filte ent ged r , stra fee Defe ctive d pump iner APS s Defe devi trainer cti ce Defe ve regu lato ctive r alt Defe ctive ernator or d Defe eter ctive injec iorated Defe b tion tive nozz attery injec Defe le tion tive timi injec ng tion pum p (ra ck, p lung er st

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

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 idling

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 (1)

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

WD600-3

Repair Clean Replace Replace age, clog Clog ging ged , air fuel Defe in fu tank tive el sy a ir br i njec stem Eng eath tin p ine o er ump il vis over hole cosi flow ty is v too high alve

Leak

TROUBLESHOOTING

WD600-3

S-1

Causes

20-307

(1)

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 safe ry re ctive ty sw lay ba Defe itch ctive ttery te rmin adju Defe al co 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

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

20-308 (1)

—

Replace Replace Replace Replace Replace Replace Adjust Replace Replace

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

Carry out troubleshooting for defective wiring of starting circuit

Troubleshooting

Specific gravity of electrolyte, voltage of battery is low

WD600-3

S-2

TROUBLESHOOTING

(2)

Engine turns but no exhaust smoke comes out (fuel is not being injected)

• Supply of fuel impossible • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter) ★ Standards for use of fuel KIND OF FLUID

AMBIENT TEMPRATURE 14 32 50 68 86°F –10 0 10 20 30°C ASTM D975 No. 2

Diesel fuel ASTM D975 No. 1

Causes

Brok en Defe injectio n pu ctive mp in Seiz dri ed, b jection pum ve shaft roke Clog ,k p (ra n fe ged ed p ck, p ey fuel u Clog l u m nge f p pi ilter ge r sei zed) Lack d feed p , straine ston r ump of fu el stra Clog iner ge Clog d, leakin ged g fu el pi fue Defe ping ctive l tank a i r bre e ngin Imp athe rope e sto rh r fue pm otor ole l use d

General causes why engine turns but no exhaust smoke comes out

Questions

Confirm recent repair history Operated for long period Degree of use Exhaust gas suddenly (when starting again) stopped coming out Replacement of filters has not been carried out according to operation manual Fuel tank is found to be empty There is leakage from fuel piping, crushed piping Mud is stuck to fuel tank cap When starting switch is turned ON, linkage does not move

Check items

When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pipe sleeve nut is loosened Rust and water are found when fuel is drained Inspect injection pump directly

Troubleshooting

When control rack is pushed, it is found to be heavy or does not return Inspect feed pump directly 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 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

WD600-3

Replace Replace Replace Clean Clean Add Repair Repair Replace Replace

Does not move even when engine stop motor linkage is disconnected

20-309 (1)

TROUBLESHOOTING

S-2

(3)

Defe ctive , bro Defe ken valv ctiv e sys e in Wor ject tem ion n pi (valv pum ston e, ro Clog p cker ring ( r a ged leve ck, p , cyl r, etc fuel inde l u Clog n .) ger filte r lin ged stuc r, st e r f eed r k) Clog pum ainer ged p st air c rain Defe lean er ctiv er e e AP l e men Defe S de t ctiv vice e or Lea dete kag rior ated Clog e, clog ging ged batt , air ery i n ject Clog in fu ion ged el sy n o z fuel zle, s Imp defe tem tank rop ctiv air b e sp Defe er fuel r eath ray , ctiv er h e fu oil use ole d el co ntro l lev er li nka ge

Causes

Exhaust gas comes out but engine does not start (fuel is being injected)

General causes why exhaust gas comes out but engine dose not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel and oil

Confirm recent repair history

Questions

Degree of use

Operated for long period

Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel has been used Replacement of filters has not been carried out according to operation manual Type of oil is not used according to operation manual Rust is found when fuel is drained Dust indicator is red Indicator lamp does not light up Starting motor cranks engine slowly

Check items

Mud is stuck to fuel tank cap When fuel lever is placed at FULL position, it does not contact stopper 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 There is leakage from fuel piping When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out Even when fuel control lever is moved, fuel injection pump lever does not move Remove head cover and inspect directly When control rack is pushed, it is found to be heavy or does not return When compression pressure is measured, it is found to be low 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 When air cleaner element is inspected directly, it is found to be clogged APS combustion portion does not become warm even when starting switch is turned to HEAT Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response or pump is heavy Speed of some cylinders does not change when operating on reduced cylinders When fuel cap is inspected directly, it is found to be clogged

20-310 (1)

Repair

Replace

Clean

Clean

Repair

Replace

Repair

Clean

Clean

Clean

Replace

Replace

Replace

Play, stiffness in fuel control lever linkage 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

WD600-3

TROUBLESHOOTING

S-3

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 c i n t ion er ctiv n e fe Wor ed p ozzle, d n pi efec u m ston p tive Seiz spra ring ed t , y cylin urbo der Imp c h arge rope r, in r va Clog terfe lve ge clea renc ranc e Clog d fuel t e ank ged air b , lea Defe king reat her ctiv fuel e co hole pipi Imp n ng t a ct rope of v r adju alve Bro stm , va k ent lve diap en inje of in se a t hrag ction j ectio m, b pum n pu roke p bo mp n ai stop r pu ost com leve mp pe n r sa t o 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 idling 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

WD600-3

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 (1)

TROUBLESHOOTING

S-4

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 k s h rod aft b Bro e s y ken stem eari , sei n g ( v Bro zed alve ken gea , roc pum r tr a ker Bro i p n leve a ken uxil r, et iary fuel c.) Lack equ pum ipm p dr of fu e i n v e t e sh l Clog aft, ged key fuel Clog f i lter, ged s f t e r a ed p Bro ken ump iner , sei stra Clog zed iner feed ged , lea pum Clog k i p pi n g fu ged ston el p fuel Defe i p t a ing nk a ctiv ir br e in eath ject Fail ion ure pum er hole in c has p (ra 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

Carry out troubleshooting in chassis volume

Remove oil pan and inspect directly When gear train is inspected, it does not turn

20-312 (1)

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

Remove head cover and inspect directly

—

WD600-3

TROUBLESHOOTING

S-5

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

Defe c

• Air in fuel system • Defective governor mechanism

Defe

tive ope ratin ctiv o of e a gov Defe djus erno tme ctiv r e op n t of g Low erat ove ion spe rnor e o d f con Lack is to trol o lo of fu rack w el Clog ged f eed Clog pum ged p st fuel rain Clog f i lter, er ged, stra air in iner Clog c i r cuit ged betw , air Clog een in ci fuel rcui ged tank t f betw u Defe el ta and een ctiv n feed k feed air b e fu pum el fe reat pum p ed p her a nd n hole ump ozzl e

Causes

Confirm recent repair history Degree of use

Operated for long period Occurs at fixed speed range

Questions

Condition of hunting

Occurs at low idling 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

WD600-3

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 (1)

TROUBLESHOOTING

S-6

S-6 Engine lacks output Carry out troubleshooting to decide if the cause is in the enginer or in the machine. (Measure engine stall speed).

• • • •

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 urbo lem Wor cha ent n pi rger s , int ton Clog e r r i n fere g ged , cy l nce fuel inde Clog filte r ged r , s feed tr Clog pum ainer ged p st inje Seiz rain c tion ed i er noz njec Imp z le, d t i on p rope efec ump r va tive Defe plun lve spra clea ctiv ge r y r e a con nce Ben t a ct t fue o l f leve valv Clog r lin e an ged ka g d va , lea e, d Clog lve k ing efec se a t ged f tive u e f l pip uel adju Brok t a nk ing en in st m air b e nt jecti Inco reat on p rrec h u e mp r t h p o boo Oil l osit le st co eve l too ion of s mpe t op nsat high leve or d iaph r ragm

General causes why engine lacks output

Causes

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 idling 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 idling 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 (1)

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

WD600-3

TROUBLESHOOTING

S-7

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust gas is black

Seiz ed t urbo Clog cha rger ged , int air c erfe lean Wor renc er e n pi e lem ston ent Clog ring , cy l ged inde , sei Imp zed r rope inje ctio r inj n no ecti Defe on t zzle ctiv imin e in g ject Imp i on p rope ump r va lve Crus (exc clea hed, e ssi ranc clog ve i e g njec ed m Leak tion uffle age ) r of ai r bet Defe wee ctiv n tur e co boch ntac Defe arge t of ctive r and valv i n jecti e, v cylin Defe alve on p der h ctiv seat ump ead e AP (rac S no k, pl zzle ung er s eize d)

• Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel

Causes

Confirm recent repair history Degree of use

Operated for long period Suddenly became black

Questions

Color of exhaust gas

Gradually became black Blue under light load

Engine oil must be added more frequently Power was lost

Suddenly Gradually

Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive

Check items

Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

When air cleaner is inspected directly, it is found to be clogged When compression pressure is measured, it is found to be 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 Injection pump test shows that injection amount is incorrect When valve clearance is checked directly, it is found to be outside standard value

WD600-3

Replace

Clean

Repair

Replace

Adjust

Replace

Repair

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

When muffler is removed, exhaust gas color returns to normal When control rack is pushed, it is found to be heavy or does not return

20-315 (1)

TROUBLESHOOTING

S-8

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

Brok en p isto n rin Wor g n pi s ton Clog ring ged , cyl brea inde Lea ther r lin kag er or b e fro reat Lea m oil f he r kag ilter hos e fro e , oil Lea mo kag coo il pi e fro ler ping Lea m oil d kag e fro rain Bro mo plug ken il pa oil c n, c Wor oole ylin de r n se r he a al a d, e Wor t tur t c. bine n se a e l nd at b Wor low n, b er e roke nd Dus Turb nr t su och cked ear sea arge l, se Wor i n r from al su n va l r v i f n a e take ce Brok (ste m, g syst en in em uide jecti Oil l on p ), br eve ump oke l too n se b oos t high al 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 cooling water 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 idling, 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 (1)

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

WD600-3

TROUBLESHOOTING

S-9

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 al a Defe t tur pipe ctiv boc e sa h arge f ety Exh valv r tur aus e bine t ga end s is 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

Check items

Oil filter caution lamp stays on even when oil pressure rises 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

WD600-3

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

Amount of blow-by gas

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

Black

20-317 (1)

TROUBLESHOOTING

S-10

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 j ecti Defe xc es on n ctiv s ive 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 f ue l l sea Defe pipi l ins ctiv ng, ide e ad f ue l feed just Defe filte men pum r ctiv t of e in p (pis f ue l ject t o ion n l eve ) noz r lin zle ( ka g loos e e re tain ing ca p )

• 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 idling 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 (1)

Repair

Adjust

Repair

Repair

Adjust

Replace

Replace

Adjust

When engine speed is measured, low idling 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

WD600-3

TROUBLESHOOTING

S-11

S-11 Oil is in cooling water, or water spurts back, or water level goes down General causes why oil is in cooling water Causes Bro ken oil c oole Bro ken r co re, O cylin -ring der Insu hea ffici d, c ent y l inde p Bro rotr r he ken usio ad g oil c n of aske oole Brok cylin t r for en c d er li ylin p owe ne r der Inte r tra line rnal in O-ri crac ng, ks in Brok hole en s c s ca y lind eal o used er b n wa lock by p ter p 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

WD600-3

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 cooling water (corrosion resistor valve is closed)

20-319 (1)

TROUBLESHOOTING

S-12

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 i n er in ged side , b roke Bro oil p ken n oi an suct l pipe Defe ion insi pipe ctiv de o e oi braz il pa Insu l pu ing n mp ffici p ortio ent Defe n oil l eve ctiv l in Defe e regul oil p ator ctiv an e valv r elie Lea e f va king lve Defe , crush ed h ctiv ydra e oil l Defe ulic eve ctiv pipi l sen e oi ng sor l pre Wat ssur er, f e uel sen in o sor Clog il 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 idling

Check items

Condition when oil pressure lamp lights up

Lights up at low, high idling 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

When oil filter is inspected directly, it is found to be clogged Remove oil pan and inspect directly 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 (1)

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".

Troubleshooting

Oil is cloudy white or smells of diesel oil

WD600-3

TROUBLESHOOTING

S-13

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

Questions

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

Bro ken oil c oole Defe r co ctiv re, O e no -ring zzle Bro ken hold prec cylin er s omb leev der e usti h Clog on c ead, h ged e ham a d wat ber) gask er p et (i Wor ump nclu n, d brea ding ama ther Defe ged h ctiv rear ole, e se se a l defe al o Lea ctive surf f pu kag a ce seal mp e of or a fuel Defe uxil from ct in iary noz side e qu zle h ipm inje Defe olde ctio e nt ctiv n pu r ret e th m a e i r Dam ning p mos aged tat s ca p eat cylin Crac der liner ks in O-rin side Bro g, ho cylin ken les m d e afte r blo ade r-co c 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 cooling water 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 idling, 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

WD600-3

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 (1)

TROUBLESHOOTING

S-14

S-14 Water temperature becomes too high (overheating) General causes why water 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 t or f ator ctiv in core e , lea ther Defe mos ka g ctiv e tat ( ew doe ater Insu s no ffici tem t op e p nt c erat Fan e n) ooli ure belt ng w g a ug 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 a ske rque O-rin Crac t con g, ho k in v e c les m rter ylin Defe oil t der ade ctive emp 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 water level sensor lights up Fan belt whines under sudden load

Check items

Cloudy white oil is floating on cooling water Cooling water 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 water temperature

Troubleshooting

Temperature difference between top and bottom radiator tanks is too small When radiator is inspected through water filler port, the core is found to be clogged When a function test is carried out on the thermostat, it does not open at the cranking temperature When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low Remove oil pan and inspect directly

Carry out troubleshooting for chassis

Carry out troubleshooting for chassis

Temperature difference between top and bottom radiator tanks is excessive

20-322 (1)

—

Replace

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

—

WD600-3

S-15

TROUBLESHOOTING

S-15 Abnormal noise is made fl Judge if the noise is an internal noise or an external noise.

Wor

• Abnormality due to defective parts • Abnormal combustion noise • Air sucked in from intake system

n pi ston Seiz ring ed t , cyl u rboc inde Mis r lin harg sing er er, i , sei nter Clog zed fere bus ged nce hing , sei Defe zed ctiv inje e c i t n ion Defe ject n ion ctiv pum ozzle e in Defo ject p (ra ion rme ck, p pum d fa lung Imp p (e n, in er s rope x t cess erfe eize r a ive renc d) Bro djus inje ken e t m o ctio f fan ent valv n) of v Imp b e sy e lt alve rope stem clea r ge (val Leak ranc ar tr ve, age e a r in b ocke of ai ackl r lev Defe r be ash twee er, e ct in n tu side tc.) Lea rboc muf kag h f a ler ( e fro r g e r an di ma Seiz d cy ir co viding b ed c linde mpr o rank r he esso ard out sha ad ft, b r pip of p ositi eari ing ng on)

General causes why abnormal noise is made

Causes

Confirm recent repair history

Questions

Degree of use

Operated for long period Gradually occurred

Condition of abnormal noise

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

Blue under light load Black

Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

Check items

Seal on injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy

Troubleshooting

Remove gear cover and inspect directly (flywheel housing top cover) 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 Injection pump test shows that injection amount is incorrect Fan is deformed, or belt is loose When valve clearance is checked directly, it is found to be outside standard value Remove cylinder head cover and inspect directly When muffler is removed, abnormal noise disappears Check for leakage from air compressor piping

WD600-3

Replace

Replace

Replace

Repair

Repair

Replace

Adjust

Repair

Adjust

Replace

Replace

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

Replace

Remove oil pan and inspect

20-323 (1)

TROUBLESHOOTING

S-16

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 be a 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 da m Valv a r tra ngin per) e sy i e n s a ba c 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 st uc 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 idling 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 (1)

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

WD600-3

TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (EA MODE) 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 water temperature sensor system high level) ............................. 20-382 EA-18 Error code [145] (Abnormality in water temperature sensor system low level)............................... 20-383 EA-19 Error code [151] (Abnormal rise in water 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

WD600-3

20-351 (1)

EA-37 EA-38 EA-39 EA-40 EA-41 EA-42 EA-43 EA-44 EA-45 EA-46 EA-47 EA-48 EA-49

Error code [431] (Abnormality 1 in idling validation switch system) ................................................ 20-399 Error code [432] (Idling validation process error) ............................................................................ 20-401 Error code [441] (Abnormality in battery voltage low level)............................................................. 20-404 Error code [442] (Abnormality in battery voltage high level) ........................................................... 20-404 Error code [451] (Abnormality in fuel rail pressure sensor system high level) ................................ 20-405 Error code [452] (Abnormality in fuel rail pressure sensor system low level) ................................. 20-406 Error code [455] (Abnormality in fuel rail actuator system current) ................................................. 20-407 Error code [467] (Abnormality in timing rail actuator control).......................................................... 20-408 Error code [468] (Abnormality in fuel rail actuator control).............................................................. 40-408 Error code [514] (Abnormality in fuel rail actuator) ......................................................................... 20-408 Error code [527] (Abnormality in dual output solenoid A system) ................................................... 20-409 Error code [551] (Abnormality 2 in idling validation switch system) ................................................ 20-409 Error code [554] (Abnormality in fuel rail pressure sensor in range)............................................... 20-410

20-352 (1)

WD600-3

TROUBLESHOOTING

METHOD OF ERROR CODE DISPLAY

METHOD OF ERROR CODE DISPLAY · ERROR CODE DISPLAY 1. An error code display device with tricolor lamps is installed at the foot of the operator's seat. 2. The error code display device is composed of three lamps of different colors, e.g. orange (1), yellow (2) and red (3), selector switch (4) and diagnosis switch (5). 3. Checking blown lamps 1) When turning the engine starting switch ON: When starting the engine starting switch ON, the three lamps light up for about two seconds to show if there is any blown lamp and then go off, if there is none. At that time, keep diagnosis switch (5) at the OFF position. 2) Manual check: It can be checked whether a lamp is blown or not by turning diagnosis switch (5) ON, after the engine starting switch has been turned ON and if there is no engine trouble occurred. If each of the three lamps lights up, it is normal. A lamp which does not light up may well be replaced, as it is all likely blown. If there is any engine trouble occurred at that time, an error code is displayed. 4. Always keep diagnosis switch (5) at the OFF position (normal position), except when seeing an error code.

Example of display: When displaying error code [253]

·

An engine controller displays the engine conditions in the following two modes. 1. Display of engine trouble If any of the three color lamps lights up while the engine is running, or when the engine starting switch is in the ON position, it indicates that an engine trouble has occurred and also the nature and extent of such a trouble. 2. Display of error code By calling an error code in the display after the engine starting switch is turned ON but when the engine is not run, a three-digit error code may be confirmed through times that the lamp flashes. ·

Display of nature and extent of engine trouble 1. When the orange lamp lights up: This indicates that the engine controller has recorded some abnormality in the engine. The device automatically regulates the engine output depending upon nature of such abnormality. 2. When the yellow lamp lights up: This indicates that some abnormality has occurred in the engine, but that such abnormality is still light enough to tolerate the engine to keep running.

WD600-3

20-353 (1)

TROUBLESHOOTING

METHOD OF ERROR CODE DISPLAY

3. When the red lamp lights up: This indicates that some serious abnormality has occurred in the engine, and that the engine must be stopped immediately. ·

Display of error code (Method for confirming three-digit error code) 1. Turn the engine starting switch ON and turn diagnosis switch (5) ON. 2. In this condition, the lamps light up and then go off, if there is no blown lamp. (A function of checking a blown lamp) If there is an engine trouble occurred, meanwhile, an error code for the trouble is displayed by the time that the red lamp flashes. At that time, the orange (white) lamp remains lit, while the error code is displayed. 3. Counting error code (Example: Case of Error Code 253) At first the yellow lamp flashes once. (Starting display of error code) All the lamps go off for about one second. The red lamp repeats flashing so many times as the third digit number of the error code. (Example: 2 times) All the lamps go off for about one second. The red lamp repeats flashing so many times as the second digit number of the error code. (Example: 5 times) All the lamps go off for about one second. The red lamp repeats flashing so many times as the first digit number of the error code. (Example: 3 times) All the lamps go off for about one second. The yellow lamp flashes once. (The end of that error code number) The processes of 2) through 9) are repeated. 4. When plural troubles have occurred: If it is suspected that more than two engine troubles have occurred at a time, push up selector switch (4) for about two seconds, then the display advances to the next error code number. In case only one trouble has occurred, on the other hand, the display shows the same error code number. Continue to advance the display until the same error code number is shown to read out all the error codes. Push down selector switch (4) to return to the immediately preceding error code. 5. Turning off diagnosis switch Turn diagnosis switch (5) OFF. (Return to normal condition) 6. An error code is deleted, once the engine trouble is removed and the engine starting switch is turned OFF.

20-354 (1)

WD600-3

TROUBLESHOOTING

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

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

System with abnormality

Nature of abnormality

Condition when normal

Abnormality in controller memory

Failure of memory hardware inside controller or communications failure in internal processor

—

112

Abnormality in timing rail actuator

• Abnormality in timing rail Excessive difference between timing rail command fuel value and actual timing fuel Judgment value (reference): Difference more than 400 mm3/st or less than –750 mm3/st (when coolant temperature is 0°C or above)

—

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

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

113

Abnormality with electric current in timing rail actuator system

115

Abnormality in engine speed sensor 2 system

• No signal is input from engine speed sensor circuit system 2 ECMA (27), (28): Signal 1 ECMA (37), (38): Signal 2

• Resistance of engine speed sensor Between SP2 (A) and (B) (signal 1):1 – 2 kz Between SP1 (A) and (B) (signal 2):1 – 2 kz

116

Abnormality in timing rail pressure sensor system high level

• Abnormality has occurred in timing rail pressure sensor circuit ECMA (33): 4.78 V or more detected

• Voltage of timing rail pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (33) and (18) (signal): 0.42 – 0.58 V (engine stopped)

117

Abnormality in timing rail pressure sensor system low level

• Abnormality has occurred in timing rail pressure sensor circuit ECMA (33): 0.30 V or less detected

• Voltage of timing rail pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (33) and (18) (signal): 0.42 – 0.58 V (engine stopped)

118

Abnormality in fuel pump pressure sensor system high level

• Abnormality has occurred in fuel pump pressure sensor circuit ECMA (32): 4.78 V or more detected

• Voltage of fuel pump pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (32) and (18) (signal): 0.42 – 0.58 V (engine stopped)

119

Abnormality in fuel pump pressure sensor system low level

• Abnormality has occurred in fuel pump pressure sensor circuit ECMA (32): 0.30 V or less detected

• Voltage of fuel pump pressure sensor Between ECMA (5) and (18) (power source): 4.75 – 5.25 V Between ECMA (32) and (18) (signal): 0.42 – 0.58 V (engine stopped)

121

Abnormality in engine speed sensor 1 system

• 15. No signal is input from engine speed sensor circuit system 2 to one of following ECMA (27), (28): Signal 1 ECMA (37), (38): Signal 2

• Resistance of engine speed sensor Between SP2 (A) and (B) (signal 1): 1 – 2 kz Between SP1 (A) and (B) (signal 2): 1 – 2 kz

122

Abnormality in boost pressure sensor system high level

• Abnormality has occurred in boost pressure sensor circuit ECMA (35): 4.72 V or more detected

• Voltage of boost pressure sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (35) and (17) (signal): 0.42 – 0.58 V (engine stopped)

123

Abnormality in boost pressure sensor system low level

• Abnormality has occurred in boost pressure sensor circuit ECMA (35): 0.30 V or less detected

• Voltage of boost pressure sensor Between ECMA (6) and (17) (power source): 4.75 – 5.25 V Between ECMA (35) and (17) (signal): 0.42 – 0.58 V (engine stopped)

111

20-356 (1)

WD600-3

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 1500 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 1500 rpm

• Engine makes abnormal explosion sound or emits white smoke, then engine speed becomes 1500 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 1500 rpm

• Engine makes abnormal explosion sound or emits white smoke, then engine speed becomes 1500 rpm1

• 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

WD600-3

20-357 (1)

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

—

132

Abnormality in throttle sensor system low level

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

—

135

Abnormality in oil pressure sensor system high level

141

Abnormality in oil pressure sensor system low level

Nature of abnormality

Condition when normal

• 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)

• 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)

• 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 1000 rpm Max. 0.09 MPa { 0.9 kg/cm2} At 1500 rpm Max. 0.15 MPa { 1.5 kg/cm2} At 1800 rpm Max. 0.18 MPa {1.85 kg/cm2} At 2000 rpm Max. 0.21 MPa { 21 kg/cm2}

143

Abnormal drop in oil pressure (level 1)

144

Abnormality in water temperature sensor system high level

145

Abnormality in water temperature sensor system low level

151

Abnormal rise in water temperature

• Water 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 (1)

Overspeed

—

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

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

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

• Resistance of water 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

—

WD600-3

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

• Abnormality in throttle controller system • 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

• Abnormality in throttle controller system • 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 water temperature sensor • Defective wiring harness and connector of water temperature sensor circuit • Defective engine controller

—

• Defective water temperature sensor • Defective wiring harness and connector of water 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). —

WD600-3

• Defective engine • Defective water 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 (1)

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

—

316

431

20-360 (1)

Abnormality 1 in idling validation switch system

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

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

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

—

—

—

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

• Voltage of accelerator limit switch relay Between C9(3) – (6): Min. 5 V (pedal depressed) Max. 1 V (pedal released) Between C9(3) – (5): Max. 1 V (pedal depressed) Min. 5 V (pedal released)

WD600-3

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 idling speed to 1,500 rpm

—

• Red lamp lights up —

WD600-3

• 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 wiring harness and connector of idling validation switch • Defective accelerator limit switch relay • Defective engine controller

20-361 (1)

TROUBLESHOOTING

User code

System with abnormality

432

Idling 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 idling validation ON signal, OFF signal do not match ECMB (12): Idling OFF signal ECMB (13): Idling ON signal

• Resistance of idling switch Between L14A(1) – (2): Max. 1 z (pedal released) Between L14A(1) – (3): Max. 1 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 idling validation switch ECMB (12): Idling OFF signal ECMB (13): Idling ON signal

• Resistance of idling 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 idling validation switch system

554

Abnormality in fuel rail pressure sensor in range

20-362 (1)

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

—

—

WD600-3

TROUBLESHOOTING

Action by controller

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

Problem that appears on machine

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

—

—

—

• Defective idling validation switch • Defective wiring harness and connector of idling validation switch • Defective throttle controller • Defective accelerator limit switch relay • 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

—

WD600-3

• 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 idling 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 (1)

TROUBLESHOOTING

SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM

SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM

20-364 (1)

WD600-3

TROUBLESHOOTING

WD600-3

SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM

20-365 (1)

EA-1, EA-2

TROUBLESHOOTING

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



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






     

         



  

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20-366 (1)



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WD600-3

TROUBLESHOOTING

EA-3

EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system) 

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 ! " Ω

! " Ω

  
        
         ##$% #% &#

 

 ! " Ω

! " Ω

EA-3 Related electrical circuit diagram

WD600-3

20-367 (1)

EA-4

TROUBLESHOOTING

EA-4 Error code [115] (Abnormality in engine speed sensor 2 system) Cause

Remedy

1 • Turn starting switch OFF. • Disconnect SP1 and SP2.

Is resistance between SP1 (male) NO (A) and (B), and between SP2 (male) (A) and (B) 1k – 2kΩ?

Defective engine speed sensor

Replace

Defective engine speed sensor

Replace

Defective engine speed sensor

Replace

Defective engine speed sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (37) and SP2 (female) (A)

Repair or replace

YES

2 • Turn starting switch OFF. • Disconnect SP1 and SP2.

Is resistance between SP1 (male) NO (A) and ground, and between SP2 (male) (A) and ground more than 10 MΩ?

YES

3 • Turn starting switch OFF. • isconnect SP1 and SP2.

Is resistance between SP1 (male) (A) and SP2 (male) (A), and NO between SP1 (male) (B) and SP2 (male) (B) less than 10 Ω?

YES

4 • Remove engine speed sensor.

Is engine speed sensor damaged?

NO

YES

5 • Turn starting switch OFF. • Disconnect ECMA and SP1.

Is resistance between ECMA (female) (37) and SP2 (female) (A), and between ECMA (female) (37) and surrounding wiring harnesses as shown in Table 1?

NO

YES

6 • Turn starting switch OFF. • Disconnect ECMA and SP1.

Is resistance between ECMA (female) (38) and SP2 (female) (B), and between ECMA (female) (38) and surrounding wiring harnesses as shown in Table 2?

NO

Defective contact, disconnection, or short circuit in wiring harness between Repair or ECMA (female) (38) and SP2 (female) replace (B)

YES

7 • Turn starting switch OFF. • Disconnect ECMA and SP2.

Is resistance between ECMA (female) (27) and SP1 (female) (A), and between ECMA (female) (27) and surrounding wiring harnesses as shown in Table 3?

NO

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (27) and SP1 (female) (A)

Repair or replace

YES

8 • Turn starting switch OFF. • Disconnect ECMA and SP2.

Is resistance between ECMA (female) (28) and SP1 (female) (B), and between ECMA (female) (28) and surrounding wiring harnesses as shown in Table 4?

NO

Defective contact, disconnection, or short circuit in wiring harness between Repair or ECMA (female) (28) and SP1 (female) replace (B)

YES Defective engine controller

20-368 (1)

Replace

WD600-3

TROUBLESHOOTING

EA-4

Table 1 ECMA (female), SP2 (female) Between ECMA (37) and SP2 (A) Between ECMA (37) and surrounding wiring harnesses

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

Table 3 ECMA (female), SP1 (female) Between ECMA (27) and SP1 (A) Between ECMA (27) and surrounding wiring harnesses

ECMA (female), SP2 (female) Between ECMA (38) and SP2 (B) Between ECMA (38) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

Table 3 Resistance value Max. 10 Ω Min. 1 MΩ

ECMA (female), SP1 (female) Between ECMA (28) and SP1 (B) Between ECMA (28) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

EA-4 Related electrical circuit diagram

WD600-3

20-369 (1)

EA-5

TROUBLESHOOTING

EA-5 Error code [116] (Abnormality in timing rail pressure sensor system high level)  






3 4 ( 
% 3 ' ') "*  %

3 ' ') "* 66% 3 4 (   
%

.* 
  ( (  ''(' ( /01 )( (2



4  ) ' 7' '  ('

5 '   "   #  
   "    #  ''() "') *'   *("   2



!

3 ' ') "* 66% 3 4 (   
%

5 '   "   ,  
  !  "   ,  ''() "') *'   *("   +2



3 ' ') "* 66% 3 4 (   
%



 

  
 !"  #  
 !"  #  ''() "') *' 

"

5 '   "   --  
    "   --  ''() "') *'   *("   -2


    $% & Ω %  Ω


7

4  (  (( (' *(' '  "') *' "
7' ('

  #  
 '7  4  (  (( (' *(' '  "') *' "
7' ('

  ,  
 '7 ! 4  (  (( (' *(' '  "') *' "
7' ('

  --  
 '7  4  ) ('('

 +

    !"  ,  
! !"  ,  ''() "') *' 


7


    $% & Ω %  Ω

   
 
    !"  --  
  $% & Ω !"  --  %  Ω ''() "') *'  EA-5 Related electrical circuit diagram

20-370 (1)

WD600-3

TROUBLESHOOTING

EA-6

EA-6 Error code [117] (abnormality in timing rail pressure sensor system low level) ($ 2$ '    
  #       $ $+  %
 3

4 2$*
56 *
 4
(* $ * % $% &+ .-

"1

 -.

7!& %' %"% *% 6*$$(* $$ *

6&

7!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$     !"  
!" 

6%* * *6&

/0

2$ *$%$ &     !"  
!" # -.      !"   $(** (% %*% +*$$$ $ $+  %
 3

4
(* $ * % $% &+ .88 4 7%$& &   


/0

!

2$ *$%$ &     !"  
!" #      !" -.   $(** (% %*% +*$$$ $ $+  %
 ,3

4
(* $ * % $% &+ .88 4 7%$& &   


/0

"

2$ *$%$ &     !" ,, 
!" -. #      !" ,,  $(** (% %*% +*$$$ $ $+  %
 3

4
(* $ * % $% &+ .88 4 7%$& &   


/0


  

 7!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$   6%* *   !"  
!" *6& 

7!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$   6%* *   !" ,, 
!" *6&  7!& %' % &  * *

6&


 


  

  !"#
!"

               

     
       $(** (% %*% +*$$$

   

     
       $(** (% %*% +*$$$

)  Ω %  Ω


 


 ,   !"#
!" 

$%$ & '(

$%$ & '( )  Ω %  Ω

  !"#
!"     ,, 
      ,,  $(** (% %*% +*$$$

$%$ & '( )  Ω %  Ω

EA-6 Related electrical circuit diagram

WD600-3

20-371 (1)

EA-7

TROUBLESHOOTING

EA-7 Error code [118] (Abnormality in fuel pump pressure sensor system high level)   

2 3( % 2  '  ') "* 
%

.*   (  ( ''(' (  /,0 )( ( 1






2 '  ') "* 55% 23(   %



3    6 6 6' ' ('

4 '  "    #       "   
 #   ''(  ) "') * '  *("    1



6 

3  (  (( (' *(' '   "') * ' " 6 ' (' '6     #     

!

2 '  ') "* 55% 2 3(   %

4 '  "    ,    
 !  "    ,   ''(  ) "') * '  *("    +1



3  (  (( (' 6 ' (' *(' '   "') * ' " '6     ,     !

"

2 '  ') "* 55% 23(   %

4 '  "    -+       "   
 -+   ''(  ) "') * '  *("    -1



              !"  #     $% & Ω !"  #  %  Ω  ''(  ) "') * '

3  (  (( (' *(' '   "') * ' " 6 ' ('    -+   '6     6  3  ) ('('

  +           !"  ,   !  $% & Ω !"  ,  %  Ω  ''(  ) "') * '

             !"  -+      $% & Ω !"  -+  %  Ω  ''(  ) "') * ' EA-7 Related electrical circuit diagram

20-372 (1)

WD600-3

TROUBLESHOOTING

EA-8

EA-8 Error code [119] (Abnormality in fuel pump pressure sensor system low level) ($

"1



4 2$*
56*   4
(* $*% $%&+ .-

2$ '      -. #      $ $+  %
 3

7!&%' !( 6("6 6*$$(* $$ *

2$ *$%$&    !"    !" -. #     !"   $(** (% %*% +*$$$ $ $+  %
 3

7!&%' & &# %$& &% # * $+ * &%*&(% % %*% +*$$  6%* *   !"    !" *6& 

6&

/ 0

4
(* $*% $%&+ .88 47%$& &    

/ 0

!

2$ *$%$&    !"    !" -. #     !"   $(** (% %*% +*$$$ $ $+  %
 ,3

4
(* $*% $%&+ .88 47%$& &    

/ 0

"

2$ *$%$&    !" ,   !" -. #     !" ,  $(** (% %*% +*$$$ $ $+  %
 3

4
(* $*% $%&+ .88 47%$& &    

/ 0


  

7!&%' & &# %$& &% # * $+ * &%*&(% % %*% +*$$  6%* *   !"    *6& !" 

7!&%' & &# %$& &% # * $+ * &%*&(% % %*% +*$$  6%* * *6&   !" ,   !"  7!&%' % & * *

6&


  



            

  

  !"#  !"

$%$& '(

)  Ω

%  Ω


 


 ,              $(** (% %*% +*$$$

  !"#  !"             $(** (% %*% +*$$$

$%$& '(

)  Ω

%  Ω

  !"#  !"    ,       ,  $(** (% %*% +*$$$

$%$& '(

)  Ω

%  Ω

EA-8 Related electrical circuit diagram

WD600-3

20-373 (1)

EA-9

TROUBLESHOOTING

EA-9 Error code [121] (Abnormality in engine speed sensor 1 system) ★ Carry out troubleshooting for error code [115].

20-374 (1)

WD600-3

TROUBLESHOOTING

EA-10

EA-10 Error code [122] (Abnormality in boost pressure sensor system high level)   

4 5 )  & 4  (  (* # + 
&

0+    )   ) (()( )  1,,2 *) ) 3






4 (  (* # + 66& 45 )    &



5 ! )) 8( ( )(

 (   #    -     "  #   
 -   (()  * #(* + (  +)#    ,3



8 

5 ! )   ) ) )( +)( (   #(* + ( # 8 ( )(    $     (8  

!

4  (  (* # + 66& 4 5 )    &

 (   #    7    
 "  #    7   (()  * #(* + (  +)#    ,3



5 ! )   ) ) )( +)( (   #(* + ( # 8 ( )( (8     -     "

"

4  (  (* # + 66& 4 5 )    &

          "#  $    "#  $   (()  * #(* + (

 (   #    ./       #   
 ./   (()  * #(* + (  +)#    .3



   !    %& ' Ω &  Ω

5 ! )   ) ) )( +)( (   #(* + ( # 8 ( )( (8     ./      8  5 ! * )()(

  ,          !   "#  -   "  %& ' Ω "#  -  &  Ω  (()  * #(* + (

  .           !   "#  ./      %& ' Ω "#  ./  &  Ω  (()  * #(* + ( EA-10 Related electrical circuit diagram

WD600-3

20-375 (1)

EA-11

TROUBLESHOOTING

EA-11 Error code [123] (Abnormality in boost pressure sensor system low level) )%

#3



5 %,
67,    5
), %,& %&'- 0/

% (     /0 $      % %- &
 4

9"'&( % 7,%%), %%,

% ,%&%'  !  "# *   "# $   !  "# /0 *  %),,)& &,& -,%%% % %- &
 4

9"'&( ''$ &%''&$ , %-, '&,')& & &,& -,%%  7&, , !  "# *   "# ,7' 

7'

1!2

5
), %,& %&'- 088 5 9&%'' !    

1!2

!

% ,%&%'  !  "#    "# /0 $   !  "#   %),,)& &,& -,%%% % %- &
 .4

5
), %,& %&'- 088 59&%'' !    

1!2

"

% ,%&%'  !  "# .   "# /0 $   !  "# .  %),,)& &,& -,%%% % %- &
 4

5
), %,& %&'- 088 59&%'' !    

1!2


  

9"'&( ''$ &%''&$ , %-, '&,')& & &,& -,%%  !  "#    "# 

7&, , ,7'

9"'&( ''$ &%''&$ , %-, '&,')& & &,& -,%%  7&, , ,7' !  "# .   "#  9"'&( & ',,

7'


   



!  "#$  "#

            

  

 !       !    %),,)& &,& -,%%%

+  Ω

&  Ω


 


 . !  "#$  "# 

%&%' ()

 !  *     !  *  %),,)& &,& -,%%%

%&%' ()

+  Ω

&  Ω

!  "#$  "#

 %&%' ()

 !  .     !  .  %),,)& &,& -,%%%

+  Ω

&  Ω

EA-11 Related electrical circuit diagram

20-376 (1)

WD600-3

TROUBLESHOOTING

EA-12

EA-12 Error code [131] (Abnormality in accelerator sensor system high level) Cause Display troubleshooting of throttle controller system (HT mode) "TH-1 Abnormality in accelerator pedal sensor system is displayed" and carry out "TH-4 Abnormality in electronic governor voltage command system".

Are results of TH-1 and TH-4 free from abnormality?

• Turn starting switch OFF. • Disconnect ECMB and L13.

Is resistance between ECMB (female) (11) and L13 (female) (2), and between ECMB (female) (11) and surrounding wiring harnesses as shown in Table 1?

Remedy

1 NO

Defective throttle controller system

Repair

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (11) and L13(female) (2)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (29) and L13 (female) (1)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (26) and L13 (female) (3)

Repair or replace

Defective engine controller

Replace

YES

2 NO

YES

3 • Turn starting switch OFF. • Disconnect ECMB and L13.

Is resistance between ECMB (female) (29) and L13 (female) (1), and between ECMB (female) (29) and surrounding wiring harnesses as shown in Table 2?

NO

YES

4 • Turn starting switch OFF. • Disconnect ECMB and L13.

Is resistance between ECMB (female) (26) and L13 (female) (3), and between ECMB (female) (26) and surrounding wiring harnesses as shown in Table 3?

NO

YES

Table 1

Table 2

ECMB (female), L13 (female)

Resistance value

Between ECMA (11) and L13(2)

Max. 10 z

Between ECMB (11) and surrounding wiring harnesses

Min. 1 Mz

ECMB (female), L13 (female) Between ECMB (29) and L13(1) Between ECMB (29) and surrounding wiring harnesses

Resistance value Max. 10 z Min. 1 Mz

Table 3 ECMB (female), L13 (female) Between ECMB (26) and L13(3) Between ECMB (26) and surrounding wiring harnesses

WD600-3

Resistance value Max. 10 z Min. 1 Mz

20-377 (1)

TROUBLESHOOTING

EA-12, EA-13

EA-12 Related electrical circuit diagram

EA-13 Error code [132] (Abnormality in accelerator sensor system low level) a Carry out troubleshooting for error code [131].

20-378 (1)

WD600-3

TROUBLESHOOTING

EA-14

EA-14 Error code [135] (Abnormality in oil pressure sensor system high level) Cause

Remedy

1 • Disconnect CLPR. • Turn starting switch ON.

NO

When CLPR is disconnected, does error code [135] go out?

YES Defective oil pressure sensor

Replace

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

Is resistance between ECMA (female) (6) and CLPR (female) (A), and between ECMA (female) (6) and surrounding wiring harnesses as shown in Table 1?

NO

Defective contact, disconnection, or short circuit in wiring harness between Repair or ECMA (female) (6) and CLPR (female) replace (A)

YES 3 • Turn starting switch OFF. • Disconnect ECMA and CLPR.

Is resistance between ECMA (female) (17) and CLPR (female) (B), and between ECMA (female) (17) and surrounding wiring harnesses as shown in Table 2?

NO

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

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (24) and CLPR (female) (C)

Repair or replace

Defective engine controller

Replace

YES 4 • Turn starting switch OFF. • Disconnect ECMA and CLPR.

Is resistance between ECMA (female) (24) and CLPR (female) (C), and between ECMA (female) NO (24) and surrounding wiring harnesses as shown in Table 3?

YES

Table 1 ECMA (female), CLPR (female) Between ECMA (6) and CLPR (A) Between ECMA (6) and surrounding wiring harnesses

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

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

Resistance value Max. 10 Ω Min. 1 MΩ

Table 3 ECMA (female), CLPR (female) Between ECMA (24) and CLPR (C) Between ECMA (24) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

EA-14 Related electrical circuit diagram

WD600-3

20-379 (1)

EA-15

TROUBLESHOOTING

EA-15 Error code [141] (Abnormality in oil pressure sensor system low level) Cause

Remedy

1 Is voltage between CLPR (A) and NO (B), and between (C) and (B) as shown in Table 1?

• Insert T-adapter to CLPR. • Turn starting switch ON.

Defective oil pressure sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (6) and CLPR (female) (A)

Repair or replace

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

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (24) and CLPR (female) (C)

Repair or replace

Defective engine controller

Replace

YES

2 Is resistance between ECMA (female) (6) and CLPR (female) (A), and between ECMA (female) (6) and surrounding wiring harnesses as shown in Table 2?

• Turn starting switch OFF. • Disconnect ECMA and CLPR.

NO

YES

3 Is resistance between ECMA (female) (17) and CLPR (female) (B), and between ECMA (female) (17) and surrounding wiring harnesses as shown in Table 3?

• Turn starting switch OFF. • Disconnect ECMA and CLPR.

NO

YES

4 Is resistance between ECMA (female) (24) and CLPR (female) (C), and between ECMA (female) (24) and surrounding wiring harnesses as shown in Table 4?

• Turn starting switch OFF. • Disconnect ECMA and CLPR.

NO

YES

Table 1

Table 2 CLPR

Voltage

Between (A) and (B)

4.75 – 5.25 V

Between ECMA (6) and CLPR (A)

Between (C) and (B)

0.42 – 0.58 V

Between ECMA (6) and surrounding wiring harnesses

ECMA (female), CLPR (female)

Between ECMA (17) and CLPR (B) Between ECMA (17) and surrounding wiring harnesses

Max. 10 Ω Min. 1 MΩ

Table 4

Table 3 ECMA (female), CLPR (female)

Resistance value

Resistance value Max. 10 Ω Min. 1 MΩ

ECMA (female), CLPR (female) Between ECMA (24) and CLPR (C) Between ECMA (24) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

EA-15 Related electrical circuit diagram

20-380 (1)

WD600-3

TROUBLESHOOTING

EA-16

EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))  





      


       
   

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



WD600-3

,




+#  +#     #    +#  

-   ".  #                     

20-381 (1)

EA-17

TROUBLESHOOTING

EA-17 Error code [144] (Abnormality in water 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 water 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 (1)

WD600-3

TROUBLESHOOTING

EA-18, EA-19

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

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





      


-     '  
   (

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



WD600-3






+   ,   *   ' 

) * 

-*     , '     

) *       ', '      ' 

20-383 (1)

EA-20, EA-21

TROUBLESHOOTING

EA-20 Error code [153] (Abnormality in intake air temperature sensor system high level) Cause

Remedy

1 • Turn starting switch OFF. • Disconnect IMTP

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

NO

Defective intake air temperature sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (23) and IMTP (female) (A)

Repair or replace

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

Repair or replace

Defective engine controller

Replace

YES

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

Is resistance between ECMA (female) (23) and IMTP (female) (A), and between ECMA (female) (23) NO and surrounding wiring harnesses as shown in Table 1?

YES

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

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

YES

Table 1 ECMA (female), IMTP (female) Between ECMA (23) and IMTP (A) Between ECMA (23) and surrounding wiring harnesses

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

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

Resistance value Max. 10 Ω Min. 1 MΩ

EA-20 Related electrical circuit diagram

EA-21 Error code [154] (Abnormality in intake air temperature sensor system low level) a Carry out troubleshooting for error code [153].

20-384 (1)

WD600-3

TROUBLESHOOTING

EA-22

EA-22 Error code [221] (Abnormality in atmospheric pressure sensor system high level) Cause

Remedy

1 • Disconnect AAPR. • Turn starting switch ON.

NO

When AAPR is disconnected, does error code [221] go out?

YES

Defective atmospheric pressure sensor

Replace

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

Is resistance between ECMA (female) (6) and AAPR (female) (A), and between ECMA (female) (6) and surrounding wiring harnesses as shown in Table 1?

NO

Defective contact, disconnection, or short circuit in wiring harness between Repair or ECMA (female) (6) and AAPR (female) replace (A)

YES 3 • Turn starting switch OFF. • Disconnect ECMA and AAPR.

Is resistance between ECMA (female) (17) and AAPR (female) (B), and between ECMA (female) (17) and surrounding wiring harnesses as shown in Table 2?

NO

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

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (34) and AAPR (female) (C)

Repair or replace

Defective engine controller

Replace

YES 4 • Turn starting switch OFF. • Disconnect ECMA and AAPR.

Is resistance between ECMA (female) (34) and AAPR (female) (C), and between ECMA (female) NO (34) and surrounding wiring harnesses as shown in Table 3?

YES

Table 1 ECMA (female), AAPR (female) Between ECMA (6) and AAPR (A) Between ECMA (6) and surrounding wiring harnesses

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

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

Resistance value Max. 10 Ω Min. 1 MΩ

Table 3 ECMA (female), AAPR (female) Between ECMA (34) and AAPR (C) Between ECMA (34) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

EA-22 Related electrical circuit diagram

WD600-3

20-385 (1)

EA-23

TROUBLESHOOTING

EA-23 Error code [222] (Abnormality in atmospheric pressure sensor system low ) Cause

Remedy

1 Is voltage between AAPR (A) and NO (B), and between (C) and (B) as shown in Table 1?

• Insert T-adapter to AAPR. • Turn starting switch ON.

Defective atmospheric pressure sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (6) and AAPR (female) (A)

Repair or replace

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

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (34) and AAPR (female) (C)

Repair or replace

Defective engine controller

Replace

YES

2 Is resistance between ECMA (female) (6) and AAPR (female) (A), and between ECMA (female) (6) and surrounding wiring harnesses as shown in Table 2?

• Turn starting switch OFF. • Disconnect ECMA and AAPR.

NO

YES

3 Is resistance between ECMA (female) (17) and AAPR (female) (B), and between ECMA (female) (17) and surrounding wiring harnesses as shown in Table 3?

• Turn starting switch OFF. • Disconnect ECMA and AAPR.

NO

YES

4 Is resistance between ECMA (female) (34) and AAPR (female) (C), and between ECMA (female) (34) and surrounding wiring harnesses as shown in Table 4?

• Turn starting switch OFF. • Disconnect ECMA and AAPR.

NO

YES

Table 1

Table 2 AAPR

Voltage

Between (A) and (B)

4.75 – 5.25 V

Between (C) and (B)

0.42 – 0.58 V

ECMA (female), AAPR (female) Between ECMA (6) and AAPR (A) Between ECMA (6) and surrounding wiring harnesses

Between ECMA (17) and AAPR (B) Between ECMA (17) and surrounding wiring harnesses

20-386 (1)

Max. 10 Ω Min. 1 MΩ

Table 4

Table 3 ECMA (female), AAPR (female)

Resistance value

Resistance value Max. 10 Ω Min. 1 MΩ

ECMA (female), AAPR (female) Between ECMA (34) and AAPR (C) Between ECMA (34) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

WD600-3

TROUBLESHOOTING

EA-23

EA-23 Related electrical circuit diagram

WD600-3

20-387 (1)

EA-24

TROUBLESHOOTING

EA-24 Error code [234] (Overspeed)  






      

         

$%&

"

             



$%&

      

      

$%&

20-388 (1)

# 

   !     

!    !



!    !   

        

 

        

 

        

 

WD600-3

TROUBLESHOOTING

EA-25

EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage) 

".

 3
& &( ) $ 3 4'  " *$

,

/ &   " *  "  0 1! Ω2

4   )*'



6

4   )*'



6

4  ' "'' '& )'& &  &( )&     %+ " *

6& '& &6

- 3
& &( ) $ 3 4'  " *$

/ &   " *  " '& ) %!! 5Ω2

,

-

!

3
& &( ) $ 3 4'   " *$

/ &     %+ " * "     %+ " , &&'"( &( )&  )' 
 %2

-

"

3
& &( ) $ 34'   " $

/ &     ! "  " ,     ! " &&'"( &( )&  )' 
 2

-

   %+ " *     %+ " &&'"( &( )&

4  ( '&'&

6


 


 %    *

4  ' "'' '& '& )'& &  &( )&  6& &6    ! " 

 

#$ %! Ω

$ % Ω

        ! "     ! " &&'"( &( )&

 

#$ %! Ω

$ % Ω

EA-25 Related electrical circuit diagram

WD600-3

20-389 (1)

EA-26, EA-27

TROUBLESHOOTING

EA-26 Error code [259] (Abnormality in fuel shut-off valve)  





      





          



'     ! #    

)!# !   "!! # #

 

$ $  % $   %  ! !  !$ 

    

)!#  

 

)!# &

 




         ! !   "!! # #

   $ $  % $   %  ! !  !$ 

(

!






"

         ! &






EA-27 Error code [261] (Abnormal rise in fuel temperature)  





      


       
   

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



20-390 (1)

,




+#  +#     # #     

-   ".  #                     

WD600-3

TROUBLESHOOTING

EA-28, EA-29

EA-28 Error code [263] (Abnormality in fuel temperature sensor system high level) Cause

Remedy

1 • Turn starting switch OFF. • Disconnect FLTP.

Is resistance between FLTP (male) (A) and (B) 600 – 36k Ω?

NO

Defective fuel temperature sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (26) and FLTP (female) (A)

Repair or replace

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

Repair or replace

Defective engine controller

Replace

YES

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

Is resistance between ECMA (female) (26) and FLTP (female) (A), and between ECMA (female) (26) and surrounding wiring harnesses as shown in Table 1?

NO

YES

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

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

YES

Table 1 ECMA (female), FLTP (female) Between ECMA (26) and FLTP (A) Between ECMA (26) and surrounding wiring harnesses

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

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

Resistance value Max. 10 Ω Min. 1 MΩ

EA-28 Related electrical circuit diagram

EA-29 Error code [265] (Abnormality in fuel temperature sensor system low level) a Carry out troubleshooting for error code [263].

WD600-3

20-391 (1)

EA-30

TROUBLESHOOTING

EA-30 Error code [316] (Abnormality in fuel pump actuator system current) 

 ,

 2
$ $& ' )33" 2 4%  "

- $        . / 0 Ω1

()

4   66 %$

6

()

4   66 %$

6

4  % %% %$ '%$ $  $& '$     ##     

6$ %$ $6

*+ 2
$ $& ' )33" 2 4%  "

- $        &$% %$ ' # 5Ω1

*+

!

2
$ $& ' )33" 2 4%     "

- $     ##     ()       ##  $$% & $& '$  '% 
 #1

*+

"

2
$ $& ' )33" 2 4%     "

- $          ()         $$% & $& '$  '% 
 1

*+

   ##        ##  $$% & $& '$

4  & %$%$

6


 


 #      

4  % %% %$ '%$ $  $& '$  6$ %$ $6         

 

      

 

!" # Ω

             $$% & $& '$

!" # Ω

" # Ω

" # Ω

EA-30 Related electrical circuit diagram

20-392 (1)

WD600-3

TROUBLESHOOTING

EA-31, EA-32

EA-31 Error code [318] (Abnormality in fuel pump actuator)  






     

         



  

1

2  #3  % &   

4%& %  




!   ! #$!  $ % % %! 


  

" &     % % %


  

4%&    % %     


  

4%&  




4%& :




      !       !   "    



  !   ! #$!  $ % % %! 

!





"

  

 &      '$ ( % % %    )*$+,)-./0



 #  %   56678  56698   !   #     

#





  #    % :

$





EA-32 Error code [343] (Abnormality in controller internal communication)                       


         !"  !#  " $    !"  !#       


WD600-3





%    &'(') *  +






%    &'(') *  +



01  //




    ,  01  //

./ 

./ 

20-393 (1)

EA-33

TROUBLESHOOTING

EA-33 Error code [346] (Abnormality in controller power down) 1 Is battery terminal connected normally?

NO

Defective connection of battery terminal

Repair

YES 2 • Turn starting switch OFF. • Disconnect battery terminal.

Is voltage of battery 17.3 – 34.7 V ?

NO

Drop in battery voltage

Charge or replace

Blown slow blow fuse

Replace

Defective contact, disconnection, or short circuit in wiring harness between slow blow fuse inlet and battery (+)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (3)(4)(5) and slow blow fuse outlet

Repair or replace

Defective engine controller

Replace

YES 3 NO

Is slow blow fuse blown?

