CEBM022903
Shop Manual
WA500-6 WHEEL LOADER
SERIAL NUMBERS
WA500-6
A93001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. 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 recommended that customers contact their distributor for information on the latest revision.
December 2013 Printed in USA
Copyright 2013 Komatsu DataKom Publishing Division 00-1d
FOREWORD
CONTENTS
12
CONTENTS
00
00
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
60
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
90
DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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40-52
b
40-85
b
30-210
b
40-20
b
40-53
b
40-86
b
30-211
b
40-21
b
40-54
b
40-87
b
30-212
b
40-22
b
40-55
b
40-88
b
30-213
b
40-23
b
40-56
b
40-89
b
30-214
b
40-24
b
40-57
b
40-90
b
Page
Rev
b
30-215
30-183
b
30-184
WA500-6
Mark
Mark
Mark
00-2-7 d
FOREWORD Mark
Page
Rev
40-91
Page
Rev
Page
Rev
Page
Rev
b
40-124
b
40-157
b
40-190
b
40-92
b
40-125
b
40-158
b
40-191
b
40-93
b
40-126
b
40-159
b
40-192
b
40-94
b
40-127
b
40-160
b
40-193
b
40-95
b
40-128
b
40-161
b
40-194
b
40-96
b
40-129
b
40-162
b
40-195
b
40-97
b
40-130
b
40-163
b
40-196
b
40-98
b
40-131
b
40-164
b
40-197
b
40-99
b
40-132
b
40-165
b
40-198
b
40-100
b
40-133
b
40-166
b
40-199
b
40-101
b
40-134
b
40-167
b
40-200
b
40-102
b
40-135
b
40-168
b
40-201
b
40-103
b
40-136
b
40-169
b
40-202
b
40-104
b
40-137
b
40-170
b
40-203
b
40-105
b
40-138
b
40-171
b
40-204
b
40-106
b
40-139
b
40-172
b
40-205
b
40-107
b
40-140
b
40-173
b
40-206
b
40-108
b
40-141
b
40-174
b
40-207
b
40-109
b
40-142
b
40-175
b
40-208
b
40-110
b
40-143
b
40-176
b
40-209
b
40-111
b
40-144
b
40-177
b
40-210
b
40-112
b
40-145
b
40-178
b
40-211
b
40-113
b
40-146
b
40-179
b
40-212
b
40-114
b
40-147
b
40-180
b
40-213
b
40-115
b
40-148
b
40-181
b
40-214
b
40-116
b
40-149
b
40-182
b
40-215
b
40-117
b
40-150
b
40-183
b
40-216
b
40-118
b
40-151
b
40-184
b
40-217
b
40-119
b
40-152
b
40-185
b
40-218
b
40-120
b
40-153
b
40-186
b
40-219
b
40-121
b
40-154
b
40-187
b
40-220
b
40-122
b
40-155
b
40-188
b
40-221
b
40-123
b
40-156
b
40-189
b
40-222
b
00-2-8 d
Mark
Mark
Mark
WA500-6
FOREWORD Mark
Page
Rev
40-223
Page
Rev
Page
Rev
Page
Rev
b
40-256
b
40-289
b
40-322
b
40-224
b
40-257
b
40-290
b
40-323
b
40-225
b
40-258
b
40-291
b
40-324
b
40-226
b
40-259
b
40-292
b
40-325
b
40-227
b
40-260
b
40-293
b
40-326
b
40-228
b
40-261
b
40-294
b
40-327
b
40-229
b
40-262
b
40-295
b
40-328
b
40-230
b
40-263
b
40-296
b
40-329
b
40-231
b
40-264
b
40-297
b
40-330
b
40-232
b
40-265
b
40-298
b
40-331
b
40-233
b
40-266
b
40-299
b
40-332
b
40-234
b
40-267
b
40-300
b
40-333
b
40-235
b
40-268
b
40-301
b
40-334
b
40-236
b
40-269
b
40-302
b
40-335
b
40-237
b
40-270
b
40-303
b
40-336
b
40-238
b
40-271
b
40-304
b
40-337
b
40-239
b
40-272
b
40-305
b
40-338
b
40-240
b
40-273
b
40-306
b
40-339
b
40-241
b
40-274
b
40-307
b
40-340
b
40-242
b
40-275
b
40-308
b
40-341
b
40-243
b
40-276
b
40-309
b
40-342
b
40-244
b
40-277
b
40-310
b
40-343
b
40-245
b
40-278
b
40-311
b
40-344
b
40-246
b
40-279
b
40-312
b
40-345
b
40-247
b
40-280
b
40-313
b
40-346
b
40-248
b
40-281
b
40-314
b
40-347
b
40-249
b
40-282
b
40-315
b
40-348
b
40-250
b
40-283
b
40-316
b
40-349
b
40-251
b
40-284
b
40-317
b
40-350
b
40-252
b
40-285
b
40-318
b
40-351
b
40-253
b
40-286
b
40-319
b
40-352
b
40-254
b
40-287
b
40-320
b
40-353
b
40-255
b
40-288
b
40-321
b
40-354
b
WA500-6
Mark
Mark
Mark
00-2-9 d
FOREWORD Mark
Page
Rev
40-355
Page
Rev
Page
Rev
Page
Rev
b
40-388
b
40-421
b
40-454
b
40-356
b
40-389
b
40-422
b
40-455
b
40-357
b
40-390
b
40-423
b
40-456
b
40-358
b
40-391
b
40-424
b
40-457
b
40-359
b
40-392
b
40-425
b
40-458
b
40-360
b
40-393
b
40-426
b
40-459
b
40-361
b
40-394
b
40-427
b
40-460
b
40-362
b
40-395
b
40-428
b
40-461
b
40-363
b
40-396
b
40-429
b
40-462
b
40-364
b
40-397
b
40-430
b
40-463
b
40-365
b
40-398
b
40-431
b
40-464
b
40-366
b
40-399
b
40-432
b
40-465
b
40-367
b
40-400
b
40-433
b
40-466
b
40-368
b
40-401
b
40-434
b
40-467
b
40-369
b
40-402
b
40-435
b
40-468
b
40-370
b
40-403
b
40-436
b
40-469
b
40-371
b
40-404
b
40-437
b
40-470
b
40-372
b
40-405
b
40-438
b
40-471
b
40-373
b
40-406
b
40-439
b
40-472
b
40-374
b
40-407
b
40-440
b
40-473
b
40-375
b
40-408
b
40-441
b
40-474
b
40-376
b
40-409
b
40-442
b
40-475
b
40-377
b
40-410
b
40-443
b
40-476
b
40-378
b
40-411
b
40-444
b
40-477
b
40-379
b
40-412
b
40-445
b
40-478
b
40-380
b
40-413
b
40-446
b
40-479
b
40-381
b
40-414
b
40-447
b
40-480
b
40-382
b
40-415
b
40-448
b
40-481
b
40-383
b
40-416
b
40-449
b
40-482
b
40-384
b
40-417
b
40-450
b
40-483
b
40-385
b
40-418
b
40-451
b
40-484
b
40-386
b
40-419
b
40-452
b
40-485
b
40-387
b
40-420
b
40-453
b
40-486
b
00-2-10 d
Mark
Mark
Mark
WA500-6
FOREWORD Mark
Page
Rev
40-487
Page
Rev
Page
Rev
Page
Rev
b
40-520
b
40-553
b
40-586
b
40-488
b
40-521
b
40-554
b
40-587
b
40-489
b
40-522
b
40-555
b
40-588
b
40-490
b
40-523
b
40-556
b
40-589
b
40-491
b
40-524
b
40-557
b
40-590
b
40-492
b
40-525
b
40-558
b
40-591
b
40-493
b
40-526
b
40-559
b
40-592
b
40-494
b
40-527
b
40-560
b
40-593
b
40-495
b
40-528
b
40-561
b
40-594
b
40-496
b
40-529
b
40-562
b
40-595
b
40-497
b
40-530
b
40-563
b
40-596
b
40-498
b
40-531
b
40-564
b
40-597
b
40-499
b
40-532
b
40-565
b
40-598
b
40-500
b
40-533
b
40-566
b
40-599
b
40-501
b
40-534
b
40-567
b
40-600
b
40-502
b
40-535
b
40-568
b
40-601
b
40-503
b
40-536
b
40-569
b
40-602
b
40-504
b
40-537
b
40-570
b
40-603
b
40-505
b
40-538
b
40-571
b
40-604
b
40-506
b
40-539
b
40-572
b
40-605
b
40-507
b
40-540
b
40-573
b
40-606
b
40-508
b
40-541
b
40-574
b
40-607
b
40-509
b
40-542
b
40-575
b
40-608
b
40-510
b
40-543
b
40-576
b
40-609
b
40-511
b
40-544
b
40-577
b
40-610
b
40-512
b
40-545
b
40-578
b
40-611
b
40-513
b
40-546
b
40-579
b
40-612
b
40-514
b
40-547
b
40-580
b
40-613
b
40-515
b
40-548
b
40-581
b
40-614
b
40-516
b
40-549
b
40-582
b
40-615
b
40-517
b
40-550
b
40-583
b
40-616
b
40-518
b
40-551
b
40-584
b
40-617
b
40-519
b
40-552
b
40-585
b
40-618
b
WA500-6
Mark
Mark
Mark
00-2-11 d
FOREWORD Mark
Page
Rev
40-619
Page
Rev
Page
Rev
Page
Rev
b
40-652
b
40-685
b
40-718
b
40-620
b
40-653
b
40-686
b
40-719
b
40-621
b
40-654
b
40-687
b
40-720
b
40-622
b
40-655
b
40-688
b
40-721
b
40-623
b
40-656
b
40-689
b
40-722
b
40-624
b
40-657
b
40-690
b
40-723
b
40-625
b
40-658
b
40-691
b
40-724
b
40-626
b
40-659
b
40-692
b
40-725
b
40-627
b
40-660
b
40-693
b
40-726
b
40-628
b
40-661
b
40-694
b
40-727
b
40-629
b
40-662
b
40-695
b
40-728
b
40-630
b
40-663
b
40-696
b
40-729
b
40-631
b
40-664
b
40-697
b
40-730
b
40-632
b
40-665
b
40-698
b
40-731
b
40-633
b
40-666
b
40-699
b
40-732
b
40-634
b
40-667
b
40-700
b
40-733
b
40-635
b
40-668
b
40-701
b
40-734
b
40-636
b
40-669
b
40-702
b
40-735
b
40-637
b
40-670
b
40-703
b
40-736
b
40-638
b
40-671
b
40-704
b
40-737
b
40-639
b
40-672
b
40-705
b
40-738
b
40-640
b
40-673
b
40-706
b
40-739
b
40-641
b
40-674
b
40-707
b
40-740
b
40-642
b
40-675
b
40-708
b
40-741
b
40-643
b
40-676
b
40-709
b
40-742
b
40-644
b
40-677
b
40-710
b
40-743
b
40-645
b
40-678
b
40-711
b
40-744
b
40-646
b
40-679
b
40-712
b
40-745
b
40-647
b
40-680
b
40-713
b
40-746
b
40-648
b
40-681
b
40-714
b
40-747
b
40-649
b
40-682
b
40-715
b
40-748
b
40-650
b
40-683
b
40-716
b
40-749
b
40-651
b
40-684
b
40-717
b
40-750
b
00-2-12 d
Mark
Mark
Mark
WA500-6
FOREWORD Mark
Page
Rev
Mark
Page
Rev
40-751
b
( )
40-784
40-752
b
( )
( )
40-753
b
( )
40-754
( )
Page
Rev
Page
Rev
b
50-14
b
50-47
b
40-785
b
50-15
b
50-48
b
( )
40-786
b
50-16
b
50-49
b
b
( )
40-787
b
50-17
b
50-50
b
40-755
b
( )
40-788
b
50-18
b
50-51
b
( )
40-756
b
( )
40-789
b
50-19
b
50-52
b
( )
40-757
b
( )
40-790
b
50-20
b
50-53
b
( )
40-758
b
( )
40-791
b
50-21
b
50-54
b
( )
40-759
b
( )
40-792
b
50-22
b
50-55
b
( )
40-760
b
( )
40-793
b
50-23
b
50-56
b
( )
40-761
b
( )
40-794
b
50-24
b
50-57
b
( )
40-762
b
( )
40-795
b
50-25
b
50-58
b
( )
40-763
b
( )
40-796
b
50-26
b
50-59
b
( )
40-764
b
( )
40-797
b
50-27
b
50-60
b
( )
40-765
b
( )
40-798
b
50-28
b
50-61
b
( )
40-766
b
( )
40-799
b
50-29
b
50-62
b
( )
40-767
b
( )
40-800
b
50-30
b
50-63
b
( )
40-768
b
( )
40-801
b
50-31
b
50-64
b
( )
40-769
b
( )
40-802
b
50-32
b
50-65
b
( )
40-770
b
50-33
b
50-66
b
( )
40-771
b
50-1
b
50-34
b
50-67
b
( )
40-772
b
50-2
b
50-35
b
50-68
b
( )
40-773
b
50-3
b
50-36
b
50-69
b
( )
40-774
b
50-4
b
50-37
b
50-70
b
( )
40-775
b
50-5
b
50-38
b
50-71
b
( )
40-776
b
50-6
b
50-39
b
50-72
b
( )
40-777
b
50-7
b
50-40
b
50-73
b
( )
40-778
b
50-8
b
50-41
b
50-74
b
( )
40-779
b
50-9
b
50-42
b
50-75
b
( )
40-780
b
50-10
b
50-43
b
50-76
b
( )
40-781
b
50-11
b
50-44
b
50-77
b
( )
40-782
b
50-12
b
50-45
b
50-78
b
( )
40-783
b
50-13
b
50-46
b
50-79
b
WA500-6
Mark
Mark
00-2-13 d
FOREWORD Mark
Page
Rev
50-80
Page
Rev
Page
Rev
Page
Rev
b
50-113
b
50-146
b
50-179
b
50-81
b
50-114
b
50-147
b
50-180
b
50-82
b
50-115
b
50-148
b
50-181
b
50-83
b
50-116
b
50-149
b
50-182
b
50-84
b
50-117
b
50-150
b
50-183
b
50-85
b
50-118
b
50-151
b
50-184
b
50-86
b
50-119
b
50-152
b
50-185
b
50-87
b
50-120
b
50-153
b
50-186
b
50-88
b
50-121
b
50-154
b
50-187
b
50-89
b
50-122
b
50-155
b
50-188
b
50-90
b
50-123
b
50-156
b
50-189
b
50-91
b
50-124
b
50-157
b
50-190
b
50-92
b
50-125
b
50-158
b
50-191
b
50-93
b
50-126
b
50-159
b
50-192
b
50-94
b
50-127
b
50-160
b
50-193
b
50-95
b
50-128
b
50-161
b
50-194
b
50-96
b
50-129
b
50-162
b
50-195
b
50-97
b
50-130
b
50-163
b
50-196
b
50-98
b
50-131
b
50-164
b
50-197
b
50-99
b
50-132
b
50-165
b
50-198
b
50-100
b
50-133
b
50-166
b
50-199
b
50-101
b
50-134
b
50-167
b
50-200
b
50-102
b
50-135
b
50-168
b
50-201
b
50-103
b
50-136
b
50-169
b
50-202
b
50-104
b
50-137
b
50-170
b
50-203
b
50-105
b
50-138
b
50-171
b
50-204
b
50-106
b
50-139
b
50-172
b
50-205
b
50-107
b
50-140
b
50-173
b
50-206
b
50-108
b
50-141
b
50-174
b
50-207
b
50-109
b
50-142
b
50-175
b
50-208
b
50-110
b
50-143
b
50-176
b
50-209
b
50-111
b
50-144
b
50-177
b
50-210
b
50-112
b
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WA500-6
FOREWORD
SAFETY
12
SAFETY
00
SAFETY NOTICE
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these operations require the use of tools specially designed for the specific purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety and take the necessary actions to deal with the situation. 5.
Keep all tools in good condition and learn the correct way to use them.
Mistakes in operation are extremely dangerous. Read the Operation & Maintenance Manual carefully BEFORE operating the machine.
6.
Only qualified workers must carry out work and operations which require a license or qualification.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. For the locations of the labels and detailed explanation of the precautions, see the Operation & Maintenance Manual.
7.
Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes or clothes with buttons missing.
8.
Avoid working for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
General Precautions
• •
3.
00
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
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. WARNING!
Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation.
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 warning signs on the controls in the operator’s compartment.
WA500-6
Safety Points 1
Good arrangement
2
Correct work clothes
3
Following work standard
4
Making and checking signs
5
Prohibition of operation and handling by unlicensed workers
6
Safety check before starting work
7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9
Good physical condition and preparation
10
Precautions against work which you are not used to or work with which you are too familiar
00-3
FOREWORD Preparations for Work 1.
2.
3.
4.
00
Before adding oil or making repairs, park the machine on hard, level ground, apply the parking brake, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower the work equipment (blade, ripper, bucket) to the ground. If this is not possible, insert the lock 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. When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.
Precautions During Work 1.
SAFETY
00
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 coolant and oil in the circuits are hot when the engine is stopped; be careful not to get burned. Wait for the oil and coolant 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.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Gasoline or other fuels should never be used to clean parts. Clean parts with appropriate solvents.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
10. When installing hoses and wires, be sure that they do not get damaged by contact with other parts when the machine is being operated. 11. Before starting work, stop the engine. When working on or around a rotating part, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), be extremely careful not to get rolled or caught in rotating or moving parts. 12. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Before starting the engine, open the windows and doors so that the area is well ventilated. 13. When installing high-pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous; be extremely careful when installing tubes for highpressure circuits. Also check that connecting parts are correctly installed. 14. 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. 15. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
When raising heavy components (in excess of 25 kg (55 lb)), use a hoist or crane. Check that the wire rope, chains, and hooks are not damaged. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
16. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
5.
When removing a cover which is under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Loosen these bolts gradually and alternately to release the pressure and then remove the cover.
18. When jump-starting the machine, only use a machine of similar size and voltage. Never use an arc welder or other electrical generating equipment to jump-start the machine. Carefully review the safety and procedures for jump-starting the machine.
6.
When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.
4.
00-4
17. Be careful when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly; never let anyone stand at either end of the track.
WA500-6
FOREWORD
GENERAL
GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. (00) Index and Foreward
00
(20) Standard Value Tables Section 20 explains the standard values for a new machine and judgment criteria for testing, adjusting, and troubleshooting. This Standard Value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. (30) Testing and Adjusting Section 30 explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. (40) Troubleshooting
Section 00 explains the safety information, basic information, Torque tables, conversion tables, Coating Materials table, electric wire code information.
Section 40 includes the troubleshooting charts correlating Problems to Causes.
(01) General
(50) Disassembly and Assembly
Section 01 lists the general machine dimensions, performance specifications, component weights, and fuel, coolant, and lubricant specification charts.
Section 50 explains the order to be followed when removing, installing, disassembling, or assembling each component, as well as precautions to be taken for these operations.
(10) Structure, Function, and Maintenance Standard
(60) Air Conditioner
Section 10 explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgment standards when inspecting disassembled parts.
Section 60 explains the operations and troubleshooting procedures for the air conditioning system as well as precautions to be taken for these operations. (90) Diagrams and Schematics Section 90 has the foldout drawings for the machine.
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. Some attachments and optional parts in this Shop Manual may not be available in certain areas. You can find complete technical information about the engine in a separate manual.
WA500-6
00-5 D
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL Volumes
00
00
Revised Edition Mark
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark (bcd…) is recorded on the bottom, outside corner of the pages.
Chassis volume: Issued for every machine model
Revisions
Engine volume: Issued for each engine series
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Electrical volume: One issued to cover all models
Symbols
Attachment volume: One issued to cover all models These various volumes are designed to avoid duplication of information. To deal with all repairs for any model, it is necessary that chassis, engine, electrical, and attachment manuals be available.
00
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Distribution and Updating
Item
★
1.
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
2.
00
See the page number on the bottom of the page. File the pages in correct order.
Remarks
Safety
00
Any additions, amendments, or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
Filing Method
00
Following examples show how to read the page number:
Places that require special Tightening attention for tightening torque torque during assembly.
Example: 10 - 3
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water, or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
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
00-6
WA500-6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS Hoisting
00
00
5.
★ 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.
Making Signs 1.
2.
3.
WARNING! Slinging with one rope may cause the load to turn during hoisting, the rope to untwist, or the rope to slip from its original winding position on the load, which can result in a dangerous accident.
00
Only one appointed worker must make signs. Coworkers must communicate with each other frequently.
6.
•
The sign maker must always stand in front of the load and guide the operator safely.
•
Do not stand under the load. Do not step on the load.
Precautions Precautions for Sling Work
00
00
1.
Check the slings before starting sling work.
2.
Wear gloves during sling work. Use leather gloves, if available.
3.
Measure the weight of the load visually and check its center of gravity.
4.
Use a proper sling according to the weight of the load and method of slinging. If the wire ropes you use are too thick when slinging a light load, the load may slip and fall.
WA500-6
Limit the hanging angle to 60°, as a rule. •
The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator’s seat and where he can see the working condition easily.
• •
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
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 following table shows the variation of allowable load in kN (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1,000 kg) vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN (2,000 kg) of total weight can be suspended. This weight is reduced to 9.8 kN (1,000 kg) when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as much as 39.2 kN (4,000 kg) if they sling a 19.6 kN (2,000 kg) load at a lifting angle of 150°.
7.
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
8.
Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.
00-7
FOREWORD 9.
HOISTING INSTRUCTIONS
Apply 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.
Precautions for Using Overhead Hoist Crane
00
WARNING! Heavy parts (25 kg (55 lb) or more) must be lifted with a hoist, etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol.
1.
Before starting work, inspect the wire ropes, brake, clutch, controller, rails, overwind stop device, ground fault prevention breaker, crane collision prevention device, and power application warning lamp, and check safety.
2.
Observe the signs for sling work.
3.
Operate the hoist at a safe place.
4.
Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.
5.
Do not sling a load at a slant. Do not move the crane while the slung load is swinging.
6.
Do not raise or lower a load while the crane is moving longitudinally or laterally.
7.
Do not drag a sling.
8.
When lifting a load, stop it just after it leaves the ground and check safety, and then lift it.
9.
Consider the travel route in advance and lift a load to a safe height.
10. Do not use twisted or kinked wire ropes. 11. When lifting a load, observe the following. •
•
• •
Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes by hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it again. Do not lift the load at a slanted angle.
12. When lowering a load, observe the following. • • •
When lowering a load, stop it temporarily at 30 cm (12 in) above the floor, and then lower it slowly. Check that the load is stable, and then remove the sling. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions for Using Mobile Crane
11. After operating the hoist, do not swing the control switch.
00
★ Read the Operation & Maintenance Manual provided with the crane in advance and operate the crane safely.
00-8
10. Place the control switch at a position where it is not an obstacle to work and passage.
12. Remember the position of the main switch so that you can turn off the power immediately in an emergency.
WA500-6
FOREWORD 13. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault prevention breaker, check that the devices related to that switch are not in operational state. 14. If there is an obstacle around the hoist, stop the operation. 15. After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m (6.6 ft) above the floor. Do not leave the sling installed to the hook.
HOISTING INSTRUCTIONS
Selecting Wire Ropes
00
★ Use adequate ropes depending on the weight of parts to be hoisted. Refer to the following table. Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Rope Diameter
Allowable load
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
★ The allowable load value is 1/6 of the breaking strength of the rope used. ★ Safety coefficient: 6
WA500-6
00-9
FOREWORD
AIR CONDITIONER CIRCUITS
AIR CONDITIONER CIRCUITS
00
Precautions for Handling Hoses and Tubes
00
Observe these precautions when connecting and disconnecting hoses and tubes in the air conditioner circuit. WARNING! The air conditioner of this machine uses a refrigerant (air conditioner gas: R134a) which has fewer factors to cause the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
Disconnecting Hoses and Tubes
00
★ Ask professional tradesmen to perform the collecting and filling operation of the refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. WARNING! If the refrigerant gas gets in your eyes, you may lose your sight. If the refrigerant gas contacts your skin, your skin may be frozen. Wear safety glasses, safety gloves, and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person.
Connecting Hoses and Tubes 1.
When installing the air conditioner circuit hoses and tubes, be careful that dirt, dust, water, etc. does not get into them.
2.
When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.
3.
Check that each O-ring is not damaged or deteriorated.
4.
When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings.
00
★ See example of O-ring in the graphic. O-rings are fitted to every joint of the hoses and tubes. ★ For the tightening torque, see the precautions for installation in the appropriate Disassembly and Assembly sections.
00-10
WA500-6
FOREWORD
MAINTENANCE STANDARD TERMS
MAINTENANCE STANDARD TERMS
00
The Structure, Function and Maintenance section explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard Size and Tolerance • • •
To be accurate, the finishing size of parts is a little different from one to another. To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. The temporary size set is called the standard size and the range of difference from the standard size is called the tolerance. • Tolerance with the symbols (+) or (-) is indicated on the right side of the standard size as shown in this table. Standard Size
Tolerance
120
-0.022 -0.126
★ Tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example: 120 (-0.022/-0.126) •
•
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and their relationship is shown in the graphic and this table. Standard Size 60
Tolerance Shaft
Hole
-0.030 -0.076
+0.046 +0
Standard Clearance and Standard Value • • • •
The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. When some parts are repaired, the clearance is generally adjusted to the standard clearance. A value of performance and function of new products or equivalent is called the standard value, which is indicated by a range or a target value. When some parts are repaired, the value of performance/function is set to the standard value.
Standard Interference • • •
When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the interference. The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
WA500-6
00-11
FOREWORD
MAINTENANCE STANDARD TERMS
Repair Limit and Allowable Value or Allowable Dimension • • • •
The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the repair limit. If a part is worn to the repair limit, it must be replaced or repaired. The performance and function of a product lowers while it is used. A value at which the product can be used without causing a problem is called the allowable value or allowable dimension. If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, it must be judged after considering the operating condition and customer’s requirement.
Clearance Limit • •
Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the clearance limit. If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
Interference Limit • • •
The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. The interference limit shows the repair limit of the part of smaller tolerance. If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
00-12
WA500-6
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
00
To maintain the performance of the machine over a long period and to prevent failures or other problems before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it includes sections on handling electric equipment and handling hydraulic equipment (particularly gear oil and hydraulic oil).
Handling Electric Equipment
00
Handling Wiring Harnesses and Connectors
00
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main Failures Occurring in Wiring Harness 1.
00
Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times.
2.
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. If there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
WA500-6
00-13
FOREWORD 3.
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Disconnections in wiring If the wiring is held and the connectors are pulled apart, components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, the soldering may be damaged, or the wiring may be broken.
4.
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure). If high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Be careful not to splash water over the connector. The connector is designed to prevent water from entering but, at the same time, if water does enter, it is difficult for it to be drained. If water gets into the connector, the pins will be short-circuited by the water. If any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5.
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass; there will be a defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. ★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. ★ If there is oil or water in the compressed air, the contacts will become even dirtier. Remove the oil and water from the compressed air completely before cleaning with compressed air.
Removing, Installing, and Drying Connectors and Wiring Harnesses 1.
00
Disconnecting connectors A. Hold the connectors when disconnecting. •
•
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.
★ Never pull with one hand.
00-14
WA500-6
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
B. When removing from clips •
Both the connector and clip have stoppers, which are engaged with each other when the connector is installed.
•
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing the stoppers. ★ If the connector is twisted up and down or to the left or right, the housing may break.
C. 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. ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur. Always cover the connector.
2.
Connecting connectors A. Check the connector visually. • • •
Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or 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 got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector.
WA500-6
00-15
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
B. Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position.
C. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. If the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position. ★ If the connector cannot be corrected easily, remove the clamp and adjust the position. ★ If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. D. Heavy duty wire connector (DT 8-pole, 12-pole) •
Disconnection While pressing both sides of locks (a) and (b), pull out female connector (2). • • •
•
(1): Male connector (2): Female connector (a), (b): Locks
Connection i.
Push in female connector (2) horizontally until the lock clicks. (Arrow 1)
ii.
Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. (Arrows 1, 2, 3)
★ Lock (a) is pulled down (not set completely) and lock (b) is set completely. • • •
00-16
(1): Male connector (2): Female connector (a), (b): Locks
WA500-6
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
E. 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 the following steps. i.
Disconnect the connector and wipe off the water with a dry cloth. ★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact. Remove all oil and water from the compressed air before 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 regulate the time that the hot air is used in order that the connector or related parts do not get too hot; extreme heat will deform or damage 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, blow it with contact restorer and reassemble.
WA500-6
00-17
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Handling Controller
00
The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine; be extremely careful when handling the controller. • • •
•
•
Do not place objects on top of the controller. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the controller in a place where it is exposed to rain.
Do not place the controller on oily or damp surfaces, or on soil. Do not place the controller in a hot place, even for a short time. Place it on a suitable dry stand. Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
Troubleshooting Electric Circuits
00
1.
Always turn the power OFF before disconnecting or connecting connectors.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Disconnect and connect the related connectors several times to check.
3.
Always connect any disconnected connectors before going to the next step. ★ If the power is turned ON with the connectors still disconnected, unnecessary abnormal displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably a defective contact in that circuit.
00-18
WA500-6
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Handling Hydraulic Equipment
00
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 in places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs. It is preferable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being soiled by leaking oil. Do not use rags to block openings. Do not drain oil out onto the ground; collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage; this is an even more effective method.
5.
Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil. It is preferable to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit. If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
WA500-6
00-19
FOREWORD 6.
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
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 3 µ) particles that the filter, built in the hydraulic equipment, cannot remove; it is an extremely effective device.
00-20
WA500-6
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Handling Connectors Used for Engines
00
The following engines use the connectors described in this section. • • • • • • •
95E-5 107E-1 114E-3 125E-5 140E-5 170E-5 12V140E-3
★ Your machine has a 140E-5 diesel engine.
Slide Lock Type
00
FRAMATOME-3, FRAMATOME-2 ★ 95 – 170, 12V140 engines •
Pressure sensors and NE speed sensor Engine
Sensor
125, 170, 12V140
Intake air pressure sensor in intake manifold: PIM
125, 170, 12V140
Oil pressure sensor: POIL
95, 107, 114
Oil pressure switch
95 – 170, 12V140
Ne speed sensor of flywheel housing: NE
125, 170, 12V140
Ambient pressure sensor: PAMB
Disconnect connector (1) according to the following procedure. 1.
Slide lock (L1) to the right.
2.
While pressing lock (L2), pull out connector (1) toward you.
3.
Even if lock (L2) is pressed, connector (1) cannot be pulled toward you if part A does not float. In this case, float part A with a small screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
WA500-6
00-21
FOREWORD
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Pull Lock Type
00
PACKARD-2 ★ 95 – 170, 12V140 engines •
Temperature sensors Engine
Sensor Intake air temperature sensor in intake manifold: TIM
95 – 170, 12V140
Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc.
•
Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Push Lock Type
00
★ 95, 107, 114 engines Connector BOSCH0-03
Sensor Fuel pressure sensor in common rail
Disconnect connector (3) according to the following procedure. •
While pressing lock (C), pull out connector (3) in the direction of the arrow. ★ 114 engine (see graphic)
•
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. ★ 107 engine (see graphic)
00-22
WA500-6
FOREWORD •
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
★ 107, 114 engines
•
Connector
Sensor
SUMITOMO-04
Intake air pressure/temperature sensor in intake manifold
While pressing lock (D), pull out connector (4) in the direction of the arrow.
★ 95, 125 – 170, 12V140 engines •
While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Connector
Sensor
AMP-3
Fuel pressure sensor in common rail: PFUEL, etc.
Connector
Valve
SUMITOMO-2
Injection pressure control valve of fuel supply pump: PCV
WA500-6
00-23
FOREWORD
•
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT
Connector
Sensor
SUMITOMO-3
Speed sensor of fuel supply pump: G
Pull the connector straight up.
Turn-housing Type (Round Green Connector)
00
★ 140 engine ★ Intake air pressure sensor in intake manifold (CANNON-04): PIM etc. 1.
Disconnect connector (6) according to the following procedure. A. Turn housing (H1) in the direction of the arrow. ★ When the connector is unlocked, housing (H1) becomes heavy to turn. B. Pull out housing (H1) in the direction of the arrow. ★ Housing (H1) is left on the wiring harness side.
2.
Connect the connector according to the following procedure. A. Insert the connector to the end, while setting its groove. B. Turn housing (H1) in the direction of the arrow until it clicks.
00-24
WA500-6
FOREWORD
PRECAUTIONS FOR OPERATIONS
PRECAUTIONS FOR OPERATIONS
00
★ When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given in this section.
Precautions when Carrying Out Removal Work
00
• • • •
If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit 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 unplugging the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. •
•
Face seal type hoses and tubes Nominal Number
Plug (nut end)
Sleeve Nut (elbow end)
02
07376-70210
02789-20210
03
07376-70315
02789-20315
04
07376-70422
02789-20422
05
07376-70522
02789-20522
06
07376-70628
02789-20628
10
07376-71034
07221-21034
12
07376-71234
07221-21234
Split flange type hoses and tubes Nominal Number
Flange (hose end)
Sleeve Head (tube end)
Split Flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
WA500-6
00-25
FOREWORD •
PRECAUTIONS FOR OPERATIONS
If the part is not under hydraulic pressure, the following corks can be used. Dimensions
Nominal Number
Part Number
06
D
d
L
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 • • • • • • • • • • • • •
00
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two to 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 eyebolts, check that there is no deformation or deterioration; screw them in fully; and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps, and other hydraulic equipment removed for repair, always bleed the air in the following manner: 1.
Start the engine and run at low idle.
2.
Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping the cylinder 100 mm (3.94 in) from the end of its stroke.
3.
Next, operate the hydraulic cylinder three to four times to the end of its stroke.
4.
After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, do the same procedure.
00-26
WA500-6
FOREWORD
PRECAUTIONS FOR OPERATIONS
Precautions when Completing the Operation 1.
Refilling with coolant, oil, and grease •
•
•
• 2.
•
•
Intake and exhaust system • Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for air suction and exhaust gas leakage. • If any part is loosened or damaged, retighten or repair it. Cooling system • Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for coolant leakage. • If any part is loosened or damaged, retighten or repair it. Fuel system • Check the piping for damage; the mounting bolts and nuts for looseness; and the joints for fuel leakage. • If any part is loosened or damaged, retighten or repair it.
Checking muffler and exhaust pipe for damage and looseness • •
5.
Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. ★ For the tightening torque, see ENGINE AND COOLING SYSTEM: Cylinder Head in the Disassembly and Assembly section.
Checking engine piping for damage and looseness •
4.
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. • 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. • Check the oil level again. If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts. ★ For details, see WORK EQUIPMENT: Bleeding Air from Work Equipment Circuit in the Testing and Adjusting section. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
Checking cylinder head and manifolds for looseness • •
3.
00
Visually check the muffler, exhaust pipe, and their mounting parts for cracks or damage. • If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe, and their mounting parts for looseness. • If any bolt or nut is loosened, retighten it.
Checking muffler function • Check the muffler for abnormal sound and sound different from that of a new muffler. • If any abnormal sound is heard, repair the muffler. ★ Refer to both the Troubleshooting and the Disassembly and Assembly sections.
WA500-6
00-27
FOREWORD
PUSH-PULL COUPLER
PUSH-PULL COUPLER WARNING!
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see WORK EQUIPMENT: Releasing Residual Pressure in Hydraulic Circuit in the Testing and Adjusting section.
WARNING!
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Prepare a container to receive the oil.
Type 1 Disconnection 1.
2.
00
00
00
Release the residual pressure from the hydraulic tank. ★ For details, see WORK EQUIPMENT: Releasing Residual Pressure in Hydraulic Circuit in the Testing and Adjusting section. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm (0.14 in). Do not hold the rubber cap portion (4).
3.
After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks.
4.
Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare a container to receive the oil.
Connection
00
1.
Hold the hose adapter (1) or hose (5) and insert it in the mating adapter (3), aligning them with each other. Do not hold the rubber cap portion (4).
2.
After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm (0.14 in). This does not indicate an abnormality.
00-28
WA500-6
FOREWORD
Type 2 Disconnection
PUSH-PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1 and turn the lever (4) to the right (clockwise).
3.
Hold in the condition in Steps 1 and 2 and pull out the whole body (2) to disconnect it.
Connection •
00
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect the body.
WA500-6
00-29
FOREWORD 12 Type 3
Disconnection
PUSH-PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface (a) of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1 and push until the cover (3) contacts surface (a) of the hexagonal portion at the male end.
3.
Hold in the condition in Step 1, and pull out the whole body (2) to disconnect it.
Connection 1.
00
Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface (a) of the hexagonal portion at the male end to connect the body.
00-30
WA500-6
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Adhesives
Category
Code
Part No.
LT-1A
790-129-9030
Quantity 150 g
Container Tube
• Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
• Used in places requiring an immediately effective, strong adhesive. • Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal, and non-metal.
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat, chemicals • Used for anti-loosening and sealant purposes for bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
• Used as adhesive or sealant for metal, glass, or plastic.
LT-4
790-129-9040
250 g
Polyethylene container
• Used as sealant for machined holes.
Holtz 790-126-9120 MH 705
75 g
Tube
• Used as heat-resisting sealant for repairing engine.
2g
Polyethylene container
• Quick hardening-type adhesive. • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of rubbers, plastics, and woods.
Three bond 1735
179-129-9140
metals,
Aronalpha 201
790-129-9130
50 g
Polyethylene container
• Quick hardening-type adhesive. • Quick cure-type (maximum strength after 30 minutes). • Used mainly for adhesion of rubbers, plastics, and metals.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
• Features: Resistance to heat, chemicals • Used at joint portions subject to high temperature.
LG-1
790-129-9010
200 g
Tube
• Used as adhesive or sealant for gaskets and packing of power train case, etc.
Can
• Features: Resistance to heat • Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. • Used as sealant for heat-resistant gasket for high-temperature locations such as engine precombustion chamber, exhaust pipe.
Gasket sealant LG-3
WA500-6
Main Applications, Features
790-129-9070
1 kg
00-31
FOREWORD Category
Code
LG-4
LG-5
COATING MATERIALS Part No.
790-129-9020
790-129-9080
Quantity
Container
200 g
Tube
• Features: Resistance to water, oil • Used as sealant for flange surface, thread. • Also possible to use as sealant for flanges with large clearance. • Used as sealant for mating surfaces of final drive case, transmission case.
1 kg
Polyethylene container
• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Tube
• Features: Silicon-based, resistant to heat, cold. • Used as sealant for flange surface, thread. • Used as sealant for oil pan, final drive case, etc.
Gasket sealant 250 g
LG-7
09920-00150
150 g
Tube
• Features: Silicon-based, quick hardening type. • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Three bond 1211
790-129-9090
100 g
Tube
• Used as heat-resisting sealant for repairing engines.
LM-G
09940-00051
60 g
Can
• Used as lubricant for sliding parts (to prevent squeaking).
LM-P
09940-00040
200 g
Tube
• Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
• General purpose type
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2-160CNCA
Various
Various
• Used for normal temperature, light load bearing at places in contact with water or steam.
SYG2-400M
Grease
00-32
09940-00011
Molybdenum disulphide lubricant
Molybdenum disulphide lubricant
LG-6
Main Applications, Features
400 g Belows type (10 per case)
• Used for places with heavy load.
WA500-6
FOREWORD
STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE
00
Standard Tightening Torques of Bolts and Nuts
00
★ Tighten metric nuts and bolts to the torque in this table, unless otherwise specified. ★ The following table corresponds to the bolts in Figure A. Thread Diameter of Bolt
Width across Flat
mm
mm
N•m
lbf ft
6
10
11.8 – 14.7
8.7 – 10.8
8
13
27 – 34
19.9 – 25.1
10
17
59 – 74
43.5 – 54.6
12
19
98 – 123
72.3 – 90.7
14
22
157 – 196
115.8 – 144.6
16
24
245 – 309
180.7 – 227.9
18
27
343 – 427
253.0 – 314.9
20
30
490 – 608
361.4 – 448.4
22
32
662 – 829
488.3 – 611.4
24
36
824 – 1,030
607.8 – 759.7
27
41
1,180 – 1,470
870.3 – 1,084.2
30
46
1,520 – 1,910
1,121.1 – 1,408.7
33
50
1,960 – 2,450
1,445.6 – 1,807.0
36
55
2,450 – 3,040
1,807.0 – 2,242.2
39
60
2,890 – 3,630
2,131.6 – 2,677.4
Figure A
• •
Tightening Torque
Figure B
The widths across flats against the thread diameters of flanged bolts (marked with *) in Figure A are the ones indicated in the table for bolts shown in Figure B. Values of tightening torques shown in the table for Figure A are applied.
WA500-6
00-33
FOREWORD
STANDARD TIGHTENING TORQUE
The following table corresponds to the bolts in Figure B. Thread Diameter of Bolt
Width across Flat
Tightening Torque
mm
mm
N•m
lbf ft
lbf in
6
10
5.9 – 9.8
–
52.22 – 86.74
8
12
13.7 – 23.5
10.1 – 17.3
–
10
14
34.3 – 46.1
25.3 – 34.0
–
12
27
74.5 – 90.2
54.9 – 66.5
–
Tightening Torques for Split Flange Bolts
00
★ Tighten split flange bolts to the torque in this table, unless otherwise specified. Thread Diameter
Width across Flat
Tightening Torque
mm
mm
N•m
lbf ft
10
14
59 – 74
43.5 – 54.6
12
17
98 – 123
72.3 – 90.7
16
22
235 – 285
173.3 – 210.2
Tightening Torques for O-Ring Boss Piping Joints
00
★ Tighten the O-ring boss piping joints to the torques in this table, unless otherwise specified. Thread Diameter
Width across Flat
mm
mm
Norminal No.
00-34
Tightening Torque N•m (lbf ft) Range
Target
02
14
35 – 63 (25.8 – 46.5)
44 (32.5)
03, 04
20
84 – 132 (62.0 – 97.4)
103 (76.0)
05, 06
24
128 – 186 (94.4 – 137.2)
157 (115.8)
10, 12
33
363 – 480 (267.7 – 354.0)
422 (311.3)
14
42
746 – 1,010 (550.2 – 744.9)
883 (651.3)
Varies depending on type of connector.
WA500-6
FOREWORD
STANDARD TIGHTENING TORQUE
Tightening Torques for O-Ring Boss Plugs
00
★ Tighten the O-ring boss plugs to the torques in this table, unless otherwise specified. Thread Diameter
Width across Flat
Tightening Torque - N•m (lbf ft)
mm
mm
Range
Target
08
08
14
5.88 – 8.82 (4.3 – 6.5)
7.35 (5.4)
10
10
17
9.8 – 12.74 (7.2 – 9.4)
11.27 (8.3)
12
12
19
14.7 – 19.6 (10.8 – 14.5)
17.64 (3.0)
14
14
22
19.6 – 24.5 (14.5 – 18.1)
22.54 (16.6)
16
16
24
24.5 – 34.3 (18.1 – 25.3)
29.4 (21.7)
18
18
27
34.3 – 44.1 (25.3 – 32.5)
39.2 (28.9)
20
20
30
44.1 – 53.9 (32.5 – 39.8)
49.0 (36.1)
24
24
32
58.8 – 78.4 (43.4 – 57.8)
68.6 (50.6)
30
30
32
93.1 – 122.5 (68.7 – 90.4)
107.8 (79.5)
33
33
–
107.8 – 147.0 (79.5 – 108.4)
124.4 (91.8)
36
36
36
127.4 – 176.4 (94.0 – 130.1)
151.9 (112.0)
42
42
–
181.3 – 240.1 (133.7 – 177.1)
210.7 (155.4)
52
52
–
274.4 – 367.5 (202.4 – 271.1)
323.4 (238.5)
Norminal No.
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type)
00
★ Tighten the hoses (taper seal type and face seal type) to the torques in this table, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening Torque - N•m {lbf ft}) Nominal Size of Hose
Width across Flats
02
19
Range
Target
34 – 54 (25.0 – 39.8)
Taper Seal Type
Face Seal Type
Nominal Thread Thread size Root Diameter (mm) Size (mm) (Reference) Threads per inch, Thread series –
9/16 – 18UN
14.3
14
–
–
44 (32.4) 34 – 63 (25.0 – 46.4)
22
54 – 93 (39.8 – 68.5)
74 (54.5)
–
11/16 –16UN
17.5
24
59 – 98 (43.5 – 72.2)
78 (57.5)
18
–
–
04
27
84 – 132 (61.9 – 97.3)
103 (75.9)
22
13/16 – 16UN
20.6
05
32
128 – 186 (94.4 – 137.1) 157 (115.7)
24
1 - 14UNS
25.4
06
36
177 – 245 (130.5 – 180.7) 216 (159.3)
30
1 3/16 – 12UN
30.2
(10)
41
177 – 245 (130.5 – 180.7) 216 (159.3)
33
-
–
(12)
46
197 – 294 (145.3 – 216.8) 245 (180.7)
36
–
–
(14)
55
246 – 343 (181.4 – 252.9) 294 (216.8)
42
–
–
03
★ The face seal joints with the dimension in ( ) are also used, depending on the specification.
WA500-6
00-35
FOREWORD
STANDARD TIGHTENING TORQUE
Tightening Toques for Face Seal Joints
00
★ Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines, etc. to the torques shown in the following table. ★ Apply the following torques to the face seal joint while their threaded parts are coated with engine oil (wetted). Tightening Torque N•m (lbf ft)
Outer Width Diameter of across Flats Pipe (mm) (mm)
Face Seal
Range
Target
Nominal No. – Number of Threads, Type of Thread
Thread Diameter (mm) (Reference)
8
19
14 – 16 (10.3 – 11.8)
15 (11.1)
9/16 –18UN
14.3
10
22
24 – 27 (17.7 – 19.9)
25.5 (18.8)
11/16 –16UN
17.5
12
24 (27)
43 – 47 (31.7 – 34.7)
45 (33.2)
13/16 –16UN
20.6
15 (16)
30 (32)
60 – 68 (44.3 – 50.2)
64 (47.2)
1 –14UN
25.4
22 (20)
36
90 – 95 (66.4 – 70.1)
92.5 (68.2)
1-3/16 – 12UN
30.2
★ The face seal joints with the dimension in ( ) are also used, depending on the specification.
