VEBM500100

Shop Manual

WHEEL LOADER
SERIAL NUMBER WA500H20051 and up

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

l WA500-3H mount the SA6D140E-3 engine.

For details of this engine, see the 140-3 Series Engine Shop Manual

© 2001
All Rights Reserved
Printed in Europe 10-01

10-1 WF450-3 / WF450T-3

FOREWORD

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.

00-2 WA500-3H
FOREWORD CONTENTS
12
00 CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

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

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

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

WA500-3H 00-3
FOREWORD SAFETY

12
00 SAFETY

00 SAFETY NOTICE

00 IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.

00 GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.

5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.

00 PREPARATIONS FOR WORK

1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.

2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert
the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers
and hang warning signs on them.

3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

00-4 WA500-3H
FOREWORD SAFETY

4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.

00 PRECAUTIONS DURING WORK

1. 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.

2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.

3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

WA500-3H 00-5
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from
damage. Always use lifting equipment which has ample
capacity. Install the lifting equipment at the correct
places. Use a hoist or crane and operate slowly to pre-
vent the component from hitting any other part. Do not
work with any part still raised by the hoist or crane.

5. When removing covers which are under internal pres-

sure 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.

6. When removing components, be careful not to break or

damage the wiring, Damaged wiring may cause electri-
cal fires.

7. When removing piping, stop the fuel or oil from spilling

out. If any fuel or oil drips on to the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to
slip, or can even start fires.

8. As a general rule, do not use gasoline to wash parts. In

particular, use only the minimum of gasoline when
washing electrical parts.

9. Be sure to assemble all parts again in their original

places. Replace any damaged part 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.

10. 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 pres-
sure circuits. Also check that connecting parts are cor-
rectly installed.

11. 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.

12. When aligning two holes, never insert your fingers or

hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the

measuring tool is correctly assembled before taking any
measurements.

14. 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.

00-6 WA500-3H
FOREWORD GENERAL
12
00 GENERAL
This shop manual has been prepared as an aid to improve the charts correlating “Problems” to “Causes” are also
quality of repairs by giving the serviceman an accurate included in this section.
understanding of the product and by showing him the correct
way to perform repairs and make judgements. Make sure DISASSEMBLY AND ASSEMBLY
you understand the contents of this manual and use it to full
effect at every opportunity. This section explains the order to be followed when
removing, installing, disassembling or assembling each
This shop manual mainly contains the necessary technical component, as well as precautions to be taken for these
information for operations performed in a service workshop. operations.
For ease of understanding, the manual is divided into the fol-
lowing sections. These sections are further divided into each MAINTENANCE STANDARD
main group of components.
This section gives the judgement standards when
GENERAL inspecting disassembled parts.

This section lists the general machine dimensions, per-

formance specifications, component weights, and fuel,
coolant and lubricant specification charts.

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.

TESTING, ADJUSTING AND TROUBLESHOOT-

ING

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
NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.

WA500-3H 00-7
FOREWORD HOW TO READ THE SHOP MANUAL

12
00 HOW TO READ THE SHOP MANUAL

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

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series

Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models

These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is
necessary that chassis, engine, electrical and attachment be available.

00 DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you
start any work.

00 FILING METHOD
1. See the page number on the bottom of the page. File the pages in correct order.
2. Following examples show how to read the page number:
Example:

10 - 3

Item number (10. Structure and Function)

Consecutive page number for each item

3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the
example.
Example:
10-4
10-4-1
Added pages
10-4-2

10-5

00 REVISED EDITION MARK

When a manual is revised, an edition mark (jkl…) is recorded on the bottom outside corner of the pages.

00 REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.

00 SYMBOLS

00-8 WA500-3H
FOREWORD HOW TO READ THE SHOP MANUAL

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

Symbol Item Remarks

Special safety precautions are
Safety necessary when performing the
work.
Special technical precautions or
other precautions for preserving
★ Caution
standards are necessary when
performing the work.
Weight of parts or systems. Cau-
tion necessary when selecting
Weight
hoisting wire or when working
posture is important, etc.
Places that require special atten-
Tightening
tion for tightening torque during
torque
assembly.
Places to be coated with adhe-
Coat
sives and lubricants etc.

Places where oil, water or fuel

Oil, water
must be added, and the capacity.
Places where oil or water must
Drain be drained, and quantity to be
drained.

WA500-3H 00-9
FOREWORD HOISTING INSTRUCTIONS

12
00 HOISTING INSTRUCTIONS

00 HOISTING

WARNING! 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 indi-
cated clearly with the symbol

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

00 WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing)
Rope diameter Allowable load
mm kN tons
10 9.8 1.0
11.2 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used.

00-10 WA500-3H
FOREWORD HOISTING INSTRUCTIONS

2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the
hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

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

WARNING! 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 dan-
gerous 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 (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at
various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an
excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°

WA500-3H 00-11
FOREWORD COATING MATERIALS

12
00 COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene • Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
• Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
500 g
Adhesives

Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
• Quick hardening type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 • Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tem-
648-50 container
perature.
• Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
• Features: Resistance to heat
Gasket seal- • Used as sealant for flange surfaces and bolts
ant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
• Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

00-12 WA500-3H
FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main applications, features

• Features: Resistance to water, oil
• Used as sealant for flange surface, thread.
LG-4 790-129-9020 200 g Tube • Also possible to use as sealant for flanges
with large clearance.
• Used as sealant for mating surfaces of final
drive case, transmission case.
• Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container • Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket seal- • Features: Silicon based, resistant to heat,
ant cold.
LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case,
etc.
• Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
• Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
• Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
• Used as lubricant for sliding parts (to pre-
LM-G 09940-00051 60 g Can
Molybdenum

vent squeaking).
disulphide
lubricant

• Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
• Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum

400 g (10 per

SYG2-400M Belows type • Used for places with heavy load.
case)

WA500-3H 00-13
FOREWORD STANDARD TIGHTENING TORQUE

12
00 STANDARD TIGHTENING TORQUE

00 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35

Thread diameter of bolt Width across flats

mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8

00-14 WA500-3H
FOREWORD STANDARD TIGHTENING TORQUE

12
TIGHTENING
00 TORQUE OF HOSE NUTS
Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5

00 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3

00 TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5

WA500-3H 00-15
FOREWORD ELECTRIC WIRE CODE

12
00 ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

00 CLASSIFICATION BY THICKNESS
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

00 CLASSIFICATION BY COLOR AND CODE

Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Primary

1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary

4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue

00-16 WA500-3H
FOREWORD CONVERSION TABLES

12
00 CONVERSION TABLES

00 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.
A. Locate the number 50 in the vertical column at the left side, take this as j, then draw a horizontal line from j.

B. Locate the number 5 in the row across the top, take this as k, then draw a perpendicular line down from k.

C. Take the point where the two lines cross as l. This point l gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

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

WA500-3H 00-17
FOREWORD CONVERSION TABLES

12

Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-18 WA500-3H
FOREWORD CONVERSION TABLES

12

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

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

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

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

WA500-3H 00-19
FOREWORD CONVERSION TABLES

12

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 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-20 WA500-3H
FOREWORD CONVERSION TABLES

12

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/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 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

WA500-3H 00-21
FOREWORD CONVERSION TABLES

12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

00-22 WA500-3H
 01 GENERAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT AND LUBRICATNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14

WA500-3H 01-1
GENERAL
12

01-2 WA500-3H
 12
SPECIFICATIONS

Machine model WA500-3H

Serial number WA500H20051 and up

Operating weight 28,810 kg (63,515 lb)

Weight

Distribution (front) 13,360 kg (29,454 lb)

Distribution (rear) 15,450 kg (34,061 lb)

Bucket capacity (piled) 5.0 m³ (6.5 yd³)

Rated load 7,740 kg (17,064 lb)

Travel speed:
FORWARD 1st 7.1 km/h (4.4 mph)
FORWARD 2nd 12.6 km/h (7.8 mph)
Performance

FORWARD 3rd 21.2 km/h (13.2 mph)

FORWARD 4th 34.8 km/h (21.6 mph)
REVERSE 1st 7.9 km/h (4.9 mph)
REVERSE 2nd 14.1 km/h (8.8 mph)
REVERSE 3rd 23.5 km/h (14.6 mph)
REVERSE 4th 38.1 km/h (23.7 mph)

Gradeability 25 deg

Turning radius (bucket at carry - outside corner of

7315 mm (24 ft 0 in)
bucket)

Overall length 9105 mm (29 ft 10 in)

Overall width (Chassis) 3,190 mm (10 ft 5 in)

Bucket width (with bolt on cutting edge) 3400 mm (11 ft 2 in)

Overall height (top of cab) 3860 mm (12 ft 8 in)

Overall height (bucket raised) 6175 mm (20 ft 3 in)

Wheelbase 3600 mm (11 ft 10 in)

Dimensions

Tread 2400 mm (7 ft 10 in)

Minimum ground clearance 450 mm (1 ft 5 in)

Height of bucket hinge pin 590 mm (1 ft 11 in)

Dumping clearance (tip of cutting edge) 3170 mm (10 ft 5 in)

Dumping reach (tip of cutting edge) 2025 mm (6 ft 8 in)

Bucket dump angle 45 deg

Bucket tilt angle (SAE carrying position) 48 deg

Digging depth (10° dump angle) 375 mm (1 ft 2 in)

 GENERAL SPECIFICATIONS

Machine model WA500-3H

Serial number WA500H20051 and up

Model Komatsu SA6D140E-3 diesel engine

Type 4-cycle, water cooled, direct injection, turbocharged, waterjacket,

aftercooled
No. of cylinders - bore x stroke
6 - 140 mm (5.5") x 165 mm (6.5")
Piston displacement
15 L (930 in³) (15,200 cc)
Engine

Gross power @ 2100 rpm 250kW (335 HP)

Maximum torque (gross) @ 1400 rpm 908 N•m (670 lbf ft)

High idle 2300 rpm

Low idle 725 rpm

Fuel consumption ratio 220 g/kW •h (164 g/HP•h)

Starting motor 24 V, 11.1 kW

Alternator 24 V, 60 A
Battery 12 V, 200 Ah x 2

Torque converter 3-element, single-stage, single-phase (TCA40-1C)

Transmission Planetary gear, constant-mesh multiple-disc, hydraulic actuated,

Power train

modulation type

Reduction gear Spiral bevel gear, splash lubrication

Differential Straight bevel gear

Final drive Planetary gear, single stage, splash lubrication

Drive type Front / rear wheel drive

Front axle Fixed frame full-floating type

Axle, Wheel

Rear axle Center pin support full-floating type

Tire 29.5 - 25 - 22 pr tubeless (L3)

Wheel rim 25.00 x 25 WTB

Inflation pressure Front tire 4.5 kgf/cm2 (64.0 lbf/in2)

Inflation pressure Rear tire 3.5 kgf/cm2 (49.8 lbf/in2)

Service brakes Front / rear wheel braking, separate front/rear wheel, wet disc,
Brakes

hydraulically actuated

Parking brake Drive shaft, wet type disc brake, hydraulically released spring type

01-4 WA500-3H
 GENERAL SPECIFICATIONS

Machine model WA500-3H

Serial number WA500H20051 and up

Steering system

Type Articulated steering

Structure Fully hydraulic power steering

Hydraulic Work equipment pump 348 L (Gear type: SAR(4) - 160)

Pump
Delivery Switch pump 135 L (Gear type: SAR(3) - 63)

Steering pump 172 L (Gear type: SAR(3) - 80)

PPC pump 60 L (Gear type: SAR(1) - 28)

Hydraulic system

Control valve Set pressure for work equipment Spool type 210 kg/cm2 (2986.9 lbf/in2)

Set pressure for steering Orbit-roll valve type 210 kg/cm2 (2986.9 lbf/in2)

Cylinder Boom cylinder qty. - bore x stroke Reciprocating piston 2-200 x 839 (mm)

Bucket cylinder qty. - bore x Reciprocating piston 1-225 x 613 (mm)

stroke
Reciprocating piston 2 - 110 x 486 (mm)
Steering cylinder qty. - bore x
stroke
Work equipment

Linkage type Single link (Z-bar linkage)

Bucket edge type Flat edge with bolt on cutting edge

WA500-3H 01-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE

Machine model WA500-3H Machine model WA500-3H

Serial No. WA500H20051 and up Serial No. WA500H20051 and up

Engine 3,549 lb (1,610 kg) Hydraulic tank 507 lb (230 kg)

Radiator 732 lb (332 kg) Hydraulic pump 45 lb (20.3 kg)

Transmission with torque con- 2,524 lb (1,145 kg) Switch and PPC pump 42 lb (19 kg)
verter

Torque converter assembly 474 lb (215 kg) Steering pump 27 lb (12.2 kg)

Transmission assembly 2,050 lb (930 kg) PPC valve 8 lb (3.5 kg)

Damper 201 lb (91 kg) Main control valve 199 lb (90 kg)

Upper drive shaft 40 lb (18 kg) Steering cylinder (each) 104 lb (47 kg)

Center drive shaft 73 lb (33 kg) Boom cylinder (each) 600 lb (272 kg)

Front drive shaft 99 lb (45 kg) Bucket cylinder 631 lb (286 kg)

Rear drive shaft 86 lb (41 kg) Engine hood (w/side panels) 496 lb (225 kg)

Center support 93 lb (42 kg) Front frame 4,892 lb (2,219 kg)

Front axle assembly 4,277 lb (1,940 kg) Rear frame 4,817 lb (2,185 kg)

Rear axle assembly 4,138 lb (1,877 kg) Bucket link 234 lb (106 kg)

Axle pivot (Rear axle) 114 lb (251 kg) Bellcrank 1,151 lb (522 kg)

Tire and wheel (each) 1,740 lb (789 kg) Boom including bushings 4,449 lb (2,018 kg)

Wheel (each) 591 lb (268 kg) Bucket with bolt on cutting edge 5,997 lb (2,720 kg)

Tire (each) 1,149 lb (521 kg) Counterweight 4,954 lb (2,247 kg)

Front differential assembly 591 lb (268 kg) Fuel tank 531 lb (241 kg)

Rear differential assembly 612 lb (278 kg) Battery (each) 117 lb (53 kg)

Planetary carrier (each) 137 lb (62 kg) Floor, dash, console 472 lb (214 kg)

Planetary hub (each) 227 lb (103 kg) Cab (ROPS) 1,005 lb (456 kg)

Steering valve 52 lb (23.5 kg) Air conditioner unit 117 lb (53 kg)

Orbit-roll valve 12 lb (5.3 kg) Operator’s seat 119 lb (54 kg)

Brake valve (Tandem) 19 lb (8.5 kg) Front support 209.4 lb (95 kg)

Brake valve (Single) 12 lb (5.3 kg) Rear support 253.5 lb (115 kg)

01-6 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
FUEL, COOLANT AND LUBRICATNTS

Ambient Temperature Capacity

Kind of
Reservoir -22 -4 14 32 50 68 86 104 122°F
fluid Specified Refill
-30 -20 -10 0 10 20 30 40 50°C

SAE 30

Engine oil SAE 10W 42 liters 37 liters

pan with filter SAE 10W-30 11.1 gal 9.8 gal

SAE 15W-40

Torque Engine oil SAE 30W

converter,
SAE 10W 70 liters 62 liters
transmission
18.5 gal 16.4 gal
case and oil
cooler
SAE 10W
Hydraulic 284 liters 175 liters
system 74.9 gal 46.2 gal

Drive axles - 78 liters 78 liters

Axle oil See "AXLE OIL " on page 01-10.
(front & rear) 20.6 gal 20.6 gal

NLGI No. 2. See "GREASE" on page 01-11. Lubricate as

Pins Grease ---
instructed

ASTM No. 2. See "DIESEL FUEL" on page 448 liters

Fuel tank Diesel fuel ---
01-11. 118.3 gal
ASTM No. 1

Cooling 99 liters
Coolant See "COOLANT SPECIFICATIONS" on page 01-12. ---
system 26.2 gal

Other equipment will be necessary when operating the machine at temperatures below -20o C (-4o F). Consult your Komatsu
distributor for your needs.
API: American Petroleum Institute
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers

Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

WA500-3H 01-7
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
ENGINE OIL
NORMAL OPERATION
Oil performance recommendations are as follows:

The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability. SAE 15W-40 multi-viscosity heavy duty engine oil meeting the
American Petroleum Institute (API) performance classification of CF-4 or CG-4 is recommended.

NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.

A sulfated ash content of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control.
The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all
engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead
to excessive oil consumption.

The API service symbol displays the following information: the upper half of the symbol displays the appropriate oil
categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.

Oil viscosity recommendations are as follows:

The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil
is recommended for most operating climates, refer to the table for oil viscosity recommendations for extreme climates.

Limited use of low viscosity oils, such as SAE 10W-30 is allowed to ease starting and provide sufficient oil flow at
ambient temperatures below -5°C (+23°F). However, continuous use of low viscosity oils can decrease engine life due to
wear.

Special "break-in" lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
"break-in" as specified for normal operation.

Remark
Single grade oil may be mixed with multigrade oil (SAE 10W-30, SAE 15W-40), but make sure the single
grade oil matches the temperature range in the table. We recommend genuine Komatsu oil which has
been specifically formulated and approved for use in engine and hydraulic work equipment applications.

Use of fuels with high sulfur content necessitates more frequent oil changes.

Fuel sulfur content Oil change interval

0.5 to 1.0 % 1/2 of regular interval

More than 1.0% 1/4 of regular interval

Additional information regarding lubricating oil availability throughout the world is available in the "E.M.A. Lubricating
Oils Data Book for Heavy Duty Automotive and Industrial Engines." The data book may be ordered from the Engine
Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone
number is (312) 644-6610.

01-8 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12

Engine Oil
[CD or CE] Anti-freeze
Gear oil Grease
SAE10W, 30, 40, 10W30, Coolant
Supplier [GL-4 or GL-5] [Lithium base]
15W40 [ethylene glycol base]
SAE80, 90, 140 NLGI No. 2
(The 15W-40 oil marked Permanent Type
* is CE)
E010-CD G090 G2-LI AF-ACL
E030-CD G0140 G2-LI-S AF-PTL
Komatsu
E010-30CD AF-PT (winter, one-
E015-40CD season type)
Diesel sigma S super die- Rotra MP GR MU/EP
AGIP sel multi-grade -
*Sigma turbo
Amoco *Amoco 300 Multi-purpose gear oil PYKON premium grease -
Arcofleet S3 plus Arco HD gear oil Litholine HEP 2
ARCO -
Arco EP moly D
Vanellus C3 Gear oil EP Energrease LS-EP2 Anti-freeze
BP
Hypogear EP
*RPM delo 400 Universal thuban Marfak all-purpose 2 AF engine coolant
Caltex
RPM delo 450 Universal thuban EP Ultra-duty grease 2
*Turbomax EP MS3 Anti-freeze
*RX super EPX Spheerol EPL2
Castrol CRD Hypoy
Hypoy B
Hypoy C
Chevron *Delo 400 Universal gear Ultra-duty grease 2 -
*Fleet motor oil Universal gear lubri- Super-sta grease
Conoco -
cant
Multiperformance 3C Tranself EP Glacelf
ELF -
Performance 3C Tranself EP type 2
Essolube D3 Gear oil GP Beacon EP2 All-season coolant
Exxon *Essolube XD-3 Gear oil GX
(Esso) *Essolube XD-3 Extra
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Anti-freeze and coolant
Gulf
*Super Duty plus lubricant Gulfcrown EP special
Delvac 1300 Mobilube GX Mobilux EP2
Mobil *Delvac super Mobilube HD Mobilgrease 77 -
10W-30, 15W-40 Mobilgrease special
* Supreme duty fleet motor Multipurpose 4092 Multipurpose white grease
oil Multipurpose 4140 705 Anti-freeze and sum-
Pennzoil
707L White bearing mer coolant
grease

WA500-3H 01-9
GENERAL FUEL, COOLANT AND LUBRICATNTS
12

Engine Oil
[CD or CE] Anti-freeze
Gear oil Grease
SAE10W, 30, 40, 10W30, Coolant
Supplier [GL-4 or GL-5] [Lithium base]
15W40 [ethylene glycol base]
SAE80, 90, 140 NLGI No. 2
(The 15W-40 oil marked Permanent Type
* is CE)
Petrofine FINA kappa TD FINA potonic N Albania EP grease
-
FINA potonic NE
Shell Rimura X Spirax EP Albania EP grease
-
Spirax heavy duty
Sun Sunoco GL5 gear oil Sunoco ultra prestige 2EP Sunoco anti-freeze and
-
Sun prestige 742 summer coolant
Texaco *Ursa super plus Multigear Multifak EP2 Coda 2055 startex anti-
Ursa premium Starplex 2 freeze coolant
Total Rubia S Total EP Multis EP2 Antigal/anti-freeze
*Rubia X Total transmission TM
Union *Guardol MP gear lube LS Unoba EP -
Veedol *Turbostar Multigear Anti-freeze
*Diesel star Multigear B -
MDC Mutligear C

ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with adequate low
temperature properties such as SAE 5W-20 or 5W-30.

The oil supplier must be responsible for meeting the performance service specifications.

Remark
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.

TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL

Use API performance classification CE engine oil.

When using SAE 5W-20 engine oil in the work equipment hydraulic system in cold areas, return to SAE 10W when the cold
season ends.

AXLE OIL
For axle oil, use only the recommended oil as follows:

SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL

* It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise may
result, durability should not be affected.

01-10 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS

GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.

DIESEL FUEL
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

Remark
The precise tolerances of diesel injection systems require that the fuel be kept clean and free of dirt and/or
water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.

For normal service above -12°C (+10°F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is
recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.

At operating temperatures below -12°C (+10°F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce fuel
economy.

Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel.
However, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.

Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel.

The viscosity of the fuel must be kept above 1.3 cSt at 100°C (212°F) to provide adequate fuel system lubrication.

WA500-3H 01-11
GENERAL FUEL, COOLANT AND LUBRICATNTS

COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).

Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled See “SUPPLEMENTAL COOLANT
ADDITIVES” on page 14. The coolant mixture must be drained and replaced at the specified service interval shown in the
"MAINTENANCE SCHEDULE CHART" in your ORPERATION AND MAINTENANCE MANUAL or every two years of
operation, whichever comes first.

WATER
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must
meet the following standards:

Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause
scale deposits to develop in the engine.

Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. "Softened" water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.

Remark
Never use water alone in the cooling system because corrosion will occur.

ANTIFREEZE
In climates where the temperature is above -37°C (-34°F), use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is
required. Never use more than 68 percent antifreeze under any condition.

An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should
not be used due to reduced heat transfer rates.

Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.

Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain
corrosion protection.

Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.

01-12 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS
12
Remark
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system.
Sealer or anti-leak additives will cause plugging problems in the cooling system.

Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing.

The following table shows the approximate percentage of antifreeze solution required for various temperatures.

Percentage of Antifreeze Concentration

Approximate Freezing Point Specific Gravity at 60°F (16°C)
by Volume
+32°F (0°C) 0 1.000

+20°F (-7°C) 15 1.025

+10°F (-12°C) 25 1.040

0°F (-18°C) 33 1.053

-10°F (-23°C) 40 1.062

-20°F (-29°C) 45 1.070

-30°F (-34°C) 48 1.074

-40°F (-40°C) 53 1.080

-50°F (-46°C) 56 1.083

-60°F (-51°C) 59 1.088

-70°F(-57°C) 62 1.092

-80°F(-62°C) 65 1.095

-90°F(-68°C) 67 1.097

-92°F(-96°C) 68 1.098

In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor SCA, to protect the engine cooling
system.

WA500-3H 01-13
GENERAL FUEL, COOLANT AND LUBRICATNTS

SUPPLEMENTAL COOLANT ADDITIVES

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal
operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and
attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners
which contain these additives must be added to maintain corrosion protection.

2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.

3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.

4. SCA is recommended to inhibit corrosion in the cooling system for the following reasons:

• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over-concentration occurs
• Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES

Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.

New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in the
"MAINTENANCE SCHEDULE CHART" in your ORPERATION AND MAINTENANCE MANUAL with a service DCA4
filter.

Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly charged
with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table entitled, “DCA4
Unit Guide”.

If coolant is added between drain intervals, additional SCA will be required.

COOLANT TESTING FOR CONDITIONER CONCENTRATION

When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA
concentration must not fall below 1.0 unit per 3.8 liters (1 US gal) or exceed 2.0 units per 3.8 liters (1 US gal) of coolant. The
only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis.
For this reason, the coolant inhibitor should be maintained as shown in the "GUIDES TO MAINTENANCE" in your
ORPERATION AND MAINTENANCE MANUAL.
Remark
Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to
cooling system components. Over concentration can cause formation of "gel" that can cause restriction,
plugging of passages and overheating.
REPLENISHING COOLANT CONDITIONER

Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a
service DCA4 filter as specified in the "MAINTENANCE SCHEDULE CHART" in your ORPERATION AND
MAINTENANCE MANUAL. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 liters (1 US gal) of
antifreeze.
Remark
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.

01-14 WA500-3H
GENERAL FUEL, COOLANT AND LUBRICATNTS

SCA UNIT MAINTENANCE GUIDE

Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must
be supplied through periodic additions of supplemental coolant additives to the coolant.

To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon] of
coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil and
filter change interval.

Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use the
appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under
“General”.

The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer
to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or exceed 0.5
units per liter [0.5 units per U.S. gallon or exceed 2.0 units per U.S. gallon].

DCA4 Unit Guide

Fleetguard Part No. DCA4 Units

DCA4 Coolant Filter

WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0

DCA4 Liquid (1 Pint)

DCA60L 1760 (55 US gal)
DCA80L

DCA4 Powder 20
DCA95

DCA4 Precharge and Service Filters

System Capacity Precharge Filter Service Filter

(See NOTE 1) (See NOTE 3)
Liters Gallons
19-26 5-7 WF-2072 WF-2070
30-38 8-10 WF-2073 WF-2071
42-57 11-15 WF-2074 WF-2071
61-76 16-20 WF-2075 WF-2071
80-114 21-30 WF-2076 WF-2072
118-190 31-50 (See NOTE 2) WF-2073

NOTE 1:After draining and replacing coolant, always precharge the cooling system to maintain the SCA concentration
between 1.0 and 2.0 units per 3.8 liters (1 US gal).

WA500-3H 01-15
GENERAL FUEL, COOLANT AND LUBRICATNTS
Remark
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant
can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling
system components.

NOTE 2: To precharge cooling systems larger than 114 liters (30 gal) do the following:

• Install appropriate service filter listed in the above table based on cooling system capacity.

Example: 95 gal (360 liters) cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units

• The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part number
DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.

NOTE 3: Change the coolant filter at every engine oil and filter change interval to protect the cooling system.

Maintain a nominal SCA concentration of 1.0 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5 unit per 3.8
liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters (1 US gal) indicates an
over-concentrated coolant solution.

To check the SCA concentration level, use coolant test kit, CC-2606. Instructions are included with the test kit.

SCA Unit Concentration Guide

Number of Solution A Drops to

Coolant Condition Action Required
Cause Color Change

0 - 10 Drops Extremely under-concentrated -- less Initially charge the system to a

than 0.4 SCA units per 3.8 liters (1 US minimum of 1.0 SCA unit per 3.8 liters
gal) (1 US gal).

11 - 16 Drops Marginally under-concentrated -0.45 Add SCA liquid units to maintain 1.0
to 0.8 SCA units per 3.8 liters (1 US SCA unit per 3.8 liters (1 US gal)
gal) minimum or change the DCA 4 coolant
filter.
17 - 25 Drops Acceptable - 0.85 to 1.3 SCA units per None
3.8 liters (1 US gal)

26 - 35 Drops Highly acceptable - 1.35 to 2.0 SCA None

units per 3.8 liters (1 US gal)

36 - 55 Drops Marginally over-concentrated - 2.1 to Review maintenance practice.

3.3 SCA units per 3.8 liters (1 US gal)
Over 55 Drops Extremely over-concentrated
Drain 50% of the coolant and replace
with water antifreeze mixture. Retest
the system for correct SCA unit
concentration.

01-16 WA500-3H
 10 STRUCTURE AND FUNCTION

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
TORQUE CONVERTER AND TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
HYDRAULIC CIRCUIT FOR POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRANSMISSION CUTAWAY FOLDOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
OPERATION OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
TRANMISSION CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
ECMV (ELECTRONIC CONTROL MODULATION VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
OUTLINE OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ECMV AND PROPORTIONAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ECMV AND FILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
ACTUATION OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
LUBRICATING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
PILOT FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
LIMITED SLIP (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
DEMAND VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
STEERING SPOOL AT NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59

WA500-3H 10-1
STRUCTURE AND FUNCTION
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
FLOW AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
FLOW AMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
STEERING VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
RELIEF VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
ORBIT-ROLL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
STOP VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
DIVERTER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
BRAKE CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
RIGHT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
LEFT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
ACCUMULATOR (FOR BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
MACHINES WITH STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
OIL FILTER BY-PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
ACCUMULATOR (FOR PPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
FOR BUCKET / BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
FOR OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
PPC VALVE NEUTRAL POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
PPC VALVE POSITIONS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
2-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
FLOAT SELECTOR VALVE AND UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
BOOM AND DUMP SPOOLS AT HOLD POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
BOOM SPOOL AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
BOOM SPOOL AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
BOOM SPOOL AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
BUCKET SPOOL AT DUMP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
BUCKET SPOOL AT TILT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142

10-2 WA500-3H
STRUCTURE AND FUNCTION
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
AIR CONDITIONING (GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
BASIC INFORMATION ON AIR CONDITIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
PRINCIPLE OF COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
REFRIGERANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
FREON-TYPE GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
REFRIGERATOR OIL (LUBE OIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
AIR CONDITONING CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
RECEIVER WITH SIGHT GLASS (LIQUID TANK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
MONITOR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
MAIN MONITOR DISPLAY FUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
MAIN MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
TROUBLE DATA DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
MAINTENANCE MONITOR DISPLAY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MAINTENANCE MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
TRANSMISSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
SYSTEM STRUCTURE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
TRANSMISSION CONTROLLER POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
INPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
ECSS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
CONNECTOR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
SPEEDOMETER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
ENGINE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
RADIATOR WATER LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
ENGINE OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-199
ENGINE WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
TORQUE CONVERTER OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
ELECTRICAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205

WA500-3H 10-3
STRUCTURE AND FUNCTION
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
KICK-DOWN / HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
WHEN KICK-DOWN SWITCH IS OPERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
KICK-DOWN SWITCH OPERATION CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
ELECTRIC PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
PARKING BRAKE EMERGENCY RELEASE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
EMERGENCY BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
PARKING SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
NEUTRALIZER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ECSS WIRING DIAGRAM - FOLDOUT 10-225-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2 . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-4, (Sheet 1) (Part 2 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-5, (Sheet 1) (Part 3 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-6, (Sheet 1) (Part 4 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-7, (Sheet 1) (Part 5 of 5) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-8, (Sheet 2) (Part 1 of 4) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-9, (Sheet 2) (Part 2 of 4) . . . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4) . . . . . . . . . . 10-225
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4) . . . . . . . . . . . 10-225
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
ENGINE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-226
ENGINE - FRAME - FLOOR HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-227

10-4 WA500-3H
STRUCTURE AND FUNCTION GENERAL
12
GENERAL

OUTLINE

The power from the engine (1) is transmitted from the flywheel to damper (2) through the ring gear. The damper alleviates the
torsional vibration caused by the variation of the engine torque and transmits the power to torque converter (4) through drive
shaft (3). The torque converter converts the delivered torque according to the variation in the load on the oil used as the
medium, and transmits the power to the input shaft of transmission (10). The engine power then is transmitted to PPC pump
(7), steering pump (9), hydraulic pump (8), switch pump (6), and torque converter charging pump (5) through the pump driv-
ing gear in torque converter (4).

In transmission (10), the six hydraulic clutches are operated by the forward-reverse spool and the speed change spools in the
transmission valves, which are themselves activated by solenoid valves. Thus, the desired travel speed can be selected from
among the 4 forward and 4 reverse gear speeds.

A multiple disc parking brake is installed to the output shaft of transmission (10). At the front end, the power from the output
shaft passes through center drive shaft (12) and front drive shaft (14) and is transmitted to front differential (15), at the rear end
it is transmitted to rear differential (20) by rear drive shaft (19).

The power transmitted to front differential (15) and rear differential (20) is transmitted to the axle shafts.

The power from the axle shafts has its speed reduced by final drives (16) and (21), and it is then transmitted to tires (18) and
(23) through the planetary carrier.

WA500-3H 10-5
STRUCTURE AND FUNCTION GENERAL
12

1. Engine 9. Steering pump 17. Front brake

2. Damper 10. Transmission 18. Front tire

3. Upper drive shaft 11. Parking brake 19. Rear drive shaft

4. Torque converter 12. Center drive shaft 20. Rear differential

5. Torque converter charging pump 13. Center support 21. Rear final drive

6. Switch pump 14. Front drive shaft 22. Rear brake

7. PPC pump 15. Front differential 23. Rear tire

8. Hydraulic pump 16. Front final drive

10-6 WA500-3H
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER

RADIATOR AND OIL COOLER

1. Radiator
2. Coolant level sensor
3. Fan guard
4. Torque converter oil cooler
5. Hydraulic oil cooler
SPECIFICATIONS:
Radiator
• Radiator core type: G7 type
• Total heat dissipation area: 98.44 m2
• Cross-sectional area of water flow: 193.8 cm2

A. Coolant inlet port Torque converter oil cooler

B. Coolant outlet port • Type: PTO-OL (multiple disc type)
C. Hydraulic oil outlet port • Heat dissipation area: 1829 m2
D. Hydraulic oil inlet port • Type: SF-2 (Air to Air)
E. Torque converter oil outlet port • Heat dissipation area: 14.04 m2
F. Torque converter oil inlet port

Hydraulic oil cooler

• Type: PTO-LS (multiple disc type)
• Heat dissipation area: 1.147 m2

WA500-3H 10-7
STRUCTURE AND FUNCTION DAMPER
12
DAMPER

1. Coupling 5. Bearing

2. Output shaft 6. Outer body

3. Cover 7. Rubber cushion

4. Bearing 8. Inner body

FUNCTION

The damper reduces the twisting and vibration caused by the variations in the engine torque, and acts to protect the engine and
other parts from such twisting and vibration.

10-8 WA500-3H
STRUCTURE AND FUNCTION DAMPER
12
OPERATION

The engine power is transmitted to the flywheel and outer body (6) and rubber cushion (7) absorbs the twist and vibration of
the engine. The engine power is then transmitted through the inner body (8) to output shaft (2). From here, the engine power is
transmitted through the coupling to the torque converter and drive shaft.

WA500-3H 10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
12
TORQUE CONVERTER AND TRANSMISSION PIPING

1. Transmission 7. a. Oil cooler (water-cooled type)

2. Transmission valve 7. b. Oil cooler (air-cooled type)

3. Torque converter 8. Torque converter charging pump

4. Accumulator 9. Parking brake solenoid valve

5. Parking brake emergency release valve 10. Oil filter

6. Radiator 11. Parking brake

10-10 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
12

MEMORANDUM

WA500-3H 10-11
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR POWER TRAIN
12
HYDRAULIC CIRCUIT FOR POWER TRAIN

10-12 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
12
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN

1. Transmission case 11. Pilot oil filter 22. Flow detector valve

2. Strainer 12. Parking brake solenoid valve 23. Pressure control valve

13. Parking brake emergency release

3. Torque converter charging pump 24. FORWARD clutch
valve

4. Torque converter oil filter 14. Accumulator 25. REVERSE clutch

5. Main relief valve 15. Parking brake 26. 3rd clutch

6. Torque converter relief valve 16. FORWARD ECMV 27. 4th clutch

7. Torque converter 17. REVERSE ECMV 28. 2nd clutch

8. a. Oil cooler (water-cooled type) 18. 3rd ECMV 29. 1st clutch

8. b. Oil cooler (air-cooled type) 19. 4th ECMV

9. Transmission lubrication 20. 2nd ECMV

10. Lubrication relief valve 21. 1st ECMV

WA500-3H 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
12
TORQUE CONVERTER AND PTO

10-14 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
12
Flow of motive force

The torque converter is installed between the damper and transmission.

The motive force from the damper passes through the drive shaft and enters
drive case (7). Drive case (7), pump (10) and PTO gear (drive) (13) are
fixed with bolts. They are rotated directly by the rotation of the engine.

The motive force of pump (10) uses oil to rotate turbine (8). This transmits
motive force to transmission input shaft (12).

The motive force of drive case (7) passes through PTO gear (drive) (13)
and is also used as the motive force to drive the gear pump.

Flow of oil

The oil pressure is adjusted by the torque converter relief valve and then
enters inlet port A, passes through the oil passage in housing (9) and flows
to pump (10). In pump (10) centrifugal force is applied. The oil enters tur-
bine (8) and the energy of the oil is transmitted to the turbine.

Turbine (8) is fixed to transmission input shaft (12), so the motive force is
transmitted to the transmission input shaft (12).

The oil from turbine (8) is sent to stator (11) and again enters the pump.
However, part of the oil passes from the stator through outlet port B and is
sent to the cooler.

WA500-3H 10-15
STRUCTURE AND FUNCTION TRANSMISSION
12
TRANSMISSION

1. Main relief, torque converter relief valve 6. Parking brake

2. Transmission valve 7. Output coupling (front)

3. Transmission input shaft 8. Output coupling (rear)

4. Transmission 9. Oil filler port

5. Transfer 10. Strainer

10-16 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12

A. To torque converter I. Mount port for parking brake actuation pilot lamp

B. From torque converter case J. To torque converter charging pump

C. Breather mount port K. To REVERSE clutch

D. From oil filter L. To 3rd clutch

E. Transmission main oil pressure port M. To 1st clutch

F. To parking brake emergency release valve N. To 2nd clutch

G. Lubricating oil pressure port O. To 4th clutch

H. From oil cooler P. To FORWARD clutch

WA500-3H 10-17
STRUCTURE AND FUNCTION TRANSMISSION
12
TRANSMISSION CUTAWAY FOLDOUT
Refer to FOLDOUT 10-18 in Section 90.

1. Input shaft 11. No. 3 clutch 21. No. 6 gear (90 teeth)

2. No. 1 sun gear (22 teeth) 12. No. 3 ring gear (75 teeth) 22. No. 6 clutch

3. No. 1 planet gear (24 teeth) 13. No. 4 sun gear (33 teeth) 23. No. Output shaft

4. No. 1 ring gear (90 teeth) 14. No. 4 planet gear (21 teeth) 24. No. 5 carrier

5. No. 1 clutch 15. No. 4 ring gear (21 teeth) 25. No. 3, 4 carrier

6. No. 1 idler gear (70 teeth) 16. No. 4 clutch 26. No. 2 planet gear (23 teeth)

7. Lubrication relief valve 17. No. 5 sun gear (39 teeth) 27. No. 2 sun gear (23 teeth)

8. No. 2 clutch 18. No. 5 planet gear (21 teeth) 28. No. 2 carrier

9. No. 3 sun gear (15 teeth) (Output

19. No. 5 ring gear (75 teeth) 29. No. 1 carrier
shaft)

10. No. 3 planet gear (30 teeth) 20. No. 5 clutch 30. No. 2 ring gear (75 teeth)

10-18 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
OUTLINE

The transmission consists of a 4-FORWARD, 4-REVERSE speed Speed range Clutch combination
planetary gear transmission, transfer, and transmission F1 No.2, No. 6
control valve. In the transmission, the motive force of the input shaft is
changed by the combination of No.1 or No.2 clutch with No. 3, 4, 5 or 6 F2 No.2, No. 5
clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft F3 No.2, No. 4
F4 No.2, No. 3

R1 No.1, No. 6

R2 No.1, No. 5
R3 No.1, No. 4

R4 No.1, No. 3

OPERATION OF CLUTCH
Engaged

The oil sent from the transmission control valve passes through the oil
passage inside the transmission. When it reaches the rear piston (1), it
moves the piston (1).

When the piston (1) moves, disc (2) and plate (3) are pressed together. Ring
gear (4) is meshed with disc (2), so the rotation is stopped.

Disengaged

When the supply of oil from the transmission control valve is shut off, the
pressure of the oil is acting on the rear of piston (1) is reduced. The piston
is then pushed back to the right by return spring (5), and disc (2) and plate
(3) are separated. Ring gear (4) then rotates freely, and no motive force is
transmitted.

WA500-3H 10-19
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 1ST

In 1st FORWARD, No. 2 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).

No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (15) in position. No. 6
clutch is actuated by the hydraulic oil pressure applied to the clutch piston and holds gear (29) to carrier (32).

The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).

Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). This carrier is connected to No. 5 carrier (32) through No. 4 ring gear (23, so when No. 6 clutch is
actuated, the rotation of carrier (32) is transmitted to gear (29) and rotates output shaft (31).

10-20 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 2ND

In 2nd FORWARD, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).

No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (27) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).

Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). The rotation of carrier (33) is transmitted through ring gear (23) to carrier (32).

Ring gear (27) is held in position by No. 5 clutch, so the rotation of carrier (32) rotates planetary gear (26). The planetary gear
rotates on the inside of ring gear (27), and rotates sun gear (25). The sun gear rotates output shaft (31).

WA500-3H 10-21
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 3RD

In 3rd FORWARD, No. 2 clutch and No. 4 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).

No. 2 clutch and No. 4 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (23) in position.

The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (14) through sun gear (13).

Ring gear (15) is held in position by No. 2 clutch, so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). Ring gear (23) is held in position by No. 4 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (22) rotates on the inside of ring gear (23), and rotates sun gear (21). The sun gear rotates output shaft (31).

10-22 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12
FORWARD 4TH

In 4th FORWARD, No. 2 clutch and No. 3 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).

No. 2 clutch and No. 3 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (19) in position.

The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (14) through sun gear (13).

Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). Ring gear (19) is held in position by No. 3 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (18). The planetary (18) rotates on the inside of ring gear (19), and rotates sun gear (17), which forms one unit
with output shaft (31).

WA500-3H 10-23
STRUCTURE AND FUNCTION TRANSMISSION
12
REVERSE 1ST

In 1st REVERSE, No. 1 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).

No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks carrier (35) in position. No. 6 clutch
is actuated by the hydraulic pressure applied to the clutch piston and hold ring gear (29) in position.

The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (10) through sun gear (9).

Carrier (35) is held in position by No. 1 clutch, so the rotation of planetary gear rotates the ring gear. Ring gear (15) rotates in
the opposite direction from the input shaft. Ring gear (15) rotates carrier (34), and the rotation of carrier (34) rotates ring gear
(23), which then rotates carrier (32). Carrier (32) rotates No. 6 clutch (30). When No. 6 clutch is actuated, the rotation of car-
rier (32) is transmitted to gear (29) and rotates output shaft (31).

10-24 WA500-3H
STRUCTURE AND FUNCTION TRANSMISSION
12

MEMORANDUM

WA500-3H 10-25
STRUCTURE AND FUNCTION TRANMISSION CONTROL VALVE
12
TRANMISSION CONTROL VALVE

1. ECMV for FORWARD clutch A. FORWARD clutch oil pressure port

2. ECMV for REVERSE clutch B. REVERSE clutch oil pressure port

3. ECMV for 3rd clutch C. 3rd clutch oil pressure port

4. ECMV for 4th clutch D. 4th clutch oil pressure port

5. ECMV for 2nd clutch E. 2nd clutch oil pressure port

6. Parking brake solenoid valve F. 1st clutch oil pressure port

7. ECMV for 1st clutch G. To parking brake emergency release valve

8. Pilot filter H. To parking brake emergency release valve (Pilot pressure)

10-26 WA500-3H
STRUCTURE AND FUNCTION TRANMISSION CONTROL VALVE

ECMV actuation table

Clutch
Speed range
FORWARD REVERSE 3rd 4th 2nd 1st

Auto ● ●
N
Manual ● ● ● ●

F1 ● ●

F2 ● ●

F3 ● ●

F4 ● ●

R1 ● ●

R2 ● ●

R3 ● ●

R4 ● ●

★ When at manual N, the clutch of the speed range where the gear shift lever is placed, is ON.

WA500-3H 10-27
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
ECMV (ELECTRONIC CONTROL MODULATION VALVE)

A. To clutch 1. Connector

D. Drain port 2. Connector

P. From pump

T. Clutch drain port

10-28 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12

3. Spring 7. Pin

4. Pressure control valve spool 8. Spring

5. Proportional solenoid 9. Flow detector valve spool

6. Fill switch

WA500-3H 10-29
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
OUTLINE OF ECMV
The ECMV (Electronic Control Modulation Valve) consist of two valves:
The pressure control valve and the flow detection valve.
Pressure control valve

The proportional solenoid receives the flow of electricity sent from the
transmission controller, and the pressure control valve converts this into
hydraulic pressure.
Flow detection valve

This valve is actuated by a trigger from the pressure control valve and has
the following functions:

1. When the clutch is filled with oil, it sends a signal (fill signal) to the
controller to inform the controller that the filling is completed.

2. While oil pressure is applied to the clutch, it outputs a signal (fill

signal) to the controller to inform the controller of the existence of the
oil pressure.

ECMV AND PROPORTIONAL SOLENOID

There is one proportional solenoid installed to each ECMV. It generates
propulsion as shown in the diagram on the right according to the command
current from the transmission controller.

The propulsion generated by the proportional solenoid acts on the pressure

control valve spool and generates oil pressure as shown in the diagram on
the right. In this way, the command current is controlled and the propulsion
force varies to actuate the pressure control valve and control the oil flow
and oil pressure.

ECMV AND FILL SWITCH

There is one fill switch installed to each ECMV. When the filling of the
clutch is completed, the fill switch is turned on by the action of the flow
detection valve. With this signal, the oil pressure starts the build-up.

10-30 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
ACTUATION OF ECMV
The ECMV is controlled by the command current from the transmission
controller to the proportional solenoid and the fill switch output signal. The
relationship between ECMV proportional solenoid command current and
the clutch input pressure and fill switch output signal is as shown in the
diagram on the right.

Range A: Before shifting gear (when draining)

Range B: Fill starts (during trigger)
Range C: Fill completed
Range D: Pressure adjustment
Range E: During filling

1. Before gear shifting (during draining) - Range A in graph.

When no current is flowing to proportional solenoid (5), proportional
solenoid (5) is pushed back by the reaction of pressure control valve
spring (3) through pressure control valve spool (4), so pressure control
valve (4) drains the oil at clutch port A through drain port T.

When this happens, there is no hydraulic force acting on flow

detection valve spool (9), so flow detection valve spool (9) is
separated from fill switch (6) by the reaction force of fill switch spring
(8).

WA500-3H 10-31
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
2. Start of fill (when trigger command is input to pressure control valve) -
Range B in graph (See graph on page prior).
When there is no oil inside the clutch, if the trigger current is applied
to proportional solenoid (5) (if the maximum current is applied), the
proportional solenoid moves and pressure control valve spool (4)
moves to the left.
As a result, the circuit between pump port P and the pressure control
valve output port B opens, and oil passage through orifice “a” of flow
direction valve spool (9) and starts to fill the clutch.

3. Filling completed (pressure control valve set to default pressure)

Range C in graph (See graph on page prior).

A. To reduce the transmission shock, action must be taken to prevent

peak pressure from being generated at clutch port A when the
filling is completed. In order to do this, the electric current in
proportional solenoid (5) is lowered to the default pressure before
the filling is completed and pressure control valve spool (4) is
moved to the right.
This allows a small amount of oil to leak from pressure control
valve output port B to drain port T. In this way, the generation of
peak pressure at clutch port A can be prevented when the filling is
completed.

B. When the clutch is filled with oil, the oil stops flowing from
pressure control valve output port B to clutch port A. The area
receiving the pressure on the left and right sides of orifice a of
flow detection valve spool (9) is different. The left side is larger,
so when the oil pressure on both sides of orifice a becomes equal,
fill switch spring (8) is compressed, and as a result, pin (7)
contacts fill switch (6) and sends the clutch fill completion signal
to the shift controller. At this point, the default pressure current is
flowing to proportional solenoid (5), and the oil pressure is set to
the default pressure setting by pressure control valve spool (4).

10-32 WA500-3H
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
4. Adjusting pressure (Range D in graph)
When electric current flows to proportional solenoid (5), the solenoid
generates a force proportional to the current. The total of this
propulsion force of the solenoid and the propulsion force of the oil
pressure at the clutch port and the reaction force of pressure control
valve spring (3) is balanced. Flow detection valve spool (9) is pushed
to the right by the difference in the force of the oil pressure applied to
both sides of orifice a, and it continues to send the fill signal to the
shift controller.

WA500-3H 10-33
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
12
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE

1. Body 6. Main relief valve A. Drain port (torque converter relief) P1 Main relief oil pressure detection port

2. Torque converter relief valve 7. Valve spring B. Drain port

3. Valve spring 8. Piston spring C. From pump

4. Piston 9. Piston D. Drain port

5. Piston spring E. To torque converter

OUTLINE
Specified pressure
1. Main relief valve
Main relief valve (6) sets the pressure of the transmission oil. 35.9 kgf/cm2 (510.6 lbf/
Main relief pressure
in2) engine at rated speed
2. Torque converter relief valve
Torque converter relief valve (2) acts to protect the torque converter Torque converter inlet 8.5 kgf/cm2 (120.8 lbf/in2)
port pressure cracking pressure
from abnormally high pressure. It relieves the pressure when the
pressure at the port of the torque converter goes above the inlet
specified pressure.

10-34 WA500-3H
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
12
MAIN RELIEF VALVE
OPERATION

The oil from the torque converter charging pump passes through the filter,
enters port A of the main relief valve, and then passes through orifice a and
enters port B. When the oil from the pump fills the circuit, the pressure
starts to raise. When the oil pressure in the circuit rises, the oil entering port
B pushes piston (4). The reaction compresses spring (7) and moves main
relief valve (6) to the left to open the passage between port A and port C.
When this happens, the oil from the pump is relieved from port A to port C
and flows from port C into the torque converter. The oil pressure at port A
at this point is 35.9 kgf/cm2 (510.6 lbf/in2) when the engine is at rated
speed.

TORQUE CONVERTER RELIEF VALVE

OPERATION

The oil relieved from the main relief valve flows from port C into the
torque converter, and at the same time, passes through orifice b and enters
port D. When the oil fills the circuit to the torque converter, the oil pressure
starts to raise.

When the oil pressure in the circuit to the torque converter rises, the oil
entering port D pushes piston (9). The reaction compresses spring (3), and
moves relief valve (2) to the right to open the passage between port C and
port E. When this happens, the oil from port C is relieved to port E and
flows to the transmission lubrication circuit. The oil pressure at port C at
this point is 8.5 kg/cm2 (120.8 lbf/in2) cranking (starting) pressure.

WA500-3H 10-35
STRUCTURE AND FUNCTION LUBRICATING RELIEF VALVE
12
LUBRICATING RELIEF VALVE

1. Piston A. From oil cooler

2. Spring B. Drain

3. REVERSE clutch housing C. Drain

OUTLINE
Unit: kgf/cm2 (lbf/in2)
The lubricating relief valve is assembled to the left face of the REVERSE
clutch housing, and protects the lubricating circuit and oil cooler
Specified value

Pressure when normal 1.5 - 2.3 (21.3 - 32.7)

Cracking pressure 3.0 (42.6)

10-36 WA500-3H
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
12
TORQUE CONVERTER OIL FILTER

OPERATION

The oil from the torque converter charging pump enters the filter inlet port
A and passes from the outside of element (2) to the inside. It then flows to
the outlet port B.

If the element (2) is clogged with dirt, or the oil temperature is low, the
pressure at the inlet port A rises. When this happens, the oil from the inlet
port A opens relief valve (1) and flows directly to the outlet port B. This
prevents damage to the pump or element (2).

WA500-3H 10-37
STRUCTURE AND FUNCTION PILOT FILTER
12
PILOT FILTER

SPECIFICATIONS

Filter mesh size: 10

Filtering area: 0.063 m2 (630 cm2)
Element pressure resistance: 4.9 MPa (50 kg/cm 2)

OUTLINE

The oil flows from the transmission case to pump to torque converter oil filter, and is then divided and flows to the torque
converter and transmission control valve.
There is a pilot filter installed at the inlet port of the transmission control valve, and this filters the dirt out of the oil flowing to
the control valve.

10-38 WA500-3H
STRUCTURE AND FUNCTION TRANSFER
12
TRANSFER

1. Transmission output shaft 5. Output shaft

2. Transfer input gear (teeth 28) 6. Front coupling

3. Transfer idler gear (teeth 45) 7. Rear coupling

4. Output gear (teeth 43) 8. Parking brake

OUTLINE

The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts.

TRANSMISSION PATH

Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output
gear (4) through idler gear (3) and output shaft (5).

Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive
shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft.

WA500-3H 10-39
STRUCTURE AND FUNCTION DRIVE SHAFT
12
DRIVE SHAFT

1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft

3. Center drive shaft

OUTLINE

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

When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during
operations, the axle in front and behind the engine and transmission change position.

To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the
components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in
angle and length.

10-40 WA500-3H
STRUCTURE AND FUNCTION CENTER SUPPORT
12
CENTER SUPPORT

1. Front coupling 3. Grease fitting

2. Case 4. Rear coupling

FUNCTION

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

WA500-3H 10-41
STRUCTURE AND FUNCTION AXLE
12
AXLE

FRONT

10-42 WA500-3H
STRUCTURE AND FUNCTION AXLE
12
REAR

WA500-3H 10-43
STRUCTURE AND FUNCTION DIFFERENTIAL
12
DIFFERENTIAL

NORMAL - (STANDARD)

FRONT

1. Slide gear (18 teeth) 4. Pinion (10 teeth)

2. Bevel pinion (9 teeth) 5. Shaft

3. Bevel gear (37 teeth)

10-44 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
REAR

1. Bevel gear (37 teeth) 4. Pinion (10 teeth)

2. Shaft 5. Bevel pinion (9 teeth)

3. Slide gear (18 teeth)

WA500-3H 10-45
STRUCTURE AND FUNCTION DIFFERENTIAL
12
OUTLINE

The motive force from the drive shaft passes through bevel pinion (1) and
is transmitted to the bevel gear (5). The bevel gear changes the direction of
the motive force by 90° and at the same time reduces the speed. It then
transmits the motive force through the differential (4) to the sun gear shaft
(2).

WHEN DRIVING STRAIGHT FORWARD

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

WHEN TURNING

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

10-46 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
LIMITED SLIP (OPTION)

1. Washer 5. Cover 9. Case

2. Disc 6. Shaft 10. Pinion

3. Plate 7. Side gear 11. Bevel pinion

4. Pressure ring 8. Shaft

Operation of limited slip differential

The power transmitted from the transmission goes from bevel pinion (11) to case (9), pressure ring (4), shaft (8), pinion (10),
side gear (7) and is then divided and sent to left and right shafts (6). A brake mechanism consisting of disc (2) and
washer (1) is assembled at the rear face of side gear (7), and the brake torque is generated in proportion to the torque
transmitted from pressure ring (4) to shaft (8).
In order for this brake torque to act to suppress the rotation in relation to side gear (7) and case (9), it is made difficult for left
and right side gears (7) to rotate mutually, and the action of the differential is suppressed.

WA500-3H 10-47
STRUCTURE AND FUNCTION DIFFERENTIAL
12
Mechanism for generation of brake torque of left and right side
gears (6)

Shaft (8) is supported by the cam surface cut into the mating surfaces of
left and right pressure rings (4). The power (= torque) transmitted from
pressure ring (4) to shaft (8) is transmitted by the cam surface, but force Fa
to separate left and right pressure rings (4) is generated in proportion to the
torque transmitted by the angle of this cam surface. This separation load Fa
acts as a brake on the rear face of left and right side gears (7) and
generates brake torque.

When travelling is straight line

1. When there is no imbalance between drive force of left and right

wheels
[The road surface condition (friction coefficient) for the left and right
wheels and the load on the wheels are uniform, so there is no misalign-
ment of the center line of the load to the bucket].
The power from the transmission is divided uniformly to the left and
right by the limited slip differential. Under these conditions, the limit
for wheel slip for the left and right wheels is the same, so even if the
power from the transmission exceeds the wheel slip limit, the wheels
on both sides slip and the differential is not actuated.
No load is applied to the brake at the rear surface of the side gear.

10-48 WA500-3H
STRUCTURE AND FUNCTION DIFFERENTIAL
12
2. When there is imbalance between drive force of left and right wheels
[The road surface condition (friction coefficient) for the left and right
wheels and the load on the wheels are not uniform and the wheel on
one side tends to slip more than the wheel on the other side.]

Example 1: When wheel on one side is on soft ground surface during

digging operations

Example 2: When wheel on one side is on asphalt surface and wheel

on other side is on snow during snow clearing operations

Example 3: When imbalance is created in load on left and right wheels

by traveling on slope.

The power from the transmission is divided uniformly to the left and
right by the actuating gear. However, if the divided drive force exceeds
the wheel slip limit on the side where the wheel is slipping, a drive
force equal to the excess is sent through the brake at the rear face of
the side gear and the case to the brake on the opposite side (side where
wheel is locked), and is supplied to the wheel on the side which is
locked. If this excess drive force becomes greater than the braking
force, the differential starts to be actuated.

Difference in wheel drive force for each type of differential when

wheel on one side is slipping.

Wheel drive force (taken as 1 for wheel that is slipping)

Slipping wheel Locked wheel Total (proportional)

Limited slip
differential 1 2.64 3.64 (1.82)
(option)

Torque
proportioning
1 1.38 2.38 (1)
differential
(standard)

Normal
1 1 2 (0.84)
differential

On road surfaces where the wheel on one side is likely to slip, the limited slip differential increases the drive force 1.82 times
that of the torque proportioning differential supplied as standard.

When turning

The actuating gear built into the limited slip differential is the same as the gear used on the normal differential, so the
difference in rotation of the inside and outside wheels generated when turning can be generated smoothly.

WA500-3H 10-49
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE

1. Axle shaft 4. Planetary carrier

2. Planetary gear (29 Teeth) 5. Sun Gear (18 Teeth)

3. Ring gear (78 Teeth) 6. Wheel

OUTLINE

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

10-50 WA500-3H
STRUCTURE AND FUNCTION FINAL DRIVE
12
OPERATION

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

WA500-3H 10-51
STRUCTURE AND FUNCTION AXLE MOUNT
12
AXLE MOUNT

10-52 WA500-3H
STRUCTURE AND FUNCTION AXLE MOUNT
12

1. Front axle 4. Rear frame

2. Rear axle 5. Axle mounting bolts

3. Front frame

FRONT AXLE

The front axle (1) receives the force directly during operations, so it is fixed directly to the front frame (3) by axle mounting
bolts (5).
REAR AXLE

The rear axle (2) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the
ground when traveling over soft ground.

WA500-3H 10-53
STRUCTURE AND FUNCTION CENTER HINGE PIN
12
CENTER HINGE PIN

1. Front axle 4. Rear frame

2. Rear axle 5. Upper hinge pin

3. Front frame 6. Lower hinge pin

OUTLINE

The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5) and (6). The steering cylin-
ders are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle
to give the desired angle, that is the desired turning radius.

10-54 WA500-3H
STRUCTURE AND FUNCTION TIRE AND WHEEL
12
TIRE AND WHEEL
The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with
the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose. Therefore it is
very important to select the correct tires for the type of work and bucket capacity.

1. Tire 4. Lock ring

2. Rim 5. Side ring

3. Air valve

SPECIFICATIONS

Tire type: 29.5 x 25, 22PR

TRA code:
Nominal size of wheel:
Nominal inflation pressure:
L3
22.00 x 25WTB
FRONT tire: 4.5 kgf/cm² (64.0 psi)
REAR tire: 3.5 kgf/cm² (49.8 psi)

WA500-3H 10-55
STRUCTURE AND FUNCTION STEERING PIPING
12
STEERING PIPING

1. Steering cylinder (R.H.) 5. Hydraulic pump 9. Stop valve (L.H.)

2. Orbit-roll valve 6. Oil cooler 10. Steering valve

3. Stop valve (R.H.) 7. Switch pump and PPC pump 11. Steering cylinder (L.H.)

4. Hydraulic tank 8. Steering pump

JOYSTICK STEERING ASSEMBLY DIAGRAM & STEERING LINE ASSEMBLY DIAGRAM

See Section 90 for illustration, Joystick Steering Assembly Diagram and Steering Line Assembly Diagram,
FOLDOUTS 10-54-1 thru 10-54-2.

10-56 WA500-3H
STRUCTURE AND FUNCTION STEERING COLUMN
12
STEERING COLUMN

1. Steering wheel 3. Joint

2. Steering column 4. Orbit-roll valve

WA500-3H 10-57
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING VALVE

1. Safety valve (with suction) 4. Relief valve

2. Check valve 5. Demand spool

3. Steering spool

10-58 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
DEMAND VALVE OPERATION
STEERING SPOOL AT NEUTRAL

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

When the pressure at pressure-receiving camber I reaches a certain value (set by spring {5}), notch f opens, and the oil from
the steering pump flows to the drain circuit. At the same time, notch g closes, and the oil from the switch pump all flows to the
main control valve.

WA500-3H 10-59
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED

When steering spool (2) is pressed (operated), pressure-receiving chamber III and the drain circuit are shut off, and at the same
time notch c opens. When this happens, the pressure in pressure-receiving chamber III rises, and demand spool (1) moves to
the right in the direction of the arrow until notch h closes. The passage from port B to the main control valve is shut off, so the
oil from switch pump pushes up merge check valve (3), and merges with the oil at port A from the steering pump.

The merged oil passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The oil returning
from the cylinder passes through notch e and enters the drain circuit. In this condition, the pressure before passing through
notch c goes to pressure-receiving chamber I, and the pressure after passing notch c goes to pressure-receiving chamber II.
Demand spool (1) moves to maintain the pressure difference on the two sides of notch c at a constant value. Therefore, a flow
corresponding to the amount of opening notch c is discharged from the cylinder port. These pressure differences (control
pressure) are set by spring (5).

10-60 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED

The extra oil from the switch pump is not needed, so the steering pump pressure rises until notch g closes, and shuts off the
merge passage at port B. The pressure difference on the two sides of notch c is controlled only by notch f, so the excess oil
from the steering pump is drained from notch f to drain the circuit (when this happens, notch g is completely closed.

The oil from steering pump passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The
oil returning from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the
switch pump is sent from port B to the main control valve.

WA500-3H 10-61
STRUCTURE AND FUNCTION STEERING VALVE
12
FLOW AMP

1. Steering spool 5. Cap A. From orbit-roll valve

2. Valve housing (body) 6. Bolt B. From orbit-roll valve

3. Spring seat 7. Orifice C. Passage (inside housing)

4. Return spring

FLOW AMP OPERATION

1. Spool at neutral (Orbit-roll valve not actuated)

When the Orbit-roll valve is not actuated, both pilot port PiA and pilot port PiB are connected through the Orbit-roll to the
drain (return) circuit, so steering spool (1) is kept at neutral by return spring (4).

10-62 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
2. Spool actuated (oil flows to port PiA)

When oil flows to port PiA, the pressure inside the cap end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering from port PiA passes through the hole in spring seat (3), through orifice (7) in steering spool (1), and then
flows to the opposite end (B end).

Port PiB is connected to the drain circuit through the Orbit-roll valve, so the oil flowing to end B is drained. The pressure
generated at port PiA is proportional to the amount of oil flowing in, so steering spool (1) moves to a position where the
opening of the flow amp notch balances the pressure generated with the force of return spring (4).

WA500-3H 10-63
STRUCTURE AND FUNCTION STEERING VALVE
12
3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)

When steering wheel (Orbit-roll valve) is stopped, ports PiA and PiB are both connected to the drain circuit through the
Orbit-roll valve. For this reason, steering spool (1) is returned to neutral position by return spring (4).

10-64 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING VALVE OPERATION
NEUTRAL

The steering wheel is not being operated, so steering spool (1) does not move. The oil from the steering pump enters port A,
the oil from the switch pump enters port B.

When the pressure at ports A and B rises, demand spool (4) moves to the left in the direction of the arrow. The oil from the
steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and
flows to the main control valve.

WA500-3H 10-65
STRUCTURE AND FUNCTION STEERING VALVE
12
TURNING RIGHT

When the steering wheel is turned to the right, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the left in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (4) of the spool, and the oil flows to the bottom end of the left cylinder and the rod end of the right cylinder to
turn the machine to the right.
The oil from the left and right cylinders passes through load check valve (3) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.

10-66 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
TURNING LEFT

When the steering wheel is turned to the left, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the right in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (3) of the spool, and the oil flows to the bottom end of the right cylinder and the rod end of the left cylinder to
turn the machine to the left.
The oil from the left and right cylinders passes through load check valve (4) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.

WA500-3H 10-67
STRUCTURE AND FUNCTION STEERING VALVE
12
STEERING RELIEF VALVE

1. Adjustment screw
2. Spring
3. Plug
4. Pilot popper
5. Valve seat

FUNCTION

The steering relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the
steering valve is actuated. When the steering valve is being actuated, if the steering circuit goes above the set pressure of this
valve, oil is relieved from this valve. When the oil is relieved, the flow control spool of the demand valve is actuated, and the
oil is drained to the steering circuit.

10-68 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
RELIEF VALVE OPERATION

When the pressure in the circuit rises, and it reaches the pressure set by adjustment screw (1) and spring (2), pilot poppet (4)
opens, and the oil is drained. When this happens, the balance in pressure between pressure-receiving chamber I and
pressure-receiving chamber II is lost, so demand spool (6) moves to the left in the direction of the arrow.

When demand spool (6) moves, the oil from the steering pump is drained, and the oil from the switch pump is released to the
main control valve. This prevents the pressure in the steering circuit from going above the set value.

WA500-3H 10-69
STRUCTURE AND FUNCTION STEERING VALVE
12
SAFETY VALVE (WITH SUCTION)
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring

FUNCTION

The safety valve is installed to the steering valve. It has the following two
functions:

1. When the steering valve is at neutral, if any shock is applied to the

cylinder, and an abnormal pressure is generated, the oil is relieved
from the valve. In this way, it functions as a safety valve to prevent
damage to the cylinder or hydraulic piping.

2. If negative pressure is generated at cylinder end, it functions as a

suction valve to prevent a vacuum from forming.

OPERATION

ACTING AS RELIEF VALVE

Port A is connected to the cylinder circuit and port B is connected to the

drain circuit. Oil passes through the hole in poppet (1) and acts on the
different areas of diameters d1 and d, so check valve poppet (3) and relief
valve poppet (2) are firmly seated in position.

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

When pilot poppet (4) opens, the pressure at the back of poppet (1) drops,
so poppet (1) moves and is seated with pilot poppet (4).

10-70 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
Compared with the pressure at port A, the internal pressure is low, so relief
valve poppet (2) opens. When this happens, the oil flows from port A to
port B, and prevents any abnormal pressure from forming.

ACTING AS SUCTION VALVE

When negative pressure is formed at port A, the difference in area of

diameters d3 and d4 causes check valve poppet (3) to open. When this
happens, the oil from port B flows to port A, and prevents any vacuum
from forming.

WA500-3H 10-71
STRUCTURE AND FUNCTION STEERING VALVE
12
ORBIT-ROLL VALVE

1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator

3. Drive shaft 7. Center pin 11. Lower cover

4. Valve body 8. Sleeve 12. Check valve

10-72 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
OUTLINE

The steering valve is connected directly to the shaft of the steering wheel. It
switches the flow of oil from the steering pump to the left and right steering
cylinders to determine the direction of travel of the machine.

The orbit-roll valve, broadly speaking, consists of the following

components: Rotary type spool (9) and sleeve (8), which have the function
of selecting the direction, and the Girotor set (a combination of rotor (5)
and stator (10)), which acts as a hydraulic motor during normal steering
operations, and as a hand pump (in fact, the operating force of the steering
wheel is too high, so it cannot be operated) when the steering pump or
engine have failed and the supply of oil has stopped.

STRUCTURE

Spool (9) is directly connected to the drive shaft of the steering wheel, and
is connected to sleeve (8) by center pin (7) (it does not contact the spool
when steering wheel is at neutral) and centering spring (2).

The top of drive shaft (3) is meshed with center pin (7), and forms one unit
with sleeve (8), while the bottom of the drive shaft is meshed with the
spline of rotor (5) of the Girotor.

There are four ports in valve body (4), and they are connected to the pump
circuit, tank circuit, and the circuits at the head end and bottom end of the
steering cylinders. The pump port and tank port are connected by the check
valve inside the body. If the pump or engine fail, the oil can be sucked in
directly from the tank by the check valve.

WA500-3H 10-73
STRUCTURE AND FUNCTION STEERING VALVE
12
CONNECTION BETWEEN HAND PUMP AND SLEEVE

The diagrams above show the connections with the sleeve ports used to
connect the suction and discharge ports of the Girotor.

If the steering wheel has been turned to the right, ports a, c, e, g, i, and k
are connected by the vertical grooves in the spool to the pump side. At the
same time, ports b, d, f, h, j, and l are connected to the head end of the left
steering cylinder in the same way.

In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the
Girotor set. They are connected to ports l, b, and d, so oil is sent to the
cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the
pump.

If the steering wheel is turned 90°, changes to the condition shown in Fig. 2. In this case ports 1, 2, and 3 are the suction ports,
and are connected to ports i, k, and c. Ports 5, 6, and 7 are the discharge ports, and are connected to ports d, f, and h.

10-74 WA500-3H
STRUCTURE AND FUNCTION STEERING VALVE
12
In this way the ports of the Girotor acting as delivery ports are connected to
ports which are connected to the end of the steering valve spool. The ports
acting as suction ports are connected to the pump circuit Adjusting delivery
in accordance with angle of the steering wheel:
For every 1/7 turn of the steering wheel, the inner teeth of the Girotor
gear advances one position so the oil flow from the pump is adjusted
by this movement. In this way, the oil delivered from the pump is
directly proportional to the amount the steering wheel is turned.

FUNCTION OF CENTER SPRING

Centering spring (2) consists of four layers of leaf springs crossed to form
an X shape. The springs are assembled in spool (9) and sleeve (8) as shown
in the diagram on the right. When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle variation) arises between the
spool and the sleeve. Because of this, the ports in the spool and sleeve are
connected and oil is sent to the cylinder. When the turning of the steering
wheel is stopped, the Girotor also stops turning, so no more oil is sent to
the cylinder and the oil pressure rises.

To prevent this, when the turning of the steering wheel is stopped, the
action of the centering spring only allows it to turn by an amount equal to
the difference in angle of rotation (angle variation) of the sleeve and spool,
so the steering wheel returns to the NEUTRAL position.

WA500-3H 10-75
STRUCTURE AND FUNCTION STOP VALVE
12
STOP VALVE

1. Boot 5. Spring A. From orbit-roll

2. Wiper 6. Spool B. To steering valve

3. Seal 7. Spring DR. To drain

4. Poppet

10-76 WA500-3H
STRUCTURE AND FUNCTION DIVERTER VALVE
12
DIVERTER VALVE

1. Spool A. From steering pump

2. Valve body B. To steering valve
3. Check valve C. To hydraulic tank
4. Check valve D. Sensor mounting port
E. Ground driven steering pump port
F. Ground driven steering pump port
G. From hydraulic tank

FUNCTION

If the engine stops or the pump seizes while the machine is traveling, it becomes impossible to steer, the rotation of the
transmission is used to turn the ground driven steering pump to make steering possible.

WA500-3H 10-77
STRUCTURE AND FUNCTION DIVERTER VALVE
12
OPERATION

1. 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 ground driven steering pump is rotated by the transmission,
so oil from port A of the diverter valve (1) pushes open check valve (2) and
enters port B.

Pressure oil from steering pump is flowing to port D, so it pushes spool (3)
in the direction of the arrow. As a result, the oil from port B flows to port C
and is drained to the hydraulic tank.

10-78 WA500-3H
STRUCTURE AND FUNCTION DIVERTER VALVE
12
2. Failure in pump or engine when machine is traveling.

If there is a failure in the pump or engine when the machine is traveling, the
rotation of the wheels is transmitted through the transfer to rotate the
ground driven steering pump. The steering pump is not rotating, so no oil
pressure is formed at port D.

As a result, spool (3) is pushed in the direction of the arrow by spring (4).
The oil from the ground driven steering pump passes from port A through
port B and flows to the steering valve to make steering possible.

The ground driven steering pump is designed so that it can rotate both
directions.

WA500-3H 10-79
STRUCTURE AND FUNCTION DIVERTER VALVE
12

MEMORANDUM

10-80 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
BRAKE

BRAKE PIPING

1. Brake valve (right) 7. Filter 13. Transmission control valve

2. Hydraulic tank 8. Accumulator 14. Parking brake (built into transmission)

3. Parking brake switch 9. Parking brake valve 15. Brake valve (left)

4. Emergency release parking brake

10. Slack adjuster (rear) 16. Front brake (left)
switch

5. Rear brake (right) 11. Rear brake (left) 17. Slack adjuster (front)

6. Charge valve 12. PPC pump (also for brake) 18. Front brake (right)

WA500-3H 10-81
STRUCTURE AND FUNCTION BRAKE
12

MEMORANDUM

10-82 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
BRAKE CIRCUIT DIAGRAM

1. Hydraulic tank 7. Rear slack adjuster 13. Brake valve (left)

2. Brake, PPC pump 8. Rear brake cylinder 14. Transmission (case)

3. Charge valve 9. Front slack adjuster 15. Torque converter charging pump

16. Transmission control valve

4. Check valve 10. Front brake cylinder
(Parking brake valve)
5. Accumulator (rear brake) 11. Check valve 17. Emergency parking brake

12. Accumulator (Front brake,

6. Brake valve (right) 18. Parking brake
emergency parking brake)

WA500-3H 10-83
STRUCTURE AND FUNCTION BRAKE
12
BRAKE VALVE
RIGHT BRAKE VALVE

1. Brake pedal (left, right brake) 6. Spool (right brake) A. Pilot port (right brake)
2. Rod (right brake) 7. Lower cylinder (right brake) B. To rear brake (right brake)

3. Pilot piston (right brake) 8. Rod (left brake) C. To front brake (right brake)

4. Spool (right brake) 9. Spool (left brake) D. Drain (left, right brake)
5. Upper cylinder (right brake) 10. Cylinder (left brake) E. To pilot port (left brake)

10-84 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
LEFT BRAKE VALVE

Remark
Legend is at left.

OUTLINE

There are two brake valves installed in parallel under the front of the operator’s cab, and these are actuated by depressing the
pedal.

When the right pedal is depressed, oil is sent to the brake cylinders to apply the brakes.

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

In addition, the left brake pedal operates the transmission cut-off switch to actuate the transmission solenoid valve electrically
and set the transmission to neutral.

WA500-3H 10-85
STRUCTURE AND FUNCTION BRAKE
12
OPERATION

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 cylinder.

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

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 PP enters port G from orifice d, and pushes pilot
piston (11). The spring pushes spool (3) down, so the operation is the same
as when the right brake valve is depressed.

10-86 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
Applying brake when upper valve fails (right brake valve)
Even if there is leakage of oil in the upper piping, spool (5) is moved down
mechanically when pedal (1) is depressed, and the lower portion is actuated
normally. The upper brake is not actuated.

Applying brake when lower valve fails (right brake valve)

Even if there is leakage of oil in the lower piping, the upper portion is actu-
ated 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 operat-
ing force of the pedal, and the pressure in the space in the lower portion is
balanced with the pressure in the space in the upper portion. When spools
(3) and (5) move to the end of their stroke, the circuits between ports A and
C and between ports B and D are fully opened, so the pressure in the space
in the upper and lower portions and the pressure in the left and right brake
cylinders is the same as the pressure from the pump. Therefore, up to the
point where the piston moves to the end of its stroke, the effect of the brake
can be adjusted by the amount that the pedal is depressed.

WA500-3H 10-87
STRUCTURE AND FUNCTION BRAKE
12
Brake released (right brake valve)
Upper portion
When brake pedal (1) is released and the operating force is removed from
the top of the spool, the back pressure from the brake cylinder and the force
of the spool return spring move spool (3) up. Drain port a is opened and the
oil from the brake cylinder flows to the hydraulic tank return circuit to
release the rear brake.

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

10-88 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
CHARGE VALVE

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

FUNCTION

The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and store it in the
accumulator.

When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load
on the pump.

WA500-3H 10-89
STRUCTURE AND FUNCTION BRAKE
12Operation

1. Valve body 4. PPC relief valve (R2)

2. Main relief valve (R3) 5. Relief valve (H1)

3. Relief valve (R1)

10-90 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
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.

2. When oil is supplied to accumulator

A. Cut-in condition
When the pressure at port B is lower than the set pressure of the
relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.

The spring chamber at the right end of spool (15) is also shut off
from port T, so the pressure rises, and the pressure at port P also
rises in the same way.

When the pressure at port P goes 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.

WA500-3H 10-91
STRUCTURE AND FUNCTION BRAKE
12
B. When cut-out pressure is reached
When the pressure at port B (accumulator pressure) reaches the
set pressure of the relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.

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 equiva-

lent to the load on spring (14), so the supply of oil to port B is
stopped.

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.

10-92 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
ACCUMULATOR (FOR BRAKE)
FUNCTION

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

1. Valve
2. Top cover
3. Cylinder
4. Piston

SPECIFICATIONS:

Gas used: Nitrogen gas

Charge amount: 4,000 cc
Charging pressure: 35 ± 1.5 kgf/cm2 (at 50° C)
(497.8 ± 21.3 lbf/in2[at 122° F])

WA500-3H 10-93
STRUCTURE AND FUNCTION BRAKE
12
SLACK ADJUSTER

1. Bleeder 4. Piston A. Inlet port

2. Cylinder 5. Spring B. Outlet port
3. Check valve

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: 0.1 + 0.1 kg/cm2 (1.42 ± 1.42 lbf/in2)

Check valve cracking pressure: 9.5 ± 0.5 kg/cm2 (13.51 ± 7.1 lbf/in2)
Check valve closing pressure: 6.0 ± 0.5 kg/cm2 (85.3 ± 7.1 lbf/in2)

10-94 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
OPERATION

1. When brake pedal is depressed

Before the brake is depressed, piston (4) is returned by the distance of
stroke 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 the 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 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.

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.

WA500-3H 10-95
STRUCTURE AND FUNCTION BRAKE
12
BRAKE

1. Guide pin 5. Outer gear (138 Teeth)

2. Return spring 6. Inner gear (105 Teeth)

3. Cylinder 7. Plate

4. Brake piston 8. Disc

FUNCTION

The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.

10-96 WA500-3H
STRUCTURE AND FUNCTION BRAKE
12
OPERATION

When the brake pedal is depressed, the pressure oil from the brake valve
moves brake piston (4) to the right in the direction of the arrow. This brings
disc (8) and plate (7) into contact, and friction is generated between the
disc and plate. The wheel is rotating together with the disc, so the machine
speed is reduced, and the machine is stopped by this friction.

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

WA500-3H 10-97
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKING BRAKE

PARKING BRAKE CONTROL

1. Parking brake switch 4. Parking brake solenoid valve

2. Parking brake emergency release switch 5. Transmission (built-in parking brake)

3. Transmission control valve

OUTLINE

See FOLDOUT 10-96 for electrical parking brake control diagram.

The parking brake is a wet-type multiple-disc brake built into the transmission. It is installed to the output shaft bearing, and
uses the pushing force of a spring to apply the brake mechanically and hydraulic power to release the brake.

When parking brake switch (1) installed in the operator’s compartment is switched ON, parking brake solenoid valve (4)
installed to the transmission control valve (3) shuts off the oil pressure and applies the parking brake. When the parking brake
switch is turned OFF, the oil pressure in the cylinder releases the parking brake.

When the parking brake is applied, the neutralizer relay shuts off the electric current to the transmission solenoid valve and
keeps the transmission at neutral.

10-98 WA500-3H
STRUCTURE AND FUNCTION PARKING BRAKE
Emergency release switch (2) for the parking brake is installed for use when moving the machine, if the machine has stopped
(the parking brake is automatically applied) because of trouble in the engine or drive system.

PARKING BRAKE

1. Output shaft 4. Plate

2. Piston 5. Spring

3. Disc

OUTLINE

The parking brake is a wet-type multiple-disc brake. It is actuated mechanically by a spring and applies the braking force to
output shaft (1) of the transmission.

The pushing force of spring (5) pushes piston (2), plate (4), and disc (3) into contact and applies the braking force to stop
output shaft (1).

WA500-3H 10-99
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKING BRAKE SOLENOID VALVE

OPERATION

Parking brake applied (solenoid deactivated)

When the parking brake switch in the operator’s compartment is turned
ON, the solenoid is turned OFF and spool (6) is pushed to the left by spring
(5). When this happens, the passage between pump port P and parking
brake port A is closed, and the pressure oil from the pump does not flow to
the parking brake.

At the same time, the pressure oil from the parking brake flows from port A
to port T and is drained. As a result, the disc inside the parking brake is
pushed by the spring and the parking brake is applied.

When the parking brake switch is turned OFF, the solenoid is turned ON
and spool (6) is moved to the right. As a result, the pressure oil from the
pump passes from port P through the inside of spool (6), flows to port A
and then flows to the parking brake. At the same time, port T is closed, so
the oil is not drained. As a result, the spring inside the parking brake is
pushed back by the oil pressure and the parking brake is released.

10-100 WA500-3H
STRUCTURE AND FUNCTION PARKING BRAKE
12
PARKINGBRAKE EMERGENCY RELEASE
SOLENOID VALVE
1. Valve assembly
2. Solenoid valve

A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake (accumulator circuit)

FUNCTION

The emergency release solenoid valve is installed between the transmission and the transmission control valve. If the engine
breaks down and no oil pressure is supplied from the transmission pump, it is possible to actuate the solenoid for the parking
brake release switch in the operator’s compartment. This allows the accumulator charge pressure in the brake circuit to flow to
the parking brake cylinder.

OPERATION

When the parking brake is emergency release ➀ is turned ON, solenoid

valve ➁ is actuated and the pressure stored in the accumulator ➂ enters
from port P. The circuit is switched by pilot pressure, so the oil flows from
port A to the parking brake, to release the parking brake.

WA500-3H 10-101
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC

HYDRAULIC PIPING

1. Main control valve 6. PPC valve 11. Radiator 16. Steering cylinder

2. Bucket cylinder 7. Solenoid valve 12. Oil cooler 17. Boom cylinder

3. Steering valve 8. Switch, PPC pump 13. Hydraulic pump

4. Orbit-roll valve 9. Check valve 14. Steering Pump

5. Hydraulic tank 10. Accumulator 15. Cut-off valve

HYDRAULIC LINE ASSEMBLY

See Section 90 for illustration, Hudraulic Line Assembly, FOLDOUT 10-100-1 thru 10-100-3.

10-102 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
OUTLINE

The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the
movement of the bucket and attachment.

The oil in hydraulic tank (5) is sent to the main control valve (1) by hydraulic pump (13). When the bucket and boom spools of
the main control valve are at HOLD, the oil passes through the drain circuit of the main control valve, is filtered by the filter
inside the hydraulic tank, and then returns to the tank.

When the work equipment control levers are operated, the bucket or boom spool of the PPC valve (6) moves, and the spools of
the main control valve are actuated by hydraulic pressure, so oil flows from the main control valve to boom cylinder (17) or
bucket cylinder (2) to move the boom or bucket.

Control of the maximum pressure in the hydraulic circuit is carried out by the relief valve inside the main control valve. A
safety-suction valve is installed to the bucket cylinder circuit to protect the circuit.

Accumulator (10) is installed in the PPC pilot circuit, so this makes it possible to lower the boom to the ground even when the
engine is stopped.

Hydraulic tank (5) is a pressurized sealed type and is equipped with a breather with relief valve. This compresses the inside of
the tank and also prevents negative pressure, so this prevents cavitation of the pump.

WA500-3H 10-103
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC CIRCUIT DIAGRAM
MACHINES WITH STANDARD SPECIFICATIONS

10-104 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC

1. Hydraulic tank 12. PPC valve 15. Bucket cylinder

2. Oil filter 13. Main control valve 16. Orbit-roll valve

3. Breather 13A. Main relief valve 17. Stop valve

4. Switch, PPC pump 13B. Bucket spool 18. Steering valve

5. Torque converter charging pump 13C. Safety valve with suction 18A. Demand spool

6. Hydraulic pump 13D. Unloader valve 18B. Steering spool

7. Steering pump 13E. Float selector valve 18C. Steering relief valve

8. Strainer 13F. Boom spool 18D. Safety valve with suction

9. Accumulator charge valve 13G. Suction valve 19. Steering cylinder

10. Check valve 13H. Slow return valve 20. Cut-off valve

11. Accumulator 14. Boom cylinder 21. Oil cooler

WA500-3H 10-105
STRUCTURE AND FUNCTION HYDRAULIC
12

MEMORANDUM

10-106 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC CIRCUIT DIAGRAM

See Section 90 for illustration, Hydraulic Circuit Diagram, FOLDOUT 10-105.

WA500-3H 10-107
STRUCTURE AND FUNCTION HYDRAULIC
12

MEMORANDUM

10-108 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
WORK EQUIPMENT LEVER LINKAGE

1. Boom lever 4. Bucket lever 7. Solenoid valve for boom lever

2. Kick-down switch 5. Attachment lever 8. Safety lever lock

3. Hold switch 6. Solenoid valve for bucket lever 9. PPC valve

WA500-3H 10-109
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC TANK

10-110 WA500-3H
STRUCTURE AND FUNCTION HYDRAULIC
12
OIL FILTER BY-PASS VALVE
OPERATION

When the filter is clogged

By-pass valve (1) opens and the oil returns directly to the tank without
passing through the filter.
By-pass valve set pressure: 1.27 kgf/cm2 (18.06 lbf/in2)

When negative pressure is formed in the return circuit

Valve (2) moves up and acts as a check valve.
By-pass valve set pressure: 0.26 kgf/cm2 (3.69 lbf/in2)

BREATHER
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 cylinders are being used, the oil level in the hydraulic
circuit changes and the temperature rises. If the hydraulic pressure rises
above set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.

WA500-3H 10-111
STRUCTURE AND FUNCTION HYDRAULIC
12
ACCUMULATOR (FOR PPC VALVE)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications:
Type of gas: Nitrogen gas
Gas amount: 500 cc
Actuation Pressure:
Maximum: 35 kg/cm2 (497.8 lbf/in2)
Minimum: 12 kg/cm2 (170.6 lbf/in2)

FUNCTION

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

OPERATION

After the engine stops, if the PPC valve is at hold, chamber A inside the
bladder is compressed by the oil pressure in chamber B.

When the PPC valve is operated, the oil pressure in chamber B goes below
30 kg/cm2 (426.7 lbf/in2). When this happens, the bladder is expanded by
the pressure of the nitrogen gas in chamber A, and the oil inside chamber B
is used as the pilot pressure to actuate the main control valve.