YES

4 • Turn starting switch OFF. • Disconnect slow blow fuse inlet terminal and battery (+) terminal.

Is resistance between slow blow fuse inlet and battery (+), and between slow blow fuse inlet and surrounding wiring harnesses as shown in Table 1?

NO

YES 5 • Turn starting switch OFF. • Disconnect ECMB and slow blow fuse outlet terminal.

Is resistance between ECMB (female) (3)(4)(5) and slow blow fuse NO outlet, and between ECMB (female) (3)(4)(5) and surrounding wiring harnesses as shown in Table 2?

YES

Table 2

Table 1 Slow blow fuse inlet, battery (+) Between slow blow fuse inlet and battry (+) Between slow blow fuse inlet and surrounding wiring harness

Resistance value Max. 10 z Min. 1 Mz

ECMB (female), C slow blow fuse outlet Between ECMB (3)(4)(5) and slow blow fuse outlet Between ECMB (3)(4)(5) and surrounding wiring harness

Resistance value Max. 10 z Min. 1 Mz

EA-33 Related electrical circuit diagram

20-394 (1)

WD600-3

TROUBLESHOOTING

EA-34

EA-34 Error code [384] (Abnormality in preheating heater control system) Cause

Remedy

1 • Turn starting switch OFF. • Disconnect preheating relay L62.

NO

Is resistance between L62 (male) (1) and (2) 200 – 400 z?

Defective heater relay

Replace

Defective contact, disconnection short circuit wiring harness between ECMA (female) (2) – L62 (female) (1)

Repair or replace

There is ground fault or short-circuiting in the wiring harness between ECMA(female)(2)and L62(female)(1).

Repair or replace

There is a disconnection or connection fault in the wiring harness between L62(female)(2) and the chassis.

Repair or replace

Defective engine controller

Replace

YES

2 • Turn starting switch OFF. • Disconnect L62.

Is the wiring harness resistance value between ECMA(female) (2) NO and C62(female) (1) as indicated in Table 1?

YES

3 • Turn starting switch OFF. • Disconnect ECMA, L62.

Is the resistance value between the chassis and ECMA(female)(2) NO or L62(female)(1) as indicated in Table 1?

YES

4 Is the resistance value in the wiring harness between L62(female)(2) and the chassis as indicated in Table 1?

NO

YES Table 1 ECMA (female), preheating relay (L62)

Resistance value

Between ECMA (2) and L62(female)(2)

Max. 10 z

Between ECMA (2) and L62(female)(2) – chassis

Min. 1M z

EA-34 Related electrical circuit diagram

WD600-3

20-395 (1)

TROUBLESHOOTING

EA-35

EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) a Carry out troubleshooting for error code [143].

20-396 (1)

WD600-3

TROUBLESHOOTING

EA-36

EA-36 Error code [423] (Abnormality in timing rail pressure sensor system in range) Cause

Remedy

1

• Remove timing rail pressure sensor and fuel rail pressure sensor. • Insert T-adapter into TPR and RPR. • Turn starting switch ON.

Is voltage between TPR (C) and (B) same as voltage between RPR (C) and (B)?

• Turn starting switch OFF. • Disconnect ECMA and TPR.

Is resistance between ECMA (female) (5) and TPR (female) (A), and between ECMA (female) (5) and surrounding wiring harnesses as shown in Table 1?

NO

Defective timing rail pressure sensor

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (5) and TPR (female) (A)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (18) and TPR (female) (B)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMA (female) (33) and TPR (female) (C)

Repair or replace

Defective engine controller

Replace

Excessive suction resistance of fuel filter

Repair or replace

YES

2 NO

YES

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

Is resistance between ECMA (female) (18) and TPR (female) (B), and between ECMA (female) (18) and surrounding wiring harnesses as shown in Table 2?

NO

YES

4 • Turn starting switch OFF. • Disconnect ECMA and TPR.

Is resistance between ECMA (female) (33) and TPR (female) (C), and between ECMA (female) NO (33) and surrounding wiring harnesses as shown in Table 3?

YES

5 • Start engine.

Is negative pressure at suction side (tank side) of fuel filter more than 27kPa{203mmHg}?

YES

Table 1 ECMA (female), TPR (female) Between ECMA (5) and TPR (A) Between ECMA (5) and surrounding wiring harnesses

NO

Table 2 Resistance value

ECMA (female), TPR (female)

Max. 10 Ω

Between ECMA (18) and TPR (B)

Min. 1 MΩ

Between ECMA (18) and surrounding wiring harnesses

Resistance value Max. 10 Ω Min. 1 MΩ

Table 3 Between ECMA (33) and TPR (C)

Resistance value

Between ECMA (33) and TPR (C)

Max. 10 Ω

Between ECMA (33) and surrounding wiring harnesses

WD600-3

Min. 1 MΩ

20-397 (1)

TROUBLESHOOTING

EA-36

EA-36 Related electrical circuit diagram

20-398 (1)

WD600-3

TROUBLESHOOTING

EA-37

EA-37 Error code [431] (Abnormality 1 in idling validation switch system) Cause

Remedy

1 • Turn starting switch OFF. . Disconnect ECMB and C9.

Is resistance between ECMB (female) (21) and C9 (female) (3), NO and between ECMB (female) (21) and surrounding wiring harnesses as shown in Table 1?

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (21) and C9 (female) (3)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (13) and C9 (female) (6)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (12) and C9 (female) (5)

Repair or replace

Defective accelerator limit switch relay

Replace

Defective engine controller

Replace

YES

2 • Turn starting switch OFF. • Disconnect ECMB and C9.

Is resistance between ECMB (female) (13) and C9 (female) (6), NO and between ECMB (female) (13) and surrounding wiring harnesses as shown in Table 2?

YES

3 • Turn starting switch OFF. • Disconnect ECMB and C9.

Is resistance between ECMB (female) (12) and C9 (female) (5), NO and between ECMB (female) (12) and surrounding wiring harnesses as shown in Table 3?

YES

4 • Insert T-adapter in C9. • Turn starting switch ON.

Is voltage between C9(3) and (6) and between (3) and (5) as shown in Table 4?

NO

YES

Table 1 ECMB (female), C9 (female) Between ECMA (21) and C9 (3) Between ECMB (21) and surrounding wiring harnesses

Table 2 Resistance value

Between ECMB (12) and C9 (5) Between ECMB (12) and surrounding wiring harnesses

WD600-3

Resistance value

Max. 10 z

Between ECMB (13) and C9 (6)

Max. 10 z

Min. 1 Mz

Between ECMB (13) and surrounding wiring harnesses

Min. 1 Mz

Table 3 ECMB (female), C9 (female)

ECMB (female), C9 (female)

Table 4 Resistance value Max. 10 z Min. 1 Mz

Voltage C9

Pedal depressed

Pedal released

Between (3) and (6)

Min. 5 V

Max. 1 V

Between (3) and (5)

Max. 1 V

Min. 5 V

20-399 (1)

TROUBLESHOOTING

EA-37

EA-37 Related electrical circuit diagram

20-400 (1)

WD600-3

TROUBLESHOOTING

EA-38

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

Remedy

1 • Turn starting switch OFF. • Disconnect L14A.

Is resistance between L14A NO (female) (1) and (2), and between (1) and (3) as shown in Table 1?

Defective idling validation switch

Replace

Defective contact, disconnection, or short circuit in wiring harness between C8 (female) (31) and L14A (male) (1)

Repair or replace

NO

Defective contact, disconnection, or short circuit in wiring harness between C8 (female) (9) and L14A (male) (2)

Repair or replace

YES

2 • Turn starting switch OFF. • Disconnect C8 and L14A.

Is resistance between C8 (female) (31) and L14A (male) (1), NO and between C8 (female) (31) and surrounding wiring harnesses as shown in Table 2?

YES

3 • Turn starting switch OFF. • Disconnect C8 and L14A.

Is resistance between C8 (female) (9) and L14A (male) (2), and between C8 (female) (9) and surrounding wiring harnesses as shown in Table 3?

YES

4 • Turn starting switch OFF. • Disconnect C8 and L14A.

Is resistance between C8 (female) (20) and L14A (male) (3), and between C8 (female) (20) and surrounding wiring harnesses as shown in Table 4?

NO

Defective contact, disconnection, or short circuit in wiring harness between C8 (female) (20) and L14A (male) (3)

Repair or replace

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

Is resistance between C8 (female) (17) and C9 (female) (1), NO and between C8 (female) (17) and surrounding wiring harnesses as shown in Table 5?

Defective contact, disconnection, or short circuit in wiring harness between C8 (female) (17) and (9)

Repair or replace

5

YES

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

Is resistance between C9 (female) (2) and C8 (female) (31), NO and between C9 (female) (2) and surrounding wiring harnesses as shown in Table 6?

Defective contact, disconnection, or short circuit in wiring harness between C9 (female) (2) and chassis ground or between C8 (female) (31) and chassis ground

Repair or replace

Defective throttle controller

Replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (21) and C9 (female) (3)

Repair or replace

Defective contact, disconnection, or short circuit in wiring harness between ECMB (female) (13) and C9 (female) (6)

Repair or replace

YES

7 • Insert T-adapte to C9. • Turn starting switch ON.

Is voltege between C9 (1) and (2) NO as shown in Table 7?

YES

8 • Turn starting switch OFF. • Disconnect ECMB and C9.

Is resistance between ECMB (female) (21) and C9 (female) (3) and between ECMB (female) (21) NO and surrounding wiring harnesses as shown in Table 8?

YES

9 • Turn starting switch OFF. • Disconnect ECMB and C9.

Is resistance between ECMB (female) (13) and C9 (female) (6) NO and between ECMB (female) (13) and surrounding wiring harnesses as shown in Table 9?

YES

Go to next page 10.

WD600-3

20-401 (1)

EA-38

TROUBLESHOOTING

From previous page 9.

Cause

Remedy

10 Is resistance between ECMB (female) (12) and C9 (female) (5) NO and between ECMB (female) (12) and surrounding wiring harnesses as shown in Table 10?

• Turn starting switch OFF. • Disconnect ECMB and C9.

Defective contact, disconnection or short circuit in wiring harness between ECMB (female) (12) and C9 (female) (5)

Repair or replace

Defective accelerator limit switch relay

Replace

Defective engine controller

Replace

YES

11 Is voltage between C9 (female) (3) and (6) and between (3) and (5) as shown in Table 11?

• Insert T-adapter in C9. • Turn starting switch ON.

NO

YES

Table 2

Table 1

C8 (female), L14A (male)

Resistance

L14A (female)

Pedal

Resistance

Between (1) and (2)

Released (idling ON)

Max. 1 z

Between C8 (31) and L14A (1)

Max. 1 z

Depressed (idling OFF)

Max. 1 z

Between C8 (31) and surrounding wiring harnesses

Min. 1 Mz

Between (1) and (3)

Table 4

Table 3 C8 (female), L14A (male)

C8 (female), L14A (male)

Resistance

Between C8 (9) and L14A (2) Between C8 (9) and surrounding wiring harnesses

Resistance

Max. 1 z

Between C8 (20) and L14A (3)

Max. 1 z

Min. 1 Mz

Between C8 (20) and surrounding wiring harnesses

Min. 1 Mz

Table 6

Table 5 C8 (female), C9 (male)

Resistance

Between C8 (17) and C9 (1) Between C8 (17) and surrounding wiring harnesses

C9 (female), C8 (male)

Resistance

Max. 1 z

Between C9 (2) and C8 (31)

Max. 1 z

Min. 1 Mz

Between C9 (2) and surrounding wiring harnesses

Min. 1 Mz

Table 8

Table 7 Between C9 (1) and (2)

Voltage

Pedal depressed

20 -- 30 V

Pedal released

Max. 1 V

ECMB (female), C9(male)

Resistance

Between ECMB (21) and C9 (3)

Max. 10 z

Between ECMB (21) and surrounding wiring harnesses

Min. 1 Mz

Table 10

Table 9 ECMB (female), C9 (male)

Resistance

ECMB (female), C9 (male)

Resistance

Between ECMB (13) and C9 (6)

Max. 10 z

ECMB (12) and C9 (5)

Max. 10 z

Min. 1 Mz

Between ECMB (12) and surrounding wiring harnesses

Min. 1 Mz

Between ECMB (13) and surrounding wiring harnesses Table 11

Voltage C9

Pedal depressed

Pedal released

Between (3) and (6)

Min. 5 V

Max. 1 V

Between (3) and (5)

Max. 1 V

Min. 5 V

20-402 (1)

WD600-3

TROUBLESHOOTING

EA-38

EA-38 Related electrical circuit diagram

WD600-3

20-403 (1)

TROUBLESHOOTING

EA-39, EA-40

EA-39 Error code [441] (Abnormality in battery voltage low level) a Carry out troubleshooting for error code [346].

EA-40 Error code [442] (Abnormality in battery voltage high level) a Carry out troubleshooting for error code [346].

20-404 (1)

WD600-3

TROUBLESHOOTING

EA-41

EA-41 Error code [451] (Abnormality in fuel rail pressure sensor system high level)  





5 /( % 5  '  ') "* 
%

0*   (  (
 ''(' (  12#3 )( ( 4



5  '  ') "* 77% 5 /(   %

/    '  .' ' ('

6 '  "    #       "   
 #   ''(  ) "') * '  *("    4



. 

/  (  (( (' *(' '   "') * ' " . ' ('    #     '.  

!

5  '  ') "* 77% 5 /(   %

6 '  "    ,     !  "   
 ,   ''(  ) "') * '  *("    +4



/  (  (( (' *(' '   "') * ' " . ' ('    ,     '.  !

"

5  '  ') "* 77% 5 /(   %

6 '  "    -       "   
 -   ''(  ) "') * '  *("    -4



          !"  #     !"  #   ''(  ) "') * '

     $% & Ω

         !"  -     !"  -   ''(  ) "') * '

     $% & Ω

%  Ω

/  (  (( (' *(' '   "') * ' " . ' ('    -     '.   /  ) ('(' . 

  +        !"  ,   ! !"  ,   ''(  ) "') * '

      $% & Ω %  Ω

%  Ω

EA-41 Related electrical circuit diagram

WD600-3

20-405 (1)

EA-42

TROUBLESHOOTING

EA-42 Error code [452] (Abnormality in fuel rail pressure sensor system low level) ($ 5$ '       #       $ $+  %
 8

4 5$*
62 *  4
(* $ * % $% &+ .-

"1

 -.

3!& %' !( *% 2*$$(* $$ *

2&

/0

5$ *$%$ &     !"   !" #      !" -.   $(** (% %*% +*$$$ $ $+  %
 8

4
(* $ * % $% &+ .77 4 3%$& &    

/0

!

5$ *$%$ &     !"   !" -. #      !"   $(** (% %*% +*$$$ $ $+  %
 ,8

4
(* $ * % $% &+ .77 4 3%$& &    

/0

"

5$ *$%$ &     !" ,  !" -. #      !" ,  $(** (% %*% +*$$$ $ $+  %
 8

4
(* $ * % $% &+ .77 4 3%$& &    

/0


  

3!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$   2%* *   !"   !" *2& 

3!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$   2%* *   !"   !" *2& 

3!& %' &  & # %$& & % # * $+ * &%*&(% % %*% +*$$   2%* *   !" ,  !" *2&  3!& %' % &  * *

2&


  

  

  !"# !" 

               

              $(** (% %*% +*$$$

   

              $(** (% %*% +*$$$

)  Ω %  Ω


 


 ,   !"# !" 

$%$ & '(

$%$ & '( )  Ω %  Ω

  !"# !"



    ,        ,  $(** (% %*% +*$$$

$%$ & '( )  Ω %  Ω

EA-42 Related electrical circuit diagram

20-406 (1)

WD600-3

TROUBLESHOOTING

EA-43

EA-43 Error code [455] (Abnormality in fuel rail actuator system current) 

 ,

 .
# #% & )//" . 0$ "

 #       1 2 3 Ω4

()

0   # $#

-

()

0   # $#

-

0  $ $$ $# &$# #  #% &#     '    

-# $# #-

*+

.
# #% & )//" . 0$ "

 #       %#$ $# &  5Ω4

*+

!

.
# #% & )//" . 0$    "

 #     '          () '  ##$ % #% &#  &$ 
 4

*+

"

.
# #% & )//" . 0$    "

 #         ()         ##$ % #% &#  &$ 
 4

*+


           '        '  ##$ % #% &#

0  $ $$ $# &$# #  #% &#  -# $# #-         0  % $#$#

-


   

     

 

!"  Ω

            ##$ % #% &#

!"  Ω

"  Ω

"  Ω

EA-43 Related electrical circuit diagram

WD600-3

20-407 (1)

EA-44, EA-45, EA-46

TROUBLESHOOTING

EA-44 Error code [467] (Abnormality in timing rail actuator control) a Carry out troubleshooting for error code [112].

EA-45 Error code [468] (Abnormality in fuel rail actuator control) Cause

Remedy

 • Turn starting switch ON.

Is another error code displayed at

NO

same time? Go to

YES —

troubleshooting for service code displayed

• Start engine

When engine is run at rated speed, does output go up or down, or does exhaust temperature go up?

NO

YES Defective fuel rail actuator

Replace

Clogging, looseness, breakage, or

Repair or

leakage from fuel filter, piping

replace

! Is there clogging, looseness,

NO

breakage, or leakage from fuel filter, piping?

YES

" NO

Is fuel rail actuator screen clogged with dirt?

YES Clogged fuel rail actuator screen

Clean or replace

# Is engine oil diluted with fuel?

NO

Defective fuel rail actuator or defective

Replace

engine controller

YES Broken injector O-ring

Replace

EA-46 Error code [514] (Abnormality in fuel rail actuator) a Carry out troubleshooting for error code [468].

20-408 (1)

WD600-3

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 idling validation switch system) a Carry out troubleshooting for error code [431].

WD600-3

20-409 (1)

EA-49

TROUBLESHOOTING

EA-49 Error code [554] (Abnormality in fuel rail pressure sensor in range)  




*
$ % # +# #  $#   # +# #  $#! * , # -+# $

 
! * # #% & ./!

, $ % 

  /.    $ % 


  3

1  # +# #  $#

* # #% & .00! * 1 $  

!

, #        

        /.   ##$% #% &#   &$    3

1 $  $$ $# &$# #  #% &# 
+# $#     

  #+  



:2

:2

!

* # #% & .00! * 1 $  

!


+ 

, #       ( 

  /.       (  ##$% #% &#   &$    '3

1 $  $$ $# &$# #  #% &# 
+# $#    ( 

  #+  

:2

"

* # #% & .00! * 1 $  

!

4! , #       ) 

  /.       )  ##$% #% &#   &$    )3

:2

1 $  $$ $# &$# #  #% &# 
+# $#    ) 

  #+  

#

* 2# %!

, % +# #  $ /.  5  $   # $# & '657'")8%93

:2

     

      

      ##$% #% &# 


      ! " Ω

  )   

     ) 

   ))  ##$% #% &# 


      ! " Ω

20-410 (1)

!  Ω

1 % $#$ #


+ 

   $ #   $   #


+# $# #+ 

  '   

  
       ( 

   ! " Ω   (  !  Ω ##$% #% &# 

!  Ω

WD600-3

TROUBLESHOOTING

EA-49

EA-49 Related electrical circuit diagram

WD600-3

20-411 (1)

TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)

Electrical circuit diagram for main monitor .......................................................................................... 20-454 Electrical circuit diagram for lamp and horn ........................................................................................ 20-456 M- 1 Main monitor does not work ....................................................................................................... 20-457 M- 2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up ...................................................................................................................................... 20-458 M- 3 Speedometer display does not work properly ........................................................................... 20-459 M- 4 Abnormality in shift indicator ...................................................................................................... 20-460 a) Displays N even when directional lever is at F .................................................................... 20-460 b) Displays N even when directional lever is at R ................................................................... 20-460 c) Does not display N even when directional lever is at N ..................................................... 20-460 d) Does not display 1st even when speed control lever is at 1st ........................................... 20-461 e) Does not display 2nd even when speed control lever is at 2nd ........................................ 20-461 f)

Does not display 3rd even when speed control lever is at 3rd .......................................... 20-461

g) Does not display 4th even when speed control lever is at 4th .......................................... 20-461 M- 5 High beam display does not light up .......................................................................................... 20-463 M- 6 Turn signal display does not light up ......................................................................................... 20-464 a) L.H. turn signal display does not light up ............................................................................ 20-464 b) R.H. turn signal display does not light up ............................................................................ 20-464 M- 7 Abnormality in parking lamp display ......................................................................................... 20-465 a) Parking lamp display does not light up ............................................................................... 20-465 b) Parking lamp display stays lighted up ................................................................................. 20-465 M- 8 Abnormality in preheating display ............................................................................................. 20-466 a) Preheating display does not light up ................................................................................... 20-466 b) Preheating display stays lighted up ..................................................................................... 20-466 M- 9 Night lighting of monitor does not light up ............................................................................... 20-467 M-10 Abnormality in front working lamp ............................................................................................ 20-468 a) Neither monitor display nor front working lamp light up .................................................. 20-468 b) Working lamp lights up but monitor display does not light up ......................................... 20-468 c) Monitor display lights up but working lamp does not light up .......................................... 20-468 M-11 Abnormality in rear working lamp .............................................................................................. 20-470 a) Neither monitor display nor rear working lamp light up ................................................... 20-470 b) Working lamp lights up but monitor display does not light up ......................................... 20-470 c) Monitor display lights up but working lamp does not light up .......................................... 20-470 M-12 Abnormality in transmission cut-off ........................................................................................... 20-472 a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not change ................................................................................................ 20-472 b) Transmission cut-off does not work or stays working ........................................................ 20-472

WD600-3

20-451 (1)

M-13 Abnormality in parking brake dragging warning ...................................................................... 20-473 a) When parking brake is applied, buzzer sounds intermittently and caution lamp flashes even when directional lever is at N ......................................................................... 20-473 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 ....................................... 20-473 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated ....................................................................................... 20-474 a) Actuated continuously ........................................................................................................... 20-474 b) Not actuated ........................................................................................................................... 20-474 M-15 Abnormality in buzzer .................................................................................................................. 20-475 a) Buzzer does not sound for 3 seconds during self-check when starting switch is turned ON ............................................................................................................................... 20-475 b) Buzzer always sounds ........................................................................................................... 20-475 M-16 Condition of monitor switches is not stored in memory .......................................................... 20-476 M-17 Abnormality in failure display mode .......................................................................................... 20-477 a) Failure display mode does not work .................................................................................... 20-477 b) Count for time elapsed since failure in failure display mode does not advance ............. 20-477 M-18 Abnormality in emergency steering display .............................................................................. 20-478 a) Emergency steering display does not flash ......................................................................... 20-478 b) Emergency steering display stays flashed .......................................................................... 20-478 M-19 Failure code is not sent to main monitor (abnormality in network) ........................................ 20-479

20-452 (1)

WD600-3

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR

20-454 (1)

WD600-3

TROUBLESHOOTING

WD600-3

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR

20-455 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN

ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN

20-456 (1)

WD600-3

TROUBLESHOOTING

M-1

M-1 Main monitor does not work 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

YES

Defective main monitor

1 Is voltage between L05 (1), (2) – (3) normal? • 20 – 30 V • Turn starting switch ON.

2 YES Is resistance between L05 (female) NO (3) and chassis ground normal?

• Turn starting switch OFF. • Disconnect L05. • Max. 1 Ω

NO

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L05 (female) (1), replace (2) and FS2 (female) (9) Defective contact or disconRepair or nection in wiring harness replace between L05 (female) (3) and LR5 (male) (3)

M-1 Related electrical circuit diagram

WD600-3

20-457 (1)

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

20-458 (1)

WD600-3

TROUBLESHOOTING

M-3

M-3 Speedometer display does not work properly 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 gap between the speed sensor and gear is normal.

Cause

2 YES

Is resistance between CN3 (male) (1) and (2) normal?

Is resistance YES between L07 1 (female) (1) and (2) normal?

• 500 Ω – 1 kΩ NO • Turn starting switch OFF. • Disconnect L07.

• 500 Ω – 1 kΩ • Turn starting switch NO OFF. • Disconnect CN3.

Defective main monitor

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L07 (female) (1), replace (2) – TM2 (9), (10) CN3 (female) (1), (2)

Defective speed sensor

Replace

M-3 Related electrical circuit diagram

WD600-3

20-459 (1)

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 gear is shifted 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 (8) and chassis ground normal?

• 20 – 30V NO • Turn starting switch

Remedy

Defective main monitor

Replace

Short circuit with power source in harness between L05 (female) (8) and neutral relay

Repair or replace

ON.

• Directional lever: N

20-460 (1)

WD600-3

TROUBLESHOOTING

d) Does not display 1st even when speed control lever is at 1st

1 YES Is voltage between L05 (12) and chassis ground normal?

• Turn starting

NO

switch ON.

• Speed control lever : 1st

M-4

Cause

Remedy

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (12) and C1A (female) (3)

Repair or replace

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (13) and C1A (female) (10)

Repair or replace

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (14) and C1A (female) (5)

Repair or replace

Defective main monitor

Replace

Defective contact or disconnection in wiring harness between L05 (female) (15) and C1A (female) (11)

Repair or replace

e) Does not display 2nd even when speed control lever is at 2nd

1 YES Is voltage between L05 (13) and chassis ground normal?

• Turn starting

NO

switch ON.

• Speed control lever : 2nd

f)

Does not display 3rd even when speed control lever is at 3rd

1 YES Is voltage between L05 (14) and chassis ground normal?

• Turn starting

NO

switch ON.

• Speed control lever : 3rd

g) Does not display 4th even when speed control lever is at 4th

1 YES Is voltage between L05 (15) and chassis ground normal?

• 20 – 30 V • Turn starting

NO

switch ON.

• Speed control lever : 4th

WD600-3

20-461 (1)

TROUBLESHOOTING

M-4

M-4 Related electrical circuit diagram

20-462 (1)

WD600-3

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. Check the bulb for breakage.

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

WD600-3

20-463 (1)

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 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

20-464 (1)

WD600-3

TROUBLESHOOTING

M-7

M-7 Abnormality in parking lamp display 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) Parking lamp display does not light up fl Before carrying out troubleshooting, check the bulb for breakage.

Cause

1 YES Is voltage between L06 (11) and chassis ground normal?

• 20 – 30V NO • Turn starting switch ON. • Turn parking switch ON.

Remedy

Defective main monitor

Replace

Short circuit with chassis ground in harness between L06 (female) (11) and LR2 (14), FR2 (6) and F15 (female) (1)

Repair or replace

Defective main monitor

Replace

Defective parking brake indicator switch

Replace

Defective contact or disconnection in wiring harness between L06 (female) (11) and F15 (female) (1)

Repair or replace

b) Parking lamp display stays lighted up

YES 1 Is voltage between L06 (11) and chassis ground normal?

• 20 – 30 V • Turn starting switch ON.

NO

2 YES Is resistance between L06 (female) (11) and F15 (female) (1) normal?

• Max. Ω NO • Turn starting switch OFF. • Disconnect L06 and F15.

M-7 Related electrical circuit diagram

WD600-3

20-465 (1)

TROUBLESHOOTING

M-8

M-8 Abnormality in preheating display 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) Preheating display does not light up Cause

1 YES Is resistance between E27 and L05 (female)(19) normal ?

• Max. 1Ω NO • Turn starting switch OFF. • Disconnect L05 and E27

Remedy

Defective main monitor (monitor module)

Replace

Defective contact or disconnection in wiring harness between E27 and L05 (female) (19)

Repair or replace

b) Preheating display stays lighted up

Cause

1 YES Is voltage between L05 (female) (19) and chassis ground normal?

NO • Max. 1V • Turn starting switch ON. • Disconnect L05 and E27

Remedy

Defective main monitor (monitor module)

Replace

Short circuit with power source in wiring harness between E27 and L05 (female) (19)

Repair or replace

M-8 Related electrical circuit diagram

20-466 (1)

WD600-3

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

WD600-3

20-467 (1)

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

20-468 (1)

WD600-3

TROUBLESHOOTING

M-10

M-10 Related electrical circuit diagram

WD600-3

20-469 (1)

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.

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 (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

20-470 (1)

WD600-3

TROUBLESHOOTING

M-11

M-11 Related electrical circuit diagram

WD600-3

20-471 (1)

TROUBLESHOOTING

M-12

M-12 Abnormality in transmission cut-off 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) 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) Transmission cut-off does not work or stays working fl Carry out T-15 of TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM.

20-472 (1)

WD600-3

TROUBLESHOOTING

M-13

M-13 Abnormality in parking brake dragging warning 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 gear is shifted normally (F, N, R).

a) When parking brake is applied, buzzer sounds intermittently and caution lamp flashes even when directional lever is at N Cause

1 YES

Defective main monitor

Is voltage between L05 (8) and chassis ground normal?

• 20 – 30 V • Turn starting switch

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L05 (female) (8) – replace L57 (female) (1)

NO

ON.

• Directional lever: N 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 fl Check that the synchronous flash signal is normal. Cause Remedy

YES 1 Is voltage between L05 (8) and chassis ground normal?

•0–5V • Turn starting switch ON.

2 YES Is resistance between L05 NO (female) (8) and (3) normal?

• 3 kΩ – 4 kΩ NO • Turn starting switch

Defective main monitor

Replace

Short circuit with power source in wiring harness between L05 (female) (8) and L57 (female)(1)

Repair or replace

Defective main monitor

Replace

OFF.

• Disconnect L05. M-13 Related electrical circuit diagram

WD600-3

20-473 (1)

TROUBLESHOOTING

M-14

M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated fl Before disconnecting or connecting connectors, surely 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) Actuated continuously Cause

2 YES YES Does buzzer stop 1 and lamp go out? Does buzzer stop and lamp go out?

• Turn starting switch NO ON. • Connect L19 (female) (5) to chassis ground.

• Turn starting switch ON. NO • Connect L07 (6) to chassis ground.

Defective maintenance monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L07 (female) (6) replace and L19 (female) (5)

Defective main monitor

Replace

b) Not actuated Cause

2 YES YES Do buzzer and 1 lamp work? Do buzzer and lamp work?

• Turn starting switch NO ON. • Disconnect L19.

• Turn starting switch ON. NO • Disconnect L07.

Remedy

Defective maintenance monitor

Replace

Short circuit with power source in harness between L07 (female) (6) and L19 (female) (5)

Repair or replace

Defective main monitor

Replace

M-14 Related electrical circuit diagram

20-474 (1)

WD600-3

TROUBLESHOOTING

M-15

M-15 Abnormality in buzzer fl Before disconnecting or connecting connectors, surely 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) Buzzer does not sound for 3 seconds during self-check when starting switch is turned ON Cause

Defective contact or disconnection in wiring harness Repair or between L06 (female) (8) replace and L43 (male) (1)

YES 1 Does buzzer sound?

2 YES

Defective buzzer

Is voltage between • Turn starting switch L42 (female) and ON. NO chassis ground • Contact L43 (female) normal?

to chassis ground.

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L42 (female) (1) replace and FS2 (female) (9)

• 20 – 30 V NO • Turn starting switch ON.

b) Buzzer always sounds Cause

YES

Defective main monitor

Remedy

Replace

1 Does buzzer stop when L06 is disconnected?

YES 2

Does buzzer stop • Disconnect L06. when L19 is • Turn starting NO disconnected? switch ON.

3 YES

Does buzzer stop • Disconnect L19. when L43 is • Turn starting NO disconnected? switch ON. • Disconnect L43. NO • Turn starting switch ON.

Go to Troubleshooting for maintenance monitor

—

Short circuit with power source in harness between L06 (female) (8) and L43 (male) (1)

Repair or replace

Defective buzzer

Replace

M-15 Related electrical circuit diagram

WD600-3

20-475 (1)

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

20-476 (1)

WD600-3

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

WD600-3

20-477 (1)

TROUBLESHOOTING

M-18

M-18 Abnormality in emergency steering display 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

a) Emergency steering display does not flash

YES 2

Remedy

Defective main monitor

Replace

Defective contact or discon -nection in wiring harness between R01 (female) (2) and chassis ground

Repair or replace

Defective contact or discon -nection in wiring harness between L05 (female) (11) and R01 (female) (1)

Repair or replace

Defective emergency steering lamp switch

Replace

Is voltage between

YES L05 (11) and 1 Is resistance between R01 (male) (1) and (2) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect R01.

3 YES

chassis ground normal?

Is resistance between L05 (female) (11) and R01 NO (female) (1) normal?

•0–2V • Turn starting switch ON.

• Max. 1 Ω NO • Turn starting switch OFF. • Disconnect L05 and R01.

NO

b) Emergency steering display stays flashed Cause

2 YES

Is resistance between R01 (male) (1) and (2) normal?

• Min. 1 Ω • Start engine. • Disconnect R01.

Is voltage between YES L05 (11) and 1 chassis ground normal?

• 20 – 30 V • Start engine.

NO

NO

Remedy

Defective main monitor

Replace

Short circuit with chassis ground in harness between L05 (female) (11) and R01 (female) (1)

Repair or replace

Defective emergency steering lamp switch

Replace

M-18 Related electrical circuit diagram

20-478 (1)

WD600-3

TROUBLESHOOTING

M-19

M-19 Failure code is not sent to main monitor (abnormality in network) fl 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. Set dipswitch 3 at the rear of the main monitor to “F”. MDC : Multiple Display and Condition. Cause

2 YES Is voltage between YES LM1 (male) (5) and 1 (6) normal? Is voltage between L08 (male) (1) and (2) normal?

• Repeats 0V and

• Repeats 0V and

NO

12V • Turn starting switch ON. • Disconnect LM1.

12V NO • Turn starting switch ON. • Disconnect L08.

Applicable controller is defective

Remedy

Replace

Defective contact or disconnection in wiring harness between L08 (female) (1) Repair or (3) – LM1 (male) (5), L08 replace (female) (2) (4) – LM1 (male) (6)

Defective main monitor

Replace

M-19 Related electrical circuit diagram

WD600-3

20-479 (1)

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 water 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 water temperature gauge ............................................................... 20-521 c) Abnormality in torque converter oil temperature gauge ................................................... 20-522

WD600-3

20-501 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR

ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR

20-502 (1)

WD600-3

TROUBLESHOOTING

WD600-3

ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR

20-503 (1)

TROUBLESHOOTING

K-1

K-1

When starting switch is turned ON, all display on maintenance monitor do not light up for 3 seconds Maintenance monitor does not work

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) No lamps on maintenance monitor light up Cause

YES

Defective monitor module of maintenance monitor

1 YES

Is voltage between L18 (1), (2) – (3) normal?

3 Is voltage between

YES FS1 (female) (2) • 20 – 30 V • Turn starting switch ON.

NO

2 Is resistance between L18 (female) (3),(14), L19 (8) and chassis ground normal?

and chassis ground normal?

• 20 – 30 V • Disconnect FS1. NO • Turn starting switch ON.

• Max. 1 Ω • Turn starting switch ON. NO • Disconnect L18.

b) Some lamps do not light up

(1)

Replace

Defective contact or disconnection in wiring harness Repair or between L18 (female) (1), replace, or (2) – FS2 (9) – fuse I-10 – replace fuse FS1 (male) (2), or blown fuse I-10 Defective contact or disconnection in wiring harness between FS1 (female) (2) – Repair or replace, or LR6 (1) – slow blow fuse replace fuse battery relay, or blown slow blow fuse (80A) Defective contact or disconnection in wiring harness Repair or between L18 (3),(14), L19 replace (female) (8) – LR4 (12) – chassis ground

Cause

Defective monitor module of maintenance monitor

20-504

Remedy

Remedy

Replace

WD600-3

TROUBLESHOOTING

K-2

K-2

When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out even after 3 seconds

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

Defective monitor module of maintenance monitor

Remedy

Replace

K-1,2 Related electrical circuit diagram

WD600-3

20-505 (1)

TROUBLESHOOTING

K-3

K-3

When engine is started immediately after starting switch is turned ON within 3 seconds, no lamps on maintenance monitor go out

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 When starting engine, is voltage between L19 (female) (1) and chassis ground normal?

• 20 – 30 V NO • Disconnect L19. • Start engine. • Measure when starting motor is turning (starting switch at START).

Defective monitor module of maintenance monitor

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L19 (female) (1) replace and neutral relay

K-3 Related electrical circuit diagram

20-506 (1)

WD600-3

TROUBLESHOOTING

K-4

K-4

When engine is stopped and starting switch is turned ON, CHECK item display flashes

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) Engine oil level display flashes fl Before starting troubleshooting, check the engine oil level again. (Check that the engine oil level is correct.) Cause

2 YES Is resistance betYES ween L18 (female) 1 (13) and chassis ground normal? Is resistance between E10 (male) • Max. 1 Ω NO (1) and chassis • Turn starting switch ground normal? OFF.

• Disconnect L18. • Max. 1 Ω • Turn starting switch NO OFF. • Disconnect E10.

Remedy

Defective monitor module of maintenance monitor

Replace

Defective contact or disconnection in wiring harness between L18 (female) (13) – LR4 (4) – ER1 (3) – E10 (female) (1)

Repair or replace

Defective engine oil level sensor

Replace

K-4 a) Related electrical circuit diagram

WD600-3

20-507 (1)

TROUBLESHOOTING

K-4

b) Engine water level display flashes fl Before starting troubleshooting, check the engine water level again. (Check that the engine water 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 radiator water level sensor

Replace

K-4 b) Related electrical circuit diagram

20-508 (1)

WD600-3

TROUBLESHOOTING

K-5 fl fl fl fl

K-5

When engine is stopped and starting switch is turned ON, CAUTION item display flashes

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 Error Code [527] is not displayed in the engine controller.

a) Engine oil pressure display flashes (Check that the engine oil pressure is correct.) Cause

YES 1 Is indication set normal when engine oil pressure relay L64 is replaced?

2 YES

• Replace engine oil pressure relay with dust indicator relay (L80).

Is resistance between L18 (female) (10) and chassis ground normal?

NO • Max. 1 Ω • Disconnect L18. • Turn starting switch OFF.

NO

Remedy

Defective engine oil pressure relay

Replace

Defective maintenance monitor module

Replace

Defective contact or discon-nection in wiring harness between L18 (female) (10) and L64 (3), (6), CL1 (12) and chassis ground

Repair or replace

K-5 a) Related electrical circuit diagram

WD600-3

20-509 (1)

TROUBLESHOOTING

K-5

b) Battery charge level display flashes

Cause

2 YES Is voltage between YES L18 (female) (12) 1 and chassis ground normal? Is voltage between alternator terminal • 20 – 30 V R and chassis • Start engine. ground normal?

• 20 – 30 V • Start engine.

NO

NO

Defective monitor module of maintenance monitor

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L18 (female) (12) – replace LR4 (6) – ER1 (9) – alternator terminal R

Defective alternator

Replace

K-5 b) Related electrical circuit diagram

20-510 (1)

WD600-3

TROUBLESHOOTING

K-5

c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)

Cause

4 YES Defective monitor module of maintenance monitor Is voltage between YES L18 (11) and Defective contact or disconchassis ground 3 nection in wiring harness normal? between L18 (female) (11) – Is resistance betYES ween B08 (female) • Start engine. NO LR2 (8) – BR1 (6) – B08 (female) (1) (2) and chassis • Max. 3 V 2 ground normal? Defective contact or disconnection in wiring harness Is resistance • Max. 1 Ω between B08 (female) (2) – YES between B13 • Turn starting switch NO B13 (female) (1), or between (male) (1) and (2) B13 (female) (2) – BR1 (4) – OFF. normal? 1 chassis ground • Disconnect B08. Is resistance between B08 (male) (1) and (2) normal?

• Max. 1 Ω • Start engine. • Disconnect B08.

• Max. 1 Ω • Start engine. • Disconnect B13.

NO

NO

Remedy

Replace

Repair or replace

Repair or replace

Defective brake Replace accumulator charge oil pressure switch (B13 end) Defective brake Replace accumulator charge oil pressure switch (B08 end)

K-5 c) Related electrical circuit diagram

WD600-3

20-511 (1)

TROUBLESHOOTING

K-5

d) Air cleaner clogged display flashes (Check that there is no clogging of the air cleaner.)

Cause

YES

Remedy

Defective dust indicator sensor

Replace

Defective dust indicator relay

Replace

1 Does display go out when E19 is disconnected?

YES 2

• Start engine. • Disconnect E19.

Does display go out when dust NO indicator relay L80 is interchanged?

4 YES Is resistance betYES ween L80 (female) (6) and chassis 3 ground normal? Is voltage between • Max. 1 Ω NO E19 (female) (1) • Turn starting switch NO and chassis OFF. ground normal?

• Disconnect L80.

• Turn starting switch NO ON. • Disconnect E19. • 20 – 30 V

5 YES Is resistance betFrom A ween L18 (female) (15) and chassis ground normal?

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect L18.

To A Defective contact or disconnection in wiring harness Repair or between L80 (female) (6) – replace LR5 (2) – chassis ground Short circuit with chassis ground in wiring harness between E19 (female) (1) – ER1 (5) – LR4 (5) – L80 (female) (2) (short circuit or contact with chassis ground)

Repair or replace

Defective monitor module of maintenance monitor

Replace

Defective contact or disconRepair or nection in wiring harness between L18 (female) (15) replace and L80 (female) (3)

K-5 d) Related electrical circuit diagram

20-512 (1)

WD600-3

TROUBLESHOOTING

K-6 fl fl fl fl fl

K-6

CAUTION item display is flashing, but caution buzzer does not sound

The buzzer does not sound for CHARGE or ENGINE OIL LEVEL. 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 fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between fuse I-10 – FS2 (9) – L42. Cause

YES

Defective monitor module of maintenance monitor

2

Remedy

Replace

Does buzzer sound

YES when L19 (female) 1 Is voltage between L42 (female) (1) and chassis ground normal?

(4) is connected to chassis ground?

• Turn starting switch ON.

• 20 – 30 V • Disconnect L42. • Turn starting switch NO ON.

3 YES Does buzzer sound when L43 (female) NO (1) is connected to chassis ground?

• Turn starting switch ON.

NO

Defective contact or disconnection in wiring harness Replace between L19 (female) (4) and L43 (male) (1)

Defective buzzer

Replace

Defective contact or disconRepair or nection in wiring harness between fuse I-10 – FS2 (9) replace – L42 (female) (1)

K-6 Related electrical circuit diagram

WD600-3

20-513 (1)

TROUBLESHOOTING

K-7 fl fl fl fl

K-7

No monitor display lights up, but caution buzzer sounds

Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.

Cause

2 YES Is resistance betYES ween L19 (female) 1 (4) and chassis ground normal? Is resistance between L43 (female) • Min. 1 MΩ NO (1) and chassis • Turn starting switch OFF. ground normal? • Disconnect L06, L19,

and L43. • Min. 1 MΩ • Turn starting NO switch OFF. • Disconnect L42 and L43.

Remedy

Defective monitor module of maintenance monitor

Replace

Short circuit with chassis ground in wiring harness between L19 (female) (4) – L43 (male) (1) – L06 (female) (8) (contact with chassis ground)

Repair or replace

Defective buzzer

Replace

K-7 Related electrical circuit diagram

20-514 (1)

WD600-3

TROUBLESHOOTING

K-8 fl fl fl fl

K-8

CAUTION item display is flashing, but central CHECK lamp or central CAUTION lamp does not flash

Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that there are no blown lamp bulbs. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.

a) CHECK lamp

Cause

Defective monitor module of maintenance monitor

YES 1 Does CHECK lamp light up when L19 (female) (2) is connected to chassis ground?

2 YES Does CHECK lamp

light up when L06 • Disconnect L19. (male) (10) is • Turn starting NO connected to chassis switch ON. ground?

• Disconnect L06. NO • Turn starting switch ON.

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L19 (female) (2) replace and L06 (female) (10)

Defective main monitor

Replace

b) CAUTION lamp Cause

Defective monitor module of maintenance monitor

YES 1 Does CAUTION lamp light up when L19 (female) (3) is connected to chassis ground?

2 YES Does CAUTION

lamp light up when • Disconnect L19. L06 (male) (9) is • Turn starting NO connected to chassis switch ON. ground? • Disconnect L06. NO • Turn starting switch ON.

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between L19 (female) (3) replace and L06 (female) (10)

Defective main monitor

Replace

K-8 a), b) Related electrical circuit diagram

WD600-3

20-515 (1)

TROUBLESHOOTING

K-9 fl fl fl fl

K-9

No maintenance monitor display lights up, but central CHECK lamp or central CAUTION lamp lights up

Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.

a) CHECK lamp Cause

1 YES Is resistance between L19 (female) (2) and chassis ground normal?

• Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect L06 and L19.

Defective monitor module of maintenance monitor

Remedy

Replace

Short circuit with chassis ground in wiring harness Repair or between L19 (female) (2) replace and L06 (female) (10) (contact with chassis ground)

b) CAUTION lamp Cause

1 YES Is resistance between L19 (female) (3) and chassis ground normal?

• Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect L06 and L19.

Defective monitor module of maintenance monitor Short circuit with chassis ground in wiring harness between L19 (female) (3) and L06 (female) (9) (contact with chassis ground)

Remedy

Replace

Repair or replace

K-9 Related electrical circuit diagram

20-516 (1)

WD600-3

TROUBLESHOOTING

K-10

K-10 Only night lighting of monitor does not light up when lamp switch is turned ON fl fl fl fl

Before disconnecting or connecting connectors, always turn starting switch OFF. Before carrying out troubleshooting, check that there are no blown lamp bulbs. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.

Cause

1 YES Is voltage between L21 (female) (1) and (2) normal?

• 20 – 30 V NO • Disconnect L21. • Turn starting switch ON. • Turn lamp switch ON.

Disconnection in wiring harness of lamp holder

Remedy

Replace

Defective contact or disconRepair or nection in wiring harness between L21 (female) (1) replace and FS2 (5)

K-10 Related electrical circuit diagram

WD600-3

20-517 (1)

TROUBLESHOOTING

K-11

K-11 Night lighting of monitor lights up even when lamp switch is OFF 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

2 YES Is voltage between YES FS2 (female) (4) 1 and chassis ground normal?

Is lamp switch normal?

• Max. 1 V NO • Disconnect FS2. • Turn lamp switch OFF. • Turn starting switch ON.

• Turn starting switch OFF. NO • Disconnect L02. • Check that continuity between L02 (male) (1) and (5) is as shown in table below when lamp switch is turned ON-OFF.

Switch

Continuity

ON

YES

OFF

NO

Remedy

Contact of +24V with wiring harness between FS2 (male) (4) – fuse box – FS2 (5) – L21 (female) (1)

Repair or replace

Contact of +24V with wiring harness between L02 (female) (5) and FS2 (female) (4)

Repair or replace

Defective lamp switch

Replace

K-11 Related electrical circuit diagram

20-518 (1)

WD600-3

TROUBLESHOOTING

K-12, 13

K-12 Service meter does not work 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. YES

Defective service meter

1 Is voltage between L22 (female) (2) and (1) normal?

Cause

3 YES Is resistance betYES ween L22 (female) (1) and chassis 2 ground normal? Is voltage between

• 20 – 30 V terminal R of • Start engine. • Disconnect L22. NO alternator and chassis ground

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect L22.

normal?

• 20 – 30 V • Start engine.

NO

Remedy

Replace

Defective contact or disconnection in wiring Repair or harness between L22 (female) (2), LR4 (6), ER1 (9) replace and terminal R of alternator Defective contact or disconnection in wiring harness between L22 (female) (1), CL1 (12) and chassis ground

Repair or replace

Defective alternator

Replace

K-13 Service meter is running even when engine is stopped 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. YES

Defective service meter

1 Is voltage between L22 (female) (2) and (1) normal?

Cause

2 YES Is voltage between

• Max. 3 V alternator terminal • Turn starting NO R and chassis ground normal? switch ON. • Disconnect L22. • Max. 3 V NO • Turn starting switch ON.

Remedy

Replace

Contact of +24V with wiring Repair or harness between L22 (female) (2) – LR4 (6) – ER1 replace (9) – alternator terminal R

Defective alternator

Replace

K-12,13 Related electrical circuit diagram

WD600-3

20-519 (1)

TROUBLESHOOTING

K-14

K-14 Abnormality in gauges 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) Abnormality in fuel gauge fl Before carrying out troubleshooting, check the fuel level again. (Check that the fuel level is correct.) (1) Little or nothing is displayed YES

Cause

Remedy

Defective fuel sensor

Replace

Defective maintenance monitor module

Replace

Defective contact or disconnection in wiring harness between R05 (female) (1), LR4 (10) and L18 (female) (6)

Repair or replace

Defective contact or disconnection in wiring harness between R05 (female) (2) and chassis ground

Repair or replace

1 3 YES

Does fuel gauge indicates FULL when short connector is connected to R05 (female)?

YES 2

• Disconnect R05. Is resistance bet• Connect short ween R05 (female) connector to R05 (2) and chassis NO (female). ground normal? • Turn starting • Max. 1 Ω switch ON. • Turn starting switch OFF. • Disconnect R05.

Is resistance between L18 (female) (6) and chassis ground normal when short connector is connected to R05?

• Max. 1 Ω NO • Turn starting switch OFF. • Connect short connector to R05 (female). • Disconnect L18.

NO

(2) Display always shows FULL Cause

YES 1 Do all display areas on fuel gauge go out when R07 is disconnected?

2 YES

Is resistance bet• Disconnect R07. ween R07 (female) • Turn starting NO (1) and chassis ground normal? switch ON.

• Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect L18 and R07.

Remedy

Defective fuel sensor

Replace

Defective monitor module of maintenance monitor

Replace

Short circuit with chassis ground in wiring harness between R07 (female) (1) – LR4 (10) – L18 (female) (6)

Repair or replace

K-14 a) Related electrical circuit diagram

20-520 (1)

WD600-3

TROUBLESHOOTING

K-14

b) Abnormality in engine water temperature gauge (1) Nothing is displayed Cause

YES 1 Does engine water 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 water 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 water temperature sensor

Replace

Defective monitor module of maintenance monitor

Replace

1 When short connector is connected to E04 (female), does engine water 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

WD600-3

20-521 (1)

TROUBLESHOOTING

K-14

c) Abnormality in torque converter oil temperature gauge (1) Nothing is displayed Cause

YES 1 Does torque converter oil temperature gauge show minimum level when CN18 is disconnected?

2 YES

• Disconnect CN18. • Turn starting NO switch ON.

Is resistance between CN18 (female) (1) and chassis ground normal?

• Turn starting NO switch OFF. • Disconnect L18 and CN18. • Min. 1 MΩ

(2) Display shows lowest level and does not move

YES

Remedy

Defective torque converter oil temperature sensor

Replace

Defective monitor module of maintenance monitor

Replace

Short circuit with chassis ground in wiring harness between CN18 (female) (1) – TM2 (8) – L18 (female) (5) (contact with chassis ground)

Repair or replace

Cause

Remedy

Defective torque converter oil temperature sensor

Replace

Defective monitor module of maintenance monitor

Replace

1 When short connector is connected to CN18, does torque converter oil temperature gauge display area rise one stage at a time, and finally do all lamps go out?

3 YES YES 2 Is resistance

• Disconnect CN18. between CN18 • Connect short (female) (2) and NO chassis ground connector to normal? CN18 (female). • Max. 1 Ω • Turn starting • Turn starting switch ON. switch OFF. • Disconnect CN18.

Is resistance between L18 (female) (5) and chassis ground normal when short connector is connected to CN18 (female)?

• Max. 1 Ω NO • Turn starting switch OFF. • Connect short connector to CN18 (female). • Disconnect L18.

NO

Defective contact or disconRepair or nection in wiring harness between CN18 (female) (1) – replace TM2 (8) – L18 (female) (5) Defective contact or disconnection in wiring harness Repair or between CN18 (female) (2) replace – TM2 (15) – LR4 (12) – chassis ground

K-14 c) Related electrical circuit diagram

20-522 (1)

WD600-3

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

Electrical circuit diagram for power supply, engine starting, engine stopping system .................... 20-603 Electrical circuit diagram for transmission control system ................................................................. 20-604 Electrical circuit diagram for parking brake .......................................................................................... 20-606 Electrical circuit diagram for lamp and horn ........................................................................................ 20-607 E-1

Engine does not start ................................................................................................................... 20-608

E-2

Preheating fault ............................................................................................................................ 20-614

E-3

Parking brake does not have effect ............................................................................................. 20-615 a) Parking brake has no effect when parking brake switch is turned ON .............................. 20-615 b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops ..................................................................................... 20-615

E-4

Parking brake is applied when machine is traveling ................................................................. 20-616

E-5

Parking brake is released when starting switch is turned ON .................................................. 20-618

E-6

Transmission does not change to neutral when parking brake is applied, but parking brake works normally ................................................................. 20-618

E-7

Transmission does not work properly ........................................................................................ 20-620 a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit .............................................................................. 20-622 b) No continuity in travel FORWARD solenoid circuit ............................................................. 20-626 c) No continuity in travel REVERSE solenoid circuit ............................................................... 20-628 d) Short circuit to chassis ground in directional solenoid circuit ........................................... 20-630 e) Abnormality in shift solenoid circuit .................................................................................... 20-636 f)

Short circuit to chassis ground in shift solenoid circuit ..................................................... 20-641

E- 8 When hold switch is pressed, gear speed is not fixed or reset ................................................ 20-646 E- 9 Kick-down system does not work ............................................................................................... 20-646 E-10 Power window does not work ..................................................................................................... 20-647 a) Power window does not rise (This troubleshooting shows about L.H. power window) .................................................. 20-647 b) Power window does not lower (This troubleshooting shows about L.H. power window) .................................................. 20-648 E-11 Abnormality in front working lamp ............................................................................................ 20-650 E-12 Abnormality in rear working lamp .............................................................................................. 20-650 E-13 Abnormality in transmission cut-off ........................................................................................... 20-650 E-14 Abnormality in parking brake dragging warning ...................................................................... 20-650 E-15 Abnormality in buzzer .................................................................................................................. 20-650

WD600-3

20-601 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING, ENGINE STOPPING SYSTEM

WD600-3

20-603 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

20-604 (1)

WD600-3

TROUBLESHOOTING

WD600-3

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

20-605 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

20-606 (1)

WD600-3

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN

ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN

WD600-3

20-607 (1)

E-1

TROUBLESHOOTING

E-1

Engine does not start

fl When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the starting switch OFF before starting. fl When connecting the T-adapter (or socket adapter), connect to the connector specified as CNct( ). fl After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. Starting motor does not turn

YES

3

5 YES

Is voltage between YES starting motor terminal (B) and chassis normal?

• 20 – 30 V • Turn starting switch OFF.

Is there continuity

YES between starting

both connection terminals of R12 and R13 of battery relay normal?