For 102, 107, and 114 Engine Series (Bolts and Nuts)
00
Tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque in this table, unless there are special instructions. Tightening Torque Thread Size Bolts and Nuts mm
N•m
kgm
lbf ft
lbf in
6
10 ±2
1.02 ±0.20
–
88.51 ±17.70
8
24 ±4
2.45 ±0.41
17.70 ±2.95
–
10
43 ±6
4.38 ±0.61
31.72 ±4.43
–
12
77 ±12
7.85 ±1.22
56.79 ±8.85
–
14
–
–
–
–
For 102, 107, and 114 Engine Series (Eye Joints)
00
Tighten the metric eye joints of the 102, 107, and 114 engine series to the torque in this table, unless there are special instructions. Thread Size
00-36
Tightening Torque
mm
N•m
kgm
lbf ft
lbf in
6
8 ±2
0.81 ±0.20
–
70.81 ±17.70
8
10 ±2
1.02 ±0.20
–
88.51 ±17.70
10
12 ±2
1.22 ±0.20
–
106.21 ±17.70
12
24 ±4
2.45 ±0.41
212.42 ±35.40
–
14
36 ±5
3.67 ±0.51
26.55 ±3.69
–
WA500-6
FOREWORD
STANDARD TIGHTENING TORQUE
For 102, 107, and 114 Engine Series (Taper Screws)
00
★ Tighten the taper screws (unit: inch) of the 102, 107, and 114 engine series to the torque in this table, unless there are special instructions. Tightening Torque Material
In Cast Iron or Steel
In Aluminum
Thread Size (inch)
N•m
kgm
lbf ft
N•m
kgm
lbf ft
1/16
15 ±2
1.53 ±0.20
11.06 ±1.48
5 ±1
0.51 ±0.10
3.69 ±0.74
1/8
20 ±2
2.04 ±0.20
14.75 ±1.48
15 ±2
1.53 ±0.20
11.06 ±1.48
1/4
25 ±3
2.55 ±0.31
18.44 ±2.21
20 ±2
2.04 ±0.20
14.75 ±1.48
3/8
35 ±4
3.57 ±0.41
25.81 ±2.95
25 ±3
2.55 ±0.31
18.44 ±2.21
1/2
55 ±6
5.61 ±0.61
40.57 ±4.43
35 ±4
3.57 ±0.41
25.81 ±2.95
3/4
75 ±8
7.65 ±0.82
55.32 ±5.90
45 ±5
4.59 ±0.51
33.19 ±3.69
WA500-6
00-37
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
How to Read Electric Wire Code ★ The information about the wires unique to each machine model is described in the Troubleshooting section. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example:
AEX
0.85
L ---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code.
Indicates size of wire by nominal No.
Indicates type of wire by symbol. . (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
00-38
WA500-6
FOREWORD
CONVERSION TABLES
CONVERSION TABLES
00
Method of Using the Conversion Table
00
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 b; then draw a horizontal line from b. B. Locate the number 5 in the row across the top; take this as c; then draw a perpendicular line down from c. C. Take the point where the two lines cross as d. This point d 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; 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; 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. c
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
d b
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
WA500-6
00-39
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
00-40
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
WA500-6
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
WA500-6
00-41
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
00-42
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
1439.4
1432.1
WA500-6
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
WA500-6
00-43
FOREWORD
CONVERSION TABLES
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 you want to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If you want 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 -40.4 -37.2 -34.4 -31.7 -28.9
-40 -35 -30 -25 -20
°F -40.0 -31.0 -22.0 -13.0 -4.0
°C -11.7 -11.1 -10.6 -10.0 -9.4
11 12 13 14 15
°F 51.8 53.6 55.4 57.2 59.0
-28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
-22.8 -22.2 -21.7 -21.1 -20.6
7.8 8.3 8.9 9.4 10.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
00-44
°C 46 47 48 49 50
°F 114.8 116.6 118.4 120.2 122.0
°C 27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
°F 117.8 179.6 181.4 183.2 185.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
WA500-6
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Specification Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
WA500-6
01-1 b
GENERAL
SPECIFICATIONS
SPECIFICATIONS Dimension Drawing
01-2 b
WA500-6
GENERAL
SPECIFICATIONS
Weight
Specification Tables Machine Model Name
WA500-6
Serial Number
A93001 and up
Operating weight
kg (lb)
32,230 (71,054.9)
Front wheel load
kg (lb)
15,090 (33,267.7)
Rear wheel load
kg (lb)
17,140 (37,787.2)
Bucket capacity (Heaped) with Bolt-on cutting edge (BOC)
m3 (yd3)
5.6 (7.3)
Rated load
kg (lb)
9,250 (20,392.7)
km/h (mph)
7.7 (4.8)
Dimension
Performance
Travel speed F1 Travel speed F2
km/h (mph)
12.5 (7.8)
Travel speed F3
km/h (mph)
22.3 (13.9)
Travel speed F4
km/h (mph)
34.9 (21.7)
Travel speed R1
km/h (mph)
8.6 (5.3)
Travel speed R2
km/h (mph)
13.0 (8.1)
Travel speed R3
km/h (mph)
24.8 (15.4)
Travel speed R4
km/h (mph)
37.5 (23.3)
Maximum drawbar pull (Forward)
kN (lbf)
288.3 (64,812.4)
Maximum drawbar pull (Reverse)
kN (lbf)
256.4 (57,641.0)
Gradeability
deg.
25
Minimum turning radius (Center of outside tire)
mm (in)
6,430 (253.1)
Turning radius (BOC tip) (with BOC)
mm (in)
7,650 (301.2)
Overall length (with BOC)
mm (in)
9,815 (386.4)
Overall width
mm (in)
3,190 (125.6)
Bucket width (with BOC)
mm (in)
3,400 (133.9)
Overall height (ROPS at cab top)
mm (in)
3,785 (149.0)
Overall height with bucket lifted up
mm (in)
6,430 (253.1)
Wheelbase
mm (in)
3,780 (148.8)
Tread
mm (in)
2,400 (94.5)
Minimum ground clearance
mm (in)
450 (17.7)
Maximum hinge pin height of bucket
mm (in)
4,755 (187.2)
Dumping clearance (with BOC)
mm (in)
3,295 (129.7)
Dumping reach (with BOC)
mm (in)
1,500 (59.1)
Bucket tilt-forward angle
deg.
46
Bucket tilt-back angle (Operating posture)
deg.
50
mm (in)
435 (17.1)
Digging depth (Approx. 10°)
★ BOC: Abbreviation for Bolt-On Cutting edge
WA500-6
01-3 b
GENERAL
SPECIFICATIONS
Machine Model Name
WA500-6
Serial Number
A93001 and up
Model name
SAA6D140E-5 4-cycle, water-cooled, direct injection type with turbocharger, air-cooled aftercooler, and water-cooled EGR
Type Number of cylinders – Bore x Stroke
l (gal)
15.2 (4.0)
kW (HP) /rpm
263 (353) /1,900
Max. torque
N•m (lbf ft /rpm
178.9 (131.9) /1,250
Rated fuel consumption
g/kWh (g/HPh)
216.2 {161}
Max. speed at no load
rpm
2,150
Min. speed at no load
rpm
675
Performance
Starting motor
24 V, 11 kW
Alternator
24 V, 75 A
Battery
12 V, 170 Ah x 2
Axle
Power Train
Torque converter
3-element, 1-stage, 2-phase
Transmission
Planetary type, multi-disc type, forward-reverse 4-stage
Reduction gear unit
Spiral bevel gear type, splash lubrication type
Differential
Straight bevel gear type
Final drive
Planetary gear single-reduction type, splash lubrication type
Drive wheel
Front and rear wheel drive
Front axle
Fixed frame, full-float type
Rear axle
Center pin support type, full-float type
Size
29.5-25-33-22PR(L3)
Tires
Rim size
• Rear wheel
Brake
25.00 x 25WTB
Inflation pressure: • Front wheel
Foot brake
kPa (psi)
440 (63.8) 392 (56.9) Independent front and rear wheel brakes, enclosed wet multi-disc type Full hydraulic type
Hand brake Steering System
6 – 140 x 165 (0.23 – 5.51 x 6.50)
Flywheel horsepower
Total piston displacement Engine
mm (in)
Drive shaft braking system of wet disc type Hydraulically released spring-driven type
Steering system Type Structure
01-4 b
Articulated steering Fully-hydraulic power steering
WA500-6
Hydraulic Pump Delivery Control Valve Cylinder
Hydraulic System
GENERAL
SPECIFICATIONS
Machine Model Name
WA500-6
Serial Number
A93001 and up
Work equipment hydraulic pump
l (gal) /min
321 (84.8) /min Variable displacement piston pump HPV190
Steering pump
l (gal) /min
120 (31.7) /min Variable displacement piston pump LPV90
Cooling fan pump
l (gal) /min
70 (18.5) /min Variable displacement piston pump LPV45
Power train pump
l (gal) /min
189 (49.9) / min Gear pump SAR (3) 112
Hydraulic cooling pump
l (gal) /min
94 (24.8) /min Gear pump SAL (3) 80
EPC and brake pump
l (gal) /min
54 (14.3) /min Gear pump SAR (1) 28)
Set pressure for work equipment
MPa (psi)
34.3 (4,974.8) 3-spool type with HI valve
Set pressure for steering system
MPa (psi)
24.5 (3,553.4) Spool type
Number of lift cylinders Bore x Stroke
mm (in)
Double-acting piston type 2 160 x 898 (6.3 x 35.4)
Number of bucket cylinders Bore x Stroke
mm (in)
Double-acting piston type 1 185 x 675 (7.3 x 26.6)
Number of steering cylinders Bore x Stroke
mm (in)
Double-acting piston type 2 100 x 486 (3.9 x 19.1)
Motor Work Equipment
Fan motor
Fixed displacement piston type: LMF40
Work equipment Type of link Shape of bucket cutting edge
WA500-6
Single link Straight bolt-on cutting edge
01-5 b
GENERAL
WEIGHT TABLE
WEIGHT TABLE WARNING!
This weight table is prepared for your reference when handling or transporting the components.
Unit: kg (lbs) Machine Model Name
WA500-6
Serial Number
A93001 and up
Engine (dry weight)
1,700 (3,748)
Muffler assembly
50 (110)
Radiator (including air conditioner condenser) (dry weight)
326 (719)
Torque converter (including drive gear) (dry weight)
558 (1,230)
Transmission (dry weight)
1,106 (2,438)
Center drive shaft
45 (99)
Front drive shaft
45 (99)
Rear drive shaft
40 (88)
Center support
42 (93)
Front axle
2,250 (4,960)
Rear axle
2,084 (4,594)
Front differential
368 (811)
Rear differential
390 (860)
Planetary carrier assembly (1 piece)
69 (152)
Wheel hub (1 piece)
114 (251)
Axle pivot (front)
104 (229)
Axle pivot (rear)
126 (278)
Wheel (1 piece)
267 (589)
Tire (standard: 29.5-25-22PR L3) (1 piece)
532 (1,173)
Steering demand valve
24 (53)
Steering cylinder (1 piece)
53 (117)
Hydraulic tank (dry weight)
412 (908)
Work equipment hydraulic pump
106 (234)
Power train, EPC pump
22 (49)
Steering pump
39 (86)
Hydraulic cooling pump
13 (29)
Cooling fan pump
25 (55)
Torque converter oil cooler
70 (154)
Fan motor
13.4 (30)
Fan
29.1 (64)
Work equipment valve
110 (243)
Lift cylinder (1 piece)
282 (622)
Bucket cylinder
289 (637)
Engine hood
265 (584)
Radiator guard
355 (783)
Front frame
2,565 (5,655)
Rear frame
2,650 (5,842)
01-6 b
WA500-6
GENERAL
WEIGHT TABLE Unit: kg (lbs) Machine Model Name
WA500-6
Serial Number
A93001 and up
Bucket link (including bushing)
157 (346)
Bellcrank (including bushing)
754 (1,662)
Lift arm (including bushing)
2,105 (4,641)
Bucket (5.2 m3 with teeth and segment edge)
2,960 (6,526)
Bucket (5.6 m3 with bolt-on cutting edge)
3,005 (6,625)
Counterweight
2,480 (5,468)
Fuel tank
220 (485)
Battery (1 piece)
56 (124)
Cab (including console box and dashboard)
987 (2,176)
Air conditioner unit
33 (73)
Operator seat
36 (80)
WA500-6
01-7 b
GENERAL
FUEL, COOLANT, AND LUBRICANTS
FUEL, COOLANT, AND LUBRICANTS AMBIENT TEMPERATURE RESERVOIR
FLUID TYPE
-22 -30
-4 -20
14 -10
32 0
50 10
68 20
86 30
104°F 40°C
122°F 50°C
Komatsu EOS0W30
Engine oil (Note 1)
Komatsu EOS5W40
Engine oil pan
Komatsu EO10W30-DH Engine oil
Komatsu EO15W40-DH Komatsu EO30-DH
Transmission case
Power train oil (Note 2)
TO10
Power train oil
TO10
Hydraulic oil
HO46-HM
Hydraulic system Komatsu E010W30-DH Engine oil Komatsu EO15W40-DH Axle oil (Note 3)
AX080
Axle Power train oil (Note 4)
Pin / Bushing Grease fitting
TO50
Hypergrease (Note 5)
G2-T, G2-TE
Lithium EP grease
G2-L1
Cooling system
Supercoolant (Note 6)
Fuel tank
Diesel fuel
AF-NAC ASTM Grade #1-DS15 / DS500 ASTM Grade # 2-DS15 / DS500
★ ASTM: American Society of Testing and Material Reservoirs
Capacity
Engine Oil Pan
Transmission Case
Hydraulic System
Front Axle
Rear Axle
Fuel Tank
Cooling System
Liters
45
95
460
95
95
473
120
US gal
11.9
25.1
121.5
25.0
25.0
125.0
31.7
Liters
45 (37)
76
337
95
95
–
–
US gal
11.9 (9.8)
20.1
89.0
25.0
25.0
–
–
Specified
Refill
★ Value in brackets ( ) applies to the oil level of engine oil pan alone.
01-8 b
WA500-6
GENERAL
FUEL, COOLANT, AND LUBRICANTS
Remark Use diesel fuel only. This engine uses an electronically controlled, high-pressure fuel injection system to obtain good fuel economy and low emissions. For this reason, it requires high-precision parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, the durability may drop markedly. Note
Explanation
1
HTHS (High-Temperature High-Shear Viscosity 150°C [302°F]), specified by ASTM D4741 must be equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
2
Power train oil has different properties from engine oil. Be sure to use the recommended oil.
3
Axle oil AX080 prevents squealing from the brakes and LSD (Limited Slip Differential). If only AX080 is recommended, use Komatsu genuine AX080 or equivalent.
4
When the ambient temperature is higher than 45° C (113° F) and the machine operation hour is longer than 12 hours/day, use TO50 instead of AX080. Squealing of the brakes may occur with the use of TO50 but there is no problem with the brake performance or durability.
★ For machines with the LSD (Limited Slip Differential), use AX080 regardless of the ambient temperature. Do not use TO50. Hypergrease (G2-T, G2-TE) is a high-performance grease. 5
In the following cases, we recommend use of G2-T or G2-TE. • Every 10 hours greasing for the first 50 hours on a new machine while it is being broken in • When it is needed to improve the lubrication of the grease to prevent squealing of the pin or bushing If the machine is equipped with an automatic greasing system, see details about the system. Supercoolant (AF-NAC) • The coolant has the important function of preventing corrosion as well as preventing overheating and freezing. • Even in areas where freezing is not an issue, the use of antifreeze coolant is essential. • Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze, and cooling properties and can be used continuously for two years or 4,000 hours. • Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
6
• For details about the ratio when diluting supercoolant with water, see Clean Inside of Cooling System in the Operations and Maintenance manual. • When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F) (never dilute with water). • To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%. • On machines equipped with an aluminum alloy radiator, not using Komatsu genuine Supercoolant may cause the corrosion of the tubes in the radiator core resulting in leakage. Only Komatsu genuine Supercoolant provides both high freezing protection and high corrosion protection for aluminium alloy systems as well as cylinder liner cavitation protection.
WA500-6
01-9 b
GENERAL
FUEL, COOLANT, AND LUBRICANTS
MEMORANDUM
01-10 b
WA500-6
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Engine and Transmission Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Cooling Fan Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Cooling Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 Reversible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Drive Line Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Power Train System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Without Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 With Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Power Train Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42 Torque Converter without Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Power Transmission Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 Torque Converter with Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 Power Transmission Route: Lockup Clutch Disengaged . . . . . . . . . . . . . . . . . . . . . 10-59 Power Transmission Route: Lockup Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61 Torque Converter Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 Transmission with Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 Disc Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78 Power Transmission Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 Transmission Control Valve (without Lockup Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92 Transmission Control Value (with Lockup Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 ECMV (Electronic Control Modulation Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100 Pressure Control Valve and Fill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101 Operation of ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 For Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 Main Relief Valve and Torque Converter Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . 10-108 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 Lubrication Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 WA500-6
10-1 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
Torque Converter Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114 Torque Converter Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116 Center Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126 Front Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . 10-127 Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128 Rear Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129 Limited Slip Differential (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145 Steering Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146 Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148 Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155 Safety Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159 Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164 Joystick Steering Lever Linkage (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166 Emergency Steering (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169 Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169 Diverter Valve (for emergency steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176 Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176 Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178 Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184 Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187 PPC Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191 Accumulator (for Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194 Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200 Parking Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202 Emergency Parking Brake Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204 UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206 Axle Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206 Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214 Hydraulic Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214 Work Equipment Control Lever Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217 Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220 Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-222 Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-227 10-2 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
LS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230 CO Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230 Work Equipment Hydraulic Pump HPV190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232 LS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-239 PC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-245 PC-EPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-252 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-256 CLSS (Closed Center Load-Sensing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-270 Function and Operation of Each Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-276 Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-276 LS Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-282 LS Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-284 ECSS Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-286 Accumulator Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-288 Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-290 Accumulator (for PPC Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-295 Work Equipment Electric Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-296 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-302 Work Equipment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-302 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-306 Bucket 5.6 M3 (with Bolt-On Cutting Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-306 Bucket 5.2 M3 (with Teeth and Segment Edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-307 Bucket Positioner and Boom Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-308 Work Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-309 CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-311 ROPS Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-311 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-313 Air Conditioner Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-313 Cooling Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-314 Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-315 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-316 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-318 Air Conditioner Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-319 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-322 Machine Monitor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-322 Machine Monitor Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-324 Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330 Machine Monitor Operation Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332 Items Displayed on Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-333 Character Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-343 Operator Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-344 Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-347 Service Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-348 Electrical System Failure History Display Function . . . . . . . . . . . . . . . . . . . . . . . . 10-352 Mechanical System Failure History Display Function . . . . . . . . . . . . . . . . . . . . . . 10-354 Real-Time Monitor Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-355 Engine Reduced-Cylinder (Cylinder Cut-out) Function . . . . . . . . . . . . . . . . . . . . . 10-361 No Injection Cranking Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362 Adjustment Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-363 WA500-6
10-3 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
Maintenance Monitoring Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-365 Operating Information Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-369 Optional Device Selecting Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371 Machine Serial Number Input Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371 Model Selection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371 Load Meter Function (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-372 Rear Side of Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-379 Connector Signal Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-381 Work Equipment Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-389 Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-389 Work Equipment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-391 Remote Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-399 Lift Arm Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-401 Semi-Automatic Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-406 Pump Swash Plate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-409 Joystick Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-412 Real-Time Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-414 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-419 Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-420 Transmission Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-423 Electrical Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-423 Transmission Controller Gearshifting Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-425 Auto-Shift Points Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-429 Transmission Controller Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-430 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-433 Transmission Cutoff Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-436 ECSS Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-438 Economy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-440 Cooling Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-441 Right FNR Switch Control (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-445 Joystick Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-447 Real-Time Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-450 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-458 Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-459 ELECTRONIC TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-462 Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-464 Engine Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-466 Engine Stopping Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-468 Preheating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-469 Parking Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-471 Backup and Stop Lamp circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-476 Small Lamp and Head Lamp Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-478 Working Lamp Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-479 Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-480 Wiper and Window Washer Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-481 Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-484 Input Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-484 Output Shaft Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-484 Left Brake Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-485 10-4 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
Transmission Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-486 Torque Converter Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-486 Hydraulic Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-486 Axle Oil Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-486 Kickdown Hold Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-487 Joystick Knob (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-488 Right FNR Switch (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-489 Lift Arm Angle Sensor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-490 Loader Pump Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491 Lift Arm Cylinder Bottom Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-491 Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped) . . . . . . . . . . 10-491 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-493 Parking Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-494 Stop Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-494 Air Cleaner Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-495 Transmission Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-496 Steering Oil Pressure Sensor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-497 Radiator Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-498 Brake Accumulator Pressure Switch (front and rear) . . . . . . . . . . . . . . . . . . . . . . . 10-499 Battery Electrolyte Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-500 Accelerator Pedal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-501 Emergency Brake Pressure Switch (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-502 Emergency Brake Pressure Switch (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-502 KOMTRAX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-504 KOMTRAX Terminal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-504 KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-505 Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-506
WA500-6
10-5 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
MEMORANDUM
10-6 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
ENGINE AND COOLING SYSTEM Cooling System
1.
Radiator
A.
Aftercooler outlet
2.
Aftercooler
B.
Coolant inlet
3.
Hydraulic oil cooler
C.
Coolant inlet
4.
Coolant subtank
D.
Aftercooler inlet
5.
Coolant level sensor
E.
Hydraulic oil cooler outlet
6.
Torque converter oil cooler
F.
Hydraulic cooler inlet
7.
Air conditioner
G.
Coolant outlet
8.
Cooling fan
9.
Cooling fan motor
10. Fan guard
WA500-6
10-7 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-8 b
ENGINE AND COOLING SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Specifications Radiator
Hydraulic Oil Cooler (1)
Hydraulic Oil Cooler (2)
Aftercooler
Torque Converter Oil Cooler
Core type
Aluminum tube in 4-column
PTO-OL
PTO-OL
Straight fin 10-hole tube type
PTO-LS
Fin pitch mm (in)
4.0/2P (0.16/2P)
100 x 385 x 17 (3.9 x 15.2 x 0.7)
100 x 558 x 17 (3.9 x 22.0 x 0.7)
6.0/2P (0.24/2P)
150 x 620 x 20-stage (5.9 x 24.4 x 20-stage)
Total heat dissipation surface m2 (ft2)
59.90 (644.76)
1.2187 (13.118)
1.829 (19.687)
21.57 (232.18)
3.254 (35.026)
Cross-sectional area of flow cm2 (in2)
50.845 (7.881)
—
—
—
—
Pressure valve cracking pressure kg/cm² (psi)
0.714 ±0.153 (10 ±2)
—
—
—
—
Vacuum valve cracking pressure kg/cm² (psi)
0 – 0.051 (0 – 1)
—
—
—
—
WA500-6
10-9 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Engine and Transmission Mount
10-10 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Unit: mm (in) No
Check Item
1
Shim thickness of mount
2
Clearance between stopper and support
3
Shim thickness of mount
4
Clearance between stopper bolt and bracket
Criteria
Remedy
Shim thickness: 0.5 mm (0.020 in), 1.0 mm (0.039 in) (Shim thickness and number of shims used to be the same as that employed on the actual machine.) A clearance of 1.5 mm (0.059 in) minimum to be provided between the stopper and support. Shim thickness: 0.5 mm (0.020 in), 1.0 mm (0.039 in) (Shim thickness and number of shims used to be the same as that employed on the actual machine.)
Adjust
A clearance of 1 to 1.5 mm (0.039 to 0.059 in) minimum to be provided between the stopper and bracket.
Torque Values Designation
N•m
lbf ft
D
235 – 285
173 – 210
E
662 – 829
488 – 611
WA500-6
10-11 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Joint
Unit: mm (in) No
Check Item
1
Ring gear
2
Backlash of ring gear and torque converter case gear
Criteria
Remedy
–
–
0.059 – 0.240 (0.002 – 0.009)
Replace
Torque Values Designation
N•m
lbf ft
A
98 – 123
72 – 91
Outline •
The ring gear is installed to the flywheel of the engine.
•
The internal teeth of the ring gear are meshed with the external teeth of the torque converter lockup clutch housing to transmit the power from the engine to the torque converter.
10-12 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MEMORANDUM
WA500-6
10-13 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Cooling Fan Pump Type: LPV45
10-14 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
P1:
ENGINE AND COOLING SYSTEM
Pump discharge port
PAEPC: EPC output pressure pickup plug PEPC:
EPC valve basic pressure input port
PS:
Pump suction port
TO:
Drain port
1.
Servo valve
2.
Air bleeder
Torque Values Designation
N•m
lbf ft
lbf in
AA
11.8 – 14.7
–
104 – 130
BB
107.8 – 142.2
80 – 105
–
CC
98 – 123
72 – 91
–
DD
7.8 – 9.8
–
69 – 87
EE
27.4 – 34.3
20 – 25
–
FF
68.6 – 83.4
51 – 62
–
WA500-6
10-15 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-16 b
ENGINE AND COOLING SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Shaft
2.
Oil seal
3.
Case
4.
Rocker cam
5.
Shoe
6.
Piston
7.
Cylinder block
8.
Valve plate
9.
Spring
ENGINE AND COOLING SYSTEM
10. Servo piston
Torque Values Designation
N•m
lbf ft
DD
34.3 – 44.1
25 – 33
EE
59 – 74
44 – 55
FF
19.6 – 24.5
15 – 18
WA500-6
10-17 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-18 b
ENGINE AND COOLING SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Function •
The pump converts the rotation and torque transmitted to its shaft to oil pressure and delivers pressurized oil to the load.
•
It is possible to change the delivery by changing the swash plate angle.
Structure •
Cylinder block (7) is supported to shaft (1) by spline (11).
•
Shaft (1) is supported by the front and rear bearings (12).
•
The end of piston (6) has a spherical hollow and is combined with shoe (5).
•
Piston (6) and shoe (5) form a spherical bearing.
•
Shoe (5) is kept pressed against flat surface (A) of rocker cam (4) and slid circularly.
•
Rocker cam (4) slides around ball (13).
•
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
•
Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation.
•
This surface is designed so that the oil pressure balance is maintained at a suitable level.
•
The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
WA500-6
10-19 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Operation of Pump •
Cylinder block (7) rotates together with shaft (1); shoe (5) slides on flat surface (A).
•
Rocker cam (4) slants around ball (13). As a result, angle (a), between center line (X) of rocker cam (4) and the axis of cylinder block (7), changes.
•
Angle (a) is the swash plate angle.
•
With the condition of center line (X), rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7); flat surface (A) functions as cam against shoe (5).
•
Piston (6) slides on the inside of cylinder block (7); a difference between volumes (E) and (F) is created inside cylinder block (7).
•
A single piston (6) sucks and discharges the oil by the amount of (F) - (E).
•
As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.
•
The volume of chamber (F) grows larger and, in the process, the oil is suctioned.
10-20 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) [swash plate angle (a) = 0], the difference between volumes (E) and (F) inside cylinder block (7) becomes 0 (zero).
•
Suction and discharge of pressurized oil is not carried out in this state. Pumping action is not performed. However, the swash plate angle is not set to 0 (zero).
•
Swash plate angle (a) is in proportion to the pump delivery.
ENGINE AND COOLING SYSTEM
Control of Delivery •
If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (A) increases.
•
Swash plate angle (a) is changed with servo piston (10).
•
Servo piston (10) reciprocates straight according to the signal pressure of the servo valve.
•
This straight motion is transmitted to rocker cam (4).
•
Rocker cam (4), supported with ball (13), slides around ball (13).
WA500-6
10-21 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Servo Valve
10-22 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
P:
EPC valve basic pressure
PE:
Control piston pressure
PH
Pump discharge pressure
T:
Drain port
1.
Plug
2.
Lever
3.
Retainer
4.
Seat
5.
Spool
6.
Piston
7.
Sleeve
8.
Spring
ENGINE AND COOLING SYSTEM
Torque Values Designation
N•m
lbf in
DD
5.9 – 8.8
52 – 78
EE
9.8 – 12.7
87 – 112
WA500-6
10-23 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Torque Values Designation
N•m
lbf ft
lbf in
C
27.4 – 34.3
20 – 25
–
D
8.8 ±1.0
–
78 ±9
10-24 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Function •
The servo valve controls the current input to the EPC valve and the pump delivery (Q) so that they are related as shown in the diagram to the right.
•
The output pressure of the EPC valve flows in the piston chamber to push piston (6).
•
Piston (6) pushes spool (5) until it is balanced with the spring.
•
Then, the orifice of the servo piston pressure passage is connected to the pump discharge passage by the notch of spool (5) and the discharge pressure is led to the servo piston.
•
When the rocker cam is pushed up by the servo piston, a position feedback is applied and lever (2) moves to compress spring (8).
•
When spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are cut off.
•
Pressure in the servo piston chamber drops and the rocker cam returns in the direction of a maximum swash plate angle.
•
These processes are repeated until the swash plate is fixed to a position where the EPC output pressure is balanced with spring (8) force.
•
The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure, the greater the swash plate angle.
WA500-6
10-25 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Cooling Fan Motor Type: LMF40
P: From fan pump T: From cooler to tank TC: To tank
10-26 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Torque Values Item
N•m
lbf ft
lbf in
1
98 – 123
72 – 91
–
2
9.8 – 12.7
–
87 – 113
Specifications Type
Capacity
Rated Speed
Rated Flow
Check Valve Cracking Pressure
LMF40
40 cc/rev
1,190 rpm
47.6 liter/min. (12.57 gal/min)
0.45 kg/cm² (6 psi)
WA500-6
10-27 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-28 b
ENGINE AND COOLING SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Output shaft
2.
Case
3.
Thrust plate
4.
Piston assembly
5.
Cylinder block
6.
Valve plate
7.
End cover
8.
Center spring
9.
Check valve
ENGINE AND COOLING SYSTEM
10. Pilot valve 11. Reversible valve spool 12. Safety valve
No.
Check Item
Criteria Standard Size
13 Spool return spring
14 Check valve spring
Remedy Repair Limit
Free Length x Outside Diameter mm (in)
Installed Length mm (in)
Installed Load
Free Length
Installed Load
44.8 x 12.0 (1.76 x 0.47)
33.0 (1.30)
58.8 N (13.22 lbf)
—
47.1 N (10.59 lbf)
13.0 x 6.5 (0.51 x 0.26)
9.5 (0.37)
1.96 N (0.44 lbf)
—
1.57 N (0.35 lbf)
If damaged or deformed, replace spring
Torque Values Item
N•m
lbf in
D
9.8 – 12.7
87 – 112
WA500-6
10-29 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Hydraulic Motor Function The hydraulic motor is a swash plate-type axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of Operation •
The oil sent from the hydraulic pump flows through valve plate (7) into cylinder block (5).
•
This oil can flow on only one side of the (Y – Y) line connecting the top dead center and bottom dead center of the stroke of piston (4).
•
The oil sent to one side of cylinder block (5) presses piston (4) [2 or 3 pieces] and generates force (F1).
•
A single piston force F1 [F1(kg) = P (kg/cm²) x D²/4 (cm²)].
•
This force is applied to thrust plate (2).
•
Since thrust plate (2) is fixed to a certain angle (a) to output shaft (1), the force is divided into components (F2) and (F3).
•
The radial component (F3) generates torque [T = F3 x ri] against the (Y – Y) line connecting the top dead center and bottom dead center.
•
The result of this torque [T =(F3 x ri)] rotates cylinder block (5) through piston (4).
•
This cylinder block (5) is coupled to output shaft (1) with the spline.
•
Output shaft (1) rotates and torque is transmitted.
10-30 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Suction Valve Function •
When the pump stops rotating, hydraulic oil does not flow into the motor.
•
Since the motor is revolved by the force of inertia, the pressure on the outlet side of the motor rises.
•
When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil. This process prevents cavitation.
Operation When the pump is started •
When the hydraulic oil from the pump is supplied to port (P) and the pressure on the (MA) side rises.
•
When starting torque is generated in the motor, the motor starts to revolve.
•
The oil on the outlet (MB) side of the motor returns through port (T) to the tank.
When the pump is stopped •
When the engine stops, the pump input revolution becomes 0 rpm.
•
Hydraulic oil from the pump is not supplied to port (P).
•
As the hydraulic oil does not flow to the (MA) side of the motor, the motor speed decreases gradually to stop.
•
If the motor shaft is revolved by the force of inertia while the oil flow to port (P) decreases, the oil in port (T) on the outlet side is sent by suction valve (1) to the (MA) side. This process prevents cavitation.
WA500-6
10-31 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Reversible Valve When the ON/OFF solenoid is de-energized •
When ON/OFF solenoid (1) is de-energized, hydraulic oil from the pump is cut off by valve (2.
•
Port (C) is connected to the tank circuit.
•
Spool (3) is pressed to the right by spring (4).
•
As a result, motor port (MA) opens and the hydraulic oil flows into the motor to revolve it in the normal direction (clockwise).
When the ON/OFF solenoid is energized •
When ON/OFF solenoid (1) is energized, valve (2) switches.
•
Hydraulic oil from the pump flows through port (C) into spool chamber (D).
•
Hydraulic oil in chamber (D) compresses spring (4).
•
Spool (3) moves to the left.
•
As a result, motor port (MB) opens and hydraulic oil flows into the motor to revolve it in reverse (counterclockwise).
10-32 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Safety Valve Function •
When the engine is started, the pressure in port (P) of the motor is heightened in some cases.
•
Safety valve (1) is installed to protect the fan system circuit.
Operation •
If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the pressurized oil into port (T).
•
By this operation, abnormally high pressure is prevented from being generated in port (P).
WA500-6
10-33 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
POWER TRAIN Drive Line Components
Outline •
The power from engine (1) is transmitted to torque converter (2) through the flywheel and ring gear. Torque converter (2) converts the transmitted toque according to the fluctuation of the load by using oil as a medium and then transmits the power to the input shaft of transmission (3). The engine power is also transmitted through the pump drive gear (PTO) of torque converter (2) to steering pump (4), torque converter charging pump (5), EPC pump (6), cooling pump (7), work equipment pump (8), and fan pump (9) to drive these pumps.
•
Transmission (3) operates six hydraulic clutches through the solenoid valve-based operation of the directional spool and gearshift spool to select one of four gear speeds in the forward or reverse travel direction. Selection of a speed is done by using the electrically-controlled switch.
•
Multi-disc type parking brake (10) is installed on the transmission. The power from the front side output shaft is transmitted through center drive shaft (11) and front drive shaft (13) to front differential (14).
•
On the rear side, the power is transmitted to rear differential (19) from rear drive shaft (18).
•
The power being transmitted to front differential (14) and rear differential (19) is then transmitted to the axle shaft.
•
The power from the axle shaft is reduced in speed by final drives (15) and (20) and then transmitted to tires (17) and (22) through the planetary carrier.
10-34 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Train System Diagram Without Lockup Clutch
1.
Engine
9.
2.
Torque converter
10. Parking brake
17. Front tire
3.
Transmission
11. Center drive shaft
18. Rear drive shaft
4.
Steering pump
12. Center support
19. Rear differential
5.
Torque converter charging pump
13. Front drive shaft
20. Rear final drive
6.
EPC and brake pump
14. Front differential
21. Wet-type multi-disc brake
7.
Hydraulic cooling pump
15. Front final drive
22. Rear tire
8.
Work equipment pump
WA500-6
Cooling fan pump
16. Wet-type multi-disc brake
10-35 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
With Lockup Clutch
10-36 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Engine
2.
Torque converter
3.
Transmission
4.
Steering pump
5.
Torque converter charging pump
6.
EPC and brake pump
7.
Hydraulic cooling pump
8.
Work equipment pump
9.
Cooling fan pump
POWER TRAIN
10. Parking brake 11. Center drive shaft 12. Center support 13. Front drive shaft 14. Front differential 15. Front final drive 16. Wet-type multi-disc brake 17. Front tire 18. Rear drive shaft 19. Rear differential 20. Rear final drive 21. Wet-type multi-disc brake 22. Rear tire 23. Lockup clutch
WA500-6
10-37 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Drive Shaft
10-38 b
1.
Front drive shaft
2.
Center support
3.
Center drive shaft
4.
Rear drive shaft
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WARNING!
POWER TRAIN
Observe the following precautions for the tightening torque of the spider mounting bolts.
1.
There are two types (new and old type) of spider mounting bolts which have the same part number. ★ Different tightening torques are specified for the new bolt and the old bolt.
2.
Since the new and old bolts cannot be distinguished from each other by appearance, the existing spider mounting bolts cannot be reused. You must use a new spider mounting bolt. ★ The specified torque for the new bolt is lower than that for the old bolt. Accordingly, if the new bolt is tightened to the torque for the old bolt, it may be broken during operation and the machine may not be able to travel.
3.
When retightening, removing, or installing the bolts, you must replace the existing bolts with new bolts and tighten them to the torque specified for them. ★ A new part number is set for the new bolt. For the new part number, see the Parts Book. * Spider mounting bolts (A, C, E): 107 – 127 N•m (79 – 94 lbf ft)
* Bolts of new tightening torque (new bolt values) Shaft mounting bolts (B, D, F): 98 – 123 N•m (72 – 91 lbf ft)
Torque Values Designation
N•m
lbf ft
G
490 – 608
361 – 448
WA500-6
10-39 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Front Drive Shaft
Center Drive Shaft
10-40 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Rear Drive Shaft
Outline •
The power from the engine is transmitted through the torque converter, transmission, and transfer. From the transfer, part of the power is then transmitted to the rear axle through rear drive shaft (4). The remaining portion of the power is transmitted to the front axle through center drive shaft (3), center support (2), and front drive shaft (1).
•
The drive shafts have a purpose besides simple power transmission.
•
When the positions of the transmission and front and rear axles change because of the traveling or working impacts during articulation or travel of the machine, the drive shaft absorbs the fluctuations in the angle and length by using the universal joint and slip joint so that the power is transmitted without damaging the parts.
WA500-6
10-41 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Train Piping Diagram
10-42 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Transmission
2.
Torque converter
3.
Transmission control valve
4.
Power train pump
5.
Torque converter oil cooler
6.
Torque converter oil filter
WA500-6
POWER TRAIN
10-43 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Converter without Lockup Clutch (Torque converter, PTO, and input transfer)
10-44 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
A.
From main relief valve
B.
From transmission control valve
C.
Torque converter outlet oil pressure pickup port
D.
To transfer case
1.
Hydraulic and brake cooling pump (if equipped) mounting port
2.
Cooling fan pump mounting port
3.
Transmission input shaft speed sensor
4.
Input transfer
5.
Torque converter and PTO
6.
Work equipment hydraulic pump mounting port
7.
Steering pump, power train pump, and EPC brake pump mounting port
8.
Torque converter regulator valve
Specifications Type
Stall Torque Ratio
3-element, 1-stage, 1-phase
2.84
Torque Values Designation
N•m
lbf ft
lbf in
EE
9.8 – 12.7
–
87 – 112
FF
24.5 – 34.3
18 – 25
–
GG
34.3 – 44.1
25 – 33
–
HH
19.6 – 29.4
15 – 22
–
JJ
53.9 – 63.7
40 – 47
–
KK
49.0 – 68.6
36– 51
–
WA500-6
10-45 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
1.
Flywheel
9.
2.
Pilot
10. Input transfer drive gear (Number of teeth: 59)
3.
Drive case
11. Transmission input shaft
4.
Turbine
12. Input transfer driven gear (Number of teeth: 47)
5.
Stator
13. PTO drive gear (Number of teeth: 88)
6.
Pump
14. Spacer
7.
PTO idler gear (Number of teeth: 51)
15. Boss
8.
Stator shaft
10-46 b
Torque converter output shaft
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
Check Item
Criteria
Remedy
1
Backlash between PTO idler gear and PTO gear A
0.192 – 0.492 (0.008 –0.019)
2
Backlash between PTO idler gear and PTO gear B
0.192 – 0.492 (0.008 –0.019) Tolerance Standard Size
3
4
5
6
Tolerance for fitness of bearing in PTO gear A (Small)
Tolerance for fitness of bearing in PTO gear A (Large)
Tolerance for fitness of bearing in PTO gear B (Small)
Tolerance for fitness of bearing in PTO gear B (Large)
Hole
Outside diameter
100 (3.94)
0 (0) -0.015 (-0.0006)
-0.010 (-0.00039) -0.045 (-0.00177)
Inside diameter
55 (2.17)
+0.030 (+0.0012) +0.011 (+0.0004)
0 (0) -0.015 (-0.0006)
Outside diameter
150 (5.91)
0 (0) -0.018 (-0.0007)
+0.026 (+0.00102) -0.014 (-0.00055)
Inside diameter
85 (3.35)
+0.035 (+0.0014) +0.013 (+0.0005)
0 (0) -0.020 (-0.0008)
Outside diameter
100 (3.94)
0 (0) -0.015 (-0.0006)
-0.010 (-0.00039) -0.045 (-0.00177)
Inside diameter
55 (2.17)
+0.030 (+0.0012) +0.011 (+0.0004)
0 (0) -0.015 (-0.0006)
Outside diameter
125 (4.92)
0 (0) -0.018 (-0.0007)
+0.026 (+0.00102) -0.014 (-0.00055)
Inside diameter
70 (2.76)
+0.030 (+0.0012) +0.011 (+0.0004)
0 (0) -0.015 (-0.0006)
7.
PTO gear A (Number of teeth: 84)
8.
PTO gear B (Number of teeth: 84)
WA500-6
Shaft
Replace
10-47 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Values Designation
N•m
lbf ft
lbf in
B
441 – 490
325 – 361
–
C
49.0 – 58.8
36 – 43
–
D
153 – 190
113 – 140
–
E
59 – 74
44 – 55
–
F
98 – 123
72 – 901
–
G
9.8 – 12.7
–
87 – 112
10-48 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN Unit: mm (in)
No.
1
Check Item
Criteria
2 Wear of output shaft seal ring
3
Standard Size
Tolerance
Repair Limit
80 (3.15)
-0.040 (-0.0016) -0.070 (-0.0028)
79.92 (3.15)
65 (2.56)
+0.030 (+0.0012) –0 (0)
65.1 (2.56)
3 (0.12)
-0.01 (-0.0004) -0.03 (-0.0012)
2.7 (0.11)
Outside diameter of pilot
Inside diameter of sleeve seal ring contact surface Width
Remedy
Repair by hard chromium-plating or replace
Replace
Thickness
2.7 (0.11)
±0.1 (±0.0039)
2.55 (0.10)
Inside diameter of PTO drive gear seal ring contact surface
170 (6.70)
+0.040 (+0.0016) –0 (0)
170.5 (6.71)
Repair by hard chromium-plating or replace
Tolerance Standard Size 4
5
6
7
Tolerance for fitness of PTO idler gear bearing
Tolerance for fitness of input transfer drive gear bearing (Large)
Tolerance for fitness of input transfer drive gear bearing (Small)
Tolerance for fitness of input transfer driven gear bearing
Shaft
Hole
Outside diameter
125 (4.92)
–0.(0)000 -0.020 (-0.0008)
-0.028 (-0.0011) -0.068 (-0.0027)
Inside diameter
70 (2.76)
+0.012 (+0.0005) -0.007 (-0.0003)
–0 (0).000 -0.015 (-0.0006)
Outside diameter
150 (5.91)
–0 (0)0 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.0020)
Inside diameter
85 (3.35)
+0.059 (+0.0023) +0.037 (+0.0015)
–0 (0)00 -0.020 (-0.0008)
Outside diameter
140 (5.51)
–0 (0)0 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.0020)
Inside diameter
80 (3.15)
+0.051 (+0.0020) +0.032 (+0.0013)
–0.(0)000 -0.015 (-0.0006)
Outside diameter
125 (4.92)
–0 (0)000 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.0020)
Inside diameter
80 (3.15)
+0.051 (+0.0020) +0.032 (+0.0013)
–0.(0)000 -0.015 (-0.0006)
8
Backlash between PTO drive gear and PTO idler gear
0.192 – 0.492 (0.0076 – 0.0194)
9
Backlash between input transfer drive gear and driven gear
0.190 – 0.486 (0.0075 – 0.0191)
10
11
Clearance between cage and case of input transfer drive gear
Clearance between cage and case of input transfer driven gear
WA500-6
Standard Clearance
Clearance Limit
0.40 – 1.60 (0.016 – 0.063) (Standard shim thickness: 1.0 (0.039))
—
0.60 – 1.80 (0.024 – 0.071) (Standard shim thickness: 1.0 (0.039))
—
Replace
10-49 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Transmission Route
The power from the engine
(From left bottom)
Flywheel (1)
Output shaft (8)
Drive case (2), pump (3), and PTO drive gear (4) rotate together
Drive gear (9)
Oil is used as medium
Driven gear (10)
Turbine (6) and boss (7)
Transmission input shaft (11)
(To right top) •
The power transmitted to PTO drive gear (4) is then transmitted through PTO idler gear (5) and PTO gear.
•
It is then used as the pump driving power.
10-50 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Oil Flow
•
The oil flows to the torque converter relief valve through the main relief valve; there the valve regulates the oil pressure to below the set pressure.
•
The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2), and spacer (3).
•
The oil is given a centrifugal force by pump (4) and then enters turbine (5) to transmit its energy to turbine (5).
•
The oil from turbine (5) is sent to stator (6) and then returned to pump (4). Part of this oil is sent to the oil cooler through stator (6), oil passage of stator shaft (2), outlet port (B), and the torque converter regulator valve.
WA500-6
10-51 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Converter with Lockup Clutch (Torque converter, PTO, and input transfer)
10-52 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
A.
From main relief valve
B.
From lockup clutch ECMV
C.
From transmission control valve
D.
Torque converter outlet oil pressure pickup port
E.
To transfer case
1.
Hydraulic and brake cooling pump (if equipped) mounting port
2.
Cooling fan pump mounting port
3.
Transmission input shaft speed sensor
4.
Input transfer
5.
Torque converter and PTO
6.
Work equipment hydraulic pump mounting port
7.
Steering pump, power train, and PPC pump mounting port
8.
Torque converter regulator valve
Torque Values Designation
N•m
lbf ft
lbf in
FF
53.9 – 63.7
40 – 47
–
GG
49.0 – 68.6
36 – 51
–
HH
34.3 – 44.1
25 – 33
–
JJ
19.6 – 29.4
15 – 22
–
KK
24.5 – 34.3
18 – 25
–
LL
9.8 – 12.7
–
87 – 112
Specifications
Type
Stall Torque Ratio
3-element, 1-stage, 2-phase
2.73
WA500-6
10-53 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
1.
Flywheel
11. Input transfer drive gear (Number of teeth: 59)
2.