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12
PPC VALVE
FOR BUCKET / BOOM

P = From PPC pump P3 = To RAISE end of main control valve boom spool

P1 = To TILT end of main control valve bucket spool P4 = To DUMP end of main control valve bucket

P2 = To LOWER end of main control valve boom spool T = Drain

WA500-3H 10-113
STRUCTURE AND FUNCTION HYDRAULIC

1. Bolt 4. Collar 7. Metering spring

2. Piston 5. Retainer 8. Valve

3. Plate 6. Centering spring 9. Body

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FOR OPTIONAL ATTACHMENT

P = From PPC pump P3 = To main control valve attachment spool

P2 = To main control valve attachment spool T = Drain

WA500-3H 10-115
STRUCTURE AND FUNCTION HYDRAULIC
12

1. Bolt 4. Collar 7. Metering spring

2. Piston 5. Retainer 8. Valve

3. Plate 6. Centering spring 9. Body

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PPC VALVE NEUTRAL POSITION

The oil from the PPC pump enters port P of the PPC valve, but the circuit is closed by spool (8), so the oil is drained from the
relief valve (1). At the same time, the oil at port PA1 of the main control valve is drained from port f of spool (8). In addition,
the oil at port PB1 is drained from port g of spool (10).

WA500-3H 10-117
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC VALVE POSITIONS FUNCTIONS
The PPC valve supplies pressure oil from the charging pump to the side
face of the spool of each control valve according to the amount of travel of
the control lever. This pressure oil actuates the spool.

OPERATION

1. Control lever at "hold". (Fig. 1)

Ports PA1, PA4, PB1, 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 hole (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 PA1 (same as pressure at port P4)
and the force of the return spring of the control valve are balanced.

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3. Control lever moved back from slightly operated position to hold (Fine
control) (Fig. 3)
When plate (10) starts to be pushed back, piston (2) is pushed up by a
force corresponding to the force of centering spring (6) and the pres-
sure at port P4. At the same time, fine control hole (f) of valve (8) is
connected to drain chamber D, so the oil at port P4 escapes. If the
pressure at port P4 drops too far, valve (8) is pushed down by spring
(7). Fine control hole (f) is shut off from drain chamber D, and at
almost the same time it is connected to pump pressure chamber PP.
The pump pressure is supplied until the pressure at port PA1 returns to
a pressure equivalent to the position of the lever. When the spool of the
control valve returns, the oil in drain camber D flows in from fine
control hole (f1) of the valve which has not moved. The extra oil then
flows through port P1 to chamber PB1.

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 PA1 to push the spool of the control valve. The oil
returning from chamber PB1 flows from port P1 through fine hole (f1)
to drain chamber D.

WA500-3H 10-119
STRUCTURE AND FUNCTION HYDRAULIC
12
PPC RELIEF VALVE

1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw

FUNCTION

The PPC relief valve is between the PPC brake pump and the PPC valve.
When the PPC pump is not being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved through this valve to
protect the pump and circuit from damage.

OPERATION

The relief valve is installed to the charge valve. Port A is connected to the
pump circuit, and port C is connected to the drain circuit.
The oil passes through the orifice of main valve (1) and fills port B. In
addition, pilot poppet (4) is seated in valve seat (3).

When the pressure at port A and B reaches the set pressure, pilot poppet (4)
opens and the oil pressure at port B escapes from port D to port C to lower
the pressure at port B.

When the pressure at port B goes down, a difference in pressure is

generated at ports A and B by the orifice in 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.

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12
CUT-OFF VALVE

1. Unload valve C. Port C (from hydraulic pump)

2. Check valve P. Port P (from steering valve)

3. Cut-off valve T1. Port1 (to tank)

4. Screen T2. Port T2 (to tank)

FUNCTION

The cut-off valve is installed between the switch pump and the main control valve. Depending on the operating condition, it
switches the oil from the switch pump to the main control valve or to the drain circuit.

The cut-off valve is operated by hydraulic pressure.

WA500-3H 10-121
STRUCTURE AND FUNCTION HYDRAULIC
12
OPERATION

Cut-off operation conditions

O: Cut-off (drain)
X: Not actuated (to main control valve)

More than Less than Kick-down

175 kg/cm2 175 kg/cm2 switch
(2489 lbf/in2) (2489 lbf/in2) “ON”

O X X

1. When the work equipment valve is held.

The oil at the switch pump (the oil from the steering valve) presses up
check valve (1), merges with the oil from the work equipment pump
and flows to the work equipment valve.

2. When the work equipment valve is activated.

A. When the work equipment pump pressure is lower than the cut-off
pressure.
As when the work equipment valve is held, the oil at the switch
pump (the oil from the steering valve) pushes up check valve (1),
merges with the oil from the work equipment pump and flows to
the work equipment valve.

B. When the work equipment pump pressure is higher than the

cut-off pressure.
When the cut-off pressure is reached, the pressure of the oil in
chamber a opens cut-off valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2) chamber c and is
drained. The oil in unload valve (3) chamber d passes through ori-
fices e and f, and into chamber b causing the oil pressure in cham-
ber d decrease, and unload valve (3) to open. Thus, the oil from
the switch pump is drained.

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STRUCTURE AND FUNCTION HYDRAULIC
12

MEMORANDUM

WA500-3H 10-123
STRUCTURE AND FUNCTION HYDRAULIC
12
MAIN CONTROL VALVE
2-SPOOL

PA1. From PPC valve P4 A1. To bucket cylinder bottom end

PA2. From PPC valve P2 A2. To boom cylinder bottom end

PB1. From PPC valve P1 B1. To bucket cylinder head end

PB2. From PPC valve P3 B2. To boom cylinder head end

P. From pump D1. Drain port

P1. From PPC valve P2 D2. Drain port

P2. From PPC valve P3 T. Drain port

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1. Main relief valve 6. Body

2. Bucket spool return spring 7. Suction valve

3. Boom spool return spring 8. Unloader valve

4. Boom spool 9. Safety valve (with suction)

5. Bucket spool 10. Float selector valve

WA500-3H 10-125
STRUCTURE AND FUNCTION HYDRAULIC
12
3-SPOOL

A1. To attachment cylinder D1. Drain port PA2. From PPC valve P4

A2. To bucket cylinder bottom D2. Drain port PA3. From PPC valve P2

A3. To boom cylinder bottom P. From pump PB1. From option PPC valve

B1. To attachment cylinder P1. From PPC valve P2 PB2. From PPC valve P1

B2. To bucket cylinder head P2. From PPC valve P3 PB3. From PPC valve P3

B3. To boom cylinder head PA1. From option PPC valve T. Drain port

10-126 WA500-3H
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1. Main relief valve 7. Attachment spool

2. Attachment spool return spring 8. Body

3. Bucket spool return spring 9. Unloader valve

4. Boom spool return spring 10. Suction valve

5. Boom spool 11. Safety valve (with suction)

6. Bucket spool 12. Float selector valve

WA500-3H 10-127
STRUCTURE AND FUNCTION HYDRAULIC
12
OUTLINE

The main control valve controls the actuation of the boom attachments and the bucket in the hydraulic system. It has a tandem
circuit which gives priority to the bucket circuit.

The oil from the pump enters port P. The maximum pressure is set by the main relief valve. The oil passes through the by-pass
circuit of dump spool (5) and lift spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to
the tank. If the dump and lift spools are actuated, the oil flows to the dump and lift cylinders.

However, the circuit gives priority to the bucket, so when the dump spool is being operated, even if the lift spool is operated,
the lift arm will not move.

There are two safety valves (with suction valves) (10) to protect the circuit if abnormal pressure is generated in the bucket
circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up for any lack
of oil.

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12
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut

Set pressure: 210 kg/cm2 (2986.9 lbf/in2)

FUNCTION

The relief valve is installed to the inlet portion of the main control valve. If
the oil goes above the set pressure, the relief valve drains the oil to the tank
to set the maximum pressure for the work equipment circuit, and to protect
the circuit.

OPERATION

Port A is connected to the pump circuit and port B is connected to the drain
circuit. The oil passes through the orifice of the main valve (1) and fills
port B. Pilot poppet (3) is seated in valve seat (2).

If the pressure port A and port B reaches the set pressure of pilot poppet
spring (4), pilot poppet (3) opens, and the oil pressure at port B escapes
from port D to port C, so the pressure at port B drops.

When the pressure at port B drops, a difference in pressure between port A

and port B is created by the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through port C, and flows to the
drain circuit to release the abnormal pressure.

The set pressure can be varied by changing the tension of pilot poppet
spring (4). To change the set pressure, remove cap nut, loosen lock nut (6)
and turn adjustment screw (5), to adjust the set pressure as follows:

Tighten to increase pressure

Loosen to decrease pressure

WA500-3H 10-129
STRUCTURE AND FUNCTION HYDRAULIC
12
SAFETY VALVE (WITH SUCTION)

1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body

Set pressure: 230 kg/cm2 (3271.3 lbf/in2)

FUNCTION

The safety valve is in the bucket cylinder circuit inside the main control
valve. If any abnormal pressure is generated by any shock to the cylinder
when the main control valve is at the neutral position, this valve relieves
the abnormal pressure to prevent damage to the cylinder.

OPERATION

1. Operation as safety valve.

Port A is connected to the cylinder circuit and port B is connected to
the drain circuit. The oil pressure at port A is sent to port D from the
hole in pilot piston (4). It is also sent to port C by the orifice formed
from main valve (2) and pilot piston (4). Pilot piston (4) is secured to
the safety valve, and the size of the cross-sectional surface
(cross-sectional area) has the following relationship: d2 > d1 > d3 > d4.

If abnormal pressure is created at port A, suction valve (1) is not

actuated because of relationship d2 > d1 , but the relationship between
port A and port C is d3 > d4, so main valve (2) receives oil pressure
equivalent to the difference between the areas of d3 and d4. If the oil
pressure reaches the force (set pressure) of main valve spring (3),
main valve (2) is actuated, and the oil from port A flows to port B.

10-130 WA500-3H
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OPERATION AS SUCTION VALVE

If any negative pressure is generated at port A, port D is connected with

port A, so there is also a negative pressure at port D. The tank pressure of
port B is applied to port E, so the safety valve receives oil pressure a,
which is equal to the difference in the area of d2 and d1 because of the tank
pressure at port E. Therefore, oil pressure e moves the valve in the direc-
tion of opening, and oil pressure a acts to move suction valve (1) in the
direction of closing.

When the pressure at port A drops (and comes close to negative pressure),
it becomes lower than hydraulic pressure e. The relationship becomes oil
pressure e > oil pressure a + force of valve spring (5), and suction valve
(1) opens to let the oil from port B flow into port A and prevent any negative
pressure from forming at port A.

SUCTION VALVE

1. Main poppet
2. Sleeve
3. Spring

FUNCTION

This valve acts to prevent any negative pressure from forming in the
circuit.

OPERATION

If any negative pressure is generated at port A (boom cylinder rod end)

(when a pressure lower than tank circuit port B is generated), main poppet
(1) is opened because of the difference in area between d1 and d2, and oil
flows from port B at the tank end to port A at the cylinder port end.

WA500-3H 10-131
STRUCTURE AND FUNCTION HYDRAULIC
12
FLOAT SELECTOR VALVE AND UNLOAD VALVE
FUNCTION

The float selector valve and unload valve are inside the main control valve.
When the boom lever is operated to the FLOAT position, the float selector
valve detects this, and it acts to actuate the unload valve and set the boom
to the FLOAT position.

OPERATION

If the boom lever is pushed further from the LOWER position, it is set to
the FLOAT position and the PPC valve is set to the same condition as for
the LOWER position. The pressure at port A becomes high pressure and
the pressure at port B becomes low pressure.

The oil from the setting valve fills chamber F and chamber E.

If the difference in pressure between port A and port B becomes greater

than the specified pressure, float selector valve (2) is moved to the right,
and port C and port D open.

When port C opened, the oil pressure in chamber E drops, unload valve (4)
is moved up in the direction of the arrow, and the oil from the pump flows
to the drain circuit, and also flows to the rod end of the boom cylinders.

The oil at the bottom end of the boom cylinders is connected to the drain
circuit and forms the FLOAT position.

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12
BOOM AND DUMP SPOOLS AT HOLD POSITION

OPERATION

The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).

Bucket spool (1) is at HOLD, so the by-pass circuit is open. The oil at port A passes around the spool and flows to port B.
Boom spool (2) is also at HOLD, so the by-pass circuit is open. The oil at port B passes around the spool and flows to port C
in the drain circuit. From here it passes through the filter and returns to the tank.

The oil from the PPC pump passes through check valve (13) and enters port L of the PPC valve. However, the boom and
bucket levers are at the HOLD position, so the oil returns from PPC relief valve (12) to the hydraulic tank.

WA500-3H 10-133
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT RAISE POSITION

OPERATION

When boom lever (3) is pulled, pressure oil from port L of the PPC valve flows to port N and port S. The oil in port T passes
through port M and flows to the drain circuit. The pressure oil in port S pushes the piston against the force of the spring and
moves boom spool (2) to the RAISE position.

The oil flows from the pump through the by-pass circuit of the bucket spool, and then flows to the by-pass circuit of boom
spool (2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port H to
port I, and goes to the bottom end of the cylinder.

At the same time, the oil at the rod end of the cylinder flows from port K to drain port C, and returns to the tank. Therefore, the
boom rises.

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STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT LOWER POSITION

OPERATION

When boom lever (3) is pushed, pressure oil from port L of the PPC valve flows to port M and port T. In addition the oil at
port S is connected to the drain circuit. The pressure oil at port T pushes the piston against the force of the spring and moves
boom spool (2) to the LOWER position

The oil from the pump passes through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool
(2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port J to port
K, and goes to the rod end of the cylinder.

At the same time, the oil at the bottom end of the cylinder flows from port I to drain port C, and returns to the tank. Therefore,
the boom goes down.

WA500-3H 10-135
STRUCTURE AND FUNCTION HYDRAULIC
12
BOOM SPOOL AT FLOAT POSITION

OPERATION

When boom lever (3) is pushed to the FLOAT position, the spool of the PPC valve moves further from the LOWER position to
the FLOAT position. Pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W.
In addition, the pressurized oil at port S flows to port N.

The pressure oil at port T pushes the piston against the force of the spring and moves boom spool (2) to the LOWER position.

If the pressure difference between port W and port X goes above the specified level, valve (7) moves to the right and opens
ports C1 and C to connect them to the drain circuit. When port C1 is connected to the drain circuit, unload valve (8) moves up,
and the oil from the pump flows to the drain circuit.

Therefore, the oil at the rod end of the cylinder flows from port K, and then flows from unload valves (8) to the drain circuit.
At the same time, the oil at the bottom end of the cylinder flows from port I to port C, and then flows to the drain circuit.
Therefore, the boom is set to the FLOAT condition.

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12
BUCKET SPOOL AT DUMP POSITION

OPERATION

When bucket lever (4) is pushed, pressure oil from port L of the PPC valve flows to port V via port Q. In addition, the oil at
port R is connected to the drain circuit. The pressure oil at port V pushes the piston against the force of the spring and moves
bucket spool (1) to the DUMP position.

The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) then flows from port F and enters port G, and goes to the rod end of the cylinder.

At the same time, the oil at the bottom end of the cylinder flows from port D to drain port C, and returns to the tank. Therefore,
the bucket is dumped.

WA500-3H 10-137
STRUCTURE AND FUNCTION HYDRAULIC
12
BUCKET SPOOL AT TILT POSITION

OPERATION

When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows to port R via port P. The oil in port V is
connected to the drain circuit. The pressure oil at port R pushes the piston against the force of the spring and moves bucket
spool (1) to the TILT position.

The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) flows from port D to port E, and goes to the bottom end of the cylinder.

At the same time, the oil at the rod end of the cylinder flows from port G to drain port C, and returns to the tank. Therefore, the
bucket is tilted.

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STRUCTURE AND FUNCTION HYDRAULIC
12

MEMORANDUM

WA500-3H 10-139
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT

WORK EQUIPMENT LINKAGE

1. Bucket 6. Bucket link

2. Bellcrank 7. Bucket hinge pin

3. Bucket cylinder 8. Cord ring

4. Boom cylinder 9. Cord ring

5. Boom

10-140 WA500-3H
STRUCTURE AND FUNCTION WORK EQUIPMENT
12

WA500-3H 10-141
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BUCKET

1. Bucket
2. Tooth
3. Corner tooth

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STRUCTURE AND FUNCTION WORK EQUIPMENT
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MEMORANDUM

WA500-3H 10-143
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
BUCKET POSITIONER AND BOOM KICK-OUT

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12
BUCKET POSITIONER
The bucket positioner is electrically actuated and is used to automatically
obtain the optimum digging angle for the bucket.

When the bucket is moved from the DUMP position to the TILT position,
and it reaches the desired angle, the dump lever is automatically moved
from the TILT position to the neutral.

Lever (4) is secured by bolts to dump cylinder rod (3). A proximity switch
(1) is fixed by bolts to the cylinder.

When the bucket is moved from the DUMP position to the TILT position,
the dump cylinder rod moves to the left. At the same time, lever (4) also
moves to the left. When it reaches the desired position, lever (4) separates
from proximity switch, and the bucket lever returns to neutral.

BOOM KICK-OUT
The boom kick-out is electrically operated and acts to stop the lift arm.
When the lift arm reaches the desired position before the maximum height,
the lift arm lever is returned to neutral.

Plate (5) is secured to the lift arm. A proximity switch (2) is fixed to the
frame. When the lift arm is moved from the LOWER position to the
RAISE position, the lift arm rises. When it reaches the desired position, the
proximity switch and plate come into contact and the lift arm lever is
returned to neutral.

WA500-3H 10-145
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
PROXIMITY SWITCH
FUNCTION

Proximity switches are installed by a support to the boom and bucket cylinders. The lift arm RAISE position and the TILT
BACK position can be selected to match the operating conditions. When these positions are reached, a pulse is generated from
the switch, the electric current flows to a magnet and the lift or dump lever is returned to the hold position. When this happens,
the main control valve is also returned to hold and the movement of the lift arm or bucket stops.

OPERATION OF PROXIMITY SWITCH

BOOM RAISE

When the boom is lower than the set position for the boom kick-out, the detection unit (steel plate) is on the sensing surface of
the proximity switch. Electricity flows through the proximity switch. The relay switch is at OFF and the electric current of the
magnet switch coil is shut off.

When the boom lever is moved to the RAISE position, the lever cam and the cam follower keep the lift spool in the RAISE
position, so the boom arm goes up.

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KICK-OUT

When the boom goes up and reaches the set position for the kick-out (that is, the detection unit (steel plate) is separated from
the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the magnet
coil. This actuates the magnet, the cam is pulled out of the cam detent, and the lift spool is returned to the neutral position by
the return spring.

ACTION OF PROXIMITY SWITCH

Position When detector is in position at detection When detector is separated from detection surface
surface of proximity switch of proximity switch

Proximity switch actuation display Lights up Goes out

Proximity switch load circuit Current flows Current shut off

(relay switch circuit)

Relay switch load circuit Current flows Current shut off

(Solenoid circuit)

BUCKET TILT

HOLD

When the bucket is dumped beyond the set position for the bucket leveler, the sensor (steel plate) is above the detection surface
of the bucket proximity switch, so electric current flows in the proximity switch load circuit. The positioner relay is turned ON
and the current for the solenoid is shut off.

WA500-3H 10-147
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
TILT

When the bucket lever is moved to the TILT position, the bucket spool is held at the TILT position by the cam follower and
cam on the lever, and the bucket tilts.

POSITIONED

When the bucket tilts and reaches the set position for the bucket leveler (that is, the detection unit (steel plate) is separated
from the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the dump spool is returned to the neutral
position by the return spring.

ACTION OF PROXIMITY SWITCH

Position When sensor is in position at detection When sensor is separated from detection surface of
surface of proximity switch proximity switch

Proximity switch actuation display Lights up Goes out

Positioner relay Current flows Current shut off

Solenoid (for bucket) Current shut off Current flows

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STRUCTURE AND FUNCTION CAB
12
CAB

1. Front glass 3. Rear wiper

2. Front wiper 4. Door

WA500-3H 10-149
STRUCTURE AND FUNCTION ROPS CANOPY
12
ROPS CANOPY

1. ROPS guard 2. Cab

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STRUCTURE AND FUNCTION AIR CONDITIONER
12
AIR CONDITIONER

AIR CONDITIONER PIPING

1. Vent 4. Dry receiver 7. Hot water inlet port

2. Window defroster 5. Air conditioner condenser 8. Hot water outlet port

3. Vent 6. Compressor 9. Air conditioner unit

WA500-3H 10-151
STRUCTURE AND FUNCTION AIR CONDITIONER
12
AIR CONDITIONING (GENERAL)

BASIC INFORMATION ON AIR CONDITIONERS

UNITS RELATED TO REFRIGERATION

HEAT
The kinetic energy of the molecular activity of a substance takes the form of heat. If a substance is given heat by any other
substance, its temperature will rise. If heat is taken away by another body, the temperature will decrease.

1. Quantity of heat.
If the heat is transferred from one substance to another, the temperatures of both substances will change. The amount of
change in temperature will depend on the quantity of heat transferred. The quantity of heat is indicated in units of calories
(cal) or kilocalories (Kcal). One cal denotes the quantity of heat required to raise the temperature of 1g of water by 1
degree. One Kcal denotes the quantity of heat required to raise the temperature of 1 kg of water by 1 degree.

2. Specific heat.
The quantity of heat required to raise or lower the temperature of substance varies depending on the type, weight, and
amount of change in temperature of the substance. The quantity of heat required to raise the temperature of one unit
weight of a substance by 1 degree is called the "specific heat" of the substance. The unit of the specific heat is "kcal/kg C”.
The specific heat is often indicated with a numerical value without the unit.

The larger the specific heat of a substance, the more difficult it is for the substance to warm up and cool down. The
specific heat of water is 1, the largest value of any solid or liquid.

Substance Specific heat (Kcal/kg° C)

Water 1.0

Alcohol 0.57

Ice 0.49

Iron 0.11

Copper 0.09

Aluminum 0.21

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TEMPERATURE
When cooling or warming a substance, the units of warmth or coolness measurement are expressed as degrees C (Centigrade)
or F (Fahrenheit).

1. Scales of temperature.
The temperature at which water freezes at the standard barometric pressure
(1 barometric pressure) (the "freezing point"):
Centigrade . . . . . . . . . . . . . . . . 0 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F)

Temperature at which water boils at the standard barometric pressure (the

"boiling point"):
Centigrade . . . . . . . . . . . . . . . 100 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 212 degrees ( F)

On the Centigrade scale, the scale is equally divided into 100 graduations
ranging from 0 to 100 degrees. One graduation is 1° C. A temperature
below the freezing point (a subzero temperature) is indicated by a negative number, such as -a° C.

On the Fahrenheit scale, the scale is divided into 180 graduations ranging from 32 to 212 degrees. One graduation is 1° F. A
temperature below 0° F is called subzero temperature and indicated by a negative number, such as -B F.

Relationship between the Centigrade and the Fahrenheit scales:

Centigrade and Fahrenheit temperatures can be converted according to the following formulas:

Centigrade temperature (°C) = (°F -32) x 5/9

Fahrenheit temperature (°F) = °C x 9/5 + 32

2. Absolute temperature (Kelvin scale)

At zero degrees on the absolute scale ("absolute zero"), the molecular activity of all substances ceases. Absolute
temperature, lowest temperature in the natural world, often is for theoretical studies.

Relationships between the absolute temperature scale and the Centigrade and Fahrenheit temperature scales:
0° C is 273° K (on the Kelvin scale) in the absolute temperature system. One degree in the Kelvin scale equals one degree
in the Centigrade scale.

On the Fahrenheit temperature scale, 0° F is equivalent to 460° R (on the Rankine scale). One degree in the Rankine scale
is equivalent to one degree on the Fahrenheit scale.

Thus, their relationships are as follows:

Absolute temperature (°K) = (°C) + 273
0° K = -273° C.
Absolute temperature (°R) = (°F) + 460
0° R = -460° F.

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PRESSURE
The force acting on a unit area is called "pressure". Normally, the force
acting on a unit area of 1 cm2 is indicated in unit of kg.
Unit of pressure: kg/cm2.

1. Absolute pressure.
The pressure actually imposed on the wall of a vessel by the gas inside
is called “absolute pressure”. The “complete vacuum pressure”, in
which no molecular activity occurs, is defined as the zero pressure.
The absolute pressure is used in the same manner as the absolute
temperature when treating problems theoretically. The unit of absolute
pressure is kg/cm2 abs.

2. Gauge pressure.
The pressure measured with a pressure gauge at zero barometric pressure is called the gauge pressure. This pressure
indicates the difference between the absolute pressure and the atmospheric pressure. For a theoretical calculation, the
gauge pressure must be converted into the absolute pressure. In most cases, pressure refers to the gauge pressure. The unit
gauge pressure is kg/cm2 g, which distinguishes it from ordinary pressure.

3. Atmospheric pressure.
This is the pressure of the air. The standard atmospheric pressure is 1.03 kg/cm2 abs. at sea level, equivalent to a mercury
column of 760 mm (Hg) or to a water column of 10.3 m. The relationship between the absolute pressure and the gauge
pressure is simple:

Absolute pressure = Gauge pressure + Atmospheric pressure.

Even if the gauge pressure of a gas in a container is zero, the gas is actually subject to a pressure of 1.03 kg/cm2 abs.

4. Vacuum and the degree of the vacuum.

Normally, a pressure gauge has a red zone on its scale to indicate the
pressure below 0 kg/cm2. Any gas pressure indicated in the red zone is
below the atmospheric pressure.

The term "vacuum" refers to a given space filled with gas at a pressure
below the atmospheric pressure. A “perfect vacuum” refers to a space
completely empty of gas pressure (an absolute pressure of 0 kg/cm2
abs).

The degree of vacuum applies to the static pressure below the

atmospheric pressure and is indicated in terms of absolute pressure in
units of cm Hg. On the gauge scale, the atmospheric pressure is set at
zero and the perfect vacuum is set at 76 cm Hg. To convert the reading, h cm Hg, of the vacuum gauge into the absolute
pressure P kg/cm2 abs., the following formula is used:
P = 1.03 x (1 - h/76)

In this case, the degree of vacuum is (76-h) cm Hg.

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HUMIDITY
The amount of water contained in the air is called the humidity. Humidity is generally classified into absolute humidity and
relative humidity.

1. Absolute humidity.
The absolute humidity is the weight of moisture per kg of dry air contained in the wet air, expressed in units of x kg/kg.
Practically, an air diagram is used to indicate the weight of moisture contained in 1 kg of wet air. For example, if 30 g of
moisture is contained in 1 kg of wet air, the absolute humidity on the air diagram is indicated as follows:

Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg.

2. Relative humidity.
The ratio between the water partial pressure P (kg/cm2) of the wet air and the max. partial pressure Ps contained in the
water at that humidity (the water partial pressure of the saturated air) is called the "relative humidity".

That is, Relative humidity = P/Ps x 100 (%).

Generally, when we speak of humidity, we mean relative humidity. This is the humidity obtained from a home hygrometer
or a weather forecast.

PRINCIPLE OF COOLING

1. Why do coolers cool?

We have all experienced the cold feeling when we are sweating and
the wind blows, or when we put a liquid like alcohol on our skin. This
feeling occurs because water and alcohol draw heat from the
surrounding area when evaporating and turning into gas. If we express
this another way, if we apply heat to a liquid it turns into gas. This is
called evaporation latent heat.

In a cooler, freon (R134a) is used instead of alcohol. When the liquid

freon (R134a) turns into gas, it takes latent heat from its surroundings.
However, if it is allowed to disperse as a gas, this is uneconomical. We
need a device which can collect this gas and turn it back into liquid before evaporating it again, and then repeat this cycle
continuously. A cooler is such a device. The fluid which turns into a liquid and then becomes a gas to cool the
surroundings is called the refrigerant.

2. Refrigerator using evaporation latent heat

The liquid refrigerant freon (R134a) is sent under high pressure
through a valve where it is allowed to expand and is sent to the heat
exchanger. The refrigerant takes heat from the air in the room (or cab)
sucked in by low pressure vapor (moist vapor), turns into gas (super
heated vapor) and is discharged. The air which has lost its heat is
blown into the cooled room. This is the basic principle of the cooler,
but using only this device to cool is uneconomical and not very
practical.

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3. Refrigeration method (Vapor compression)
The refrigerant gas is compressed by a compressor (adiabatic
compression) and changes to high temperature and high compression.
It is then sent to the condenser and undergoes forced cooling in the
condenser to be turned to liquid. If this liquefied refrigerant is
expanded suddenly at the expansion valve, it changes into a low
temperature and low pressure mist and flows inside the evaporator.

The refrigerant, which enters the evaporator as a mist, passes through

the fins of the evaporator and takes latent evaporation heat from the
surrounding air. This causes it to evaporate and turn to its original
gaseous condition. In this way it acts to cool the surrounding air.

4. Refrigerating cycle
The refrigerating cycle of an air conditioner consists of the
compressor, condenser, expansion valve, and evaporator as shown in
the diagram. Refrigerant is circulated in this sealed circuit
(refrigeration cycle), and heat is transferred from the low temperature
source (air inside the operator’s compartment) to the high temperature
source (outside air) to give the cooling. This is called the evaporation
compression refrigeration system, the most widely used form of
cooling used for bus coolers, room air conditioners, and small
refrigerators.

A. Flow of refrigerant

i. The liquid refrigerant which leaves the receiver is expanded suddenly at the expansion valve. It becomes a low
temperature, low pressure mist and flows to the evaporator.

ii. The refrigerant mist which flows into the evaporator takes heat from the air (air inside the operator’s
compartment) at the surface of the evaporator. It evaporates and is further heated, and is then sucked into the
compressor as a gaseous refrigerant.

The air inside the operator’s compartment is sucked into the cooling unit by a fan, is cooled on the evaporator
surface, and is then sent out into the operator’s compartment again.

iii. The gaseous refrigerant evaporated in the evaporator is sucked into the compressor.

iv. The gaseous refrigerant is compressed in the compressor, and is then sent to the condenser at high temperature
and high pressure.

v. In the condenser, the gaseous refrigerant is cooled. It becomes a liquid refrigerant again and flows to the receiver.

By repeating the above steps (1) to (5), the heat is taken from the air at the surface of the evaporator, and heat is
dissipated to the air at the surface of the condenser to produce cooling inside the operator’s compartment.
Remark
The temperature and pressure of the refrigerant vary according to the air flow and temperature of the front
surface of the condenser.

In this way, the refrigerant circulates during the refrigeration cycle to carry out the refrigeration action.

In refrigerators using the evaporation latent heat of the refrigerant at present used, if the gaseous refrigerant is not
liquefied at near normal temperature, it cannot take evaporation latent heat from the surrounding material to
carry out refrigeration (cooling).

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Generally speaking, for a gas to be liquefied, it must be
pressurized. However, if it is cooled at the same time as being
pressurized, it can be liquefied easily.

For this reason, compressors and condensers are needed in

the present refrigerating systems.

B. Properties of R-134a
Using R-134a as an example, let us explain how the refrigerant
can be liquefied.

High temperature (70° C), high pressure (15 kg/cm2) gaseous

refrigerant is compressed in the compressor. It then enters the
condenser where it is cooled and liquefied.

R-134a starts to liquefy at about 62° C at 15 kg/cm2, so the

temperature of the refrigerant need only be brought below 62° C.

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C. Temperature and pressure in the refrigeration cycle

1. Receiver 4. Compressor

2. Evaporator 5. Blower

3. Condenser 6. Expansion valve

In the refrigeration cycle, the refrigerant transforms from a liquid to a gas (evaporation) and from a gas to a liquid
(condensation). Both the temperature and pressure of the refrigerant vary throughout the refrigeration cycle.

The figure above indicates variations of the temperature and pressure in the refrigeration cycle. (The numbers in the
diagram are taken from the design values of a standard air conditioner, and are given only for reference. These values
vary depending on the conditions for the actual cycle).

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5. Heating cycle
The heating cycle uses cooling water taken from the engine cooling system.

A. The cooling water absorbs the heat from the engine, and its flow is controlled by the water valve to enter the heater
core.

B. In the heater core, the heat of the cooling water is transferred to the air at the surface of the core.

C. The heat is sent by the blower to the operator’s compartment.

D. The cooling water which has given up its heat in the heater core returns to the engine.

By repeating the above steps (A) to (B), the inside of the operator’s compartment is heated.

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REFRIGERANTS
The refrigerant plays the most important role in the refrigeration cycle. Various kinds of refrigerants are available for various
types of applications. The most critical characteristic of a refrigerant is the ease with it liquefies and vaporizes at normal or low
temperatures. However, only a few kinds of refrigerants are used in air conditioners, depending on various conditions, such as
the type of compressor, evaporation temperature (pressure), and condensation temperature (pressure).
Ammonia and freon type gases, which satisfy the requirements, are widely used. Air conditioners usually use "freon type"
gases because of their safety and the small size required for a refrigeration system.
FREON-TYPE GASES
Components in this system are compatible with Refrigerant 134a (CCL2F2 - Dichlorodifluoromethane). Use of other
refrigerants would not achieve performance characteristics, and more importantly, would, in most cases, chemically
deteriorate components.

SAFETY PRECAUTIONS
WARNING! The refrigerant R-134a can be a fire and health hazard if handled incorrectly. Avoid
contact with the substance and never expose it to extreme heat, sparks or open flame.

WARNING! The substance used in the air conditioning system, called R-134a is basically a safe,
nontoxic refrigerant. However, when it is exposed to an open flame, it changes to a very
highly poisonous and deadly phosgene gas. This phosgene gas will tarnish bright metal
surfaces.

WARNING! The liquid refrigerant will boil (or vaporize at -29.8° C (-21.7° F) at atmospheric pressure
(or when it is exposed to the air). It also evaporates so rapidly that the gas may displace
the oxygen in the area, if it happens to be a small enclosed area. Therefore, whenever
the system is worked on, a safe practice would be to work on it in a well ventilated area.

WARNING! The refrigerant, when exposed to the air, is approximately -29 C (-21 F). Upon contact
with the skin, the effect is just like frostbite. Treat the same as you would for frostbite.

WARNING! If the refrigerant contacts the eyes, immediately flush the eyes with water and continue to
do so until the temperature is above the freezing point. Consult an eye specialist
immediately. Blindness could result from an injury of this sort and it is highly
recommended that safety goggles be worn whenever servicing the system. If the air
conditioning system must be discharged, do it out of doors or in a well ventilated area
where no extreme heat or open flame is present. Release the refrigerant slowly as it will
suck the oil from the compressor if the system is opened too fast.

WARNING! Always use the correct type of hoses for the air conditioning system. Do not use any hose
which is not specified for refrigeration use. Never apply heat of any sort on any of the air
conditioning hoses or components of the system while it is charged. The extra heat could
cause the pressure of the refrigerant in the system to become excessive and cause a
dangerous rupture.

WARNING! Be sure the pressurized refrigerant containers are never exposed to or stored in an area
where the temperature could exceed 52° C (125° F).

WARNING! Do not discard empty refrigerant containers where they might be subjected to a tempera-
ture of 52° C (125° F) or higher.

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WARNING! Do not add alcohol or other liquid driers to the system to prevent freeze up. The
desiccant in the dryer prefers alcohol to water and will discharge moisture to absorb
alcohol.

WARNING! Refrigerant oil is the exception to the rule that water and oil do not mix. If left in an open
container it will absorb moisture and Refrigerant oil is the exception to the rule that water
and oil do not mix. If left in an open container it will absorb moisture and may cause
freeze-ups at the expansion valve or sludge build up.

REMEMBER:

A. Wear safety goggles.

B. Keep refrigerant away from heat, flame or sparks.

C. Do not smoke or have an open flame near when discharging refrigerant.

D. Work in a well ventilated area.

E. Avoid physical contact with refrigerant.

REFRIGERATOR OIL (LUBE OIL)

The lubricant used in air conditioners is generally called refrigerator oil. Its purpose in the compressor is to minimize wear of
the piston, cylinder walls, and other frictional parts like bearings, and to prevent them from seizing by removing the heat
created by friction. In addition, the substance helps prevent leakage of refrigerant by maintaining a uniform thin oil film on the
contact surface of parts.

Freon type refrigerant dissolves in oil better than ammonia does. When the freon is dissolved in oil, the freezing point of the
oil goes down, which causes no hindrance to the use of the oil at low temperatures. The flash point and the ignition point of the
refrigerant oil are ordinarily 160° C to 170° C and 200° C to 220° C, respectively.

The lube oil for air conditioners will contact refrigerant. Thus, the viscosity of the oil when mixed with refrigerant is an
important factor in the selection of the refrigerant oil. The lube oil used in air conditioners is a mineral oil refined from
petroleum, and various types are available. The refrigerant has a large effect on the durability of the compressor and therefore,
the oil must conform to that specified for each compressor.

Characteristics of SUNISO (SUNISO is a U.S. specification) refrigerator oil:.

1. Chemical stability
The oil is resistant to chemical reactions with the refrigerant or any other substance in the system.

2. Thermal stability
No carbon deposits are formed at high temperatures in the valve and delivery (discharge) portion of the compressor.

3. Low wax content

The flocculent material does not separate from the oil-refrigerant mixture in the low temperature portion of the
refrigeration system.

4. Low pour point

The oil in the refrigeration system does not freeze because the pour point is lower than the lowest temperature in the
system.

5. High insulation resistance

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6. Proper viscosity
Excessive wear of the compressor is prevented because the proper viscosity is maintained even at high temperatures. Suf-
ficient fluidity of the oil is maintained at low temperatures and a satisfactory oil film is formed at all times.

7. Cleanliness of oil
No dust, or foreign matter that accelerate the deterioration of oil are mixed in the oil. Thus, the cylinder liners and bear-
ings will not get flawed and oil grooves will not get clogged.

AIR CONDITONING CONDENSER

FUNCTION

In a refrigeration system, the job of the condenser is to convert the heated,

high pressure gaseous refrigerant compressed in the compressor back into a
liquid refrigerant. Heat at the same time dissipates into the atmosphere. An
auxiliary fan helps force the heat exchange.

GENERAL DESCRIPTION

In the condenser, the quantity of heat to be emitted from the gaseous

refrigerant depends on the quantity of heat absorbed from the room air in
the evaporator and the work to be done to compress the gas in the
compressor. Accordingly, the effect of the heat radiation on the cooling
effect is so large that the forced cooling is performed by two special
cooling fans, in addition to the cooling fan for the engine radiator. This
independent condenser helps prevent overheating of the engine and does
not effect engine performance.

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1. 2-Stage control of condenser fan motor
The electric fan of the condenser is controlled to two speeds by the
pressure of the refrigerant on the pressure side.

If the pressure of the refrigerant on the high pressure side rises above
18 kg/cm2, the pressure switch is turned ON and the fan motor runs at
high speed.

When the pressure of the refrigerant on the high pressure side drops
below 14 kg/cm2, the pressure switch is turned OFF and a resistor
reduces the voltage to make the fan motor run at low speed.

This extends the life of the fan motor, and also avoids the unnecessary
use of electricity.

2. Pressure switch
This switches ON and OFF according to the pressure of the
refrigerant.
ON: 14 kg/cm2 (199 psi)
OFF: 18 kg/cm2 (266 psi)

Pressure switch (1)

3. Defrosting device
Frost can build up on the evaporator fins if their temperature drops below freezing. Efficiency will suffer, so a thermistor
has been provided, attached to the evaporator fins, to signal when the fins are too cold. If so, the controller will turn off the
magnetic clutch, stopping the compressor.

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4. Magnetic clutch
The compressor pulley incorporates a magnetic clutch to connect and
disconnect from the engine. The clutch engages whenever current is
supplied to its magnet stator coil (air conditioning is switched on). The
drive belt then can power the compressor.

5. Electric fan motor

This turns the electric fan and carries out the forced cooling of the
condenser.

Fan (1)

Fan motor (2)

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AIR CONDITIONER COMPRESSOR
The compressor is a pump to raise the pressure of the refrigerant. As the
refrigerant pressure increases, so does its temperature, and the high
temperature refrigerant gas then will condense rapidly in the condenser by
releasing heat to the surroundings.

The compressor illustrated here, a swash plate type, operates paired pistons
on the swash plate. Rotation of the shaft and attached swash plate operates
the pistons in their bores. The swash plate and shoes convert rotary motion
of the shaft to reciprocating motion of the pistons.

Intake stroke: When the piston moves to the left, the right side of the piston
draws the refrigerant through the suction valve while the discharge valve is
held closed against the valve plate.

Discharge stroke: When the piston moves to the left, the left side of the pis-
ton forces out the refrigerant through the discharge valve while the suction
valve is held closed against the valve plate.

A shaft seal and seal plate seal the compressor shaft. The cutaway drawing
illustrates a typical arrangement.

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RECEIVER WITH SIGHT GLASS (LIQUID TANK)
The refrigerant liquefied in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the
evaporator according to the cooling load.

A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and a fusible
plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from inside the
refrigeration cycle.

If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the
expansion valve, and obstruct refrigerant flow.

1. Body 3. Drier

2. Sight glass 4. Drier

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1. Fusible plug
A fusible plug, also called a melt bolt, has a hole through its center
which is filled with special solder that melts at 103° to 110° C. If the
condenser cannot ventilate properly, and thoroughly dissipate the heat,
the special solder in the fusible plug will melt. The refrigerant escapes
to the open air before the pressure in the condenser and receiver can
increase enough to damage them.

When the special solder melts at 103° to 110° C, the pressure of the
refrigerant is approximately 30 kg/cm2.

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AIR CONDITIONER UNIT
OUTLINE

In this all-season-type air conditioner unit, the air is cooled and

dehumidified through the evaporator and reheated to the proper
temperature through the heater for a comfortable cab atmosphere. In hot
weather, only the evaporator operates and in cold weather, mainly the
heater operates. In other seasons, particularly rainy and humid weather, the
heater and evaporator operate to dehumidify and heat the air.

1. BLOWER SWITCH
Acts as the main switch and is used for controlling the air flow when
cooling or heating.

This switch controls the air flow to three levels:

Low Medium High

If the button is pushed to the OFF position, the air conditioner will
stop.

2. AIR CONDITIONER SWITCH

Switching when cooling (power for compressor)

When the button is pressed, the switch is turned on and the pilot lamp lights up.

When the button is pressed again, the switch is turned off and the pilot lamp goes out.

If the air conditioner switch is turned on but the blower switch is still off, the air conditioner will not work (the pilot lamp
does not light up).

Turn the air conditioner switch on after turning the blower switch on.

3. TEMPERATURE CONTROL
These buttons (arrow up or arrow down) control the temperature during cooling or heating.

Move the lever towards (left) the Cool position to lower the temperature; move the lever towards (right) the WARM
position to raise the temperature.

If the air conditioner switch and blower switch are turned on, and the lever is moved to the WARM position, the air
conditioner will give dehumidifying and heating.

4. AIR SOURCE SELECTOR

This lever switches the source of air during cooling or heating.

FRESH (right - outside air is brought in) This is used for normal cooling and heating. Fresh air from the outside is used in
addition to the air inside the operator’s compartment.

RECIRC (left - inside air is recirculated) This is used for quick cooling and heating.

In this position, only the air inside the operator’s compartment is used.

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MONITOR SYSTEMS

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, readings for
the gauges, speedometer, and service meter).

There are also various switches built into the monitor panel which function to operate the machine. The main monitor uses the
network wiring to send signals to the controller and functions to display the following information:
Shift indicator: 1st - 4th, N, F, R (F and R are optional).
HOLD
Failure action code, failure code, time elapsed since failure (failure data display mode).

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MAIN MONITOR

1. Check lamp 4D. Shift indicator 5A. Not used

2. Caution lamp 4E. Speedometer 5B. Travel damper switch (option)

3. Caution items 4F. Shift hold 5C. Working lamp (front) switch

3A. Ground driven steering actuated

4G. Parking brake 5D. Working lamp (rear) switch
(option)

4H. Ground driven steering normal

4. Pilot items 5E. Transmission cut-off switch
(option)

4A. Turn signal (left) 4I. Not used 5F. Auto shift, manual selector switch

4B. Turn signal (fight) 4J. Failure action code

4C. High Beam 5. Switches

OUTLINE

The main monitor has a display function for the speedometer and other gauges, and a switching function to control the electric
components and controllers.
There is one CPU (Central Processing Unit) installed internally, and this processes the signals from the sensors and outputs the
display.
A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches.

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MAIN MONITOR DISPLAY FUCTION

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MAIN MONITOR SWITCH FUNCTION

Item Function Display Actuation

E.C.S.S. function is actuated or Lights up E.C.S.S. function actuated

E.C.S.S. stopped each time switch is
pressed Goes out E.C.S.S. function stopped

Front working lamp lights up or Lights up Front working lamp lights up

Working lamp goes out each time switch is
(front) pressed when side lamps are Goes out Front working lamp goes out
lighted up

Rear working lamp lights up or Lights up Rear working lamp lights up

Working lamp goes out each time switch is
(rear) pressed when side lamps are Goes out Rear working lamp goes out
lighted up.

Transmission cut-off function is Lights up Cut-off function actuated

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

Auto shift mode switches to Lights up Manual mode

Manual manual mode when switch is
pressed Goes out Auto shift mode

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TROUBLE DATA DISPLAY MODE

Item Switch operation Actuation

Method of switching to With engine stopped and starting switch turned ON,
trouble data display mode press 2nd switch from top on left side of main monitor
(switch below ground driven steering display) and
work lamp (front switch simultaneously for at least 5
seconds
All switch displays (LEDs) go out, and failure
code is displayed on speedometer display and
time elapsed since failure is displayed on fail-
ure action code display.
1. Failure code is two-digit display given in
numbers or letters. The display for the fail-
ure now occurring flashes and the display
for past failures lights up.
2. The time elapsed since failure is displayed as
a three-digit number to show how long ago
the failure occurred (the oldest failure time
is displayed. Any time greater than 999H is
displayed as 999H).
3. A maximum of 9 times are stored in memory
for the failure codes.

Method of sending failure Press working lamp (front) switch Failure code and time elapsed since failure
code change to next item.

Clearing failure code Press working lamp (rear) switch for at least 2 seconds Failure code and time lapsed since failure
being displayed are cleared.
Failure code for problem now occurring
(flashing display cannot be cleared.

Resetting from travel data Press 2nd switch from top on left side of main monitor Changes to normal display
display mode (switch below ground driven steering display) and
front working lamp switch simultaneously for at least
5 seconds, or start the engine.

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MAINTENANCE MONITOR

OUTLINE

The maintenance monitor has a display function for the caution items and gauges, and switch functions to control the work
equipment controller.

The maintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms.

The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the
display and output.

A liquid crystal display and LEDs are used for the display portions. The switches are embossed sheet switches.

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MAINTENANCE MONITOR DISPLAY FUNCTION

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MAINTENANCE MONITOR SWITCH FUNCTION

Item Function Display Actuation

Sets stopping position in LOWER Flashes (2.5 sec) Sets stopping position
Remote boom
direction for remote boom positioner
positioner LOWER
(boom position when switch is pressed is Goes out ---
position setting
recorded)

Sets stopping position in RAISE direction Flashes (2.5 sec) Sets stopping position
Remote boom
for remote boom positioner (boom
positioner RAISE
position when switch is pressed is Goes out ---
position setting
recorded)

Remote boom positioner function

Goes out
Off

Remote boom positioner RAISE

Selection of remote Sets remote boom positioner in stopping RAISE lights up
stop function ON
boom positioner direction (Switches function each time
RAISE/LOWER switch is pressed) Remote boom positioner LOWER
LOWER lights up
stop function ON

Remote boom positioner RAISE/

RAISE, LOWER light up
LOWER stop function ON

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ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
TRANSMISSION SYSTEM
OUTLINE OF SYSTEM

The all-range electronic control automatic transmission system consist of the transmission controller, directional and speed
levers, engine speed sensor, speed sensor, and all-speed-range ECMV (transmission clutch modulation valve).

The transmission controller controls the shifting to the appropriate speed range according to the lever position and travel speed
signal.

To reduce shock when shifting gear (engaging the clutch), all-speed-range ECMV carries out modulation control.

A travel damper function and joystick steering control function are available as options, and these controls are possible if the
function is installed to the machine.

To improve durability, there is a safety function which prevents the machine from moving suddenly when the engine is started,
and a transmission protection function which protects the clutch when the direction of travel is changed.

The self-diagnostic function always observes the input and output condition, and displays the output condition on the two
7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality
occurs, it displays a failure code. Depending on the condition, it also displays a failure action code on the main monitor and
flashes the caution lamp to improve safety.

The transmission controller has a communications function, and it sends the speed range (N, 1st-4th) data to the main monitor,
which displays the speed range. (If the joystick mode is used, it also displays F and R.)

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SYSTEM STRUCTURE DIAGRAM

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FUNCTION
1. Auto-shift function.
Shifting the transmission up or down is carried out when the engine speed is above 1450 rpm. Shifting is decided by sig-
nals from the directional lever, speed lever, and travel speed sensor according to (Table 1 Automatic gear shift change
point table) recorded in the memory of the transmission controller.

A. Speed lever (1st - 4th).

This controls the maximum speed range (available speed range) for automatic gear shifting.
Example: Speed lever at 4th: 2nd - 4th
Speed lever at 2nd: 2nd only

B. Directional lever N position.

To prevent the vehicle from moving accidentally, when the lever is at neutral position, only the 2nd clutch is engaged.

C. Directional lever F position.

When the directional lever is operated from N to F, the transmission turns ON the F and 2nd ECMVs (F2).
(Automatic start in 2nd)

i. Shift up (when speed lever is at 4th) When the accelerator pedal is depressed to increase the engine speed and the
travel speed rises, when the travel speed reaches approximately 9.3 km/h, the ECMV 3rd is turned ON, and at the
same time, 2nd is turned OFF. (Shifting to F3)

When the travel speed rises further to approximately 17.6 km/h, the ECMV 4th is turned ON, and at the same
time, 3rd is turned OFF. (Shift to F4)

ii. Shift down (speed lever at 4th)

When traveling in 4th, if the accelerator pedal is let back, and the travel speed comes down to approximately 15.6
km/h, the ECMV 3rd is turned ON, and 4th is turned OFF. (Shift to F3)

When the travel speed goes down to approximately 9.8 km/h, the ECMV 2nd is turned ON, and 3rd is turned
OFF. (Switches to F2)

D. Directional lever R position

Automatic gear shifting is carried out according to the travel speed between 2nd and 4th speeds (when the speed lever
is at 4th) in the same way as when the speed lever is at the F position.

E. Skip shift
When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accelerator pedal depressed, if the travel
speed is less than 8 km/h, the gear shifts down to 2nd to make it easier to accelerate. If the travel speed is more than 8
km/h, the speed range is maintained, and when the engine speed goes above 1450 rpm, the gear is shifted to a range
that matches the travel speed.

F. Gear shift prevention interval.

To prevent shift hunting after shifting gear, a time interval is set to maintain the speed range. The gear shift
prevention interval differs according to the shift pattern. For details, see [Table 1 Automatic gear shift change point
table].

2. Modulation control.
The modulation control acts to reduce the shock when shifting gear (when engaging the clutch). It uses the data for the
engine speed, transmission oil temperature, and gear shift pattern to control the clutch oil pressure (including the charac-
teristics when starting) to match the condition of the hydraulic circuit to control all speed ranges to the optimum according
to the data in the transmission modulation table stored in the transmission controller memory. In addition, to reduce the
torque cut, it carries out modulation control of the ECMV at the side which switches OFF also.

The transmission modulation data table is set for each transmission oil temperature. In addition, it has a learning function
(transmission clutch piston data) to prevent any abnormal time lag when shifting gear.

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3. HOLD function.
When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes
down, the transmission does not shift down. However, when switching between forward and reverse, the transmission
normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the
travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling ground, or when
traveling downhill.)

4. Kickdown function.
When operator turns the kick down switch ON, it overrides the auto shift and switches down forcibly to 1st if the
conditions (speed range, travel speed) in [Table 1 Automatic gear shift change point table, 5. Kickdown] are fulfilled.

5. Travel mode.

A. Manual mode (option).

It is possible to switch between auto and manual shift. When using the manual mode, the gear is shifted according to
the operation of the speed lever. When traveling in F2, it is also possible to use the kick down function.

B. Joystick steering control function (option).

i. If the machine is equipped with the joystick steering function, the operator can switch between steering wheel
and joystick steering mode as desired.

ii. The transmission controller controls the signals from the travel system. (The steering system is controlled by the
work equipment controller.)

iii. When switching the steering between steering wheel and joystick steering, always stop the machine first, return
the speed lever to the N position, then switch the steering. When this is done, the transmission controller is set to
the neutral safety condition to prevent the machine from suddenly moving.

6. Safety function.

A. Neutral safety.
When the engine is started, if the directional lever is at any position other than N, the transmission controller keeps
the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started,
the neutral safety is canceled.

B. Speed lever priority.

It is possible to shift down immediately by operating the speed lever, so the engine can be used as a brake when
traveling downhill.

C. Transmission protection.
When traveling in 3rd or 4th speed, the travel speed is controlled and a warning buzzer sounds to protect the
transmission when shifting between forward and reverse.

i. Speed range control.

When the speed range control and travel speed fulfill the conditions for range I, the transmission shifts down to
2nd.When the speed range control and travel speed fulfill the conditions for range II, the speed range is
maintained and the transmission shifts down to 2nd according to the deceleration. (For details, see Fig. 1 F-R
selection gear shift pattern, table 1 Automatic gear shift change point table, 7. F-R selection.)

ii. Alarm buzzer.

When the speed range control and travel fulfill the conditions for range III, the alarm buzzer sounds to warn the
operator. (If the engine speed is above 1700 rpm and the travel speed is above 13 km/h, or the travel speed is
above 14 km/h). (See Fig. 2 F-R selection alarm buzzer range.)

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D. Manual shift.
If the travel speed sensor is abnormal and it is impossible to detect the travel speed data, the transmission is set to
manual (shift) mode.

Table 1: Automatic gear shift change point table.

Item Speed Travel speed Gear shift
range (Km/h) prevention interval

1. Basic shift change. 1➞2 5.1 (5.3) or above 2

2➞3 8.7 (9.2) or above 2

3➞4 16.5 or above 1

4➞3 Less than 14.5 1

3➞2 Less than 9.2 (8.7) 2

2. Engine speed. 4 ➞2 Less than 1.0 o

(less than 1450 rpm)
3➞2 Less than 1.0 0

3. Engine speed. 4➞2 Less than 8.0 2

(less than 1450 rpm
more than 1450 rpm) 3➞2 Less than 8.0 2

4. Shift when HOLD is ON. 1➞2 5.1 0

2➞3 8.7 0

3➞4 16.5 0

5. Shift down when kick down 2➞1 Whole range 5

is ON.
3➞1 Less than 12.0 5

4➞1 Less than 12.0 5

6. FR selection (range I) 4➞2 (Remark 1)

(F ➞) N ➞_ R 3➞2 2
(R ➞) N ➞ F 1➞2

7. FR selection (range II) (Remark 2)

(F ➞) N ➞ R ➞4 16.5 or above 2
(R ➞) N ➞ F ➞3 Less than 14.5 - 16.5

86. FR selection ➞4 16.5 or above

(F ➞) N ➞ R ➞3 Less than 8.7 - 16.5 0
(R ➞) N ➞ F ➞2 Less than 8.7
Remark 1
When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel
speed is less than 13 km/h.
Remark 2
When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed
is 16 km/h or above, the speed range maintained and the transmission shifts down to 2nd according to
deceleration.

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7. Self-diagnostic function
The transmission controller always observes the input and output signals of the automatic gear shifting system. It carries
out self diagnosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following
data to the main monitor.

A. Normal display:
Transmission controller LEDs display output range.

B. Failure code display:

If an abnormality is detected, the nature of the failure is displayed as a code. For details of failure code, see Table 2
Failure code table.

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Table 2: Failure code table.

System Main Monitor

Code Item
Short Circuit Disconnection Action Code

10 Back-up alarm relay O O None

11 None --- --- ---

12 F ECMV solenoid O O Call

13 R ECMV solenoid O O Call

14 1st ECMV solenoid O O Call

15 2nd ECMV solenoid O O Call

16 3rd ECMV solenoid O O Call

17 4th ECMV solenoid O O Call

18 None --- --- ---

19 Joystick direction switch O O E00

20 Directional switch signal O O Call

21 Range switch signal O O None

22 Travel speed sensor X O E00

23 Engine speed sensor O O E00

24 Abnormality in memory (EEPROM) --- --- None

25 Transmission oil temperature sensor O X E01

26 F ECMV fill switch O X Call

27 R ECMV fill switch O X Call

28 1st ECMV fill switch O X Call

29 2nd ECMV fill switch O X Call

30 3rd ECMV fill switch O X Call

31 4th ECMV fill switch O X Call

32 F or R ECMV fill switch X O E00

33 1st, 2nd, 3rd, or 4th ECMV fill switch X O E00

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8. Communications function
The transmission controller is equipped with a communications function using S-NET. It always maintains
communications with the main monitor, and when the engine is started, it receives model, travel damper availability, and
tire compensation data.

When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to
warn the operator in order to increase safety.

The failure code can recognize the codes recorded in the main monitor memory using the main monitor problem history
mode. For details of operating the main monitor, see the section on the main monitor.

9. Travel damper (option)

If the machine is equipped with a travel damper function, the operator can use this function by operating a switch.

When the engine is started, the availability of the travel damper function is transmitted from the main monitor, and the
troubleshooting function can also be actuated for the travel damper system.

TRANSMISSION CONTROLLER POWER SOURCE

When the starting switch is turned ON and the supply voltage is more than 20V, and +20V or more is supplied to the
transmission controller solenoid power source input, it is possible to drive each solenoid valve.

If the supply voltage is less than 19V, all outputs are turned OFF and the solenoids cannot carry out control (travel is
impossible).

INPUT SIGNALS
1. Directional lever (F,N,R) signal
This signal is a +24V/OPEN digital signal, and when it is normal, one of F, N, or R signals (+24V) is input.

2. Speed lever (1st - 4th) signal

This signal is a +24V/OPEN digital signal and +24V is input for the signal for the lever position.

3. Kickdown switch
This signal is a +24V/OPEN digital signal and +24V is input when the kick down switch on the work equipment control
lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. 4.

4. FORWARD switch
This signal is a +24V/OPEN digital signal and +24V is input when the HOLD switch on the work equipment control lever
is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point.

5. Neutralizer relay signal

This signal is a +24V/OPEN digital signal and +24V is input when the parking brake switch is pressed.
When signal is OPEN, the transmission controller maintains the neutral condition.

6. Transmission cut-off signal

This signal is a GND/OPEN digital signal, and when the transmission cut-off switch is operated (using the left brake), it
changes to GND. When it is actuated, the transmission controller changes to the neutral output condition, and when it is
restored, it sets to a suitable speed range for the travel speed at that point.

7. Manual mode signal

This signal is a GND/OPEN digital signal, and when the manual mode switch is ON, GND is input.

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8. Fill switch (F, R, 1st - 4th signals)
This signal is a GND/OPEN digital signal, and is installed to each ECMV. The switch is operated by oil pressure.
When the ECMV is on, GND is input.

9. Engine selection signal

This signal is a GND/OPEN digital signal, and when the engine is started, the type of engine mounted is judged from this
signal. (The speed conversion data is different.)

Table 3 Engine selection signal table

Input signal Engine Speed conversion data

GND Komatsu 6

10. Memory clear signal

This signal is a GND/OPEN digital signal. It is normally OPEN. When clearing the memory, start the engine, then input
OPEN ➞ GND ➞ OPEN signals.

11. Engine speed sensor signal

This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for
control. When the engine speed is 1450 rpm or above, it is called the engine speed ON mode, and when the speed is less
than 1450 rpm, it is called the engine speed OFF mode.
Komatsu engine: Speed P (rpm) = Input frequency (Hz) x 60/6

12. Travel speed sensor signal

This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for
control.
To convert to the travel speed, the tire compensation data (communications data from the main monitor) are added. In
addition, the acceleration is also calculated to judge the travel speed for gear shifting.
Speed P (rpm) = Input frequency (Hz) x 60/ 59
Travel speed V (km/h) = Speed P (rpm)/ (101.6 x tire compensation value k) or Travel speed V (km/h) = Input
frequency (Hz)/(99.9 x tire compensation value k)

13. Transmission oil temperature sensor signal

This signal is an analog signal and converts 0 - 5 V inside the controller to temperature. This is used for selecting the mod-
ulation table when shifting gear.

14. Communications signal (S-NET)

This receives the following data set in the main monitor and is used for control.

A. Model selection
It selects the automatic gear shift change point data table for each model to use for shifting gear.

B. Tire compensation data

This adds the compensation value (covering a range from 0.86 to 1.14) to the speed data from the travel speed sensor
to obtain an accurate travel speed.

C. Travel damper function selection This is a function selection signal and judges if the travel damper function exists. It
controls the travel damper system, including troubleshooting.

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OUTPUT SIGNALS
1. Transmission modulation valve (ECMV command current)
This signal is an electrical output (0 - 1A). There are six types of ECMV: R and F for direction, and 1st, 2nd, 3rd, and 4th for
each speed range. This valve is a pressure control valve and converts to a pressure matching the value of the current flowing to
the solenoid. Therefore, it controls the oil pressure for the clutch selected for each speed range and controls the engagement of
each independent clutch. In addition, only the 2nd clutch is actuated when the transmission is at neutral.

Table 4: Combination of speed ranges and ECMV

ECMV/
F R 1st 2nd 3rd 4th
Speed range

F1 O O

F2 O O

F3 O O

F4 O

R1 O O

R2 O O

R3 O O

R4 O O
O = ON

2. Backup lamp relay signal

This signal is a +24V digital (ON/OFF) output. It is actuated when the directional lever is placed at R and lights up the
backup lamp and caution lamp.

3. F1 (cut-off) signal
This signal is a +24V digital (ON/OFF) output. This signal is output when the kick down is operated and sets the machine
to Fl.

4. Engine speed signal

This outputs a signal at the same cycle as the engine speed sensor signal input to the transmission controller.

5. Communications signal (main monitor display data)

For details of the display position and operation of the main monitor, see the section on the main monitor.

A. Speed range
1st speed range output: [1]
2nd speed range output: [2]
3rd speed range output: [3]
4th speed range output: [4]
Neutral: [N]

B. F / R display
F / R are displayed in the joystick steering mode (option).

C. HOLD display
The pilot display is given on the main monitor when the HOLD function is ON.

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LED DISPLAY
When the engine is started, the display goes first to 1. “Program quality display mode”, and next to 2. “Output speed range
display mode”. However, if any abnormality is detected, it goes immediately to the troubleshooting mode.

1. Program quality display mode.

When the power source is on, it switches once every second.

2. Output speed range display mode.

LED display X. Y. (Both dots are out)
X: Direction ECMV drive condition FORWARD [F]: F, REVERSE [R]: A, Neutral: O
Y: Speed range ECMV drive condition 1 - 4.

3. Troubleshooting display mode (currently existing failure)

A cycle of [E-(2 sec)], [Code (2 sec)] is repeated.

A. When there is one abnormal item.

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B. When there are two abnormal items.

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ECSS SYSTEM

1. Main monitor 6. ECSS valve assembly 7. Charge control solenoid valve (Sol 2)

2. ECSS switch 6A. Main spool 8. Accumulator

3. Combination switch 6B. Solenoid valve (Sol 1) 9. Work equipment control valve

4. Controller 6C. Charge valve 10. Boom cylinder

6D. Shut-off valve (for manual pressure

5. Travel speed sensor
release)

1. Electronically Controlled Suspension System (ECSS)

Accumulators charged with high pressure gas in this system is turned ON and OFF automatically by the controller accord-
ing to the travel condition of the machine to give vertical elasticity to the work equipment. With this system, rolling of the
machine body is reduced during high speed travel to improve the operator comfort and prevent spill of the load. As a
result, the working efficiency is heightened.

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2. System
ECSS consists of the following electronic devices.

A. ECSS controller (Transmission ECSS controller)

B. Input devices: ECSS switch (System switch), Travel speed sensor,

speed range signal switch.

C. Output devices: Solenoid valve (Accumulator) 1, Charge control

solenoid valve 2.

ECSS is turned on and off with the ECSS switch on the main monitor.
If this system (switch) is turned ON, the ECSS LED on the main
monitor lights up

ECSS circuit

OPERATION

If the ECSS switch is turned on, the solenoid valve (Sol 1) is excited and the valve is changed, then the main spool is pushed
and the circuits between the lift cylinder bottom and accumulator and between the lift cylinder head and tank are connected.

A. Operating condition
This system operates when the speed range is 2nd through 4th and the travel speed is 5 km/h or higher.

B. Stopping of operation
When the travel speed is lowered to 3 km/h or the transmission is shifted into 1st or the ECSS switch is turned off, the
main spool is returned by the spring, and the circuits between the lift cylinder bottom and accumulator and between
the lift cylinder head and tank are disconnected.

C. Accumulator charge circuit

The accumulator charge circuit of ECSS prevents the boom from falling.

D. Charging of accumulator
The accumulator is charged by utilizing the oil pressure in the between the pump and work equipment valve when the
lift arm or bucket is operated. The charge pressure of the accumulators is 75 kgf/cm2 (1066.7 lbf/in2), which is
regulated with the charge valve in the ECSS valve.

E. No charging of accumulator
While ECSS is working, the accumulator cannot be charged since the charge control solenoid valve (Sol 2) is turned
off. The reason for this setting is to prevent the lift arm from rising when the accumulator is charged while the bucket
is operated.

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3. Contents of control
The controller receives the inputs in the left columns of the following table and gives the outputs in the right columns to
control the system.
Inputs Outputs

ECSS switch Travel speed Solenoid 1 Solenoid 2

Speed range
(to turn on/off system) (Remark 1) (Accumulator) (Charge control)

1 OFF All ranges --- X O

2 2nd or higher Min. 5 km/h O X

3 --- --- --- ---

4 ON 1 --- X O

Max. 5 km/h
5 2nd or higher X O
Remark 2

Remark 1
ECSS is turned on and off with the ECSS switch on the main monitor. If this system is turned ON, the red
ECSS LED on the main monitor lights up.

The ON-OFF condition of the system is kept even after the engine is stopped and the starter switch is
turned OFF. When the starter switch is turned on the next time, the system is set in the previous condition.

Main monitor function

Starter switch OFF ➞ machine stops ➞ starter switch ON
(When system is turned ON ➞ system ON)
(When system is turned OFF ➞ system OFF)

Remark 2
When the output is turned off, and if the travel speed exceeds 5 km/h, the output is turned on.
When the output is turned on, it is kept turned on until the travel speed lowers to 3 km/h.

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4. Self diagnosis function
This system always observes the condition of the system and displays the condition of the system (see LED code in the
table below) of the controller self diagnostic display.

If any abnormality occurs in either the controller itself or in the input or output devices, the controller diagnoses this, turns
all outputs OFF and displays the error code (failure code) on the self diagnostic display and main monitor.

LED Code
LED display Content System condition

Error code d0 Abnormality in solenoid 1, 2 (relief) system Abnormality

A. Display on controller
See the section on the transmission controller (controller LED).

B. Display on main monitor

See the section on the trouble data display on the main monitor.

5. Controller
The new travel damper controller is included inside the transmission controller.

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MEMORANDUM

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TRANSMISSION CONTROLLER

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CONNECTOR SIGNALS
CNC1 CNC3A CNC4
1 Joystick N output 1 NC 1 NC
2 Buzzer signal 2 NC 2 Engine speed
3 Relief solenoid 3 NC 3 NC
4 Engine speed output 4 NC 4 NC
5 Low pressure solenoid 5 NC 5 NC
6 GND 6 Pressure sensor power supply (+24v) 6 NC
7 Power supply (+24 V) 7 Potentio power supply 7 NC
8 F1 output 8 NC 8 NC
9 Damper solenoid 5 9 NC 9 GND (for rotate sensor)
10 High pressure solenoid 10 ENC select 10 NC
11 Back lamp relay 11 T/M oil temp. Sensor 11 Network (-)
12 GND 12 NC 12 Network (-)
13 Power supply (+24 V) 13 NC CNC5
CNC2 14 NC 1 GND (for plus)
1 Sol. power supply (+24V) 15 NC 2 Speed
2 ECMV 3 (+) 16 GND (for pressure sensor) 3 GND
3 NC 17 GND (for potentio) 4 GND
4 ECMV 4 (+) 18 NC 5 Kick down SW
5 NC 19 Joystick ON/OFF SW 6 T/M cut-off SW
6 NC 20 Pressure SW 7 Joystick N (NC)
7 ECMV F (+) CNC3B 8 Joystick F (NC)
8 ECMV R (+) 1 Pressure SW B 9 Joystick R (NC)
9 ECMV 1 (+) 2 Fill SW F 10 GND (for plus)
10 ECMV 2 (+) 3 Fill SW 1 11 Fill SW 3
11 P GND 4 NC 12 Fill SW 4
12 Sol. power supply (+24V) 5 Direction F 13 Hold SW
13 ECMV 3 (-) 6 Direction R 14 Manual SW
14 NC 7 Range SW 1 15 Joystick N (NO)
15 ECMV 4 (-) 8 Range SW 3 16 Joystick F (NO)
16 NC 9 Damper SW 17 Joystick R (NO)
17 ECMV F (-) 10 Fill SW R
18 ECMV R (-) 11 Fill SW 2
19 ECMV 1 (-) 12 NC
20 ECMV 2 (-) 13 Direction N
21 P GND 14 Neutralizer relay
15 Range SW 2
16 Range SW 4

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SENSORS
FUNCTION

The sensors are a contact type sensor with one end grounded to the chassis. The signal from the sensor is input directly to the
monitor panel, and when the contacts are closed, the panel judges the signal to be normal. However, the engine oil pressure
uses a relay to reverse the sensor signal.

Sensor detection item Sensor method When normal When abnormal

Speedometer sensor Electromagnetic - -

Engine oil level Contact ON OFF

Radiator water level Contact ON OFF

Engine oil pressure Contact OFF ON

Engine water temperature Resistance --- ---

Torque converter oil temperature Resistance --- ---

Engine speed sensor Electromagnetic --- ---

Fuel level sensor Resistance --- ---

SPEEDOMETER SENSOR
FUNCTION

The speedometer sensor is installed to the transmission output gear. A pulse voltage is generated by the rotation of the gear
teeth, and signal is sent to the machine monitor to display the travel speed.

1. Connector 2. Magnet 3. Case

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ENGINE SPEED SENSOR
FUNCTION

The engine speed sensor is installed to the ring gear portion of the flywheel housing. A pulse voltage is generated by the
rotation of the gear teeth, and a signal is sent to the controller and monitor panel.

1. Magnet 3. Case 5. Connector

2. Terminal 4. Boot

ENGINE OIL PRESSURE SENSOR

FUNCTION

This sensor is installed to the engine block and the diaphragm detects the oil pressure. If the pressure goes below the specified
pressure, the switch is turned ON, and a relay is actuated to turn the output OFF. This makes the maintenance monitor flash to
warn of the abnormality. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.

1. Plug 3. Contact 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal

WA500-3H 10-197
STRUCTURE AND FUNCTION SENSORS
12
RADIATOR WATER LEVEL SENSOR
FUNCTION

The sensor is installed to the top of the radiator. If the coolant goes below the specified level, the float goes down and the
switch is turned OFF. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.

1. Float 2. Sensor 3. Connector

ENGINE OIL LEVEL SENSOR

FUNCTION

This sensor is installed to the side face of the oil pan. When the oil goes below the specified level, the float goes down and the
switch is turned OFF. This makes the maintenance monitor flash, and the check lamp to also light up at the same time to warn
of the abnormality.

1. Connector 3. Float

2. Bracket 4. Switch

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STRUCTURE AND FUNCTION SENSORS
12
FUEL LEVEL SENSOR
FUNCTION

The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down as the level of the fuel changes.
As the float moves up and down, the arm actuates a variable resistance, and this sends a signal to the maintenance monitor to
display the fuel level. When the display the maintenance monitor reaches the specified level, the warning lamp flashes.

1. Connector 4. Body 7. Spacer

2. Float 5. Spring

3. Arm 6. Contact

WA500-3H 10-199
STRUCTURE AND FUNCTION SENSORS
12
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR

FUNCTION

These sensors are installed to the engine cylinder block and transmission case. The change in the temperature changes the
resistance of the thermistor, and a signal is sent to the maintenance monitor to display the temperature. If the display on the
maintenance monitor reaches the specified position, the lamp flashes and the buzzer sounds to warn of the abnormality.

1. Connector 2. Plug 3. Thermistor

10-200 WA500-3H
STRUCTURE AND FUNCTION SENSORS
12

MEMORANDUM

WA500-3H 10-201
STRUCTURE AND FUNCTION ELECTRICAL
12
ELECTRICAL

ENGINE STARTING CIRCUIT

FUNCTION

To ensure safety when starting the engine, the system is equipped with a neutral safety circuit. This makes it impossible for the
engine to start if the directional lever is not at the N (Neutral) position.
OPERATION

When the directional lever is placed at the N (Neutral) position contacts of the directional lever switch are closed. In this
condition, if the starting switch is turned to the START position, current flows in the following circuit.

[1] Battery (+) ➞ starting switch terminal B ➞ starting switch terminal C ➞ safety relay terminal S ➞ safety relay
terminal B ➞ directional lever switch terminal N ➞ ground, so the safety relay is closed.
In addition, current flows from starting switch terminal BR ➞ battery relay coil ➞ ground, so the battery relay switch is
closed. This forms the following circuit.

[2] Battery (+) ➞ battery relay ➞ starting motor terminal B ➞ safety relay terminal B ➞ safety relay terminal C ➞
starting motor terminal C, and the engine starts.

If the directional lever is at any position other than N (Neutral), circuit [1] is not formed, and the engine does not start.

10-202 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
SAFETY RELAY

WA500-3H 10-203
STRUCTURE AND FUNCTION ELECTRICAL
12
ENGINE STOP CIRCUIT

OPERATION

When the starting is turned ON, electric current flows in the following circuit.

[1] Battery (+) ➞ starting switch terminal B ➞ starting switch terminal BR ➞ fuel cut solenoid ➞ ground connection.

When electric current flows to the fuel cut solenoid, the fuel governor is put in the FREE position by the fuel control linkage.

Fuel flows to the fuel injection pump and the engine starts.

When the starting switch is turned OFF, circuit [1] is shut off, but the engine is rotating, so there is still voltage at terminal R of
the alternator. For this reason, the following circuit is formed.

[2] Alternator terminal R ➞ battery relay terminal BR ➞ ground connection.

The battery relay is maintained, but because of the diode inserted into the circuit, no electric current flows to the fuel cut
solenoid, so the engine stops.

10-204 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ELECTRICAL TRANSMISSION CONTROL

1. Transmission cut-off selector switch 6. Maintenance monitor 11. Speed sensor

2. Parking brake switch 7. Relays 12. Transmission cut-off switch

3. Directional lever 8. Fuse boxes 13. Brake valve (left)

4. Speed lever 9. Transmission controller 14. Brake valve (right)

5. Kick-down switch 10. Transmission control valve

1 Selection of F, R, and N positions Using directional lever

2 Selection of speed range
3 Kick-down switch
4 Transmission cut-off function
5 Transmission cut-off selector function
6 Neutralizer
7 Neutral safety function
8 Warning function
Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch without using the speed lever. If direc-
tional lever is operated to R or N, speed range automatically returned to 2nd.
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. In this way, it is possible
to obtain the same or greater ease of operation as on conventional loaders with the left brake when carrying out
scooping work or when loading or unloading the machine from a trailer.
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 pre-
vents 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.

WA500-3H 10-205
STRUCTURE AND FUNCTION ELECTRICAL

COMBINATION SWITCH

OUTLINE

The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does
not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is
secured to the body by three screws.
When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric
current to flow to that circuit only.

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
Turn signal indicator lever automatically returns to central position after machines turns left
5 Self cancel
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
10 Parking brake switch Applies or releases parking brake

10-206 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
OPERATION

Directional lever (1) and shaft (2) of the speed lever of the combination
switch form one unit with magnet (3), and magnet (3) also moves together
with lever (1).

Control switch (5) with built-in hole IC (4) is installed at the bottom of
magnet (3), and hole IC (4) is positioned on the board to match each posi-
tion.

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.

WA500-3H 10-207
STRUCTURE AND FUNCTION ELECTRICAL
12
KICK-DOWN / HOLD SWITCH

1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness

KICK-DOWN SWITCH
OPERATION

The kick-down (shifting down from 2nd ➞ 1st) is actuated only when
traveling in F2.

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.

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

HOLD SWITCH
The hold switch is installed to the boom lever, and when the hold switch is pressed, the speed range displayed on the main
monitor transmission indicator is held.

Press the hold switch again to cancel.

10-208 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS
NORMAL OPERATION
(When directional lever is at F and speed lever is at 2nd)

1. When directional lever is at F.

If the directional lever is set to the F position, the electric current flows from battery (+) ➞ directional lever terminals 1 -
2 ➞ transmission controller FORWARD CNC3B terminal 5, and then flows from CNC2 terminal 7 ➞ F solenoid ➞
CNC2 terminal 17 as the FORWARD output signal, and the FORWARD solenoid valve is actuated.

If the parking brake is placed at the RELEASED position, electricity flows from battery (+) ➞ parking brake safety relay
terminals 5 - 3 ➞ parking brake switch terminals 3 - 2 ➞ neutralizer relay terminals 1 - 2 ➞ ground, and terminals 3 - 5 of
the neutralizer relay are connected.

2. When speed lever is at 2nd.

When the speed lever is at the 2nd position, the signal is in put to transmission controller 2nd CNC3B terminal 15, and
electricity flows as the 2nd signal from CNC2 terminal 10 ➞ 2nd solenoid ➞ CNC2 terminal 20, and the 2nd solenoid is
actuated.

WA500-3H 10-209
STRUCTURE AND FUNCTION ELECTRICAL
12
WHEN KICK-DOWN SWITCH IS OPERATED
(Operation with speed lever at F2 position)
(When kick down switch is pressed ON)

When the kick-down switch is pressed, the main monitor network signal (-) enters from CNL08 terminal 2 to controller CNC5
terminal 5. The kick-down circuit is formed inside the controller and the solenoid output signal flows from CNC2 terminal 7
and terminal 9 to the F solenoid and 1st solenoid, the solenoid valves are actuated, and the speed range is set to F1.

This kick-down circuit continues to be actuated even if the kick-down switch is returned. (Self-hold circuit)

In this way, if the kick-down switch is pressed when the speed lever is at F2, the transmission is automatically shifted to F1. At
the same time, the self-hold function of the kick-down circuit keeps the condition at F1 even if the switch is released or is
pressed several times.

10-210 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
KICK-DOWN SWITCH OPERATION CANCELED
(When directional lever is set to N or R)

If the directional lever is operated to the R position, the contact of terminal F of the lever is turned off, so the electricity stops
flowing from battery (+) ➞ speed lever switch terminals 1 - 2 ➞ transmission controller.

The FORWARD circuit inside the transmission controller is opened, so electricity stops flowing to the kick-down circuit. As a
result, the kick-down self-hold circuit is canceled and the 1st solenoid stops actuating. (Even if the directional lever is set to
the N position, the same operation as above is carried out and the kick-down circuit is canceled.)

The FORWARD circuit is also opened, so the F solenoid also stops actuating.

When the directional lever is set to the R position, current flows from battery speed lever terminals 1 - 4 ➞ transmission
controller CNC3B terminal 6 ➞ CNC 2-8 terminal (Reverse circuit formations R (+) signal inside controller) ➞ R solenoid ➞
controller (-) CNC2 terminal 18, and the REVERSE solenoid valve is actuated.

At the same time, electricity flows from transmission controller 2nd signal (+) CNC2 terminal 10 ➞ 2nd solenoid ➞ CNC2
terminal 20, and the 2nd solenoid valve is actuated to set to R2.

WA500-3H 10-211
STRUCTURE AND FUNCTION ELECTRICAL
12

MEMORANDUM

10-212 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ELECTRIC PARKING BRAKE CONTROL

1. Parking brake emergency release

5. Transmission control valve 9. Charge valve
switch

2. Neutralizer relay 6. Parking brake solenoid valve 10. Accumulator

3. Parking brake safety relay (parking

7. Parking brake (built into transmission)
brake emergency release relay)

8. Parking brake emergency release

4. Parking brake switch
valve

OUTLINE

The parking brake is a wet type multiple disc brake built into the transmission. When electricity flows to the parking brake
solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder and releases the parking
brake.

When the flow of electricity is stopped, the hydraulic pressure from the transmission pump is shut off. The hydraulic pressure
inside the parking brake cylinder passes through the parking brake solenoid valve and is drained. The force of the brake spring
then applies the parking brake.

WA500-3H 10-213
STRUCTURE AND FUNCTION ELECTRICAL
12
FUNCTION

1. Applying and releasing parking brake

The parking brake is applied or released by using the parking brake switch (combination switch).

2. Automatic parking brake

When the engine stops (when the starting switch is OFF), the parking brake is automatically applied to prevent the
machine from running away when the operator is away from his seat.

3. Emergency brake
If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be
ensured, the parking brake is applied automatically to act as an emergency brake.

4. Parking brake safety

It is dangerous if the parking brake can be released simply by turning the starting switch ON after the automatic parking
brake has been applied. Therefore, to ensure safety, the system is designed so the brake cannot be released unless the
starting switch is turned ON and then the parking brake switch is also turned ON.

5. Neutralizer
The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this problem, the
caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. In addition to this,
when the parking brake is applied, the transmission is forcibly shifted to neutral to make it impossible to drive the
machine.
However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is
applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on
railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the
emergency brake is applied.

6. Parking brake emergency release solenoid valve

If the supply of pressure oil from the transmission pump should stop because of some failure, it is possible to actuate the
emergency relief solenoid valve with the parking brake emergency release switch in the operators compartment. This
sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake.

10-214 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
PARKING BRAKE EMERGENCY RELEASE SWITCH

EMERGENCY BRAKE SWITCH

WA500-3H 10-215
STRUCTURE AND FUNCTION ELECTRICAL
12
PARKING SAFETY RELAY
NEUTRALIZER RELAY

10-216 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
OPERATION

1. Starting switch OFF

When the starting switch is turned OFF, the battery relay is opened, so electricity does not flow to the parking brake
circuit. For this reason, if the starting switch is at the OFF position, no electric current flows to the parking brake solenoid
valve, regardless of whether the parking brake switch is ON (applied) or OFF (released), so the parking brake is actuated
(Automatic parking brake).

WA500-3H 10-217
STRUCTURE AND FUNCTION ELECTRICAL
12
2. Starting switch ON

A. When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit ➀ from the battery + ➞ starting switch ➞ battery relay coil ➞ ground, so the
battery relay is closed. When this happens, electric current flows in circuit ➁ from the battery + ➞ battery relay ➞
parking brake switch terminal 1 - 3 ➞ parking brake safety relay terminal 1 - 2 ➞ ground. In this way, the parking
safety relay is actuated and safety relay terminals 3 - 5 are closed.

When this happens, circuit ➂ is formed from the battery + ➞ battery relay ➞ parking safety relay terminal 5 - 3 ➞
parking safety relay terminal 1 - 2 ➞ ground. From this point, the parking safety relay is in the condition of circuit ➂
until the starting switch is turned OFF.

In this condition, electric current does not flow to the parking brake solenoid valve, so the parking brake is actuated.

In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric current does not flow to the
transmission directional circuit, and the transmission is shifted to neutral.

10-218 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
B. When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit ➀ from the battery + ➞ starting switch ➞ battery relay coil ➞ ground, so the battery
relay is closed. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not
actuated. For this reason, the electric current does not flow to the parking brake solenoid valve, so after the automatic
parking brake is applied, the parking brake is not released automatically even when the starting switch is turned ON.

In addition, the electric current does not flow to the transmission directional circuit, so the machine does not move.

WA500-3H 10-219
STRUCTURE AND FUNCTION ELECTRICAL
12
3. Parking brake switch OFF (released)
When the parking brake switch is turned from ON to OFF after the starting switch is turned ON

If the parking brake switch is turned from ON (actuated) to OFF (released), the circuit for terminals 2 and 3 of the parking
brake switch is connected, and the parking brake safety relay is also actuated. For this reason, electric current flows in
circuit ➀ from the battery + ➞ battery relay ➞ parking brake safety relay ➞ parking brake switch, and then flows to
circuits ➁ and ➂ given below.

➁ This circuit is formed from the emergency brake switch ➞ parking brake solenoid valve ➞ ground, and the parking
brake is released.

➂ This circuit is formed from the battery + ➞ battery relay ➞ neutralizer relay terminal 3 - 5 ➞ transmission directional
circuit, so when the directional lever is operated, the machine will move.

10-220 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied) after carrying out operations with the parking brake switch OFF
(released), the circuit in the diagram above is formed.

Electric current does not flow to the parking brake solenoid valve, so the oil pressure from the transmission pump to the
parking brake cylinder is shut off. At the same time, the oil pressure inside the parking brake cylinder passes through the
parking brake valve and is drained, so the parking brake is applied by the force of the spring.

In addition, at the same time, the neutralizer relay is reset, so the circuit between terminals 3 and 5 is opened, and no
electricity flows to the transmission directional circuit, so the transmission is shifted to neutral. This kind of neutralizer
relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts
the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the
parking brake still applied.

WA500-3H 10-221
STRUCTURE AND FUNCTION ELECTRICAL
12
5. When main brake oil pressure drops (emergency brake actuated)
OPERATION

If the oil pressure in the main brake line drops, the emergency brake switch installed to the accumulator is opened.
For this reason, the electric current stops flowing to the parking brake solenoid valve, so the oil pressure inside the parking
brake cylinder is drained and the parking brake is applied.

However, in this case, the condition is different from the case where the parking brake switch is ON (applied), because
there is electric current flowing to the neutralizer relay coil.

For this reason, electric current flows to the transmission directional circuit, and it is possible to engage the transmission
clutch. In this way, it is possible to use the engine brake when the emergency brake is applied, so the braking distance
becomes shorter. At the same time, if the emergency brake has been applied and it is necessary to move the machine (for
example, if the emergency brake is applied when the machine is on a railway crossing), it is possible to move the machine
by operating the transmission lever.

10-222 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
6. Parking brake emergency release
OPERATION

If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake
cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored
in the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time,
electric current flows to the emergency parking brake release solenoid valve.

The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the
parking brake.

The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position
after the emergency release.

WA500-3H 10-223
STRUCTURE AND FUNCTION ELECTRICAL
12
7. Function of parking brake neutralizer relay

OUTLINE

When the parking brake is being actuated, the transmission is held at neutral to prevent the parking brakes from dragging
if the machine is operated by mistake.

OPERATION

A. When the parking brake is actuated (ON), electricity flows from the battery relay ➞ parking brake switch terminals
1 - 3 ➞ parking brake safety relay terminal 1 ➞ ground. As a result, the safety relay coil is actuated, and safety relay
terminals 3 and 5 are connected to form the circuit.

B. When the parking brake switch is OFF (released) and the engine is started, the circuit in Item A is not formed, so the
parking brake switch must be turned ON.