• 20 – 30 V • Turn starting switch OFF.

• Turn starting switch OFF.

• 20 – 30 V • Disconnect E13. • Directional lever: Neutral • Turn starting switch to START.

Does battery relay make sound NO of actuation?

NO • 20 – 30 V • Turn starting switch ON. • Check voltage YES between chassis and both terminals connected by thick 6 cable. Is voltage between NO

motor terminal (E) and chassis?

Is voltage between E13 (female) (1) and chassis normal?

4

• Starting switch ON ↔ OFF.

2

1

Is voltage between YES both battery relay terminals and chassis normal?

NO

NO

NO

20-608 (1)

WD600-3

TROUBLESHOOTING

E-1

Cause

Defective starting motor assembly

Replace

Defective contact or discon -nection in cable between battery relay and starting motor

Repair or replace

• If answer is NO for both terminals: Defective contact or disconnection in wiring har -ness between battery and battery relay • If answer is NO for one terminal: Defective battery relay

8 YES Is resistance YES between R13 (female) and 7 chassis normal? Is voltage between NO • Max. 1 Ω starting switch terminal BR and • Turn starting switch chassis normal? OFF.

• 20 – 30 V • Turn starting switch ON.

Remedy

Repair or replace

Defective battery relay

Replace

Defective contact or discon -nection in wiring harness between starting switch terminal BR – L09 (2) – LR4 (9) – R03 (diode) (2), (1) – R12 (female)

Replace

Defective contact or discon -nection in wiring harness between R13 and chassis ground

Repair or replace

Defective starting switch

Replace

Defective contact or disconnection in starting motor ground cable

Repair or replace

• Disconnect R13.

NO

Go to A on next page

WD600-3

20-609 (1)

TROUBLESHOOTING

E-1

YES

YES 11 Is voltage between YES L57 (female) (5) and chassis normal?

13 YES

Is voltage between YES starting switch terminal C and 12 • 20 – 30 V chassis normal? Is voltage between • Disconnect L57. starting switch NO • 20 – 30 V • Turn starting NO terminal B and • Turn starting switch switch to START. chassis normal? to START.

9 Does starting From A motor rotate when neutral relay is replaced?

• Replace neutral

• 20 – 30 V • Turn starting

relay (L57) with stop lamp relay (L53). • FR lever: Neutral • Turn starting switch to START.

NO

switch OFF.

YES 10

Is voltage between L57 NO (female) (1) and (2) normal?

15

• 20 – 30V • Disconnect L57. • Directional lever:

YES

Is voltage between YES L05 (female) (8) and chassis normal?

Neutral

• Turn starting switch

17 Is voltage YES between L04 (3) and chassis normal?

• 20 – 30 V • Disconnect L05. • Turn starting

to START.

switch ON.

16 Is voltage between L04 (female) (1) NO and chassis normal?

14

• 20 – 30 V • Connect T-adapter NO to L04.

• Directional lever: N. • Turn starting switch ON.

YES

• 20 – 30 V • Disconnect L04. • Turn starting

Is resistance between L57 (female) (2) and NO chassis normal?

switch ON.

• Max. 1 Ω • Turn starting switch OFF.

19 Does battery relay make sound NO of actuation?

• Starting switch

• Disconnect L57.

ON ↔ OFF.

NO

NO

20-610 (1)

WD600-3

TROUBLESHOOTING

E-1

Cause

Defective neutral relay

Remedy

Replace

Defective contact or disconnection in wiring harness between L57 (female) (3) – LR4 (8) – ER1(10) – E19 (2) – Repair or replace (1) and E08 (female) (1) or E22 (2) – (1) and E09 (female) (1) Defective contact or discon- Repair or nection in wiring harness replace between starting switch terminal C – L09 (3) – L57 (female) (5)

Defective starting switch Defective contact or disconnection in wiring harness between starting switch terminal B - L09 (1) – FS3 (4) – fuse I-12, FS3 (6) – LR5 (1)– slow blow fuse 30A – battery relay

Replace

Repair or replace

Defective contact or disconnection in wiring harness between L57 (female) (1) - L05 (female) (8)

18 YES Is voltage between C3B (female) (13) and chassis normal?

NO • 20 – 30 V • Disconnect C3B. • Turn starting switch ON.

Carryout troubleshooting of M-4, T-8.

Defective contact or disconnection in wiring harness Replace between L04 (female) (3) and C3B (female) (13)

Defective directional lever Replace switch

20 YES Are both voltages between battery relay terminal M and chassis normal?

• 20 – 30 V • Turn starting switch

NO

ON.

21 Are both voltages between battery relay A02, A03 and A04, A05 connection terminals normal?

• 20 – 30 V • Turn starting

Defective contact or disconnection in wiring harness between battery relay Repair or slow blow fuse 80A – LR6 replace (1) – FS1 (2) fuse I-9 – FS2 (8) – L04 (female) (1) Defective battery relay or defective contact or disconnection in wiring harness between battery battery relay

Repair or replace

Defective battery relay

Replace

Go to B on next page

NO

switch ON. Defective contact or disconnection in wiring harness between L57 (female) (2) – LR5 (2) and chassis ground

WD600-3

Repair or replace

20-611 (1)

E-1

TROUBLESHOOTING

Cause

23 YES Is resistance YES between A03, A05 and chassis 22 normal? Is voltage between From B starting switch • Max. 1 Ω terminal BR and • Turn starting chassis normal? switch OFF.

• Turn starting switch ON. • 20 – 30 V

20-612 (1)

NO

• Disconnect A03, A05. NO

Remedy

Defective contact or disconnection in wiring harness between starting switch Repair or terminal BR – L09 (2) – LR4 replace (9) – R03 (diode) (2), (1) – RA1 (1) – A02, A04 (female) Defective contact or disconRepair or nection in wiring harness between A03, A05 – RA1 (2) replace and chassis ground

Defective starting switch

Replace

WD600-3

TROUBLESHOOTING

E-1

E-1 Related electrical circuit diagram

WD600-3

20-613 (1)

E-2

TROUBLESHOOTING

E-2

Preheating fault

fl Check that Error Code [384] is not displayed in the engine controller.

Cause

2 YES Has the resistance YES value returned to normalcy after 1 replacing the heater relay? Is the resistance

value between • Replace the E31 and E24 or heater relay. between E32 and E25 normal? • Max. 1Ω NO • Turn starting switch OFF. • Disconnect E31, E24, E32 and E25

NO

Remedy

Heater relay fault

Replace

Heater fault

Replace

Disconnection or connection fault in wiring harness between E31 and E24 or between

Repair or replace

E-2 Electrical circuit diagram for APS system

20-614 (1)

WD600-3

TROUBLESHOOTING

E-3

E-3

Parking brake does not have effect

fl When carrying out troubleshooting of the brake system, stop the machine on flat ground. fl When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the starting switch OFF before starting. fl When connecting the T-adapter (or socket adapter), connect to the connector specified as CNct( ). fl After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check. a) Parking brake has no effect when parking brake switch is turned ON Cause

YES

Defective parking brake switch

1 Does condition become normal when L01 is disconnected?

Remedy

Replace

Contact of wiring harness Repair or at L01 (female) (2) end replace and (3) end

YES 2 Is resistance

• Start engine. between L01 (Charge brake oil NO (female) (2) and (3) pressure) normal?

3 YES

Is voltage between CN10 (female) (1) • Disconnect L01. • Turn starting NO and chassis normal? switch OFF.

• Disconnect L58. • Disconnect L59.

• Max. 1 V NO • Start engine. (Charge brake oil pressure) • Turn parking brake switch ON.

Defective parking brake solenoid

Replace

Contact of wiring harness Repair or at L01 (female) (2) end replace and

b) Parking brake has no effect and does not work as emergency brake when parking brake pressure drops

Cause

1 YES Is parking brake normal when C01 and C02 are disconnected?

• Turn starting NO switch ON. • Turn parking brake switch ON, then OFF.

WD600-3

Remedy

Defective emergency brake switch (C01, C02)

Replace

Defective parking brake solenoid

Replace

20-615 (1)

TROUBLESHOOTING

E-4

E-4

Parking brake is applied when machine is traveling

fl When carrying out troubleshooting of the brake system, stop the machine on flat ground. fl When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the starting switch OFF before starting. fl When connecting the T-adapter (or socket adapter), connect to the connector specified as CNct( ). fl After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check.

2 YES Is resistance YES between CN10 (female) (2) and chassis normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L59.

NO

YES

1 Is voltage between CN10 (female) (1) and chassis normal?

4 YES

• 20 – 30 V • Start engine. (Charge brake oil pressure)

3

YES

Does condition become normal when parking brake safety relay is replaced?

• Replace parking brake safety relay (L59) with stop lamp relay (L53). • Start engine. (Charge brake oil pressure)

Is continuity of L01 (male) NO (1)(2)(3) as shown in Table 1?

5

NO

• Turn starting switch OFF. • Operate parking brake switch ON/OFF. • Disconnect L01.

Does condition become normal when B09 and B10 are connected to short connector?

• Connect short connector to B09 (female) and B10 (female). • Start engine. (Charge brake oil pressure)

YES 7 Is resistance YES between L59 (female) (1) and (3) normal? 6 Is voltage between L59 (female) (5) NO and chassis normal?

• 20 – 30 V • Turn starting switch ON. • Disconnect L59.

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L59.

NO

NO

NO

Table 1

20-616 (1)

Operation

Between (2) – (3)

Between (1) – (3)

ON (Parking)

Min. 1 MΩ

Max. 1 Ω

OFF (Travel)

Max. 1 Ω

Min. 1 MΩ

WD600-3

E-4

TROUBLESHOOTING

Cause

Defective parking brake solenoid

Remedy

Replace

Defective contact or disconnection in wiring harness Repair or between CN10 (female) (2) replace and chassis

Defective parking brake safety relay

Replace

Defective emergency brake switch

Replace

Defective contact or discon-

11 YES nection in wiring harness Is voltage between YES B10 (female) (1) and chassis 10 normal? Is voltage between YES B09 (female) (1) • 20 – 30 V NO and chassis • Turn starting switch ON. 9 normal? • Turn parking brake Is resistance switch ON → OFF. • 20 – 30 V • Disconnect B10. YES between L59 • Turn starting (female) (2) and NO switch ON. chassis normal? 8 • Turn parking brake switch ON → OFF. • Max. 1 Ω Is voltage between • Disconnect B09. • Turn starting L59 (female) (1) and chassis normal?

switch OFF. • Disconnect L59.

• 20 – 30 V • Turn starting switch ON. NO • Turn parking brake switch ON. • Disconnect L59.

NO

between B10 (female) (2) – BR1 (8) – LR4 (14) – TH2 (11) – CN10 (female)

Repair or replace

Defective contact or disconRepair or nection in wiring harness between B09 (female) (2) replace and B10 (female) (1) Defective contact or disconnection in wiring harness Repair or between B09 (female) (1) – replace BR1 (7) – LR4 (13) – L01 (female) (2) Defective contact or disconnection in wiring harness between L59 (female) (2) and chassis

Repair or replace

Defective contact or disconnection in wiring harness between L59 (female) (1) and L01 (female) (3), or between FS2 (female) (7) and L01 (female) (1)

Repair or replace

Defective contact or disconRepair or nection in wiring harness replace between L59 (female) (1) and L59 (female) (3) Defective contact or disconRepair or nection in wiring harness replace between L59 (female) (5) – FS2 (7) – fuse I-9

Defective parking brake switch

WD600-3

Replace

20-617 (1)

TROUBLESHOOTING

E-5

E-5, E-6

Parking brake is released when starting switch is turned ON

fl When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the starting switch OFF before starting. fl When connecting the T-adapter (or socket adapter), connect to the connector specified as CNct( ). fl After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original condition before going on to the next check.

Cause

YES 1 Is problem removed when parking safety relay (L59) is replaced?

YES 2

Does it become • Replace parking safety relay (L59) normal when L01 with stop lamp NO is disconnected? relay (L53). • Turn starting • Disconnect L01. switch ON. • Turn starting NO • Start engine. (Stop engine after charging brake oil pressure)

E-6

switch ON. • Start engine. (Stop engine after charging brake oil pressure)

3 YES Is there continuity between L59 (female) (3) and (5)?

• Disconnect L59. NO • Turn starting switch OFF. • Turn parking brake switch OFF.

Remedy

Defective parking safety relay

Replace

Defective parking brake switch

Replace

Contact of wiring harness Repair or between L59 (5) and replace (female)(3)(1) Contact of wiring harness Repair or between L01 (female) (1) replace and (2)

Transmission does not change to neutral when parking brake is applied, but parking brake works normally

fl Carry out T-16 of TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM.

20-618 (1)

WD600-3

TROUBLESHOOTING

E-5, E-6

E-3, 4, 5 Related electrical circuit diagram

WD600-3

20-619 (1)

TROUBLESHOOTING

E-7

E-7

Transmission does not work properly

fl Before disconnecting or connecting connectors, surely 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.

Stop the machine on flat ground and put blocks under the tires.

1. Install a T-adopter (or socket adopter) to transmission connector T01, then check the voltage between the pins in Table 1 and chassis ground. 2. Turn starting switch ON.

¤

Do not start the engine.

3. Turn the parking brake switch ON, then OFF (release) again. 4. If required, press the right-hand foot brake pedal. fl If the left-hand brake pedal is pressed, the transmission is cut off and cannot be checked. 5. Check the voltage and continuity according to Table 1. Then, go to the troubleshooting shown in the right columns of Table 2 and Table 3 according to the inspection result shown in those tables.

Pin No. Operation of lever

(1) H

(2) G

(3) F

T01 (4) (F) (R) (GND) (GND) Remedy E D C B A

FR lever

¤

Table 1 Normal operation table of transmission

Forward (F) Reverse (R)

Gear shift lever

Perform tester check of the transmission solenoid control circuit according to the following procedure.

1st

b

c

c

c

c

2nd

c

b

c

c

c

3rd

c

c

b

c

c

4th

c

c

c

b

c

b

c

c

c

b

c

Go to Table 2.

Go to Table 2.

c : 0 – 0.5V (Continuity) b : 20 – 30V (Battery voltage)

Table 2 Result of check during operation of directional lever Check result

Cause

Troubleshooting

Defective transmission cutb [Battery volt- off switch, parking brake or Go to E-9-a). age] is zero. neutralizer relay circuit c There is not [continuity] (Forward side).

Defective circuit on forward Go to E-9-b). side.

c There is not [continuity] (Reverse side).

Defective circuit on reverse Go to E-9-c). side.

c [Continuity] is higher than specification.

Contact of circuits on forward and reverse sides with each other

Go to E-9-d).

Table 3 Result of check during operation of gear shift lever Check result

Cause

Troubleshooting

b [Battery volt- Defective power supply age] is zero. circuit Go to E-9-e).

20-620 (1)

c There is not [continuity]

Defective circuit on gear shifting side

c [Continuity] is higher than specification.

Contact of circuits on gear shifting side

Go to E-9-f).

WD600-3

TROUBLESHOOTING

E-7

a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit

3 YES Is resistance YES between L12 (male) (1) and (2) normal?

2 YES

Does condition become normal when transmission cut-off selector switch to turn OFF?

• Max. 1Ω • Turn starting switch OFF. • Disconnect L12.

NO

YES

• Start engine.

4

NO

• Replace neutralizer relay (L58) with stop lamp relay (L53). • Start engine.

1

NO

Is resistance between L04 (female) (10) and chassis ground normal?

YES

Does condition become normal when replacing neutralizer relay is replaced?

YES 5 Does condition become normal when parking brake safety relay is replaced?

• Replace parking brake relay (L59) with stop lamp relay (L53). • Start engine.

• Max. 1Ω • Turn starting switch OFF. • Disconnect L04.

7 Is voltage between YES L58 (fremale) (1) and chassis ground normal?

6 Is resistance of L01 (male) (1), (2) and NO (3) conformed to Table 1?

• Turn starting switch OFF. • Disconnect L01.

• 20 – 30 V • Turn starting switch ON. • Disconnect L58. • Turn on parking brake switch, then release it.

NO

NO

NO

Table 1 Operation

Terminals (1) – (3) Terminals (3) – (2)

ON (Parking)

Max. 1 Ω

Min. 1 Ω

OFF (Travel)

Min. 1 Ω

Max. 1 Ω

20-622 (1)

WD600-3

TROUBLESHOOTING

E-7

Cause

Remedy

Defective contact or disconnection in wiring harness Repair or between L12 (female) (1) and L06 (female) (3) or replace between L12 (female) (2) and CL1 (female) (12).

Defective transmission cut-off switch

Replace

Defective neutralizer relay Replace

Defective parking brake safety relay Defective contact or disconnection in wiring harness between L58 (female) (3) and C3A (female) (19) or between L58 (female) (2), CL1 (female) (12) and chassis ground

2 YES Is voltage between

YES L59 (female) (5) and chassis ground 1 Is resistance between L01 (female) (3) and L59 (female) (1) and (3) normal?

• Max. 1 Ω • Turn starting

normal?

• 20 – 30 V • Turn starting switch ON. • Disconnect L59.

NO

NO

Replace

Repair or replace

Defective contact or disconnection in wiring harness between L59 (female) (2), CL1 (12) and chassis ground Defective contact or disconnection in wiring harness between L59 (female) (5) and FS2 (female) (7)

Repair or replace

Defective contact or disconnection in wiring harness between L01 (female) (3) and L59 (female) (1) and (3)

Repair or replace

switch OFF.

• Disconnect L01 and L59.

Defective parking brake switch Defective contact or disconnection in wiring harness between L04 (female) (10), LR5 (3) and chassis ground

WD600-3

Replace

Repair or replace

20-623 (1)

TROUBLESHOOTING

E-7

E-7 a) Related electrical circuit diagram

20-624 (1)

WD600-3

TROUBLESHOOTING

E-7

b) No continuity in travel FORWARD solenoid circuit

2 YES Is resistance YES between T01 (female) (A) and chassis ground normal?

1 Is voltage between T01 (female) (D) and chassis ground normal?

• Max. 1 Ω • Turn starting

NO

switch OFF.

• Disconnect T01.

• 20 – 30 V • Disconnect T01. • Turn starting

YES 3

Is voltage between TL1 (male) (5) and switch ON. • Release parking NO chassis ground normal? brake

(Turn switch OFF).

• Shift FR lever to Forward.

• 20 - 30 V • Disconnect TL1. • Turn starting switch ON.

• Release parking brake (Turn switch OFF). • Shift FR lever to Forward.

YES 4

Is voltage between C1A (female) (2) and chassis NO ground normal?

YES 5

• 20 - 30 V • Connect T-adapter

Is voltage between C3B (female) (5) NO and chassis ground normal?

to C1A. • Turn starting switch ON. • Release parking brake (Turn switch OFF). • Shift FR lever to Forward.

20-626 (1)

6

Is voltage between L04 (female) (2) and chassis NO ground normal?

• 20 - 30 V • Connect T-adapter in C3B.

• Turn starting switch ON.

• Release parking brake (Turn switch OFF). • Shift FR lever to Forward.

E-7 b) Related electrical circuit diagram

YES

7 YES

Is voltage between L04 (female) (1) • 20 - 30 V • Connect T-adapter NO and chassis ground normal? in L04.

• Turn starting

• 20 – 30 V NO switch ON. • Disconnect L04. Release parking • Turn starting switch ON. brake (Turn switch OFF). • Shift FR lever to Forward. •

WD600-3

TROUBLESHOOTING

E-7

Cause

Defective forward solenoid Defective contact or disconnection in wiring harness between T01 (female) (A), TL1 (7), CL1 (12) and chassis ground

Defective contact or disconnection in wiring harness between TL1 (female) (5), T03 (1), and T01 (D) (female) Defective contact or disconnection in wiring harness between C1A (female) (2), C1 (2), and TL1 (male) (5)

Remedy

Replace

Repair or replace

Repair or replace

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (2) and C3B (female) (5)

Repair or replace

Defective forward-reverse Replace and gear shift switch Defective contact or disconnection in wiring harness between L04 (female) (1), FS2 (8), and fuse I (9)

WD600-3

Repair or replace

20-627 (1)

TROUBLESHOOTING

E-7

c) No continuity in travel REVERSE solenoid circuit

2 YES Is resistance betYES ween T01 (female) (A) and chassis ground normal?

1 Is voltage between T01 (female) (C) and chassis ground normal?

• Max. 1 Ω • Turn starting

NO

switch OFF.

• Disconnect T01.

• 20 – 30 V • Turn starting

YES 3

Is voltage between switch ON. TL1 (male) (6) and • Disconnect T01. NO chassis ground • Release parking normal?

brake (Turn switch ON, then OFF). • Set directional lever to REVERSE.

YES 4

Is voltage between • 20 - 30 V C1A (female) (9) • Disconnect TL1. and chassis NO • Turn starting ground normal?

switch ON.

• Release parking brake. • Set directional lever to REVERSE.

• 20 - 30 V • Insert T-adapter in C1A.

• Turn starting switch ON.

• Release parking brake. • Shift FR lever to Reverse.

YES 5

Is voltage between C3B (female) (6) NO and chassis ground normal?

• 20 - 30 V • Insert T-adapter in C3B.

• Turn starting switch ON.

• Release parking brake. • Shift FR lever to Reverse.

E-7 c) Related electrical circuit diagram

20-628 (1)

YES 6

Is voltage between L04 (female) (4) and chassis NO ground normal?

• 20 - 30 V • Insert T-adapter in L04.

• Turn starting switch ON. • Release parking brake. • Shift FR lever to Reverse.

7 YES Is voltage between L04 (female) (1) and chassis NO ground normal?

• 20 - 30 V • Disconnect L04. • Turn starting

NO

switch ON.

WD600-3

TROUBLESHOOTING

E-7

Cause

Defective forward solenoid Defective contact or disconnection in wiring harness between T01 (female) (A), TL1 (7), CL1 (12) and chassis ground

Defective contact or disconnection in wiring harness between TL1 (female) (6), T04, and T01 (female) (c) Defective contact or disconnection in wiring harness between C1A (female) (9), C1 (9), and TL1 (male) (6)

Remedy

Replace

Repair or replace

Repair or replace

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (4) and C3B (female) (6)

Repair or replace

Defective forward-reverse Replace and gear shift switch Defective contact or disconnection in wiring harness between L04 (female) (1), FS2, (8), and fuse I (9)

WD600-3

Repair or replace

20-629 (1)

TROUBLESHOOTING

E-7

d) Short circuit to chassis ground in directional solenoid circuit 1) Short circuit to chassis ground in travel FORWARD circuit

YES 6 Is resistance bet-

YES ween L04 (male) 5 Is resistance bet-

YES ween L04 (male) 4 Is resistance betYES ween TL1 (male) (6) and chassis ground normal? 3 Is resistance bet-

YES ween TL1 (female) 2 Is resistance betYES ween T01 (female) 1 (C) and connector body normal?

Is resistance between T01 (male) (c) and chassis ground normal? Is resistance between (A), (B), (C), (E), (F), (G), (H) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

20-630 (1)

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01 and TL1.

(6) and (1), (2), (3), (4), (5), (7) normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01 and TL1.

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect TL1, L04 and L67.

(4) and (2), (5), (6), (7), (8) normal?

(4) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect L04.

NO

• Min. 1 MΩ • Turn starting NO switch OFF. • Disconnect L04. • Set directional lever to N or F.

NO

NO

NO

NO

WD600-3

TROUBLESHOOTING

E-7

Cause

7 YES Is resistance between L04 (male) (2) and chassis ground normal?

• Min. 1 MΩ • Turn starting

NO

Defective transmission & joystick steering controller

Remedy

Replace

Short circuit with chassis or ground wire in harness Repair or between L04 (female) (2) replace and C3B (female) (5)

switch OFF.

• Disconnect L04 and C3B.

Defective transmission control switch

Replace

Defective transmission control switch

Replace

Short circuit with chassis or ground wire in harness Repair or between TL1 (male) (5) and replace C1A (male) (2) Short circuit of harness between TL1 (female) (5) and T01 (female) (D) and harness between TL1 (female) (1), (2), (3), (4), (6), (7) and T01 (female) (A), (C), (E), (F), (G) and (H) with each other

Defective insulation between T01 (female) (D) and connector body Defective insulation between T01 (male) (D) and connector body, or short circuit of harness and chassis ground with T01 (D) in control valve and defective insulation among pins of T01

WD600-3

Repair or replace

Repair or replace

20-631 (1)

TROUBLESHOOTING

E-7

2) Short circuit to chassis ground in travel REVERSE circuit

YES 6 Is resistance bet-

YES ween L04 (male) 5 Is resistance bet-

YES ween L04 (male) 4 Is resistance betYES ween TL1 (male) (6) and chassis ground normal? 3 Is resistance bet-

YES ween TL1 (female) 2 Is resistance betYES ween T01 (female) 1 (C) and connector body normal?

Is resistance between T01 (male) (c) and chassis ground normal? Is resistance between (A), (B), (D), (E), (F), (G), (H) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

20-632 (1)

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01 and TL1.

(6) and (1), (2), (3), (4), (5), (7) normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01 and TL1.

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect TL1, L04 and C1A.

(4) and (2), (5), (6), (7), (8) normal?

(4) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect L04.

NO

• Min. 1 MΩ • Turn starting NO switch OFF. • Disconnect L04. • Set directional lever to N or F.

NO

NO

NO

NO

WD600-3

TROUBLESHOOTING

E-7

Cause

7 YES Is resistance between L04 (male) (4) and chassis ground normal?

• Min. 1 MΩ • Turn starting

NO

Defective transmission & joystick steering controller

Remedy

Replace

Short circuit with chassis or ground wire in harness Repair or between L04 (female) (4) replace and C3B (female) (6)

switch OFF.

• Disconnect L04 and C3B.

Defective transmission control switch

Replace

Defective transmission control switch

Replace

Short circuit with chassis or ground wire in harness Repair or between TL1 (male) (6) and replace C1A (male) (9) Short circuit of harness between TL1 (female) áE and T01 (female) (C) and harness between TL1 (female) (1), (2), (3), (4), (5), (7) and T01 (female) (A), (D), (E), (F), (G) and (H) with each other

Defective insulation between T01 (female) (C) and connector body Defective insulation between T01 (male) (C) and connector body, or short circuit of harness and chassis ground with T01 (C) in control valve and defective insulation among pins of T01

WD600-3

Repair or replace

Repair or replace

20-633 (1)

TROUBLESHOOTING

E-7

E-7 d) Related electrical circuit diagram

20-634 (1)

WD600-3

TROUBLESHOOTING

E-7

e) Abnormality in shift solenoid circuit 1) 1st gear

Cause

4 YES

Remedy

To A

Is voltage between YES L04 (5) and chassis ground normal?

3

Is resistance betYES ween T01 (female) (B) and chassis ground normal? 2 Is voltage between YES L04 (female) (1) and chassis 1 ground normal?

Is resistance between L04 (female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

• Max. 1 Ω • Turn starting

Defective gear shift lever

• 20 – 30 V • Turn starting

NO switch

switch ON.

• Connect T-branch to L04.

• Set gear shift lever to 1st.

switch OFF. • Disconnect T01.

NO

• 20 – 30 V • Turn starting switch ON. • Disconnect L04.

NO

NO

Defective contact or disconnection in wiring harness between T01 (female) (B), TL1 (7), CL1 (12), and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (1), FS2 (8), and fuse I (9)

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (10), LR5 (3), and chassis ground

Repair or replace

8 YES Defective solenoid for 1st Is voltage between YES T01 (female) (H) and chassis 7 ground normal? Is voltage between

YES TL1 (male) (1) and 6 Is voltage between

YES C1A (3) and chassis ground 5 normal? Is voltage between From A C3B (7) and chassis ground normal?

• 20 – 30 V • Turn starting

• 20 – 30 V • Insert T-adapter in

(1)

• 20 – 30 V • Disconnect TL1. • Turn starting

• 20 – 30 V • Disconnect T01. • Turn starting

gear speed

Replace

Defective contact or disconnection in wiring harRepair or NO ness between TL1 (female) replace (1) and T01 (female) (H)

switch ON.

• Set gear shift lever to 1st.

NO switch ON. • Set gear shift lever to 1st.

C1A. NO • Turn starting switch ON. • Set gear shift lever to 1st.

switch ON. • Insert T-adapter in NO C3B. • Set gear shift lever to 1st.

20-636

chassis ground normal?

Replace

Defective contact or disconnection in wiring harness between C1A (female) (3) and TL1 (male) (1)

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (5) and C3B (female) (7)

Repair or replace

WD600-3

TROUBLESHOOTING

E-7

2) 2nd gear

Cause

4 YES

Remedy

To A

Is voltage between YES L04 (6) and chassis ground normal?

3

Is resistance betYES ween T01 (female) (B) and chassis ground normal? 2 Is voltage between

YES L04 (female) (1) and chassis 1 Is resistance between L04 (female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

• Max. 1 Ω • Turn starting

NO switch

NO

• 20 – 30 V • Turn starting switch ON. • Disconnect L04.

NO

NO

Defective contact or disconnection in wiring harness between T01 (female) (B), TL1 (7), CL1 (12), and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (1), FS2 (8), and fuse I (9)

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (10), LR5 (3), and chassis ground

Repair or replace

8 YES Defective solenoid for 2nd Is voltage between YES T01 (female) (G) and chassis 7 ground normal? Is voltage between

YES TL1 (male) (2) and 6 Is voltage between

YES C1A (10) and chassis ground 5 Is voltage between From A C3B (15) and chassis ground normal?

• 20 – 30 V • Turn starting

normal?

• 20 – 30 V • Insert T-adapter in

• 20 – 30 V • Disconnect TL1 • Turn starting

• 20 – 30 V • Disconnect T01. • Turn starting

gear speed

Replace

Defective contact or disconnection in wiring harRepair or NO ness between TL1 (female) replace (2) and T01 (female) (G)

switch ON.

• Set gear shift lever to 2nd.

NO switch ON. • Set gear shift lever to 2nd.

C1A. NO • Turn starting switch ON. • Set gear shift lever to 2nd

switch ON. • Insert T-adapter in NO C3B. • Set gear shift lever to 2nd.

WD600-3

chassis ground normal?

Replace

switch OFF.

• Disconnect L04. • Set gear shift lever to 2nd.

switch OFF. • Disconnect T01.

ground normal?

Defective gear shift lever

• 20 – 30 V • Turn starting

Defective contact or disconnection in wiring harness between C1A (female) (10) and TL1 (male) (2)

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (6) and C3B (female) (15)

Repair or replace

20-637 (1)

TROUBLESHOOTING

E-7

3) 3rd gear

Cause

4 YES

Remedy

To A

Is voltage between YES L04 (7) and chassis ground normal?

3

Is resistance betYES ween T01 (female) (B) and chassis ground normal? 2 Is voltage between YES L04 (female) (1) and chassis 1 ground normal?

Is resistance between L04 (female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

• Max. 1 Ω • Turn starting

Defective gear shift lever

• 20 – 30 V • Turn starting

NO switch

switch ON.

• Connect T-branch to L04.

• Set gear shift lever to 3rd.

switch OFF. • Disconnect T01.

NO

• 20 – 30 V • Turn starting switch ON. • Disconnect L04.

NO

NO

Defective contact or disconnection in wiring harness between T01 (female) (B), TL1 (7), CL1 (12), and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (1), FS2 (8), and fuse I (9)

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (10), LR5 (3), and chassis ground

Repair or replace

8 YES Defective solenoid for 3rd Is voltage between YES T01 (female) (F) and chassis 7 ground normal? Is voltage between

YES TL1 (male) (3) and 6 Is voltage between

YES C1A (5) and chassis ground 5 normal? Is voltage between From A C3B (8) and chassis ground normal?

• 20 – 30 V • Turn starting

• 20 – 30 V • Insert T-adapter in

(1)

• 20 – 30 V • Disconnect TL1 • Turn starting

• 20 – 30 V • Disconnect T01. • Turn starting

gear speed

Replace

Defective contact or disconnection in wiring harRepair or NO ness between TL1 (female) replace (3) and T01 (female) (F)

switch ON.

• Set gear shift lever to 3rd.

NO switch ON. • Set gear shift lever to 3rd.

C1A. NO • Turn starting switch ON. • Set gear shift lever to 3rd

switch ON. • Insert T-adapter in NO C3B. • Set gear shift lever to 3rd.

20-638

chassis ground normal?

Replace

Defective contact or disconnection in wiring harness between C1A (female) (5) and TL1 (male) (3)

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (7) and C3B (female) (8)

Repair or replace

WD600-3

TROUBLESHOOTING

E-7

4) 4th gear

Cause

4 YES

Remedy

To A

Is voltage between YES L04 (8) and chassis ground normal?

3

Is resistance betYES ween T01 (female) (B) and chassis ground normal? 2 Is voltage between YES L04 (female) (1) and chassis 1 ground normal?

Is resistance between L04 (female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

• Max. 1 Ω • Turn starting

Defective gear shift lever

• 20 – 30 V • Turn starting

NO switch

switch ON.

• Connect T-branch to L04.

• Set gear shift lever to 2nd.

switch OFF. • Disconnect T01.

NO

• 20 – 30 V • Turn starting switch ON. • Disconnect L04.

NO

NO

Defective contact or disconnection in wiring harness between T01 (female) (B), TL1 (7), CL1 (12), and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (1), FS2 (8), and fuse I (9)

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (10), LR5 (3), and chassis ground

Repair or replace

8 YES Defective solenoid for 4th Is voltage between YES T01 (female) (E) and chassis 7 ground normal? Is voltage between

YES TL1 (male) (4) and 6 Is voltage between

YES C1A (11) and chassis ground 5 Is voltage between From A C3B (16) and chassis ground normal?

• 20 – 30 V • Turn starting

normal?

• 20 – 30 V • Insert T-adapter in

• 20 – 30 V • Disconnect TL1 • Turn starting

• 20 – 30 V • Disconnect T01. • Turn starting

gear speed

Replace

Defective contact or disconnection in wiring harRepair or NO ness between TL1 (female) replace (4) and T01 (female) (E)

switch ON.

• Set gear shift lever to 4th.

NO switch ON. • Set gear shift lever to 4th.

C1A. NO • Turn starting switch ON. • Set gear shift lever to 4th

switch ON. • Insert T-adapter in NO C3B. • Set gear shift lever to 4th.

WD600-3

chassis ground normal?

Replace

Defective contact or disconnection in wiring harness between C1A (female) (11) and TL1 (male) (4)

Repair or replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between L04 (female) (8) and C3B (female) (16)

Repair or replace

20-639 (1)

TROUBLESHOOTING

E-7

E-7 e) Related electrical circuit diagram

20-640 (1)

WD600-3

TROUBLESHOOTING

f)

E-7

Short circuit to chassis ground in shift solenoid circuit 1) Short circuit to chassis ground in 1st solenoid circuit

Cause

YES 4 Is resistance bet-

YES ween TL1 (male) (1) and (2), (3), (4), (5), (6), (7) normal?

3 Is voltage between YES TL1 (male) (1) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (H) and chassis ground normal? Is resistance between (A), (B), (C), (D), (E), (F), (G) and chassis ground normal?

Is resistance between T01 (female) (H) and (A), (B), (C), (D), (E), (F), (G) normal?

switch OFF. and TL1.

• Min. 1 MΩ • Turn starting switch OFF.

NO

• Disconnect T01.

5 YES Is resistance From A between L04 (female) (5) and (2), (4), (6) normal?

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect L04,

L04 and C1A. • Turn starting switch ON.

NO

NO

NO

switch OFF.

• Disconnect TL1, L04 and C1A.

• 0 – 0.5V • Disconnect TL1,

• Min. 1 MΩ • Turn starting • Disconnect T01

• Min. 1 MΩ • Turn starting

NO

Remedy

To A Short circuit with wiring harness between following couples in wiring harness between TL1 (male) (1) and C1A (female) (3); TL1 (male) (2) and C1A (female) (10), TL1 (male) (3) and C1A (female) (5), TL1 (male) (4) and C1A (female) (11), TL1 (male) (5) and C1A (female) (2), TL1 (male) (6) and C1A (female) (9), and TL1 (male) (7) and chassis ground

Short circuit with power source in wiring harness between TL1 (male) (1) and C1A (female) (3)

Repair or replace

Repair or replace

Short circuit with wiring harness between following groups in wiring harness between T01 (female) (H) Repair or and TL1 (female) (1); T01 replace (female) (A), (B), (C), (D), (E), (F), (G) and TL1 (female) (2), (3), (4), (5), (6), (7) Defective insulation between T01 (male) (H) and connector body, or short Repair or circuit of harness and replace chassis ground with T01 (H) in control valve and defective insulation among pins of T01

Defective transmission control switch Short circuit with wiring harness between following groups in wiring harness between C1A (female) (3) and TL1 (male) (1); C1A (female) (2), (5), (9), (10), (11) and TL1 (male) (2), (3), (4), (5), (6)

Replace

Repair or replace

TL1 and C1A.

WD600-3

20-641 (1)

TROUBLESHOOTING

E-7

2) Short circuit to chassis ground in 2nd solenoid circuit

Cause

YES 4 Is resistance bet-

YES ween TL1 (male) (2) and (1), (3), (4), (5), (6), (7) normal?

3 Is voltage between YES TL1 (male) (2) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (G) and chassis ground normal? Is resistance between (A), (B), (C), (D), (E), (F), (H) and chassis ground normal?

Is resistance between T01 (female) (G) and (A), (B), (C), (D), (E), (F), (H) normal?

switch OFF. and TL1.

• Min. 1 MΩ • Turn starting switch OFF.

NO

• Disconnect T01.

5 YES Is resistance From A between L04 (female) (6) and (2), (4), (5) normal?

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect L04,

and C1A. • Turn starting switch ON.

NO

NO

NO

switch OFF.

• Disconnect TL1, L04 and C1A.

• 0 – 0.5V • Disconnect TL1, L04

• Min. 1 MΩ • Turn starting • Disconnect T01

• Min. 1 MΩ • Turn starting

NO

Remedy

To A Short circuit with wiring harness between following couples in wiring harness between TL1 (male) (2) and C1A (female) (10); TL1 (male) (1) and C1A (female) (3), TL1 (male) (3) and C1A (female) (5), TL1 (male) (4) and C1A (female) (11), TL1 (male) (5) and C1A (female) (2), TL1 (male) (6) and C1A (female) (9), and TL1 (male) (7) and chassis ground

Short circuit with power source in wiring harness between TL1 (male) (2) and C1A (female) (5)

Repair or replace

Repair or replace

Short circuit with wiring harness between following groups in wiring harness Repair or between T01 (female) (G) replace and TL1 (female) (2); T01 (female) (A), (B), (C), (D), (E), (F), (H) and TL1 (female) (1), (3), (4), (5), (6), (7) Defective insulation between T01 (male) (G) and connector body, or short Repair or circuit of harness and replace chassis ground with T01 (G) in control valve and defective insulation among pins of T01

Defective transmission control switch

Replace

Short circuit with wiring harness between following groups in wiring harness Repair or between C1A (female) (10) replace and TL1 (male) (2); C1A (female) (2), (3), (5), (9), (11) and TL1 (male) (1), (3), (4), (5), (6)

TL1 and C1A.

20-642 (1)

WD600-3

TROUBLESHOOTING

E-7

3) Short circuit to chassis ground in 3rd solenoid circuit

Cause

YES 4 Is resistance bet-

YES ween TL1 (male) (3) and (1), (2), (4), (5), (6), (7) normal?

3 Is voltage between YES TL1 (male) (3) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (F) and chassis ground normal? Is resistance between (A), (B), (C), (D), (E), (G), (H) and chassis ground normal?

Is resistance between T01 (female) (F) and (A), (B), (C), (D), (E), (G), (H) normal?

switch OFF. and TL1.

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

NO

5 YES Is resistance betFrom A ween L04 (female) (7) and (2), (4), (5), (6) normal?

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect L04,

L04 and C1A. • Turn starting switch ON.

NO

NO

NO

switch OFF.

• Disconnect TL1, L04 and C1A.

• 0 – 0.5V • Disconnect TL1,

• Min. 1 MΩ • Turn starting • Disconnect T01

• Min. 1 MΩ • Turn starting

NO

Remedy

To A Short circuit with wiring harness between following couples in wiring harness between TL1 (male) (3) and C1A (female) (5); TL1 (male) (1) and C1A (female) (3), TL1 (male) (2) and C1A (female) (10), TL1 (male) (4) and C1A (female) (11), TL1 (male) (5) and C1A (female) (2), TL1 (male) (6) and C1A (female) (9), and TL1 (male) (7) and chassis ground

Repair or replace

Short circuit with power source in wiring harness between TL1 (male) (3) and C1A (female) (5)

Repair or replace

Short circuit with wiring harness between following groups in wiring harness between T01 (female) (F) and TL1 (female) (3); T01 (female) (A), (B), (C), (D), (E), (G), (H) and TL1 (female) (1), (2), (4), (5), (6), (7)

Repair or replace

Defective insulation between T01 (male) (F) and connector body, or short circuit of harness and chassis ground with T01 (F) in control valve and defective insulation among pins of T01

Defective transmission control switch Short circuit with wiring harness between following groups in wiring harness between C1A (female) (5) and TL1 (male) (3); C1A (female) (2), (3), (9), (10), (11) and TL1 (male) (1), (2), (4), (5), (6)

Repair or replace

Replace

Repair or replace

TL1 and C1A.

WD600-3

20-643 (1)

TROUBLESHOOTING

E-7

4) Short circuit to chassis ground in 4th solenoid circuit

Cause

YES 4 Is resistance bet-

YES ween TL1 (male) (4) and (1), (2), (3), (5), (6), (7) normal?

3 Is voltage between YES TL1 (male) (4) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (E) and chassis ground normal? Is resistance between (A), (B), (C), (D), (F), (G), (H) and chassis ground normal?

Is resistance between T01 (female) (E) and (A), (B), (C), (D), (F), (G), (H) normal?

switch OFF. and TL1.

• Min. 1 MΩ • Turn starting switch OFF.

NO

• Disconnect T01.

L04 and C1A. • Turn starting switch ON.

NO

NO

switch OFF.

• Disconnect TL1, L04 and C1A.

• 0 – 0.5V • Disconnect TL1,

• Min. 1 MΩ • Turn starting • Disconnect T01

• Min. 1 MΩ • Turn starting

NO

To A Short circuit with wiring harness between following couples in wiring harness between TL1 (male) (4) and C1A (female) (11); TL1 (male) (1) and C1A (female) (3), TL1 (male) (2) and C1A (female) (10), TL1 (male) (3) and C1A (female) (5), TL1 (male) (5) and C1A (female) (2), TL1 (male) (6) and C1A (female) (9), and TL1 (male) (7) and chassis ground

• Min. 1 MΩ • Turn starting

Repair or replace

Short circuit with wiring harness between following groups in wiring harness between T01 (female) (E) and TL1 (female) (4); T01 (female) (A), (B), (C), (D), (E), (F), (G) and TL1 (female) (1), (2), (3), (5), (6), (7)

Repair or replace

Defective insulation between T01 (male) (E) and Repair or connector body, or short replace circuit of harness and chassis ground with T01 (E) in control valve and defective insulation among pins of T01

Defective transmission control switch

switch OFF.

• Disconnect L04, TL1 and C1A.

20-644 (1)

NO

Repair or replace

Short circuit with power source in wiring harness between TL1 (male) (4) and C1A (female) (11)

5 YES Is resistance betFrom A ween L04 (female) (8) and (2), (4), (5),(6) normal?

Remedy

Replace

Short circuit with wiring harness between following Repair or groups in wiring harness replace between C1A (female) (11) and TL1 (male) (4); C1A (female) (2), (3), (5), (9), (10) and TL1 (male) (1), (2), (3), (5), (6)

WD600-3

TROUBLESHOOTING

E-7

E-7 f) Related electrical circuit diagram

WD600-3

20-645 (1)

TROUBLESHOOTING

E-8

E-8, E-9

When hold switch is pressed, gear speed is not fixed or reset Gear speed is not shifted up

fl Carry out T-13 of TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM.

E-9

Kick-down system does not work Gear speed is not shifted down

fl Carry out T-14 of TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM.

20-646 (1)

WD600-3

TROUBLESHOOTING

E-10

E-10 Power window does not work fl fl fl fl

Before disconnecting or connecting connectors, surely 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 fuse (12) is not blown.

a) Power window does not rise (This troubleshooting shows about L.H. power window) Cause

4 YES Is resistance betYES ween L92 (female) (6) and chassis 3 ground normal?

Is resistance

YES between CL19 (female) and L92 (female) (3) normal?

2 YES

1 Is there continuity between CL18 (female) and CL19 (male)?

Is voltage between CL18 and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect CL19 and L92.

• 20 – 30V • Turn starting switch ON. 5 • Set left-hand Is resistance power window between CL18 switch to UP NO (male) and L91 position. (female) (3) normal?

• Turn starting switch OFF. • Disconnect CL18 and CL19.

NO

YES

Defective relay (L92)

Replace

Defective contact or disconnection in wiring harness between L92 (female) (6), NO CL1 (12) and chassis ground

Repair or replace

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L19 and L92.

NO

6 YES

Does condition YES become normal when relay is replaced?

Defective contact or disconnection in wiring harness between CL19 (female), CL2 (2) and L92 (female) (13)

Defective relay (L91)

Defective contact or disconnection in wiring harness between L91 (female) (2), CL1 (12) and chassis ground

Repair or replace

between L41 (female) (5) Is voltage between and L91 (female) (1) YES L91 (female) (5) and chassis 9 Defective contact or discoground normal? Is voltage between nnection in wiring harness YES L41 (female) (1) and NO between OP2 (male) and • 20 – 30V • 20 – 30V L91 (female) (5) chassis ground • Turn starting • Turn starting 8 normal? switch ON. switch ON. Defective contact or discoIs resistance bet• Disconnect L91. • 20 – 30V • Disconnect L91. nnection in wiring harness ween L41 (male) • Turn starting • Set left-hand between L41 (female) (1) NO NO (1) and (5) switch ON. and OP2 (male) power window normal?

WD600-3

Repair or replace

Replace

Is voltage between From A L91 (female) (1) and chassis ground normal?

• Disconnect L41. • Max. 1 Ω • Turn starting NO switch OFF. • Disconnect L41. • Set left-hand power window switch to UP position.

Replace

Defective power window motor

Defective contact or disco-

switch to UP position.

Repair or replace

To A

• Turn starting NO switch ON. • Replace L91 (Left-hand UP relay) with L93 (Right-hand UP relay). • Set left-hand power window switch to UP Defective contact or discoposition. nnection in wiring harness between CL18 (male), CL2 NO (1) and L91 (female) (3)

10 YES nnection in wiring harness

7

Remedy

Defective switch (L41)

Repair or replace

Repair or replace

Repair or replace

Repair or replace

20-647 (1)

E-10

TROUBLESHOOTING

fl fl fl fl

Before disconnecting or connecting connectors, surely 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 fuse (12) is not blown.

b) Power window does not lower (This troubleshooting shows about L.H. power window) Cause

4 YES Is resistance betYES ween L91 (female) (6) and chassis 3 ground normal?

Is resistance YES between CL18 (male) and L91 (female) (3) normal?

2 Is voltage between YES CL19 and chassis ground normal?

1 Is there continuity between CL18 (female) and CL19 (male)?

• 20 – 30V • Turn starting switch ON. • Set left-hand power window switch to DOWN NO position.

• Max. 1 Ω • Turn starting switch OFF. • Disconnect CL18 and L92.

YES

Defective contact or disconnection in wiring harness between L91 (female) (6), NO CL1 (12) and chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between CL18 (male), CL2 (1) and L91 (female) (3)

Repair or replace

Defective relay (L92)

Replace

6 YES

Is resistance between CL19 (female) and L92 (female) (3) normal?

NO

Replace

NO

5

• Turn starting switch OFF. • Disconnect CL18 and CL19.

Defective relay (L91)

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L92 and L91.

Does condition YES become normal when relay is replaced?

To A

• Turn starting NO switch ON. • Replace L92 (Left-hand UP relay) with L94 (Right-hand DOWN relay). • Set left-hand power window switch to Defective contact or discoDOWN position. nnection in wiring harness between CL19 (female), NO CL2 (2) and L92 (female) (3)

Replace

Defective contact or disconnection in wiring harness between L92 (female) (2), CL1 (12) and chassis ground

Repair or replace

Defective contact or disco-

between L41 (female) (6) Is voltage between Is voltage between and L92 (female) (1) YES L92 (female) (5) From A L92 (female) (1) and chassis 9 and chassis Defective contact or discoground normal? ground normal? Is voltage between nnection in wiring harness YES L41 (female) (1) and NO between OP2 (male) and • 20 – 30V • 20 – 30V L92 (female) (5) chassis ground • Turn starting • Turn starting 8 normal? switch ON. switch ON. Defective contact or discoIs resistance bet• Disconnect L91. • 20 – 30V • Disconnect L91. nnection in wiring harness ween L41 (male) • Turn starting • Set left-hand between L41 (female) (1) NO NO (1) and (6) switch ON. and OP2 (male) power window normal?

switch to DOWN position.

20-648 (1)

• Disconnect L41. • Max. 1 Ω • Turn starting NO switch OFF. • Disconnect L41. • Set left-hand power window switch to DOWN position.

Repair or replace

Defective power window motor

10 YES nnection in wiring harness

7

Remedy

Defective switch (L41)

Repair or replace

Repair or replace

Repair or replace

Replace

WD600-3

TROUBLESHOOTING

E-10

E-10 Related electrical circuit diagram

WD600-3

20-649 (1)

TROUBLESHOOTING

E-11, E-12, E-13, E-14, E-15

E-11 Abnormality in front working lamp fl Go to Troubleshooting M-10.

E-12 Abnormality in rear working lamp fl Go to Troubleshooting M-11.

E-13 Abnormality in transmission cut-off fl Go to Troubleshooting T-15.

E-14 Abnormality in parking brake dragging warning fl Go to Troubleshooting M-13, M-14.

E-15 Abnormality in buzzer fl Go to Troubleshooting M-15.

20-650 (1)

WD600-3

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)

POWER TRAIN H- 1 Machine does not move .............................................................................................................. 20-702 H- 2 Machine does not travel smoothly (machine jerks) .................................................................. 20-703 H- 3 Lock-up clutch cannot be disengaged (engine stalls) ............................................................... 20-703 H- 4 Machine lacks power or speed when traveling ......................................................................... 20-704 H- 5 Excessive time lag when starting machine or shifting gear ..................................................... 20-706 H- 6 Torque converter oil temperature too high ................................................................................ 20-707 STEERING SYSTEM H- 7 Steering wheel does not turn ...................................................................................................... 20-708 H- 8 Steering does not turn [machine with joystick] ......................................................................... 20-709 H- 9 Turning, response of steering is poor ......................................................................................... 20-710 H-10 Turning, response of steering is poor [machine with joystick] ................................................. 20-712 H-11 Steering is heavy .......................................................................................................................... 20-714 H-12 Joystick is heavy [machine with joystick] .................................................................................. 20-714 H-13 Steering wheel shakes or jerks .................................................................................................... 20-715 H-14 Steering shakes or there is excessive shock [machine with joystick] ...................................... 20-716 H-15 Turning radius is different between left and right at maximum steering ................................ 20-716 BRAKE SYSTEM H-16 Wheel brakes do not work or braking effect is poor ................................................................. 20-718 H-17 Wheel brakes are not released or brakes drag .......................................................................... 20-720 H-18 Parking brake does not work or braking effect is poor ............................................................. 20-721 H-19 Parking brake is not released or brake drags (including emergency release system) ........... 20-722 WORK EQUIPMENT H-20 Blade does not rise ....................................................................................................................... 20-723 H-21 Blade moves slowly or does not have sufficient lifting power ................................................. 20-724 H-22 Blade becomes slow at certain height when raising ................................................................. 20-725 H-23 Lift cylinder cannot hold down blade ......................................................................................... 20-725 H-24 Blade has large amount of hydraulic drift .................................................................................. 20-725 H-25 Blade fluctuates while working ................................................................................................... 20-726 H-26 Blade drops momentarily when lever is operated from HOLD to RAISE ................................ 20-726 H-27 Blade does not tilt ......................................................................................................................... 20-727 H-28 Blade moves slowly or has insufficient tilt power ..................................................................... 20-728 H-29 Blade does not pitch ..................................................................................................................... 20-729 H-30 Blade pitch movement is slow or lacks power .......................................................................... 20-729 H-31 Work equipment lever does not move smoothly ...................................................................... 20-730

WD600-3

20-701 (1)

H-1

TROUBLESHOOTING

TROUBLESHOOTING TABLE Ask the operator the following points. • Did the machine suddenly stop moving? Yes = Component seized or damaged. • Was there any abnormal noise when this machine stopped moving? Yes = Component broken. Checks before troubleshooting • Is oil level in transmission case correct? • Is monitor display normal? • Is drive shaft broken?

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

Air suck ing Pum up a Cau p de t su ctio fect ses Ope n si ive ratin de o g f p o Ope ump ratin f modu latin g of Pilo g m relie t red odu f latin ucin Sea g va valve d g va l rin efec lve l v e sp g spo tive , g Tran roov ring ol d smi e efec d e of tr t e s tive s r i i orat ans on c Rota mis ed, lutc ting sion o h p c s erat l utch eize Sha clut ion d ft se ch d defe of s a e c l f t poo r ecti ive Dam ing v l de ( oil s in ro e age fect eali tatin to in ive Ope n g g t e defe ratio clut rnal ch c c n p t i a o v rt of Ope e) f so ircu ratin leno it de tran g of id v fect smi cont alve ive s s i on rol v defe alve ctiv spoo e l de fect ive (bitin g or dirt caug ht in side )

H-1 Machine does not move

a

No.

Remedy Problems

1

Abnormal noise between pump and filter

2

Machine does not move in any speed range (Item 1 normal)

3

Machine moves normally in certain speed ranges

4

Machine will not move when T/C oil temperature rises

5 7

Transmission modulating pressure too low

8

Pilot pressure defective

6

b c

×

d e

×

f

g

h

i

j

× × × × × ×

k

l

×

Low at every speed range Low at certain speed ranges Indicator fluctuates violently

Note 1: If the solenoid valve and hydraulic pressure are normal, the “l” in the Causes column indicates that the valve spool does not work. Note 2: If the transmission clutch pressure is low, but the cause cannot be found in the above table, a possible cause is cracks in the valve or transmission.