Pilot
12. Transmission input shaft
3.
Lockup clutch housing
13. Input transfer driven gear (Number of teeth: 47)
4.
Turbine
14. PTO drive gear (Number of teeth: 88)
5.
Stator
15. Spacer
6.
Drive case
16. Free wheel
7.
Pump
17. Race
8.
PTO idler gear (Number of teeth: 51)
18. Lockup clutch disc
9.
Stator shaft
19. Lockup clutch piston
10. Torque converter output shaft
10-54 b
20. Boss
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
Check Item
Criteria
Remedy
1
Backlash between PTO idler gear and PTO gear A
0.192 – 0.492 (0.0076 – 0.0194)
2
Backlash between PTO idler gear and PTO gear B
0.192 – 0.492 (0.0076 – 0.0194) Tolerance Standard Size
3
4
5
6
Tolerance for fitness of bearing in PTO gear A (Small)
Tolerance for fitness of bearing in PTO gear A (Large)
Tolerance for fitness of bearing in PTO gear B (Small)
Tolerance for fitness of bearing in PTO gear B (Large)
Hole
Outside diameter
100 (3.94)
–0 (0).000 -0.015 (-0.0006)
-0.010 (-0.00039) -0.045 (-0.00177)
Inside diameter
55 (2.17)
+0.030 (+0.0012) +0.011 (+0.0004)
–0.(0).000 -0.015 (-0.0006)
Outside diameter
150 (5.91)
–0 (0)..000 -0.018 (-0.0007)
+0.026 (+0.00102) -0.014 (-0.00055)
Inside diameter
85 (3.35)
+0.035 (+0.0014) +0.013 (+0.0005)
– 0 (0)..000 -0.020 (-0.0008)
Outside diameter
100 (3.94)
–0.(0).000 -0.015 (-0.0006)
-0.010 (-0.00039) -0.045 (-0.00177)
Inside diameter
55 (2.17)
+0.030 (+0.0012) +0.011 (+0.0004)
–0.(0).000 -0.015 (-0.0006)
Outside diameter
125 (4.92)
–0 (0)..000 -0.018 (-0.0007)
+0.026 (+0.00102) -0.014 (-0.00055)
Inside diameter
70 (2.76)
+0.030 (+0.0012) +0.011 (+0.0004)
–0.(0).000 -0.015 (-0.0006)
7.
PTO gear A (Number of teeth: 84)
8.
PTO gear B (Number of teeth: 84)
WA500-6
Shaft
Replace
10-55 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit mm (in) No.
1
Check Item
Criteria Standard Size
Tolerance
Repair Limit
80 (3.15)
-0.040 (-0.0016) -0.070 (-0.0028)
79.92 (3.15)
40 (1.57)
+0.025 (+0.0010) –0.(0)000
40.1 (1.58)
3 (0.12)
-0.01 (-0.0004) -0.03 (-0.0012)
2.7 (0.11)
Outside diameter of pilot
Inside diameter of pilot seal ring contact surface 2 Wear of output shaft seal ring
Width
Remedy
Repair by hard chromium-plating or replace
Replace
Thickness
1.7 (0.07)
±0.1 (±0.0040)
1.55 (0.06)
Inside diameter of stator shaft seal ring contact surface
65 (2.56)
+0.030 (+0.0012) –0.(0)000
65.1 (2.56)
Repair by hard chromium-plating or replace
Wear of output shaft seal ring
3 (0.12)
-0.01 (-0.0004) -0.03 (-0.0012)
2.7 (0.11)
Replace
3
10-56 b
Width
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
4
Inside diameter of PTO drive gear seal ring contact surface
5
POWER TRAIN Criteria
Remedy
170 (6.70)
+0.040 (+0.0016) –0.(0)000
170.5 (6.71)
Inside diameter of race free wheel transfer surface
102.555 (4.038)
±0.008 (±0.0003)
102.585 (4.039)
6
Inside diameter of stator shaft free wheel transfer surface
83.6 (3.29)
+0.004 (+0.00016) -0.009 (-0.00035)
83.57 (3.29)
7
Inside diameter of sliding portion of bushing
83.71 (3.30)
+0.015 (+0.0006) –0 (0).000
83.79 (3.30)
8
Thickness of sliding portion of bushing
6 (0.24)
±0.05 (±0.00197)
5.5 (0.22)
9
Thickness of clutch disc
5.4 (0.21)
±0.1 (±0.0040)
4.9 (0.19)
Repair by hard chromium-plating or replace
Tolerance Standard Size 10 Tolerance for fitness of PTO idler gear bearing
Tolerance for fitness of 11 input transfer drive gear bearing (Large)
Tolerance for fitness of 12 input transfer drive gear bearing (Small)
Tolerance for fitness of 13 input transfer driven gear bearing
Shaft
Hole
Outside diameter
125 (4.92)
0 (0).000 -0.020 (-0.0008)
-0.028 (-0.0011) -0.068 (-0.0027)
Inside diameter
70 (2.76)
+0.012 (+0.0005) -0.007 (-0.0003)
0.(0)000 -0.015 (-0.0006)
Outside diameter
150 (5.91)
0 (0).000 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.00204)
Inside diameter
85 (3.35)
+0.059 (+0.0023) +0.037 (+0.0015)
0.(0)000 -0.020 (-0.0008)
Outside diameter
140 (5.51)
0 (0)00 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.00204)
Inside diameter
80 (3.15)
+0.051 (+0.0020) +0.032 (+0.0013)
0.(0)0 -0.015 (-0.0006)
Outside diameter
125 (4.92)
–0 (0)00 -0.020 (-0.0008)
-0.012 (-0.0005) -0.052 (-0.00204)
Inside diameter
80 (3.15)
+0.051 (+0.0020) +0.032 (+0.0013)
–0.(0)00 -0.015 (-0.0006)
14
Backlash between PTO drive gear and PTO idler gear
0.192 – 0.492 (0.0076 – 0.0194)
15
Backlash between input transfer drive gear and driven gear
0.190 – 0.486 (0.0075 – 0.0191)
Clearance between cage and case of 16 input transfer drive gear
17
Clearance between cage and case of input transfer driven gear
WA500-6
Standard Clearance
Clearance Limit
0.40 – 1.60 (0.016 – 0.063) (Standard shim thickness: 1.0 (0.039))
—
0.60 – 1.80 (0.024 – 0.071) (Standard shim thickness: 1.0 (0.039))
—
Replace
10-57 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Values Designation
N•m
lbf ft
lbf in
A
441 – 490
325 – 361
–
B
49.0 – 58.8
36 – 43
–
C
153 – 190
113 – 140
–
D
59 – 74
44 – 55
–
E
98 – 123
72 – 91
–
F
9.8 – 12.7
–
87 – 112
10-58 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Transmission Route: Lockup Clutch Disengaged
•
Drive case (3) is disconnected from boss (9) and turbine (8).
•
Lockup torque converter works as an ordinary torque converter. The power from the engine
(From left bottom)
Flywheel (1)
Output shaft (10)
Clutch housing (2), drive case (3), pump (5), and PTO drive gear (6) rotate together
Drive gear (11)
Oil is used as medium
Driven gear (12)
Turbine (8) and boss (9)
Transmission input shaft (13)
(To right top) •
The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and the PTO gear, and then used as the pump driving power.
WA500-6
10-59 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Transmission Route: Lockup Clutch Engaged
•
Drive case (3) is connected to boss (9) and turbine (8).
•
Lockup torque converter is locked up. The power from the engine
(From left bottom)
Flywheel (1)
Output shaft (10)
Clutch housing (2), drive case (3), pump (5), and PTO drive gear (6) rotate together
Drive gear (11)
Lockup clutch (4)
Driven gear (12)
Boss (9)
Transmission input shaft (13)
(To right top) •
The power being transmitted to PTO drive gear (6) is then transmitted through PTO idler gear (7) and the PTO gear, and then used as the pump driving power.
10-60 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Oil Flow
•
The oil flows to the torque converter relief valve through the main relief valve; there the value regulates the oil pressure to below the set pressure. The oil flows to pump (4) through inlet port (A) and oil passage of case (1), stator shaft (2), and spacer (3).
•
The oil is given a centrifugal force by pump (4) and then it enters turbine (5) to transmit its energy to turbine (5).
•
The oil from turbine (5) is sent to stator (6) and then returned to pump (4). Part of this oil is sent to the oil cooler through stator (6), oil passage of stator shaft (2), outlet port (B), and torque converter regulator valve.
WA500-6
10-61 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Converter Regulator Valve
A.
From torque converter
B.
To oil cooler
C.
Drain
D.
Torque converter outlet port oil pressure pickup port
3.
Spool
4.
Valve body
Outline •
This valve is provided at the torque converter outlet circuit in order to secure an optimum performance of the torque converter by adjusting its set oil pressure. Set pressure: . . . . . . . . . . . . . . . . . . 4.28 ±0.51 kg/cm² (61 ±7 psi)
10-62 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
1
Check Item
Criteria
Clearance between spool and valve body
Tolerance
Standard Size
Shaft
32 (1.26)
-0.050 (-0.0020) -0.066 (-0.0026)
Hole
Standard Clearance
Clearance Limit
+0.025 (+0.0010) + 0 (0).000
0.050 – 0.091 (0.0020 – 0.0036)
0.111 (0.0044)
Standard Size 2
Valve spring
Remedy
Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
126.6 (4.98)
106.5 (4.19)
205 N (46.09 lbf)
122.8 (4.83)
195 N (43.84 lbf)
Replace
Torque Values Designation
N•m
lbf in
AA
9.8 – 12.7
87 – 112
Operation •
The oil from the torque converter is conducted to chamber (D) through port (A) and orifice (a).
•
When the oil pressure force generated in chamber (D) is less than the tension of spring (1), spool (2) is pressed to the left, closing port (A) and port (B).
•
If the oil pressure force generated in chamber (D) becomes greater than the tension of spring (1), spool (2) is pressed to the right, opening port (A) and port (B).
WA500-6
10-63 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Transmission with Lockup Clutch (transmission, transfer, and parking brake) .
10-64 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
1.
Transfer
2.
Parking brake
3.
Transmission
4.
Emergency steering pump mounting port
5.
Oil filler tube mounting port
6.
Speed sensor
7.
Lubrication relief valve
8.
Transmission control valve
9.
Torque converter drain tube mounting port
10. Drain valve 11. Drain plug
A.
To torque converter
B.
To parking brake emergency release valve
C.
To lockup clutch
D.
To parking brake emergency release valve (to parking brake)
E.
From oil cooler
F.
From power train pump
G.
From parking brake emergency release valve
Torque Values Designation
N•m
lbf ft
AA
98.0 – 123.0
72 – 91
BB
128.0 – 186.0
94 – 137
CC
44.1 – 53.9
33 – 40
DD
34.3 – 63.7
25 – 47
EE
49.0 – 68.6
36 – 51
FF
72.6 – 146.0
54 – 108
GG
58.8 – 78.4
43 – 58
HH
49.0 – 78.4
36 – 58
WA500-6
10-65 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
12. Transmission lubricant temperature sensor 13. Strainer
10-66 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
H.
To input transfer lubrication
J.
Parking brake oil pressure pickup port
K.
From main relief valve
L.
From lockup clutch ECMV
POWER TRAIN
M. From F clutch ECMV (to F clutch) N.
To 4th clutch
P.
From R clutch ECMV (to R clutch)
R.
From 3rd clutch ECMV (to 3rd clutch)
S.
To 2nd clutch
T.
To transmission and transfer lubrication
U.
From lubrication relief valve
V.
From 2nd clutch ECMV
W. From 4th clutch ECMV X.
To 1st clutch
Y.
From 1st clutch ECMV
Torque Values Designation
N•m
lbf ft
lbf in
CC
44.1 – 53.9
33 – 40
–
JJ
29.4 – 49.0
22 – 36
–
KK
9.8 – 12.7
–
87 – 112
WA500-6
10-67 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-68 b
POWER TRAIN
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
1.
Transmission input shaft
24. 2nd piston return spring
2.
Tie bolt
25. 2nd clutch piston
3.
R ring gear (Hub)
26. 2nd clutch housing
4.
R planetary pinion (Number of teeth: 24)
27. 3rd and 4th carriers
5.
R ring gear (Number of teeth: 70)
28. 3rd piston return spring
6.
F planetary pinion (Number of teeth: 23)
29. 3rd clutch piston
7.
F ring gear (Number of inside teeth: 75)
30. 3rd and 4th clutch housings
8.
4th ring gear (Number of inside teeth: 73)
31. 4th clutch piston
9.
4th planetary pinion (Number of teeth: 28)
32. 4th piston return spring
10. 3rd planetary pinion (Number of teeth: 20)
33. F and 4th clutch cages
11. 3rd ring gear (Number of inside teeth: 76)
34. F piston return spring
12. 2nd ring gear (Number of teeth: 76)
35. F sun gear (Number of teeth: 29)
13. 2nd planetary pinion (Number of teeth: 20)
36. F carrier
14. 1st hub
37. F clutch piston
15. Transmission output shaft (4th sun gear) (Number of teeth: 17)
38. R and F clutch housings
16. Transfer input gear (Number of teeth: 50)
39. R clutch piston
17. 2nd sun gear (Number of teeth: 36)
40. Washer spring
18. 1st clutch housing
41. R piston return spring
19. 1st clutch piston
42. R carrier
20. 2nd carrier
43. Clutch disc
21. 3rd sun gear (Number of teeth: 36)
44. Clutch plate
22. 1st piston return spring
45. R clutch cage
23. 2nd clutch housing
46. R sun gear (Number of teeth: 22)
WA500-6
10-69 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Outline •
The transmission consists of the united planetary gear mechanism and disc clutch that provide four forward and four reverse gear speeds.
•
The transmission selects a single rotating direction and a single gear speed by fixing the planetary gear mechanism and two of six disc clutches by using ECMV.
•
The transmission transmits the power (being transmitted to the transmission input shaft) to the output shaft after selecting a single speed from the 1st to 4th speeds, both in forward and reverse travel. In this case, the gear speed change is done by F and R clutches plus combinations of four speed clutches.
Number of Plates and Discs Used Clutch No.
Number of Plates
Number of Discs
R clutch
6
7
F clutch
6
7
4th clutch
3+2
4
3rd clutch
2+2
3
2nd clutch
2+1
3
1st clutch
3+2
4
Combinations of Clutches at Respective Gear Speeds and Reduction Ratio Gear Speed
Clutch Used
Reduction Ratio
Forward 1st speed
F x 1st
3.586
Forward 2nd speed
F x 2nd
1.935
Forward 3rd speed
F x 3rd
1.153
Forward 4th speed
F x 4th
0.677
Neutral
—
—
Reverse 1st speed
R x 1st
3.182
Reverse 2nd speed
R x 2nd
1.717
Reverse 3rd speed
R x 3rd
1.023
Reverse 4th speed
R x 4th
0.601
10-70 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA500-6
1.
Transfer idler gear (Number of teeth: 71)
2.
Transfer output gear (Number of teeth: 72)
3.
Output shaft
4.
Front coupling
5.
Rear coupling
6.
Parking brake
POWER TRAIN
10-71 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-72 b
POWER TRAIN
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
Check Item
Criteria Standard Size
1
R clutch spring (10 springs)
Remedy Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
77 (3.03)
70.2 (2.76)
48.1 N (10.81 lbf)
72.4 (2.85)
41.2 N (9.26 lbf)
2
F clutch spring (10 springs)
77 (3.03)
71.7 (2.82)
37.3 N (8.39 lbf)
72.4 (2.85)
31.4 N (7.06 lbf)
3
4th clutch spring (10 springs)
48.5 (1.91)
44.2 (1.74)
59.8 N (13.44 lbf)
45.6 (1.80)
51.0 N (11.47 lbf)
4
3rd clutch spring (10 springs)
39.8 (1.57)
33 (1.30)
94.1 N (21.15 lbf)
37.4 (1.47)
80.4 N (18.07 lbf)
5
2nd clutch spring (10 springs)
39.8 (1.57)
34.9 (1.37)
67.7 N (15.22 lbf)
37.4 (1.47)
57.9 N (13.02 lbf ft)
6
1st clutch spring (10 springs)
46 (1.81)
39 (1.54)
110 N (24.73 lbf)
43.2 (1.70)
93.2 N (20.95 lbf)
Total assembled thickness of 7 discs and 6 plates for R clutch
Standard Size
Tolerance
Repair Limit
7
54.2 (2.13)
±0.36 (±0.014)
50.5 (1.99)
8
Total assembled thickness of 7 discs and 6 plates for F clutch
54.2 (2.13)
±0.36 (±0.014)
50.5 (1.99)
9
Total assembled thickness of 4 discs and 5 plates for 4th clutch
45.0 (1.77)
±0.30 (±0.012)
41.8 (1.65)
10
Total assembled thickness of 3 discs and 4 plates for 3rd clutch
35.0 (1.38)
±0.26 (±0.010)
32.6 (1.28)
11
Total assembled thickness of 3 discs and 3 plates for 2nd clutch
26.4 (1.04)
±0.24 (±0.009)
24.8 (0.98)
12
Total assembled thickness of 4 discs and 5 plates for 1st clutch
45.0 (1.77)
±0.30 (±0.012)
41.8 (1.65)
Thickness of clutch disc
R, F, 2nd
5.0 (0.197)
±0.1 (±0.004)
4.5 (0.18)
13
4th, 3rd, 1st
5.0 (0.197)
±0.1 (±0.004)
4.2 (0.17)
R, F
3.2 (0.126)
±0.1 (±0.004)
2.9 (0.11)
4th, 3rd, 1st
5.0 (0.197)
±0.1 (±0.004)
4.5 (0.18)
3.2 (0.126)
±0.1 (±0.004)
2.9 (0.11)
5.0 (0.197)
±0.1 (±0.004)
4.5 (0.18)
Width
4.5 (0.177)
-0.01 (-0.0004) -0.03 (-0.0012)
4.05 (0.16)
Thickness
5.2 (0.205)
±0.12 (±0.005)
5.05 (0.199)
Width
4.0 (0.157)
-0.01 (-0.0004) -0.03 (-0.0012)
3.60 (0.14)
Thickness
5.0 (0.197)
±0.15 (±0.006)
4.85 (0.19)
14
Thickness of clutch plate
Replace
2nd
Wear of R spacer 15 seal ring
Wear of R clutch 16 cage seal ring
WA500-6
10-73 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN Unit: mm (in)
No.
17
Check Item Wear of F clutch cage seal ring
Wear of seal ring of 18 3rd and 4th carrier
Wear of 3rd spacer 19 seal ring
Wear of 1st clutch 20 cage seal ring
21
22
Wear of output shaft seal ring
Wear of output shaft seal ring
Backlash between 23 sun gear and planetary pinion Backlash between 24 output shaft and planetary pinion Backlash between 25 planetary pinion and ring gear 26
Criteria
Remedy
Width
4.0 (0.157)
-0.01 (-0.0004) -0.04 (-0.0016)
3.60 (0.14)
Thickness
5.0 (0.197)
±0.15 (±0.006)
4.85 (0.19)
Width
4.0 (0.157)
-0.01 (-0.0004) -0.04 (-0.0016)
3.60 (0.14)
Thickness
5.0 (0.197)
±0.15 (±0.006)
4.85 (0.19)
Width
3.0 (0.118)
-0.01 (-0.0004) -0.03 (-0.0012)
2.70 (0.11)
Thickness
3.3 (0.130)
±0.1 (±0.004)
3.15 (0.124)
Width
4.5 (0.177)
-0.01 (-0.0004) -0.03 (-0.0012)
4.05 (0.16)
Thickness
5.8 (0.228)
±0.15 (±0.006)
5.65 (0.22)
Width
3.0 (0.118)
-0.01 (-0.0004) -0.03 (-0.0012)
2.70 (0.11)
Thickness
3.1 (0.122)
±0.1 (±0.004)
2.95 (0.116)
Width
2.5 (0.098)
-0.01 (-0.0004 -0.03 (-0.0012)
2.25 (0.09)
Thickness
1.7 (0.067)
±0.1 (±0.004)
1.55 (0.06)
R, F
0.13 – 0.32 (0.0051 – 0.0126)
3rd, 2nd
0.12 – 0.33 (0.0047 – 0.0130) Replace
4th
0.11 – 0.30 (0.0043 – 0.0118)
R, F
0.15 – 0.38 (0.0059 – 0.0150)
4th, 3rd, 2nd
0.13 – 0.36 (0.0051 – 0.0142)
Backlash between transfer input gear and idler gear
0.19 – 0.48 (0.0075 – 0.0189) Tolerance Standard Size
Tolerance for fitness 27 of transfer input gear bearing (Rear)
Tolerance for fitness 28 of transfer input gear bearing (Front)
Hole
Outside diameter
160 (6.30)
0 (0) -0.025 (-0.0010)
-0.012 (-0.0005) -0.052 (-0.0020)
Inside diameter
90 (3.54)
+0.045 (+0.0018) +0.023 (+0.0009)
0 (0) -0.020 (-0.0008)
Outside diameter
160 (6.30)
0 (0) -0.025 (-0.0010)
0 (0) -0.040 (-0.0016)
Inside diameter
90 (3.54)
+0.045 (+0.0018) +0.023 (+0.0009)
0 (0) -0.020 (-0.0008)
29 Clearance between cage and case
10-74 b
Shaft Hole
Standard Clearance
Clearance Limit
1.61 – 2.39 (0.063 – 0.094) (Standard shim thickness: 2.0 (0.079))
—
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Values Designation
N•m
lbf ft
B
157 – 177
116 – 131
C
98.0 – 123.0
72 – 91
D
58.8 – 73.5
43 – 54
WA500-6
10-75 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-76 b
POWER TRAIN
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
Check Item
Criteria
1
Outside diameter of coupling oil seal contact surface (Rear)
2
Outside diameter of coupling oil seal contact surface (Front)
3
Backlash between idler gear and output gear
Remedy
Standard Size
Tolerance
Repair Limit
105 (4.13)
–0 (0).000 -0.087 (-0.0034)
104.8 (4.13)
105 (4.13)
–0.(0)000 -0.087 (-0.0034)
104.8 (4.13)
Repair by hard chromium-plating or replace
0.19 – 0.48 (0.007 – 0.019) Tolerance Standard Size
4
5
6
7
8
Shaft
Hole
Tolerance for fitness of Outside idler gear bearing diameter
180 (7.09)
–0.(0)000 -0.025 (-0.0010)
–0.(0)000 -0.040 (-0.0016)
Inside diameter
100 (3.94)
+0.059 (+0.0023) +0.037 (+0.0015)
–0 (0).000 -0.020 (-0.0008)
190 (7.48)
–0.(0)000 -0.030 (-0.0012)
-0.014 (-0.0006) -0.060 (-0.0024)
105 (4.13)
+0.059 (+0.0023) +0.037 (+0.0015)
–0.(0)000 -0.020 (-0.0008)
150 (5.91)
–0.(0)000 -0.020 (-0.0008)
-0.020 (-0.0008) -0.040 (-0.0016)
85 (3.35)
+0.045 (+0.0018) +0.023 (+0.0009)
–0.(0)000 -0.020 (-0.0008)
Outside Tolerance for fitness of diameter output shaft bearing Inside (Rear) diameter Outside Tolerance for fitness of diameter output gear bearing Inside (Front) diameter
Clearance between cage and case
Clearance between cover and cage
Standard Clearance
Clearance Limit
0.63 – 1.37 (0.025 – 0.054) (Standard shim thickness: 1.0 (0.039))
—
0.48 – 1.32 (0.019 – 0.052) (Standard shim thickness: 0.5 (0.020))
—
Replace
Torque Values Designation
N•m
lbf ft
C
98.0 – 123.0
72 – 91
D
824 – 1030
608 – 760
WA500-6
10-77 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Disc Clutch Structure •
Disc clutch is used for fixing ring gear (1). It consists of piston (2), plate (3), disc (4), pin (5), return spring (6), and washer (8).
•
Inside teeth of disc (4) are engaged with outside teeth of ring gear (1).
•
Plate (3) is assembled to clutch housing (7) with pin (5).
Operation When clutch is engaged (fixed) •
The oil from ECMV is sent under pressure to the rear side of piston (2) through the oil passage of housing (7) and pushes piston (2) to the left.
•
Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by using the friction force generated between them.
•
Since inside teeth of disc (4) are engaged with outside teeth of ring gear (1), movement of ring gear (1) is stopped.
When clutch is disengaged (released) •
As the oil from ECMV is stopped, piston (2) is pushed back to the right by return spring (6).
•
The friction force between plates (3) and discs (4) is released and ring gear (1) is released.
•
Washer spring (8) is installed between plate (3) of the pin block and disc (4). This spring quickens return of piston (2) as the clutch is disengaged by providing smooth separation of plate (3) and disc (4). At the same time, it is used to prevent dragging.
10-78 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-79 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Power Transmission Route Forward 1st Gear Speed
10-80 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ F ring gear (4) of F clutch and 1st hub (16) of 1st clutch are fixed hydraulically. The power from torque converter Input shaft (1) F sun gear (2) F planetary pinion (3) F carrier (10) 3rd and 4th carrier (11) 3rd planetary pinion (12)
3rd ring gear (13)
3rd sun gear (20)
2nd carrier (14)
1st clutch housing (15) 1st hub (16) Output shaft (23)
WA500-6
10-81 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Forward 2nd Gear Speed
10-82 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ F ring gear (4) of F clutch and 2nd ring gear (18) of 2nd clutch are fixed hydraulically. The power from torque converter Input shaft (1) F sun gear (2) F planetary pinion (3) F carrier (10) 3rd and 4th carrier (11) 3rd planetary pinion (12)
3rd ring gear (13)
3rd sun gear (20)
2nd carrier (14)
2nd planetary pinion (17) 2nd sun gear (19) Output shaft (23)
WA500-6
10-83 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Forward 3rd Gear Speed
10-84 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically. The power from torque converter Input shaft (1) F sun gear (2) F planetary pinion (3) F carrier (10) 3rd and 4th carrier (11) 3rd planetary pinion (12) 3rd ring gear (20) Output shaft (23)
WA500-6
10-85 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Forward 4th Gear Speed
10-86 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ F ring gear (4) of F clutch and 4th ring gear (22) of 4th clutch are fixed hydraulicall.y. The power from torque converter Input shaft (1) F sun gear (2) F planetary pinion (3) F carrier (10) 3rd and 4th carrier (11) 4th planetary pinion (21) Output shaft (23)
WA500-6
10-87 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Reverse 1st Gear Speed
10-88 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ R ring gear (7) of R clutch and 1st hub (16) of 1st clutch are fixed hydraulically. The power from torque converter Input shaft (1) R sun gear (5) R planetary pinion (6) R ring gear (9) (R carrier (8) is fixed with R ring gear (7) = R ring gear (9) rotation direction is opposite to input shaft (1)) F carrier (10) 3rd and 4th carrier (11) 3rd planetary pinion (12)
3rd ring gear (13)
3rd sun gear (20)
2nd carrier (14)
1st clutch housing (15) 1st hub (16) Output shaft (23)
WA500-6
10-89 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Transfer Outline ★ The transfer is installed in the output side of the transmission and fixed to the transmission case with the bolt. Operation ★ Power transmitting route Transmission output shaft (1) Transfer input gear (2) Transfer idler gear (3) Transfer output gear (4) Output shaft (5)
Center drive shaft
Front drive shaft
Rear drive shaft
Front axle
Rear axle
10-90 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-91 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Transmission Control Valve (without Lockup Clutch)
10-92 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
A.
1st clutch oil pressure pickup port
B.
4th clutch oil pressure pickup port
C.
3rd clutch oil pressure pickup port
D.
F clutch oil pressure pickup port
E.
R clutch oil pressure pickup port
F.
Torque converter relief pressure pickup port
G.
Main relief oil pressure pickup port
H.
From power train pump
J.
2nd clutch oil pressure pickup port
K.
To PTO and input transfer lubrication
L.
To parking brake emergency release valve (to parking brake)
M. To parking brake emergency release valve
1.
1st clutch ECMV
2.
4th clutch ECMV
3.
3rd clutch ECMV
4.
F clutch ECMV
5.
Parking brake solenoid valve
6.
R clutch ECMV
7.
Main relief valve and torque converter relief valve
8.
Last chance filter
9.
2nd clutch ECMV
10. Check valve
Torque Values Designation
N•m
lbf ft
lbf in
AA
19.6 – 24.5
15 – 18
–
BB
24.5 – 34.3
18 – 25
–
CC
47.0 – 53.9
35 – 40
–
DD
7.8 – 9.8
–
69 – 87
EE
6.9 – 7.8
–
61 – 69
FF
93.1 – 122.5
69 – 90
–
GG
128 – 186
94 – 137
–
HH
15.7 – 19.6
12 – 15
–
JJ
34.3 – 44.1
25 – 33
–
KK
44.1 – 53.9
33 – 40
–
LL
9.8 – 12.7
–
87 – 112
WA500-6
10-93 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Operation Table of ECMV ECMV Gear Speed
F
R
1st 2nd 3rd
4th
❍
A N
❍
M F1
❍
F2
❍
F3
❍
F4
❍
❍
❍
❍
❍ ❍ ❍ ❍
R1
❍
R2
❍
R3
❍
R4
❍
❍ ❍ ❍ ❍
A: Automatic shifting M: Manual shifting
★ When the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed selected with the gear shift lever operation.
10-94 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-95 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Transmission Control Value (with Lockup Clutch)
10-96 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
A.
1st clutch oil pressure pickup port
B.
4th clutch oil pressure pickup port
C.
3rd clutch oil pressure pickup port
D.
F clutch oil pressure pickup port
E.
R clutch oil pressure pickup port
F.
Torque converter relief pressure pickup port
G.
Main relief oil pressure pickup port
H.
From power train pump
J.
Lockup clutch ECMV oil pressure pickup port
K.
2nd clutch oil pressure pickup port
L.
To PTO and input transfer lubrication
M. To parking brake emergency release valve (to parking brake) N.
To parking brake emergency release valve
1.
1st clutch ECMV
2.
4th clutch ECMV
3.
3rd clutch ECMV
4.
F clutch ECMV
5.
Parking brake solenoid valve
6.
R clutch ECMV
7.
Main relief valve and torque converter relief valve
8.
Last chance filter
9.
Lockup clutch ECMV
10. 2nd clutch ECMV 11. Check valve
Torque Values Designation
N•m
lbf ft
lbf in
AA
24.5 – 34.3
18 – 25
–
BB
47.0 – 53.9
35 – 40
–
CC
7.8 – 9.8
–
69 – 87
DD
6.9 – 7.8
–
61 – 69
EE
93.1 – 122.5
69 – 90
–
FF
128 – 186
94 – 137
–
GG
15.7 – 19.6
12 – 15
–
HH
34.3 – 44.1
25 – 33
–
JJ
44.1 – 53.9
33 – 40
–
KK
9.8 – 12.7
–
87 – 112
LL
19.6 – 24.5
15 – 18
–
WA500-6
10-97 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Operation Table of ECMV ECMV Gear Speed
F
R
1st 2nd 3rd 4th L/U ❍
A N
❍
M F1
❍
F2
❍
F3
❍
F4
❍
❍
❍
❍
❍ ❍
❍ ❍
❍ ❍
R1
❍
R2
❍
R3
❍
R4
❍
❍
❍ ❍
❍ ❍
❍ ❍
❍
L/U: Lockup clutch ECMV A: Automatic shifting M: Manual shifting
★ When the directional lever is in the N (Neutral) position during manual shifting, the speed clutch for the gear speed selected with the gear shift lever operation. Outline •
The oil from the pump flows to the transmission control valve through the oil filter.
•
Oil flow is divided into the main relief circuit and clutch actuation circuit.
•
The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used to actuate the clutch and parking brake through the last chance filter.
•
The oil relieved from the main relief valve is supplied to the torque converter.
•
When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to the command current from the transmission controller in order to reduce the gear shifting shocks. The ECMV also keeps the clutch pressure constant during travel.
•
If the F, R, or 1st – 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to set the transmission in the desired gear speed.
•
In the 2nd, 3rd, and 4th speed travel, the lockup clutch ECMV operates at a speed greater than the speed being specified from the transmission controller.
10-98 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ There are two types of ECMVs used. Their differences and distinctions are listed in the following table. Printing on Name Plate (A)
Flow Detector Valve
Fill Switch (Operation pressure)
Clutch Used
D*******
Installed (without slit)
Installed 2.45 kg/cm² (35 psi)
F, R, 1st, 2nd, 3rd, 4th
K*******
Not installed
Not installed
L/U
★ L/U indicates the lockup clutch ECMV
WA500-6
10-99 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
ECMV (Electronic Control Modulation Valve) For F, R, 1st, 2nd, 3rd, and 4th clutch ★ Do not try to disassemble the ECMV since an adjustment for maintaining the performance is needed.
A.
To clutch
1.
Fill switch connector
P.
From pump
2.
Proportional solenoid connector
T.
Drain
3.
Flow ate pickup valve
Dr. Drain
4.
Fill switch
P1. Clutch oil pressure pickup port
5.
Proportional solenoid
6.
Pressure control valve
7.
Nameplate
Torque Values Designation
N•m
lbf in
AA
11.27 ±1.47
100 ±13
BB
4.9 – 6.9
43 – 61
10-100 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Pressure Control Valve and Fill Switch ★ The ECMV consists of one pressure control valve and one fill switch. Pressure Control Valve •
The pressure control valve receives the current sent from the transmission controller with a proportional solenoid.
•
The valve converts the current into oil pressure.
Fill Switch The fill switch detects that the clutch is filled with oil and has the following functions. 1.
Outputs a signal (a fill signal) to the controller to indicate that filling is completed when the clutch is filled with oil.
2.
Keeps outputting signals (fill signals) to the controller to indicate whether or not oil pressure is applied while oil pressure is applied to the clutch. Range A: . . . . . . . . . . . . . . . . Before shifting gear (when draining) Range B: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . During filling Range C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulation Range D: . . . . . . . . . . . . . . . . . . . . During filling (during triggering) Point E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of filling Point F: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finish of filling
★ The logic is that the controller does not recognize completion of filling even if the fill switch is turned ON during triggering (Range D).
ECMV and Proportional Solenoid •
For each ECMV, one proportional solenoid is installed.
•
The proportional solenoid generates thrust according to the command current from the controller, as shown in the graph to the right. ★ Current – propulsion force characteristics of proportional solenoid (figure to the right)
WA500-6
10-101 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure to the right.
•
The thrust is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil.
POWER TRAIN
★ Propulsion force - Hydraulic pressure characteristics of proportional solenoid (figure to the right) ECMV and Fill Switch ★ For each ECMV, one fill switch is installed. If the clutch is filled with oil, the fill switch is turned ON by the pressure of the clutch. The oil pressure is built up according to this signal.
Operation of ECMV •
ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal.
•
The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below. Range A: . . . . . . . . . . . . . . . . Before shifting gear (when draining) Range B:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . During filling Range C: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulation Range D: . . . . . . . . . . . . . . . . . . . . During filling (during triggering) Point E: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start of filling Point F: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Finish of filling
★ The logic is that the controller does not recognize completion of filling even if the fill switch is turned ON during triggering (Range D).
10-102
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Before Shifting Gear (when draining) (Range A in chart) •
While no current is flowing in proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).
•
At this time, since no oil pressure is applied to flow rate pickup valve (4), fill switch (5) is turned OFF.
During Filling (Range B in chart) •
If a current is given to proportional solenoid (1) while there is no oil in the clutch, a hydraulic force, balanced with the solenoid force, is applied to chamber (B) and pushes pressure control valve (3) to the left. This conducts oil through pump port (P) and orifice (a) of flow rate pickup valve (4) to start filling the oil to the clutch chamber.
•
At this time, differential pressure is generated between the upper stream and down stream of orifice (a) of flow rate pickup valve (4). This differential pressure pushes flow rate pickup valve (4) to the left.
•
As the clutch chamber is filled up with oil and the oil flow from pump port (P) to clutch port (A) is stopped, differential pressure before and after orifice (a) of flow rate pickup valve (4) disappears. As the result, flow rate pickup valve (4) is pushed to the right, turning ON fill switch (5).
WA500-6
10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Pressure Regulation (Range C in chart) •
If current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
•
This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in the clutch port and the repulsive force of pressure control valve spring (2). In this manner, the pressure is settled.
10-104
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
For Lockup Clutch ★ Do not try to disassemble the ECMV since an adjustment for maintaining the performance is needed.
A.
To clutch
1.
Proportional solenoid connector
P.
From pump
2.
Sleeve
T.
Drain
3.
Proportional solenoid
Dr. Drain
4.
Pressure control valve
P1. Clutch oil pressure pickup port
5.
Nameplate
Torque Values Designation
N•m
lbf in
AA
11.27 ±1.47
100 ±13
BB
4.9 – 6.9
43 – 61
WA500-6
10-105 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Outline ECMV for Lockup Clutch •
This valve is used to switch the clutch in order to regulate the clutch oil pressure to the set pressure.
•
Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of connecting the lockup clutch smoothly, thereby reducing shocks resulting from gearshift.
•
This also prevents generation of peak torque in the power train. These arrangements make the machine comfortable for the operator and enhance durability of the power train. ★ When changing from torque converter travel to direct travel
★ At gearshift (in direct travel)
10-106 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Operation When Clutch is Disengaged (released) •
While no current is flowing into proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T).
When Clutch is Engaged (fixed) •
As current is conducted to proportional solenoid (1), the oil pressure being balanced with the solenoid force is applied to chamber (B), pushing pressure control valve (3) to the left. This opens pump port (P) and clutch port (A) to start filling oil to the clutch.
•
As the clutch is filled with oil, the solenoid thrust is balanced with the sum of the thrust generated from the oil pressure of the clutch port and the tension of the pressure control valve spring (2). In this manner, the pressure is settled.
WA500-6
10-107 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Main Relief Valve and Torque Converter Relief Valve
A.
Drain (torque converter relief)
B.
Drain
C. From pump D.
Drain
E.
To torque converter
P1. Main relief oil pressure pickup port P2. Torque converter relief pressure pickup port
6.
Body
7.
Piston
8.
Torque converter relief valve
9.
Piston
10. Main relief valve
10-108 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No.
1
2
Check Item
Criteria Standard Size
Clearance between main relief valve and valve body
Clearance between torque converter relief valve and valve body
Tolerance Shaft
Hole
Standard Clearance
Clearance Limit
28 (1.10)
-0.035 (-0.0014) +0.013 (+0.0005) 0.035 – 0.058 -0.045 (-0.0018) +0 (0).000 (0.0014 – 0.0023)
0.078 (0.0031)
22 (0.87)
-0.035 (-0.0014) +0.013 (+0.0005) 0.035 – 0.058 -0.045 (-0.0018) +0.(0).00 (0.0014 – 0.0023)
0.078 (0.0031)
Standard Size 3
Remedy
Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
128 (5.04)
78.3 (3.08)
479.1 N (107.71 lbf)
124.2 (4.89)
456 N (102.51 lbf)
Main relief valve spring (Outside)
4
Main relief valve spring (Inside)
108 (4.25)
78.3 (3.08)
365.5 N (82.17 lbf)
104.8 (4.13)
347 N (78.01 lbf)
5
Torque converter relief valve spring
50 (1.97)
43 (1.69)
134.3 N (30.19 lbf)
48.5 (1.91)
127 N (28.55 lbf)
Replace
Torque Values Designation
N•m
lbf ft
lbf in
AA
9.8 – 12.74
–
87 – 113
BB
44.1– 53.9
33 – 40
–
WA500-6
10-109 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Outline Torque Converter Relief Valve •
The torque converter relief valve regulates the torque converter inlet circuit pressure below the set pressure to protect the torque converter from abnormally high pressure. Set pressure: . . . . . . . . . 8.57 kg/cm² (122 psi) (cracking pressure)
Main Relief Valve •
The main relief valve regulates the pressure in the transmission and brake hydraulic circuits below the set pressure. Set pressure: . . . . . . . . 37.12 kg/cm² (528 psi) (at rated engine speed)
Operation Torque Converter Relief Valve •
The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3).
•
As the oil pressure to the torque converter goes beyond the set pressure, the oil conducted to chamber (G) pushes piston (4). The resulting resisting force pushes torque converter relief valve (3) to the right, opening ports (E) and (A).
•
As the result, the oil in port (E) is drained through port (A).
Main Relief Valve •
The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve, and orifice (a) of main relief valve (1).
•
As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2). The resulting resisting force pushes spool (1) to the left, opening ports (C) and (E).
•
This operation conducts the oil from port (E) to the torque converter.
10-110 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-111 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Lubrication Relief Valve
A.
From oil cooler
B.
Drain
C.
Lubricant pressure pickup port
3.
Valve body
4.
Spool
Function •
The lubrication relief valve is installed to the transmission valve.
•
This valve is used for maintaining the pressure of the lubrication circuit below the set pressure. Set pressure: . . . . . . . . . . 2.65 kg/cm² (38 psi) (cracking pressure)
10-112 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm No.
1
Check Item
Criteria
Clearance between spool and valve body
Standard Size 22 (0.87)
Tolerance Shaft
Hole
Valve spring
Standard Clearance
-0.035 (-0.0014) +0.013 (+0.0005) 0.035 – 0.058 -0.045 (-0.0018) +0.000 (+0.000) (0.0014 – 0.0023) Standard size
2
Remedy Clearance Limit 0.078 (0.0031)
Repair limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
59.7 (2.35)
37 (1.46)
97.4 N (21.9 lbf)
57.9 (2.28)
92.6 N (20.8 lbf)
Replace
Torque Values Designation
N•m
lbf ft
lbf in
AA
58.5 – 78.4
43 – 58
–
BB
9.8 – 12.74
–
87 – 113
WA500-6
10-113 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Converter Oil Cooler
1.
Torque converter oil cooler
A.
Inlet port
B.
Outlet port
C.
Coolant inlet
D.
Coolant outlet
Outline •
Oil from the torque converter is heated by power transmitting energy.
•
This oil enters the torque converter oil cooler through inlet port (A) to be cooled by the engine coolant.
•
It then flows into the transmission lubrication system through outlet port (B).
10-114 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-115 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Converter Oil Filter
10-116 b
A.
Inlet port
B.
Outlet port
1.
Relief valve
2.
Element
3.
Drain plug
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Specifications Filtering area: . . . . . . . . . . . . . . . . . 8,900 cm2 x 2 (1,379.5 in2 x 2) Relief pressure: . . . . . . . . . . . . . . . . . . . . . . . 3.26 kg/cm² (46 psi)
Operation •
Oil from the torque converter charge pump enters filter inlet port (A). It passes from the outside to the inside of element (2) and flows to outlet port (B).
•
When element (2) is clogged with foreign matter or when low oil temperature has caused pressure at inlet port (A) to increase, oil from inlet port (A) opens relief valve (1) to flow to outlet port (B) directly, preventing the pump and element (2) from being damaged.
WA500-6
10-117 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Center Support
1.
Front coupling
2.
Case
3.
Breather
4.
Rear coupling
Outline •
The center support is installed between the center drive shaft and front drive shaft that are provided on the front frame.
•
With the articulating frame, this part is constantly twisting from side to side. There is likely to be a large stress on the drive shaft.
•
The center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and, in this way, to improve the durability of the drive shafts.
10-118 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
MEMORANDUM
WA500-6
10-119 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-120 b
POWER TRAIN
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm No
1
Check Item
Criteria Tolerance
Standard Size
Clearance between case and bearing
Remedy
Shaft
Standard Clearance
Clearance Limit
Hole
140 (5.51)
– 0 (0).000 -0.036 (-0.0014) -0.018 (-0.0007) -0.061 (-0.0024)
-0.018 to -0.061 (-0.0007 to -0.0024)
-0.015 (-0.0006)
2
Clearance between case and bearing
130 (5.12)
0.(0)00 -0.036 (-0.0014) -0.018 to - 0.061 -0.018 (-0.0007) -0.061 (-0.0024) (-0.0007 to - 0.0024)
-0.015 (-0.0006)
3
Clearance between coupling shaft and bearing
80 (3.15)
+0.051 (+0.0020) –0 (0).000 +0.032 (+0.0013) -0.015 (-0.0006)
-0.032 to -0.066 (-0.0013 to -0.0026
-0.029 (-0.0011)
4
Clearance between coupling shaft and bearing
75 (2.95)
+0.051 (+0.0020) –0.(0)000 +0.032 (+0.0013) -0.015 (-0.0006)
-0.032 to -0.066 (-0.0013 to -0.0026
-0.029 (-0.0011)
5
Wear of oil seal contact surface
6
Wear of oil seal contact surface
7
End play of coupling shaft
Standard Size
Tolerance
Repair Limit
95 (3.74)
–0 (0)000 -0.087 (-0.0034)
-0.18 (-0.0071)
105 (4.13)
–0.(0)000 -0.087 (-0.0034)
-0.18 (-0.0071)
Preload 3.9 N•m (35 lbf in) max.
Replace
Repair by chromiumplating or replace
Replace
Torque Values Designation
N•m
lbf ft
A
932 ±98
687 ±72
B
65.7 ±6.9
49 ±5
WA500-6
10-121 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Axle Front Axle
10-122 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Oil filler plug
2.
Front axle
3.
Level plug
4.
Front differential
5.
Front brake
6.
Final drive
7.
Drain plug
POWER TRAIN
Torque Values Designation
N•m
lbf ft
lbf in
AA
29.4 – 39.2
22 – 29
–
BB
58.8 – 78.4
43 – 58
–
CC
343 – 441
253 – 325
–
DD
127 – 176
947 – 130
–
EE
490 – 608
361 – 448
–
FF
3.9 – 6.9
–
35 – 61
GG
824 – 1030
608 – 760
–
WA500-6
10-123 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Rear Axle
10-124 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Level plug
2.
Oil filler plug
3.
Rear axle
4.
Rear differential
5.
Rear brake
6.
Final drive
7.
Drain plug
8.
Oil temperature sensor
POWER TRAIN
Torque Values Designation
N•m
lbf ft
lbf in
AA
29.4 – 39.2
22 – 29
–
BB
58.8 – 78.4
43 – 58
–
CC
127 – 176
94 – 130
–
DD
245 - 309
181 – 228
–
EE
343 – 441
253 – 325
–
FF
490 – 608
361 – 448
–
GG
3.9 – 6.9
–
35 – 61
HH
59 – 74
44 – 55
–
JJ
29.4 – 49.0
22 – 36
–
WA500-6
10-125 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Differential Front Differential
10-126 b
1.