C. When the parking brake is being actuated, electricity does not flow to the neutralizer relay coil, so neutralizer relay
terminal 3 and terminal 5 are separated and no electricity flows to the transmission directional circuit. In this way,
when the parking brake is applied, the transmission is held at neutral.

10-224 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ELECTRICAL DIAGRAM
See Section 90 for;

ECSS WIRING DIAGRAM - FOLDOUT 10-225-1

JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2

ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5)

ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-4, (Sheet 1) (Part 2 of 5)
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-5, (Sheet 1) (Part 3 of 5)
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-6, (Sheet 1) (Part 4 of 5)
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-7, (Sheet 1) (Part 5 of 5)

ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-8, (Sheet 2) (Part 1 of 4)

ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-9, (Sheet 2) (Part 2 of 4)
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4)
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4)

ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12

CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13

WA500-3H 10-225
STRUCTURE AND FUNCTION ELECTRICAL
12
ENGINE HARNESS DIAGRAM

10-226 WA500-3H
STRUCTURE AND FUNCTION ELECTRICAL
12
ENGINE - FRAME - FLOOR HARNESS DIAGRAM

WA500-3H 10-227
STRUCTURE AND FUNCTION ELECTRICAL
12

MEMORANDUM

10-228 WA500-3H
 20 TESTING, ADJUSTING AND
TROUBLESHOOTING

12-+
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
HANDLING EQUIPMENT IN FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
RELEASING REMAINING PRESSURE IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
MEASURING FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
REDUCED CYLINDER MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
BLEEDING AIR FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
CHECK FOR LEAKAGE IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ADJUSTING SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TESTING AND ADJUSTING ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TESTING AND ADJUSTING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
RUN-IN STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
PERFORMANCE TEST STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
TORQUE CONVERTER STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
AIR CONDITIONER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
SHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
OPERATING FORCE OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
TRAVEL OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
OPERATING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
TORQUE CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
TRANSMISSION OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
TORQUE CONVVERTER AND TRANSMISSION HYDRAULIC CIRCUIT FLUSHING . . . . . . . . . . . . . . . 20-34
TRANSMISSION VALVE FAILS - MOVING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
MEASURING OPERATING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
STEERING STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42

WA500-3H 20-1
TESTING AND ADJUSTING
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
PEDAL PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
INSPECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
CALCULATING PISTON STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
MEASURING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
MANUAL RELEASE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
ADJUSTING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
RELEASING REMAINING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
BOOM POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
TROUBLESHOOTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
ELECTRICAL CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
(ELECTRIC CONTROL MECHANISM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING SYSTEMS OF:
D MODE - ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM). . . . . . . . . . . . . . . . 20-401
E MODE - CHASSIS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
J MODE - JOYSTICK STEERING CONTROLLER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
M MODE - MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
T MODE - TRANSMISSION CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1201
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1301

20-2 WA500-3H
TESTING AND ADJUSTING
12
★ For further detail information, refer to Engine Shop Manual.
★ Heed the following precautions when referring to the Standard Value Tables for testing, adjusting and troubleshooting:

A. The standard values in tables are those established for a new machine and are given as reference values for the point
at which the machine is shipped from the factory. These values should be used only as a guide when estimating wear
after the machine is operated and when carrying out repairs.

B. Permissible values shown in the tables are estimations based on the results of test performed on the machines shipped
from the factory, so they should be used together with the information on the repair condition and other information
such as the operating history of the machine itself when judging the condition of the machine.

C. These standard values do not form a basis for judging claims.

WARNING! Before testing, adjusting, or troubleshooting, park the machine on level ground,
install the safety bar, and use blocks to prevent the machine from moving.

WARNING! When working with others, always use signals and keep unauthorized people
away from the machine.

WARNING! Wait for the engine coolant water to cool before checking the coolant level. If the
radiator cap is removed while the coolant is still hot, the coolant will spurt out and
cause burns. Be careful to stay away from the fan, fan belt and other moving
parts

WA500-3H 20-3
TESTING AND ADJUSTING
12

MEMORANDUM

20-4 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE - IN
12
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS

Machine model WA500-3H

Engine model Komatsu SA6D140E-3
Standard value for
Item Measure condition Unit new machine Service limit value

High idle 2300 ±50 2300 ±100

rpm
Engine speeds Low idle 725 ±50 725 ±75
Rated speed kW/rpm 250 / 2100 250 / 2100
At T.C. stall and W.O.T. (Wide Open
Intake manifold pressure Throttle) mm Hg 800 min. 670 min.

At T.C. stall and W.O.T. at restriction mm H2O

Intake air restriction indicator port New element: 380 762 max.

Minimum at low idle kgf/cm2 1.2 .08

Lubricating oil pressure (lbf/in2) 17.0 1.13
with SAE 15W-40 oil &
coolant temperature in kgf/cm2 340 2.1
operating range Minimum at high idle 49.7 29.8
(lbf/in2)
Fuel filter inlet restriction Maximum restriction at high idle mm Hg 220 max. 220 max.
Coolant temperature in operating range:
Blow-by pressure • Service Tool orifice size: 7.67 mm mm H2O 150 max. 300 max.
• At T.C. stall and W.O.T.
Exhaust back pressure Maximum at T.C. stall and W.O.T. mm Hg 105 max. 105 max.
Maximum operating temperature at engine
Coolant temperature outlet ° C/° F 100 / 212 max. 100 / 212 max.

Engine cold:
Valve clearance Intake valves mm 0.35 0.35
Exhaust valves 0.57 0.57
Deflection when pressed with finger force
Alternator belt of approximately 98 N (22 lbf) mm 13 - 16 13 - 16

Air conditioner Deflection when pressed with finger force

compressor belt tension of approximately 58.8 N (13.2 lbf) mm 10 - 15 10 - 15

★ For further detailed information, refer to Engine Shop Manual.

WA500-3H 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS

Machine model WA500-3H

Engine model Komatsu SA6D140E-3
Standard value for
Item Measurement condition Unit Service limit value
new machine
Engine stall speeds:
• Coolant temperature in operating range
Torque converter • Torque converter oil temperature in operat- 2140 ±100 2140 ±100
ing range rpm
Hydraulic • Hydraulic oil at normal operating tempera- 2180 ±100 2180 ±150
ture
Full 1820 ±100 1820 ±200
24.5 ±4.9 @ 48°
Accelerator pedal: (5.5 ±1.1 @ 48°)
N (lbf) Max. 97 (21.8)
Operating force 53.9 @ 35°
(12.1 @ 35°)
Operating angle:
x1 degree 48
x2 degree 34 - 35

Stopper height (L) mm 55.8 ---

Measurement condition Unit Standard value for Service limit value

Item new machine

Shift lever operating force and stroke

• Directional lever operating force
N-F N (lbf) 5.88 + 4.9 / - 2.94 Max. 16.66
N-R (1.32 + 1.10 / 0.66) (3.74)
• Speed lever operating force • Measure at center of lever knob
1st - 2nd
2nd - 3rd • Engine stopped N (lbf) 5.88 + 4.9 / - 2.94 Max. 16.66
3rd - 4th (1.32 + 1.10 / 0.66) (3.74)
• Directional lever travel
N-F
N-R mm 35 ±10 35 ±20
• Speed lever travel
1st - 2nd -3rd -4th
mm 35 ±10 35 ±20

20-6 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Item Measurement condition Unit Standard value for Service limit value
new machine

Oil pressure of torque converter and

transmission. 4 ±1 4 ±1
• Torque converter outlet port oil pressure (56.8 ±14.22) (56.8 ±14.22)

• Torque converter inlet port oil pressure 0.83 ±0.1 0.83 ±0.1
(8.5 ±1) (8.5 ±1)
• ECMV output (clutch) oil pressure
1st • Torque converter oil
temperature: 60 - 80° C
2nd, 3rd, 4th, F-R kgf/cm2 33.5 ±2 33.5 ±2
• Engine speed: High idling (lbf/in2) 476.4 ±28.4) 476.4 ±28.4)
• Main relief valve 35.5 ±1.5 35.5 ±1.5
Low idling • Manual switch ON (476.4 ±21.3) (476.4 ±21.3)

High idling 33 ±1.5 33 ±1.5

(469.3 ±21.3) (469.3 ±21.3)
36 ± 1.5 36 ± 1.5
• Lubrication pressure (oil cooler outlet (512.0 ±21.3) (512.0 ±21.3)
port)
2.15 ±0.85 2.15 ±0.85
(30.5 ±12.0) (30.5 ±12.0)
Tire inflation pressure
• Specified pressure
Tire and wheel
• Fitting of wheel lock ring
(A)
(B)
• Clearance of wheel lock ring mm Max. 2.5 -
(C) Max. 4.0 -

2 - 10 -

Steering wheel Road surface: Flat, horizontal, mm Max. 50 50 - 100

• Steering wheel play dry, paved surface: N (lbf) 12.25 ±2.45 Max. 19.6 (4.4)
• Steering wheel operating force • Hydraulic temp.:45 - 55° C (2.75 ±0.55)
• Operating time of steering wheel
Low idle • Machine posture:
High idle Facing straight Sec. Max. 5.5 Max. 6.5
Sec. Max. 3.1 Max. 4.5
• Turning speed • Engine speed: High idling
Turns 3.6 ±0.4 Max. 4.5
Clearance between front and rear frame Engine speed: 1200 rpm mm 25 ±2 -

WA500-3H 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Standard value for
Testing and measuring item Measurement condition Unit new machine Service limit value

Steering oil pressure 210 +10/-3 210 +10/-3

• Main relief oil pressure 2 (43.0 + 0.014/-0.004) (43.0 + 0.014/-0.004)
• Hydraulic temperature: 45 - 55° C kgf/cm
• Engine speed: High idle (lbf/in2) 38 +4/-2 38 +4/-2
• Orbit-roll output pressure (0.054 +0.005/-0.002) (0.054 +0.005/-0.002)
Brake pedal
• Operating force N (lbf) 294 ±29.4 Max. 421.4
(66.0 ±6.60) (94.7)
• Engine speed: Low idle
• Operating angle • Hydraulic temperature: 45-55°C degree 45 -

• Play mm 15 +1/-0 -
Accumulator
• Charge cut-in pressure 60 +5/-0 60 +5/-0
Point where brake oil pressure warn- 853.4 +71.1/-0 853.4 +71.1/-0
ing lamp goes out • Engine speed: Low idle kgf/cm2
• Hydraulic temperature: 45-55°C (lbf/in2)
• Charge cut-out pressure
Point where oil pressure is going up 100 +10/-0 100 +10/-0
and then starts to go down (1422.3 +142.2/-0) (1422.3 +142.2/-0)
Warning buzzer pressure
• Actuating starting • Coolant temperature: kgf/cm2 6.0 ±0.1 6.0 ±0.1
• Actuating stopping Inside operating range (lbf/in2) (85.3 ±1.4) (85.3 ±1.4)
• Road surface: Flat, horizontal, dry,
paved surface
• Speed when applying brakes: 20
km/h
• Time lag when pressing the pedal:
Brake performance 0.1 sec. mm Max. 5 Max. 5
• Brake pedal operating force: 294
±29.4 N (30 ±3 kg)
• Tire inflation pressure:
Specified pressure
• Coolant temperature:
Inside operating range kgf/cm2 Max. 5 Max. 5
Drop in brake oil pressure • Test pressure: (71.1) (71.1)
(lbf/in2)
53 kg/cm2/5 min.
Wear of brake disc • Piston stroke mm 2.2 - 5.5 Max. 8.5
• Tire inflation pressure:
Specified pressure
No
• Road surface: No
machine
Parking brake performance Flat, dry, paved surface with 1/5 machine
movement
(11°20') gradient movement
• Machine:
In operating condition
• Thickness of pad • With back plate 31.7 12.7
• Clearance between mm
• Total of both side 1.06 ±0.18 Max. 2.3
disc and pad

20-8 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Testing and measuring item Unit Standard value for Service limit value
Measurement condition new machine

Dump and lift control levers

• Lift arm control lever operating force
Hold _ Raise Max. 3.5
Raise _ Hold Max. 2.5
Max. 6
Hold _ Lower 2-4
Max. 3.5
Lower _ Hold Max. 2.5
-
Lower _ Float -
kg Max. 6
Float _ Hold 2-4
Max. 6
2-4
• Dump control lever operating force • Hydraulic temperature: 45 - 55° C
Hold _ Dump • Engine speed: Low idle Max. 3.5
Hold _ Tilt • Coolant temperature: Max. 2.5
Max. 3.5
Tilt _ Hold Inside operating range Max. 2.5
Max. 6
2-4
• Lift arm control lever travel
Hold _ Raise 52 - 82 37 - 97
Hold _ Lower 34 - 64 19 - 79
Hold _ Float 52 - 82 37 - 97
mm
• Dump control lever travel
Hold _ Dump 45 - 75 30 - 90
Hold _ Tilt 45 - 75 30 - 90
• Coolant temperature:
Relief oil pressure
Inside operating range kgf/cm2
• PPC valve 210 ±5 210 ±5
• Hydraulic temperature: 45 - 55° C (lbf/in2)
• Main control valve (2986.9 ±71.1) (2986.9 ±71.1)
• Engine speed: High idle
Operating speeds
• Lift arm lifting time • Coolant temperature: 6.8 - 7.4 Max. 8.9
• Lift arm lowering time Inside operating range 3.0 - 4.0 Max. 4.8
• Bucket dumping time • Hydraulic temperature: 45 - 55° C 1.4 - 2.0 Max. 2.4
sec.
• Bucket tilt back time • Engine speed: High idle
(Full stroke) • Steering position: Neutral 1.9 - 2.5 Max. 3.0
• Bucket tilt back time • Bucket: empty
(Horizontal position of bucket) 1.3 - 1.9 Max. 2.3
• Coolant temperature:
Inside operating range
Hydraulic drift of lift arm and bucket • Hydraulic temperature: 45 - 55° C
• Retraction of lift cylinder rod • Stop engine, leave for 5 minutes,
mm Max. 40 Max. 40
then measure for next 15 minutes.
• Retraction of dump cylinder rod • Lift arm horizontal
Max. 20 Max. 20
• Bucket horizontal
• Bucket: empty
Bucket positioner
• Clearance of switch 3-5 -
mm
Boom kick-out
• Clearance of switch 3-5 -

WA500-3H 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, it is
normal
Between C1 (7), (13) - chassis 1. Turn starting switch
OFF
Power source C1 Measure voltage
Between C2 (1), (12) - chassis 2. Insert T-adapter
20 - 30 V 3. Turn starting switch ON
Between C1 (7), (13) - (6), (12)
Between C2 (1), (12) - (11), (21)
If the condition is as shown in the table below, it is 1. Turn starting switch
normal OFF
Power source
C3A Measure voltage 2. Insert T-adapter
(signal) Between (6) - (17)
20 - 30 V 3. Turn starting switch ON
Between (6) - chassis 4. Apply parking brake
If the condition is as shown in table below, the sen-
sor is normal 1. Turn starting switch
Parking brake OFF
L01 Measure voltage
switch Parking brake ON, Between (1) - (3), 20 - 30 V 2. Insert T-adapter
3. Turn starting switch ON
Parking brake OFF, Between (1) - (3), Max. 1 V
Transmission & Travel Damper Controller

If condition is as shown in the table below, the sen-

sor is normal 1. Turn starting switch
ECMV solenoid CN4 Measure OFF
(1st) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
ECMV solenoid CN6 Measure OFF
(2nd) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
ECMV solenoid CN12 Measure OFF
(3rd) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter

If condition is as shown in the table below, it is nor-

mal 1. Turn starting switch
ECMV solenoid CN8 Measure OFF
(4th) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
ECMV solenoid CN16 Measure OFF
(F) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
ECMV solenoid CN14 Measure OFF
(R) (male) resistance Between (1) - (2) 5 - 15 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ

20-10 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Connector Inspection Measurement

Name of component number Judgement table
method conditions
If the condition is as shown in the table below, it is
normal
1st - CN5 Speed lever at measurement
(male) |position:
2nd - CN7 Max. 1 Ω 1. Turn starting switch
(male) Measure Between (1) - chassis OFF
3rd - CN13 resistance 2. Insert T-adapter
(male) 3. Turn starting switch ON
4th - CN9 Speed lever not at measurement
(male) position:
Min. 1 Ω
Between (1) - chassis

ECMV fill switch If the condition is as shown in the table below, it is 1. Turn starting switch
Transmission & Travel Damper Controller

normal OFF
2. Disconnect connector
Directional lever at measurement 3. Connect T-adapter
position: 4. Start engine
Max. 1 Ω 5. Place directional lever
Between (1) - chassis at N
F - CN17 6. Turn manual switch ON
(male) Measure 1. Turn starting switch
R - CN15 resistance OFF
(male) Directional lever not at
measurement position: 2. Disconnect connector
3. Connect T-adapter
4. Start engine
Min. 1 Ω
5. Turn transmission cut-
off (lamp OFF)
Between (1) - chassis 6. Turn parking brake
switch OFF
7. Depress brake
If condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Transmission oil CN11 Measure OFF
temperature sensor (male) resistance Normal temperature (25° C) 3.8 - 4.8 Ω 2. Disconnect connector
3. Connect T-adapter
100° C Between (1) - chassis 3.6 - 3.9 Ω
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Transmission oil
C2 Measure Normal temperature (25° C) OFF
temperature 4.4 - 4.6 Ω
resistance Between (11) - (17) 2. Disconnect connector
(controller)
3. Connect T-adapter
100° C Between (11) - (17) 2.1 - 2.3 Ω

WA500-3H 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Connector Inspection Measurement

Name of component number Judgement table
method conditions
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Engine speed E04 Measure OFF
sensor (male) resistance Between (1) - (2) 500 - 1000 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1) - (2 - chassis) Min. 1 MΩ
If condition is as shown in the table below, it is 1. Turn starting switch
Engine speed C4 normal OFF
Transmission & Travel Damper Controller

Measure voltage
(controller) (male) Measure with AC range 2. Disconnect connector
Max. 0.5 V 3. Start engine
Between (2) - (9)
If the condition is as shown in the table below, the
sensor is normal
1. Screw in until speed sensor contacts ring gear,
Engine speed - Adjust -
then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as
above.
If condition is as shown in the table below, it is
normal 1. Turn starting switch
CN3 Measure OFF
(male) resistance Between (1) - (2) 500 - 1000 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1) - (2 - chassis) Min. 1 MΩ
Speed If the condition is as shown in the table below, the
sensor is normal
1. Screw in until speed sensor contacts ring gear,
- Adjust -
then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as
above.

20-12 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Speed lever Speed lever at 1st.
20 - 30 V
(1st) Between (7) - chassis
Speed lever not at 1st.
Max. 1 V
Between (7) - chassis
If the condition is as shown in the table below, it is
normal
Speed lever Speed lever at 2nd.
20 - 30 V
(2nd) Between (15) - chassis
Speed lever not at 2nd.
Max. 1 V
Between (15) - chassis
If the condition is as shown in the table below, the
sensor is normal
Speed lever Speed lever at 3rd.
20 - 30 V
(3rd) Between (8) - chassis
Speed lever not at 3rd.
Transmission & Travel Damper Controller

Max. 1 V
Between (8) - chassis
If the condition is as shown in the table below, it is
normal
Speed lever Speed lever at 4th.
20 - 30 V
(4th) Between (16) - chassis
Controller

1. Turn starting switch

Speed lever not at 4th. OFF
C3B Measure voltage Between (16) - chassis Max. 1 V
2. Disconnect connector
If the condition is as shown in the table below, the 3. Start engine
sensor is normal
Directional
Directional lever at F
lever 20 - 30 V
Between (5) - chassis
(F)
Speed lever not at F.
Max. 1 V
Between (5) - chassis
If the condition is as shown in the table below, it is
normal
Directional
Directional lever at R
lever 20 - 30 V
Between (6) - chassis
(R)
Speed lever not at R.
Max. 1 V
Between (6) - chassis
If the condition is as shown in the table below, the
sensor is normal
Directional
Directional lever at N
lever 20 - 30 V
Between (13) - chassis
(N)
Speed lever not at N.
Max. 1 V
Between (13) - chassis
S-NET If the condition is as shown in the table below, the
between sensor is normal
transmission
and main Between (4), (12) - chassis 4-8V
controller

WA500-3H 20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, it is
normal
1. Turn starting switch
Kick-down switch ON OFF
Kick-down Switch
Between (1) - (2) Max. 1 Ω 2. Insert T-adapter
3. Turn starting switch ON
Kick-down switch OFF
Between (1) - (2) Min. 1 MΩ
L15 Measure
Transmission & Travel Damper Controller

(male) resistance If the condition is as shown in the table below, the

sensor is normal
1. Turn starting switch
Hold switch ON OFF
Hold Switch
Between (3) - (4) Max. 1 Ω 2. Disconnect connector
3. Connect T-adapter
Hold switch OFF
Between (3) - (4) Min. 1 MΩ

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

normal
1. Turn starting switch
Transmission L12 Measure When operated normally OFF
cut-off switch (male) resistance Between (1) - (2) - chassis Max. 1 Ω 2. Disconnect connector
3. Connect T-adapter
When left brake is depressed
Between (1) - (2) - chassis Min. 1 MΩ

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

sensor is normal
Controller

1. Turn starting switch

Manual Manual switch ON OFF
C5 Measure voltage 20 - 30 V
Switch Between (14) - chassis 2. Insert T-adapter
3. Turn starting switch ON
Manual switch OFF
Max. 1 V
Between (14) - chassis
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Power source CN3 OFF
Measure voltage
(male) Between (1) - (2) - chassis 2. Insert T-adapter
20 - 30 V 3. Turn starting switch ON
Main Monitor

Between (1) - (2) - (3)

If the condition is as shown in the table below, the
sensor is normal
Engine running (at above 1/2 1. Turn starting switch
Charge (alternator) L05 Measure voltage throttle. 28 ±2 V OFF
Between (5) - (3) 2. Insert T-adapter
Starting switch ON
Max. 1 V
Between (5) - (3)
* If the battery is old, or after starting in cold areas, the voltage may not rise for some time.

20-14 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Directional switch Measure Directional lever at N OFF
L05 20 - 30 V
(N) voltage Between (8) - (3) 2. Insert T-adapter
3. Turn starting switch ON
Directional lever not at N Max. 1 V
Between (8) - (3)
If the condition is as shown in the table below, it is
normal
Starting switch 1. Turn starting switch
L09 Measure Starting switch at start 20 - 30 V OFF
terminal C (male) voltage Between (3) - chassis 2. Insert T-adapter
Starting switch at OFF or ON Max. 1 V
Between (3) - chassis
If the condition is as shown in the table below, the
sensor is normal
Starting switch 1. Turn starting switch
L04 Measure Engine started 20 - 30 V OFF
terminal C voltage Between (4) - (3) 2. Insert T-adapter
Maintenance Monitor Related

Starting switch OFF or ON Max. 1 V

Between (4) - (3)
If the condition is as shown in the table below, it is
normal
1. Turn starting switch
Starting switch L09 Measure Starting switch ON OFF
20 - 30 V
terminal BR (male) voltage Between (2) - chassis 2. Disconnect connector
3. Connect T-adapter
Starting switch OFF Max. 1 V
Between (2) - chassis
If the condition is as shown in the table below, the
sensor is normal
Starting switch Measure Starting switch ON 1. Turn starting switch
terminal BR L07 voltage Between (2) - chassis 20 - 30 V OFF
2. Insert T-adapter
Starting switch OFF
Between (2) - chassis Max. 1 V

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

normal
1. Turn starting switch
Parking brake CN19 Measure Parking brake ON OFF
indicator switch (male) resistance Between (1) - (2) Max. 1 Ω 2. Disconnect connector
3. Connect T-adapter
Parking brake OFF
Between (1) - (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Directional switch Measure Directional lever at F OFF
(F) L08 voltage Between (7) - chassis 20 - 30 V 2. Insert T-adapter
3. Turn starting switch ON
Directional lever not at F
Between (7) - chassis Max. 1 V

WA500-3H 20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Directional switch Measure Directional lever at R OFF
(R) L08 20 - 30 V
voltage Between (8) - chassis 2. Insert T-adapter
3. Turn starting switch ON
Directional lever not at R
Max. 1 V
Between (8) - chassis
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Power source Measure OFF
L18
voltage Between (1), (2) - chassis 2. Insert T-adapter
20 - 30 V 3. Turn starting switch ON
Between (1), (2) - (3)
If the condition is as shown in the table below, the
sensor is normal
1. Turn starting switch
Engine water tem- E06 Measure 50° C Approxiately OFF
perature sensor (male) resistance Between (A) - (B) 19 Ω 2. Disconnect connector
3. Connect T-adapter
100°C Approxiately
Between (A) - (B) 3.6 Ω
Maintenance Monitor Related

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

normal
1. Turn starting switch
Torque converter Normal temperature (25° C) Approxiately
CN18 Measure OFF
oil temperature Between (1) - (2) 40 Ω
(male) resistance 2. Disconnect connector
sensor
3. Connect T-adapter
130° C Approxiately
Between (1) - (2) 1.7 Ω
If the condition is as shown in the table below, the 1. Turn starting switch
sensor is normal OFF
R07 Measure Approxiately 2. Disconnect connector
Fuel level sensor Float raised to stopper 3. Drain fuel
(male) resistance 4 Ω
4. Remove fuel level
Approxiately sensor
Float lowered to stopper
85 Ω 5. Connect T-adapter

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

normal
1. Turn starting switch
Radiator water G01 Measure Water level normal OFF
level sensor (male) resistance Between (1) - (2) Max 1 Ω 2. Disconnect connector
3. Connect T-adapter
Water level low
Between (1) - (2) Min. 1 MΩ

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

sensor is normal
1. Turn starting switch
Engine oil pressure: Min. 1.3 kgf/
Engine oil pressure OFF
Measure cm2 (18.4 lbf/in2) (Start engine) Min. 1 MΩ
sensor E11 2. Disconnect connector
resistance Between (A) - (C)
3. Connect T-adapter
Engine oil pressure: Max. 0.7 kgf/ 4. Start engine
cm2 (9.9 lbf/in2) (Starting switch Max. 1 Ω
ON) Between (A) - (C)

20-16 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Accumulator pressure:
Brake B08 1. Turn starting switch
Min. 55 ±5 kgf/cm2 (782.2 +71.1 Max. 1 Ω
accumulator low (male) Measure OFF
lbf/in2) Between (1) - (2)
pressure switch B13 resistance 2. Disconnect connector
(male) Depress brake and lower accumula- 3. Connect T-adapter
tor pressure to below 45 ±5 kg/cm2
(640.0 ±71.1 lbf/in2) Between (1) - Min. 1 MΩ
(2)
If the condition is as shown in the table below, it is
normal
Engine running (at above 1/2
Maintenance Monitor Related

throttle) 28 ±2 V 1. Turn starting switch

Charge (alternator) Measure Between (12) -(3), (14) OFF
L18
voltage 2. Insert T-adapter
Starting switch ON 3. Start engine
Max. 1 V
Between (12) -(3), (14)
*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, the
sensor is normal
1. Turn starting switch
Engine oil level E10 Measure Oil level normal OFF
sensor (male) resistance Between (1) - (2) Max. 1 Ω 2. Disconnect connector
3. Connect T-adapter
Oil level abnormal
Between (1) - (2) Min. 1 MΩ
Measurement
If the condition is as shown in the table below, it is
conditions
normal
E19
(male) Measure Air cleaner normal
Dust indicator
E20 continuity Between E19 (1) - E20 (1) Continuity
(female)
Air cleaner clogged or engine
stopped - No continuity
No continuity
Between E19 (1) - E20 (1)

WA500-3H 20-17
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12

WARNING! Check carefully that there is no one in the surrounding area before starting inspection.

★ When carrying out operations during inspection, raise the work equipment control lever stand for operations, and
lower it when traveling.
★ Turn the starting switch OFF before inserting the T-adapter, or making any connections.

Measurement
Name of component Judgement table
conditions
If the condition is as shown in Table 1, the monitor panel is normal

Table 1 (CHECK, CAUTION portion)

Connector Monitor item Measurement Sensor
Display
No. (input connector) conditions signal input
Flashing 15 - 20 V
Maintenance Monitor Related

Engine water level Engine stopped,

(8) - (3), (14) Starting switch ON OFF Max. 1 V

Engine oil level Engine stopped, Flashing 15 - 20 V

CHECK, (13) - (3), (14) Starting switch ON OFF Max. 1 V
CAUTION 1. Connect T-adapter
portion Engine oil pressure Flashing 15 - 20 V
Start engine
(10) - (3), (14) OFF Max. 1 V
L18
(male) Flashing 15 - 20 V
Brake oil pressure
Start engine
(11) - (3), (14) OFF Max. 1 V

Battery charge Flashing Max. 10 V

Start engine
(12) - (3), (14) OFF Min. 12 V

Air cleaner Flashing 15 - 20 V

Start engine
(15) - (3), (14) OFF Max. 1 V

20-18 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Measurement
Name of component Judgement table
conditions
Table 2 (Gauge portion)
Maintenance Monitor Related

1. Turn starting switch

OFF, then insert
dummy resistance or
Gauge measure resistance of
portion sensor.

2. Turn starting switch

ON and check display

WA500-3H 20-19
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
Parking brake emergency cancel 1. Turn starting switch
Parking brake
Measure switch ON 20 - 30 V OFF
emergency cancel L90
voltage Between (1) - (2) and (3) - (4) 2. Insert T-adapter
switch
3. Turn starting switch ON
Parking brake emergency cancel
switch OFF Max. 1 V
Between (1) - (2) and (3) - (4)
If the condition is as shown in the table below, it is
normal
Parking brake Parking brake emergency cancel 1. Turn starting switch
emergency cancel Measure switch ON 20 - 30 V OFF
B14
solenoid voltage Between (1) - (2) 2. Insert T-adapter
3. Turn starting switch ON
Parking brake emergency cancel
switch ON Max. 1 V
Between (1) - (2)
If the condition is as shown in the table below, the
sensor is normal
Accumulator pressure: Min. 40
1. Turn starting switch
Emergency brake B09, B10 Measure
±5 kg/cm2 (568.9 ±71.1 lbf/in2) Max. 1 Ω OFF
Between B09 (1) - B10 (2)
Others

switch (male) resistance 2. Disconnect connector

Depress brake and lower accumu- 3. Connect T-adapter
lator pressure to below37 ±5 kg/
cm2 (526.2 ±71.1 lbf/in2) Min. 1 M
Between B09 (1) - B10 (2)
If the condition is as shown in the table below, it is
normal
Accumulator pressure: Min. 40
1. Turn starting switch
±5 kg/cm2 (568.9 ±71.1 lbf/in2) 20 - 30 V
Emergency brake Measure OFF
BR1 Between (7) - (8)
switch voltage 2. Insert T-adapter
Depress brake and lower accumu- 3. Turn starting switch ON
lator pressure to below 37 ±5 kg/
Max. 1 V
cm2 (526.2 ±71.1 lbf/in2)
Between B09 (1) - B10 (2)
If the condition is as shown in the table below, the
sensor is normal
When
When 1. Turn starting switch
screwdriver is
Bucket positioner Between screwdriver is OFF
Measure not brought
proximity switch F05 brought close 2. Insert T-adapter
voltage close
3. Turn starting switch ON
(1) - (2) 20 - 30 V Max. 3 V
(1) - (3) 20 - 30 V 20 - 30 V
(2) - (3) Max. 3 V 20 - 30 V

20-20 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal
When
When
screwdriver is 1. Turn starting switch
Between screwdriver is
Boom kick-out Measure not brought OFF
F06 brought close
proximity switch voltage close 2. Insert T-adapter
3. Turn starting switch ON
(1) - (2) 20 - 30 V Max. 3 V
(1) - (3) 20 - 30 V 20 - 30 V
(2) - (3) Max. 3 V 20 - 30 V
Others

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

normal 1. Turn starting switch
Boom kick-out Measure OFF
L16 Between (1), (2) 19 - 23 Ω
solenoid resistance 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Bucket positioner Measure OFF
L17 Between (1), (2) 19 - 23 Ω
solenoid resistance 2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis Min. 1 MΩ

WA500-3H 20-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
12
Connector Inspection Measurement
Name of component Judgement table
number method conditions
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Power source Measure OFF
L28 Between (8), (17), (18) - (9), (18)
voltage voltage 2. Insert T-adapter
When actuated 20 - 30 V 3. Turn starting switch ON
When not actuated Max. 1 V
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Joystick R CNR Measure OFF
(right) solenoid (male) resistance Between (1) - (2) 10 - 20 Ω 2. Disconnect connector
3. Connect T-adapter
Between (1) - chassis Min. 1 MΩ
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Joystick L CNL Measure OFF
(left) solenoid (male) resistance Between (1) - (2) 10 - 20 Ω 2. Disconnect connector
Joystick Controller

3. Connect T-adapter
Between (1) - chassis Min. 1 MΩ
If the condition is as shown in the table below, it is
normal
Joystick neutral switch between (1) - (3) 1. Turn starting switch
Joystick neutral Measure OFF
NEUTRAL
switch resistance Not at N Max 1 Ω 2. Disconnect connector
3. Connect T-adapter
At N
Min. 1 MΩ
Between (1) - chassis
If the condition is as shown in the table below, it is
normal 1. Turn starting switch
Joystick Measure OFF
L27
potentiometer voltage Between (20) - (9) 2. Insert T-adapter
3. Turn starting switch ON
When actuated 0.5 - 4.5 V
If the condition is as shown in the table below, the
sensor is normal 1. Turn starting switch
Between (1) - (2) 0-5Ω OFF
Joystick JS7 Measure
2. Disconnect connector
potentiometer (male) resistance
Between (2) - (3) 4-5Ω 3. Connect T-adapter
4. Start engine
Between (3) - (1) 0-5Ω

20-22 WA500-3H
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

No. Check or Measurement item Tool Description Tool Number Remarks

799-203-8001 Digital display
1 Engine speeds Digital Optical Tachometer 799-203-9000 L: 60 - 20,000 rpm
(Kit) H: 60 - 19,999 rpm
2 Intake manifold pressure Pressure gauge See Engine Shop Manual
3 Intake air restriction Water manometer See Engine Shop Manual
4 Lubricating oil pressure Pressure gauge See Engine Shop Manual
5 Fuel filter inlet restriction Vacuum gauge See Engine Shop Manual
6 Blow-by pressure Tool, adapter & manometer See Engine Shop Manual
7 Exhaust back pressure Mercury manometer See Engine Shop Manual
8 Coolant temperature Digital temperature gauge See Engine Shop Manual
Commercially ---
9 Valve clearance Feeler gauge
available
Alternator, fan & water pump drive ---
10 Tension gauge ST-1138
belts
Smoke detector 799-201-9000 Discoloration
11 Exhaust gas color Commercially 0-70% with standard color
Smoke meter % x 1/10 ~ Bosch index
available
Brake test kit 793-520-1805
12 Brake oil pressure
Nipple 793-520-1851
79A-264-0020 0 - 294.2 N (0 - 30 kg)
13 Operating effort Push-pull scale
79A-264-0090 0 - 490.3 N (0 - 50 kg)
Commercially ---
14 Stroke, hydraulic drift Scale
available
15 Work equipment speed Stop watch Commercially available ---
Commercially ---
16 Measuring brake disc wear Calipers
available
Moving machine when there is failure
17 Plate 793T-685- 1110 ---
in transmission valve
18 Measuring voltage, resistance value Tester 79A-264-0210 ---
T-adapter
799-601-7400 ---
assembly
799-601-7310 SWP12P
Troubleshooting of wiring, harness,
19
sensors 799-601-7320 SWP16P
Adapter
799-601-7340 M8P
799-601-7380 JFC2P

WA500-3H 20-23
TESTING AND ADJUSTING SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
TOOL N
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

20-24 WA500-3H
TESTING AND ADJUSTING ENGINE

ENGINE
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL
Section 12 for tools and proper procedure.

TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

MEASURING EXHAUST TEMPERATURE

ADJUSTING VALVE CLEARANCE

MEASURING COMPRESSION PRESSURE

MEASURING BLOW-BY PRESSURE

MEASURING OIL PRESSURE

HANDLING EQUIPMENT IN FUEL CIRCUIT

RELEASING REMAINING PRESSURE IN FUEL SYSTEM

MEASURING FUEL PRESSURE

REDUCED CYLINDER MODE OPERATION

BLEEDING AIR FROM FUEL SYSTEM

CHECK FOR LEAKAGE IN FUEL SYSTEM

ADJUSTING SPEED SENSOR

TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING FAN BELT TENSION

HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT

RUN-IN STANDARD

PERFORMANCE TEST STANDARDS

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

WA500-3H 20-25
TESTING AND ADJUSTING TORQUE CONVERTER STALL SPEEDS
12
TORQUE CONVERTER STALL SPEEDS
★ Measurement conditions
• Coolant temperature: Inside operating range
• Hydraulic oil temperature: 45 - 55°C (113 - 131°F)
• Torque converter oil temperature: 70 - 90°C (158 - 194°F)
★ Check that the low and high idle speeds are at the standard value.
★ Before measuring at each stall speed, install tachometer (A), using the
instructions that came with it.

WARNING! Apply the parking brakes and block the

tires.

1. Measuring torque converter stall

A. Start engine and run at low idle.

B. Put the directional lever in FORWARD or REVERSE, and speed

control lever in the highest speed range.

C. Using the brake, stop the machine and measure the engine speed
when the accelerator pedal is fully depressed.
★ Turn the transmission cut-off selector switch (1) to the OFF
position and use the left brake. (Check that the pilot lamp is
OFF).
★ Do not run at the stall speed for more than 20 seconds and do
not let the torque converter oil temperature raise above 120°C
(248°F).
★ Turn the parking brake switch OFF (release).

AIR CONDITIONER BELT

1. Testing
Measure deflection “c” of the belt when it is pushed with force of
approximately 58.8 N (13.22 lbf) at a point midway between the fan
pulley and the air conditioner compressor pulley.
★ Deflection “c” of belt (standard value): 10 - 15 mm

2. Adjusting

A. Loosen mount bolt and nut, and the adjustment plate bolt and nut.

B. Move the position of the air conditioner compressor to adjust the

tension of the belt.

C. When the position of the air conditioner compressor is correct,

tighten adjustment plate bolt and nut, and the mounting bolt and
nut to secure it in position.

D. After adjusting the belt tension, repeat the testing procedure above
to check that the tension is adjusted within the standard value.

20-26 WA500-3H
TESTING AND ADJUSTING SHIFT LEVERS
12
SHIFT LEVERS
★ Measurement conditions:
• Engine stopped
• Torque converter oil temperature: 60 - 80° C (140 - 176° F)
• Measure at center of lever knob

OPERATING FORCE OF SPEED LEVER

Install push-pull scale l2 or a spring balance to the center of the control
lever knob, and measure the operating force when the lever is pulled in the
direction of operation.
★ Carry out the measurement for each speed range.

TRAVEL OF SPEED LEVER

Make a mark (1) at the center of the control lever knob, and measure the
travel when the lever is operated in the direction of operation.

WA500-3H 20-27
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
ACCELERATOR PEDAL

OPERATING FORCE
1. Measuring procedure

A. Put push-pull scale "A" in contact with the accelerator pedal at

point 150 mm from pedal fulcrum "a".
★ The center of push-pull scale must be in contact with a point
150 mm from the pedal fulcrum.

B. Start the engine, push the pedal in the direction of operation and
measure the maximum value when pushing from low idle to the end of the pedal travel (high idling).
Remark
There is no testing and adjustment (unit is electronically controlled).

20-28 WA500-3H
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
OPERATING ANGLE
1. Measuring procedure

A. Stop the engine.

B. Put angle gauge "A" in contact with the accelerator pedal, then
measure the operating angle from low idle to high idle, and
calculate operating angle a = a1 - a2.

2. Adjusting procedure

A. Remove the cover under the cab, and open the inspection cover on
the right side of the engine.

B. Loosen nut (1) and adjust bolt (2) so that pedal stroke angle is 13°.

Remark
See drawing on previous page.

WA500-3H 20-29
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
TORQUE CONVERTER AND TRANSMISSION

OIL PRESSURE
★ Measurement conditions
• Coolant temperature: Inside operating range.
• Torque converter oil temperature: 60 - 80°C
• Engine speed: High idle
• Manual switch ON

WARNING! Apply the parking brake and block the

tires.

1. Measuring main relief pressure

A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.

B. Remove oil pressure measurement plug (PT1/8) (1), then install

oil pressure gauge C1 60 kgf/cm2 (853.4 lbf/in2).

C. Start the engine and measure the oil pressure with the engine at
low idling and high idling.

2. Adjusting main relief valve

WARNING! Adjust the main relief valve with the

engine stopped.

If the main relief pressure is not within the standard value, adjust as
follows:

A. Remove plug (1) and washer (2).

B. Remove inner spring (3) and outer spring (4).

C. Adjust by changing the thickness of shim (5).

★ Standard shim thickness: 3.0 mm (0.5 x 6)
★ Amount of adjustment for one shim: 0.4 kg/cm2 (5.68 lbf/in2).

20-30 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
3. Measuring torque converter relief (inlet port) pressure

A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.

B. Remove oil pressure measurement plug (PT1/8) (1), then install

oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).

C. Start the engine and measure the oil pressure with the engine at
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.)

4. Measuring torque converter outlet port pressure

A. Remove the cover at the left side of the transmission.

B. Remove oil pressure measurement plug (1) at the bottom of the

torque converter oil temperature sensor, then install oil pressure
gauge C1 60 kg/cm2 (853.4 lbf/in2).

C. Start the engine and measure the oil pressure with the engine at
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.)

WA500-3H 20-31
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
5. Measuring ECMV output (clutch) pressure

A. Remove the cover at the front of the engine and the cover at the
rear of the operator’s compartment.

B. Remove the oil pressure measurement plug for the clutch to be

measured.
• Plug for measuring 1st clutch pressure: (1)
• Plug for measuring 2nd clutch pressure: (2)
• Plug for measuring 3rd clutch pressure: (3)
• Plug for measuring 4th clutch pressure: (4)
• Plug for measuring reverse clutch pressure: (5)
• Plug for measuring forward clutch pressure: (6)

Gasket sealant (LG-5)

C. Install oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).

D. Start engine and measure the 1st, 2nd, 3rd, and 4th clutch
pressures under the following conditions at high idling.

i. Leave the directional lever at neutral.

ii. Turn the main monitor manual switch ON.

iii. Place the gear shift lever at the speed range to be measured.

E. Start the engine and measure the forward and reverse clutch
pressures under the following conditions at high idling.

WARNING! Put blocks under the tires and depress

the brake securely.

F. Turn the transmission cut-off selector switch OFF (lamp off).

i. Turn the parking brake switch OFF.

ii. Depress the brake.

iii. Turn the main monitor manual switch ON and place the
gearshift lever in 4th.

iv. Keep the brake depressed and place the directional lever at
F or R.

G. Measuring lubricating oil pressure (oil cooler outlet port)

i. Remove the cover at the left side of the rear frame.

ii. Remove the oil pressure measurement plug (1), then, install
oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).

20-32 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
iii. Start the engine and measure the oil pressure with the engine at high idling. (If the pressure is not affected by any
adjustments, it may indicate possible need for repair.)

WA500-3H 20-33
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
HYDRAULIC CIRCUIT FLUSHING
★ Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the life of the torque
converter and transmission, and will cause internal damage. To prevent this, flush the system to remove the dirt or metal
particles in the hydraulic circuit.

1. Flush the circuit if the following conditions apply.

A. If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are
circulating in the hydraulic circuit.

B. When the torque converter and transmission have been overhauled or repaired.

2. Install the flushing element.

A. Drain the oil from the filter case.

B. Remove the two transmission oil filters, then install two flushing elements (561-15-55670).
★ After flushing the system, assemble the parts that were removed, and the parts inside the case.

3. Fill the transmission case with oil.

Add fresh oil through the oil filler port to the specified level, and run the engine to circulate the oil through the system.
Then check the level again.

Transmission case: 62 liters

4. Carry out flushing as follows.

A. After starting the engine, run the engine for approximately 20 minutes at low idling without operating the speed lever
or directional lever.
★ From time to time, raise the engine speed to approximately 1500 rpm.
★ If the ambient temperature is low and the engine coolant temperature gauge does not enter the green range,
continue the warming-up operation longer.

B. Travel or carry out actual operations for at least 20 minutes.

★ Use all the speed ranges (FORWARD, REVERSE, and 1st - 4th).

C. Repeat the procedure in 4-A, and run the engine at low idling for approximately 20 minutes.

20-34 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
5. Replace the flushing element.

A. Using the procedure in step 2-A, replace the flushing element with the standard element (424-16-11140).

WARNING! If the flushing element is used for a long time, there will be premature clogging, so always
replace the flushing element with the standard element.

B. Add oil and check the level again.

6. Replace the transmission fail safe filter.

A. Use a wrench to turn portion (A) of fail safe filter case (1) to
remove it.
★ If there is any dirt inside the filter case, wash the case.

B. Remove element (2) and replace with a new element.

C. Install new O-ring (3) to the outside circumference of the case.

★ Coat the outside circumference of the O-ring with a small
amount of grease.

D. Install the case.

Case: 39.2 Nm (28.9 lbf ft)

WA500-3H 20-35
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
TRANSMISSION VALVE FAILS - MOVING MACHINE
★ If the machine cannot be moved because of a failure in any part of the
transmission valve system (electrical system, solenoid valves, spools,
etc.), it is possible to move the machine by installing plate N.

WARNING! Plate N is only for emergency use when

the machine cannot be moved by any
other means because of a failure in the
transmission control valve system. DO
NOT install plate N to the ECMV except
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.

WARNING! When carrying out this operation keep

strictly to the procedure and pay careful
attention to safety when moving the
machine.

WARNING! To prevent the machine from moving,

lower the work equipment completely to
the ground, apply the parking brake, and
put blocks under the tires.

WARNING! Carry out the operation with the engine

stopped.

WARNING! Be careful not to burn yourself if the oil is

hot.

1. Remove the cover at the bottom of the operator’s cab, and the cab at
the bottom of the step on the left side.

2. Remove valve cover (1).

★ Wash the area around the ECMV, clean and remove all dirt and
mud.

3. Disconnect wiring connectors (2) thru (13).

★ For details of precautions when removing the wiring connectors, see Section 30, TRANSMISSION CONTROL
VALVE, REMOVAL.

20-36 WA500-3H
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMIS-
12
4. Depending on the direction for moving the machine (forward or
reverse), remove the following 2 ECMV solenoids (14) and install
plate N.
• FORWARD: F solenoid and 2nd solenoid
• REVERSE: R solenoid and 2nd solenoid
★ If there is any mistake in the selection of the solenoid to
remove, there is danger that the transmission may be
damaged.
★ Install plate N with the protruding surface facing the ECMV.
Check also that there is an O-ring installed to the mating
surface.
★ Be careful not to let any dirt or mud get inside the removed
solenoid or valve

5. Depress the left brake pedal securely.

6. Start the engine, release the parking brake, then release the brake pedal
gradually to allow the machine to start, then move the machine.

WARNING! Remove the blocks from under the tires.

WARNING! WARNING! When the engine is started,

the transmission is also engaged to start
the machine. To ensure safety when
starting the engine, check carefully that
the direction of travel and area around the
machine are safe, and always keep the
brake pedal depressed when starting.

WARNING! After moving the machine, stop the

engine, apply the parking brake, put
blocks under the tires.

WA500-3H 20-37
TESTING AND ADJUSTING STEERING WHEEL
12
STEERING WHEEL

MEASURING PLAY
★ Measurement conditions
• Engine speed: Stopped
• Machine posture: Facing straight forward
Method of measurement

A. Move the steering wheel 2 or 3 times lightly to the left and right,
check that the steering mechanism is at the neutral position, then
make a mark on the outside frame of the machine monitor.

B. Turn the steering wheel to the right, and make a mark at the
position where the operating force starts to become heavy (when
the steering valve lever starts to move).

C. Turn the steering wheel to the left in the opposite direction from
Step 2, and make a mark at the point where the operating force
becomes heavy (when the steering valve lever starts to move).
Then measure the distance in a straight line between the marks
made in Step 2 and Step 3.

MEASURING OPERATING FORCE

★ Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Engine water temperature: Within green range on engine water
temperature gauge
• Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
• Tire inflation pressure: Specified pressure
• Engine speed: Low idling (bucket empty)

Measurement method

A. Install push-pull scale l2 to the steering wheel knob.

B. Start the engine.

★ After starting the engine, raise the bucket approximately 400 mm and remove the safety bar.

C. Pull push-pull scale l2 in the tangential direction and measure the value when the steering wheel moves smoothly.
★ Avoid measuring when the steering wheel starts to move.

20-38 WA500-3H
TESTING AND ADJUSTING STEERING WHEEL
12
MEASURING OPERATING TIME
★ Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Engine water temperature: Within green range on engine water
temperature gauge
• Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
• Tire inflation pressure: Specified pressure
• Engine speed: Low and high idling

Measurement method

A. Start the engine.

★ After starting the engine, raise the bucket approximately 400 mm and remove the safety bar.

B. Operate the steering wheel to the end of its stroke to turn the machine to the left or right.

C. Measure the time taken to operate the steering wheel to the end of the stroke to the right (left).
★ Operate the steering wheel as quickly as possible without using force.
★ Carry out the measurements both at low idling and high idling, and to both the left and right.

WA500-3H 20-39
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
STEERING OIL PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)

WARNING! Install the safety bar to the frame.

MEASURING
1. Measuring steering relief pressure

A. Remove oil pressure measurement plug (PT1/8) (1) from the

elbow at the right steering cylinder head end, then install oil
pressure gauge C1 400 kgf/cm2 (5689.3 lbf/in2).

B. Start the engine, run the engine at high idling, then turn the
steering wheel to the right and measure the pressure when the
relief valve is actuated.
★ When removing the oil pressure measurement plug on the left
steering cylinder, turn the steering wheel to the left.

2. Measuring steering pilot pressure

A. Disconnect pilot hose (2) or (3) from steering valve (1).

B. Install the adapter and oil pressure gauge 60 kgf/cm2

(853.4 lbf/in2) inside tool C1.

C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.

★ Hose (2): Turn steering to right

Hose (3): Turn steering to left

20-40 WA500-3H
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
3. Measuring Orbit-roll output pressure

A. Disconnect Orbit-roll output hose (1) or (2).

B. Install the adapter and oil pressure gauge 60 kgf/cm2

(853.4 lbf/in2) inside tool C1.

C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.
★ Hose (1): Turn steering to right
Hose (2): Turn steering to left

ADJUSTING

WARNING! Always stop the engine before adjusting

the pressure.

1. Adjusting steering relief valve

A. Loosen locknut (2) of steering relief valve (1), then turn

adjustment nut (3) to adjust.
★ Turn the adjustment screw to adjust the set pressure as
follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTERCLOCKWISE
★ Pressure adjustment for one turn of adjustment screw:
Approximately 151 kg/cm2 (2147.7 lbf/in2)

WA500-3H 20-41
TESTING AND ADJUSTING STEERING STOP VALVE
12
STEERING STOP VALVE

TESTING
1. Set the front and rear frames 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.

WARNING! Measure the clearance with the engine

stopped.

★ Measure the clearance between the front frame and rear frame
when steering stop valve contact surface (3) and stopper bolt (1)
coming into contact and the turning stops. - Standard clearance a:
40 ±5 mm

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

1. Loosen locknut (2), tighten stopper bolt (1), and make sure that there is no contact with the steering stop valve.

2. Start the engine, run at low idling, then turn the steering wheel slowly to bring the front and rear frames into contact.
When turning, be extremely careful not to get your arm or any other part of your body caught between the front and rear
frames.

3. Stop the engine, then loosen the stopper bolt until it contacts the steering stop valve contact surface.

4. Set the front and rear frames facing straight.

5. Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2).
★ Carry out the procedure in Steps 1 - 5 to adjust both the left and right sides.

6. Start the engine, turn the machine, and check that clearance a between the front and rear frames is within the standard
value for both the left and right and that the steering stopper valve and stopper bolt come into contact and the steering is
stopped.

20-42 WA500-3H
TESTING AND ADJUSTING BRAKE PEDAL
12
BRAKE PEDAL
★ Measurement conditions
• Engine water temperature: Within green range on engine water
temperature gauge
• Engine speed: Low idling

OPERATING FORCE
1. Install push gauge (1) to the operator’s foot.
★ Align the center of the push gauge with the center of the pedal.

2. Start the engine, run at low idling, and measure the operating force
when the pedal is depressed.

TRAVEL
1. Install push gauge (1) to the operator’s foot.
★ Align the center of the push gauge with the center of the pedal.

2. Start the engine, and measure pedal angle a1 when running at low
idling, and pedal angel a2 when the pedal is depressed with a force of
294 N (66 lbf)
★ Install angle gauge (2) to the brake pedal when measuring.

PEDAL PLAY
1. Start the engine.

2. Push the brake pedal lightly by hand, and measure pedal angle a3 when
the pedal starts to become heavy.

WA500-3H 20-43
TESTING AND ADJUSTING BRAKE PERFORMANCE
12
BRAKE PERFORMANCE
★ Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec.
• Tire inflation pressure: Specified pressure

MEASUREMENT METHOD

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.
★ Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
★ Switch the transmission cut-off switch ON when carrying out this operation.

4. Measure the distance from the point where the brakes were applied to the point where the machine stopped.
★ Repeat this measurement three times and take the average.

20-44 WA500-3H
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
12
TESTING BRAKE OIL PRESSURE

WARNING! Put blocks securely under the tires.

1. Inspecting

A. Remove bleeder screw (1), then install oil pressure gauge tool 1
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.

B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.

C. Depress the left brake and measure the brake oil pressure.

2. Measuring drop in brake piston pressure

A. Remove bleeder screw (1), then install oil pressure gauge tool l
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.

B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.

C. Stop engine, depress the left brake pedal, leave for 5 min. with the
oil pressure at 50 kgf/cm2 (711 lbf/in2), and measure the drop in
★ Be careful not to move the brake pedal for 5 minutes.
★ After completing the operation, bleed the air from the brake
circuit again.

WA500-3H 20-45
TESTING AND ADJUSTING BRAKE DISC WEAR
12
BRAKE DISC WEAR
★ Brake oil pressure: 50 ±5 kg/cm2 (711 ±71 lbf/in2)

WARNING! 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 calipers M to measure depth a from the end face of the housing to
the spring guide.
★ When measuring, keep the brake pedal depressed.

4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain
the brake oil.
★ After draining the brake oil, check that the brake piston has
returned to the end of its stroke.

5. Measure depth b from the end face of the housing to the spring guide
pin.

Calculating Piston Stroke

S=a-b S = Max. 8.5 mm

20-46 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
PARKING BRAKE
Performance

★ Measurement conditions
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved surface with 1/5 (11°20') gradient.
• Machine: In operation condition

Measuring Procedure

1. Start the engine, set the machine facing in a straight line, then drive the
machine up a 1/5 grade slope with the bucket empty.

2. Depress the brake, stop the machine, set the directional lever to the
neutral position, then stop the engine.

3. Turn the parking brake switch ON, then slowly release the brake pedal,
and the machine must not move at all.
★ Carry out the measurement in two ways. Once with the machine
facing uphill, and once more with the machine facing downhill.

WA500-3H 20-47
TESTING AND ADJUSTING PARKING BRAKE
12
OIL PRESSURE
1. Measuring parking brake inlet port
★ Torque converter oil temperature: 60 - 80° C (140 - 176° F)

A. Remove the transmission side cover.

B. Remove oil pressure measurement plug (PT1/8) (1), then install

oil pressure gauge C1 60 kgf/cm2 (853 lbf/in2)

C. Turn the parking brake switch OFF.

D. Start the engine and measure with the engine running at low idling
and high idling.

2. Measuring parking brake pilot pressure

★ Torque converter oil temperature: 60 - 80° C (140 - 176° F)

A. Remove the cover at the front of the engine and the cover at the
top of the transmission.

B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).

C. Start the engine and measure at high idling.

20-48 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
3. Measuring parking brake solenoid valve output pressure
★ Torque converter oil temperature: 60 - 80° C (140 - 176° F)

A. Remove the cover at the front of the engine and the cover at the
top of the transmission.

B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).

C. Turn the parking brake switch OFF.

D. Start the engine and measure at high idling.

WA500-3H 20-49
TESTING AND ADJUSTING PARKING BRAKE
12
DISC WEAR
★ If the parking brake effect becomes weak, measure the wear of the
parking brake disc as follows.

WARNING! To prevent the machine from moving,

lower the work equipment completely to
the ground and put blocks under the tires.

WARNING! Always stop the engine before carrying

out this procedure.

1. Drain oil from the transmission case.

Transmission case: 62 liters (16.37 gal)

2. Remove one of two plugs (1) on each side.

3. Using calipers M, measure depth a from the end face of cage (2) to
piston (3).
• Standard depth a: Max. 40.3 mm

4. If depth a is greater than the specified value, remove parking brake

disc (4), and check thickness W of the disc. For details, see
DISASSEMBLY AND ASSEMBLY, PARKING BRAKE DISC,
REMOVAL.
• Dimension W: Min. 3.2 ±0.1 mm
★ If the thickness of the parking brake disc is below the standard
value, replace it.

20-50 WA500-3H
TESTING AND ADJUSTING PARKING BRAKE
12
MANUAL RELEASE METHOD
★ The parking brake is controlled by hydraulic pressure, so if there
should be any failure in the transmission and it becomes impossible to
release the parking brake, it is possible to release it manually to move
the machine.

WARNING! The manual release of the parking brake

is designed only to move the machine
from a dangerous working area to a safe
place where repairs can be carried out.
This method must not be used except
when there has been a failure

WARNING! To prevent the machine from moving,

lower the work equipment completely to
the ground and put blocks under the tires.

WARNING! Always stop the engine before carrying

out this procedure.

1. Remove two plugs (1).

★ After releasing the parking brake, coat the plugs with gasket
sealant (LG-5), then tighten the plugs.

2. Remove two cage mounting bolts (2), then screw them into the plug
mount gradually in turn.
★ When bolts (2) are screwed in, piston (3) is pulled and the parking
brake is released.

WA500-3H 20-51
TESTING AND ADJUSTING PPC VALVE
12
PPC VALVE

OIL PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° f)

MEASURING

1. Measuring PPC pump pressure

A. Remove the cover at the top of the pump.

B. Remove oil pressure measurement plug (PT1/8) (1), then install

oil pressure gauge C1 400 kgf/cm2 (2942 lbf/in2).

C. Start the engine and measure the oil pressure at high idling.

2. Measuring PPC valve basic pressure (orbit-roll basic pressure)

A. Disconnect hose (1), then install the adapter and oil pressure
gauge 60 kgf/cm2 (853 lbf/in2) in tool C1.

B. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.

20-52 WA500-3H
TESTING AND ADJUSTING PPC VALVE
12
3. Measuring PPC valve output pressure

WARNING! Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.

WARNING! Operate the control levers several times

to release the pressure in the PPC
accumulator circuit.

A. Remove the main control valve cover.

B. Remove oil pressure detection plug (PT1/8) (1) of the circuit to be

measured, then install oil pressure gauge C1 60 kgf/cm2 (853 lbf/
in2).
★ Plug A: Boom LOWER, boom FLOAT
Plug B: Boom RAISE
Plug C: Boom DUMP
Plug D: Boom TILT

C. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.

ADJUSTING

1. Adjusting PPC relief valve

Loosen locknut (2) of PPC relief valve (1), then turn adjustment screw
(3) to adjust.
★ Turn the adjustment screw to adjust as follows:
• To INCREASE the pressure, turn clockwise.
• To DECREASE the pressure, turn counter clockwise.
★ Amount of adjustment - for one turn of adjustment screw:
18.3 kg/cm2 (260 lbf/in2)

Locknut: 83.4 ±4.9 Nm (61.5 ±3.6 lbf ft)

★ After completion of the adjustment, re-check the accumulator

charge cut-in pressure and cut-out pressure again. Refer to
ACCUMULATOR CHARGE PRESSURE.

WA500-3H 20-53
TESTING AND ADJUSTING PPC VALVE
12PPC
ADJUSTING LINKAGE
1. Remove cover (1) at the bottom of the work equipment control lever.

2. Adjust dimension a from nut (1) of the PPC valve linkage to the top
surface of the floor.
• Dimension a (target value): 54 mm

3. Loosen nuts (2) and (3), then adjust the installed height of trunnion (5)
so that there is no play in lever (4).

4. After adjusting, tighten nuts (2) and (3).

20-54 WA500-3H
TESTING AND ADJUSTING ACCUMULATOR
12
ACCUMULATOR

CHARGE PRESSURE
MEASURING
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)

WARNING! Stop the engine, then depress the brake

pedal at least 100 times to release the
pressure inside the accumulator circuit.

1. Disconnect accumulator inlet port hose (1), then install the adapter and
oil pressure gauge 400 kg/cm2 (2942 lbf/in2) in tool C1.

2. Measure the accumulator charge cut-in pressure. Start the engine, run
at low idling, and measure the oil pressure when the brake oil pressure
warning pilot lamp on the maintenance monitor goes out.

3. Measure the accumulator charge cut-out pressure. After the

accumulator charge cut-in, the pressure rises. Measure the oil pressure
at the point where the oil pressure gauge indicator suddenly drops after
rising.

ADJUSTING
★ When the accumulator charge cut-out pressure is adjusted, the cut-in
pressure also changes because of the valve area ratio. For this reason,
there is no cut-in pressure adjustment nut.

1. Loosen locknut (2) of the accumulator charge cut-out valve (1), then
turn adjustment screw (3) to adjust.
★ Turn the adjustment screw to adjust as follows:
• To INCREASE the pressure, turn clockwise.
• To DECREASE the pressure, turn counter clockwise.
★ Amount of adjustment - for one turn of adjustment screw:
57 kg/cm2 (810 lbf/in2)

Locknut: 10.78 ±0.98 Nm (7.9 ±0.72 lbf ft))

★ After completion of the adjustment, repeat the above procedure

for test to check the accumulator charge cut-in pressure and
cut-out pressure again.

WA500-3H 20-55
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT

HYDRAULIC PRESSURE
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)

WARNING! Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.

1. Measuring work equipment relief pressure

A. Raise bucket portion a approximately 30 - 50 mm and set portion

b in contact with the ground.

B. Stop the engine, then operate the work equipment control lever
and check that the bottom surface of the bucket (both portion a
and portion b is in contact with the ground.
★ After lowering the bucket to the ground, operate the work
equipment control lever several times to release the
remaining pressure in the piping.

C. Remove the cover at the top of the main control valve.

D. Remove oil pressure measurement plug (PT1/8) (1), then install

oil pressure gauge C1 400 kgf/cm2 (2942 lbf/in2).

20-56 WA500-3H
TESTING AND ADJUSTING WORK EQUIPMENT
12
E. Start the engine, raise the lift arm approximately 400 mm, run the
engine at high idling, tilt the bucket back, then measure the oil
pressure when the relief valve is actuated.

WARNING! After measuring, repeat the procedure

used when installing the oil pressure
gauge to release the pressure inside the
circuit, then remove the oil pressure
gauge.

ADJUSTING
1. Adjusting work equipment relief valve.

A. Loosen locknut (2) of work equipment relief valve (1), then turn
adjustment screw (3) to adjust.
★ Turn the adjustment screw to adjust as follows.
To INCREASE the pressure, turn clockwise.
To DECREASE the pressure, turn counter clockwise.
★ Amount of adjustment for one turn of adjustment screw:
52.9 kg/cm2 (752 lbf/in2)

Locknut: 39.2 ±9.8 Nm (28.9 ±7.2 lbf ft)

★ After completion of the adjustment, repeat the above procedure to

measure the work equipment relief pressure again.

WA500-3H 20-57
TESTING AND ADJUSTING WORK EQUIPMENT
12
RELEASING REMAINING PRESSURE
1. Releasing remaining pressure between each hydraulic cylinder and control valve.
★ If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining
pressure from the circuit as follows:

A. Stop the engine.

B. Release the oil filler cap slowly to release the pressure inside the tank.

C. Operate the control levers.

★ 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 approximately 5 minutes, then stop the engine and operate the control levers.
★ Repeat the above operation 2 - 3 times to release all the remaining pressure.

2. Releasing remaining pressure in brake accumulator circuit.

★ If the piping between the brake accumulator and emergency parking brake valve, between the accumulator and check
valve, and between the accumulator and brake valve is to be disconnected, release the remaining pressure from the
circuit as follows.
★ Stop the engine.
★ Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit.

3. Releasing remaining pressure PPC accumulator circuit.

★ If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from
the circuit as follows:
• Repeat the above operation 2 - 3 times to release all the remaining pressure.

20-58 WA500-3H
TESTING AND ADJUSTING WORK EQUIPMENT
12
LEVER LINKAGE
ADJUSTING
★ Always stop the engine before adjusting the work equipment lever
linkage.
★ Check that the operating effort of the work equipment control lever is
within the standard value.

1. Do as follows to set solenoid (1) in a pulled condition.

A. Disconnect wiring connectors (F05) (2) and (F06) (3).

F05: Proximity switch for bucket positioner
F06: Proximity switch for boom kick-out

B. Connect a T-adapter, then connect the terminals between (1)

and (2).
★ Check that the solenoid is pulled l2 mm.

2. With the solenoid pulled, move solenoid (1) so that clearances a

between boom lever cam (4) and boom lever cam follower (5) and
between bucket lever cam (6) and bucket lever cam follower (7) are
each 0 - 0.5 mm.
★ Carry out the adjustment with the boom and bucket levers at the
HOLD position.

3. Operate the boom lever and adjust distance c between the pins of rod
(8) so that clearance b between the notches at both ends of boom lever
cam (4) and boom lever cam follower (5) is 0 - 1 mm.
★ Distance c between pins of rod (8): 337 mm

4. Operate the bucket lever and adjust distance c between the pins of rod
(8) so that clearance d between the notches (1 place) bucket lever cam
(6) and bucket lever cam follower (7) is 0 - 1 mm.
★ Distance c between pins of rod (8): 337 mm

WA500-3H 20-59
TESTING AND ADJUSTING BLEEDING AIR
12
BLEEDING AIR

WARNING! Put blocks securely under the tires

1. Bleeding air from brake system

A. Remove cap (1) of the bleeder screw, insert a vinyl hose into the
screw, and insert the other end in a container.

B. Start the engine.

C. Depress the brake pedal, then loosen the bleeder screw and bleed the air.
★ This operation is carried out with two workers. One worker operates the brake pedal while the other bleeds the
air from the bleeder screw.
★ When depressing the brake pedal, use the left pedal.

D. When no more air bubbles come out with the fluid from the hose, depress the pedal fully and tighten the bleeder
screw while the oil is still flowing.
★ Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level
in the oil tank and add more oil if necessary.
★ To bleed the air completely, bleed the air first from the cylinder which is farthest from the brake pedal.

2. Bleeding air from the hydraulic cylinders.

A. Start the engine and run at idling for approximately 5 minutes.

B. Run the engine at low idling, the raise and lower the boom 4 - 5 times in succession.
★ Operate the piston rod to a point approximately 100 mm before the end of its stroke. Do not relieve the circuit
under any circumstances.

C. Run the engine at full throttle and repeat step B. After that, run the engine at low idling, and operate the piston rod to
the end of its stroke to relieve the circuit.

D. Repeat steps B and C to bleed the air from the bucket cylinder.
★ When the cylinder has been replaced, bleed the air before connecting the piston rod.

20-60 WA500-3H
TESTING AND ADJUSTING BUCKET POSITIONER
12
BUCKET POSITIONER
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)

TESTING
1. Start the engine, operate the bucket and actuate proximity switch (1),
then stop the engine and measure clearance a between the proximity
switch and angle (2).
★ Standard clearance a: 3 - 5 mm

2. Run the engine at mid-range speed (1500 rpm), actuate the proximity
switch, and check that the bucket angle is 0 - 1° facing down when the
bucket is lowered to the ground. Measure dimension b between the
center of the proximity switch to the tip of the angle.
★ Measure three times and take the average.
★ Standard dimension b: 15 mm

ADJUSTING
1. If dimension a is not within the standard value, adjust as follows:

A. Adjust mounting nut (4) so that clearance c between the tip of the
switch protector (3) and the sensing surface of proximity switch
(1) is the standard value.
★ Standard clearance c: 0.5 - 1.0 mm

Mount nut: 17.15 ±2.45 Nm (12.6 ±1.8 lbf ft))

B. Adjust with washer (5) and shim (6) so that clearance a between
the sensing surface of proximity switch (1) and angle (2) is the
standard value.

★ Adjust with shim (6) so that clearance a is within the standard

value for the whole stroke of the angle.Secure in position,
making sure that the center of proximity switch sensing
surface and the angle do not move away from the center.
★ After adjusting, operate the bucket lever and check that the
proximity switch is actuated normally.

2. If the bucket angle and dimension b are not within the standard value,
move the switch protector (3) to adjust

WA500-3H 20-61
TESTING AND ADJUSTING BOOM POSITIONER
12
BOOM POSITIONER
★ Hydraulic oil temperature: 45 - 55° C (113 - 131° F)

WARNING! Always be sure to apply the safety lock to

work equipment control lever.

TESTING
1. Start the engine, operate the boom lever to actuate proximity switch
(1), then stop the engine and measure dimension a between the center
of proximity switch (1) and the top of plate (2).
★ Standard clearance a: 0 - 5 mm

2. Measure dimension b between the proximity switch sensing surface

and the plate.
★ Standard dimension b: 3 - 5 mm

ADJUSTING
1. If the dimension a is not within the standard value, move the plate to
adjust.

2. If dimension b is not within the standard value, adjust proximity

switch mounting nut (3).

Mounting nut: 17.15 ± 2.45 Nm (12.6 ±1.8 lbf ft )

★ After adjusting, operate the boom lever and check that the proximity switch is actuated normally.

20-62 WA500-3H
TESTING AND ADJUSTING BOOM POSITIONER
12
Proximity switch actuation pilot lamp (red)
The proximity switch is equipped with a pilot lamp which shows when it is
being actuated, so use this when adjusting.

Proximity switch
actuation Lights up Goes out
pilot lamp

When detector is positioned at detection surface When detector has moved away from detection surface of
Detector position
of proximity switch proximity switch

Bucket
positioner

Boom kick-out

WA500-3H 20-63
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
12
TRANSMISSION CONTROLLER
★ The transmission controller is equipped with a learning function to self compensate so that it provides a constant gear
shifting feeling to match the changes in the transmission clutches occurring with the wear.

If the transmission is overhauled or replaced, the transmission controller keeps the control command values learned to
match the previous transmission. For this reason, transmission shock or abnormal noise may occur. After operating the
machine for a short time, the controller will learn to match the condition of the new transmission and will gradually return
to the normal condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to
reset the learning data and to carry out initial learning as follows.

1. Method for resetting learning control data

★ Do as follows to return all the previously learned control data in
the controller to the default values.

A. Check that the starting switch is at the OFF position.

B. Remove the cover at the right side of the work equipment control
box.

C. Disconnect wiring connector (C3B) (1) and connect T-adapter P

to the controller only (leave the harness hanging).

D. Turn the starting switch ON.

★ Do not start the engine.

E. Short circuit between terminals No. (1) to (16) for at least one second, then return them to free condition.

2. Initial learning method

★ To adjust the controller learning control data for each clutch from the default settings to the optimum values, first
carry out the above Step 1 "Method of resetting learned control data", then do as follows.

A. Stall the torque converter. For details, see ENGINE SHOP MANUAL.

B. Operate the speed lever and directional lever as follows.

N → F1 → F2 → F3 → F4 → N → R1 → N
★ Operate the levers with the engine running at low idling, the transmission cut-off selector switch at OFF, and the
manual switch at ON.
★ It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.

20-64 WA500-3H
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
12
C. When the torque converter oil temperature gauge rises to the 2nd level on the maintenance monitor, return engine
to low idling.
★ Target value for torque converter oil temperature: 40 - 50° C (104 - 122° F)
★ There is no problem if oil temperature gauge goes down to the lst level.

D. Operate the speed lever and directional lever twice in succession as follows:

N → F1 → F2 → F3 → F4 → F3 → F2 → F1 → N → R1 → N

★ Operate the levers with engine running at low idling, transmission cutoff selector switch at OFF, and the manual
switch at ON.
★ Hold for the following periods of time for each speed range.
• Speed range 4 only: 3 seconds
• Other speed ranges: 2 seconds
★ After carrying out gear shifting operation in Step B, if engine is stopped before carrying out the gear shifting
operation in Step D, repeat Step B again.
★ It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.

WARNING! Check area around the machine to be sure it is safe and depress the left brake securely
when shifting gear.

WA500-3H 20-65
TESTING AND ADJUSTING MAIN MONITOR
12
MAIN MONITOR

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

1. On the back of the monitor panel are 4 switches identified as

DIP SW1 (1), DIP SW2 (2), DIP SW3 (3), and DIP SW4 (4).
The settings of these switches has an effect on the speedometer
readout and ride control.

2. When the rubber caps are removed, a rotary switch can be seen
inside. Using a flat-blade screwdriver, turn the dipswitch to adjust
the settings per the tables on the following pages.

20-66 WA500-3H
TESTING AND ADJUSTING MAIN MONITOR
3. DIP SW1, DIP SW2, and DIP SW3 are rotary switches.
Controls model and weather the monitor
DIP SW1 displays miles per hour (mph) or kilometers per
hour (Km/h).

Adjusts for different tire sizes, so speedometer

DIP SW2
readout is correct.

Sets monitor panel to display either engine

DIP SW3
speed (rpm) or road speed, not both.

DIP SW1, DIP SW2, and DIP SW3 SWITCH SETTINGS

DIP SW3
Tire Size DIP SW1 DIP SW2 Tachometer
Speedometer
(See Note)

29.5 x 25 km/h 5 4 0 1
29.5 x 25 mph D 4 0 1
★ The tachometer feature will only work on loaders equipped with the "Autoshift" transmission.

4. DIP SW4 is a combination of 4 small ON/OFF switches.

DIP SW4 Setting is for ride control (E.C.S.S.)

DIP SW4 SWITCH SETTINGS

Switch No. Without ECSS With ECSS

1 ON ON

2 ON ON

3 ON OFF

4 OFF OFF

WA500-3H 20-67
TESTING AND ADJUSTING MAIN MONITOR
12

MEMORANDUM

20-68 WA500-3H
 TROUBLESHOOTING GENERAL

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-112
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
JUDGEMENT OF POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
PRECAUTIONS WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
METHODS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING
PARTS DURING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
PREVENTING RECURRENCE OF TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
OIL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
CLEANING FRAGMENTS OF DAMAGED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
CATEGORY OF TROUBLESHOOTING CODE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE. . 20-120
METHOD OF USING MATRIX TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
METHOD OF USING ENGINE RELATED CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124

WA500-3H 20-101
TROUBLESHOOTING
12

MEMORANDUM

20-102 WA500-3H
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and
parking brake are securely fitted.

WARNING! When carrying out the operation with two or more workers, keep strictly to the
agreed signals, and do not allow any unauthorized person to come near.

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

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating
parts.

WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the
battery first.

WARNING! When removing the plug or cap from a location which is under pressure from oil,
water or air, always release the internal pressure first. When installing measuring
equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.

When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a
short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure
that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the
user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investiga-
tion and to carry out troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the failure occurred?

C. Did the failure occur suddenly, or were there problems with the machine condition before this?

D. Under what conditions did the failure occur?

E. Had any repairs been carried out before the failure? When were these repairs carried out?

F. Has the same kind of failure occurred before?

WA500-3H 20-103
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4. Confirming the failure.

A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.

5. Troubleshooting

A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.

B. The basic procedure for troubleshooting is as follows.

i. Start from the simple points.

ii. Start from the most likely points.

iii. Investigate other related parts or information.

6. Measures to remove root cause of failure.

A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.

B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

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SEQUENCE OF EVENTS IN TROUBLESHOOTING

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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to pre-
vent failures or other troubles before they occur, correct operation, mainte-
nance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mecha-
tronics and is aimed at improving the quality of repairs. For this purpose, it
gives sections on ’Handling electric equipment’ and ’Handling hydraulic
equipment’ (particularly hydraulic oil).

PRECAUTIONS 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 protector 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.

2. Main failures occurring in wiring harness

A. Faulty contact of connectors

(faulty contact between male and female).
Problems with faulty 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 oxidation of the contact
surfaces.

B. Defective compression or soldering of connectors

The pins of the male and female connectors are in contact
at the compressed terminal or soldered portion, but there
is excessive force on the wiring, and the plating peels to
cause improper connection or breakage.

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C. Disconnections in wiring
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or the
soldering may be damaged, or the wiring may be broken.

D. High pressure water entering a 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.
The connector is designed to prevent water from entering, but if
water does enter, it is difficult for it to be drained. Therefore, if
water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in, immediately
dry the connector or take other appropriate action before passing
electricity through it.

E. Oil, grease 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, and this will cause a defective
contact.
If there is oil or grease or dirt stuck to the connector, wipe it off
with a dry cloth or blow dry with air, and spray it with a contact
restorer.
★ When wiping the mating portion of the connector, be careful
not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all water
and oil has been removed.

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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
3. Removing, installing, and drying connectors and wiring harnesses.

A. Disconnecting connectors

i. 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.

ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up and
down, the housing may break.

iii. When disconnecting male and female connectors, release the

lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.

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iv. Action to take after removing connectors.
After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.

B. Connecting connectors

i. Check the connector visually.

• Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).
• Check that there is no deformation, faulty contact, corrosion, or damage to the connector pins.
• Check that there is no damage or breakage to the outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has gotten
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.
★ If there is any damage or breakage, replace the connector.

ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.

iii. Correct any protrusion of the boot and any misalignment of

the wiring harness.
For connectors fitted with boots, correct any protrusion or the
boot. In addition, if the wiring harness is misaligned, or the
clamp is out of position, adjust it to its correct position.
★ When blowing with dry air, there is danger that the oil in
the air may cause improper contact, so clean with prop-
erly filtered air.

WA500-3H 20-109
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and check
that there is no looseness of the clamp.

C. 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:

i. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with air, there is the risk that
oil in the air may cause a faulty contact, so avoid
blowing with air.

ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but be careful not to
make the connector or related parts too hot, as this will
cause deformation or damage to the connector.

iii. 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.

★ After completely drying the connector, spray it with con-

tact restorer and reassemble.

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HANDLING CONTROL BOX
1. The control box contains a microcomputer and electronic control
circuits.
This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.

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.

5. 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 har-
ness connectors connected to the control box. Fit an arc welding
ground close to the welding point.

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TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
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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 maintenance of
hydraulic equipment should be carried out in a specially prepared dust
proof workshop, and the performance should be confirmed with
special test equipment.

3. Seal or cover all openings of disconnected piping

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag, this
could cause particles or dirt to get into the system.
Drain all oil into a container and not unto the ground and be sure to
follow the proper environmental regulation for any disposal of oil.

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.

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5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the cir-
cuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.

6. Flushing operations
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is carried out with the
specified hydraulic oil.

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

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12
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item standard Remedy
Lubricating oil, cooling water

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 converter, transmission oil) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace
equipment
Electrical

10. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring - Repair or replace
12. Check operation of instruments - Repair or replace
13. Check for abnormal noise, smell - Repair
mechanical
Hydraulic,
equipment

14. Check for oil leakage - Repair

15. Carry out air bleeding - Bleed air
Adjust, repair or
16. Check effect of parking brake, wheel brake -
replace
17. Check battery voltage (engine stopped) 23 - 26 V Repair or replace
18. Check battery electrolyte level - Add or replace
19. Check for discolored, burnt, exposed wiring - Repair or replace
Electrical equipment

20. Check for missing wiring clamps, hanging wire - Repair

21. Check for water leaking on wiring (pay particular attention to Disconnect
water leaking on connectors or terminals) - connector and dry
22. Check for blown, corroded fuses - Replace
23. Check alternator voltage (engine running at 1/2 throttle or above)
(If the battery charge is low, the voltage may be approximately. 25V 27.5 - 29.5 V Check, repair or
immediately after charging replace
24. Sound of actuation of battery relay
(when starting switch is turned ON, OFF - Replace

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12
JUDGEMENT OF POWER TRAIN
To judge if any abnormality in the power train is in the electrical system of the transmission or in the transmission itself, use
the following judgement flow chart. If the abnormality is in the electrical system, carry out troubleshooting for E-5, and if the
abnormality is in the transmission system, go to troubleshooting T-1 - T-4.

Testing transmission solenoid

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower
the bucket to the ground and stop the engine. Then apply the parking brake and
put blocks under the wheels to prevent the machine from moving.

1. Install a T-adapter checker to connector CNFT1, and check the voltage between the connector pins and the chassis ground.

2. Turn the start switch ON.

★ Do not start the engine under any circumstances.

3. Turn the parking brake switch ON ➞ OFF (release).

4. When using the foot brake, press the right brake so that the transmission cut-off is not turned off.

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12
PRECAUTIONS WHEN TROUBLESHOOTING

SAFETY

WARNING! Stop the machine on level ground, and check that the safety pins and parking brake are
correctly applied, and that the tires are blocked.

WARNING! When working in groups, use agreed upon signals and do not allow unauthorized per-
sons near machine.

WARNING! Be careful not to get burned by hot parts or get caught in rotating parts.

WARNING! Always disconnect the cable from the negative (-) terminals of the battery before discon-
necting any wiring.

WARNING! Always release the pressure before removing the plugs or caps of any place under
hydraulic or air pressure, and connect all measuring tools correctly.

METHODS FOR TROUBLESHOOTING

★ Just because a failure occurs, do not immediately start to disassemble the machine.
• The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be
unknown.

As a result,
• The customer and operator will lose confidence in you.
• Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.

To avoid these problems, use the following procedure when troubleshooting.

1. Ask the customer and operator the following questions about the breakdown.

A. Was there anything unusual before the machine broke down?

B. Have there been any other problems apart from the one reported?

C. Did the breakdown occur suddenly, or had there been signs of trouble before?

D. What was the machine doing when break down occurred?

E. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?

F. Had the same kind of failure occurred before?

2. Check the following items which can be checked simply by visual checks etc.

A. Check oil level.

B. Check for leakage of oil from piping or hydraulic equipment.

C. Check travel of control levers.

D. Check stroke of spool in control valves.

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3. Reenact the failure and check the condition of the machine (particular conditions at the time of failure).

A. Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or
by feeling.

B. Compare extent of failure with standard values.

C. Check safety before carrying out any check.

D. Did not make any check or measurement that will make the condition worse.

4. Try to locate the possible causes for the failure.

The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical
control.
In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as
follows;
• Transmission itself, or transmission control valve.
• Transmission electric control.
• To decide which of the two is the location of the failure, refer to “JUDGMENT ON POWER TRAIN”.

5. Carry out troubleshooting using the troubleshooting charts.

There are the following two types of troubleshooting charts.

A. TROUBLESHOOTING TABLE
POWER TRAIN
STEERING SYSTEM
BRAKE AND AIR SYSTEM
WORK EQUIPMENT SYSTEM

B. TROUBLESHOOTING FLOW CHART

ELECTRICAL SYSTEM

The troubleshooting charts consist of:

i. Items which can be checked easily.

ii. Items which are likely to be the cause of such failures.

Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points.
• Check related items.
• Check that there are no other failures or breakdowns.

6. Investigate causes of breakdown

• Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur
again. To investigate and remove the original cause, see "Actions to take to prevent failures from occurring again".

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12
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR
ASSEMBLING PARTS DURING TROUBLESHOOTING
Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting".

When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and
bottom.

Check the match marks, or make match marks to prevent mistakes when installing.

If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the
part to see if there is any problem with it and remove the problem before trying to disassemble the part.

When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before
coating with gasket sealant.

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PREVENTING RECURRENCE OF TROUBLE
• The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment.
However, it is not able to establish the root cause of the damage or failure.
• Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention
what action should be taken to prevent a recurrence of the root cause.
• In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while refer-
ring to the following items.
• Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the
Shop Manual.

HYDRAULIC EQUIPMENT
OIL CHECKS
The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign
matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and
then take appropriate action.

1. Oil checks
• Check for water contamination.
Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate.
• Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank
and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a
contamination checker.
• Viscosity check
Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory.

2. Check of contamination point

If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is
necessary to find out where the contamination is occurring and also to take steps to prevent it.
Water: Oil storage tank, breather, etc.
Sand: Oil replenishing or replacing method, etc.
Rubber: Cylinder packing, etc.
Metal: Wear or damage to hydraulic equipment such as pump and motor, as well as transmission
and torque converter, etc.

3. Oil cleaning and replacement

If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil
refresher or replace it.
★ If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher.
★ When washing the oil, also wash or replace the strainer and replace the filter.

CLEANING FRAGMENTS OF DAMAGED PARTS

If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil.

In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other
foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the
engine or hydraulic equipment.

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12
METHOD OF USING TROUBLESHOOTING CHARTS

CATEGORY OF TROUBLESHOOTING CODE NUMBER

Troubleshooting code No. Troubleshooting of Component

D - 00 ECSS (Electronically Controlled Suspension System)

E - 00 Chassis Electrical System - See Remark

H - 00 Hydraulic and Mechanical System

J - 00 Joystick Steering Controller System

K - 00 Maintenance Monitor System

M - 00 Main Monitor System

S - 00 Engine System - See ENGINE SHOP MANUAL

T - 00 Transmission Controller System

Remark
Troubleshooting code number E-00 Engine Electrical System are found in the ENGINE SHOP MANUAL.

METHOD OF USING TROUBLESHOOTING TABLE FOR EACH

TROUBLESHOOTING MODE.
1. Troubleshooting code number and problem.
The title of the troubleshooting chart gives the troubleshooting code, service code and failure mode (problem with the
machine). (See Example (1)).

2. Distinguishing conditions.
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small
letters (for example, (a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in the failure
mode. (See Example (2)).

3. Method of following troubleshooting chart.

• Check or measure the item inside , and according to the answer, follow either the YES line or the NO line to
go to the next condition box. (Note: The number at the top right corner of the condition box 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. (See Example (3))
• Below the condition box, there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the condition box are correct or the answer to the question inside the
condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to the question in NO,
then follow the NO line.
• Below the condition box 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
the 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 the first item 1.

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4. General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the
top of the page and marked with a .(See Example (4)).
The precautions marked  are not given in the condition box, but must always be followed when carrying out the
check inside the condition box.

5. Troubleshooting tools
When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING,
ADJUSTING AND TROUBLESHOOTING.

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 for each failure mode
(problem).

< Example >

(1) M-15 Abnormality in buzzer
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
(3)

(4)
 Before carrying out troubleshooting, check that all the related connectors are properly inserted.
 Always connect any disconnected connectors before going on to the next step.

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12
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of fail-
ures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steer-
ing system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate
the problems accurately and swiftly.

Step 1. Questioning the operator 1. Steering does not work Symptom [Example]
The questions to ask the operator are given below the
failure symptom. If the answers to the questions match the Ask the operator about the following points.
information given, follow the arrow to reach the probable • Did the steering suddenly stop working? ➛ Breakage in
cause of the failure. steering equipment
Consider the contents of the questions and consult the table • Did the steering gradually become heavy? ➛ Internal wear
while proceeding to Steps 2 and 3 to grasp the true cause. of steering equipment, defective seal.