20-702 (1)

WD600-3

H-2, H-3

TROUBLESHOOTING

H-2 Machine does not travel smoothly (machine jerks) • •

There is hunting. Lock-up lamp flashes

Causes • Drop in main relief pressure • Worn clutch seal ring

Remedy

  

See H-4

H-3 Lock-up clutch cannot be disengaged (engine stalls)

a Remedy No.

p sole ctuati o n of noid v lock-u alve lock-u p valv p clutc e h Seized

tive a

Defec

Defec

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

tive a

ctuati

o n of

lock-u

Causes

Checks before troubleshooting • Is the oil level in the transmission case correct?

b c

C

Problems

1

Lock-up pressure does not become "0"

2

Lock-up clutch is not disengaged even when lock-up pressure is "0"

3

Operation of lock-up valve is normal

4

Operation of lock-up solenoid valve is normal

WD600-3

20-703 (1)

TROUBLESHOOTING

H-4

H-4 Machine lacks power or speed when traveling Causes ed str ainer Air su cked in a t s uc Defec tion s tive p ide of ump pump Drop in per forma nce o Drop f engin in set p ress e ure of Excess main ive oil relief leakag valve e insid Defec (torqu e torqu tive to e con e conv rq ue c verter erter (d Defecti onver valve) efectiv ter fre v e o pe e e r w s a e ti h a o l e n of to ring, lo Coole el r, pipin rque c ose plu onver g) g b ey ter reli Dama ond to e ge ins f r v q a u lv e con e, dete ide to v erter o rque c Torqu riorate e con onver utlet p d sprin verter ter (tu ort da g rbine lock-u mage rivet b p d oe d s not r o k e n) engag e

a. Abnormality at all speed ranges Checks before troubleshooting • Are the transmission oil filter and strainer clogged? • Is the oil level in the transmission case correct? • Is there any external oil leakage from the piping or valve joints? • Is there any dragging of the wheel brake and parking brake? • How are the tire inflation pressure and shape of tire tread? • Is working method correct?

Clogg

Checking for abnormalities • Engine high idling speed • Torque converter stall speed • Machine travel speed • Transmission clutch pressure • Torque converter lock-up pressure • Main relief pressure Remedy No.

Problems

1

Abnormal noise comes from between pump and filter

2

Torque converter stall speed is high

3

Torque converter stall speed is low

4

7

Low at every speed range (Item 2 abnormal) Set pressure of Indicator is unstable and transmission is low fluctuates excessively Low after entering torque converter lock-up Hydraulic pressure at torque converter inlet port is low (Items 4 - 6 normal)

8

Hydraulic pressure at torque converter outlet port is low (Item 7 normal)

9

Pieces of iron and aluminium stuck to strainer and drain plug of transmission case

10

Hydraulic pressure at pump outlet port is low

11

When oil temperature rises, oil pressure drops

5 6

b c d e

A C

f g h

i

j

k

A

See "Torque converter lock-up does not engage".

See "Torque converter lock-up does not engage".

a

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

20-704 (1)

WD600-3

H-4

TROUBLESHOOTING

b. Torque converter lock-up does not engage

Causes in set p re ss ure o f Defec tive lo main relief ck-up valve Defec solen oid tive o perati o Defec n of lo tive o ck-up perati solen o n of Worn oid va lock-u lock-u lve sp p valv p clutc ool e Worn h spool p iston lock-u s eal rin p clutc g Crack h disc ed loc k-up c lutch case

Ask the operator the following questions • Did the problem suddenly happen? Yes = Internal seizure, damage • When this happened, was there any abnormal noise? Yes = Broken part Checks before troubleshooting • Is the oil level in the transmission case correct? • Is there any external oil leakage? • Is electricity flowing to the lock-up solenoid? (Use a checker.)

Drop

Checking for abnormalities • Main relief pressure • Lock-up oil pressure • Machine travel speed

a

b c d e

f g

Remedy No.

Problems

1

Main relief pressure is low

2

With Item 1 normal, lock-up pressure is low or "0"

3

Solenoid is normal in Item 2 (proper continuity, no short circuit)

4

Solenoid is defective in Item 2 (no continuity, there is short circuit)

5

With Items 1 - 4 normal, lock-up pressure is low

6

Oil pressure is normal in Item 5

7

Lock-up pressure is low and main pressure is also low

8

Lock-up takes time to engage

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

WD600-3

20-705 (1)

TROUBLESHOOTING

H-5

H-5 Excessive time lag when starting machine or shifting gear

Air suck ing Pum up a Cau p de t su ctio fect ses Mod n si ive de o ulat i f ng v pum Thro alve p ttle spri fole Ope n g o f qu d ratio e terio ick r n of rate Sea etur quic d, o l rin n va k re p g, g lve turn Rota roov clog eration valv ting e of ged of s e poo c t defe rans lutc Sha l de h de ctiv mis ft se fect e sion fect al ri ive ive c ng i l u (oil t c n ro h seal de f e tatin ing ctiv g cl defe e utch ctiv circ e ) uit d efec tive

Checks before troubleshooting • Is oil level in transmission case correct? • Is there any leakage of oil from joints of piping or valves?

a

No.

Remedy Problems

1

Abnormal noise between pump and filter

2

Excessive time lag in every speed range

3

Machine moves normally in certain speed ranges

4

Transmission modulating pressure too low in every speed range

5

As in item 4; indicator fluctuates violently

6

Torque converter oil temperature is above operating range

×

b c

d e

×

×

f

g

h

× × ×

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

20-706 (1)

WD600-3

TROUBLESHOOTING

H-6

H-6 Torque converter oil temperature too high

e, p

lu g

lo o s

e,

Ask the operator the following points. • Does not torque converter oil temperature go up during torque converter stall, and down when the torque converter is not stalled? Yes = Normal (Incorrect selection of gear speed)

Air suck ing Pum up a Cau p de t su ses ctio fect Ope n si ive ratio de o f pu n of Lea mp torq ka ue c pum ge of o onv il in e p or r ter r turb side t elie o ine f va crac rque co lv e d e fe ked n vert ) ctiv e r (s e eal ring d e fe

ctiv

Checks before troubleshooting • Is oil level in transmission case correct? • Is filter clogged? Checking for abnormalities fl If the oil temperature is normal but the oil temperature gauge is outside the operating range, the oil temperature gauge is defective.

Tank to Pump

a

No.

Remedy Problems

1

Pump makes abnormal noise when oil temperature is low

2

High idling and low idling speeds are too low

3

Hydraulic pressure at inlet port of torque converter too low

4

Transmission modulating pressure too low

×

Torque converter

b c

×

×

d

×

The following symbols are used to indicate the action to be taken when a cause of failure is located. X: Replace : Repair A: Adjust C : Clean

WD600-3

20-707 (1)

H-7

TROUBLESHOOTING

H-7 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 itch ctiv m p pum e ch Defe p arge cti valv Defe ve Orbi e t -roll ctiv e st Defe op v ctiv alve e ac Defe tuat ctiv i on o e ac f de Defe tuat man ion ctiv d sp e o f s stee a ool Defe fety ring -suc ctiv s e pi t p i o o n va ol ston lve 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 pump valve roll valve

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.

20-708 (1)

WD600-3

H-8

TROUBLESHOOTING

H-8 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 e d in Defe a t su ctiv ctio e P n en Defe PC p d of ctiv ump e ch pum Defe arge p ctiv v alve e Or 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 a ctua Defe t op v oid tion ctiv alve valv e o f a e dem ctua Defe tion and ctiv e sa of s spo Defe fety teer o l -suc ctiv ing spo tion Defe e 2-wa ol valv y re ctiv e stric e pi tor v ston 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

×

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

Steering valve

Stop

Joystick valve

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.

WD600-3

20-709 (1)

TROUBLESHOOTING

H-9

H-9 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 Orb e Defe it-ro ctiv ll 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.

20-710 (1)

WD600-3

TROUBLESHOOTING

H-10

H-10 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

×

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

Stop

Joystick valve

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.

20-712 (1)

WD600-3

ctiv e ac Defe tuat ion ctiv of s e sa Defe teer fety ctiv ing suct e spo ion 2-w Defe ol ay r valv ctiv estr e e pi icto ston r va seal lve

Defe

TROUBLESHOOTING

Steering valve

m n

× × Valve

WD600-3

H-10

Cylinder

o p

× ×

20-713

(1)

H-11, H-12

TROUBLESHOOTING

H-11 Steering is heavy Checking for abnormalities • Is the steering difficult to turn? Yes = Go to H-7 or H-8 • Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they are abnormal.

Defe ctiv e Or Defe bit-r Cau ctiv oll ses e ac Defe tuat ion ctiv o e f sto actu Inte p va rfer atio enc lve n of e of stee stee ring ring whe spool el o r ste erin g sh aft

Ask the operator the following questions. • Did the problem suddenly start? Yes = Related equipment broken • Was there previously any symptom, such as heavy 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? • Is the tire inflation pressure correct?

Orbit- Stop roll valve

a

No. 1

Remedy Problems

Others

d

× × × ×

Steering is heavy when turned in both directions (left and right)

2

Steering is heavy when turned in one direction (left or right)

3

Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected

5

When steering relief pressure is measured

6

When Orbit-roll output pressure is measured, oil pressure is found to be low

4

S/V

b c

Oil pressure is low in both directions (left and right) Oil pressure is low in one direction (left or right)

H-12 Joystick is heavy [machine with joystick] Causes and Remedy • Abnormality of joystick (×) (The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in the joystick.)

20-714 (1)

WD600-3

TROUBLESHOOTING

H-13

H-13 Steering wheel shakes or jerks Checking for abnormalities • Is the steering difficult to turn? Yes = Go to H-9 • Is there any abnormal noise from around the steering equipment?

Defe ctiv e ch Defe arg Cau ctiv ses e Or e valve Defe bit-r ctiv oll e ac Defe tuat ctiv ion e ac of s Defe tuat top ion ctiv valv of d em e Defe a e i man n ctiv r e l d sp i e e ac f v ool Defe a tuat lve ctiv ion of s Defe e safet teer y-su ctiv ing ctio e pi spo n va ston ol lve seal

Checks before troubleshooting • Is the steering wheel play correct? • Is there any abnormality in the connection between the steering shaft and the Orbit-roll? • Is the tire inflation pressure correct?

Charge Orbit- Stop valve roll valve

a

No. 1

Remedy Problems Steering wheel shakes or jerks in one direction (left or right)

3

During operations or when traveling (when steering), steering wheel shakes or jerks in both directions (left and right)

4

During operations or when traveling (when steering), steering wheel shakes or jerks in one direction (left or right)

5

Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke

6

Work equipment also jerks

7

When steering relief pressure is measured

9 10 11

d e

× × × × × ×

f

g

×

Cylinder

h

×

Steering wheel shakes or jerks in both directions (left and right)

2

8

b c

Steering valve

When Orbit-roll output pressure is measured

Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in in one direction (left or right) Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in in one direction (left or right)

When PPC value (Orbit-roll) basic pressure is measured, oil pressure is found to be unstable

WD600-3

20-715 (1)

TROUBLESHOOTING

H-14, H-15

H-14 Steering shakes or there is excessive shock [machine with joystick] Checking for abnormalities • Is the steering difficult to turn? Yes = Go to H-10 • Is there any abnormal noise from around the steering equipment?

Defe ctiv e ch Defe arg Cau ctiv ses e Or e valve Defe bit-r ctiv oll e actu Defe atio ctiv n of e ac Defe joys tuat ctiv tick ion e sole of s a ctua Defe top noid tion ctiv valv valv e o e m f e dem Defe ain relie and ctiv e f s p v actu a o Defe l o v l e atio ctiv n of e sa Defe stee fety r ctiv i s n ucti e 2on v g spoo Defe way l alve ctiv rest e pi r i ctor ston valv seal e

Checks before troubleshooting • Is any failure code for the electrical system displayed on the main monitor? • Is the steering wheel play correct? • Is there any abnormality in the connection between the steering shaft and the Orbit-roll? • Is the tire inflation pressure correct?

Charge Orbit- Joy- Stop stick valve valve roll

a

No. 1

Remedy Problems

3 4

Steering wheel shakes or jerks in both directions (left and right)

5

Steering wheel shakes or jerks in one direction (left or right)

6

During operations or when traveling (when steering), steering wheel shakes or jerks in both directions (left and right)

7

During operations or when traveling (when steering), steering wheel shakes or jerks in one direction (left or right)

8

Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke

9

Confirm recent repair

10

When steering relief pressure is measured When Orbit-roll output pressure is measured When joystick solenoid valve output pressure is measured

11 12 13 14 15 16

×

d e

f

× × × ×

g

h

×

Valve

Cylinder

i

j

× ×

Abnormality only in steering wheel mode

When steering mode switch is switched

2

× ×

b c

Steering valve

Abnormality only in joystick mode Abnormality in both modes

Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in in one direction (left or right) Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in in one direction (left or right) Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in in one direction (left or right)

When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is found to be unstable

H-15 Turning radius is different between left and right at maximum steering Causes and Remedy • Defective adjustment of stop valve (t)

20-716 (1)

WD600-3

H-16

TROUBLESHOOTING

H-16 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 lato e p r ch isto Defe arge n se ctiv al o e le valv Defe r de ft br e fect ctiv a k e va i e ve b r ight Defe 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 ston ator Brea e actua s e al 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).

20-718 (1)

WD600-3

Defe ctiv e br Defe ake ctiv pist e on s actu Brea eal atio kag n of e in brak side e pi brak ston e

TROUBLESHOOTING

Wheel brake

×

WD600-3

H-16

l m n Others

×

20-719

(1)

H-17

TROUBLESHOOTING

H-17 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 l a a c ed b k ad t rake ion of just br er 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

20-720 (1)

Slack adjuster

b c

× × × ×

Wheel brake

d e

×

WD600-3

TROUBLESHOOTING

H-18

H-18 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 s o l g br eno ctiv e br i ake Defe ake eme d valve ctiv spri rgen e ac n cy r g Wor tuat elea n br ion se v ake of p alve disc arki ng b rake 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

WD600-3

×

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

20-721 (1)

H-19

TROUBLESHOOTING

H-19 Parking brake is not released or brake drags (including emergency release system)

Defe ctiv e pa Defe rkin Cau ctiv g br ses e pa ake Defe rkin s o leno g br ctiv e br i ake Seiz ake eme d valve ed pist rgen on s Eme wheel cy r eal elea br rgen se v cy b ake dis alve c, p rake late swit ch f or w hee l bra ke h as b een ac

tuat

ed

Checking for abnormalities • Is there any abnormality in the power train system? Yes = Carry out Troubleshooting H-1 – H-3 (Power train hydraulic system)

SOL

a

No.

Problems

Remedy ×

1

When emergency release switch is turned ON, parking brake is released (not released with parking brake switch)

2

When manual method for release of parking brake is carried out, parking brake is released (not released with parking brake switch or emergency release switch)

3 4 5 6

When parking brake inlet port pressure is measured (when parking brake switch is operated) When parking brake output pressure is measured (when emergency release switch is operated)

Value

Parking brake

b c

× ×

Wheel

d e

×

Oil pressure is normal Oil pressure is low Oil pressure is normal Oil pressure is low

7

When parking brake solenoid valve output pressure is measured, oil pressure is found to be low

8

When oil pressure in wheel brake piping is measured, oil pressure is found to be less than emergency brake actuation pressure (3.6 ±0.49 MPa {37 ± 5 kg/cm2})

fl The power train main relief pressure is used for the parking brake release pressure, so if any abnormality is felt in the parking brake release system, check the condition of actuation of the power train (the emergency release circuit uses the wheel brake circuit pressure).

20-722 (1)

WD600-3

H-20

TROUBLESHOOTING

H-20 Blade does not rise Bloc kag e in Pum Cau p PT suction ses O is port Fau not of p lty h b u e m y ing drau p or Fau driv lic a exce lty P en nd s PC p ssiv w e am ump itch oun Defe pum t of ctiv p air c e ac onta tuat ion ined Defe of d ctiv in o ema e ac il Defe nd s tuat i poo ctiv o n e ac of re l Defe tuat lief ctiv ion valv e ac of s e Inte t poo uati rnal l on o dam f ma Dam age in re age valv lief d lif e bo valv t cy dy ( e lind l i ft sp er p ool) isto n se al

Ask the operator the following points. • Did the problem suddenly fail to rise? Yes = Seizure or damage to various units • Was unusual noise produced? (Where did it emanate from?) • Were there previous signs of blade slowing down ? Yes = Wear of parts of flattening of spring Checks before troubleshooting • Is oil level in hydraulic tank correct? • Is travel of work equipment lever correct?

Tank-pump

a

No.

Remedy C Problems

1

The blade is unable to pitch, tilt, or rise

2

The machine body can be lifted up by the blade however the blade is unable to rise. Or the blade can tilt however the blade is unable to rise.

3

The blade can rise under no load but cannot rise under load

4

The hydraulic pump produces an abnormal noise

5

Lift cylinder has large amount of hydraulic drift

6

When the engine is at full, steering action is light and excessively fast

7

When the engine is at full, steering action is heavy and slow

WD600-3

b c

× × ×

Steering valve

d

e

×

PPC valve

f

g

× × ×

Work equipment control valve

h

i

Cylinder

j

× ×

20-723 (1)

TROUBLESHOOTING

H-21

H-21 Blade moves slowly or does not have sufficient lifting power

Bloc

Fault check There is strong relationship between faults involving lifting force and lifting speed. Such faults appear initially in the form of insufficient lifting speed. Measure the lifting speed of the blade when loaded and refer to the standard value table to determine whether or not there is a fault.

Fau

kag e of suct Cau lty h ion ses ydra port ulic o f pu Defe and mp ctiv swit or e e ac ch p xces tuat u sive mp ion Defe amo of d ctiv unt ema e ac of a Defe nd s tuat ir co ion poo ctiv ntai e o l f a Defe ned relie ctua in o f va tion ctiv l il e v o e a f ctua Inte s p o rnal ol tion dam o f mai Dam age n re age or w lief d lif orn valv t cy valv e an lind e bo d fa er p dy ulty isto n se imp al rope rly a djus ted

Checks before troubleshooting • Is travel of work equipment lever correct? • Seizure of bushing in work equipment linkage? (Does emits abnormal noise?)

Tankpump

a

No.

Remedy C Problems

1

Blade Pitch and tilt force and speed are abnormal and blade lifting speed is low

2

Blade Pitch and tilt force and speed are normal but blade lifting speed is slow

3

Same as item 1 except that work equipment linkage lifting speed becomes particularly low when oil temperature rises

4

Hydraulic pump emits abnormal noise

5

When the engine is at full, steering action is light and excessively fast

6

When the engine is at full, steering action is heavy and slow

7

Cylinder has a large amount of hydraulic drift

8

The relief pressure of relief valve of work equipment control valve

20-724 (1)

Steering valve

b

×

c

×

PPC valve

d e

× × ×

Work equipment control valve

f

g

×

Cylinder

h

×

WD600-3

TROUBLESHOOTING

H-22, H23, H-24

H-22 Blade becomes slow at certain height when raising Checks before troubleshooting • External deformation of lift cylinder Cause • Swollen or internally damaged lift cylinder tube fl Regarding other faults occurring during blade rise, refer to item "H-21 Blade moves slowly or does not have sufficient lifting power"

H-23 Lift cylinder cannot hold down blade Refer to item "H-21 Blade moves slowly or does not have sufficient lifting power". Checks before troubleshooting • Is travel of work equipment lever correct? Cause • Defective lift cylinder rod side suction valve seat of work equipment control valve • Oil leakage from lift cylinder piston seal

H-24 Blade has large amount of hydraulic drift Ask the operator the following points. • Did the hydraulic drift suddenly become large? Yes = Dit lodged in valve or spool in the position • Did the hydraulic drift gradually become large? Yes = worn parts Troubleshooting and cause • When measuring hydraulic drift, internal leakage of lift cylinder makes oil leakage noise. = Damaged cylinder packing • When measuring hydraulic drift, lift cylinder does not make oil leakage noise. = Defective oil sealing of blade lift spool = Defective check valve between pipings

WD600-3

20-725 (1)

TROUBLESHOOTING

H-25, H-26

H-25 Blade fluctuates while working During excavation or ground leveling when the work equipment lever is in the "HOLD" position, the blade moves up and down in accordance with the terrain. Troubleshooting and cause Check the amount of hydraulic drift and whether or not can be lifted up bjy the lift cylinder. 1. If the amount of hydraulic drift is greater than the standard value, refer to item "H-24 Blade has large amount of hydraulic drift". 2. If the machine body can not be lifted up by the lift cylinder, refer to item "H-23 Lift cylinder cannot hold down blade". 3. If amount of hydraulic drift is normal and the machine body can be lifted up by the lift cylinder after the blade is moved several times to cause the lift cylinder to move through its entire stroke. = The trouble is due to the generation of a vacuum in the cylinder, fl If a vacuum is generated frequently = defective suction valve on lift cylinder rod side

H-26 Blade drops momentarily when lever is operated from HOLD to RAISE The blade drops momentarily under the own weight when the work equipment lever is gradually shifted from the "HOLD" position to the "RAISE" position while the engine is at low idling. When the work equipment lever is put completely into the "RAISE" position, the blade moves normally. Cause • Defective seating of work equipment control valve or blade spool check valve

20-726 (1)

WD600-3

H-27

TROUBLESHOOTING

H-27 Blade does not tilt Bloc kag e in Pum Cau p PT suction ses O is port Defe n o ot b f pu ctiv eing mp e hy Defe or e driv drau ctiv xces en lic a e PP sive n d st C pu amo eeri Defe mp unt ng p ctiv of a ump e ac ir co tuat ntai ion Defe ned o ctiv in o f de e ac il m a Defe nd s tuat ion poo ctiv e sp of re l Defe ool lief ctiv valv e ac e Inte tuat rnal i o n dam of m Dam age ain d va relie age d til lve f va bod t cy lve lind y (ti er p lt sp isto o ol) n se al

Ask the operator the following points. • Did the blade suddenly cease to move? Yes = Seized or damaged equipment • Was any abnormal noise emitted? (Where did it emanate from?) • Were there previous signs of the blade slowing down? Yes = Wear parts or flattening of spring Check before troubleshooting • Is travel of the work equipment lever correct?

Tank-pump

a

No.

Remedy C Problems

1

Blade cannot be operated and unable to tilt

2

The machine body can be lifted up by the blade however the blade is unable to tilt. Or the blade can rise but the blade is unable to tilt.

3

The hydraulic pump produces an abnormal noise

4

Tilt cylinder has large hydraulic drift

5

Steering action is light and excessively fast when the engine is at full

6

Steering action is heavy and slow when the engine is at full

WD600-3

b c

× × ×

Steering valve

d

e

×

Work equipment control valve

PPC valve

f

g

h A

× × ×

i

Cylinder

j

× ×

20-727 (1)

H-28

TROUBLESHOOTING

H-28 Blade moves slowly or has insufficient tilt power

Bloc

Fault check • Check deficient tilt force by performing actual work. • Measure the operating speed of the blade and check it against the standard value table to determine whether or not it is normal.

Fau

kag e in suct Cau lty h ion ses ydra port ulic o f pu Defe and mp ctiv swit or e e ac ch p xces tuat u sive mp ion Defe amo of d ctiv unt ema e ac of a Defe nd s tuat ir co ion poo ctiv ntai e o l f a ned Defe relie ctua in o f va tion ctiv il l e v o e a f ctua Defe spo ol tion ctiv e o a f Inte ctua mai rnal n re tion ly w lief of s Dam orn valv afet or d e an age ama y valve d til d in t cy corr (wit g e valv lind er p e bo h suctio ectly ad isto d just n va y (ti n se ed lve) lt sp al of t h ool) e til t cy lind er

Checks before troubleshooting • Is the travel of work equipment lever correct? • Seizure of bushing in work equipment linkage? (Does emits abnormal noise?)

Tankpump

a

No.

Remedy C Problems

1

Blade lifting force and lifting speed are abnormal and also blade tilt force and tilt speed are abnormal

2

Blade lifting force and lifting speed are normal but blade tilt force and tilt speed are abnormal

3

Phenomena of item 1 become particularly bad when the oil temperature increases

4

The hydraulic pump emits an abnormal noise

5

Steering action is light and excessively fast when the engine is at full

6

Steering action is heavy and slow when the engine is at full

7

The tilt cylinder has a large amount of hydraulic drift

8

The relief pressure of relief valve of work equipment control valve is also low

9

The discharge volume of the hydraulic pump is low

20-728 (1)

Steering valve

b

×

c

×

PPC valve

d e

Main control valve

f A

× × × ×

g

Cylinder

h i

× ×

WD600-3

TROUBLESHOOTING

H-29, H-30

H-29 Blade does not pitch If the blade cannot be pitched or tilted when the work equipment lever is operated (while pressing the switch at the top of the lever), go to "H-27 Blade does not tilt". If the blade can be tilted, but does not pitch, the possible causes are as follows. • Defective operation of tilt or pitch switch at top of lever. • Defective operation of solenoid valve of deco valve.

H-30 Blade pitch movement is slow or lacks power If bothe the blade tilt and blade pitch movement is slow or lacks power, go to "H-28 Blade moves slowly or has insufficient tilt power". If there is no abnormality in the tilt operation, and only the pitch operation is abnormal, the possible causes are as follows. • Defective operation of solenoid valve of dico valve. • Defective operation of selector valve of deco valve. • Solenoid valve of deco valve clogged.

WD600-3

20-729 (1)

H-31

TROUBLESHOOTING

H-31 Work equipment lever does not move smoothly Seiz ure of c Ben ontr Cau t PP ol le ses C va ver Inco lve o f rota spo rrec ol ting t cle Poo part aran r ro s of ce b und link e Fore t nes wee s ign n o P f PC v PPC mat Dist ter l alve valv ortio odg e bo bod no ad i y an dy a Ben n PP d sp nd s t wo f valve b C ool poo valv rk e o d y Stic l quip e due king m t o e non nt c of d Inco -uni ontr eten rrec form ol v t of t cle alve w tigh Poo o rk e aran s po teni r ro quip ce b ng o und men ol etw f va Fore nes e lve m t s e c ign n o o n f w t wor oun mat rol v o r k ting k eq ter l equ a l v e sp odg uipm bolt ipm ed i s ool e e n n t nw t c o c o n ork n t r t o r ol v l va equ alve lve ipm bod ent bod y an con y an d sp trol d sp valv ool e sp ool ool

Fault check Using the standard value table, check whether or not the operating effort of the lever is large.

Lever

a

No.

Remedy Problems

1

Movement of work equipment lever becomes sluggish when load is applied and oil pressure increase

2

Movement of work equipment lever becomes sluggish along with change in oil temperature

3

Movement of work equipment lever becomes partially sluggish irrespective of oil pressure and temperature

4

Movement of work equipment lever becomes generally sluggish irrespective of oil pressure and temperature

5

Movement of work equipment lever does not become light even when the link of the control lever is disconnected at the valve connection part and the lever operated

20-730 (1)

×

b c

×

Work equipment control valve

PPC valve

d e C

× ×

×

f

g

h

i

× × × ×

j

k C

WD600-3

TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (T MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)

Method of displaying action code and failure code ...........................................................................20-802 Judgement table for transmission control system .............................................................................20-803 Action taken by controller when abnormality occurs, and problems on machine .........................20-804 Electrical circuit diagram for transmission control system ...............................................................20-808 T- 1

Failure code [10] (Short circuit, disconnection, or short circuit with power supply in lock-up solenoid) is displayed ..................................................................................................20-810

T- 2

Failure code [12] (Short circuit, disconnection, or short circuit with power supply in F solenoid) is displayed ................................................................................................................20-811

T- 3

Failure code [13] (Short circuit, disconnection, or short circuit with power supply in R solenoid) is displayed ................................................................................................................20-812

T- 4

Failure code [14] (Short circuit, disconnection, or short circuit with power supply in 1st solenoid) is displayed ................................................................................................................20-813

T- 5

Failure code [15] (Short circuit, disconnection, or short circuit with power supply in 2nd solenoid) is displayed ................................................................................................................20-814

T- 6

Failure code [16] (Short circuit, disconnection, or short circuit with power supply in 3rd solenoid) is displayed ................................................................................................................20-815

T- 7

Failure code [17] (Short circuit, disconnection, or short circuit with power supply in 4th solenoid) is displayed ................................................................................................................20-816

T- 8

Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed

T- 9

..................................................................................................................................20-817

Failure code [20] (Short circuit, disconnection in directional switch system) is displayed

..................................................................................................................................20-818

T-10

Failure code [21] (Short circuit, disconnection in shift switch system) is displayed ......... 20-822

T-11

Failure code [22] (Disconnection in travel speed sensor system) is displayed ..................20-825

T-12

Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed

T-13

..................................................................................................................................20-826

When hold switch is pressed, gear speed is not fixed or reset Shift up does not work .............................................................................................................20-827

T-14

Kick-down does not work Shift down does not work ........................................................................................................20-827

T-15

Transmission cutoff does not work or stays working ...........................................................20-828

T-16

Neutralizer does not work or stays working ..........................................................................20-829

T-17

Buzzer does not work ................................................................................................................20-830

T-18

Abnormality in network system ...............................................................................................20-831

T-19

Abnormality in transmission controller power supply ..........................................................20-832

T-20

Short circuit in travel speed sensor system ...........................................................................20-833

T-21

Abnormality in machine selection wiring harness ................................................................20-834

WD600-3

20-801 (1)

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 1000 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.

20-802 (1)

WD600-3

JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

TROUBLESHOOTING

JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

Location of failure

Failure mode

Failure code

1 Travel is impossible

Short circuit, disconnection in lock-up solenoid 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

2 Directional lever and direction of travel are different 3 Machine travels forward when directional lever is not at F 4 Machine travels in reverse when directional lever is not at R.

c

c c

c c c

9 Kickdown does not work 10 Transmission is not cut off with left brake 11 It is possible to travel even when parking brake is applied

H-2, H-3

c c

7 There is shift hunting when shifting gear 8 Speed range cannot be controlled with speed control lever

E-1, H-1

c

5 There is excessive gearshifting shock 6 There is shift hunting when traveling

Troubleshooting code when no abnormality display is given

c c

T-14, E-7 c

T-15 c

T-16, E-3

12 If F-R lever is operated when traveling at high speed, alarm buzzer does not sound

c

T-17

13 Alarm buzzer continues to sound

c

T-17, J-1

14 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 — — — — — —

WD600-3

20-803 (1)

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE (1) TRANSMISSION CONTROLLER SYSTEM Failure code

10

12

13

14

15

16

17

20-804 (1)

Abnormal system

Nature of abnormality

Abnormality in lock-up solenoid

1) Defective lock-up solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (8) – C1 (female) (8) – T06 (1) 3) Defective contact or disconnection in wiring harness between lockup solenoid T06 (female) (2) and chassis ground 4) Defective transmission & joystick controller

Abnormality in F solenoid system

1) Defective F solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (8) – C1 (female) (2) – TL1 (5) – T01 (D) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis – TL1 (7) – T01 (A) 4) Defective transmission & joystick controller

Abnormality in R solenoid system

1) Defective R solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (9) – C1 (female) (9) – TL1 (6) – T01 (C) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis – TL1 (7) – T01 (A) 4) Defective transmission & joystick controller

Abnormality in 1st solenoid system

1) Defective 1st solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (3) – C1 (female) (3) – TL1 (1) – T01 (H) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis – TL1 (7) – T01 (B) 4) Defective transmission & joystick controller

Abnormality in 2nd solenoid system

1) Defective 2nd solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (frmale) (10) – C1 (female) (10) – TL1 (2) – T01 (G) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis–TL1 (7)–T01 (B) 4) Defective transmission & joystick controller

Abnormality in 3rd solenoid system

1) Defective 3rd solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (5) – C1 (female) (5) – TL1 (3) – T01 (F) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis – TL1 (7) – T01 (B) 4) Defective transmission controller

Abnormality in 4th solenoid system

1) Defective 4th solenoid 2) Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in wiring harness between transmission & joystick controller C1A (female) (11) – C1 (female) (11) – TL1 (4) – T01 (E) 3) Short circuit with chassis ground, defective contact, disconnection in wiring harness between chassis – TL1 (7) – T01 (B) 4) Defective transmission controller

WD600-3

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance) 1) Resistance between transmission & joystick controller C1A (8) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (8) and chassis ground when lock-up system is turned OFF: Max. 1 V

Action by controller when abnormality is detected None in particular

Problem that appears on machine when there is abnormality Lock-up system does not work or it keeps operating

T-1

1) Resistance between transmission & joystick controller C1A (female) (2) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (2) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

1) Resistance between transmission & joystick controller C1A (female) (9) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (9) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

1) Resistance between transmission & joystick controller C1A (female) (3) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (3) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

1) Resistance between transmission & joystick controller C1A (female) (10) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (10) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

1) Resistance between transmission & joystick controller C1A (female) (5) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (5) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

1) Resistance between transmission & joystick controller C1A (female) (11) and chassis ground: 5 – 15 Ω 2) Voltage between transmission & joystick controller C1A (11) and chassis ground at neutral: Less than 1 V

It is impossible to Neutral (F, R, 1st, 2nd, 3rd, 4th travel solenoid output: off)

WD600-3

Troubleshooting code

T-2

T-3

T-4

T-5

T-6

T-7

20-805 (1)

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

TROUBLESHOOTING

Failure code

19

20

21

22

23

20-806 (1)

Abnormal system

Abnormality in joystick directional switch

Abnormality in directional switch signal system

Nature of abnormality

1) Defective joystick directional lever F, N, R switch 2) Disconnection between joystick directional lever connector JS1 (8) and chassis ground When the wiring harness is in any of the following conditions with the switch not pressed 3) Defective contact or disconnection in wiring harness between transmission & joystick controller C5A (female) (8) – C5 (female) (8) – JS1 (2) – joystick lever connector (4) or short circuit with chassis ground in wiring harness between C5A (female) (16) –C5 (female) (16) – JS1 (3) – joystick lever connector (3) 4) Defective contact or disconnection in wiring harness between transmission & joystick controller C5A (female) (7) –C5 (female) (7) – JS1 (4) – joystick lever connector (4) or short circuit with chassis ground in wiring harness between C5A (female) (15) –C5 (female) (15) – JS1 (5) – joystick lever connector (5) 5) Defective contact or disconnection in wiring harness between transmission & joystick controller C5A (female) (9) –C5 (female) (9) – JS1 (6) – joystick lever connector (6) or short circuit with chassis ground in wiring harness between C5A (female) (17) –C5 (female) (17) – JS1 (7) – joystick lever connector (7) 1) Defective directional lever 2) Defective combination switch power source Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in the following wiring harness 3) Wiring harness between transmission & joystick controller C3B (female) (5) and L04 (2) 4) Wiring harness between transmission & joystick controller C3B (female) (13) and L04 (3) 5) Wiring harness between transmission & joystick controller C3B (female) (6) and L04 (4) 6) Defective transmission & joystick controller

Abnormality in shift switch signal system

1) Defective directional lever 2) Defective combination switch power source Short circuit with power source, short circuit with chassis ground, defective contact, disconnection in the following wiring harness 3) Wiring harness between transmission & joystick controller C3B (female) (7) and L04 (5) 4) Wiring harness between transmission & joystick controller C3B (female) (15) and L04 (6) 5) Wiring harness between transmission & joystick controller C3B (female) (8) and L04 (7) 6) Wiring harness between transmission & joystick controller C3B (female) (16) and L04 (8) 7) Defective transmission & joystick controller

Disconnection in speed sensor

1) Defective speed sensor 2) Defective adjustment of speed sensor mount 3) Defective contact or disconnection in wiring harness between transmission & joystick controller C5A (female) (2) – C5 (female) (2) – TL1 (11) – T05 (1) 4) Defective contact or disconnection in wiring harness between transmission & joystick controller C5A (female) (10) – C5 (female) (10) – TL1 (12) – T05 (2) 5) Defective transmission & joystick controller

Abnormality in engine speed sensor system

1) Defective engine speed sensor 2) Defective adjustment of engine speed sensor mount 3) Defective contact or disconnection in wiring harness between transmission & joystick controller C4 (female) (2) – E06 (1) 4) Defective contact or disconnection in wiring harness between transmission & joystick controller C4 (female) (9) – E06 (2) 5) Defective transmission & joystick controller

WD600-3

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance) 1) Resistance between joystick directional lever connector (8) and chassis ground: Less than 1 Ω The following conditions are when the switch is not pressed 2) Resistance between transmission & joystick controller C5A (female) (8) and chassis ground: Less than 1 Ω 3) Resistance between transmission & joystick controller C5A (female) (7) and chassis ground: Less than 1 Ω and resistance between C5A (female) (15) and chassis ground: Min. 1 MΩ 4) Resistance between transmission & joystick controller C5A (female) (9) and chassis ground: Less than 1 Ω and resistance between C5A (female) (17) and chassis ground: Min. 1 MΩ

Action by controller when abnormality is detected Neutral (F, R, 1st, 2nd, 3rd solenoid output: off)

Problem that appears Troubleon machine when shooting there is abnormality code Cannot travel in joystick mode (possible in steering wheel mode)

T-8

1) Voltage between combination switch L04 (1) and chassis ground: 20 – 30 V 2) Voltage for only 1 system in accordance with position of directional lever: 20 – 30 V (Others: Less than 1 V) F: Between transmission & joystick controller C3B (5) – chassis ground N: Between transmission & joystick controller C3B (13) – chassis ground R: Between transmission & joystick controller C3B (6) – chassis ground

It is impossible to • Shifts to neutral travel immediately when short circuit with power supply is detected • When there is no signal (disconnection), holds previous signal condition for 2 seconds

1) Voltage between combination switch L04 (1) and chassis ground: 20 – 30 V 2) Voltage for only 1 system in accordance with position of range lever: 20 – 30 V (Others: Less than 1 V) 1st: Between transmission & joystick controller C3B (7) – chassis ground 2nd: Between transmission & joystick controller C3B (15) – chassis ground 3rd: Between transmission & joystick controller C3B (8) – chassis ground 4th: Between transmission & joystick controller C3B (16) – chassis ground

• If 2 signals are input, 1) it judges speed range position in order of priority 4←3←2←1 • When there is no 2) signal (disconnection), holds previous signal condition (speed range position)

Auto-shift limit is different from range position selected by operator (OP) Impossible to shift gear in manual mode

Resistance between travel speed sensor T05 1) Switches to manual 1) (1) and (2): 500 – 1,000 Ω mode (OP) 2) Voltage between transmission & joystick 2) Shifts gear controller C5A (female) (2) and (10): Min. 0.5 V according to operation of range lever

Does not carry out auto-shift (OP) Switches to manual shift

1) Switches to manual 1) mode (OP) 2) 2) Shifts gear according to operation of range lever

Does not carry out auto-shift (OP) Switches to manual shift

1) 2)

1) 2)

Resistance between engine speed sensor E06 (1) and (2): 100 – 500 Ω Voltage between transmission & joystick controller C4 (female) (2) and (9)

WD600-3

T-9

T-10

T-11

T-12

20-807 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

20-808 (1)

WD600-3

TROUBLESHOOTING

WD600-3

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM

20-809 (1)

TROUBLESHOOTING

T-1

T-1 Failure code [10] (Short circuit, disconnection, or short circuit with power supply in lock-up solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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 Check that the lock-up indicator is flashing. Cause

4 YES YES 3 Is resistance

YES between C1A

(female) (8) and chassis ground normal?

2 YES 1 Is resistance between T06 (male) (1) and (2) and between (1), (2) and chassis ground normal?

Is resistance between C1A (female) (8) and T01 (female) (1) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A and T06.

NO

switch OFF.

• Disconnect C1A

• Between (1) and

and T06. (2): 5 – 15 Ω • Between (1), (2) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T06.

From A

5 YES

Is voltage between C1A (female) (8) and chassis ground normal?

• Turn starting

NO

switch ON.

Is resistance between T06 (female) (2) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T06. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T06 (female) (2) and chassis ground Short circuit with chassis ground or another part in harness between C1A (female) (8) and T06 (female) (1) Defective contact or disconnection in wiring harness between C1A (female) (8) and T06 (female) (1)

Repair or replace

Repair or replace

Repair or replace

Defective lock-up solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C1A (female) (8) and T06 (female) (1)

Repair or replace

• Disconnect C1A and T06.

• Max. 1 V

T-1 Related electrical circuit diagram

20-810 (1)

WD600-3

TROUBLESHOOTING

T-2

T-2 Failure code [12] (Short circuit, disconnection, or short circuit with power supply in F solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (2) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (D) and (A) and between (D), (A) and chassis ground normal?

Is resistance between C1A (female) (2) and T01 (female) (D) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A and T01.

NO

switch OFF.

• Disconnect C1A

• Between (D) and

and T01. (A): 5 – 15 Ω • Between (D), (A) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

From A

5 YES

Is voltage between C1A (female) (2) and chassis ground normal?

• Turn starting

NO

switch ON.

Is resistance between T01 (female) (1) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T01 (female) (A) and chassis ground Short circuit with chassis ground or another part in harness between C1A (female) (2) and T01 (female) (D) Defective contact or disconnection in wiring harness between C1A (female) (2) and T01 (female) (D)

Repair or replace

Repair or replace

Repair or replace

Defective F solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C1A (female) (2) and T01 (female) (D)

Repair or replace

• Disconnect C1A and T01.

• Max. 1 V

T-2 Related electrical circuit diagram

WD600-3

20-811 (1)

TROUBLESHOOTING

T-3

T-3 Failure code [13] (Short circuit, disconnection, or short circuit with power supply in R solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (9) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (A) and (C) and between (A), (C) and chassis ground normal?

Is resistance between C1A (female) (9) and T01 (female) (C) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A and T01.

NO

switch OFF.

• Disconnect C1A

• Between (A) and

and T01. (C): 5 – 15 Ω • Between (A), (C) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01. From A

5 YES

Is voltage between C1A (female) (9) and chassis ground normal?

• Max. 1 V • Turn starting

NO

Is resistance between T01 (female) (A) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T01 (female) (A) and chassis ground Short circuit with chassis ground or another part in harness between C1A (female) (9) and T01 (female) (C)

Defective contact or disconnection in wiring harness between C1A (female) (9) and T01 (female) (C)

Repair or replace

Repair or replace

Repair or replace

Defective R solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power source in wiring harness between C1A (female) (9) and T01 (female) (C)

Repair or replace

switch ON.

• Disconnect C1A and T01.

T-3 Related electrical circuit diagram

20-812 (1)

WD600-3

TROUBLESHOOTING

T-4

T-4 Failure code [14] (Short circuit, disconnection, or short circuit with power supply in 1st solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (3) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (B) and (H) and between (B), (H) and chassis ground normal?

Is resistance between C1A (female) (3) and T01 (female) (H) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

NO

• Disconnect C1A

• Between (B) and

and T01. (H): 5 – 15 Ω • Between (B), (H) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

From A

5 YES

Is voltage between C1A (female) (3) and chassis ground normal?

• Max. 1 V • Turn starting

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Go to A Defective contact or disconnection in wiring harness between T01 (female) (B) and chassis ground Short circuit with chassis ground or another part in harness between C1A (female) (3) and T01 (female) (H)

Repair or replace

Repair or replace

• Disconnect C1A, T01 and L05.

switch OFF.

Is resistance between T01 (female) (B) and chassis ground normal?

Remedy

NO

Defective contact or disconnection in wiring harness between C1A (female) (3) and T01 (female) (H)

Repair or replace

Defective 1st solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power source in wiring harness between C1A (female) (3) and T01 (female) (H)

Repair or replace

switch ON.

• Disconnect C1A, T01 and L05.

T-4 Related electrical circuit diagram

WD600-3

20-813 (1)

TROUBLESHOOTING

T-5

T-5 Failure code [15] (Short circuit, disconnection, or short circuit with power supply in 2nd solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (10) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (B) and (G) and between (B), (G) and chassis ground normal?

Is resistance between C1A (female) (10) and T01 (female) (G) normal?

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A,

• Max. 1 Ω • Turn starting

T01 and L05.

NO

switch OFF.

• Disconnect C1A

• Between (B) and

and T01. (G): 5 – 15 Ω • Between (B), (G) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

From A

5 YES

Is voltage between C1A (female) (10) and chassis ground normal?

• Max. 1 V • Turn starting

NO

Is resistance between T01 (female) (B) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T01 (female) (B) and chassis ground Short circuit with chassis ground or another part in harness between C1A (female) (10) and T01 (female) (G) Defective contact or disconnection in wiring harness between C1A (female) (10) and T01 (female) (G)

Repair or replace

Repair or replace

Repair or replace

Defective 2nd solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C1A (female) (10) and T01 (female) (G)

Repair or replace

switch ON.

• Disconnect C1A, T01 and L05.

T-5 Related electrical circuit diagram

20-814 (1)

WD600-3

TROUBLESHOOTING

T-6

T-6 Failure code [16] (Short circuit, disconnection, or short circuit with power supply in 3rd solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (5) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (B) and (F) and between (B), (F) and chassis ground normal?

• Between (B) and

Is resistance between C1A (female) (5) and T01 (female) (F) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A, T01 and L05.

switch OFF. • Disconnect C1A and T01.

NO

(F): 5 – 15 Ω

• Between (B), (F)

NO

Is resistance between T01 (female) (B) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T01 (female) (B) and chassis ground Short circuit with chassis ground in harness between C1A (female) (5) and T01 (female) (F) Defective contact or disconnection in wiring harness between C1A (female) (5) and T01 (female) (F)

Repair or replace

Repair or replace

Repair or replace

Defective 3rd solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C1A (female) (5) and T01 (female) (F)

Repair or replace

and chassis ground: Min. 1 MΩ

• Turn starting switch OFF. • Disconnect T01. From A

5 YES

Is voltage between C1A (female) (5) and chassis ground normal?

• Max. 1 V • Turn starting

NO

switch ON.

• Disconnect C1A, T01 and L05.

T-6 Related electrical circuit diagram

WD600-3

20-815 (1)

T-7

TROUBLESHOOTING

T-7 Failure code [17] (Short circuit, disconnection, or short circuit with power supply in 4th solenoid) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C1A

(female) (11) and chassis ground normal?

2 YES 1 Is resistance between T01 (male) (B) and (E) and between (B), (E) and chassis ground normal?

Is resistance between C1A (female) (11) and T01 (female) (E) normal?

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A,

• Max. 1 Ω • Turn starting

T01 and L05.

NO

switch OFF.

• Disconnect C1A

• Between (B) and

and T01. (E): 5 – 15 Ω • Between (B), (E) NO and chassis ground: Min. 1 MΩ • Turn starting switch OFF. • Disconnect T01.

From A

5 YES

Is voltage between C1A (female) (11) and chassis ground normal?

• Max. 1 V • Turn starting

NO

Is resistance between T01 (female) (B) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect T01. NO

NO

Remedy

Go to A Defective contact or disconnection in wiring harness between T01 (female) (B) and chassis ground Short circuit with chassis ground in harness between C1A (female) (11) and T01 (female) (E) Defective contact or disconnection in wiring harness between C1A (female) (11) and T01 (female) (E)

Repair or replace

Repair or replace

Repair or replace

Defective 3rd solenoid

Replace

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C1A (female) (11) and T01 (female) (E)

Repair or replace

switch ON.

• Disconnect C1A, T01 and L05.

T-7 Related electrical circuit diagram

20-816 (1)

WD600-3

T-8

TROUBLESHOOTING

T-8 Failure code [19] (Short circuit, or disconnection in joystick directional switch system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between JS1 2 Is voltage

YES between JS1 (1) 1 Is voltage between JS1 (8) and (2), (3), (4), (5), (6), (7) as shown in Table 1?

and chassis normal?

• 20 – 30 V • Turn starting switch ON.

(female) (8) – chassis normal?

• Max. 1 Ω • Turn starting

Is voltage between C5A (female) (7), (8), (9), (15), (16), (17) and chassis as shown in table 1?

• Turn starting

NO

switch ON

Defective transmission & joystick steering controller Short circuit, short circuit with chassis ground, defective contact, or disconnection in wiring harness between JS1 (female) (2), (3), (4), (5), (7) and C5A (female) (7), (8), (9), (15), (16), (17)

Defective contact or disconnection in wiring harness between JS1 (female) (8) and chassis

NO

switch OFF.

• Disconnect JS1.

Short circuit, short circuit with chassis ground, defective contact, or disconnection in wiring harness between C3A (male) (6) and chassis

NO

• Turn starting switch ON.

Defective joystick lever

NO

Remedy

Replace

Repair or replace

Repair or replace

Repair or replace

Replace

Table 1 Voltage on each position of joystick lever Position Terminal

F

N

R

JS1 (male) (8) – (2)

Between C5A (8) and chassis

20 – 30 V

Max. 1 V

Max. 1 V

JS1 (male) (8) – (3)

Between C5A (16) and chassis

Max. 1 V

20 – 30 V

20 – 30 V

JS1 (male) (8) – (4)

Between C5A (7) and chassis

Max. 1 V

20 – 30 V

Max. 1 V

JS1 (male) (8) – (5)

Between C5A (15) and chassis

20 – 30 V

Max. 1 V

20 – 30 V

JS1 (male) (8) – (6)

Between C5A (9) and chassis

Max. 1 V

Max. 1 V

20 – 30 V

JS1 (male) (8) – (7)

Between C5A (17) and chassis

20 – 30 V

20 – 30 V

Max. 1 V

T-8 Related electrical circuit diagram

WD600-3

20-817 (1)

TROUBLESHOOTING

T-9

T-9 Failure code [20] (Short circuit, or disconnection in directional switch system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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.

YES 6 YES 5 Is voltage YES between C3B (5) and chassis ground normal? 4 Is resistance between

YES C3B (female) (5) and 3 Is resistance

YES between L04 2 Is voltage between

YES L04 (female) (1) 1 Is resistance between L04 (female) (1) and chassis ground normal?

• Min. 1 MΩ • Disconnect FS2 and L04. • Turn starting switch OFF.

20-818 (1)

and chassis ground normal?

• 20 – 30 V • Turn starting switch ON.

(female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

chassis ground and between C3B (female) (5) and (6), (13) normal?

• Min. 1 MΩ • Disconnect L04, C3B and L08. • Turn starting switch OFF.

• 20 – 30 V • Turn starting switch ON. • Set directional lever to F.

Is resistance between C3B (female) (6) and chassis ground and between C3B (female) (6) and (13) normal

• Min. 1 MΩ • Disconnect L04, C3B and L08. • Turn starting switch OFF.

NO

NO

NO

NO

NO

NO

WD600-3

T-9

TROUBLESHOOTING

Cause

Remedy

Defective transmission &

10 YES joystick steering

Is voltage

Is voltage between YES L04 (2), (3), (4) and chassis ground as 9 shown in Table 1?

YES between C3B (13) and chassis ground normal?

8 YES 7 Is voltage between C3B (6) and chassis ground normal? • 20 – 30 V • Turn starting switch ON. • Set directional lever to R.

Is resistance between C3B (female) (13) and chassis ground normal?

• Min. 1 MΩ • Disconnect L04, C3B and L08. • Turn starting switch OFF.

• 20 – 30 V • Turn starting switch ON. • Set directional lever to N.

• Turn starting switch ON.

NO

NO

Defective directional switch Defective contact or disconnection in wiring harness between L04 (female) (3) and C3B (female) (13), or defective lever Short circuit with chassis ground in harness between L04 (female) (3) and C3B (female) (13)

NO

Defective contact or disconnection in wiring harness between L04 (female) (4) and C3B (female) (6), or defective lever Short circuit with chassis ground in harness between L04 (female) (4) and C3B (female) (6), or short circuit of harness between L04 (female) (4) and C3B (female) (6) and harness between L04 (female) (3) and C3B (female) (13) with each other Defective contact or disconnection in wiring harness between L04 (female) (2) and C3B (female) (5), or defective lever Short circuit with chassis ground in harness between L04 (female) (2) and C3B (female) (5), or short circuit of harness between L04 (female) (2) and C3B (female) (5) and harness between L04 (female) (3) and C3B (female) (13) with each other Defective contact or disconnection in wiring harness between fuse I (9) and L04 (female) (1)

NO

Replace

controller

Defective contact or disconnection in wiring harness between L04 (female) (10) and chassis ground

Short circuit with chassis ground in harness between FS2 (female) (8) and L04 (female) (1)

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Table 1 Directional lever position F

N

R

Between L04 (2) – chassis

20 – 30 V

Max. 1 V

Max. 1 V

Between L04 (3) – chassis

Max. 1 V

20 – 30 V

Max. 1 V

Between L04 (4) – chassis

Max. 1 V

Max. 1 V

20 – 30 V

Terminal

WD600-3

20-819 (1)

TROUBLESHOOTING

T-9

T-9 Related electrical circuit diagram

20-820 (1)

WD600-3

T-10

TROUBLESHOOTING

T-10Failure code [21] (Short circuit, or disconnection in shift switch system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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.

Table 1 Directional lever position 1st

2nd

3rd

4th

Between L04 (5) – chassis

20 – 30 V

Max. 1 V

Max. 1 V

Max. 1 V

Between L04 (6) – chassis

Max. 1 V

20 – 30 V

Max. 1 V

Max. 1 V

Between L04 (7) – chassis

Max. 1 V

Max. 1 V

20 – 30 V

Max. 1 V

Between L04 (8) – chassis

Max. 1 V

Max. 1 V

Max. 1 V

20 – 30 V

Terminal

YES 6

YES 5 Is voltage YES between C3B (7) and chassis normal? 4 Is resistance between

YES C3B (female) (7) – 3 YES 2 Is voltage

YES between L04 (1) 1 Is resistance between L04 (female) (1) and chassis ground normal?

• Min. 1 MΩ • Disconnect FS2, L04. • Turn starting switch OFF.

20-822 (1)

and chassis ground normal? • 20 – 30 V • Turn starting switch ON.

Is resistance between L04 (female) (10) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect L04.

chassis and between C3B (female) (7) – (8), (15), (16) normal?

• Min. 1 MΩ • Disconnect L04, C3B. • Turn starting switch OFF.

Is resistance between C3B (female) (8) – chassis and between C3B (female) (8) – (15), (16) normal?

• Min. 1 MΩ • Disconnect L04, C3B. • Turn starting switch OFF.

NO

• 20 – 30 V • Turn starting switch ON. NO • Set speed control lever to 1st.

NO

NO

NO

NO

WD600-3

TROUBLESHOOTING

T-10

Cause

12 YES Defective transmission & Is voltage between YES L04 (5), (6), (7) and 11 chassis ground as shown in Table 1?

From A

Is voltage between C3B (16) and chassis normal? • 20 – 30 V • Turn starting switch ON. • Set directional lever to 2nd.

• Turn starting switch ON.