Pinion gear (Number of teeth: 12)
2.
Bevel pinion (Number of teeth: 9)
3.
Shaft
4.
Side gear (Number of teeth: 24)
5.
Bevel gear (Number of teeth: 38)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Front Differential (with Limited Slip Differential)
WA500-6
1.
Pinion gear (Number of teeth: 12)
2.
Bevel pinion (Number of teeth: 9)
3.
Shaft
4.
Side gear (Number of teeth: 24)
5.
Bevel gear (Number of teeth: 38)
10-127 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Rear Differential
10-128 b
1.
Pinion gear (Number of teeth: 12)
2.
Bevel pinion (Number of teeth: 9)
3.
Shaft
4.
Side gear (Number of teeth: 24)
5.
Bevel gear (Number of teeth: 38)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Rear Differential (with Limited Slip Differential)
WA500-6
1.
Pinion gear (Number of teeth: 12)
2.
Bevel pinion (Number of teeth: 9)
3.
Shaft
4.
Side gear (Number of teeth: 24)
5.
Bevel gear (Number of teeth: 38)
10-129 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ This diagram shows the front differential mechanism.
10-130 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No
Check Item
Criteria Standard Size
1
Clearance in side bearing outer race of differential gear assembly
2
Clearance in side bearing inner race of differential gear assembly
3
Clearance in outer race of bevel pinion shaft bearing
4
Clearance in inner race of bevel pinion shaft bearing
5
Clearance in outer race of bevel pinion shaft bearing
6
Clearance in inner race of bevel pinion shaft bearing
7
Clearance between differential carrier and cage
8
Clearance between spider and differential pinion bushing
9
Clearance between pinion and differential pinion bushing
Remedy
Tolerance Standard Clearance
Clearance Limit
Shaft
Hole
200 (7.87)
0 (0) -0.015 (-0.0006)
+0.012 (+0.00047) -0.013 (-0.00051)
-0.013 – 0.027 (-0.0005 – 0.0011)
—
130 (5.12)
+0.090 (+0.0035) +0.065 (+0.0026)
0.(0) -0.025 (-0.0010
-0.065 to -0.115 (-0.0026 to -0.0045)
—
215 (8.46)
0 (0) -0.030 (-0.0012)
-0.050 (-0.0020) -0.079 (-0.0031)
-0.020 to -0.079 (-0.0008 to -0.0031)
—
100 (3.94)
+0.045 (+0.0018) +0.023 (+0.0009)
0 (0) -0.020 (-0.0008)
-0.023 to -0.065 (-0.0009 to -0.0026)
—
165 (6.50)
+0.21 (+0.0083) +0.10 (+0.0039)
+0.063 (+0.0025) – 0 (0)
-0.037 to -0.21 (-0.0015 to -0.0083)
—
75 (2.95)
+0.039 (+0.0015) +0.020 (+0.0008)
–0.(0) -0.015 (-0.0006)
-0.020 to -0.054 (-0.0008 to -0.0021)
—
320 (12.60)
-0.018 (-0.0007) -0.075 (-0.0030)
+0.057 (+0.0022) –0.(0)
0.018 – 0.132 (0.0007 – 0.0052)
—
40 (1.57)
-0.13 (-0.0051) -0.18 -0.0071)
+0.03 (+0.0012) -0.02 -0.0008)
0.021 to -0.11 (0.00083 to -0.00433)
—
46 (1.81)
-0.025 (-0.0010 -0.050 (-0.0020)
+0.03 (+0.0012) -0.02 (-0.0008)
0.005 – 0.080 (0.0002 – 0.0031)
10 Backlash of bevel gear
0.30 – 0.45 (0.012 – 0.018)
11 Backlash of differential gear
0.36 – 0.51 (0.014 – 0.020)
12 End play of bevel pinion gear
Max. 0.64 (Max. 0.025)
Free rotational torque of bevel gear
Max. 8.34 N•m (Max. 6.15 lbf ft)
14 Rear runout of bevel gear
0.1 (0.004)
13
15
Clearance between bolt and cap
WA500-6
Replace
0.08 – 0.13 (0.003 – 0.005)
10-131 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ This diagram shows the front differential mechanism.
10-132 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No 1
Check Item
Criteria
Remedy
Standard Size
Tolerance
Repair Limit
4 (0.16)
±0.05 (±0.0020)
3.8 (0.15)
Thickness of side gear washer
2
Thickness of bevel pinion gear washer
3 (0.12)
±0.08 (±0.0031)
1.35 (0.05)
3
Wear of oil seal contact surface
105 (4.13)
0 (0) -0.087 (-0.0034)
—
Replace
Torque Values Designation
N•m
lbf ft
B
490 – 608
361 – 448
C
824 – 1030
608 – 760
D
27 – 34
20 – 25
E
245 – 309
181 – 228
F
1520 – 1910
1121 – 1409
G
107.8 – 147.0
80 – 108
WA500-6
10-133 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Outline •
The power from the engine is transmitted through the torque converter, transmission, and drive shafts to the front and rear axles.
•
In each axle, the direction of the power is changed by 90° and the rotation speed is reduced by bevel pinion (1) and bevel gear (5). The power is then transmitted through the differential mechanism to axle shafts (2).
•
The power of the axle shaft is further reduced in speed by the final drive of the planetary gear type and then transmitted to the wheels.
While Machine is Traveling Straight •
While the machine is traveling straight, the right and left wheels rotate at the same speed.
•
Pinion gears (4) in the differential assembly do not rotate and the power of carrier (6) is transmitted through pinion gears (4) and side gears (3) to right and left axle shafts (2) evenly.
While Machine is Turning •
While the machine is turning, the right and left wheels rotate at different speeds.
•
Pinion gears (4) and side gears (3) in the differential assembly rotate and transmit the power of carrier (6) to axle shafts (2), depending on the difference in rotation speed between the right and left wheels.
10-134 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Limited Slip Differential (if equipped)
1.
Washer
2.
Disc
3.
Plate
4.
Pressure ring
5.
Cover
6.
Shaft
7.
Side gear
8.
Shaft
9.
Case
10. Pinion 11. Bevel gear
WA500-6
10-135 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Operation of Limited Slip Differential •
The power from the transmission is transmitted through bevel gear (11), case (9), pressure rings (4), shaft (8), and pinion (10) to side gears (7), and then distributed to the right and left shafts (6).
•
The brake mechanism, consisting of disc (2) and plate (3), is installed to the back side of each side gear (7). It generates braking torque in proportion to the torque transmitted from pressure rings (4) to shaft (8).
•
Since the brake torque restricts the rotation of side gears (7) and case (9), right and left side gears (7) cannot rotate freely; thus the operation of the differential is restricted.
Generation of Braking Torque by Right and Left Side Gears (7) •
Shaft (8) is supported on the cam surfaces made on the surfaces of pressure rings (4) which are facing each other.
•
The power (= torque) transmitted from pressure rings (4) to shaft (8) is transmitted on the cam surfaces.
•
Force (Fa) to separate both pressure rings (4) is generated by inclination of the cam surfaces in proportion to the transmitted torque. Separating load (Fa) acts on the brake on the back side of each side gear (7) to generate braking torque.
While Machine is Traveling Straight 1.
When drive forces of right and left wheels are balanced. ★ [When the road conditions (coefficients of friction) under both wheels and the wheel loads are even and the center of the load is at the center of the bucket.] • •
The power from the transmission is distributed evenly by the differential gears to the right and left. Under this condition, the slip limits of the right and left wheels are the same. When the power from the transmission exceeds the slip limits, both wheels slip and the differential does not work. No load is applied to the brake on the back side of each side gear.
10-136 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 2.
POWER TRAIN
When drive forces of right and left wheels are unbalanced. ★ [When the road conditions (coefficients of friction) under both wheels and the wheel loads are uneven and either wheel slips more easily.]
• •
• • •
★ Example 1: When either wheel is on soft ground in digging work. ★ Example 2: When either wheel is on snow and the other one is on asphalt in snow removing work. ★ Example 3: When the right and left wheel loads are unbalanced in travel on a slope. The power from the transmission is distributed evenly by the differential gears to the right and left. If the distributed drive force limits the wheel slip limit on the slipping side, the excess of the drive force is transmitted through the brake on the back side of the side gear and the case to the brake on the opposite side (locked side) and given to the locked wheel. Only when the excessive drive force exceeds the braking force, the differential starts working. On a road where either wheel slips easily, the drive force of the limited slip differential is 1.82 times as great as that of the ordinary differential. The table shows the difference of wheel drive force in each type of differential when either wheel slips. Wheel Drive Force (Drive force of slipping wheel is 1) Slipping Wheel
Locked Wheel
Total (Ratio)
Limited slip differential (if equipped)
1
2.64
3.64 (1.82)
Ordinary differential
1
1
2 (1)
While Machine is Turning •
The differential gears in the limited slip differential operate similarly to those in the ordinary differential.
•
In this manner, a difference in rotation speed between the outer and inner tires, necessary for turning, is generated smoothly.
WA500-6
10-137 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
★ This diagram shows the front limited slip differential mechanism.
10-138 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No
Check Item
Criteria Standard Size
1
Clearance in side bearing outer race of differential gear assembly
Remedy
Tolerance Standard Clearance Shaft
Hole
200 (7.87)
0 (0) -0.015 (-0.0006)
+0.012 (+0.00047) -0.013 – 0.027 -0.013 (-0.00051 – 0.00106) (-0.00051)
—
130 (5.12)
+0.090 (+0.0035) +0.065 (+0.0026)
–0 (0) -0.025 (-0.0010)
-0.065 to -0.115 (-0.0026 to - 0.0045)
—
215 (8.46)
–0 (0) -0.030 (-0.0012)
-0.050 (-0.0020) -0.079 (-0.0031)
-0.020 to -0.079 (-0.0008 to -0.0031)
—
100 (3.94)
+0.045 (+0.0018) 0.023 (0.0009)
–0 (0) -0.020 (-0.0008)
-0.023 to -0.065 (-0.0009 to -0.0026)
—
165 (6.50)
+0.21 (+0.0083) +0.10 (+0.0039)
+0.063 (+0.0025) –0 (0)
-0.037 to -0.21 (-0.0015 to -0.0083)
—
75 (2.95)
+0.039 (+0.0015) +0.020 (+0.0008)
–0 (0) -0.015 (-0.0006)
-0.020 to -0.054 (-0.0008 to -0.0021)
—
320 (12.60)
-0.018 (-0.0007) -0.075 (-0.0030)
+0.057 (+0.0022) –0 (0)
0.018 – 0.132 (0.0007 – 0.0052)
—
2
Clearance in side bearing inner race of differential gear assembly
3
Clearance in outer race of bevel pinion shaft bearing
4
Clearance in inner race of bevel pinion shaft bearing
5
Clearance in outer race of bevel pinion shaft bearing
6
Clearance in inner race of bevel pinion shaft bearing
7
Clearance between differential carrier and cage
8
Backlash of bevel gear
0.30 – 0.45 (0.012 – 0.018)
9
Backlash of differential gear
0.36 – 0.51 (0.014 – 0.020)
10 End play of bevel pinion gear
Max. 0.64 (Max. 0.025)
Free rotational torque of bevel gear
Max. 8.34 N•m (Max. 6.15 lbf ft)
12 Rear runout of bevel gear
0.1 (0.0039)
11
13
Clearance between bolt and cap
Replace
0.08 – 0.13 (0.0031 – 0.0051) Standard Size
14 Thickness of plate
Clearance Limit
Tolerance
Repair Limit
±0.02 (±0.0008)
3.6 (0.1417)
±0.07 (±0.0028)
3.915 (0.154)
3.4 (0.134) 3.5 (0.138)
15 Thickness of disc
WA500-6
3.2 (0.126)
10-139 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN Unit: mm (in)
No
Check Item
Criteria
16
Clearance between disc and plate (end play)
0.2 – 0.8 (0.0079 – 0.0315) Standard Size
Remedy
Tolerance
Repair Limit
±0.05 (±0.0020)
3.8 (0.1496)
0 (0) -0.087 (-0.0034)
—
3.75 (0.1476) 17 Thickness of washer 4.0 (0.1575)
Replace
4.25 (0.1673) 18
Wear of coupling seal sliding surface
105 (4.134)
Torque Values Designation
N•m
lbf ft
B
490 – 608
361 – 448
C
824 – 1030
608 – 760
D
27 – 34
19.91 – 25.08
E
245 – 309
181 – 228
F
1520 – 1910
1121 – 1409
G
107.8 – 147.0
80 – 108
10-140 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Final Drive
WA500-6
1.
Axle shaft
2.
Sun gear (Number of teeth: 17)
3.
Ring gear (Number of teeth: 70)
4.
Planetary carrier
5.
Planetary gear (Number of teeth: 26)
6.
Wheel
10-141 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Torque Values Designation
N•m
lbf ft
B
44.1 – 53.9
33 – 40
C
245 – 309
181 – 228
D
98 – 123
72 – 91
E
157 – 196
116 – 145
F
27 – 34
20 – 25
G
58.8 – 78.4
43 – 58
H
59 – 74
44 – 55
10-142 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Unit: mm (in) No
Check Item
Criteria Tolerance
Standard Size 1
Clearance between planetary shaft and bearing
2
Clearance between ring gear hub and bearing
3
Thickness of ring gear mounting retainer
Remedy
Hole
50.8 (1.999)
+0.029 (+0.0011) +0.016 (+0.0006)
+0.013 (+0.0005) +0 (0)
-0.003 to -0.029 (-0.0001 to -0.0011)
—
220.662 (8.687)
+0.063 (+0.0025) +0.034 (+0.0013)
+0.025 (+0.0010) 0 (0)
-0.009 to -0.063 (-0.0004 to -0.0025)
—
Standard Size
Tolerance
Repair Limit
22 (0.866)
±0.1 (±0.0039)
21.6 (0.850)
Backlash of planetary gear and sun gear
0.19 (0.0075)
5
Backlash of planetary gear and ring gear
0.20 (0.0079)
6
Standard shim thickness of wheel hub
2.3 (0.0906) Standard Size
Clearance between wheel hub and bearing
8
Clearance between tube and bearing
9
Clearance between wheel hub and bearing
WA500-6
Clearance Limit
Shaft
4
7
Standard Clearance
Tolerance
Replace
Standard Clearance
Clearance Limit
-0.036 (-0.0014) -0.068 (-0.0027)
-0.036 to -0.119 (-0.0014 to -0.0047)
—
190 (7.48)
-0.045 (-0.0018) -0.074 (-0.0029)
+0.072 (+0.0028) +0 (0).000
0.045 – 0.146 (0.0018 – 0.0057)
—
260 (10.24)
+0 (0) -0.004 (-0.00016)
-0.063 (-0.0025) -0.095 (-0.0037)
-0.059 to -0.095 -0.0023 to -0.0037)
—
Shaft
Hole
314.325 (12.375)
+0.051 (+0.0020) +0 (0).000
10-143 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
Outline The final drive is reduced by the planetary gear unit in order to gain increased force and then drive force is transmitted to the tires. Operation •
Power transmitted from the differential mechanism to sun gear (2) through axle shaft (1) is transmitted to planetary gear (5).
•
The planetary gear rotates inside fixed ring gear (3) to transmit reduced rotation to planetary carrier (4).
•
The power is transmitted to wheel (6) mounted onto the planetary carrier.
10-144 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
STEERING SYSTEM Steering Piping Diagram
1.
Steering cylinder (right)
6.
Steering pump
2.
Steering valve
7.
EPC and brake pump
3.
Stop valve (right)
8.
Steering control valve
4.
Work equipment pump
9.
Stop valve (left)
5.
Hydraulic tank
10. Steering cylinder (left)
WA500-6
10-145 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Steering Column
10-146 b
1.
Steering wheel
2.
Steering column
3.
Joint
4.
Steering valve
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Unit: mm (in) No
Check Item
5
Clearance between steering shaft and column bearing
Criteria Tolerance
Standard Size 19 (0.75)
Shaft
Hole
Remedy Standard Clearance
Clearance Limit
Replace
–0 (0) +0.15 (+0.006) 0.05 – 0.23 0.4 (0.016) -0.08 (-0.003) +0.05 (+0.002) (0.002 – 0.009)
Torque Values Designation
N•m
lbf ft
C
49 – 62
36 – 45
D
12 – 25
9 - 18
E
29.4 ±2.9
22 ±2
F
30 – 39
22 – 29
WA500-6
10-147 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Steering Control Valve
1.
Relief valve
A.
To steering cylinder
2.
Relief valve
B.
To steering cylinder
3.
Relief valve
Pa.
From steering valve
4.
Unload spool
Pb.
From steering valve
5.
Main spool
P.
From steering pump
PR. From steering pump (LS line)
10-148 b
T1.
Return
T2.
Drain
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Unit: mm (in) No
Check Item
Criteria Standard Size
1
Steering spool return spring
Remedy Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Allowable Load
37.2 (1.46)
32.0 (1.26)
56.9 N (12.79 lbf)
—
45.1 N (10.14 lbf)
2
Load check valve spring
20.9 (0.82)
18.3 (0.72)
2.9 N (0.65 lbf)
—
2.5 N (0.56 lbf)
3
Unload spool return spring
69.7 (2.74)
68.5 (2.70)
147.1 N (33.07 lbf)
—
120.6 N (27.11 lbf)
4
Relief valve spring
24.0 (0.94)
22.19 (0.87)
182.4 N (41.01 lbf)
—
145.1 N (32.62 lbf)
WA500-6
Replace
10-149 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Operation of Steering Control Valve When steering spool is at neutral position
•
The oil from the steering pump is conducted to port (A).
•
When the steering spool is at neutral, pressure-receiving chamber (II) is connected to the drain circuit through orifice (b) and notch (c) is closed.
•
Closed notch (c) increases pressure of oil in port (A). This increased pressure is then led through orifice (a) to pressurereceiving chamber (I) to drive demand spool (1) to the left.
•
As pressure of pressure-receiving chamber (I) reaches a specific level (this level is set from spring (3)), notch (f) opens to conduct oil from the steering pump to the drain circuit. Notch (g) also opens at this time to lead oil from the steering pump to low-pressure relief valve (4).
•
The pressure generated at low-pressure relief valve (4) is input to the steering pump as the pilot pressure (LS pressure) to be used for controlling the steering pump flow rate.
10-150 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
When steering spool is in operation
•
Operating the steering conducts oil from the steering valve to steering spool (2), pushing steering spool (2) to the right. Notch (c) opens as pressure-receiving chamber (II) and drain circuit are disconnected.
•
This operation increases pressure in pressure-receiving chamber (II), thereby moving demand spool (1) to the right.
•
The oil being conducted through notches (c) and (d) pushes load check valve (5) and then flows to the cylinder. Return oil from the cylinder flows to the drain circuit through notch (e).
•
At this time, the pressure of oil before passing through notch (c) is conducted to pressure-receiving chamber (I) and the pressure after passing through notch (c) is led to pressure-receiving chamber (II). Demand spool (1) operates so that the difference in pressures before and after passing through notch (c) may be maintained at constant level. The flow rate to the cylinder port depends on the opening of notch (c). These differences in the pressure are set from spring (3).
WA500-6
10-151 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Neutral
•
Since the steering wheel is not operated, steering spool (2) does not move.
•
The oil from the steering pump flows in port (A).
•
Demand spool (1) moves to the left as the pressure in port (A) increases.
•
Part of the oil from the steering pump is drained through port (B) of the spool and the other is conducted to the lowpressure relief valve through port (C).
10-152 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Turning right
•
Turning the steering wheel to the right activates the steering valve, moving steering (2) to the left.
•
The oil from the steering pump enters port (A) and then enters steering spool (2) through demand spool (1). This flow pushes open load check valve (6) of the spool. The oil is conducted to the bottom side of the left cylinder and the rod side of the right cylinder to turn the machine to the right.
•
The oil returned from the left and right cylinders is drained through the passage inside the steering spool.
WA500-6
10-153 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Turning left
•
Turning the steering wheel to the left activates the steering valve, moving steering (2) to the right. The oil from the steering pump enters port (A) and then enters steering spool (2) through demand spool (1). This flow pushes open load check valve (5) of the spool. The oil is conducted to the rod side of the left cylinder and the bottom side of the right cylinder to turn the machine to the left.
•
The oil returned from the left and right cylinders is drained through the passage inside the steering spool.
10-154 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Steering Relief Valve Function •
The steering relief valve is contained in the steering valve. This valve is used to set the maximum pressure of the steering circuit for the steering valve in operation.
•
If the pressure of the steering circuit increases beyond the relief valve-specified level while the steering valve is in operation, oil is relieved from this valve. The relief activates the spool of the demand valve, draining the oil to the steering circuit. 1.
Adjustment screw
2.
Spring
3.
Plug
4.
Pilot poppet
5.
Valve seat
WA500-6
10-155 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Operation of Steering Relief Valve
•
As the pressure of the circuit increases and reaches the level set from adjustment screw (1) and spring (2), pilot poppet (3) opens to drain the oil.
•
This breaks down the balance between pressure-receiving chambers (I) and (II) and, as the result, demand spool (4) is driven to the left.
•
The movement of demand spool (4) drains oil in the steering pump, preventing the steering circuit pressure from increasing beyond the set value.
10-156 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Safety Suction Valve FunctionP The safety valve installed on the steering valve has two functions. •
The safety valve function protects the steering cylinder or hydraulic piping from damages when an abnormal pressure is generated due to an impact applied to the steering cylinder while the steering valve is at neutral. In such a case, abnormal pressure is relieved from this valve.
•
The suction valve function prevents a vacuum state from occurring in the circuit when negative pressure is generated on the steering cylinder side. 1.
Poppet
2.
Safety valve poppet
3.
Check valve poppet
4.
Pilot poppet
5.
Spring
Operation of Safety Valve •
Port (A) and port (B) are connected to the cylinder circuit and drain circuit, respectively. After being conducted through poppet (1) hole, the oil works on the different areas of diameters (d1) and (d2). Check valve poppet (3) and safety valve poppet (2) are securely seated.
•
As the pressure of port (A) reaches the level specified from the safety valve, pilot poppet (4) opens. The oil flows around pilot poppet (4) and then flows to port (B) through the hole.
WA500-6
10-157 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
The opening of pilot poppet (4) decreases the pressure on the backside of poppet (1), starting the movement of poppet (1). By this movement, pilot poppet (4) is seated in its place.
•
Since the inside pressure is lower than that of port (A), safety valve poppet (2) opens. As the result, the oil is conducted from port (A) to port (B) and abnormally high pressure is prevented from being generated.
STEERING SYSTEM
Operation of Suction Valve •
As negative pressure is generated on port (A), check valve poppet (3) opens due to the difference in areas between diameters (d1) and (d3).
•
As the result, the oil is conducted from port (B) to port (A), preventing a vacuum from occurring.
10-158 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Steering Valve
WA500-6
1.
Needle bearing
7.
Center pin
2.
Centering spring
8.
Sleeve
3.
Drive shaft
9.
Spool
4.
Valve body
10. Stator
5.
Rotor
11. Lower cover
6.
Cover
10-159 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Outline •
The steering valve is directly connected to the shaft of the steering wheel.
•
The steering wheel operation activates the steering valve using the oil from the PPC pump as the pilot pressure. The oil from the steering valve is conducted through the steering valve to either the left or right steering cylinders to determine the machine traveling direction.
•
The steering valve is roughly divided into spool (9) and sleeve (8) which has the rotary selecting function. This valve is configured with the Gerotor set (combination of rotor (5) and stator (10)). In the normal steering operation, this set functions as a hydraulic motor. If the supply of oil is stopped due to a failure on the steering pump or engine, it functions as a hand pump to supply pilot pressure to the steering valve.
Structure •
Spool (9) is directly connected to the drive shaft of the steering wheel. It is also connected to sleeve (8) through center pin (7) (it is detached from the spool when the steering wheel is at Neutral) and the centering spring.
•
The top of drive shaft (3) is engaged with center pin (7) and thus combined with sleeve (8). The bottom is engaged with the spline of rotor (5) of the Gerotor set.
•
Valve body (4) has four ports. These ports are respectively connected to the pump circuit, tank circuit, steering cylinder head side and bottom side. The ports on the pump side and tank side are connected to the check valve in the body. If the pump or engine fails, this check valve permits suction of oil directly from the tank.
10-160 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Connection of Hand Pump and Sleeve •
The connections of suction and discharge openings of the Gerotor and sleeve ports are shown in the figure to the right.
•
If the steering wheel is turned to the right, ports (a), (c), (e), (g), (i), and (k) are connected to the pump side by the vertical grooves of the spool. Similarly, ports (b), (d), (f), (h), (j), and (l) are connected to the steering cylinder head side.
•
Under the condition in figure SBW00725, ports (1), (2), and (3) are in the discharge state of the Gerotor set and connected to ports (l), (b), and (d) and the oil is sent to the steering cylinder.
•
Ports (5), (6), and (7) are also connected and the oil from the pump flows in them.
•
The figure to the right shows the state after turning the steering wheel 90° from the previous condition. Here, ports (1), (2), and (3) are set to the suction state and connected to ports (i), (k), and (c). On the other hand, ports (5), (6), and (7) are set to the discharge state and connected to ports (d), (f), and (h).
WA500-6
10-161 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
•
As shown previously, the ports in the discharge state of the Gerotor are connected to the ports which are connected to the steering cylinder. The ports in the suction state are connected to the pump circuit.
•
Delivery adjustment is tailored to the steering angle of the steering wheel.
STEERING SYSTEM
The internal gear of the Gerotor advances by one tooth as the steering wheel rotates by 1/7 of a turn and discharges the oil from the pump according to the steering angle of the steering wheel. The discharge amount varies in proportion to the steering angle of the steering wheel.
10-162 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Role of Centering Spring •
Centering spring (2) is configured with three flat springs and four plate springs being laminated. This spring is assembled between spool (9) and sleeve (8) (see figure to the right). As the steering wheel is turned, the spool compresses the spring, generating a difference in rotation angle (angular displacement) between the spool and sleeve. This connects the spool and the port of the sleeve and sends oil to the cylinder.
•
As rotation of the steering wheel is stopped, rotation of the Gerotor is also stopped; the flow of oil to the cylinder is also stopped. This results in an increase in the oil pressure.
•
The center spring is used to avoid trouble. As rotation of the steering wheel is stopped, the center spring turns the sleeve by the difference in rotation angle (angular displacement) between the sleeve and spool in order to return the steering wheel to the Neutral position.
WA500-6
10-163 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Stop Valve
10-164 b
1.
Boot
A.
From steering valve
2.
Wiper
B.
To steering control (demand) valve
3.
Seal
DR: Drain
4.
Poppet
5.
Spring
6.
Spool
7.
Spring
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Joystick Steering Lever Linkage (if equipped) Joystick Steering System
1.
Joystick (steering lever)
2.
HI/LOW selector switch
3.
Console fore-aft adjustment lever
4.
Joystick ON/OFF switch
5.
Lock
6.
Steering lock switch
7.
Pad
8.
Console tilt lever
9.
Armrest adjustment lever
10. Lock cable
WA500-6
10-165 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Steering Cylinder
Unit: mm (in) No
1
2
3
4
Check Item Clearance between steering cylinder rod, bushing at frame connection, and mounting pin
Criteria Standard Size 65 (2.56)
Tolerance Shaft
Hole
Remedy Standard Clearance
–0 (0).000 +0.174 (+0.0069) 0.100 – 0.248 -0.074 (-0.0029) +0.100 (+0.0039) (0.0039 – 0.0098)
Clearance between steering cylinder bottom, –0 (0).000 +0.174 (+0.0069) 0.100 – 0.248 bushing at frame 65 (2.56) -0.074 (-0.0029) +0.100 (+0.0039) (0.0039 – 0.0098) connection, and mounting pin
Steering cylinder and front frame connection
Steering cylinder and rear frame connection
10-166 b
Boss Width
Hinge Width
Clearance Limit — Replace —
Standard Clearance (clearance between a + b)
75 ±1.2 (2.95 ±0.05)
79 ±1 (3.11 ±0.04)
1.8 – 6.2 (0.07 – 0.24)
75 ±1.2 (2.95 ±0.05)
79 ±1 (3.11 ±0.04)
1.8 – 6.2 (0.07 – 0.24)
After shim adjustment Max. 0.5 (0.020)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Unit: mm (in) No
Check Item
Criteria Standard Size
1
Clearance between piston rod and bushing
60 (2.362)
Tolerance Shaft
Hole
–0.030 –0.076 (–0.012) (–0.030)
+0.151 –0.006 (+0.006) (–0.0002)
Remedy Standard Clearance
Clearance Limit
0.024 – 0.227 (0.001 – 0.009)
0.527 (0.021)
2
Tightening torque of cylinder head
785 ±78.5 N•m {579 ±58 lbf ft}
3
Tightening torque of cylinder piston
1,770 ±180 N•m {1,306 ±133 lbf ft} (Width across flat: 60 mm)
4
Tightening torque of cylinder head port side plug
9.8 - 12.74 N•m {87 – 113 lbf in}
WA500-6
Replace pin and bushing
Retighten
10-167 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
MEMORANDUM
10-168 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Emergency Steering (if equipped) Piping Diagram
WA500-6
1.
Diverter valve
2.
Steering pump
3.
Hydraulic tank
4.
Emergency steering pump
5.
Transmission
10-169 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Diverter Valve (for emergency steering)
10-170 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Check valve
2.
Check valve
3.
Check valve
4.
Check valve
5.
Spool
6.
Valve body
A.
From emergency steering pump
B.
From emergency steering pump
D.
To steering demand valve
L.
Sensor mounting port
P.
From steering pump
S.
From hydraulic tank
T.
To hydraulic tank
STEERING SYSTEM
Function Where steering is disabled because the engine stops or the steering pump seizes while the machine is traveling, this function enables you to operate the steering wheel by using the rotations of the transmission to operate the emergency steering pump.
WA500-6
10-171 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-172 b
STEERING SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Unit: mm (in) No
Check Item
Criteria Tolerance
Standard Size 1
Clearance between body and spool 26 (1.02)
Shaft
Hole
-0.008 (-0.0003) -0.012 (-0.0005)
+0.015 (+0.0006) +0.009 (0.0004)
Standard Size 2
Spool return spring
Remedy Standard Clearance
Clearance Limit
0.017 – 0.027 (0.0007 – 0.0011)
—
Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
92 (3.62)
64 (2.52)
91.2 N (20.50 lbf)
90.5 (3.56)
86.3 N (19.40 lbf)
3
Check valve spring
54.4 (2.14)
38 (1.50)
4.0 N (0.90 lbf)
37.4 (1.47)
3.8 N (0.85 lbf)
4
Check valve spring
54.5 (2.15) 46.5 (1.83)
1.96 N (0.44 lbf)
53.6 (2.11)
1.84 N (0.41 lbf)
Replace
Torque Values Designation
N•m
lbf ft
B
30.5 ±3.5
23 ±3
C
66.5 ±7.5
49 ±6
D
58.8
43
WA500-6
10-173 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
Operation ★ If the pump and engine are normal.
•
If the steering pump and engine are operating normally, the steering pump is operated by the engine and oil can be sent to the steering valve to enable steering.
•
The emergency steering pump is operated by the transmission and push-open check valve (2) from port (A) of diverter valve (1) to direct the flow toward port (B). Spool (3) is pressed to the left as pressure oil flows from the steering pump toward port (D). For that reason, oil at port (B) flows to port (C) to be drained to the hydraulic tank.
10-174 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING SYSTEM
★ If the machine is running and the pump or engine has failed.
•
In a case where the machine is running and the pump or engine has failed, rotations from the tires operate the emergency steering pump through the transmission. No pressure oil appears at port (D) because the steering pump is not operating. For that reason, spool (3) is pressed by spring (4) to the right. The oil from the emergency steering pump goes through port (A) and port (B) and then flows to the steering valve to enable steering.
★ The emergency steering pump is enabled for normal and reverse rotations.
WA500-6
10-175 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
BRAKE SYSTEM Piping Diagram
1.
Accumulator charge valve
11. Front brake (right)
2.
Brake valve
12. Front brake (left)
3.
EPC and brake pump
13. Rear brake (right)
4.
Slack adjuster (rear)
14. Rear brake (left)
5.
Emergency parking brake cancel valve
15. Brake valve (right)
6.
Slack adjuster (front)
16. Brake valve (left)
7.
Transmission
17. Emergency brake switch (front)
8.
Accumulator
18. Emergency brake switch (rear)
9.
Accumulator (rear brake)
19. Hydraulic tank
10. Accumulator (front brake)
10-176 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA500-6
BRAKE SYSTEM
10-177 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Brake Valve
A.
To front brake
B.
To rear brake
PA. From accumulator charge valve ACC1 port PB. From accumulator charge valve ACC2 port TA. Drain port TB. Drain port
10-178 b
1.
Rod
2.
Piston
3.
Spool (for rear)
4.
Spool (for front)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Unit: mm (in) Standard Size No
Check Item
Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Length
Installed Load
5
Return spring
71.7 (2.82)
58.6 (2.31)
95.8 N (21.54 lbf)
66.1 (2.60)
—
—
6
Control spring
11 (0.43)
10 (0.39)
22.8 N (5.13 lbf)
—
—
—
7
Control spring
51.2 (2.02)
49.7 (1.96)
41.1 N (9.24 lbf)
—
—
—
8
Control spring
31 (1.22)
—
—
—
—
—
9
Control spring
23.5 (0.93)
—
—
—
—
—
10 Return spring
40.1 (1.58)
27.5 (1.08)
17.2 N (3.87 lbf)
—
—
—
Remedy
Replace
WA500-6
10-179 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Outline •
The brake valve is installed in the lower, front side of the operator’s seat. Pressing the brake pedal conducts oil to the brake piston, operating the brake.
•
The left side and right side brake pedals are mechanically interlocked. Pressing one of the pedals operates the other pedal at the same time.
•
Working with the transmission cutoff switch, the brakes operate the transmission control valve electrically to set the transmission to the neutral position.
Operation When brake operated •
Pedal (1) pressing effort is transmitted to spool (4) through rod (2), piston (3), and spring (5).
•
As spool (4) is pushed to the right, connection is cut off between port (A) and port (T). The oil from the pump and accumulator is conducted to port (A) through port (PA) to operate the front brake cylinder.
•
The pressing effort transmitted to spool (4) is further transmitted through plunger (7) to spool (6).
•
As spool (6) is pushed to the right, connection is cut off between port (B) and port (T). The oil from the pump and accumulator is conducted to port (B) through port (PB) to operate the rear brake cylinder.
10-180 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
When one side of brake alone is operated (when the other brake failed) •
Even when only one of the brakes remains operable due to leakage of oil in the front or rear brake system, brake pedal (1) pressing effort mechanically moves spool (4) and spool (6) to the right.
•
The oil from the pump is normally supplied to the normal brake piston, enabling it to continue the operation. The brake, therefore, is capable of stopping the machine as needed to ensure the intended safety level.
WA500-6
10-181 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Balancing Operation •
If the front brake cylinder is filled with oil and oil pressure between port (PA) and port (A) increases, the oil is conducted from orifice (e) of spool (4) to chamber (E).
•
The oil pushes spool (4) resisting against spring (5), disconnecting ports (PA) and (A).
•
Since port (A) is kept disconnected from port (T), the brake is kept operated by the oil pressure applied to the brake cylinder.
•
If ports (PA) and (A) of spool (4) are disconnected, the front brake cylinder is filled with the oil and the pressure in the line between ports (PB) and (B) rises simultaneously. The oil then flows through orifice (f) of spool (6) to chamber (F).
•
The oil pushes up spool (6) by the moving distance of spool (4) and disconnects port (PB) from port (B).
•
Since port (B) is kept disconnected from port (T), the brake is kept operated by the oil pressure applied to the brake cylinder.
•
The operating force of the front brake circuit (port A side) is balanced against the pedal pressing effort and the operating force of the rear brake circuit (port B side) is balanced against that of the front brake circuit (port A side).
•
When spools (4) and (6) are moved to the stroke end, ports (PA) and (A) connect completely; ports (PB) and (B) also connect completely. As a result, the oil pressure in the front and rear brake cylinders is equal to the oil pressure from the pump.
•
The braking force can be adjusted by adjusting the pedal pressing effort until spools (4) and (6) are moved to the stroke end.
10-182 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
As brake is released •
If pedal (1) is released, the operating pressure being applied to spool (4) is reduced. Spool (4) is pushed back by the back pressure on the brake cylinder and the tension of the spool return spring.
•
Ports (A) and (T) are connected and the back pressure oil on the brake cylinder is drained through port (T); the front brake is released.
•
In the same manner as spool (4) was pushed back, spool (6) is also pushed back by the back pressure on the brake cylinder and the spool return spring tension.
•
Ports (B) and (T) are connected and the back pressure oil on the brake cylinder is drained through port (T); the rear brake is released.
WA500-6
10-183 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Slack Adjuster
1.
Cylinder
A.
Inlet port
2.
Check valve
B.
Outlet port
3.
Piston
4.
Spring
5.
Bleeder
Function The slack adjuster is installed on the brake oil line leading to the brake piston from the brake valve, and functions to keep the time lag during brake operation at a fixed level. Specifications Hydraulic oil pressure of piston: . . . . . . . . . . . . . . . . . . . . 0.10 (+0.10/0) kg/cm² (1.42 (+1.42/0) psi) Check valve cracking pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.48 ±0.51 kg/cm² (135 ±7 psi) Check valve closing pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.02 ±0.51 kg/cm² (86 ±7 psi)
10-184 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Unit: mm (in) No
6
Check Item
Criteria Tolerance
Standard Size
Clearance between body and piston
55 (2.17)
Shaft
Hole
-0.030 (-0.0012) -0.076 (-0.0030)
+0.074 (+0.0029) +0 (0).000
Standard size 7
8
Spring
Standard Clearance
Clearance Limit
0.030 – 0.150 (0.0012 – 0.0059)
0.25 (0.010)
Repair limit
Free Length
Installed Length
Installed Load
198 (7.80)
60 (2.36)
39.2 N (8.81 lbf)
39.2 (1.54)
33 (1.30)
66.7 N (14.99 lbf)
Slack adjuster spring
Remedy
Free Length
Replace
Allowable Load
Torque Values Designation
N•m
lbf ft
lbf in
A
50 – 65
37 – 48
–
B
60 – 75
44 – 55
–
C
7–9
–
62 – 80
WA500-6
10-185 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Operation When the brake pedal is pressed down •
Before the brake is pressed down, piston (4) is restored equal to the amount of stroke (S) (a full stroke). When the brake pedal is pressed down, oil discharged from the brake valve branches into right and left cylinders (2) from port (P) of the slack adjuster to move piston (4) equal to the amount of stroke (S) to the right and the left.
•
This move causes brake piston (7) to move equal to stroke (S). At this time, the relationship between brake piston (7) and the disc is that the clearance is reduced to zero and no braking force is generated.
•
As the brake valve is kept pressed down further, oil pressure from the brake valve exceeds the specified value to open check valve (3). Port (C) is imposed pressure to function as the braking force. The time lag when the brake is in operation is maintained at the same value.
When the brake pedal is released •
When the brake is released, return spring (8) of the brake piston (7) equal to the amount of oil of stroke (S) and the brake returns to its released state. In other words, return stroke (T) of brake piston (7) depends on the amount of oil of piston stroke (S). The braking time lag stays the same regardless of the amount of wear of the brake disc.
10-186 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Accumulator Charge Valve
A1.
To work equipment valve
A2.
To Orbitrol
ACC1. To brake valve PA ACC2. To brake valve PB
WA500-6
PP.
From pump
T.
Drain
10-187 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
1.
Valve body
2.
Main relief valve (R3)
3.
Relief valve (R1)
4.
Relief valve (R2)
5.
Relief valve (H1)
Function •
The accumulator charge valve keeps the oil pressure from the pump to the set pressure and stores it in the accumulator.
•
If the oil pressure rises above the set pressure, the oil from the pump is led to the drain circuit to reduce the load on the pump.
10-188 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Operation ★ When oil is not supplied to accumulator (Cutout state) •
Since the pressure at port (B) is higher than the set pressure of relief valve (R1), piston (2) is forced to move upward by the hydraulic pressure of port (B). As this move opens poppet (1), port (C) and port (T) are connected.
•
As the right-most spring chamber of spool (6) leads to port (C) of relief valve (R1), tank pressure prevails.
•
Oil from the pump enters port (P) and pushes spool (6) to the right with a low pressure equivalent to the load of spring (5), and then flows from port (A) to the steering valve and the work equipment valve.
•
At the same time, it flows to the tank through orifices (7), (4), and (3).
★ When oil is supplied to accumulator 1.
Cut-in state • If the pressure at port (B) drops below the set pressure of relief valve (R1), piston (2) is returned downward by the tension of spring (8). This causes valve seat (9) to closely contact poppet (1) to disconnect port (C) from port (T). • The right-hand side spring chamber of spool (6) also gets shuttered off from port (T) to increase pressure, leading pressure at port (P) to rise as well. • When pressure at port (P) exceeds the pressure at port (B) (accumulator pressure), oil supply to the accumulator starts. This timing is determined by the area size of orifice (7) and the pressure differential before and after (equivalent to the load of spring (5)). A fixed amount of oil is supplied regardless of the engine speed; the remaining amount flows to port (A).
WA500-6
10-189 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 2.
BRAKE SYSTEM
When pressure reaches cut-out pressure. • When pressure at port (B) (accumulator pressure) reaches the set pressure for relief valve (R1), poppet (1) leaves valve seat (9) to generate a flow of oil, creating the relief operation. • The relief operation creates vertical pressure differential for piston (2). Piston (2) moves upward to force poppet (1) to open, shorting ports (C) and (T). • As the right-most spring chamber of spool (6) leads to port (C) of relief valve (R1), tank pressure prevails. • Since the pressure at port (P) also drops to the level equivalent to the load of spring (5), oil supply to port (B) is stopped as well.
Safety Relief Valve (R3) •
If the pressure at port (P) (pump pressure) rises above the set pressure for relief valve (R3), the oil from the pump resists spring (10) and pushes ball (11) upward to cause oil to flow into the tank circuit, thus protecting the circuit by defining the maximum pressure for the brake circuit.
10-190 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
PPC Relief Valve
1.
Main valve
2.
Spring
3.
Valve seat
4.
Pilot poppet
5.
Spring
6.
Screw
Function •
The PPC relief valves are located between the EPC brake pump and the EPC valve and between work equipment units.
•
When the PPC valve is not operating or when any abnormal pressure has occurred in the EPC circuit, oil from the pump is relieved from this valve in order to protect the pump and the circuit from damage.
WA500-6
10-191 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Operation •
The relief valve is installed on the charge valve. Port (A) is connected to the pump circuit and port (C) to the drain circuit.
•
Oil runs through the orifice of main valve (1) and fills port (B).
•
Pilot poppet (4) is seated on valve seat (3).
•
When pressure at ports (A) and (B) reaches the set pressure, pilot poppet (4) opens and oil pressure at port (B) is carried from port (D) to port (C), causing pressure at port (B) to drop.
•
When pressure at port (B) drops, the orifice of main valve (1) functions to allow a pressure differential to occur at ports (A) and (B), causing main valve (1) to open due to pressure from port (A). Oil in port (A) is drained to port (C) for relief.
10-192 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Accumulator (for Brake) Function •
The accumulator is installed between the charge valve and brake valve.
•
The space between cylinder (3) and free piston (4) is filled with nitrogen gas.
•
The nitrogen gas absorbs the hydraulic pulses generated by the hydraulic pump and secures the braking force and operability when the engine stops by utilizing its compressibility.
Specifications Gas used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nitrogen gas Amount of gas . . . . . . . . . . . . . . . . . . . . . . . . 3,750 cc (228.84 in3) Charging pressure . . . . . . . . . . . . . . .34.67 ±1.02 kg/cm² (at 20°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (493 ±15 psi) (at 68° F) 1.
Valve
2.
Top cover
3.
Cylinder
4.
Piston
WA500-6
10-193 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Brake
10-194 b
1.
Guide pin
2.
Return spring
3.
Cylinder
4.
Brake piston
5.
Outer gear
6.
Hub gear
7.
Plate
8.
Disc
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA500-6
BRAKE SYSTEM
10-195 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Unit: mm (in) No
Check Item
Criteria
Remedy
Standard Size 9
Return spring
Repair Limit
Free Length
Installed Length
Installed Load Hole
Free Length
Allowable Load
104.8 (4.13)
96.5 (3.80)
452 N (101.61 lbf)
102.7 (4.04)
338 N (75.99 lbf)
Standard Size
Tolerance
Repair Limit
2.4 (0.094)
—
2.15 (0.085)
11 Thickness of disc
5.1 (0.201)
—
4.6 (0.181)
12 Assembled thickness of plate discs
84.9 (3.34)
—
79.4 (3.13)
13 Wear of seal contact surface
430 (16.93)
–0 (0).000 -0.155 (-0.006)
—
14 Wear of piston seal contact surface
420 (16.54)
+0.097 (+0.004) +0 (0).000
—
15 Wear of piston seal contact surface
455 (17.91)
+0.097 (+0.004) +0 (0).000
—
10 Plate thickness
Standard Strain
Repair Limit
0.5 (0.020)
0.7 (0.028)
0.45 (0.018)
0.65 (0.026)
Replace
16 Strain of plate contact surface 17 Strain of disc contact surface 18 Backlash of outer gear and plate
0.24 – 0.72 (0.009 – 0.028)
19 Backlash of inner gear and disc
0.19 – 0.62 (0.007– 0.024)
Torque Values Designation
N•m
lbf ft
AA
157 – 196
116 – 145
BB
98 – 123
72 – 91
10-196 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Function •
All the four wheels are equipped with a main brake, which is a wet-type multi-disc brake.
•
When the brake pedal is pressed down, pressure oil from the slack adjuster moves brake piston (4), in the direction shown by an arrow mark, to press disc (8) to contact plate (7). This generates a friction force between the disc and the plate. While the wheel is rotating with the disc, this friction causes the machine to slow down and stop.
•
When the brake pedal is released, back pressure on brake piston (4) is released and the force of return spring (2) moves the piston, in the direction shown by an arrow mark, to release the brake.
WA500-6
10-197 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Parking Brake Control
1.
Parking brake switch
2.
Parking brake emergency release switch
3.