Checks before starting [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 leaks and loose bolts. These checks
may avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting are items
which must be considered particularly for that symptom
before starting troubleshooting.
Step 3. Using cross-reference table
A. Operate the machine to carry out the checks in the
troubleshooting item column.
Mark the items where the results match the
symptom.
★ It is not necessary to follow the troubleshoot-
ing checks in order; follow an order which is
easiest to carry out troubleshooting.
• Is the oil level in the hydraulic tank correct?
• Is the type of oil correct?
• Are there any oil leaks from the steering control valve?
• Has the safety bar been removed from the frame?
[Example 1]
No. Problem Remedy
1 Steering does work to the left or right.
2 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]
Causes

B. Find the appropriate cause from the cause column.

a b c d e
If the symptom appears, the O, marks on that line
Problems Remedy
indicate the possible causes. (For item No. 2 in the X C A X
X
table on the right, the possible causes are c or e.)
If there is only one O: 1 O O O O
Carry out the other troubleshooting items (where 2 ● ●
the same cause is marked with check if the symp- 3 O O
tom appears, then repair. 4 O O
If there are two O: 5 O O
Go on to Step 3) to narrow down the possible
causes.

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3) Operate the machine and check the troubleshooting items
other than those in 1).
Operate the machine and check the items in the same way

Causes
as in 1) and if the symptom appears, mark that item. (In
the chart on the right, the symptom appears again for item
a b c d e
5).
Remedy
X C X A X
Problems
4) Find the appropriate cause from the cause column. In the
1 O O O O
same way as in Step 2), if the symptom appears, the O
2 O ●
marks on that line indicate the possible causes. (For item
3 O O
No.5 in the table on the right, the possible causes are b or
4 O O
e.)
5 ● ●
5) Narrow down the possible causes.
There is one common cause among the causes located in Applicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
Steps 2) and 4). (One cause marked O, appears on the line
for both items.) This cause is common to both the
symptoms in troubleshooting Steps 1) and 3).
Ignore these causes
★ The causes which are not common to both
troubleshooting items (items which are not marked O
for both symptoms) are unlikely causes, so ignore them.

Causes
Common causes
(In the example given on the right, the causes for
Troubleshooting Item 2 are c or e, and the causes for
a b c d e
Troubleshooting Item 5 are b or e, so cause e is Remedy
common to both.) X C X A X
Problems
1 O O O O
6) Repeat the operations in Steps 3), 4) and 5) until one 2 ● ●
cause (one common cause) remains. 3 O O
★ If the causes cannot be narrowed down to one cause, 4 O O
narrow the causes down as far as possible. 5 ● ●

7) Remedy
If the causes are narrowed down to one common cause,
take the action given in the remedy column.
Causes

The symbols given in the remedy column indicate the

following:
a b c d e Action to take
X: Replace Remedy
: Repair X C X A X
Problems
A: Adjust 1 O O O O
C: Clean 2 O ●
3 O O
4 O O
5 O ●

WA500-3H 20-123
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
METHOD OF USING ENGINE RELATED CHARTS
Using troubleshooting charts for engine-related failure
This troubleshooting chart is divided into three sections:
questions, check items, and troubleshooting.
The questions and check items are used to pinpoint high
probability causes that can be located from the failure
symptoms or simple inspection without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are used to
check the high probability causes to make final confirmation.

[Questions]
Sections (A) + (B) in the chart on the right corresponds to the
items where answers can be obtained from the user. The items
in (B) are items that can be obtained from the user, depending
on the user’ level.

[Check items]
The serviceman carries out simple inspection to narrow down
the causes. The items under (C) in the chart on the right
correspond to this.
The service man narrows down the causes from information
(A) that he has obtained from the user and the results of (C)
that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in order of probability, starting
with the causes that have been marked with having the highest
probability from information gained from [Questions] and
[Check items]

Causes

(1) (2) (3)

(A) (a)
Ques-
tions

(b)
(c)
(B) (d) O
(e) O
Check items

(C)

i ●
Trouble-
shooting

ii ●
iii ●

20-124 WA500-3H
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12
The basic method of using the troubleshooting chart is as follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with O, and these,
causes that have high probability are marked with a .
Check each of the [Questions] and [Check items] in turn and mark
the O or the in the chart for items where the problem appeared.
The vertical column (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting for that item to
ake final confirmation of the cause.
❇1. For [Confirm recent repair history] in the
[Questions Section, ask the user, and mark the Cause
column with to use as reference for locating the
cause of the failure. However, do not use this when
making calculations to narrow down the causes.
❇2. Use the in the Cause column as reference for
[Degree of use (operated for long period)] in the
[Questions] section as reference.As a rule do not use
it when calculating the points for locating the cause,
but it can be included if necessary to determine the
order for troubleshooting.

Causes

Defective injection pump (excessive injection)

Seized turbocharger, interference

Clogged seized injection nozzle

Clogged air cleaner element
Worn piston ring, cylinder

Improper injection timing

❇1 Confirm recent repair history
❇2 Degree of use Operated for long period

WA500-3H 20-125
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12• Example of troubleshooting when exhaust gas is black
Let assume that [Clogged air cleaner] is taken to be the cause of the black gas. Three symptoms have causal relationship
with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us
explain here the method of using this causal relationship to pin point the most probable cause.

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

Causes

Defective injection pump (rack, plunger seized)

Defective injection pump (excessive injection)

Air leaks between turbo charger and head

Defective contact of valve, valve seat
Seized turbocharger, interference

Clogged seized injection nozzle

Clogged air cleaner element
Worn piston ring, cylinder

Improper injection timing

improper valve clearance

Crushed clogged muffler
Legend
O: Possible causes (judging from questions and check items)
: Most probable causes (judging from questions and check items)
: Possible causes do to length of use (used for a long period)
●: Items to confirm the cause
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black O O
Questions

Color of exhaust gas Gradually became black O O

Blue under light load
Engine oil must be added more frequently
Suddenly O O O
Power was lost
Gradually O O O O
Non-specified fuel has been used O O
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular O O O O O
Check items

When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low O
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 O O
Muffler is crushed
Air leaks between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy ●
When air cleaner is inspected, it is found to be clogged ●
Troubleshooting

When compression pressure is measured, it is found to be low ● ●

Speed of some cylinder does not change when operating on reduced cylinders ●
When check is made using delivery method, timing found to be incorrect ●
Injection pump test shows that injection amount is incorrect ●
When valve clearance is checked, it is found to be outside standard value ●
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 ●
Replace

Replace
Replace

Replace

Replace
Replace
Adjust
Adjust
Adjust

Repair
Clean

Remedy

20-126 WA500-3H
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12

Five causes

Step 1

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 O and marks where the horizon-

tal lines for the three symptoms and the vertical col-
umns for the causes intersect.
(1) Clogged air cleaner element:----------------- O
(2) Air leaks between turbocharger and head:--O O
(3) Clogged, seized injection nozzle:------------O
(4) Defective contact of valve, valve seat:------O
(5) Worn piston ring, cylinder:-------------------O

Step 3

The calculation in Step 2 show that the closet relation-

ship 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.

WA500-3H 20-127
TROUBLESHOOTING METHOD OF USING ENGINE RELATED
12

MEMORANDUM

20-128 WA500-3H
 TROUBLESHOOTING CONNECTORS

12
CONNECTOR ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-153
CONNECTOR NUMBERS, TYPES AND PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-163

WA500-3H 20-151
TROUBLESHOOTING
12

MEMORANDUM

20-152 WA500-3H
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
12
CONNECTOR ARRANGEMENT DIAGRAM
See foldouts in Section 90.

Connector Arrangement Diagram - FOLDOUT 20-153-1 Sheet 1 (Part 1 of 5)

Connector Arrangement Diagram - FOLDOUT 20-153-2 Sheet 1 (Part 2 of 5)
Connector Arrangement Diagram - FOLDOUT 20-153-3 Sheet 1 (Part 3 of 5)
Connector Arrangement Diagram - FOLDOUT 20-153-4 Sheet 1 (Part 4 of 5)
Connector Arrangement Diagram - FOLDOUT 20-153-5 Sheet 1 (Part 5 of 5)
3D Connector Arrangement Diagram - FOLDOUT 20-153-6 Sheet 2 (Part 1 of 2)
3D Connector Arrangement Diagram - FOLDOUT 20-153-7 Sheet 2 (Part 2 of 2)

WA500-3H 20-153
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS
12
CONNECTOR NUMBERS, TYPES AND PINS
The address column in the table below shows the address in the connector arrangement diagram.

Connector
Type No. of pins Place of use
Number

A10 4 Blower relay (Hi)

A11 4 Blower relay (M2)

A12 4 Condenser relay

A13 4 Blower relay (M1)

A14 4 Condenser relay (Hi)

A14 4 Relay

A14 X 2 Relay

A15 2 Hi / Lo switch

A15 4 Magnet clutch relay

A15 4 Compressor clutch relay

A15 4 Compressor clutch relay

A16 SWP 12 Air conditioner controller

A17 SWP 16 Air conditioner controller

A18 SWP 8 L.H. detection servo motor

A19 SWP 8 R.H. detection servo motor

A4 X 2 Air servo motor

A5 M 2 Thermistor

A6 SWP 6 Air mix servo motor

A7 M 6 Blower motor and resistor

A8A S 10 Intermediate connector (air conditioner relay)

A8B S 8 Intermediate connector (air conditioner relay)

A9 4 Blower relay (Main)

AF1 X 2 Solenoid 1 (relief) (ECSS)

AF2 X 2 Solenoid 5 (charge) (ECSS)

ASS 2 Air suspension seat

B01 X 2 Condenser

B03 2 Window washer

B04 2 Window washer

B05 2 Diode

B06 2 Diode

B07 X 2 Condenser (lower)

20-154 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

B08 X 2 Brake accumulator low pressure switch

B09 X 2 Emergency brake switch

B10 X 2 Emergency brake switch

B11 X 1 Condenser (Hi/Low)

B12 X 1 Condenser (Hi/Low)

B13 X 2 Brake accumulator low pressure switch

B14 X 2 Parking brake emergency release solenoid

BR1 SWP 14 Intermediate connector

C01 M 6 Front wiper motor

C02 9 Radio

C03 M 2 Front working lamp

C04 M 2 Front working lamp

C05 4 Warning lamp switch

C06 2 Room lamp

C07 M 4 Rear wiper motor

C08 1 Cigar lighter

C09 1 Cigar lighter

C1 MIC 13 Transmission and ECSS controller

C11 1 Door switch (RH room) lamp

C12 1 Door switch (LH) room lamp

C13 1 Ground

C16 2 Working lamp (side LH)

C16 2 Side working lamp

C17 2 Working lamp (side RH)

C17 2 Side working lamp

C2 MIC 21 Transmission and ECSS controller

C38G 1 Memory clear switch

C3A AMP040 20 Transmission and ECSS controller

C3B AMP040 16 Transmission and ECSS controller

C4 AMP040 12 Transmission and ECSS controller

C5 MIC 17 Transmission and ECSS controller

CL1 S 12 Intermediate connector (working lamp, radio)

CL18 1 Intermediate connector

CL19 1 Intermediate connector

WA500-3H 20-155
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

CL2 6 (M) Intermediate (window regulator)

CL20 1 Intermediate connector

CL26 1 Intermediate connector

CL3 M 6 Intermediate connector (air conditioner)

CL4 M 6

CL4 S 10 Intermediate connector (air conditioner)

CN14 2 Radio connection

CN10 X 2 Parking brake solenoid

CN11 X 2 Transmission oil temperature sensor

CN12 JFC 2 3rd solenoid (Transmission)

CN13 X 1 3rd fill switch (Transmission)

CN14 JFC 2 R solenoid (Transmission)

CN15 X 1 R fill switch (Transmission)

CN16 JFC 2 F solenoid (Transmission)

CN17 X 1 F fill switch (Transmission)

CN18 X 2 Torque converter oil temperature sensor (monitor)

CN19 X 2 Parking brake indicator switch

CN3 X 2 Speed sensor

CN4 JFC 2 1st solenoid (Transmission)

CN5 X 1 1st fill switch (Transmission)

CN6 JFC 2 2nd solenoid (Transmission)

CN7 X 1 2nd fill switch (Transmission)

CN8 JFC 2 4th solenoid (Transmission)

CN9 X 1 4th fill switch (Transmission)

CNL X 2 Joystick solenoid (L)

CNR X 2 Joystick solenoid (R)

D01 2 Diode (for neutral switch)

D02 2 Diode (for neutral switch)

D1 2 Diode (ECSS)

D2 2 Diode (ECSS)

E01 1 Slow blow fuse (120A)

E02 1 Slow blow fuse (80A)

E07 1 Heater relay

E08 1 Heater relay

20-156 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

E09 1 Heater relay

E12 X 1 Air conditioner compressor

E13 X 2 Starting motor

E14 1 Ground start motor

E15 1 Alternator terminal B

E16 1 Alternator terminal R

E17 1 Alternator terminal E

ECSS SWP 3 Intermediate connector

Engine - CN1 Boost pressure sensor

Engine - CN1 Common rail fuel pressure sensor

Engine - CN2 Boost pressure sensor

Engine - CN2 Common rail fuel pressure sensor

Engine - IJ1 No. 1 fuel injector

Engine - IJ2 No. 2 fuel injector

Engine - IJ3 No. 3 fuel injector

Engine - IJ4 No. 4 fuel injector

Engine - IJ5 No. 5 fuel injector

Engine - IJ6 No. 6 fuel injector

Engine - POH Oil pressure high-pressor switch

Engine - POL Oil pressure low-pressor switch

Engine - PV1 Fuel supply pump PCV1

Engine - PV2 Fuel supply pump PCV2

Engine - SG G revolution sensor

Engine - SNE NE revolution sensor

Engine - TFL Fuel temperature sensor

Engine - TWH Water temperature high-temperature sensor

Engine - TWL Water temperature low-temperature sensor

Intermediate connector (air conditioner, engine water temperature

ER1 SWP 14
sensor)

ER2 31 Intermediate connector (engine controller)

ER3 31 Intermediate connector (engine controller)

EST X 3 Remove when installing emergency steering

F01 M 3 Head lamp (RH)

F02 M 3 Front combination lamp (RH)

F03 M 3 Front combination lamp (LH)

WA500-3H 20-157
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

F04 M 3 Head lamp (LH)

F05 X 3 Proximity switch for bucket

F06 X 3 Proximity switch for boom kick-out

F07 1 Horn

F08 1 Horn

F09 1 Horn

F10 1 Horn

F11 X 2 Switch pump cut-off solenoid

F12 KES 1 2 Diode

FR1 X 10 Intermediate connector

FR2 X 4 Intermediate connector (boom, bucket SIG)

FS1 L 2 Power source

FS2 S 12 Fuse

FS3 M 6 Fuse

FS4 L 2 Power source

FS5 M 6 Fuse

FS6 M 4 Fuse

GND1 1 GRD (opt.)

GND2 1 GRD (opt.)

GR1 X 4 Intermediate connector (working lamp)

GRE SWP 6 Grease

JL57 DT2 6

JL58 DT2 6

JL59 DT1 6 Power (engine controller)

JL60 DT1B 8 Ground (engine controller)

JL61 DT2B 8 Ground (engine controller)

JS1 S 1 Buzzer (J/S)

JS10 5 Selector switch

JS11 3 Steering neutral interlock relay

JS12 M 8 Intermediate connector (joystick switch)

JS14 M 8 Intermediate connector (joystick lever switch)

JS3 1-pin connector 1 Cut-off switch power source

JS4 1-pin connector 2 Cut-off switch GND

JS5 2 Joystick ON-OFF switch

20-158 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

JS6 X 3 Neutral switch

JS7 3 Potentiometer

JS8 5 Caution relay

JS9 5 Solenoid cut relay

JSA (male) 1-pin connector 1 Intermediate connector (neutral)

JSB (male) 1-pin connector 1 Intermediate connector (neutral)

JSC 1-pin connector 1 Neutral (J/S)

JSD 1-pin connector 1 Neutral (J/S)

L01 SWP 6 Parking brake switch

L02 SWP 6 Light and dimmer switch

L02 Yazaki 9 Radio

L03 SWP 6 Turn signal and hazard switch

L04 SWP 14 F/R and speed switch

L05 AMP040 20 Main monitor

L06 AMP040 16 Main monitor

L07 AMP040 12 Main monitor

L08 AMP040 8 Main monitor

L09 M 4 Starting switch

L10 S 10 Wiper switch

L12 X 2 Transmission cut-off switch

L13 X 3 Accelerator potentiometer

L14 X 3 Accelerator limit switch

L15 M 4 Kick-down and hold switch

L16 2 Boom kick-out solenoid

L17 2 Bucket positioner solenoid

L18 AMP040 16 Maintenance monitor

L19 AMP040 8 Maintenance monitor

L20 AMP040 16 Maintenance monitor

L21 2 Maintenance monitor

L25 24 Engine throttle controller

L26 MIC 21 Work equipment and joystick controller

L27 MIC 20 Work equipment and joystick controller

L28 MIC 16 Work equipment and joystick controller

L32 2 Intermediate connector

WA500-3H 20-159
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

L32 M 2 Intermediate connector (power source, GND)

L33 M 2 Intermediate connector (boom kick-out output)

L34 8 Opt. equipment control

L34 S 8 Intermediate connector (network, buzzer output) (Opt.)

L42 1-pin connector 1 Caution buzzer

L43 1-pin connector 1 Caution buzzer

L44 6 Wiper relay

L46 3 Flasher unit

L48 5 Bucket relay

L49 5 Boom relay

L52 5 Hazard relay

L53 5 Stop lamp relay

L54 5 Back-up lamp relay

L55 5 Horn relay

L56 5 Pre-heat relay

L57 5 Neutral relay

L58 5 Neutralizer relay

L59 5 Parking brake safety relay

L60 6 Front working lamp relay

L61 6 Rear working lamp relay

L62 5 Engine stop relay

L63 1-pin connector 1 Horn switch

L64 KES 0 5 Engine oil pressure relay

L80 KES 0 5 Dust indicator relay

L81 AMP070 12 Engine controller

L81 X 2 Stop lamp switch

L82 5 Switch pump cut-off relay

L82 AMP070 18 Engine controller

L84 AMP070 20 Engine controller

L86 AMP070 10 Engine controller

L87 AMP070 14 Engine controller

L90 4 Parking brake emergency release switch

L91 5 ECSS relay

L92 5 Relay pwr window LH - up

20-160 WA500-3H
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

L93 5 Relay pwr window LH - down

L94 5 Relay pwr window RH - up

L95 5 Relay pwr window RH - down

L96 Yazaki 7 Power window switch (RH)

L97 Yazaki 7 Power window switch (LH)

LL1 12 Intermediate (to Engine Gov. floor harness)

LL1 12 Intermediate connector to engine controller

LL2 2 Engine controller signal ground

LL2 2 Engine controller

LL2 14 Intermediate (to Engine Gov. floor harness)

LL2 14 Intermediate connector to engine controller

LL3 2 E16 control power

LM1 S 10 MDC monitor panel

LR1 S 12 Intermediate connector (lamp)

LR11 SWP 14 Intermediate connector (boom switch) (opt. not available)

LR2 SWP 14 Intermediate connector

LR4 SWP 14 Intermediate connector (monitor related)

LR5 X 4 Intermediate connector (power source, GND)

LR6 L 2 Intermediate connector (power source)

LR7 31 Intermediate connector (engine controller)

LR8 31 Intermediate connector (engine controller)

OP1 1-pin connector 1 Fuse outlet

OP2 1-pin connector 1 Fuse outlet (power source)

OP4 1 Key on (opt.)

OP4 1 Intermediate connector

OP5 1 Key on (opt.)

OP5 1 Intermediate connector

PWR1 1 Motor pwr window regulator LH

PWR1 1 Motor pwr window regulator RH

PWR2 1 Motor pwr window regulator LH

PWR2 1 Motor pwr window regulator RH

R01 2 Diode

R02 2 Diode

R03 2 Diode

WA500-3H 20-161
TROUBLESHOOTING CONNECTOR NUMBERS, TYPES AND PINS

Connector
Type No. of pins Place of use
Number

R04 2 Diode

R07 X 2 Fuel level sensor

R08 M 6 Rear combination lamp (LH)

R09 M 6 Rear combination lamp (RH)

R10 1 Ground for tail lights

R10 1 Ground for tail lights

R11 Terminal 1 Battery

R12 Terminal 1 Battery relay (key switch BR)

R13 Terminal 1 Battery relay

R15 Terminal 1 Slow blow fuse (80A)

R17 Terminal 2 Slow blow fuse (30A)

R18 1-pin connector 1 License lamp

R19 1-pin connector 1 License lamp (GND)

RES 2 Resistance (diode J/S)

RPM 1 RPM select

RPM1 1 RPM (opt.)

RPM2 1 RPM (opt.)

SEL M 2 Engine select

SEL2 M 2 Joystick function selection

SEL3 2 Remote positioner select

T02 2 Diode

TAC 1 Tachograph

TM1 SWP 14 Intermediate connector (transmission)

TM2 SWP 16 Intermediate connector (transmission)

20-162 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.

WA500-3H 20-163
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

20-164 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

WA500-3H 20-165
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

20-166 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

WA500-3H 20-167
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

20-168 WA500-3H
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

WA500-3H 20-169
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12

20-170 WA500-3H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12

WA500-3H 20-171
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12

20-172 WA500-3H
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12

WA500-3H 20-173
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR
12

MEMORANDUM

20-174 WA500-3H
 TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ECM

12 (ELECTRIC CONTROL MECHANISM)

EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL MECHANISM) . . . . . . . . . . . . . . . . 20-202

TRANSMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
MAINTENANCE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
JOYSTICK STEERING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
METHOD OF DISPLAYING ACTION AND FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
CHART OF ACTION CODES, FAILURE CODES AND RE-ENACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
TRANSMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
ECSS CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
JOYSTICK CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-224
ACTION CODE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
TRANSMISSION CONTROLLER LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226

WA500-3H 20-201
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL
MECHANISM)

TRANSMISSION CONTROL SYSTEM

20-202 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Function of equipment at input end.

A. F/R switch.
This detects the condition of operation of directional lever and inputs it to the controller as a digital (ON-OFF) signal.
(On machines equipped with joystick, the signal from the joystick switch is also input.)

B. Speed range switch.

This detects the condition of operation of speed lever and inputs it to the controller as a digital (ON-OFF) signal.

C. Manual selector switch.

This detects the condition of operation of the manual selector switch and inputs it to the controller as a digital (ON-
OFF) signal.

D. Transmission cut-off selector switch.

This detects the condition of operation of the transmission cut-off switch, and controls the signal of the ON-OFF
signal from CUT-OFF oil pressure switch to the controller signal.

E. Hold switch.
This detects the condition of operation of the hold switch or shift up switch (when using the joystick) and inputs it to
the controller as a digital (ON-OFF) signal.

F. Kick-down switch.
This detects the condition of operation of the kick-down switch or shift-down switch (when using the joystick) and
inputs it to the controller as a digital (ON-OFF) signal.

G. Engine speed sensor.

This detects the speed of the engine flywheel as the engine speed and inputs it to the controller as a pulse (rotation)
signal.

H. Cut-off oil pressure switch.

This detects the condition of operation of the left brake pedal from the brake circuit oil pressure, and inputs it to the
controller as a digital (ON-OFF) signal. (When the main monitor cut-off switch is ON.)

I. Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the controller as a pulse
(rotation) signal. (The speed sensor is also used with the main monitor system.)

J. Transmission oil temperature sensor.

This detects the temperature of the transmission oil and inputs it to the controller as a analog (resistance) signal.

K. Speed range switch. (F, R, 1st, 2nd, 3rd, 4th)

This detects the condition of actuation of the ECMV flow detection valve and inputs it to the controller as a digital
(ON-OFF) signal.

L. Neutralizer relay.
This detects the condition of actuation of the parking brake and inputs it to the controller as a digital (ON-OFF)
signal.

2. Limit function of controller (outlet port).

A. Auto-shift function:
This calculates the optimum speed range from the signals from the switches and sensors, and outputs it to the ECMV
as an analog (current) signal in order to shift up or down.

WA500-3H 20-203
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
B. Modulation control function:
This calculates the optimum modulation pattern from the signals from the switches and sensors in order to reduce the
shock when shifting up or down, and outputs it to the ECMV of both the clutch to be engaged and the clutch to be
disengaged as an analog (current) signal.

C. Hold function:
When the hold switch is turned ON, it outputs a signal to the ECMV to stop the auto-shift and hold it at the same
speed range.

D. Kick-down function:
When the kick-down switch is turned ON, if it matches the control conditions, the signal is output to the ECMV to
shift down to 1st.

E. Manual shift function:

When the manual shift is turned ON, the signal is output to the ECMV to shift the speed to the selected speed range
with the shift lever.
For machines with joysticks, when operating in the manual mode, the hold switch becomes the shift-up switch and
the kick- down switch becomes the shift-down switch, so the transmission is shifted up or down within the range of
the speeds selected by the speed range switch (the range of speeds self-between 1st and the selected speed range).

F. Parking brake neutralizer function:

To prevent seizure of the parking brake, the signal from the neutralizer relay stops the out-put of the directional signal
to the ECMV and holds the transmission at neutral even if the directional lever is operated to F or R.

G. Back-up lamp drive function:

The signal from the directional switch is sent to the back-up lamp relay as a digital (ON- OFF) signal.

H. Buzzer function:
The signal is sent through the main monitor to the alarm buzzer as a digital (ON-OFF) signal according to the
condition of the input signal.

I. Self-diagnostic function:
The controller always observes the directional switch, speed range switch, speed sensor, engine speed sensor,
transmission oil temperature sensor, the 6 ECMV fill switches at the input side, and the 8 ECMV solenoids at the
output side to check that no abnormality occurs in the back-up lamp relay systems.

J. Network communication with main monitor:

i. The controller communicates the actuated speed range through the network.

ii. The controller communicates the actuated F/R position through the network. (Machines with joystick.)

iii. It communicates the condition of actuation of the hold mode through the network.

iv. If any abnormality is detected by the self-diagnostic function, it communicates the details of the abnormality
through the network.

3. Functions of output equipment.

A. ECMV solenoid valve. (F, R, 1st, 2nd, 3rd, 4th)

The solenoid receives the signal from the controller, is driven, and controls the transmission clutch oil pressure.

B. Back-up lamp relay.

The relay receives the signal from the controller, is driven, and turns the power for the back-up lamp relay ON-OFF.

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4. Main monitor display.
For details, see MAIN MONITOR.

WA500-3H 20-205
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
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MAIN MONITOR SYSTEM

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TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end

A. Parking brake oil pressure switch

This detects the condition of actuation of the parking brake and inputs it to the main monitor as a digital (ON-OFF)
signal.

B. Engine speed sensor.

This detects the speed of the engine flywheel as the engine speed and inputs it to the main monitor as a pulse
(rotation) signal.

C. Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the main monitor as a pulse
(rotation) signal. (The speed sensor is also used with the transmission control system.)

D. Engine water temperature sensor.

This detects the temperature of the engine cooling water and inputs it to the main monitor as an analog (resistance)
signal.

E. Transmission directional switch.

This detects the condition of operation of the directional lever to the “N” position and inputs it to the main monitor as
a digital (ON-OFF) signal. (The transmission directional switch is also used for the transmission control system.)

F. Emergency steering detection switch.

This detects the condition of actuation of the emergency steering hydraulic circuit and inputs into the main monitor as
a digital (ON- OFF) signal.

G. Turn signal, hazard switch.

This detects the condition of operation of the turn signal and hazard switch, and inputs it to the main monitor as a
digital (ON-OFF) signal.

H. Dimmer switch.
This detects the condition of operation of the dimmer switch and inputs it to the main monitor as a digital (ON-OFF)
signal.

I. Head lamp relay/rear lamp relay.

This detects the condition of actuation of the relay from the secondary outlet voltage of the head lamp relay and rear
lamp relay, and inputs it to the main monitor as a digital (ON-OFF) signal.

J. Preheating relay.
Optional equipment, detects actuation of the relay from the secondary outlet voltage of the preheating relay, and
inputs it to the main monitor as a digital (ON-OFF) signal.

K. Maintenance monitor.

i. CHECK lamp signal.

This inputs the CHECK lamp drive signal (the output signal from the maintenance monitor) to the main monitor
as a digital (ON-OFF) signal.

ii. CAUTION lamp signal.

This inputs the CAUTION lamp drive signal (the output signal from the maintenance monitor) to the main
monitor as a digital (ON-OFF) signal.

iii. Lamp synchronous signal.

This inputs the lamp synchronous signal (the output signal from the maintenance monitor) to the main monitor as
a digital (ON-OFF) signal.

WA500-3H 20-207
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
L. Starting switch.

i. Terminal BR.
This detects the condition of operation of the starting switch to the ON position and inputs it to the main monitor
as a digital (ON-OFF) signal.

ii. Terminal C.
This detects the condition of operation of the starting switch to the START position and inputs it to the main
monitor through the neutral relay as a digital (ON-OFF) signal.

M. Alternator (terminal R).

This detects the condition of electricity generated by the alternator and inputs it to the main monitor as an analog
(voltage) signal.

2. Network communication with controllers.

A. With transmission, ECSS controller.

i. The speed range (1 - 4) now being used is communicated.

ii. The directional position (F, N, R) now being selected is communicated (machines with joystick).

iii. When the hold function is actuated, the actuation signal is communicated.

iv. If any abnormality occurs in the transmission control system or ECSS control system, the details of the
abnormality are communicated.

B. With work equipment, joystick controller:

If any abnormality occurs in the transmission control system or joystick control system, the details of the abnormality
are communicated.

3. Functions of main monitor

A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)

B. Speedometer function:
The speedometer is displayed on the meter portion by the signal from the speed sensor. (When the system is set to the
tachometer display specification, the tachometer is displayed on the meter portion by the signal from the engine speed
sensor.)

C. Transmission shift indicator function:

The speed range or directional N is displayed on the shift indicator portion by the network communication from the
transmission and ECSS controller.

D. Transmission directional indicator function:

(Machines with joystick) The directional F or R is displayed at the bottom of the speedometer portion by the network
communication from the transmission and ECSS controller. (Even on machines with joystick, the directional N is
displayed on the shift indicator portion.)

E. Hold indicator function

When the hold mode is actuated, the hold indicator is lighted up by the network communication from the
transmission and ECSS controller.

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TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
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F. Turn signal pilot lamp function:
The left or right turn signal pilot lamps are made to flash (in the case of hazard the lamps on both sides flash) by the
signal from the turn signal and hazard switch.

G. Hi beam pilot lamp function:

When the Hi beam is used, the Hi beam pilot lamp is lighted up by the signal from the dimmer switch.

H. CHECK lamp function:

The CHECK lamp is made to flash by the CHECK lamp signal from the maintenance monitor. When this happens,
the flashing of the the lamp on the maintenance monitor and flashing of the CHECK lamp are synchronized by the
flash synchronous signal from the maintenance monitor.

I. CAUTION lamp function:

The CAUTION lamp is made to flash by the CAUTION lamp signal from the maintenance monitor. When this
happens, the flashing of the lamp on the maintenance monitor and the flashing of the CAUTION lamp are
synchronized by the flash synchronous signal from the maintenance monitor.

J. Emergency steering indicator function:

The emergency steering pilot lamp is made to flash by the signal from the emergency steering detection switch.

K. ECSS switch function (machines equipped with ECSS):

For details, see ECSS CONTROL SYSTEM.

L. Working lamp switch function (front, rear):

The condition of operation of the working lamp switch is output to the working lamp relay as a digital (ON-OFF)
signal. At the same time, the indicator is lighted up by the signal from the working lamp relay.

M. Parking brake dragging warning function:

If the directional lever (switch) is set to the F or R position when the parking brake is still applied (ON), the
CAUTION lamp flashes and the alarm buzzer sounds intermittently.

N. Action code and failure code display function:

If an abnormality signal is received by network communication from the controllers, the action code (normally
displayed) or failure code (when failure code is displayed) are displayed on the speedometer portion. At the same
time, when the abnormality code is received, the total hours of operation of the machine is calculated by the signal
from the alternator terminal R, and this is displayed as the elapsed time since failure on the failure mode display.

4. Functions of equipment at output end.

A. Alarm buzzer:
This receives the signal from the main monitor and generates the alarm sound. (The alarm buzzer is also used for the
maintenance monitor system.)

B. Front, rear working lamp relay:

This receives the signal from the controller and switches the power for the front or rear working lamp relay ON-OFF
according to the switching of the relay.

WA500-3H 20-209
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
MAINTENANCE MONITOR SYSTEM

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TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end.

A. Fuel level sensor:

This detects the fuel level in the fuel tank and inputs it to the maintenance monitor as an analog (resistance) signal.

B. Engine water temperature sensor:

This detects the temperature of the engine cooling water and inputs it to the maintenance monitor as an analog
(resistance) signal.

C. Torque converter oil temperature sensor:

This detects the temperature of the torque converter oil and inputs it to the maintenance monitor as an analog
(resistance) signal.

D. Engine water level switch:

This detects the level of the engine cooling water in the radiator reservoir tank and inputs it to the maintenance
monitor as a digital (ON-OFF) signal.

E. Engine oil level switch:

This detects the level of the oil in the engine oil pan and inputs it to the maintenance monitor as a digital (ON-OFF)
signal.

F. Brake accumulator low-pressure switch:

This detects the oil pressure in the wheel brake accumulator circuit and inputs it to the maintenance monitor as a
digital (ON-OFF) signal.

G. Engine oil pressure switch:

This detects the engine oil pressure inputs it to the maintenance monitor as a digital (ON- OFF) signal.

H. Air cleaner clogging switch:

This detects the clogging condition of the air cleaner and inputs it to the maintenance monitor as a digital (ON-OFF)
signal.

I. Alternator (terminal R):

This detects the condition of generation of electricity by the alternator and inputs it to the maintenance monitor as an
analog (electricity generation) signal.

J. Starting switch (terminal C):

This detects the condition of operation of the starting switch to the START position and inputs it through the neutral
relay to the maintenance monitor as a digital (ON-OFF) sensor.

2. Control functions of maintenance monitor.

A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)

B. Fuel gauge:
The fuel gauge is displayed and the pilot lamp flashes or goes out according to the signal from the fuel level sensor.

C. Engine water temperature gauge:

The engine water temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal from
the engine water temperature sensor.

WA500-3H 20-211
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
D. Torque converter oil temperature gauge:
The torque converter oil temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal
from the torque converter oil temperature sensor.

E. Engine water level pilot lamp:

The pilot lamp flashes or goes out according to the signal from the engine water level signal.

F. Engine oil level pilot lamp:

The pilot lamp flashes or goes out according to the signal from the engine oil level sensor.

G. Brake oil pressure caution lamp:

The caution lamp flashes or goes out according to the signal from the brake accumulator low-pressure switch.

H. Engine oil pressure caution lamp:

The caution lamp lights up, flashes, or goes out according to the signal from the engine oil pressure switch.

I. Battery charge caution lamp:

The caution lamp lights up, flashes, or goes out according to the signal from alternator terminal R.

J. Air cleaner clogging caution lamp:

The caution lamp flashes or goes out according to the signal from the air cleaner clogging sensor.

K. Service meter:
The service meter is driven by the signal from the engine oil pressure switch.

L. Output to main monitor:

The CHECK lamp signal, CAUTION lamp signal, and flash synchronous signal are output to the main monitor as a
digital (ON-OFF) signal according to the condition of the input signal.

M. Alarm buzzer function:

The digital (ON-OFF) signal is output to the alarm buzzer according to the condition of the input signal.

3. Functions of equipment at output end.

A. Main monitor:
This receives the signal from the maintenance monitor and makes the CHECK lamps or CAUTION lamps flash.

B. Alarm buzzer:
This receives the signal from the maintenance monitor and makes the buzzer sound. (The alarm buzzer is also used
for the main monitor system.)

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TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12

MEMORANDUM

WA500-3H 20-213
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
ECSS(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)
CONTROL SYSTEM
This system has functions in the transmission controller, and judges the function by the select signal from the main monitor
when the engine is started.

20-214 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end High.

A. ECSS actuation switch:

This detects the condition of actuation of the ECSS switch and inputs it to the controller as a digital (ON-OFF) signal.

B. Output speed range signal:

This detects the condition of the output speed range. (The ECSS system carries out control with the same controller as
the transmission control system, so the speed range switch signal is also used inside the controller.)

C. Speed sensor:
This detects the speed of the transmission output shaft as the travel speed (speed) and inputs it to the controller as a
pulse (rotation) signal. (The ECSS system carries out control with the same controller as the transmission control
system, so the speed sensor signal is also used inside the controller.)

D. Charge oil pressure switch:

This detects the basic oil pressure of the damper circuit and inputs it to the controller as a digital (ON-OFF) signal.

E. Boom bottom oil pressure switch:

This detects the oil pressure of the boom cylinder bottom circuit and inputs it to the controller as a digital (ON-OFF)
signal.

F. Pressure release switch:

This switch is the drive power to the selector solenoid (SOL4) by the operation of the pressure release switch. (The
signal from the pressure release switch does not pass through the controller, and is output directly to the selector
solenoid (SOL4). It is actuated at the same time has the normal return solenoid valve (SOL1).)

2. Control function of controller

A. Damper function:
To prevent pitching and bouncing of the bucket, the input signals from the switches and sensors are output as a digital
(ON-OFF) signal to the relief solenoid (SOL1), High-1) pressure solenoid (SOL2), Low-pressure solenoid (SOL3),
and pressure release solenoid (SOL4).

B. Accumulator charge function:

To prevent the oil pressure in the accumulator circuit from dropping and the boom from going down when the damper
function is actuated, the signal from the charge oil pressure sensor is output to the charge solenoid (SOL5) as a digital
(ON-OFF) signal.

C. Pressure release function:

The pressure release switch signal drives the pressure release solenoid (SOL4) to release the remaining pressure in
the boom cylinder circuit during the disassembly and assembly operation. (The pressure release switch signal does
not pass through the controller, it can be input directly to the pressure release solenoid (SOL4).)

D. Self-diagnostic function:
The controller always observes the system to check that no abnormality has occurred in the systems for the four
solenoids at the output end.

E. Network communication with main monitor:

If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality through the
network. (The ECSS system carries out control with the same controller as the transmission control system, so the
network communication circuit is used in both systems.)

WA500-3H 20-215
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
3. Functions of equipment at output end.

A. Return solenoid valve (SOL1):

This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom
cylinder head circuit and the hydraulic tank.

B. High-pressure solenoid valve (SOL2):

This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom
cylinder bottom circuit and the high-pressure accumulator.

C. High-pressure solenoid valve (SOL3):

This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom
cylinder bottom circuit and the low-pressure accumulator.

D. Pressure release check solenoid valve (SOL4):

The return solenoid valve (SOL1) and the pressure release check solenoid valve (SOL4) are turned ON-OFF through
the relay. The valve receives the signal from the controller or the pressure release switch, and the solenoid is driven to
open or close the circuit between the boom cylinder bottom circuit and the damper (high-pressure, low-pressure
accumulator) circuit.

E. Accumulator pressure solenoid valve (SOL5):

This receives the signal from the controller, and the solenoid is driven to open or close the circuit between the
hydraulic pump circuit and the damper (high-pressure, low-pressure accumulator) circuit.

4. Main monitor display

For details, see MAIN MONITOR SYSTEM.

20-216 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12

MEMORANDUM

WA500-3H 20-217
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
JOYSTICK STEERING CONTROL SYSTEM
This section describes only the items related to steering in the joystick steering control system. For details of the transmission,
see TRANSMISSION CONTROL SYSTEM.

20-218 WA500-3H
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
1. Functions of equipment at input end.

A. Joystick ON-OFF switch:

This detects the condition of operation of the joystick ON-OFF switch and inputs it to the controller as a digital
(ON-OFF) signal.

B. System cut-off switch:

This detects the slide position of the joystick lever stand and inputs it to the controller as a digital (ON-OFF) signal.

C. Joystick neutral switch:

This detects the neutral position of the steering lever and inputs it to the controller as a digital (ON-OFF) signal.

D. Joystick potentiometer:
This detects the angle of operation of the steering lever and inputs it to the controller as an analog (current) signal.

2. Control functions of controller.

A. System cut-off function:

This actuates or stops the system according to the signals from the system cutoff switch and joystick ON-OFF switch.
Joystick neutral interlock function When starting the engine, if the joystick is not at the neutral position, the engine
cannot be started.

B. Steering function:
This calculates the signal from the steering potentiometer and outputs an analog (current) signal corresponding to this
to the left and right steering solenoids.

C. Solenoid stop function:

If any abnormality occurs in the system, this outputs a signal to the solenoid cut relay as a digital (ON-OFF) signal.

D. Buzzer drive function:

If any abnormality occurs in the system, this turns the digital (ON-OFF) signal to the caution relay OFF and actuates
the buzzer.

E. Self-diagnostic function:
The controller always observes the condition to check that there is no abnormality in the joystick potentiometer and
joystick neutral switch systems at the input end and the left and right steering solenoids, solenoid cut relay, and
caution relay systems at the output end.

F. Network communication with main monitor:

If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality to the main
monitor through the network. (The joystick control system carries out control with the same controller as the work
equipment control system, so the network communication circuit is used in both systems.)

3. Functions of equipment at output end

A. Left, right steering solenoid valve:

This receives the signal from the controller and drives the solenoid to control the solenoid valve output pressure
effortlessly.

B. Steering neutral interlock relay:

This receives the signal from the controller and drives the solenoid to drive the neutral safety relay when the engine is
started.

WA500-3H 20-219
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM
12
C. Solenoid cut relay:
This receives the signal from the controller and drives the solenoid to switch the circuit at the return side of the
steering solenoid ON-OFF.

D. Caution relay:
This receives the signal from the controller and drives the relay to switch the alarm buzzer circuit ON-OFF.

4. Main monitor display

For details, see MAIN MONITOR SYSTEM.

20-220 WA500-3H
TROUBLESHOOTING METHOD OF DISPLAYING ACTION AND
12
METHOD OF DISPLAYING ACTION AND FAILURE CODE
1. Outline
The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of
the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals
between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine
controller uses a special parallel signal.)

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 three
types of action code: E00, E0N + CALL (E0N and CALL are
displayed alternately), 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.

A. A total of 9 failure codes can be saved in memory.

B. The data that is saved to memory is as follows:

i. Failure code

ii. Time elapsed since failure (up to 1000 hours)

C. The failures are saved in the order that they occur. If a failure code
already exists in the memory, the repeat failure code is not saved.

D. If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved.
It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the
main monitor set switch.

WA500-3H 20-221
TROUBLESHOOTING
12
5. Switch operation procedure actuation
Switch operation
Trouble data memory mode display
1. Stop engine
2. Turn starting switch ON
3. Push operation mode switch (1) and
head lamp switch (2) simultaneously
and keep pressed for at least 5
seconds.
Going to next failure code
4. Press head lamp switch (2).
Clearing failure code
5. Keep rear lamp switch (3) pressed
for at least 2 seconds.
Quitting trouble data memory display
mode
6. Push operation mode switch (1) and
head lamp switch (2) simultaneously
and keep pressed for at least 5
seconds. Or start the engine.
20-222
METHOD OF DISPLAYING ACTION AND
Actuation
The failure code is displayed on
the speedometer display and
the time elapsed since failure is
displayed on the action code
display.
If there is no failure, the
speedometer display shows
[CC] and the action code
display shows [0000].
The failure code and time
elapsed since failure are
displayed in turn (when this is
done, the failure code for the
latest failure is displayed first).
If the failure still exists, the
display flashes; if the failure
has been restored, the display
lights up.
The failure and elapsed time on
the display are cleared.
If the failure still exists, the
failure code is not cleared.
The display returns to the
normal display.
WA500-3H
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE
12
CHART OF ACTION CODES, FAILURE CODES AND RE-ENACTION
• After an error occurs, turn starting switch OFF and if the display goes out, it is possible to re-enact the problem as follows.
• For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING SELF
DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY.
• Re-enaction marks:
★ Turn starting switch ON (with engine stopped)
❑ Start engine
■ Carry out operation to actuate actuator

TRANSMISSION CONTROLLER
TRANSMISSION CONTROL SYSTEM

Main Failed system Re-enaction

monitor Failure Alarm
Item Short Discon- Short Discon- Memory
action code buzzer
code circuit nection circuit nection

None 10 Back-up lamp O O ■ ★ O X

12 F ECMV solenoid O O ❑ ■ O O

13 R ECMV solenoid O O ❑ ■ O O

14 1st ECMV solenoid O O ❑ ■ O O

CALL
15 2nd ECMV solenoid O O ❑ ■ O O

16 3rd ECMV solenoid O O ❑ ■ O O

17 4th ECMV solenoid O O ❑ ■ O O

E00 19 Joystick directional switch O O ❑ ■ O X

CALL 20 Directional switch signal O O ★ ★ O O

None 21 Range switch signal O O ★ ★ O X

22 Travel speed sensor X O ★ ★ O O

E00
23 Engine speed sensor O O ❈ ★ O X

None 24 EEP ROM abnormality ★ ★ O X

E01+
25 Transmission oil temperature sensor O X ★ ★ O O
CALL

26 F ECMV fill switch O X ❑ ❑ O O

27 R ECMV fill switch O X ❑ ❑ O O

28 1st ECMV fill switch O X ❑ ❑ O O

CALL
29 2nd ECMV fill switch O X ❑ ❑ O O

30 3rd ECMV fill switch O X ❑ ❑ O O

31 4th ECMV fill switch O X ❑ ❑ O O

32 F, R ECMV fill switch X O ■ ■ O X

E00
33 1st, 2nd, 3rd, 4th ECMV fill switch X O ■ ■ O X

★ E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.

WA500-3H 20-223
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE
12
ECSS CONTROL SYSTEM
Main Failed system Re-enaction
monitor Failure Alarm
Item Short Discon- Short Discon- Memory
action code buzzer
code circuit nection circuit nection

None d0 ECSS relay O O ■ ★ O X

JOYSTICK CONTROLLER

Main Failed system Re-enaction

monitor Failure Alarm
Item Memory
action code Short Discon- Short Discon- buzzer
code circuit nection circuit nection

None 56 Caution relay O O ★ ■ O X

57 Steering solenoid (R) O O ■ ■ O O

58 Steering solenoid (L) O O ■ ■ O O

59 Steering solenoid (R) O O ★ ★ O O

CALL
60 Steering solenoid (L) O O ★ ★ O O

61 Cut relay (sit solenoid) O O ★ ■ O O

62 Neutral switch O O ★ ★ O O

E00 63 Potentiometer O O ★ ★ O X

★ E59 and E60 cannot be distinguished, so they are issued at the same time.
★ Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.

ENGINE CONTROLLER
Remark
See ENGINE SHOP MANUAL for engine fault codes.

Main
monitor Failure
Item
action code
code

Shuts down engine

CALL 91
See engine controller display and ENGINE SHOP MANUAL

E00 91 See engine controller display and ENGINE SHOP MANUAL

Move to safe location

E01 91
See engine controller display and ENGINE SHOP MANUAL

20-224 WA500-3H
TROUBLESHOOTING
12
ACTION CODE TABLE.
Transmission control system
Action
code
Problem system
Disconnection in travel
speed sensor system
Disconnection, short
E00 circuit, or abnormality in
system engine speed
sensor
Disconnection in fill
switch
E01 + Short circuit in
CALL transmission oil
temperature sensor
Short with ground in fill
switch
Disconnection, short
circuit with ground, or
short circuit in shift lever
system
CALL Disconnection, short
circuit with ground, or
short circuit in F,R ECMV
solenoid system
Disconnection, short
circuit with ground, or
short circuit in speed range
ECMV solenoid system
WA500-3H
CHART OF ACTION CODES, FAILURE
Joystick control system
Action
Action by operator
buzzer
Action of machine Problem system Action of machine
Automatic gear shifting Disconnection, Shifts to neutral Normal manual
not carried out (changes to short circuit with (possible to switch to gear shifting
manual gear shifting) ground, or short manual) possible
circuit in joystick
FNR signal system
Engine speed taken as Normal operation
2100 rpm (there is shock No possible but there
--- ---
when shifting gear) is shock when
shifting gear
Clutch engaged with out Normal operation
fill signal (there is shock possible but there
--- ---
when shifting gear) is shock when
shifting gear
Suitable gear shifting data Travel under own
for transmission oil power possible,
temperature cannot be --- --- Yes move to safe place
selected (there is shock then call for service
when shifting gear)
Shifts to neutral, travel
impossible (modulation --- ---
output OFF)
Shifts to neutral, travel
impossible (controller
--- ---
input judged as N)
Stop machine
immediately, turn
Shifts to neutral, travel Yes starting switch
impossible (ECMV OFF, then call for
--- --- service
output OFF)
Shifts to neutral, travel
impossible (ECMV
--- ---
output OFF)
20-225
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12
TRANSMISSION CONTROLLER LED DISPLAY
The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and input/output
errors. The display shows two characters at the same time, and changes these in turn to give the display.

When the engine is started, “Program part No. display mode" appears, followed by "Output speed range display mode". If
there is any abnormality in the controller, it changes to "Troubleshooting mode". The failure mode is saved to memory by the
main monitor.

1. Method of displaying failure codes for transmission controller

20-226 WA500-3H
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12
Table 1 (Output speed range display mode)
Display Content Display Content

0.1. NEUTRAL, 1st F.4. FORWARD, 4th

0.2. NEUTRAL, 2nd A.1. REVERSE, 1st

0.3. NEUTRAL, 3rd A.2. REVERSE, 2nd

0.4. NEUTRAL, 4th A.3. REVERSE, 3rd

F.1. FORWARD, 1st A.4. REVERSE, 4th

F.2. FORWARD, 2nd F.F. Neutral safety condition

F.3. FORWARD, 3rd

WA500-3H 20-227
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DIS-
12

MEMORANDUM

20-228 WA500-3H
 TROUBLESHOOTING OF ECSS (D MODE)

ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)

JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
D-1 ECSS DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
A. ERROR CODE (d0) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
B. NO ABNORMALITY DISPLAY IS GIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
1. DOES NOT WORK AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
D-2 ECSS CANNOT BE CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407

WA500-3H 20-401
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER
12
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
ECSS Control System

Failure code Abnormal system Nature of abnormality

1. ECSS relay.
2. Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between transmission
d0 ECSS relay controller C1 (female) (3) and ECSS relay L90 (1).
3. Defective contact or disconnection in wiring harness between ECSS relay
L90 (female) (2) and chassis ground.
4) Defective transmission controller.

Action by Problem that

controller when appears on machine Troubleshooting
Condition when normal (voltage, current, resistance)
abnormality is when there is code
detected abnormality
1) Resistance of relay coil: 200 - 400Ω
2) Resistance of wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 Swaying (pitching,
(female) (1): Max. 1Ω bouncing) of
ECSS function: D-1
3) Voltage between transmission controller C1 (3) and machine when
OFF a)
chassis ground: Less than 1 V (Command OFF); 20 traveling at high
V or above (Command ON). speed (2nd - 4th)
4) Resistance of wiring harness between ECSS relay
L90 (female) (2) and chassis ground: Max. 1

20-402 WA500-3H
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER
12

MEMORANDUM

WA500-3H 20-403
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
12
D-1 ECSS DOES NOT WORK
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Carry out troubleshooting with the starting switch ON.
• Check that the ECSS switch on the main monitor is ON.
A. ERROR CODE (D0) IS DISPLAYED
Cause Remedy
4 Yes
Defective ECSS controller Replace
Yes Is resistance between
L90 (female) (2) and
chassis normal?
1) Max. 1Ω. Defective contact or
3 disconnection in wiring Repair or
2) Turn starting switch
OFF. No harness between L90 replace
Yes Is resistance between (female (2) and chassis.
L90 (female) (1) and 3) Disconnect L90.
chassis normal?
1) Max. 1Ω.
2) Turn starting switch
OFF. Short circuit with ground
2 in wiring harness between Repair or
3) Disconnect L90
and C1. No C1 (female) (3) and L90 replace
Is resistance between (female) (1) and chassis
L90 (female) (1) and
Yes chassis normal when
C1 (male) (3) is
1 grounded to chassis?
Is troubleshooting code 1) Max. 1Ω. Defective contact or
displayed when L90 is 2) Turn starting switch disconnection in wiring Repair or
replaced with another OFF. harness between C1 replace
No (female (3) and L90
relay of the same type? 3) Disconnect L90 (female (1)
and C1.
1) Turn starting switch
OFF.
2) Interchange with
another relay of same Defective ECSS relay Replace
type. No
3) ECSS switch: ON

20-404 WA500-3H
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
D-1 A. Related electrical circuit diagram

WA500-3H 20-405
TROUBLESHOOTING D-1 ECSS DOES NOT WORK
12
B. NO ABNORMALITY DISPLAY IS GIVEN
1. DOES NOT WORK AT ALL
• Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
Cause Remedy
2 Yes
Defective ECSS controller Replace
Yes Is voltage between C3B
(9) and chassis normal?
1 Go to troubleshooting
Defective main monitor of main monitor
Is resistance between 1) Max. 1Ω. No
L06 (female) (7) and 2) Turn starting switch
chassis normal when ON.
C3B (male) (9) is 3) Main monitor ECSS
switch: ON. Defective contact or
grounded to chassis? disconnection in wiring
1) Max. 1Ω. No harness between L06 Repair or replace
2) Turn starting switch (female (7) and C3B
(female (9)
OFF.
3) Disconnect L06.

D-1 B. Related electrical circuit diagram

20-406 WA500-3H
TROUBLESHOOTING D-2 ECSS CANNOT BE CANCELED
12
D-2 ECSS CANNOT BE CANCELED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes
Defective ECSS controller Replace
Yes Is voltage between C3B
(female) (9) and chassis
1 normal?
Defective main monitor Go to troubleshooting
1) 20 - 30 V No of main monitor
Is resistance between 2) Turn starting switch
C3B (female) (9) and ON.
chassis normal? 3) Main monitor ECSS
switch: OFF. Short circuit with ground
in wiring harness between Repair or replace
1) Max. 1Ω. No C3B (female) (9) and L06
2) Turn starting switch (female) (7)
OFF.
3) Disconnect L06.

D-2. Related electrical circuit diagram

WA500-3H 20-407
TROUBLESHOOTING D-2 ECSS CANNOT BE CANCELED
12

MEMORANDUM

20-408 WA500-3H
 TROUBLESHOOTING OF CHASSIS
ELECTRICAL SYSTEM (E MODE)

Remark
Troubleshooting of the ENGINE electrical system (E MODE) is found in the ENGINE SHOP MANUAL.

E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502

A. STARTING MOTOR DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
B. STARTING MOTOR TURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
E-2 ENGINE DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
E-5 PARKING BRAKE DOES NOT HAVE EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON
(ACTUATED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT
WORK AS EMERGENCY BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON . . . . . . . . . . . . . . . 20-520
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS
APPLIED (BUT PARKING BRAKE WORKS NORMALLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
E-9 KICK-DOWN SWITCH DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING
NORMAL GEAR SHIFT OPERATIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
B. KICK-DOWN IS NOT CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
E-10 BOOM KICK-OUT CANNOT BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-530
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-16 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533

WA500-3H 20-501
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
E-1 ENGINE DOES NOT START
• When connecting or disconnecting T-adapter (or socket adapter) or short connector to carry out checks, always turn the
starting switch OFF before starting.
• When connecting T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
A. STARTING MOTOR DOES NOT TURN

Yes
a
3
Yes Is voltage between
starting motor
terminal (B) and
chassis normal? Yes
b
1) 20 - 30 V
2) Turn starting
switch OFF. 5
Yes Is voltage between
battery relay terminals
and chassis normal?
1) 20 - 30 V.
2) Turn starting switch
ON.
3) Check voltage
2 between chassis and
both terminals c
Yes Is there continuity connected by thick No
cable.
between starting
motor terminal (E) 4
and chassis?
Does battery relay
make sound of
1) Turn starting No actuation?
switch OFF.
1) Starting switch
ON↔OFF.
Yes
d
6

Is voltage between
both connection
1 terminals of R12
No and R13 of
Is voltage between battery relay
E13 (female) (1) normal?
and chassis
normal? 1) 20 - 30 V
2) Turn starting
1) 20 - 30 V switch OFF.
2) Disconnect E13. e
3) Directional No
lever: Neutral
4) Turn starting
switch to
START.

f
No

g
No

20-502 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12

Cause Remedy

a Defective starting motor Replace

Defective contact or
b disconnection in cable Repair or
between battery relay and replace
starting motor

• If answer is NO for
both terminals:
Defective contact or
disconnection in
wiring harness
c between battery and Repair or
replace
battery relay
• If answer is NO for
one terminal:
Defective battery
relay

d Defective battery relay Replace

Defective contact or
disconnection in wiring
Yes harness between starting Replace
switch terminal BR - L09
8 (2) - LR4 (9) - R03 (diode)
(2), (1) - R12 female)
Yes Is resistance between
R13 (female) and
7 chassis normal?
Is voltage between 1) Max. 1Ω. Defective contact or
e starting switch 2) Turn starting switch disconnection in wiring Repair or
terminal BR and OFF. No harness between R13 and replace
chassis normal? 3) Disconnect R13. chassis ground
1) 20 - 30 V
2) Turn starting switch
ON.
Defective battery relay Replace
No

Defective contact or Repair or

f disconnection in starting replace
motor ground cable

g Go to A on next page -

WA500-3H 20-503
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12

Yes
a

Yes
b

11
Yes Is voltage between 13 Yes
L57 (female) (5) c
9 and chassis normal? Yes Is voltage between
starting switch
Does starting 1) 20 - 30 V. terminal C and
motor rotate 2) Disconnect 12 chassis normal?
A when neutral L57. d
relay is 3) Turn starting Is voltage between 1) 20 - 30 V. No
replaced? switch to starting switch 2) Turn starting
START. terminal B and switch to START.
1) Replace No chassis normal?
neutral relay
(L57) with 1) 20 - 30 V.
stop lamp 2) Turn starting e
relay (L53). switch OFF. No
2) FR lever:
Neutral
3) Turn starting
switch to
START. 16 Yes
f
10 Yes Is voltage between
L04 (3) and chassis
Is voltage between normal?
L57 (female) (1)
No and (2) normal? 1) 20 - 30 V.
2) Connect T- g
1) Disconnect L57. 15 adapter to L04. No
2) Directional 3) Directional lever:
lever: Neutral Yes Is voltage between N Yes
3) Turn starting 4) Turn starting
switch to L04 (female) (1) switch ON. h
START. and chassis normal? 18
1) 20 - 30 V. Yes Are both voltages
2) Disconnect L04. between battery
3) Turn starting relay terminals
switch ON. and chassis
normal?
1) 20 - 30 V.
2) Turn starting i
17 switch ON. No
3) Check voltage
Does battery relay of both lines
make sound of between
No actuation? chassis and 2
terminals
14 1) Starting switch where thick
Yes
ON↔OFF. cable is j
Is resistance connected.
between L57
No (female) (2) and
chassis normal? 19
1) Max. 1Ω. Are both voltages
2) Turn starting between battery
switch OFF. No relay R12 and
3) Disconnect L57. R13 connection
terminals normal?
1) 20 - 30 V.
2) Turn starting
switch OFF.
k
No

l
No

20-504 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
Cause Remedy

a Defective neutral relay Replace

Defective contact or
b disconnection in wiring
harness between L57 (female) Repair or
(3) - LR4 (8) - R01, R02 replace
(diode) - ER1 (10) - E13
(female) (1)
Defective contact or
disconnection in wiring
Repair or
harness between starting
replace
c switch terminal C - L09 (3) -
L57 (female) (5)

d Defective starting switch Replace

Defective contact or
disconnection in wiring
harness between starting
Repair or
e switch terminal B - L09 (1) -
replace
FS3 (4) - fuse I-12, FS3 (6) -
LR5 (1) - R17 - slow blow
fuse 30A - battery relay

f Defective contact or
disconnection in wiring Repair or
harness between L04 (female) replace
(3) and L57 (female) (1)

Defective directional lever

g switch Replace

Defective contact or
h disconnection in wiring har-
ness between battery relay - Repair or
slow blow fuse 80A - R15 - replace
LR6 (1) - FS1 (2) fuse I-9 -
FS2 (8) - L04 (female) (1)
• If answer is NO for
both terminals:
Defective contact or
disconnection in
wiring harness
i between battery and Repair or
replace
battery relay
• If answer is NO for
one terminal:
Defective battery
relay

j Defective battery relay Replace

Defective contact or
disconnection in wiring
Yes harness between starting Repair or
switch terminal BR - L09 (2) - replace
21 LR4 (9) - R03 (diode) (2), (1)
- R12 (female)
Yes Is resistance between
R13 (female) and chassis
20 normal?

Is voltage between starting 1) Max. 1Ω. Defective contact or

2) Turn starting switch disconnection in wiring Repair or
k switch terminal BR and
harness between R13 and replace
chassis normal? OFF. No
3) Disconnect R13. chassis ground
1) Turn starting switch
ON.
2) 20 - 30 V.
Defective starting switch Replace
No

Defective contact or
disconnection in wiring Repair or
l harness between L57 (female) replace
(2) - LR5 (2) - chassis ground

WA500-3H 20-505
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
B. STARTING MOTOR TURNS

Yes
a

4 Yes
b
Yes
Is resistance between
E03 (female) (8) and
chassis normal?
c
1 1) Max. 1Ω. No
2) Turn starting
3 switch OFF.
Does engine stop 3) Disconnect E03.
motor work?
Yes Is voltage between Yes
E03 (7) and chassis d
1) Turn starting normal?
switch ON ↔
OFF and check 1) 20 - 30 V.
visually. 2) Connect T-
adapter to E03. Yes
3) Turn starting e
switch ON. 5
7
Does engine stop
No motor when engine Yes Is resistance
stop relay is between L62
replaced (female) (2) and
chassis normal?
2 1) Replace engine 6 1) Max. 1Ω.
stop relay (L62) 2) Turn starting
Is voltage between with stop lamp Is voltage between switch ON.
E03 (female) (4) relay (L53). L62 (female) (1) 3) Disconnect f
No and chassis normal? 2) Turn starting No and chassis normal? L62. No
switch ON ↔
1) 20 - 30 V. OFF and check 1) 20 - 30 V.
2) Disconnect E03. visually. 2) Disconnect L62.
3) Turn starting 3) Turn starting
switch OFF. switch ON.

g
No

h
No

20-506 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12

Cause Remedy

Defective adjustment of
a wire between engine stop Replace
solenoid and lever

b Defective engine stop Replace

solenoid

Defective contact or
disconnection in wiring
c harness between E03 (female) Repair or
replace
(8) - ER2 (5) - ER1 (10) -
chassis ground

d Defective engine stop Replace

relay

8 Yes Defective engine stop

solenoid Replace
Is resistance between
e E03 (female) (5) and
(7) normal? Defective contact or
disconnection in wiring
1) Turn starting switch harness between E03 (female) Repair or
ON. (5) - ER2 (3) - LR3 (5) - L62
2) Disconnect E03. No (female) (5), or between E03 replace
(female (7) - ER2 (4) - LR3
(6) - L62 (female) (3)

Defective contact or
disconnection in wiring Repair or
f harness between L62 (female) replace
(2) chassis ground

Defective contact or
disconnection in wiring Repair or
g harness between L62 (female) replace
(1) and L09 (female) (2)

Blown fuse I-14, or defective

contact or disconnection in
Repair or
h wiring harness between F2
(female) (11) - LR3 (3) - ER2 replace
(1) - E03 (female (4)

WA500-3H 20-507
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12
E-1 Related electrical circuit diagram

20-508 WA500-3H
TROUBLESHOOTING E-1 ENGINE DOES NOT START
12

MEMORANDUM

WA500-3H 20-509
TROUBLESHOOTING E-2 ENGINE DOES NOT STOP
12
E-2 ENGINE DOES NOT STOP
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
Cause Remedy
Yes Defective adjustment
between engine stop motor Adjust
1 and stop lever

Does engine stop motor Yes Defective engine stop

work? motor Replace

1) Turn starting switch 2

ON ↔ OFF and check
Is voltage between Defective contact or
visually. disconnection in wiring
E03 (7) and (8) harness between E03 (female)
No normal? Yes (3) - ER2 (2) - LR3 (4) - L62 Repair or
1) 20 - 30 V. (female) (6), or between L62 replace
3 (female) (3) - LR3 (6) - ER2
2) Connect T-
adapter to E03, (4) - E03 (female) (7), or
Is voltage between defective relay L62)
engine stop E03 (3) and (8)
motor connector No normal?
(8 pin).
3) Turn starting 1) 20 - 30 V.
switch OFF. 2) Turn starting 4 Yes Defective engine stop
switch OFF. motor Replace
3) Connect T- Is voltage between
adapter to E03. E03 (4) and (8)
No normal?
Defective contact or
1) 20 - 30 V. disconnection in wiring
2) Connect T-adapter harness between E03 (female) Repair or
to E03. No (4) - ER2 (1) - LR3 (3) - FS2 replace
(female) (11), or blown fuse
I-14

20-510 WA500-3H
TROUBLESHOOTING E-2 ENGINE DOES NOT STOP
12
E-2 Related electrical circuit diagram

WA500-3H 20-511
TROUBLESHOOTING E-3 ENGINE STOPS WHEN MACHINE IS
12
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING
• Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
Cause Remedy
1 Yes Defective adjustment
between engine stop motor Adjust
and stop lever
Does engine stop motor
work?
2 Yes Defective engine stop
motor Replace
1) Turn starting switch
ON ↔ OFF and Does voltage
between E03 (7) and
check visually. No 3 Yes
(8) switch between 0 Defective engine stop Replace
V and 20 - 30 V? Is voltage between L62 relay
(female) (2) and
1) Connect T- No (female) (1) normal?
adapter to E03. Defective contact or
2) Turn starting 1) 20 - 30 V. disconnection in wiring
switch ON ↔ 2) Disconnect L62 harness between starting
Repair or
OFF. (engine stop relay. No switch terminal BR - L09 (2) - replace
3) Turn starting switch L62 (female) (1)
ON.

20-512 WA500-3H
TROUBLESHOOTING E-3 ENGINE STOPS WHEN MACHINE IS
12
E-3 Related electrical circuit diagram

WA500-3H 20-513
TROUBLESHOOTING E-5 PARKING BRAKE DOES NOT HAVE EF-
12
E-5 PARKING BRAKE DOES NOT HAVE EFFECT
• When carrying out troubleshooting of the brake system, stop the machine on flat ground.
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA().
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS
TURNED ON (ACTUATED)
Cause Remedy
Yes Defective parking brake
switch Replace
1
Does connection
become normal when
L01 is disconnected? Yes Contact of wiring harness Repair or
at L01 (female) (2) end replace
1) Start engine 2 and (3) end
(charge brake oil
pressure). Is resistance between
L01 (female) (2) and
No (3) normal? 3 Yes Defective parking brake Replace
1) Disconnect L01. Is voltage between solenoid
2) Turn starting CN10 (female) (1) and
switch OFF. No chassis normal?
3) Disconnect L58.
4) Disconnect L59. 1) Max. 1 V.
2) Start engine. Contact of wiring harness Repair or
(Charge brake oil No at L01 (female) (2) end replace
pressure).
3) Turn parking brake
switch ON.

B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS

(DOES NOT WORK AS EMERGENCY BRAKE)
Cause Remedy
1 Yes Defective parking brake
switch (B09) Replace
Does condition become
normal when B09 is
disconnected? 2 Yes Defective parking brake
switch (B10) Replace
1) Turn starting switch Does condition become
ON. normal when B10 is
2) Turn parking brake No disconnected?
switch ON↔OFF. Defective parking brake
solenoid Replace
1) Turn starting switch No
ON.
2) Turn parking brake
switch ON↔OFF.

20-514 WA500-3H
TROUBLESHOOTING E-5 PARKING BRAKE DOES NOT HAVE EF-
12

MEMORANDUM

WA500-3H 20-515
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
• When carrying out troubleshooting of the brake system, stop the machine on flat ground.
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.

2 Yes
a
Yes Is resistance between
CN10 (female) (2)
and chassis normal?
1) Max. 1Ω.
2) Turn starting b
switch OFF. No
3) Disconnect L59.
Yes
c
1 4
Yes Does connection Yes
Is voltage between become normal d
CN10 (female) (1) when parking brake
and chassis normal? safety relay is
replaced?
1) 20 - 30 V. 1) Replace parking
2) Start engine. brake safety relay
(Charge brake oil (L59) with stop
pressure). lamp relay (L53).
2) Start engine.
(Charge brake oil
3 pressure)

Is continuity of L01 5
(male) (1)(2)(3) as
No shown in Table 1. Does condition
become normal
1) Turn starting No when B09 and B10
switch OFF. are connected to
2) Operating parking short connector?
brake switch
ON/OFF. 1) Connect short
3) Disconnect L01. connector to B09
(female) and B10
(female).
2) Start engine.
(Charge brake oil
pressure) Yes
e

7
Yes Is resistance
between L59
(female) (1) and
(3) normal?

1) Max. 1Ω
2) Turn starting
6 switch OFF.
3) Disconnect L59.
Is voltage between
L59 (female) (5) f
No and chassis normal? No
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Disconnect L59.

g
No

h
No

20-516 WA500-3H
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
Table 1
Operation Between (2) - (3) Between (1) - (3)

ON (Parking) Min. 1 MΩ Max. 1 Ω

OFF (Travel) Max. 1 Ω Min. 1 MΩ

Cause Remedy

a Defective parking brake Replace

solenoid

Defective contact or
disconnection in wiring Repair or
harness between CN10 replace
b (female) (2) and chassis

c Defective parking brake Replace

safety relay

d Defective parking brake Replace

switch

Defective contact or
Yes disconnection in wiring
harness between B10 (female) Repair
or
11 (2) - BR1 (8) - LR4 (14) - TH2 replace
(11) - CN10 (female)
10 Yes Is voltage between
B10 (female) (1) and
Yes Is voltage between chassis normal?
B09 (female) (1) and Defective contact or
chassis normal? 1) 20 - 30 V.
2) Turn starting switch disconnection in wiring Repair or
1) 20 - 30 V. ON. No harness between B09 (female) replace
2) Turn starting 3) Turn parking brake (2) and B10 (female) (1)
9 switch ON. switch ON↔OFF.
3) Turn parking 4) Disconnect B10.
Yes Is resistance between brake switch
L59 (female) (2) and ON↔OFF. Defective contact or
chassis normal? 4) Disconnect B09. disconnection in wiring
harness between B09 (female) Repair
or
1) Max. 1Ω. No (1) - BR1 (7) - LR4 (13) - L01 replace
2) Turn starting switch (female) (2)
8 OFF.
3) Disconnect L59.
e Is voltage between
L59 (female) (1) Defective contact or
and chassis disconnection in wiring Repair or
normal? No harness between L59 (female) replace
(2) and chassis
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Turn parking Defective contact or
brake switch disconnection in wiring
ON. harness between L59 (female) Repair or
4) Disconnect No (1) and L01 (female) (3), or replace
L59. between FS2 (female) (7) and
L01 (female) (1)

Defective contact or
disconnection in wiring Repair or
f harness between L59 (female) replace
(1) and L59 (female) (3)

Defective contact or
disconnection in wiring Repair or
g harness between L59 (female) replace
(5) and FS2 (7) - fuse I-9

h Defective parking brake Replace

switch

WA500-3H 20-517
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12
E-6 Related electrical diagram

20-518 WA500-3H
TROUBLESHOOTING E-6 PARKING BRAKE IS APPLIED WHEN
12

MEMORANDUM

WA500-3H 20-519
TROUBLESHOOTING E-7 PARKING BRAKE IS RELEASED WHEN
12
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS
TURNED ON
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOL( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.

Cause Remedy
Yes Defective parking brake
safety relay Replace
1

Is problem removed Yes Defective parking brake

when parking safety switch Replace
switch (L59) is 2
replaced?
Does it become
normal when L01 is
1) Replace parking No disconnected? Yes Contact of wiring harness Repair or
brake safety relay between L59 (5) and
(L59) with stop 1) Disconnect L01. (female) (3)(1) replace
3
lamp relay (L53). 2) Turn starting
2) Turn starting switch switch ON. Is there continuity
ON. 3) Start engine. between L59 (female)
3) Start engine. (Stop engine No (3) and (5)?
(Stop engine after after charging
charging brake oil brake oil 1) Turn parking brake
pressure) pressure) switch OFF. Contact of wiring harness Repair or
2) Turn starting switch between L01 (female) (1) replace
No and (2)
OFF.
3) Disconnect L59.

20-520 WA500-3H
TROUBLESHOOTING E-7 PARKING BRAKE IS RELEASED WHEN
12
E-7 Related electrical diagram

WA500-3H 20-521
TROUBLESHOOTING E-8 TRANSMISSION DOES NOT CHANGE TO
12
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN
PARKING BRAKE IS APPLIED (BUT PARKING BRAKE
WORKS NORMALLY)

Cause Remedy
1 Yes
Defective neutralizer relay Replace
Is voltage between
neutralizer relay L58
(female) (5) - chassis
normal? Short circuit with power
source in wiring harness Repair or
1) Max. 1 V. No between L58 (female) (5) replace
2) Disconnect neutralizer and C3A (female) (6)
relay L58.
3) Turn starting switch
ON.
4) Shift directional lever
between F, N, and R,
and check each
voltage.

20-522 WA500-3H
TROUBLESHOOTING E-8 TRANSMISSION DOES NOT CHANGE TO
12
E-8 Related electrical diagram

WA500-3H 20-523
TROUBLESHOOTING E-9 KICK-DOWN SWITCH DOES NOT WORK
12
E-9 KICK-DOWN SWITCH DOES NOT WORK
• When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
• When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
• After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to original
condition before going on to the next check.

A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY

DURING NORMAL GEAR SHIFT OPERATIONS)
Cause Remedy
4 Yes Repair or
Defective main monitor replace
3 Yes Is resistance between
L08 (male) (2), (4)
and GND normal? Defective transmission Repair or
Is resistance between
L08 (female) (2), (4)
2 Yes and GND normal 1) Max. 1Ω. No controller replace
when L15 (female) 2) Turn starting switch
(2) is grounded to OFF.
Is resistance between chassis? 3) Disconnect L08. Defective contact or
Yes C5 (female) (5) and disconnection in wiring Repair or
GND normal when
1) Max. 1Ω. No harness between L15 (female) replace
L15 (female) (1) is (2) and L08 (female) (2), (4)
grounded to chassis? 2) Turn starting switch
1 OFF.
3) Disconnect L15
Is resistance between 1) Max. 1 Ω and L08.
L15 (male) (1) and (2) 2) Turn starting switch 4) Ground L15
normal? OFF. (female) (2) to Defective contact or
3) Disconnect L15 chassis. disconnection in wiring Repair or
and C5. harness between L15 (female) replace
1) Max. 1Ω 4) Ground L15 No (1) and L5 (female) (5)
2) Turn starting switch (female) (1) to
OFF. chassis.
3) Disconnect L15.
4) Press kick-down Defective kick-down
switch. switch Replace
No

B. KICK-DOWN IS NOT CANCELED

Cause Remedy
Yes Defective kick-down
switch Replace
1
Does condition become 3 Yes Defective transmission Repair or
normal when L15 is controller replace
disconnected? Yes Is resistance between
L08 (female) (2), (4) -
GDN normal when C5 Defective contact, or short
(female) (5) is circuit in wiring harness
2 grounded to chassis? between C5 (female) (5) - L15 Repair or
1) Max. 1Ω. No (female) (1) and in wiring replace
Is voltage between harness between L15 (female)
2) Turn starting switch (2) - L08 (female) (2)
No L15 (female) (2), OFF.
L08 (female) (2), (4)
- GDN normal? 3) Disconnect C5 and L08.
4) Turn kick-down switch OFF.
1) Max. 1 V. 5) Ground C5 (female) (5) to chassis. Short circuit with power
2) Turn starting switch source in wiring harness Repair or
OFF. No between L15 (female) (2) - replace
3) Disconnect C5 and L08 (female) (2), (4)
L08.

20-524 WA500-3H
TROUBLESHOOTING E-9 KICK-DOWN SWITCH DOES NOT WORK
12
E-9 Related electrical diagram

WA500-3H 20-525
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
E-10 BOOM KICK-OUT CANNOT BE USED
• Before carrying out troubleshooting, check that all related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that fuse I (10) is normal. If it is blown, check for a short circuit with ground in the wiring harness between
fuse I (10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)

Yes
a

Yes
b

6
Yes Is voltage between
L49 (2) and
1 chassis ground
normal?
Does condition 5
become normal
when L49 is Yes Is voltage between 1) 20 - 30 V.
replaced with a F06 (1) and chassis 2) Turn starting c
relay of same type? ground normal? switch ON. No
3) Bring a screw-
1) Interchange with 1) 20 - 30 V. driver close to
a relay of same 2) Turn starting boom kick-out
type. 4 switch ON. proximity
switch.
Yes Is resistance
between F06
(female) (3) and
chassis ground d
normal? No

3 1) Max. 1Ω.
2) Turn starting
Yes Is resistance switch OFF.
between L16 3) Disconnect F06.
(female) (1) and (2)
normal?
2 1) 19 - 23 1Ω.
2) Disconnect L16. e
No
Is voltage between
No each pin of F06 as
shown in Table 1?
f
1) See Table 1. No
2) Turn starting
switch ON.
g
No

Table 1

When screwdriver is close When screwdriver is not close

Between (1) and (2) 20 - 30 V Max. 3 V

Between (1) and (3) 20 - 30 V 0 - 30 V

Between (2) and (3) Max. 3 V 20 - 30 V

20-526 WA500-3H
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12

Cause Remedy

a Defective boom relay Replace

Defective contact or
Yes disconnection in wiring Repair or
harness between L49 (female) replace
7 (5) and L16 (female) (1)

b Is resistance between
L16 (female) (2) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1) Max. 1Ω. No harness between L16 (female) replace
(2) - LR5 (2) - chassis ground
2) Turn starting switch
OFF.
3) Disconnect L16.
Defective contact or
disconnection in wiring
harness between L49 (female) Repair or
c (2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO6 (female)
(2)

Defective contact or
disconnection in wiring
harness between fuse I (10) -
FS2 (10) - L49 (female) (3), Repair or
d between FS2 (10) - LR2 (1) - replace
FR12 (1) - F06 (female) (1), or
between FS2 (10) - L32 (1) -
L33 (1) - L49 (female) (1)

Defective contact or
disconnection in wiring Repair or
e harness between F06 (female) replace
(3) and chassis ground

f Defective boom kick-out Replace

solenoid

g Defective boom Replace

proximity switch

WA500-3H 20-527
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12
E-10 Related electrical diagram

20-528 WA500-3H
TROUBLESHOOTING E-10 BOOM KICK-OUT CANNOT BE USED
12

MEMORANDUM

WA500-3H 20-529
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between
fuse I (10) - FS2 (10) - L48 (1) (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1).

Yes
a

Yes
b

6
Yes Is voltage between
L48 (2) and
1 chassis ground
normal?
Does condition 5
become normal
when L48 is Yes Is voltage between 1) 20 - 30 V.
replaced with a F05 (1) and chassis 2) Turn starting c
relay of same type? ground normal? switch ON. No
3) Bring a screw-
1) Interchange with 1) 20 - 30 V. driver close to
a relay of same 2) Turn starting bucket
type. 4 switch ON. positioner
proximity
switch.
Yes Is resistance
between F05
(female) (3) and
chassis ground d
normal? No

3 1) Max. 1Ω.
2) Turn starting
Yes Is resistance switch OFF.
between L17 3) Disconnect F05.
(female) (1) and (2)
normal?
2 1) 19 - 23 1Ω.
2) Disconnect L17. e
No
Is voltage between
No each pin of F05 as
shown in Table 1?
f
1) See Table 1. No
2) Turn starting
switch ON.
g
No

Table 1

When screwdriver is close When screwdriver is not close

Between (1) and (2) 20 - 30 V Max. 3 V

Between (1) and (3) 20 - 30 V 0 - 30 V

Between (2) and (3) Max. 3 V 20 - 30 V

20-530 WA500-3H
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12

Cause Remedy

a Defective bucket relay Replace

Defective contact or
Yes disconnection in wiring Repair or
harness between L48 (female) replace
7 (5) and L17 (female) (1)

b Is resistance between
L17 (female) (2) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1) Max. 1Ω. No harness between L17 (female) replace
(2) - LR5 (2) - chassis ground
2) Turn starting switch
OFF.
3) Disconnect L17.
Defective contact or
disconnection in wiring
harness between L48 (female) Repair or
c (2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO5 (female)
(2)

Defective contact or
disconnection in wiring
harness between fuse I (10) -
FS2 (10) - L48 (female) (3), Repair or
d between FS2 (10) - LR2 (1) - replace
FR12 (1) - F05 (female) (1), or
between FS2 (10) - L32 (1) -
L33 (1) - L48 (female) (1)

Defective contact or
disconnection in wiring Repair or
e harness between F05 (female) replace
(3) and chassis ground

f Defective bucket Replace

positioner solenoid

g Defective bucket Replace

proximity switch

WA500-3H 20-531
TROUBLESHOOTING E-11 ABNORMALITY IN BUCKET POSITION-
12
E-11 Related electrical diagram

20-532 WA500-3H
TROUBLESHOOTING E-12 ABNORMALITY IN LIGHTING UP OF
12
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP
• Go to Troubleshooting M-10.

E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP

• Go to Troubleshooting M-11

E-14 ABNORMALITY IN TRANSMISSION CUT-OFF

• Go to Troubleshooting M-12.

E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING

• Go to Troubleshooting M-13, M-14.

E-16 ABNORMALITY IN BUZZER

• Go to Troubleshooting M-15, M-18.

20-533 WA500-3H
TESTING AND ADJUSTING E-16 ABNORMALITY IN BUZZER
12

MEMORANDUM

20-534 WA500-3H
 TROUBLESHOOTING OF JOYSTICK STEERING
CONTROLLER SYSTEM (J MODE)

JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . . . . . . . 20-703

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
JOYSTICK CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN
OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN
OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT
RELAY OUTPUT) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING
NEUTRAL SIGNAL) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING
LEVER POTENTIOMETER SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-717
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
J-12 DISCONNECTION IN STEERING LEFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719

WA500-3H 20-701
TROUBLESHOOTING
12

MEMORANDUM

20-702 WA500-3H
TROUBLESHOOTING JUDGEMENT TABLE FOR JOYSTICK CON-
12
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM
RELATED PARTS

WA500-3H 20-703
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR

JOYSTICK CONTROLLER SYSTEM

Failure
Abnormal system Nature of abnormality
code

1. Defective caution relay

2. Short circuit with ground, defective contact, or disconnection in wiring harness
between work equipment controller L28 (female) (13) and JS8 (1)
56 Joystick caution relay system
3. Defective contact or disconnection in wiring harness between caution relay J8
(female) (2) and chassis ground
4. Defective work equipment controller

1. Defective R solenoid
2. Defective steering solenoid cut relay
3. Short circuit in wiring harness between work equipment controller L26 (female) (6)
and (16)

Steering (R) (right) solenoid Short circuit with ground, defective contact, or disconnection in the following wiring
57
system harness:
4. Wiring harness between work equipment controller L26 (female) (6) and R (2)
5. Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6. Wiring harness between steering solenoid cut relay JS9 (5) and R (1)
7. Defective work equipment controller

1. Defective L solenoid
2. Defective steering solenoid cut relay
3. Short circuit in wiring harness between work equipment controller L26 (female) (7)
and (16)

Steering (L) (left) solenoid Short circuit with ground, defective contact, or disconnection in the following wiring har-
58
system ness:
4. Wiring harness between work equipment controller L26 (female) (7) and L (2)
5. Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6. Wiring harness between steering solenoid cut relay JS9 (5) and L (1)
7. Defective work equipment controller

Short circuit with power source 1. Defective R solenoid

in wiring harness between 2. Short circuit with power source in wiring harness between work equipment
59
steering (R) (right) solenoid controller L26 (female) (6) and R (2)
system 3. Defective work equipment controller

Short circuit with power source 1. Defective L solenoid

in wiring harness between 2. Short circuit with power source in wiring harness between work equipment
60 controller L26 (female) (7) and L (2)
steering (L) (left) solenoid sys-
tem 3. Defective work equipment controller

20-704 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12

Problem that appears Trouble-

Action by controller
Condition when normal (voltage, current, resistance) on machine when shooting
abnormality is detected
there is abnormality code

1. Joystick caution relay: ON (voltage between L28 (15) and

chassis ground: 20 - 30 V)
2. Resistance of relay coil between work equipment controller
L28 (female) (13) and J chassis ground: 200 - 400
Joystick caution
3. Resistance of wiring harness between work equipment Caution output: OFF J-1
actuated
controller L28 (female) (13) and caution relay JS8 (female)
(1): Less than 1
4. Resistance of wiring harness between caution relay JS8
(female) (2) and chassis ground: Less than 1

1. Steering solenoid cut relay: ON (voltage between L26 (8)

and chassis ground: 20 - 30 V)
2. Resistance of steering R solenoid: 10 - 20
3. Resistance between work equipment controller L26
(female) (6), (16) and chassis ground: Min. 1M Steering R, L solenoid
output: OFF and steering Impossible to use
Resistance of the following wiring harness: Less than 1 solenoid cut relay output: joystick and joystick J-2
4. Wiring harness between work equipment controller L26 OFF and caution relay: caution actuated
(female) (6) - R (female) (2) OFF
5. Wiring harness between work equipment controller L26
(female) (16) - JS9 (female) (3)
6. Wiring harness between steering solenoid cut between JS9
(female) (5) and L (female (1)

1 Steering solenoid cut relay: ON (voltage between L26 (8)

and chassis ground: 20 - 30 V)
2. Resistance of steering L solenoid: 10 - 20
3. Resistance between work equipment controller L26
(female) (7), (16) and chassis ground: Min. 1M Steering R, L solenoid
output: OFF and steering Impossible to use
Resistance of the following wiring harness: Less than 1 solenoid cut relay output: joystick and joystick J-3
4. Wiring harness between work equipment controller L26 OFF and caution relay: caution actuated
(female) (7) - L (female) (2) OFF
5. Wiring harness between work equipment controller L26
(female) (16) - JS9 (female) (3)
6. Wiring harness between steering solenoid cut between JS9
(female) (5) and L (female (1)

Steering R, L solenoid
Joystick lever at neutral output: OFF and steering Impossible to use
Voltage between work equipment controller L26 (female) (6) solenoid cut relay output: joystick and joystick J-4
and chassis ground: Less than 1 V OFF and caution relay: caution actuated
OFF

Steering R, L solenoid
Joystick lever at neutral output: OFF and steering Impossible to use
Voltage between work equipment controller L26 (female) (6) solenoid cut relay output: joystick and joystick J-5
and chassis ground: Less than 1 V OFF and caution relay: caution actuated
OFF

WA500-3H 20-705
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12

Failure
Abnormal system Nature of abnormality
code

1. Defective steering solenoid relay

2. Short circuit with ground, defective contact, or disconnection in wiring harness
Steering solenoid. cut relay between work equipment controller L26 (female) (8) and JS9 (1)
61
system 3. Defective contact or disconnection in wiring harness between NEUTRAL SW (1)
and chassis ground
4. Defective work equipment controller

1. Defective joystick neutral SW

2. Short circuit with ground, defective contact, or disconnection in wiring harness
between work equipment controller L27 (female) (17) - D01 (2), (1) - NEUTRAL
62 Joystick neutral SW system SW (3)
3. Defective contact or disconnection in wiring harness between NEUTRAL SW (1)
and chassis ground
4. Defective work equipment controller

1. Defective boom angle potentiometer

2. Short circuit with power source, short circuit with ground, defective contact, or
disconnection in wiring harness between work equipment controller L27 (female)
(20) and JS7 (1)
3. Short circuit with power source, short circuit with ground, defective contact, or
63 Joystick potentiometer system disconnection in wiring harness between work equipment controller L27 (female)
(9) and JS7 (2)
4. Short circuit with power source, short circuit with ground, defective contact, or
disconnection in wiring harness between work equipment controller L27 (female)
(10) and JS7 (3)
5. Defective work equipment controller

20-706 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12

Problem that appears Trouble-

Action by controller
Condition when normal (voltage, current, resistance) on machine when shooting
abnormality is detected
there is abnormality code

Resistance between work equipment controller L27 (female) Steering R, L solenoid

(17) and chassis ground: Min. 1 M Less than 1 output: OFF and steering Impossible to use
solenoid cut relay output: oystick and joystick J-6
OFF and caution relay: caution actuated
OFF

Voltage between work equipment controller L27 (female) (20) Steering R, L solenoid
and L27 (9): 0.5 - 4.5 V (voltage when joystick is at neutral: output: OFF and steering Impossible to use
Approx. 2.5 V) solenoid cut relay output: joystick and joystick J-7
OFF and caution relay: caution actuated
OFF

1. Steering solenoid cut relay: ON (voltage between L26 (8)

and chassis ground: 20 - 30 V)
Steering R, L solenoid
2. Resistance of relay coil between work equipment controller
L28 (female) (8) and chassis ground: 200 - 400 output: OFF and steering Impossible to use
solenoid cut relay output: joystick and joystick J-8
3. Resistance of wiring harness between work equipment OFF and caution relay: caution actuated
controller L28 (female (8) and JS9 (female) (1)
OFF
4. Resistance of wiring harness between steering solenoid cut
relay JS9 (female) (2) and chassis ground: Less than 1

WA500-3H 20-707
TROUBLESHOOTING J-1 FAILURE CODE [56] (SHORT CIRCUIT,
12
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN
CAUTION RELAY OUTPUT) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting any connector
Cause Remedy
Yes
Defective joystick boom Replace
1 controller

3 Yes
Is resistance Defective contact or
between L28 Yes disconnection in wiring Repair or
(female) (18) and Is resistance between harness between JS8(1) replace
chassis normal? 2 JS8 (female) (2) and and JS1(15)
chassis normal?
1. Disconnect L28 Is resistance between Defective contact or
2. 200 - 400 Ω JS8 (male) (1) and disconnection in wiring
No (2) normal? 1. Disconnect JS8 No harness between JS8(2) - Repair or
2. Max. 1 Ω LGL(2) - L23 (female) replace
1. Disconnect JS8 (10)
2. 200 - 400 Ω
Defective caution lamp Replace
No relay

J-1 Related electrical circuit diagram

20-708 WA500-3H
TROUBLESHOOTING J-2 FAILURE CODE [57] (SHORT CIRCUIT IN
12
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT
SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick Replace
Yes Is resistance between controller
L26 (female) (6) and
(16) normal?
Short circuit in wiring
3 1. Min. 1 MΩ. harness between L26
2. Turn starting (female) (6) and CNR
Yes Is resistance between switch OFF. No (female) (2) and between Repair or
L26 (female) (16) 3. Disconnect L26. L26 (female) (16) and JS9 replace
and chassis normal? (female) (5) and CNR
(female) (1)
2 1. Min. 1 MΩ.
2. Turn starting
Yes Is resistance between switch OFF.
L26 (female) (6) and 3. Disconnect JS9 Short circuit with chassis
chassis normal? and L26 ground in writing harness Repair or
between L26 (female) (16) replace
1 1. Min. 1 MΩ. No and JS9 (female) (3)
2. Turn starting
is failure code switch OFF.
displayed when 3. Disconnect L26 Short circuit with chassis
JS9 is replaced and CNR No ground in writing harness Repair or
with other relay of between L26 (female) (6) replace
same type? and CNR (female) (2)

1. Turn starting
switch OFF. Defective steering Replace
2. Interchange No solenoid cut relay
with another relay
of same type.
3. Turn starting
switch ON.