NO

NO

10 YES

Is resistance YES between C3B 9 (female) (16) and chassis normal? Is voltage YES between C3B (15) NO • Min. 1 MΩ and chassis • Disconnect L04, C3B. 8 normal? • Turn starting Is resistance switch OFF. • 20 – 30 V between C3B YES (female) (15) and • Turn starting NO (16) chassis switch ON. 7 normal? • Set directional Is voltage • Min. 1 MΩ lever to 2nd. between C3B (8) • Disconnect L04, NO and chassis C3B. normal? • Turn starting switch OFF. • 20 – 30 V • Turn starting NO switch ON. • Set directional lever to 3rd.

joystick steering controller

Replace

Defective lever

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (8) and C3B (female) (16), or defective lever

Repair or replace

Go to A

Replace

Short circuit to chassis ground between L04 (female) (8) and C3B (female) (16)

Repair or replace

Defective contact or disconnection in wiring harness between L04 (female) (6) and C3B (female) (15), or defective lever

Repair or replace

Short circuit to chassis ground between L04 (female) (6) and C3B (female) (15), or short circuit inwiring harnass between L04 (female) (8) and C3B (female) (16) Defective contact or disconnection between L04 (female) (7) and C3B (female) (8), or defective lever Short circuit with chassis ground in harness between L04 (female) (7) and C3B (female) (8), or short circuit in wiring harness between L04 (female) (7) and C3B (female) (8) – L04 (female) (6) and C3B (female) (15), or between L04 (female) (8) and C3B (female) (16) Defective contact or disconnection between L04 (female) (5) and C3B (female) (7), or defective lever Short circuit with chassis ground in wiring harness between L04 (female) (5) and C3B (female) (7), or short circuit between L04 (female) (5) and C3B (female) (7), or between L04 (female) (6) and C3B (female) (15), or between L04 (female) (7) and C3B (female) (8), or between L04 (female) (8) and C3B (female) (16) Defective contact or disconnection in wiring harness between fuse I (9) and L04 (female) (1) Defective contact or disconnection in wiring harness between L04 (female) (10) and chassis Short circuit with chassis ground in wiring harness between FS2 (female) (8) and L04 (female) (1)

WD600-3

Remedy

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

Repair or replace

20-823 (1)

TROUBLESHOOTING

T-10

T-10 Related electrical circuit diagram

20-824 (1)

WD600-3

TROUBLESHOOTING

T-11

T-11 Failure code [22] (Disconnection in travel speed sensor) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

3 YES YES 2 Is resistance between C5A

YES (female) (2) and T05 1 Is resistance between T05 (male) (1) and (2) and between (1), (2) and chassis ground normal?

• Between (1) and

(2): 500 – 1000 Ω • Disconnect T05. • Turn starting switch OFF.

(female) (1) normal?

Is resistance between C5A (female) (10) and T05 (female) (2) normal?

NO • Max. 1 Ω • Disconnect C5A, T05 and L07.

• Max. 1 W • Disconnect T05,

• Turn starting switch OFF. NO

C5A and L07.

• Turn starting switch OFF.

NO

Defective transmission & joystick steering controller Defective contact or disconnection in wiring harness between C5A (female) (10) and T05 (female) (2) Defective contact or disconnection in wiring harness between C5A (female) (2) and T05 (female) (1) Defective speed sensor

Remedy

Replace

Repair or replace

Repair or replace

Replace

T-11 Related electrical circuit diagram

WD600-3

20-825 (1)

TROUBLESHOOTING

T-12

T-12 Failure code [23] (Short circuit, or disconnection in engine speed sensor system) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance

YES between C4 (female) 2 Is resistance

YES between C4 1 Is resistance between E06 (male) (1) and (2) normal? • 100 – 500 Ω • Disconnect E06. • Turn starting switch OFF.

(female) (2) and E06 (female) (1) normal

• Max. 1 Ω • Disconnect C4, E06 and L07. • Turn starting switch OFF.

(2) and chassis ground normal?

• Min. 1 MΩ • Disconnect C4, E06 and L07. • Turn starting switch OFF.

NO

NO

6 YES

From A

Is resistance YES between C4 (female) (2) and 5 (9) normal?

Is resistance between C4 (female) (9) and chassis ground normal?

• Min. 1 MΩ • Disconnect C4 and E06. • Turn starting switch OFF.

• Min. 1 MΩ NO • Disconnect C4, E06 and L07. • Turn starting switch OFF.

NO

Remedy

Go to A

Is resistance between C4 (female) (9) and E06 (female) (2) normal?

Defective contact or disconnection in wiring harness between C4 NO (female) (9) and E06 • Max. 1 Ω • Disconnect C4 and E06. (female) (2) • Turn starting switch Short circuit with chassis OFF. ground in harness between C4 (female) (2) NO and E06 (female) (1) Defective contact or disconnection in wiring harness between C4 (female) (2) and E06 (female) (1)

Repair or replace

Repair or replace

Repair or replace

Defective engine speed sensor

Replace

Defective transmission & joystick steering controller

Replace

Short circuit of harness between C4 (female) (2) and E03 (female) (1) and harness between C4 (female) (9) and E06 (female) (2) with each other

Repair or replace

Short circuit with chassis ground in harness between C4 (female) (9) and E06 (female) (2)

Repair or replace

T-12 Related electrical circuit diagram

20-826 (1)

WD600-3

T-13, T-14

TROUBLESHOOTING

T-13 When hold switch is pressed, gear speed is not fixed or reset Shift-up does not work 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

YES 1 Is resistance between C5A (female) (13) and chassis normal?

2 YES

Is resistance between L15 • Disconnect C5A. (male) (3) and (4) • Hold switch NO normal? ON: Max. 1 Ω OFF: Min. 1 MΩ

• Disconnect L15. • Hold switch

NO

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit with chassis ground, defective contact, or disconnection in wiring harness between C5A (female) (13) and L15 (female) (3)

Repair or replace

Defective hold switch

Replace

ON: Max. 1 Ω OFF: Min. 1 MΩ

T-14 Kick-down does not work Shift-down does not work YES 1 Is resistance between C5A (female) (5) and chassis normal?

2 YES

Is resistance between L15 • Disconnect C5A. (male) (1) and (2) • Kick-down NO normal? switch ON: Max. 1 Ω OFF: Min. 1 MΩ

• Disconnect L15. • Kick-down switch

NO

Cause

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit with chassis ground, defective contact, or disconnection in wiring harness between C5A (female) (5) and L15 (female) (1)

Repair or replace

Defective kick-down switch

Replace

ON: Max. 1 Ω OFF: Min. 1 MΩ

T-13, T-14 Related electrical circuit diagram

WD600-3

20-827 (1)

TROUBLESHOOTING

T-15

T-15 Transmission cutoff does not work or stays working 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

Defective transmission & joystick steering controller

YES 1 Is resistance between C5A (female) (6) and chassis normal?

2 YES

Is resistance between L12 • Disconnect C5A. • Transmission NO (male) (1) and (2) normal? cut-off switch ON: Max. 1 Ω OFF: Min. 1 MΩ

• Disconnect L12. • Transmission

NO

• Short circuit with chassis ground, defective contact, or disconnection in wiring harness between C5A (female) (6) and L12 (female) (1) • Short circuit with chassis ground in wiring harness between C5A (female) (6) and L06 (female) (3)

Defective transmission cut-off switch

Remedy

Replace

Repair or replace

Replace

cut-off switch ON: Max. 1 Ω OFF: Min. 1 MΩ

T-15 Related electrical circuit diagram

20-828 (1)

WD600-3

TROUBLESHOOTING

T-16

T-16 Neutralizer does not work or stays working fl fl fl fl

Check that the parking brake works normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Cause

YES

4 YES

1 Is voltage between C3A (19) and chassis normal? • Turn starting switch ON. • Parking brake switch: ON → OFF • 20 – 30 V

Is resistance between L58 NO (female) (2) and chassis normal? • Disconnect L58. • Max. 1 Ω

Is resistance YES between C3A (female) (6) and 3 C3A (female) (19) Is voltage normal? YES between L58 • Disconnect C3A and L58. (female) (1) and • Short circuit L58 chassis normal? 2 (female) (3) and (5) • Max. 1 Ω • Disconnect L58.

• Turn starting NO switch ON. • Parking brake switch: ON → OFF • 20 – 30 V

NO

Remedy

Defective transmission & joystick steering controller

Replace

Defective neutralizer relay

Replace

Defective contact or disconnection in wiring harness between C3A (female) (6) – L58 (female) NO (5), L58 (female) (3) – C3A (female) (19) Short circuit with chassis ground, defective contact, or disconnection in wiring harness between L58 (female) (1) and L01 (female) (2)

Defective contact or disconnection in wiring harness between L58 (female) (2) and chassis

Repair or replace

Repair or replace

Repair or replace

T-16 Related electrical circuit diagram

WD600-3

20-829 (1)

TROUBLESHOOTING

T-17

T-17 Buzzer does not work fl fl fl fl

Check that the main monitor alone and alarm buzzer alone work normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).

Cause

2 YES YES 1 Is resistance between C2 (female) (10) and chassis normal? • Disconnect C1 and L08. • Min. 1 MΩ

Is resistance between C2 (female) (10) and L08 (female) (6) normal?

• Disconnect C1 and L08. • Max. 1 Ω

NO

NO

Remedy

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between C2 (female) (10) and L08 (female) (6)

Repair or replace

Short circuit with chassis ground in wiring harness betwen C2 (female) (10) and L08 (female) (6)

Repair or replace

T-17 Related electrical circuit diagram

20-830 (1)

WD600-3

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

WD600-3

20-831 (1)

TROUBLESHOOTING

T-19

T-19 Abnormality in transmission controller power supply fl fl fl fl

Check that fuse II (6) is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).

Cause

YES 1 Is voltage between C1A (7), (13), C2 (1), (12) and C1A (6), (12), C2 (11), (21) normal?

• 20 – 30 V • Turn starting switch ON.

2 YES

NO

Is resistance between C1A (female) (6), (12) and chassis, and C2 (female) (11), (21) and chassis normal?

• Max. 1 Ω • Turn starting

NO

switch OFF.

• Disconnect C1A

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit with chassis ground, defective contact or disconnection in wiring harness between C1A (female) (7), (13) and FS5 (female) (6), and between C2 (female) (1), (12) and OP5 (female) (1)

Repair or replace

Defective contact or disconnection in wiring harness between C1A (female) (6), (12) and chassis, and between C2 (female) (1), (12) and chassis

Repair or replace

and C2.

T-19 Related electrical circuit diagram

20-832 (1)

WD600-3

T-20

TROUBLESHOOTING

T-20 Short circuit in travel speed sensor 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.

Cause

2 YES Is resistance YES between C5A (female) (2) and 1 (10) normal? Is resistance between C5A (female) (2) and chassis normal?

• Min. 1 MΩ • Turn starting

• Min. 1 MΩ NO • Turn starting switch OFF. • Disconnect C5A, T05 and L07.

NO

switch OFF.

• Disconnect C5A, BC01 and L07.

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit in wiring harness betwen C5A (female) (2) – L07 (female) (1) – T05 (male) (1) or short circuit in wiring harness between C5A (female) (10) – L07 (female) (2) – T05 (female) (2)

Repair or replace

Short circuit in wiring harness betwen C5A (female) (2) – TM2 (9) – CN3 (female) (2), or short circuit in between C5A (female) (2) and L07 (female) (1)

Repair or replace

T-20 Related electrical circuit diagram

WD600-3

20-833 (1)

TROUBLESHOOTING

T-21

T-21 Abnormality in machine selection wiring harness fl Check that machine selection connector is properly selected. 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 resistance between C3B (female) (2), (3), (10) and C1A (female) (6), (12) normal?

• Turn starting

NO

switch OFF.

• Disconnect C3B

Remedy

Defective transmission & joystick steering controller

Replace

Defective machine selection connector, or defective contact or disconnection in wiring harness

Repair or replace

and C1A.

Table 1 Machine model Connector

WA600-3

Between C3B (female) (2) and C1A (female) (6), (12)

Min. 1 MΩ

Between C3B (female) (3) and C1A (female) (6), (12)

Max. 1 Ω

Between C3B (female) (10) and C1A (female) (6), (12)

Min. 1 MΩ

T-21 Related electrical circuit diagram

20-834 (1)

WD600-3

TROUBLESHOOTING OF JOYSTICK STEERING SYSTEM (J MODE) (ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT CONTROL)

Judgement table for joystick control system ......................................................................................20-902 Action taken by controller when abnormality occurs and problems on machine ..........................20-904 Electrical circuit diagram for joystick steering system .......................................................................20-908 J- 1

Failure code [56] (Short circuit, or disconnection in caution relay output) is displayed ....20-910

J- 2

Failure code [57] (Short circuit in steering right solenoid (detected when signal is output)) is displayed ................................................................................................................20-911

J- 3

Failure code [58] (Short circuit in steering left solenoid (detected when signal is output)) is displayed ................................................................................................................20-912

J- 4

Failure code [59] (Short circuit in steering right solenoid (power supply side)) is displayed ...................................................................................................................................20-913

J- 5

Failure code [60] (Short circuit in steering left solenoid (power supply side)) is displayed ...................................................................................................................................20-914

J- 6

Failure code [61] (Short circuit, or disconnection in steering solenoid cut relay output) is displayed .....................................................................................................................20-915

J- 7

Failure code [62] (Short circuit, or disconnection in joystick steering neutral circuit) is displayed ......................................................................................................................20-916

J- 8

Failure code [63] (Short circuit, or disconnection in joystick steering potentiometer) is displayed ........................................................................................................20-917

J- 9

Abnormality in power supply, or power supply voltage ........................................................20-918

J-10

Abnormality in joystick steering ON-OFF circuit ......................................................................20-919

J-11

Disconnection in steering right solenoid ..................................................................................20-920

J-12

Disconnection in steering left solenoid .....................................................................................20-921

WD600-3

20-901 (1)

TROUBLESHOOTING

JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM

JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM

Self-diagnostic display (abnormality display)

Troubleshooting code when no abnormality display is given

Abnormality in joystick ON-OFF circuit

Abnormality in power supply, or power supply voltage

Short circuit, or disconnection in joystick potentiometer

Short circuit, or disconnection in joystick steering neutral switch

Short circuit, or disconnection in steering solenoid cut relay output

Short circuit in steering left solenoid (power supply side)

Short circuit in steering right solenoid (power supply side)

Short circuit in steering left solenoid (detected when signal is output)

Failure mode

Short circuit in steering right solenoid (detected when signal is output)

Failure code

Short circuit, or disconnection in joystick caution relay output

Location of failure

56 57 58 59 60 61 62 63 — — 1

Buzzer does not stop

2

Steering does not turn to left

3

Steering does not turn to right

4

Steering is always turned to left

5

Steering is always turned to right

6

Both steering and transmission do not work at all

fi

T-17

fi fi

fi fi fi fi fi fi fi fi fi fi fi fi

H-7, H-8, H-9, H-10, J-9, J-12 H-7, H-8, H-9, H-10, J-9, J-11

fi fi

J-9, J-10

Troubleshooting code when failure code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 — —

20-902 (1)

WD600-3

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE JOYSTICK CONTROL SYSTEM Failure code

56

57

Abnormal system

Joystick caution relay

Steering right solenoid

Portion of abnormality 1) Defective caution relay 2) Short circuit with ground, defective contact, or disconnection in wiring harness between C2 (female) (9) – L65 (1) 3) Short circuit with ground, defective contact, or disconnection in wiring harness between C2 (female) (19) – L65 (2) – chassis ground 4) Defective transmission & joystick steering controller 1) Defective steering right solenoid 2) Defective steering solenoid cut relay 3) Short circuit in wiring harness between C2 (female) (2) – (13) Short circuit with ground, defective contact, or disconnection in the following wiring harness 4) Wiring harness between C2 (female) (2) – L27 (2) 5) Wiring harness between C2 (female) (13) – L67 (3) 6) Wiring harness between L67 (female) (5) – L27 (1) 7) Defective transmission & joystick steering controller

1) Defective steering left solenoid 2) Defective steering solenoid cut relay 3) Short circuit in wiring harness between C2 (female) (3) – (14) Short circuit with ground, defective contact, or disconnection in the following wiring harness 4) Wiring harness between C2 (female) (3) – L26 (2) 5) Wiring harness between C2 (female) (14) – L67 (3) 6) Wiring harness between L67 (female) (5) – L26 (1) 7) Defective transmission & joystick controller

58

Steering left solenoid

59

Short circuit with power supply in steering right solenoid circuit

1) Defective steering right solenoid 2) Short circuit with power source in wiring harness between C2 (female) (2) – L27 (2) 3) Defective transmission & joystick steering controller

Short circuit with power supply in steering left solenoid circuit

1) Defective steering left solenoid 2) Short circuit with power source in wiring harness between C2 (female) (3) – L26 (2) 3) Defective transmission & joystick steering controller

60

20-904 (1)

WD600-3

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance)

Action by controller when abnormality is detected

Problem that appears on machine when there is abnormality

1) Joystick caution relay: ON (voltage between C2 (9) – (19): 20 – 30 V) 2) Resistance of relay coil between C2 (female) (9) – (19): 200 – 400 Ω 3) Resistance of wiring harness between C2 (female) (9) – L65 (female) (1): Less than 1 Ω 4) Resistance of wiring harness between L65 (female) (2) – C2 (19): Less than 1 Ω

Caution output: OFF

1) Steering solenoid cut relay: ON (voltage between C2 (2) and chassis ground: 20 – 30 V) 2) Resistance of steering right solenoid: 10 – 20 Ω 3) Resistance between C2 (female) (2), (13) – chassis ground: Min. 1 MΩ Resistance of the following wiring harness: Less than 1 Ω 4) Wiring harness between C2 (female) (2) – L27 (female) (2) 5) Wiring harness between C2 (female) (13) – L67 (female) (3) 6) Wiring harness between L67 (female) (5) – L27 (female) (1)

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

1) Steering solenoid cut relay: ON (voltage between C2 (3) – chassis ground: 20 – 30 V) 2) Resistance of steering left solenoid: 10 – 20 Ω 3) Resistance between C2 (female) (3), (14) – chassis ground: Min. 1 MΩ Resistance of the following wiring harness: Less than 1 Ω 4) Wiring harness between C2 (female) (3) – L26 (female) (2) 5) Wiring harness between C2 (female) (14) – L67 (female) (3) 6) Wiring harness between L67 (female) (5) – L27 (female) (1)

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

When joystick lever is at neutral Voltage between C2 (female) (2) – chassis ground: Less than 1 V

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

Impossible to use joystick and joystick caution actuated

When joystick lever is at neutral Voltage between C2 (female) (3) – chassis ground: Less than 1 V

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

Impossible to use joystick and joystick caution actuated

WD600-3

Troubleshooting code

Joystick caution actuated

J-1

Impossible to use joystick and joystick caution actuated

J-2

Impossible to use joystick and joystick caution actuated

J-3

J-4

J-5

20-905 (1)

TROUBLESHOOTING

Failure code

61

62

63

20-906 (1)

Abnormal system

Steering solenoid cut relay

Joystick neutral switch

Joystick potentiometer

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

Portion of abnormality 1) Defective steering solenoid cut relay 2) Short circuit with ground, defective contact, or disconnection in wiring harness between C1A (female) (1) – C1 (female) (1) – L67 (female) (1) 3) Short circuit with ground, defective contact, or disconnection in wiring harness between JS5 (3) – chassis ground 4) Defective transmission & joystick steering controller

1) Defective joystick neutral switch 2) Short circuit with ground, defective contact, or disconnection in wiring harness between C5A (female) (11) – C5 (female) (11) – JS5 (female) (1) 3) Defective contact or disconnection in wiring harness between JS5 (3) – chassis ground 4) Defective transmission & joystick steering controller

1) Defective boom angle potentiometer 2) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between C3A (female) (3) – JS2 (1) 3) Short circuit with power source, defective contact, or disconnection in wiring harness between C3A (female) (7) – JS2 (2) 4) Short circuit with power supply, short circuit with ground, defective contact, or disconnection in wiring harness between C3A (female) (17) – JS2 (female) (3) 5) Defective transmission & joystick steering controller

WD600-3

TROUBLESHOOTING

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS, AND PROBLEMS ON MACHINE

Condition when normal (voltage, current, resistance)

Action by controller when abnormality is detected

Resistance between C5A (female) (11) – chassis ground: Min. 1 MΩ (joystick at neutral), Less than 1 Ω (joystick angled ± 5 – 15° from neutral)

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

Impossible to use joystick and joystick caution actuated

Voltage between C3A (female) (3) – (17): 0.5 – 4.5 V Steering right, left (voltage when joystick is at neutral: Approx. 2.5 V) solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

Impossible to use joystick and joystick caution actuated

Steering right, left solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay output: OFF

Impossible to use joystick and joystick caution actuated

1) Steering solenoid cut relay: ON (voltage between C1A (1) – chassis ground: 20 – 30 V) 2) Resistance of relay coil between C1A (female) (1) – chassis ground: 200 – 400 Ω 3) Resistance of wiring harness between C1A (female) (1) – L67 (female) (1): Less than 1 Ω 4) Resistance of wiring harness between steering solenoid cut relay L67 (female) (2) – chassis ground: Less than 1 Ω

WD600-3

Problem that appears on machine when there is abnormality

Troubleshooting code

J-6

J-7

J-8

20-907 (1)

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM

20-908 (1)

WD600-3

TROUBLESHOOTING

WD600-3

ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM

20-909 (1)

TROUBLESHOOTING

J-1

J-1 Failure code [56] (Short circuit, or disconnection in caution relay output) is displayed fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step. fl Always turn the starting switch OFF before disconnecting any connector. Cause

4 YES YES 3 YES 2 YES

1 Is failure code displayed when L65 is replaced with other relay of same type?

• Turn starting switch OFF. • Replace L65 with another relay of same type. • Turn starting switch ON.

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2.

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2.

Is resistance between C2 (female) (9) and C2 (female) (19) normal?

• 200 – 400 Ω • Turn starting switch OFF. • Disconnect C2.

Is resistance between C2 (female) (9) and chassis ground normal?

Is resistance between C1 (female) (19) and chassis ground normal?

NO

5 YES

NO

Is resistance between C2 (female) (9) and L65 (female) (1) normal?

• Max. 1 Ω NO • Turn starting switch OFF. • Disconnect C2 and L65.

NO

Defective transmission & joystick steering controller

Remedy

Replace

Short circuit with chassis ground in harness between NO C2 (female) (19) and L65 (female) (2)

Repair or replace

Short circuit with chassis ground in harness between C2 (female) (1) and L65 (female) (1)

Repair or replace

Defective contact or disconnection in wiring harness between C2 (female) (19) and L65 (female) (2)

Repair or replace

Defective contact or disconnection in wiring harness between C2 (female) (9) and L65 (female) (1)

Defective caution (J/S) relay

Repair or replace

Replace

J-1 Related electrical circuit diagram

20-910 (1)

WD600-3

TROUBLESHOOTING

J-2

J-2 Failure code [57] (Short circuit in steering right solenoid (detected when signal is output)) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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 When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause

4 YES Defective transmission &

Is resistance

YES between C2 2 YES 1 Is failure code displayed when L67 is replaced with other relay of same type?

• Turn starting switch OFF. • Replace L67 with other relay of same type. • Turn starting switch ON.

Is resistance between C2 (female) (2) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2 and L27.

(female) (13) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2 and L67.

NO

NO

joystick controller

Is resistance YES between C2 (female) (2) and 3 (13) normal? • Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2.

NO

NO

Short circuit of wiring harness between C2 (female) (2) and L27 (female) (2) and wiring harness between C2 (female) (13) and L67 (female) (3) with each other

Remedy

Replace

Repair or replace

Short circuit with chassis ground in harness between C2 (female) (13) and L67 (female) (3)

Repair or replace

Short circuit with chassis ground in harness between C2 (female) (2) and L27 (female) (2)

Repair or replace

Defective steering solenoid cut relay

Replace

J-2 Related electrical circuit diagram

WD600-3

20-911 (1)

TROUBLESHOOTING

J-3

J-3 Failure code [58] (Short circuit in steering left solenoid (detected when signal is output)) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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 When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause

4 YES Defective transmission &

YES 2 YES 1 Is failure code displayed when L67 is replaced with other relay of same type?

• Turn starting switch OFF. • Replace L67 with other relay of same type. • Turn starting switch ON.

Is resistance between C2 (female) (3) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2 and L26.

Is resistance between C2 (female) (14) and chassis ground normal?

• Min. 1 MΩ • Turn starting switch OFF. • Disconnect C2 and L67.

NO

NO

Is resistance YES between C2 (female) (3) and 3 (14) normal? • Min. 1 MΩ • Turn starting switch OFF. • Disconnect L26.

NO

NO

Remedy

joystick controller

Replace

Short circuit of wiring harness between C2 (female) (3) and L26 (female) (2) and wiring harness between C2 (female) (14) and L67 (female) (3) with each other

Repair or replace

Short circuit with chassis ground in harness between C2 (female) (14) and L67 (female) (3)

Repair or replace

Short circuit with chassis ground in harness between C2 (female) (3) and L26 (female) (2)

Repair or replace

Defective steering solenoid cut relay

Replace

J-3 Related electrical circuit diagram

20-912 (1)

WD600-3

TROUBLESHOOTING

J-4

J-4 Failure code [59] (Short circuit in steering right solenoid (power supply side)) is displayed fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step.

Cause

1 YES 1 Is voltage between C2 (female) (2) and chassis ground normal?

• Max. 1 V • Turn starting switch ON.

NO

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C2 (female) (2) and L27 (female) (2)

Repair or replace

J-4 Related electrical circuit diagram

WD600-3

20-913 (1)

TROUBLESHOOTING

J-5

J-5 Failure code [60] (Short circuit in steering left solenoid (power supply side)) is displayed fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step. fl Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).

Cause

1 YES 1 Is voltage between C2 (female) (3) and chassis ground normal?

• Max. 1 V • Turn starting switch ON.

NO

Remedy

Defective transmission & joystick steering controller

Replace

Short circuit with power supply in wiring harness between C2 (female) (3) and L26 (female) (2)

Repair or replace

J-5 Related electrical circuit diagram

20-914 (1)

WD600-3

J-6

TROUBLESHOOTING

J-6 Failure code [61] (Short circuit, or disconnection in steering solenoid cut relay output) is displayed fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed Cause Remedy on the monitor display, the problem has been removed. fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Always connect any disconnected connectors 4 YES before going on to the next step. Go to A Is resistance fl When the joystick steering lever is not being between L67 YES Defective contact or used, leave it at the neutral position and 3 (female) (2) and disconnection in wiring chassis ground turn the joystick steering Is resistance harness between L67 Repair or normal? selector switch ON. (female) (2) and chassis YES between C1A replace • Max. 1 Ω NO (female) (1) and ground • Turn starting chassis ground 2 normal?

YES 1 Is failure code displayed when L67 is replaced with other relay of same type?

• Turn starting

Is resistance between C1A (female) (1) and L67 (female) (1) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C1A and L67.

switch OFF. • Disconnect C1A and L67.

NO

switch OFF.

• Replace L67 with NO other relay of same type. • Turn starting switch ON. From A

5 YES Is resistance between C5A (female) (11) and JS5 (female) (1) normal?

• Max. 1 Ω NO • Turn starting switch OFF. • Disconnect C5A and JS5. J-6 Related electrical circuit diagram

WD600-3

switch OFF.

• Disconnect L67. NO

Short circuit with chassis ground in harness between C1A (female) (1) and L67 (female) (1)

Defective contact or disconnection in wiring harness between C1A (female) (1) and L67 (female) (1)

Repair or replace

Repair or replace

Defective steering solenoid cut relay

Replace

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between C5A (female) (11) and JS5 (female) (1)

Repair or replace

20-915 (1)

TROUBLESHOOTING

J-7

J-7 Failure code [62] (Short circuit, or disconnection in joystick steering neutral circuit) is displayed fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step.

Cause

Defective transmission & joystick controller or defective installation of joystick potentiometer

YES 2 YES

1 Is resistance between C5A (female) (11) and chassis ground normal?

Remedy

Replace

Defective contact or

Is resistance between C5A (female) (11) and chassis ground normal?

4 YES disconnection in wiring YES 3

• Disconnect C5A. • Pull JST lever to

Is resistance right or left end. between JS5 • Max. 1 Ω NO (male) (1) and (3) normal?

Is resistance between JS5 (female) (3) and chassis ground normal?

• Disconnect JS5. NO • Max. 1 Ω

• Disconnect JS5. • Pull JST lever to NO

• Disconnect C5A. • Min. 1 MΩ

harness between JS5 (female) (1) and C5A (female) (11) Defective contact or disconnection in wiring harness between JS5 (female) (3) and chassis ground

Repair or replace

Repair or replace

Defective neutral switch

Replace

Short circuit with chassis ground in harness between JS5 (female) (1) and C5A (female) (11)

Repair or replace

Defective neutral switch

Replace

right or left end.

• Max. 1 Ω 5 YES Is resistance between JS5 NO (male) (1) and (3) normal?

• Disconnect JS5. • Min. 1 MΩ

NO

J-7 Related electrical circuit diagram

20-916 (1)

WD600-3

TROUBLESHOOTING

J-8

J-8 Failure code [63] (Short circuit, or disconnection in joystick steering lever potentiometer) is displayed fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step. fl After connecting the T-adapter, turn the starting switch ON.

Cause

YES 2 Does voltage YES between C3A (female) (3) – (17) change?

1 Does voltage between C3A (7) – (17) change? • 4.9 – 5.1 V

3 YES Does resistance 3

between JS2 • Turn joystick lever to left or to NO (male) (1) and (3) change? right. • 0.5 – 4.5 V • Turn joystick lever to left or to right. • 0.2 – 5 kΩ

NO

NO

Remedy

Defective joystick potentiometer, neutral position misaligned

Repair, adjust neutral position again

Short circuit with power supply short circuit with ground, defective contact, or disconnection in wiring harness between C3A (female) (3) – JS2 (female) (1)

Repair or replace

Defective joystick potentiometer

Replace

Defective transmission & joystick steering controller

Replace

J-8 Related electrical circuit diagram

WD600-3

20-917 (1)

J-9

TROUBLESHOOTING

J-9 Abnormality in power supply, or power supply voltage fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Check that fuse I (10) is normal. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step.

Cause

1 YES Is voltage between C1A (female) (7), (13) – chassis normal?

• 20 – 30 V • Turn starting

NO

switch ON.

Remedy

Defective transmission & joystick steering controller

Replace

Defective contact or disconnection in wiring harness between C1A (female) (7), (13) – Fuse (II) (15)

Repair or replace

J-9 Related electrical circuit diagram

20-918 (1)

WD600-3

TROUBLESHOOTING

J-10

J-10 Abnormality in joystick steering ON-OFF circuit fl Before carrying out troubleshooting, check that all the related connectors are properly inserted. fl Check that fuse I (11) is normal. fl When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. fl Always connect any disconnected connectors before going on to the next step.

Cause

YES

Remedy

Defective transmission & joystick steering controller

Replace

Defective system cutoff switch

Replace

1 Is voltage between C3A (19) – chassis normal?

3 YES Is voltage YES between JS3 (female) – and 2 chassis normal? Is resistance between

• 20 – 30 V • Turn starting L27 (female) (14) and switch ON. chassis normal when NO • Turn joystick S4 (male) is grounded to chassis? ON- OFF switch: • Turn starting ON. switch OFF. • Disconnect S4 and L27. • Max. 1 Ω

• 20 – 30 V • Turn starting switch ON.

NO

NO

Defective contact or disconnection in wiring harness between fuse I (11) – FS2 (10) – L32 (1) – JS3 (female) Defective contact or disconnection in wiring harness between L27 (female) (14) – JS5 (1), (2) – S4 (male), or defective joystick ON–OFF switch

Repair or replace

Replace switch, or repair or replace

J-10 Related electrical circuit diagram

WD600-3

20-919 (1)

TROUBLESHOOTING

J-11

J-11 Disconnection in steering right solenoid 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 When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause

4 YES Defective transmission & YES 3 Is resistance

YES between C2 2 YES 1 Is resistance between L27 (male) (1) and (2) normal? • 10 – 20 Ω • Turn starting switch OFF. • Disconnect L27.

Is resistance between C2 (female) (2) and L27 (female) (2) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C2 and L27.

(female) (13) and L67 (female) (3) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C2 and L67.

NO

NO

Is resistance between L27 (female) (1) and L67 (female) (5) normal?

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect L27 and L67. NO

joystick controller Defective contact or disconnection in wiring harness between L27 (female) (1) and L67 (female) (5) Defective contact or disconnection in wiring harness between C2 (female) (13) and L67 (female) (3) Defective contact or disconnection in wiring harness between C2 (female) (2) and L27 (female) (2)

Defective joystick steering right solenoid valve

Remedy

Replace

Repair or replace

Repair or replace

Repair or replace

Replace

J-11 Related electrical circuit diagram

20-920 (1)

WD600-3

J-12

TROUBLESHOOTING

J-12 Disconnection in steering left solenoid 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 When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Cause

4 YES Defective transmission & Is resistance

YES between L26 (female) (1) and L67 3 Is resistance

YES between C2 2 YES 1 Is resistance between L26 (male) (1) and (2) normal? • 10 – 20 Ω • Turn starting switch OFF. • Disconnect L26.

Is resistance between C2 (female) (3) and L26 (female) (2) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C2 and L26.

(female) (14) and L67 (female) (3) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C2 and L67.

NO

NO

(female) (5) normal?

NO • Max. 1 Ω • Turn starting switch OFF. • Disconnect L26 and L67. NO

joystick controller Defective contact or disconnection in wiring harness between L26 (female) (1) and L67 (female) (5) Defective contact or disconnection in wiring harness between C2 (female) (14) and L67 (female) (3) Defective contact or disconnection in wiring harness between C2 (female) (3) and L26 (female) (2)

Defective joystick steering left solenoid valve

Remedy

Replace

Repair or replace

Repair or replace

Repair or replace

Replace

J-12 Related electrical circuit diagram

WD600-3

20-921 (1)

TROUBLESHOOTING OF THROTTLE CONTROL SYSTEM (TH MODE)

Judgement table for throttle controller system related parts ............................................................. 20-953 Electric circuit diagram of throttle controller system ........................................................................... 20-954 TH-1 Abnormality in accelerator pedal sensor system is displayed ................................................. 20-955 TH-2 Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system is displayed .......... 20-956 TH-3 Disconnetion in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system ............................. 20-957 TH-4 Abnormality in electronic governor voltage command system ............................................... 20-958 TH-5 Abnormality in brake pedal switch system ................................................................................ 20-959 a) Abnormality in left brake pedal switch .................................................................................. 20-959 b) Abnormality in right brake pedal switch ............................................................................... 20-960 TH-6 Abnormality in RPM-SET ON/OFF switch system ..................................................................... 20-961 TH-7 Short circuit, disconnection, or short circuit with power supply in backup lamp relay ......... 20-962

WD600-3

20-951 (1)

TROUBLESHOOTING

JUDGEMENT TABLE FOR THROTTLE CONTROLLER SYSTEM RELATED PARTS

3

Engine speed can be set while RPM SET ON/OFF switch is OFF

4

RPM-SET IDLE-UP/RESUME IDLE-DOWN switch does not work

5

Backup lamp and backup buzzer do not work

WD600-3

fi fi

fi

Diagonosis code when failure code is not displayed

Engine speed does not change even if RPM SET ON/OFF switch operated

Short circuit or disconnection in backup lamp relay

2

fi

Abnormality in power supply system of throttle controller system

fi

Abnormality in RPM-SET ON/OFF switch system

Engine speed does not rise even if accelerator pedal is pressed

Abnormality in brake pedal switch system

1

Abnormality in electronic governor voltage command system

Failure mode

Abnormality in accelerator pedal sensor system

Location of failure

Disconnection in RPM-SET IDLE-UP/RESUME IDLE0DOWN switch system

JUDGEMENT TABLE FOR THROTTLE CONTROLLER SYSTEM RELATED PARTS

TH-1

fi

TH-6

fi fi

TH-6 TH-2, 3

fi

TH-7

20-953 (1)

TROUBLESHOOTING

ELECTRIC CIRCUIT DIAGRAM OF THROTTLE CONTROLLER SYSTEM

ELECTRIC CIRCUIT DIAGRAM OF THROTTLE CONTROLLER SYSTEM

20-954 (1)

WD600-3

TH-1

TROUBLESHOOTING

TH-1 Abnormality in accelerator pedal sensor system is displayed 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

3 YES YES 2 YES 1 Is resistance between C6 (female) (9) and L13A (male) (1) normal?

• Max. 1 Ω • Turn starting

Is resistance between C6 (female) (9) and chassis ground normal?

Is resistance between C6 (female) (22) and L13A (male) (3) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C6

• Min. 1 MΩ • Turn starting

NO

and L13.

NO

switch OFF.

• Disconnect C6 and L13A.

NO

switch OFF.

• Disconnect C6 and L13A.

6 YES YES Is voltage between L13A (1) and (2) 5 normal? Is resistance

YES between C6 From A

4

Is resistance between C6 (female) (22) and L13A (male) (3) normal?

• Max. 1M Ω • Turn starting switch OFF. • Disconnect C6 and L13A.

(female) (9), (22) and chassis ground normal?

• Min. 1 MΩ • Turn starting

• At low idling:

NO

0.5 – 1.6 V At high idling: (Low idling voltage + 2.1 V) – 4.75 V • Turn starting switch ON.

NO

switch OFF.

• Disconnect C6 and L13A.

NO

Go to A Disconnection or defective contact in wiring harness between C6 (female) (22) – L13A (male) (3) Short circuit with chassis ground in wiring harness between C6 (female) (9) – L13A (male) (1) Disconnection or defective contact in wiring harness between C6 (female) (9) – L13A (male) (1)

Remedy

—

Repair or replace

Repair or replace

Repair or replace

Defective throttle controller

Replace

Defective accelerator pedal potentiometer

Replace

Short circuit of wiring harness between C6 (female) (22) – L13A (male) (3) with wiring harness between C6 (9) – L13A (male) (1) Short circuit with chassis ground in wiring harness between C6 (female) (22) – L13A (male) (3)

Repair or replace

Repair or replace

TH-1 Related electrical circuit diagram

WD600-3

20-955 (1)

TH-2

TROUBLESHOOTING

TH-2 Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system is displayed fl When a connector is disconnected and a T-adapter is inserted for troubleshooting while abnormality is detected or when the T-adapter is removed and the connector is connected again, if the throttle lock ON/OFF switch indicator stops flashing, the condition has returned to normal. 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

3 YES Is resistance between C8 (female) (30) and chassis ground normal?

YES 2 YES 1 Is resistance between C12 (male) (1), (2) and (3) as shown in Table 1?

• Disconnect C12 • Turn starting switch OFF.

Is resistance between C8 (female) (19) and chassis ground normal?

• Min. 1 MΩ • Turn starting

• Max. 1M Ω • Turn starting

NO

switch OFF.

• Disconnect C8 and C12.

NO

switch OFF.

Remedy

Defective throttle controller

Replace

Short circuit with chassis ground in wiring harness between C8 (female) (30) – C12 (male) (3)

Repair or replace

Short circuit with chassis ground in wiring harness between C8 (female) (19) – C12 (male) (1)

Repair or replace

Defective SET IDLE-UP /RESUME IDLE-DOWN switch

Replace

• Disconnect C8 and C12.

NO

Table 1 Switch Terminal

RPM-SET IDLEUP switch ON

RESUME•IDLEDOWN switch ON

OFF

Between C12 (male) (2) – (3)

Min. 1 MΩ

Max. 1 Ω

Min. 1 MΩ

Between C12 (male) (1) – (2)

Max. 1 Ω

Min. 1 MΩ

Min. 1 MΩ

TH-2 Related electrical circuit diagram

20-956 (1)

WD600-3

TH-3

TROUBLESHOOTING

TH-3 Disconnetion in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch 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. Cause

4 YES Defective throttle YES 3 YES 2 YES 1 Is resistance between C12 (male) (1), (2) and (3) as shown in Table 1?

• Disconnect C12 • Turn starting switch OFF.

Is resistance between C8 (female) (19) and C12 (male) (1) normal?

• Max. 1 Ω • Turn starting

Is resistance between C8 (female) (30) and C12 (male) (3) normal?

• Min. 1 Ω • Turn starting

Is resistance between C12 (female) (2) and chassis ground normal?

• Max. 1 Ω • Turn starting

controller Disconnection in wiring harness between C12 NO (male) (2) – chassis ground

switch OFF.

• Disconnect C12. NO

switch OFF.

• Disconnect C8 and C12.

switch OFF. • Disconnect C8 and C12.

NO

NO

Remedy

Replace

Repair or replace

Disconnection in wiring harness between C8 (female) (30) – C12 (male) (3)

Repair or replace

Disconnection in wiring harness between C8 (female) (19) – C12 (male) (1)

Repair or replace

Defective RPM-SET IDLEUP/RESUME IDLE-DOWN switch

Replace

Table 1 Switch Terminal

RPM-SET IDLEUP switch ON

RESUME•IDLEDOWN switch ON

OFF

Between C12 (male) (2) – (3)

Min. 1 MΩ

Max. 1 Ω

Min. 1 MΩ

Between C12 (male) (1) – (2)

Max. 1 Ω

Min. 1 MΩ

Min. 1 MΩ

TH-3 Related electrical circuit diagram

WD600-3

20-957 (1)

TROUBLESHOOTING

TH-4

TH-4 Abnormality in electronic governor voltage command 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.

Cause

3 YES YES 2 Is resistance

Is resistance between C7 (female) (11) and BCMB (female) (29) normal?

• Min. 1 Ω • Turn starting switch OFF. • Disconnect C7 and BCMB.

Is voltage between C7 (female) (11) and chassis ground normal?

YES between C7

• At low idling:

1

• At high idling: 3.8 – 5 V • Turn starting switch ON.

(female) (11) and chassis ground normal?

• Min. 1 MΩ • Turn starting

NO

Remedy

Short circuit with power source in wiring harness between C7 (female) (11) – BCMB (female) (29)

Repair or replace

Defective throttle controller

Replace

Short circuit with chassis ground in wiring harness between C7 (female) (11) – BCMB (female) (29)

Repair or replace

Disconnection or defective contact in wiring harness between C7 (female) (11) – BCMB (female) (29)

Repair or replace

Max. 0.5 V

NO

switch OFF.

• Disconnect C7 and BCMB.

NO

TH-4 Related electrical circuit diagram

20-958 (1)

WD600-3

TH-5

TROUBLESHOOTING

TH-5 Abnormality in brake pedal switch system fl Check that fuse (10) is normal. 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) Abnormality in left brake pedal switch

Cause

4 YES Defective throttle YES 3 Is resistance

YES between C13A 2 YES 1 Is resistance between C8 (female) (40) and C13A (female) (2) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C8, C13A and C4.

WD600-3

Is resistance between C8 (female) (40) and chassis ground normal?

• Max. 1M Ω • Turn starting switch OFF. • Disconnect C8, C13A and C4.

NO

(female) (1) and FS2 (female) (9) normal?

• Min. 1 Ω • Turn starting switch OFF.

• Disconnect C13A, C14 and FS2.

NO

controller

Is voltage between C8 (female) (40) and chassis ground normal?

• Press left brake •

Defective left brake pedal

NO switch

pedal: Max. 1 V Release left brake pedal: 17 – 30 V Turn starting switch ON.

NO

Remedy

Replace

Replace

Disconnection or defective contact in wiring harness between C13A (female) (1) – FS2 (female) (9)

Repair or replace

Short circuit with chassis ground in wiring harness between C8 (female) (40) – C13A (female) (2)

Repair or replace

Disconnection or defective contact in wiring harness between C8 (female) (40) – C13A (female) (2)

Repair or replace

20-959 (1)

TH-5

TROUBLESHOOTING

b) Abnormality in right brake pedal switch

Cause

4 YES Defective throttle YES 3 Is resistance

YES between C14 2 YES 1 Is resistance between C8 (female) (40) and C14 (female) (2) normal?

• Max. 1 Ω • Turn starting switch OFF. • Disconnect C8, C13A and C14.

Is resistance between C8 (female) (40) and chassis ground normal?

• Max. 1M Ω • Turn starting switch OFF. • Disconnect C8, C13A and C14.

(female) (1) and FS2 (female) (9) normal?

• Min. 1 Ω • Turn starting switch OFF.

• Disconnect C13A, C14 and FS2.

NO

NO

controller

Is voltage between C8 (female) (40) and chassis ground normal?

• Press right brake •

Defective right brake

NO pedal switch

pedal: Max. 1 V Release right brake pedal: 17 – 30 V Turn starting switch ON.

NO

Remedy

Replace

Replace

Disconnection or defective contact in wiring harness between C14 (female) (1) – FS2 (female) (9)

Repair or replace

Short circuit with chassis ground in wiring harness between C8 (female) (40) – C14 (female) (2)

Repair or replace

Disconnection or defective contact in wiring harness between C8 (female) (40) – C14 (female) (2)

Repair or replace

TH-5 Related electrical circuit diagram

20-960 (1)

WD600-3

TH-6

TROUBLESHOOTING

TH-6 Abnormality in RPM-SET ON/OFF switch 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.

Cause

3 YES YES 2 Is resistance

YES between C11 1 Is resistance between C11 (male) (3) and (4) normal?

• RPM-SET ON/OFF switch ON: Max. 1 Ω OFF: Min. 1 MΩ • Turn starting switch OFF. • Disconnect C11.

(female) (3) and chassis ground normal?

• Min. 1 Ω • Turn starting

Is voltage between C8 (female) (10) and chassis ground normal?

• RPM-SET ON/OFF

NO

switch OFF: Max. 1 V ON: 17 – 30 V • Turn starting switch OFF.

NO

switch OFF.

• Disconnect C11. NO

Defective throttle controller Short circuit with chassis ground, disconnection, defective contact, or short circuit with power source in wiring harness between C8 (female) (10) – C11 (female) (4) Disconnection or defective contact in wiring harness between C11 (female) (3) – chassis ground Defective RPM-SET ON/OFF switch

Remedy

Replace

Repair or replace

Repair or replace

Replace

TH-6 Related electrical circuit diagram

WD600-3

20-961 (1)

TH-7

TROUBLESHOOTING

TH-7 Short circuit, disconnection, or short circuit with power supply in backup lamp relay fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. 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

4 YES YES 3 Is resistance between C8 (female) (7) and chassis ground normal?

YES 2 YES 1 Backup relay is replaced with other relay of same type?

• Turn starting

Is resistance between C8 (female) (7) and L76 (female) (1) normal?

• Max. 1 Ω • Turn starting

• Min. 1 MΩ • Turn starting switch OFF.

• Disconnect C8 and L76.

NO

switch OFF. • Disconnect C8 and L76.

switch OFF.

• Replace backup

NO

Is resistance between L76 (female) (2) and chassis ground normal?

• Max. 1 Ω • Turn starting switch OFF.

• Disconnect C8 and L76.

NO

Remedy

Go to A

Defective contact or disconnection in wiring harness between L76 NO (female) (2) and chassis ground Short circuit with chassis ground in harness between C8 (female) (7) and L76 (female) (1) Defective contact or disconnection in wiring harness between C8 (female) (7) and L76 (female) (1)

Repair or replace

Repair or replace

Repair or replace

Defective backup lamp relay

Repair

Defective throttle controller

Repair

Short circuit with power source in wiring harness between C8 (female) (7) and L76 (female) (1)

Repair or replace

relay with other relay of same type.

• Turn starting switch ON. • Set directional lever to R. From A

5 YES

Is voltage between C8 (female) (7) and chassis ground normal?

• Turn starting

NO

switch ON.

• Disconnect C8 and L76.

• Max. 1 V

TH-7 Related electrical circuit diagram

20-962 (1)

WD600-3

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 .................. 30-10 STARTING MOTOR Removal and Installation ........................... 30-14 ALTERNATOR Removal and Installation ........................... 30-15 RADIATOR Removal ...................................................... 30-16 Installation .................................................. 30-18 ENGINE AND TORQUE CONVERTER ASSEMBLY Removal ...................................................... 30-19 Installation .................................................. 30-22 TORQUE CONVERTER Removal ...................................................... 30-23 Installation .................................................. 30-24 Disassembly ............................................... 30-25 Assembly .................................................... 30-31 TRANSMISSION Removal ...................................................... 30-38 Installation .................................................. 30-40 Disassembly ............................................... 30-41 Assembly .................................................... 30-56 TRANSMISSION VALVE Removal and Installation ........................... 30-72 TRANSFER Disassembly ............................................... 30-73 Assembly .................................................... 30-82 CENTER SUPPORT Removal and Installation ........................... 30-92 Disassembly ............................................... 30-94 Assembly .................................................... 30-96 DRIVE SHAFT Disassembly ............................................... 30-99 Assembly .................................................. 30-102 FRONT AXLE Removal .................................................... 30-105 Installation ................................................ 30-106 WD600-3

FRONT DIFFERENTIAL Removal .................................................... 30-107 Installation ................................................ 30-108 REAR AXLE Removal .................................................... 30-109 Installation ................................................ 30-112 REAR DIFFERENTIAL Removal .................................................... 30-113 Installation ................................................ 30-114 DIFFERENTIAL GEAR Disassembly ............................................. 30-115 Assembly .................................................. 30-119 FINAL DRIVE Disassembly ............................................. 30-127 Assembly .................................................. 30-129 ORBIT-ROLL Removal and Installation ......................... 30-132 STEERING CYLINDER Removal .................................................... 30-133 Installation ................................................ 30-134 STEERING VALVE Removal .................................................... 30-135 Installation ................................................ 30-136 BRAKE VALVE Removal and Installation ......................... 30-137 BRAKE VALVE (R.H.) Disassembly ............................................. 30-138 Assembly .................................................. 30-140 BRAKE VALVE (L.H.) Disassembly ............................................. 30-142 Assembly .................................................. 30-144 SLACK ADJUSTER Removal and Installation ......................... 30-146 Disassembly ............................................. 30-147 Assembly .................................................. 30-148 BRAKE Removal and Installation ......................... 30-149 Disassembly ............................................. 30-150 Assembly .................................................. 30-153

30-1 (2)

HYDRAULIC PUMP Removal .................................................... 30-157 Installation ................................................ 30-158 HYDRAULIC TANK Removal .................................................... 30-159 Installation ................................................ 30-160 HYDRAULIC FILTER Removal and Installation ......................... 30-161 PPC VALVE Removal and Installation ......................... 30-162 Disassembly and Assembly .................... 30-163 DECO VALVE Removal and Installation ......................... 30-164 WORK EQUIPMENT VALVE Removal .................................................... 30-165 Installation ................................................ 30-166 PITCH & TILT CYLINDER Removal and Installation ......................... 30-167 LIFT CYLINDER Removal .................................................... 30-168 Installation ................................................ 30-169 CENTER HINGE PIN Removal .................................................... 30-170 Installation ................................................ 30-175 WORK EQUIPMENT Removal .................................................... 30-178 Installation ................................................ 30-181 BULKHEAD Removal .................................................... 30-182 Installation ................................................ 30-183 FLOOR FRAME Removal .................................................... 30-184 Installation ................................................ 30-186 COUNTERWEIGHT Removal and Installation ......................... 30-187 FUEL TANK Removal .................................................... 30-188 Installation ................................................ 30-189 CAB Removal .................................................... 30-190 Installation ................................................ 30-192 STOP VALVE Removal and Installation ......................... 30-193 ACCUMULATOR Removal and Installation ........................ 30-194 ACCUMULATOR CHARGE VALVE Removal and Installation ......................... 30-195 PARKING BRAKE SOLENOID VALVE Removal and Installation ......................... 30-196 DIVERTER VALVE Removal and Installation ......................... 30-197 EMERGENCY STEERING PUMP Removal and Installation ......................... 30-198

30-2 (2)

PARKING BRAKE Removal and Installation ......................... 30-199 PARKING BRAKE CALIPERS Disassembly ............................................. 30-200 Assembly .................................................. 30-201 PARKING BRAKE PAD Removal and Installation ......................... 30-202 REAR TIRES Removal and Installation ......................... 30-203 AIR CONDITIONER COMPRESSOR Removal and Installation ......................... 30-204 AIR CONDITIONER CONDENSER Removal and Installation ......................... 30-205 RECEIVER TANK Removal and Installation ......................... 30-206 AIR CONDITIONER UNIT Removal .................................................... 30-207 Installation ................................................ 30-208 MONITOR Removal and Installation ......................... 30-209

WD600-3

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies 1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. 2) Any special techniques applying only to the installation procedure are marked 1, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF cccc ASSEMBLY ............... Title of operation

¤ ...................................................................... Precautions related to safety when carrying out the operation 1. X X X X (1) ..................................................... Step in operation fl .................................................................. Technique or important point to remember when removing XXXX (1). 2. t t t t (2): ............................................... 1 Indicates that a technique is listed for use during installation 3. assembly (3) 6 .................................................................... Quantity of oil or water drained

INSTALLATION OF cccc ASSEMBLY .... . Title of operation • Carry out installation in the reverse order to removal. 1 ............................................................. Technique used during installation fl .................................................................. Technique or important point to remember when installing t t t t (2). • Adding water, oil ................................. Step in operation fl ............................................................ Point to remember when adding water or oil

-.........................................................Quantity when filling with oil and water 2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools 1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

WD600-3

30-3 (2)

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. fl Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number

Plug (nut end)

02 03 04 05 06 10 12

07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234

Sleeve nut (elbow end) Use the two items below as a set 07221-20210 07221-20315 07221-20422 07221-20522 07221-20628 07221-21034 07221-21234

(Nut), (Nut), (Nut), (Nut), (Nut), (Nut), (Nut),

07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219

(Plug) (Plug) (Plug) (Plug) (Plug) (Plug) (Plug)

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

04 05

07379-00400 07379-00500

07378-10400 07378-10500

07371-30400 07371-30500

Part Number

06 08 10 12 14 16 18 20 22 24 27

07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734

30-4 (2)

Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34

Taper 1/8

ød

Nominal number

øD

3) If the part is not under hydraulic pressure, the following corks can be used.

L DEW00401

WD600-3

DISASSEMBLY AND ASSEMBLY

2. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the steering, bucket, and boom cylinders to the end of their stroke 3 - 4 times, stop the engine, loosen air bleed plug (1), bleed the air from the hydraulic tank, then tighten plug (1) again. 4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this operation until no more air comes out from the plug. 5. After doing this, run the engine at normal speed. fl When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. fl For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

WD600-3

30-5 (2)

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST fl Tools with part number 79cT-ccc-cccc can not be supplied (they are items to be locally manufactured). fl Necessity: : .......... Cannot be substituted, should always be installed (used) b : .......... Extremely useful if available, can be substituted with commercially available part. New/remodel: N : .......... Tools with new part numbers, newly developed for this model. R : .......... Tools with upgraded part numbers, remodeled from items already available for other models. Blank: .... Tools already available for other models, used without any modification fl Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component

Symbol

Part No.