Transmission control valve
4.
Parking brake solenoid valve
5.
Transmission (containing parking brake)
Outline •
The parking brake is installed at the output shaft with the wet-type, multi-disc brake being built in the transmission. Using the pressing force of the spring, it mechanically operates to relieve the oil pressure.
•
If parking brake switch (1) installed to the operator’s cab is turned ON, parking brake solenoid valve (4) installed to transmission control valve (3) shuts off the oil pressure and the parking brake is applied. If parking brake switch (1) is turned OFF, the hydraulic force in the cylinder releases the parking brake.
•
The neutralizer relay cuts off current to the transmission solenoid valve as long as operation of the parking brake is continued in order to maintain the transmission at the neutral position.
•
Parking brake emergency release switch (2) is provided to permit movement of a machine currently stopped due to an engine or drive system problem (parking brake of the machine is enabled).
10-198 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
MEMORANDUM
WA500-6
10-199 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Parking Brake
10-200 b
1.
Output shaft
2.
Spring (outside)
3.
Spring (inside)
4.
Piston
5.
Parking brake oil port
6.
Plate
7.
Disc
8.
Wave spring
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Unit: mm (in) No.
Check Item
Criteria Standard Size
9
Parking brake spring (outside)
10 Parking brake spring (inside)
Repair Limit
Free Length
Installed Length
Installed Load
Free Length
Installed Load
94 (3.70)
72.6 (2.86)
1,266 N 1,203 N 91.2 (3.59) (284.61 lbf) (270.45 lbf)
94 (3.70)
72.6 (2.86)
662 N 630 N 91.2 (3.59) (148.82 lbf) (141.63 lbf)
Standard Size
Tolerance
Repair Limit
4.0 (0.16)
±0.05 (±0.002)
3.9 (0.15)
7.0 (0.28)
±0.05 (0.002)
6.9 (0.27)
Strain
—
0.05 (±0.002)
0.6 (0.024)
Thickness
3.2 (0.13)
±0.08 (±0.003)
2.97 (0.117)
Load of wave spring (testing height: 3.2 mm or 0.126 in)
626.4 N (140.82 lbf)
±176.5 N (±39.68 lbf)
533 N (119.82 lbf)
11 Plate
Replace
Thickness
12 Disc 13
Remedy
Torque Values Designation
N•m
lbf ft
AA
98 - 123
72 - 91
Outline •
The parking brake is a wet-type, multi-disc brake operated mechanically with springs (2) and (3) to apply braking to output shaft (1).
•
The tension of springs (2) and (3) presses disc (7) against plate (6) with piston (4) to stop output shaft (1).
•
When releasing, the oil pressure from parking brake oil port (5) operates piston (4) to release the pressing force being applied to disc (7) and plate (6).
WA500-6
10-201 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Parking Brake Solenoid Valve
1.
Coil (ON-OFF type)
2.
Push pin
3.
Spring
4.
Spool
5.
Block
6.
Check valve
Torque Values Designation
N•m
lbf ft
lbf in
AA
47.0 – 53.9
35 – 40
–
BB
6.9 – 7.8
–
61 – 69
CC
9.8 – 12.7
–
87 – 112
DD
44.1– 53.9
33 –- 40
–
10-202 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Operation ★ When parking brake is applied (when solenoid is de-energized). •
As the parking brake switch is turned ON, the solenoid is turned OFF. As the result, spool (1) is pushed back in the left direction by the tension of spring (2).
•
Pump port (P) is disconnected from parking brake port (A), stopping flow of the pressurized oil from the pump to the parking brake. At the same time, the oil that was working as back pressure of the parking brake is drained through port (A) and port (T).
•
As the back pressure of the piston is drained, the piston being pushed back by the spring contacts the plate and disc closely to enable the parking brake.
★ When parking brake is released (when solenoid is energized). •
If the parking brake switch is turned OFF, the solenoid is turned ON and spool (1) is moved to the right.
•
The pressurized oil from the pump flows to the parking brake through port (P), inside of spool (1) and port (A). At the same time, port (T) is closed and the oil is not drained.
•
As oil pressure is applied to the back side of the piston, it compresses the spring, separating the plate and disc from each other. As the result, the parking brake is released.
WA500-6
10-203 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
Emergency Parking Brake Release Valve Function •
The emergency release solenoid valve is installed between the transmission and transmission control.
•
This valve operates the solenoid of the parking brake release switch installed at the operator’s seat when oil pressure is not available from the power train pump due to engine failure, etc. in order to supply accumulator charge pressure in the brake circuit to the parking brake. 1.
Valve
2.
Solenoid valve
A. To parking brake B. From parking brake valve C. From pilot circuit T. Drain P. From brake valve (accumulator circuit)
Operation •
When parking brake emergency release switch (1) is turned to ON, solenoid valve (2) starts operating and oil pressure from accumulator (3) enters port (P).
•
Pilot pressure then switches the circuit and the pressure moves to the parking brake from port (A) to release the parking brake.
10-204 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BRAKE SYSTEM
MEMORANDUM
WA500-6
10-205 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
UNDERCARRIAGE AND FRAME Axle Mount
10-206 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
1.
Front axle
2.
Rear axle
3.
Rear frame
4.
Front frame
5.
Axle mount bolt
Torque Values Designation
N•m
lbf ft
A
2450 – 3038
1807 – 2241
Outline •
Front axle (1) is directly fixed to front frame (4) with axle mount bolt (5) as it is directly subjected to the working force.
•
Rear axle (2) has a swaying structure at the center of the rear axle to enable each tire to make contact with the ground during travel on soft ground.
WA500-6
10-207 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-208 b
UNDERCARRIAGE AND FRAME
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
Unit: mm (in) No.
Check Item
Criteria Tolerance
Standard Size
Remedy Standard Clearance
Clearance Limit
0.056 – 0.626 (0.002 –0.025)
1.6 (0.063)
Shaft
Hole
310 (12.20)
-0.056 (-0.002) -0.137 (-0.005)
+0.489 (+0.019) 0 (0)
2
Clearance between hole and shaft on front support side (before press-fitting of bushing)
320.2 (12.61)
+2.300 (+0.091) +0.800 (+0.031)
+0.089 (+0.0035) 0 (0)
—
—
3
Clearance between hole and shaft on rear support side (after pressfitting of bushing)
260 (10.24)
-0.056 (-0.002) -0.137 (-0.005)
+0.481 (+0.0189) -0.008 (-0.0003)
0.048 –0.618 (0.0019 – 0.0243)
1.6 (0.063)
4
Clearance between hole and shaft on rear support side (before press-fitting of bushing)
270.2 (10.64)
+2.300 (+0.091) +0.800 (+0.031)
+0.089 (+0.0035) 0 (0)
—
—
5
Thickness of thrust plate
1
Clearance between hole and shaft on front support side (after pressfitting of bushing)
Standard Size
Tolerance
Repair Limit
22 (0.87)
-0.10 (-0.004) -0.25 (-0.010)
—
6
Thickness of thrust washer
5 (0.20)
+0.1 (+0.004) -0.3 (-0.012)
—
7
Thickness of rear bushing
5 (0.20)
±0.1 (±0.004)
—
8
Thickness of front bushing
5 (0.20)
±0.1 (±0.004)
—
Replace (Bushing is adhered to support on both front and rear.)
Replace
Torque Values Designation
N•m
lbf ft
A
1519 – 1911
1120 – 1409
B
245 – 309
181 – 228
WA500-6
10-209 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
Center Hinge Pin
1.
Front axle
2.
Front frame
3.
Rear frame
4.
Rear axle
5.
Upper hinge pin
6.
Lower hinge pin
Outline •
Front frame (2) and rear frame (3) are coupled to each other through the bearings and center hinge pins (5) and (6).
•
The right and left steering cylinders connect the front frame and rear frame and adjust the articulating angle of the frame, or the turning radius of the machine.
10-210 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
Unit: mm (in) No.
Check Item
Criteria Standard Size
1
2
3
Clearance between upper hinge pin and bearing
4
Clearance between upper hinge pin and spacer (large)
5
Clearance between rear frame and spacer (large)
WA500-6
Tolerance Standard Clearance
Clearance Limit
Shaft
Hole
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
+0.054 (+0.0021) 0 (0)
0.036 – 0.112 (0.0014 – 0.0044)
—
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
+0.054 (+0.0021) 0 (0)
0.036 – 0.112 (0.0014 – 0.0044)
—
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
0 (0) -0.020 (-0.0008)
0.016 – 0.058 (0.0006 – 0.0228)
—
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
+0.054 (+0.0021) 0 (0)
0.036 – 0.112 (0.0014 – 0.0044)
—
130 (5.12)
-0.043 (-0.0017) -0.106 (-0.0041)
+0.063 (+0.0025) 0 (0)
0.043 – 0.169 (0.0017 – 0.0067)
—
Clearance between upper hinge pin and rear frame
Clearance between upper hinge pin and spacer (small)
Remedy
Replace
10-211 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME Unit: mm (in)
No.
Check Item
6
Clearance between front frame and lower hinge bearing
7
Clearance between lower hinge pin and bushing
8
Clearance between lower hinge pin and bearing
9
Clearance between front frame and upper hinge bearing
Clearance between lower hinge 10 rear frame and bushing
Clearance in seal fitting part of 11 lower hinge
Clearance in seal fitting part of 12 upper hinge pin
13
14
Height of upper hinge pin spacer (small) Height of upper hinge pin spacer (large)
Criteria
Remedy
155 (6.10)
0 (0) -0.025 (-0.0010)
-0.048 (-0.0019) -0.088 (-0.0035)
-0.023 to -0.088 (-0.0009 to -0.0035)
—
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
+0.054 (+0.0021) 0 (0)
0.036 – 0.112 (0.0014 – 0.0044)
—
100 (3.94)
-0.036 (-0.0014) -0.058 (-0.0023)
0 (0) -0.020 (-0.0008)
0.016 – 0.058 (0.0006 – 0.0023)
—
160 (6.30)
0 (0) -0.025 (-0.0010)
-0.050 (-0.0020) -0.090 (-0.0035)
-0.025 to -0.090 (-0.0010 to -0.0035)
—
125 (4.92)
-0.043 (-0.0017) -0.083 (-0.0033)
+0.063 (+0.0025) 0 (0)
0.043 – 0.146 (0.0017 – 0.0057)
—
115 (4.53)
+0.280 (+0.0110) +0.180 (+0.0071)
+0.054 (+0.0021) 0 (0)
-0.126 to -0.280 (-0.0050 to -0.0110)
—
135 (5.31)
+0.310 (+0.0122) +0.210 (+0.0083)
+0.063 (+0.0025) 0 (0)
-0.147 to -0.310 (-0.0058 to -0.0122)
—
Standard Size
Tolerance
Repair Limit
35 (1.38)
±0.1 (±0.004)
—
101.5 (4.00)
±0.1 (±0.004)
—
Standard thickness of shim 15 between upper hinge and retainer
2.3 (0.091)
Standard thickness of shim 16 between upper hinge and retainer
1.6 (0.06)
Standard thickness of shim 17 between lower hinge and retainer
1.6 (0.06)
10-212 b
Replace
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
UNDERCARRIAGE AND FRAME
MEMORANDUM
WA500-6
10-213 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM Hydraulic Piping Diagram
10-214 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Hydraulic tank
2.
Work equipment pump
3.
Cooling fan pump
4.
Hydraulic cooling pump
5.
Steering pump
6.
Tandem pump (power train + EPC and brake)
7.
Steering demand valve
8.
Steering cylinder
9.
Bucket cylinder
HYDRAULIC SYSTEM
10. Work equipment valve 11. Lift cylinder 12. Charge valve (built-in EPC relief valve) 13. Accumulator 14. Hydraulic oil cooler
WA500-6
10-215 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Work Equipment Control Lever Linkage
1.
Lift arm control lever
7.
Armrest adjustment lever
2.
Bucket control lever
8.
Kickdown switch
3.
Hold switch
9.
Cancel switch (Load meter specifications)
4.
Subtotal switch (Load meter specifications)
10. Armrest
5.
Work equipment lock lever
11. Work equipment EPC valve
6.
RH console forward-reverse slide lever
10-216 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Hydraulic Tank
1.
Hydraulic tank
A.
EPC return port
2.
Oil level sight gauge
B.
Main return port
3.
Breather
C.
Hydraulic oil cooler return port
4.
Oil filler port
D.
Steering and loader pump suction port
5.
Filter bypass valve
E.
Emergency steering suction port
6.
Oil filter
F.
Emergency steering return port
7.
Strainer
G.
EPC pump suction port
8.
Drain valve
H.
Steering return port
J.
Steering drain port
K.
Brake valve return port
L.
Cooling fan pump and hydraulic cooling pump suction port
M. Pump case drain port
WA500-6
10-217 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation of Oil Filter Bypass Valve ★ In the case where the filter is clogged: Bypass valve (1) opens and oil returns to the tank bypassing the filter. Bypass valve set pressure: . . . . . . . . . . . . . . . 1.53 kg/cm² (22 psi)
★ In the case where the return circuit turns negative pressure: Whole valve (2) is held up to serve as the check valve. Check valve set pressure: . . . . . . . . . . . . . . . . . 0.24 kg/cm² (3 psi)
10-218 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Breather Function ★ Prevention of negative pressure in tank Since the tank is pressurized and enclosed, if the oil level in it lowers, negative pressure is generated. At this time, poppet (3) is opened by the differential pressure between the tank pressure and the atmospheric pressure to prevent generation of the negative pressure. ★ Prevention of pressure rise in tank If the pressure rises to above a specified level while the circuit is in operation, due to an increase or decrease of oil level and a temperature rise, sleeve (4) is operated to relieve pressure in the hydraulic tank. 1.
Body
2.
Filter element
3.
Poppet
4.
Sleeve
WA500-6
10-219 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Steering Pump
10-220 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
P1.
Pump discharge port
P1L.
Pump pressure input port
PD.
Drain port
PD2.
Drain plug
PD6.
Drain port
PEN.
Control pressure pickup plug
PLS.
Load pressure input port
POP.
External pilot pressure input port
PS.
Pump suction port
1.
Pump body
2.
Servo valve
3.
Air bleeder
HYDRAULIC SYSTEM
Torque Values Designation
N•m
lbf ft
lbf in
A
11.8 – 14.7
–
104 – 130
B
9.8 – 12.7
–
87 – 112
C
34.3 – 63.7
25 – 47
–
D
7.8 – 9.8
–
69 – 87
E
19.6 – 24.5
15 – 18
–
F
68.6 – 83.4
51 – 62
–
WA500-6
10-221 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Pump Unit
10-222 b
PA.
Control basic pressure output port
PD4.
Drain port
PD5.
Drain port
PE.
Control pressure input port
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
1.
Bearing
6.
Piston
11. Servo piston
2.
Shaft
7.
Cylinder block
12. Spring
3.
Case
8.
Valve plate
13. Oil seal
4.
Rocker cam
9.
Spring
14. Ball
5.
Shoe
10. Shoe retainer
Torque Values Designation
N•m
lbf ft
EE
34.3 – 44.1
25 – 33
WA500-6
10-223 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
The pump converts the engine rotation torque, transmitted to its shaft, to oil pressure and delivers pressurized oil corresponding to the load.
•
It is possible to change the delivery by changing the swash plate angle.
Structure •
Cylinder block (6) is supported on shaft (1) through spline (a). Shaft (1) is supported with front and rear bearings.
•
The end of piston (5) has a spherical hollow and is combined with shoe (4).
•
Piston (5) and shoe (4) form a spherical bearing.
•
Rocker cam (3) is supported on case (2) and ball (9) and has flat surface (A).
•
Shoe (4) is kept pressed against the plane of rocker cam (3) and slides circularly.
•
Shoe (4) leads high-pressure oil to form a static pressure bearing and slides.
•
Piston (5) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (6).
•
Cylinder block (6) seals the pressurized oil to valve plate (7) and carries out relative rotation.
•
This surface is designed so that the oil pressure balance is maintained at a suitable level.
•
The oil inside each cylinder chamber of cylinder block (6) is suctioned and discharged through valve plate (7).
10-224 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation of Pump •
Cylinder block (6) rotates, together with shaft (1), and shoe (4) slides on flat surface (A).
•
Rocker cam (3) slants around ball (9). As a result, angle (a) between center line (X) of rocker cam (3) and the axis of cylinder block (6) changes.
•
Angle (a) is the swash plate angle.
•
When the condition of center line (X) of rocker cam (3) has swash plate angle (a) to axial direction of cylinder block (6), flat surface (A) functions as a cam against shoe (4).
•
Piston (5) slides on the inside of cylinder block (6); a difference between volumes (E) and (F) is created inside cylinder block (6).
•
A single piston (5) sucks and discharges the oil by the amount (F) – (E).
•
As cylinder block (6) rotates and the volume of chamber (E) decreases, the pressurized oil is discharged.
•
The volume of chamber (F) increases and, in this process, the oil is suctioned.
•
As center line (X) of rocker cam (3) matches the axial direction of cylinder block (6) [swash plate angle (a) = 0], the difference between volumes (E) and (F) inside cylinder block (6) becomes 0.
•
Suction and discharge of pressurized oil is not carried out in this state. Pumping action is not performed. (Actually, however, the swash plate angle is not set to 0.)
•
Swash plate angle (a) is in proportion to the pump delivery.
WA500-6
10-225 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Control of Delivery •
If the swash plate angle (a) increases, the difference between volumes (E) and (F) increases and pump delivery (Q) increases.
•
Swash plate angle (a) is changed with servo piston (11).
•
Servo piston (11) reciprocates straight according to the signal pressure of the CO and LS valves.
•
This straight motion is transmitted to rocker cam (3).
•
Rocker cam (3), supported with ball (9), slides around ball (9).
10-226 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Servo Valve
P1.
Pump discharge pressure port
PE. Control pressure output port T.
WA500-6
Drain port
10-227 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-228 b
HYDRAULIC SYSTEM
1.
Nut
9.
Piston
2.
Plate
10. Seal
3.
Plug
11. Piston
4.
Spring
12. Sleeve
5.
Seat
13. Spool
6.
Plug
14. Seat
7.
Spool
15. Retainer
8.
Plug
16. Spring
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
LS Valve PA.
Pump pressure input
PE.
Control piston pressure
PLS.
LS pressure input
PPL.
CO valve output pressure
PPLS.
LS pump pressure input
CO Valve PA.
Pump pressure input
PPL.
CO valve output pressure
T.
Drain
Torque Values Designation
N•m
lbf ft
DD
27.4 – 34.3
20 – 25
EE
29.4 – 39.2
22 – 29
WA500-6
10-229 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
LS Valve Function •
The LS valve controls the pump delivery according to the stroke of the control lever, or the demand flow for the actuator.
•
The LS valve detects the demand flow for the actuator from differential pressure (PLS) between control valve inlet pressure (PPLS) and control valve outlet pressure (PLS) and controls main pump delivery (Q). ((PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (PLS) is the LS differential pressure.)
•
The pressure loss caused by the flow of oil through the opening of the control valve spool (= LS differential pressure PLS) is detected, and then pump delivery (Q) is controlled to keep that pressure loss constant and supply the pump delivery according to the demand flow for the actuator.
•
Main pump discharge pressure (PA), LS pump pressure (PPLS), and LS pressure (PLS) are led to the LS valve. The relationship between LS differential pressure (PLS) and pump delivery (Q) changes as shown in the diagram.
CO Valve Function •
When the pump pressure in the hydraulic circuit reaches the maximum level, the CO (Cut-off) valve minimizes the pump swash plate angle and protects the circuit by suppressing the rise of pressure.
•
The minimum pump swash plate angle given reduces the pump suction torque to improve fuel economy.
Operation 1.
Function of spring • The spring load of spring (2) on the CO valve is determined by the pump discharge pressure (PA).
2.
When the load on the actuator is small and pump discharge pressure (PA) is low • The pressing force of spool (5) is decreased and spool (3) is a little to the right (Fig. 1 on next page). At this time, ports (C) and (D) are connected to each other and the pressure in the LS valve is drain pressure (PT). • At this time, ports (F) and (G) of the LS valve are connected to each other. As a result, the pressure in port (J) becomes drain pressure (PT) and servo piston (6) moves to the left. • Consequently, the pump delivery is increased.
3.
When the load on the actuator is large and pump discharge pressure (PA) reaches the maximum pressure • The pressing force of spool (5) is increased and spool (3) is a little to the left (Fig. 2 on next page). At this time, ports (C) and (B) are connected to each other and the pressure in the LS valve is pump pressure (PA). • At this time, ports (F) and (G) of the LS valve are connected to each other. As a result, the pressure in port (J) becomes pump pressure (PA) and servo piston (6) moves to the right. • Consequently, the pump delivery is decreased.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ When load is light (Fig. 1)
★ When load is heavy (Fig. 2)
WA500-6
10-231 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Work Equipment Hydraulic Pump HPV190
10-232 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Outline The pump unit is composed of the variable capacity swash plate type piston pump, PC valve, LS valve, and EPC valve. IM.
PC mode selector current
PA.
Pump discharge port
PB.
Pump pressure input port
PD1.
Case drain port
PD2.
Drain plug
PEN.
Control pressure pickup port
PEPC.
EPC basic pressure port
PEPCC. EPC basic pressure pickup port PLS.
Load pressure input port
PLSC.
Load pressure pickup port
PM.
PC mode selector pressure pickup port
PS.
Pump suction port
1.
Main pump
2.
LS valve
3.
PC valve
4.
PC-EPC valve
Torque Values Designation
N•m
lbf ft
lbf in
AA
19.6 – 27.4
15 – 20.
–
BB
11.8 – 14.7
–
104 – 130
CC
98.1 – 122.6
72 – 90
–
WA500-6
10-233 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-234 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Shaft
2.
Cradle
3.
Front case
4.
Rocker cam
5.
Shoe
6.
Piston
7.
Cylinder block
8.
Valve plate
9.
End cover
HYDRAULIC SYSTEM
10. Impeller 11. Servo piston 12. PC valve
Torque Values Designation
N•m
lbf ft
DD
637 – 764.4
470 – 564
EE
246.3 – 308.7
182 – 228
FF
98 – 123
72 – 91
GG
27– 34
20 – 25
WA500-6
10-235 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
The pump converts the engine rotation torque, transmitted to its shaft, to oil pressure and delivers pressurized oil corresponding to the load.
•
It is possible to change the delivery by changing the swash plate angle.
Structure •
Cylinder block (7) is supported to shaft (1) by spline (14).
•
Shaft (1) is supported by front and rear bearings (15).
•
The end of piston (6) has a spherical hollow and is combined with shoe (5). Piston (6) and shoe (5) form a spherical bearing.
•
Rocker cam (4) has flat surface (A). Shoe (5) is always pressed against this surface while sliding in a circular movement.
•
Rocker cam (4) conducts high-pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides.
•
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
•
Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level.
•
The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation of Pump •
Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on flat surface (A).
•
Rocker cam (4) moves along cylindrical surface (B). Angle (a), between center line (X) of rocker cam (4) and the axial direction of cylinder block (7), changes.
•
Angle (a) is the swash plate angle.
•
When the condition of center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as a cam against shoe (5).
•
Piston (6) slides on the inside of cylinder block (7). A difference between volumes (E) and (F) is created inside cylinder block (7).
•
A single piston (6) sucks and discharges the oil by the amount (F) – (E).
•
As cylinder block (7) rotates and the volume of chamber (E) decreases, the pressurized oil is discharged.
•
The volume of chamber (F) increases and, in this process, the oil is suctioned.
•
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) [swash plate angle (a) = 0], the difference between volumes (E) and (F) inside cylinder block (7) becomes 0.
•
Suction and discharge of pressurized oil is not carried out in this state. Pumping action is not performed. (Actually, however, the swash plate angle is not set to 0.)
•
Swash plate angle (a) is in proportion to the pump delivery.
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10-237 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Control of Delivery •
If swash plate angle (a) increases, the difference between volumes (E) and (F) increases and pump delivery (Q) increases.
•
Servo piston (12) is used for changing swash plate angle (a).
•
Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves.
•
This linear movement is transmitted to rocker cam (4) through slider (13).
•
Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement.
•
The space of the pressure receiving area of servo piston (12) is not identical on the left side and right side. Main pump discharge pressure (self-pressure) (PP) is always brought to the pressure chamber of the small diameter piston side.
•
Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end.
•
The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
10-238 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
LS Valve
1.
Sleeve
PA.
Pump port
2.
Piston
PDP.
Drain port
3.
Spool
PLP.
LS control pressure output port
4.
Spring
PLS.
LS pressure input port
5.
Seat
PP.
Pump port
6.
Sleeve
PPL.
Control pressure input port
7.
Plug
PSIG.
Drain port
8.
Locknut
Function •
The LS (load-sensing) valve detects the load of the actuator and controls the delivery.
•
This valve controls pump delivery (Q) according to differential pressure (PLS) [= (PP) – (PLS)] (called LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure (PLS).
•
Main pump pressure (PP), pressure (PLS) (called the LS pressure) coming from the control valve output, and pressure (PSIG) (called the LS selector pressure) from the proportional solenoid valve enter this valve.
WA500-6
10-239 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation ★ When the control valve is situated at neutral
10-240 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
•
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and pump discharge pressure (PP) brought to port (H) of sleeve (8).
•
The magnitude of the force resulting from this LS pressure (PLS), the force of spring (4), and the pump discharge pressure (selfpressure) (PP) determine the position of spool (6).
•
Before starting the engine, servo piston (12) is pressed to the left (see the figure to the right).
•
If the control lever is in neutral when the engine is started, LS pressure (PLS) is set to 0 kg/cm² {0 psi}. (It is connected with the drain circuit through the control valve spool.)
•
Spool (6) is pushed to the right. Port (C) and port (D) will disconnect.
•
Shuttle valve output pressure (PPH) enters the large diameter side of the piston from port (K).
•
Pump pressure (PP) is present in port (J) on the small diameter side of the piston.
•
Depending on the difference in the areas on servo piston (12), servo piston (12) moves in the direction to minimize the swash plate angle.
WA500-6
10-241 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ Action for the direction of maximizing the pump delivery
•
When the difference between pump discharge pressure (PP) and LS pressure (PLS) (LS differential pressure (PLS)) decreases [for example, when the area of opening of the control valve increases and pump discharge pressure (PP) drops], spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4).
•
When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve.
•
The PC valve is connected to the drain port; the pressure across circuits (D) and (K) becomes drain pressure (PT). ★ The operation of the PC valve is explained later.
•
The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT). Pump pressure (PP) enters port (J) at the small diameter end; servo piston (12) is pushed to the left side. In this manner, servo piston (12) is moved in the direction to make the delivery larger.
10-242 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ Action for the direction of minimizing the pump delivery
•
If LS differential pressure (PLS) increases (for example, when the area of the control valve opening decreases and the pump pressure (PP) increases), spool (6) is pressed to the right by the force of pump pressure (PP).
•
As a result of the movement of spool (6), shuttle valve output pressure (PPH) flows from port (C) to port (D), then from port (K) to the large diameter side of the piston.
•
While main pump pressure (PP) is present in port (J) of the smaller diameter side of the piston, servo piston (12) is pressed to the right by its area difference between the larger and the smaller diameter sides. As the result, servo piston (12) moves in the direction to minimize the swash plate angle.
WA500-6
10-243 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ When servo piston is balanced
★ Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). •
If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position.
•
The swash plate of the pump will be held in an intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.]
•
The formula (A0): (A1) = 3: 5 represents the relation of pressure-receiving areas across the end of servo piston (12). (PP): (PEN) = 5:3 represents the pressure applied across the piston when balanced.
•
The force of spring (4) is adjusted to determine the balanced stop position of this spool (6) at the center of the standard when (PP) – (PLS) = 14.28 kg/cm² (203 psi).
10-244 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
PC Valve
1.
Plug
5.
Retainer
PA.
Pump port
2.
Servo piston assembly
6.
Seat
PA2.
Pump pressure pilot port
3.
Pin
7.
Cover
PDP.
Drain port
4.
Spool
8.
Wiring
PM.
Mode selector pressure pilot port
PPL.
Control pressure output port (to LS valve)
Function •
The PC valve controls the flow to a certain rate corresponding to the discharge pressure (regardless of how much the control valve stroke is increased) when pump discharge pressure (PP1) (selfpressure) and (PP2) (other pump pressure) are high.
•
An increase in the pump discharge pressure due to increased load during work results in reducing the pump delivery.
•
If the pump discharge pressure drops, it increases the delivery from the pump.
•
In this case, the relation between the mean discharge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and pump delivery (Q) is shown in the figure if the relation is represented as the parameter of the current value (X) to be given to the PC-EPC valve solenoid.
•
The controller continues counting the actual engine speed.
•
During low speed, command current flows from the controller to the PC-EPC valve solenoid according to the engine speed to reduce the pump delivery.
WA500-6
10-245 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation ★ When the actuator load is small and pump pressures (PP1) and (PP2) are low
10-246 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Action of PC-EPC Valve Solenoid (1) •
Command current (X) is sent to PC-EPC valve solenoid (1) from the pump controller.
•
This command current (X) works on the PC-EPC valve and outputs the signal pressure to change the force of pushing piston (2).
•
Spool (3) stops at a position where the combined force pressing spool (3) becomes balanced between a set force of spring (4) and pump pressure (PP1) (self-pressure) and other pump pressure (PP2).
•
The pressure [port (C) pressure] output from the PC valve is changed depending on the above position.
•
The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
★ Other pump pressure denotes the pressure of the pump situated on the opposite side. • •
For the front pump pressure, the other pump pressure is that of the rear pump. For the rear pump pressure, the other pump pressure is that of the front pump.
WA500-6
10-247 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-248 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Action of Spring •
The load of spring (4) at the PC valve is determined by the position of the swash plate.
•
The spring load changes as servo piston (9) makes spring (4) elongate or contract.
•
If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).
•
The load of spring (4) also changes according to the PC-EPC valve solenoid command current (X).
•
Port (C) of the PC valve is connected to port (E) of the LS valve.
•
Self-pressure (PP1) enters port (B) and the small diameter end of servo piston (9); other pump pressure (PP2) enters port (A).
•
When pump pressures (PP1) and (PP2) are small, spool (3) is positioned in the left side.
•
Ports (C) and (D) are connected; the pressure entering the LS valve becomes drain pressure (PT).
•
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the left side.
•
The pump delivery is set to the increasing trend.
•
Spring (4) extends as servo piston (9) moves and weakens the spring force.
•
As the spring force is weakened, spool (3) moves to the right; the connection between port (C) and port (D) is shut off; and the pump discharge pressure ports (B) and (C) are connected.
•
The pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move of servo piston (9) is stopped.
•
Stop position of servo piston (9) (= pump delivery) is determined by a position where the press force generated by pressures (PP1) and (PP2) on spool (3) and the other press force by the PC-EPC valve solenoid are balanced with the force of spring (4).
WA500-6
10-249 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ When the actuator load is large, and the pump discharge pressure is high
Outline •
When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right increases and spool (3) is moved to the position shown in the above diagram.
•
Part of the pressure to be conducted from port (C) to the LS valve flows from port (B) to ports (C) and (D) through the LS valve. At the end of this flow, the level of this pressure becomes approximately half of main pump pressure (PP2).
10-250 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation •
When port (E) and port (G) of the LS valve are connected, the pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9).
•
If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to port (C) and acts to make the pump deliver the minimum.
•
When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).
•
When spool (3) moves to the left, the openings of port (C) and port (D) increase.
•
The pressure on port (C) (= J) is decreased and the rightward movement of servo piston (9) is stopped.
•
The position in which servo piston (9) stops at this time is further to the right than the position when pump pressures (PP1) and (PP2) are low.
•
The relationship between the average pump pressure (PP1 + PP2)/ 2 and average pump delivery (Q) is shown in the diagram to the right.
•
If command voltage (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/2 and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel.
•
The force of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the pump pressure applied to spool (3). The relationship between the average pump pressure (PP1 + PP2)/2 and pump delivery (Q) moves from (A) to (B) as command current (X) is increased.
WA500-6
10-251 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
PC-EPC Valve
1.
Connector
C.
To PC valve
2.
Coil
P.
From pilot pump
3.
Body
T.
To tank
4.
Spring
5.
Spool
6.
Rod
7.
Plunger
Torque Values Designation
N•m
lbf in
AA
0.1 – 0.3
1–3
BB
9.8 – 12.7
87 – 112
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion.
•
On receiving signal current (i) from the controller, the EPC valve generates EPC output pressure in proportion to the signal current and outputs it to the PC valve.
Operation 1.
When signal current is 0 (coil is de-energized) • When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. • Spool (5) is pushed to the left by spring (4). • Port (P) is closed and the oil from the pilot pump does not flow to the PC valve. • The oil from the PC valve is drained through ports (C) and (T) to the tank.
WA500-6
10-253 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 2.
When signal current is very small (coil is energized) • When a very small signal current flows to coil (2), coil (2) is energized and a propulsion force is generated on the right side of plunger (7). • Rod (6) pushes spool (5) to the right and pressurized oil flows from port (P) to port (C). • Pressure on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become greater than the propulsion force of plunger (7). • Spool (5) is pushed to the left and port (P) is shut off from port (C). • Port (C) and port (T) are connected. • Spool (5) moves so that the propulsion force of plunger (7) is in balance with the pressure of port (C) + spring load of spring (4). • The circuit pressure between the EPC valve and PC valve is controlled in proportion to the size of the signal current.
3.
When signal current is maximum (coil is energized) • As the signal current flows to coil (2), coil (2) is energized. • When this happens, the signal current is at its maximum; the propulsion force of plunger (7) is also at its maximum. • Spool (5) is pushed toward the right side by rod (6). • Hydraulic oil from port (P) flows to port (C) with maximum flow rate. As the result, the circuit pressure between the EPC and PC valves becomes maximum. • Since port (T) is closed, pressurized oil does not flow to the tank.
10-254 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
MEMORANDUM
WA500-6
10-255 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Control Valve For outside views and sectional views, only the 4-spool valve (with ECSS control valve) is shown. Outside View
10-256 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
A1.
To bucket cylinder head
A2.
To lift arm cylinder bottom
A3.
To lift arm cylinder bottom
ACC.
To ECSS accumulator
B1.
To bucket cylinder bottom
B2.
To lift arm cylinder head
B3.
To bucket cylinder bottom
CP.
Pressure sensor installation port
CR.
Pressure pickup port
P1.
From front work equipment hydraulic pump
P2.
From rear work equipment hydraulic pump
PA1.
From bucket dump controller
PA2.
From lift arm raise controller
PACC.
From ECSS controller
PB1.
From bucket tilt controller
PB2.
From lift arm lower controller
PLS.
To work equipment hydraulic pump LS port
PP.
From pilot pump
PPS.
To work equipment hydraulic pump
T.
To tank
TS.
To tank
1.
Bucket valve
2.
Lift arm valve
3.
ECSS control valve
4.
Lift arm Hi and bucket Hi valves
5.
Cover 1
6.
Cover 2
7.
Lift arm suction valve
8.
Accumulator charge valve
Torque Values Designation
N•m
lbf ft
lbf in
9A
156.8 – 196
116 – 145
–
10A
27.5 – 34.3
20 – 25
–
11A
58.8 – 73.6
43 – 54
–
12A
9.8 – 12.7
–
87 – 112
WA500-6
10-257 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Sectional View (1/6)
10-258 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
1.
Load check valve (Bucket head)
2.
Load check valve (Lift arm bottom)
3.
Load check valve (Lift arm Hi) and (Lift arm bottom)
4.
Load check valve (Bucket Hi) and (Bucket bottom)
5.
Pressure compensation valve (Lift arm head)
6.
Load check valve (Bucket bottom)
Unit: mm (in) No.
Check Item
Criteria Standard Size
7
Check valve spring
Remedy Repair Limit
Free Length x Outside Diameter
Installed Length
Installed Load
Free Length
Installed Load
38.9 x 11.5 (1.53 x 0.45)
30.0 (1.18)
29.4 N (6.61 lbf)
—
23.5 N (5.28 lbf)
If damaged or deformed, replace spring
Torque Values Designation
N•m
lbf ft
BB
372.7 – 411.9
275 – 304
WA500-6
10-259 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
(2/6)
10-260 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Spool (Boom Hi)
2.
Spool (Bucket Hi)
3.
Spool (ECSS control)
4.
Spool (Lift arm)
5.
Spool (Bucket)
HYDRAULIC SYSTEM
Unit: mm No.
Check Item
Criteria Standard Size
6
Spool return spring
Remedy Repair Limit
Free Length x Outside Diameter
Installed Length
Installed Load
Free Length
Installed Load
54.5 x 34.8 (2.15 x 1.37)
51.2 (2.02)
393 N (88.35 lbf)
—
315 N (70.81 lbf)
7
Spool return spring
54.2 x 34.8 (2.13 x 1.37)
51.2 (2.02)
417 N (93.75 lbf)
—
333 N (74.86 lbf)
8
Spool return spring
58.1 x 33.0 (2.29 x 1.30)
51.5 (2.03)
351 N (78.91 lbf)
—
280 N (62.95 lbf)
9
Spool return spring
51.6 x 33.0 (2.03 x 1.30)
45.0 (1.77)
351 N (78.91 lbf)
—
280 N (62.95 lbf)
10 Spool return spring
54.9 x 24.2 (2.16 x 0.95)
52.0 (2.05)
251 N (56.43 lbf)
—
201 N (45.19 lbf)
11 Spool return spring
66.9 x 36.1 (2.63 x 1.42)
63.5 (2.50)
263 N (59.12 lbf)
—
210 N (47.21 lbf)
12 Spool return spring
53.2 x 22.3 (2.09 x 0.88)
33.0 (1.30)
274 N (61.60 lbf)
—
219 N (49.23 lbf)
WA500-6
If damaged or deformed, replace spring
10-261 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
(3/6)
10-262 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
1.
Safety-suction valve (bucket head)
2.
Suction valve (bucket Hi) and (bucket bottom)
3.
Suction valve (lift arm head)
4.
Safety-suction valve (bucket bottom)
Unit: mm No.
Check Item
Criteria Standard Size
5
Suction valve spring
Remedy Repair Limit
Free Length x Outside Diameter
Installed Length
Installed Load
Free Length
Installed Load
46.8 x 7.5 (1.84 x 0.30)
40.6 (1.60)
5.5 N (1.24 lbf)
—
4.4 N (0.99 lbf)
If damaged or deformed, replace spring
Torque Values Designation
N•m
lbf ft
AA
137.3 – 156.9
101 – 116
WA500-6
10-263 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
(4/6)
10-264 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
HYDRAULIC SYSTEM
Unload valve
Bucket Valve 2.
EPC valve (Tilt)
3.
Load check valve (Dump)
4.
Load check valve (Tilt)
5.
EPC valve (Dump)
6.
Safety-suction valve (Tilt)
7.
Spool
8.
Safety-suction valve (Dump)
Torque Values Designation
N•m
lbf ft
AA
34.3 – 44.1
25 – 33
BB
147.1 – 186.3
109 – 137
CC
19.6 – 24.5
15 – 18
WA500-6
10-265 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
(5/6)
10-266 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Lift Arm Valve 1.
EPC valve (Lower and float)
2.
Load check valve (Lift)
3.
LS shuttle valve
4.
Pressure compensation valve (Lower)
5.
EPC valve (Raise)
6.
Suction valve (Lower and float)
7.
Suction valve (Lower and float)
8.
Spool
ECS Valve 9.
Spool
10. EPC valve 11. Accumulator charge valve
Unit: mm No.
Check Item
Criteria Standard Size
Remedy Repair Limit
Free Length x Outside Diameter
Installed Length
Installed Load
Free Length
Installed Load
41.5 x 8.5 (1.63 x 0.33)
31.5 (1.24)
5.9 N (1.33 lbf)
—
4.72 N (1.06 lbf)
13 Valve spring
19.2 x 7.2 (0.76 x 0.28)
16.1 (0.63)
19.6 N (4.41 lbf)
—
15.7 N (3.53 lbf)
14 Suction valve spring
62.5 x 20.0 (2.46 x 0.79)
39.0 (1.54)
3.04 N (0.68 lbf)
—
2.43 N (0.55 lbf)
12 Check valve spring
If damaged or deformed, replace spring
Torque Values Designation
N•m
lbf ft
lbf in
BB
78.4 – 102.9
58 – 76
–
CC
108 – 147
80 – 108
–
DD
323.6 – 402
239 – 297
–
EE
9.8 – 12.7
–
87 – 112
FF
19.6 – 24.5
15 – 18
–
GG
24.5 – 34.3
18 – 25
–
HH
19.6 – 27.5
15 – 20
–
WA500-6
10-267 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
(6/6)
10-268 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Lift Arm Hi and Bucket Hi Valves 1.
Load check valve (Lift arm Hi)
2.
Spool (Lift arm Hi)
3.
Load check valve (Bucket Hi)
4.
Spool (Bucket Hi)
5.
Suction valve (Bucket Hi)
6.
Unload valve
7.
Main relief valve
8.
LS bypass valve
Torque Values Designation
N•m
lbf ft
AA
19.6 – 24.5
15 – 18
BB
147.1 – 186.3
109 – 137
CC
65.7– 85.3
49 – 63
DD
49 – 58.5
36 – 43
EE
34.3 – 44.1
25 – 33
WA500-6
10-269 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
CLSS (Closed Center Load-Sensing System) Outline of CLSS
Features •
Fine control not influenced by load
•
Controllability enabling digging even with fine control
•
Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations
•
Energy saving using variable pump control
Structure •
CLSS is configured with a variable capacity piston pump, control valves, and respective actuators.
•
The hydraulic pump is configured with pump body, PC valve, and LS valve.
10-270 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Basic Principle Pump Swash Plate Angle Control •
The pump swash plate angle (pump delivery) is controlled so that the LS differential pressure (PLS), which is the differential pressure between the pump discharge pressure (PPS) and LS pressure (PLS) (the actuator load pressure) at the control valve outlet, is constant.
•
[LS differential pressure (PLS) = Pump discharge pressure (PPS) – LS pressure (PLS)]
•
The pump swash plate angle shifts toward the maximum position if LS differential pressure (PLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high).
•
If LS differential pressure becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
LS Differential Pressure (PLS) and Pump Swash Plate Angle ★ For details about the functions, see Work Equipment Hydraulic Pump HPV190 in this section.
WA500-6
10-271 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Pressure Compensation Control .
•
The valve (pressure compensation valve) to balance the load is installed to the lift arm head outlet side of the control valve.
•
When actuators are operated simultaneously, the pressure difference (P) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless of the size of the load (pressure).
•
The flow of oil from the pump is divided (compensated) in proportion to the area of openings (S1) and (S2) of each valve.
•
This prevents the bucket from becoming inoperable because of excessive oil flow to the lift arm head due to the lowering of the lift arm under its own weight and compound operation of the bucket.
10-272 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
MEMORANDUM
WA500-6
10-273 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-274 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Bucket valve
2.
Lift arm valve
3.
ECSS valve
4.
Lift arm Hi valve
5.
Bucket Hi valve
6.
Bucket spool
7.
Lift arm spool
8.
ECSS spool
9.
Lift arm spool
HYDRAULIC SYSTEM
10. Bucket spool 11. Pressure compensation valve 12. Suction valve 13. Load check valve 14. Accumulator charge valve 15. Main relief valve Set pressure: 349.76 ±5.10 kg/cm² (4975 ±73 psi) 16. Unload valve Cracking pressure: 19.99 ±2.04 kg/cm² (284 ±29psi) 17. Safety suction valve Set pressure: 369.14 ±5.10 kg/cm² (5250 ±73 psi)
WA500-6
10-275 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function and Operation of Each Valve Pressure Compensation Valve (Installed on the cylinder head side of the lift arm valve) ★ When a high load is applied to the lift arm
10-276 b
1.
Main pump
2.
Valve
3.
Shuttle valve
4.
Piston
5.
Spring
6.
LS shuttle valve
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
High load pressure is generated during independent operation of the lift arm and compound operation with the bucket.
•
When the lift arm load pressure becomes higher than the bucket, the pressure compensation valve operates as a load check valve to prevent reverse oil flow in the circuit.
Operation •
Actuator circuit pressure (B) becomes higher than pump discharge pressure (PPS) and LS pressure (PLS).
•
Shuttle valve (3) of the pressure compensation valve moves to the right.
•
Actuator circuit pressure (B) and spring chamber (C) are connected.
•
Piston (4) is pressed by spring (5) to the left.
•
Valve (2) is pressed by piston (4) to the left and pump outlet circuit (A) is closed. This prevents reverse flow of oil from actuator circuit (B) to pump outlet circuit (A).
WA500-6
10-277 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ Compound operation (lift arm lower + bucket tilt) .
10-278 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
If the load pressure is lower than the bucket and the flow rate starts increasing during compound operation, the pressure compensation valve compensates the pressure.
•
On the bucket side, the load pressure is higher and the flow rate starts to decrease.
Operation •
If the load pressure on the bucket side rises during compound operation, the flow rate of actuator circuit pressure (B) starts to increase.
•
As LS pressure (PLS) rises on the bucket side, shuttle valve (3) of the pressure compensation valve is pressed to the left.
•
Hydraulic oil flows through the internal passage of piston (4) to spring chamber (C).
•
Piston (4) and valve (2) are pressed to the left and the outlet side of pump circuit (PPS) is cut off.
•
Outlet pressure (A) (spool meter-in downstream pressure) becomes equal to the bucket outlet pressure.
•
Pump pressure (PPS) (spool meter-in upstream pressure) becomes equal for all actuators.
•
Pump pressure (PPS) and outlet pressure (A) become equal for all spools.
•
Pump flow rate is distributed in proportion to the opening area of the respective spools.
WA500-6
10-279 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Shuttle Valve in the Pressure Compensation Valve ★ If holding pressure of port (B) > LS pressure in spring chamber (C)
1.
Hydraulic pump
2.
Valve
3.
Shuttle valve
4.
Piston
Function •
Shuttle valve (3) is pressed to the right by port (B) pressure and ports (B) and (D) are cut off.
•
Holding pressure of port (B) is led to spring chamber (C) and piston (4) is pressed to the left to prevent it from being separated from valve (2).
10-280 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Area Ratio of Pressure Compensation Valve
Function •
The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2). Area ratio = (A2)/(A1)
•
Since the area ratio is less than 1, spool meter-in downstream pressure < maximum load pressure and the oil flow is divided greater than by the area ratio of the opening.