J-2 Related electrical circuit diagram

WA500-3H 20-709
TROUBLESHOOTING J-3 FAILURE CODE [58] (SHORT CIRCUIT IN
12
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT
SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick Replace
Yes Is resistance between controller
L26 (female) (7) and
3 (16) normal? Short circuit in wiring
harness between L26
Yes Is resistance between 1. Min. 1 MΩ. (female) (7) and CNL
L26 (female) (16) 2. Turn starting (female) (2) and between Repair or
2 and chassis normal? switch) OFF. No L26 (female) (16) and JS9 replace
3. Disconnect L26. (female) (5) and CNL
Yes Is resistance between 1. Min. 1 MΩ. (female) (1)
L26 (female) (17) 2. Turn starting
1 and chassis normal? switch) OFF.
3. Disconnect JS9 Short circuit with chassis
Is failure code 1. Min. 1 MΩ. and L26. No ground in wiring harness Repair or
displayed when 2. Turn starting between L26 (female) (16) replace
JS9 is replaced switch) OFF. and JS9 (female) (30
with other relay of 3. Disconnect L26
same type? and CNL.
Short circuit with chassis
1. Turn starting No ground in wiring harness Repair or
switch OFF. between L26 (female) (7) replace
2. Interchange and CNL (female) (2)
with other relay of
same type.
3. Turn starting Defective steering Replace
switch ON. No solenoid cut relay

20-710 WA500-3H
TROUBLESHOOTING J-4 FAILURE CODE [59] (SHORT CIRCUIT IN
12
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT
SOLENOID (HOT END) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (6)
and chassis Short circuit with power
normal? source in wiring power
source in wiring harness
between L26 (female) (6) - Repair or
1. Max. 1V. No CNR (female) (2) or CNR replace
2. Turn starting (female) (1) - JS9 (female)
switch ON. (5)

WA500-3H 20-711
TROUBLESHOOTING J-5 FAILURE CODE [60] (SHORT CIRCUIT IN
12
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT
SOLENOID (HOT END) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (6)
and chassis Short circuit with power
normal? source in wiring power
source in wiring harness
between L26 (female) (7) - Repair or
1. Max. 1V. No CNL (female) (2) or CNL replace
2. Turn starting (female) (1) - JS9 (female)
switch ON. (5)

20-712 WA500-3H
TROUBLESHOOTING J-6 FAILURE CODE [61] (SHORT CIRCUIT,
12
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN
STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (2) and
Yes Is resistance between chassis normal?
L28 (female) (8) and Defective contact or
chassis normal? 1. Max. 1 Ω. disconnection in wiring
2. Turn starting harness between JS9 Repair or
2 1. Max. 1 MΩ. switch OFF. No (female) (2) - JS12 (2) - replace
2. Turn starting 3. Disconnect JS9. LR (3) - chassis ground
Yes Is resistance between switch OFF.
L28 (female) (8) and 3. Disconnect L26
chassis normal when and JS9.
JS9 (female) (1) is Short circuit with chassis
1 grounded to chassis? No ground in wiring harness Repair or
between L28 (female) (8) replace
1. Max. 1 Ω. and JS9 (female) (1)
Is failure code
displayed when 2. Turn starting
JS9 is replaced switch OFF. Defective contact or
with another relay 3. Disconnect L26 disconnection in wiring
of same type? and JS9. No harness between L28 Repair or
(female) (8) and JS9 replace
1. Turn starting (female) (1)
switch OFF.
2. Interchange
with another relay Defective steering Replace
of same type. No solenoid cut relay
3. Turn starting
switch ON.

WA500-3H 20-713
TROUBLESHOOTING J-7 FAILURE CODE [62] (SHORT CIRCUIT,
12
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• Turn the starting switch ON.
Cause Remedy
2 Yes
Defective joystick Replace
Yes Is resistance between steering controller
L27 9female) (17)
and chassis normal? 4 Yes Defective contact or
disconnection in wiring Repair or
1. disconnect L27. 3 Yes Is resistance between harness between JS6
2. Operate joystick JS6 (female) (1) and (female) (3) - D01 - L27 replace
1 lever fully to left or Is resistance between chassis normal? (female) 917)
right. JS6 9male) (1) and
Is resistance 3. Max. 1Ω. No (3) normal? 1. Disconnect JS6.
between L27 2. Max. 1 Ω. Defective contact or
(female) (17) and 1. Disconnect JS6. No disconnection in wiring Repair or
chassis normal? 2. Operate joystick harness between JS6 replace
lever fully to left or (female) (1) - JS12 (2) -
1. Disconnect L27. right. LR5 (3) - chassis ground
2. Max. 1Ω. 3. Max. 1Ω.
Defective neutral switch Replace
No
5 Yes
Short circuit with chassis
Is resistance between ground in wiring harness Repair or
JS6 9male) (1) and between JS6 (female) (3) - replace
No (3) normal? D01 - L27 (female) (17)

1. Disconnect JS6.
2. Max. 1Ω. Defective neutral switch Replace
No

20-714 WA500-3H
TROUBLESHOOTING J-8 FAILURE CODE [63] (SHORT CIRCUIT,
12
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DIS-
PLAYED
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
• After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
Replace,
Defective joystick adjust
Yes potentiometer, neutral neutral
position misaligned position
2 again
Yes Does voltage Short circuit with power
between L27 (20) source, short circuit with
and (9) change? 3 Yes ground, defective contact Repair or
or disconnection in wiring replace
1 1. Operate joystick Does voltage harness between L27
lever to left or right. between JS7 (male) (female) (20) and JS7
Is voltage between 2. 0.5 - 4.5 V. No (1) and (3) change? (female) (1)
L27 (10) and (9)
normal? 1. Turn starting
switch OFF. Defective joystick Replace
1. 4.9 - 5.1 V. 2. Disconnect JS7. No potentiometer
3. Operate joystick
lever to left and
right.
4. 0.2 - 5 kΩ.
Defective remote boom & Replace
No joystick steering controller

J-8 Related electrical circuit diagram

WA500-3H 20-715
TROUBLESHOOTING J-9 ABNORMALITY IN POWER SOURCE,
12
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Check that fuse I (11) is normal.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective joystick steering Replace
controller
Is voltage between
L26 (female) (8), Defective contact or
(18) and chassis disconnection in wiring
normal? No harness betwen L26 Repair or
(female) (8), (18) - L32 (1) replace
1. 20 - 30 V. - FS2 (10) - fuse I (11)
2. Turn starting
switch ON.

20-716 WA500-3H
TROUBLESHOOTING J-10 ABNORMALITY IN JOYSTICK STEER-
12
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL
SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Check that fuse I (11) is normal.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Yes
Defective joystick steering Replace
controller

1 3 Yes
Defective system cut-off Replace
Yes Is voltage between switch
Is voltage between JS3 (female) and
l27 (female) (14) 2 chassis normal? Defective contact or
and chassis disconnection in wiring
normal? 1. 20 - 30 V. No harness between fuse I Repair or
Is resistance between 2. Turn starting (11) - FS2 (10) - L32 91) - replace
1. 20 - 30 V. L27 (female) (14) switch ON. JS3 (female)
2. Turn starting and chassis normal
switch ON. No when S4 (male) is
grounded to chassis? Defective contact or
No disconnection in wiring
harness between L27 Repair or
1. Turn starting (female) (14) - JS5 (1), (2) replace
switch OFF. - S4 (male) or defective
2. disconnect S4 and joystick ON - OFF switch
L27.
3. Max. 1Ω

WA500-3H 20-717
TROUBLESHOOTING J-11 DISCONNECTION IN STEERING RIGHT
12
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (5) and
chassis normal when Defective contact or
Is resistance between CNR (female) (1) is disconnection in wiring
2 Yes L26 (female) (15) grounded to chassis? No harness between JS9 Repair or
and chassis normal (female) (5) and CNR replace
when JS9 (female) 1. Max. 1 Ω. (female) (1)
(3) is grounded to 2. Turn starting
Is resistance between chassis?
Yes L26 (female) (6) and switch OFF. Defective contact or
chassis normal when 3. Disconnect JS9. disconnection in wiring
1 CNR (female) (2) is 1. Max. 1 Ω. harness between L26 Repair or
grounded to chassis? 2. Turn starting (female) (16) and JS9 replace
switch OFF. No (female) (3)
Is resistance 3. Disconnect L26
between CNR 1. Max. 1 Ω. and JS9.
(male) (1) and (2) Defective contact or
2. Turn starting disconnection in wiring
normal? switch OFF. harness between L26 Repair or
3. Disconnect L26. 9female) (6) and CNR replace
1. Max. 1 Ω. No (female) (20
2. Turn starting
switch OFF.
3. Disconnect Defective joystick steering Replace
CNR. No right solenoid valve

20-718 WA500-3H
TESTING AND ADJUSTING J-12 DISCONNECTION IN STEERING LEFT
12
J-12 DISCONNECTION IN STEERING LEFT SOLENOID
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Cause Remedy
4 Yes
Defective joystick steering Replace
3 Yes Is resistance between controller
JS9 (female) (5) and
chassis normal when Defective contact or
Is resistance between CNL (female) (1) is disconnection in wiring
2 Yes L26 (female) (16) grounded to chassis? No harness between JS9 Repair or
and chassis normal (female) (5) and CNL replace
when JS9 (female) 1. Max. 1 Ω. (female) (1)
(3) is grounded to 2. Turn starting
Is resistance between chassis?
Yes L26 (female) (7) and switch OFF. Defective contact or
chassis normal when 3. Disconnect JS9. disconnection in wiring
1 CNR (female) (2) is 1. Max. 1 Ω. harness between L26 Repair or
grounded to chassis? 2. Turn starting (female) (16) and JS9 replace
switch OFF. No (female) (3)
Is resistance 3. Disconnect L26
between CNL 1. Max. 1 Ω. and JS9.
(male) (1) and (2) Defective contact or
2. Turn starting disconnection in wiring
normal? switch OFF. harness between L26 Repair or
3. Disconnect L26. 9female) (7) and CNL replace
1. Max. 1 Ω. No (female) (20
2. Turn starting
switch OFF.
3. Disconnect Defective joystick steering Replace
CNL. No right solenoid valve

WA500-3H 20-719
TESTING AND ADJUSTING J-12 DISCONNECTION IN STEERING LEFT
12

MEMORANDUM

20-720 WA500-3H
 TROUBLESHOOTING OF MAIN MONITOR
SYSTEM (M MODE)

M-1 MAIN MONITOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903

M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,
ALL LAMPS STAY LIGHTED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-904
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-905
M-4 ABNORMALITY IN SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R
WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAY F
WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-907
E. DOES NOT DISPLAY 1ST - 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-907
M-5 HIGH BEAM DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
M-7 ABNORMALITY IN PARKING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
B. PARKING LAMP DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
M-8 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-911
M-9 NIGHT LIGHTING DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
M-10 ABNORMALITY IN FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-914
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . 20-914
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . 20-914
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . 20-914
M-11 ABNORMALITY IN REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-916
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . . 20-916
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . 20-916
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . 20-916
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED,
CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE . . . . . . . . . . . . 20-918
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF,
MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION IS ACTUATED
WHEN PEDAL IS DEPRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF
SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED . . . . . . . . . . . . . . . . . . 20-918
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF
MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF) . . . . . . . . . . . . . . . . . . . 20-918
E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURN ON),
BUT CUT-OFF FUNCTION IS NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-919
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS
(INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN WHEN
DIRECTIONAL LEVER IS AT N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND
CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS

WA500-3H 20-901
TROUBLESHOOTING
AT POSITION OTHER THAN N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION
LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED . . . . . . . . . . . . . . 20-922
A. ACTUATED CONTINOUSLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
B. NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
M-15 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON
(FOR 3 SECONDS) (DURING SELF-CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
B. BUZZER ALWAYS SOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY . . . . . . . . . . . . . . . . . . . . 20-924
M-17 ABNORMALITY IN FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
A. DOES NOT ENTER FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY
MODE DOES NOT ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . 20-926
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 20-927
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . 20-927
B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-927
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY . . . . . . . . . . . . . . . . . . . . . 20-928
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . 20-928
B. EMERGENCY STEERING DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-928
M-21 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-929
M-22 ABNORMALITY IN ECSS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK . . . . . . . . . . . . . . 20-930
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) . . . . . . . 20-931

20-902 WA500-3H
TROUBLESHOOTING M-1 MAIN MONITOR DOES NOT WORK
12
M-1 MAIN MONITOR DOES NOT WORK
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.

Cause Remedy
Yes
Defective main monitor Replace
1
Is voltage between
L05 (1), (2) - (3) Defective contact or
normal? 2 Yes disconnection in wiring
harness between L05 Repair or
1. 20 - 30 V. (female) (1), (2) and FS2 replace
2. Turn starting Is resistance between (female) (9)
switch ON. No L05 (female) (3) and
chassis ground
normal?
Defective contact or
disconnection in wiring Repair or
1. Turn starting No harness between L05
switch OFF. (female) (3) and LR5 replace
2. Disconnect L05. (male) (3)
3. Max. 1 Ω.

M-1 Related electrical circuit diagram

WA500-3H 20-903
TROUBLESHOOTING M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
12
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.

Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (4) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
harness between L05 replace
1. 20 - 30 V. No (female) (4) and L57
2. Turn starting (female) (3)
switch to START.

M-2 Related electrical circuit diagram

20-904 WA500-3H
TROUBLESHOOTING M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
12
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Check that the gap between the speed sensor and gear is normal.

Cause Remedy
2 Yes
Defective main monitor Replace
Yes
Is resistance between
1 L07 (female) (1) and
(2) normal?
Defective contact or dis-
Is resistance connection L07 (female) Repair or
between CN3 1. 500 Ω - 1 kΩ. Yes (1), (2) - TM2 (9), (10) - replace
(male) (1) and (2) 2. Turn starting CN3 (female) (1), (2)
normal? switch OFF.
3. Disconnect L07.
1. 500 Ω - 1 kΩ.
2. Turn starting Defective speed sensor Replace
switch OFF. No
3. Disconnect
CN3.

M-3 Related electrical circuit diagram

WA500-3H 20-905
TROUBLESHOOTING M-4 ABNORMALITY IN SHIFT INDICATOR
12
M-4 ABNORMALITY IN SHIFT INDICATOR
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Check that the transmission shifts.
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (7) and
chassis ground Defective contact or dis-
normal? No connection in wiring har- Repair or
ness between L08 (female) replace
1. 20 - 30 V. (7) and L04 (female) (2)
2. Turn starting
switch ON.
3. Directional
lever: F

B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R

Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (8) and
chassis ground Defective contact or dis-
normal? No connection in wiring har- Repair or
ness between L08 (female) replace
1. 20 - 30 V. (8) and L04 (female) (4)
2. Turn starting
switch ON.
3. Directional
lever: R.

C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND

DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (8) and
chassis ground Short circuit with power
normal? No source in wiring harness
between L08 (female) (8) Repair or
1. 0 - 5 V. and L04 (female) (4) or replace
2. Turn starting defective transmission
switch ON. lever
3. Directional
lever: N

20-906 WA500-3H
TROUBLESHOOTING M-4 ABNORMALITY IN SHIFT INDICATOR
12
D.DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND
DISPLAY F WHEN DIRECTIONAL LEVER IS AT R
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L08 (7) and
chassis ground Short circuit with power
normal? No source in wiring harness
between L08 (female) (7) Repair or
1. 0 - 5 V. and L04 (female) (2) or replace
2. Turn starting defective transmission
switch ON. lever
3. Directional
lever: N

E. DOES NOT DISPLAY 1ST - 4TH

Cause Remedy
1 Yes See Troubleshooting of
transmission controller ---
system (T-mode)
Is there
abnormality in
S-NET? Defective main monitor Replace
No
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Speed lever: 1.

M-4 Related electrical circuit diagram

WA500-3H 20-907
TROUBLESHOOTING M-5 HIGH BEAM DOES NOT LIGHT UP
12
M-5 HIGH BEAM DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
2 Yes
Defective main monitor Replace
Yes
Is resistance between
1 L06 (female) (13)
and chassis ground Defective contact or dis-
normal? No connection in wiring har- Repair or
Is voltage L06 ness between L06 (female) replace
(12) and chassis 1. Max. 1 Ω. (13) and L02 (female) (3)
ground normal? 2. Turn starting switch OFF.
3. Disconnect L06.
4. Dimmer switch: HI beam Defective contact or dis-
1. 20 - 30 V. connection in wiring har- Repair or
2. Turn starting ness between L06 (female) replace
switch ON. No (12) and L02 (female) (2)

M-5 Related electrical circuit diagram

20-908 WA500-3H
TROUBLESHOOTING M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
12
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L06 (14) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L06 Repair or
(female) (14) and L03 replace
1. Repeats 0 V and 20 - 30 V. (female) (4)
2. Turn starting switch ON.
3. Turn LH turn signal ON.

B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP

Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L06 (15) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L06 Repair or
(female) (15) and L03 replace
1. Repeats 0 V and 20 - 30 V. (female) (3)
2. Turn starting switch ON.
3. Turn RH turn signal ON.

M-6 Related electrical circuit diagram

WA500-3H 20-909
TROUBLESHOOTING M-7 ABNORMALITY IN PARKING DISPLAY
12
M-7 ABNORMALITY IN PARKING DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP
Cause Remedy
3 Yes
Defective main monitor Replace
Yes
Is resistance between
2 CN19 (female) (2)
and chassis ground Defective contact or
normal? disconnection in wiring Repair or
Yes No harness between CN19
Is voltage between (female) (1) and chassis replace
1 L06 (11) and chassis 1. Max. 1 Ω. ground
ground normal? 2. Turn starting switch OFF.
3. Disconnect CN19. Defective contact or
Is resistance disconnection in wiring
between CN19 1. 20 - 30 V. No harness between L06 Repair or
(male) (1) and (2) 2. Turn starting (female) (11) - TM2 (7) - replace
normal? switch ON. CN19 (female) (1)
3. Turn parking
1. Max. 1 Ω. switch ON.
2. Disconnect Defective parking brake Replace
CN19. No indicator switch
3. Turn starting
switch ON.
4. Turn parking
switch ON.

B. PARKING LAMP DISPLAY STAYS LIT UP

Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
CN19 (1) and chas-
1 sis ground normal?
Short circuit with power
1. 0 - 2 V. No source in harness between Repair or
Is resistance 2. Turn starting L06 (female) (11) - TM2 replace
between CN19 switch ON. (7) - CN19 (female) (1)
(male) (1) and (2) 3. Turn parking
normal? switch OFF.
Defective parking brake Replace
1. Max. 1 Ω. No indicator switch
2. Disconnect
CN19.
3. Turn starting
switch ON.
4. Turn parking
switch OFF.

M-7 Related electrical circuit diagram

20-910 WA500-3H
TROUBLESHOOTING M-8 NOT USED
12
M-8 NOT USED

WA500-3H 20-911
TROUBLESHOOTING M-9 NIGHT LIGHTING DOES NOT LIGHT UP
12
M-9 NIGHT LIGHTING DOES NOT LIGHT UP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the lamp bulbs are not blown.
● Check that fuse I - 6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness
between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (16) and
chassis ground Defective contact or
normal? No disconnection in wiring Repair or
harness between L05 replace
1. 20 - 30 V. (female) (16) and FS2 (5)
2. Turn starting switch ON.
3. Turn small lamp switch ON.

M-9 Related electrical circuit diagram

20-912 WA500-3H
TROUBLESHOOTING M-9 NIGHT LIGHTING DOES NOT LIGHT UP
12

MEMORANDUM

WA500-3H 20-913
TROUBLESHOOTING M-10 ABNORMALITY IN FRONT WORKING LAMP
12
M-10 ABNORMALITY IN FRONT WORKING LAMP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L60
(female) (1) - L05 (17) - replace
CL1 (female) (7)
Is voltage between
L60 (1) and Yes
chassis ground Defective front working Replace
normal? 3 lamp relay

1. 0 - 3 V. Yes Is voltage between 4 Yes Defective contact or

2. Turn starting L60 (6) and chassis disconnection in wiring
switch ON. 2 ground normal? Is voltage between harness between L06 Repair or
L06 (1) and chassis (female) (1) and L60 replace
1. 0 - 3 V. No ground normal? (female) (6)
Is voltage between 2. Turn starting
No L60 (2), (5) and switch ON. 1. 20 - 30 V.
chassis ground 2. Turn starting Defective main monitor Replace
normal? switch ON. No
1. 20 - 30 V. Defective contact or
2. Turn starting disconnection in wiring
switch ON. No harness between L60 Repair or
(female) (2), (5) and FS5 replace
(female) (1)

B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (17) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L05 Repair or
(female) (17) and L60 replace
1. 20 - 30 V. (female) (1)
2. Turn starting
switch ON.

C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause Remedy
Defective contact or
disconnection in wiring
harness between L60 (1) - Repair or
CL1 (7) - C03 (female) replace
(1), C04 (female) (1) or
blown working lamp bulb

20-914 WA500-3H
TROUBLESHOOTING M-10 ABNORMALITY IN FRONT WORKING LAMP
12
M-10 Related electrical circuit diagram

WA500-3H 20-915
TROUBLESHOOTING M-11 ABNORMALITY IN REAR WORKING LAMP
12
M-11 ABNORMALITY IN REAR WORKING LAMP
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L61
(female) (1) - L05 (18) - replace
LR1 (female) (12)
Is voltage between
L61 (1) and Yes
chassis ground Defective rear working Replace
normal? 3 lamp relay

1. 0 - 3 V. Yes Is voltage between 4 Yes Defective contact or

2. Turn starting L61 (6) and chassis disconnection in wiring
switch ON. 2 ground normal? Is voltage between harness between L06 Repair or
L06 21) and chassis (female) (2) and L61 replace
1. 0 - 3 V. No ground normal? (female) (6)
Is voltage between 2. Turn starting
No L61 (2), (5) and switch ON. 1. 20 - 30 V.
chassis ground 2. Turn starting Defective main monitor Replace
normal? switch ON. No
1. 20 - 30 V. Defective contact or
2. Turn starting disconnection in wiring
switch ON. No harness between L61 Repair or
(female) (2), (5) and FS5 replace
(female) (2)

B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (18) and Defective contact or
chassis ground disconnection in wiring
normal? No harness between L05 Repair or
(female) (18) and L61 replace
1. 20 - 30 V. (female) (1)
2. Turn starting
switch ON.

C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause Remedy
Defective contact or
disconnection in wiring
harness between L61 (1) - Repair or
LR1 (12) - G02 (female) replace
(1), G04 (female) (1) or
blown working lamp bulb

20-916 WA500-3H
TROUBLESHOOTING M-11 ABNORMALITY IN REAR WORKING LAMP
12
M-11 Related electrical circuit diagram

WA500-3H 20-917
TROUBLESHOOTING M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
12
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS
PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES
NOT CHANGE
Cause Remedy

Defective main monitor Replace

B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF,

MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION IS ACTUATED
WHEN PEDAL IS DEPRESSED
Cause Remedy
1 Yes Defective contact or
disconnection in wiring Repair or
Is voltage between harness between L06 replace
L06 (3) and (female) (3) and C5
(female) (60
chassis ground
normal?
Defective main monitor Replace
1. 0 - 3 V. No
2. Turn starting
switch ON.
3. disconnect L12.

C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF

SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED
Cause Remedy
2 Yes Defective contact or
disconnection in wiring Repair or
Yes harness between L12
Is resistance between (female) (1) and C5 replace
1 L12 (female) (2) and (female) (6)
chassis ground
normal?
Is resistance Defective contact or
between L12 disconnection in wiring Repair or
1. Max. 1 Ω. No harness between L12
(male) (1) and (2) 2. Turn starting (female) (2) and chassis replace
normal? switch OFF. ground
3. Disconnect L12.
1. Max. 1 Ω.
2. Turn starting defective transmission Replace
switch OFF. No cut-off switch
3. Disconnect L12.

D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF

MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)
Cause Remedy
1 Yes
Defective transmission Replace
controller
Is voltage between
C5 (6) and chassis
ground normal? Defective contact or dis-
connection in wiring har- Repair or
1. Max. 3 V. No ness between C5 (female) replace
(6) and L06 (female) (3),
L12 (female) (1)

20-918 WA500-3H
TROUBLESHOOTING M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
12
E.MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH
TURN ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED
Cause Remedy
1 Yes
Defective transmission Replace
cut-off switch
Does cut-off
function work 2 Yes
when L12 is Defective main monitor Replace
disconnected?
Does cut-off
1. Disconnect L06. No function work when 3 Yes
2. Turn starting L06 is disconnected? Defective transmission Replace
switch ON. Is voltage between controller
C5 (6) and chassis
1. Disconnect L06. No ground normal? Short circuit with power
2. Turn starting source in harness between Repair or
switch ON. 1. Disconnect L12. No L06 (female) (3) - C5
2. Turn starting (female) (6) - L12 replace
switch ON. (female) (10
3. 20 - 30 V.

M-12 Related electrical circuit diagram

WA500-3H 20-919
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
12
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS
(INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN WHEN
DIRECTIONAL LEVER IS AT N.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (8) and
chassis ground
normal? Defective contact or
disconnection in wiring
1. 20 - 30 V. No harness between L05 Repair or
2. Turn starting (female) (8) - JSA replace
switch ON. (female) (1) - L04
3. Directional (female) (3)
lever: N.

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
★ Check that the synchronous flash signal is normal.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (8) and
chassis ground Short circuit with power
normal? source in wiring harness
2 Yes between L05 (female) (8) - Repair or
JSB (male) (1), JSA replace
1. 0 - 5 V. Is resistance between (female) (1) - L04
2. Turn starting L05 (male) 98) and (female) (3) or defective
switch ON. No (3) normal? directional lever
3. Directional
lever: Other than 1. 3 - 4 kΩ.
N. 2. Turn starting Defective main monitor Replace
switch OFF. No
3. Disconnect L05.

20-920 WA500-3H
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
12
M-13 Related electrical circuit diagram

WA500-3H 20-921
TROUBLESHOOTING M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,
12
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,
BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,
OR THEY ARE NOT ACTUATED
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. ACTUATED CONTINOUSLY
Cause Remedy
2 Yes
Defective maintenance Replace
Yes monitor
Does buzzer stop
1 and lamp go out?
Defective contact or
disconnection in wiring Repair or
1. Turn starting No harness between L07
Does buzzer stop switch ON. (female) (6) and L19 replace
and lamp go out? 2. Connect L19 (female) (5)
(female) (5) to
1. Turn starting chassis ground.
switch ON. Defective main monitor Replace
2. Connect L07 (6) No
to chassis ground.

B. NOT ACTUATED
Cause Remedy
2 Yes
Defective maintenance Replace
Yes monitor
Does buzzer and
1 lamp work?
Short circuit with power
1. Turn starting No source in harness between Repair or
Does buzzer and switch ON. L07 (female) (6) and L19 replace
lamp work? 2. Disconnect L19. (female) (5)

1. Turn starting
switch ON. Defective main monitor Replace
2. Disconnect L07 No

M-14 Related electrical circuit diagram

20-922 WA500-3H
TROUBLESHOOTING M-15 ABNORMALITY IN BUZZER
12
M-15 ABNORMALITY IN BUZZER
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3
SECONDS) (DURING SELF-CHECK)
Cause Remedy
Yes Defective contact or
disconnection in wiring Repair or
1 harness between L06 replace
(female) (8) and L43
(male) (1)
Does buzzer
sound?
2 Yes
Defective buzzer Replace
1. Turn starting Is voltage between
switch ON. L42 (female) and
2. Contact L43 No chassis ground
(female) to normal? Defective contact or
chassis ground. disconnection in wiring Repair or
1. 20 - 30 V. No harness between L42 replace
2. Turn starting (female) (1) and FS2
switch ON. (female) (9)

B. BUZZER ALWAYS SOUNDS

1 Yes
Does buzzer stop
when L06 is
disconnected? 2 Yes
1. Disconnect L06. Does buzzer stop
2. Turn starting when L19 is
switch ON. No disconnected?
1. Disconnect L19.
2. Turn starting
switch ON.
Cause Remedy
Defective main monitor Replace
Go to Troubleshooting for
Maintenance Monitor ---
3 Yes Short circuit with power
Does buzzer stop source in harness between Repair or
when L43 is L06 (female) (8) and L43 replace
No disconnected? (male) (1)

1. Disconnect L43.
2. Turn starting Defective buzzer Replace
switch ON. No

M-15 Related electrical circuit diagram

WA500-3H 20-923
TROUBLESHOOTING M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN
12
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN
MEMORY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L07 (10) and
chassis ground
normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L07 replace
2. turn starting (female) (10) and L09
switch ON. (female) (2)

M-16 Related electrical circuit diagram

20-924 WA500-3H
TROUBLESHOOTING M-17 ABNORMALITY IN FAILURE DISPLAY MODE
12
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. DOES NOT ENTER FAILURE DISPLAY MODE
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (5) and
chassis ground Short circuit with power
normal? source in wiring harness
between L05 9female) (5) Repair or
1. 0 - 5 V. No - LR4 (6) - ER1 (9) - replace
2. Turn starting alternator terminal R, or
switch ON. defective alternator

B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY

MODE DOES NOT ADVANCE
Cause Remedy
1 Yes
Defective main monitor Replace
Is voltage between
L05 (5) and
chassis ground Defective contact or
normal? disconnection in wiring
harness between L05 Repair or
(female) (5) - LR4 (6) - replace
1.20 - 30 V. No ER1 (9) - alternator
2. Start engine. terminal R or defective
alternator

M-17 Related electrical circuit diagram

WA500-3H 20-925
TROUBLESHOOTING M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CON-

M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION

CONTROLLER
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 Yes Go to Troubleshooting of
Transmission Controller Replace
System (T Mode)
Is resistance between
Yes L08 (female) (6) and Defective contact or
chassis ground disconnection in wiring
1 normal when C1 No harness between L08 Repair or
(female) (2) is (female) (6) and C1 replace
grounded to chassis? (female) (2)
Does buzzer sound
when C1 (female) 1. Max. 1Ω.
(2) is grounded to 2. Turn starting switch OFF.
chassis? 3. disconnect L01 and C1
Defective main monitor Replace
1. Turn starting No
switch ON.
2. Disconnect C1.
3. Connect C1
(female) (2) to
chassis ground.

M-18 Related electrical circuit diagram

20-926 WA500-3H
TROUBLESHOOTING M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DIS-
12
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL
DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP
Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (10) and chassis
1 ground normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L05
Is emergency 2. Turn starting (female) (10) and EST replace
steering selection switch ON. (female) (2)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector

B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP

Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (10) and chassis
1 ground normal? Defective contact or
disconnection in wiring Repair or
1. 0 - 2 V. No harness between L05
Is emergency 2. Turn starting (female) (10) and EST replace
steering selection switch ON. (female) (2)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector

M-19 Related electrical circuit diagram

WA500-3H 20-927
TROUBLESHOOTINGM-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DIS-
12
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION
DISPLAY
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP
Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (11) and chassis
1 ground normal? Defective contact or
disconnection in wiring Repair or
1. 20 - 30 V. No harness between L05
Is emergency 2. Turn starting (female) (11) and EST replace
steering selection switch ON. (female) (1)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector

B. EMERGENCY STEERING DISPLAY STAYS LIT UP

Cause Remedy
2 Yes
Defective main monitor Replace
Yes Is voltage between
L05 (10) and chassis
1 ground normal?
Short circuit with power
1. 0 - 2 V. No source in harness between Repair or
Is emergency 2. Turn starting L05 (female) (11) and EST replace
steering selection switch ON. (female) (1)
connector
disconnected?
Defective disconnection of
emergency steering Disconnect
No selector connector

M-20 Related electrical circuit diagram

20-928 WA500-3H
TROUBLESHOOTING M-21 NOT USED
12
M-21 NOT USED

WA500-3H 20-929
TROUBLESHOOTING M-22 ABNORMALITY IN ECSS SYSTEM
12
M-22 ABNORMALITY IN ECSS SYSTEM
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● ECSS: Electronic Controlled Suspension System.
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED
Cause Remedy

Defective main monitor Replace

B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK
Cause Remedy
2 Yes Go to Troubleshooting for
ECSS Controller System ---
Yes Is voltage between (D Mode)
C3B (9) and chassis
1 ground normal?
Defective contact or
Is voltage between 1. Max. 3 V. disconnection in wiring Repair or
L06 (7) and 2. Turn starting harness between L06 (7) replace
chassis ground switch ON. No and C3B (9)
normal?
1. Max. 3 V.
2. Turn starting Defective main monitor Replace
switch ON. No

M-22 Related electrical circuit diagram

20-930 WA500-3H
TROUBLESHOOTING M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
MALITY IN NETWORK)
● Before carrying out troubleshooting, check that all the related connectors are properly inserted.
● Always connect any disconnected connectors before going on to the next step.
● Set dipswitch 3 at the rear of the main monitor to "F".
● MDC: Multiple Display and Condition.
Cause Remedy
2 Yes
Applicable controller is Replace
1 Yes defective
Is voltage normal
Is voltage between between pins of
L08 (male) (1) and connectors in table Defective contact or
(2) normal? below? disconnection in wiring
harness between L08 Repair or
1. Repeats 0 V and 1. Repeats 0 V and No (female) (1) (3), L08 replace
12 V. 12 V. (female) (2) (4) -
2. Turn starting 2. Turn starting applicable connector pins
switch ON. switch ON.
3. Disconnect L08. 3. Disconnect
connector to be
measured.
Defective main monitor Replace
No

M-23 Related electrical circuit diagram

WA500-3H 20-931
TROUBLESHOOTING M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12

MEMORANDUM

20-932 WA500-3H
 TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (T MODE)

JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . 20-1204

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS
ON MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1206
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1212
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN F SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1214
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN R SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1216
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1218
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1220
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1222
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1224
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL
SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1226
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1228
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1232
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1236
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED
SENSOR SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1238
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED . . . . 20-1240
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1241
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1242
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1243
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1244
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1245
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1246
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1247
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1248
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL
SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1250
T-23 HOLD SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1253

WA500-3H 20-1201
TROUBLESHOOTING
T-24 KICK-DOWN SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1254
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1255
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1256
T-27 BUZZER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1257
T-28 NETWORK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1258
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1259
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1260
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM . . . . . . . . . . . . 20-1261
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1262
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1263
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1264
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1265
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1266
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1267

Remark
See Electrical Diagram in section 90.

20-1202 WA500-3H
TROUBLESHOOTING
12

MEMORANDUM

WA500-3H 20-1203
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION
12
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER
SYSTEM RELATED PARTS

Self diagnostic display (abnormality display)

(Location of failure)

Short circuit, disconnected in joystick directional switch system

Short circuit, disconnection in engine speed sensor system

Short circuit, disconnected in directional switch system

Short circuit, disconnection in memory (EEP ROM)

Short circuit in transmission oil temperature system
Short circuit, disconnected in 2nd ECMV solenoid
Short circuit, disconnected in 3rd ECMV solenoid

Short circuit, disconnected in range switch system

Short circuit, disconnection in back-up lamp relay

Short circuit, disconnected in 4th ECMV solenoid

Short circuit, disconnected in 1st ECMV solenoid
Short circuit, disconnected in R ECMV solenoid
Short circuit, disconnected in F ECMV solenoid

Short circuit in 2nd ECMV fill switch system

Short circuit in 3rd ECMV fill switch system
Short circuit in 4th ECMV fill switch system
Short circuit in 1st ECMV fill switch system
Disconnection in travel speed sensor system

Short circuit in R ECMV fill switch system

Short circuit in F ECMV fill switch system
Transmission controller error
(Failure code)
No. Failure mode 10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31
1 Travel is impossible X X X X X X X X X X X X X X X
2 Auto-shifting is not carried out X
3 Directional lever and direction of travel are different X
4 Machine travels forward when directional lever is not at F X X
5 Machine travels in reverse when directional lever is not at R X X
6 Shifts down regardless of travel speed X
7 Shifts up regardless of travel speed X
8 Speed range is not same as position of lever X
9 There is excessive shock while shifting gears X X X
10 There is shift hunting when traveling X
11 There is shift hunting when shifting gears X
12 Speed range can not be controlled with speed lever X
13 Back-up lamp and buzzer do not work X
14 Shift can not be held
15 Kick-down does not work
16 When kick-down is actuated, there is no scooping power
17 Transmission is not cut off with left brake
18 It is possible to travel even when parking brake is applied
19 If F-R lever is operated when traveling at high speed, alarm
buzzer does not sound
20 Alarm buzzer continues to sound
21 Main monitor does not display transmission controller
information (alarm buzzer, fail code, etc.)
22 Gear shifting speed is abnormal (tire compensation)
T-10

T-12
T-13
T-14
T-15
T-16
T-17
T-18
T-19
T-20
T-11
T-1
T-2
T-3
T-4
T-5
T-6
T-7
T-8
T-9

Troubleshooting code when no error code is displayed

20-1204 WA500-3H
 12

WA500-3H
TROUBLESHOOTING

X
T-21 Disconnection in F or R ECMV fill switch system

X
T-22

32 33
Disconnection in 1st, 2nd, 3rd, or 4th ECMV fill switch system

-
Abnormality in hold switch signal system

X
-

-
Abnormality in kick-down switch signal system

X
X
-

-
Abnormality in transmission cut-off signal system

X
-

-
Abnormality in neutralizer signal system

X
(Failure code)
-

-
Abnormality in alarm buzzer signal system

X
X
(abnormality display)
Self diagnostic display

-
Abnormality in network signal system

X
Transmission controller error

-
Abnormality in network signal system or main monitor

X
T-29
T-28
T-26
T-25
T-23
display is given

E-1, H-1

T-28, J-1
H-2, H-3

T-24, E-9

T-27, H-17, E-5

when no abnormality
Troubleshooting code
JUDGEMENT TABLE FOR TRANSMISSION

20-1205
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
OCCURS AND PROBLEMS ON MACHINE
1. TRANSMISSION CONTROLLER SYSTEM

Failure
Abnormal System Nature of Abnormality
Code

1) Defective back-up lamp.

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C1
10 Back-up lamp relay (female) (11) and L54 (1). a
3) defective contact or disconnection in wiring harness between back-up lamp
relay L54 (female) (2) and chassis ground.
4) Defective transmission controller.

1) Defective F ECMV.
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (7) - TM2 (4) - CN16 (1).
12 Abnormality in F ECMV system b
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (17) - TM2 (5) - CN16
(2).
4) Defective transmission controller.

1) Defective R ECMV.
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (8) - TM2 (1) - CN14 (1).
13 Abnormality in R ECMV system c
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (18) - TM2 (2) - CN14
(2).
4) Defective transmission controller.

1) Defective 1st ECMV.

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
14 Abnormality in 1st ECMV system (female) (9) - TM1 (1) - CN4 (1). d
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (19) - TM1 (2) - CN4 (2).
4) Defective transmission controller.

1) Defective 2nd ECMV.

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
15 Abnormality in 2nd ECMV system (female) (10) - TM1 (4) - CN6 (1). e
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (20) - TM1 (5) - CN6 (2).
4) Defective transmission controller.

1) Defective 3rd ECMV.

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (2) - TM1 (7) - CN12 (1).
16 Abnormality in 3rd ECMV system f
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (13) - TM1 (8) - CN12
(2).
4) Defective transmission controller.

20-1206 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12

Action by controller Problem that appears Trouble-

Condition when normal (voltage, current, resistance) when abnormality is on machine with shooting
detected abnormality Code

1) Resistance of relay coil: 200 - 400 Ω.

2) Voltage between transmission controller C1 (11) and chassis
ground at neutral: Less than 1 V. Back-up lamp is not
Neutral
a 3) Resistance in wiring harness between transmission controller actuated when driving in T-1
(All ECMV outputs: OFF)
C1 (female) (11) and L54 (female) (1): Max. 1 Ω. reverse.
4) Resistance in wiring harness between back-up lamp relay L54
(female) (2) and chassis ground: Max. 1 Ω.

1) Resistance of solenoid between transmission controller C2

(female) (7) and (17): 10 - 20 Ω.
2) Voltage between transmission controller C2 (7) and chassis
ground at neutral: Less than 1 V.
Neutral
b 3) Resistance between transmission controller C2 (female) (7), It is impossible to travel. T-2
(All ECMV outputs: OFF)
(17) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (7), (17) - TM2 (4), (5) - CN16 (1), (2):
Less than 1 Ω.

1) Resistance of solenoid between transmission controller C2

(female) (8) and (18): 10 - 20 Ω.
2) Voltage between transmission controller C2 (8) and chassis
ground at neutral: Less than 1 V.
Neutral
c 3) Resistance between transmission controller C2 (female) (8), It is impossible to travel. T-3
(All ECMV outputs: OFF)
(18) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (8), (18) - TM2 (1), (2) - CN14 (1), (2):
Less than 1 Ω.

1) Resistance of solenoid between transmission controller C2

(female) (9) and (19): 10 - 20 Ω.
2) Voltage between transmission controller C2 (9) and chassis
ground at neutral: Less than 1 V.
Neutral
d 3) Resistance between transmission controller C2 (female) (9), It is impossible to travel. T-4
(All ECMV outputs: OFF)
(19) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (9), (19) - TM1 (1), (2) - CN4 (1), (2):
Less than 1 Ω.

1) Resistance of solenoid between transmission controller C2

(female) (10) and (20): 10 - 20 Ω.
2) Voltage between transmission controller C2 (10) and chassis
ground at neutral: Less than 1 V.
Neutral
e 3) Resistance between transmission controller C2 (female) (10), It is impossible to travel. T-5
(All ECMV outputs: OFF)
(20) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (10), (20) - TM1 (4), (5) - CN6 (1), (2):
Less than 1 Ω.

1) Resistance of solenoid between transmission controller C2

(female) (2) and (13): 10 - 20 Ω.
2) Voltage between transmission controller C2 (2) and chassis
ground at neutral: Less than 1 V.
Neutral
f 3) Resistance between transmission controller C2 (female) (2), It is impossible to travel. T-6
(All ECMV outputs: OFF)
(13) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (2), (13) - TM1 (7), (8) - CN12 (1), (2):
Less than 1 Ω.

WA500-3H 20-1207
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN

Failure
Abnormal System Nature of Abnormality
Code

1) Defective 4th ECMV.

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C2
(female) (4) - TM1 (10) - CN8 (1).
17 Abnormality in 4th ECMV system g
3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (15) - TM1 (11) - CN8
(2).
4) Defective transmission controller.

1) Defective joystick directional lever F, N, R switch.

2) Disconnection between directional lever connector (8) and chassis ground.

When the wiring harness is in any of the following conditions with switch not
pressed:
3) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (8) - JS14 (2) - joystick lever connector (2), or short
circuit with chassis ground in wiring harness between C5 (female) (16) - JS14
19 Abnormality in joystick directional switch (3) - joystick lever connector (3). h
4) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (7) - JS14 (4) - joystick lever connector (4), or short
circuit with chassis ground in wiring harness between C5 (female) (15) -
JS14 (5) - joystick lever connector (5).
5) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (9) - JS14 (6) - joystick lever connector (6), or short
circuit with chassis ground in wiring harness between C5 (female) (7) -
JS14 (7) - joystick lever connector (7).

1) Defective directional lever.

2) Defective combination switch power source.

Abnormality in directional switch signal Short circuit with power source, short circuit with chassis ground, defective contact,
20 i
system disconnection in the following wiring harness:
3) Wiring harness between transmission controller C3B (female) (5) and L04 (2).
4) Wiring harness between transmission controller C3B (female) (13) and L04 (3).
5) Wiring harness between transmission controller C3B (female) (6) and L04 (4).

1) Defective directional lever.

2) Defective combination switch power source.

Short circuit with power source, short circuit with chassis ground, defective contact,
21 Abnormality in range switch signal system disconnection in the following wiring harness: j
3) Wiring harness between transmission controller C3B (female) (7) and L04 (5).
4) Wiring harness between transmission controller C3B (female) (15) and L04 (6).
5) Wiring harness between transmission controller C3B (female) (8) and L04 (7).
6) Wiring harness between transmission controller C3B (female) (16) and L04 (8).

1) Defective speed sensor.

2) Defective adjustment of speed sensor mount.
3) Defective contact or disconnection in wiring harness between transmission
22 Disconnection in speed sensor controller C5 (female) (2) - TM2 (9) - CN3 (1). k
4) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (10) - TM2 (10) - CN3 (2).
5) Defective transmission controller.

1) Defective engine speed sensor.

2) Defective adjustment of engine speed sensor mount.
3) Short circuit with chassis ground, defective contact or disconnection in wiring
harness between transmission controller C4 (female) (2) - LR3 (7) - ER2 (6) -
23 Abnormality in engine speed sensor system l
E04 (2).
4) Defective contact or disconnection in wiring harness between transmission
controller C4 (female) (9) - LR3 (8) - ER2 (7) - E04 (3).
5) Defective transmission controller.

20-1208 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Action by controller Problem that appears Trouble-
Condition when normal (voltage, current, resistance) when abnormality is on machine with shooting
detected abnormality Code

1) Resistance of solenoid between transmission controller C2 (female)

(4) and (15): 10 - 20 Ω
2) Voltage between transmission controller C2 (4) and chassis
ground at neutral: Less than 1 V.
Neutral
g 3) Resistance between transmission controller C2 (female) (4), It is impossible to travel. T-7
(All ECMV outputs: OFF)
(15) and chassis ground: Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C2 (female) (4), (15) - TM1 (10), (11) - CN8 (1), (4):
Less than 1 Ω.

1) Resistance of solenoid between joystick directional lever connector

(8) and chassis ground: Less than 1 V.

The following conditions are when the switch is not pressed:

2) Voltage between transmission controller C5 (female) (8) and chassis
ground at neutral: Less than 1 V.
and resistance between C5 (female) (16) and chassis ground:
Min. 1 MΩ. Can not travel in joystick
Neutral
h mode (possible in T-8
3) Resistance between transmission controller C5 (female) (7), and (All ECMV outputs: OFF)
chassis ground: Less than 1 V. steering wheel mode)
and resistance between C5 (female) (15) and chassis ground:
Min. 1 MΩ.
4) Resistance in wiring harness between transmission controller
C5 (female) (9) and chassis ground: Less than 1 Ω.
and resistance between C5 (female) (17) and chassis ground:
Min. 1 MΩ.

1) Voltage between combination switch L04 (1) and chassis ground: • Shift to neutral
immediately when short
20 - 30 V.
circuit with power source
2) Voltage for only 1 system in accordance with position of directional
is detected.
i lever: 20 - 30 V (Others: Less than 1 V) It is impossible to travel T-9
• When there is no signal
F: Between transmission controller C3B (5) - chassis ground.
(disconnection), holds
N: Between transmission controller C3B (13) - chassis ground. previous signal condition
R: Between transmission controller C3B (6) - chassis ground. for 2 seconds.

1) Voltage between combination switch L04 (1) and chassis ground: • If signals are input, it 1) Auto-shift limit is
20 - 30 V. judges speed range different from
2) Voltage for only 1 system in accordance with position of directional position in order of range position
lever: 20 - 30 V (Others: Less than 1V) priority 4←3←2←1. selected by
j T-10
1st: Between transmission controller C3B (7) - chassis ground. • When there is no signal operator.
2nd: Between transmission controller C3B (15) - chassis ground. (disconnection), holds 2) Impossible to shift
3rd: Between transmission controller C3B (8) - chassis ground. previous signal condition gear in manual
4th: Between transmission controller C3B (16) - chassis ground. (speed range position). mode.

1) Switches to manual
1) Does not carry out
1) Resistance between speed sensor CN3 (1) and (2): 500 - 1,000 Ω. mode.
auto-shift.
k 2) Voltage between transmission controller C5 (female) (2) and (10): 2) Shifts gear according T-11
2) Switches to manual
Min. 0.5 V. to operation of speed
shift.
lever

1) Resistance between engine speed sensor E04 (2) and (3):

It is possible to travel with
100 - 500 Ω. There is gearshifting
l engine speed taken as T-12
2) Voltage between transmission controller C4 (female) (2) and (9): shock.
2,100 rpm.
Min. 0.5 V.

WA500-3H 20-1209
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Failure
Abnormal System Nature of Abnormality
Code

24 Abnormality in memory (EEPROM) 1) Defective transmission controller. m

1) Defective transmission oil temperature sensor.

Short circuit in transmission oil temperature 2) Short circuit with chassis ground in wiring harness between transmission
25 n
sensor system. controller C3A (female) (11) - TM2 (13) - CN11 (1).
3) Defective transmission controller.

1) Defective F ECMV fill switch.

2) Short circuit with chassis ground in wiring harness between transmission
26 Short circuit in F ECMV fill switch system. o
controller C3B (female) (2) - TM2 (6) - CN17 (1).
3) Defective transmission controller.

1) Defective R ECMV fill switch.

2) Short circuit with chassis ground in wiring harness between transmission
27 Short circuit in R ECMV fill switch system. p
controller C3B (female) (10) - TM2 (3) - CN15 (1).
3) Defective transmission controller.

1) Defective 1st ECMV fill switch.

2) Short circuit with chassis ground in wiring harness between transmission
28 Short circuit in 1st ECMV fill switch system. q
controller C3B (female) (3) - TM1 (3) - CN5 (1).
3) Defective transmission controller.

1) Defective 2nd ECMV fill switch.

Short circuit in 2nd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission
29 r
system. controller C3B (female) (11) - TM1 (6) - CN7 (1).
3) Defective transmission controller.

1) Defective 3rd ECMV fill switch.

Short circuit in 3rd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission
30 s
system. controller C5 (female) (11) - TM1 (9) - CN13 (1).
3) Defective transmission controller.

1) Defective 4th ECMV fill switch.

Short circuit in 4th ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission
31 t
system. controller C5 (female) (12) - TM1 (12) - CN9 (1).
3) Defective transmission controller.

1) Defective fill switch.

2) F ECMV fill switch:
Defective contact or disconnection in wiring harness between transmission
Disconnection in F or R ECMV fill switch controller C3B (female) (2) - TM2 (6) - CN17 (1).
32 u
system 3) R ECMV fill switch:
Defective contact or disconnection in wiring harness between transmission
controller C3B (female) (10) - TM2 (3) - CN15 (1).
4) Defective transmission controller.

1) Defective fill switch.

Defective contact or disconnection in the following wiring harness:

2) 1st ECMV fill switch:
Between transmission controller C3B (female) (3) - TM1 (3) - CN5 (1).
Disconnection in 1st, 2nd, 3rd, or 4th ECMV 3) 2nd ECMV fill switch:
33 v
fill switch system Between transmission controller C3B (female) (11) - TM1 (6) - CN7 (1).
4) 3rd ECMV fill switch:
Between transmission controller C5 (female) (11) - TM1 (9) - CN13 (1).
5) 4th ECMV fill switch:
Between transmission controller C5 (female) (12) - TM1 (12) - CN9 (1).
6) Defective transmission controller.

20-1210 WA500-3H
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN
12
Action by controller Problem that appears Trouble-
Condition when normal (voltage, current, resistance) when abnormality is on machine with shooting
detected abnormality Code

Stops learning function and There is gearshifting

m 1) Shock when shifting gear is reduced by learning function. T-13
uses default data shock.

1) Resistance between transmission oil temperature sensor CN11 (1) Uses low temperature data
and (2): 38 - 48 kΩ {approx. 25° C (77° F)} for transmission oil There is gearshifting
n T-14
2) Voltage between transmission controller C3A (female) (11) and temperature when shifting shock.
(17): 1 - 5 V. gear

1) Resistance between transmission controller C3B (female) (2) and Neutral

o It is impossible to travel. T-15
chassis ground at neutral (F ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C3B (female) (10) and Neutral

p It is impossible to travel. T-16
chassis ground at neutral (R ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C3B (female) (3) and Neutral

q It is impossible to travel. T-17
chassis ground at neutral (1st ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C3B (female) (11) and Neutral

r It is impossible to travel. T-18
chassis ground at neutral (2nd ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C5 (female) (11) and Neutral

s It is impossible to travel. T-19
chassis ground at neutral (3rd ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C5 (female) (12) and Neutral

t It is impossible to travel. T-20
chassis ground at neutral (4th ECMV: OFF): Min. 1 MΩ. (All ECMV outputs: OFF)

1) Resistance between transmission controller C3B (female) (2) and

Uses data without fill
chassis ground at FORWARD (F ECMV: ON): Less than 1 Ω. There is gearshifting
u switch signal when shifting T-21
2) Resistance between transmission controller C3B (female) (10) and shock.
gear
chassis ground at REVERSE (R ECMV: ON): Less than 1 Ω.

1) Resistance between transmission controller C3B (female) (3) and

chassis ground when traveling at 1st (1st ECMV: ON):
Less than 1 Ω.
2) Resistance between transmission controller C3B (female) (11) and
chassis ground when traveling at 2nd (2nd ECMV: ON):
Uses data without fill
Less than 1 Ω. There is gearshifting
v switch signal when shifting T-22
3) Resistance between transmission controller C5 (female) (11) and shock.
gear
chassis ground when traveling at 3rd (3rd ECMV: ON):
Less than 1 Ω.
4) Resistance between transmission controller C5 (female) (12) and
chassis ground when traveling at 4th (4th ECMV: ON):
Less than 1 Ω.

WA500-3H 20-1211
TROUBLESHOOTING T-1 FAILURE CODE [10] (SHORT CIRCUIT,
12
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP
RELAY) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
L54 (female) (1) and
3 chassis ground
normal? Short circuit with chassis
Is resistance between ground in wiring harness Repair or
1) Min. 1 MΩ. No between C1 (female) (11) replace
2 Yes C1 (female) (11) and and L54 (female) (1)
chassis normal when 2) Turn starting switch
L54 (female) (1) is OFF.
grounded to chassis? 3) Disconnect C1 and
Is resistance between L54.
Yes L54 (female) (2) and
chassis ground 1) Max. 1 Ω. Disconnection in wiring
normal? 2) Turn starting switch harness between C1 Repair or
OFF. No (female) (11) and L54 replace
1 (female) (1)
3) Disconnect C1 and
Is troubleshooting code 1) Max. 1 Ω . L54.
10 displayed when the 2) Turn starting switch
relay is interchanged OFF.
with a relay of same 3) Disconnect L54.
type? Disconnection in wiring
harness between L54 Repair or
1) Turn starting switch No (female) (2) - LR5 (2) - replace
OFF. chassis ground
2) Interchange relay with
of same type.
3) Turn starting switch
ON. Defective back-up lamp Replace
4) Directional lever: R No relay

5 Yes Defective transmission

controller Replace
A Is voltage between C1
(female) (11) and
chassis normal?
Short circuit with power
source in wiring harness Replace
1) Turn starting switch No between C1 (female) (11) or replace
OFF. and L54 (female) (1)
2) Disconnect C1 and
L54.
3) Less than 0.1 V.

T-1 Related electrical circuit diagram

20-1212 WA500-3H
TROUBLESHOOTING T-1 FAILURE CODE [10] (SHORT CIRCUIT,
12

MEMORANDUM

WA500-3H 20-1213
TROUBLESHOOTING T-2 FAILURE CODE [12] (SHORT CIRCUIT,
12
T-2 FAILURE CODE [12] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN16 (female) (1)
and chassis normal
when C2 (female)
(7) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (7) - TM2 (4) -
2) Turn starting switch CN16 (female) (1)
C2 (female) (17) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN16.
Is resistance between Short circuit with chassis
CN16 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (17) replace
OFF. No - TM2 (5) - CN16 (female)
(17) is grounded to 3) Disconnect C2 and (2)
chassis? CN16.
1
Is resistance between 1) Max. 1 Ω.
CN16 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN16. (female) (17) - TM2 (5) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN16 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN16. Defective F solenoid Replace
No

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (7) and chassis
normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (7) - or repair
Yes Is voltage between TM2 (4) - CN16 (1)
C2 (female) (7) and CN16.
(17) normal? 3) Less than 0.1 V.

1) 5 - 15 Ω.
2) Turn starting switch
OFF. Short circuit with chassis
5 ground in wiring harness
3) Disconnect C2 and
Is resistance between CN16. between C2 (female) (17)
A C2 (female) (7) and - TM2 (5) - CN16 (female) Repair or
chassis normal? No (2) and wiring harness replace
between C2 (female) (7) -
1) Min. 1 MΩ. TM2 (4) - CN16 (female)
2) Turn starting switch (1)
OFF.
3) Disconnect C2 and
CN16.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (7) - replace
No TM2 (4) - CN16 (female)
(1)

20-1214 WA500-3H
TROUBLESHOOTING T-2 FAILURE CODE [12] (SHORT CIRCUIT,
12
T-2 Related electrical circuit diagram

WA500-3H 20-1215
TROUBLESHOOTING T-3 FAILURE CODE [13] (SHORT CIRCUIT,
12
T-3 FAILURE CODE [13] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN14 (female) (1)
and chassis normal
when C2 (female)
(8) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes 1) Max. 1 Ω. No (female) (8) - TM2 (1) -
Is resistance between 2) Turn starting switch CN14 (female) (1)
2 C2 (female) (18) and OFF.
chassis normal? 3) Disconnect C2 and
CN14.
Is resistance between Short circuit with chassis
CN14 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (18) replace
OFF. No - TM2 (2) - CN14 (female)
(18) is grounded to 3) Disconnect C2 and (2)
chassis? CN14.
1
Is resistance between 1) Max. 1 Ω.
CN14 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN14. (female) (18) - TM2 (2) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN14 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN14. Defective R solenoid Replace
No

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (8) and chassis
normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (8) - or repair
Yes Is voltage between TM2 (1) - CN14 (1)
C2 (female) (8) and CN14.
(18) normal? 3) Less than 0.1 V.

1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN14. between C2 (female) (18)
A C2 (female) (8) and - TM2 (2) - CN14 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (8) -
TM2 (1) - CN14 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN14.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (8) - replace
No TM2 (1) - CN14 (female)
(1)

20-1216 WA500-3H
TROUBLESHOOTING T-3 FAILURE CODE [13] (SHORT CIRCUIT,
12
T-3 Related electrical circuit diagram

WA500-3H 20-1217
TROUBLESHOOTING T-4 FAILURE CODE [14] (SHORT CIRCUIT,
12
T-4 FAILURE CODE [14] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN4 (female) (1)
and chassis normal
when C2 (female)
(9) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (9) - TM1 (1) -
2) Turn starting switch CN4 (female) (1)
C2 (female) (19) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN4.
Is resistance between Short circuit with chassis
CN4 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (19) replace
OFF. No - TM1 (2) - CN4 (female)
(19) is grounded to 3) Disconnect C2 and (2)
chassis? CN4.
1
Is resistance between 1) Max. 1 Ω.
CN4 (male) (1) and (2), 2) Turn starting switch Defective contact or
and between (1), (2) and OFF. disconnection in wiring
chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN4. (female) (19) - TM1 (2) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN4 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN4. Defective 1st solenoid Replace
No

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (9) and chassis
normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (9) - or repair
Yes Is voltage between TM1 (1) - CN4 (1)
C2 (female) (9) and CN4.
(19) normal? 3) Less than 0.1 V.
1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN4. between C2 (female) (19)
A C2 (female) (9) and - TM1 (2) - CN4 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (9) -
TM1 (1) - CN4 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN4.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (9) - replace
No TM1 (1) - CN4 (female)
(1)

20-1218 WA500-3H
TROUBLESHOOTING T-4 FAILURE CODE [14] (SHORT CIRCUIT,
12
T-4 Related electrical circuit diagram

WA500-3H 20-1219
TROUBLESHOOTING T-5 FAILURE CODE [15] (SHORT CIRCUIT,
12
T-5 FAILURE CODE [15] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN6 (female) (1)
and chassis normal
when C2 (female)
(10) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (10) - TM1 (4) -
2) Turn starting switch CN6 (female) (1)
C2 (female) (20) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN6.
Is resistance between Short circuit with chassis
CN6 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (20) replace
OFF. No - TM1 (5) - CN6 (female)
(20) is grounded to 3) Disconnect C2 and (2)
chassis? CN6.
1
Is resistance between 1) Max. 1 Ω.
CN6 (male) (1) and (2), 2) Turn starting switch Defective contact or
and between (1), (2) and OFF. disconnection in wiring
chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN6. (female) (20) - TM1 (5) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN6 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN6. Defective 2nd solenoid Replace
No

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (10) and chas-
sis normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (10) or repair
Yes Is voltage between - TM1 (4) - CN6 (1)
C2 (female) (10) and CN6.
(20) normal? 3) Less than 0.1 V.
1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN6. between C2 (female) (20)
A C2 (female) (10) and - TM1 (5) - CN6 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (10)
- TM1 (4) - CN6 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN6.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (10) replace
No - TM1 (4) - CN6 (female)
(1)

20-1220 WA500-3H
TROUBLESHOOTING T-5 FAILURE CODE [15] (SHORT CIRCUIT,
12
T-5 Related electrical circuit diagram

WA500-3H 20-1221
TROUBLESHOOTING T-6 FAILURE CODE [16] (SHORT CIRCUIT,
12
T-6 FAILURE CODE [16] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN12 (female) (1)
and chassis normal
when C2 (female)
(2) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
Yes Is resistance between 1) Max. 1 Ω. No (female) (2) - TM1 (7) -
2) Turn starting switch CN12 (female) (1)
C2 (female) (13) and OFF.
2 chassis ground 3) Disconnect C2 and
normal? CN12.
Is resistance between Short circuit with chassis
CN12 (female) (2)
Yes and chassis normal 1) Min. 1 MΩ. ground in wiring harness Repair or
when C2 (female) 2) Turn starting switch between C2 (female) (13) replace
OFF. No - TM1 (8) - CN12 (female)
(13) is grounded to 3) Disconnect C2 and (2)
chassis? CN12.
1
Is resistance between 1) Max. 1 Ω.
CN12 (male) (1) and 2) Turn starting switch Defective contact or
(2), and between (1), (2) OFF. disconnection in wiring
and chassis normal? 3) Disconnect C2 and harness between C2 Repair or
CN12. (female) (13) - TM1 (8) - replace
1) Between (1) and (2): No
5 - 15 Ω. CN12 (female) (2)
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN12. Defective 3rd solenoid Replace
No

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (2) and chassis
normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (2) - or repair
Yes Is voltage between TM1 (7) - CN12 (1)
C2 (female) (2) and CN12.
(13) normal? 3) Less than 0.1 V.
1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN12. between C2 (female) (13)
A C2 (female) (2) and - TM1 (8) - CN12 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (2) -
TM1 (7) - CN12 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN12.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (2) - replace
No TM1 (7) - CN12 (female)
(1)

20-1222 WA500-3H
TROUBLESHOOTING T-6 FAILURE CODE [16] (SHORT CIRCUIT,
12
T-6 Related electrical circuit diagram

WA500-3H 20-1223
TROUBLESHOOTING T-7 FAILURE CODE [17] (SHORT CIRCUIT,
12
T-7 FAILURE CODE [17] (SHORT CIRCUIT, DISCONNECTION,
SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS
DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Yes Is resistance between
2 chassis ground
Is resistance between
CN8 (female) (2)
Yes and chassis normal
when C2 (female)
(15) is grounded to
chassis?
1
Is resistance between 1) Max. 1 Ω.
CN8 (male) (1) and (2), 2) Turn starting switch
and between (1), (2) and OFF.
chassis normal? 3) Disconnect C2 and
1) Between (1) and (2): CN8.
5 - 15 Ω.
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN8.
No
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
CN8 (female) (1)
and chassis normal
when C2 (female)
(4) is grounded to Defective contact or
3 chassis? disconnection in wiring Repair or
harness between C2 replace
1) Max. 1 Ω. No (female) (4) - TM1 (10) -
2) Turn starting switch CN8 (female) (1)
C2 (female) (15) and OFF.
3) Disconnect C2 and
normal? CN8.
Short circuit with chassis
1) Min. 1 MΩ. ground in wiring harness Repair or
2) Turn starting switch between C2 (female) (15) replace
OFF. No - TM1 (11) - CN8 (female)
3) Disconnect C2 and (2)
CN8.
Defective contact or
disconnection in wiring
harness between C2 Repair or
No (female) (15) - TM1 (11) - replace
CN8 (female) (2)
Defective 4th solenoid Replace

7 Yes Defective transmission

controller Replace
Yes Is voltage between C2
(female) (4) and chassis
normal?
1) Turn starting switch Short circuit with power
6 source in wiring harness Replace
OFF.
2) Disconnect C2 and No between C2 (female) (4) - or repair
Yes Is voltage between TM1 (10) - CN8 (1)
C2 (female) (4) and CN8.
(15) normal? 3) Less than 0.1 V.
1) 5 - 15 Ω.
2) Turn starting switch
5 OFF. Short circuit with chassis
3) Disconnect C2 and ground in wiring harness
Is resistance between CN8. between C2 (female) (15)
A C2 (female) (4) and - TM1 (11) - CN8 (female) Repair or
chassis normal? (2) and wiring harness replace
No between C2 (female) (4) -
TM1 (10) - CN8 (female)
1) Min. 1 MΩ. (1)
2) Turn starting switch
OFF.
3) Disconnect C2 and
CN8.
Short circuit with chassis
ground in wiring harness Repair or
between C2 (female) (4) - replace
No TM1 (10) - CN8 (female)
(1)

20-1224 WA500-3H
TROUBLESHOOTING T-7 FAILURE CODE [17] (SHORT CIRCUIT,
12
T-7 Related electrical circuit diagram

WA500-3H 20-1225
TROUBLESHOOTING T-8 FAILURE CODE [19] (SHORT CIRCUIT,
12
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN
JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes Defective transmission
controller Replace
Yes Is voltage between
C5 (female) (7), (8),
(9), (15), (16), (17) Short circuit, short circuit
and chassis as shown with chassis ground,
3 in Table 1? defective contact, or
disconnection in wiring Repair or
Yes Is resistance between 1) Turn starting switch No harness between JS15 replace
ON. (female) (2), (3), (4), (5),
JS15 (female) (8) (6), (7) - C5 (female) (7),
2 and chassis normal? (8), (9), (15), (16), (17)
Yes Is voltage between 1) Min. 1 MΩ.
JS15 (1) and chassis 2) Turn starting switch Defective contact, or
normal? OFF. disconnection in wiring
3) Disconnect JS15. harness between JS15 Repair or
1) 20 - 30 V. No (female) (8) - JS14 (8) - replace
1
2) Turn starting switch LR5 (2) - chassis
ON.
Is voltage between JS15
(8) and terminals (2),
(3), (4), (5), (6), and (7) Short circuit, short circuit
as shown in Table 1? with chassis ground,
defective contact, or Repair or
disconnection in wiring replace
1) Turn starting switch No harness between C3A
ON. (male) (6) - JS14 (1) - LR5
(1) - chassis

Defective joystick lever Replace

No

Table 1: Voltage of each direction position of joystick lever.

When directional switch is pressed

Terminal
F N R

JS15 (male) (8) - (2) Between C5 (8) and chassis 20 - 30 V Max. 1 V Max. 1 V

JS15 (male) (8) - (3) Between C5 (16) and chassis Max. 1 V 20 - 30 V 20 - 30 V

JS15 (male) (8) - (4) Between C5 (7) and chassis Max. 1 V 20 - 30 V Max. 1 V

JS15 (male) (8) - (5) Between C5 (15) and chassis 20 - 30 V Max. 1 V 20 - 30 V

JS15 (male) (8) - (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 - 30 V

JS15 (male) (8) - (7) Between C5 (17) and chassis 20 - 30 V 20 - 30 V Max. 1 V

20-1226 WA500-3H
TROUBLESHOOTING T-8 FAILURE CODE [19] (SHORT CIRCUIT,
12
T-8 Related electrical circuit diagram

WA500-3H 20-1227
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN
DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Yes
a
6
Is resistance
between C3B
Yes (female) (6) and
chassis, and
between C3B
(female) (6) and
5 (13) normal?

Yes Is voltage between 1) Min. 1 MΩ.

C3B (5) and chassis 2) Disconnect L04,
normal? C3B, and JSA.
3) Turn starting
1) 20 - 30 V. switch OFF.
2) Turn starting b
4 switch ON. No
3) Directional lever:
Is resistance F
between C3B
Yes (female) (5) and
chassis, and
between C3B
(female) (5) and
(6), (13) normal?
1) Min. 1 MΩ.
2) Disconnect L04, c
C3B, and JSA. No
3) Turn starting
3 switch OFF.

Yes Is voltage between

L04 (1) and chassis
normal?
1) 20 - 30 V.
2) Turn starting d
switch ON. No

2
Yes Is resistance
between L04
(female) (1) and
chassis normal?

1 1) Min. 1 MΩ.
2) Disconnect FS2 e
Is resistance and L04. No
between L04 (male) 3) Turn starting
(1) and (2), (3), and switch OFF.
(4) as shown in
Table 1?
1) Disconnect L04.
2) Turn starting f
switch OFF. No

g
No

20-1228 WA500-3H
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,

Cause Remedy
10 Yes Defective transmission
controller Replace
9 Yes Is voltage between
C3B (13) and chassis
Yes Is failure code normal? Defective contact, or
displayed when L57 disconnection in wiring Repair or
8 1) 20 - 30 V. No harness between L04
is replaced with 2) Turn starting switch (female) (3) and C3B replace
relay of same type? ON. (female) (13)
Yes Is resistance between
C3B (13) and chassis 3) Directional lever: N
normal? 1) Turn starting switch
OFF. Defective neutral relay Replace
7 1) Min. 1 MΩ. 2) Interchange with No
2) Disconnect L04, relay of same type.
Is voltage between C3B, L57, and L05. 3) Turn starting switch Short circuit with chassis
a C3B (6) and 3) Turn starting switch ON. ground in wiring harness
chassis normal? OFF. 4) Directional lever: N between L04 (female) (3)
and C3B (female) (13), Repair or
1) 20 - 30 V. No between L04 (female) (3) - replace
2) Turn starting JSA (1) - L05 (female) (8),
switch ON. and between JSA (female)
3) Directional lever: (1) and L57 (female) (1)
R
Defective contact, or
disconnection in wiring Repair or
No harness between L04
(female) (4) and C3B replace
(female) (6)

Short circuit with chassis

ground in wiring harness
between L04 (female) (4)
and C3B (female) (6), or
short circuit in wiring Repair or
b harness between L04 replace
(female) (4) - C3B
(female) (6) and wiring
harness between L04
(female) (3) and C3B
(female) (13)

Defective contact, or
disconnection in wiring Repair or
c harness between L04 replace
(female) (2) and C3B
(female) (5)

Short circuit with chassis

ground in wiring harness
between L04 (female) (2)
and C3B (female) (5), or
short circuit wiring
d harness between L04 Repair or
(female) (2) - C3B replace
(female) (5) and wiring
harness between L04
(female) (4) - C3B
(female) (6), and between
L04 (female) (3) and C3B
(female) (13)

Defective contact, or
disconnection in wiring
e harness between fuse I (9) Repair
replace
or
- FS2 (8) - L04 (female)
(1)

Short circuit with chassis

f ground in wiring harness Repair or
between FS2 (female) (8) replace
and L04 (female) (1)

g Defective directional and Replace

speed switch

WA500-3H 20-1229
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12
Table 1
Directional Position
Terminal
F N R
L04 (male) (1) - (2) Max. 1Ω Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (3) Min. 1 MΩ Max. 1Ω Min. 1 MΩ
L04 (male) (1) - (4) Min. 1 MΩ Min. 1 MΩ Max. 1Ω

T-9 Related electrical circuit diagram

20-1230 WA500-3H
TROUBLESHOOTING T-9 FAILURE CODE [20] (SHORT CIRCUIT,
12

MEMORANDUM

WA500-3H 20-1231
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
12
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN
RANGE SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Yes
a
6
Is resistance
between C3B
Yes (female) (8) and
chassis, and
between C3B
(female) (8) and
5 (15) (16) normal?

Yes Is voltage between 1) Min. 1 MΩ.

C3B (7) and chassis 2) Disconnect L04
normal? and C3B.
3) Turn starting
1) 20 - 30 V. switch OFF.
2) Turn starting
4 switch ON.
3) Speed lever: 1st b
Is resistance No
between C3B
Yes (female) (7) and
chassis, and
between C3B
(female) (7) and
(8), (15) (16)
normal?
1) Min. 1 MΩ.
2) Disconnect L04 c
and C3B. No
3) Turn starting
3 switch OFF.

Yes Is voltage between

L04 (1) and chassis
normal?
1) 20 - 30 V.
2) Turn starting d
switch ON. No

2
Yes Is resistance
between L04
(female) (1) and
chassis normal?

1 1) Min. 1 MΩ.
2) Disconnect FS2 e
Is resistance and L04. No
between L04 (male) 3) Turn starting
(1), (5), (6), (7), and switch OFF.
(8) as shown in
Table 1?
1) Disconnect L04.
2) Turn starting f
switch OFF. No

g
No

20-1232 WA500-3H
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,

Cause Remedy
10 Yes
Go to A -
Yes Is resistance between
C3B (16) and chassis
9 normal?
8 Yes Is voltage between 1) Min. 1 MΩ. Short circuit with chassis
C3B (15) and chassis 2) Disconnect L04 ground in wiring harness Repair or
normal? and C3B. No between L04 (female) (8) replace
Is resistance between 3) Turn starting switch and C3B (female) (16)
C3B (female) (15) 1) 20 - 30 V. OFF.
Yes and chassis, and
2) Turn starting switch
between C3B ON.
(female) (15) and 3) Speed lever: 2nd
(16) normal? Defective contact, or
7 disconnection in wiring Repair or
harness between L04
Is voltage between 1) Min. 1 MΩ. No (female) (6) and C3B replace
a C3B (8) and 2) Disconnect L04 (female) (15)
chassis normal? and C3B.
3) Turn starting switch
1) 20 - 30 V. OFF. Short circuit with chassis
2) Turn starting ground in wiring harness
switch ON. between L04 (female) (6)
3) Speed lever: 3rd and C3B (female) (15), or
No short circuit in wiring
harness between L04 Repair or
(female) (6) - C3B replace
(female) (15) and wiring
harness between L04
(female) (8) - C3B
(female) (16)

Defective contact, or
disconnection in wiring Repair or
harness between L04 replace
(female) (7) and C3B
No (female) (8)

Short circuit with chassis

ground in wiring harness
between L04 (female) (7)
and C3B (female) (8), or
b short circuit in wiring
harness between L04 Repair or
(female) (7) - C3B replace
(female) (8), between L04
(female) (6) - C3B
(female) (15), and between
L04 (female) (8) - C3B
(female) (16)

Defective contact, or
disconnection in wiring Repair or
c harness between L04 replace
(female) (5) and C3B
(female) (7)

Short circuit with chassis

ground in wiring harness
between L04 (female) (5)
and C3B (female) (7), or
d short circuit in wiring
harness between L04
(female) (5) - C3B Repair or
(female) (7), between L04 replace
(female) (6) - C3B
(female) (15), between
L04 (female) (7) - C3B
(female) (8), and between
L04 (female) (8) - C3B
(female) (16)

Defective contact, or
disconnection in wiring
harness between fuse I (9) Repair
replace
or
e - FS2 (8) - L04 (female)
(1)

Short circuit with chassis

ground in wiring harness Repair or
f between FS2 (female) (8) replace
and L04 (female) (1)

g Defective speed switch Replace

WA500-3H 20-1233
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,

11 Yes
h
Is voltage between C3B
From A (16) and chassis
normal?
1) 20 - 30 V.
2) Turn starting switch i
ON. No
3) Speed lever: 4th.

20-1234 WA500-3H
TROUBLESHOOTING T-10 FAILURE CODE [21] (SHORT CIRCUIT,
12

Cause Remedy

h Defective transmission Replace

controller

Defective contact, or
disconnection in wiring Repair or
i harness between L04 replace
(female) (8) and C3B
(female) (16)

Table 1
Directional Position
Terminal
1st 2nd 3rd 4th
L04 (male) (1) - (5) Max. 1Ω Min. 1 MΩ Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (6) Min. 1 MΩ Max. 1Ω Min. 1 MΩ Min. 1 MΩ
L04 (male) (1) - (7) Min. 1 MΩ Min. 1 MΩ Max. 1Ω Min. 1 MΩ
L04 (male) (1) - (8) Min. 1 MΩ Min. 1 MΩ Min. 1 MΩ Max. 1Ω

T-10 Related electrical circuit diagram

WA500-3H 20-1235
TROUBLESHOOTING T-11 FAILURE CODE [22] (DISCONNECTION
12
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED
SENSOR SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
3 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (10) and
chassis normal when
CN3 (female) (2) is Defective contact, or
2 grounded to chassis? disconnection in wiring
harness between C5 Repair or
Yes Is resistance between 1) Max. 1 Ω. No (female) (2) - TM2 (9) - replace
C5 (female) (2) and 2) Disconnect C3, C5, CN3 (female) (1)
1 chassis normal when and L07.
CN3 (female) (1) is 3) Turn starting switch
grounded to chassis? OFF.
Is resistance between Defective contact, or
CN3 (male) (1) and (2), 1) Max. 1 Ω. disconnection in wiring
and between (1), (2) and 2) Disconnect C3, C5, harness between C5 Repair or
chassis normal? and L07. No (female) (10) - TM2 (10) - replace
3) Turn starting switch CN3 (female) (2)
1) Between (1) and (2): OFF.
500 - 1000 Ω.
2) Between (1), (2) and
chassis: Min. 1 MΩ. Defective speed sensor Replace
3) Disconnect CN3. No
4) Turn starting switch
OFF.

T-11 Related electrical circuit diagram

20-1236 WA500-3H
TROUBLESHOOTING T-11 FAILURE CODE [22] (DISCONNECTION
12

MEMORANDUM

WA500-3H 20-1237
TROUBLESHOOTING T-12 FAILURE CODE [23] (SHORT CIRCUIT,
12
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN
ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 Yes
Go to A -
Yes Is resistance between
C4 (female) (9) and
3 chassis normal when
E04 (female) (3) is Defective contact, or
Yes Is resistance between grounded to chassis? disconnection in wiring
C4 (female) (2) and harness between C4 Repair or
chassis normal? 1) Max. 1 Ω. No (female) (9) - LR3 (8) - replace
2
2) Disconnect C4, ER2 (7) - E04 (female) (3)
Yes Is resistance between 1) Min. 1 MΩ. E04, and L07.
C4 (female) (2) and 2) Disconnect C4, 3) Turn starting switch
chassis normal when E04, and L07. OFF. Short circuit with chassis
E04 (female) (2) is 3) Turn starting switch ground in wiring harness
1 grounded to chassis? OFF. between C4 (female) (2) - Repair or
LR3 (7) - ER2 (6) - E04
Is resistance between 1) Max. 1 Ω. No (female) (2), and between replace
E04 (male) (2) and (3) 2) Disconnect C4, C4 (female) (2) and L07
normal? E04, and L07. (female) (3)
3) Turn starting switch
1) 100 - 500 Ω. OFF.
2) Disconnect CN3. Defective contact, or
3) Turn starting switch disconnection in wiring
OFF. harness between C4 Repair or
No (female) (2) - LR3 (7) - replace
ER2 (6) - E04 (female) (2)

Defective engine speed Replace

No sensor

6 Yes Defective transmission

controller Replace
Yes Is resistance between
C4 (female) (2) and (9)
5 normal? Short circuit with chassis
ground in wiring harness
Is resistance between 1) Min. 1 MΩ. between C4 (female) (2) - Repair or
From A C4 (female) (9) and 2) Disconnect C4, E04, LR3 (7) - ER2 (6) - E04
chassis normal? and L07. No (female) (2), and between replace
3) Turn starting switch C4 (female) (9) - LR3 (8) -
1) Min. 1 MΩ. OFF. ER2 (7) - E04 (female) (3)
2) Disconnect C4, E04,
and L07.
3) Turn starting switch Short circuit with chassis
OFF. ground in wiring harness Repair or
between C4 (female) (9) - replace
No LR3 (8) - ER2 (7) - E04
(female) (3)

20-1238 WA500-3H
TROUBLESHOOTING T-12 FAILURE CODE [23] (SHORT CIRCUIT,
T-12 Related electrical circuit diagram

WA500-3H 20-1239
TROUBLESHOOTING T-13 FAILURE CODE [24] (SHORT CIRCUIT,
12
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN
EEP ROM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Defective transmission Replace

controller

20-1240 WA500-3H
TROUBLESHOOTING T-14 FAILURE CODE [25] (SHORT CIRCUIT
12
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL
TEMPERATURE SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
Cause Remedy
3 Yes Defective transmission
controller Replace
Yes
Is resistance between
2 C3A (female) (11) and Short circuit in wiring
(17) normal? harness between C3A
Yes Is resistance between (female) (11) - TM2 (13) - Repair or
C3A (female) (11) CN11 (female) (1) and replace
1 and chassis normal? 1) Min. 1 MΩ. No wiring harness between
2) Turn starting switch C3A (female) (17) - TM2
1) Min. 1 MΩ. OFF. (14) - CN11 (female) (2)
Is resistance between 2) Turn starting switch 3) Disconnect C3A
CN11 (male) (1) and OFF. and CN11.
(2), and between (1), (2) 3) Disconnect C3A
chassis normal? Short circuit with chassis
and CN11. ground in wiring harness
between C3A (female) Repair or
1) Between (1) and (2): No (11) - TM2 (13) - CN11 replace
38 - 48 kΩ (normal (female) (1)
temperature: 25o C
[77o F])
2) Between (1), (2) and Defective transmission oil Replace
chassis: Min. 1 MΩ. No temperature sensor
3) Turn starting switch
OFF.
4) Disconnect CN11.