Part Name

792-400-1110

Bracket

1

2

795-902-1430

Push tool

1

795-902-1410

Sleeve

1

01050-32240

Bolt

3

01050-32235

Bolt

3

795-902-1420

Sleeve

1

795-902-1440

Push tool

1

01582-02016

Nut

2

795-902-1450

Bolt

2

01050-32050

Bolt

4

6

790-331-1110

Wrench

1

Tightening of cylinder head

7

790-471-1001

Lifting tool

1

Removal, installation of cylinder head

8

795-601-1110

Push tool

1

Removal of water pipe

795-799-5410

Adapter

1 N

795-799-5420

Remover

1 N

Disassembly, assembly of engine

798-621-1140

Push tool

1 N

Bolt

3

01582-02218

Nut

3

795-621-1130

Push tool

1 N

01050-32280

Bolt

5

12 Commercially

Feeler gauge

1

Assembly of engine

1

793-613-1110

Wrench

1

2

792-201-0200

Wrench

1

Removal, installation of pump

4

5

A

9

10 795-902-1460

11

available

Disassembly, assembly of torque converter

Engine slinging jig

1

3

Disassembly, assembly of engine

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

A

Installation of front seal

Installation of rear seal

Assembly of engine

Assembly of engine

Disassembly, assembly of transmission

A

799-301-1500

Leak tester

1

Check of operation of clutch piston

Disassembly, assembly of transfer

A

799-301-1500

Leak tester

1

Check of operation of clutch piston

30-6 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

Component Disassembly, assembly of transfer

Symbol

SPECIAL TOOL LIST

Part No.

D 33 790-438-1120

1

Part Name Centering tool

1

790-201-2850

Spacer

1

790-201-2750

Spacer

1

790-101-5401

Push tool kit

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

4

793T-623-1140 Push tool Disassembly, assembly H of differential

Spacer

1 N

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

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

10 793T-622-1180 Push tool

1 N

Micrometer

1

11 792-525-1220

Adapter

1

792-533-1400

Wrench

1

792-525-1000

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

Centering of transmission center support

1 N

73T-623-1150 5

790-101-5401

WD600-3

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

Press fitting of main bearing outer race

Press fitting of sub bearing outer race

Press fitting of differential case bearing

Adjusting preload of bearing

30-7 (2)

DISASSEMBLY AND ASSEMBLY

Component

Symbol 1

Disassembly, assembly of rear brake

2

SPECIAL TOOL LIST

Part No.

Part Name

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

K

2

30-8 (2)

New/ SkeNeceressity Q’ty model tch Nature of work, remarks

• 02215-11622

• Nut

2

793-520-2640

Push tool

1

790-438-1030

Guide

1

790-438-1050

Bar

2

790-101-2102

Puller (30ton)

1

790-101-1102

Pump

1

790-101-2300

Push puller

1

• 790-101-2310 • Block

1

• 790-101-2330 • Nut

1

• 790-101-2340 • Washer

1

• 790-101-2350 • Leg

2

• 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

790-438-1020

Guide

1

790-438-1040

Screw

1

790-101-2102

Puller

1

790-101-1102

Pump

1

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

WD600-3

DISASSEMBLY AND ASSEMBLY

Component

Symbol

SPECIAL TOOL LIST

Part No. 799-703-1200

Charging air conditioner X with gas

WD600-3

1

Part Name Service tool kit

790-703-1120

Vacuum pump (220V) Vacuum pump (240V)

799-703-1400

Gas leak detector

799-703-1110

New/ SkeNeceressity Q’ty model tch Nature of work, remarks 1 1 1

Charging air conditioner with gas

1

30-9 (2)

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS H2 Plate

H5 Push tool

30-10 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

H5 Spacer

H6 Push tool

WD600-3

30-11 (2)

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

H7 Push tool

H10 Push tool

30-12 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

J1 Fixture

J2 Plate

WD600-3

30-13 (2)

DISASSEMBLY AND ASSEMBLY

STARTING MOTOR

REMOVAL OF STARTING MOTOR ¤

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. Open engine left side cover (1). 2. Disconnect connectors (2) (E08) and (3) (E09). 3. Disconnect cable (4). 4. Disconnect cable (5) between upper and lower starting motors. 5. Remove the mounting bolts, then remove starting motor (6). 0

Starting motor: 18kg × 2pcs

fl The mounting bolts of the upper and lower starting motors are also used to install the ground cable.

INSTALLATION OF STARTING MOTOR •

Carry out installation in the reverse order to removal.

30-14 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

ALTERNATOR

REMOVAL OF ALTERNATOR ¤

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. Open engine right side cover. 2. Disconnect alternator terminals (1) (E15) and (2) (E16) and (3)(E17). 3. Loosen locknuts (4). 4. Loosen adjustment rod (7) and mounting bolt (5). 5. Remove lock bolt (6) and move adjustment rod (7) outside. 6. Loosen alternator mounting bolt (8), then remove belt (9). 1 7. Remove mounting bolt (8), then remove alternator (10). 0

Alternator: 12kg

INSTALLATION OF ALTERNATOR •

Carry out installation in the reverse order to removal.

1 fl Adjust the deflection of the belt to the specified value. For details, see TESTING AND ADJUSTING ALTERNATOR BELT TENSION.

WD600-3

30-15 (2)

DISASSEMBLY AND ASSEMBLY

RADIATOR

REMOVAL OF RADIATOR ¤

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. Open right and left side covers (1), then remove engine hood (2). 0

Engine hood: 73kg

2. Loosen drain valve (3) and drain the engine cooling water. = Engine cooling water: Approx. 160 ¬

3. Lift off radiator grille (4). 0

Radiator grille: 29kg

4. Disconnect radiator water level sensor connector (5) (G01). 5. Remove baffle plate (6). 6. Remove radiator guard mounting bolts (7).

30-16 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

RADIATOR

7. Disconnect tail lamp connector (8) (GR1). 8. Remove baffle plates (9) and (10). 9. Remove radiator guard mounting bolts (11).

10. Remove right and left side pillar mounting bolts (12). 11. Remove the mounting bolts, then remove the radiator guard (13). 0 Radiator guard: 270kg 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 (14). 13. Disconnect 2 hoses (15) of the hydraulic oil cooler. fl Prepare plugs to stop the oil from flowing out.

14. Disconnect hose (16) between the radiator and water pump.

WD600-3

30-17 (2)

DISASSEMBLY AND ASSEMBLY

RADIATOR

15. Disconnect 2 hoses (17) of the fuel cooler.

16. Disconnect aeration hose (18). 17. Disconnect engine cooling water return hose (19). 18. Disconnect sub-tank hose (20). 19. Disconnect two hoses (21) to after-cooler. 20. Remove upper and lower fan guards (22). 21. Remove fan (23) and place it on the radiator side. 22. Disconnect right and left radiator supports (24) from the radiator, then let it fall down on the engine side. 23. Apply corrugated cardboard [1] to the radiator side, and lower fan (23) slowly and tense rope [2] so that the fan will not fall down outward. 0

Fan: 46kg

24. Remove mounting bolts (25), then sling and remove radiator (26). 0

Radiator: 630kg

INSTALLATION OF RADIATOR •

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 water level again.

30-18 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

ENGINE AND TORQUE CONVERTER ASSEMBLY

REMOVAL OF ENGINE AND TORQUE CONVERTER ASSEMBLY ¤

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 the radiator . For details, see REMOVAL OF RADIATOR. 2. Disconnect engine oil drain valve (1) from the fitting portion. 3. Disconnect connectors (2) (ER1, ER2, ER3). 4. Disconnect body grounding terminals (3) (E18, R10). 5. Disconnect wire (4) (E01) between the alternator and slow blow fuse on the slow blow fuse side.

6. Disconnect torque converter lockup wiring harness connector (5) (T08).

7. Disconnect heater hot water supply hose (6). 8. Disconnect heater hot water return hose (7). 9. Disconnect tube (8) between engine oil cooler and torque converter oil cooler. 10. Disconnect hose (9) between water pump and torque converter oil cooler.

WD600-3

30-19 (2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND TORQUE CONVERTER ASSEMBLY

11. Disconnect cable (10) connecting with battery relay from engine starting motor. 12. Disconnect grounding cable (11) from main frame. 13. Disconnect two air compressor hoses (12). fl Plug the hoses to prevent foreign objects from entering. fl Collect new fleon gas using tool X1.

14. Disconnect hose (13) between fuel tank and fuel filter. 15. Remove the bulkhead. For details, see REMOVAL OF BULKHEAD.

16. Disconnect steering pump suction tube (14). fl Plug the tube to prevent foreign objects from entering. 17. Disconnect discharge tube (15) between the steering valve and steering pump.

18. Disconnect switch pump suction tube (16). 19. Disconnect discharge tube (17) between the steering valve and switch pump. 20. Remove mounting bolts (18) and lift off steering and switch pump assembly (19). 0

30-20 (2)

Steering and switch pump assembly: 39kg

WD600-3

DISASSEMBLY AND ASSEMBLY

ENGINE AND TORQUE CONVERTER ASSEMBLY

21. Disconnect transmission pump suction tube (20). 22. Disconnect discharge tube (21) between the transmission and transmission pump.

23. Disconnect discharge hose (22) between the accumulator charge valve and PPC pump.

24. Disconnect PPC pump suction tube (23). 25. Remove mounting bolts (24) and transmission and PPC pump assembly (25). 26. Disconnect work equipment pump suction tube (26). 27. Disconnect discharge tube (27) between the work equipment valve and work equipment pump. 28. Remove mounting bolts (28) and work equipment pump assembly (29). 29. Disconnect torque converter oil temperature sensor connector (30) (E07). 30. Disconnect tube (31) between the torque converter and torque converter oil cooler. 31. Disconnect hose (32) between the torque converter and transmission. 32. Disconnect air hose (33) between the torque converter and transmission. 33. Disconnect drive shaft (34).

WD600-3

1

30-21 (2)

DISASSEMBLY AND ASSEMBLY

ENGINE AND TORQUE CONVERTER ASSEMBLY

34. Remove engine front mount (35) and rear mount (36). 2 35. Sling and remove engine and torque converter assembly (37) slowly. 0

Engine and torque converter assembly: 3,240kg fl When lifting off the engine and torque converter assembly, check that the all wires, hoses and connectors are disconnected.

INSTALLATION OF ENGINE AND TORQUE CONVERTER ASSEMBLY •

Carry out installation in the reverse order to removal.

1 9 Drive shaft mounting bolt: 98 – 123Nm {10.0 – 12.5kgm} 2 9 Mounting bolt: 824 – 1030Nm {84 – 105kgm} •

Refilling with water Add water to the specified level. Run the engine to circulate the water through the system. Then, check the water level again.

30-22 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

REMOVAL OF TORQUE CONVERTER ¤

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 the bulkhead. For details, see REMOVAL OF BULKHEAD. 2. Disconnect steering pump suction tube (1). fl Plug the tube to prevent foreign objects from entering. 3. Disconnect discharge tube (2) between the steering valve and steering pump. 4. Disconnect switch pump suction tube (3). 5. Disconnect discharge tube (4) between the steering valve and switch pump. 6. Remove mounting bolts (5) and steering and switch pump assembly (6). 0

Steering and switch pump assembly: 39kg

7. Disconnect transmission pump suction tube (7). 8. Disconnect discharge tube (8) between the transmission and transmission pump.

9. Disconnect discharge hose (9) between the accumulator charge valve and PPC pump.

WD600-3

30-23 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

10. Disconnect PPC pump suction tube (10). 11. Remove mounting bolts (11) and transmission and PPC pump assembly (12). 12. Disconnect work equipment pump suction tube (13). 13. Disconnect discharge tube (14) between work equipment valve and work equipment pump. 14. Remove mounting bolts (15) and work equipment pump (16). 15. Disconnect torque converter oil temperature sensor connector (17) (E07). 16. Disconnect hose (18) connected to the oil cooler. 17. Disconnect hose (19) connected to the transmission. 18. Disconnect connecting hose (20) between torque converter and transmission. 19. Disconnect drive shaft (21).

1

20. Disconnect torque converter lockup wiring harness connector (22) (T06). 21. Remove 16 mounting bolts (23), then sling and remove torque converter assembly (24). 2 0

Torque converter assembly: 340kg

INSTALLATION OF TORQUE CONVERTER •

Carry out installation in the reverse order to removal. 1 9 Drive shaft mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 2 9 Torque converter mounting bolt: 98 – 123Nm {10 – 12.5kgm}

30-24 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

DISASSEMBLY OF TORQUE CONVERTER

1 793-613-1110 2 792-201-0200

Wrench Wrench

1 1

Sketch

b b

New/Remodel

Part Name

Q'ty

A

Part No.

Necessity

Symbol

Special tools

1. Coupling 1) Set torque converter assembly (1) horizontally. 2) Remove coupling (2). 2. Lockup valve assembly Remove lockup valve assembly (3). 3. Relief valve assembly Remove relief valve assembly (4). 4. Lubrication tubes Remove lubrication tubes (5) and (6).

5. Pilot 1) Set torque converter assembly (1) with the pilot side up. 2) Remove the mounting bolts and pilot (7), using forcing screw [1].

6. Lock bolt of output shaft fl Note that the bolt has left-hand threads. 1) Remove seal ring (8). 2) Remove bolt (9) by “turning it to the right”. 3) Remove washer (10).

WD600-3

30-25 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

7. Housing 1) Remove 30 mounting bolts (12) of housing (11).

2) Using puller [2], pull housing (11) out of the boss of the turbine. fl Hold the boss of the turbine. fl A half of the inner race of the bearing comes out. 3) Using hanging bolt [3], remove housing (11).

4) Remove bearing (13) and lockup piston (14) from housing (11).

8. Lockup clutch disc Remove disc (15).

30-26 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

9. Lockup clutch case 1) Sling torque converter assembly and remove cover (16). 2) Remove drain plug (17) to drain the oil from the torque converter. 3) Remove 36 mounting bolts (19) from pump (18) and lower the torque converter assembly onto the block.

4) Using hanging bolt [4], remove case (20).

10. Turbine assembly Remove turbine assembly (21).

11. Stator assembly 1) Remove rings (59). 2) Pull up and remove stator assembly (22), turning it “clockwise”.

WD600-3

30-27 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

12. Output shaft 1) Turn over torque converter assembly (1). 2) Remove mounting bolts (23). 3) Using forcing screw [5], remove output shaft assembly (24).

4) Check the thickness and quantity of shims (25), then keep them. 5) Secure stator shaft (27) with several bolts (26). fl This step is for loosening the pump holding nuts from the pump side.

6) Remove cage (36) from the output shaft. 7) Remove snap ring (37), spacer (38), and bearing (39).

13. Pump assembly 1) Using tool A1, remove nut (28).

30-28 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

2) Remove spacer (29). 3) Remove pump assembly (30).

4) Remove bolt (31) and plate (32), and then remove gear (34) and outer race (44) from pump (33).

14. Stator shaft 1) Remove the bolts tightened temporarily. 2) Using hanging bolt [6], remove stator shaft assembly (35).

15. Pump drive gear assembly fl Since all of the 3 assemblies have the same structure, the procedure for disassembling only 1 assembly is described below. 1) Using tool A2, remove nut (58). fl When loosening the nut, prevent the pump drive gear from turning with a bar.

WD600-3

30-29 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

2) Using push tool [9], pull out pump drive gear (50) and remove bearing (51). fl Apply the push tool to the base of the gear shaft to secure the gear shaft, and then remove the pump drive gear by hitting it, taking care not to damage the threads.

3) Remove ring (52), and then remove bearing (53) from pump drive gear (50). 4) Remove bearing outer races (54) and (55), and then remove ring (56) from housing (57). fl Since bearings (51) and (53), bearing outer races (54) and (55), and rings (52) and (56) are an assembly, keep them together, checking their part Nos. and match marks.

30-30 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

ASSEMBLY OF TORQUE CONVERTER

•

1 793-613-1110 2 792-201-0200

Wrench Wrench

1 1

Sketch

b b

New/Remodel

Part Name

Q'ty

A

Part No.

Necessity

Symbol

Special tools

Precautions for assembly fl Clean the all parts and check them for dirt or damage before installing. fl Coat the sliding surfaces of the parts with engine oil before installing. fl Install the piston seal ring with the pressure receiving side directed to the housing.

1. Pump drive gear assembly fl Since all of the 3 assemblies have the same structure, the procedure for disassembling only 1 assembly is described below. fl The bearing of the pump drive gear is an assembly. When assembling its inner race, outer race, and seat, check their part Nos. and match marks. 1) Install ring (56) to housing (57). 2) Using push tool [11], press fit bearing outer races (54) and (55). 3) Using push tool [10], press fit bearing (53) to pump drive gear (50). 4) Install ring (52).

5) Set the pump drive gear. Then, using push tool [12], press fit bearing (51). fl Place the pump drive gear on the block and fix its end, and then press fit the bearing. fl When press fitting the bearing, do not damage the threads of the gear shaft.

WD600-3

30-31 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

6) Using tool A2, tighten nut (58). fl When tightening the nut, prevent the pump drive gear from turning with a bar. 3 Nut: 416.8 ± 24.5 Nm {42.5 ± 2.5 kgm} 7) Similarly to 1) - 6) above, assemble the other pump drive gear assemblies.

2. Stator shaft 1) Fit spacer (41) to stator shaft (40) and install bearing (42). 2) Install seal ring (43). 8 Seal ring: Grease (G2-LI)

3) Using hanging bolt [6], install stator shaft assembly (35) to the torque converter case.

3. Pump assembly 1) Set outer race (44) and gear (34) to pump (33). 2) Fit spacer (32) and tighten bolt (31). 8 Bolt (31): Adhesive (LT-2) 3 Bolt (31): 58.8 – 73.5 Nm {6 – 7.5 kgm}

30-32 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

3) Install pump assembly (30) to the stator shaft. fl Since the nut will be tightened, secure the pump assembly temporarily with several bolts. 4) Fit spacer (29).

5) Using tool A1, tighten nut (28). 8 Nut: Adhesive (LT-2) 3 Nut: 441.3 – 490.3 Nm {45 – 50 kgm}

3. Output shaft fl Use an inner race and an outer race having the same serial No. and match mark to assemble each bearing. 1) Install bearing (39) to the shaft. 2) Fit spacer (38) and install snap ring (37).

3) Install outer race (45) (a half) to cage (36). 4) Fit oil seal (46). 8 Press fitting part of oil seal: Gasket sealant (LG-5) 8 Lip of oil seal: Grease (G2-LI) 5) Install the output shaft to cage (36), and then install the other half outer race (45).

WD600-3

30-33 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

6) Using hanging bolt [7], install output shaft assembly (24).

7) Adjust the shims according to the following procedure. i) Install 4 bolts (26) equally spacing them without setting the shims. 3 Bolt: 8.8 – 10.8 Nm {0.9 – 1.1 kgm} ii) Measure clearance “a” between stator shaft (40) and cage (36) at 4 points equally spaced on the circumference and obtain the average clearance. fl Dispersion of measured clearances: Max. 0.05 mm iii) Prepare shims so that “the measured clearance” – “the thickness of the shims” will be 0 – 0.05 mm. fl A maximum clearance of 0.05 mm will be made. iv) Set the prepared shims and tighten mounting bolts (26). 8 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

4. Stator 1) Install stator (47) to outer race (46), and then install snap ring (48).

30-34 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

2) Install stator assembly (22), turning it “clockwise”. 3) Install rings (59).

5. Turbine assembly fl Use an inner race and an outer race having the same serial No. and match mark to assemble each bearing. 1) Install inner race (49) (a half) to the boss of the turbine assembly. 2) Install turbine assembly (21).

6. Lockup clutch case 1) Install guide bolt [8] to the bolt hole by the cut for the drain plug on case (20). 2) Using hanging bolt and matching the guide bolt to mounting hole “b” of pump (18), install case (20).

WD600-3

30-35 (2)

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

3) Tighten 36 mounting bolts (19) and 2 drain plugs (17) from pump (18) side. 8 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 49.0 – 58.8 Nm {5.0 – 6.0 kgm} 3 Drain plug: 14.7 – 19.6 Nm {1.5 – 2.0 kgm} 4) Install cover (16). 3 Mounting bolt: 58.8 – 73.5 Nm {6.0 – 7.51 kgm}

7. Lockup clutch disc Install disc (15).

8. Housing fl Use an inner race and an outer race having the same serial No. and match mark to assemble each bearing. 1) Fit the seal rings and install piston (14) to housing (11). fl Fit 2 sets of the seal rings back to back. 2) Install bearing (13) to the housing.

3) Using hanging bolt [3], install housing (11) and tighten mounting bolts (12) temporarily. 4) Install the bearing inner race (49) (the other half). 5) Tighten 30 mounting bolts (12). 8 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98.1 – 122.6 Nm {10 – 12.5 kgm}

30-36 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER

9. Lock bolt of output shaft fl Note that the bolt has “left-hand threads”. 1) Install washer (10). 2) Tighten bolt (9) by turning it to the left. 8 Lock bolt: Adhesive (LT-2) 3 Lock bolt: 176.4 – 215.6 Nm {10 – 22 kgm} 3) Install seal ring (8). 8 Seal ring: Grease (G2-LI)

10. Pilot Install pilot (7). 8 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

11. Lubrication tube 1) Set torque converter assembly (1) on its side. 2) Install lubrication tubes (6) and (5). 3 Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm} 12. Relief valve assembly Install relief valve assembly (4). 13. Lockup valve assembly Install lockup valve assembly (3). 3 Mounting bolt: 44.1 – 53.9 Nm {4.5 – 5.5 kgm} 14. Coupling Install coupling (2).

WD600-3

30-37 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

REMOVAL OF TRANSMISSION ¤

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. Drain the hydraulic oil and transmission oil. = Hydraulic oil: 215 ¬ = Transmission oil: 110 ¬ 2. Remove the floor frame. For details, see REMOVAL OF FLOOR FRAME. 3. Disconnect hoses (1) from the diverter valve. 4. Remove brackets (2) and (3). 5. Disconnect tubes (4). 6. Disconnect drain hose (5). 7. Remove mounting bolts (6), then remove emergency steering pump (7). 8. Remove filler tube (8). 9. Remove guard (9), then disconnect drive shaft (10). 0

Center drive shaft: 56kg

1

10. Disconnect speed sensor connector (11) (T05). 11. Disconnect hoses (12) and (13) of the diverter valve. 12. Disconnect tubes (14) and (15) between the diverter valve and hydraulic tank. 13. Disconnect transmission connector (16) (T01). 14. Remove bracket (17), then disconnect hose (18) between the switch pump and steering valve. 15. Disconnect hose (19) between the PPC pump and accumulator charge valve. 16. Disconnect hose (20) and remove clamp (21), then remove tube (22). 17. Disconnect tube (23) between the oil cooler and transmission.

30-38 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

18. Disconnect trunnion greasing hose (24). 19. Disconnect hose (25). 20. Loosen bands (26). 21. Remove clamp (27) from bracket (30).

22. Remove clamp (28), then disconnect tube (29) from the transmission valve. 23. Disconnect hose (31) between the torque converter and transmission. 24. Disconnect upper drive shaft (32). 0

Upper drive shaft: 27kg

25. Disconnect rear drive shaft (33). 0

2

3

Rear drive shaft: 57kg

26. Remove suction tube (34) connected to the transmission pump. fl Disconnect this tube from the intermediate clamp. 27. Disconnect drain tube (35). fl Remove bracket (30).

28. Remove transmission mounting bolts (36), then remove cap (37). 29. Remove mounting bolt (38), then remove bracket (39). 4 fl Sling the transmission temporarily.

WD600-3

30-39 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

30. Remove trunnion mounting bolts (40), then remove transmission (41). 5 0 Transmission: 1,465kg fl Adjusting the level of the transmission with lever blocks [1], sling slowly.

INSTALLATION OF TRANSMISSION •

Carry out installation in the reverse order to removal.

1 9 Center drive shaft: 157 – 196Nm {16 – 20kgm} 2 9 Upper drive shaft: 98 – 123Nm {10 – 12kgm} 3 9 Rear drive shaft: 157 – 196Nm {16 – 20kgm} 4 9 Cap and bracket mounting bolt: 245 – 309Nm {25.0 – 31.5kgm} 5 9 Trunnion mounting bolt: 157 – 196Nm {16 – 20kgm} fl Using tool D33, center the center support and transmission. •

Refilling with oil -

Hydraulic oil: 215 ¬

- Transmission oil: 110 ¬ Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

30-40 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

DISASSEMBLY OF TRANSMISSION Special tool Part No. A

799-301-1500

Part Name Leak tester

Q'ty 1

1. Control valve assembly 1) Remove tubes (1), (2) and (3).

2) Remove 11 mounting bolts. fl Different length of bolts are used. Check bolt length then remove. fl Do not remove bolts which do not indicate in diagram. 3) Using eyebolts [1] (thread dia. = 10mm, pitch = 1.5mm), lift off control valve assembly (4). 0

Control valve assembly: 70kg

2. Sleeve Using eyebolt [2] (16mm, P = 2.0), remove sleeves (6).

3. Oil supply pipe Remove 4 mounting bolts, then remove oil supply pipe (7).

WD600-3

30-41 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

4. Coupling cage 1) Using eyebolts, sling the transmission and transfer case, then put on blocks [3]. 0

Transmission and transfer case: 1,350kg fl Take care not to crush the lubrication tube on the underside of the case.

2) Remove mounting bolts (8), then remove plate (9). 3) Remove 8 mounting bolts, then pull coupling cage (10) out of the transmission case by using forcing screws. 0

Coupling cage: 30kg

4) Further disassemble the coupling cage according to the following procedure. i) Set the coupling cage to the press, then remove coupling (11) by using push tool [4] (Outside diameter: 90mm).

ii) Remove snap ring (12). iii) Set the coupling cage to the press, then remove bearing (13) by using push tool [5] (Outside diameter: 120mm).

30-42 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

iv) Remove oil seal (14).

5. Collar Remove collar (15) from the shaft.

6. Transmission case 1) Remove 16 mounting bolts. fl Plate (16) mounting bolt is 5mm longer than the others. Keep it separately.

2) Using eyebolts [6] (12mm, P = 1.75), sling transmission case (17) temporarily. 0 Transmission case: 115kg 3) Using a forcing screw, sling and remove transmission case (17).

WD600-3

30-43 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

7. Tie bolts fl Using tool A, check the operation of the piston before removing the tie bolts.

fl Referring to disassembly of transfer, leave two tie bolts to remove transmission from the transfer case. Remove 17 tie bolts (18). fl Make marks on the two shorter tie bolts among 17 tie bolts.

8. Housing and carrier assembly 1) Using eyebolts [7] (14mm, P = 2.0), sling and remove housing and carrier assembly (19). 0 Housing and carrier assembly: 55kg fl Take care not to screw the eyebolts untill they contact with housing.

2) Further disassemble the housing and carrier assembly, according to the following procedure. i) Remove snap ring (20). ii) Set the housing and carrier to the press, then remove carrier (22) from housing (21) by using push tool [8] (Outside diameter: 135mm).

30-44 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

iii) Remove snap ring (23). iv) Set the housing and carrier assembly to the press, then remove bearing (24) by using push tool [9] (Outside diameter: 155mm).

v) Remove collar (25). vi) Pull out the roll pin and remove pin (26), then remove thrust washers (27), planetary gear (28) and needle bearing (29).

9. Guide pin Remove guide pin (30). 10. Spring Remove spring (31).

WD600-3

30-45 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

11. Plate, disc and spring Remove plate (32), disc (33) and spring (34). 12. Ring gear Remove ring gear (35).

13. No. 1 piston and housing 1) Using eyebolts [7] (14mm, P = 2.0), sling and remove piston and housing (36). 0 Piston and housing: 30kg 2) Remove piston (38) from housing (37).

14. Spring Remove springs (39). 15. Disc, plate and spring Remove disc (40), plate (41) and spring.

16. No. 2 piston, housing and No. 3 piston 1) Remove snap ring (43). 2) Using eyebolts [7] (14mm, P = 2.0), sling and remove the No. 2 piston and housing together with No. 3 piston (44), ring gear and plate. 0

30-46 (2)

No. 2 piston, housing, No. 3 piston, ring gear and plate: 65kg

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

3) Disassemble the piston and housing according to the following procedure. i) Remove plate (46), ring gears (47) and (48). ii) Remove No. 2 piston (50) and No. 3 piston (51) from housing (49).

iii) Remove snap ring (52) of ring gear (47).

17. Spring Remove spring (53). 18. Disc, plate and spring Remove disc (54), plate (55) and spring (56).

19. Collar Remove collar (57). 20. Housing Using eyebolts [7] (14mm, P = 2.0), sling and remove housing (58). 0

WD600-3

Housing: 25kg

30-47 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

21. Shaft and carrier assembly 1) Using bolt (8) and collar (9), sling and remove shaft and carrier assembly (59). 0

Shaft and carrier assembly: 50kg

2) Disassemble the shaft and carrier assembly according to the following procedure. i) Set the assembly to the press, then remove shaft (61) from carrier (60).

ii) Remove sun gear (62) from the carrier. iii) Set the assembly to the press, then remove bearing (63) by using push tool [10] (Outside diameter: 80mm).

iv) Remove sun gear (64) from the carrier .

30-48 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

v) Set the assembly to the press, then remove sun gear (65) by using push tool [11] (Outside diameter: 100mm).

vi) Set the assembly to the press, then remove bearing (66) by using push tool [12] (Outside diameter: 85mm). vii) Pull the roll pin out of carrier (67) and remove pin (68), then remove thrust washers (69), planetary gear (70) and needle bearings (71).

22. Collar Remove collar (72).

WD600-3

30-49 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

23. Rotary clutch 1) Remove snap ring (73). 2) Using eyebolts [6] (12mm, P = 1.75), sling and remove rotary clutch (74). 0

Rotary clutch: 75kg

3) Further disassemble the rotary clutch according to the following procedure. i) Remove 22 mounting bolts (75). ii) Using forcing screws, remove case (76).

iii) Remove hub (77). iv) Using puller [13] and push tool [14] (Outside diameter: 115mm), remove bearing (78).

v) Remove disc (79), spring (80) and plate (81).

30-50 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

¤

TRANSMISSION

Be extremely careful since the tension of 217kg is applied to the snap ring.

vi) Set the rotary clutch to the press and hold the belleville spring with push tool [15] (Inside diameter: 180mm), then remove the snap ring. vii) Loosen the press gradually, then remove snap ring (82) and belleville spring (83).

viii)Remove piston (84). ix) Set it to the press, then remove bearing (85) by using push tool [14] (Outside diameter: 105mm).

24. Housing and carrier assembly 1) Using eyebolts [7] (14mm, P = 2.0), sling and remove housing and carrier assembly (86). 0

Hosing and carrier assembly: 55kg

2) Further disassemble the housing carrier assembly according to the following procedure. i) Remove snap ring (87). ii) Set the assembly to the press, then remove carrier assembly by using push tool [17] (Outside diameter: 120mm)

WD600-3

30-51 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

iii) Pull out the roll pin and remove pin (89), then remove thrust washer (90), planetary gear (91) and needle bearing (92).

iv) Remove 3 mounting bolts, then remove collar (93) with forcing screws.

v) Remove snap ring (94). vi) Set the assembly to the press, then remove bearing (95) by using push tool [8] (Outside diameter: 165mm).

25. Guide pin Remove guide pin (96). 26. Spring Remove spring (97). 27. Disc, plate and spring Remove disc (98), plate (99) and spring (100).

30-52 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

28. Sun gear Remove snap ring (101), then remove sun gear (102).

29. Shaft and carrier 1) Inserting a pin (95mm or longer) in the hole (Diameter: 8mm) of the shaft, remove shaft and carrier assembly (103). 0

Shaft and carrier assembly: 50kg

2) Further disassemble the shaft and carrier assembly according to the following procedure. i) Remove 3 mounting bolts, then remove plate (104). ii) Remove snap ring (105), then remove ring gear (106).

iii) Remove snap ring (107). iv) Set the assembly to the press, then remove carrier (108) by using push tool [18] (Inside diameter: 210mm).

WD600-3

30-53 (2)

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 [12] (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).

30-54 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

30. No. 5 piston and housing 1) Using eyebolt [7] (14mm, P = 2.0), sling and remove No. 5 piston and housing assembly (118). 0

No. 5 piston and housing assembly: 40kg 2) Remove piston (120) from housing (119).

31. Spring Remove spring (121). 32. Disc, plate and spring Remove disc (122), plate (123) and spring (124).

33. Ring gear Remove ring gear (125).

34. No. 6 piston and housing 1) Using eyebolt [7] (14mm, P = 2.0), sling and remove No. 6 piston and housing (126). 0 No. 6 piston and housing: 40kg 2) Remove piston (128) from housing (127).

WD600-3

30-55 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

ASSEMBLY OF TRANSMISSION fl Precautions for assembly • Before installing the parts, apply engine oil (EO10-CD) to their rotary portions and sliding portions. • Apply grease (G2-LI) to each seal ring, and fit it evenly. • When installing each bearing, apply adhesive (ThreeBond 1373B) to its inside and outside surfaces to be fixed. • When install a disc, match its notch to the mating part. • Check that each snap ring is fitted.

Preparation work Clean each part and remove all burrs. 1. No. 6 piston and housing 1) Fit the seal ring, then install piston (128) to housing (127). fl Set the seal ring groove on the housing side as shown in the figure. 2) Fit the O-ring to the transfer case, then sling No. 6 piston and housing (126) using eyebolts [7] (14mm, P = 2.0). Then, install the assembly with matching the dowel pin.

2. Guide pin Install guide pin (96). fl Length of guide pin: 150mm 3. Ring gear Install ring gear (125).

30-56 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

4. Disc, plate and spring 1) Install disc (122), plate (123) and spring (124). fl Note that spring (124) is different from the other springs. Free length: 8mm 5. Spring Install spring (121).

6. No. 5 piston and housing assembly 1) Install the seal ring, then install piston (120) to housing (119). fl For installation of the seal ring, see 1-1). 2) Using eyebolts [7] (14mm, P = 2.0), sling and install No. 5 piston and housing assembly (118) with matching the dowel pin. fl When installing the assembly, check that spring (121) will not fall through the clearance between the housing and transfer case. 3) Using bolt [19] (14mm, P = 2.0, ¬ = 200mm) and nut, insert the dowel pin of the housing.

7. Shaft and carrier assembly 1) Assemble the shaft and carrier assembly according to the following procedure. i) Install the seal ring and set needle bearing (117), planetary gear (116) and thrust washer (115), then insert pin (114) and install the roll pin.

WD600-3

30-57 (2)

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 [8] (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 [12] (Inside diameter: 105mm).

vii) Install carrier (108) to the shaft with push tool [8]. viii)Install snap ring (107).

30-58 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

ix) Install ring gear (106), then install snap ring (105). x) Install sun gear (102), then install snap ring (101).

xi) Install plate (104).

2) Inserting a pin in the hole of the shaft, sling and install shaft and carrier assembly (103). fl Fit the tooth surfaces of the planetary gear and ring gear to each other.

8. Disc, plate and spring Install disc (98), plate (99) and spring (100), then remove bolt [19].

WD600-3

30-59 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

9. Spring Install spring (97).

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 [26] (Outside diameter: 175mm). ii) Install snap ring (94).

iii) Install collar (93), the tighten the three mounting bolts. 8 Mounting bolt: 13.7 ± 1.0Nm {1.4 ± 0.1kgm} 3 V-groove on periphery of collar: Gasket sealant (LG-I) iv) Set needle bearing (92), planetary gear (91) and thrust washer (90) and install pin (89), then install the roll pin.

30-60 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

v) Set the assembly to the press, then install carrier assembly (88) with push tool [8] (Inside diameter: 135mm). vi) Install snap ring (87).

2) Using eyebolts [7] (14mm, P = 2.0), sling and install housing carrier assembly (86).

11. Rotary clutch 1) Assemble the rotary clutch according to the following procedure. i) Install the seal ring and set the rotary clutch to the press, then press fit bearing (85) by using push tool [14] (Outside diameter: 125mm). ii) Install the seal ring, then install piston (84).

iii) Set belleville spring (83), snap ring (82) and spacer retainer. iv) Set it to the press and hold the belleville spring by using push tool [15] (Inside diameter: 180mm), then press fit snap ring (82).

WD600-3

30-61 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

v) Set it to the press, then press fit bearing (78) to hub (77) by using push tool [14] (Inside diameter: 125mm). vi) Set hub (77) to the rotary drum.

vii) Disc, plate and spring Install disc (79), plate (81) and spring (80).

viii)Install case (76), then tighten mounting bolt (75). 9 Mounting bolt: 112.8 ± 9.8Nm {11.5 ± 1.0kgm}

2) Using eyebolts [6] (12mm, P = 1.75), sling and install rotary clutch (74). fl Push in the rotary clutch until the snap ring groove of the shaft appears. 3) Install snap ring (73).

30-62 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

12. Collar Install the seal ring, then install collar (72).

13. Housing Using eyebolt [7] (14mm, P = 2.0), sling and install housing (58).

14. Collar Install collar (57). 15. Guide pin Install guide pin (30). fl Length of pin: 255mm

16. Disc, plate and spring Install disc (54), plate (55) and spring (56). 17. Spring Install spring (53).

WD600-3

30-63 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

18. No. 2 piston, housing and No. 3 piston 1) Install the seal ring, then install No. 2 piston (50) and No. 3 piston (51) to housing (49). fl For installation of the seal ring, see 1-1). 2) Using eyebolt [7] (14mm, P = 2.0), sling and install the No. 2 piston, housing and No. 3 piston (44). fl Take care not to drop the No. 3 piston.

19. Shaft and carrier assembly 1) Assemble shaft and carrier assembly (67) according to the following procedure. i) Set needle bearing (71), planetary gear (70) and thrust washer (69), and install pin (68), then install the roll pin.

ii) Set the assembly to the press, then press fit bearing (66) by using push tool [20] (Inside diameter: 95mm). iii) Set the assembly to the press, then press sun gear (65) by using push tool [16] (Outside diameter: 120mm).

iv) Install sun gear (64).

30-64 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

v) Set the assembly to the press, then press fit bearing (63) by using push tool [13] (Outside diameter: 105mm). vi) Install sun gear (62).

vii) Install the seal ring to shaft (61). viii)Set the assembly to the press, then press fit shaft (61) to carrier assembly (60) by using push tool [21] (Inside diameter: 75mm).

2) Using bolt (8) and collar (9), sling and install shaft and carrier assembly (59). 3) Hit the shaft to press fit the bearing part.

20. Ring gear Install ring gear (48).

WD600-3

30-65 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

21. Ring gear Install snap ring (52), then install ring gear (47).

22. Plate Matching the roll pin, install plate (46), then install snap ring (43). fl Check that the snap ring installed to the ring gear is securely set between the plate and carrier.

23. Disc, plate and spring Install disc (40), plate (41) and spring (42). 24. Spring Install spring (39).

25. No. 1 piston and housing 1) Install the seal ring, then install piston (38) to housing (37). fl For installation of the seal ring, see 1-1). 2) Using eyebolt [7] (14mm, P = 2.0), sling and install the No. 1 piston and housing (36).

30-66 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

26. Ring gear Install ring gear (35).

27. Disc, plate and spring Install disc (32), plate (33) and spring (34). 28. Spring Install spring (31).

29. Housing and carrier assembly 1) Assemble shaft and carrier assembly according to the following procedure. i) Set needle bearing (29), planetary gear (28) and thrust washer (27), and install pin (26), then install the roll pin.

ii) Install the seal ring, then install collar (25), matching the dowel pin.

WD600-3

30-67 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

iii) Install the seal ring to the housing and set them to the press, then install bearing (24) by using push tool [22] (Outside diameter: 185mm). iv) Install snap ring (23).

v) Set the assembly to the press, then install carrier assembly to housing (21) by using push tool [22] (Inside diameter: 145mm). vi) Install snap ring (20).

2) Using eyebolts [7] (14mm, P = 2.0), sling and install housing carrier assembly (19), matching the dowel pin.

30. Tie bolts Install 17 tie bolts (18). 9 Tie bolt: 166.7 ± 9.8Nm {17 ± 1kgm} fl When the transfer has been removed, install it to the transfer case, referring to the installation procedure of the transfer.

30-68 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

31. Check of operating condition of piston Using tool A, check the operation and stroke of the piston. fl Air pressure: 0.3 – 0.5MPa {3 – 5kg/cm2} fl Piston stroke mm Piston

Stroke

No.1

4.0

No.2

4.0

No.3

3.2

No.5

3.2

32. Transmission case 1) Install the O-ring to the transfer case, then sling transmission case (17) temporarily, using eyebolts [6] (12mm, P = 1.75). 2) Matching the dowel pin, install transmission case (17). fl When installing, confirm that the bolt for plate (16) is 5mm longer than the other bolts. fl Install the bolt 60mm long to the portion marked with ª.

33. Collar Install collar (15).

34. Coupling and cage assembly 1) Assemble the coupling and cage assembly according to the following procedure. i) Using push tool [23] (Outside diameter: 145mm), install oil seal (14). 8 Oil seal lip surface: Grease (G2-LI)

WD600-3

30-69 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

ii) Set the assembly to the press, then install bearing (13) by using push tool [24] (Outside diameter 165mm). iii) Install snap ring (12).

vi)

Set the assembly to the press, then install coupling (11) with push tool [25] (Outside diameter 90mm).

2) Using eyebolts (12mm, P = 1.75), sling and install coupling and cage assembly (10). 3) Install the O-ring, and install collar (9), then tighten mounting bolt (8). 9 Mounting bolt: 279.5 ± 29.4Nm {28.5 ± 3.0kgm}

35. Oil supply pipe 1) Using the eyebolts, sling the TORQFLOW transmission and transfer, then place it on blocks [3].

30-70 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSMISSION

2) Install oil supply pipe (7).

36. Sleeve Install the O-ring, then install sleeve (6).

37. Control valve assembly 1) Fit O-ring using eyebolts [1] (thread dia. = 10mm, pitch = 1.5mm), install control valve assembly (4). 2) Install 11 mounting bolts. 9 Mounting bolt: 49.0 ± 4.9Nm {5.0 ± 0.5kgm} fl Check bolt length, then install.

3) Install tubes (3), (2) and (1).

WD600-3

30-71 (2)

DISASSEMBLY AND ASSEMBLY

TRANSMISSION VALVE

REMOVAL OF TRANSMISSION VALVE ¤

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 the mounting bolts, then remove step (1) and cover as an assembly. 2. Disconnect transmission solenoid valve connector (2) (T01). 3. Remove lubrication tubes (3) and (4). 1 fl Before removing tube (3), remove the sleeve nut of tube (4). 4. Remove tube (5). 5. Remove the mounting bolts, then remove transmission valve (6). 2 0

Transmission valve: 65kg

INSTALLATION OF TRANSMISSION VALVE •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 19.6 – 24.5Nm {2.0 – 2.5kgm} 2 9 Transmission valve mounting bolt: 44.1 – 53.9Nm {4.5 – 5.5kgm}

30-72 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

DISASSEMBLY OF TRANSFER ASSEMBLY Special tool Part No. A

799-301-1500

Part Name Leak tester

Q'ty 1

1. Control valve assembly 1) Remove tubes (1), (2) and (3).

2) Remove 11 mounting bolts. fl Different length of bolts are used. Check bolt length then remove. fl Do not remove bolts which do not indicate in diagram. 3) Using eyebolts [1] (thread dia. = 10mm, pitch = 1.5mm), lift off control valve assembly (4). 0

Control valve assembly: 70kg

2. Sleeve Using eyebolt [2] (16mm, P = 2.0), remove sleeves (6).

3. Lubrication tube Remove the joint bolts, then remove lubrication tube (7). 4. Oil supply pipe Remove oil supply pipe (8). 5. Shaft mounting bolt Loosen shaft mounting bolt (9).

WD600-3

30-73 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

6. Strainer 1) Using the eyebolts, sling and set transmission and transfer case on block [3] with the transfer case down. 0

Transmission and transfer: 1,350kg

2) Remove cover (11). fl Since the cover may jump out because of the spring, hold it when removing the bolts. 3) Remove spring (12) and strainer (13), then remove flange (14).

7. Coupling and cage assembly 1) Remove mounting bolts (15), then remove plate (16). 2) Remove 8 mounting bolts, then sling and remove coupling and cage assembly (17), using forcing screws.

8. Collar Remove collar (18) from the shaft.

30-74 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

9. Transmission case 1) Remove 16 mounting bolts. fl The bolts for plate (19) are 5mm longer than the other ones. Store them separately.

2) Using eyebolts [4] (12mm, P = 1.75), sling transmission case (20) temporarily. 3) Using a forcing screws, sling and remove transmission case (20).

10. Tie bolt fl Using tool A, check the operation of the piston before disassembly.

Remove 15 tie bolts (21) other than the bolts marked with ª.

WD600-3

30-75 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

11. Transmission Using eyebolts [5] (14mm, P = 2.0), sling and remove transmission (22).

12. Cage 1) Remove 4 mounting bolts, then remove cage (23), using a forcing screws. 2) Remove outer race (24) from cage (25).

13. No. 1 gear 1) Remove gear (26). 2) Using a puller, remove 2 bearings (27) from gear (28).

14. Cage 1) Remove the mounting bolts, then remove the fitted part of the cage, using forcing screws. 2) Using eyebolts [1] (10mm, P = 1.5), sling and remove cage (29). fl Since the cage is thick, lift it straight up.

30-76 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

3) Remove outer race (30) from cage (31).

15. No. 3 gear 1) Remove No. 3 gear (32). 2) Using a puller, remove bearing (33) from the gear.

16. Coupling Remove coupling (34).

17. Cage 1) Remove cage (35). 2) Remove oil seal (36) from cage (37).

WD600-3

30-77 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

18. Shaft 1) Remove mounting bolt (9) and plate (38), then remove shaft (39).

2) Remove snap ring (40), then remove inner race (41) from shaft (42).

19. Bearing Remove bearing (43) from the transfer case.

20. Cage 1) Remove the mounting bolts, then remove cage (44) and shim (45), using forcing screws. fl Check the thickness and number of the shims, then store them. 2) Remove outer race (46) from cage (47).

30-78 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

21. Cage 1) Remove the mounting bolts, then remove cage (48), using forcing screws. fl Check the thickness and number of the shims (49), then store them. 2) Remove outer race (50) from cage (51).

22. Cage 1) Remove the mounting bolts, then remove cage (52) and shims (53), using forcing screws. fl Check the thickness and number of the shims, then store them. 2) Remove outer race (54) from cage (55).

23. No. 2 gear 1) Remove No. 2 gear (56). 2) Using a puller, remove bearing (57) from gear (58).

24. Outer race Remove outer race (59) from the transfer case.

WD600-3

30-79 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

25. Coupling and cage assembly 1) Remove the mounting bolts, then remove coupling and cage assembly (60), using forcing screws [6] (12mm, P = 1.75).

2) Further disassemble the coupling and cage assembly according to the following procedure. i) Remove mounting bolts (61), then remove coupling and bearing (62) and shims (63) from cage (64), by using push tool [7] (Outside diameter: 125mm). fl Check the thickness and number of the shims, then store them.

ii) Remove collar (65) and outer race (66) from cage (67).

iii) Using push tool [8] (Outside diameter: 105mm), remove coupling (68). iv) Remove bearing (69) and (70), then remove outer race (71). Remove oil seal (72) from cage (73).

30-80 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

26. No. 4 gear and collar 1) Take No. 4 gear (74) and collar (75) out of the transfer case.

WD600-3

30-81 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

ASSEMBLY OF TRANSFER Preparation work • Clean each part carefully and check that it is free from dirt, stain, etc. 1. Cage 1) Using push tool [9] (Outside diameter: 190mm), press fit outer race (46) to cage (47).

2) Install the O-ring, then install cage (44) and shim (45). fl Standard thickness of shim: 2mm

2. Cage 1) Using push tool [9] (Outside diameter: 190mm), press fit outer race (50) to cage (51).

2) Install the O-ring, then install cage (48) and shim (49). fl Standard thickness of shim: 2mm

30-82 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

3. No. 1 gear 1) Using push tool [10] (Outside diameter: 105mm), press fit 2 bearings (27) to gear (28). 2) Install gear (26). i) Turn over the transfer case.

4. Cage 1) Using push tool [11] (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 [12] 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).

WD600-3

30-83 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

6. No. 4 gear and collar Set No. 4 gear (74) and collar (75) in the transfer case.

7. No. 3 gear 1) Using push tool [13] (Outside diameter: 105mm), install bearing (33) to the gear. 2) Install No. 3 gear (32).

8. Cage 1) Using push tool [11] (Outside diameter: 190mm), press fit outer race (30) to cage (31).

2) Install the O-ring, then sling and install cage (29), using eyebolt [1] (10mm, P = 1.5).

30-84 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

9. Adjusting preload of No. 3 gear bearing 1) Turn over the transfer case, then remove inspection cover (76). 2) Set tool [14] and measure the preload with a torque wrench. fl Standard preload: 0.1 – 1.0Nm {0.01 – 0.10kgm} fl If the preload is out of the standard range, adjust it with shim (48). fl Move the No. 4 gear so that its teeth will not interfere with the bearing.

10. Outer race Using push tool [11] (Outside diameter: 190mm), press fit outer race (59) to the transfer case.

11. No. 2 gear 1) Using push tool [10] (Outside diameter: 105mm), install 2 bearings (57) to gear (58). 2) Install No. 2 gear (56).

12. Cage 1) Using push tool [9] (Outside diameter: 190mm), press fit outer race (54) to cage (55).

WD600-3

30-85 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

2) Install the O-ring, then install shim (53) and cage (52). fl Standard thickness of shim: 2mm

13. Adjusting preload of No. 2 gear bearing 1) Set tool [18] to the No. 3 gear and measure the preload with a torque wrench. fl Standard preload: 0.3 – 2.9Nm {0.03 – 0.310kgm} fl If the preload is out of the standard range, adjust it with shim (53). 2) Install inspection cover (76). fl Check that each gear does not have play.

14. Coupling and cage assembly 1) Assemble the coupling and cage assembly according to the following procedure. i) Using push tool [15] (Outside diameter: 155mm), install oil seal (72) to cage (73). 8 Oil seal fitting surface: Gasket sealant (ThreeBond 110B) 8 Oil seal lip surface: Grease (G2-LI) fl Thinly apply the gasket sealant to the oil seal fitting surface on the cage side. Wipe off projected sealant. ii) Using push tool [11] (Outside diameter: 185mm), press fit outer race (66) to cage (67). iii) Install bearing (69), collar (65) and bearing (70), then press fit outer race (71) to cage (67), using push tool [11] (Outside diameter: 185mm).

30-86 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

iv) Install the O-ring, then install cage (76) to cage (77) and measure clearance S by using a filler gauge. v) Install shim (63). Adjustment shim value = Clearance S + (0.05 to 0.10)

vi) Using push tool [19] (Outside diameter: 125mm), press fit coupling (68) to cage (78). 2) Install the O-ring, then install cage and coupling assembly (60) to the transfer case.

15. No. 4 gear and collar Reverse the transfer case, then position No. 4 gear and collar (75).

16. Bearing Using push tool [16] (Outside diameter: 145mm), press fit bearing (43) to the transfer case.

WD600-3

30-87 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

17. Shaft 1) Using push tool [17] (Inside diameter: 90mm), press fit inner race (41) to shaft (42), then install snap ring (40).

2) Matching the spline, install shaft (39), then install plate (38) and tighten mounting bolt (9). 9 Mounting bolt: 931.7 ± 98.1Nm {95 ± 10kgm}

18. Cage 1) Using push tool [15] (Outside diameter: 135mm), install oil seal (36) to cage (37). 8 Oil seal fitting surface: Gasket sealant (ThreeBond 110B) 8 Oil seal lip surface: Grease (G2-LI) fl Thinly apply the gasket sealant to the oil seal fitting surface on the cage side. Wipe off projected sealant. 2) Install cage to the transfer case.

19. Coupling Install coupling (34) with matching the spline of the shaft. fl Install the coupling to the same position as the coupling on the front output side.

30-88 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

20. Transmission 1) Install the O-ring to cage (25). 2) Install the seal ring, then sling and install transmission (22), using eyebolt [5] (14mm, P = 2.0) and matching the dowel pin. fl Install the seal ring evenly.

21. Tie bolts Install 15 tie bolts (21). 9 Tie bolt: 166.7 ± 9.8Nm {17 ± 1kgm}

22. Check of operating condition of piston Using tool A, check the operation and stroke of the piston. fl Air pressure: 0.3 – 0.5MPa {3 – 5kg/cm2} fl Piston stroke mm Piston

Stroke

No.1

4.0

No.2

4.0

No.3

3.2

No.4

3.2

23. Transmission case 1) Install the O-ring to the transfer case, then sling transmission case (20) temporarily, using eyebolts [4] (12mm, P = 1.75). 2) Matching the dowel pin, install transmission case (20). fl When installing, confirm that the bolt for plate (19) is 5mm longer than the other bolts. fl Install the bolt 60mm long to the portion marked with ª.

WD600-3

30-89 (2)

DISASSEMBLY AND ASSEMBLY

TRANSFER

24. Collar Install collar (18).

25. Coupling and cage assembly 1) Using the eyebolts (12mm, P = 1.75), sling and install coupling and cage assembly (17). 2) Install the O-ring, then install plate (16) and tighten the mounting bolts (15). 9 Mounting bolt: 279.5 ± 29.4Nm {28.5 ± 3.0kgm}

26. Strainer 1) Install flange (14), then install strainer (13) and spring (12). 2) Install cover (11).

27. Shaft mounting bolt 1) Using hooks, sling transmission and transfer assembly (10), and place it on block [3].

30-90 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

TRANSFER

2) Loosen shaft mounting bolts (9). 9 Mounting bolt: 931.7 ± 98.1Nm {95 ± 10kgm} 28. Oil supply pipe Install oil supply pipe (8). 29. Lubrication tube Install the gasket, then install lubrication tube (7) and tighten the joint bolts. 30. Sleeve Install the O-ring, then install sleeve (6).