WA500-6
10-281 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
LS Shuttle Valve ★ Supply of LS pressure
10-282 b
1.
Hydraulic pump
2.
Main spool
3.
Pressure compensation valve
4.
Valve
5.
Check valve
6.
LS circuit
7.
LS shuttle valve
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
The LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.
•
Pressure compensation valve (3) upstream pressure (spool meter-in downstream pressure) is led through main spool (2) to LS shuttle valve (7).
•
Connected to actuator port (B) through valve (4), and makes LS pressure = actuator load pressure.
•
Orifice (a) inside main spool (2) has a small diameter concurrently serving as a throttle.
Operation •
If main spool (2) is operated, pump discharge pressure (PPS) flows to actuator circuit (B).
•
Pump discharge pressure (PPS) is led through orifice (a) of main spool (2) to LS circuit (PLS).
•
When actuator circuit (B) rises to the necessary pressure level, pump discharge pressure (PPS) rises.
•
Check valve (5) in main spool (2) opens and the high pressure in LS circuit (PLS) flows out to actuator circuit (B).
•
Pressure in LS circuit (PLS) becomes approximately equal to that of actuator circuit pressure (B).
WA500-6
10-283 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
LS Bypass Valve
1.
Hydraulic pump
2.
Main spool
3.
Pressure compensation valve
4.
LS shuttle valve
5.
LS bypass valve
6.
LS circuit
Function •
Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
•
Slows down the rising rate of the LS pressure to prevent a sudden change of hydraulic pressure.
•
The bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the circuit resistance between throttle (c) of main spool (2) and LS shuttle valve (4).
•
Effective LS differential pressure drops to improve the dynamic stability of the actuator.
10-284 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
MEMORANDUM
WA500-6
10-285 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
ECSS Control Valve
10-286 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
The controller automatically turns on and off the accumulator charged with high-pressure gas according to the travel condition.
•
The ECSS control valve gives elasticity to the vertical movement of the work equipment and reduces rocking of the machine body during high-speed travel in order to improve the comfort of the operator and prevent spillage of material, resulting in higher working efficiency.
Operation •
If the travel speed exceeds 5 km/h (3 mph), the signal is sent to solenoid valve (2) and the pressure is applied to (a).
•
Spool (1) moves to the right.
•
As spool (1) moves, the line from (PR) to accumulator (ACC) is closed and the lines from (A2) to accumulator (ACC) and from (B2) to (T) are opened. As a result, the ECSS is turned ON.
•
While the travel speed is below 4 km/h (2.5 mph), the signal is not sent to solenoid valve (2) and spool (1) is in neutral. At this time, the line from (PR) to accumulator (ACC) is opened and accumulator (ACC) is charged.
•
If accumulator (ACC) is charged up to the set pressure, check valve (5) is closed and the pressure in accumulator (ACC) does not rise any further.
WA500-6
10-287 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Accumulator Pressure Relief Valve If the pressure in accumulator (ACC) needs to be relieved, loosen plug (3) and nut (4) to open circuits (PR) and (TS).
10-288 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
MEMORANDUM
WA500-6
10-289 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Accumulator Charge Valve
10-290 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Screw
2.
Poppet (Safety valve)
3.
Spring (Safety valve)
4.
Spring (Main pressure reducing valve)
5.
Pressure reducing valve spool
6.
Poppet (Check valve)
7.
Spring (Check valve)
CR.
Pressure pickup port
P.
From main pump
PR.
To accumulator through ECSS spool
TS1.
To tank
TS2.
To tank
TS3.
To tank
HYDRAULIC SYSTEM
Torque Values Designation
N•m
lbf ft
BB
98.1 – 122.5
72 – 90
CC
24.5 – 34.3
18 – 25
DD
19.6 – 27.5
15 – 20
WA500-6
10-291 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-292 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ When valve is in neutral and (P) is low
Function Discharge pressure (P) of the hydraulic pump is reduced and the oil is supplied to the ECSS accumulator. Operation •
Poppet (2) is pressed by spring (3) against the seat and the line from port (P1) to port (T) is closed.
•
Poppet (6) is pressed to the left and the line from port (P1) to port (PR) is closed.
•
Poppet (6) is moved to the right by pressure (P1) and the line from (P1) to (PR) is opened. If (P1) < (PR), poppet (6) is pressed to the left by spring (7) and the line from (P1) to (PR) is closed.
WA500-6
10-293 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
★ When load pressure (P) is high
Operation •
If pressure (P) rises above the set pressure, poppet (3) opens and the hydraulic oil flows through port (P1), hole (a) in spool (5), opening of poppet (2), and tank port (T).
•
In this manner, differential pressure is made before and after hole (a) in spool (5). Spool (5) moves to close the opening between ports (P) and (P1). Pressure (P) is reduced to a certain pressure (the set pressure) by the open area at this time and supplied as pressure (P1).
10-294 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Accumulator (for PPC Circuit) Function The accumulator is installed between the charge valve and work equipment valve. If the engine is stopped with the lift arm raised, compressed nitrogen gas pressure in the accumulator feeds the pilot oil pressure to the work equipment valve for operation. In this manner, the lift arm and bucket are enabled to descend under their own weight. Specifications Type of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nitrogen gas Amount of gas: . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 cc (30.51 in3) Max. operating pressure: . . . . . . . . . . . . . . . 39.97 kg/cm² (569 psi) Min. operating pressure: . . . . . . . . . . . . . . . . . . . . . 0 kg/cm² (0 psi) 1.
Gas plug
2.
Shell
3.
Poppet
4.
Holder
5.
Bladder
6.
Oil port
Operation •
After the engine is stopped, chamber (A) in the bladder is compressed by oil pressure in chamber (B).
•
When the work equipment EPC solenoid is tripped by operating the work equipment EPC lever, pressure inside nitrogen gas chamber (A) expands the bladder and the oil in chamber (B) operates the work equipment valve as the pilot pressure.
WA500-6
10-295 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Work Equipment Electric Lever
Torque Values Designation
N•m
lbf in
1
6.9 – 9.8
61 – 87
2
11.8 – 14.7
104 – 130
3
3.4 – 4.4
30 – 39
10-296 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
MEMORANDUM
WA500-6
10-297 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-298 b
HYDRAULIC SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Lever
2.
Rod
3.
Centering spring
4.
Metering spring
5.
Nut
6.
Rod
7.
Detent spring
8.
Retainer
9.
Lever
HYDRAULIC SYSTEM
10. Potentiometer 11. Seat 12. Ball 13. Detent spring 14. Rod 15. Body 16. Solenoid 17. Bushing 18. Body 19. Retainer 20. Rod
Torque Values Designation
N•m
lbf in
CC
11.8 – 14.7
104 – 130
DD
1.0 – 2.0
9 – 18
WA500-6
10-299 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Function •
When lever (1) is operated, rod (20) moves up and down and rotates potentiometer (10) according to the operating distance of the lever.
•
The operating angle (stroke) of the control lever is sensed with the potentiometer and output as a signal voltage to the controller.
•
A potentiometer is installed. It outputs two signal voltages which are opposite to each other as shown in the diagram to the right.
10-300 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC SYSTEM
Operation ★ When work equipment control lever is operated • • •
Rod (20) is pushed up by spring (4) according to the operating distance of lever (1). Lever (9) and rod (14), installed to the rotary shaft of potentiometer (10), are connected to each other. Potentiometer (10) outputs signal voltage according to the vertical stroke of the rod.
★ When work equipment is operated to lift arm lower (or to lift arm raise or bucket tilt) • • • • •
If rod (2) on the lift arm lower side is pushed down by lever (1), ball (12) touches projection (a) of rod (14) in the middle of the stroke (before electric detent operation starts). If rods (2) and (14) are pushed in further, ball (12) pushes up retainer (8), supported on detent spring (7), and escapes out to go over projection (a) of rod (14). At this time, rod (20) on the opposite side is pushed up by spring (4). If rod (20) is pushed up while the current is flowing in solenoid (16), nut (5) is attracted by bushing (17). In this manner, rod (20) is kept pushed up and the lift arm lower state is kept even if the lever is released.
★ When lift arm lower operation of work equipment control lever is reset • •
Lever (1) is returned from the lift arm lower position by pushing down rod (20) with a force larger than the attractive force of the solenoid. The lift arm lower state also can be reset and lever (1) can be returned to the neutral position by turning off the current in the solenoid.
WA500-6
10-301 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT Work Equipment Linkage
10-302 b
1.
Bucket
6.
Bucket link
2.
Bellcrank
7.
Bucket hinge pin
3.
Bucket cylinder
8.
Bucket hinge pin
4.
Lift cylinder
9.
Bell crank pin
5.
Lift arm
10. Cord ring
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA500-6
WORK EQUIPMENT
10-303 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-304 b
WORK EQUIPMENT
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm (in) No.
Check Item
Criteria Standar d Size
1
Tolerance Shaft
Clearance between bushing and pin at each end of bucket link
Hole
Remedy Standard Clearance Clearanc Limit e
120 (4.72)
-0.036 +0.307 (-0.0014) (+0.0121) -0.090 +0.220 (-0.0035) (+0.0087)
0.256 – 0.397 (0.010 – 0.016)
1.0 (0.039)
2
Clearance between bushing and pin connecting lift arm and bucket
120 (4.72)
-0.036 +0.307 (-0.0014) (+0.0121) -0.090 +0.220 (-0.0035) (+0.0087)
0.256 – 0.397 (0.010 – 0.016)
1.0 (0.039)
3
Clearance between bushing and pin connecting lift arm and frame
140 (5.51)
-0.043 +0.395 (-0.0017) (+0.0156) -0.106 +0.295 (-0.0042) (+0.0116)
0.338 – 0.501 (0.013 – 0.020)
1.0 (0.039)
4
Clearance between bushing and pin connecting bucket cylinder bottom and frame
125 (4.92)
-0.043 +0.395 (-0.0017) (+0.0156) -0.106 +0.295 (-0.0042) (+0.0116)
0.338 – 0.501 (0.013 – 0.020)
Replace 1.0 (0.039) [Replace if pin has scuff mark]
5
Clearance between bushing and pin connecting bucket cylinder rod and bell crank
125 (4.92)
-0.043 +0.395 (-0.0017) (+0.0156) -0.106 +0.295 (-0.0042) (+0.0116)
0.338 – 0.501 (0.013 – 0.020)
1.0 (0.039)
6
Clearance between bushing and pin connecting bellcrank and lift arm
160 (6.30)
-0.043 +0.395 (-0.0017) (+0.0156) -0.106 +0.295 (-0.0041) (+0.0116)
0.338 – 0.501 (0.013 – 0.020)
1.0 (0.039)
7
Clearance between bushing and pin connecting lift cylinder bottom and frame
120 (4.72)
-0.036 +0.307 (-0.0014) (+0.0121) -0.090 +0.220 (-0.0035) (+0.0087)
0.256 – 0.397 (0.010 – 0.016)
1.0 (0.039)
8
Clearance between bushing and pin connecting lift cylinder rod and lift arm
120 (4.72)
-0.036 +0.307 (-0.0014) (+0.0121) -0.090 +0.220 (-0.0035) (+0.0087)
0.256 – 0.397 (0.010 – 0.016)
1.0 (0.039)
Width of Hinge
Boss-to-Boss Width
Standard Clearance (Clearance of a+b)
153 (6.02)
150 (5.91)
3.0 (0.118)
10 Connecting part of lift arm and frame
183 (7.20)
180 (7.09)
3.0 (0.118)
11 Connecting part of lift arm and bucket
183 (7.20)
180 (7.09)
3.0 (0.118)
12 Connection of bucket link and bucket
183 (7.20)
180 (7.09)
3.0 (0.118)
13 Connecting part of bellcrank and bucket link
183 (7.20)
180 (7.09)
3.0 (0.118)
9
Connecting part of bucket cylinder and frame
14 Connecting part of lift cylinder and frame
153 (6.02)
150 (5.91)
3.0 (0.118)
15 Connecting part of bellcrank and lift arm
316 (12.44)
313 (12.32)
3.0 (0.118)
Connecting part of bucket cylinder and bellcrank
155 (6.10)
150 (5.91)
5.0 (0.197)
17 Connecting part of lift arm and lift cylinder
153 (6.02)
150 (5.91)
3.0 (0.118)
16
WA500-6
Adjust [Insert shims to both sides so that clearance will be below 1.5 mm (0.059 in) on each side]
10-305 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Bucket Bucket 5.6 M3 (with Bolt-On Cutting Edge)
1.
Bucket
2.
Bolt-on cutting edge (BOC) Unit: mm (in)
No. 3
Check Item Wear on edge
Criteria
Remedy
Standard Size
Repair Limit
38 (1.50)
15 (0.59)
Turn over or replace
Torque Values Designation
N•m
lbf ft
CC
800 – 1200
649 – 885
10-306 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Bucket 5.2 M3 (with Teeth and Segment Edge)
Unit: mm (in) No. 1
Check Item
Criteria
Remedy
Standard Size
Repair Limit
38 (1.50)
23 (0.91)
Wear on bucket teeth
Replace
2
Clearance in bucket tooth mounting parts
3
Wear on segment edge
Max. 0.5 mm (0.02 in) (Clearance between edge) 38 (1.50)
15 (0.59)
Adjust or replace Turn over or replace
Torque Values Designation
N•m
lbf ft
EE
880 – 1,200
649 – 885
FF
1878 ±279
1385 ±206
GG
1040 ±157
767 ±116
WA500-6
10-307 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Bucket Positioner and Boom Kickout
Unit: mm (in) No.
Check Item
Criteria
1
Clearance of bucket positioner switch
3 – 5 (0.1181 – 0.1968)
2
Clearance of lift arm position detection switch
0.5 – 1 (0.0197 – 0.0394)
Remedy Adjust
10-308 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
Work Equipment Lubrication
WA500-6
1.
Steering cylinder
A.
Lift cylinder pin left
2.
Bell crank
B.
Lift cylinder pin right
3.
Lift arm
C.
Bucket cylinder (bottom side)
4.
Bucket cylinder
D.
Lift cylinder (bottom side) right
5.
Front frame
E.
Lift cylinder (bottom side) left
6.
Lift cylinder
F.
Steering cylinder (rod side) right
7.
Rear frame
G.
Steering cylinder (rod side) left
H.
Center support
10-309 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-310 b
WORK EQUIPMENT
J.
Rear axle (thrust plate)
K.
Rear axle mount (rear)
L.
Rear axle mount (front)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
CAB AND ITS ATTACHMENTS ROPS Cab
WA500-6
1.
Front glass
2.
Front wiper
3.
Door
4.
Rear wiper
10-311 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Torque Values Designation
N•m
lbf ft
1
1177 – 1471
868 – 1085
10-312 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Air Conditioner Air Conditioner Piping Diagram
1.
Air outlet duct
5.
Condenser
2.
Air conditioner unit
6.
Hot water take-out port
3.
Compressor
7.
Hot water return port
4.
Receiver
Specifications Refrigerant used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R134a Refrigerant refilling volume (g) . . . . . . . . . . . . . . . . . . . . . 1,250 ±50
WA500-6
10-313 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Cooling Circuit Diagram
10-314 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Air Conditioner Unit
WA500-6
A.
Hot water outlet
B.
Hot water inlet
C.
Refrigerant inlet side
D.
Refrigerant outlet side
10-315 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Condenser
1.
Fin
2.
Tube
3.
Refrigerant gas outlet port
4.
Refrigerant gas inlet port
Function •
The condenser cools and liquefies the high-pressure and high-temperature refrigerant from the compressor.
•
If the fins are crushed or are clogged with dust, heat exchange efficiency is degraded and complete liquefaction of the refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit is increased, applying extra load to the engine or degrading the cooling effect. Be very careful when handling the condenser and during the daily inspection.
Specifications Fin pitch (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Total heat dissipation surface (m2) . . . . . . . . . . . . . . . . . . . . . . 6.55 Max. pressure used kg/cm² (psi) . . . . . . . . . . . . . . . . . .36.71 (522)
10-316 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Compressor
1.
Case
2.
Clutch
A.
Suction service valve
B.
Discharge service valve
Function •
Other than circulating the refrigerant, the compressor compresses the refrigerant gas from the evaporator to high-pressure, high-temperature refrigerant so that it may be easily regenerated (liquefied) at normal temperature.
•
Its built-in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure.
Specifications Number of cylinders – Bore x Stroke (mm) . . . . . . . . 5 – 35 x 28.6 Piston capacity (cc/rev) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Allowable maximum speed (rpm) . . . . . . . . . . . . . . . . . . . . . 4,000 Refrigerant oil used: . . . . . . . . . . . . . . . . . . . . . . . . . Sanden SP-20 Refrigerant oil refilling volume (cc) . . . . . . . . . . . . . . . . . . . . . . 175
WA500-6
10-317 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Receiver
A.
From condenser
B.
To air conditioner unit
1.
SIght glass
Function •
The receiver is used to store liquefied high-pressure, high-temperature refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation.
•
The receiver eliminates foreign substances in the circulation circuit and water content in the refrigerant by using the builtin filter and desiccating agent.
•
Sight glass (1) allows you to inspect the flow of the refrigerant.
Specifications Effective cubic capacity (cm3) . . . . . . . . . . . . . . . . . . . . . . . . . . 578 Weight of desiccating agent (g) . . . . . . . . . . . . . . . . . . . . . . . . . 300
10-318 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Air Conditioner Panel Manual Air Conditioner Specification
Display Unit Displayed Items
Display Range
Display Method
Temperature
See above figure
All segments below applicable level come on (8-step display)
2
Volume
See above figure
All segments below applicable level come on (4-step display)
3
Circulation of internal air and introduction of external air
When circulating internal air and introducing external air
The display indicates which is currently taking place – internal air circulation or external air introduction, responding to the operation of the internal/external air changeover switch.
Air conditioner
When air conditioner switch is turned ON
Turns ON air conditioner switch, this lamp lights up.
No.
Display Category
1
Display Color
Remarks
Black
Liquid crystal
Gauges
Pilot
4
WA500-6
10-319 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
Switch Block No.
Type
Function
Operation
5
Internal/external air changeover switch
It is used for selecting the internal air circulation or external air introduction (The pilot indication on the display unit varies depending on the given setting.)
Internal air circulation External air introduction
6
Air conditioner switch
It turns on or off the cooling and the dehumidifying heating function.
OFF ON
This switch turns on or off the main power of the air conditioner. ON: Display unit indicates the setting being specified when power was turned OFF. OFF: Turns off the display unit and stops the fan.
OFF ON
7
Main power switch
8
Fan switch
It controls volume of air sent from the fan. (Adjusted in four steps [LO, M1, M2, HI])
LO HI
9
Temperature adjusting switch
It is used to control output temperature. (8-step adjustment)
Low temperature High temperature
Outline •
The CPU (central processing unit) installed on the panel processes input signals from respective sensors and operation signals of the panel switches to display and output them.
•
The self-diagnosis function of the CPU makes the troubleshooting easier.
Input and Output Signals JAE IL-AG5-14P [CN-C48] Pin No.
Signal Name
Input and Output Signals
1
GND
—
2
Sensor ground
—
3
Internal/external air changeover damper actuator limiter
Input
4
External air temperature sensor
Input
5
Evaporator temperature sensor
Input
6
Internal air temperature sensor
Input
7
Starting switch (ON)
Input
8
Night lamp signal
Input
9
NC
—
10
NC
—
11
NC
—
12
NC
—
13
Day light sensor 2
Input
14
Day light sensor 1
Output
10-320 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CAB AND ITS ATTACHMENTS
JAE IL-AG5-22P [CN-C47] Pin No.
Signal Name
Input and Output Signals
1
NC
—
2
NC
—
3
Blower motor relay
Input
4
Internal/external air changeover damper actuator output 1
Output
5
Internal/external air changeover damper actuator output 2
Output
6
Mode selector actuator output 2
Output
7
Mode selector actuator output 1
Output
8
Air mix damper actuator output 2
Output
9
Air mix damper actuator output 1
Output
10
Actuator potentiometer power supply (5 V)
—
11
NC
—
12
NC
—
13
NC
—
14
NC
—
15
Magnet clutch
Input
16
Air mix damper actuator limiter
Input
17
Mode selector actuator limiter
Input
18
Air mix damper actuator potentiometer
Input
19
Mode selector actuator potentiometer
Input
20
Blower gate
Input
21
Blower feedback
Input
22
Actuator potentiometer ground
—
WA500-6
10-321 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM Machine Monitor System Outline •
In the machine monitor system, each monitor on the network monitors and controls the machine condition with the sensors installed on various parts of the machine, and then sends the result as network information to the machine monitor, which displays the information to notify the operator of the machine condition.
•
The machine monitor displays the information in the operator (normal) mode or service mode.
Operator Mode •
The operator mode displays the information to the operator normally. The major functions displayed in the operator mode are described here.
1.
Items always displayed: • Meters (speedometer or engine tachometer) • Gauges (engine coolant temperature gauge, torque converter oil temperature gauge, hydraulic oil temperature gauge, and fuel level gauge) • Pilot indicators • Service meter The following items are displayed according to the set state of the optional device selecting function: • Load meter calculated weight • Hours • Display of travel speed/engine speed on the character display
2.
Items displayed when abnormality is detected: • Caution lamps • Action code (if the monitor panel mode selector switch (>) is pressed and released while an action code is displayed, the failure code (six digits) is displayed.)
3.
At the replacement period of a filter or oil, the character display displays that filter or oil (maintenance monitoring function).
4.
In addition to the above, the following display, setting, and adjustment functions are provided using the character display and the machine monitor mode selector switch, which is the operation switch of the character display. A. Load meter (if equipped) • Loaded/no loaded calibration • Reset of calibration • Display/non-display of load meter • Printer output format (printer (if equipped)) B. C. D. E. F. G. H. I.
Displaying odometer Resetting filter oil replacement time Inputting telephone number Selecting a language Adjusting brightness of the night lighting for the machine monitor Adjusting time of clock (load meter (if equipped)) Selecting travel speed and engine speed display Setting display/non-display of travel speed and engine speed on the character display
10-322 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Service Mode •
The service mode function is provided for the ease of troubleshooting the controllers on the network (including the machine monitor itself). The major functions used in the service mode are described here.
1.
Electrical system failure history display function The electrical system failures for each controller are saved in the machine monitor and displayed. The information about these failures is also deleted with this function.
2.
Mechanical system failure history display function The mechanical system failures of each controller are saved in the machine monitor and displayed.
3.
Real-time monitoring function The input and output signals recognized by each controller on the network are displayed in real time.
4.
Engine reduced-cylinder mode function This function is used to stop fuel injection to each cylinder from the fuel injector in order to determine the cylinder with defective combustion.
5.
No injection cranking function This function is used to lubricate the engine internally before starting the engine after long-term storage of the machine.
6.
Adjustment function Function provided to correct and adjust the installation errors and manufacturing dispersion of the sensors, solenoid valves, etc. Function for changing the control characteristic data upon request of the user.
7.
Maintenance monitoring function Changes the filter and oil replacement time and allows ON/OFF selection of the function.
8.
Operating information display function Displays fuel consumption per operating hour.
9.
Optional device selecting function Verifies the installation of optional devices or changes their setting.
10. Machine serial number input function Enters the machine serial number to identify the machine. 11. Model selection function Enters the information for the applicable model. 12. Initialize function Sets the machine monitor to the state set when the machine was delivered.
WA500-6
10-323 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Machine Monitor Circuits Starting and Lighting
10-324 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Load Meter
WA500-6
10-325 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Sensing
10-326 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Power Supply and Network
WA500-6
10-327 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Electrical Circuit Diagram
10-328 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA500-6
ELECTRICAL SYSTEM
10-329 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Machine Monitor
10-330 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
1.
Torque converter oil temperature gauge
26. Maintenance caution lamp
2.
Torque converter oil temperature caution lamp
27. Battery electrolyte level caution lamp (if equipped)
3.
Engine coolant temperature gauge
28. Battery charge circuit caution lamp
4.
Engine coolant temperature caution lamp
29. Steering oil pressure caution lamp
5.
Speedometer or engine tachometer
30. Emergency steering pilot lamp
6.
Display of the unit of speedometer or engine tachometer
31. Output mode pilot lamp (Power mode)
7.
Turn signal pilot lamp (left)
32. Preheater pilot lamp
8.
Head lamp high beam pilot lamp
33. Semi-auto digging pilot lamp
9.
Turn signal pilot lamp (right)
34. Auto-grease pilot lamp (not used)
10. Hydraulic oil temperature gauge
35. Joystick pilot lamp (if equipped)
11. Hydraulic oil temperature caution lamp
36. Directional selector pilot lamp (not used)
12. Fuel level gauge
37. ECSS pilot lamp (not used)
13. Fuel level caution lamp
38. Economy operation indicator lamp
14. Central warning lamp
39. Shift position pilot lamp (forward/reverse)
15. Brake oil pressure caution lamp
40. Shift position pilot lamp (gear speed)
16. Engine oil pressure caution lamp
41. Shift indicator
17. Water separator caution lamp (not used)
42. Auto-shift pilot lamp
18. Engine oil level caution lamp
43. Lockup pilot lamp
19. Radiator coolant level caution lamp
44. Shift hold pilot lamp
20. Parking brake pilot lamp
45. Display of bucket loading (if equipped)
21. Air cleaner clogging caution lamp
46. Addition mode: Total loading display/Reduction mode: Display of level (if equipped)
22. Transmission oil filter clogging caution lamp
47. Working object display (if equipped)
23. Axle oil temperature caution lamp
48. Addition/reduction mode display (if equipped)
24. Modulation clutch temperature caution lamp (not used)
49. Character display
25. Cooling fan reverse rotation pilot lamp
WA500-6
10-331 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Machine Monitor Operation Switches
1.
Load meter display selector switch (if equipped) •
2.
10-332 b
Total mass display Load meter mode selector switch (if equipped)
•
Material selection
•
Addition/reduction selection
3.
Character display mode selector switch
4.
Character display item selector switch
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Items Displayed on Monitor Condition for judging that the engine is running: When at least two of the following conditions are met, or CAN communication error (transmission controller: DAQRKR or (engine controller: DB2RKR) and the charge level is equal to or exceeds the specified level. 1.
Turning ON the starting switch is recorded (IGN-C signal was entered).
2.
Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above after that).
3.
Engine speed is 500 rpm or above.
●
Lighting
❍
Flashing (1.6 sec., 50% duty)
✩
Intermittent (Period: 240 msec., ON: 80 msec., OFF: 160 msec.)
As per separate setting condition
Signal Detection Controller
When error is made
Red
Lights when error (E03, E02) occurs on each controller and at the same time displays message.
Other than above, see “Operating condition – Central warning lamp” column of relevant items.
—
—
—
—
—
—
—
—
—
Back light: For night Back light (various lighting When small lamp is back lights) turned ON of LED
—
—
—
—
—
—
Monitor
5
Indicates “0” if error is made in communication other than when engine speed is selected or tilt positioner set angle is displayed.
—
Switchable to speedometer The first digit is fixed at 0. — Engine Number of display digits (4-digits): 0 – 3990
14
Central warning lamp
WA500-6
Engine speed
Central Warning
Display of Message
Individual Display
Alarm Buzzer
Central Warning
Engine: Running Display of Message
Individual Display
Device Alarm Buzzer
Item
Reset
No.
Engine: Stopped
Display Color
Remarks
White
Central warning lamp Gauges and meters Back light
Operating State
Detection time (sec)
Detection
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
LED
Fixed LCD
—
—
—
—
—
10-333 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Fixed LCD
—
—
—
—
Central Warning —
Display of Message
Individual Display
Alarm Buzzer
Display of Message
Central Warning —
Engine: Running
—
Signal Detection Controller
Travel speed
Other than when engine speed is not selected and tilt positioner set angle is displayed
Individual Display
Device Alarm Buzzer
Item
Reset
No.
Engine: Stopped
Display Color
Operating State
Detection time (sec)
Detection
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Remarks
TM
Switchable to tachometer Number of display digits (4-digits): 0 – 99 (middle 2 out of 4 digits are used.) Switching between speedometer/ tachometer Displayed just 3 seconds when instruction is given from work equipment controller. Number of display digits is 1-digit (-5 to 5) (middle 2 out of 4-digits are used, unit is not displayed). Operation completion sound (short beep) and cancel sound (long beep sound) are given simultaneously.
Lamp does not light up when error is made in communication.
—
—
—
—
—
—
—
BBC
❍
●
❍
❍ Remarks
Fixed LCD
●
—
TM
5
Overrun prevention (in lockup release torque converter mode) alarm
10-334 b
Fixed LCD
Fixed LCD
Alarm is issued when information of “Overrun prevention (in lockup release torque converter mode) alarm detecting” is obtained from transmission controller, and is continued at least 3 minutes.
Note 1
❍
●
❍
❍ Remarks
Overrun prevention (when lockup release torque converter mode) alarm notice
Alarm is issued when information of “Overrun prevention (in lockup release torque converter mode) alarm notice” is obtained from transmission controller, and is kept at least 3 minutes.
❍ Remarks
Gauges and meters
Tilt positioner set position display
❍ Remarks
When tilt positioner set angle is displayed.
●
—
TM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
6
Unit display
LCD
Signal Detection Controller
Central Warning
Display of Message
When engine speed is selected
—
—
— r/min —
— r/min —
—
When speed [km/H] is selected
—
—
— km/h —
— km/h —
— Monitor
When speed [MPH] is selected
—
—
— MPH —
— MPH —
—
—
—
—
When tilt positioner set angle is displayed
—
—
Alarm Buzzer
Central Warning
Display of Message
Individual Display
Device Alarm Buzzer
Item
Engine: Running
Reset
No.
Engine: Stopped
Individual Display
Detection time (sec)
Display Color
Operating State
Detection Unit
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
—
—
Remarks
BBC
Note 1 Central Warning Lamp
Buzzer
Main Part (*1)
Message
Overrun notice
●
❍
❍ (flashing)
—
Overrun
●
❍
❍ (flashing)
Overrun prevention
•
When the engine speed is displayed on the center LCD, the display flashes.
•
When the travel speed is displayed, it is switched to the engine speed and the display flashes.
(*1)
WA500-6
10-335 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Device
Torque Pointer: converter oil Movement temperature
20
5
———
❍ ● ●
———
Remarks
MAX position: 135°C (275°F) Red zone start point: 120°C (248°F) Level: 110°C (230°F) 1/4 of full scale: 80°C (176°F) (See figures Min. position: at end of 50°C (122°F) table.) Monitor When sensor is grounded: Max. of gauge When sensor is disconnected or hot shorted: Min. of gauge b@CENS does not display character message.
3
— ● ——— ● ——
❍ ● ●
When abnormality is detected
———
When abnormality is detected
———
❍ ● ●
——— ———
Red
—————————
Engine Indicator: coolant Alarm: LED temperature Min. 105°C (221°F) caution lamp
10-336 b
(b@CENS) Red
❍ ● ●
B@CENS Red
1
Engine Pointer: coolant Movement temperature Alarm: Min. 102°C (216°F) and [No abnormality is detected (CA144 and CA145 are not generated)]
4
10
— ● —
CA145 CA144 B@BCNS Red
3
— ● —
DGT1KX Red
When abnormality is detected
1
(b@CENS)
Operation of gauges and meters
Torque Alarm: Min. converter oil Indicator: 130°C (266°F) and LED temperature [No abnormality is caution lamp detected (DGT1KX is not generated)]
10
B@CENS
————————— Alarm: Min. 120°C (248°F) and [No abnormality is detected (DGT1KX is not generated)]
2
Engine: Running
DGT1KX
1
Engine: Stopped
CA145 CA144 B@BCNS
Item
Reset
No.
Operating State
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message Display Color
Detection Time (sec)
Detection
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Signal Detection Controller
ELECTRICAL SYSTEM
Engine monitor
(See figures at end of table.)
MAX position: 135°C (275°F) Level: 85°C (185°F) 1/4 of full scale: 65°C (149°F) Min. position: 50°C (122°F)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
1
❍ ● ●
When abnormality is detected
20
5
———
❍ ● ●
B@HANS Red
10
Pointer: Movement
Fuel level
13
Fuel level Indicator: caution lamp LED
WA500-6
Max. position: 125°C (257°F) Red zone start point: 100°C (212°F) Level: 85°C (185°F) (green graduations only) 1/4 of full scale: 65°C (149°F) (See figures (green graduations Monitor at end of only) table.) Min. position: 50°C (122°F) When sensor is — grounded: Max. of gauge When sensor is disconnected or hot shorted: Min. of gauge
———
DGH2KX
Alarm: Min. 100°C (212°F) and [No abnormality is detected (DGH2KX is not generated)] Hydraulic oil Indicator: temperature LED caution lamp
12
Remarks
—————————
Min. 61.3
10
1
———
———
—
— ● —
— ● —
Red
Operation of gauges and meters
11
Hydraulic oil Pointer: temperature Movement
B@HANS
10
Engine: Running
Signal Detection Controller
Device
Engine: Stopped
DGH2KX
Item
Reset
No.
Operating State
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message Display Color
Detection Time (sec)
Detection
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
MAX position: 100%: 10 3/4 of full scale: 75% Level: 50%: 32 1/4 of full scale: 25%: 49.5 Red zone start point: See specified LED (See figures lighting percent or Monitor at end of resistance. table.) Min. position: 0%: 85 When sensor is disconnected or hot shorted: Gauge EMPTY When sensor is grounded: Gauge FULL
10-337 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Actual gear speed
39 40
Shift position pilot lamp
LED
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message
[When F is selected] and [Engine is stopped]
1
0
✩ ● ●
———
Green
[When R is selected] and [Engine is stopped]
1
0
✩ ● ●
———
Green
When F is selected
0
0
— ● —
— ● —
Green
When N is selected
0
0
— ● —
— ● —
Green
When R is selected
0
0
— ● —
— ● —
Green
When 4th gear speed is selected
0
0
— ● —
— ● —
Green
When 3rd gear speed is selected
0
0
— ● —
— ● —
Green
When 2nd gear speed is selected
0
0
— ● —
— ● —
Green
When 1st gear speed is selected
0
0
— ● —
— ● —
Green
———
———
—
If error is made in communication, display is held until key is turned OFF.
Upper line: F, N, R Lower line: 1, 2, 3, 4 Shift 9-segment If error is made in 41 indicator LCD communication, display is held until key is turned OFF.
0
0
———
———
—
When auto-shift is selected
0
0
— ● —
— ● —
Green
———
———
Green
— ● —
— ● —
Green
———
———
—
———
— ● —
Green
———
———
—
— ● —
— ● —
Auto-shift 42 pilot lamp
Shift hold 44 pilot lamp
LED
If error is made in communication, display is held until key is turned OFF. When auto-shift and shift hold are selected
LED
Lockup 43 pilot lamp
LED
Turn signal pilot lamp
LED
7 9
10-338 b
0
0
If error is made in communication, display is held until key is turned OFF. When lockup functions
Others
Display Color
Reset
Item
Engine: Running
Detection
No.
Operating State
Detection Engine: Time Stopped (sec)
Device
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
0
0
If error is made in communication, display is held until key is turned OFF. When turn signal switch is input (including when key is OFF)
0
0
Signal Detection Controller
ELECTRICAL SYSTEM
Remarks
Monitor TM
TM
Green Monitor
Displayed on right of [Gear speed display]. Interlocked with shift valve. In neutral, however, gear speed is not displayed. Displayed on left of [FNR display]. N when F or R solenoid value is OFF.
Functions when key is OFF to provide hazard function interlocking with turn signal switch.
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Engine oil level 18 caution lamp
WA500-6
LED
Signal Detection Controller
———
———
—
Remarks
1
— ● —
❍ ● ●
Below specified value (R) (OPEN) (detection time is continued) and in 45 seconds after engine is started (No detection time)
5
1
— ● —
❍ ● ●
Below specified pressure (F) (OPEN) (detection time is continued) and 45 seconds after engine is started (No detection time) * When engine is stopped, condition of “45 seconds after engine is started” is not applied.
1
1
— ● —
❍ ● ●
Red
Front
Below specified pressure (R) (OPEN) (detection time is continued) and 45 seconds after engine is started (No detection time) * When engine is stopped, condition of “45 seconds after engine is started” is not applied.
1
1
— ● —
❍ ● ●
Red
Rear
———————
—
Red
Front
Red
Rear
Monitor
Engine oil pressure reduction error is received
❍ ● ●
Normal oil level (CLOSED)
———
Low oil level (OPEN) continues 2 seconds. For 300 seconds after engine is stopped, however, no error is detected.
2G42ZG
5
2G43ZG
Below specified value (F) (OPEN) (detection time is continued) and in 45 seconds after engine is started
At normal operation LED
Monitor
— ● —
2
1
— ● —
❍ ● ●
B@BAZG
Engine oil pressure 16 caution lamp
Blue
0
B@BAZG
LED
Others
Brake oil pressure caution lamp
— ● —
0
Normal oil pressure (CLOSED)
15
Display Color
When high beam is functioning: Head lamp ON and High beam ON
B@BAZK
LED
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message
Head lamp high 8 beam pilot lamp
Reset
Item
Engine: Running
Detection
No.
Operating State
Detection Engine: Time Stopped (sec)
Device
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Red
———
—
———
Red
Engine
If alarm is detected when key is turned ON, first information is kept until Monitor engine oil reaches normal oil level even if engine is started.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
When parking brake is not applied (CLOSED)
———
———
— Monitor
0
Sensor detects clogging (OPEN)
2
✩ ● ●
Red
———
———
—
———
— ● —
———
——— — ● —
0
1
Clogging (OPEN) and torque converter oil temperature > 50°C
2
1
———
When abnormality is detected
3
———
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AA1ANX
Other than when parking brake is applied and gearshift lever is at N position, and during starting engine
———
Red
Red
———
—
———
Red
5
5
— ● ——— ● ——
Red
Temperature increase (1 or 2 below) 1. Oil temperature is above 130°C (266°F) for 5 seconds. 2. When travel speed is above 35 km/h (22 mph) while brake oil temperature, 125°C (257°F) and above, is detected continuously for 5 seconds. It is released when oil temperature, 125°C and below, is detected continuously for 5 seconds.
5
5
❍ ● ●
B@C7NS
—
Temperature increase (Min. 120°C) (notice alarm)
Red
When abnormality is detected
———
When abnormality is detected
———
❍ ● ●
———
———
Monitor
—
————————
DGR2KX DGR2KA
LED
B@BCZK
Red
Other than below
Axle oil temperature 23 caution lamp
Display Color
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message — ● —
OFF
Others
LED
Monitor Red
— ● —
Normal (CLOSED) Transmission oil filter 22 clogging caution lamp
— ● —
When parking brake is applied (OPEN)
Normal (CLOSED) LED
— ● —
B@BCZK
1
Remarks
—
15BONX
LED
30
———
B@C7NS
Air cleaner 21 clogging caution lamp
———
LED Low coolant level (OPEN)
Engine: Running
DGR2KX DGR2KA
Parking 20 brake pilot lamp
Normal coolant level (CLOSED)
DHT2L6
Radiator coolant level 19 caution lamp
Reset
Item
Detection
No.
Operating State
Detection Engine: Time Stopped (sec)
Device
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Signal Detection Controller
ELECTRICAL SYSTEM
If abnormality is detected while engine is stopped, Monitor alarm is continued even after engine is started.
Monitor
—
—
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Steering oil 29 pressure caution lamp Emergency 30 steering pilot lamp
0
Fan switch and solenoid disagree.
0
0
Ordinary
———
LED
10
1
WA500-6
———
—
— ● —
—
—
———
———
———
———
❍ ● ●
Insufficient alternator voltage (Hysteresis on the right figure), no starting motor C signal input, and during running of engine
30
1
———
When abnormality is detected
3
1
❍ ● ●
Red
———
Red
—
————————
—
—
— ● —
Red
Normal operation [Operation of divider (= Below S/T pressure CN3-3=OPEN)] and [Travel speed, min. 1 km/h]
1
1
Power mode = P
0
0
Power mode = Other than P
— ● — ———
— ● —
— ● —
———
———
— ● —
— ● —
Monitor
If abnormality is detected while engine is stopped, alarm is continued even after engine is started. See figures on alternator terminal R voltage.
Red
Not in operation
———
Simultaneously displays contents on message display.
Monitor
—
In operation (CN3-3 = OPEN) When abnormality is detected
LED
———
Option is not applied
LED
LED
Display Color Red
Normal voltage (hysteresis on the right figure)
Holds in position Output mode 31 pilot lamp (power mode)
— ● — — ● —
B@GAZK
Sensors: Less than 2 V
— Monitor
30 h or less before maintenance or maintenance time Normal
LED
———
B@GAZK
LED
As indicated at right
0
As indicated at right
Cooling fan reverse rotation
Remarks
Cooling fan reverse rotation state is displayed. — ● — — ● — Orange Trans- While fan is reversed, mission message is displayed on character display. COOLING FAN REVERSE ROTATION — ❍ — — — ❍ — — Orange
AB00MA
28
Battery charge circuit caution lamp
————————
DDE5MA
Others
Battery electrolyte level 27 caution lamp
0
AB00L6
26
Maintenance caution lamp
LED
0
DDE5MA
Cooling fan 25 reverse rotation pilot lamp
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message
Cooling fan forward drive
Reset
Item
Engine: Running
Detection
No.
Operating State
Detection Engine: Time Stopped (sec)
Device
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Signal Detection Controller
ELECTRICAL SYSTEM
————————
—
Green
Implemented only when “Emergency steering Monitor enabled” is specified on optional setting on monitor panel.
Monitor
Green Trans- Selection of power mode mission is displayed.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LED
35
Joystick pilot lamp
———
———
—
— ● —
— ● —
Red
———
———
—
— ● —
— ● —
Green
When error is made in communication
———
———
—
Option is not applied
————————
—
Operation of steering wheel
————————
—
In preheating (with signal)
0
0
When auto digging switch is OFF LED
Others
Semi-auto 33 digging pilot lamp
Other than below
LED
When auto digging switch is ON
0
0
Economy operation indicator lamp
LED
Remarks
Engine
BBC
Monitor
Operation of joystick system only when joystick optional setting is made.
0
0
— ● — — — ● — — Green
Trans- CAN input signal from mission transmission controller
Joystick lever neutral lock (Output from work equipment controller)
0
0
✩ ❍ ● — ✩ ❍ ● — Green
BBC
Operation of FR prohibition function during locking of joystick steering only when joystick optional setting is made.
0
0
✩ ❍ ● — ✩ ❍ ● — Green
Trans- CAN input signal from mission transmission controller
Key ON and transmission controller in other than N (joystick) only when joystick optional setting is made.
0
0
✩ ❍ ● — ✩ ❍ ● — Green
BBC
FNR lever priority caution (only machine equipped with steering wheel and joystick) only when joystick optional setting is made.
1
0
✩ ❍ ●
✩ ❍ ● — Green
Trans- CAN input signal from mission transmission controller
———
———
—
When error is made in communication 38
Display Color
Preheating pilot lamp
Engine: Running
Alarm Buzzer Individual Display Central Warning Display of Message Alarm Buzzer Individual Display Central Warning Display of Message
32
Reset
Item
Operating State
Detection Engine: Time Stopped (sec)
Detection
No.
Device
Category
Operating condition: Engine operating condition included, error detection time counted (As indicated at right)
Signal Detection Controller
ELECTRICAL SYSTEM
Economy mode
0
0
— ● —
— ● —
Green
Other than above
0
0
———
———
—
CAN input signal from work equipment controller
CAN input signal from work equipment controller
Transmission
★ Priority of sounding of buzzer: Continual (❍) > Intermittent (✡) > Cancellation of operation > Check of acceptance of operation.
10-342 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Character Display Function You can change the display and settings on the machine monitor by using the character display function. The operator can use the functions shown in the “Operator disclosure function” section in the following figure. For instructions on how to use the operator mode, see the Operation and Maintenance Manual. .
★ *1: When an ID entered from the ID Entry screen is approved, the display changes directly to the Select Function screen without displaying the ID Entry screen until the starting switch is turned OFF.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Operator Mode Functions Self-Check Screen (0th layer) •
The self-check function operates three seconds after the key is turned ON.
•
After the key is ON, it automatically starts and ends the self-check function operation.
•
After three seconds, the 1st layer appears automatically.
•
In self-check mode, the mode switch is disabled.
Normal Screen (1st layer) •
After the self-check, the screen shown in the figure to the right is automatically displayed.
•
Press the switch to move to the 2nd layer.
★ The clock is displayed only for the load meter.
•
Select Displayed for the “10. Engine speed or travel speed display on character display and normal screen” item in the optional setting. When the travel speed is displayed on the LCD at the center of the monitor, the engine speed is displayed on the character display.
•
When the engine speed is displayed on the LCD, the travel speed is displayed on the character display.
•
For machines with SI specification, the travel speed unit is km/h; for ones with non-SI specification, the optional setting is respected.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Failure Code Screen (1st layer) •
Pressing the > switch when the Warning screen is on display changes the display to the Failure Code screen.
•
If multiple failure codes are present, pressing the > switch sequentially displays them from the item of higher priority downward. If items have the same priority, the item that occurred most recently will be displayed first.
★ Example of a failure code screen (simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 seconds in the normal screen display. *2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the Failure Code screen or if a new alarm is turned ON. *3: Pressing the > switch on the normal screen before 10 seconds pass changes the display to the initial Failure Code screen.
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10-345 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Operator Disclosure Function Functions available for the operator (2nd layer or lower) •
For the 2nd layer or lower, the screen automatically returns to the 1st layer if any switch operation is not done for at least 60 seconds.
•
Optional items are not displayed if not selected.
•
The language is displayed as set in the Language selection function.
•
For operation after selecting each menu, see the corresponding menu item. (Press the switch to select each menu.)
★ Function available for the operator (2nd layer and lower)
*1: This display is not available when the load meter function is turned OFF using the Optional Select option of the Service mode. *2: This menu is not available when the function to display the travel speed/rpm on the character display is turned OFF using the Optional Select option of the Service mode.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Service Mode Functions The Service mode function is used to troubleshoot the controllers on the network (including the machine monitor itself). When making initial and optional settings for the sensors, use the Service mode of the machine monitor. Procedure for Switching to Service Mode 1.
Entering the Service mode. A. Turn the starting switch of the machine ON to power the machine monitor. B. When the normal Service Meter screen or alarm screen is on the character display of the machine monitor, press the machine monitor mode selector switches 1 (■) and 2 (<) simultaneously for five seconds. • The INPUT ID screen is displayed.