T-14 Related electrical circuit diagram

WA500-3H 20-1241
TROUBLESHOOTING T-15 FAILURE CODE [26] (SHORT CIRCUIT
12
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (2) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN17 (male) (1) and 2) Disconnect C3B and between C3B (female) (2) replace
chassis normal? CN17. No - TM2 (6) - CN17 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN17.
3) Turn starting switch
OFF. Defective F ECMV fill Replace
No switch

T-15 Related electrical circuit diagram

20-1242 WA500-3H
TROUBLESHOOTING T-16 FAILURE CODE [27] (SHORT CIRCUIT
12
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (10) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness
CN15 (male) (1) and 2) Disconnect C3B and between C3B (female) Repair or
chassis normal? CN15. No (10) - TM2 (3) - CN15 replace
3) Turn starting switch (female) (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN15.
3) Turn starting switch
OFF. Defective R ECMV fill Replace
No switch

T-16 Related electrical circuit diagram

WA500-3H 20-1243
TROUBLESHOOTING T-17 FAILURE CODE [28] (SHORT CIRCUIT
12
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (3) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN5 (female) (1) and 2) Disconnect C3B and between C3B (female) (3) replace
chassis normal? CN5. No - TM1 (3) - CN5 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN5.
3) Turn starting switch
OFF. Defective 1st ECMV fill Replace
No switch

T-17 Related electrical circuit diagram

20-1244 WA500-3H
TROUBLESHOOTING T-18 FAILURE CODE [29] (SHORT CIRCUIT
12
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (11) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness
CN7 (female) (1) and 2) Disconnect C3B and between C3B (female) Repair or
chassis normal? CN7. No (11) - TM1 (6) - CN7 replace
3) Turn starting switch (female) (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN7.
3) Turn starting switch
OFF. Defective 2nd ECMV fill Replace
No switch

T-18 Related electrical circuit diagram

WA500-3H 20-1245
TROUBLESHOOTING T-19 FAILURE CODE [30] (SHORT CIRCUIT
12
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are property inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (11) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN13 (female) (1) and 2) Disconnect C5 and between C5 (female) (11) - replace
chassis normal? CN13. No TM1 (9) - CN13 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN13.
3) Turn starting switch
OFF. Defective 3rd ECMV fill Replace
No switch

T-19 Related electrical circuit diagram

20-1246 WA500-3H
TROUBLESHOOTING T-20 FAILURE CODE [31] (SHORT CIRCUIT
12
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (12) and
1 chassis normal?
Short circuit with chassis
Is resistance between 1) Min. 1 MΩ. ground in wiring harness Repair or
CN9 (female) (1) and 2) Disconnect C5 and between C5 (female) (12) replace
chassis normal? CN9. No - TM1 (12) - CN9 (female)
3) Turn starting switch (1)
1) Min. 1 MΩ. OFF.
2) Disconnect CN9.
3) Turn starting switch
OFF. Defective 4th ECMV fill Replace
No switch

T-20 Related electrical circuit diagram

WA500-3H 20-1247
TROUBLESHOOTING T-21 FAILURE CODE [32] (SHORT CIRCUIT
12
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL
SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
Yes
Defective transmission Replace
controller

Yes
2
Yes Is resistance between
C3B (female) (2)
and chassis normal
when CN15 (female)
(1) is grounded to
1 chassis?
Is resistance between 1) Max. 1 Ω.
C3B (female) (10) and 2) Turn starting switch
chassis normal when OFF.
CN17 (female) (1) is 3) Disconnect C3B.
grounded to chassis?
4
Yes Is E32 displayed
when CN15 (female)
3 (1) is grounded to
chassis?
Is E32 displayed
when CN17 (female) 1) Turn starting switch
(1) is grounded to OFF. Defective R ECMV fill
chassis? 2) Disconnect CN15 No switch Replace
3) Start engine
1) Turn starting switch 4) Transmission cut-
OFF. off switch: OFF
2) Disconnect CN17 5) Parking brake
3) Start engine switch: OFF
4) Transmission cut- 6) Depress brake.
off switch: OFF 7) Directional lever: R
5) Parking brake
switch: OFF
6) Depress brake.
7) Directional lever: F
Defective F ECMV fill Replace
No switch

1) Max. 1 Ω.
2) Turn starting switch Defective contact, or
OFF. disconnection in wiring
3) Disconnect C3B. harness between C3B Repair or
No (female) (2) - TM2 (3) - replace
CN15 (female) (1)

Defective contact, or
disconnection in wiring Repair or
harness between C3B replace
No (female) (10) - TM2 (6) -
CN17 (female) (1)

T-21 Related electrical circuit diagram

20-1248 WA500-3H
TROUBLESHOOTING T-21 FAILURE CODE [32] (SHORT CIRCUIT
12

MEMORANDUM

WA500-3H 20-1249
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR
4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
• This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Yes
a
6
Yes Is E33 displayed
when CN7
5 (female) (1) is
grounded to
Yes Is E33 displayed chassis?
when CN5 (female) 1) Turn starting
4 (1) is grounded to switch OFF.
chassis? 2) Disconnect
Is resistance
between C5 CN7. b
Yes (female) (12) and 1) Turn starting 3) Start engine. No
chassis normal switch OFF. 4) Directional
3 when CN9 (female) 2) Disconnect CN5. lever: N
(1) is grounded to 3) Start engine. 5) Speed lever:
chassis? 4) Directional lever: 2nd
Is resistance N c
between C5
Yes (female) (11) and 1) Max. 1 Ω. 5) Speed lever: 1st No
2) Turn starting
chassis normal switch OFF.
2 when CN13 3) Disconnect CN9
(female) (1) is and C5.
Is resistance grounded to
between C3B chassis? d
Yes (female) (11) and No
chassis normal
when CN7 (female) 1) Max. 1 Ω.
(1) is grounded to 2) Turn starting
1 chassis? switch OFF.
3) Disconnect CN13
Is resistance 1) Max. 1 Ω. and C5.
between C3B 2) Turn starting e
(female) (3) and switch OFF. No
chassis normal 3) Disconnect CN7
when CN5 (female) and C3B.
(1) is grounded to
chassis?
1) Max. 1 Ω.
2) Turn starting f
switch OFF. No
3) Disconnect CN5
and C3B.

g
No

20-1250 WA500-3H
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12

Cause Remedy
8 Yes Defective transmission
controller Replace
7 Yes Is E33 displayed when
CN9 (female) (1) is
Is E33 displayed grounded to chassis?
a when CN13 Defective 4th ECMV fill Replace
(female) (1) is 1) Turn starting switch No switch
grounded to OFF.
chassis? 2) Disconnect CN9.
3) Start engine.
1) Turn starting 4) Directional lever: N
switch OFF. 5) Speed lever: 4th
2) Disconnect
CN13. Defective 3rd ECMV fill Replace
3) Start engine. No switch
4) Directional lever:
N
5) Speed lever: 3rd Defective 2nd ECMV fill
b switch Replace

c Defective 1st ECMV fill Replace

switch

Defective contact, or
disconnection in wiring Repair or
d harness between C5
(female) (12) - TM1 (12) - replace
CN9 (female) (1)

Defective contact, or
disconnection in wiring Repair or
e harness between C5 replace
(female) (11) - TM1 (9) -
CN13 (female) (1)

Defective contact, or
disconnection in wiring Repair or
f harness between C3B replace
(female) (11) - TM1 (6) -
CN7 (female) (1)

Defective contact, or
disconnection in wiring Repair or
g harness between C3B replace
(female) (3) - TM1 (3) -
CN5 (female) (1)

WA500-3H 20-1251
TROUBLESHOOTING T-22 FAILURE CODE [33] (SHORT CIRCUIT
12
T-22 Related electrical circuit diagram

20-1252 WA500-3H
TROUBLESHOOTING T-23 HOLD SWITCH SYSTEM
12
T-23 HOLD SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

Cause Remedy
Yes Defective transmission
controller Replace
1

Is resistance between C5 Short circuit with chassis

(female) (13) and ground, defective
2 Yes contact, or disconnection Repair or
chassis normal? in wiring harness between replace
C5 (female) (13) and L15
Is resistance between (female) (3)
1) Disconnect C5. No L15 (male) (3) and (4)
2) Hold switch normal?
ON: Max. 1 Ω.
OFF: Min. 1 MΩ. Defective hold switch Replace
1) Disconnect L15. No
2) Hold switch
ON: Max. 1 Ω.
OFF: Min. 1 MΩ.

T-23 Related electrical circuit diagram

WA500-3H 20-1253
TROUBLESHOOTING T-24 KICK-DOWN SWITCH SYSTEM
12
T-24 KICK-DOWN SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

Cause Remedy
Yes Defective transmission
controller Replace
1

Is resistance between C5 Short circuit with chassis

(female) (5) and ground, defective
2 Yes contact, or disconnection Repair or
chassis normal? in wiring harness between replace
C5 (female) (5) and L15
Is resistance between (female) (1)
1) Disconnect C5. No L15 (male) (1) and (2)
2) Hold switch normal?
ON: Max. 1 Ω.
OFF: Min. 1 MΩ. Defective kick-down Replace
1) Disconnect L15. No switch
2) Hold switch
ON: Max. 1 Ω.
OFF: Min. 1 MΩ.

T-24 Related electrical circuit diagram

20-1254 WA500-3H
TROUBLESHOOTING T-25 TRANSMISSION CUT-OFF SIGNAL
12
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

Cause Remedy
Yes Defective transmission
controller Replace

1
1) Short circuit with
chassis ground,
Is resistance between C5 defective contact, or
(female) (6) and disconnection in
chassis normal? wiring harness
between C5 (female)
(6) and L12 (female)
1) Disconnect C5. Yes (1)
2) Transmission cut-off Repair or
switch 2) Short circuit with replace
2
ON: Max. 1 Ω. chassis ground,
OFF: Min. 1 MΩ. defective contact, or
Is resistance between disconnection in
No L12 (male) (1) and (2) wiring harness
normal? between C5 (female)
(6) and L06 (female)
(3)
1) Disconnect L12.
2) Transmission cut-off
switch
ON: Max. 1 Ω. Defective transmission Replace
OFF: Min. 1 MΩ. No cut-off switch

T-25 Related electrical circuit diagram

WA500-3H 20-1255
TROUBLESHOOTING T-26 NEUTRALIZER RELAY SIGNAL SYS-
12
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM
• Check that the parking brake works normally.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.

Cause Remedy
Yes Defective transmission
controller Replace
1 4 Yes

Is voltage between C3B Defective neutralizer relay Replace

(14) and (9) normal? Is resistance between
Yes C3A (female) (6)
1) Insert T-adapter. and C3B (female)
3 (14) normal? Defective contact, or
2) Turn starting switch
ON. disconnection in wiring
Yes harness between C3A Repair or
3) Parking brake switch: Is voltage between
ON↔OFF. L58 (female) (1) and 1) Disconnect C3A, No (female) (6) - L58 replace
4) 20 - 30 V. 2 (female) (5), L58 (female)
chassis normal? C3B, and L58.
2) Short circuit L58 (3) - C3B (female) (14)
Is resistance between (female) (3) and
No L58 (female) (2) and 1) Disconnect L58. (5).
chassis normal? 2) Turn starting switch 3) Max. 1 Ω. Short circuit with chassis
ON. ground, defective contact,
3) Parking brake or disconnection in wiring Repair or
1) Disconnect L58. switch: ON↔OFF. No harness between L58 replace
2) Max. 1 Ω. 4) 20 - 30 V. (female) (1) and L01
(female) (2)

Defective contact, or
disconnection in wiring Repair or
No harness between L58 replace
(female) (2) and chassis

T-26 Related electrical circuit diagram

20-1256 WA500-3H
TROUBLESHOOTING T-27 BUZZER SIGNAL SYSTEM
12
T-27 BUZZER SIGNAL SYSTEM
• Check that the main monitor and alarm buzzer work normally.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

2 Yes Is resistance between
Yes Is resistance between
C1 (female) (2) and
1 chassis normal?
Is resistance between C1 1) Disconnect C1.
(female) (2) and chassis 2) Make short circuit
normal? between L08, and
chassis.
1) Disconnect C1, L08, 3) Max. 1 Ω.
and RES.
3) Min. 1 MΩ.
No
Cause Remedy
3 Yes Defective transmission
controller Replace
C1 (female) (2) and
chassis normal?
Short circuit, defective
1) Disconnect C1 and contact, or disconnection Repair or
L08. in wiring harness between replace
2) 4k - 7kΩ. No C1 (female) (2) - L34 (5) -
RES (female) (1)
Defective contact, or
disconnection in wiring
harness between C1 Repair or
(female) (2) L08 (female) replace
(6)

Short circuit with chassis

ground in wiring harness
between C1 (female) (2) - Repair or
No L08 (female) (6), L34 replace
(male) (5) - RES (female)
(1)

T-27 Related electrical circuit diagram

WA500-3H 20-1257
TROUBLESHOOTING T-28 NETWORK SYSTEM
12
T-28 NETWORK SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (4),
1 (12) and chassis Defective contact, or
normal? disconnection in wiring
harness between C3B
Is resistance between (female) (4), (12), and L08 Repair or
C3B (female) (4), (12) 1) Max. 1 Ω. No (female) (1, (3), or L34 replace
and chassis normal? 2) Turn starting switch (male) (1), or LM1 (male
OFF. (5))
3) Disconnect C3B, L08,
1) Min. 1 MΩ. L34, and LM1.
2) Turn starting switch 4) Make short circuit Short circuit with chassis
OFF. between L08 (female) ground in wiring harness
3) Disconnect C3B, L08, (1), (3), and chassis. between C3B (female) (4), Repair or
L34, and LM1. (12), and L08 (female) (1), replace
No (3), or L34 (male) (1), or
LM1 (male) (5)

T-28 Related electrical circuit diagram

20-1258 WA500-3H
TROUBLESHOOTING T-29 TRANSMISSION CONTROLLER POW-
12
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
• Check that fuse (II) is normal.
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.
• Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).

Cause Remedy
Yes Defective transmission
controller Replace
1

Is resistance between C1 Short circuit with ground,

(7), (13), C2 (1), (12) -
C1 (6), (12), C2 (11),
(21) normal?
2 (female) (7), (13) and C2 replace
1) 20 - 30 V.
2) Turn starting switch Is resistance between
ON. No C1 (female) (6), (12)
and C2 (female) (11),
(21) - chassis normal?
1) Max. 1 Ω.
2) Turn starting switch
OFF.
3) Disconnect C1 and
C2.
defective contact, or dis-
Yes connection in wiring Repair or
harness between C1
(female) (1), (12) - FS5
(female) (6)
Defective contact, or
disconnection in wiring
harness between C1 Repair or
No (female) (6), (12) and C2 replace
(female) (11), (21) -LR5
(female) (3) - chassis

T-29 Related electrical circuit diagram

WA500-3H 20-1259
TROUBLESHOOTING T-30 SHORT CIRCUIT IN TRAVEL SPEED
12
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
Yes Defective transmission
controller Replace
2
Yes Is resistance between
C5 (female) (2) and Short circuit in wiring
1 (10) normal? harness between C5
(female) (2) - L07
Is resistance between C5 1) Min. 1 MΩ. (female) (1) - TM2 (9) -
(female) (2) and chassis 2) Turn starting switch CN3 (male) (1) and wiring Repair
replace
or
normal? OFF. No harness between C5
3) Disconnect C5, CN3, (female) (10) - L07
1) Min. 1 MΩ. and L07. (female) (2) - TM2 (10) -
2) Turn starting switch CN3 (female) (2)
OFF.
3) Disconnect C5, CN3,
and L07.
Short circuit in wiring
harness between C5
(female) (2) - TM2 (9) - Repair or
No CN3 (female) (1) and replace
between C5 (female) (2) -
L07 (female) (1)

T-30 Related electrical circuit diagram

20-1260 WA500-3H
TROUBLESHOOTING T-31 DISCONNECTION IN TRANSMISSION
12
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE
SENSOR SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
4 Yes Defective transmission
controller Replace
Yes
Is resistance between
3 C3A (female) (17)
and chassis normal? Short circuit with chassis
Is resistance between ground in wiring harness Repair or
between C3A (female) replace
C3A (female) (17)
Yes and chassis normal 1) Min. 1 MΩ. No (17) - TM2 (14) - CN11
when CN11 (female) 2) Turn starting switch (female) (2)
2 (2) is grounded to OFF.
chassis? 3) Disconnect C3A
and CN11.
Is resistance between Defective contact or
Yes C3A (female) (17) 1) Max. 1 Ω. disconnection in wiring
and chassis normal 2) Turn starting switch harness between C3A Repair or
when CN11 (female) OFF. No (female) (17) - TM2 (14) - replace
1 (1) is grounded to
chassis? 3) Disconnect C3A. CN11 (female) (2)
Is resistance between
CN11 (male) (1) - (2) 1) Max. 1 Ω.
and between (1), (2) 2) Turn starting switch
chassis normal? Defective contact or
OFF. disconnection in wiring
3) Disconnect C3A. harness between C3A Repair or
1) Between (1) and (2): No (female) (11) - TM2 (13) - replace
3.8 - 4.8 Ω (normal CN11 (female) (1)
temperature: 25o C
[77o F])
3.6 - 3.9 Ω (100o C Defective transmission oil Replace
temperature sensor
[212o F] No
2) Between (1), (2) and
chassis: Min. 1 MΩ.
3) Turn starting switch
OFF.
4) Disconnect CN11.

T-31 Related electrical circuit diagram

WA500-3H 20-1261
TROUBLESHOOTING T-32 DISCONNECTION IN F ECMV FILL
12
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (2) and
1 chassis normal when
CN17 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN17 (1) and chassis harness between C3B Repair or
normal? 1) Max. 1 Ω. No (female) (2) - TM2 (6) - replace
2) Disconnect C3B. CN17 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN17. Defective F ECMV fill Replace
4) Start engine. No switch
5) Transmission cut-off
switch: OFF (lamp
out).
6) Parking brake switch:
OFF
7) Depress brake.

T-32 Related electrical circuit diagram

20-1262 WA500-3H
TROUBLESHOOTING T-33 DISCONNECTION IN R ECMV FILL
12
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (10) and
1 chassis normal when
CN15 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN15 (1) and chassis harness between C3B Repair or
normal? 1) Max. 1 Ω. No (female) (10) - TM2 (3) - replace
2) Disconnect C3B. CN15 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN15. Defective R ECMV fill Replace
4) Start engine. No switch
5) Transmission cut-off
switch: OFF (lamp
out).
6) Parking brake switch:
OFF
7) Depress brake.

T-33 Related electrical circuit diagram

WA500-3H 20-1263
TROUBLESHOOTING T-34 DISCONNECTION IN 1ST ECMV FILL
12
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (3) and
1 chassis normal when
CN5 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN5 harness between C3B Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (3) - TM1 (3) - replace
2) Disconnect C3B. CN5 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN5. Defective 1st ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 1st.

T-34 Related electrical circuit diagram

20-1264 WA500-3H
TROUBLESHOOTING T-35 DISCONNECTION IN 2ND ECMV FILL
12
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C3B (female) (11) and
1 chassis normal when
CN7 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN7 harness between C3B Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (11) - TM1 (6) - replace
2) Disconnect C3B. CN7 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN7. Defective 2nd ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 2nd.

T-35 Related electrical circuit diagram

WA500-3H 20-1265
TROUBLESHOOTING T-36 DISCONNECTION IN 3RD ECMV FILL
12
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (11) and
1 chassis normal when
CN13 (female) (1) is Defective contact or
Is voltage between grounded to chassis? disconnection in wiring
CN13 (1) and chassis harness between C5 Repair or
normal? 1) Max. 1 Ω. No (female) (11) - TM1 (9) - replace
2) Disconnect C5. CN13 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Disconnect CN13. Defective 3rd ECMV fill Replace
4) Start engine. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 3rd.

T-36 Related electrical circuit diagram

20-1266 WA500-3H
TROUBLESHOOTING T-37 DISCONNECTION IN 4TH ECMV FILL
12
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM
• Before carrying out troubleshooting, check that all the related connectors are properly inserted.
• Always connect any disconnected connectors before going on to the next step.

Cause Remedy
2 Yes Defective transmission
controller Replace
Yes Is resistance between
C5 (female) (12) and
1 chassis normal when
CN9 (female) (1) is Defective contact or
grounded to chassis? disconnection in wiring
Is voltage between CN9 harness between C5 Repair or
(1) and chassis normal? 1) Max. 1 Ω. No (female) (12) - TM1 (12) - replace
2) Disconnect C5. CN9 (female) (1)
1) 20 - 30 V. 3) Turn starting switch
2) Turn starting switch OFF.
OFF.
3) Start engine. Defective 4th ECMV fill Replace
4) Disconnect CN9. No switch
5) Directional lever: N
6) Manual switch: ON
7) Speed lever: 4th.

T-37 Related electrical circuit diagram

WA500-3H 20-1267
TROUBLESHOOTING T-37 DISCONNECTION IN 4TH ECMV FILL
12

MEMORANDUM

20-1268 WA500-3H
 TROUBLESHOOTING AIR CONDITIONING
(DENSO)

AIR CONDITIONER / HEATER (DENSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1302

VISUAL AND AUDIBLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1302
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE) . . . . . . . . . . . . . . 20-1303
NORMAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1303
INSUFFICIENT REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1303
REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED) . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
MOISTURE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
COMPRESSOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING . . . . . . . . . . . . . . . 20-1305
AIR IN THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1305
EXPANSION VALVE OPENS TOO FAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1305
TROUBLESHOOTING THE ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1306
BLOWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1306
ELECTRICAL CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
COOLER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
AIR CONDITIONER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
MAGNETIC CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
CONDENSER FAN OPERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1311
ERROR MESSAGE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1314
A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER . . . . . . . . . . . . . . . . . . . 20-1314
B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER . . . . . . . . . . . . . . . . . . . 20-1314
C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS . . . . . . . . . . . . . . . 20-1315
D. PROBLEM - NO HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1315
E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE
POWER IS TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1315
F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST
BUTTON IS PUSHED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1316
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1318
WIRE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1319
INSPECTION AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1320

WA500-3H 20-1301
TROUBLESHOOTING AIR CONDITIONER / HEATER (DENSO)
12
AIR CONDITIONER / HEATER (DENSO)

VISUAL AND AUDIBLE INSPECTION

• Is the drive belt loose?
• Are condenser fins blocked, clogged, or covered with dirt or dust? (Condenser and air conditioner efficiency both will
suffer).
• Is the air filter clogged? (Clogged air filter will reduce air flow and lower the cooling capacity).
• Are oil stains present in the refrigeration cycle connections and joints? (Stains are evidence of compressor oil, usually
accompanied by refrigerant).
• Does the system contain the correct refrigerant quantity as seen in the sight glass? (Only a small quantity of bubbles
appear).
• Is the system louder than usual? (Abnormal noise).

Component Check these items

Compressor Shaft, cylinder head

Worn or damaged bearing.

Magnetic clutch Contact between stator and rotor.
Loose mounting screw on stator.

Upside down blower motor

Blower motor
Loose blower mounting

V-belt Improper tension

Worn mounting
Idle pulley
Worn or damaged bearing

Improper fastening or mounting of

Piping parts bracket or clamp
Incorrect clearance.

20-1302 WA500-3H
12
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)
• Trouble often can be detected and diagnosed for repair with the help of a manifold gauge. The manifold gauge unit
indicates the refrigeration system pressure on both sides (high and low pressure sides) simultaneously on the two dials.

Remark
Be sure air has been purged from the charging hoses of the manifold gauge by using the refrigerant pressure in the
system.

NORMAL CONDITIONS

After engine warm-up, check the following conditions

Engine speed 1500 rpm

A/C inlet temperature 30-35oC (85-95oF)

Blower speed HI

Temperature control Maximum cooling

Remark
Gauge indications before A/C operation, both high and low
pressure sides: 5-8 kg/cm² (71-114 psi).

INSUFFICIENT REFRIGERANT
Check and
Problem Cause
remedy

Pressure low on both Quantity of Check for gas leak

low pressure side refrigerant is too and repair.
and the high small.
pressure side. Replenish
refrigerant.
Bubbles visible in Gas leakage
sight glass. If pressure near 0,
evacuate air after
Air output is not repairing leak.
cool.
TROUBLESHOOTING AIR CONDITIONER / HEATER (DENSO)
12
REFRIGERANT FAILS TO CIRCULATE (SYSTEM
CLOGGED)
Check and
Problem Cause
remedy
Vacuum is Clogging of A/C -Check condition of
immediately system. receiver, expansion
indicated on low valves, etc.
pressure side
(completely -A temperature
clogged). difference occurs
between IN and
Vacuum gradually OUT of the
indicated on low defective parts.
pressure side
(partially clogged). -Evacuate air after
repair.

MOISTURE IN SYSTEM
Check and
Problem Cause
remedy

Normal operation at Moisture in -Check condition of

first; vacuum on low expansion valve expansion valve, etc.
pressure side is freezes.
indicated after time. -Replace receiver (or
dryer)

-Evacuate air after

repair.

COMPRESSOR FAILURE
Check and
Problem Cause
remedy

Pressure on low Compressor defect. -Check compressor

pressure side is high; condition.
pressure on high -Compressor unit is
pressure side is low. cool to the touch if
there is a
When the A/C is compression
turned off, the low malfunction.
and high pressure
sides quickly
equalize.

20-1304 WA500-3H
12
EXCESSIVE
REFRIGERANT OR INSUFFICIENT
CONDENSER COOLING
Check and
Problem Cause
remedy
Pressure high on Excessive -Check refrigerant
both sides. refrigerant. quantity and slowly
vent excess if
Bubbles not visible Poor condenser overcharged.
in the sight glass. cooling.
-Check and repair
Poor cooling condenser fan.
performance.
-Check engine
cooling system.

AIR IN THE SYSTEM

Check and
Problem Cause
remedy

Pressure is high on Air has entered into -Replace refrigerant.

both sides. the system.
-Evacuate the air
Low pressure is hot after repairs.
to the touch.

Bubbles are visible

in the sight glass.

EXPANSION VALVE OPENS TOO FAR

Check and
Problem Cause
remedy

Pressure is high on Expansion valve -Check condition of

both sides. fault (problem expansion valves.
frequently occurs
Frost after replacing -Check temperature
(condensation) expansion valves). sensing bulb
appears on low condition and
pressure side piping. installation.
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
TROUBLESHOOTING THE ELECTRICAL CIRCUIT
The flow charts on the following pages break down air conditioning problems into two categories: blower-related problems
and cooling equipment related problems. Check for blower troubles first, including such items as gauge fuse, circuit breaker,
heater relay, blower motor, blower resistor, and blower switch. Then check other air conditioning electrical components like
air conditioner fuse and switch, magnetic clutch and relay, sensors and wiring (input to amplifier) and amplifier. Cooler circuit
troubleshooting steps are shown on the next flow chart.

BLOWER TROUBLESHOOTING
Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart.
Descriptions of the inspection methods can be found on the pages that follow the flow chart.

20-1306 WA500-3H
12
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
ELECTRICAL CIRCUIT CHECKS
HEATER RELAY
Steps 4 and 5

Turn on the ignition switch and check input voltage at terminal 5 and 3.
If no voltage (0V), there should be open circuit between heater relay and
gauge fuse, or between heater relay and the battery. Inspect the
continuity with a circuit tester or ohmmeter. Repair or replace as
necessary.

Standard: terminal No. 1-3 continuity

terminal No. 2-4 continuity
terminal No. 4-5 no continuity

Applying the battery voltage between terminal Nos. 1 and 3, check

continuity between terminal 4 and 5 (point is closed).

BLOWER SWITCH
Step 6

If the blower doesn’t operate correctly, remove the blower switch

connector and check the continuity between the terminals with each
switch position. If all conditions are good reconnect the blower switch.

Check continuity between the heater relay terminals and the blower
switch terminals as follows.

1. Check continuity between the heater relay terminal 1 and blower

switch terminal 12, and between blower switch terminal 9 and
vehicle ground.

2. Check the resistance between the heater relay terminal 4 and

blower switch terminal 9 with each blower switch position.

When changing blower switch position from OFF to HI, the resistance
value should change from a high value to a low value.

20-1308 WA500-3H
12
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit
have been ruled out. Details about these procedures appear on the pages that follow.
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
COOLER CIRCUIT TROUBLESHOOTING
AIR CONDITIONER SWITCH
Step 1 and 2

Turn on blower switch and air conditioner switch, check voltage of the
amplifier at terminal 10. If 12 volts is not present (battery voltage),
wiring between the air conditioner fuse and amplifier input terminals is
faulty (open circuit), or the A/C switch is defective.

MAGNETIC CLUTCH RELAY

Step 4 and 4-1

Check that continuity exists between terminal no. 1 and 3 but not
between terminals 2 and 4. Apply battery voltage between terminal 1
and 3, check continuity between terminals 2 and 4 (the point is closed).

20-1310 WA500-3H
12
CONDENSER FAN OPERATION CIRCUIT
Step 2-2

Turn on the blower switch and A/C switch. Then inspect the condenser
fan operation.

Conditions
Fan
A/C Magnetic Coolant Refrigerant speed
switch Clutch Temperature pressure

Below 83o C
Stop
ON or (181o F)
OFF
OFF
Above 90o C Below 12.5 kg/cm2
HI
(194o F) (178 psi)

Below 83o C
ON ON LO
(181o F)

Below 83o C Above 15.5 kg/cm2

(181o F) (221 psi)

ON ON Below 12.5 kg/cm2 H!

o (178 psi)
Above 90 C
(194o F)
Above 15.5 kg/cm2
(221 psi)

Under low coolant temperature and low thermal load (low room and
ambient temperature) conditions, fan rotates at low speed with the
magnetic clutch on, while as the coolant temperature increases, fan
starts high speed rotation.

In case of high thermal load, the fan rotates at high speed also.

Check four relays used in the condenser fan operation.

a. Engine main relay (identical to the heater relay).
b. Condenser fan relay (3), identical to magnetic clutch relay.
c. Condenser fan relay (2) differs slightly from the heater relay in the
terminal layout. Check continuity as follows: continuity between
terminals 5 and 2, 1 and 3. No continuity between terminals 1 and
4.

Applying battery voltage between terminals 5 and 2, check the

continuity between terminals 1 and 4 (point is closed). Note that the
diode permits current flow between terminal 5 and terminal 2 in only
one direction.
TROUBLESHOOTING TROUBLESHOOTING THE ELECTRICAL
12
If the thermistor signal is wrong, check resistance of the thermistor. Its
resistance characteristics are shown in the illustration.

Idle speed check

When the air conditioner switch is turned ON, idle speed should
increase. Make sure the speed changes.

20-1312 WA500-3H
12
TROUBLESHOOTING
12
ERROR MESSAGE TABLES
• Setup: Controller set on Temp. 60o F (16o C), defrost “off”, and fan on high.
A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER
Possible Cause
1. Open electric condenser power
circuit.
2. Defective electric condenser relay
(circuit).
3. Open electric condenser voltage
detection circuit.
4. Improper wiring installation.
5. Defective controller.
B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER
Possible Cause
1. Abnormal A/C refrigerant
pressure(s).
* Cool weather operation may cause
low pressure short cycling.
2. Opened compressor clutch circuit.
3. Opened pressure switch detection
circuit.
4. Defective controller.
20-1314
ERROR MESSAGE TABLES
Inspection Remedy
Check electric condenser circuit
a. Repair wiring.
breaker for power, voltage, and
b. Replace open circuit breaker.
continuity.
Check for output voltage on the yellow a. Repair the connections / wiring.
wire, at the relay coil. Check the b. Replace the defective relay.
voltage and continuity across the relay
contacts.
Check for input voltage on the brown
a. Repair the wiring or connector.
wire, at the controller.
Applicable to systems without an EC. a. See note #3.
Check for output voltage on the yellow
a. Replace the controller.
wire, at the controller.
Inspection Remedy
Check the refrigerant pressures with a. Check the condenser operation for
gauges. air and refrigerant blockage.
High side greater than: b. Leak check system, repair the
320 psig (R12), or 350 psig leaks and recharge the system.
(R134a). c. Relocate the low pressure switch
Low side less than: to the evaporator outlet.
3 - 6 psig.*
Check for output voltage on the green a. Repair the connections/wiring.
wire at the compressor. Check the wire b. Replace the defective switch(es)
connections. Check for continuity or the thermostat.
across the pressure switch(es) and c. Replace the defective compressor
thermostat. Check continuity of clutch clutch.
solenoid to the ground.
Check for an input voltage on the tan a. Repair the connections/ wiring.
wire, at the controller.
Check for output voltage on the green a Replace the controller.
wire, at the controller.
WA500-3H
12
C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS
• Occurs particularly when vapor charging in cold weather.

1. E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction side
pressure must rise above 45 psig to reset the E1 error message.

2. When the system is fully charged, the E1 error message should not appear under normal operating conditions.

3. In order to continue charging, by-pass the LPS, turn the controller “off” then “on”, and set the controller to 60o F (16o C).
This will reset the controller and force into the air conditioning mode.

4. If the LPS can’t be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the
compressor clutch solenoid. Take care not to short out the controller clutch circuit.

5. E1 error message may occur while charging, when the compressor is wired hot.

D. PROBLEM - NO HEAT

Possible Cause Inspection Remedy

1. Opened heat solenoid circuit. Poor Check for an output voltage on the a. Repair connections/wiring.
connection, loss of voltage. white wire, at the heat solenoid valve.
Check solenoid continuity to the
ground.

2. Defective heat solenoid or improper Check for coolant blockages in the a. Repair or replace the valve.
installation. heat solenoid valve and hoses. Check b. Reverse the coolant hoses to the
the direction of coolant flow (feel the valve.
hoses).

3. Defective controller. Check for output voltage on the white a. Replace the controller.
wire, at the controller.

E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF,

WHEN THE POWER IS TURNED ON

Possible Cause Inspection Remedy

1. Fan wires shorted to ground or
vehicle chassis.
Disconnect controller from the a. Disconnect the ground and repair
external harness, Individually check the shorted wiring.
continuity of the orange and black fan
wires to ground, in the external
harness.
TROUBLESHOOTING
12
F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS
DEFROST BUTTON IS PUSHED.
Possible Cause
1. Defective preset thermostat inside
evaporator. Opened preset
thermostat circuit. Broken
thermostat wiring. Evaporator coil
temperature too cold for A/C
operation.
2. Ambient cab temperature too cool
{below 60o F (16o C)}.
3. Opened ambient cab temperature
probe (thermistor).
20-1316
ERROR MESSAGE TABLES
Inspection
Push, hold defrost / temperature a.
decrease buttons simultaneously. b If “OP”, repair connections or
Check display for “OP” or “CL”
readout. Disconnect red leads, and c.
check for continuity across thermostat
terminals.
Set controller at 68-70o F (20-21o C), a.
in A/C mode. Warm-up ambient
temperature probe with fingers or heat b.
gun.
Push, hold temp. Decrease/increase a.
buttons simultaneously. Display will
read 40o F (4o C) if probe is defective.
Disconnect the controller, check for b.
continuity across black probe leads. c.
Check resistance of thermistor.
Remedy
If “CL”, go to step 2.
wiring to preset thermostat.
Replace preset thermostat.
Verify if compressor clutch will
pull in or not.
If not go to step 3.
If display reads 49o F (9o C), at
room temperature, replace
thermistor.
Repair connections/wiring.
If 10k Ω ±20%, thermistor is
good. If 100k-1M Ω, replace
thermistor.
WA500-3H
12
Notes:

1. Wire colors may vary with installation. Refer to the wiring schematic.

2. For 24V controllers, resistor (R17) must be clipped and removed from the circuit board, refer to illustration. If resistor
is not clipped on 24V system, the controller display will light up, but the blower fan will not turn on.

3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together,
on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.

4. Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in
damage to the controller.

5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short
cycling of the compressor.

6. Eagle climate controllers are designed to use normally closed heat solenoid valves.

7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more.
The current drain from the controller’s memory may result in a dead vehicle battery. An optional ignition relay may be
installed to disable the controller’s memory function, when the key switch is turned off.
TROUBLESHOOTING WIRING DIAGRAM
12
WIRING DIAGRAM

20-1318 WA500-3H
12
NOTES:

1. Position the ambient temperature probe near waist high level, out of air flow and sun load.

2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st
and 2nd rows, to a depth of the coil height minus 1 inch.

WIRE CHART

Socket Size Color Wire function Connector Detail

1 10GA Red Battery positive in

2 18GA Red 1/2 evaporator coil thermostat in

3 18GA Black 1/2 ambient thermistor in

4 18GA Red 1/2 evaporator coil thermostat in

5 N/A N/A Not used

6 18GA Black 1/2 ambient thermistor in

7 14GA Orange Fan positive out

Dk.
8 16GA Clutch out
Green

Dk.
9 18GA Ignition switch in
Blue

10 14GA Black Fan negative out

11 18GA Brown Condenser blown fuse in

12 16GA White Heat solenoid out

13 18GA Tan Pressure switch detect in

14 16GA Yellow Condenser fan relay out

15 12GA Black Battery negative in

16 N/A N/A Not used

TROUBLESHOOTING WIRING DIAGRAM
12
INSPECTION AREAS

Main inspection areas

Sensor circuit
Wire harness

Body ground

Servomotors
Connectors
No. Problem

Fuse
Other inspection items

1 Fuse blows easily. X X X X

Heater relay, blower motor, blower

2 No blower operation. X X X X
resistor, blower switch.

3 Blower speed does not change. X X X X Blower resistor, blower switch.

Magnetic clutch and relay,

4 No compressor operation. X X X X compressor, heater relay, A/C
switch, A/C amplifier.

Engine speed signal lines, A/C

5 A/C lamp does not light. X X X
amplifier, A/C switch.

A/C lamp flashes (only for Compressor, drive belt, A/C

6 X X X X X
compressor with lock sensor). amplifier, magnetic clutch.

No A/C operation (cooled air

7 X X X X X
does not come out).

Water temperature switch (for

Cab temperature does not
8 X X X X X X variable compressor type) A/C
decrease (insufficient cooling).
amplifier.

Engine coolant volume, A/C

9 Warm air does not come out. X
temperature control, heater radiator.

Relays (for condenser fan, radiator

10 No condenser fan operation. X X X X X fan), condenser fan motor, condenser
fuse.

No engine idle speed increase Idle-up actuator, vacuum hose line,

11 X X X
when A/C switch is turned on. air conditioner amplifier.

20-1320 WA500-3H
 30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
TRANSMISSION CONTROL VALVE (ECMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96

WA500-3H 30-1
DISASSEMBLY AND ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
DIFFERENTIAL, NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
REMOVAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
INSTALLATION (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
REMOVAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
INSTALLATION (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
FINE DISASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-126
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 30-127
FINE ASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
ORBITAL STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
ENSURE A CLEAN WORKING ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-148
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-155
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-159
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-163
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
BRAKE ASSEMBLY (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-169
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170

30-2 WA500-3H
DISASSEMBLY AND ASSEMBLY
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-181
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-192
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
FLOOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-232
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-235
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237

WA500-3H 30-3
DISASSEMBLY AND ASSEMBLY
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
RECEIVER TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-239
COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
INSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242

30-4 WA500-3H
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

1. When removing or installing unit assemblies

A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal
operation; the order of work for the installation operation is not given.

B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation

WARNING! Safety precautions to observe when performing an operation

1. XXX Text of or name of procedural step

A. Text of procedural step if 1 was procedural name

★ Technique or important point

Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).

(COMPONENT) INSTALLATION Title of operation

• Installation is the reverse of removal. Overall directive

Special technique during assembly or installation (note that this symbol is
left-aligned).

(Component/assembly) Specification

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.

3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure,
see the SPECIAL TOOL LIST later in this section.

WA500-3H 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION
★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.

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.
• 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 alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
• Fit the following blind plugs into the piping after disconnecting it during disassembly operations.

1. Hoses and tubes using sleeve nuts

Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set

02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)

03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)

04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)

05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)

06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)

10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)

12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

2. Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number

04 07379-00400 07378-10400 07371-30400

05 07379-00500 07378-10500 07371-30500

30-6 WA500-3H
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
3. If the part is not under hydraulic pressure, the following corks can be
used:

Dimensions
Nominal
Part Number
number
D d L

06 07049-00608 6 5 8

08 07049-00811 8 6.5 11

10 07049-01012 10 8.5 12

12 07049-01215 12 10 15

14 07049-01418 14 11.5 18

16 07049-01620 16 13.5 20

18 07049-01822 18 15 22

20 07049-02025 20 17 25

22 07049-02228 22 18.5 28

24 07049-02430 24 20 30

27 07049-02734 27 22.5 34

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 pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
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 eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

WA500-3H 30-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.

OTHER PRECAUTIONS
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.

A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.

B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.

C. Raise the engine speed and repeat Step 2 to bleed the air. Repeat this procedure until no more air comes out from the
plugs.

D. After completing bleeding the air, tighten the plugs.

Plug: 11.3 ±1.5 Nm (8.33 ±1.10 lbf ft)

E. After repair or long storage, follow the same procedure.

30-8 WA500-3H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
12
SPECIAL TOOL LIST
Remark
Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
Remark
Necessity: ■: . . . . . . . . . . . . Cannot be substituted, should always be installed (used)
●: . . . . . . . . . . .Extremely useful if available, can be substituted with commercially
available part
Remark
New/remodel: N: . . . . . . . . .Tools with new part numbers, newly developed for this model
R: . . . . . . . .Tools with upgraded part numbers, remodeled from items already
available for other models
Blank: . . . . Tools already available for other models, used without any
modification
Remark
Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).

New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
Installation of engine
1 790-331-1110 Wrench ■ 1 Tightening of head assembly
cylinder head
1 795-521-1110 Push tool ■ 1
2 790-101-5221 Grip ■ 1
2 Press fitting of front seal
3 01010-51225 Bolt ■ 1
Installation of engine 4 01050-31640 Bolt ■ 3
A
front seal, rear seal 1 795-931-1210 Sleeve jig ■ 1
2 795-931-1220 Sleeve jig ■ 1
3 Press fitting of front sea
3 01050-31625 Bolt ■ 3
4 01050-31645 Bolt ■ 3
1 793T-615-1230 Push tool ■ 1 N ●
2 793T-615-1240 Spacer ■ 1 N ● Press fitting of oil seal and
Assembly of damper 1
3 790-101-5421 Grip ■ 1 dust seal

4 01010-51240 Bolt ■ 1
Removal, installation of round
2 790-102-1871 Wrench ■ 1
nut
B 1 790-201-2730 Spacer ■ 1
2 791-520-4140 Screw ■ 1
Disassembly,
3 02215-11622 Nut ■ 2
assembly of PTO Press fitting of PTO gear
3 4 01643-32780 Washer ■ 2 bearing inner race
Puller (294.2 kN
5 790-101-2102 ■ 1
{30 ton})
6 790-101-1102 Pump ■ 1

Disassembly, 1 790-501-5200 Repair stand ■ 1

assembly of torque C 2 790-901-2110 Bracket ■ 1
converter assembly 3 790-310-2160 Plate ■ 1
Checking actuation of clutch
799-301-1500 Oil leak tester ■ 1
piston
Disassembly, 1 796-514-2000 Remover ■ 1 Removal of No.3 planet gear
assembly of 2
2 796-515-2140 Adapter ■ 1 shaft
transmission
assembly D 790-201-1702 Push tool kit ■ 1
Removal fitting of No.3, No.4
4 1741 ■ 1
carrier bushing
5021 ■ 1

WA500-3H 30-9
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
Disassembly, Centering of body and upper
1 790-452-1200 Pilot ring tool ■ 1
assembly of orbital F cover
steering valve 2 790-452-1100 Installer set ■ 1 Press fitting of spacer
Removal, installation 1 790-520-2510 Bracket ■ 1
Removal, installation of
of differential 1
assembly 2 790-520-2610 Plaste ■ 1 differential assembly

790-501-5000 Repair stand ■ 1 100V

1
790-501-5200 Repair stand ■ 1 220V, 240V
2
2 790-901-2110 Bracket ■ 1
3 793-310-2160 Plate ■ 1
Disassembly, 1 793T-622-1120 Push tool ■ 1 N ●
assembly of
differential assembly 2 793T-622-1130 Spacer ■ 1 N ● Press fitting of dust seal and
3
3 790-101-5421 Grip ■ 1 oil seal of coupling cage

4 01010-51240 Bolt ■ 1
1 792-525-1000 Micrometer ■ 1
4 Adjusting preload of bearing
2 792-525-1230 Adapter ■ 2
1 793T-622-1110 Plate ■ 1 N ●
Press fitting of oil seal of
5 2 790-101-5421 Grip ■ 1
outer drum
3 01010-51240 Bolt ■ 1
Removal, installation of
6 793T-622-1150 Fixture ■ 3 N ● wheel hub
1 793-520-1805 Brake tester ■ 1 N
7 Checking leakage of brake oil
H 2 793-520-1851 ■ 1 N

Disassembly, 1 793-520-2680 Installer ■ 1

assembly of final 2 791-580-1600 Push tool ■ 1
drive assembly 3
4
5 Installation of floating seal
8
6 (gear end)
7
8
9
10 792-530-1630 Stud ■ 4
1 793-520-2680 Installer ■ 1
2 791-580-1600 Push tool ■ 1 N
3

Disassembly, 4
Installation of floating seal
assembly of brake 9 5
(hub end)
assembly 6
7
8
9

30-10 WA500-3H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
1 793-520-2630 Bar ■ 2
2 793-520-2640 Push tool ■ 1
3 793-520-2530 Guide ■ 1
4 790-101-2300 Push puller ■ 1
Press fitting bearing of top
1 5 center hinge portion
6
Puller (294.2 kN
7 790-101-2102 ■ 1
Removal, installation {30 ton})
K
of center hinge pins 8 790-101-1102 Pump ■ 1
1 793-520-2550 Guide ■ 1
2 01010-31480 Bolt ■ 2
3 01643-31445 Washer ■ 2
Press fitting bearing of bottom
2 4 793-520-2640 Push tool ■ 1 center hinge portion
Puller (294.2 kN
5 790-101-2102 ■ 1
{30 ton})
6 790-101-1102 Pump ■ 1
790-502-1003
1 or Repair stand ■ 1
1 790-502-2000
2 790-101-1102 Pump ■ 1
Wrench Removal, installation of
2 790-330-1100 ■ 1
assembly cylinder head
Socket (width
3 790-302-1290 across flats ■ 1 Removal, installation of nut
60 mm)
1 790-201-1500 Push tool ■ 1 Press fitting of dust seal
2 Steering cylinder
3 Boom cylinder
4
4 Bucket cylinder
5
Disassembly, All cylinders
assembly of hydraulic U 6
cylinder assemblies 1 790-201-1702 Push tool kit ■ 1 Press fitting of roll bushing
2 Steering cylinder
3 Boom cylinder
5
4 Bucket cylinder
5
All cylinders
6
1 790-720-1000 Expander ■ 1 Expansion of piston ring
2 796-720-1660 Ring ■ 1
Steering cylinder
3 07281-01159 Clamp ■ 1
6 4 796-720-1690 Ring ■ 1
Boom cylinder
5 07281-02169 Clamp ■ 1
6 796-720-1720 Ring ■ 1
Bucket cylinder
7 07281-02429 Clamp ■ 1
Wrench
1 790-102-2303 ■ 1
assembly
Removal, installation of round
1 Wrench
2 790-102-2303 ■ 1 head
assembly
Disassembly,
assembly of X 3 790-102-4310 Pin ■ 1
accumulator 1 790-720-1000 Expander ■ 1 Expansion of piston ring
2 2 796-720-1660 Ring ■ 1
3 07281-01159 Clamp ■ 1
3 792-610-1700 Charging tool ■ 1 Charging with N2 gas

WA500-3H 30-11
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New
Component Symbol Part Number Part Name Necessity Qty Sketch Nature of work, remarks
Remodeled
1 799-703-1200 Service tool kit ■ 1

Charging air condi- 2 799-703-1100 ■ 1 110V

tioning with R134a X 4 3 799-703-1110 Vacuum pump ■ 1 220V
freon gas 4 799-703-1120 ■ 1 240V
5 799-703-1400 Gas leak tester ■ 1

30-12 WA500-3H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3-2 SPACER

H6 FIXTURE

WA500-3H 30-13
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
H5-1 PLATE

H3-1 PUSH TOOL

30-14 WA500-3H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
B1-2 SPACER

B1-1 PUSH TOOL

WA500-3H 30-15
DISASSEMBLY AND ASSEMBLY ENGINE

ENGINE
Remark
As for the disassembly and assembly of engine components (see the following list). Refer to the ENGINE SHOP
MANUAL.

ALTERNATOR

CYLINDER HEAD

ENGINE FRONT SEAL

ENGINE OIL COOLER

ENGINE REAR SEAL

FUEL INJECTION PUMP

NOZZLE HOLDER

STARTING MOTOR

THERMOSTAT

TURBOCHARGER

WATER PUMP

30-16 WA500-3H
DISASSEMBLY AND ASSEMBLY ENGINE

MEMORANDUM

WA500-3H 30-17
DISASSEMBLY AND ASSEMBLY RADIATOR

RADIATOR

REMOVAL

WARNING! Stop the machine on level ground and install the safety bar to the front and rear frames.
Lower the bucket to the ground and stop the engine. Apply the parking brake and put
blocks under the wheels to prevent the machine from moving.

WARNING! Loosen the hydraulic tank filler cap slowly to release the pressure inside the tank. Then
operate the control levers several times to release the remaining pressure in the
hydraulic system.

1. Remove engine hood assembly, see ENGINE HOOD REMOVAL.

2. Open radiator drain valve (1), and drain coolant.

Coolant: 99 liters (26.2 gal.)

3. Disconnect aeration hose (2) and return hose (3).

4. Disconnect make-up line (4).

5. Remove fan guard (5).

6. Disconnect radiator outlet hose (6).

7. Disconnect torque converter cooler outlet and inlet hoses (7).

8. Disconnect hydraulic cooler outlet and inlet hoses (8).

30-18 WA500-3H
DISASSEMBLY AND ASSEMBLY RADIATOR
9. Remove cover (9) at front bottom of radiator.

10. Loosen radiator mounting bolts (10).

11. Sling radiator assembly (11) and remove mounting bolt (10).
• Disconnect supports from radiator, loosen supports at frame,
and rotate out of way.

12. Lift off radiator assembly.

• Sling the radiator assembly, and lift off while moving radiator to
the rear.
• Be careful, and make sure the cooling fan does not interfere with
the radiator core.

Radiator assembly: 332 kg (732 lb.)

INSTALLATION

• Carry out installation in the reverse order to removal.

• Install so that the clearances between the fan and fan guard at the left and right, and the top and bottom are the same.
• Add coolant through the radiator filler neck to the specified level.

Coolant: 99 liters (26.2 gal.)

• Add transmission oil through the oil filler to the specified level.
• Run the engine to circulate the oil and coolant through the system.
• Recheck oil and coolant levels again.

WA500-3H 30-19
DISASSEMBLY AND ASSEMBLY DAMPER

DAMPER

REMOVAL

WARNING! Stop the machine on level ground and

install the safety bar to the front and rear
frames. Lower the bucket to the ground
and stop the engine. Apply the parking
brake and put blocks under the wheels to
prevent the machine from moving.

1. Remove engine hood assembly. For details, see ENGINE HOOD

REMOVAL.

2. Remove bulkhead assembly. For details, see BULKHEAD REMOVAL.

3. Disconnect switch pump suction tube (1) and outlet hose (2), then
remove switch pump + PPC pump (3).

4. Disconnect hydraulic pump suction tube (4) and outlet tube (5), then
remove hydraulic pump (6).

5. Disconnect steering pump outlet hose (7), remove tube (8) at pump end.

6. Disconnect damper lubrication tubes (9) and (10).

7. Disconnect drive shaft (11).

8. Pull out flange (12).

9. Remove mounting bolt (13).

• Remove the mounting bolt, insert a guide bolt, then sling the
cover and push the cover out with forcing screws.

10. Lift off cover assembly (14).

Cover: 32 kg (71 lb)

11. Sling damper assembly (15), then remove mounting bolt (16) and insert
guide bolt.
• Pull out the damper assembly using forcing screws.

Damper assembly: 60 kg (132 lb)

30-20 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER

INSTALLATION
• Carry out installation in the reverse order to removal.

Mounting bolts: 110.7 ±12.7 Nm (82 ±9 lbf ft)

WA500-3H 30-21
DISASSEMBLY AND ASSEMBLY DAMPER

DISASSEMBLY
1. Cover assembly.

A. Remove elbows (1) and (2).

B. Remove mounting bolts, then using forcing screws, remove

cover (3).
• Tighten the two forcing screws uniformly.

C. Remove oil seal (4) and o-ring (5) from cover (3).

D. Turn over cover (6), then pull out shaft (7).

Cover: 29 kg (64 lb)

30-22 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
E. Remove snap rings (8) and bearing (9) from shaft (7).

F. Remove snap rings (10). (11), and oil seal (12) from cover (6).

2. Damper.

A. Remove spacer (14).

B. Using forcing screws, remove flange (13).

• Tighten the two forcing screws evenly.

WA500-3H 30-23
DISASSEMBLY AND ASSEMBLY DAMPER
C. Remove inner body (15) and rubber (16).

D. Remove snap ring (17) and oil seal (18) from the inner body.

E. Remove flange (20) from outer body (19).

• Screw in the mounting bolts, then tap with a hammer to
remove.

30-24 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER

ASSEMBLY
1. Damper assembly.

A. Install flange (20) at bottom of outer body (19).

Contact surface of flange and outer body: Gasket

sealant (LG-4).

B. Press fit oil seal (18) in the inner body (15), then assemble
snap ring (17).
• Fit the snap ring securely in the groove. Set the oil seal
with the sleeve on the snap ring side, and fit it close in
contact with the snap ring.

Inside surface portion (hatched portion) of inner body

(15): Lithium base molybdenum disulphide extreme
pressure grease.

• Fill the circumference uniformly with grease.

Lip of oil seal: Lithium base molybdenum disulphide

extreme pressure grease.

★ Brand of Lithium base molybdenum disulphide extreme pressure

grease.
• Kyoto Oil Malleolus No.2 or equivalent.
• Show Shell Sunlight TB-2 or equivalent.
• Nippon Sekiyu Molytex No.2 or equivalent.

C. Assemble inner body (15) in outer body (19), then assemble

rubber (16).

Whole surface of rubber: Grease (G2-LI)

Outer surface of inner body: Grease (G2-LI)

Inner surface of outer body: Grease (G2-LI)

Between inner body and rubber: Grease (G2-LI)

WA500-3H 30-25
DISASSEMBLY AND ASSEMBLY DAMPER
• Fill clearance b at four places evenly with 270 g (9.5 oz)
of grease.

D. Install flange (13), and tighten mounting bolts.

Contact surface of flange and outer body: Gasket

sealant (LG-4).

Mounting bolts: 66.6 ±6.9 Nm (49 ±5 lbf.ft.)

2. Cover assembly.

A. Fit snap ring (11), then fit snap ring (10) after press fitting the oil
seal (12) in cover (6).
• Press fit the oil seal with the lip face on the bearing side.

B. Assemble snap rings (8) and bearing (9) to shaft (7).

Bearing portion C (hatched portion): Lithium base

molybdenum disulphide extreme pressure grease.

Remark
Do not leave any space when filling with grease.

★ Brand of Lithium base molybdenum disulphide extreme

pressure grease.
• Kyoto Oil Malleolus No.2 or equivalent.
• Show Shell Sunlight TB-2 or equivalent.
• Nippon Sekiyu Molytex No.2 or equivalent.

30-26 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
C. Press fit shaft (7) into cover (6).

D. Press fit oil seal (4) into cover (3), and install o-ring (5).

Oil seal portion d (hatched portion): Lithium base

molybdenum disulphide extreme pressure grease.

★ Brand of Lithium base molybdenum disulphide extreme

pressure grease.
• Kyoto Oil Malleolus No.2 or equivalent.
• Show Shell Sunlight TB-2 or equivalent.
• Nippon Sekiyu Molytex No.2 or equivalent.

WA500-3H 30-27
DISASSEMBLY AND ASSEMBLY DAMPER
E. Set cover (3) on mounting position, and tighten the mounting bolts.

F. Install elbows (1) and (2).

Elbow (1) and (2): Thread tightener (LT-2).

Elbow (1): 3.9 ±1.0 Nm (3 ±1 lbf ft)

★ Be careful of the direction of elbow (2).

30-28 WA500-3H
DISASSEMBLY AND ASSEMBLY DAMPER
3. Greasing.

A. Assemble damper to the engine, and connect the grease hose, then
fill the inside of the damper with grease (310g) from portion e.

Damper portion e (hatched portion): Lithium base

molybdenum disulphide extreme pressure grease.

★ Brand of Lithium base molybdenum disulphide extreme

pressure grease.
• Kyoto Oil Malleolus No.2 or equivalent.
• Show Shell Sunlight TB-2 or equivalent.
• Nippon Sekiyu Molytex No.2 or equivalent.

WA500-3H 30-29
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-

TORQUE CONVERTER AND TRANSMISSION

REMOVAL

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then apply the parking brake and put blocks
under the wheels to prevent the machine from moving.

WARNING! Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate
the control levers several times to release the remaining pressure in the hydraulic piping.

1. Drain oil.

Hydraulic oil: 175 liter (46.2 gal)

Transmission: 62 liter (16.4 gal)

2. Remove bulkhead assembly. For details, see BULKHEAD REMOVAL.

3. Remove floor frame assembly. For details, see FLOOR FRAME REMOVAL.

4. Remove drive shaft between switch + PPC pump, loader pump, and engine - torque converter.
For details, see HYDRAULIC PUMP REMOVAL.

5. Disconnect drive shaft (1) between transmission and rear differential

at the transmission end.

6. Disconnect drive shaft (2) between transmission and center support

at the differential end.

7. Disconnect hose (3) from oil cooler on left side of transmission and
hose (4) leading to transmission valve.

8. Disconnect transmission oil outlet tube (5).

30-30 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
9. Disconnect hoses (6) and (7) leading to steering valve at right side
of transmission.

10. Disconnect hose (8) to loader control valve.

11. Disconnect hydraulic tank outlet hose (9).

12. Remove clamps (10) and (11), then remove tube (12).

13. Disconnect hoses (13) and (14) leading to emergency brake valve
from transmission control valve.

14. Disconnect grease supply hose (15) at bottom of transmission support.

15. Disconnect connectors (16), (17), and (18) at bottom left of floor
frame (LR1 - 6 and TM1, 2).

16. Disconnect (19) at left side of center of machine (FR1, 2).

WA500-3H 30-31
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
17. Remove filler tube (20).

18. Remove two mount bolts (21) at torque converter end.

19. Disconnect parking brake hose (22) at bottom left of transfer.

20. Remove four mount bolts (23) at transfer end.

21. Raise transmission assembly (24) and remove cushion.

22. Remove mounting bolts (26), then remove bracket (27).

• Remove bracket (27) and move transmission assembly to the

left while slowly raising the assembly.

30-32 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-

INSTALLATION
• Carry out installation in the reverse order to removal.

• Adjust mount at the transfer end as shown in diagram to the right.

Drive shaft: 110.7 ±12.7 Nm (81 ±9 lbf ft)

Mount bolt: 744.8 ±83.3 Nm (549 ±61 lbf ft)

Bracket mounting bolts: 274.4 ±29.4 Nm (202 ±22 lbf ft)

REFILLING HYDRAULIC TANK AND TRANSMISSION CASE WITH OIL.

Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil
level again.

WA500-3H 30-33
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-

DISCONNECTION
1. Remove torque converter and transmission assembly. For details,
see TORQUE CONVERTER, TRANSMISSION REMOVAL.

2. Disconnect suction tube (1).

3. Remove flange (2).

4. Remove tube (3) between torque converter and transfer.

5. Remove support (4).

6. Disconnect connector (5).

7. Remove mounting bolts (6), then lift off torque converter

assembly (7).

• Using a lever block set, set with the torque converter end at the top.
• After setting the assembly in position, check that it is stable,
before removal of the lifting tool.

CONNECTION
• Carry out connection in the reverse order to disconnection.
• Make the protrusion from the shaft equal.
• Be careful when pushing in. If the assembly is pushed in by force,
seal ring (8) may be damaged.

Input shaft seal ring: G2-LI

Torque converter mounting bolts: 110.7 ±12.7 Nm (81 ±9 lbf ft)

30-34 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

TORQUE CONVERTER

DISASSEMBLY
1. Disconnect torque converter and PTO assembly from transmission
assembly.
• For details, see TORQUE CONVERTER, TRANSMISSION
DISCONNECTION.

2. PTO assembly

A. Set tool C to torque converter and PTO assembly (1).

B. Remove holder (2) and coupling (3).

C. Using eye bolts a, sling PTO assembly.

D. Using forcing screw b, lift off PTO assembly (4).

E. Disassemble PTO assembly as follows.

i. Remove retainer (5).

ii. Remove oil seal (6) from retainer (5).

iii. Remove bearing (7).

WA500-3H 30-35
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iv. Using tool B2, remove nut (8).

v. Using puller d, push out gear (9).

• At this point, put in contact with the bearing outer race
and push the gear out. Do not remove the gear.

vi. Remove bearing (10a).

vii. Using snap ring pliers, remove snap ring (11)

viii. Remove spacer (12).

ix. Using gear puller e, pull out outer races (13a) and (13b)
approx. 10 mm (0.394 in).

x. Remove gear (9), then remove outer races (13a) and (13b)
and spacer (14).

xi. Remove spacer (40) and bearing (10b) from gear (9).

3. Turbine case assembly

A. Leave two pump mounting bolts (15) on diagonally opposite

sides and remove other mounting bolts.

B. Set with case at top and remove remaining two mounting bolts.

C. Using eye bolt c, remove turbine and case assembly (16).

30-36 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
D. Disassemble turbine and case assembly as follows.

i. Remove shaft (17) and gear (18).

ii. Using snap ring pliers, remove snap ring (19).

iii. Remove spacer (20).

iv. Insert two round bars f from 8.5 drill hole and remove
turbine assembly (21).

v. Push the inner race of the bearing with a forcing screw.

vi. Using snap ring pliers, remove snap ring (23) from case (22).

vii. Using push tool g, remove bearing (24).

4. Stator

A. Remove snap ring (25).

B. Remove stator (26).

WA500-3H 30-37
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
5. Stator shaft, pump assembly.

A. Remove 10 mounting bolts (27).

B. Remove stator shaft and pump assembly (28) from housing (29).

C. Disassemble stator shaft and pump assembly as follows.

i. Remove two plugs (31) of stator shaft (30).

ii. Using round bar h, knock out bearing inner race from
hole where plug has been removed, then remove pump
assembly (32).

iii. Remove bolts, then remove retainer (33), pump (34), and
guide (35).

iv. Remove bearing (36) from guide (35).

30-38 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

ASSEMBLY
1. Stator shaft, pump assembly.

A. Assemble stator shaft and pump assembly as follows:

i. Using push tool j, press fit bearing (36) {outside

diameter: 120 mm (4.724 in)} to guide (35).
• After press fitting the bearing, apply drops (6 cc)
of engine oil (EO10-CD or EO30-CD) and rotate
10 times.

ii. Align with oil groove and install guide (35) and retainer (33)
to pump (34).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 59 - 74 Nm (44 - 55 lbf ft)

iii. Install seal ring (39) to stator shaft (30).

• Apply grease to the seal ring and make the
protrusion from the shaft uniform.

iv. Using push tool k, press fit pump assembly (32) to stator
shaft (30).

WA500-3H 30-39
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
v. Install two plugs (31) to stator shaft (30).
• Do not coat the plugs with adhesive.

Plug: 3 - 6 Nm (2 - 4 lbf ft)

B. Set housing (29) to tool C.

C. Install stator shaft and pump assembly (28).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 59 - 74 Nm (44 - 55 lbf ft)

2. Stator.

A. Install stator (26).

B. Using snap ring pliers, install snap ring (25).

3. Turbine case assembly.

A. Assemble turbine case assembly as follows:

i. Using push tool g, press fit bearing (24) to case (22).

ii. Using snap ring pliers, install snap ring (23).

30-40 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iii. Using push tool l, press fit turbine assembly (21) to
case (22).
• Support the inner race of the case bearing and press fit
the turbine assembly.
• After press fitting, apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) and rotate 10 times.

iv. Install spacer (20).

v. Using snap ring pliers, install snap ring (19).

vi. Using push tool m, press fit inner race (37) to shaft (17).

vii. Install gear (18) and shaft (17) to case (22).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 59 - 74 Nm (44 - 55 lbf ft)

WA500-3H 30-41
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
B. Using eyebolt c, install turbine and case assembly (16), then
tighten 24 mounting bolts (15).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 49 - 59 Nm (36 - 44 lbf ft)

4. PTO assembly.

A. Assemble PTO assembly as follows:

i. Using push tool (n), press fit bearing (10b) {inside diameter:
50 mm (1.969 in)} to gear (9).

ii. Set gear (9) to each pump mount portion of housing (38).

Gear (spline portion): Grease (G2-LI)

iii. Using push tool p, press fit outer race (13b) {outside
diameter: 90 mm (3.543 in).
• Be careful of the mounting direction.

30-42 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
iv. Install spacer (14).

v. Using push tool p, press fit outer race (13a) {outside

diameter: 90 mm (3.543 in)}.
• Be careful of mounting direction.

vi. Fit spacer (40), the using puller q, press fit bearing (10a)
{inside diameter: 50 mm (1.969 in)}.

vii. Install spacer (12).

viii. Using snap ring pliers, install snap ring (11).

WA500-3H 30-43
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ix. Using tool B2, tighten mounting nut (8).

Mounting nut: Thread tightener (LT-2)

Mounting nut: 392 - 441 Nm (289 - 325 lbf ft)

• After tightening the mounting nut, apply drops (6 cc)

of engine oil (EO10-CD or EO30-CD) to bearings
(10a) and (10b) and rotate 10 times. Then check the
tightening torque of the mounting nut again.

x. Using push tool r, press fit bearing (7) (outside diameter:

130 mm) to coupling mount portion of housing (38).
• After tightening the mounting nut, apply drops (6 cc)
of engine oil (EO10-CD or EO30-CD) to bearings (7)
and rotate 10 times.

xi. Using push tool, press fit oil seal (6) to retainer (5).

Lip of oil seal: Grease (G2-LI)

• Coat the oil seal press-fitting surface of the retainer

with gasket sealant (LG-5).
• When coating with gasket sealant, coat the hole in
the housing thinly, and wipe off all gasket sealant that
is squeezed out.

xii. Fit O-ring and install retainer (5).

O-ring: Grease (G2-LI)

B. Fit O-ring, then using eyebolts a, install PTO assembly (4).

O-ring: Grease (G2-LI)

30-44 WA500-3H
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
C. Fit O-ring and install coupling (3) and holder (2).

O-ring: Grease (G2-LI)

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 157 - 196 Nm (116 - 145 lbf ft)

WA500-3H 30-45
DISASSEMBLY AND ASSEMBLY TRANSMISSION

TRANSMISSION

DISASSEMBLY
1. Torque converter and PTO assembly.

A. Disconnect torque converter and PTO assembly. For details,

see TORQUE CONVERTER, TRANSMISSION
DISCONNECTION.

2. Cover.
Remove cover (1) from top of transmission control valve.

3. Main relief valve.

Remove main relief valve (3).

4. Transmission control valve.

A. Remove wiring harness (4).

• Disconnect the ECMV solenoid connector. For details,
see TRANSMISSION CONTROL VALVE ASSEMBLY
(ECMV ASSEMBLY) REMOVAL.

B. Remove parking brake hose (5).

C. Lift off transmission control valve assembly (6).

• Remove the bolts at the positions marked by arrows in the
diagram on the right.

5. Lubrication tube.
Remove lubrication tube (7) from front of transfer.

6. Sleeves.

A. Using eyebolt a, remove four sleeves (8) {length: 74mm

(2.913 in)} and 1 sleeve (9) {length: 79mm (3.110 in)}.

30-46 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
7. Transmission, transfer assembly.

A. Using eyebolts b and chain block, raise transmission and transfer

assembly (10), then set on block c with transfer assembly at
bottom.

B. Using eyebolts d, sling transmission assembly (11), then using

forcing screw e, disconnect from transfer assembly.

8. Transmission assembly.

A. Remove 6 mounting bolts (12) from output shaft end of

transmission case assembly (11).

B. Set transmission case assembly (11) on block c.

C. Remove 15 mounting bolts (13) from input shaft of transmission

case assembly (11).

WA500-3H 30-47
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Remove two tie bolts (14) shown in diagram on the right,
and install eyebolts f.

E. Lift off transmission assembly (16) from transmission case

(15), and set to g.

9. Checking actuation of clutch piston.

A. Install four sleeves (8) and 1 sleeve (9) to transmission

assembly (16).

B. Using tool D1, check actuation of piston before disassembling.

C. After checking actuation of piston, remove four sleeves (8)

and 1 sleeve (9).

10. Input shaft, No. 1 carrier, housing assembly.

A. Remove remaining 10 tie bolts (14).

B. Using eyebolts h, remove input shaft and No. 1 carrier and

housing assembly (17), and put on block c.

C. Disassemble input shaft, No. 1 carrier and housing assembly

(17) as follows:

i. Using snap ring pliers, remove snap ring (19).

ii. Remove No. 2 sun gear (20).

30-48 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Support housing (21), then using push tool i, push input
shaft (22) with press and remove.

iv. Using snap ring pliers, remove snap ring (166) from input
shaft (22).

v. Remove seal ring (167).

vi. Using snap ring pliers, remove snap ring (25).

• Remove from the bearing inner race end.

vii. Support housing (21), then using push tool j, push No. 1
carrier assembly (26) with press and remove.

viii. Remove spacer (27).

ix. Using snap ring pliers, remove snap ring (169).

x. Remove bearing (170).

xi. Remove seal ring (171).

WA500-3H 30-49
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Disassemble No. 1 carrier assembly as follows:

i. Remove snap ring (23).

ii. Remove No. 1 ring gear (24).

iii. Remove shaft (29) and ball (173) from No. 1 carrier.
• Be careful not to lose ball (173).

iv. Remove two thrust washers (174), needle bearing (175),

and planetary gear (176).

v. Remove sun gear (30) and spacer (31).

vi. Using push tool k, remove spacer and bearing assembly (32).

vii. Using snap ring pliers, remove snap ring (33) from spacer
and bearing assembly (32).

viii. Using push tool l, remove bearing (34).

ix. Using snap ring pliers, remove snap ring (36) from No. 1
carrier.

x. Using push tool m, remove bearing (37).

30-50 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
11. No 1 spring.
Remove No. 1 spring (38).

12. No 1 plates, springs, No 1 discs.

Remove four No. 1 plates (39), 20 springs (41), and four
No. 1 discs (40).

13. Guide pins, plate.

Remove five guide pins (42) and plate (43).

14. Valve, spring.

Remove valve (44) and spring (45).

WA500-3H 30-51
DISASSEMBLY AND ASSEMBLY TRANSMISSION
15. No 1, No 2 piston, housing assembly.

A. Using eyebolts n, lift off No. 1 and No. 2 piston and

housing assembly (46).
• Tap with a copper hammer to pull out the dowel pin,
then remove.
• When raising the housing assembly, be careful not to drop
the No. 2 piston.

B. Using eyebolt o, remove No. 1 piston (48) from No. 1

housing (47).

C. Turn over No. 1 housing, then remove No. 2 piston (52).

D. Remove seal ring (49) from No. 1 piston (48).

E. Remove seal ring (53) from No. 2 piston (52).

F. Remove seal rings (50) and (51) from No. 1 housing (47).

16. Plate.
Remove plate (54).

17. No. 2 springs.

Remove 10 No. 2 springs (164).

30-52 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
18. No. 2 discs, springs, No. 2 plates.
Remove four No. 2 discs (55), 20 springs (56), and four No. 2
plates (57).

19. Spacer.

A. Using snap ring pliers, remove snap ring (58).

B. Remove spacer (59).

20. No. 2 carrier, housing assembly.

A. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).

B. Using snap ring pliers, remove snap ring (61) from bearing
inner end.

C. Support No. 2 housing assembly (62), then using push tool q,

push No. 2 carrier assembly (63) with press and remove.
• Push the No. 2 carrier.

WA500-3H 30-53
DISASSEMBLY AND ASSEMBLY TRANSMISSION
D. Disassemble No. 2 housing assembly (62) as follows:

i. Using snap ring pliers, remove snap ring (64).

ii. Support No. 2 housing (65), then using push tool r, push
bearing (66) with press and remove.

iii. Remove seal ring (67) from No. 2 housing (65).

E. Disassemble No. 2 carrier assembly (63) as follows:

i. Remove spacer (68).

ii. Remove ring gear (69).

iii. Insert thin rods into four holes (70) for removing snap
ring, then push snap ring (71), and remove No. 2 carrier
assembly (163) from ring gear (72).

30-54 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iv. Remove shaft (73) and ball (74) from No. 2 carrier (163).
• Be careful not to lose ball (74).

v. Remove two thrust washers (75), needle bearing (76),

and planetary gear (77).

21. No. 3 springs.

Remove 10 No. 3 springs (78).

22. No. 3 discs, springs, No. 3 plates.

Remove three No. 3 discs (79), 20 springs (80), and two No. 3
plates (81).

23. No 3 piston.

A. Remove No. 3 piston (82).

B. Remove seal ring (158).

24. Guide pins.

Remove five guide pins (162).

25. No. 3 ring gear.

Remove No. 3 ring gear (83).

26. No. 3, No. 4 housing, No. 4 piston assembly.

A. Using eyebolts s, liftoff No. 3 and No. 4 housing and piston

assembly (159).
• Tap with a copper hammer to pull out the dowel pin,
then remove.

B. Turn over No. 3 and No. 4 housing (84), and remove No. 4
piston (86).

WA500-3H 30-55
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Remove seal ring (87) from No. 4 piston (86).

D. Remove two seal rings (85) from No. 3 and No. 4 housing (84).

27. No. 4 springs.

Remove 10 No. 4 springs (88).

28. No. 4 discs, springs, No. 4 plates.

Remove three No. 4 discs (89), 15 springs (90), and two No. 4
plates (91).

29. No. 3, No. 4 carrier assembly.

A. Using bar t, push up No. 3 and No. 4 carrier assembly (92)

and remove.

B. Disassemble No. 3 and No. 4 carrier assembly as follows:

i. Using tool D2, pull out No. 3 shaft (93) and remove.
• Be careful not to lose ball (94).

ii. Remove two thrust washers (95), needle bearing (96), and
No. 3 planetary gear (97).

30-56 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Using round bar, knock pin (98) into No. 4 shaft (99).

iv. Using round bar u, knock out No. 4 shaft (99) from No. 3
carrier end and remove.

v. Remove two thrust washers (100), needle bearing (101),

and No. 4 planetary gear (102).

vi. Using push tool v, push bearing (103) with press and remove.

vii. Remove bushing (161).

viii. Remove No. 3 and No. 4 seal ring (104).

WA500-3H 30-57
DISASSEMBLY AND ASSEMBLY TRANSMISSION
30. No. 4 sun gear.

A. Using snap ring pliers, remove snap ring (105).

B. Remove spacer (106) and No. 4 sun gear (107).

31. No. 4 ring gear.

A. Remove snap ring (108).

B. Remove No. 4 ring gear (109).

32. No. 5 housing, No. 5 piston assembly.

A. Using eyebolts w, lift off No. 5 housing and No. 5 piston

assembly (110).
• When raising the housing, be careful not to drop the No. 5
piston.

B. Using eyebolt o, remove No. 5 piston (112) from No. 5

housing (181).

C. Remove seal ring (113) from No. 5 piston (112).

D. Remove seal ring (111) from No. 5 housing (110).

30-58 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
33. No. 5 plate.
Remove No. 5 plate (114).

34. No. 5 springs.

Remove 10 No. 5 springs (115).

35. No. 5 discs, springs, No. 5 plate.

Remove two No. 5 discs (116), 10 springs (117), and No. 5 plate (118).

36. Guide pins.

Remove 5 guide pins (119).

37. No. 5 ring gear.

Remove No. 5 ring gear (120).

38. No. 5 plate.

Remove No. 5 plate (121).

39. No. 5 carrier assembly.

A. Remove nine mounting bolts (122).

B. Remove No. 5 carrier assembly (123).

• Tap with a copper hammer to pull out the dowel pin,
then remove.

C. Remove spacer (124) from No. 5 carrier assembly (123).

D. Disassemble No. 5 carrier assembly (123) as follows.

i. Using snap ring pliers, remove snap ring (182).

WA500-3H 30-59
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ii. Remove shaft (125) and ball (126).
• Be careful not to lose ball (126).

iii. Remove two thrust washers (127), needle bearing (128), and
planetary gear (129).

40. No. 5 sun gear.

Remove No. 5 sun gear (130).

41. Spring, pin.

Remove spring (131) and pin (132).

42. No. 6 discs, springs, No. 6 plates.

Remove three No. 6 discs (133), 15 springs (134), and two No. 6
plates (135).

43. No. 6 piston.

A. Remove No. 6 piston (136).

B. Remove seal ring (156).

44. Guide pins.

Remove five guide pins (153).

45. Seal ring.

Remove seal ring (154) from housing (149).

30-60 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
46. No 6 hub.
Remove No. 6 hub (137).

47. Output shaft.

A. Support cage, then push output shaft (139) with press and remove.

B. Remove two seal rings (140) from output shaft (139).

48. Cage assembly.

A. Using snap ring pliers, remove snap ring (142).

B. Support No. 6 housing assembly (143), then using push tool x,

push cage assembly (144) with press and remove.

C. Using push tool nn, push bearing (145) with press and remove
from cage (146).

D. Remove two seal rings (147).

WA500-3H 30-61
DISASSEMBLY AND ASSEMBLY TRANSMISSION
49. No. 6 housing assembly.

A. Using snap ring pliers, remove snap ring (148).

B. Using push tool y, remove bearing (150), bushing (151), and

ball (152) from housing (149).
• Be careful not to lose ball (152).

30-62 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION

ASSEMBLY
1. No. 6 housing assembly.

A. Using push tool z, press fit bearing (150) to No. 6 housing (149).

B. Using push tool aa, press fit bushing (151) and ball (152) to
No. 6 housing (149).

C. Using snap ring pliers, install snap ring (148).

2. Cage assembly.

A. Install two seal rings (147) to cage (146).

Seal ring: Grease (G2-LI)

B. Using push tool bb, No. 6 housing assembly (143) to cage

assembly (144) with press.
• Push the inner race of bearing (150).

C. Using snap ring pliers, install snap ring (142).

3. Output shaft.

A. Install two seal rings (140) to output shaft (139).

Seal ring: Grease (G2-LI)

WA500-3H 30-63
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Using push tool cc, press fit bearing (145) to output shaft (139)
with press.

C. Set No. 6 housing assembly (143) to g.

D. Using push tool dd, press fit output shaft and bearing
assembly (155).
• Push bearing (145) of the output shaft.

4. Seal ring.
Install seal ring (154) to No. 6 housing (149).
• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

5. Guide pin.
Install guide pin (153).

6. No. 6 piston.
Install seal ring (156) to No. 6 piston (136).
• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

7. No. 6 gear.

A. Install No. 6 gear (137).

30-64 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Install No. 6 piston (136).

8. No. 6 plates, springs, No. 6 discs.

Install two No. 6 plates (135), 15 springs (134), and three No. 6
discs (133).

9. Pin, spring.
Install pin (132) and spring (131).

10. No. 5 sun gear.

Install No. 5 sun gear (130).

11. No. 5 carrier assembly.

A. Assemble No. 5 carrier assembly as follows:

i. Assemble needle bearing (128) to planetary gear (129),

put washers (127) to both ends, then set to No. 5 carrier.
• Align the center of each part with the shaft hole.

ii. Install shaft (125) and ball (126).

• Check that the gear rotates smoothly.

B. Using snap ring pliers, install snap ring (182).

WA500-3H 30-65
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Align position of dowel pin and install No. 5 carrier
assembly (123).
• Tap with a copper hammer to knock in the dowel pin.

D. Install 9 mounting bolts (122).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 157 - 177 Nm (116 - 131 lbf ft)

E. Assemble spacer (124).

12. No. 5 housing assembly.

A. Assemble No. 5 housing assembly as follows:

i. Install No. 5 ring gear (120) to No. 5 plate (121).

ii. lnstall guide pins (119).

iii. Install two No. 5 discs (116), 10 springs (117), and No. 5
plate (118).

iv. Install 10 No. 5 springs (115).

v. Install No. 5 plate (114).

vi. Install seal ring (113) to No. 5 piston (112).

• Set the groove of the seal ring facing the direction
receiving the pressure.

Seal ring: Grease (G2-LI)

vii. Install seal ring (111) to No. 5 housing (181).

• Set the groove of the seal ring facing the direction
receiving the pressure.

Seal ring: Grease (G2-LI)

viii. Install No. 5 piston (112) to No. 5 housing.

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DISASSEMBLY AND ASSEMBLY TRANSMISSION
ix. Align position of dowel pin and install No. 5 housing and
No. 5 piston assembly (110).
• Be careful not to drop the No. 5 piston. Tap with a
copper hammer to knock in the dowel pin.

B. Fit clamps ee to No. 5 housing assembly (157) to hold in position.

C. Using eyebolts w, install No. 5 housing assembly (157).

13. No. 4 ring gear.

A. Install No. 4 ring gear (109).

B. Install snap ring (108).

14. No. 4 discs, springs, No. 4 plates.

Install three No. 4 discs (89), 15 springs (90), and two No. 4
plates (91).

15. Springs.
Install 10 springs (88).

WA500-3H 30-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION
16. No. 4 piston.
Install seal ring (87) to No. 4 piston (86).
• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

17. No. 3 piston.

Install seal ring (158) to No. 3 piston (82).
• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

18. No. 3, No. 4 housing.

A. Install two seal rings (85) to No. 3 and No. 4 housing (84).
• Set the groove of the seal ring facing the direction
receiving the pressure.

Seal ring: Grease (G2-LI)

B. Install No. 3 piston (82) and No. 4 piston (86) to No. 3 and
No. 4 housing (84).

C. Using eyebolts s, lift off No. 3 and No. 4 housing assembly (159).
• When raising the housing, be careful not to drop the No. 4
piston.
• Tap with a copper hammer to knock in the dowel pin.

19. No. 4 sun gear, spacer.

A. Install No. 4 sun gear (107) and spacer (106).

B. Using snap ring pliers, install snap ring (105).

20. No. 3, No. 4 carrier assembly.

A. Assemble No. 3 and No. 4 carrier assembly as follows:

i. Install seal ring (104) to No. 3 and No. 4 carrier (160).

Seal ring: Grease (G2-LI)

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DISASSEMBLY AND ASSEMBLY TRANSMISSION

ii. Using tool D3, press fit bushing (161) to No. 3 and No. 4
carrier (160).

iii. Using push tool ee, press fit bearing (103) to No. 3 and
No. 4 carrier (160).

iv. Assemble needle bearing (101) to No. 4 planetary gear

(102), put thrust washers (100) to both ends, then set to
No. 4 carrier.
• Align the center of each part with the shaft hole.

v. Align roll pin hole and install No. 4 shaft (99).

• The deviation between the position of the No. 4 shaft
and carrier roll pin hole must be less than 0.2 mm
(0.008 in).

vi. Install roll pin (98).

• Install so that the side of the roll pin with the slit is
facing the planetary gear.

vii. Assemble needle bearing (96) to No. 3 planetary gear (97),

and put thrust washers (95) to both ends, then set to No. 4
carrier.

viii. Install No. 3 shaft (93) and ball (94).

• Check that the gear rotates smoothly.

WA500-3H 30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION
B. Install No. 3 and No. 4 carrier assembly (92).
• Put plate ff to No. 3 and No. 4 carrier assembly (92), then
press fit the bearing inner race portion to the output shaft.

21. No. 3 ring gear.

Install No. 3 ring gear (83).

22. Guide pins.

Install guide pins (162).

23. No. 3 discs, springs, No. 3 plates.

Install three No. 3 discs (79), 20 springs (80), and two No. 3
plates (81).

24. No. 3 springs.

Install 10 No. 3 springs (78).

25. No. 2 carrier, housing assembly.

A. Assemble No. 2 carrier assembly as follows:

i. Set snap ring to No. 2 carrier (163) and install ring gear (72).

ii. Set snap ring (71) in groove of ring gear (72).

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DISASSEMBLY AND ASSEMBLY TRANSMISSION
iii. Assemble needle bearing (76) to planetary gear (77), put
thrust washers (75) to both ends, then set to No. 2 carrier.
• Align the center of each part with the shaft hole.

iv. Install shaft (73) and ball (74).

• Check that the gear rotates smoothly.

v. Install spacer (68) and ring gear (69) to No. 2 carrier

assembly.

B. Assemble No. 2 housing assembly as follows:

i. Install seal ring (67) to No. 2 housing (65).

Seal ring: Grease (G2-LI)

ii. Support No. 2 housing (65), then using push tool gg,
press fit bearing (66) with press.

iii. Using snap ring pliers, install snap ring (64).

WA500-3H 30-71
DISASSEMBLY AND ASSEMBLY TRANSMISSION
C. Support No. 2 carrier assembly (63), then using push tool hh,
press fit No. 2 housing assembly (62) with press.
• Press fit the bearing inner race.

D. Using snap ring pliers, install snap ring (61).

E. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).

26. Spacer.

A. Install spacer (59).

B. Using snap ring pliers, install snap ring (58).

27. No. 2 plates, springs, No. 2 discs.

Install four No. 2 plates (57), 20 springs (56), and four No. 2
discs (55).

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DISASSEMBLY AND ASSEMBLY TRANSMISSION
• Assemble discs (55), springs (56), and plates (57) in the
order shown in the diagram.

28. No. 2 springs.

Install 10 No. 2 springs (164).

29. Plate.
Install plate (54).

30. No. 1 piston, housing assembly.

A. Install seal ring (49) to No. 1 piston (48).

• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

B. Install seal ring (53) to No. 2 piston (52).

• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

C. Install seal rings (50) and (51) to No. 1 housing (47).

• Set the groove of the seal ring facing the direction receiving
the pressure.

Seal ring: Grease (G2-LI)

D. Install No. 1 piston (48) and No. 2 piston (52) to No. 1

housing (47).

WA500-3H 30-73
DISASSEMBLY AND ASSEMBLY TRANSMISSION
E. Using eyebolts n, lift off No. 1 piston and housing assembly (46).
• When raising the housing assembly, be careful not to drop
No. 2 piston.
• Tap with a copper hammer to knock in the dowel pin.

31. Spring, valve.

Install spring (45) and valve (44).

32. No. 1 carrier assembly.

A. Using push tool ii, press fit bearing (37) to No. 1 carrier (165).

B. Using snap ring pliers, install snap ring (36).

C. Assemble needle bearing (175) to planetary gear (176), put

thrust washers (174) to both ends, then set to No. 1 carrier.
• Align center of each part with the shaft hole.

D. Install shaft (29) and ball (173).

• Check that the gear rotates smoothly.

E. Set No. 1 ring gear (24) to No. 1 carrier assembly.

F. Using snap ring pliers, install snap ring (23).

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DISASSEMBLY AND ASSEMBLY TRANSMISSION
33. Input shaft.

A. Install seal ring (167) to input shaft (22).

Seal ring: Grease (G2-LI)

B. Using snap ring pliers, install snap ring (166).

C. Support No. 1 carrier assembly (26), then using push tool i,

press fit input shaft (22) with press.
• Press fit until snap ring (166) of the input shaft contacts
the bearing.

34. Spacer, sun gear.

Install spacer (31) and sun gear (30).

35. Bearing, spacer.

A. Using push tool jj, press fit bearing (34) to spacer (136).

B. Using push tool kk, press fit spacer and bearing assembly (32).
• After assembling, check that the bearing rotates easily.

C. Using snap ring pliers, install snap ring (33).

36. No. 2 sun gear.

A. Install No. 2 sun gear (20).

B. Using snap ring pliers, install snap ring (19).

37. Input shaft, No. 1 carrier assembly.

Raise input shaft and No. 1 carrier assembly (168) and install.