31. Control valve assembly 1) Fit O-ring and using eyebolts [1] (thread dia. = 10mm, pitch = 1.5mm), raise control valve assembly (4) and install. 2) Tighten 11 mounting bolts. 9 Mounting bolt: 49.0 ± 4.9Nm {5.0 ± 0.5kgm} fl Check the length of the bolt before installing.

3) Install tubes (1), (2) and (3).

WD600-3

30-91 (2)

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

REMOVAL OF CENTER SUPPORT ¤

Stop the machine on level ground and fully steer to the left 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. Disconnect center drive shaft (1).

1

0 Center drive shaft: 56kg fl When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling. 2. Disconnect front drive shaft (2). 2 fl When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling. 3. Disconnect grease tube (3). 4. Sling the center support temporarily, then remove mounting bolts (4). 3 5. Sling and remove center support (5). 0 Center support: 47kg fl If there are shims between the center support and frame, check its quantity to refer when assembling.

INSTALLATION OF CENTER SUPPORT •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 157 – 196Nm {16 – 20kgm} 2 9 Mounting bolt: 157 – 196Nm {16 – 20kgm}

30-92 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

3 fl Install tool D33 and dial gauge [1] to the center support, then turn the coupling on the center support side to set the transmission coupling face and center support face in parallel with each other and center them. fl Adjust the shims on the center support mounting face. fl After adjusting the shims, tighten the mounting bolts. 9 Mounting bolt: 490.0 – 608.0Nm {50.0 – 62kgm} fl Parallelism: 0.1 max.

WD600-3

30-93 (2)

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

DISASSEMBLY OF CENTER SUPPORT 1. Coupling Remove center bolt (1), then remove retainer (2), O-ring (3), and coupling (4).

2. Retainer Remove mounting bolts (5). fl Remove all mounting bolts by rotating coupling.

3. Shaft 1) Set shaft case assembly (6) on press stand. 2) Push out shaft (7) with press. fl Be careful because the shaft will fall out suddenly.

3) Remove spacer (8), bearing cone (9) and retainer (5) from shaft.

30-94 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

4. Oil seal 1) Remove oil seal (10) and O-ring (11) from retainer.

2) Remove oil seal (12) from case. 5. Case Remove bearing cone (13) and bearing outer race (14) and (15).

WD600-3

30-95 (2)

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

ASSEMBLY OF CENTER SUPPORT 1. Bearing outer race Assemble bearing outer race (14) and (15) to case (16).

2. Oil seal Assemble oil seal (10) to retainer (5). 2 Outer circumference of oil seal : Grease (G2-LI)

3. Bearing cone Assemble retainer (5) shaft and press fit bearing cone (9). fl After assembling bearing, check that there is no clearance at tip of shaft. fl Assemble spacers. 2 Lip of seal : Grease (G2-LI) 2 Inner circumference of bearing : Grease (G2-LI)

4. Case 1) Assemble O-ring (11) in retainer. fl Insert O-ring completely in groove.

30-96 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

2) Stand shaft and insert case (16). fl Fill “a” and “b” of case completely with grease.

5. Retainer Secure retainer (5) to case. fl Be careful that O-ring does not get caught when installing. 9 Mounting bolt : 65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}

6. Bearing seal 1) Press fit bearing (13) to shaft. 2) Assemble oil seal (12) to case. fl Concave or protrusion of oil seal: even to end surface of case: ± 0.5mm 2 Seal : Grease (G2-LI)

7. Coupling Assemble coupling (4), install O-ring (3) and retainer (2), and secure center bolt (1). 3 Center bolt : 931 ± 98 Nm {95 ± 10 kgm}

WD600-3

30-97 (2)

DISASSEMBLY AND ASSEMBLY

CENTER SUPPORT

8. Inspection of end play Check that end play is within specified range. fl End play : Less than 0.22 mm fl If end play is “O”, with the seal and bearing coated with grease check that the free rotating torque is less than 3.9 Nm {0.4kgm}.

30-98 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

DISASSEMBLY OF DRIVE SHAFT 1. Shaft 1) Remove shaft (2) fl Make match makes a before removing to ensure that the position does not change.

fl Cover (1) and (1A) is caulked with punch at four places, so it must not be removed unless necessary. fl When removing cover (1) and (1A) be extremely careful not to damage cover (1), (1A) and yoke (3). fl When removing the caulking, raise the caulking with a screwdriver.

2) Remove mounting bolts (4), then remove spider assembly (5). fl Make match marks on yoke and spider.

WD600-3

30-99 (2)

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

3) Remove bearing caps (6) from spider assembly. fl Remove strap (7) of cap

4) When replacing bearing (8), seal (9), and plastic washer (10) from bearing cap (6), replace whole cap assembly.

2. Yoke 1) Remove mounting bolts (11) from yoke (3), then remove spider assembly (12). fl Stamp match marks on the yoke and spider.

2) Remove bearing caps (13) from spider assembly.

30-100 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

3) When replacing bearing (14), seal (15), and plastic washer (16) from bearing cap (13), replace whole cap assembly.

WD600-3

30-101 (2)

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. 2 Mounting bolts : 142.2 ± 9.8 Nm {14.5 ± 1.0 kgm}

2. Shaft 1) Assemble bearing (8) and seal (9) in bearing cap (6). 2 Bearing seal : Grease (G2-LI)

30-102 (2)

WD600-3

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. 9 Mounting bolt : 142.2 ± 9.8 Nm {14.5 ± 1kgm}

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)

WD600-3

30-103 (2)

DISASSEMBLY AND ASSEMBLY

DRIVE SHAFT

5) If cover (1) and (1A) has been removed, do as follows. • Front and rear drive shaft. Insert seal and retainer to cover (1) and shaft (2), assemble cover (1), then caulk with a punch on diagonally opposite sides. • Center drive shaft. Insert shaft (2) to cover (1A), assemble cover (1A), then caulk with a punch on diagonally opposite sides.

30-104 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

REMOVAL OF FRONT AXLE ¤

Stop the machine on level ground and install the safety bar on the frame.

1. Set block [1] to the front frame. fl Since the machine body moves forward, keep the parking brake turned off. fl Remove the work equipment. For details, see REMOVAL OF WORK EQUIPMENT.

2. Sling and remove tires (1). 0

1

Tires: 1,450kg

3. Put blocks [2] under the rear wheels.

4. Disconnect hose (2) for the parking brake. 5. Disconnect hose (3) for both front brakes.

6. Disconnect front drive shaft (4). 2 fl When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling. 0

WD600-3

Front drive shaft: 56kg

30-105 (2)

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

7. Sling the front axle temporarily, then remove mounting bolt (5). 3 8. Slowly sling and remove front axle (6). fl Remove the front axle by operating the crane so that it will not interfere with the boom end. 0

Front axle: 3,065kg

INSTALLATION OF FRONT AXLE •

Carry out installation in the reverse order to removal.

1 9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm} 2 9 Mounting bolt: 157.0 – 196.0Nm {16.0 – 20.0kgm} 3 9 Mounting bolt: 2450.0 – 3038.0Nm {250.0 – 310.0kgm} •

Bleeding air from brake Bleed air from front brake. For details, see BLEEDING AIR.

30-106 (2)

WD600-3

FRONT DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY

REMOVAL OF FRONT DIFFERENTIAL 1. Remove the front axle. For details see REMOVAL OF FRONT AXLE. 2. Remove drain plug (1) from right and left final drives, and drain oil. = Axle oil: 124 ¬ each 3. Remove mounting bolts (2), then remove cover (3). fl Remove the cover with the top mark up. 1 4. Install bolt [1] to the end of drive shaft (4), then pull out the shaft. 5. Sling and remove drive shaft (4). 0

Drive shaft: 50kg

6. Remove the mounting bolt, then remove shaft (5). 2 fl Check the number of the shims.

7. Remove parking brake disc cover (6).

8. Remove plate (7), then remove pad (8).

3

9. Remove calipers and spring cylinder (9). 10. Remove plate (10).

4

11. Remove mounting bolts, then remove disc plate (11). 5

WD600-3

30-107 (2)

FRONT DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY

12. Remove mounting bolts (12).

6

13. Sling front differential (13) temporarily, then disconnect it from the axle, using forcing screws [2]. 14. Sling and remove front differential (13). 0

Front differential: 510kg

INSTALLATION OF FRONT DIFFERENTIAL •

Carry out installation in the reverse order to removal.

1 9 Cover mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 2 fl Adjustment procedure of shims of shaft 1) Tighten the shaft evenly to the specified torque without inserting any shim, and measure clearance A. • Specified torque: 3.9 ± 1.0Nm {0.4 ± 0.1kgm} 2) Combine shims so that clearance between the shaft end and differential cap will become B. • Clearance B: 0.1 ± 0.05mm 3) Insert the shims and tighten the mounting bolt. 9 Mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 34 8 Plate mounting bolt: Adhesive (LT-2) 9 Plate mounting bolt: 824.0 – 1030.0Nm {84.0 – 105.0kgm} 5 8 Disc mounting bolt: Adhesive (LT-2) 9 Disc mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm} 6 9 Differential mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm}

30-108 (2)

WD600-3

REAR AXLE

DISASSEMBLY AND ASSEMBLY

REMOVAL OF REAR AXLE ¤

Stop the machine on level ground and install the safety bar on the frame and put blocks under the wheels.

1. Set blocks [1] on right and left sides of the rear axle. fl Set these block to prevent the tires from jumping up when removed. 2. Raise the machine body with jacks (5ton) [2], then set support stand [3] under the counter weight.

3. Adjusting jack [2], set blocks [4]. 4. Sling tire (1) temporarily, then remove the hub nuts. 5. Sling and remove tires (1). 0

1

Tires: 1,450kg

6. Disconnect rear drive shaft (2). 2 fl When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling. 0

Drive shaft: 57kg

7. Disconnect hose (3) from the brake valve. 8. Disconnect tubes (4) and (5) connected to right and left brakes from the slack adjuster. 3

WD600-3

30-109 (2)

DISASSEMBLY AND ASSEMBLY

REAR AXLE

9. Disconnect rear support grease tubes (6) and (7). 10. Disconnect front support grease tube (8). fl Disconnect the clamp on the frame side.

11. Secure the axle support and rear axle by tightening them with lever block [5] with a chain, etc.

12. Sling either one side temporarily and support the other side on a garage jack, then remove the support mounting bolts. 4 13. Balancing rear axle (9), lower it slowly. 0 Rear axle: 2,965kg fl Operate the crane and garage jack to pull out the rear axle from under the frame.

14. Sling and remove front support (10) from the rear axle. 0

30-110 (2)

Front support: 126kg

WD600-3

DISASSEMBLY AND ASSEMBLY

REAR AXLE

15. Remove the mounting bolt from front support (10), then remove retainer (11). 5 16. Remove packings (12) and (13) from the front support. 17. Remove 2 bushings (14) from the front support. fl Remove all dirt and oil from the bushings and front support bushing fitting face. 6

18. Remove thrust cover (16) and outer thrust washer (17) from rear support (15). 7 0

Thrust cover: 38kg

19. Remove thrust plate (18) from rear support (15), then remove inner thrust washer (17). 8

WD600-3

30-111 (2)

DISASSEMBLY AND ASSEMBLY

REAR AXLE

20. Remove rear support (15) from the rear axle. 0

Rear support: 153kg

21. Remove packing (19) from rear support (15). 22. Remove bushing (20) from the rear support. fl Remove all dirt and oil from the bushings and rear support bushing fitting face.

INSTALLATION OF REAR AXLE •

Carry out installation in the reverse order to removal.

1 9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm} 2 9 Mounting bolt: 157.0 – 196.0Nm {16.0 – 20.0kgm} 3 fl Bleed air from the slack adjuster. For details, see BLEEDING AIR FROM EACH PORTION. 4 9 Support mounting bolt: 2450.0 – 3038.0Nm {250.0 – 310.0kgm} 5 9 Mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 69 fl Apply Loctite Prism 411 to the sticking face on the support side, then stick the bushing quickly. fl The set time is 30 – 60 seconds. 78 9 Mounting bolt: 245.0 – 309.0Nm {25.0 – 31.5kgm}

30-112 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

REAR DIFFERENTIAL

REMOVAL OF REAR DIFFERENTIAL 1. Remove the rear axle . For details see REMOVAL OF REAR AXLE. 2. Remove drain plugs (1) from right and left final drives, and drain oil. = Axle oil: 124 ¬ each 3. Remove mounting bolt (2), then remove cover (3). fl Remove the cover with the top mark up. 1 4. Install bolt [1] to the end of drive shaft (4), then pull out the shaft. 5. Sling and remove drive shaft (4). 0

Drive shaft: 50kg

6. Remove the mounting bolt, then remove shaft (5). 2 fl Check the number of the shims.

7. Remove front support (6) from the rear axle. 0

Front support: 126kg

8. Remove the mounting bolts, then remove differential (7). 3 0

WD600-3

Rear differential : 508kg

30-113 (2)

DISASSEMBLY AND ASSEMBLY

REAR DIFFERENTIAL

INSTALLATION OF REAR DIFFERENTIAL •

Carry out installation in the reverse order to removal.

1 9 Cover mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 2 fl Adjustment procedure of shims of shaft 1) Tighten the shaft evenly to the specified torque without inserting any shim, and measure clearance A. • Specified torque: 3.9 ± 1.0Nm {0.4 ± 0.1kgm} 2) Combine shims so that clearance between the shaft end and differential cap will become B. • Clearance B: 0.1 ± 0.05mm 3) Insert the shims and tighten the mounting bolt. 9 Mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 3 9 Differential mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm}

30-114 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY 1. Set differential assembly (1) on special tools H3. 4 Differential assembly : 230kg fl Install bracket and plate in H3 to unit repair stand in H3, and set defferential assembly (1) to H3 assembly.

2. Pinion assembly 1) Remove case (2).

2) Remove oil seal (3) and dust seal (3A) from case.

3) Screw in forcing screws [1] (Thread dia. = 18 mm, Pitch = 1.75 mm), and fit out pinion assembly (4). fl Check number of shims (5).

WD600-3

30-115 (2)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

3. Differential gear case assembly 1) Remove left and right locks (6), and with a bar, turn nut (7) until it becomes loose.

2) Remove mounting bolts (9) of cap (8).

3) Remove nut and lift out differential gear case assembly(10).

30-116 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

FINE DISASSEMBLY OF PINION ASSEMBLY 4. Bearing, collar, cage 1) Support cage (11), push shaft with press and push out pinion.

2) Remove bearing (12) and collar from cage.

3) Remove outer races (13) and (14) from cage (11).

5. Pinion, bearing 1) Remove snap ring (15), then remove bearing (16). 2) Remove bearing (17).

WD600-3

30-117 (2)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY 6. Bevel gear (large) Remove mounting bolts, using eye-bolts [2] (Thread dia. = 16 mm, Pitch = 2.0 mm), lift off bevel gear (18).

7. Bevel gear (small) Remove thrust plate (19) and bevel gear (20). 8. Pinion gear, cross shaft Remove pinion gears (21), cross shaft (22), and washers (23) as assembly.

9. Bevel gear (small) Remove bevel gear (24) and thrust plate. 10. Bearing Remove bearing (26) from case (25).

30-118 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

ASSEMBLY OF DIFFERENTIAL GEAR FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE 1. Bearing Using press fit kit H10 (Inner diameter: 120 mm ), press fit bearing (26) to case (25).

2. Bevel gear (small) Install thrust and small bevel gear (24) to case. fl Align thrust with dowel pin and install.

3. Pinion gear, cross shaft Assemble pinion gears (21) and washers (23) with cross shaft (22). fl Align washer groove with dowel pin of case and install.

4. Bevel gear (small) Install bevel gear (20) and thrust plate (19).

WD600-3

30-119 (2)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

5. Bevel gear (large) Using eye-bolts [2] (thread dia. = 16 mm, Pitch = 2.0 mm), lift and install bevel gear (18). fl Align pin hole of thrust and dowel pin on case side and install.

FINE ASSEMBLY OF PINION ASSEMBLY 6. Bearing 1) Using press fit kit H6 (Inner diameter: 26 mm), install pinion bearing (17).

2) Using press fit kit H9 (Inner diameter: 55 mm), install bearing (16). 2 Rotating surface of bearing : Engine oil (EO30-CD) 3) Install snap ring (15).

7. Cage 1) Install outer race (14) by using H8 and install outer race (13) by using H9. 2) Install cage (11) to pinion assembly.

30-120 (2)

WD600-3

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). 3 Mounting bolt : 279.3 ± 29.4 Nm {28.5 ± 3.0 kgm} 2 Mounting bolt : Tread tightener (LT-2)

WD600-3

30-121 (2)

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 – 1030 Nm {84 – 105 kgm} fl Fit the balancer [6] to bolt hole of coupling, and measure the rotating torque. fl Rotating torque : Max. 50 N {5.1 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

30-122 (2)

Rotate bevel gear 20 – 30 times to settle in, then tighten bolts.

WD600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

fl Bearing pre-load adjustment steps are as follows. 1) Install tool H11 to cap on both sides.

2) Measure dimension “a” by using H11.

3) Add 0.47 ± 0.09 mm to dimension “a” and set scale on tool H11. fl The added dimension becomes the amount of bending of the case, given before pre-load and given after preload. 4) Tighten adjusting nut with bar until increased amount becomes 0.47 ± 0.09 mm.

fl Caution for pre-load adjustment When adjusting nut is overtightened, in case the amount of increased bending surpasses the standard measurement, return adjusting nut to position before adjusting. Then while rotating bevel gear, lightly tap bearing cap and bevel gear with plastic hammer, and check that there is no clearance in position b.

WD600-3

30-123 (2)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

13. Adjusting tooth contact, backlash Adjust the backlash, and at the same time adjust tooth contact. 1) Adjust backlash as follows: i) Movement of bevel gear is done with adjusting nuts (7). At this time, so as not to change pre-load pressurization of bearing, turn nuts on both sides, the same amount each, in same direction. ii) Put dial gauge [3] in vertical contact with forward and reverse sides of outer edge of bevel gear tooth face, and while turning adjusting nut, adjust until gauge meter fluctuation becomes 0.33 – 0.46 mm. fl Measure at 3 or 4 places, and keep the pinion gear fixed when measuring. 2) Adjust tooth contact as follows: i) Adjust bevel pinion by adjusting shims between differential case and bearing cage. ii) Adjusting tooth contact For details, see ADJUSTING TOOTH CONTACT.

30-124 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

3) Adjusting tooth contact Coat face 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth. Tooth contact

Cause

Procedure for adjustment

The tooth contact pattern should start from about 5 mm from the toe of the bevel gear and cover about 50% of the length of the tooth. It should be in the center of the tooth height.

Adjust the pinion gear by adjusting the shims at the cage. Adjust the bevel gear in the same way as when adjusting back lash.

Pinion gear is too far from bevel gear.

1. Reduce shims at pinion gear to bring closer to bevel gear. 2. Move bevel gear further away from pinion gear and adjust backlash correctly.

Pinion gear is too close to bevel gear.

1. Increase shims at pinion gear to move away from bevel gear. 2. Move bevel gear closer to pinion gear and adjust backlash correctly.

Bevel gear is too close to pinion gear.

1. Reduce shims at pinion gear to bring closer to bevel gear. 2. Move bevel gear further away from pinion gear and adjust backlash correctly.

Bevel gear is too far from pinion gear.

1. Increase shims at pinion gear to move away from bevel gear 2. Move bevel gear closer to pinion gear and adjust backlash correctly.

fl When adjusting the driven gear, do not change the pre-load of the bearing. Tnrn the left and right adjusting nut, the same amount each (check by the number of notches), in the same direction.

WD600-3

30-125 (2)

DISASSEMBLY AND ASSEMBLY

DIFFERENTIAL GEAR

14. Lock After adjusting tooth contact and backlash, install lock (6). 3 Mounting bolt: 98 ± 123 Nm {10.0 ± 12.5 kgm} 2 Mounting bolt : Thread tightener (LT-2)

30-126 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

DISASSEMBLY OF FINAL DRIVE ¤

Stop the machine on level ground and install the safety bar on the frame.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Set block [1] to the front frame. fl Remove the work equipment. For details, see REMOVAL OF WORK EQUIPMENT. 2. Sling and remove tires (1). 0

Tires: 1,450kg

3. Using tools J1, secure the brake housing and wheel hub. fl Install tools J1 to 3 places equally spaced. fl Do not remove tools J1 before adjusting the preload of the wheel bearing. 4. Remove drain plug (2), and drain oil. = Axle oil: 124 ¬ fl Turn the tire on the opposite side to set the drain plug to the bottom. 5. Remove bolts (3), and remove cover (4). 6. Install bolt [1] to drive shaft (5) so that the shaft will be pulled out easily. 7. Pull out drive shaft (5), then sling and remove it. 0

Drive shaft: 50kg

8. Remove 3 bolts, then sling and remove planetary carrier (7). fl Use eyebolt [2]. fl When removing the planetary carrier, keep it horizontal with a bar, etc. 0

WD600-3

Planetary carrier: 115kg

30-127 (2)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

9. Remove mounting bolts (8), then remove retainer (9). fl Check the number of the shims inside the retainer. 10. Sling and remove ring gear (10). 0

Ring gear: 80kg

11. Disassembly of planetary gear 1) Using a press, pull out shaft (11), then remove pinion gear (12). fl If the shaft is projected by about 25mm, the lock ball falls. Take care not to lose them. fl Write a No. on the case so that the removed parts will not be mixed with the other parts.

2) Remove 2 bearings (13) from pinion gear (12). fl Keep the fitted parts such as bearings as a set so that they will not be combined with the other parts.

12. Disassembly of ring gear 1) Remove lock plates (15) from ring gear hub (14), then remove ring gear (16). 2) Remove bearing (17) from ring gear hub (14).

30-128 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

ASSEMBLY OF FINAL DRIVE 1. Assembly of ring gear 1) Press fit bearing (17) to ring gear hub (14). fl After press fitting the bearing, check that there is not any gap between bearing and hub. 2) Fit ring gear hub (14) to ring gear (16), then install lock plate (15). fl Install the lock plate with the wider side in. fl Degrease the screw holes sufficiently. 8 Mounting bolt: Adhesive (LT-2) 9 Mounting bolt: 27.0 – 34.0Nm {2.8 – 3.5kgm}

2. Assembly of planetary carrier 1) Install bearings (13) to pinion gear (12), then set them to the carrier case. 2) Matching the hole of the pinion to that of the carrier case, press fit shaft (11). fl Press fit the shaft with the lock ball hole outward. Stop before the hole, then adjust the holes to each other.

3. Adjustment procedure of wheel bearing 1) Insert ring gear (10) in the axle housing, then secure retainer (9) with mounting bolts (8) without inserting any shim. 9 Mounting bolt: 57.9 – 67.7Nm {5.9 – 6.9kgm} fl Turn the hub by 5 – 6 turns and tighten the bolts alternately and evenly.

WD600-3

30-129 (2)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

2) Measure thickness b of retainer (9) in advance.

3) Measure distance a between the retainer and end of the axle housing with depth gauge [3] or slide calipers through the measuring hole of the retainer. fl Measure the distance at 2 places, then obtain the average. fl Thickness of shim: a – b + 0.3mm fl Select the shims so that its quantity will be the minimum. fl Install the selected shims and retainer (9), then tighten mounting bolts (8) alternately and evenly to the specified torque. 8 Mounting bolt: Adhesive (LT-2) 9 Mounting bolt: 245.0 – 309.0Nm {25.0 – 31.5kgm}

4. Remove tools J1. 5. Install the O-ring to the planetary carrier (7), then sling bolt [2] and install the planetary carrier in the ring gear. fl Keep the planetary carrier and ring gear in parallel with each other with a bar, etc., and insert the carrier, matching it to the stud bolt. 6. Tighten 3 mounting hexagon socket head bolt (6). 9 Mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm}

30-130 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

7. Install drive shaft (5). fl If it is difficult to insert the drive shaft, 1) Remove the snap ring and pull out the sun gear halfway, then insert a pipe having the diameter of the drive shaft in the empty hole. 2) Pushing down and revolving the inserted pipe in either direction, press in the drive shaft. fl If the sun gear is not engaged with the pinion gear, engage it by turning the tire on the opposite side.

8. Install the O-ring, then install final drive case cover (4) and tighten bolt (3). 9 Mounting bolt: 98.0 – 123.0Nm {10.0 – 12.5kgm} 9. Tighten drain plug (2). 9 Drain plug: 59.0 – 78Nm {6.0 – 8.0kgm}

10. Sling tire (1), and install it to the wheel hub. fl Turning the tire on the opposite side, match the stud bolts to the mounting holes of the wheel. 9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm}

11. Refilling with oil 1) Remove level plug (18) and oil filler plug (19). Add oil until it flows out of the level check hole, then tighten the plugs. 9 Plug: 127.0 – 176.0Nm {13.0 – 18.0kgm}

WD600-3

30-131 (2)

DISASSEMBLY AND ASSEMBLY

ORBIT-ROLL

REMOVAL OF ORBIT-ROLL ¤

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 boot (1).

1

2. Remove joint lock bolt (2). 3. Disconnect drain hose (3). 4. Disconnect hose (4) of the left-hand stop valve. 5. Disconnect hose (5) of the charge valve. 6. Disconnect hose (6) of the right-hand stop valve. 7. Remove mounting bolt (7), then remove orbit-roll (8). 8. Remove 4 lock bolts(9), then remove joint (10). 9. Remove mounting bolt (11), then remove bracket (12) from orbit-roll (8). 2

INSTALLATION OF ORBIT-ROLL •

Carry out installation in the reverse order to removal.

1 9 Joint lock bolt: 55.9 ± 7.8Nm {5.7 ± 0.8kgm} 2

•

9 Bracket mounting bolt: 51.9 ± 7.8Nm {5.3 ± 0.8kgm} After installing the orbit-roll, check the operation of the steering system.

30-132 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

REMOVAL OF STEERING CYLINDER ¤

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. Set safety bar (1).

2. Disconnect grease tube (2).

3. Disconnect bottom hose (3). 4. Remove mounting bolt (4), then pull out pin (5). 5. Disconnect head hose (6). 6. Remove mounting bolt (7), then pull out pin (8). 7. Sling and remove steering cylinder (9). 0 Steering cylinder: 84kg 1 fl Check the number of shims installed on both head and bottom sides.

WD600-3

30-133 (2)

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

INSTALLATION OF STEERING CYLINDER •

Carry out installation in the reverse order to removal.

¤

When aligning the position of the pin hole, use a bar. Never put your fingers in the pin hole.

1 fl Adjust the shims so that the clearance on the bottom side will be the specified value. Specified values: a + b = 0.5mm max.

fl Adjust the shims so that the clearance on the head side will be the specified value. Specified value: c + d = 0.5mm max. •

Bleeding air Bleed air from the steering cylinder. For details, see BLEEDING AIR.

30-134 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

STEERING VALVE

REMOVAL OF STEERING VALVE ¤

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 the mounting bolt, then remove cover (1).

2. Remove inspection cover (2).

3. Disconnect tubes (3) and (4) going to the steering cylinder. fl Take care not to drip check valve and orifice (5) and (6).

4. Disconnect hose (7) coming from the right stop valve and hose (8) coming from the left stop valve. 5. Remove U-bolt (9) and disconnect tube (10) coming from the steering pump. 6. Remove U-bolt (11) and disconnect tube (12) coming from the switching pump. 7. Disconnect tube (13) coming from the loader pump. 8. Disconnect drain tube (14). 9. Remove mounting bolts (15) and lift off steering valve assembly (16). 0

WD600-3

Steering valve assembly: 35kg

30-135 (2)

DISASSEMBLY AND ASSEMBLY

STEERING VALVE

INSTALLATION OF STEERING VALVE •

Carry out installation in the reverse order to removal.

•

When installing the check valve and orifice, confirm that their front and rear directions are aligned properly. After installing the all parts, secure the tubes with the bolts. When installing the tubes and valves, check that the O-rings are no damage and deterioration, then fit the tubes and the valves securely.

• •

•

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.

30-136 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

REMOVAL OF BRAKE VALVE ¤

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. Disconnect transmission cut-off switch connector (1) (L12). (Left brake valve only) 2. Disconnect hose (2) from the accumulator. 3. Disconnect drain hose (3). 4. Disconnect pilot tube (4). 5. Pull out pin (5). fl Be careful not to lose L-pin. 6. Remove pedal (6). 7. Disconnect brake pedal cancel switch connector (7). 1 Connector (7): Left brake valve (C13A) : Right brake valve (C14) 8. Remove plunger (8), then remove boot (9). 9. Remove 4 mounting bolts (10), then remove brake valve (11).

INSTALLATION OF BRAKE VALVE 1 Adjust the sensor so that it will operate when the pedal end moves 16 mm. •

Carry out installation in the reverse order to removal.

•

After installing the brake valve, check the operation of the brake.

WD600-3

30-137 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

DISASSEMBLY OF BRAKE VALVE (R.H.) (TANDEM BRAKE VALVE) 1. Remove snap pin (1) and L-pin (2), then pull out pedal plate fitting pin (3). fl Take care not to lose the L-pin. 2. Remove pedal plate (4). 3. Remove seat (5), boot (6) and pedal stopper (7).

4. Remove mounting bolt (8), then remove bracket (9).

5. Remove mounting bolt (10), then disconnect flange (11) and cylinder (12). 6. Remove holder (13) and springs (14), (15) and (16) from cylinder (12).

7. Pull rod (17) out of flange (11). 8. Pull pilot piston (18) out of rod (17). 9. Remove the snap ring from pilot piston (18), then remove retainers (20) and (21). 10. Remove dust seal (22) and O-ring (23) from flange (11).

30-138 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

11. Disconnect cylinders (22) and (23). 12. Remove return spring (24) and O-ring (25).

13. Pull spool (26) out of cylinder (22). 14. Remove piston (27) and spring (28) from spool (26). 15. Remove snap ring (29) from spool (26), then remove retainer (30).

16. Remove nut end (31) from cylinder (23), then remove spring (32). 17. Remove O-ring (33) from nut end (31).

18. Pull spool (34) out of cylinder (23). 19. Pull piston (35) out of spool (34). 20. Remove snap ring (36) from spool (34), then remove retainer (37).

WD600-3

30-139 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

ASSEMBLY OF BRAKE VALVE (R.H.) (TANDEM BRAKE VALVE) 1. Install retainer (37) to spool (34), then secure it with snap ring (36). 2. Insert piston (35) in spool (34). fl Apply engine oil. 3. Insert spool (34) in cylinder (23).

4. Install O-ring (33) to nut end (31). 5. Install spring (32) to nut end (31), then install them to cylinder (23). 9 Nut end: 152.0 ± 24.5Nm {15.5 ± 2.5kgm}

6. Install retainer (30) to spool (26), then install snap ring (29). 7. Install spring (28) and piston (27) to spool (26). 8. Insert spool (26) in cylinder (22).

9. Install O-ring (25) to cylinder (22). 10. Set spring (24) to cylinder (23).

30-140 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

11. Press fit dust seal (22) to flange (11), then install O-ring (23). 12. Install retainers (21) and (20) to pilot piston (18), then install snap ring (19). 13. Insert pilot piston (18) in rod (17).

14. Set holder (13) to cylinder (12), then install springs (14), (15) and (16). 15. Assemble cylinder (12) and flange (11), and secure them with mounting bolt (10). 9 Mounting bolt: 66.2 ± 7.3Nm {6.75 ± 0.75kgm}

16. Set bracket (9) on the flange (11), then secure it with mounting bolt (8). 9 Mounting bolt: 66.2 ± 7.3Nm {6.75 ± 0.75kgm}

17. Install pedal stopper (7) and boot (6) to bracket, then set seat (5). 18. Set pedal plate (4) to bracket (9), then insert pin (3). 19. Install snap pin (1) and L-pin (2) to pin (3).

WD600-3

30-141 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

DISASSEMBLY OF BRAKE VALVE (L.H.) (SINGLE BRAKE VALVE) 1. Remove snap pin (1) and L-pin (2), then pull out pedal plate fitting pin (3). fl Take care not to lose the L-pin. 2. Remove pedal plate (4). 3. Remove seat (5), boot (6) and pedal stopper (7).

4. Remove mounting bolt (8), then remove bracket (9).

5. Remove mounting bolt (10), then disconnect flange (11) and cylinder (12). 6. Remove holder (13) and springs (14), (15) and (16) from cylinder (12).

7. Pull rod (17) out of flange (11). 8. Remove snap ring (18) from rod (17), then remove retainers (19) and (20). 9. Remove dust seal (21) and O-ring (22) from flange (11).

30-142 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

10. Remove nut end (23) from cylinder (12), then remove spring (24). 11. Remove O-ring (25) from nut end (23).

12. Pull spool (26) out of cylinder (12). 13. Pull piston (27) out of spool (26). 14. Remove snap ring (28) from spool (26), then remove retainer (29).

WD600-3

30-143 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

ASSEMBLY OF BRAKE VALVE (L.H.) (SINGLE BRAKE VALVE) 1. Install retainer (29) to spool (26), then secure it with snap ring (28). 2. Insert piston (27) in spool (26). fl Apply engine oil. 3. Insert spool (26) in cylinder (12).

4. Install O-ring (25) to nut end (23). 5. Install spring (24) to nut end (23), then install them to cylinder (12). 9 Nut end: 152.0 ± 24.5Nm {15.5 ± 2.5kgm}

6. Install dust seal (21) and O-ring (22) to flange (11). 7. Install retainers (20) and (19) to rod (17), then install snap ring (18). 8. Insert rod (17) in flange (11).

9. Install holder (13) to cylinder (12), then set springs (16), (15) and (14). 10. Install cylinder (12) to flange (11), then secure them with mounting bolt (10). 9 Mounting bolt: 66.2 ± 7.3Nm {6.75 ± 0.75kgm}

30-144 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

11. Set bracket (9) to flange (11), then secure them with mounting bolt (8). 9 Mounting bolt: 66.2 ± 7.3Nm {6.75 ± 0.75kgm}

12. Install pedal stopper (7), boot (6) and seat (5). 13. Set pedal plate (4) and insert pin (3), then install L-pin (2) and snap pin (1).

WD600-3

30-145 (2)

DISASSEMBLY AND ASSEMBLY

SLACK ADJUSTER

REMOVAL OF SLACK ADJUSTER ¤

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. Disconnect hose (1) of the brake valve. 2. Disconnect tubes (2) and (3) of right and left brakes. 1 3. Remove mounting bolt (4), then remove slack adjuster (5).

INSTALLATION OF SLACK ADJUSTER •

Carry out installation in the reverse order to removal.

1 9 Tube sleeve nut: 68.6 ± 9.8 {7.0 ± 1.0kgm} •

Bleeding air Bleed air. For details, see BLEEDING AIR.

30-146 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

SLACK ADJUSTER

DISASSEMBLY OF SLACK ADJUSTER 1. Bleeder Remove bleeder (2) from body (1).

2. Cylinder Remove mounting bolts, then disconnect body (1) and cylinder (4) together with bracket (3).

¤

There is spring tension inside the cylinder, so hold the contact surfaces and be careful when removing.

3. Piston 1) Remove spring (5) and O-ring (6). 2) Remove piston (7), then remove O-ring fl Use a rod of 10mm diameter and push out the piston slowly. fl Be careful not to damage the thread with the rod.

4. Poppet fl Do not disassemble the poppet unless necessary. If it is disassembled, replace the whole cylinder assembly. 1) Remove cover (8) from cylinder (4), then remove plug (9), spring (10) and poppet (11). fl When removing the poppet, blow in air from the oil hole in the cylinder. fl Hold the oil port of the cylinder by hand, and do not pump in air suddenly. fl Be careful not to change the combination of poppet (11) and cylinder (4). When replacing, replace the poppet and cylinder as an assembly. 2) Remove O-ring (12) from poppet.

WD600-3

30-147 (2)

DISASSEMBLY AND ASSEMBLY

SLACK ADJUSTER

ASSEMBLY OF SLACK ADJUSTER 1. Poppet 1) Fit O-ring (12) on poppet (11). 2) Install poppet (11), spring (10), plug (9) and cover (8), then assemble cylinder (4).

2. Piston 1) Install O-ring (13) on piston (7). 2) Insert piston (7) in cylinder (4). fl Check that the piston moves smoothly.

3. Cylinder 1) Install O-ring (6) and spring (5) in cylinder. fl Installed road of spring 43.1 Nm {4.4 kg} 2) Install body (1) and cylinder (4) together with bracket (3).

4. Bleeder Install bleeder (2).

30-148 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE

REMOVAL OF BRAKE ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put the safety bar on the frame and set blocks under the wheels to prevent the machine from moving.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove the final drive. For details, see REMOVAL OF FINAL DRIVE 2. Disconnect brake tube (1).

1

3. Sets tools J1. 4. Sling the brake and wheel hub temporarily, then remove mounting bolts (2). 2 5. Sling and remove brake and wheel hub (3). 0

Brake and wheel hub: 195kg

6. Remove bearing (5) and retainer (6) from axle (4).

INSTALLATION OF BRAKE •

Carry out installation in the reverse order to removal.

1 fl Bleed air from the brake. For details, see BLEDING AIR FROM EACH PORTION, of TESTING AND ADJUSTING,. 2 9 Brake and wheel hub mounting bolt: 824.0 – 1030.0Nm {84.0 – 105.0kgm} 3 fl Adjust the preload of the bearing. For details, see ASSEMBLY OF FINAL DRIVE.

WD600-3

30-149 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE

DISASSEMBLY OF BRAKE (FRONT, REAR) 1. Cylinder Using eye-bolt [1] (Tread dia. = 16 mm, Pitch = 2.0 mm), lift out cylinder (1).

fl Disassemble cylinder with following steps: 1) Screw in eye-bolts [1] (Tread dia. = 16 mm, Pitch 2.0 mm), push in spring by using bar [2], then pull out pin (2). 2) Remove spring (3) and shaft (4).

3) Remove piston (5).

2. Plate, disc 1) Remove plate (6).

30-150 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE

2) Remove disc (7). fl When removing the disc and plates, put counter marks on the inner gear and disc, and outer gear and plate before removing. fl The discs are made of soft material, so be careful not to damage then when removing. fl Remove discs and plates alternately.

3. Gear assembly 1) Remove 3 tools J1.

2) Using eyebolt [3] (Thread dia.=12mm, Pitch =1.75mm), lift off gear (8). 3) Remove plate (9) from gear (8).

4) Remove floating seal (10) and oil seal (11) from gear (8).

WD600-3

30-151 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE

4. Floating seal, outer race 1) Remove floating seal (12) from hub (13). 2) Remove outer races (14) and (15) from hub (13).

30-152 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE

ASSEMBLY OF BRAKE (FRONT, REAR) 1. Outer race, floating seal 1) Using push tool [4], press fit outer race (15) to hub (13). 2) Using push tool [5], press fit outer race (14) to hub (13).

3) Using tool H9, install floating seal (12) to hub (13). 2 Seal contact surface : Engine oil (EO30-CD) fl Assemble O-ring (12) to floating seal. fl Use alcohol to completely remove all the white blooming from the surface of the O-ring. fl Remove all oil and grease from the floating seal and hub O-ring contact surface. fl Tighten tool J3 uniformly to prevent twisting of the floating seal O-ring. After press fitting, measure height t at 4 places around the circumference and check that the difference in dimension t at all four places is within 1 mm.

2. Gear assembly 1) Using tool J2, install oil seal (11) to gear (8). 2 Lip of oil seal : Grease (G2-LI) 2 Mating surface of oil seal hub : Thread tightener (Loctite #648)

WD600-3

30-153 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE

2) Using tool J3, install floating seal (10) to gear (8). 2 Seal contact surface : Engine oil (EO30-CD) fl Assemble O-ring (10) to floating seal. fl Use alcohol to completely remove all the white blooming from the surface of the O-ring. fl Remove all oil and grease from the floating seal and retainer O-ring contact surface. fl Tighten tool J3 uniformly to prevent twisting of the floating seal O-ring. After press fitting, measure height t at 4 places around the circumference and check that the difference in dimension t at all four places is within 1 mm.

3. Assemble plate (9), then using eyebolt [3] (Thread dia.=12mm, Pitch=1.75mm), raise gear (8) and install.

4. Install 3 tools J1.

30-154 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BRAKE

5. Disc, plate 1) Install disc (7).

2) Install plate (6). fl Align notched portion of outer teeth of plate and assemble. fl Align the counter marks on the disc and inner gear, and plate and outer gear, then assemble the plates and discs in turn.

6. Cylinder fl Assemble cylinder with following steps: 1) Set piston (5) at bottom.

2) Install shaft (4) and spring (3). 3) Screw in eye-bolts [1] (Thread dia. = 6 mm, Pitch = 2.0 mm), push in spring with bar [2], then install pin (2).

WD600-3

30-155 (2)

DISASSEMBLY AND ASSEMBLY

BRAKE

4) Fit O-ring and using eye-bolts [1] (Thread dia. = 16 mm, Pitch = 2.0 mm), match with guide bolt [4] and lift and install cylinder assembly (1). 2 Mounting bolt : Thread tightener (LT-2) 3 Mounting bolt : 245 – 309 Nm {25.0 – 31.5kgn}

30-156 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

REMOVAL OF HYDRAULIC PUMP ¤

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 the bulkhead. For details, see REMOVAL OF BULKHEAD. 2. Steering and switch pump 1) Disconnect steering pump suction tube (1). fl Plug the tube to prevent foreign objects from entering. 2) Disconnect discharge tube (2) between the steering valve and steering pump. 3) Disconnect switch pump suction tube (3). 4) Disconnect discharge tube (4) between the steering valve and switch pump. 5) Remove mounting bolts (5) and lift off steering and switch pump assembly (6). 0

Steering and switch pump assembly: 39 kg

3. Transmission and PPC pump 1) Disconnect transmission pump suction tube (7). 2) Disconnect discharge tube (8) between the transmission and transmission pump.

3) Disconnect discharge tube (9) between the accumulator charge valve and PPC pump.

WD600-3

30-157 (2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

4) Disconnect PPC pump suction tube (10). 5) Remove mounting bolts (11) and transmission and PPC pump assembly (12). 4. Work equipment pump 1) Disconnect work equipment pump suction tube (13). 2) Disconnect discharge tube (14) between the work equipment valve and work equipment pump. 3) Remove mounting bolts (15) and work equipment pump (16).

INSTALLATION OF HYDRAULIC PUMP •

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.

30-158 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

REMOVAL OF HYDRAULIC 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.

¤

Loosen the filler cap to release the pressure from the hydraulic tank.

1. Sling and remove ladder floor (1). 0

Ladder floor: 120kg

2. Loosen hydraulic tank drain valve (2), and drain oil. = Hydraulic oil: 200 ¬ 3. Remove mounting bolts (3) from the bottom of the hydraulic tank. 1

4. Disconnect return tube (4) coming from the charge valve. 5. Disconnect return tube (5) coming from work equipment valve. 6. Disconnect tube (6) going to the hydraulic oil cooler. 7. Disconnect hydraulic pump tube (7).

8. Disconnect emergency steering suction tube (8). 9. Disconnect emergency steering return tube (9).

WD600-3

30-159 (2)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

10. Disconnect return tube block (10) and tube (11) together and move them toward the chassis. 11. Disconnect return hose (12) coming from the brake valve.

12. Disconnect hydraulic tank breather hose (13). 13. Sling the hydraulic tank temporarily and remove mounting bolts (14). 2 14. Lift off hydraulic tank assembly (15). 0

Hydraulic tank assembly: 362kg

INSTALLATION OF HYDRAULIC TANK •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm} 2 9 Mounting bolt: 490.0 – 608.0Nm {50.0 – 62.0kgm} •

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.

30-160 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

HYDRAULIC FILTER

REMOVAL OF HYDRAULIC FILTER ¤

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. Loosen plugs (2) to release the residual pressure. 3. Remove covers (3).

1

4. Remove spring (4) and valve (5), then remove hydraulic filter (6).

INSTALLATION OF HYDRAULIC FILTER •

Carry out installation in the reverse order to removal.

1 9 Plug: 9.8 – 12.7Nm {1.0 – 1.3kgm}

WD600-3

30-161 (2)

DISASSEMBLY AND ASSEMBLY

PPC VALVE

REMOVAL OF PPC VALVE ¤

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), then loosen plugs (2) on the hydraulic tank to release the residual pressure in the hydraulic circuit. 1 2. Remove console box cover (3). 3. Disconnect control rods (4). 4. Disconnection of hoses from PPC valve 1) Disconnect blade left tilt hose (5). 2) Disconnect blade right tilt hose (6). 3) Disconnect blade raise hose (7). 4) Disconnect blade lower hose (8). 5) Disconnect hose (9) of the accumulator charge valve. 6) Disconnect drain hose (10). 5. Remove 6 mounting bolts (11), then remove PPC valve (12) and bracket together.

INSTALLATION OF PPC VALVE •

Carry out installation in the reverse order to removal.

1 9 Plug: 9.8 – 12.7Nm {1.0 – 1.3kgm}

30-162 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

PPC VALVE

DISASSEMBLY OF PPC VALVE 1. Remove bolt (1). 2. Remove plate (2). 3. Remove seal (3), then remove collar (4). 4. Remove valve assembly and center spring (7) from valve body (10). 5. Remove collars (11), then remove retainer (6), shims (12), and spring (8) from valve (9).

ASSEMBLY OF PPC VALVE 1. Push shims (12), spring (8), and retainer (6) into valve (9), and install collars (11). 2. Install center spring (7) and valve assembly to valve body (10). 3. Install spool (5). 4. Fit O-ring and install collar (4). 5. Install seal (3). 6. Fit plate (2) and install bolt (1). 3 Bolt : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

WD600-3

30-163 (2)

DISASSEMBLY AND ASSEMBLY

DECO VALVE

REMOVAL OF DECO VALVE ¤

Stop the machine on level ground and put blocks under the wheels and set the boom on the support stand, then confirm that the boom will not lower by itself.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove inspection cover (1).

2. Disconnect lockup solenoid connector (FD1) (2).

3. Disconnect tubes (3), (4), (5), (6), (7), and (8). 4. Disconnect hoses (9) and (10). 5. Remove the mounting bolts and lift off deco valve (11). 0

Deco valve: 90kg

INSTALLATION OF DECO VALVE •

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.

30-164 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT VALVE

REMOVAL OF WORK EQUIPMENT VALVE ¤

Stop the machine on level ground and put blocks under the wheels and set the work equipment on the support stand, then confirm that the boom will not lower by itself.

¤

Disconnect the cable from the negative (–) terminal of the battery.

1. Remove cover (1) under the lift cylinder.

2. Disconnect lift cylinder head hose (2) from tube (4). 3. Disconnect lift cylinder bottom hose (3) from tube (5). fl Before disconnecting, confirm that no pressure is remaining.

4. Remove clamp U-bolts (6) and (7) of tubes (4) and (5).

5. Remove the mounting bolt, then remove tube (8) of the loader pump.

WD600-3

30-165 (2)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT VALVE

6. Disconnect tubes (10) and (11) going to the deco valve.

7. Disconnect brade lowering PPC tube (12). 8. Remove clamp (13), then disconnect brade raising PPC tube (14). 9. Disconnect brade right tilting PPC tube (15). 10. Disconnect brade left tilting PPC tube (16).

11. Disconnect drain tube (17). fl Disconnect the clamp. 12. Sling and remove the work equipment valve (18). 0

Work equipment valve: 75kg

INSTALLATION OF WORK EQUIPMENT VALVE •

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.

30-166 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

PITCH & TILT CYLINDER

REMOVAL OF PITCH & TILT CYLINDER ¤

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. Disconnect hose (1) on the pitch and tilt cylinder head side and tube (2) on the bottom side. fl Checking the residual pressure, disconnect the hoses. 2. Pull out bottom pin (3). fl Pull out the pin until the cylinder can be removed. fl Sling the cylinder temporarily. 3. Pull out head pin (4). fl Pull out the pin until the piston can be removed. fl Sling the cylinder temporarily. 4. Lift off pitch and tilt cylinder assembly (5). 0

Pitch and tilt cylinder assembly: 184kg

INSTALLATION OF PITCH & TILT CYLINDER •

¤

Carry out installation in the reverse order to removal. When aligning the position of the pin hole, use a bar. Never put your fingers in the pin hole.

WD600-3

30-167 (2)

DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER

REMOVAL OF LIFT CYLINDER ASSEMBLY ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put blocks under the wheels.

¤

Loosen the filler cap to release the pressure gradually from the hydraulic tank, then operate the work equipment level three to four times to decrease the pressure within the piping up to the ambient pressure level.

1. Disconnect head-side hose (1) and bottom-side hose (2) for the lift cylinder. fl Disconnect the hoses with confirmation to existence of the remained compressed air. 2. Pull out head-side pin (3). fl Pull it up to the position where the piston can be removed. fl Sling the cylinder temporarily.

3. Disconnect grease tube (4) for the bottom-side pin.

4. Pull out bottom-side pin (5). fl Pull it up to the position where the piston can be removed. fl Sling the cylinder temporarily. 5. Sling and remove lift cylinder assembly (6). 0

30-168 (2)

lift cylinder assembly: 205kg

WD600-3

DISASSEMBLY AND ASSEMBLY

LIFT CYLINDER

INSTALLATION OF LIFT CYLINDER ASSEMBLY •

¤

Carry out installation in the reverse order to removal. Use stick, bar or similar tool to align the holes for the pin and never put a finger into the hole.

WD600-3

30-169 (2)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

REMOVAL OF CENTER HINGE PIN ¤

Stop the machine on level ground and place a support stand under the bucket, then put blocks under the wheels to prevent the machine from moving.

¤

Loosen the filler cap and release the pressure from the hydraulic tank gradually, then operate the work equipment control lever 3 – 4 times to release the pressure from the piping.

1. Remove the floor frame. For details, see REMOVAL OF FLOOR FRAME. 2. Disconnect hoses (1) and (2) between the stop valve and steering valve. 3. Remove bracket (3). 4. Remove the mounting bolt , then remove clamp (4). fl Bind the hoses and harnesses, and shift them toward the front frame. 5. Disconnect drain hose (5) of the work equipment valve. 6. Disconnect PPC hoses (Orange) (6), (Yellow) (7), (Blue) (8) and (Red) (9). 7. Disconnect drain hose (10) of the work equipment valve. 8. Disconnect hose (11) of the hydraulic oil cooler. 9. Disconnect hose (12) of the work equipment valve. 10. Disconnect hose (13) between the switch pump and steering valve. 11. Disconnect hose (14) between the steering pump and steering valve. 12. Disconnect hoses (15) and (16) of the parking brake solenoid valve. 13. Disconnect hose (17) of the front brake slack adjuster. 14. Remove drive shaft guard (18).

30-170 (2)

WD600-3

CENTER HINGE PIN

DISASSEMBLY AND ASSEMBLY

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.

19. Remove the mounting bolt, then remove retainer (21). fl Check the number of shims installed between the retainer and frame. 3

WD600-3

30-171 (2)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

20. Adjust height carefully and set so that lower hinge pin (22) can be removed easily by hand.

21. Remove spacer (23).

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). 5

30-172 (2)

WD600-3

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.

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.

WD600-3

30-173 (2)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

28. Remove bearing (33).

29. Remove retainer (34). 6 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).

30-174 (2)

WD600-3

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 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}

WD600-3

30-175 (2)

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

4 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 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}

30-176 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

CENTER HINGE PIN

6 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. 215 ¬ 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.

WD600-3

30-177 (2)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

REMOVAL OF WORK EQUIPMENT ¤

Stop the machine on level ground and lower the work equipment completely to the ground, then put the safety bar on the frame and set blocks under the wheels to prevent the machine from moving.

1. Set blocks [1] and [2] under the left and right straight frame.

2. Sling lift cylinder (1), remove lock bolt (2), and pull out head pin (3). 1 fl After pulling out the pin, start the engine and retract the lift cylinder. At this time, secure the cylinder with wires, etc. so that it will not fall.

3. Sling Y-link (4), remove the lock bolt, and pull out blade pin (5). 2 fl If shims are inserted, record its quantity.

4. Remove lock bolt (6) and pull out cord ring (7) and frame pin (8). 3 fl If shims are inserted, record its quantity. 5. Lift off the Y-link. 0

30-178 (2)

Y-link: 549kg

WD600-3

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

6. Sling H-link (9), remove lock bolt (10), and pull out the cord ring and pin (11). 4 fl If shims are inserted, record its quantity. 7. Lift off the H-link. 0

H-link: 486kg

8. Remove cover (12) and (15). 9. Disconect hoses (13) and (14) from connector.

WD600-3

30-179 (2)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

10. Remove left and right trunnion caps (16). fl Make match marks on the left and right trunnion caps. 5 11. Strat engine, and move machine slowly in reverse to disconnect work equipment assembly from machine.

12. Sling bar (17), remove lock bolt (18), and pull out pin (19). 13. Lift off the bar. 0

Bar: 62kg

14. Sling trunnion (20) and remove mounting bolts (21). 15. Lift off the trunnion. fl Take care not to damage the spherical surface. 0

Trunnion: 58kg

16. Sling trunnion support (22), remove lock bolt (23), and pull out pin (24). 6 fl If shims are inserted, record its quantity. 17. Lift off the trunnion support. 0

30-180 (2)

Trunnion support: 1,266kg

WD600-3

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

INSTALLATION OF WORK EQUIPMENT •

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.

¤

When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.

1 8 Mounting pin: Lubricant (LM-G) 2 8 Mounting pin: Lubricant (LM-G) For shim thickness a, b press fit bushings (25), (27) then tighten to the specified tightening torque and measure the clearance at four places equally spaced around the circumference of flanges (26), (28) with no shims inserted. Take the average clearance for three places and subtract 0 – 0.1 mm to give the value for shim thickness a, b. 34 8 Mounting pin: Lubricant (LM-G) fl Clearance c + d = Max. 1.5mm fl Take care that the cord ring will not be caught. fl When installing Y-link (4) and H-link (9), match the stamps on them to each other.

5 3 Trunnion cap mounting bolt: 632 – 828Nm {64.5 – 84.5kgm} 6 fl Clearance e + f = Max. 1.5mm

WD600-3

30-181 (2)

DISASSEMBLY AND ASSEMBLY

BULKHEAD

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.

¤

Collect the air conditioner refrigerant.

1. Remove engine hood (1). 0

Engine hood: 80kg

2. Remove side hoods (2) on both sides. 0

Side hood: 38kg

3. Remove inspection covers (3), (4) and (5). 0

Inspection cover (3): 30kg

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).

30-182 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

BULKHEAD

11. Remove clamps (15) and disconnect dust indicator hose (16).

12. Disconnect heater hose clamp (17) and air conditioner hose clamp (18). 13. Remove 4 front mounting bolts (19). fl Sling the bulkhead temporarily.