2.
Input the ID. A. Press the < or > switch. The value at the cursor position increases or decreases. Select a desired value using the switch. • ID to enter the Service mode is 6491.
B. Completing operations equivalent to four digits (1) brings you to the ELECTRIC FAULT screen. ★ If you input an incorrect value, press the ■ switch to return the cursor to the highest-order digit and re-enter values from there. ★ If you press the ■ switch while the cursor is at the highest-order digit, the normal Service Meter screen or alarm screen is returned. ★ If any switch operation is done for at least 60 seconds during the ID input, the normal Service Meter screen or alarm screen is returned. . REMARK If the starting switch is turned OFF in the Service mode, the normal Service Meter screen or alarm screen is returned the next time the starting switch is turned ON.
WA500-6
10-347 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Service Mode Menu .
★ Pressing the < or > switch at the Service mode menu displays a different screen. Use the switch to select a target operation menu screen. ★ If you press the switch when the selection screen is displayed, the menu screen/operation screen of each function appears. ★ If you press the ■ switch when the selection screen is displayed, the normal Service Meter screen or alarm screen is returned the next time the starting switch is turned ON. Electrical System Failure History Display Function (ELECTRIC FAULT) ★ The ** field displays the total number of the failure history currently recorded (maximum of 20 histories can be stored). •
This function is used to check the electrical system failure history of each controller saved in the machine monitor.
•
For the failure codes displayed in the electrical system failure history, see the Troubleshooting section. After each failure is repaired and the normal operation is confirmed, delete the failure history.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
10-348 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Mechanical System (MACHINE FAULT)
Failure
History
ELECTRICAL SYSTEM Display
Function
The ** field displays the total number of the failure history currently recorded (maximum of 20 histories can be stored). •
This function is used to check the mechanical system failure history of each controller saved in the machine monitor.
•
For the failure codes displayed in the mechanical system failure history, see the Troubleshooting section.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Real-Time Monitoring Function (REAL-TIME MONITOR) •
This function is used to check the input and output signals, etc. recognized by each controller on the network.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) •
This function is used to stop fuel injection to each cylinder from the fuel injector in order to determine the cylinder with defective combustion.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
No Injection Cranking Function (NO INJECTION) •
This function is used when lubricating the engine, with the engine stopped, when restarting the engine after long-term storage of the machine.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Adjustment Function (TUNING) •
This function is used if you have changed or added sensors, valves, or controllers. The installation errors and manufacturing dispersion of the sensors, solenoid valves, etc. are corrected and adjusted, and control characteristic data is changed upon request of the user.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Maintenance Monitoring Function (MAINTENANCE MONITOR) •
This function is used for changing the filter and oil replacement timing and making an ON/OFF selection of this function.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
•
See also Filter, Oil Replacement Time Display in the Operation section of the Operation and Maintenance Manual.
Operating Information Display Function (OPERATION INFO) •
This function is used for displaying fuel consumption per operating hour.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Optional Device Selecting Function (OPTIONAL SELECT) •
This function is used to display the installed state of an optional device or change the setting of that device.
•
Use this function after any optional device is installed or removed.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
10-350 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Machine Serial Number Input Function (MACHINE No. SET) This function is used to display or set the machine serial number of the machine. •
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Model Selection Function (MACHINE) ★ The lower column displays the currently selected model. •
This function is used to display or select the machine model.
•
For the operating procedure for this function, see MACHINE MONITOR SYSTEM: Normal and Special Functions of Machine Monitor in the Testing and Adjusting section.
Initialize Function (INITIALIZE) •
This function is used to set the machine monitor to the state set when delivered.
•
Since this function is specially handled by the factory, no modification is allowed.
★ Do not use this function.
WA500-6
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Electrical System Failure History Display Function 1.
Display of electrical system failure history and selection for clearing the entire electrical system failure history • The items are displayed in the sequential order by the latest occurrence time from the latest one. • The items which have not been reset are displayed before the items which have been reset. • Pressing the > switch scrolls the items from the newer ones to the older ones. • Pressing the < switch scrolls the items from the older ones to the newer ones. • After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed. • Pressing the ■ switch changes the screen to the “Electrical system failure history selected” screen. • Pressing the switch changes the screen to the “Electrical system failure history individual cleared” screen or the “Electrical system failure history all cleared” screen.
2.
Selection of electrical system failure history (1st layer) • Pressing the < switch changes the screen to the Select Initialization screen. • Pressing the > switch changes the screen to the “Select display of mechanical system failure history” screen. • Pressing the ■ switch changes the screen to the normal screen or alarm screen. • Pressing the switch changes the screen to the “Display electrical system failure history” screen.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
3.
Display of electrical system failure history and the electrical system failure history all clear selected (2nd layer) • The items are displayed in the sequential order by the latest occurrence time from the latest one. • The items which have not been reset are displayed before the items which have been reset. • Pressing the > switch scrolls the items from the newer ones to the older ones. • Pressing the < switch scrolls the items from the older ones to the newer ones. • Pressing the ■ switch changes the screen to the “Display electrical system failure history” screen. • Pressing the switch changes the screen to the “Display electrical system failure history” screen. ★ If there is only one history, the current screen does not change to the “Electrical system failure history all clear” screen (only the “Electrical system failure history individual clear” screen is displayed).
4.
Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer) • Select YES or NO with the < or > switch. The cursor “_” blinks on the selected item. ★ If YES is selected and the ■ switch is pressed, clearing is executed. ★ If NO is selected and the ■ switch is pressed, clearing is cancelled and the display changes as described below. • If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history” screen of the corresponding failure. (Returns to the screen before the “Electrical system failure history individual clear” (“Electrical system failure history all clear”) screen).) • If clearing is executed (YES), the current screen returns to the “Display electrical system failure history” screen of the corresponding next failure. • After all the failure histories are cleared, the current screen returns to the “Select electrical system failure history” screen. • By default, the cursor is on NO (cancel) to prevent an accidental reset. • You cannot delete a failure which has not been reset. At this time, the operation cancel peeps for one second. • If any failure history is cleared, the operation acceptance peeps (ON for 0.1 sec., OFF for 0.1 sec., ON for 0.1 sec.). • When the ALL CLEAR (clearing all histories) option is selected and there is a history to be cleared, clearing is assumed to be completed.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Mechanical System Failure History Display Function 1.
Display of mechanical system failure history • The items are displayed in the sequential order by the latest occurrence time from the latest one. • The items which have not been reset are displayed before the items which have been reset. • Pressing the > switch scrolls the items from the newer ones to the older ones. • Pressing the < switch scrolls the items from the older ones to the newer ones. • Pressing the ■ switch changes the screen to the “Mechanical system failure history selected” screen.
2.
Selection of mechanical system failure history (1st layer) • Pressing the > switch changes the screen to the “Select real-time monitor” screen. • Pressing the < switch changes the screen to the “Select display of electrical system failure history” screen. • Pressing the ■ switch changes the screen to the normal screen or alarm screen. • Pressing the switch changes the screen to the “Mechanical system failure history selected” screen.
3.
Display of mechanical system failure history (2nd layer) • The items are displayed in the sequential order by the latest occurrence time from the latest one. • The items which have not been reset are displayed before the items which have been reset. • Pressing the > switch scrolls the items from the older ones to the newer ones. • Pressing the < switch scrolls the items from the newer ones to the older ones. • Pressing the ■ switch changes the screen to the “Mechanical system failure history selected” screen.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Real-Time Monitor Function •
The real-time monitor function displays the information saved in the controllers mounted on the machine in real time.
•
This function is used for testing, adjusting, or troubleshooting the machine.
•
This function classifies the items and data by the relevant controllers and then displays the results. It has two display modes for the normal display mode and the 2-item display mode for displaying two data items simultaneously.
Operating Procedure 1.
Hold the ■ switch and < switch simultaneously for at least five seconds to change the screen to the ID Input screen.
2.
Use the < and > switches to input the ID and then press the switch to enter the screen for the service person.
3.
Using the < and > switches, display the “Real-time monitor selection” screen and then press the switch.
4.
Press the switch to display the “Monitor information display/ selection” screen. ★ Pressing the < and > switches selects transmission controller information, engine controller information, work equipment controller information, and the 2-item display function in order.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 5.
ELECTRICAL SYSTEM
Press the switch while each selection screen is displayed. The Display 1-Item screen or “Select 2-items display information” screen appears. ***: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Item name %%%%%: . . . . . . . . . . . . . . . . . . . . . . Data and unit (Unit: SI unit) $$$$: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ID number
★ Items displayed on the Display 1-Item screen change in order by pressing the < and > switches to display information held by the controller.
6.
Input the ID. ★ “00000” is displayed during screen transition. •
Input a value between 0 and 9 at the cursor (_) position. First, the cursor appears at the highest-order digit. Each time the > or < switch is pressed, the digit changes by 1 between 0 and 9.
•
Select a desired digit and press the switch. The cursor moves to the 2nd position.
• •
Select the digits for all the positions in the same manner. Input a value at the lowest-order digit and press the switch to move to the screen to select the display of the 2nd item. ★ If you press the ■ switch during the processing, the screen returns to the “Select 2 items display information” screen.
•
In the display of the 2-items mode, input the ID of information to display two items simultaneously. The ID displayed is the same as the ID number displayed on the Display 1-Item screen.
7.
Items displayed on the Display 1-Item screen change in order by pressing the < and > switches to display the information held by the controller.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Display Contents of the Real-Time Monitor The state of the controller input and output signals can be checked using the real-time monitor function of the monitor. The following table shows the display items and display contents in normal operation for the real-time monitor function on the machine monitor.
No.
Item
ID No.
Display of Item
1
Monitor software part No.
20200
VERSION
2
Application version
20221 VERSION (APP)
3
Data version
20222
4
5
6
7
8
9
10
11
Engine Speed
01001
Travel speed 40000
Fuel level
Fuel level
04202
04207
Engine coolant temperature
04103
Torque converter oil temperature
40100
Torque converter oil temperature
40101
Hydraulic oil temperature
04401
WA500-6
VERSION (DATA)
Contents of Display Data
Display Contents in Normal Operation
Part No. of software Depends on the software part number is displayed Application version Depends on application version number number is displayed Data version number Depends on data version is displayed
ENG SPEED
Engine speed is displayed
Lo: 800 ±25 rpm Hi: 2000 ±50 rpm (P-mode) 1900 ±50 rpm (E-mode) T/C stall: 1800 ±100 rpm (P-mode) 1730 ±100 rpm (E-mode)
SPEED
Travel speed is displayed
F1/R1: 6.7/7.3 km/h ±5% (P-mode, T/C) F2/R2: 11.7/12.8 km/h ±5% (P-mode, T/C) F3/R3: 20.3/22.0 km/h ±5% (P-mode, T/C) F4/R4: 33.8/37.0 km/h ±5%(P-mode, T/C)
FUEL SENSOR
Fuel level is displayed
0 – 100%
Fuel level is displayed
Gauge FULL (100%,10 ): 0.32 V Gauge 1/2 (50%, 32 ): 0.88 V Caution (61.3 ): 1.45 V Gauge EMPTY (0%, 85 ): 1.81 V
FUEL SENSOR
COOLANT TEMP
Coolant temperature Depends on machine status (°C) is displayed
TC OIL TEMP
Torque converter oil temperature is Depends on machine status (°C) displayed
TC OIL TEMP
HYD TEMP
Remarks
Torque converter oil Gauge red zone start point: temperature is • 120°C (248°F): 1.62 V • 80°C (176°F): 2.91 V displayed
Hydraulic oil temperature is displayed
Depends on machine status: °C
When sensor is disconnected or hot shorted: gauge EMPTY When sensor is grounded: gauge FULL Coolant temperature, max. 100°C (212°F) Data is obtained from engine controller. Overheat: 120°C (248°F) When sensor is disconnected or hot shorted: Min. of gauge When sensor is grounded: Max. of gauge Hydraulic tank oil temperature: Max. 100°C (212°F)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Item
ID No.
Display of Item
ELECTRICAL SYSTEM Contents of Display Data
Hydraulic oil temperature is displayed
Display Contents in Normal Operation
Gauge red zone start point: • (120°C): 1.62 V • (80°C): 2.91 V
Hydraulic oil temperature
04404
13
Brake oil temperature
30202
R BRAKE OIL
Brake oil temperature Depends on machine status (°C) is displayed
14
Brake oil temperature
30205
R BRAKE OIL
Brake oil temperature (120°C): 1.62 V is displayed (80°C): 2.91 V
15
Charge level
04302
ALTERNATOR R
16
Small lamp voltage
40200
SMALL LAMP
17
Battery electrolyte level A
40300
BATTERY A
Battery electrolyte level is displayed
18
Battery electrolyte level B
40301
BATTERY B
—
12
19
20
Lift arm angle
Lift arm angle
21
Lift arm bottom pressure
22
Lift arm bottom pressure
06001
06003
HYD TEMP
Charge level is displayed
Remarks When sensor is disconnected or hot shorted: Min. of gauge When sensor is grounded: Max. of gauge
Depends on machine status (0.0 – 30 V)
Small lamp voltage is Depends on machine status (0.0 – 30 V) displayed Only when optional setting is made
Min. 2 V
—
BOOM ANG
Standard lift arm • Lift arm top: 46.8 ±2.0 deg. Calculation results of • Lift arm bottom: -42.3 ±3.0 deg. lift arm angle are Hi lift arm displayed • Lift arm top: 49.3 ±2.0 deg. • Lift arm bottom: -40.5 ±3.0 deg.
BOOM ANG
Standard lift arm Input voltage value to • Lift arm top: 3.80 ±0.3 V lift arm angle sensor • Lift arm bottom: 1.33 ±0.5 V Hi lift arm potentiometer is • Lift arm top: 3.87 ±0.3 V displayed • Lift arm bottom: 1.38 ±0.5 V
40400
BOOM BTM PRESS
Lift arm bottom Depends on status pressure is displayed
40402
BOOM BTM PRESS
(0 kg/cm²): 0.5V (102 kg/cm²): 1.3V Lift arm bottom pressure is displayed (204 kg/cm²): 2.1V (510 kg/cm²): 4.5V
Not used.
(When arm is placed horizontally at rated loading and Hi lift arm operation lever at FULL): Approx. 184 kg/cm² (2611 psi)
Only when optional setting is made in load meter
23
Lift arm head pressure
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40500
BOOM HEAD PRESS
Lift arm head Depends on status pressure is displayed
(When arm is placed horizontally at rated loading and Hi lift arm operation lever at FULL): Approx. 5 kg/cm² (73 psi)
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Item
24
Lift arm head pressure
ELECTRICAL SYSTEM
ID No.
Display of Item
Contents of Display Data
40501
BOOM HEAD PRESS
(0 kg/cm²): 0.5V (102 kg/cm²): 1.3V Lift arm head pressure is displayed (204 kg/cm²): 2.1V (510 kg/cm²): 4.5V
Display Contents in Normal Operation
Remarks Only when optional setting is made in load meter
25
Calibration pressure
40600
CAL PRESS
Lift arm differential pressure corresponding to no load around level position at load meter calibration
26
Classified weight
40800
MES LOAD
Load meter calculated weight is Load weight [t] displayed
27
Position of rotary switch
30802
SW1, SW2, SW3
—
—
Not used.
28
Position of DIP switch
30904
SW5-1, SW5-2
—
—
Not used.
29
Position of DIP switch
30905
SW5-3, SW5-4
—
—
Not used.
30
Position of DIP switch
30906
SW6-1, SW6-2
—
—
Not used.
31
Position of DIP switch
30907
SW6-3. SW6-4
—
—
Not used.
—
Only when optional setting is made in load meter
10000000 (Head lamp = on) 00000000 (Not used) 00100000 (Starting motor C = on) 32
Input signal D_IN_0-7
40900
D-IN--0------7
The state of input signal is displayed
00000000 (Not used) 00000000 (Not used) 00000000 (Not used) 00000000 (Not used) 00000000 (Not used) 00000000 (Not used) 00000000 (Not used) 00100000 (Load meter material selector SW = ON)
Input signal 33 D_IN_8-15
40901
D-IN- 8-----15
The state of input signal is displayed
00010000 (Load meter addition/reduction selector SW = ON)
00001000 (Right turn signal on) 00000100 (Left turn signal on) 00000010 (Monitor mode SW () = ON) 00000001 (Monitor mode SW (■) = ON)
WA500-6
Not used.
• D-IN-0: Head lamp • D-IN-1: Not used • D-IN-2: Starting motor C • D-IN-3: Not used • D-IN-4: Not used • D-IN-5: Not used) • D-IN-6: Not used • D-IN-7: Not used • D-IN-8: Not used • D-IN-9: Not used • D-IN-10: Load meter material selector SW input (Only when optional setting is made in load meter) • D-IN-11: Load meter addition/reduction selector SW input (Only when optional setting is made in load meter) • D-IN-12: Winker right • D-IN-13: Winker left • D-IN-14: Monitor mode SW () • D-IN-15: Monitor mode SW (■)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
34
Item
Input signal D_IN_16-23
ID No.
40902
Display of Item
D-IN-16-----23
ELECTRICAL SYSTEM Contents of Display Data
The state of input signal is displayed
Display Contents in Normal Operation
Remarks
10000000 (Front brake oil pressure SW = ON = low level) 01000000 (Rear brake oil pressure SW = ON = low level) 00000000 (Not used) 00000000 (Not used) 00001000 (Air cleaner clogging SW = ON)
• D-IN-16: Brake oil pressure (Front) • D-IN-17: Brake oil pressure (Rear) • D-IN-18: Not used • D-IN-19: Not used • D-IN-20: Air cleaner clogging • D-IN-21: Not used • D-IN-22: Parking brake emergency release SW • D-IN-23: Load meter total weight display SW (Only when optional setting is made in load meter)
00000000 (Not used) 00000010 (Parking brake emergency release SW = ON) 00000001 (Load meter total weight display SW = ON)
10000000 (T/M filter clogging SW = ON)
00000000 (Not used) 00100000 (Parking brake = ON) 35
Input signal D_IN_24-31
40903
D-IN-24-----31
The state of input signal is displayed
00010000 (Coolant level SW = ON = low level) 00000000 (Not used) 00000100 (Engine oil level SW = ON = low level) 00000010 (Emergency steering operation SW = ON) 00000000 (Not used) 10000000 (Subtotal SW = ON)
00000000 (Not used)
• D-IN-32: Subtotal SW (Only when optional setting is made in auto grease) • D-IN-33: Cancel SW (Only when optional setting is made in auto grease) • D-IN-34: High beam • D-IN-35: Not used • D-IN-36: SW for servicing • D-IN-37: Monitor mode SW (>) • D-IN-38: Monitor mode SW (<) • D-IN-39: Not used
1000 (Buzzer = on) 0000 (Not used) 0000 (Not used) 0000 (Not used)
• D-OUT-0: Buzzer • D-OUT-1: Not used • D-OUT-2: Not used • D-OUT-3: Not used
01000000 (Cancel SW = ON)
36
Input signal D_IN_32-39
40904
D-IN-32-----39
The state of input signal is displayed
00100000 (High beam = on) 00000000 (Not used) 00001000 (SW for servicing = ON) 00000100 (Monitor mode SW (>) = ON) 00000010 (Monitor mode SW (<) = ON)
Output signal 37 D_OUT_0-3
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40952
D-OUT-0--3
The state of output signal is displayed
• D-IN-24: T/M filter clogging (Only when optional setting is made) • D-IN-25: Not used • D-IN-26: Parking brake • D-IN-27: Coolant level • D-IN-28: Not used • D-IN-29: Engine oil level • D-IN-30: Emergency steering operation (Low S/T pressure) • D-IN-31: Not used
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Engine Reduced-Cylinder (Cylinder Cut-out) Function 1.
Using the < and > switches, display the “Reduced cylinder mode selection (CYLINDER CUTOUT)” screen and then press the switch.
2.
Operating method of reduced-cylinder function • Press the > switch to move the cursor to the right (select a cylinder to issue the reduced-cylinder command). • Press the < switch to move the cursor to the left (select a cylinder to issue the reduced-cylinder command). • Press the switch to issue the monitor reduced-cylinder command. Pressing this switch repeats the output/release of the command. • Press the ■ switch to return to the “Reduced cylinder mode selection” (CYLINDER CUT-OUT) screen. The reducedcylinder commands from the monitor are all released. ★ Operation example: When the 3rd cylinder stop command is issued.
WA500-6
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
No Injection Cranking Function For starting the engine using this function, see MACHINE MONITOR SYSTEM: Service Mode: No Injection Cranking Function (NO INJECTION) in the Testing and Adjusting section. This section describes only the operating method.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Adjustment Function For making adjustments using this function, see MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING) in the Testing and Adjusting section. This section describes only the outline of the adjustment function. All references can be found in the MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING) section. ★ 01: Reset of transmission initial learning See Setting Transmission Initial Learning in the Testing and Adjusting section. ★ 02: ECMV compensation See Adjustment of Transmission ECMV Current in the Testing and Adjusting section. ★ 04: Transmission shift point adjustment function See Adjustment of Transmission L-Mode Shift Point Function in the Testing and Adjusting section. ★ 05: Adjustment of lift arm angle sensor (Raise) (for EPC lever) See Adjustment of Lift Arm Angle Sensor (Raise) (for EPC lever) Function in the Testing and Adjusting section. ★ 06: Adjustment of lift arm raise lever and variations in the dead zone of EPC See Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC in the Testing and Adjusting section. See Adjustment of Bucket Dump EPC Starting Current in the Testing and Adjusting section. ★ 07: Adjustment of lift arm lower lever and variations in the dead zone of EPC See Adjustment of Lift Arm Lower (Float) Lever and Variations in the Dead Zone of EPC in the Testing and Adjusting section. See Adjustment of Bucket Dump EPC Starting Current in the Testing and Adjusting section. ★ 08: Adjustment of bucket tilt lever and variations in the dead zone of EPC See Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC in the Testing and Adjusting section. See Adjustment of Bucket Dump EPC Starting Current in the Testing and Adjusting section. ★ 09: Adjustment of bucket dump lever and variations in the dead zone of EPC See Adjustment of Bucket Dump EPC Starting Current in the Testing and Adjusting section. ★ 10: Adjustment of 3rd EPC cylinder extraction lever and variations in the dead zone of EPC
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ 11: Adjustment of 3rd EPC cylinder retraction lever and variations in the dead zone of EPC ★ 12: Adjustment of joystick right lever and variations in the starting point of EPC Do not use this function. ★ 13: Adjustment of joystick left lever and variations in the starting point of EPC Do not use this function. ★ 14: Modification of lift arm lever pattern See Modification of Lift Arm Lever Pattern in the Testing and Adjusting section. ★ 15: Modification of bucket lever pattern See Modification of Bucket Lever Pattern in the Testing and Adjusting section. ★ 16: Adjustment of lift arm lower stop modulation See Adjustment of Lift Arm Lower Stop Modulation in the Testing and Adjusting section. ★ 17: Adjustment of pump cutoff pressure in up move of lift arm See Adjustment of Pump Cutoff Pressure in Lift Arm Raise in the Testing and Adjusting section. ★ 18: Adjustment of lift arm angle sensor (raise) (for load meter) See Adjustment of Lift Arm Angle Sensor (Raise) (Machine with Load Meter) in the Testing and Adjusting section. ★ 19: Adjustment of lift arm angle sensor (lower) (for load meter) See Adjustment of Lift Arm Angle Sensor (Lower) (Machine with Load Meter) in the Testing and Adjusting section. ★ 21: Modification of AJSS oil pressure command table pattern Do not use this function. ★ 22: Adjustment of speed limit See Adjustment of Speed Limit (Lockup Clutch Specification) in the Testing and Adjusting section.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Maintenance Monitoring Function 1.
Selection of display of maintenance monitor function (1st layer) • You can go to the destination by using the <, >, and ■ switches. See the “Function 1 for the service person: 2nd layer transition” diagram. • Press the switch to change the screen to the “Item NO. 1 is displayed” screen.
2.
Select Maintenance Item screen. • (1) Using the > switch, display items in ascending order of numbers. ★ When the last item is selected, the screen is changed to the “Default value is set” screen. • (2) Using the < switch, display items in descending order of numbers. ★ When the last item is selected, the screen is changed to the “All item timer stop/all item valid selector” screen.
WA500-6
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
A. Change maintenance interval time procedure. i.
Input a value between 0 and 9 at the cursor position.
ii.
The cursor is positioned at the highest-order digit. Pressing the > or < switch increases or decreases the value between 0 and 9.
iii. Input a desired value and press the switch. iv. The cursor moves to the 2nd position. Select the digits for all the positions by repeating Steps Aii and Aiii. v.
After selecting the digit for the lowest position, press the switch. ★ If the input interval time is acceptable, the screen changes to the check screen. ★ If the input interval time is not acceptable, the time does not change.
vi. Return the cursor to the highest-order digit. ★ The lower limit of the set value is 50h. vii. When you have entered an incorrect value to a position succeeding to the highest-order digit, move to the highest-order digit using the ■ switch and repeat the procedure from the beginning. ★ In this case, values that had been entered remain as they are until modified. viii. When the cursor is at the highest-order digit, move to the higher layer using the ■ switch. • Select YES or NO with the < or > switch. • The cursor (_) is blinking at the selected item. ★ If you select YES, press the ■ switch to execute the change. ★ If you select NO, press the switch to return to the Select Maintenance Item screen without executing the change. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. • When an interval time is changed, the remaining timer time is changed in this manner: Interval time being set – Elapsed time from the last replacement
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
B. Select enable or disable timer by item. • When the Timer by Item option is enabled, ON OFF is displayed at the lower column. • When the Timer by Item option is disabled, OFF ON is displayed at the lower column. ★ By default, the setting is ON and the timer function is enabled. • When you disable the Timer by Item option, OFF is displayed at the upper column. • When you enable the Timer by Item option, ON is displayed at the upper column. • Select YES or NO with the < or > switch. • The cursor (_) blinks on the selected item. ★ If YES is selected, the change is executed. ★ If NO is selected, the change is cancelled and the Select Maintenance Item screen is returned. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. • Specify disabling the timer or releasing the disabling by maintenance item. • If you cancel the timer disabled, interval time before having been disabled is used as the set value. • The timer remaining time is reset. ★ The reset frequency is not incremented and remains the same as before the resetting. 3.
Setting a default value • Select YES or NO with the < or > switch. • The cursor (_) blinks on the selected item. ★ If YES is selected, the change is executed. ★ If NO is selected, the change is cancelled and the Select Maintenance Item screen returns. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. • If the default value is executed, all the currently changed interval times are returned to the default values. The default value is applied to every item independent of whether or not the function is enabled for a specific item. • Timer remaining time: Default value - Elapsed time since the last replacement. ★ The reset frequency is not incremented and remains the same as before the reset. • Set enable or disable of individual items.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4.
ELECTRICAL SYSTEM
Selection between timer stop for all items and enable by item
*1: Press the switch to go to the ALL ITEMS OFF screen. *2: When ALL ITEMS OFF is selected. *3: When ALL ITEMS OFF is executed: • •
The timer function for all items is stopped and the Select Maintenance Monitor screen is restored. Setting for individual items is also disabled.
When ALL ITEMS OFF is canceled: • The operation is cancelled and the MAINTENANCE MONITOR screen is restored. *4: When ALL ITEMS ON is selected. *5: Select YES or NO with the < or > switch. The cursor (_) blinks at the selected item. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. *6: When ALL ITEMS ON is executed: • • • •
Interval time being set for all items is disabled independent of whether or not it is enabled or disabled for a specific item. The timer remaining time is reset. The reset frequency is not incremented and remains the same as before the reset. The Select Maintenance Monitor screen is restored. Setting for individual items is also enabled.
When ALL ITEMS OFF is canceled: • The operation is canceled and the Select Maintenance Monitor screen is restored.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Operating Information Display Function Outline •
The value of fuel consumption is obtained by adding the target injection amount sent from the engine controller. ★ This is not a measured but a calculated fuel consumption. Use it as a rough standard.
*1: The upper column displays fuel consumption [L/km or L/mile] per 1 km (or 1 mile) from the last reset. • • •
It is calculated from the fuel consumption and travel distance above. The unit km or mile is selected depending on that used on the odometer. Counting is stopped at 99999.9, the upper limit.
The lower column displays the average fuel consumption [L/h] from the last reset. • Counting is stopped at 99999.9, the upper limit. *2: The upper column displays the cumulative fuel consumption [L] from the last reset. •
Counting is stopped at 9999999.9, the upper limit.
The lower column displays the travel distance [km or mile] from the last reset. • The unit km or mile is selected depending on that used on the odometer. • Counting is stopped at 9999999.9, the upper limit. *3: The upper column displays the cumulative fuel consumption [L] from the last reset. •
Counting is stopped at 9999999.9, the upper limit.
The lower column displays the elapsed time [h] from the last reset. • Counting is stopped at 9999999.9, the upper limit.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
*4: Calculation of (*4) is executed when the load meter is installed. ★ The screen is not available when the load meter is not installed. The upper column displays the loaded volume [ton] from the last reset. • Counting is stopped at 199999999.9, the upper limit. • Short ton or metric ton depends on optional setting. The lower column displays the loading frequency from the last reset. • Counting is stopped at 65000, the upper limit. ★ (*1 – *4) Calculation is done only for the duration in which the engine is run. *5: Using the switch, clear data of (*1), (*2), (*3), and (*4) to return to the previous screen. Using the ■ switch, return to the previous screen without resetting. REMARK Other than the reset operation above, you can reset data by initializing the monitor panel or selecting the optional setting to OFF. Acquisition of Fuel Consumption (L) •
The monitor panel calculates the cumulative fuel consumption (L) based on the momentary fuel consumption (L/h) from the engine controller.
*6: Setting gain correction A. When the screen appears, the current set value is displayed and the cursor is placed on the (+/–) sign. B. When the cursor is placed on the sign, (+), (↔), and (–) are displayed in order every time the > or < switch is pressed. C. Press the switch to confirm the sign; ➝ cursor moves to the highest-order digit. D. The cursor appears at the highest-order digit. Each time the > or < switch is pressed, the value at the digit increases or decreases between 0 and 9. (The highest-order digit is between 0 and 2.) E. Input the desired value and press the switch to confirm the entry. F.
The cursor moves to the lowest-order digit. Select a value in the same manner as Step D.
G. Input a value at the lowest-order digit and press the switch. (The screen returns to the previous one when the entry is confirmed.) H. If the ■ switch is pressed before completing the entry, the cursor moves to the sign position. In this case, the value remains unchanged. Using the ■ switch, return to the previous screen. I.
If the value confirmed for the lowest-order digit is outside the range of -50.0 to +50.0, the cursor moves to the sign position with the value unchanged as when the ■ switch is pressed.
Processing on the Monitor Panel •
Default value: 0.0%
•
This setting allows you to correct the cumulative fuel consumption (L) in the range of -50.0 to +50.0%.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Optional Device Selecting Function ★ See MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
Machine Serial Number Input Function See MACHINE MONITOR SYSTEM: Service Mode: Machine Serial Number Input Function (MACHINE No. SET) in the Testing and Adjusting section.
Model Selection Function See MACHINE MONITOR SYSTEM: Service Mode: Model Selection Function (MACHINE WA500) in the Testing and Adjusting section.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Load Meter Function (if equipped) Outline •
The load meter displays the remaining amount of the total or target-loaded volume by classifying working objects into five types and measuring the bucket-loaded volume.
•
Functions include the ability to switch between reduction mode and addition mode, between working objects, and to display and clear total-loaded volume. To operate these functions, use the load meter mode selector switch and monitor panel mode selector switch.
•
The load meter is equipped with calibration mode, calibration clear mode, and load meter calculation stop mode. To operate these modes, use the monitor panel mode selector switch.
•
A printer (if equipped) allows you to print measured data.
★ For operating instructions, see the manual provided with the load meter. Weight Calculation The load meter calculates weight (W) by detecting the lift arm operating pressure (P) using the pressure sensor (A) installed at the lift arm cylinder bottom and pressure sensor (B) installed at its head, and calculating the center of gravity by the lift arm angle sensor (C).
Weight calculation is done based on the differential pressure (C) between the reference value (A), where the lift arm pressure with no load is saved (corrected by calibration), and the calculated lift arm pressure (B) with load. In addition, to improve its precision, the detection function calculates weight during lift arm raise operation.
The operation of the tires and work equipment generates a spring effect on the machine. However, the measured lift arm pressure (D) is provided with the characteristic shown in the figure to the right.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
The value (D) measured by the lift arm raise operation is calculated based on the value obtained as the calculated value (B) according to the following calculation criteria. •
For 0.5 seconds after lift arm raise operation start (E), the lift arm state changes from the static state to the operating state. The pressure largely fluctuates and is not stable; therefore, it is not used for calculation of the calculated value (B).
•
The spring effect of the machine is generated at intervals of approximately one second. The calculated value (B) is obtained based on the mean every one second during the period between the lift arm raise operation start and the operation end.
Determination of Lift Arm Raise Operation Start The load meter determines that the lift arm starts moving and starts weight calculation when all the following conditions are satisfied.
Condition 1
The lift arm angle is between -10 and -30°. (The range between the horizontal position and position immediately before it contacts the ground)
Condition 2
The lift arm angle changes at least 0.1° for 0.1 second. (The lift arm starts moving with minimum specified speed in raising direction.)
Determination of Lift Arm Raise Operation Stop The load meter determines that the lift arm stops moving and ends weight calculation when one of the following conditions is satisfied.
Condition 1
The lift arm angle changes to under 0.5° for 0.5 second. (The lift arm speed in raise direction is reduced below the specified speed.)
Condition 2
The lift arm angle changes to lowering direction. (When the lift arm is lowered, weight calculation finishes.)
Condition 3
The lift arm angle changes to above +20°. (At a high position, weight calculation stops.)
Condition 4
The lift arm raise speed suddenly changed. (The current angular velocity is decreased 70% or more of the previous one.)
Condition 5
Weight calculation was performed seven times.
Display of Calculated Weight The average of calculated weight values are displayed. Number of Calculations
Calculation Time (sec.)
Weight Calculation and Display Method
Only 1 time
1.5 – 2.5
Displays weight based on a single calculation result. In this case, however, the weight display blinks to inform the operator that the precision is unstable due to the short calculation time.
2 times
2.5 – 3.5
Displays weight based on the mean value of two calculation results.
Min. 3 times
3.5 – 0.0
Displays weight based on the mean value of latest three calculation results.
WA500-6
10-373 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Reduction/Addition Mode ★ Monitor display in addition mode This is the mode to display the bucket-loaded volume. Use this mode for obtaining the work rate. •
When addition mode is selected, TOTAL LOADED is displayed at the display of addition mode (1), which indicates the value obtained by adding the value at the display of calculated bucketloaded volume (3) to the value at the total-loaded volume (2).
•
Weight calculation can be displayed by cumulating up to any five working objects independently. Working objects can be selected from types A to E at the working object display (4) in mode selection.
•
The display of total-loaded volume (2) indicates up to 9,999 t unless data is cleared by the load meter subtotal switch. The display indicates a value to one decimal place (in 100 kg) in the case of a maximum 999.9 t. When it exceeds 1000 t, the decimal point display disappears and switches to the display in 1 t. ★ For details about the display of total-loaded volume, see Display of Total Loaded Volume and Display of Remaining Volume on the next page.
★ Monitor display in reduction mode This is the mode to display the bucket-loaded volume based on the preset target weight. Use this mode for constant loading work. •
When reduction mode is selected, REMAINING TARGET is displayed at the display of reduction mode (1), which indicates the value obtained by reducing the value at the display of calculated bucket-loaded volume (3) from the value specified at the display of total-loaded volume (2).
•
Weight calculation can be displayed by cumulating up to any five working objects independently. Working objects can be selected from types A to E at the working object display (4) in mode selection.
•
For the display and calculation method when the value at the display of bucket-loaded volume (3) exceeds the value at the display of remaining volume (2), use the subtraction mode. ★ Refer to the Operation Manual provided with your load meter. ★ For details about the display of the remaining volume, see Display of Total Loaded Volume and Display of Remaining Volume on the next page.
10-374 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Display of Total Loaded Volume and Display of Remaining Volume Actual Total Loaded Weight (t)
Display of Total Loaded Volume
Remarks
– -99.5
-99.9
Display of decimal point
-99.4 to -0.1
–**.*
Display of decimal point (second decimal place is rounded off).
0 – 999.4
***.*
Display of decimal point (second decimal place is rounded off).
999.5 – 9999.4
****
Display of integer (second decimal place is rounded off).
9999.5 –
9999
Display of integer
Unit of Calculated Weight •
Calculated weight values are all displayed in SI (metric ton).
•
If MPH has been selected for speed display in monitor setting, it can be switched to short ton (US ton) in Service mode optional setting.
•
If you switch it to short ton, weight display is also output in short ton (US ton) on the printer. WARNING!
In countries where the SI unit is adopted, the speed display unit and weight display unit must not be changed to a non-SI unit.
Load Meter Cancel Switch •
When switch (1) is pressed during the holding time of calculated weight (15 seconds after completion of calculation), the value at the display of bucket-loaded volume is canceled and the calculated weight is abandoned.
•
In this case, the display of total-loaded volume (display of remaining volume) newly added (reduced) is also canceled and the previous display value is returned.
Load Meter Subtotal Switch •
To clear the display of total-loaded volume (in addition mode) or display of remaining volume (in reduction mode), continuously press switch (1) for at least two seconds. Specifications
Operation after operating switch
Printer not installed
Clears the display of total loaded volume (display of remaining volume).
Printer installed
Outputs saved subtotal data on the printer. After the output, the subtotal data is cleared.
WA500-6
10-375 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Subtotal Data The following data is saved as a set when calculated weight is confirmed. •
Type of working object
•
Weight of loading in one bucket
•
Total number of loading
•
Total loaded volume Memory capacity: . . . . . . . . . . . . . . . . . . . Min. 500 times of loading
Auto Subtotal Function ★ When the printer (if equipped) is connected The 501st weight calculation is executed. After 15 minutes data is stored in RAM; up to the 500th data is printed to the printer at the same time. After the output on the printer, the subtotal data is cleared. The character display displays LOAD DATA FULL and CLEAR DATA after saving the 500th data then continues measurement. ★ When the printer (if equipped) is not connected The 501st weight calculation is executed. After 15 minutes data is stored in RAM; up to the 500th weight data by bucket is abandoned to the secure store data area. The character display displays LOAD DATA FULL and CLEAR DATA after saving the 500th data then continues measurement. ★ Display on character display after 500th data is stored.
Cumulative Data Display Function ★ Display of data • •
Total loaded volume and total number of loading in addition mode or reduction mode are displayed. Press the load meter mode selector switch to display TOTAL DATA on the character display.
10-376 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ The lower column (❈❈❈❈❈-❈❈❈❈❈h) displays cumulative hours according to the hour meter criteria. Example: In the case of the display of 12300-12450h, the cumulative data of 150 hours between 12300 and 12450 hours is displayed in the character display. Press the monitor panel mode selector switch 2 (>) or (<) to select “By the item (A) to (E)” or “All ON” at working object display (1).
•
•
In the former case, cumulative weight by type (2) and the number of loading (3) are displayed.
•
In the latter case, total loaded volume (2) of all objects from (A) to (E) and the total number of loading (3) are displayed.
Resetting Data •
Cumulative data by the item (A) to (E) or of all objects are reset.
•
Display TOTAL DATA on the character display.
•
Press the load meter selector switch (A/B) to specify either “By the item (A) to (E) or “All ON” at the working object display.
•
Press the load meter mode selector switch (A/B) for at least four seconds.
Printer Output (if equipped) ★ This function works only when the printer specified in the optional setting is installed. • •
The output format of the load meter can be selected from three types (A, B, C) of the output mode. The output format of each mode is listed in the following table.
★ For selection of output mode and output method, see your load meter User Guide. A-mode (Total printer output)
B-mode (Subtotal printer output)
C-mode (Operation record printer output)
•
Model, serial number
•
Model, serial number
•
Model, serial number
•
Date and time of printing
•
Date and time of printing
•
•
Subtotal loading data (Type/number of loading/loaded volume)
•
Loading data (Loaded volume)
Date and time of starting record, service meter
•
Subtotal loading data (Type/number of loading/loaded volume)
Date and time of ending record (printing), service meter
•
Total loading data (Total number of loading/Total loaded volume)
Subtotal loading data (Type/number of loading/loaded volume)
•
Total loading data (Total number of loading/Total loaded volume)
•
Maintenance time (Maintenance item/remaining time)
•
Total loading data (Total number of loading/Total loaded volume)
WA500-6
•
•
10-377 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Calibration •
No load calibration and load calibration are provided; the former measures the pressure with the bucket empty and the latter measures the pressure with a known weight loaded.
•
The lift arm is raised with the bucket at full tilt. In this condition, the lift arm working pressure with no load (0 kg) or a known weight loaded is saved.
•
If the center of gravity of the load is deviated from the factory-set position due to modification of the lift arm or bucket, no load or load calibration must be executed to operate the machine with high precision.
★ The saved calibration data is not cleared even after the battery has been removed for a long time. ★ No load calibration •
This function cancels the individual difference of weight inherent to the machine, for example, the weight of the working equipment. It makes compensation (B) by offsetting the error between the actual weight and the reference value (A) as shown in the figure to the right.
★ Load calibration •
This function compensates the reference pressure with the bucket loaded. It makes compensation (B) of the error between the actual pressure and the reference value (A) in the vicinity of the position where load calibration is executed (C) as shown in the figure to the right. ★ For the calibration execution method, see the load meter User Guide.
Calculation Stop •
The calculation function of the load meter is stopped.
•
During the calculation stop, the display of the load meter disappears and the speed display or engine speed display appears. No data is added to the total data in this mode.
•
To restart calculation, select the addition mode or reduction mode. ★ For the calculation stop method, see the load meter User Guide.
Function of Troubleshooting •
The machine monitors the input and output signals constantly for troubleshooting the system.
•
If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine monitor. When an abnormality occurs, it can be confirmed on the machine monitor (display of failure history).
10-378 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Rear Side of Machine Monitor
★ Do not change the settings of the spare rotary switches or spare DIP switches.
1.
Spare rotary switch (SW1)
2.
Spare rotary switch (SW1)
3.
Spare rotary switch (SW3)
4.
Spare DIP switch (SW5-1)
5.
Spare DIP switch (SW5-2)
6.
Spare DIP switch (SW5-3)
7.
Spare DIP switch (SW5-4)
8.
Spare DIP switch (SW6-1)
9.
Spare DIP switch (SW6-2)
10. Spare DIP switch (SW6-3) 11. Spare DIP switch (SW6-4)
WA500-6
10-379 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-380 b
ELECTRICAL SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Connector Signal Tables CN1 (070-20-pole) [CN-L51] Pin No.
Specifications
I/O
Group
1
—
—
—
2
Power supply of small lamp
I
—
3
Power supply of small lamp
I
4
NSW power supply (+24 V)
5
Signal Name
WA500-6
—
—
Power supply (+24 V)
—
—
—
Power supply (+24 V)
—
—
I
—
Power supply (+24 V)
NSW power supply NSW power supply (+24 V) (+24 V)
NSW power supply (+24 V)
I
—
Power supply (+24 V)
NSW power supply NSW power supply (+24 V) (+24 V)
6
SW power supply (+24 V)
I
—
Power supply (+24 V)
SW power supply (+24 V)
SW power supply (+24 V)
7
SW power supply (+24 V)
I
—
Power supply (+24 V)
SW power supply (+24 V)
SW power supply (+24 V)
8
—
—
—
—
—
—
9
GND
I
—
GND
GND
GND
10
GND
I
—
GND
GND
GND
11
D_OUT_3 (+24 V, sink 200 mA)
O
A
D/O sink
(Spare)
—
12
D_OUT_2 (+24 V, sink 200 mA)
O
A
D/O sink
(Automatic preheater relay)
—
Executed by engine controller.