WA500-3H 30-75
DISASSEMBLY AND ASSEMBLY TRANSMISSION
38. Guide pins.
Install five guide pins (42).

39. Plate.
Install plate (43).

40. No. 1 plates, springs, No. 1 discs.

Install four No. 1 plates (39), 20 springs (41), and four No. 1
discs (40).

• Assemble in the order shown in the diagram.

41. No. 1 springs.

Install 10 No. 1 springs (38).

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DISASSEMBLY AND ASSEMBLY TRANSMISSION
42. Housing.

A. Install seal ring (171) to housing (21).

Seal ring: Grease (G2-LI)

B. Using push tool al, press fit bearing (170).

C. Using snap ring pliers, install snap ring (169).

D. Install spacer (27) to No.1 carrier assembly.

E. Install housing (21).

• Fit eyebolt an to the input shaft, then fit wire and apply
slight tension to the wire, then press fit the housing.

F. Using snap ring pliers, install snap ring (25).

G. Install 10 tie bolts (14).

Tie bolt: 157 - 177 Nm (116 - 131 lbf ft)

• Do not install the two tie bolts at position where eyebolts

are installed.

43. Checking actuating condition and travel of piston.

A. Install four sleeves (8) and 1 sleeve (9) to transmission

assembly (16).

B. Using tool D1, check actuating condition and travel of piston.

★ Air pressure: 3 - 5 kg/cm2 (42 - 71 psi)

Piston Travel

No. 1 4 mm (0.158 in)

No. 2 5.5 mm (0.217 in)

No. 3 3.5 mm (0.138 in)

No. 4 4.5 mm (0.177 in)

No. 5 3 mm (0.118 in)

No. 6 4.2 mm (0.165 in)

C. Remove four sleeves (8) and 1 sleeve (9) from transmission

assembly (16).

WA500-3H 30-77
DISASSEMBLY AND ASSEMBLY TRANSMISSION
44. Transmission assembly.

A. Install dowel pin (171) from output shaft end.

B. Install eyebolts f at positions shown by arrows in diagram on right.

C. Put transmission case (15) on block c.

D. Raise transmission assembly (16) and install to transmission

case (15).

• Align the position of the mounting bolt hole on the top of

the transmission.
• Check that dowel pin (171) has entered the transmission case.

E. Remove eyebolts f, and install remaining two tie bolts (14).

Tie bolt: 157 - 177 Nm (116 - 131 lbf ft)

F. Install six mounting bolts (12) to output shaft end.

G. Install 15 mounting bolts (13) to input shaft end.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 157 - 177 Nm (116 - 131 lbf ft)

45. Transmission case assembly.

A. Set transfer assembly (172) to block c.

B. Fit O-ring, then using eyebolts d, raise transmission case (11)

and install.

Mounting bolt: 98 - 123 Nm (72 - 91 lbf ft)

30-78 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSMISSION
46. Sleeves.
Fit O-ring and install four sleeves (8) (length: 74 mm {2.913 in}) and
1 sleeve (9) (length: 79 mm {3.110 in}).

O-ring: Grease (G2-LI)

47. Lubrication tube.

Install lubrication tube (7) to transfer.

48. Transmission control valve.

A. Fit O-ring to transmission case and valve seat, then raise

transmission control valve assembly (6) and install.
• Tighten mounting bolts in positions shown in diagram on
the right.
• Check that there is an O-ring fitted to rear of the transmission
case.

B. Install parking brake hose (5).

C. Install wiring harness (4).

• Install the ECMV solenoid connector. For details,
see TRANSMISSION CONTROL VALVE (ECMV
ASSEMBLY) INSTALLATION.
49. Main relief valve.
Fit O-ring and install main relief valve (3).

Tie bolt: 44 -54 Nm (33 - 40 lbf ft)

49. Cover.
Install cover (1) to top of transmission control valve.

50. Torque converter, PTO assembly.

Connect torque converter and PTO assembly to transmission
assembly. For details, see TORQUE CONVERTER AND
TRANSMISSION CONNECTION.

WA500-3H 30-79
DISASSEMBLY AND ASSEMBLY TRANSFER

TRANSFER

DISASSEMBLY
1. Transmission.
Remove transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.

2. Parking brake assembly.

Remove parking brake assembly. For details, see PARKING BRAKE
DISASSEMBLY.

3. Input shaft cage assembly.

A. Using forcing screws a, remove input shaft cage assembly (1).

B. Remove shims (2).

• Check the number and thickness of the shims at each
mounting position, and keep in a safe place.

4. Input shaft gear assembly.

A. Remove input shaft gear assembly (3).

B. Remove bearings (4) and (5) from input shaft gear assembly (6).

5. Outer race.

A. Using push tool b, remove outer race (7) from input shaft
cage (34).

B. Remove outer race (35).

30-80 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
6. Strainer.

A. Remove cover (8).

B. Remove spring (9).

C. Remove strainer (10).

7. Intermediate shaft cage assembly.

A. Turn over transfer.

B. Using forcing screws c, remove intermediate cage assembly (11)

and shims (12).
• Check the number and thickness of the shims at each
mounting position, and keep in a safe place.

8. Intermediate shaft gear assembly.

A. Remove intermediate shaft gear assembly (14).

B. Remove two bearings (16) from intermediate shaft gear (15).

WA500-3H 30-81
DISASSEMBLY AND ASSEMBLY TRANSFER
9. Outer race.

A. Remove outer race (13) from intermediate cage (32).

B. Remove outer race (17) from transfer case.

10. Coupling.
Remove holder (18) and coupling (19).

11. Cover.

A. Using forcing screws c, remove cover assembly (22) and

shims (23).

B. Remove dust seal (25) and oil seal (26) from cover(35).

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DISASSEMBLY AND ASSEMBLY TRANSFER
12. Output shaft.
Using tool D4, remove output shaft (20) and spacer (21).

13. Cage.

A. Using forcing screws d, remove cage and bearing assembly (27).

B. Using push tool e, remove outer races (28a) and (28b),

collar (28c), and bearings (28d) and (28e) from cage (29).
• The two bearings are not interchangeable, so keep them
as separate sets.

14. Spacer.
Remove spacer (30).

15. Output shaft gear.

Remove output shaft gear (31).

WA500-3H 30-83
DISASSEMBLY AND ASSEMBLY TRANSFER

ASSEMBLY
1. Outer race.
Using push tool f, press fit outer race (17) to transfer case.

2. Intermediate shaft gear assembly.

A. Using push tool g, press fit two bearings (16) to intermediate

shaft gear.

B. Install intermediate gear assembly (14).

3. Intermediate shaft cage assembly.

A. Using push tool h, press fit outer race (13) to intermediate

shaft cage (32).

B. Fit O-ring and install shims (12) and intermediate shaft cage
assembly (11).
• Standard shim thickness: 2 mm (0.078 in)

O-ring: Grease (G2-LI)

4. Adjusting preload of intermediate shaft bearing.

A. Remove cover (33).

30-84 WA500-3H
DISASSEMBLY AND ASSEMBLY TRANSFER
B. Using tool D6 and torque wrench, measure preload of intermediate
shaft.

C. Adjust shims as follows:

i. Adjust with shims (12) so that preload is 0.29 - 0.54 Nm

(0.214 - 0.398 lbf ft).

ii. After adjusting, add a further 0.1 mm of shim.

• There are four types of shim thickness: t=0.15 mm
(0.006 in), t=0.2 mm (0.008 in), t=0.3 mm (0.012 in),
and t=1.0 mm (0.039 in)

• Check that there is no play in the gear. If there is any

play, adjust the shims again.

D. After adjusting preload, remove intermediate shaft cage assembly

(11), shims (12), and intermediate shaft gear assembly (14).

5. Outer race.

A. Using push tool i, press fit outer race (35) to transfer case.

B. Using push tool i, press fit outer race (7) to input shaft cage (34).

6. Input shaft gear assembly.

A. Using push tool j, install bearings (4) and (5) to input shaft gear (6).

B. Install input shaft gear assembly (3).

7. Input shaft cage assembly.

Install shims (2) and input shaft cage assembly (1).
• Standard shim thickness: 2 mm (0.078 in)

WA500-3H 30-85
DISASSEMBLY AND ASSEMBLY TRANSFER
8. Adjusting preload of input shaft bearing.
Using tool D7 and torque wrench, measure preload of input shaft.
If measurement is not within standard, adjust with shim (2).
• Preload standard value: 0.1 - 0.98 Nm (0.074 - 0.723 lbf ft)
• There are four types of shim thickness: t=0.15 mm (0.006 in),
t=0.2 mm (0.008 in), t=0.3 mm (0.012 in), and t=1.0 mm (0.039 in)
• Check that there is no play in the gear. If there is any play,
adjust the shims again.
• Reference: Standard value for preload when assembling input
shaft and intermediate shaft (measure at input shaft end):
0.2 - 1.27 Nm (0.148 - 0.937 lbf ft)

9. Output shaft gear.

Assemble output shaft gear (31) to transfer case.

10. Spacer.
Install spacer (30).

11. Outer race.

Using push tool k, press fit outer race (28a) to cage (29).

12. Output shaft.

Assemble output shaft (20) and spacer (21), and support with block l.

13. Cage assembly.

Fit O-ring and install cage assembly (36).

O-ring: Grease (G2-LI)

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DISASSEMBLY AND ASSEMBLY TRANSFER
14. Bearing.

A. Using tool D5, press fit bearing (28d).

B. Press fit bearing (28e) in same way.

15. Outer race.

A. Install collar (28c).

B. Using push tool l, press fit outer race (28b).

16. Cover.

A. Using push tool l, press fit oil seal (26) and dust seal (27) to
cover (37).

Oil seal: Grease (G2-LI)

Oil seal press-fitting surface:

Gasket sealant (Three Bond 1110B)

Dust seal: Grease (G2-LI)

• When coating with gasket sealant, coat the inside surface

of the hole in the housing thinly, and wipe off all the
gasket sealant that is squeezed out.

B. Adjust shims as follows:

i. Fit O-ring and install shims (23) and cover assembly (22).
• Do not tighten the mounting bolts.

O-ring: Grease (G2-LI)

ii. Put feeler gauge between shims (23) and cover assembly
(22) and measure clearance, adjust number of shims so that
clearance is 0.05 - 0.10 mm (0.002 - 0.004 in), then tighten
mounting bolts.
• Standard shim thickness: 0.25 mm (0.010 in).

WA500-3H 30-87
DISASSEMBLY AND ASSEMBLY TRANSFER
17. Coupling.

A. Install coupling (19).

B. Fit O-ring and install holder (18).

O-ring: Grease (G2-LI)

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 662 - 829 Nm (488 - 611 lbf ft)

18. Intermediate shaft gear assembly.

Install intermediate shaft gear assembly again.
• For details, see steps 2, 3, and 4.
• Assemble the shims adjusted in step 4.

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DISASSEMBLY AND ASSEMBLY PARKING BRAKE

PARKING BRAKE

DISASSEMBLY
1. Transmission.
Disconnect transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.

2. Coupling.
Remove holder (1) and coupling (2).

3. Sleeve.

A. Remove flange (3).

B. Using eyebolt I, remove sleeve (4).

4. Parking brake assembly.

A. Remove 12 mounting bolts (5).

• Do not remove four mounting bolts (6).

B. Using forcing screws a, disconnect parking brake assembly (7).

C. After removing forcing screws a from parking brake (7),

fit eyebolts b and lift off.

WA500-3H 30-89
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
5. Cover assembly.

A. Remove cover assembly (8).

B. Disassemble cover assembly as follows:

i. Remove dust seal (9) and oil seal (10).

ii. Remove bearing (11).

iii. Remove dowel pin (29).

6. Springs.
Remove 18 outer springs (12) and 18 inner springs (13).

7. Spacer assembly.

A. Remove spacer assembly (14).

B. Using push tool c, remove inner race (15) from spacer (16).

8. Piston.

A. Using eyebolts d, lift off piston (17).

B. Remove seal rings (18) and (19).

30-90 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
9. Snap ring.
Using snap ring pliers, install snap ring (20).

10. Plates, springs, discs.

Remove 9 plates (21), 8 springs (22), and 8 discs (23).

11. Gear.
Remove gear (24).

12. End plate.

Remove end plate (25).

13. Housing.
Using snap ring pliers, install snap ring (26) from housing (27).

WA500-3H 30-91
DISASSEMBLY AND ASSEMBLY PARKING BRAKE

ASSEMBLY
1. Cover.

A. Assemble cover assembly as follows:

i. Using push tool f, press fit bearing (11).

ii. Install two dowel pins (29).

iii. Using push tool, press fit oil seal (10) and dust seal (9).

Oil seal: Grease (G2-LI)

Oil seal press-fitting surface:

Gasket sealant (Three Bond 1110B)

Dust seal: Grease (G2-LI)

• When coating with gasket sealant, coat the inside surface of

the mount thinly, and wipe off all the gasket sealant that is
squeezed out.

2. Spacer assembly.

A. Using push tool e, press fit inner race (15) to spacer (16).

B. Install spacer assembly (14) to cover assembly (8).

3. Springs.
Install 18 outer springs (12) and 18 inner springs (13) to cover
assembly (8).

4. Piston.

A. Install seal rings (18) and (19) to piston (17).

• Set the groove of the seal ring facing the direction shown in
the diagram on the right.

Seal ring: Grease (G2-LI)

B. Set piston (17) on outer spring (12) and inner spring (13).
• Align the position of the hole in piston (17) and dowel pin
(27) of the cover assembly.

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DISASSEMBLY AND ASSEMBLY PARKING BRAKE
5. Housing.

A. Using snap ring pliers, install snap ring (20) to housing (27).

B. Fit O-ring and install housing (27) to cover assembly (8), then
tighten four mounting bolts (6).
• Be careful not to twist the piston against housing (27), and
tighten the bolts uniformly a little at a time.

6. Plugs.

A. Remove two plugs (28).

B. Tighten two mounting bolts of parking brake assembly together

with washers to mounting portion of plug (28).
• Tighten the bolts a little at a time in turn.
• The piston is pulled when the bolts are tightened.

7. Gear.
Install gear (24).
• Be careful of the direction of mounting.

8. Plates, springs, discs.

Install 9 plates (21), 8 springs (22), and 8 discs (23).

WA500-3H 30-93
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
9. End plate.
Install end plate (25).

10. Snap ring.

Using snap ring pliers, install snap ring (26).

11. Mounting bolts.

Remove two mounting bolts installed in Step 6 - B), then install two
plugs (28).
• Loosen the two mounting bolts a little at a time in turn.

Plug: Gasket sealant (LG-5)

12. Parking brake assembly.

Using eyebolts b, fit O-ring, raise parking brake assembly (7)
and install.
• When installing, gradually mesh the spline on the inside of
spacer assembly (14) and gear (24) with the spline of the
output shaft, and install.

O-ring: Grease (G2-LI)

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 98 - 123 Nm (72 - 91 lbf ft)

13. Sleeve.

A. Fit O-ring and install sleeve (4).

O-ring: Grease (G2-LI)

B. Fit O-ring and install flange (3).

30-94 WA500-3H
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
14. Coupling.

A. Install coupling (2).

B. Fit O-ring and install holder (1).

O-ring: Grease (G2-LI)

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 662 - 829 Nm (488 - 661 lbf ft)

15. Transmission.
Connect transmission assembly and transfer. For details,
see TRANSMISSION ASSEMBLY.

WA500-3H 30-95
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE (ECMV)

TRANSMISSION CONTROL VALVE

(ECMV)

REMOVAL

WARNING! Stop the machine on level ground and

install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
put blocks under the wheels to prevent
the machine from moving.

1. Remove cover (1) between bulkhead and cab.

2. Remove transmission top cover (2).

3. Disconnect solenoid connector (3) and fill connector (4).

• When disconnecting solenoid connector, hold the ECMV body
lightly with one hand, and hold connector housing with the other
hand as shown in diagram on the right. Then lift up connector
housing lightly in direction A and in this condition, pull it in
direction B to disconnect. Do not use force when pulling out
the wiring.

4. Remove four mounting bolts (5), then remove ECMV assembly (6).

INSTALLATION
• Carry out installation in the reverse order to removal.
• Clean around the valve before installing the ECMV assembly.
★ When fitting the solenoid connector, align lock and guide as
shown in diagram on the right, and push in. Do not twist
when inserting.

ECMV mounting bolt: 31.4 ±3.9 Nm (23 ±3 lbf ft)

30-96 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

CENTER SUPPORT

REMOVAL

WARNING! Stop the machine on level ground and

install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
put blocks under the wheels to prevent
the machine from moving.

1. Disconnect center drive shaft (1) from center support. Set a block
under the drive shaft when removing.

Center drive shaft: 33 kg (73 lb)

2. Sling front drive shaft (2) and disconnect from center support.

Front drive shaft: 45 kg (99 lb)

3. Disconnect grease tube.

4. Sling center support (4), remove mounting bolts, then remove.

• If there are shims between the center support and frame, check
the number and thickness of the shims and use as a guide when
assembling.

Center support: 42 kg (93 lb)

WA500-3H 30-97
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

INSTALLATION
• Carry out installation in the reverse order to removal.

Center drive shaft mounting bolt:

110.7 ±12.7 Nm (801 ±91 lbf ft))

Front drive shaft mounting bolt:

110.7 ±12.7 Nm (801 ±91 lbf ft)

Center support mounting bolt:

548.8 ±58.8 Nm (405 ±43 lbf ft)

30-98 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

DISASSEMBLY
1. Coupling
Remove center bolt (1), then remove retainer (2), O-ring (3), and
coupling (4).

2. Retainer
Remove mounting bolts (5) or retainer.
• Remove all mounting bolts while rotating coupling.

3. Shaft

A. Set shaft case assembly (6) on press stand.

B. Push out shaft (7) with press.

• Be careful because the shaft will fall out suddenly.

C. Remove spacer (8), bearing cone (9) and retainer (5) from shaft.

WA500-3H 30-99
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
4. Oil seal

A. Remove oil seal (10)and O-ring (11) from retainer.

B. Remove oil seal (12) from case.

5. Case
Remove bearing cone (13) and bearing outer race (14) and (15).

30-100 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

ASSEMBLY
1. Bearing outer race
Assemble bearing outer race (14) and (15), in case (16).

2. Oil seal
Assemble oil seal (10) in retainer (5).

Outer circumference of oil seal: Grease (G2-LI)

3. Bearing cone
Assemble retainer (5) shaft and press fit bearing cone (9).
• After assembling bearing, check that there is no clearance at tip
of shaft.
• Assemble spacers.

Lip of seal: Grease (G2-LI)

Inner circumference of bearing: Grease (G2-LI)

4. Case

A. Assemble O-ring (11) in retainer. Insert O-ring completely in

groove.

WA500-3H 30-101
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
B. Stand shaft and insert case (16).
• Fill a and b of case and inner circumference of oil seal
completely with grease.

5. Retainer
Secure retainer (5) in case.
• Be careful that O-ring does not get caught or damaged when
installing.

Mounting bolt: 65.7 ±6.9 Nm (49 ±5 lbf ft)

6. Bearing seal

A. Press fit bearing (13) to shaft.

B. Assemble oil seal (12) in case.

• Dimension of seal press fit and outer edge of case: ±0.5 mm
(±0.020 in)

Seal: Grease (G2-LI)

7. Coupling
Assemble coupling (4), install O-ring (3) and retainer (2), and secure
center bolt (1).

Center bolt: 931 ±98 Nm (687 ±7 lbf ft)

30-102 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
8. Inspection of end play
Check that end play is within specified range.
• End play: Less than 0.22 mm (0.009 in).
• If end play is 0, with the seal and bearing coated with grease
check that the free rotating torque is less than 3.9 Nm (3 lbf ft).

WA500-3H 30-103
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

DRIVE SHAFT

DISASSEMBLY
1. Shaft

A. Remove shaft (2)

• Make match marks a before removing to ensure that the
direction of the spider assembly does not change.

• Cover (1) and (1A) is caulked with a punch at four places,

so it must not be removed unless necessary.
• When removing cover (1) and (1A) be extremely careful not
to damage cover (1), (1A) and yoke (3).
• When removing the caulking, raise the caulking with a
screwdriver.

B. Remove mounting bolts (4), then remove spider assembly (5).

• Make match marks on yoke and spider.

30-104 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
C. Remove bearing caps (6) from spider assembly.
• Remove strap (7) of cap.

D. When replacing bearing (8), seal (9), and derling washer (10)
from bearing cap (6), replace whole cap assembly.

2. Yoke

A. Remove mounting bolts (11) from yoke (3), then remove spider
assembly (12).
• Stamp match marks on the yoke and spider.

B. Remove bearing caps (13) from spider assembly.

WA500-3H 30-105
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
C. When replacing bearing (14), seal (15), and derling washer (16)
from bearing cap (13) replace whole cap assembly.

30-106 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

ASSEMBLY
1. Yoke

A. Install bearing (14), and seal (15) to bearing cap (13).

Bearing, seal: Grease (G2-LI)

B. Assemble washer (16), and bearing cap (13) to spider

assembly (12)
• Be careful not to damage bearing with heat when welding
strap.

Bearing cap: Grease (G2-LI)

C. Assemble spider assembly (12) to yoke (3).

• Carefully align match marks.
• Clean the mounting face of the bearing cap by wiping with
a clean cloth.

Mounting bolts: 142.2 ±9.8 Nm (105 ±7 lbf ft)

2. Shaft

A. Assemble bearing (8) and seal (9) in bearing cap (6).

Bearing seal: Grease (G2-LI)

WA500-3H 30-107
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
B. Assemble washer (10)and bearing cap (6) to spider assembly (5).
• Be careful not to damage bearing with heat when welding
strap.

Bearing cap: Grease (G2-LI)

C. Assemble spider assembly (5) to shaft (2).

• Carefully align match marks.
• Clean the mounting face of the bearing cap by wiping with
a clean cloth.

Mounting bolt: 142.2 ±9.8 Nm (105 ±71 lbf ft)

D. Align match marks a, then install shaft (2) to yoke (3).

• Check that the direction of the spider assembly is the same.
• If the spline is worn, replace the whole drive shaft assembly.

Spline: Grease (G2-LI)

30-108 WA500-3H
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
E. lf cover (1) and (1A) has been removed, do as follows:
• Front and rear drive shaft.
Insert seal and retainer to cover (1) and shaft (2), assemble
cover (1), then caulk with a punch on diagonally opposite
sides.
• Center drive shaft.
Insert shaft (2) to cover (1A), assemble cover (1A), then
caulk with a punch on diagonally opposite sides.

WA500-3H 30-109
DISASSEMBLY AND ASSEMBLY FRONT AXLE

FRONT AXLE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Insert blocks ➀ and ➁ between top face (1) of left and right rear axle
housings and frame (2).

2. Start engine, operate work equipment to raise front axle, then set
block under front frame on left and right sides and operate work
equipment to lower frame.
• Check that the front wheels can be removed, then lower the work
equipment to the ground.

3. Sling left and right wheels (3), remove hub nuts, then lift off.

Tire, wheel: 789 kg (1740 lb)

4. Disconnect front drive shaft (4) at differential end.

• Make counter marks to act as a guide when assembling.

5. Disconnect brake tube (5) from slack adjuster.

6. Remove brake tubes (6) and (7).

• Seal the brake system with blind plugs after the piping
is disconnected.

30-110 WA500-3H
DISASSEMBLY AND ASSEMBLY FRONT AXLE
7. Sling one side of front axle assembly (8) and set garage jack to other
side.

8. Remove mounting bolts (9).

9. Operate crane and garage jack to lower the axle assembly.

• Be careful not to let the slack adjuster on top of the axle housing
hit the frame.

Front axle assembly: 1,940 kg (4,277 lb)

10. Pull out front axle assembly from chassis.

INSTALLATION
• Carry out installation in the reverse order to removal.

Hub nut: 470.4 ±49.0 Nm (347.2 ±36.2 lbf ft)

Drive shaft mounting bolt: 110.7 ±12.7 Nm (82 ±9 lbf ft)

Axle mounting bolt: 2744.0 ±294.0 Nm (2025 ±217 lbf ft)

REFILLING FRONT AXLE WITH OIL

• Add oil through the oil filler to the specified level.

WA500-3H 30-111
DISASSEMBLY AND ASSEMBLY REAR AXLE

REAR AXLE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Jack up chassis, set block ➀ under rear frame, and support bottom of
counterweight with stand ➁.

2. Sling left and right wheels (1), then remove hub nut and lift off.

Tire and wheel: 789 kg (1,740 lb)

3. Disconnect rear drive shaft (2) from rear axle.

Rear drive shaft: 41 kg (86 lb)

4. Disconnect hose (3) between brake pedal and slack adjuster at slack
adjuster end.

5. Disconnect tubes (4) and (5) between slack adjuster and left and right
wheel brakes.
• Be sure to remove the brake tube before removing the axle. There
is danger that it may be crushed.

30-112 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE
6. Disconnect grease tubes (6) and (7) from axle support at rear end.

7. Disconnect grease tube (8) from axle support at front end.

• Remove the clamps of the brake hose from the support.

8. Secure axle support and rear axle with chain.

9. Remove mounting bolts, then using garage jack to maintain balance,

lower axle assembly.

Rear axle assembly: 1,877 kg (4,138 lb)

10. Pull out rear axle assembly (9) from chassis.

• Support both ends of the axle with jacks.

WA500-3H 30-113
DISASSEMBLY AND ASSEMBLY REAR AXLE
11. Remove front support (10) from rear axle.
• Be careful not to damage the packing.

Front support: 95 kg (209 lb)

12. Remove packings (11) and (12) from front support.

13. Remove bushing (13) from front support.

• Remove all dirt and oil from the bushing mounting surface
inside the front support.

14. Sling rear support, and remove thrust cap (14).

30-114 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE
15. Remove thrust washer (15), thrust plate (16), and thrust washer (17)
from rear axle.

16. Lift off rear support (18).

Rear support: 115 kg (253 lb)

17. Remove packing (19) from rear support.

WA500-3H 30-115
DISASSEMBLY AND ASSEMBLY REAR AXLE
18. Remove bushing (20) from rear support.
• Remove all dirt and oil from the bushing mounting surface inside
the rear support.

INSTALLATION
• Carry out installation in the reverse order to removal.

Hub nut: 471 ±49 Nm (347 ±36 lbf ft)

Drive shaft mounting bolt: 110.7 ±12.7 Nm (745 ±8 lbf ft)

Rear support mounting bolt: 1568 ±196 Nm (1157 ±145 lbf ft)

• Soak a cloth with primer for Loctite Prism adhesive, then wipe the adhesion surface at the bushing end.

Adhesion surface at rear support end:

Instant adhesive Loctite Prism 411 (approx. 3g)

• Install the bushing within five minutes of coating it with primer.

• Do not mix the primer with adhesive when using it.
• Be careful to install the packing with the lip facing in the correct direction.

Lip of packing: Grease (G2-LI)

Rear axle mount portion: Grease (G2-LI)

30-116 WA500-3H
DISASSEMBLY AND ASSEMBLY REAR AXLE

Front support mounting bolt: 1,568 ±196 Nm (1157 ±145 lbf ft)

• Coat the bushing the same as the rear axle.

Lip of packing: Grease (G2-LI)

Front axle mount portion: Grease (G2-LI)

Thrust cap mounting bolt: 279.3 ±29.4 Nm (206 ±22 lbf ft)

Thrust plate mounting bolt: 279.3 ±29.4 Nm (206 ±22 lbf ft)

REFILLING REAR AXLE WITH OIL

• Add oil through the oil filler to the specified level.

WA500-3H 30-117
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
12
DIFFERENTIAL, NORMAL -
(STANDARD)

REMOVAL (FRONT)

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove drain plugs (1) and (2), and drain oil.

Axle oil: 78 liters (20.5 gal)

2. Operate work equipment to raise front axle, then set stand under left
side of axle.

3. Sling left wheel (3), then remove hub nut and lift off.

Tire and wheel: 789 kg (1,740 lb)

4. Remove left and right final drive covers (4).

5. Using forcing screws ➀, pull out drive shaft (5) approx. 200 mm
(7.874 in) together with sun gear (6).

30-118 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
6. Remove front drive shaft (7).

• Sling the drive shaft and lower it slowly.

7. Remove two mounting bolts of differential (8), and install guide

bolt.

• Screw in the guide bolt fully and check that all the threads have
entered the hole.
• First, screw in the guide bolt, then remove the remaining
mounting bolts.

8. Set lever block ➁ to differential case (9), and set so that differential
assembly does not fall over.
• Fit both ends of a lever block to the front frame inspection window.

9. Pull out differential (8) approx. 20 mm from axle housing (10) along
guide bolts.
• Be careful not to damage the O-ring.

10. Install tools H1-1 and H1-2 to garage jack, and insert between
differential and axle housing, then install differential to tool H1-1.

11. Adjust lever block and height of jack, and remove differential
assembly slowly.

Differential assembly: 268 kg (591 lb)

12. Operate jack and pull out differential assembly (8) to outside of chassis.

13. Remove O-ring (11).

WA500-3H 30-119
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

INSTALLATION (FRONT)
• Carry out installation in the reverse order to removal.

Drain valve: 151.9 ±24.5 Nm (112 ±18 lbf ft)

Hub nut: 470.4 ±49.0 Nm (347 ±36 lbf ft)

Drive shaft mounting bolt: 110.7 ±12.7 Nm (75 ±9 lbf ft)

Differential mounting bolt: 548.8 ±58.8 Nm (405 ±44 lbf ft)

30-120 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

REMOVAL (REAR)

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove rear axle assembly from chassis. For details, see REAR
AXLE REMOVAL.
• Do not remove the rear support from the rear axle.

2. Remove plug (1) and drain axle oil.

• Set so that the drain plug is at the bottom.

Axle oil: 78 liter (20.5 gal)

3. Remove cover (2).

4. Using forcing screws, pull out drive shaft (3).

• Pull the drive shaft out approx. 200 mm (7.874 in).

5. Using eyebolts, lift off rear differential assembly (4).

Rear differential assembly: 278 kg (612 lb)

• Remove the O-ring from the housing mating surface.

WA500-3H 30-121
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

INSTALLATION (REAR)
• Carry out installation in the reverse order to removal.

Differential mounting bolt: Thread tightener (LT-2)

Differential mounting bolt: 548.8 ±58.8 Nm (405 ±43 lbf ft)

Adjusting shims on shaft

1. Adjust the shims on the shaft if the differential assembly or axle

housing have been replaced.

2. Tighten mounting bolts of shaft (5) uniformly, then measure clearance

a between axle housing and shaft.
• Do not assemble the shims.

Tighten the mounting bolts to 3.9 ±0.1 Nm (3 lbf ft).)

3. Add 0.1 ±0.05 mm (0.004 ±0.002 in) to the measurement for

clearance a, then select a shim within that range and assemble it.
• Shim thickness: Clearance a + 0.1 ±0.05 mm (0.004 ±0.002 in)

Mounting bolt: 112.7 ±9.8 Nm (83 ±7 lbf ft)

30-122 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

DISASSEMBLY
DIFFERENTIAL GEAR ASSEMBLY

1. Set differential assembly (1) on special tools H2-1, H2-2, and H-3.

Differential assembly: 230kg (506 lb)

2. Pinion assembly

A. Remove case (2).

B. Remove oil seal (3) and dust seal (3A) from case.

C. Screw in jack screw ➀ (Thread dia. = 18 mm, Pitch = 1.75 mm),

and lift out pinion assembly (4).
• Check number of shims (5).

WA500-3H 30-123
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
3. Differential gear case assembly

A. Remove left and right locks (6), and with a bar, turn nut (7) until
it become loose.

B. Remove mounting bolts (9) of cap (8).

C. Remove nut and lift out differential gear case assembly (10).

30-124 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

FINE DISASSEMBLY OF PINION ASSEMBLY

4. Bearing, collar, cage

A. Support cage (11), push shaft with press and tack out pinion.

B. Remove bearing (12) and collar from cage.

C. Remove outer races (13) and (14) from cage (11).

5. Pinion, bearing
A. Remove snap ring (15), then remove bearing (16).

B. Remove bearing (17).

WA500-3H 30-125
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

FINE DISASSEMBLY OF DIFFERENTIAL

GEAR CASE ASSEMBLY
6. Bevel gear (large)
Remove mounting bolts, using eye-bolts ➁ (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 gear (21), cross shaft (22), and washer (23) as one unit.

9. Bevel gear (small)

Remove bevel gear (24) and thrust plate.
10. Bearing
Remove bearing (26) from case (25).

30-126 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
12
FINEASSEMBLY OF DIFFERENTIAL GEAR CASE
ASSEMBLY

1. Bearing
Using press fit kit ➂ {120 mm (4.724 in) inner diameter}, press fit
bearing (26) to case (25).

2. Bevel gear (small)

Install thrust and small bevel gear (24) in case.
• Align thrust with dowel pin and install.

3. Pinion gear, cross shaft

Assemble pinion gear (21) and washer (23) with cross shaft (22).
• Align washer groove with dowel pin of case and install.

4. Bevel gear (small)

Install bevel gear (20) and thrust plate (19).

WA500-3H 30-127
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
5. Bevel gear (large)
Using eye-bolts ➁ (thread dia. = 16 mm, Pitch = 2.0 mm), lift and
install bevel gear (18).
• Align pin hole of thrust and dowel pin on case side and install.

FINE ASSEMBLY OF PINION ASSEMBLY

6. Bearing

A. Using press fit kit ④ (26 mm inner diameter) install pinion

bearing (17).

B. Using press fit kit ➄ {55 mm (2.165 in) inner diameter}, install
bearing (16).

Rotating surface of bearing: Engine oil (EO30-CD)

C. Install snap ring (15).

7. Cage
A. Install outer races (14) and (13).

B. lnstall cage (11) to pinion assembly.

30-128 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
8. Collar
Install collar (27).

9. Bearing
Using press fit kit ④ (76 mm inner diameter), install bearing (12).

ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY

• Set differential case on special tools H1-I, H2-2, and H2-3.

10. Pinion assembly

A. Assemble shims removed when disassembled.

• Standard shims thickness: 2.1 mm (0.083in).

B. Using eye-bolts ➄ (Thread dia.=12mm, Pitch 1.75 mm), install

pinion assembly (4).

C. Remove oil seal (3) and dust seal (3A) to case.

Lip of oil seal: Grease (G2-LI)

Rear Lip of dust seal: Grease (G2-LI)

D. Fit O-ring to case, and install case (2).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 279.3 ±29.4 Nm (206 ±22 lbf ft)

WA500-3H 30-129
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
E. Insert coupling (28), fit O-ring and tighten holder.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 921 ±98 Nm (608 ±72 lbf ft)

• Fit the balancer ➅ to bolt hole of coupling, and measure

the rotating torque: Rotating torque: Max. 50.0 N (11.22 lb)

11 Differential gear assembly

Sling differential gear assembly (10) and install case.

12. Nut, cap

A. Align nut (7) with differential case groove and install.

B. Install cap (8) and tighten (9).

Mounting bolt: Thread tightener (LT-2)

Mounting bolt:
Check match marks on bearing cup before installing.
Rotate bevel gear 20 - 30 times to settle in, then tighten bolt.

30-130 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
★ Bearing pre-load adjustment steps are as follows.
C. Install tool H4-1 and H4-2 to cap on both sides.

D. Measure clearance a between tool H4-2 with tool H4-1.

E. Add 0.26 ± 0.07 mm (0.010 ±0.003 in) to measurement

dimension and set scale on tool H4-1.
• The added dimension becomes the amount of bending of the
case, given before pre-load and given after pre-load.

F. Tighten adjusting nut with bar until increased amount becomes

0.26 ±0.07 mm (0.010 ±0.003 in).

★ 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.

WA500-3H 30-131
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
13. Adjusting tooth contact, backlash
• Adjust the backlash, and at the same time adjust tooth contact.

A. Adjust backlash as follows:

i. Movement of bevel gear is done with adjusting nut (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 ➂ 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 0.3 - 0.4 mm (0.012 - 0.016 in).
• Measure at three or four places, and keep the pinion gear fixed
when measuring.

B. 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.

30-132 WA500-3H
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)
C. Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the
pinion gear forward and backward and inspect the pattern left on the teeth.

Tooth contact Cause Procedure for adjustment

Correct contact
The tooth contact pattern should start
Adjust the bevel pinion by adjusting the shims at the bevel
from about 5 mm from the toe of the
pinion cage.
bevel gear and cover about 50% of the
Adjust the bevel gear in the same way as when adjusting
length of the tooth.
backlash.
It should be in the center of the tooth
height.

1. Reduce shims at bevel

pinion to bring closer to
bevel gear.

Bevel pinion is too far from bevel gear. 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.

1. Increase shims at bevel

pinion to move away from
bevel gear.

Bevel pinion is too close to bevel gear. 2. Move bevel gear closer to
bevel pinion and adjust
backlash correctly.

1. Reduce shims at bevel

pinion to bring closer to
bevel gear.

Bevel gear is too close to bevel pinion 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.

1. Increase shims at bevel

pinion to move away
from
bevel gear.
Bevel gear is too far from bevel pinion.
2. Move bevel gear closer to
bevel pinion and adjust
backlash correctly.

★ When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and
right. Always keep the same total thickness of shims.

WA500-3H 30-133
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL, NORMAL - (STANDARD)

14. Lock
After adjusting tooth contact and backlash, install lock (6).

Mounting bolt: Thread tightener (LT-2)

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE

DISASSEMBLY

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Tire assembly
Loosen hub nut, raise chassis with work equipment or jack, insert
support stand under axle, then sling tire assembly, remove hub nuts,
and lift off tire assembly (1).

Tire and wheel: 789 kg (1,740 lb)

2. Draining oil
Remove drain plug (2) and drain oil.
Set so that the drain plug is at the bottom.

Axle oil: 78 liter (20.5 gal) (front and rear)

3. Cover
Remove mounting bolts (3), then remove cover (4).

4. Drive shaft
Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75 mm) in drive
shaft, then pull out drive shaft assembly (5) and remove.

5. Planetary carrier assembly

Remove mounting bolts (6), then using eyebolt ➁ (Thread dia.=12
mm, Pitch=1.75 mm), lift off planetary carrier assembly (7).
• Use a bar to adjust the position of the center of gravity when
removing.

Planetary carrier assembly: 90 kg (198 lb)

WA500-3H 30-135
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
6. Ring gear

A. Using tool H6, secure wheel hub (8) and brake housing (9).
• Install tool H6 at three places at equal distances.
• Do not remove tool H6 until assembly Step 3.

B. Remove mounting bolts (10), then remove retainer (11) and

ring gear (12).
• Check the number and thickness of shims on the inside of
the retainer.

Ring gear: 50 kg (110 lb)

7. Disassembly of planetary carrier

Using press, pull out shaft (13), then remove pinion gear (14).
• Lock ball (15) is fitted in the shaft, so be careful not to lose the ball.
• Write the serial number on the case and be careful not to mix the
removed parts with other parts.
• The bearings and other parts have settled as a set, so make
identification marks and be careful not to mix with other parts.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE

8. Disassembly of ring gear

A. Remove lock plates (18) from ring gear hub (17), then remove
ring gear (19)

B. Pull out bearing (20) from ring gear hub (17).

WA500-3H 30-137
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
ASSEMBLY
1. Assembly of ring gear

A. Press fit bearing (20) on ring gear hub (17).

• After press fitting the bearing, check that there is not
clearance between the rib and bearing.

B. Set ring gear hub (17) on ring gear (19), then install lock
plates (18).
• Install the lock plates with the wider ones on the inside.
• Remove all grease and oil from the bolt.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 31.4 ±2.9 Nm (23 ±2 lbf ft)

2. Assembly of planetary carrier

Set pinion gear (14) in carrier case, insert ball (15) in shaft (13),
then press fit.
• Press fit so that the hole for the lock ball is on the outside
circumference, then stop with the hole at the front and align
the holes.
• After press fitting the shaft, check that the gear rotates smoothly.

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
3. Wheel bearing adjustment

A. Insert ring gear assembly (12) in axle housing, fit retainer (11)
tighten temporarily with mounting bolts (10), and remove tool H6.

B. Measure thickness b of retainer before installing. Do not insert

shims in the retainer when tightening temporarily.
• Rotate the wheel hub 20 - 30 times and tighten the bolts to
a uniform torque.

Mounting bolt: 78.4 ±4.9 Nm (58 ±4 lbf ft)

C. Using a depth micrometer or dial gauge, insert through

measuring hole of retainer (21) and measure clearance a from
retainer to face of housing.
Measure at two places and take the average.
• 0.3 mm (0.012 in) added to measured value difference
C = a - b, becomes shim thickness.
• Use the smallest number of shims which gives the
required thickness.

WA500-3H 30-139
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
D. After installing tool H6 to brake housing and wheel hub,
remove retainer, insert the required number of shims and
retainer, then tighten mounting bolts.
• When assembling shims, after installing tool H6, always
tighten the mounting bolts uniformly to the specified
tightening torque.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 279.5 ±29.4 Nm (206 ±22 lbf ft)

4. Planetary carrier
Fit O-ring, using eye-bolts ➁ (Thread dia. = 12 mm, Pitch = 1.75 mm)
sling planetary carrier assembly (7), set in mounting position and
tighten mounting bolts (6).
• Because balance is bad, adjust the center of gravity with a bar
and install.

5. Axle shaft
Screw in bolt ➀ (Thread dia. = 12 mm, Pitch= 1.75 mm) in axle
shaft and insert axle shaft assembly (5).
• If the position of the sun gear does not match, rotate the wheel
hub to align.

6. Cover
Fit O-ring, install final drive cover (4), then tighten mounting bolts (3).

Mounting bolt: 68.6 ±9.8 Nm (51 ±7 lbf ft)

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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7. Refilling with oil
Tighten drain plug (2), then remove level plug, and add oil through
oil filter to specified level. Set the machine so that the level plug of
the final drive is at the bottom when refilling with oil.

Axle oil: Approx. 78 liter (20.5 gal) (each)

8. Tire assembly
Raise tire assembly (1), set to wheel hub, and tighten temporarily
with wheel nuts. Then jack up chassis with work equipment and jack,
remove stand under axle, lower chassis to ground and tighten wheel
nuts to specified torque.

Wheel nut: 470 ±49.0 Nm (347 ±36 lbf ft)

(Width across flats: 30 mm)

WA500-3H 30-141
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE

ORBITAL STEERING VALVE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove cover (1) from steering column.

2. Remove joint lock bolt (2).

3. Disconnect four hoses (3).

• Mark the hoses and their destinations to facilitate reassembly.

4. Remove three mounting bolts (4), then remove orbital steering valve
assembly (5).

5. Remove joint lock bolt (6), then remove joint assembly (7).

6. Remove bolt (8), then remove bracket (9).

INSTALLATION
• Carry out installation in the reverse order to removal.

Joint lock bolt: 55.9 ±7.8 Nm (41 ±6 lbf ft)

Bracket mounting bolt: 51.9 ±7.8 Nm (38 ±6 lbf ft)

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE

DISASSEMBLY
ENSURE A CLEAN WORKING ENVIRONMENT

1. Dirt or debris in the hydraulic system will cause premature wear and erratic operation. Keep all dirt and dust out of the
hydraulic circuit.

2. Use a clean work bench when disassembling or assembling the equipment.

3. Remove dirt from the exterior of the unit before disconnecting any piping.

4. Always wipe dirt off the unit before placing it on the work bench.

5. After disassembling, wash with a clean petroleum-base solvent, and blow dry with clean air. Always ensure that there are
no impurities in the solvent or air.
• If any other solvent is used, it may lead to deterioration of the rubber seal. Never wipe any part with a cloth or apply
steam to the unit.
• The solvent is flammable. Keep flames and sparks away.

PREPARATORY WORK

1. Fit blind plugs in the five ports in the valve body, clean the outside,
then remove the blind plugs.

2. Install tube nut ➀ to one of the ports.

3. Install in a vise ➁ with the end cover at the top.

• Do not clamp the valve body directly in the vise, which could
damage or break the unit.

4. Remove 7 mounting bolts (1), insert screwdriver between end cover

assembly (2) and sleeve (3), then remove end cover assembly (2).
• After removing, check that there is no damage to the edge of the hole in the end cover.

WA500-3H 30-143
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
5. Remove commutator (5) and washer (6).
• Do not remove pin (4).

6. Using two mounting bolts (1), remove commutator ring (7) and
manifold (8).

7. Using two mounting bolts (1), remove rotor set (9) and wear plate
(10) in the same way as commutator ring and manifold.

8. Insert screwdriver between sleeve (3) and valve body (11), then
remove sleeve (3).

9. Remove drive link(12).

10. Remove ball (13).

11. Remove rod (14), roller (15), rod (16), and spring (17).

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
12. Install in vise with input shaft (18) at the top, and make counter
marks with a punch in upper cover (19) and valve body (11).

13. Remove four mounting bolts (20), then grip input shaft (18), move it
up, and remove input shaft, upper cover, and valve spool assembly (23).

• The valve spool is fitted in the body with an extremely small

clearance, so if a horizontal force is applied, it will be impossible
to remove it. When removing the valve spool from the housing,
never apply any excessive force.

14. Remove upper cover assembly (22) from input shaft and valve spool
assembly (23), then remove shim (24) and spacer (25).
• Check the number and thickness of the shims, and keep in a
safe place.

15. Remove seal (26) and snap ring (27), then remove spacer (28),
seal (29), and seal ring (30) from upper cover (19).

WA500-3H 30-145
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• Seal (29) and seal ring (30) may form one unit.

16. Remove snap ring (31), thrust washer (32), thrust bearing (33),
thrust washer (34), and wave washer (35) from input shaft (18).

17. Use punch pin ➂ (3.0 mm dia, 16 mm length), to remove needle

roller (36) from input shaft (18).
• Cushion the input shaft with a wooden block to prevent damage
when striking with the hammer.

18. Set valve spool (37) facing bottom, then remove torsion bar (38)
and spacer (39) from input shaft and valve spool assembly.
• Do not remove needle roller (40) from the torsion bar.

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
19. Set valve spool (37) facing bottom, then rotate input shaft (18) until
drive link (41) comes out.

20. Set valve spool (37) facing bottom, then rotate input shaft (18)
clockwise to a point where ball comes out.
• Ball (42) may come out by itself, so be careful not to lose it.

• Do not remove ball retaining spring (43) unless it is to be

replaced. When removing it, hold the flat end with pliers and
pull up until it comes completely out from valve spool (37).
When doing this, be careful not to damage the outside of the
valve spool or the control edge.

WA500-3H 30-147
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE

ASSEMBLY
• Before assembly, wash all parts with clean petroleum based solvent
and dry with air. Never wipe with a cloth.
• Check carefully that there is no debris or paint on the edge of the
lapped surface.
• If there are no special instructions, do not coat any parts with oil
when assembling.

1. Set thrust washer (34), thrust bearing (33), and thrust washer (32) to
input shaft (18), and install snap ring (31).

2. Install wave washer (35) to thrust bearing (33) and thrust washer (34).

3. Install ball (42) inside valve spool (37).

4. To mesh the groove and ball, rotate counterclockwise and insert

input shaft (18) into valve spool (37).
• Keep the spool horizontal when doing this.

5. Fit center portion of torsion bar (38) between thrust washer (34)
and valve spool (37).

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• The positioning of the valve spool and input shaft is carried out
by inserting the torsion bar.

6. Check spline of input shaft (18) and drive link (41), and align spline
of valve spool (37), then install drive link (41).
• If the drive link and input shaft do not mesh, rotate the input
shaft slightly to carry out the meshing.
• When inserting the drive link, make sure that the torsion bar is
securely held in position.
• If the drive link is assembled correctly, there will be a clearance
of 8.89 mm (0.350 in) between the thrust washer and valve spool.
• If the relationship between the spool, drive link, and input shaft
is not correct, the steering unit will not work properly.

7. Measure diameter L of pin (40) of torsion bar (38) at several points

and check that the difference does not exceed 0.025 mm (0.010 in).

8. Set spacer (39) to torsion bar (38), then insert in valve spool and
input shaft assembly (23).

WA500-3H 30-149
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
9. Using pin ➂ (outside diameter: 3 mm), align pin hole of input shaft
(18) and torsion bar (38).

10. Using pin (1), knock pin (36) 0.8 mm in from end face of input shaft.

11. Install spacer (25) on valve spool and input shaft. If there is a lip at
one end inside the spacer, install so that the lip surface is facing the
wave washer.

12. Install input shaft and valve spool assembly (23) to valve body (11).
• The clearance is extremely small, so if any sideways pressure is
applied during assembly, it will not work properly.

13. Set shim (24) on top of thrust washer, fit seal, align counter marks of
upper cover (19), then install and tighten mounting bolts (20)
temporarily.

14. Set tool F1 in position, and install so that valve body and upper
cover are centered.

15. Tighten mounting bolts (20) and remove tool F1.

Mounting bolt: 27.4 ±2.5 Nm (20 ±2 lbf ft)

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
16. Measure width w of groove of drive link (12) at several places and
check that the difference does not exceed 0.025 mm.

17. Pull input shaft down, align drive link (12) with spline of valve spool,
then rotate spool so that end face of spool and valve body are level
with each other.

18. Align pin (40) and drive link (12) and install.

19. Using depth gauge ➅, measure installed height h of end face of

valve body and valve spool.

WA500-3H 30-151
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
• If installed height h = Within 0.063 mm it is not necessary to
adjust shim.
• If installed height h = 0.064 mm or more, repeat Steps 12
through 19 to adjust the shim height so that h = Within 0.063 mm.

20. Install ball (13).

21. Set rod (17) to spring (16), then fit to valve body (11) and install
roller (15) and rod (14).

22. Fit seal to valve body.

23. Before installing rotor, check rotor as follows.

A. Set the pin end of end cover assembly at top and spline end of
rotor assembly (9) at bottom, then check that rotor rotates freely
inside stator.

B. Measure thickness of rotor and stator, and check that the

difference is less than 0.18 mm (0.007 in).

C. Using feeler gauge ➆, check that the clearance of the rotor

from the stator is less than 0.18 mm (0.007 in).

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DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
24. Using guide pin ➇, install wear plate (10), rotor assembly (9), and
manifold (8).

25. Fit seal to end cover assembly (2).

26. Set sleeve (3) and end cover assembly (2) in position, tighten
mounting bolts (1) uniformly, then install sleeve, and remove end
cover assembly.

27. Fit washer (6) to end cover assembly (2), and install commutator (5).
• Install the commutator so that the concave part is at the end
cover assembly end.

• Determine the position so that the oval hole of the commutator

is in line with one of the bolt holes of the end cover assembly.

WA500-3H 30-153
DISASSEMBLY AND ASSEMBLY ORBITAL STEERING VALVE
28. Install commutator ring (7).

29. Rotate input shaft so that tip of drive shaft is aligned with oval hole
in commutator.

30. Set end cover assembly (2) on sleeve (3), then tighten five mounting
bolts uniformly.

Mounting bolt: 6.9 ±0.6 Nm (61 ±6 lbf in)

31. Set input shaft end facing top, then install seal ring (30) and seal (29).
• Install the seals from the small diameter end.
• Seal ring (30) and seal (29) are stuck together and are supplied
as one unit.
• Coat the new seal with oil and install from the lip end.
• When doing this, coat the inside with a small amount of grease.

32. Using tool F2, install spacer (28) from small diameter end.

33. Install snap ring (27).

34. Fit seal (26) to input shaft, and fit to upper cover.

30-154 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

STEERING CYLINDER

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Remove bolts (1), loosen bolt (2), then rotate cover (3) carefully
towards rear of machine.
• Rotate the cover using bolt (2) as the fulcrum.

• The operating space is confined, so be extremely careful when

carrying out the operation.

2. Disconnect bottom hose (4).

3. Disconnect grease tube (5).

4. Remove mounting bolt (6), then pull out pin (7).

• Note the number and thickness of the shims to use as a guideline
when assembling.

5. Disconnect head hose (8).

WA500-3H 30-155
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
6. Remove mounting bolt (9), then pull out pin (10).
• Note the number and thickness of the shims to use as a guideline
when assembling.

7. Using lever block, lift off steering cylinder (11).

• Carry out the removal operation for the cylinder using two workers.
• Be careful not to damage the cylinder rod.

Steering cylinder: 47 kg (104 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.
• Adjust the shims so that the clearance is specified value.
• Clearance a + b = Less than 1.0 mm (0.039 in) (The specified value
is the same for both the rod end and the bottom end.)

WARNING! Align position of the pin hole with a bar.

Never insert a finger into the pin hole.

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DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

DISASSEMBLY
1. Set cylinder assembly (1) in tool U1.

2. Raise lock of cylinder head (2), then using tool U2, remove cylinder
head (2) from cylinder.

3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.

4. Remove cylinder (4) from tool U1.

5. Set cylinder head and piston rod assembly in tool U1, and, using
power wrench ➀ and socket U3, loosen nut (5).
• Power wrench: x 16
• Socket U3: Width across flats: 60 mm

6. Remove nut (5), then remove piston assembly (6), and cylinder head
assembly (7) from rod (8).

WA500-3H 30-157
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
7. Disassembly of piston assembly

A. Remove wear ring (9).

B. Remove piston ring (10) from piston (11).

8. Disassembly of cylinder head assembly

A. Remove snap ring (16), then remove dust seal (17).

B. Remove rod packing (18).

C. Remove buffer ring (19).

D. Remove O-ring (20) and backup ring (21).

E. Remove O-ring (22).

F. Remove bushing (23) from cylinder head (24).

30-158 WA500-3H
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

ASSEMBLY
• Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing. Be careful not
to damage the rod packing, dust seals or O-ring when assembling.

1. Assembly of cylinder head assembly

A. Using tool U5, press fit bushing (23) to cylinder head (24).
• Be extremely careful not to deform the bushing when press
fitting.

B. Install buffer ring (19).

C. Install rod packing (18).

• Be careful to install rod packing (18) facing in the correct
direction.

D. Using push tool, install dust seal (17) to cylinder head (24).

E. Install snap ring (16).

F. Install O-ring (22).

G. Install backup ring (21) and O-ring (20).

• Do not try to force the backup ring into position.
★ Warm it in water 50 - 60° C (122 - 140° F) before fitting it.

2. Assembly of piston assembly

A. Using tool U6-1, expand piston ring (10).

• Place the piston ring on the expander and turn the handle
8 - 10 times to expand the ring.

B. Remove piston ring (10) from tool U6-1, and assemble on

piston (11).

C. Fit tool U6-2, on piston ring, then using clamp U6-3, contact
piston ring.

D. Assemble wear ring (9).

WA500-3H 30-159
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
3. Set piston rod (8) in tool U1.

4. Assemble cylinder head assembly (7) and piston assembly (6) no rod,
then fit nut (5).

5. Using power wrench ➀ and socket U3 tighten piston nut (5).

Power of power wrench (1): X16

Width across flats of nut (5): 60 mm
Tightening torque of nut: 1765 ±176 Nm
(1302 ±132 lbf ft)

6. Remove piston rod and head assembly from tool U1.

7. Set cylinder (4) in tool U1.

8. Raise piston rod and head assembly (3), and assemble in cylinder (4).

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

Cylinder head nut: 932.0 ±93.2 Nm (687 ±69 lbf ft)

10. Bend lock into notch on cylinder side.

11. Remove cylinder assembly from tool U1.

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DISASSEMBLY AND ASSEMBLY STEERING VALVE

STEERING VALVE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove bolt (1), loosen bolt (2),then rotate cover (3) carefully
towards rear of machine.
• Rotate the cover using bolt (2) as the fulcrum.
• The operating space is confined, so be extremely careful when
carrying out the operation.

2. Remove side cover (4).

3. Remove mounting bolts (5), and disconnect bracket (6).

4. Remove mounting bolts (7), and disconnect bracket (8).

5. Disconnect hose (9) between cut-off valve and hydraulic tank.

6. Disconnect hoses (10) and (11) between cut-off valve and loader circuit.

7. Disconnect hose (12) between steering valve and cut-off valve.

• Hose (12) is at the rear of the cut-off valve.

WA500-3H 30-161
DISASSEMBLY AND ASSEMBLY STEERING VALVE
8. Disconnect tubes (13) between steering valve and steering cylinder.

9. Disconnect tube (14) between steering valve and hydraulic tank.

10. Disconnect hose (15) between stop valve and steering valve.

11. Disconnect hose (16) between stop valve and steering valve.
• It is connected to both ends of the steering valve.

12. Disconnect hose (17) between steering valve and steering pump.

13. Disconnect tube (18) between switch pump and steering valve.

14. Disconnect hose (19) between steering valve and cut-off valve.

15. Remove mounting bolt (20).

16. Using guide bolt ➀, pull out steering valve assembly (21) together
with bracket approx. 200 mm (7.874 in) to center of machine.
• Remove the cut-off valve at this point.

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17. Lift off steering valve assembly (21) together with bracket.

INSTALLATION
• Carry out installation in the reverse order to removal.

• Install the cut-off valve after lowering the steering valve assembly together with the bracket to the mounting position.
• After installing the cut-off valve, use the guide bolt to move close to the frame and install.

WA500-3H 30-163
DISASSEMBLY AND ASSEMBLY BRAKE VALVE

BRAKE VALVE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove clamp (1) at front of brake valve.

2. Disconnect hose (2) between valve and hydraulic tank.

3. Disconnect hoses (3) and (4) between accumulator and valve.

4. Fit a wrench to the joint to stop it from turning.

5. Remove hoses (5) between R.H. brake valve and slack adjuster.

6. Remove clamp (6).

7. Disconnect hose (7) between R.H. brake valve and L.H. brake valve.

8. Disconnect hose (8) between valve and hydraulic tank.

9. Disconnect hose (9) between accumulator and valve.

10. Remove pedal (10).

11. Pull out snap pin (11), then pull out pin (12).
• Be careful not to lose L-shaped pin (13).

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DISASSEMBLY AND ASSEMBLY BRAKE VALVE
12. Remove mounting bolts (14), then remove brake valve assembly (15).
• Carry out the operation with two workers and remove the valve
assembly from under the floor plate.

INSTALLATION
• Reverse the removal procedure to install a brake valve assembly.

WA500-3H 30-165
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER

SLACK ADJUSTER

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove cover (1) on top of front frame.

2. Disconnect tube (2) between brake valve and slack adjuster.

3. Disconnect tube (3) between slack adjuster and left and right brake
pistons.

4. Remove mounting bolts, then remove slack adjuster (4).

• The operating space is confined, so be extremely careful when
carrying out the operation.

INSTALLATION
• Carry out installation in the reverse order to removal.

Tube: 80.9 ±12.3 Nm (60 ±9 lbf ft)

Tube: 68.6 ±9.8 Nm (51 ±7 lbf ft)

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DISASSEMBLY
1. Bleeder
Remove bleeder (2) from body (1).

2. Cylinder
Remove mounting bolts, then disconnect body (1) and cylinder (4)
together with bracket (3).

WARNING! There is spring tension inside the cylinder,

so hold the contact surfaces and be
careful when removing.

3. Piston

A. Remove spring (5) and O-ring (6).

B. Remove piston (7), then remove O-ring

• Use a rod of 10 mm (0.394 in) diameter and push out the
piston slowly.
• Be careful not to damage the thread with the rod.

4. Poppet
★ Do not disassemble the poppet unless necessary. If it is disassembled,
replace the whole cylinder assembly.

A. Remove cover (8) from cylinder (4), then remove plug (9),
spring (10) and poppet (11).
• When removing the poppet, blow in air from the oil hole in
the cylinder.
• Hold the oil port of the cylinder by hand, and do not pump
in air suddenly.
• Be careful not to change the combination of poppet (11)
and cylinder (4).
• When replacing, replace the poppet and cylinder as an assembly.

B. Remove O-ring (12) from poppet.

WA500-3H 30-167
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER

ASSEMBLY
1. Poppet

A. Fit O-ring (12) on poppet (11).

B. Install poppet (11), spring (10), plug (9) and cover (8), then
assemble cylinder (4).

2. Piston

A. Install O-ring (13) on piston (7).

B. Insert piston (7) in cylinder (4).

• Check that the piston moves smoothly.

3. Cylinder

A. Install O-ring (6) and spring (5) in cylinder.

★ Installed load of spring 43.1 Nm (9.68 lb)

B. Install body (1) and cylinder (4) together with bracket (3).

4. Bleeder
Install bleeder (2).

30-168 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)

BRAKE ASSEMBLY (FRONT AND

REAR)

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove final drive assembly. For details, see FINAL DRIVE

DISASSEMBLY.

2. Disconnect brake tube (1).

3. Set tool H6 in position, and sling brake and wheel hub assembly,
remove mounting bolts (2), then lift off brake and wheel hub
assembly (3).

Brake, wheel hub assembly: 280 kg (617 lb)

4. Remove bearing (5) and retainer (6) from axle (4).

INSTALLATION
• Carry out installation in the reverse order to removal.

Brake tube: 68.6 ±9.8 Nm (51 ±7 lbf ft)

Mounting bolt: Thread tightener (LT-2)

Brake, wheel hub mounting bolt: 548.8 ±58.8 Nm (405 ±43 lbf ft)

WA500-3H 30-169
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)

DISASSEMBLY
1. Cylinder
Using eyebolt ➀ (Thread dia. = 16 mm, Pitch = 2.0 mm), lift out
cylinder (1).

★ Disassemble cylinder with following steps:

A. Screw in eyebolts ➀ (Thread dia.=16 mm, Pitch 2.0 mm),

push in spring with bar ➁, then pull out pin (2).

B. Remove spring (3) and shaft (4).

C. Remove piston (5).

2. Plate, disc

A. Remove plate (6).

30-170 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
B. Remove disc (7).

i. When removing the disc and plates, put match marks on the
inner gear and disc, and outer gear and plate before removing.

ii. The discs are made of soft material, so be careful not to

damage them during removal.

iii. Remove discs and plates alternately.

3. Gear assembly

A. Remove tool H6.

B. Using eyebolt ➂ (Thread dia.=12 mm, Pitch =1.75 mm), lift off
gear (8).

C. Remove plate (9) from gear (8).

D. Remove floating seal (10) and oil seal (11) from gear (8).

WA500-3H 30-171
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
4. Floating seal, outer race

A. Remove floating seal (12) from hub (13).

B. Remove outer races (14) and (15) from hub (13).

30-172 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)

ASSEMBLY
1. Outer race, floating seal

A. Using push tool ④, press fit outer race (15) to hub (13).

B. Using push tool ➄, press fit outer race (14) to hub (13).

C. Using tool H9, install floating seal (12) to hub (13).

Seal contact surface: Engine oil (EO30-CD)

• Assemble O-ring (12) to floating seal.

• Use alcohol to completely remove any white blooming from
the surface of the O-ring.
• Remove all oil and grease from the floating seal and hub
O-ring contact surface.

• Tighten tool H9 uniformly to prevent twisting of the floating

seal O-ring. After press fitting, measure height at four places
around the circumference and check that the difference in
dimension t at all four places is within 1 mm (0.039 in).

2. Gear assembly

A. Using tool H5, install oil seal (11) to gear (8).

Lip of oil seal: Grease (G2-LI)

Mating surface of oil seal hub: Thread tightener

(Loctite #648)

WA500-3H 30-173
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
B. Using tool H8, install floating seal (10) to gear (8).

Seal contact surface: Engine oil (E030-CD)

• Assemble O-ring (10) to floating seal.

• Use alcohol to completely remove any white blooming from
the surface of the O-ring.
• Remove all oil and grease from the floating seal and retainer
O-ring contact surface.

• Tighten tool H8 uniformly to prevent twisting of the floating

seal O-ring. After press fitting, measure height t at four places
around the circumference and check that the difference in
dimension t at all four places is within 1 mm (0.039 in).

3. Assemble plate (9), then using eyebolt ➂ (Thread dia. = 12 mm,

Pitch = 1.75 mm), raise gear (8) and install.

4. Install tool H6.

30-174 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
5. Disc, plate

A. Install disc (7).

B. Install plate (6).

• Align notched portion of outer teeth of plate and assemble.
• 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
★ Assemble cylinder with following steps:

A. Set piston (5) at bottom.

B. Install shaft (4) and spring (3).

C. Screw in eyebolts ➀ (Thread dia. = 6 mm, Pitch = 2.0 mm),

push in spring with bar ➁, then install pin (2).

WA500-3H 30-175
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)
D. Fit O-ring and using eyebolts ➀ (Thread dia. = 16 mm,
Pitch = 2.0 mm), match with guide bolt (1) and lift and install
cylinder assembly.

Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 176.5 ±19.6 Nm (130 ±15 lbf ft)

30-176 WA500-3H
DISASSEMBLY AND ASSEMBLY BRAKE ASSEMBLY (FRONT AND REAR)

MEMORANDUM

WA500-3H 30-177
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

HYDRAULIC PUMP

(SWITCH & PPC, LOADER, TORQUE CONVERTER-

TRANSMISSION, STEERING)

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Remove engine hood assembly

For details, see ENGINE HOOD REMOVAL.

2. Remove bulkhead assembly.

For details, see BULKHEAD REMOVAL.

3. SWITCH + PPC pump assembly.

A. Disconnect hose (1) and tube (2).

B. Remove mounting bolt (3).

C. Lift off pump assembly (4).

4. Loader pump assembly.

A. Remove bolts (5), and disconnect tube (6) together with hose.

B. Disconnect hose (7).

C. Remove U-bolts (8), then remove bracket (9).

D. Remove bolt (10), then remove tube (11).

E. Remove bolt (12), then remove pump assembly (13).

F. Disconnect tube (14).

30-178 WA500-3H
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
5. Steering pump assembly.

A. Remove drive shaft assembly (15).

B. Disconnect tube (16).

C. Remove bolt (17), then remove pump assembly (18)

6. Transmission/torque converter pump assembly

A. Disconnect hose (19).

B. Disconnect tube (20).

C. Remove mounting bolt (21), then remove pump assembly (22).

INSTALLATION
• Carry out installation in the reverse order to removal.

Brake tube: 110.7 ±12.7 Nm (81 ±9 lbf ft)

WA500-3H 30-179
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

HYDRAULIC TANK

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

• Remove cover (1).

• Loosen plug (2) on top of the hydraulic tank filler and bleed air from
the tank.

1. Remove plug (3), then loosen valve (4) and drain hydraulic oil.

Hydraulic oil: 175 liters (46.23 gal)

2. Sling ladder floor (5), then remove mounting bolts and lift off.
• Be careful of the center of gravity when lifting off the ladder.

Ladder floor: 90 kg (198 lb)

3. Disconnect main suction tube (6).

4. Disconnect return tube (7) from cooler.

5. Disconnect main return tube (8).

30-180 WA500-3H
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
6. Disconnect hose (9) between brake valve and hydraulic tank.

7. Disconnect stop valve, charge valve, PPC, orbital steering valve, and
drain hoses (10).

8. Sling hydraulic tank, then remove mounting bolts (11)

and (12).

9. Lift off hydraulic tank assembly (13).

Hydraulic tank assembly: 230 kg (507 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

Plug: 11.8 ±1.0 Nm (9 ±7 lbf ft)

Hydraulic tank bolt: 277.3 ±32.3 Nm (205 ±24 lbf ft)

WA500-3H 30-181
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER

HYDRAULIC FILTER

REMOVAL

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Remove cover (1).

2. Loosen plug (2) on top of the hydraulic tank filler and bleed air from
the tank, then remove mounting bolts, and remove cover (3).

WARNING! The cover is under pressure from a

spring. Remove the cover slowly and
carefully.

3. Remove spring (4).

4. Remove bypass valve (5).

5. Remove filter (6).

INSTALLATION
• Carry out installation in the reverse order to removal.

Plug: 11.8 ±1.0 Nm (9 ±7 lbf ft)

30-182 WA500-3H
DISASSEMBLY AND ASSEMBLY PPC VALVE

PPC VALVE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

• Remove cover (1).

• Loosen plug (2) on top of the hydraulic tank filler and bleed air from
the tank.

1. Remove console box cover (3) on right side of operator’s seat.

2. Disconnect rods (4).

3. Disconnection of hoses from PPC valve

A. Disconnect hoses P1 (5) and P4 (6) for bucket control

B. Disconnect hoses P3 (7) and P2 (8) for boom control

C. Disconnect hose (9) from PPC pump

D. Remove eyebolt (10) of return hose leading to hydraulic tank.

E. After disconnecting the hoses, fit tags to distinguish them.

4. Remove mounting bolts (11), then remove PPC valve assembly (12).

INSTALLATION
• Carry out installation in the reverse order to removal.

Plug: 11.8 ±1.0 Nm (9 ±7 lbf ft)

WA500-3H 30-183
DISASSEMBLY AND ASSEMBLY PPC VALVE

DISASSEMBLY
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 collar (11), then remove retainer (6), shim (12), and
spring (8) from valve (9).

ASSEMBLY
1. Push shim (12), spring (8), and retainer (6) into valve (9), and install
collar (11).

2. Install center spring (7) and valve assembly to valve body (10).

3. Install spool (5).

4. Fit O-ring and install collar (4).

5. Install seal (3).

6. Fit plate (2) and install bolt (1).

Bolt: 44.1 ±4.9 Nm (326 ±36 lbf ft)

30-184 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE

MAIN CONTROL VALVE

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Open cover (1).

2. Loosen plug (2) on top of the hydraulic tank filter and bleed air from
tank.

3. Remove bucket cylinder assembly. For details, see BUCKET

CYLINDER REMOVAL.

4. Remove bolt (3), then remove cover (4).

5. Remove bolt (5), and loosen bolt (6), then rotate cover (7) carefully
to right.
• Rotate the cover on the right side of the chassis to the left.
• Rotate the cover using bolt (6) as the fulcrum.
• The operating space is confined, so be extremely careful when
carrying out the operation.

6. Disconnect hose (13) for bucket spool between PPC valve (P1) and
main control valve (PB1).

WA500-3H 30-185
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
7. Disconnect hose (14) for boom spool between PPC valve (P3) and
main control valve (PB2).

8. Disconnect hose (15) for bucket spool between PPC valve (P4) and
main control valve (PA1).

9. Disconnect hose (16) for boom spool between PPC valve (P2) and
main control valve (PA2).
• Remove the hose clamp.
• After disconnecting the hose, move it to the rear of the machine.
• After disconnecting the hoses, fit tags to distinguish them.

10. Disconnect hose (17) between main control valve and hydraulic tank.

11. Remove tube (18) between main control valve and bucket cylinder
together with hose.

12. Remove tube (19) between main control valve and boom cylinder.

13. Disconnect tube (20) from manifold.

14. Remove bracket (21) of tube.

15. Disconnect hose (22) between steering valve and main control valve
from main control valve.

16. Disconnect tube (23) between hydraulic tank and main control valve
from main control valve.

30-186 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
17. Remove tube (24) between main control valve and bucket cylinder
together with hose.

18. Disconnect tube (25) between main control valve and boom cylinder
from main control valve.

19. Loosen the tube clamp.

20. Remove mounting bolts and rotate main control valve (26) 90°.

21. Using eyebolts, lift off main control valve.

• Be careful of the slack adjuster bleed screw when removing.

Main valve: 91 kg (201 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

Plug: 11.8 ±1.0 Nm (9 ±7 lbf ft)

• To refill with oil (hydraulic tank),

REFILLING HYDRAULIC TANK WITH OIL

• Run engine to circulate oil through the system.

• Then check the oil level.
• Add oil through oil filler to the specified level.

WA500-3H 30-187
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
DISASSEMBLY

30-188 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
1. Spool assembly

A. Remove sleeve (1), then remove case (2).

B. Remove spring (3) and retainer (4).

C. Remove spring (5) and retainer (6).

D. Remove piston (7), spring (8), and spacer (9).

E. Remove spool assembly (10).

• Disassemble spool assembly. Remove plugs (12) and (13) from spool (11).

WA500-3H 30-189
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
2. Main relief valve

A. Remove main relief valve assembly (14).

B. Disassemble main relief valve assembly.

i. Loosen nut (15), and pull out adjustment screw (16), then
remove retainer (17), spring (18), spacer (19), and poppet (20).
• Before loosening nut (15), measure the protrusion of
screw (16) from the end face of the nut.

ii. Loosen nut (21), then remove holder (22), seat (23), and
backup ring (24).

iii. Remove snap ring (25), then remove retainer (26), valve (27),
and spring (28) from sleeve (29).

iv. Remove backup ring (30) from sleeve.

• If there is any abnormality in the sleeve or valve, replace
as an assembly.

3. Safety valve assembly with suction

Remove safety valve assembly (31).
• The safety valve cannot be adjusted when it is on the machine, so
do not disassemble it.

30-190 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
4. Suction valve assembly

A. Remove suction valve assembly (32).

B. Disassemble suction valve assembly (32).

i. Remove valve (33) together with seal (34).

ii. Remove seal (34) from valve (33).

iii. Remove spring (35) from sleeve (36).

• If there is any abnormality in the sleeve or valve, replace
as an assembly.

5. Selector valve assembly

A. Remove selector valve assembly (37).

i. Remove sleeve (38) together with seat (39).

• Seat (39) is press fitted to sleeve (38) (press fitting load:
1,177 - 7,845 N (120 -800 kg), so if there is any
abnormality replace as an assembly. (The same applies
for the sleeve.)

ii. Remove nipple (40), then remove shim (41), spring (42), and
piston (43).
• Check the number and thickness of the shims, and keep
in a safe place.

6. Check valve assembly

A. Remove plate (44), then remove spring (45) and check valve (46).

B. Remove flange (47), then remove spring (48), seal (49), and
valve (50).

WA500-3H 30-191
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
ASSEMBLY

30-192 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
1. Check valve assembly

A. Assemble valve (50), seal (49), and spring (48) in valve body (51),
then fit O-ring and install flange (47).

Flange surface: Thread tightener (LT-2)

B. Assemble check valve (46) and spring (45) in valve body, then fit
O-ring and install plate (44).

Bolts: 88.2 ±9.8 Nm (65 ±7 lbf ft)

2. Selector valve assembly

A. Assemble selector valve assembly.

B. Assemble piston (43), spring (42), and shim (41) in sleeve (38),
then fit O-ring and install nipple (40).

Nipple: 22.1 ±2.5 Nm (163 ±18 lbf ft)

C. Fit O-ring and install selector valve assembly (37).

Selector valve: 68.6 ±9.8 Nm (51 ±7 lbf ft)

3. Suction valve assembly

A. Assemble suction valve assembly.

i. Assemble spring (35) in sleeve (36).

ii. Assemble seal (34) in valve (33), and install to sleeve (36).

iii. Fit O-ring and install suction valve assembly (32).

Suction valve assembly: 186.2 ±9.8 Nm (130 ±7 lbf ft)

4. Safety valve assembly with suction

Fit O-ring and install safety valve assembly (31).

Safety valve: 186.2 ±9.8 Nm (130 ±7 lbf ft)

WA500-3H 30-193
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
5. Main relief valve assembly

A. Assemble main relief valve.

i. Install backup ring (30) and O-ring to sleeve (29).

ii. Assemble spring (28), valve (27), and retainer (26) in sleeve
(29), and install snap ring (25).

iii. Fit backup ring (24) and O-ring, and assemble seat (23) in
sleeve.

iv. Screw nut (21) into holder (22), then fit O-ring and assemble
in sleeve, and tighten nut.

Holder: 39.2 ±9.8 Nm (29 ±7 lbf ft)

Nut thread: Thread tightener (LT-2)

Nut: 152.0 ±24.5 Nm (112 ±18 lbf ft)

v. Assemble poppet (20), spacer (19), spring (18), and retainer

(17), and screw in adjustment screw (16). Adjust protrusion
from end face of nut (15) to same dimension as at time of
disassembly, then tighten with nut (15).

Nut thread: Thread tightener (LT-2)

Nut: 39.2 ±4.9 Nm (29 ±4 lbf ft)

B. Fit O-ring and install main relief valve assembly (14).

Main relief valve: 323.6 ±44.1 Nm (239 ±33 lbf ft)

6. Spool assembly

A. Assembly of spool assembly.

B. Install plugs (13) and (12) to spool (11).

Nut thread: Thread tightener (LT-2)

Nut: 24.5 ±4.9 Nm (18 ±4 lbf ft)

C. Assemble spool assembly (10) in valve body.

D. Assemble spacer (9), spring (8), and piston (7).

E. Assemble retainer (6), spring (5), retainer (4), and spring (3), then fit
O-ring and install case (2) and sleeve (1).

30-194 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
12
BUCKET CYLINDER

REMOVAL

WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks
under the wheels to prevent the machine from moving.

WARNING! Pressure in the hydraulic system must be released. Loosen oil filler cap slowly to release
pressure inside the hydraulic tank. Operate steering wheel and control levers several
times to release remaining pressure in the hydraulic piping.

1. Disconnect connector (1) for bucket positioner.

2. Disconnect grease tube (2) from bottom pin.

3. Disconnect head hose (3).

4. Disconnect bottom hose (4).

5. Sling cylinder then remove lock bolt, and remove head pin (5).Sling
from two points and be careful of the center of gravity.

6. Remove lock bolt, then remove bottom pin (6).

• If there are shims, check the number and thickness of the shims.

WA500-3H 30-195
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
7. Remove bucket cylinder assembly (7).
• Be careful not to damage the cylinder rod.

Bucket cylinder assembly: 286 kg (631 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

• When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin (6) and lock with the bolt.
★ Clearance a + b = Less than 1.0 mm (0.039 in)

WARNING! Align position of the pin hole with a bar.

Never insert a finger into the pin hole.

30-196 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

DISASSEMBLY
1. Set cylinder assembly (1) tool U1.

2. Remove mounting bolts (2) of cylinder head.

3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.

4. Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).

5. Remove O-ring (10) and backup ring (11) from piston rod (9).

WA500-3H 30-197
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
6. Disassembly of piston assembly
Remove wear ring (12) and piston ring (13) from piston (14).

7. Disassembly of cylinder assembly

A. Remove O-ring (15)and back up ring(16).

B. Remove snap ring, then remove dust seal (17).

C. Remove rod packing (18).

D. Remove bushing (19).

30-198 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.

1. Assembly of cylinder head assembly

A. Using push tool U5, press fit bushing (19) on cylinder head (20).
• Be careful not to deform the bushing when press fitting.

B. Assemble rod packing (18).

• Be careful to install the rod packing facing in the correct
direction.

C. Assemble buffer ring (21).

D. Assemble backup ring (16) and O-ring (15) in order.

• Do not try to force the backup ring into position. Heat the
backup ring in warm water (50°C to 60°C) before fitting it.

E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.

WA500-3H 30-199
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
2. Assembly of piston assembly

A. Using tool U6-1, expand piston ring (13).

• Set the piston ring on the expander and turn the handle 8 - 11
times to expand the ring.

B. Remove piston ring from tool U6-1, and assemble on piston (14).

C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.

D. Assemble wear ring (12) on piston.

3. Assemble O-ring (10) and backup ring (11) on piston rod (9).

4. Assemble cylinder head assembly (8) and piston assembly (7) on

piston rod.
• Coat backup ring (11) with grease so that it does not stick out,
and assemble carefully.

5. Assemble spacer (6), then tighten piston bolts (5).

Piston bolt: Adhesives (LT-2)

Piston bolt: 176.5 ±19.6 Nm (130 ±15 lbf ft)

30-200 WA500-3H
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
6. Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).

7. Tighten cylinder head mounting bolts (2).

Cylinder head mounting bolt: 662 ±74 Nm

(501 ±543 lbf ft)

8. Remove cylinder assembly (1) from tool U1.

WA500-3H 30-201
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

BOOM CYLINDER

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Lift off fender (1).

Fender: 25 kg (55 lb)

2. Sling boom cylinder, then remove lock bolt, and remove pin (3).
• Start the engine and operate the control lever to retract the
cylinder rod of the cylinder where the pin has been removed.
• After stopping the engine, release the remaining pressure from
the hydraulic piping.

3. Disconnect head hose (4) and bottom hose (5).

4. Fit lifting tool to bottom of boom cylinder (2), then use lever block ➀
to pull out to rear of machine.

5. Using forcing screws, remove bottom pin (6).

• If there are shims, check the number and thickness of the shim.

30-202 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Lift off boom cylinder assembly (2).
• Be careful not to damage the cylinder rod.

Boom cylinder assembly: 272 kg (600 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

• When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin and lock with the bolt.
★ Clearance a + b = Less than 1.0 mm (0.039 in)

WARNING! Align position of the pin hole with a bar.

Never insert a finger into the pin hole.

WA500-3H 30-203
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

DISASSEMBLY
1. Set cylinder assembly (1) tool U1.

2. Remove mounting bolts (2) of cylinder head.

3. Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
• Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.

4. Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).

5. Remove O-ring (10) and backup ring (11) from piston rod (9).

30-204 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Disassembly of piston assembly
Remove wear ring (12) and piston ring (13) from piston (14).

7. Disassembly of cylinder assembly

A. Remove O-ring (15)and back up ring(16).

B. Remove snap ring, then remove dust seal (17).

C. Remove rod packing (18).

D. Remove bushing (19).

WA500-3H 30-205
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.

1. Assembly of cylinder head assembly

A. Using push tool U5, press fit bushing (19) on cylinder head (20).
• Be careful not to deform the bushing when press fitting.

B. Assemble rod packing (18).

• Be careful to install the rod packing facing in the correct
direction.

C. Assemble buffer ring (21).

D. Assemble backup ring (16) and O-ring (15) in order.

• Do not try to force the backup ring into position. Heat the
backup ring in warm water 50 - 60° C (122 - 140° F) before
fitting it.

E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.

30-206 WA500-3H
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
2. Assembly of piston assembly

A. Using tool U6-1, expand piston ring (13).

• Set the piston ring on the expander and turn the handle 8 - 11
times to expand the ring.

B. Remove piston ring from tool U6-1, and assemble on piston (14).

C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.

D. Assemble wear ring (12) on piston.

3. Assemble O-ring (10) and backup ring (11) on piston rod (9).

4. Assemble cylinder head assembly (8) and piston assembly (7) on

piston rod.
• Coat backup ring (11) with grease so that it does not stick out,
and assemble carefully.

5. Assemble spacer (6), then tighten piston bolts (5).

Piston bolt: Adhesives (LT-2)

Piston bolt: 176.5 ±19.6 Nm (130 ±15 lbf ft)

WA500-3H 30-207
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).

7. Tighten cylinder head mounting bolts (2).

Cylinder head mounting bolt: 662 ±74 Nm

(501 ±543 lbf ft)

8. Remove cylinder assembly (1) from tool U1.

30-208 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

CENTER HINGE PIN

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.

1. Open cover (1) and loosen plug (2) on top of hydraulic tank to
prevent oil from flowing out from tank.

2. Remove bolt (3), then remove cover (4).

3. Remove plug (5), then loosen valve (6) and drain hydraulic oil.
When draining the hydraulic oil, drain to the level of the bottom of
each pipe.

Hydraulic oil: 140 liter (36.9 gal)

(level at bottom of piping)

4. Remove covers (7) and (8) at bottom of cab.

WA500-3H 30-209
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
5. Remove left and right steering cylinder pins (9).

• If there are shims between the pin and frame, check the number
and thickness.

6. Remove guard (10), then remove center drive shaft (11).

Center drive shaft assembly: 33 kg (73 lb)

7. Disconnect hose (12) between brake valve and slack adjuster.

8. Disconnect connectors (13) FR1 and (14) FR2.

• Disconnect the clamps under the floor.

9. Disconnect hoses (15) and (16) between steering valve and stop
valve at steering valve end.

10. Disconnect hose (17) between steering valve and oil cooler.

11. Disconnect hose (18) between work equipment control valve and
hydraulic tank.

12. Disconnect hose (19) between work equipment control valve and
loader pump.

30-210 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
13. Disconnect bypass hose (20) from hydraulic circuit at top of tank.

14. Disconnect hoses P1 (21) and P4 (22) for bucket control.

15. Disconnect hoses P3 (23) and P2 (24) for boom control.

• Disconnect the clamps at the rear frame end.

16. Using hydraulic jack to rear frame, insert block ➀ while adjusting
height.
• Put support stands ➁ under the left and right side of the frame.

17. Put support stand ➁ under counterweight.

18. Using jack under front frame, insert block ➂.

19. Remove mounting bolts, then remove retainer (25).

• If there are shims between the retainer and frame, check the
number and height.

WA500-3H 30-211
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
20. Adjust height carefully so that lower hinge pin (26) can be removed
easily by hand.

21. Remove spacer (27).

22. Remove mounting bolts, then remove retainer (28).

23. Using puller, remove upper hinge pin (29) and spacer(30).

30-212 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
24. Remove safety bar, then pull out front frame towards front and
disconnect frame.
• Be careful not to let the spacer at the top of the lower hinge get
caught in the rear frame.
• Carry out the operation carefully and pay attention to maintaining
the balance.
• Move approx. 100 mm (3.9 in) at a time.

25. Remove mounting bolts, then remove retainer (31).

• If there are shims between the retainer and frame, check the
number and thickness.

26. Remove dust seal (32) from retainer (31).

27. Remove spacer (33) and dust seal (34) from front frame.

WA500-3H 30-213
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
28. Remove bearing (35).

29. Remove retainer (36).

• If there are shims between the retainer and frame, check the
number and thickness.

30. Remove dust seal (37) from retainer.

• Remove dust seal (38) at the frame end.

31. Remove bearing (39).

30-214 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

INSTALLATION
• Carry out installation in the reverse order to removal.

Plug: 11.8 ±1.0 Nm (9 ±7 lbf ft)

• Adjust the shims so that the clearance is the specified value.

★ Clearance a + b = Less than 1.0 mm (0.039 in).

Drive shaft mounting bolt: 110.7 ±12.7 Nm

(752 ±94 lbf ft)

Outer circumference of hinge pin: Grease (G2-LI)

• Measure clearance c between retainer and frame at four places on the inside circumference, and select a shim thickness
to make the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the measured value.
• When adjusting the shim, temporarily tighten the retainer mounting bolts to act as a stopper.
• When tightening the mounting bolts, first tighten the retainer mounting bolts to the specified torque, then tighten the pin
mounting bolts.
• After selecting the shim, assemble the retainer to the specified torque.
• Remove all oil and grease from the mounting bolts and mount holes.

Mounting bolt: Thread tightener (Loctite 262)

Mounting bolt (48) when adjusting shims: 276.3 ±29.4 Nm (206 ±22 lbf ft)

Mounting bolt (48): 276.3 ±29.4 Nm (206 ±22 lbf ft)

Mounting bolt (49) when adjusting shims: 382.2 ±34.3 Nm (282 ±25 lbf ft)

WA500-3H 30-215
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

• Assemble spacer (30), insert upper hinge (29), then tap three times
with a copper hammer to settle the parts.
• Never coat spacer (30) with grease.

Outer circumference of hinge pin: Grease (G2-LI)

Mounting bolt (46): Thread tightener (Loctite 262)

Mounting bolt (46): 176.4 ±19.6 Nm (130 ±15 lbf ft)

Mounting bolt (47): 176.4 ±19.6 Nm (130 ±15 lbf ft)

• Grease on spacer (28) may prevent the mounting bolts being tightened
to the specified tightening torque. Remove any grease and tighten again.