14. Sling and remove bulkhead (20). 0 Bulkhead: 190kg fl Sling carefully, checking that each clamp, etc. is disconnected securely.

INSTALLATION OF BULKHEAD •

Carry out installation in the reverse order to removal.

•

Refilling air conditioner with refrigerant Using tool X1, refill the air conditioner with refrigerant (R134a).

WD600-3

30-183 (2)

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.

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 cooling water from flowing out. 3. Disconnect 2 air conditioner hoses (6). fl Using tool X1, collect air conditioner refrigerant (R134a). fl Be sure to use 2 spanners to disconnect the hoses. 4. Disconnect connector (7). Connector: (LR1.2.3.4.7.9), (TL1), (FR1.2), (CH1)

5. Remove clip (8), then disconnect 2 washer hoses (9). fl If any cleaning water is in the washer tank, bend the hoses and tie them with tape.

6. Disconnect hose (10) between the right-hand brake valve and rear brake, and hose (11) between the right-hand brake valve and front brake. 7. Disconnect hose (12) of the left-hand brake valve accumulator. 8. 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.

30-184 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

9. Disconnect hose (17) between the accumulator charge valve and PPC valve. 10. Disconnect PPC valve drain hose (18). 11. Disconnect hoses (19) (Right tilt blade), (20) (Left tilt blade), (21) (Raise blade) and (22) (Lower blade) between the PPC valve and work equipment valve. fl Each hose is connected by means of quick coupler. It is disconnected easily by pushing it up a little and turning it.

12. Disconnect hoses (23) and (24) between the righthand brake valve and accumulator. fl These hoses must be disconnected since there is a hanging clamp on the floor frame.

13. Disconnect right-hand brake valve drain hose (25). 14. Disconnect left-hand brake valve drain hose (26).

15. Disconnect ground cable (27). 16. Remove 4 nuts of floor frame mount (28). 1

WD600-3

30-185 (2)

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

17. Sling and remove floor frame (29). fl Sling carefully, checking that each clamp, wire, etc. is disconnected securely. 0

Floor frame: 290kg

INSTALLATION OF FLOOR FRAME •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 277.3 ± 32.3Nm {28.3 ± 3.3kgm} •

Refilling air conditioner with refrigerant Using tool X1, refill the air conditioner with refrigerant (R134a).

30-186 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

REMOVAL OF COUNTERWEIGHT ¤

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. Sling front fender (1) and remove mounting bolts (2). 1 2. Lift off the front fender. 0

Front fender: 40kg

3. Sling counterweight (3) temporarily. 4. Remove mounting bolts (4). 5. Lift off the counterweight (3). 0

Counterweight: 600kg

INSTALLATION OF COUNTERWEIGHT •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 59 – 74Nm {6.0 – 7.5kgm}

WD600-3

30-187 (2)

DISASSEMBLY AND ASSEMBLY

FUEL TANK

REMOVAL OF FUEL 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.

1. Drain fuel through drain valve (1). fl Before draining the fuel, check the remaining quantity. = Fuel (When full): 670 ¬ 2. Remove handrail (2), then remove step (3). 3. Disconnect engine oil drain valve (4). 4. Disconnect radiator drain valve (5). fl Disconnect the clamp on the top of the fuel tank. 5. Remove handrail (6), then remove step (7). 6. Remove step (8).

7. Disconnect engine oil cooler drain hose (9) and muffler drain hose (10). 8. Disconnect fuel level sensor connector (11) (R05). 9. Disconnect torque converter oil cooler coolant drain valve (12) from the fuel tank.

10. Disconnect fuel return hose (13). 11. Disconnect hose (14) of the fuel strainer.

30-188 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

FUEL TANK

12. Sling fuel tank (15) temporarily, then remove mounting bolt (16). 1 fl Place a pallet under the fuel tank, then lower the tank slowly, balancing it. 0

Fuel tank: 420kg

INSTALLATION OF FUEL TANK •

Carry out installation in the reverse order to removal.

1 3 Mounting bolt:

824.0 – 1030.0Nm {84.0 – 105.0kgm}

WD600-3

30-189 (2)

DISASSEMBLY AND ASSEMBLY

CAB

REMOVAL OF CAB ¤

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 right and left covers (1).

2. Remove ROPS mounting bolts (2). fl Sling the ROPS temporarily.

1

3. Sling and remove ROPS (3). 0

ROPS: 810kg

4. Remove screws (4), then remove plate (5).

5. Remove cover (6). 6. Disconnect bracket (7). fl Move the harness and switch toward column.

30-190 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

CAB

7. Remove cover (8). 8. Disconnect bracket (9). fl Move the harness and switch toward column. 9. Remove cover (10).

10. Remove connecting bolts (11) of column and cab.

11. Disconnect window washer vinyl tubes (12). 12. Disconnect connectors (13) (CL2), (14) (CL3), (15) (CL4) and (16) (CL1).

13. Remove cab mounting bolts (17) and (18). fl Sling the cab temporarily.

WD600-3

30-191 (2)

DISASSEMBLY AND ASSEMBLY

CAB

14. Sling and remove cab (19). fl Sling carefully, checking that each harness is disconnected securely. 0

Cab: 440kg

INSTALLATION OF CAB •

Carry out installation in the reverse order to removal.

1 9 Mounting bolt: 1520.0 – 1910.0Nm {155.0 – 195.0kgm}

30-192 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

STOP VALVE

REMOVAL OF STOP VALVE ¤

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. Disconnect hose (1) connected to steering valve. 2. Disconnect hose (2) connected to orbit-roll. 3. Disconnect return hose (3). 4. Remove the mounting bolt, then remove stop valve (4).

INSTALLATION OF STOP VALVE •

Carry out installation in the reverse order to removal.

WD600-3

30-193 (2)

DISASSEMBLY AND ASSEMBLY

ACCUMULATOR

REMOVAL OF ACCUMULATOR ¤

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.

¤

Release the pressure from the accumulator by operating the work equipment control lever and brake pedal.

1. Remove covers (1) and (2). 2. Disconnect connectors (3) (C01), (4) (C02), (5) (C03) and (6) (C04). 3. Disconnect hose (7) between the rear brake accumulator and accumulator charge valve. 4. Disconnect hose (8) between the front brake accumulator and accumulator charge valve. 5. Disconnect hose (9) connected to parking brake solenoid valve. 6. Disconnect tube (10) connected to left-hand brake valve. 7. Disconnect tube (11) connected to right-hand brake valve. fl Loosen 2 clamps of tubes (10) and (11). 8. Remove bands (12). 9. Remove mounting bolts, then remove rear brake accumulator (13) and front accumulator (14). fl Each accumulator is secured with 2 mounting bolts at its bottom.

INSTALLATION OF ACCUMULATOR •

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.

30-194 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

ACCUMULATOR CHARGE VALVE

REMOVAL OF ACCUMULATOR CHARGE VALVE ¤

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.

¤

Release the pressure from the accumulator by operating the work equipment control lever and brake pedal.

1. Remove cover (1). 2. Disconnect hose (2) connected to PPC pump. 3. Disconnect hose (3) between the accumulator charge valve and rear accumulator block for the front brake. 4. Disconnect hose (4) between the accumulator charge valve and block. 5. Disconnect hose (5) from hydraulic tank. 6. Disconnect tube (6) between the accumulator charge valve and PPC accumulator. 7. Disconnect tube (7) connected to PPC valve. 8. Remove accumulator charge valve (8).

INSTALLATION OF ACCUMULATOR CHARGE VALVE •

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.

WD600-3

30-195 (2)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE SOLENOID VALVE

REMOVAL OF PARKING BRAKE SOLENOID VALVE ¤

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. Disconnect upper connector (1) (F14). 2. Disconnect suction tubes (2). 3. Disconnect drain tube (3). 4. Remove 4 mounting bolts (4), then remove parking brake solenoid valve (5).

INSTALLATION OF PARKING BRAKE SOLENOID VALVE •

Carry out installation in the reverse order to removal.

30-196 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

DIVERTER VALVE

REMOVAL OF DIVERTER VALVE ¤

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. Loosen hydraulic tank drain valve (1), and drain oil. = Hydraulic oil : 215 ¬ 2. Disconnect connector (2) (R01). 3. Disconnect 2 hoses (3) between the diverter valve and emergency steering pump. 4. Disconnect suction tube (4). 5. Disconnect tube (4) between the diverter valve and the intermediate block. 6. Disconnect drain tube (5). 7. Disconnect tube (6) between the diverter valve and the intermediate block. 8. Remove mounting bolts of brackets (7) and (8), then remove diverter valve (9) together with the bracket. 0

Diverter valve: 50kg

INSTALLATION OF DIVERTER VALVE •

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. -

WD600-3

Hydraulic oil: 215 ¬

30-197 (2)

DISASSEMBLY AND ASSEMBLY

EMERGENCY STEERING PUMP

REMOVAL OF EMERGENCY STEERING PUMP ¤

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. Loosen hydraulic tank drain valve (1), and drain oil. = Hydraulic oil: 215 ¬ 2. Disconnect hoses (2) between the emergency steering pump and diverter valve. 3. Remove brackets (3) and (4). 4. Disconnect 2 tubes (5) connected to diverter valve. 5. Remove mounting bolts (7), then remove emergency steering pump (8). 0

Emergency steering pump: 30kg

INSTALLATION OF EMERGENCY STEERING PUMP •

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. Hydraulic oil: 215 ¬

30-198 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE

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: 20kg 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} WD600-3

30-199 (2)

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).

30-200 (2)

WD600-3

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. 3 Seal: Grease (G2-LI) 5. Install slack adjuster (2), then secure it with snap ring (1).

WD600-3

30-201 (2)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE PAD

REMOVAL OF PARKING BRAKE PAD ¤

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. Turn adjustment bolt (2) counterclockwise to increase the clearance between the pad and disc. 1 3. Secure calipers (3) with wires. 4. Remove plate (4). 2 fl Since 2 dowel pins are installed, raise the calipers a little, then remove the plate. 5. Remove pad (5).

INSTALLATION OF PARKING BRAKE PAD •

Carry out installation in the reverse order to removal.

1 fl Adjust the parking brake pad. For details, see TESTING AND ADJUSTING PARKING BRAKE of TESTING AND ADJUSTING,. 2 8 Mounting bolt: Adhesive (LT-2) 9 Mounting bolt: 824.0 – 1030.0Nm {84.0 – 105.0kgm}

30-202 (2)

WD600-3

DISASSEMBLY AND ASSEMBLY

REAR TIRES

REMOVAL OF REAR TIRES ¤

Stop the machine on level ground and set the safety bar on the frame, then put blocks under the front wheels.

1. Set blocks [1] to right and left rear axles. fl Set these blocks to prevent the tires from jumping when they are removed. 2. Lift the machine body with 2 jacks (50ton) [2], then set support stand [3] under the counterweight. 3. Sling the tire temporarily, then remove hub nuts (1). 1 4. Sling and remove tire (2). fl Tighten the sling at the center of the tire. 0

Tires: 1,450kg

INSTALLATION OF REAR TIRES •

Carry out installation in the reverse order to removal.

1 9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm} fl Match the stud bolts to the holes by turning the tire on the opposite side.

WD600-3

30-203 (2)

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.

1. Using tool X1, collect air conditioner refrigerant (R-134a) 2. Disconnect connector (1) (E12). 3. Remove adapter bolts (2) and (3). 4. Remove bracket (4) and hoses (5) and (6) together. fl Remove these parts without removing the clamp. 5. Loosen mounting bolt (7) and adjustment bolt (8). 6. Turn down the air conditioner compressor toward the engine, then remove belt (9).

7. Remove mounting bolts (10), then remove air conditioner compressor (11).

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 refrigerant (R134a).

30-204 (2)

WD600-3

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.

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 Collect the refrigerant (R134a). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR. 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 Using tool X1, refill the air conditioner with new refrigerant (R134a).

WD600-3

30-205 (2)

DISASSEMBLY AND ASSEMBLY

RECEIVER TANK

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.

1. Open bulkhead cover (1). 2. Disconnect hose (2) of the air conditioner unit. fl Collect the refrigerant (R134a). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR. 3. Disconnect hose (3).

1

4. Remove clamps (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 Using tool X1, refill the air conditioner with new refrigerant (R134a).

30-206 (2)

WD600-3

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.

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 Collect the refrigerant (R134a). For details, see REMOVAL OF 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.

WD600-3

30-207 (2)

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.

30-208 (2)

WD600-3

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.

WD600-3

30-209 (2)

40 MAINTENANCE STANDARD

Engine mount ............................................... 40- 2 Transmission mount .................................... 40- 3 Torque converter .......................................... 40- 4 Lock-up valve ................................................ 40- 6 Torque converter regulator valve ................ 40- 7 Transmission ................................................. 40- 8 Transmission solenoid valve ....................... 40-11 Transmission control valve .......................... 40-12 Transfer ......................................................... 40-16 Drive shaft ..................................................... 40-18 Center support .............................................. 40-19 Differential .................................................... 40-20 Non-spin Differential .................................... 40-24 Final drive ..................................................... 40-26 Axle mount ................................................... 40-28 Center hinge pin ........................................... 40-30 Steering column ........................................... 40-32 Steering valve ............................................... 40-33 Emergency steering pump .......................... 40-34 Diverter valve ................................................ 40-35 Steering cylinder mount .............................. 40-36 Brake valve .................................................... 40-37 Slack adjuster ............................................... 40-40 Brake .............................................................. 40-41 Parking brake ................................................ 40-42 Hydraulic pump ............................................ 40-43 PPC valve ...................................................... 40-46 Work equipment valve ................................. 40-48 Hydraulic cylinder ........................................ 40-50 Work equipment linkage .............................. 40-54 Rops canopy ................................................. 40-57

WD600-3

40-1

MAINTENANCE STANDARD

ENGINE MOUNT

ENGINE MOUNT

40-2

WD600-3

MAINTENANCE STANDARD

TRANSMISSION MOUNT

TRANSMISSION MOUNT

Unit: mm

No.

Check item

1

Thickness of shim for mounting

WD600-3

Criteria 1.5mm (out-of-parallel between coupling of center support and coupling of transmission: 0.1mm)

Remedy Adjust

40-3

MAINTENANCE STANDARD

TORQUE CONVERTER

TORQUE CONVERTER

40-4

WD600-3

MAINTENANCE STANDARD

TORQUE CONVERTER

Unit: mm

No.

Check item

1

Coupling oil seal sliding portion outside diameter

2

Criteria

Remedy

Standard size

Tolerance

Repair limit

ø 115

0 – 0.087

ø 114.8

Input shaft seal ring sliding portion inside diameter

ø 40

+ 0.025 0

ø 40.1

3

Pump housing seal ring sliding portion inside diameter

ø 140

+ 0.040 0

ø 140.5

4

Input shaft seal ring sliding portion inside diameter

ø 65

+ 0.030 0

ø 65.1

Width

4.45

0 – 0.1

4.0

5

Stator shaft seal ring wear

Thickness

5.2

± 0.1

4.7

ø 102.555

± 0.008

ø 102.585

ø 83.6

+ 0.004 – 0.009

ø 83.57

ø 83.71

+ 0.015 0

ø 83.79

6

± 0.05

5.5

5.4

± 0.1

4.8

6 7

Outer race one-way clutch transmission face inside diameter Inner race one-way clutch transmission face outside diameter

8

Bushing sliding portion inside diameter

9

Bushing sliding portion thickness

10

Clutch disc thickness

11

Clearance between clutch housing and piston (outside)

12

Clearance between clutch housing and piston (inside)

WD600-3

Standard size

Tolerance

Correction by chrome plating or replacement

Replace

Standard clearance

Clearance limit

Shaft

Hole

ø 420

– 0.5 – 0.7

+ 0.097 0

0.5 – 0.797

0.88

ø 295

– 0.110 – 0.191

+ 0.081 0

0.11 – 0.272

0.30

40-5

LOCK-UP VALVE

MAINTENANCE STANDARD

LOCK-UP VALVE

Unit: mm

No.

1

Check item

Clearance between lock-up clutch spool and body

Criteria Standard size 32

Tolerance Shaft – 0.035 – 0.045

Hole

Standard clearance

Clearance limit

+0.016 0

0.035 – 0.061

0.081

Standard size 2

Lock-up valve spring (Large)

3

Lock-up valve spring (Small)

4

Poppet spring of lock-up valve

40-6

Free length

Remedy

Repair limit

Installation Installation length load

Free length

Installation load

123.5

88.4

104.9 N {10.7 kg}

119.8

99.8 N {10.1 kg}

78.1

67.1

179.5 N {18.3 kg}

75.8

170.5 N {17.4 kg}

30

16

20.6 N {2.1 kg}

29.6

19.5 N {1.99 kg}

Replace

WD600-3

MAINTENANCE STANDARD

TORQUE CONVERTER REGULATOR VALVE

TORQUE CONVERTER REGULATOR VALVE

Unit: mm

No.

Check item

1

Clearance between popet and spool

2

Clearance between spool and body

Criteria Standard size

Tolerance Shaft

Remedy

Hole

Standard clearance

Clearance limit

22

– 0.020 – 0.030

+0.021 0

0.020 – 0.051

0.071

32

– 0.035 – 0.045

+0.016 0

0.035 – 0.061

0.081 Replace

Standard size 3

4

Poppet spring

Spool spring

WD600-3

Free length

Repair limit

Installation Installation length load

Free length

Installation load

43.9

21

22.4 N {2.28 kg}

42.6

21.6 N {2.2 kg}

87.6

80.0

96.1 N {9.8 kg}

85.0

91.2 N {9.3 kg}

40-7

MAINTENANCE STANDARD

TRANSMISSION

TRANSMISSION (1/2)

40-8

WD600-3

MAINTENANCE STANDARD

TRANSMISSION

Unit: mm

No.

Check item

Criteria Standard size

1

Reverse clutch springs (12 pieces)

Free length

Remedy Repair limit

Installation Installation length load

Free length

Installation load

68

55

146 N {14.9 kg}

64

125 N {12.6 kg}

2

Forward clutch springs (12 pieces)

68

61

78.5 N {8 kg}

64

66.7 N {6.8 kg}

3

4th clutch springs (12 pieces)

52

46

101 N {10.3 kg}

49

86.3 N {8.8 kg}

4

3rd clutch springs (12 pieces)

52

47

84.3 N {8.6 kg}

49

71.6 N {7.3 kg}

5

1st clutch springs (12 pieces)

52

42.8

155 N {15.8 kg}

49

131 N {13.4 kg}

6

Thickness of assembled 4 discs and 3 plates for reverse clutch

Standard size

Tolerance

Repair limit

39

± 0.35

36.9

7

Thickness of assembled 4 discs and 3 plates for forward clutch

39

± 0.35

36.9

8

Thickness of assembled 3 discs and 2 plates for 4th clutch

27.8

± 0.30

26.2

9

Thickness of assembled 5 discs and 4 plates for 2nd clutch

45

± 0.30

42.3

10

Thickness of assembled 3 discs and 2 plates for 3rd clutch

27.8

± 0.30

26.2

27.8

± 0.30

26.2

5.4

± 0.15

4.9

5.0

± 0.10

4.5

5.8

± 0.10

5.2

5.0

± 0.10

4.5

11

12

13

Thickness of assembled 3 discs and 2 plates for 1st clutch Forward, Reverse, Thick1st, 3rd, 4th ness of 1 disc 2nd Forward, Reverse, Thick1st, 3rd, 4th ness of 1 plate 2nd

14

Outside diameter of input shaft

170

+0.018 – 0.007

+0.018 – 0.007

15

Outside diameter of input shaft

110

+0.016 – 0.006

+0.016 – 0.006

16

Outside diameter of output shaft

130

+0.018 – 0.007

+0.018 – 0.007

17

Outside diameter of output shaft

140

+0.018 – 0.007

18

Wear of seal ring for input shaft

Width

3.0

+0.018 – 0.007 – 0.01 – 0.03

Thickness

3.7

3.55

Wear of seal ring for output shaft

Width

4.5

±0.12 – 0.01 – 0.03

Thickness

5.4

5.25

Wear of seal ring for 2nd clutch

Width

6.0

±0.12 – 0.01 – 0.03

Thickness

6.0

5.85

Wear of seal ring for output shaft

Width

4.5

±0.15 – 0.01 – 0.03

Thickness

5.2

±0.12

5.05

19

20

21

WD600-3

Replace

2.7

4.1

5.5

4.1

40-9

TRANSMISSION

MAINTENANCE STANDARD

TRANSMISSION (2/2)

Unit: mm

No. 1 2

3 4

Check item Backlash between reverse sun gear and planetary gear Backlash between reverse planetary gear and ring gear Backlash between forward sun gear and planetary gear Backlash between forward planetary gear and ring gear

Criteria 0.13 – 0.32 0.15 – 0.38 0.13 – 0.36 0.14 – 0.39

5

Backlash between 4th sun gear and planetary gear

6

Backlash between 4th planetary gear and ring gear

0.14 – 0.39

7

Backlash between 3rd sun gear and planetary gear

0.13 – 0.36

8

Backlash between 3rd planetary gear and ring gear

0.14 – 0.39

9

Backlash between 1st sun gear and planetary gear

0.13 – 0.36

10

Backlash between 1st planetary gear and ring gear

0.14 – 0.39

40-10

Remedy

0.13 – 0.36 Replace

WD600-3

TRANSMISSION SOLENOID VALVE

MAINTENANCE STANDARD

TRANSMISSION SOLENOID VALVE

Unit: mm

No.

Check item

Criteria

1

Tightening torque of solenoid valve mounting screw

147 – 177 Nm {15 – 18 kgm}

2

Tightening torque of solenoid valve terminal screw

147 – 177 Nm {15 – 18 kgm}

3

Tightening torque of solenoid valve terminal screw

68.6 – 78.5 Nm {7 – 8 kgm}

4

Tightening torque of solenoid valve connector mounting screw

58.8 – 78.5 Nm {6 – 8 kgm}

5

Tightening torque of terminal mounting screw

58.8 – 78.5 Nm {6 – 8 kgm}

6

Tightening torque of solenoid valve mounting bolt

44.1 – 49.0 Nm {4.5 – 5.0 kgm}

WD600-3

Remedy

Retighten

40-11

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE •

UPPER VALVE

40-12

WD600-3

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE Unit: mm

No.

1

Check item

Clearance between reducing valve and body

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

25

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

2

Clearance between torque converter relief valve spool and body

25

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

3

Clearance between priority valve spool and body

25

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

12

– 0.035 – 0.045

+0.011 0

0.035 – 0.056

0.08

25

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

28

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

4 5 6

Clearance between quick return valve spool and body Clearance between modulating valve spool and body Clearance between main relief valve spool and body

Standard size 7

Priority valve spring

Repair limit

Free length

Installation length

Installation load

Free length

Installation load

62

37.7

217 N {22.1 kg}

60.1

206 N {21 kg}

8

Torque converter relief valve spring

62

48

126 N {12.8 kg}

60.1

120 N {12.2 kg}

9

Modulating valve spring (Inner)

118

110

91.6 N {9.34 kg}

114.5

87.3 N {8.9 kg}

10

Modulating valve spring (Outer)

145.7

144

16.6 N {1.69 kg}

141.3

15.8 N {1.61 kg}

11

Reducing valve spring

70

57

293 N {29.9 kg}

67.9

279 N {28.4 kg}

12

Main relief valve spring (Inner)

108

80.6

337 N {34.4 kg}

104.8

320 N {32.7 kg}

13

Main relief valve spring (Outer)

128

80.6

457 N {46.6 kg}

124.1

434 N {44.3 kg}

14

Thickness of shim for reducing valve

3.5 mm (pressure per 1 piece: 63.7 kPa {0.65 kg/cm2})

15

Thickness of shim for modulation valve

3.0 mm (pressure per 1 piece: 32.4 kPa {0.33 kg/cm2})

16

Thickness of shim for priority valve

2.0 mm (pressure per 1 pieces: 25.5 kPa {0.26 kg/cm2})

17 18

Thickness of shim for torque converter relief valve Thickness of shim main relief valve

19

Tightening torque of modulation lock nut

20

Clearamce between torque converter cold relief valve spool and body (Only cold area)

21

Torque converter cold relief valve spring (Only cold area)

Adjust 2

2.0 mm (pressure per 1 piece: 25.5 kPa {0.26 kg/cm }) 0.5 mm (pressure per 1 piece: 38.2 kPa {0.39 kg/cm2}) 34.3 – 49.0 Nm {3.5 – 5.0 kg/cm} Standard size 28

Free length 92.8

WD600-3

Replace

Tolerance Shaft

Hole

–0.035 –0.045

+0.021 0

Standard size Installation Installation length load 64

201 N {20.5 kg}

Standard clearance

Clearance limit

0.035 – 0.066

0.08

Repair limit Free Installation length load 90

Replace

191 N {19.5 kg}

40-13

MAINTENANCE STANDARD

•

TRANSMISSION CONTROL VALVE

LOWER VALVE

40-14

WD600-3

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE

Unit: mm

No.

1

Check item

Clearance between FORWARD-REVERSE spool and body

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

2

Clearance between 1st speed spool and body

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

3

Clearance between 2nd speed spool and body

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

4

Clearance between 3rd speed spool and body

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

5

Clearance between 4th speed spool and body

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

6

Clearance between pilot reducing valve and body

25

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

7

Clearance between lubrication valve plunger and body

22

– 0.035 – 0.045

+0.013 0

0.035 – 0.058

0.08

Standard size 8

9

FORWARD-REVERSE, No. 1, No. 2, No. 3 and No. 4 speed spring

Pilot reducing valve spring

10

Lubrication valve spring

11

Thickness of shim for pilot reducing valve

WD600-3

Replace

Repair limit

Free length

Installation length

Installation load

Free length

Installation load

78

47

107 N {10.9 kg}

75

102 N {10.4 kg}

62

43.7

164 N {16.7 kg}

60.1

156N {15.9 kg}

39.4

37

60.8 N {6.2 kg}

38.2

57.9 N {5.9 kg}

3.0 mm (pressure per 1 piece: 25.5 kPa {0.26 kg/cm2})

Adjust

40-15

MAINTENANCE STANDARD

TRANSFER

TRANSFER

40-16

WD600-3

TRANSFER

MAINTENANCE STANDARD

Unit: mm

No.

Check item

Criteria

Remedy

Standard size

Tolerance

Repair limit

105

+0.045 +0.023

+0.045 +0.023

Outside diameter of input shaft bearing

190

0 – 0.046

0 – 0.046

3

Outside diameter of idler shaft bearing

190

0 – 0.046

0 – 0.046

4

Outside diameter of output shaft bearing

190

0 – 0.046

0 – 0.046

5

Outside diameter of output shaft bearing

105

+0.045 +0.023

+0.045 +0.023

6

Outside diameter of output shaft bearing

150

– 0.012 – 0.052

—

7

Outside diameter of output shaft bearing

85

+0.045 +0.023

+0.045 +0.023

8

Oil seal sliding surface of output shaft coupling

105

0 – 0.087

104.8

9

Oil seal sliding surface of output shaft coupling

125

0 – 0.100

124.8

10

Clearance between input cover

1

Outside diameter of idler shaft

2

Standard size 2 (shims)

Adjust valve of bearing preload 0.29–0.98 Nm {0.03–0.10 kgm} (Preload, gear as individual part)

11

Clearance between output cover and case

1 (shims)

12

Clearance between idler cover and case

2 (shims)

13

Backlash between transfer input gear and transfer idler gear

0.22 – 0.60

14

Backlash between transfer idler gear and idler gear

0.22 – 0.60

15

Backlash between output gear and idler gear

0.22 – 0.60

16

Tightening torque of coupling mounting bolt

824 – 1,030 Nm {84 – 105 kgm}

WD600-3

Replace

Measurement clearance + (0.05 – 0.10 mm)

Adjust

0.29–0.98 Nm {0.03–0.10 kgm} (Preload, gear as individual part)

Replace

Retighten

40-17

MAINTENANCE STANDARD

DRIVE SHAFT

DRIVE SHAFT

40-18

WD600-3

CENTER SUPPORT

MAINTENANCE STANDARD

CENTER SUPPORT

Unit: mm

No.

1

Check item

Clearance between case and bearing

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

140

0 – 0.018

– 0.036 – 0.061

–0.018 – –0.061

– 0.015

2

Clearance between case and bearing

130

0 – 0.018

– 0.036 – 0.061

–0.018 – –0.061

– 0.015

3

Clearance between coupling shaft and bearing

80

+0.051 +0.032

0 – 0.015

– 0.032 – –0.066

– 0.029

4

Clearance between coupling shaft and bearing

75

+0.051 +0.032

0 – 0.015

– 0.032 – –0.066

– 0.029

5

Wear of oil seal surface

6

Wear of oil seal surface

7

End play of coupling shaft

WD600-3

Standard size

Tolerance

Repair limit

95

0 – 0.087

–0.18

105

0 – 0.087

–0.18

Max. 0.22 (Preload max. 3.9 Nm {0.4 kgm})

Replace

Repair chrome plating or replace

Replace

40-19

MAINTENANCE STANDARD

DIFFERENTIAL

DIFFERENTIAL (1/2)

40-20

WD600-3

MAINTENANCE STANDARD

DIFFERENTIAL

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

WD600-3

9.81 – 19.61 KN {1,000 – 2,000 kg} 0.1 Clearance "a" + (0.1±0.05)

40-21

MAINTENANCE STANDARD

DIFFERENTIAL

DIFFERENTIAL (2/2)

40-22

WD600-3

DIFFERENTIAL

MAINTENANCE STANDARD

Unit: mm

No.

Check item

Criteria Standard size

Remedy

Tolerance

Repair limit

4.0

–

3.5

Wear of oil seal surface

110

0 – 0.087

–

3

Thickness of pinion gear washer

1.5

–

1.3

4

Tightening torque of mounting bolt

Thickness of side gear washer

2

1

WD600-3

Replace

1st step: 3.9±1.0 Nm {0.4±0.1 kgm} (when measuring clearance (no shim)) 2nd step: 113±10 Nm {11.5±1.0 kgm} (shim installed)

40-23

MAINTENANCE STANDARD

NON-SPIN DIFFERENTIAL

NON-SPIN DIFFERENTIAL

40-24

WD600-3

NON-SPIN 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

Backlash of bevel gear

0.33 – 0.46

10

End play of pinion gear

0 – 0.196

11

Free rotating torque of bevel gear

Max. 13.3 Nm {1.36 kgm}

12

Preload of bevel gear

13

Rear face runout of bevel gear

14

Standard thickness of shims for stop shaft

Wear of oil seal surface

16

Tightening torque of mounting bolt

17

Backlash of center cum and driven clutch

Replace

9.81 – 19.61 KN {1,000 – 2,000 kg} Max. 0.1 Clearance "a" + (0.1±0.05) Standard size

15

0

110

Tolerance

Repair limit

0 – 0.087

–

1st step: 3.9±1.0 Nm {0.4±0.1 kgm} (when measuring clearance (no shim)) 2nd step: 113±10 Nm {11.5±1.0 kgm} (shim installed)

Max. 0.3 Installation load Installation length

18

Spring 36.3

WD600-3

standard size

Repair limit

978.7 N {99.8 kgm}

774.7 N {74.0 kgm}

Replace both side at once

40-25

MAINTENANCE STANDARD

FINAL DRIVE

FINAL DRIVE

40-26

WD600-3

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

WD600-3

Remedy

Replace

2.1 ± 1.4 245 – 309 Nm {25 – 31.5 kgm} [Preload 2,942–27,459 N {300–2,800 kg}]

Retighten

40-27

AXLE MOUNT

MAINTENANCE STANDARD

AXLE MOUNT

Unit: mm

No.

1

Check item

Clearance of shaft and hole (Front support side)

Criteria Standard size

Tolerance Shaft

Remedy

Hole

Standard clearance

Clearance limit

350

– 0.062 – 0.151

+0.381 +0.066

0.128 – 0.532

1.0

2

Clearance of shaft and hole (Front support side)

360

+2.5 +1.0

+0.089 0

–0.911 – –2.5

–

3

Clearance of shaft and hole (Rear support side)

310

– 0.056 – 0.137

+0.381 +0.061

0.117 – 0.518

1.0

4

Clearance of shaft and hole (Rear support side)

320

+2.5 +1.0

+0.089 0

–0.911 – –2.5

–

5

Thickness of thrust plate

Standard size

Tolerance

Repair limit

26

– 0.25 – 0.39

–

5

0 – 0.1

1.3

6

Thickness of wear plate

7

Thickness of rear bushing

4.9

±0.1

–

8

Thickness of front bushing

4.9

±0.1

–

40-28

Replace

Replace

WD600-3

MAINTENANCE STANDARD

CENTER HINGE PIN

CENTER HINGE PIN

40-30

WD600-3

MAINTENANCE STANDARD

CENTER HINGE PIN

Unit: mm

No.

1

Check item

Clearance between lower hinge pin and rear frame

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

108

– 0.101 – 0.152

0 – 0.050

0.051 – 0.152

–

2

Clearance between lower hinge pin and spacer (small)

108

– 0.101 – 0.152

0 – 0.050

0.051 – 0.152

1.0

3

Clearance between lower hinge pin and bearing

107.95

– 0.051 – 0.102

+0.025 0

0.051 – 0.127

1.0

4

Clearance between lower hinge pin and spacer (large)

108

– 0.101 – 0.152

0 – 0.05

0.051 – 0.152

1.0

5

Clearance between rear frame and spacer (large)

140

– 0.250 – 0.300

– 0.150 – 0.200

0.050 – 0.150

–

6

Clearance between front frame and upper hinge bearing

160

0 – 0.025

– 0.077 – 0.127

–0.127 – –0.052

–

7

Clearance between upper hinge pin and rear frame

100

– 0.076 – 0.127

+0.025 – 0.020

0.056 – 0.152

–

8

Clearance between upper hinge pin and bearing

100

– 0.076 – 0.127

0 – 0.020

0.056 – 0.127

1.0

9

Clearance between front frame and lower hinge bearing

212.725

+0.025 0

– 0.051 – 0.102

–0.127 – –0.051

–

10

Clearance between rear frame and bushing

132

+0.131 – 0.021

+0.166 +0.110

–0.021 – 0.181

–

117.45

+0.280 +0.180

+0.025 – 0.030

–0.310 – –0.155

–

158.75

+0.310 +0.210

+0.025 – 0.025

–0.335 – –0.185

–

11 12

Clearance at press-fitted part of seal of upper hinge pin Clearance at press-fitted part of seal of lower hinge pin

Standard size

Tolerance

Repair limit

45.2

±0.1

–

88.5

±0.1

–

13

Height of lower hinge spacer (small)

14

Height of lower hinge spacer (large)

15

Shim thickness for lower hinge and retainer

2.55

16

Shim thickness for lower hinge and retainer

1.65

17

Shim thickness for upper hinge and retainer

1.50

18 19 20

Tightening torque of lower hinge retainer mounting bolt Tightening torque of lower hinge retainer mounting bolt Tightening torque of upper hinge pin mounting bolt

WD600-3

Replace

Adjust When adjusting with shim: 68.6 Nm (7 kgm) Final value: 279.0±29.4 Nm {28.5±3 kgm} When adjusting with shim: 279.0±29.4 Nm {28.5±3 kgm} Final valuue: 279.0±29.4 Nm {28.5±3 kgm} When adjusting with shim: 34.3 Nm {3.5 kgm} Final value: 279.0±29.4 Nm {28.5±3 kgm}

40-31

STEERING COLUMN

MAINTENANCE STANDARD

STEERING COLUMN

Unit: mm

No.

Check item

1

Clearance between steering shaft and column bushing

40-32

Criteria Standard size 19

Tolerance

Remedy

Shaft

Hole

Standard clearance

Clearance limit

0 – 0.08

+0.15 – 0.05

0.05 – 0.23

0.4

Replace

WD600-3

MAINTENANCE STANDARD

STEERING VALVE

STEERING VALVE

Unit: mm

No.

Check item

Criteria

Remedy

Standard size 1

2

Steering spool return spring

Load check valve spring

Repair limit

Free length Installed length Installed load

Free length

Load limit

41.8

38

74.5 N {7.6 kg}

–

58.8 N {6 kg}

20.9

13.2

8.8 N {0.9 kg}

–

7.0 N {0.71 kg}

3

Demand spool return spring

90.8

83

409.9 N {41.8 kg}

–

327.5 N {33.4 kg}

4

Relief valve spring

24.0

22.19

182.4 N {18.6 kg}

–

145.1 N {14.8 kg}

5

Check valve return spring

20.9

13.2

8.8 N {0.9 kg}

–

7.0 N {0.71 kg}

WD600-3

Replace

40-33

EMERGENCY STEERING PUMP

MAINTENANCE STANDARD

EMERGENCY STEERING PUMP (SAM3-125)

Unit: mm

No.

1

2

Check item

Remedy

Standard clearance

Clearance limit

0.10 – 0.15

0.19

0.020 – 0.043

0.075

Side clearance Clearance between inside diameter of plain bearing and outside diameter of gear shaft

3

Insertion depth of pin

4

Rotating torque of spline shaft

–

Criteria

Discharge Oil: SAE10W Temperature: 45 to 55°C

40-34

Standard size

Tolerance

14

0 –0.5

Replace

Repair limit

6.86 – 11.8 Nm {0.7 – 1.2 kgm} Revolution Pressure (rpm) (MPa {kg/cm2}) 2,500

20.6 {210}

Standard discharge (¶/min.)

Repair limit discharge (¶/min.)

276

244

–

WD600-3

MAINTENANCE STANDARD

DIVERTER VALVE

DIVERTER VALVE

Unit: mm

No.

1

Check item

Clearance between body and spool

Criteria Tolerance

Standard size

Shaft

Hole

Standard clearance

Clearance limit

40

– 0.013 – 0.015

+0.015 +0.007

0.020 – 0.030

–

Standard size 2

Spool return spring

Remedy

Free length

Repair limit

Installation Installation length load

Free length

Installation load

122.6

84

216.7 N {22.1 kg}

120.7

205.9 N {21.0 kg}

3

Check valve spring

79.2

54.5

5.6 N {0.57 kg}

77.9

5.3 N {0.54 kg}

4

Check valve spring

79.2

57.5

4.9 N {0.50 kg}

77.9

4.6 N {0.47 kg}

WD600-3

Replace

40-35

STEERING CYLINDER MOUNT

MAINTENANCE STANDARD

STEERING CYLINDER MOUNT

Unit: mm

No.

Check item

1

Clearance between mounting pin and bushing connection of steering cylinder rod and frame

2

Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame

Criteria Tolerance

Standard size

Shaft

Hole

Standard clearance

Clearance limit

75

– 0.030 – 0.076

+0.350 +0.250

0.280 – 0.426

1.0

75

– 0.030 – 0.076

+0.350 +0.250

0.280 – 0.426

1.0

Width of hinge

Standard clearance (Clearance a + b)

85 – 00.5

90.5±1.2

Max. 0.5 after adjusting shim

85 – 00.5

90.5±1.2

Max. 0.5 after adjusting shim

Width of boss 3

4

Connection of steering cylinder and front frame Connection of steering cylinder and rear frame

40-36

Remedy

Replace

WD600-3

MAINTENANCE STANDARD

BRAKE VALVE

BRAKE VALVE (LEFT)

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

–

WD600-3

Replace

40-37

MAINTENANCE STANDARD

BRAKE VALVE

(RIGHT)

40-38

WD600-3

MAINTENANCE STANDARD

BRAKE VALVE

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

Test load

Replace

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

WD600-3

40-39

SLACK ADJUSTER

MAINTENANCE STANDARD

SLACK ADJUSTER

Unit: mm

No.

1

Check item

Clearance between body and piston

Criteria Tolerance

Standard size

Shaft

55

– 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

40-40

88

Replace

Repair limit Test load

Free length

Test load

118 N {12 kg}

–

–

WD600-3

MAINTENANCE STANDARD

BRAKE

BRAKE

Unit: mm

No.

1

Check item

Return spring

Criteria

Remedy

Standard size Repair limit Installation Installation Installation Free length Free length length load load 677 N 642 N 104.8 92.4 102.7 {69 kg} {65.5 kg} Standard size

Repair limit

2.4

2.15

2

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

6

Wear of surface in contact with piston seal

7

Wear of surface in contact with piston seal

8

Deformation of friction surface of plate and disc

9 10

Backlash between outer gear and plate Backlash between inner gear and disc

WD600-3

Standard size

Tolerance 0 – 0.155

Repair limit

420

+0.097 0

–

455

+0.097 0

–

430

Replace

–

Standard size

Repair limit

Max. 0.4

0.7 0.29 – 0.62 0.17 – 0.52

40-41

PARKING BRAKE

MAINTENANCE STANDARD

PARKING BRAKE

Unit: mm

No.

1

2

3

Check item

Wear of pad

Criteria

Remedy

Standard size

Tolerance

Repair limit

Remaining thickness of friction material

22.2

–

3.7

Including backing plate

31.7

–

12.7

12.7

– 0.10 – 0.17

–

Wear of rod connecting pin

Wear of disc (Thickness of disc plate)

24

±0.5

Thickness of plate must be under 22 mm. – Less than 22 mm

4

Clearance between pad and disc (Total of both sides)

5

Clearance between brake body and plate

40-42

1.06

±0.18

Replace

Rebuild

Replace

2.1 Adjust

0.36 – 1.0

WD600-3

HYDRAULIC PUMP

MAINTENANCE STANDARD

HYDRAULIC PUMP SAL(4)-125 (Steering) + SAL(4)-100 (Switch) pump

Unit: mm

No.

Check item

1

Side clearance

2

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

3

4

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

WD600-3

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

–

40-43

HYDRAULIC PUMP

MAINTENANCE STANDARD

SAL(3)-080 (Work equipment) pump

Unit: mm

No.

Check item

1

Clearance between gear case and side plate, gear

2

Clearance between inside diameter of plain bearing and outside diameter of gear shaft

3

Insertion depth of pin

4

Rotating torque of spline shaft

–

Discharge EO10-CD 45 – 55°C

40-44

Criteria

Remedy

Standard size

Clearance limit

0.10 – 0.15

0.19

0.06 – 0.149

0.20

Replace

0

14 – 0.5 6.9 – 11.8 Nm {0.7 – 1.2 kgm} Revolution (rpm)

Discharge pressure MPa {kg/cm2}

Standard discharge (¶/min.)

Repair limit discharge (¶/min.)

2,500

20.6 {210}

184

170

—

WD600-3

MAINTENANCE STANDARD

HYDRAULIC PUMP

SAL(3)-125 (Torque converter charging) + SAL(1)-32(PPC) pump

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

WD600-3

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

–

40-45

MAINTENANCE STANDARD

PPC VALVE

PPC VALVE

Unit: mm

No.

1

Check item

Centering spring (RIGHT TILT, LOWER)

Criteria

Free length × O.D.

Standard size Installed Installed length load

Remedy Repair limit Installed Free length load

52.8 × 12.3

36.0

29.4 N {3.0 kg}

–

23.5 N {2.4 kg}

2

Centering spring (LEFT TILT, RAISE)

52.8 × 12.3

36.0

39.2 N {4.0 kg}

–

31.4 N {3.2 kg}

3

Metering spring

31.4 × 7.4

29.4

16.7 N {1.7 kg}

–

13.7 N {1.4 kg}

40-46

Replace spring if damaged or deformed

WD600-3

MAINTENANCE STANDARD

WORK EQUIPMENT VALVE

WORK EQUIPMENT VALVE

40-48

WD600-3

WORK EQUIPMENT VALVE

MAINTENANCE STANDARD

Unit: mm

No.

Check item

Criteria

Remedy

Standard size 1

Spool return spring (For tilt)

Repair limit

Free length ✕ O.D. Installed length Installed load

Free length

Load limit

54.8 ✕ 34

53.5

125 N {12.7 kg}

–

–

2

Spool return spring (For tilt, lift)

54.8 ✕ 33.7

52.2

235.5 N {24 kg}

–

–

3

Spool return spring (For tilt, lift)

30.7 ✕ 32.5

26.8

235.5 N {24 kg}

–

–

4

Spool return spring (For lift)

55.3 ✕ 16.9

40

233 N {23.8 kg}

–

–

5

Spool return spring (For lift)

86.8 ✕ 34.7

83.5

208 N {21.2 kg}

–

–

6

Main valve spring of main relief valve

39.5 ✕ 11.2

23.2

33 N {3.4 kg}

–

–

7

Check valve spring

32.6 ✕ 10.9

24.5

44 N {4.5 kg}

–

–

8

Suction valve spring

27.9 ✕ 13

19

7N {0.7 kg}

–

–

9

Poppet spring of relief valve

49.3 ✕ 12.8

41.9

259 N {26.4 kg}

47.8

208 N {21.2 kg}

Replace

WD600-3

40-49

HYDRAULIC CYLINDER

MAINTENANCE STANDARD

HYDRAULIC CYLINDER STEERING CYLINDER

Unit: mm

No.

1

2

3

4

Check item

Clearance between rod and bushing

Clearance between piston rod mounting pin and bushing Clearance between cylinder bottom mounting pin and bushing

Criteria Standard size

Shaft

Hole

Standard clearance

Clearance limit

75

– 0.030 – 0.076

+0.279 +0.065

0.095 – 0.355

–

75

– 0.030 – 0.076

+0.227 +0.047

0.077 – 0.303

–

75

– 0.030 – 0.076

+0.227 +0.047

0.077 – 0.303

–

Standard size

Tolerance

Repair limit

140

+0.15 0

–

Cylinder bore

40-50

Tolerance

Remedy

Replace

WD600-3

HYDRAULIC CYLINDER

MAINTENANCE STANDARD

LIFT CYLINDER

Unit: mm

No.

Check item

Clearance between rod and bushing (For cold area) 1 Clearance between rod and bushing 2

3

Clearance between piston rod mounting pin and inside diameter of hole Clearance between cylinder bottom mounting pin and bushing

4

Cylinder bore

5

Tightening torque of cylinder head mounting bolt

6

Tightening torque of piston mounting bolt

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

80

–0.100 –0.174

+0.0271 +0.061

0.161 – 0.445

0.745

90

–0.120 –0.207

+0.027 +0.061

0.181 – 0.477

0.777

70

–0.030 –0.076

+0.046 0

0.03 – 0.12

1.0

70

–0.030 –0.076

+0.046 0

0.03 – 0.12

1.0

160

–

+0.25 0

–

–

Replace bushing

Replace

250 ± 24.5 Nm{25.5 ± 2.5 kgm} Retighten

WD600-3

110 ± 12.3 Nm{11.25 ± 1.25 kgm }(with LT-2)

40-51

HYDRAULIC CYLINDER

MAINTENANCE STANDARD

TILT, PITCH CYLINDER

Unit: mm

No.

1

2 3

Check item

Clearance between rod and bushing

Clearance between piston rod mounting pin and bushing Clearance between cylinder bottom mounting pin and bushing

Criteria Tolerance

Standard size

Shaft

90

Remedy

Hole

Standard clearance

Clearance limit

–0.036 –0.090

+0.257 +0.048

0.084 – 0.347

–

75

–0.30 –0.40

+0.20 0

0.30 – 0.60

–

70

–0.30 –0.50

+0.174 0.100

0.40 – 0.674

–

180

–

+0.30 0

–

–

4

Cylinder bore

5

Tightening torque of cylinder head mounting bolt

343 ± 34.3 Nm{35 ± 3.5 kgm}

6

Tightening torque of piston mounting bolt

98 – 123 Nm{10 – 12.5 kgm }(with LT-2)

Replace bushing

Replace

Retighten

40-52

WD600-3

MAINTENANCE STANDARD

WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

40-54

WD600-3

MAINTENANCE STANDARD

WORK EQUIPMENT LINKAGE

Unit: mm

No.

Check item

1

Clearance between bearing and pin at joint of lift cylinder rod and blade

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Clearance between bearing and pin at joint of support and blade Clearance between bushing and pin at joint of frame and blade Clearance between bearing and pin at joint of tilt, pitch cylinder and blade Clearance between bushing and pin at joint of support and front frame Clearance between bushing and pin at joint tilt, pitch cylinder and frame Spherical clearance between trunnion cap and trunnion Clearance between bushing and pin at joint of lift cylinder bottom and frame Clearance between bearing and bushing at joint of lift cylinder and blade Clearance between bearing and bushing at joint of support and blade Clearance between bearing and bushing at joint of frame and blade Clearance between bushing and pin at joint of support and blade Clearance between pin and boss at joint of cylinder rod and blade Clearance between pin and boss at joint of support and blade Clearance between pin and boss at joint frame and blade Clearance between pin and boss at joint of tilt, pitch cylinder and blade Clearance between pin and boss at joint of support and front frame Clearance between pin and boss at joint of tilt, pitch cylinder and frame Clearance between pin and boss at joint of lift cylinder bottom and frame Clearance between bushing and boss at joint of support and blade

WD600-3

Criteria Tolerance

Remedy

Standard size

Shaft

Hole

Standard clearance

Clearance limit

70

–0.030 –0.076

+0.046 0

0.03 – 0.12

1

50

–0.025 –0.069

+0.039 0

0.025 – 0.108

1

70

–0.5 –0.6

+0.3 0

0.5 – 0.9

2

75

–0.3 –0.4

+0.2 0

0.3 – 0.6

2

75

–0.030 –0.076

+0.285 +0.184

0.214 – 0.361

1

70

–0.3 –0.5

+0.174 +0.100

0.13 – 0.674

2

195

–0.5 –1.0

+0.5 0

0.5 – 1.5

–

70

–0.030 –0.076

+0.046 0

0.030 –0.122

1

135

+0.070 –0.010

+0.24 +0.19

0.12 – 0.25

–

135

+0.070 –0.010

+0.24 +0.19

0.12 – 0.25

–

140

±0.05

+0.45 +0.35

0.30 – 0.50

1

50

–0.025 –0.069

+0.039 0

0.025 – 0.108

1

70

–0.030 –0.076

+0.1 0

0.03 – 0.176

1

50

–0.025 –0.069

+0.1 0

0.025 – 0.169

1

70

–0.5 –0.6

+0.3 0

0.5 – 0.9

2

75

–0.3 –0.4

+0.1 0

0.3 – 0.5

2

75

–0.030 –0.076

+0.1 0

0.03 – 0.176

1

70

–0.3 –0.5

+0.1 0

0.3 – 0.6

2

70

–0.030 –0.076

+0.30 +0.20

0.230 – 0.376

1

82

–0.036 –0.090

+0.054 0

0.036 – 0.144

1

Replace

40-55

WORK EQUIPMENT LINKAGE

MAINTENANCE STANDARD

Unit: mm

No.

21

Check item

Joint of lift cylinder rod and blade

Criteria

Remedy

Width between bosses

Width of hinge

Standard clearance (Clearance a + b)

+0.5 110 +0.2

0 110 – 0.2

0.2 – 0.7

22

Joint of frame and blade

140 +0.8 0.3

140 –0.2 –0.7

0.5 – 1.5

23

Joint tilt, pitch cylinder and blade

106 ± 2

100 –0.1 –0.3

4.1 – 8.3

25

Joint of tilt, pitch cylinder and frame

74 ± 1.5

26

Joint of lift cylinder bottom and frame

27

Joint of H-link and boss

40-56

110 +2.0 +0.5

89 ± 1

70 0 – 0.5

2.5 – 6

110 0 – 0.2

0.5 – 2.2

86 ± 0.8

1.2 – 4.8

—

Adjust with shims so that clearance is less than 1.5 mm on both left and right

WD600-3

MAINTENANCE STANDARD

ROPS CANOPY

ROPS CANOPY

WD600-3

40-57

90 OTHERS

BRAKE CIRCUIT DIAGRAM ................................ 90- 2 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ............................................ 90- 5 HYDRAULIC CIRCUIT DIAGRAM ....................... 90- 7 ELECTRIC CIRCUIT DIAGRAM FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL Electric circuit diagram (1/8) ......................... 90- 9 Electric circuit diagram (2/8) ......................... 90-11 Electric circuit diagram (3/8) ......................... 90-13 Electric circuit diagram (4/8) ......................... 90-15 Electric circuit diagram (5/8) ......................... 90-17 Electric circuit diagram (6/8) ......................... 90-19 Electric circuit diagram (7/8) ......................... 90-21 Electric circuit diagram (8/8) ......................... 90-23

WD600-3

90-1

OTHERS

BRAKE CIRCUIT DIAGRAM

BRAKE CIRCUIT DIAGRAM

90-2

WD600-3

OTHERS

BRAKE CIRCUIT DIAGRAM

1. Hydraulic pump (tandem) 1A. Torque converter charging pump 1B. PPC pump 2. Strainer 3. Accumulator charge valve 3A. Safety relief valve 3B. PPC relief valve 4. Check valve 5. Low pressure switch 6. Rear brake accumulator 7. Front brake accumulator 8. Emergency brake switch 9. Brake valve (left) 10. Transmission cut-off switch 11. Brake valve (right) 12. Stop lamp switch 13. Rear slack adjuster 14. Front slack adjuster 15. Parking brake solenoid valve 15A. Parking brake emergency release solenoid 16. Parking brake emergency release switch 17. Parking brake 18. Parking brake pilot lamp switch 19. Strainer

WD600-3

90-3

HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

WD600-3

Transmission case PTO case Strainer Torque converter charging pump (SAL(3)-125) PTO pump (SAL(1)-32) PTO lubrication Oil filter (3 pcs) Transmission main relief valve Pilot oil filter Pilot reducing valve Priority valve Modulating valve Quick return valve Torque converter Torque converter relief valve Torque converter regulator valve Oil cooler Lubrication valve Transmission lubrication Lubrication bypass valve Reducing valve Reverse spool Forward spool 4th spool 3rd spool 2nd spool 1st spool Emergency manual spool Solenoid valve Reverse clutch Forward clutch 4th clutch 3rd clutch 2nd clutch 1st clutch Last chance filter Lock-up valve Lock-up clutch Solenoid valve

90-5

HYDRAULIC CIRCUIT DIAGRAM

WD600-3

90-7

ELECTRIC CIRCUIT DIAGRAM (1/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-9

ELECTRIC CIRCUIT DIAGRAM (2/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-11

ELECTRIC CIRCUIT DIAGRAM (3/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-13

ELECTRIC CIRCUIT DIAGRAM (4/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-15

ELECTRIC CIRCUIT DIAGRAM (5/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-17

ELECTRIC CIRCUIT DIAGRAM (6/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-19

ELECTRIC CIRCUIT DIAGRAM (7/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-21

ELECTRIC CIRCUIT DIAGRAM (8/8) FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL

WD600-3

90-23