• Use tool K2 to press fit the bearing and spacer to the frame. Make
sure the bearing is not at an angle.
• Fill the inside of the bearing with grease.
• When assembling the bearing, be sure to assemble the spacer.
• The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
• When replacing, replace as a set.
• Press fit so that the lip of the dust seal is facing the outside.

Lip of oil seal: Grease (G2-LI)

• Measure clearance a between retainer (31) and hinge at four places

on the inside circumference, and select a shim thickness to make
the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the measured
value.
• After selecting the shim, assemble the retainer to the specified torque.

Mounting bolt (when adjusting shims):

98.0 ±9.8 Nm (72 ±7 lbf ft)

Mounting bolt: 176.4 ±19.6 Nm (130 ±15 lbf ft)

30-216 WA500-3H
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

• Using tool K1, press fit the bearing and spacer to the frame.
• When press fitting the bearing, be careful that the bearing is not at an
angle.
• Fill the inside of the bearing with grease.
• When assembling the bearing, be careful not to forget to assemble the
spacer.
• The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
• When replacing, replace as a set.
• Press fit so that the lip of the dust seal is facing the outside.

Lip of oil seal: Grease (G2-LI)

• Measure clearance a between retainer (36) and the hinge at four

places on the inside circumference, and select a shim thickness to
make the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the
measured value.
• After selecting the shim, assemble the retainer to the specified torque.

Mounting bolt (when adjusting shims):

58.8 ±5.9 Nm (43 ±4 lbf ft)

Mounting bolt: 176.4 ±19.6 Nm (130 ±15 lf ft)

• After completion of mounting the hinge pin, fill with oil and bleed the air.

A. Tighten the plug on the top of the hydraulic tank filter, then add hydraulic oil through oil filler to the specified level.

Plug on top of filter: 11.8 ±1.0 Nm (9 ±1 lbf ft)

Hydraulic oil: Approx. 140 liter (36.9 gal)

B. Run the engine to circulate the oil through the system. Then check the oil level again.

C. Bleed the air from the brake system. For details, see TESTING AND ADJUSTING.

WA500-3H 30-217
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

WORK EQUIPMENT

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove mounting pin (1) of bucket link.

• Remove cord ring.

Tie the bucket link to the tilt lever with wire.

Mounting pin: 25 kg (55 lb)

2. Remove mounting pin (2) of bucket hinge.

• Remove cord ring.

Mounting pin: 25 kg (55 lb)

3. Move machine to rear and disconnect bucket.

4. Temporarily sling bucket cylinder (3), pull pin (4), then disconnect
cylinder rod and tilt lever.
• Attach lifting tool to bucket cylinder and secure in the rear.

Bucket cylinder: 285 kg (627 lb)

Mounting pin: 30 kg (66 lb)

5. Attach lever block ➀ to boom cylinder (5), pull machine to rear

and remove mounting pin (6).

Boom cylinder: 272 kg (600 lb)

Mounting pin: 25 kg (55 lb)

30-218 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
6. Temporarily sling bellcrank (7) and bucket link, remove mounting
pin (8), then lift out from boom (9).
• Remove with the bucket link still fitted.
• Three technicians are required for removal of mounting pin
operation.

Bellcrank and bucket link: 628 kg (1,619 lb)

Mounting pin: 59 kg (130 lb)

7. Temporarily sling bucket link (10), remove mounting pin (11), then
lift out from bellcrank (7).

• Remove cord ring.

Bucket link: 106 kg (234 lb)

Mounting pin: 25 kg (55 lb)

• Note the number of shims at this location for reference when

installing.

8. Remove boom kick out switch (13).

9. Temporarily sling boom (9), pull out mounting pin of boom, then lift
out boom.
• Shims are installed at connecting point of front frame and boom,
so check the number of shims.

Boom: 2,018 kg (4,449 lb)

Mounting pin: 35 kg (77 lb)

WA500-3H 30-219
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
10. Pull out dust seal (14) and bushing (15) from boom (9).

11. Pull out dust seal (16) and bushing (17) from bellcrank (7)

30-220 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12. Pull out dust seal (18) and bushing (19) from bucket link (10).

• After long use, wear can make the pin difficult to remove. A
puller (pin puller jig) such as the one shown here can be helpful
when removing a pin.

WA500-3H 30-221
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

INSTALLATION

WARNING! Align the position of the pin hole with a

bar. Never insert a finger into the pin hole.

• Carry out installation in the reverse order to removal.

• Clearance g + h = Less than 1.0 mm (0.039 in).

• Be careful not to get cord ring (22) caught.

• Clearance e + f = Less than 1.0 mm (0.039 in).

• Be careful not to get cord ring (21) caught.

• Secure the bucket link and bellcrank with wire.

• Insert shims so that the clearance is equal on the left and right.
• Clearance c + d = Less than 1.0 mm (0.039 in).
• Be careful not to get cord ring (20) caught.

• Align the hole in the boom mount and the front frame, then insert
shims to make the clearance equal on the left and right.
• Clearance a + b = Less than 1.0 mm (0.039 in).
• After assembling the pin, set the support stand to the tip of the boom.
• Grease each pin.

30-222 WA500-3H
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

MEMORANDUM

WA500-3H 30-223
DISASSEMBLY AND ASSEMBLY BULKHEAD

BULKHEAD

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove engine hood assembly (1). For details, see ENGINE

HOOD REMOVAL.

2. Remove bulkhead left side cover (2).

• Disconnect the connector (BR1) at the bottom at the engine end
of the left side of the bulkhead.
• Reach in at the point marked by the arrow, and disconnect the
connector (BR1).

3. Remove bulkhead hood (3).

4. Remove floor plate (4).

5. Remove covers (5) and (6).

6. Disconnect hose (7) at receiver tank end.

7. Disconnect hose (8) at condenser end.

• Disconnect the accelerator control cable at the fuel pump end.

30-224 WA500-3H
DISASSEMBLY AND ASSEMBLY BULKHEAD
8. Disconnect brake hoses (9), (10), and (11).

9. Disconnect emergency brake valve connecting hoses (12), (13),

and (14).

10. Disconnect accumulator charge valve connecting hoses (15), (16),

and (17).

11. Disconnect PPC pump connecting hose (18).

12. Disconnect PPC accumulator inlet hose (19).

13. Disconnect window washer hoses (20).

14. Disconnect transmission breather (21).

• After disconnecting the hoses, fit tags to distinguish them.

15. Remove four mounting bolts (22) and (23).

16. Lift off bulkhead assembly (24).

Bulkhead assembly: 220 kg (484 lb)

INSTALLATION

• Install the hoses without twisting or interference.

• When installing the hoses, be careful not to let dirt, dust, or moisture
get inside the hoses.
• Using a gas charger (X3), charge with new freon gas (R134a).

WA500-3H 30-225
DISASSEMBLY AND ASSEMBLY ENGINE HOOD

ENGINE HOOD

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Open the left and right inspection covers.

2. Remove exhaust tube (1).

3. Remove radiator grille (2).

• Remove the baffle plate on both sides of the radiator.

4. Disconnect head lamp connector (3).

5. Disconnect water level sensor connector (4).

6. Remove six mounting bolts (5) and four mounting bolts (6).

7. Remove radiator support (7).

8. Lift off engine hood (8).

• There are clamps for the air conditioner hoses at two places
inside the engine hood on the right, so disconnect them.
• Use a lever block to maintain the balance when lifting off.

Engine hood assembly: 225 kg (496 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

30-226 WA500-3H
DISASSEMBLY AND ASSEMBLY CAB

CAB

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove covers (1) at bottom of floor frame.

2. Remove right cover (2) inside cab.

3. Disconnect electric wiring connectors (3).

4. Disconnect window washer hose (4).

5. Remove two steering post lock bolts (5).

WA500-3H 30-227
DISASSEMBLY AND ASSEMBLY CAB
6. Remove plastic mounting bolts and pull up rubber boot (6) at bottom
of steering post.

7. Remove four bolts (7), then tip steering post over fully towards
operator’s seat.
• At the same time, set the column tilt lever to the unlock position
and tip the steering column over fully toward the operator’s seat.

8. Remove two cab mounting bolts (8) and four mounting bolts (9) each
at intermediate position and rear.

9. Raise cab assembly (10) slowly and keep horizontal when lifting off.
• Be careful that there is no interference with the electric wiring at
the rear right of the floor frame
.

• Cover the steering post and plastic cover with a sheet to prevent
any damage.

Cab Assembly (ROPS): 456 kg (1,005 lb)

30-228 WA500-3H
DISASSEMBLY AND ASSEMBLY CAB

INSTALLATION
• Carry out installation in the reverse order to removal.

• When installing the cab assembly, be sure to install the seal.

• Coat the seal uniformly with adhesive.

Seal: Adhesive (Cemedyne 366E)

WA500-3H 30-229
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

FLOOR FRAME

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Remove cab assembly.

• For details, see CAB REMOVAL.

2. Remove left and right ladders (1) and (2).

Ladder: 90 kg (198 lb)

3. Remove floor plate (4) and cover (3) of bulkhead.

4. Disconnect wiring connectors (5) (TM1, 2, LR1-6).

5. Disconnect ground connection (6).

6. Disconnect hoses (7) between brake valve and slack adjuster.

7. Disconnect hose (9) between orbital steering valve (8) and

hydraulic tank.

8. Disconnect hose (10) between orbital steering valve (8) and

accumulator.

9. Disconnect hoses (11) between orbital steering valve (6) and stop valve.

10. Disconnect return hose (12) between orbital steering valve and
hydraulic tank.

11. Disconnect return hose (13) coming from PPC valve.

12. Disconnect return hose (14) coming from brake valve.

• After disconnecting the hose, install a blind plug to prevent
contamination.

30-230 WA500-3H
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
13. Remove mounting bolts (15), then remove brake hose bracket (16).

14. Disconnect PPC hoses (17).

• The hoses are fitted with self-seal couplings.

15. Disconnect hose (18) from accumulator.

16. Disconnect accumulator charge valve connecting hoses (19) and (20).

17. Disconnect PPC accumulator connecting hose (21).

18. Disconnect two window washer hoses (22).

19. Disconnect two hoses (23) from brake valve.

20. Disconnect air conditioner compressor hose (24).

• There are hose clamps at two places inside the engine hood.
Remove the hose clamps.

21. Remove clamp (25) and joint (26), then remove accelerator cable (27).

22. Disconnect heater hoses (28) and (29).

• Hose (29) is installed under the connector at the suction end of
the water pump.
• Open radiator drain valve, and drain coolant.

Coolant: 99 liters (26.2 gal.)

WA500-3H 30-231
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
23. Remove floor frame mount mounting nuts (30) (four places).

24. Lift off floor frame assembly (31).

• Check that all the clamps and wiring harnesses have been
disconnected.

Floor frame assembly: 280 kg (617 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

• Install the hoses without twisting or interference.

• When installing the hoses, be careful to prevent dirt, dust, or moisture
from getting inside the hoses.
• Using a gas charger (X3), charge with new freon gas (R134a).

Mount nut: 277.3 ±32.3 Nm (203 ±24 lbf ft)

REFILLING WITH COOLANT

• Tighten radiator drain valve and add coolant through water filler to the specified level.
• Run the engine to circulate the coolant through the system. Then check the water level again.

30-232 WA500-3H
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

COUNTERWEIGHT

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Sling counterweight (19), then remove mounting bolts, and lift

off.

• When lifting off the counterweight, be careful to maintain the balance.

Counterweight: 2,247 kg (4,954 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.

Counterweight mounting bolt: 1568 ±196 Nm (1157 ±144 lbf ft)

WA500-3H 30-233
DISASSEMBLY AND ASSEMBLY FUEL TANK

FUEL TANK

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Loosen drain valve (1) and drain fuel.

• Check the fuel level before draining.

Fuel (when full): 465 liters (122.7 gal)

2. Remove engine oil drain valve (2) from fuel tank.

3. Disconnect hose (3) between injection pump and fuel tank.

4. Disconnect hose (4) between fuel tank and feed Pump.

5. Disconnect spill hose (5).

6. Disconnect connector (6) for fuel level sensor.

7. Remove hoses (7) of blow-by and muffler.

8. Sling fuel tank assembly (8), then remove mounting bolts and slowly
lower the tank.

• Put a pallet under the tank, then be careful to maintain the

balance of the tank assembly, and lower it on to the pallet.

Fuel tank assembly: 241 kg (531 lb)

• Before pulling out the fuel tank assembly, remove breather

tube (9).
• The bottom surface of the tank is not flat, and there is danger
that it may slip, so be extremely careful when handling it.

30-234 WA500-3H
DISASSEMBLY AND ASSEMBLY FUEL TANK

INSTALLATION
• Carry out installation in the reverse order to removal.

Fuel tank mounting bolt: 931.0 ±98.0 Nm (686 ±72 lbf ft)

• Be careful of breather tube (9) when raising the tank.

WA500-3H 30-235
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT

AIR CONDITIONER UNIT

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

WARNING! Disconnect cable from negative (-)

terminal of the battery.

1. Remove cab assembly. For details, see CAB REMOVAL.

2. Remove connector (1)

3. Install freon gas collector and regenerator to plug (2), and collect
refrigerant.

4. Remove operator’s seat (3).

Operator’s seat assembly: 54 kg (119 lb)

5. Remove rear console box (4).

6. Remove console box cover (5).

7. Remove console box (6).

8. Disconnect connector (7) (CL3).

9. Disconnect connector (8) (CL2).

10. Disconnect tubes (9).

11. Disconnect heater hoses (10).

30-236 WA500-3H
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12. Remove mounting bolt (11), then remove air conditioner unit
assembly (12).
• Pull the unit out to the left and remove it.

Air Conditioner Unit: 38 kg (84 lb)

INSTALLATION
• Carry out installation in the reverse order to removal.
• Using a gas charger (X3), charge with new freon gas (R134a).

WA500-3H 30-237
DISASSEMBLY AND ASSEMBLY CONDENSER

CONDENSER

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Disconnect connector (1) (E1 2).

2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.

3. Remove bulkhead cover (3).

4. Disconnect connectors (4) (B07 and B12).

5. Disconnect hose (5) between condenser and air conditioner

compressor.

• Always fit a wrench to the condenser end.

6. Disconnect connectors (6) (B01 and B11).

7. Disconnect hose (7) between top and bottom condensers.

8. Disconnect hose (8) between receiver tank and condenser.

9. Remove mounting bolts (9), then remove condenser assembly (10).

INSTALLATION
• Carry out installation in the reverse order to removal.

• Install the hoses without twisting or interference.

• When installing the hoses, be careful not to let dirt, dust, or moisture
get inside the hoses.
• Using a gas charger (X3), charge with new freon gas (R134a).

30-238 WA500-3H
DISASSEMBLY AND ASSEMBLY RECEIVER TANK

RECEIVER TANK

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Disconnect connector (1) (E1 2).

2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.

3. Remove bulkhead cover (3).

4. Disconnect hose (4) between air conditioner compressor and

receiver tank

5. Disconnect hose (5) between receiver tank and condenser.

6. Remove U-bolts (6), then remove receiver tank assembly (7).

INSTALLATION
• Carry out installation in the reverse order to removal.

• Install the hoses without twisting or interference.

• When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses.
• Using a gas charger (X3), charge with new freon gas (R134a).

WA500-3H 30-239
DISASSEMBLY AND ASSEMBLY COMPRESSOR ASSEMBLY

COMPRESSOR ASSEMBLY

REMOVAL

WARNING! Stop the machine on level ground, install

the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.

1. Disconnect connector (1) (E1 2).

2. Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.

3. Loosen adjustment bolt (3) and lock bolt (4), then remove belt (5)
and remove from compressor.

4. Disconnect hoses (6).

5. Remove four mounting bolts (7), then remove air conditioner

compressor assembly (8).

INSTALLATION
• Carry out installation in the reverse order to removal.

• Install the hoses without twisting or interference.

• When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses.
• Using a gas charger (X3), charge with new freon gas (R134a).

30-240 WA500-3H
DISASSEMBLY AND ASSEMBLY MAIN MONITOR

MAIN MONITOR

REMOVAL
1. After disconnecting the battery cable from the negative (-) terminal,
remove dashboards (1) and (2).

2. Remove steering post cover mounting bolts (3) and (4).

3. Remove steering post cover (5).

4. Remove mounting bolt caps (7) from steering post cover (6), them
remove bolts.

5. Remove mounting bolt caps (9) from steering post cover (8), them
remove bolts and tip cover forward.

6. Remove bracket (10) at back of the main monitor.

WA500-3H 30-241
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7. Remove eight mounting bolts (12), when removing main monitor
(11), be careful not to subject it to any strong shock.

8. Disconnect wiring connectors (13), (14), (15), and (16) from the
monitor.

INSTALLING
• Install the monitor in the reverse order of removal, and be sure to
lock connectors securely.
• For adjustment procedures, see TESTING AND ADJUSTING in
section 20.

30-242 WA500-3H
 40 MAINTENANCE STANDARD

ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2

TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-13
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
MAIN RELIEF, T. C. RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
LUBRICATION RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
DIFFERENTIAL, NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-45
STEERING CYLINDER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
SAR(4)-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
SWITCH, PPC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
SAR(3)-63 + SAR(1)-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
PPC VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
FOR BUCKET AND BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
FOR AUXILIARY ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
2 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
BUCKET LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-76
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-79
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-81

WA500-3H 40-1
MAINTENANCE STANDARD ENGINE MOUNT
12
ENGINE MOUNT

40-2 WA500-3H
MAINTENANCE STANDARD ENGINE MOUNT

No. Check Item Criteria Remedy

3.0 - 7.0 mm
1 Clearance between engine mounting bracket and adjusting bolt Adjust
(0.118 - 0.276 in)

Torque Values
Item Nm lbf ft

a 275 +34
-29 203 +25
-22

b 745 ±83 550 ±62

WA500-3H 40-3
MAINTENANCE STANDARD TRANSMISSION MOUNT

TRANSMISSION MOUNT

40-4 WA500-3H
MAINTENANCE STANDARD TRANSMISSION MOUNT

No. Check Item Criteria Remedy

Shim thickness: 0.5 mm (0.020 in)

1 Thickness of shim for mounting (Decide the shim thickness so that the misalignment between the
damper output shaft and input shaft is less than 2.0 mm (0.079 in) Adjust
Clearance between stopper and There must be a clearance of at least 2 mm (0.079 in) between stopper and
2
bracket bracket around the whole circumference.

Torque Values
Item Nm lbf ft

a 277 ±32 204 ±24

b 745 ±83 550 ±62

WA500-3H 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP

TORQUE CONVERTER CHARGING PUMP

40-6 WA500-3H
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP

No. Check Item Criteria Remedy

Standard Clearance Clearance Limit

Clearance between gear case and side 0.10 - 0.15 mm 0.19 mm

1
plate, gear (0.004 - 0.006 in) (0.008 in)

Clearance between inside

0.06 - 0.149 mm 0.20 mm
2 diameter of plain bearing and
(0.002 - 0.006 in) (0.008 in)
outside diameter of gear shaft

14 +0
-0.5 mm
3 Insertion depth of pin Replace
(0.006 +0
-0.002 in)

6.9 - 11.8 Nm
4 Rotating torque of spline shaft
(5 - 9 lbf ft)

Discharge Revolution Standard Repair limit

Pressure
Oil: E010-CD (rpm) discharge discharge
Temperature: 45 - 55° C 35.9 kg/cm2 192 L/min 176 L/min
(113 - 131° F) 2500
(511 psi) (51 gal/min) (47 gal/min)

Torque Values
Item Nm lbf ft

a 277 ±31 204 ±24

WA500-3H 40-7
MAINTENANCE STANDARD DAMPER

DAMPER

40-8 WA500-3H
MAINTENANCE STANDARD DAMPER

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.009 mm -0.003 mm
Clearance between bearing 40 mm -0.034 mm -0.012 mm -0.034 mm 0.05 mm
1
and shaft (1.575 in) (-0.0004 in (-0.0005 in) (-0.0001 in (0.002 in)
-0.0013 in) -0.0013 in)

-0.013 mm
Clearance between bearing 80 mm -0.013 mm -0.030 mm -0.030 mm 0.035 mm
2
and housing (3.150 in) (-0.0005 in) (-0.0012 in) (-0.0005 in (0.0014 in)
-0.0012 in)

+0.012 mm -0.007 mm
Clearance between bearing 75 mm -0.007 mm -0.015 mm -0.027 mm 0.025 mm
3
and shaft (2.953 in) (+0.0005 in (-0.0006 in) (-0.0003 in (0.0010 in)
-0.0003 in) -0.0011 in)

+0.007 mm 0.007 mm Replace

Clearance between bearing 130 mm -0.018 mm +0.018 mm 0.036 mm 0.05 mm
4
and cover (5.118 in) -0.0007 in) (+0.0003 in (0.0003 in (0.002 in)
+0.0007 in) 0.0014 in)

-0.014 mm 0.014 mm
Clearance between retainer 135 mm -0.054 mm +0.04 mm 0.094 mm 0.13 mm
5
and cover (5.315 in) (-0.0006 in (+0.0015 in (0.0006 in (0.005 in)
-0.002 in) 0.004 in)

Standard size Tolerance Repair limit

Wear of surface in coupling 95 mm -0.087 mm -0.12 mm

6
and oil seal (3.740 in) (-0.003 in) (-0.005 in)

Wear of surface in shaft and 105 mm -0.087 mm -0.12 mm

7
oil seal (4.134 in) (-0.003 in) (-0.005 in)

Backlash of spline (shaft, 0.071 - 0.177 mm

8
coupling, and body) (0.003 - 0.007 in)

Torque Values
Item Nm lbf ft

a 110 ±12 814 ±9

b 66 ±7 49 ±5

c 4 ±1 3 ±1

d 88 ±34 65 ±25

WA500-3H 40-9
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO

TORQUE CONVERTER AND PTO

40-10 WA500-3H
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Repair
120 mm +0.035 mm 120.5 mm
1 Inside diameter of seal ring surface of retainer chrome
(4.724 in) (+0.0014 in) (4.744 in)
plating or
65 mm +0.025 mm 65.1 mm replace
2 Inside diameter of seal ring surface of sleeve
(2.559 in) (+0.0010) (2.563 in)

3.95 mm -0.1 mm 3.55 mm

Width
(0.156 in) (-0.0039 in) (0.140 in)
3 Width and thickness of seal
4.6 mm ±0.1 mm 4.14 mm
Thickness Replace
(0.181 in) (±0.0039 in) (0.163 in)

0.18 - 0.49 mm
4 Backlash of PTO gear (drive gear)
(0.007 - 0.019 in)

Torque Values
Item Nm lbf ft

a 110 ±12 814 ±9

b 66 ±7 49 ±5

c 4 ±1 3 ±1

d 88 ±34 65 ±25

WA500-3H 40-11
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO

MEMORANDUM

40-12 WA500-3H
MAINTENANCE STANDARD TRANSMISSION

TRANSMISSION

WA500-3H 40-13
MAINTENANCE STANDARD TRANSMISSION

No. Check item Criteria Remedy

Standard size Repair limit

Free Installation Installation Installation

Free length
length length load load

66 mm 56.5 mm 132.4 N 62.0 mm 112.8 N

1 No. 1 clutch spring (X 10)
(2.598 in) (2.224 in) (29.8 lbf) (2.441 in) (25.4 lbf)

59 mm 52.5 mm 63.7 N 55.5 mm 53.9 N

2 No. 2 clutch spring (X 10)
(2.323 in) (2.067 in) (14.3 lbf) (2.185 in) (12.1 lbf)

39.8 mm 33.5 mm 87.3 N 37.4 mm 74.5 N

3 No. 3 clutch spring (X 10)
(1.567 in) (1.319 in) (19.6 lbf) (1.472 in) (16.8 lbf)

39.8 mm 34.5 mm 73.6 N 37.4 mm 62.8 N

4 No. 4 clutch spring (X 10)
(1.567 in) (1.358 in) (16.6 lbf) (1.472 in) (14.1 lbf)

39.8 mm 32.5 mm 101.0 N 37.4 mm 86.3 N

5 No. 5 clutch spring (X 10)
(1.567 in) (1.280 in) (22.7 lbf) (1.472 in) (19.4 lbf)

39.8 mm 34.2 mm 77.5 N 37.4 mm 65.7 N Replace

6 No. 6 clutch spring (10 each)
(1.567 in) (1.346 in) (17.4 lbf) (1.472 in) (14.8 lbf)

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

+0.016 mm +0.031 mm
Clearance between
-0.015 mm -0.006 mm -0.006 mm +0.037 mm
7 transmission input shaft
90 mm (-0.0006 in) (+0.0006 in (+0.0012 in (+0.0015 in)
bearing and housing
(3.543 in) -0.0002 in) -0.0002 in)

+0.016 mm +0.026 mm
Clearance between
72 mm -0.013 mm -0.006 mm -0.006 mm +0.031 mm
8 transmission output shaft
(2.835 in) (-0.0005 in) (+0.0006 in (+0.0010 in (+0.0012 in)
bearing and carrier
-0.0002 in) -0.0002 in)

+0.016 mm +0.031 mm
Clearance between
100 mm -0.015 mm -0.006 mm -0.006 mm +0.037 mm
9 transmission output shaft
(3.937 in) (-0.0006 in) (+0.0006 in (+0.0012 in (+0.0015 in)
bearing and housing
-0.0002 in) -0.0002 in)

40-14 WA500-3H
MAINTENANCE STANDARD TRANSMISSION

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

10 Thickness of 4 discs and 3 plates for No. 1 35 mm ±0.26 mm 31.8 mm

clutch (1.378 in) (±0.010 in) (1.252 in)

Thickness of 3 discs and 2 plates for No. 2 35 mm ±0.26 mm

11
clutch (1.378 in) (±0.010 in)

Thickness of 3 discs and 2 plates for No. 3 25 mm ±0.22 mm

12
clutch (0.984 in) (±0.009 in)

Thickness of 4 discs and 3 plates for No. 4 25 mm ±0.22 mm

13
clutch (0.984 in) (±0.009 in) Replace
Thickness of 2 discs and 1 plates for No. 5 15 mm ±0.17 mm
14
clutch (0.591 in) (±0.007 in)

Thickness of 3 discs and 2 plates for No. 6 25 mm ±0.22 mm

15
clutch (0.984 in) (±0.009 in)

5 mm ±0.1 mm
16 Thickness of 1 disc
(0.197 in) (±0.004 in)

5 mm ±0.1 mm
17 Thickness of 1 plate
(0.197 in) (±0.004 in)

Torque Values
Item Nm lbf ft

a 167 ±10 123 ±7

b 110 ±12 81 ±9

WA500-3H 40-15
MAINTENANCE STANDARD TRANSMISSION

40-16 WA500-3H
MAINTENANCE STANDARD TRANSMISSION

No. Check item Criteria Remedy

Standard Repair
Tolerance
size limit

-0.01 mm
3.0 mm -0.03 mm 2.6 mm
Width
(0.118 in) (-0.0004 in (0.102 in)
1 Wear of seal ring for input shaft -0.0012 in)

3.5 mm ±0.1 mm 3.35 mm

Thickness
(0.138 in) (±0.0039 in) (0.132 in)

-0.01 mm
4.0 mm -0.03 mm 3.5 mm
Width
(0.158 in) (-0.0004 in (0.138 in)
2 Wear of seal ring for output shaft -0.0012 in)

Thickness 5.1 mm ±0.12 mm 4.95 mm

(0.201 in) (±0.005 in) (0.195 in)

0.13 - 0.32 mm
3 Backlash between No. 1 sun gear and planet gear
(0.005 - 0.013 in)

0.15 - 0.38 mm
4 Backlash between No. 1 planet gear and ring gear and inside teeth
(0.006 - 0.015 in) Replace
0.13 - 0.32 mm
5 Backlash between No. 2 sun gear and planet gear
(0.005 - 0.013 in)

0.15 - 0.38 mm
6 Backlash between No. 2 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)

0.12 - 0.30 mm
7 Backlash between No. 3 sun gear and planet gear
(0.005 - 0.012 in)

0.15 - 0.38 mm
8 Backlash between No. 3 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)

0.13 - 0.32 mm
9 Backlash between No. 4 sun gear and planet gear
(0.005 - 0.013 in)

0.15 - 0.38 mm
10 Backlash between No. 4 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)

0.14 - 0.35 mm
11 Backlash between No. 5 sun gear and planet gear
(0.006 - 0.014 in)

0.15 - 0.38 mm
12 Backlash between No. 5 planet gear and ring gear and inside teeth
(0.006 - 0.015 in)

WA500-3H 40-17
MAINTENANCE STANDARD TRANSFER

TRANSFER

40-18 WA500-3H
MAINTENANCE STANDARD TRANSFER

No. Check item Criteria Remedy

Standard Tolerance Standard

size Shaft Hole clearance

+0.045 mm -0.023 mm
85 mm +0.023 mm -0.020 mm -0.065 mm
1 Clearance between drive gear and bearing
(3.347 in) (+0.002 in (-0.0008 in) (-0.001 in
+0.001 in) (-0.003 in)

-0.012 mm 0.006 mm
150 mm -0.018 mm -0.052 mm -0.052 mm
2 Clearance between drive gear bearing and cage
(5.906 in) (-0.0007 in) (-0.0005 in (0.0002 in
-0.002 in) -0.002 in)

0.018 mm
150 mm -0.018 mm -0.040 mm -0.040 mm
3 Clearance between drive gear bearing and cage
(5.906 in) (-0.0007 in) (-0.002 in) (-0.0007 in
-0.002 in)

+0.059 mm -0.037 mm
95 mm -0.037 mm -0.020 mm -0.079 mm
4 Clearance between idler gear and bearing
(3.740 in) (+0.002 in (-0.0008 in) (-0.002 in
-0.002 in) -0.003 in)

0.025 mm
Clearance between drive gear bearing and case 170 mm -0.025 mm -0.040 mm -0.020 mm
5
(cover) (6.693 in) (-0.002 in) (-0.002 in) (0.001 in
Replace
-0.002 in)

+0.039 mm -0.020 mm
80 mm -0.020 mm -0.015 mm -0.054 mm
6 Clearance between output shaft and bearing
(3.150 in) (+0.0002 in (-0.0006 in) (-0.0008 in
-0.0008 in) -0.002 in)

-0.012 mm 0.006 mm
140 mm -0.018 mm -0.052 mm -0.052 mm
7 Clearance between output shaft bearing and cage
(5.512 in) (-0.0007 in) (-0.0005 in (0.0002 in
-0.002 in) -0.002 in)

+0.045 mm -0.023 mm
95 mm +0.023 mm -0.020 mm -0.065 mm
8 Clearance between spacer and bearing
(3.740 in) (+0.002 in (-0.0008 in) (-0.023 in
+0.001 in) -0.003 in)

-0.012 mm 0.013 mm
170 mm -0.025 mm -0.052 mm -0.052 mm
9 Clearance between output shaft bearing and housing
(6.693 in) (-0.002 in) (-0.0005 in (-0.0005 in
-0.002 in) -0.002 in)

Standard Repair
Tolerance
size limit

95 mm -0.087 mm 94.8 mm
10 Coupling oil seal contact surface
(3.740 in) (-0.003 in) (3.732 in)

WA500-3H 40-19
MAINTENANCE STANDARD TRANSFER

No. Check item Criteria Remedy

Preload: 0.1 - 1.0 Nm

11 Clearance between cage and case 2 (Shim) (0.07 - 0.7 lbf ft)
(Drive gear as individual part)

Preload: 0.3 - 0.55 Nm

(0.22 - 0.41 lbf ft)
12 Clearance between cover and case 2 (Shim) Adjust
Then add 0.1 mm (0.0039 in) of shim
(idler gear as individual part)

0.25 mm Preload: 0.5 - 1.0 Nm

13 Clearance between cage and cover (0.010 in) (0.4 - 0.7 lbf ft)
(Shims) (Output shaft as individual part)

14 Backlash between drive gear and idler gear 0.17 - 0.44 mm (0.007 - 0.017 in)
Replace
15 Backlash between idler gear and driven gear 0.17 - 0.44 mm (0.007 - 0.017 in)

Torque Values
Item Nm lbf ft

a 745 ±83 550 ±62

b 110 ±12 81 ±9

c 69 ±10 51 ±7

40-20 WA500-3H
MAINTENANCE STANDARD TRANSFER

MEMORANDUM

WA500-3H 40-21
MAINTENANCE STANDARD MAIN RELIEF, T. C. RELIEF VALVE

MAIN RELIEF, T. C. RELIEF VALVE

40-22 WA500-3H
MAINTENANCE STANDARD MAIN RELIEF, T. C. RELIEF VALVE

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.035 mm 0.035 mm
Clearance between main relief 25 mm -0.045 mm +0.013 mm 0.058 mm 0.08 mm
1
valve and valve body (0.984 in) (-0.0014 in (+0.0005 in) (0.0014 in (0.003 in)
-0.0018 in) 0.0023 in)

-0.035 mm 0.035 mm
Clearance between torque 22 mm -0.045 mm +0.013 mm 0.058 mm 0.08 mm
2
converter valve and valve body (0.866 in) (-0.0014 in (+0.0005 in) (0.0014 in (0.003 in)
-0.0018 in) 0.0023 in)
Replace
Standard size Repair limit

Free Installation Installation Free Installation

length length load length load

128 mm 75.3 mm 509 N 124.2 mm 483 N

3 Main relief valve spring (outer)
(5.039 in) (2.965 in) (114 lbf) (4.890 in) (109 lbf)

108 mm 75.3 mm 402 N 104.8 mm 382 N

4 Main relief valve spring (inner)
(4.252 in) (2.965 in) (90 lbf) (4.126 in) (86 lbf)

50 mm 42 mm 153 N 48.5 mm 145 N

5 Main relief valve spring
(1.969 in) (1.654 in) (34 lbf) (1.910 in) (33 lbf)

Torque Values
Item Nm lbf ft

a 49 ±4.9 Nm 36 ±4

WA500-3H 40-23
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE

LUBRICATION RELIEF VALVE

40-24 WA500-3H
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation

Free length Free length
length load load Replace

128 mm 75.3 mm 509 N 124.2 mm 483 N

1 Lubrication relief valve spring
(5.039 in) (2.965 in) (114 lbf) (4.890 in) (109 lbf)

WA500-3H 40-25
MAINTENANCE STANDARD DRIVE SHAFT

DRIVE SHAFT

40-26 WA500-3H
MAINTENANCE STANDARD DRIVE SHAFT
Torque Values
Item Nm lbf ft

a 549 ±59 405 ±44

b 110 ±12 81 ±9

c 144 ±12 106 ±9

WA500-3H 40-27
MAINTENANCE STANDARD CENTER SUPPORT

CENTER SUPPORT

40-28 WA500-3H
MAINTENANCE STANDARD CENTER SUPPORT

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.036 mm -0.018 mm
140 mm -0.018 mm -0.061 mm -0.061 mm -0.015 mm
1 Clearance between case and bearing
(5.512 in) (-0.0007 in) (-0.0014 in (-0.0007 in (-0.0006 in)
-0.0024 in) -0.0024 in)

-0.036 mm -0.018 mm
130 mm -0.018 mm -0.061 mm -0.061 mm -0.015 mm
2 Clearance between case and bearing
(5.118 in) (-0.0007 in) (-0.0014 in (-0.0007 in (-0.0006 in) Replace
-0.0024 in) -0.0024 in)

+0.051 mm 0.032 mm
Clearance between coupling shaft
80 mm +0.032 mm -0.015 mm 0.066 mm 0.029 mm
3 and
(3.150 in) (+0.0020 in (-0.0006 in) (0.0013 in (0.0011 in)
bearing
+0.0013 in) 0.0026 in)

+0.051 mm 0.032 mm
Clearance between coupling shaft
75 mm +0.032 mm -0.015 mm 0.066 mm 0.029 mm
4 and
(2.953 in) (+0.0020 in (-0.0006 in) (0.0013 in (0.0011 in)
bearing
+0.0013 in) 0.0026 in)

Tolerance Repair limit

95 -0.087 mm -0.018 mm Repair

5 Wear of oil seal surface chrome
(3.740 in) (-0.003 in) (-0.0007 in)
plating
105 mm -0.087 mm -0.018 mm or
6 Wear of oil seal surface
(4.134 in) (-0.003 in) (-0.0007 in) replace
7 End play of coupling shaft Preload max: 3.9 Nm (2.9 lbf ft)

Torque Values
Item Nm lbf ft

a 932 ±98 687 ±72

b 66 ±7 49 ±5

WA500-3H 40-29
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)

DIFFERENTIAL, NORMAL - (STANDARD)

40-30 WA500-3H
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)

No. Check item Criteria Remedy

Standard Tolerance Standard

size Shaft Hole clearance

+0.054 mm 0.014 mm
Clearance of side bearing (outer race) in differential 180 mm -0.025 mm +0.014 mm 0.079 mm
1
gear assembly (7.087 in) (-0.0010 in) (+0.0021 in (0.0006 in
+0.0006 in) 0.0031 in)

+0.045 mm -0.023 mm
Clearance of side bearing (inner race) in differential 120 mm +0.023 mm -0.020 mm -0.065 mm
2
gear assembly (4.724 in) (+0.0018 in (-0.0008 in) (-0.0009 in
+0.0009 in) -0.0026 in)

+0.026 mm 0.026 mm
171.45 mm +0.025 mm -0.014 mm -0.039 mm
3 Clearance of pinion shaft bearing (outer race)
(6.75 in) (+0.0010 in) (+0.0010 in (0.0010 in
-0.0006 in) -0.0015 in)

+0.064 mm -0.025 mm
76.2 mm +0.038 mm +0.013 mm -0.064 mm
4 Clearance of pinion shaft bearing (inner race)
(3.00 in) (+0.0025 in (+0.0005 in) (0.0010 in
+0.0015 in) -0.0025 in)

+0.030 mm
0.002 mm
76.2 mm +0.011 mm +0.013 mm
5 Clearance of pinion shaft bearing (inner race) -0.030 mm
(3.00 in) (+0.0012 in (+0.0005 in)
(-0.002 in)
+0.0004 in)

+0.034 mm 0.012 mm Replace

120 mm -0.015 mm +0.012 mm 0.049 mm
6 Clearance of pilot bearing (outer race)
(4.724 in) (-0.0006 in) (+0.0013 in (0.0005 in
+0.0005 in) 0.0019 in)

+0.039 mm -0.010 mm -0.030 mm

55 mm +0.020 mm -0.025 mm -0.064 mm
7 Clearance of pilot bearing (inner race)
(2.165 in) (+0.0015 in (-0.0004 in (-0.0012 in
+0.0008 in) -0.0010 in) -0.0025 in)

-0.020 mm +0.046 mm 0.030 mm

210 mm -0.060 mm +0.010 mm 0.106 mm
8 Clearance between differential carrier and cage
(8.268 in) (0.0008 in (+0.0018 in (0.0012 in
-0.0024 in) +0.0004 in) 0.0042 in)

-0.025 mm +0.160 mm 0.135 mm

Clearance between spider and differential pinion 40 mm -0.050 mm +0.110 mm 0.210 mm
9
bushing (1.575 in) (0.0010 in (+0.0063 in (0.0053 in
-0.0020 in) +0.0043 in) 0.0083 in)

10 Backlash of bevel gear 0.30 - 0.41 mm (0.0012 - 0.0016 in)

11 Backlash of differential gear 0.30 - 0.41 mm (0.0012 - 0.0016 in)

12 End play of pinion gear Max. 0.064 mm (0.0025 in)

13 Free rotating torque of bevel gear Max. 8.34 Nm {6.15 lbf ft)

14 Rear face runout of bevel gear 0.1 mm (0.0039 in)

15 Standard thickness of shims for stop shaft Clearance "a" + (0.1 ±0.05 mm / 0.0039 ±0.002 in)

WA500-3H 40-31
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)

40-32 WA500-3H
MAINTENANCE STANDARD DIFFERENTIAL, NORMAL - (STANDARD)

No. Check item Criteria Remedy

Standard Repair
Tolerance
size limit

+0.05 mm
4 mm -0.05 mm 3.8 mm
1 Thickness of side gear washer
(0.158 in) (+0.002 in (0.150 in)
-0.002 in)
Replace
+0.09 mm
1.5 mm -0.01 mm 1.35 mm
2 Thickness of pinion gear washer
(0.059 in) (+0.004 in (0.053 in)
-0.0004 in)

100 mm -0.087 mm
3 Wear of oil seal surface -
(3.937 in) (-0.0034 in)

Torque Values
Item Nm lbf ft

a 549 ±59 405 ±44

b 927 ±103 684 ±76

c 4 ±1 (see note 1) 3 ±0.74 (see note 1)

d 13 ±10 (see note 2) 83 ±7 (see note 2)

e 277 ±32 204 ±24

f 31 ±3 23 ±3

g 907 ±123 669 ±191

note 1 1st step when measuring clearance with no shim.

note 2 1st step when measuring clearance with shim installed.

WA500-3H 40-33
MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

40-34 WA500-3H
MAINTENANCE STANDARD FINAL DRIVE

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between planetary shaft
1
and bearing +0.015 mm -0.002 mm
55 mm -0.015 mm
+0.002 mm -0.030 mm -
(2.165 in) (-0.0006 in)
(+0.0006 in) (-0.0012 in)

+0.033 mm -0.004 mm
Clearance between ring gear hub 190 mm +0.004 mm -0.030 mm -0.063 mm
2 -
and bearing (7.480 in) (+0.0013 in (-0.0012 in) (-0.0002 in
+0.0002 in) -0.0025 in)
Replace
Standard
Tolerance Repair limit
size
3 Thickness of spacer
22 mm ±0.1 mm 21.5 mm
(0.866 in) (±0.0039 in) (0.847 in)

Backlash between planet gear and

4 0.18 - 0.43 mm (0.007 - 0.017 in)
sun gear

Backlash between planet gear and

5 0.18 - 0.54 mm (0.007 - 0.021 in)
ring gear

6 Thickness of shim for wheel hub 2.0 mm (0.079 in)

Torque Values
Item Nm lbf ft

a 31 ±3 23 ±3

b 172 ±74 127±54

c 110 ±12 81 ±9

d 277 ±32 204 ±24

e 69 ±10 51 ±7

WA500-3H 40-35
MAINTENANCE STANDARD AXLE MOUNT

AXLE MOUNT

40-36 WA500-3H
MAINTENANCE STANDARD AXLE MOUNT

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.056 mm 0.056 mm
Clearance of shaft and hole front
310 mm -0.137 mm +0.489 mm 0.626 mm 1.6 mm
1 support side (after press fitting
(12.205 in) (-0.002 in (+0.019 in) (0.002 in (0.063 in)
bushing)
-0.005 in) 0.025 in)

+2.30 mm
Clearance of shaft and hole front
320.2 mm -0.80 mm +0.089 mm
2 support side (before installing - - Replace
(12.606 in) (+0.090 in (+0.004 in)
bushing) (see note)
-0.032 in)

-0.056 mm +0.481 mm 0.048 mm

Clearance of shaft and hole front
260 mm -0.137 mm -0.008 mm 0.618 mm 1.6 mm
3 support side (after press fitting
(10.236 in) (-0.002 in (+0.019 in (0.002 in (0.063 in)
bushing)
-0.005 in) -0.0003 in) 0.024 in)

+2.30 mm
Clearance of shaft and hole front
270.2 mm -0.80 mm +0.081 mm
4 support side (before installing - -
(10.638 in) (+0.090 in (+0.003 in)
bushing
-0.032 in)

Standard
Tolerance Repair limit
size

-0.10 mm
20 mm -0.25 mm
5 Thickness of wear plate -
(0.787 in) (-0.0039 in
-0.010 in)

+0.1 mm
Replace
5 mm -0.3 mm
6 Thickness of wear plate -
(0.197 in) (+0.0039 in
-0.012 in)

5 mm ±0.1 mm
7 Thickness of rear bushing -
(0.197 in) (±0.0039 in)

5 mm ±0.1 mm
8 Thickness of front bushing -
(0.197 in) (±0.0039 in)

note The bushings must be in contact with the support at both the front and rear

Torque Values
Item Nm lbf ft

a 2746 ±294 2025 ±217

b 1569 ±196 1157 ±145

c 277 ±32 204 ±24

WA500-3H 40-37
MAINTENANCE STANDARD CENTER HINGE PIN

CENTER HINGE PIN

40-38 WA500-3H
MAINTENANCE STANDARD CENTER HINGE PIN

No. Check item Criteria Remedy

Standard Tolerance Standard

size Shaft Hole clerance

-0.036 mm 0.036 mm
Clearance between lower hinge pin and rear 100 mm -0.058 mm +0.054 mm 0.112 mm
1
frame (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)

-0.036 mm 0.036 mm
Clearance between lower hinge pin and spacer 100 mm -0.058 mm +0.054 mm 0.112 mm
2
(small) (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)

-0.036 mm 0.016 mm
Clearance between lower hinge pin and 100 mm -0.058 mm -0.020 mm 0.058 mm
3
bearing (3.937 in) (-0.001 in (-0.001 in) (0.001 in
-0.002 in) 0.002 in)

-0.036 mm 0.036 mm
Clearance between lower hinge pin and spacer 100 mm -0.058 mm +0.054 mm 0.112 mm
4
(large) (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)

-0.043 mm 0.043 mm
Clearance between rear frame and spacer 130 mm -0.106 mm +0.063 mm 0.169 mm
5
(large) (5.118 in) (-0.002 in (+0.003 in) (0.002 in
-0.004 in) 0.007 in)

-0.048 mm -0.023 mm
Clearance between front frame and upper 155 mm -0.025 mm -0.088 mm -0.088 mm
6
hinge bearing (6.102 in) (-0.001 in) (-0.002 in (-0.001 in Replace
-0.004 in) -0.004 in)

-0.036 mm 0.036 mm
Clearance between upper hinge pin and rear 100 mm -0.058 mm +0.054 mm 0.112 mm
7
frame (3.937 in) (-0.001 in (+0.002 in) (0.001 in
-0.002 in) 0.004 in)

-0.036 mm 0.016 mm
Clearance between upper hinge pin and 100 mm -0.058 mm -0.020 mm 0.058 mm
8
bearing (3.937 in) (-0.001 in (-0.001 in) (0.001 in
-0.002 in) 0.002 in)

-0.050 mm -0.025 mm
Clearance between front frame and lower 160 mm -0.025 mm -0.090 mm -0.090 mm
9
hinge bearing (6.299 in) (-0.001 in) (-0.002 in (-0.001 in
-0.004 in) -0.004 in)

-0.043 mm 0.043 mm
125 mm -0.106 mm +0.063 mm 0.169 mm
10 Clearance between rear frame and bushing
(4.921 in) (-0.002 in (+0.003 in) (0.002 in
-0.004 in) 0.007 in)

+0.280 mm -0.126 mm
Clearance at press fitted part of seal of upper 115 mm +0.180 mm +0.054 mm -0.280 mm
11
hinge pin (4.528 in) (+01011 in (+0.002 in) (-0.005 in
+0.007 in) -0.011 in)

+0.310 mm -0.147 mm
Clearance at press fitted part of seal of lower 135 mm +0.210 mm +0.063 mm -0.310 mm
12
hinge pin (5.315 in) (+0.012 in (+0.003 in) (-0.006 in
+0.008 in) -0.012 in)

WA500-3H 40-39
MAINTENANCE STANDARD CENTER HINGE PIN

No. Check item Criteria Remedy

Standard size Tolerance

13 Height of lower hinge spacer (small) 35 mm (1.387 in) ±0.1 (±0.0039 in) Replace

14 Height of lower hinge spacer (large) 101.5 mm (3.996 in) ±0.1 (±0.0039 in)

15 Shim thickness for lower hinge and retainer 2.3 mm (0.090 in)

16 Shim thickness for lower hinge and retainer 1.6 mm (0.063 in ) Adjust

17 Shim thickness for upper hinge and retainer 1.6 mm (0.063 in )

Torque Values
Item Nm lbf ft

a 177 ± 20 131 ±15

b 59 ±6 (see note 1) 44 ±4 (see note 1)

c 177 ± 20 (see note 2) 131 ±15 (see note 2)

d 98 ±10 (see note 1) 72 ±7 (see note 1)

e 277 ±32 (see note 1) 204 ±24 (see note 1)

f 277 ±32 (see note 2) 204 ±24 (see note 2)

g 385 ±42 284 ±31

note 1 When adjusting shim

note 2 Final value

40-40 WA500-3H
MAINTENANCE STANDARD CENTER HINGE PIN

MEMORANDUM

WA500-3H 40-41
MAINTENANCE STANDARD STEERING COLUMN

STEERING COLUMN

40-42 WA500-3H
MAINTENANCE STANDARD STEERING COLUMN

No. Check item Criteria Remedy

Standard Tolerance Standard Replace

size Shaft Hole clerance

+0.150 mm 0.050 mm
Clearance between steering shaft and column 19 mm -0.080 mm +0.050 mm 0.230 mm Replace
1
bushing (0.748 in) (-0.003 in) (+0.006 in (0.002 in
+0.002 in) 0.010 in)

Torque Values
Item Nm lbf ft

a 34 ±5 25 ±4

b 44 ±10 33 ±7

c 29 ±3 21 ±2

d 52 ±8 38 ±5

e 55 ±7 41 ±5

WA500-3H 40-43
MAINTENANCE STANDARD STEERING PUMP

STEERING PUMP

No. Check item Criteria Remedy

Standard clearance Clearance limit

Clearance between gear case and side plate, 0.10 - 0.15 mm 0.19 mm
1
gear (0.004 - 0.006 in) (0.007 in)
Replace
Clearance between inside diameter of plain 0.06 - 0.149 mm 0.20 mm
2
bearing and outside diameter of gear shaft (0.002 - 0.006 in) (0.008 in)
+0 +0
3 insertion depth of pin 14 -0.5 mm (0.55 -0.02 in)

4 Rotating torque of spline shaft 7 - 12 Nm (5 - 9 lbf ft)

Revolution Discharge Standard Repair limit

Discharge: (RPM) pressure discharge discharge -
- E010-CD
Temperature: 45 - 55° C 210 kg/cm2 184 L/min. 170 L/min.
2500
(113 - 131° F) (2987 psi) (49 gal/min) (45 gal/min

Torque Values
Item Nm lbf ft

a 277 ±32 204 ±24

40-44 WA500-3H
MAINTENANCE STANDARD STEERING VALVE

STEERING VALVE

No. Check item Criteria Remedy

Standard size Repair limit

Free Installation Installation Free Installation

length length load length load

37.2 mm 32 mm 57 N 45 N
1 Steering spool return spring -
(1.465 in) (1.260 in) (13 lbf) (10 lbf)

20.9 mm 13.2 mm 9 ±5 N 8N
2 Load check valve spring -
(0.823 in) (0.520 in) (2 ±1 lbf) (2 lbf) Replace

75.2 mm 68.5 mm 136 N 112 N

3 Demand spool return spring -
(2.961 in) (2.697 in) (31 lbf) (25 lbf)

24.0 mm 22.19 mm 182 N 145 N

4 Relief valve spring -
(0.945 in) (0.874 in) (41 lbf) (33 lbf)

21.6 mm 17.0 mm 2N 2N
5 Check valve return spring -
(0.850 in) (0.669 in) (0.5 lbf) (0.45 lbf)

WA500-3H 40-45
MAINTENANCE STANDARD STEERING CYLINDER MOUNT

STEERING CYLINDER MOUNT

40-46 WA500-3H
MAINTENANCE STANDARD STEERING CYLINDER MOUNT

No. Check item Criteria Remedy

Tolerance Standard
Standard size
Shaft Hole clearance

0 mm +0.200 mm 0.100 mm
Clearance between mounting pin and
60 mm -0.074 mm +0.100 mm 0.248 mm
1 bushing connection of steering cylinder
(2.362 in) (0 in (+0.008 in (0.004 in Replace
rod and frame
-0.003 in) +0.004 in) 0.010 in)

0 mm +0.200 mm 0.100 mm
Clearance between mounting pin and
60 mm -0.074 mm +0.100 mm 0.248 mm
2 bushing connection of steering cylinder
(2.362 in) (0 in (+0.008 in (0.004 in
bottom and frame
-0.003 in) +0.004 in) 0.010 in)

Standard clearance
Width of boss Width of hinge
(Clearance a + b) Max. 1.0 mm
(0.030 in)
Connection of steering cylinder and 70 +0.8 mm 74 ±1 mm 2.2 - 5.0 mm
3 after
front frame (2.756 +0.032 in) (2.913 ±0.039 in) (0.087 - 0.197 in)
adjusting
Connection of steering cylinder and 70 -0.5 mm 74 ±1 mm 3.0 - 5.5 mm shim
4
rear frame (2.756 -0.020 in) (2.913 ±0.039 in) (0.118 - 0.217 in)

WA500-3H 40-47
MAINTENANCE STANDARD BRAKE VALVE

BRAKE VALVE

RIGHT

40-48 WA500-3H
MAINTENANCE STANDARD BRAKE VALVE

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.025 mm 0.175 mm
Clearance between pedal mount 10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
1
hole and bracket hole (0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)

-0.025 mm 0.175 mm
10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
2 Clearance between roller and pin
(0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)

Standard
Tolerance Repair limit
size

30 mm
3 Outside diameter of roller -0.5 mm (0.020 in) 29.2 mm (1.150 in)
(1.181 in)
Replace
Standard size Repair limit

Free Free
Test height Test load Test load
length length

34 mm 21.8 mm 93.2 N 33 mm
4 Control spring
(1.339 in) (0.858 in) (21 lbf) (1.299 in)

46.3 mm 34.3 mm 459.0 N 45.3 mm

5 Control spring
(1.823 in) (1.350 in) (103 lbf) (1.784 in)

86.2 mm 58 mm 60.8 N 78 mm
6 Return spring
(3.394 in) (2.284 in) (14 lbf) (3.071 in)

17 mm 15 mm 69.6 N 16.2 mm
7 Spring
(0.669 in) (0.591 in) (16 lbf) (0.638 in)

31.5 mm 19.5 mm 16.7 N 28 mm

8 Return spring
(1.240 in) (0.768 in) (3.75 lbf) (1.102 in)

Torque Values
Item Nm lbf ft

a 66 ±7 49 ±5

b 152 ±25 112 ±18

c 8 ±2 6 ±1.5

WA500-3H 40-49
MAINTENANCE STANDARD BRAKE VALVE

LEFT

40-50 WA500-3H
MAINTENANCE STANDARD BRAKE VALVE

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.025 mm 0.175 mm
Clearance between pedal mount 10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
1
hole and bracket hole (0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)

-0.025 mm 0.175 mm
10 mm -0.075 mm +0.1 mm 0.025 mm 0.25 mm
2 Clearance between roller and pin
(0.394 in) (-0.001 in (+0.004 in) (0.007 in (0.010 in)
-0.003 in) 0.001 in)

Standard
Tolerance Repair limit
size

30 mm
3 Outside diameter of roller -0.5 mm (0.020 in) 29.2 mm (1.150 in)
(1.181 in)
Replace
Standard size Repair limit

Free Free
Test height Test load Test load
length length

34 mm 21.8 mm 93.2 N 33 mm
4 Control spring
(1.339 in) (0.858 in) (21 lbf) (1.299 in)

46.3 mm 34.3 mm 459.0 N 45.3 mm

5 Control spring
(1.823 in) (1.350 in) (103 lbf) (1.784 in)

86.2 mm 58 mm 60.8 N 78 mm
6 Return spring
(3.394 in) (2.284 in) (14 lbf) (3.071 in)

17 mm 15 mm 69.6 N 16.2 mm
7 Spring
(0.669 in) (0.591 in) (16 lbf) (0.638 in)

31.5 mm 19.5 mm 16.7 N 28 mm

8 Return spring
(1.240 in) (0.768 in) (3.75 lbf) (1.102 in)

Torque Values
Item Nm lbf ft

a 66 ±7 49 ±5

b 152 ±25 112 ±18

c 8 ±2 6 ±1.5

WA500-3H 40-51
MAINTENANCE STANDARD SLACK ADJUSTER

SLACK ADJUSTER

40-52 WA500-3H
MAINTENANCE STANDARD SLACK ADJUSTER

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.030 mm 0.030 mm
55 mm -0.076 mm +0.074 mm 0.150 mm 0.25 mm
1 Clearance between body and piston
(2.165 in) (-0.001 in (+0.003 in) (0.001 in (0.010 in)
-0.003 in) 0.006 in)

Standard size Repair limit Replace

Free Free
Test length Test load Test load
length length

198 mm 38 mm 43.2 N
2 Spring - -
(7.795 in) (1.496 in) (10 lbf)

39.2 mm 33 mm 66.7 N
3 Spring - -
(1.543 in) (1.299 in) (15 lbf)

Torque Values
Item Nm lbf ft

a 56 ±7 41 ±5

b 66 ±7 49 ±5

WA500-3H 40-53
MAINTENANCE STANDARD BRAKE

BRAKE

40-54 WA500-3H
MAINTENANCE STANDARD BRAKE

No. Check item Criteria Remedy

Standard size Repair limit

Free Install Free Install

Install load
length length length load

80.2 mm 69.9 mm 600.2 N 72.2 mm 539.4 N

1 Return spring
(3.158 in) (2.752 in) (135 lbf) (2.843 in) (121 lbf)

Repair
Standard size Tolerance
limit

2.3 mm ±0.08 mm 2.0 mm

2 Thickness of plate
(0.091 in) (±0.003 in) (0.079 in)

3.8 mm ±0.1 mm 3.5 mm

3 Thickness of disc
(0.150 in) (±0.004 in) (0.137 in) Replace

51.1 mm ±1.52 mm 46.0 mm

4 Total thickness of plates and discs
(2.011 in) (±0.059 in) (1.811 in)

42.0 mm +0.097 mm
5 Wear of piston seal contact surface -
(1.654 in) (+0.004 in)

38.3 mm +0.089 mm
6 Wear of piston seal contact surface -
(1.509 in) (+0.004 in)

Backlash between outer gear and 0.21 - 0.65 mm

7
plate (0.008 - 0.026 in)

Backlash between inner gear and 0.31 - 0.74 mm

8
disc (0.012 - 0.029 in)

Torque Values
Item Nm lbf ft

a 177 ±20 130 ±15

b 549 ±59 405 ±44

WA500-3H 40-55
MAINTENANCE STANDARD PARKING BRAKE

PARKING BRAKE

40-56 WA500-3H
MAINTENANCE STANDARD PARKING BRAKE

No Check item Criteria Remedy

Standard size Repair limit

Free Install Free Install

Install load
length length length load

77.7 mm 54.0 mm 1425 ±22 N 69.9 mm 1258 N

1 Parking brake spring (outside)
(3.158 in) (2.126 in) (320 ±5 lbf) (2.752 in) (283 lbf)

77.8 mm 54.0 mm 535 ±5.3 N 70.0 mm 482 N

2 Parking brake spring (inside)
(3.063 in) (2.126 in) (120 ±1 lbf) (2.756 in) (108 lbf)

Repair
Standard size Tolerance
limit

4.0 mm ±0.05 mm 3.9 mm

Thickness Replace
(0.158 in) (±0.002 in) (0.154 in)
3 Separation of plate
0.15 mm 0.6 mm
Distortion -
(0.006 in) (0.024 in)

3.2 mm ±0.1 mm 35.0 mm

Thickness
(0.126 in) (±0.004 in) (1.378 in)

Depth of 0.45 mm +0.175 mm 0.235 mm

4 Brake disc
lining groove (0.018 in) (+0.007 in) (0.009 in)

Thickness of 0.7 mm +0.075 mm

-
lining (0.028 in) (+0.003 in)

5 Load of wave spring - - -

WA500-3H 40-57
MAINTENANCE STANDARD HYDRAULIC PUMP

HYDRAULIC PUMP

SAR(4)-160

40-58 WA500-3H
MAINTENANCE STANDARD HYDRAULIC PUMP

No. Check item Criteria Remedy

Standard clearance Clearance limit

Clearance between gear case and side plate, 0.11 - 0.16 mm 0.19 mm
1 gear (0.004 - 0.006 in) (0.007 in)
Replace
Clearance between inside diameter of plain 0.06 - 0.140 mm 0.20 mm
2
bearing and outside diameter of gear shaft (0.002 - 0.006 in) (0.008 in)
+0 +0
3 Insertion depth of pin 14 -0.5 mm (0.55 -0.02 in)

4 Rotating torque of spline shaft 9.8 - 14.7 Nm (7 - 11 lbf ft)

Revolution Discharge Standard Repair limit

Discharge: (RPM) pressure discharge discharge -
- E010-CD
Temperature: 45 - 55° C 210 kg/cm2 328 L/min. 303 L/min.
2200
(113 - 131° F) (2987 psi) (87 gal/min) (80 gal/min

Torque Values
Item Nm lbf ft

a 177 ±20 130 ±15

WA500-3H 40-59
MAINTENANCE STANDARD SWITCH, PPC PUMP

SWITCH, PPC PUMP

SAR(3)-63 + SAR(1)-28

40-60 WA500-3H
MAINTENANCE STANDARD SWITCH, PPC PUMP

No. Check item Criteria Remedy

Model Standard clearance Clearance

0.10 - 0.15 mm 0.19 mm

SAR(3)-63
Clearance between gear case (0.004 - 0.006 in) (0.007 in)
1
and side plate gear 0.10 - 0.15 mm 0.19 mm
SAR(1)-28
(0.004 - 0.006 in) (0.007 in)

0.06 - 0.149 mm 0.20 mm

Clearance between inside SAR(3)-63
(0.002 - 0.006 in) (0.008 in)
2 diameter of plain bearing and Replace
outside diameter of gear shaft 0.06 - 0.149 mm 0.20 mm
SAR(1)-28
(0.002 - 0.006 in) (0.008 in)

Standard size Tolerance

10 mm -0.5 mm
SAR(3)-63
(0.394 in) (-0.020 in)
3 Insertion depth of pin
10 mm -0.5 mm
SAR(1)-28
(0.394 in) (-0.020 in)

SAR(3)-63 6.9 - 11.8 Nm (5 - 9 lbf ft)

4 Rotating torque of spline shaft
SAR(1)-28 2.0 - 4.9 Nm (1.5 - 4 lbf ft)

Revolution Discharge Standard Repair limit

(rpm) pressure discharge discharge
Discharge: -
E010-CD 210 kg/cm2 145 L/min 134 L/min
- SAR(3)-63 2500
45o - 55o C (2987 psi) (38 gal/min) (35 gal/min)
(113o - 131o F)
38 kg/cm2 67 L/min 60 L/min
SAR(1)-28 2500
(541 psi) (18 gal/min) (16 gal/min)

WA500-3H 40-61
MAINTENANCE STANDARD PPC VALVE

PPC VALVE

FOR BUCKET AND BOOM

No Check item Criteria Remedy

Standard size Repair limit

Free length Install Install Free Install

X O.D. length load length load
Replace
Centering spring 52.8 x 12.3 mm 36.0 mm 29.4 N 23.5 N
1 - spring if
(bucket DUMP, boom LOWER) (2.079 x 0.484 in) (1.417 in) (7 lbf) (5 lbf)
damaged or
Centering pin 52.8 x 12.3 mm 36.0 mm 39.2 N 31.4 N deformed
2 -
(bucket TILT, boom RAISE) (2.079 x 0.484 in) (1.417 in) (9 lbf) (7 lbf)

31.4 x 7.4 mm 29.4 mm 16.7 N 13.7 N

3 Metering spring -
(1.236 x 0.291 in) (1.158 in) (4 lbf) (3 lbf)

Torque Values
Item Nm lbf ft

a 44.1 ±4.9 33 ±4

b 17.7 ±3.9 13 ±3

40-62 WA500-3H
MAINTENANCE STANDARD PPC VALVE

FOR AUXILIARY ATTACHMENT

No Check item Criteria Remedy

Standard size Repair limit

Free length Install Install Free Install

X O.D. length load length load
Replace
Centering spring 52.8 x 12.3 mm 36.0 mm 29.4 N 23.5 N
1 - spring if
(bucket DUMP, boom LOWER) (2.079 x 0.484 in) (1.417 in) (7 lbf) (5 lbf)
damaged or
Centering pin 52.8 x 12.3 mm 36.0 mm 39.2 N 23.5 N deformed
2 -
(bucket TILT, boom RAISE) (2.079 x 0.484 in) (1.417 in) (9 lbf) (5 lbf)

31.4 x 7.4 mm 29.4 mm 16.7 N 13.7 N

3 Metering spring -
(1.236 x 0.291 in) (1.158 in) (4 lbf) (3 lbf)

Torque Values
Item Nm lbf ft

a 44.1 ±4.9 33 ±4

b 17.7 ±3.9 13 ±3

WA500-3H 40-63
MAINTENANCE STANDARD CUT-OFF VALVE

CUT-OFF VALVE

No Check item Criteria Remedy

Standard size Repair limit

Free Install Install Free Install

length length load length load

36.95 mm 3.0 mm 35.3 N 28.4 N Replace

1 Unload valve spring -
(1.455 in) (0.118 in) (8 lbf) (6 lbf)

33 mm 2.0 mm 16.7 N 1.4 N

2 Check valve spring -
(1.299 in) (0.079 in) (4 lbf) (0.32 lbf)

Torque Values
Item Nm lbf ft

a 66.2 ±7.4 49 ±6

b 2.21 ±0.25 2

c 147.1 ±9.8 109 ±7

b 34.3 ±4.9 25 ±4

40-64 WA500-3H
MAINTENANCE STANDARD CUT-OFF VALVE

MEMORANDUM

WA500-3H 40-65
MAINTENANCE STANDARD MAIN CONTROL VALVE

MAIN CONTROL VALVE

2 SPOOL VALVE

40-66 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE

No Check item Criteria Remedy

Standard size Repair limit

Free Install Install Free Install

length length load length load

64.4 mm 62.2 mm 190 N 152 N

1 Bucket spool return spring (large) -
(2.535 in) (2.449 in) (43 lbf) (34 lbf)

18.6 mm 14.9 mm 112.8 N 90 N

2 Bucket spool return spring (small) -
(0.732 in) (0.587 in) (25 lbf) (20 lbf)

64.4 mm 62.7 mm 149 N 119.6 N

3 Boom spool return spring (large) -
(2.535 in) (2.469 in) (34 lbf) (27 lbf)

18.6 mm 15.2 mm 104 N 83.4 N

4 Boom spool return spring (small) -
(0.732 in) (0.598 in) (23 lbf) (19 lbf)

89.2 mm 82.0 mm 616 N 554 N

5 Boom spool return spring (large) -
(3.512 in) (3.228 in) (139 lbf) (125 lbf)

42.0 mm 42.0 mm
6 Boom spool return spring (small) 0 - -
(1.654 in) (1.654 in)

82.4 mm 82.0 mm 182.4 N 163.8 N

7 Bucket spool return spring (large) -
(3.244 in) (2.228 in) (41 lbf) (37 lbf) Replace

42.0 mm 42.0 mm
8 Bucket spool return spring (small) 0 - -
(1.654 in) (1.654 in)

52.3 mm 38.0 mm 86.3 N 68.6 N

9 Main valve spring -
(2.059 in) (1.496 in) (19 lbf) (15 lbf)

78.2 mm 52.0 mm 18.8 N 14.7 N

10 Check valve spring -
(3.079 in) (2.047 in) (4 lbf) (3 lbf)

27.9 mm 18.0 mm 6.9 N 5.9 N

11 Suction valve spring of safety valve -
(1.098 in) (0.709 in) (2 lbf) (1 lbf)

27.9 mm 18.0 mm 6.9 N 5.9 N

12 Suction valve spring -
(1.098 in) (0.709 in) (2 lbf) (1 lbf)

53.0 mm 42.1 mm 137 N 123.6 N

13 Float selector valve spring -
(2.087 in) (1.657 in) (31 lbf) (28 lbf)

82.7 mm 47.0 mm 49 N 39 N
14 Unloader valve spring -
(3.256 in) (1.850 in) (11 lbf) (9 lbf)

49.3 mm 43.3 mm 209.9 N 167.7 N

15 Relief valve poppet spring -
(1.941 in) (1.705 in) (47 lbf) (38 lbf)

Torque Values
Item Nm lbf ft

a 321 ±47 237 ±34

b 152 ±25 112 ±18

c 88 ±10 65 ±7

d 186 ±10 137 ±7

e 69 ±10 51 ±7

f 22 ±3 16 ±2

WA500-3H 40-67
MAINTENANCE STANDARD MAIN CONTROL VALVE

3-SPOOL

40-68 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE

No Check item Criteria Remedy

Standard size Repair limit

Free Install Install Free Install

length length load length load

64.4 mm 62.2 mm 190 N 152 N

1 Attachment spool return spring (large) -
(2.535 in) (2.449 in) (43 lbf) (34 lbf)

18.6 mm 14.9 mm 112.8 N 90 N

2 Attachment spool return spring (small) -
(0.732 in) (0.587 in) (25 lbf) (20 lbf)

64.4 mm 62.2 mm 190 N 152 N

3 Bucket spool return spring (large) -
(2.535 in) (2.449 in) (43 lbf) (34 lbf)

18.6 mm 14.9 mm 112.8 N 90 N

4 Bucket spool return spring (small) -
(0.732 in) (0.587 in) (25 lbf) (20 lbf)

64.4 mm 62.7 mm 149 N 119.6 N

5 Boom spool return spring (large) -
(2.535 in) (2.469 in) (34 lbf) (27 lbf)

18.6 mm 15.2 mm 104 N 83.4 N

6 Boom spool return spring (small) -
(0.732 in) (0.598 in) (23 lbf) (19 lbf)

89.2 mm 82.0 mm 616 N 554 N

7 Boom spool return spring (large) -
(3.512 in) (3.228 in) (139 lbf) (125 lbf)

42.0 mm 42.0 mm
8 Boom spool return spring (small) 0 - -
(1.654 in) (1.654 in)

82.4 mm 82.0 mm 182.4 N 163.8 N

9 Bucket spool return spring (large) -
(3.244 in) (2.228 in) (41 lbf) (37 lbf) Replace

42.0 mm 42.0 mm
10 Bucket spool return spring (small) 0 - -
(1.654 in) (1.654 in)

82.4 mm 82.0 mm 182.4 N 68.6 N

11 Attachment spool return spring (large) -
(3.244 in) (2.228 in) (41 lbf) (15 lbf)

42.0 mm 42.0 mm
12 Attachment spool return spring (small) 0 - -
(1.654 in) (1.654 in)

52.3 mm 38.0 mm 86.3 N 68.6 N

13 Main valve spring -
(2.059 in) (1.496 in) (19 lbf) (15 lbf)

78.2 mm 52.0 mm 18.8 N 14.7 N

14 Check valve spring -
(3.079 in) (2.047 in) (4 lbf) (3 lbf)

27.9 mm 18.0 mm 6.9 N 5.9 N

15 Suction valve spring of safety valve -
(1.098 in) (0.709 in) (2 lbf) (1 lbf)

27.9 mm 18.0 mm 6.9 N 5.9 N

16 Suction valve spring -
(1.098 in) (0.709 in) (2 lbf) (1 lbf)

53.0 mm 42.1 mm 137 N 123.6 N

17 Float selector valve spring -
(2.087 in) (1.657 in) (31 lbf) (28 lbf)

82.7 mm 47.0 mm 49 N 39 N
18 Unloader valve spring -
(3.256 in) (1.850 in) (11 lbf) (9 lbf)

49.3 mm 43.3 mm 209.9 N 167.7 N

19 Relief valve poppet spring -
(1.941 in) (1.705 in) (47 lbf) (38 lbf)

WA500-3H 40-69
MAINTENANCE STANDARD MAIN CONTROL VALVE
Torque Values
Item Nm lbf ft

a 321 ±47 237 ±34

b 152 ±25 112 ±18

c 88 ±10 65 ±7

d 186 ±10 137 ±7

e 69 ±10 51 ±7

f 22 ±3 16 ±2

40-70 WA500-3H
MAINTENANCE STANDARD MAIN CONTROL VALVE

MEMORANDUM

WA500-3H 40-71
MAINTENANCE STANDARD HYDRAULIC CYLINDERS

HYDRAULIC CYLINDERS

40-72 WA500-3H
MAINTENANCE STANDARD HYDRAULIC CYLINDERS

No Check item Criteria Remedy

Standard Tolerance Standard Clearance

Cylinder
size Shaft Hole clearance limit

-0.030 mm +0.151 mm 0.036 mm

55 mm -0.076 mm +0.006 mm 0.227 mm 0.327 mm
Steering
(2.165 in) (-0.001 in (+0.006 in (0.001 in (0.013 in)
-0.003 in) +0.0002 in) 0.009 in)

-0.036 mm +0.274 mm 0.096 mm

Clearance between rod and 110 mm -0.090 mm +0.060 mm 0.364 mm 0.469 mm
1 Boom
bushing (4.331 in) (-0.001 in (+0.010 in (0.004 in (0.018 in)
-0.004 in) +0.002 in) 0.014 in)

-0.043 mm +0.203 mm 0.091 mm

120 mm -0.106 mm +0.048 mm 0.309 mm 0.469 mm
Bucket
(4.724 in) (-0.002 in (+0.008 in (0.004 in (0.018 in)
-0.004 in) +0.002 in) 0.012 in)

+0.174 mm 0.100 mm
60 mm -0.074 mm +0.100 mm 0.248 mm 1.0 mm
Steering
(2.362 in) (-0.003 in) (+0.007 in (0.004 in (0.039 in)
+0.004 in) 0.010 in)
Clearance between piston
120 mm +0.100 mm
2 rod mounting pin and Boom - - -
(4.724 in) (+0.004 in)
diameter of hole
+0.307 mm
120 mm +0.220 mm
Bucket - - - Replace
(4.724 in) (+0.012 in
+0.009 in)

0.100 mm
60 mm -0.074 mm +0.174 mm 0.248 mm 1.0 mm
Steering
(2.362 in) (-0.003 in) +0.100 mm (0.004 in (0.039 in)
0.010 in)

+0.307 mm
Clearance between cylinder
120 mm +0.220 mm
3 bottom mounting pin and Boom - - -
(4.724 in) (+0.012 in
bushing
+0.009 in)

+0.307 mm
120 mm +0.220 mm
Bucket - - -
(4.724 in) (+0.012 in
+0.009 in)

Repair
Standard size Tolerance
limit

110 mm +0.150
Steering -
(4.331 in) (+0.006 in)

200 mm +0.200
4 Cylinder bore Boom -
(7.874 in) (+0.008 in)

225 mm +0.200
Bucket -
(7.874 in) (+0.008 in)

WA500-3H 40-73
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
Torque Values
Item Nm lbf ft

a 932 ±93 687 ±69

b 177 ±18 131 ±13

c 466 ±142 344 ±105

d 177 ±20 131 ±15

e 662 ±74 488 ±54

40-74 WA500-3H
MAINTENANCE STANDARD HYDRAULIC CYLINDERS

MEMORANDUM

WA500-3H 40-75
MAINTENANCE STANDARD BUCKET LINKAGE

BUCKET LINKAGE

40-76 WA500-3H
MAINTENANCE STANDARD BUCKET LINKAGE

No Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.036 mm +0.307 mm 0.256 mm

Clearance between pin and
110 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm
1 bushing at boss ends and bucket
(4.331 in) (-0.001 in (+0.012 in (0.010 in (0.039 in)
link
-0.004 in) +0.009 in) 0.016 in)

-0.036 mm +0.307 mm 0.256 mm

Clearance between pin and
110 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm
2 bushing at joint of boom and
(4.331 in) (-0.001 in (+0.012 in (0.010 in (0.039 in)
bucket
-0.004 in) +0.009 in) 0.016 in)

-0.036 mm +0.307 mm 0.256 mm

Clearance between pin and 120 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm
3
bushing at joint of and frame (4.724 in) (-0.001 in (+0.012 in (0.010 in (0.039 in)
-0.004 in) +0.009 in) 0.016 in)

-0.036 mm +0.307 mm 0.256 mm

Clearance between pin and
120 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm Replace, also if
4 bushing at joint of bucket cylinder
(4.724 in) (-0.001 in (+0.012 in (0.010 in (0.039 in) other parts are
bottom and frame
-0.004 in) +0.009 in) 0.016 in) biting into pin
-0.036 mm +0.307 mm 0.256 mm
Clearance between pin and
120 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm
5 bushing at joint of bucket cylinder
(4.724 in) (-0.001 in (+0.012 in (0.010 in (0.039 in)
rod and lever
-0.004 in) +0.009 in) 0.016 in)

-0.043 mm +0.307 mm 0.256 mm

Clearance between pin and
140 mm -0.106 mm +0.220 mm 0.397 mm 1.0 mm
6 bushing at joint of tilt lever and
(5.512 in) (-0.002 in (+0.012 in (0.010 in (0.039 in)
frame
-0.004 in) +0.009 in) 0.016 in)

-0.036 mm +0.395 mm 0.338 mm

Clearance between pin and
120 mm -0.090 mm +0.295 mm 0.501 mm 1.0 mm
7 bushing at joint of boom cylinder
(4.724 in) (-0.001 in (+0.016 in (0.013 in (0.039 in)
bottom and frame
-0.004 in) +0.012 in) 0.020 in)

-0.036 mm +0.307 mm 0.256 mm

Clearance between pin and
120 mm -0.090 mm +0.220 mm 0.397 mm 1.0 mm
8 bushing at joint of boom cylinder
(4.724 in) (-0.001 in (+0.012 in (0.010 in (0.039 in)
rod
-0.004 in) +0.009 in) 0.016 in)

WA500-3H 40-77
MAINTENANCE STANDARD BUCKET LINKAGE

No Check item Criteria Remedy

Width of Standard clearance

Width between bosses
hinge (Clearance a + b)

143 mm 140 mm 3.0 mm

9 Joint of bucket cylinder and frame
(5.630 in) (5.512 in) (0.118 in)

153 mm 150 mm 3.0 mm

10 Joint of boom and frame
(6.024 in) (5.906 in) (0.118 in)

180 mm 176.8 mm 3.2 mm

11 Joint of boom and bucket
(7.087 in) (6.961 in) (0.126 in)
Insert shims on
145 mm 142 mm 3.0 mm both sides to
12 Joint of bucket link and bucket make clearance
(5.709 in) (5.591 in) (0.118 in)
on both left and
144 mm 142 mm 2.0 mm right sides less
13 Joint of tilt lever and bucket link
(5.670 mm) (5.591 in) (0.079 in) than 1.5 mm
(0.059 in)
240 mm 237 mm 3.0 mm
14 Joint of tilt lever and frame
(9.449 in) (9.331 in) (0.118 in)

Joint of tilt lever and bucket 143 mm 140 mm 3.0 mm

15
cylinder (5.630 in) (5.512 in) (0.118 in)

125 mm 122 mm 3.0 mm

16 Joint of boom cylinder and boom
(4.921 in) (4.803 in) (0.118 in)

123 mm 120 mm 3.0 mm

17 Joint of boom cylinder and frame
(4.843 in) (4.724 in) (0.118 in)

40-78 WA500-3H
MAINTENANCE STANDARD BUCKET

BUCKET

No. Check item Croteria Remedy

Standard size Repair limit

61 mm 23 mm Replace
1 Wear of bucket tooth
(2.402 in) (0.906 in)

Max. 0.5 mm
2 Thickness of shims for tooth (Clearance between tooth and bucket) Adjust
(Max. 0.020 in)

3 Tightening torque of mounting bolt for bucket tooth 1040 ±157 Nm

Retighten
4 Tightening torque of mounting bolt for corner tooth (767 ±116 lbf ft)

WA500-3H 40-79
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-

BUCKET POSITIONER AND BOOM KICK-OUT

No. Check item Criteria Remedy

1 Clearance of bucket positioner switch 3 - 5 mm

Adjust
2 Clearance of boom kick-out switch (0.118 - 0197 in)

3 Tightening torque of mounting bolt for adjuster 88 ±34 Nm (65 ±25 lbf ft)
Retighten
3 Tightening torque of mounting bolt for switch 18 ±2 Nm (13 ±2 lbf ft)

40-80 WA500-3H
MAINTENANCE STANDARD ROPS CAB

ROPS CAB

Torque Values
Item Nm lbf ft

a 927 ±103 684 ±76

WA500-3H 40-81
MAINTENANCE STANDARD ROPS CAB

MEMORANDUM

40-82 WA500-3H
 90 OTHERS

TRANSMISSION CUTAWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

ELECTRIACL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5

ECSS WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
JOYSTICK STEERING WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
ENGINE FLOOR HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
CAB ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . 90-31
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . 90-33
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . 90-35
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . 90-37
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . 90-39
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2) . . . . . . . . . . . . . . . . . . . . . 90-41
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2) . . . . . . . . . . . . . . . . . . . . . 90-43
PARKING BRAKE CONTROL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45

HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-51
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
HYDRAULIC LINE ASSEMBLY (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61
HYDRAULIC LINE ASSEMBLY (PART 2 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63
HYDRAULIC LINE ASSEMBLY (PART 3 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65

WA500-3H 90-1
12

MEMORANDUM
OTHERS FOLDOUT 10-18

TRANSMISSION CUTAWAY

WA500-3H 90-3
OTHERS MEMORANDUM

MEMORANDUM

90-4 WA500-3H
OTHERS FOLDOUT 10-225-1

ELECTRIACL DIAGRAMS
ECSS WIRING DIAGRAM

WA500-3H 90-5
OTHERS MEMORANDUM

MEMORANDUM

90-6 WA500-3H
OTHERS FOLDOUT 10-225-2

JOYSTICK STEERING WIRING DIAGRAM

WA500-3H 90-7
OTHERS MEMORANDUM

MEMORANDUM

90-8 WA500-3H
OTHERS FOLDOUT 10-225-3

ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 of 5)

WA500-3H 90-9
OTHERS MEMORANDUM

MEMORANDUM

90-10 WA500-3H
OTHERS FOLDOUT 10-225-4

ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 of 5)

WA500-3H 90-11
OTHERS MEMORANDUM

MEMORANDUM

90-12 WA500-3H
OTHERS FOLDOUT 10-225-5

ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 of 5)

WA500-3H 90-13
OTHERS MEMORANDUM

MEMORANDUM

90-14 WA500-3H
OTHERS FOLDOUT 10-225-6

ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 of 5)

WA500-3H 90-15
OTHERS MEMORANDUM

MEMORANDUM

90-16 WA500-3H
OTHERS FOLDOUT 10-225-7

ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 of 5)

WA500-3H 90-17
OTHERS MEMORANDUM

MEMORANDUM

90-18 WA500-3H
OTHERS FOLDOUT 10-225-8

ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 of 4)

WA500-3H 90-19
OTHERS MEMORANDUM

MEMORANDUM

90-20 WA500-3H
OTHERS FOLDOUT 10-225-9

ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 of 4)

WA500-3H 90-21
OTHERS MEMORANDUM

MEMORANDUM

90-22 WA500-3H
OTHERS FOLDOUT 10-225-10

ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 of 4)

WA500-3H 90-23
OTHERS MEMORANDUM

MEMORANDUM

90-24 WA500-3H
OTHERS FOLDOUT 10-225-11

ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 of 4)

WA500-3H 90-25
OTHERS MEMORANDUM

MEMORANDUM

90-26 WA500-3H
OTHERS FOLDOUT 10-225-12

ENGINE FLOOR HARNESS DIAGRAM

WA500-3H 90-27
OTHERS MEMORANDUM

MEMORANDUM

90-28 WA500-3H
OTHERS FOLDOUT 10-225-13

CAB ELECTRICAL DIAGRAM

WA500-3H 90-29
OTHERS MEMORANDUM

MEMORANDUM

90-30 WA500-3H
OTHERS FOLDOUT 10-54-1-1

CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5)

WA500-3H 90-31
OTHERS MEMORANDUM

MEMORANDUM

90-32 WA500-3H
OTHERS FOLDOUT 20-153-2

CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5)

WA500-3H 90-33
OTHERS MEMORANDUM

MEMORANDUM

90-34 WA500-3H
OTHERS FOLDOUT 20-153-3

CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5)

WA500-3H 90-35
OTHERS MEMORANDUM

MEMORANDUM

90-36 WA500-3H
OTHERS FOLDOUT 20-153-4

CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5)

WA500-3H 90-37
OTHERS MEMORANDUM

MEMORANDUM

90-38 WA500-3H
OTHERS FOLDOUT 20-153-5

CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5)

WA500-3H 90-39
OTHERS MEMORANDUM

MEMORANDUM

90-40 WA500-3H
OTHERS FOLDOUT 20-153-6

3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2)

WA500-3H 90-41
OTHERS MEMORANDUM

MEMORANDUM

90-42 WA500-3H
OTHERS FOLDOUT 20-153-7

3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2)

WA500-3H 90-43
OTHERS MEMORANDUM

MEMORANDUM

90-44 WA500-3H
OTHERS FOLDOUT 10-96

PARKING BRAKE CONTROL

DIAGRAM

1. Parking brake emergency release switch

2. Neutralizer relay

3. Parking brake safety relay (parking brake emergency

release relay)

4. Parking brake switch

5. Transmission control valve

6. Parking brake solenoid valve

7. Parking brake (built into transmission)

8. Parking brake emergency release valve

9. Charge valve

10. Accumulator

WA500-3H 90-45
OTHERS MEMORANDUM

MEMORANDUM

90-46 WA500-3H
OTHERS FOLDOUT 10-105

HYDRAULIC
CIRCUIT DIAGRAM

WA500-3H 90-47
OTHERS MEMORANDUM

MEMORANDUM

90-48 WA500-3H
OTHERS FOLDOUT 10-54-1-1

JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)

WA500-3H 90-49
OTHERS MEMORANDUM

MEMORANDUM

90-50 WA500-3H
OTHERS FOLDOUT 10-54-1-2

JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)

WA500-3H 90-51
OTHERS MEMORANDUM

MEMORANDUM

90-52 WA500-3H
OTHERS FOLDOUT 10-54-1-3

JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)

WA500-3H 90-53
OTHERS MEMORANDUM

MEMORANDUM

90-54 WA500-3H
OTHERS FOLDOUT 10-54-2-1

STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)

WA500-3H 90-55
OTHERS MEMORANDUM

MEMORANDUM

90-56 WA500-3H
OTHERS FOLDOUT 10-54-2-2

STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)

WA500-3H 90-57
OTHERS MEMORANDUM

MEMORANDUM

90-58 WA500-3H
OTHERS FOLDOUT 10-54-2-3

STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)

WA500-3H 90-59
OTHERS MEMORANDUM

MEMORANDUM

90-60 WA500-3H
OTHERS FOLDOUT 10-100-1

HYDRAULIC LINE ASSEMBLY (PART 1 OF 3)

WA500-3H 90-61
OTHERS MEMORANDUM

MEMORANDUM

90-62 WA500-3H
OTHERS FOLDOUT 10-100-2

HYDRAULIC LINE ASSEMBLY (PART 2 OF 3)

WA500-3H 90-63
OTHERS MEMORANDUM

MEMORANDUM

90-64 WA500-3H
OTHERS FOLDOUT 10-54-2-3

HYDRAULIC LINE ASSEMBLY (PART 3 OF 3)

WA500-3H 90-65
OTHERS MEMORANDUM

MEMORANDUM

90-66 WA500-3H