13
D_OUT_1 (+24 V, sink 200 mA)
O
A
D/O sink
(HST solenoid cutout relay)
—
For small models (Spare for medium and large models)
14
D_OUT_0 (+24 V, sink 200 mA)
O
A
D/O sink
Buzzer (Monitor)
Buzzer (Monitor)
15
Sensor power supply output (+24 V)
O
—
Sensor power supply
Lift arm pressure sensor power supply
—
16
Sensor power supply output (+5 V)
O
—
Sensor power supply
Lift arm angle sensor power supply
Lift arm pressure and angle sensor power supply
17
GND
I
—
GND
GND
GND
18
GND
I
—
GND
GND
GND
19
GND
I
—
GND
GND
GND
20
GND
I
—
GND
GND
GND
WA500-6
Form of Use
Remarks
For load meter
10-381 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
CN2 (070-18-pole + 12-pole) [CN-L52, CN-L53] Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
1
D_IN_0 (+24 V, 5 mA)
I
B
D/I +24 V
Headlamp
Headlamp
(Spare for WA800 or later)
2
D_IN_2 (24 V, 5 mA)
I
B
D/I +24 V
Starting motor C
Starting motor C
–
3
D_IN_4 (24 V, 5 mA)
I
B
D/I +24 V
(Spare)
–
–
4
D_IN_6 (24 V, 5 mA)
I
B
D/I +24 V
(Direction F)
–
For small models (Spare for medium and large models)
5
D_IN_8 (24 V, 5 mA)
I
B
D/I +24 V
(Direction R)
–
For small models (Spare for medium and large models)
6
D_IN_10 (24 V, 5 mA)
I
B
D/I +24 V
(Spare)
Load meter material selector switch output
–
7
D_IN_12 (NSW 24 V, 5 mA)
I
C
D/I +24 V
Turn signal right
Turn signal right
–
8
D_IN_14 (NSW 24 V, 5 mA)
I
C
D/I +24 V
switch input
Monitor mode switch 1 input
Switch for monitor operation
9
GND
O
—
–
SIGNAL GND
SIGNAL GND
–
10
D_IN_1 (24 V, 5 mA)
I
B
D/I +24 V
Starting motor ACC
Starting motor ACC
–
11
D_IN_3 (24 V, 5 mA)
I
B
D/I +24 V
Preheat operation
–
Executed by engine controller
12
D_IN_5 (24 V, 5 mA)
I
B
D/I +24 V
(Spare)
–
–
13
D_IN_7 (24 V, 5 mA)
I
B
D/I +24 V
(Direction N)
–
For small models (Spare for medium and large models)
14
D_IN_9 (24 V, 5 mA)
I
B
D/I +24 V
(Spare)
–
–
15
D_IN_11 (24 V, 5 mA)
I
B
D/I +24 V
(Spare)
Load meter addition/ reduction selector switch input
–
16
D_IN_13 (NSW 24 V, 5 mA)
I
C
D/I +24 V
Turn signal left
Turn signal left
–
17
D_IN_15 (NSW 24 V, 5 mA)
I
C
D/I +24 V
■ switch input
Monitor mode switch 1 ■ input
Switch for monitor operation
18
A_IN_0 (0 – 30 V)
I
H
A/I
Alternator R
Alternator R
–
19
D_IN_16 (24 V/GND, 5 mA)
I
D
D/IGND
Brake oil pressure (Front)
Brake oil pressure (Front)
–
10-382 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
20
D_IN_18 (24 V/GND, 5 mA)
I
D
D/IGND
Brake oil level (Front)
–
For WA1200 (Spare for other models)
21
D_IN_20 (24 V/GND, 5 mA)
I
D
D/IGND
22
D_IN_22 (24 V/GND, 5 mA)
I
D
D/IGND
(Spare)
Parking brake emergency release switch signal
–
23
D_IN_24 (24 V/GND, 5 mA)
I
E
D/IGND
Transmission filter clogging
Transmission filter clogging
–
24
GND
O
—
GND
Sensor GND
Sensor GND
–
25
D_IN_17 (24 V/GND, 5 mA)
I
D
D/IGND
Brake oil pressure (Rear)
Brake oil pressure (Rear)
–
26
D_IN_19 (24 V/GND, 5 mA)
I
D
D/IGND
Brake oil level (Rear)
–
For WA1200 (Spare for other models)
27
D_IN_21 (24 V/GND, 5 mA)
I
D
D/IGND
Air cleaner clogging 2
–
For WA800 later (Spare for other models)
28
D_IN_23 (24 V/GND, 5 mA)
I
D
D/IGND
(Spare)
Load meter total weight display switch input
–
29
D_IN_25 (24 V/GND, 5 mA)
I
E
D/IGND
(Seat belt fastening warning)
–
Not scheduled for installation at present (Spare)
30
A_IN_0 (0 – 30 V)
I
H
A/I
Small lamp switch
Small lamp switch
–
WA500-6
Air cleaner clogging 1 Clogging of air cleaner
–
10-383 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
CN3 (070-18-pole + 12-pole) [CN-L54, CN-L55] Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
1
D_IN_26 (24 V/GND, 5 mA)
I
E
D/IGND
Parking brake
Parking brake
–
2
D_IN_28 (24 V/GND, 5 mA)
I
E
D/IGND
Engine oil pressure
–
Executed by engine controller
3
D_IN_30 (24 V/GND, 5 mA)
I
E
D/IGND
Normal emergency steering
Normal emergency steering
–
4
D_IN_32 (24 V/GND, 5 mA)
I
F
D/IGND
Subtotal switch
Subtotal switch
For load meter
5
D_IN_34 (24 V/GND, 5 mA)
I
F
D/IGND
High beam switch
High beam switch
–
6
D_IN_36 (24 V/GND, 5 mA)
I
G
D/IGND
Service function 2
Service function 2
–
7
D_IN_38 (24 V/GND, 5 mA)
I
G
D/IGND
< switch input
8
P_IN_0(0.5Vp-p)
I
M
P/I
(Spare)
–
–
9
GND
O
–
GND
GND
GND
–
10
D_IN_27 (24 V/GND, 5 mA)
I
E
D/IGND
Engine coolant level
Engine coolant level
–
11
D_IN_29 (24 V/GND, 5 mA)
I
E
D/IGND
Engine oil level
Engine oil level
–
12
N.C.
I
E
D/IGND
N.C.
N.C.
–
13
D_IN_33 (24 V/GND, 5 mA)
I
F
D/IGND
Cancel switch
Cancel switch
For load meter
14
D_IN_35 (24 V/GND, 5 mA)
I
F
D/IGND
(Spare)
–
–
15
D_IN_37 (24 V/GND, 5 mA)
I
G
D/IGND
> switch input
Monitor mode switch 2 > input
–
16
D_IN_39 (24 V/GND, 5 mA)
I
G
D/IGND
Low steering oil pressure
Spare
–
17
P_IN_1(5Vp-p)
I
M
P/I
(Spare)
–
18
N.C.
–
–
–
N.C.
N.C.
–
19
A_IN_2 (High-resistance input)
I
J
A/I
Fuel level sensor
Fuel level sensor
–
20
A_IN_4 (High-resistance input)
I
J
A/I
Torque converter oil temperature sensor
Torque converter oil temperature sensor
–
21
A_IN_6 (High-resistance input)
A/I
Engine coolant temperature sensor (For automatic preheater)
–
Executed by engine controller
10-384 b
I
K
Monitor mode switch 2 Switch for monitor < switch input operation
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
22
A_IN_8 (0 – 5 V)
I
L
A/I
Lift arm pressure sensor (Rod)
Lift arm pressure sensor (Head)
For load meter
23
A_IN_10 (0 – 14 V)
–
–
Battery electrolyte level A
Battery electrolyte level (If equipped)
If equipped
24
GND
O
–
GND
SIGNAL GND
GND
–
25
A_IN_3 (High-resistance input)
I
J
A/I
Hydraulic oil temperature sensor
Hydraulic oil temperature sensor
–
26
A_IN_5 (High-resistance input)
I
J
A/I
Engine coolant temperature sensor
Brake oil temperature sensor
Executed by engine controller
27
A_IN_7 (0 – 5 V)
I
L
A/I
Lift arm pressure sensor (Bottom)
Lift arm pressure sensor (Bottom)
For load meter
For load meter (Shared with work Lift arm angle sensor equipment controller)
28
A_IN_9 (0 – 5 V)
I
L
A/I
Lift arm angle sensor
29
GND
O
–
GND
SIGNAL GND
GND
–
30
A_IN_11 (0 – 14 V)
–
–
–
Battery electrolyte level B
–
For WA800 later (Spare for other models)
WA500-6
10-385 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
CN4 (070 12-pole) [CN-L56] Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
1
S_NET(+)
I/O
N
S-NET
Monitor – transmission work equipment controller
–
–
2
S_NET(+)
I/O
N
S-NET
Monitor – transmission work equipment controller
–
–
Communication (CAN (+))
–
3
CAN+
I/O
P
–
Cummins engine controller, VSM controller communication (CAN (+))
4
S_NET(–)
O
N
S-NET
S_NET GND
–
–
5
S_NET(–)
O
N
S-NET
S_NET GND
–
–
6
GND
O
–
GND
S_NET shield
GND
–
7
GND
O
–
GND
CAN shield
–
CAN: twisted only
8
CAN-
I/O
P
–
Cummins engine controller communication (CAN (–))
Communication (CAN (–))
–
9
(NC)
–
–
–
–
–
–
10
(NC)
–
–
–
–
–
–
11
(NC)
–
–
–
–
–
–
12
(NC)
–
–
–
–
–
–
10-386 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
CN5 (070-14-pole) [CN-L57] Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
1
(NC)
–
–
–
–
–
–
2
RS232C_1_RTS
I/O
Q
–
RS232C serial communication
–
–
3
RS232C_1_RD
I
Q
RD
RS232C serial communication
–
–
4
(NC)
I
R
RD
N.C.
N.C.
–
5
(NC)
I/O
R
N.C.
N.C.
–
6
–
–
–
–
BUSY input for load meter printer
Printer BUSY (if equipped)
For load meter (Spare for medium and large models)
7
(NC)
–
–
–
–
–
–
8
RS232C_1_CTS
I/O
Q
–
RS232C serial communication
–
–
9
RS232C_1_TX
O
Q
TX
RS232C serial communication
Printer and personal computer TX
–
10
RS232C_1_SG
O
Q
–
RS232C serial communication
–
–
11
(NC)
O
R
–
N.C.
N.C.
–
12
(NC)
O
R
TX
N.C.
N.C.
–
13
(NC)
I/O
R
–
N.C.
N.C.
–
14
(NC)
–
–
–
N.C.
N.C.
–
CN6 (040 8-pole) [CN-L58] Pin No.
Specifications
I/O
Group
Form of Use
Signal Name
WA500-6
Remarks
1
RS232C_0_TXD
O
S
–
–
–
–
2
(NC)
–
–
–
N.C.
N.C.
–
3
RS232C_0_TXD
O
S
–
–
–
–
4
(NC)
–
–
–
N.C.
N.C.
–
5
RS232C_0_RXD
I
S
–
–
–
–
6
(NC)
–
–
–
N.C.
N.C.
–
7
RS232C_0_RXD
I
S
–
–
–
–
8
GND
O
—
–
GND
–
–
WA500-6
10-387 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Setting Switches (on circuit board) Switch No.
Specifications
I/O
Grou p
1
16 Posi rotary switch 1
I
2
16 Posi rotary switch 2
3
Form of Use
Signal Name
WA500-6
—
Selection of model
(Spare)
I
—
Selection of specification
(Spare)
16 Posi rotary switch 3
I
—
Selection of specification
(Spare)
4
2 Posi DIP switch 1
I
—
Selection of options
(Spare)
5
2 Posi DIP switch 2
I
—
Selection of options
(Spare)
6
2 Posi DIP switch 3
I
—
Selection of options
(Spare)
7
2 Posi DIP switch 4
I
—
Selection of options
(Spare)
8
2 Posi DIP switch 5
I
—
Selection of options
(Spare)
9
2 Posi DIP switch 6
I
—
Selection of options
(Spare)
10
2 Posi DIP switch 7
I
—
Selection of options
(Spare)
11
2 Posi DIP switch 8
I
—
Selection of options
(Spare)
10-388 b
Remarks
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Work Equipment Control System Work Equipment Controller
WA500-6
10-389 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-390 b
ELECTRICAL SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Work Equipment Controls Work Equipment Control Input and Output
WA500-6
10-391 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Work Equipment Control Lever Operation The work equipment controller operates the work equipment by detecting the operating stroke of raise/lower, tilt/dump from the signals of the work equipment lever potentiometer, and operating the main spool by operating each EPC valve attached to the main valve with current control.
10-392 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
•
The work equipment control lever is equipped with detent notches.
•
The lever is adjusted so that it operates at the maximum speed before each detent.
•
The range beyond lower detent is the lift arm float operation position, where the lift arm operates by external forces.
WA500-6
10-393 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Work Equipment Neutral Lock When the work equipment lock lever is operated to the lock position, the lock switch (baffle lever switch) becomes OPEN and the controller stops the operation of the work equipment by turning ON the work equipment neutral lock valve, cutting the EPC pilot basic pressure. ★ While the work equipment is locked, the detent does not operate and the lever is not held at the detent position.
•
The safety function, in which the work equipment continues to be locked until the work equipment control lever is temporarily returned to the neutral position even if the work equipment is unlocked, is incorporated.
Operation Table Operation by Man
Input of Controller
Work Equipment Control
Output of Controller
Operation of Machine
Baffle lever
Baffle lever switch
Work equipment lever potentiometer
Work equipment neutral lock valve
Oil pressure
Lower (LOCK)
OFF (OPEN)
–
ON (24V)
Cut
Lower to raise (unlocking)
OFF (OPEN)
Work equipment control lever being operated
ON (24V)
Cut
Lower to raise (unlocking)
OFF (OPEN)
After releasing, lever neutral of all work equipment detected once
OFF (OPEN)
Operating
Raise (FREE)
ON (CLOSE)
–
OFF (OPEN)
Operating
10-394 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Neutral Position and Work Equipment Speed •
The work equipment control lever has neutral play of 5% in the lever stroke. It is adjusted so that the work equipment starts to work from the position beyond the play.
•
The work equipment control lever can change the work equipment speed for the lever stroke by setting the controllers.
•
The lift arm has five changeable tables; the bucket has three.
★ For the adjustment method and the characteristics of each table, refer to MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Modification of Lift Arm Lever Pattern and Modification of Bucket Lever Pattern in the Testing and Adjusting section. Lift Arm Lever Stroke vs. Speed Table Lever Stroke -100 -90 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10
-7
7
10
20
30
40
50
60
70
80
85
90 100
No. 1
100 100 60
52
46
36
28
21
16
11
6
1
0
0
1
6
12
18
26
35
47
70 100 100 100
No. 2
100 100 72
64
57
45
37
28
21
15
9
3
0
0
3
11
19
27
37
48
62
85 100 100 100
No. 3
100 100 72
72
66
54
45
37
29
21
13
4
0
0
5
18
28
38
48
59
72
90 100 100 100
No. 4
100 100 72
72
72
64
55
46
38
28
18
7
0
0
7
23
37
50
62
74
87 100 100 100 100
No. 5
100 100 72
72
72
72
66
57
47
36
25
10
0
0
10
30
45
59
73
86 100 100 100 100 100
WA500-6
10-395 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Bucket Lever Stroke vs. Speed Table Lever Stroke
-100 -95 -90 -85 -80 -70 -60 -50 -40 -30 -20 -10 -7
7
10 20 30 40 50 60 70
80
85
90 100
No.1
100
100
80
70
60
45 35 26 18 12
7
1
0
0
1
6
12 18 26 35 47
70 100 100 100
No.2
100
100 100
90
82
70 58 47 38 28 18
5
0
0
5
18 28 38 48 58 70
90 100 100 100
No.3
100
100 100 100 100 95 87 75 60 45 30 10
0
0
10 30 45 59 73 85 95 100 100 100 100
Tilt Priority Control •
This machine has CLSS and prevents the lift arm from rising when the tilt operating stroke is large, although the bucket and the lift arm can be operated simultaneously. This ensures more efficient digging.
•
This is accomplished by limiting the maximum speed of the lift arm raise for the tilt speed (see the following table).
★ This function does not work in a dump operation, which enables simultaneous operation. Bucket tilt speed
0%
20%
40%
60%
70%
100%
Maximum speed of lift arm raise
100%
80%
30%
0%
0%
0%
10-396 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Lift Arm Stop Modulation •
The work equipment controller uses modulation to ease the stop shock of the lift arm raise/lower when the operator performs the lift arm stop operation faster than a certain speed.
•
The operation of this stop modulation function can be changed through a setting.
★ For information about changing the lift arm stop modulation and the necessary precautions, see MACHINE MONITOR SYSTEM: Adjustment Function (TUNING): Adjustment of Lift Arm Lower Stop Modulation in the Testing and Adjusting section.
★ Case A: When lever command flow rate < modulation command flow rate • Outputs according to the lever command flow rate. ★ Case B: When lever command flow rate > modulation command flow rate • Outputs according to the modulation command flow rate. a.
Modulation command flow rate Deceleration flow rate: 0.75%/mS 100% 0% 143 mS
b.
Implements modulation from 30% flow rate command or under
WA500-6
10-397 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Speed Reduction Function in Raising Cargo Lift Arm •
The speed reduction function implements the equivalent function as the cutoff function, performed with the cutoff valve in the conventional machine.
★ Only when the following conditions are simultaneously satisfied will the lift arm raise maximum speed be limited to 70%. • • •
Lift arm above horizontal (Lift arm angle sensor signal) Bucket tilt end (Tilt end proximity switch signal) Lift arm bottom pressure minimum 203.94 kg/cm² (2,901 psi) (Signal by network communication from the monitor)
•
When the lift arm raise maximum speed is changed between 70% and 100%, modulation reduce shocks to control the speed so that it does not change suddenly.
•
This function can change the condition value of the lift arm bottom pressure through the controller setting. By changing the set value of the lift arm bottom pressure, matching of the lift arm rising speed and travel speed can be changed.
★ For information about the procedure, see MACHINE MONITOR SYSTEM: Adjustment Function (TUNING): Adjustment of Pump Cutoff Pressure in Lift Arm Raise in the Testing and Adjusting section. Adjusting Lever Detent Position and Work Equipment Starting Current •
The work equipment controller has an adjusting function for correction dispersion.
•
The detent position is adjusted so that the lever potentiometer voltage at the detent position is saved, ensuring control before and after the detent. When it is not adjusted, such phenomena as “the positioner does not operate normally before and after the detent” or “the lever position of lift arm float is not normal” may occur.
•
When the work equipment starting current is not adjusted, such phenomena as “the neutral dead zone is large” or “dashing/stopping shock of the work equipment becomes large” may occur.
★ For information about the procedure, see the following topics in the Testing and Adjusting section: • • •
MACHINE MONITOR SYSTEM: Adjustment Function (TUNING): Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC MACHINE MONITOR SYSTEM: Adjustment Function (TUNING): Adjustment of Lift Arm Lower (Float) Lever and Variations in the Dead Zone of EPC MACHINE MONITOR SYSTEM: Adjustment Function (TUNING): Adjustment of Bucket Dump EPC Starting Current
10-398 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Remote Positioner Bucket Positioner This function allows the bucket to gently stop at any set position when the tilt lever is set to the detent position with the bucket level or lower.
1.
Setting stop position The stop position of the bucket changes when the positioner is operated using the bucket positioner position set switch. Condition for Availability
Bucket lever stroke: neutral and travel speed below 5 km/h (3 mph) (1)
When setting it upward from the current stop position, press the bucket positioner + position set switch position (upward). (Use the downward switch to change it downward.) Saves +1 to the current set position (memory); sounds a setting complete buzzer (pip); and the monitor displays the numerical value for three seconds.
Setting method
(2) (Set position is maintained when the key is turned off.) * When the switch is operated exceeding ±5 of the set range, the monitor displays the same value and the setting cancel buzzer (pip) sounds. For further change, release the switch once and then press it again. (3) * When the switch is operated exceeding ±5 of the set range, the monitor displays the same value and the setting cancel buzzer (pip) sounds.
WA500-6
10-399 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 2.
Resetting tilt detent • If the bucket horizontal proximity switch is operated when the bucket lever is at the tilt detent position, the detent is reset after the delay time and the bucket stops gently.
•
3.
ELECTRICAL SYSTEM
Delay time • The bucket horizontal proximity switch is set at the position where the bucket is “downward (-5).” • The flow rate to the tilt cylinder is calculated from the pump delivery. • When the necessary oil level for the set position is reached, the detent is reset and it stops gently.
Tilt stop (gentle) • After resetting the detent, a check is made for 0.05 seconds to determine whether the bucket lever is maintained by the tilt detent. If it is, the stop operation is not performed gently. • If the bucket lever is operated when stopping (gently), the faster of the target speed with the tilt lever operation and the target speed with the stop (gentle) function is selected and output. • If the bucket lever is operated in the direction of dump for 60% or more during stop (gentle) control, the stop (gentle) control is stopped and dump is output.
10-400 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Lift Arm Positioner
Function ★ Raise kickout (when raise lamp is on) • • • •
Set the lift arm lever to raise detent; reset the lift arm raise detent when the lift arm rises before the set position; and perform stop (gentle) control. When the lift arm is at positions other than the raise detent, it is raised by the operator. When raise is not selected, only raise detent operates. When the detent is turned on, the remote positioner does not operate and only the kickout function (stop at the top position of the lift arm) operates.
★ Lower lift arm stop (when lower lamp is on) • • • •
Set the lift arm lever to the float detent; start decreasing the speed when the lift arm is 10° before the set position; reset the float detent when it is 4° before the set position; and perform stop (gentle) control. If the lift arm lever is kept as it is, the lift arm starts lowering again. When lower is not selected, only float detent operates. When the detent is turned on with the lift arm angle level or lower, the remote positioner does not operate and only the float detent function (it does not stop automatically) operates.
★ The remote positioner of lower does not function as a positioner and does not stop when the detent is turned on with the lift arm angle level or lower in order to distinguish it from a float operation in grading operations.
WA500-6
10-401 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 1.
ELECTRICAL SYSTEM
Setting stop position • The stop position of the bucket changes when the positioner is operated using the bucket positioner position set switch. ★ Setting and resetting raise stop position Condition for Availability
Method of setting raise stop
Method of resetting raise stop
Lift arm lever stroke: neutral (1)
Raise the lift arm to a desired set position.
(2)
Press the remote positioner raise position set switch (less than a second).
(3)
If the position where the switch is pressed is within the set range, save the lift arm angle. The setting completion buzzer sounds (pip, pip) and the switch indicator lights up.
(4)
If it is out of the range (lift arm angle less than 0°) and in sensor errors, it is not set again. (The buzzer does not sound; the set position is not changed.)
(5)
When the set switch is operated for less than a second, the set position is always changed. (The set position is maintained when the key is turned off.)
(1)
Press and hold the remote positioner raise position set switch for a second or longer.
(2)
If it is within the set range when the switch is pressed, the position is set temporarily. If it lasts for a second or longer in (3) above, the setting cancel buzzer (pip) sounds when a second elapses; raise selection is reset; and the switch indicator goes off. *After the setting is reset, the whole lift arm angle is available.
(3)
Remote positioner raise stop control is not performed. Only boom kickout control is performed.
★ Setting and resetting lower stop position Condition for Setting
Method of setting lower stop
Method of resetting lower stop
10-402 b
Lift arm lever stroke: neutral (1)
Lower the lift arm to a desired set position.
(2)
Press the remote positioner lower position set switch (less than a second).
(3)
If the position where the switch is pressed is within the set range, save the lift arm angle. The setting completion buzzer sounds (pip, pip) and the switch indicator lights up.
(4)
If it is out of the range (other than lift arm angle of -37° to 0°) and in sensor errors, it is not set again. (The buzzer does not sound; the set position is not changed.)
(5)
When the set switch is operated for less than a second, the set position is always changed. (The set position is maintained when the key is turned off.)
(1)
Press and hold the remote positioner lower position set switch for a second or longer.
(2)
If it is within the set range when the switch is pressed, the position is set temporarily. If it lasts for a second or longer in (3) above, the setting cancel buzzer (pip) sounds when a second elapses; lower selection is reset; and the switch indicator goes off. *After the setting is reset, the whole lift arm angle is available.
(3)
Remote positioner lower stop control is not performed. Only float detent control is performed.
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ Settable range of remote positioner stop position [Raise, lower stop position settable range] Stop Position
Raise
Lower
Min. 0°
0 to -37°
* 0°: Lift arm is level.
2.
Resetting lift arm raise detent • Raise detent turns on when the lift arm lever stroke becomes 60% or more. • When the remote positioner operates, the detent goes off from 2° before stop angle to 1° past. • When the lift arm raise detent automatically goes off due to the operation of the stop (gentle) function, the lift arm raise/lower detent stays off for a second after it is turned off.
3.
Lift arm raise stop (gentle) • In the lift arm raise stop (gentle), the speed is decreased in accordance with the stop angle from a stop angle of 9° to 2° before, through lift arm angle feedback. • After resetting the lift arm detent, check whether the lift arm lever is maintained by the detent for 0.05 seconds and, if it is, (gentle) stop operation is not performed. Accelerate the raising rate of the lift arm to reach maximum speed when the lift arm angle is 10° above the stop position. • When an operation exceeding the target stop angle is performed while the detent is maintained with the lift arm raise remote positioner operated, the speed of the lift arm raise temporarily decreases and then increases.
WA500-6
10-403 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
4.
Boom kickout • When the lift arm raise detent is set when the stop position of the remote positioner is not set or above the stop position, the lift arm slowly stops before the stroke end as kickout operation, reducing stop shock due to stroke end. • In kickout operation, the detent goes off from 2° before stop angle to 2.5° past.
5.
Resetting lift arm lower detent • Lower detent turns on when the lift arm lever stroke becomes 60% or more. • When the remote positioner operates, the detent goes off from 2° before stop angle to 1° past. • When the lift arm angle is less than -37°, the detent turns on for grading operations, regardless of the operation of the remote positioner. • When the lift arm lower detent automatically goes off due to the operation of the stop (gentle) function, the lift arm raise/lower detent stays off for a second after it is turned off.
10-404 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
6.
Lift arm lower stop (gentle) • In the lift arm lower stop (gentle), the speed is decreased in accordance with the stop angle from a stop angle of 9° to 2° before, through lift arm angle feedback. • After resetting the lift arm lower detent, a check is done to determine whether the lift arm lever is maintained by the detent for 0.05 seconds. If it is, stop operation (gentle) is not performed. The lift arm lower is accelerated so that the lift arm is floating when the lift arm angle is at 10° below the stop position. • When an operation exceeding the target stop angle is performed while the detent is maintained with the lift arm lower remote positioner operated, the speed of the lift arm lower temporarily decreases and then increases. • Even during acceleration, when the lift arm angle reaches -37°, acceleration ends and float operation is set.
7.
Detent operation during engine stop • While the engine is stopped, the detent is constantly turned OFF. The lever is not held at detent position during engine stop.
8.
Adjustment of lift arm angle • The work equipment controller has an adjusting function for correcting the lift arm angle sensor installation errors. • It saves the lift arm angle sensor voltage at the lift arm top position and operates the kickout remote positioner function. • When not implementing an adjustment, such phenomena as the kickout position is “too early” and “no kickout occurs and a shock is generated at the stroke end” may occur.
WA500-6
10-405 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Semi-Automatic Digging Control of Semi-Automatic Digging •
Semi-automatic digging is a function in which digging operations can be performed only with the kickdown switch and lift arm raise operation, improving the working efficiency of less experienced operators.
•
The two modes of LOOSE mode/ROCK mode are separately used due to the characteristics of the work objects.
•
Select the bucket automatic operation pattern appropriate for the work cycle/load. ★ Mode Selection No.
Object
Mode
1
Gravel/sand
LOOSE mode
2
Quarry/blasted rock
ROCK mode
10-406 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Conditions for Starting Semi-Automatic Digging ★ Semi-automatic digging is ready with (1) to (4) below.
Condition 1
(1)
The semi-automatic digging switch is either in ROCK or LOOSE mode.
(2)
In forward (with F signal)
(3)
Lift arm angle less than -30° (almost to the ground)
(4)
Operate the kickdown switch. * Even when working in 1st, semi-automatic digging does not start without operating the kickdown switch.
★ Semi-automatic digging (automatic tilting) starts when the following conditions (1) and (2) are satisfied. Condition 2
(1)
Perform lift arm raise operation after condition 1 is satisfied.
(2)
Travel speed km/h <3.5 x ENG rpm/1,800>
Conditions for Finishing Semi-Automatic Digging ★ Automatic tilting is finished when any of the following conditions is satisfied. Conditions
(1)
Forward finished (F signal: ON OFF)
(2)
Lift arm angle level or higher
(3)
Detect tilt end (becomes full tilt)
Tilt Operation of Digging Model ★ Operation of LOOSE mode • • •
Tilt operation starts 0.5 seconds after the conditions for starting semi-automatic digging are satisfied. The speed is increased so that it becomes 100% ten seconds after starting tilt. The maximum speed depends on the engine speed.
WA500-6
10-407 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ Operation of ROCK mode • • • •
Tilt operation starts 0.6 seconds after the conditions for starting semi-automatic digging are satisfied. Tilt repeats operation/stop with different tilt time/cycle for each cycle. The number of tilts changes until loading is finished in accordance with the loading object. The maximum speed depends on the engine speed.
10-408 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Pump Swash Plate Control In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary function when engine speed is low” are included. Based on calculation results of each function, data with less pump delivery (larger pump EPC current) will be selected. ★ Horsepower loss decrease function in pump relief • •
•
Horsepower loss is decreased by controlling pump delivery in relief, changing the command value of the pump swash plate, when the work equipment pump is relieved. Output to pump EPC is changed with the input signal of the loader pump pressure sensor.
The work equipment controller operates pump EPC in 200 mA until loader pump pressure reaches 326.31 kg/cm² (4641 psi). When it becomes 336.51 kg/cm² (4786 psi) or higher, the controller operates pump EPC in 700 mA.
WA500-6
10-409 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
ELECTRICAL SYSTEM
In this control, the delivery (pump EPC current) is changed over a second from 700 mA to 200 mA in order to prevent sudden operation due to a rapid increase of flow rate, when the delivery changes in increasing direction (current decreasing direction). Pump Pressure kg/cm² (psi)
Current Value (mA)
Pump Flow Rate
339.57 (4830)
200
100%
349.76 (4975)
700
30%
★ Pickup auxiliary function when engine speed is low. •
When the engine speed and torque are low, acceleration of the engine in work equipment operation is aided by limiting the pump delivery.
10-410 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Engine speed is < 1,400 rpm. Pump flow rate restriction
• •
The work equipment controller operates pump EPC in 900 mA until engine speed reaches 500 rpm. When the speed is 1,400 rpm or higher, the controller operates pump EPC in 200 mA. Engine Speed
Current Value (mA)
Pump Flow Rate
500 rpm
900
MIN
1,000 rpm
569
40%
1,400 rpm
200
100%
WA500-6
10-411 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Joystick Steering Control ★ Joystick Steering (J/S) system • • • •
Joystick steering controls the turning speed according to the joystick lever operation angle. The standard steering system is augmented with a system for implementing Orbitrol operation using the joystick solenoid valve. Even during a joystick steering operation, you can use the steering wheel to turn the machine. The transmission controller controls validity/invalidity of the joystick steering system. When the machine monitor joystick indicator is other than lit (turned out or flashing), turning operation can not be done using the joystick lever.
★ Joystick neutral safety •
When starting the engine with the joystick steering system being valid (J/S ON/OFF switch = ON and J/S unlocked), if the joystick lever is set to other than neutral and the joystick knob FNR switch is set to other than neutral, the engine start signal is cut off to inhibit engine start by turning the neutral safety relay ON to prevent the machine from turning and starting immediately after the engine starts.
★ Joystick neutral interlock •
A safety function is incorporated in the system to disable the turning operation using the joystick lever until the lever is returned to the neutral position, even if the joystick is valid with the joystick lever in operation while the joystick steering is invalid (J/S ON/OFF switch = OFF or J/S is locked).
10-412 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ Adjustment of starting current • •
The work equipment controller has an adjusting function for correcting dispersion. The work equipment starting current usually does not require adjustment. However, if phenomena such as “the neutral dead zone is large,” “dashing/stopping shock from J/S turning is large,” or “the time lag for turning operation start is large” should occur, they can be improved by implementing an adjustment. ★ For the adjusting procedure, see the following information in the Testing and Adjusting section: • •
MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Adjustment of Joystick Steering Right Lever and Variations at EPC Starting Point MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point
★ Joystick setting •
Since the joystick is optional equipment, control is not performed unless the option setting for joystick is made valid in the optional setting of the machine monitor. In other words, the machine cannot use the joystick function unless the machine recognizes the presence of this option. ★ For information about setting options, see MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
•
The joystick cannot be simultaneously installed with the right FNR switch.
WA500-6
10-413 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Real-Time Monitor ★ Display contents of the real-time monitor • •
In the WA500-6, the state of the controller input and output signals can be checked using the real-time monitor function of the machine monitor. The following table lists the display items and display contents in normal operation of the real-time monitor in relation to the work equipment controller.
No.
Check Item
ID No.
Display of Item Name
Contents of Display Data
Display Contents in Normal Operation
Remarks
1
Software part number
20202
VERSION
Part No. of software is displayed
Depends on the software number
–
2
Application Version
20225
VERSION APP
Application version number is displayed
Depends on application version number
–
3
Data Version
20226
VERSION DATA
Data version number is displayed
Depends on data version number
–
94700
Converted value of the PUMP PRESS loader pump oil pressure is displayed
• When work equipment is in neutral: 20.39 ±20.39 kg/cm² • Work equipment relief: 346.7 ±20.39 kg/cm²
–
94701
Input voltage value of PUMP PRESS loader pump oil pressure is displayed
• When work equipment is in neutral: 0.70 ±0.2 V • Work equipment relief: 3.22 ±0.2 V
–
Loader pump EPC OUT PUMP EPC DIR command current value is displayed
• Lo (800 rpm): 421 ±30 mA • Hi (above 950 rpm): 200 ±10 mA • Work equipment relief: 700 ±10 mA • Engine stop (below 500 rpm): 900 ±10 mA
–
• When work equipment is Results of pump delivery in neutral: 170 CC/R calculation are displayed • Work equipment in relief: 23 ±10 CC/R
–
4
Loader pump pressure
5
Loader pump pressure
6
Loader pump EPC current (Command)
7
Pump delivery flow rate
94500
94600
PUMP FLOW
Standard lift arm: • Lift arm top: 47.0 ±2.0 deg. • Lift arm bottom: -43.0 ±3.0 deg.
8
Lift arm angle
06002
BOOM ANG
Calculation results of lift arm angle are displayed Hi-lift lift arm:
–
• Lift arm top: **.* ±2.0 deg. • Lift arm bottom: -**.* ±3.0 deg.
10-414 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
ID No.
Display of Item Name
ELECTRICAL SYSTEM Contents of Display Data
Display Contents in Normal Operation
Remarks
STD lift arm:
9
Lift arm angle
06005
10
Frame angle
94400
11
Number of lift arm lever operations
42100
Lever 12 potentiometer voltage lift arm 1
Lever 13 potentiometer voltage lift arm 2
14
Bucket lever operation frequency
Lever 15 potentiometer voltage bucket 1
Lever 16 potentiometer voltage bucket 2
WA500-6
42000
BOOM ANG
• Lift arm top: 3.80 ±0.3 V Input voltage value to lift • Lift arm bottom: 1.31 ±0.5 V arm angle sensor potentiometer is Hi-lift lift arm: displayed • Lift arm top: **.* ±0.3 V • Lift arm bottom: **.* ±0.5 V
Operation angle converted value of AJSS FRAME ANGLE frame potentiometer is displayed
–
–
WA500-6 has no corresponding functions.
BOOM LVR
Number of lift arm lever Display in accordance with operations is displayed in the number of lever the unit of thousand operations
–
BOOM POT1
Input voltage value to lift arm lever potentiometer 1 is displayed
• Neutral: 2.50 V ±0.10 V • Raise (before detent): 3.89 V ±0.20 V • Raise (detent position): 4.11 V ±0.20 V • Lower (before detent): 1.11 V ±0.20 V • Float (detent position): 0.89 V ±0.20 V
–
• Neutral: 2.50 V ±0.10 V • Raise (before detent): 1.11 V ±0.20 V • Raise (detent position): 0.89 V ±0.20 V • Lower (before detent): 3.89 V ±0.20 V • Float (detent position): 4.11 V ±0.20 V
–
42001
BOOM POT2
Input voltage value to lift arm lever potentiometer 2 is displayed
42101
BUCKET LVR
Number of bucket lever Display in accordance with operations is displayed in the number of lever the unit of thousand operations
–
BUCKET POT1
Input voltage value to bucket lever potentiometer 1 is displayed
• Neutral: 2.50 V ±0.10 V • Tilt (before detent): 3.89 V±0.20 V • Tilt (detent position): 4.11 V ±0.20 V Full dump: 0.89 V ±0.20 V
–
Input voltage value to bucket lever potentiometer 2 is displayed
• Neutral: 2.50 V ±0.10 V • Tilt (before detent): 1.11 V ±0.20 V • Tilt (detent position): 0.89 V ±0.20 V • Full dump: 4.11 V ±0.20 V
–
42002
42003
BUCKET POT2
10-415 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
No.
Check Item
ID No.
Display of Item Name
Contents of Display Data
17
Lift arm raise EPC current (Command)
41900
RAISE EPC DIR
EPC output command current value to lift arm raise is displayed
• Neutral: 0 ±10 mA • Max.: 896 ±10 mA
–
18
Lift arm lower EPC current (Command)
41901
LOWER EPC DIR
EPC output command current value to lift arm lower is displayed
• Neutral: ±10 mA • Before detent: 640 ±10 mA • Float position: 1,000 ±10 mA
–
19
Bucket tilt EPC current (Command)
41902
TILT EPC DIR
EPC output command current value to bucket tilt is displayed
• Neutral: 0 ±10 mA • Max.: 930 ±10 mA
–
20
Bucket dump EPC current (Command)
41903
DUMP EPC DIR
EPC output command current value to bucket dump is displayed
• Neutral: 0 ±10 mA • Max.: 848 ±10 mA
–
21
J/S EPC current (Command)
41908
AJSS EPC DIR
EPC output command current value to AJSS is displayed
22
J/S right EPC current (Command)
41904
EPC output command J/S EPC DIR RH current value to J/S right is displayed
23
J/S left EPC current (Command)
24
Lever potentiometer voltage J/S1
25
Lever potentiometer voltage J/S2
Display Contents in Normal Operation
–
Remarks
WA500-6 has no corresponding functions.
• Neutral: 0 ±10 mA • Max.: 850 ±10 mA
–
41905
EPC output command J/S EPC DIR LH current value to J/S left is displayed
42004
J/S POTI1
Input voltage value to J/S lever potentiometer 1 is displayed
• Neutral: 2.50 V ±0.10 V • When fully turned right: 1.34 V ±0.20 V • When fully turned left: 3.66 V ±0.20 V
–
42005
J/S POTI2
Input voltage value to J/S lever potentiometer 2 is displayed
• Neutral: 2.50 V ±0.10 V • When fully turned right: 1.34 V ±0.20 V • When fully turned left: 3.66 V ±0.20 V
–
3-spool valve 1, ECMV and 26 current value (Command)
41906
3RD EPC1 DIR
EPC output command current value to 3-spool valve 1 is displayed
• Neutral: 0 ±10 mA • Max.: 960 ±10 mA
–
3-spool valve 2, ECMV and 27 current value (Command)
41907
3RD EPC2 DIR
EPC output command current value to 3-spool valve 2 is displayed
• Neutral: 0 ±10 mA • Max.: 960 ±10 mA
–
28
3-spool valve lever operation frequency
Lever potentiometer 29 voltage 3-spool valve 1
10-416 b
42102
42006
3RD LVR
Number of 3-spool valve Display in accordance with lever operations is the number of lever displayed in the unit of operations thousand
–
3RD POT1
Input voltage value to 3-spool valve lever potentiometer 1 is displayed
–
• Neutral: 2.50 V ±0.10 V • Retract: 4.11 V ±0.20 V • Extract: 0.89 V ±0.20 V
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
Lever potentiometer 30 voltage 3-spool valve 2 AJSS lever 31 operation angle
ID No.
42007
94300
ELECTRICAL SYSTEM
Display of Item Name
Contents of Display Data
Display Contents in Normal Operation
Remarks
3RD POT2
Input voltage value to 3-spool valve lever potentiometer 2 is displayed
• Neutral: 2.50 V ±0.10 V • Retract: 0.89 V ±0.20 V • Extract: 4.11 V ±0.20 V
–
AJSS LEVER
Operation angle converted value of AJSS lever potentiometer is displayed
–
WA500-6 has no corresponding functions.
AJSS LEVER
Input voltage value of AJSS lever potentiometer is displayed
–
WA500-6 has no corresponding functions.
–
WA500-6 has no corresponding functions.
32
AJSS lever potentiometer voltage
33
AJSS frame potentiometer voltage
94401
FRAME ANGLE
Input voltage value of AJSS frame potentiometer is displayed
34
AJSS S/T deviation angle
94800
S/T DEFLECTION
Deviation angle value of AJSS frame and lever is displayed
–
WA500-6 has no corresponding functions.
35
Digging-inprogress flag
94900
WORK FLAG
State of digging flag is displayed
• During digging operation: ON • Other than above: OFF
–
The state of input signal is displayed
• 00000000 (Semi-auto switch = • D-IN-0: Semi-auto OFF) LOCK mode • 10000000 switch (Semi-auto switch = ON) • D-IN-1: Semi-auto • 010000000 LOOSE mode (Semi-auto switch = ON) switch • 0010000000 • D-IN-2: J/S Hi-Lo (J/S Hi-Lo selector selector switch switch)
The state of input signal is displayed
• 11000000 (State of dump) • 10000000 (Bucket level) • 00000000 (Full tilt) • 10100000 (Bucket raise set switch = ON) • 10010000 (Bucket lower set switch = ON)
• D-ON-8: Tilt end proximity switch • D-IN-9: Tilt level proximity switch • D-IN-10: Bucket positioner raise set switch • D-IN-11: Bucket positioner lower set switch
The state of input signal is displayed
• 1000000 (Work position) • 00000000 (Lock position) • 01000000 (While cranking)
• D-IN-16: Work equipment N lock switch • D-IN-17: Starter C terminal signal
36
37
38
Input signal D_IN_0-7
Input signal D_IN_8-15
Input signal D_IN_16-23
WA500-6
94301
40910
40911
40912
D-IN--0-----7
D-IN--8-----15
D-IN-16-----23
10-417 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
39
Check Item
Input signal D_IN_24-31
Input signal D_IN_32-39 (No. 33-39 don't 40 apply to work equipment controller.)
ON/OFF output 41 D_OUT_0--7
ON/OFF output 42 D_OUT_8--15
43
ON/OFF output D_OUT_16--23
ID No.
40913
40942
40952
40953
40954
Display of Item Name
ELECTRICAL SYSTEM Contents of Display Data
Display Contents in Normal Operation
Remarks
D-IN-24-----31
The state of input signal is displayed
• 0000000 • 00001000 (Lift arm raise set SW = ON) • 0000010 (Lift arm lower set SW = ON)
• D-IN-28: Lift arm positioner raise set switch • D-IN-29: Lift arm positioner lower set switch
D-IN-32-----39
The state of input signal is displayed
• There is no used items in this data. • 00000000 is constantly displayed
–
D-OUT--0------7
ON/OFF output state of SOL_OUT0 to 7 “0” is displayed when setting current output
• 10000000 (Lock position) • 00000000 (Unlock neutral) • 01000000 (Raise detent SOL = ON) • 00100000 (Float detent SOL = ON) • 0001000 (Tilt detent SOL = ON)
• D-OUT-0: Work equipment N Lock SOL • D-OUT-1: Lift arm raise detent SOL • D-OUT-2: lift arm float detent SOL • D-OUT-3: Bucket tilt detent SOL
D-OUT-8-----15
ON/OFF output state of SOL_OUT8 to 13 and ON/OFF output state of SIG_OUT0 and 1 “0” is displayed when setting current output
• 00000000 (J/S cut relay: OFF) • 10000000 (J/S cut relay: ON)
SOL-OUT-8: J/S cut relay
SIG_OUT2 – 3 HSW_OUT0 – 1 ON/OFF output state of BATT_RY_OUT is displayed
• 00001000 (Operate safety relay) • 00010000 (Display lift arm positioner lower = ON) • 00110000 (Display lift arm positioner raise/lower = ON)
• D-OUT-18: Lift arm positioner raise set indicator ON • D-OUT-19: Lift arm positioner lower indicator ON • D-OUT-20: Operation safety relay
D-OUT-16----23
* J/S = Joystick steering
10-418 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Diagnosis ★ Troubleshooting function •
The work equipment controller monitors the input and output signals constantly to troubleshoot the system.
•
If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine monitor.
•
When an abnormality occurs, it can be confirmed on the machine monitor/ KOMTRAX.
WA500-6
10-419 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Input and Output Signals Pin Assignment
DEUTSCH-24P [CN-L05] Input and Output Signals
Pin No.
Bucket lever potentio B
Input
13
Boom lever potentio B
Input
2
Loader pump press. sensor
Input
14
Third EPC lever B
Input
3
J/S potentio B
Input
15
NC
Input
4
GND_SIG_D
–
16
NC
Output
5
NC
Input
17
Semi-auto loading loose mode SW
Input
6
NC
Input
18
NC
Input
7
Bucket lever potentio A
Input
19
Boom lever potentio A
Input
8
Boom angle sensor
Input
20
Third EPC lever A
Input
9
J/S lever potentio A
Input
21
GND_SIG_A
10
GND_SIG_D
–
22
PWR_OUT_5V_0
Output
11
J/S speed Hi/Lo select SW
Input
23
Semi-auto loading lock mode SW
Input
12
NC
Input
24
NC
Input
Pin No.
Signal Name
1
10-420 b
Signal Name
Input and Output Signals
–
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
DEUTSCH-40P (1) [CN-L06] Pin No.
Signal Name
Input and Output Signals
Pin No.
Signal Name
Input and Output Signals
1
NC
Output
21
NC
Input and output
2
NC
Input
22
COMM_CAN_L_O
Input and output
3
Remote positioner leveling set SW
Input
23
NC
Input and output
4
NC
Input
24
PWR_CTR_EXT
Input
5
NC
Input
25
Starting switch (IGN-C)
Input
6
NC
Input
26
NC
Input
7
NC
Input
27
NC
Input
8
NC
Output
28
NC
Input
9
NC
Output
29
NC
–
10
NC
Input
30
NC
Input
11
NC
Output
31
NC
–
12
NC
–
32
COMM_CAN_H_O
Input and output
13
Remote positioner lifting set SW
Input
33
NC
Input and output
14
NC
Output
34
NC
–
15
NC
Input
35
Lever prohibiting equipment SW
Input
16
NC
Input
36
NC
Input
17
NC
Input
37
NC
Input
18
NC
Output
38
NC
Input
19
NC
Output
39
NC
–
20
NC
Input
40
NC
Input
WA500-6
10-421 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
DEUTSCH-40P (2) [CN-L07] Pin No.
Signal Name
Input and Output Signals
Pin No.
Signal Name
Input and Output Signals
1
PWR_IN_BATT
Input
21
GND_PWR
–
2
PWR_IN_BRY
Input
22
PWR_IN_BRY
Input
3
GND_ACT
–
23
GND_ACT
4
Safety relay
Output
24
PWR_CTR_KEY
Input
5
Bucket tilting EPC
Output
25
Third EXT EPC
Output
6
Boom lifting EPC
Output
26
J/S solenoid cut relay
Output
7
Work neutral lock solenoid
Output
27
Magnetic detent of boom lever float
Output
8
Remote positioner lifting indicator
Output
28
J/S right EPC
Output
9
NC
Input
29
NC
Input
10
Bucket cylinder tilt end SW
Input
30
Bucket positioner up set SW
Input
11
PWR_IN_BATT
Input
31
GND_PWR
–
12
PWR_IN_BRY
Input
32
GND_PWR
–
13
GND_ACT
–
33
GND_PWR
–
14
PWR_CTR_KEY
Input
34
NC
Output
15
Bucket dumping EPC
Output
35
Third RET EPC
Output
16
Boom lowering EPC
Output
36
Loader pump EPC
Output
17
Magnetic detent of boom lever lift
Output
37
Magnetic detent of bucket lever tilt
Output
18
Remote positioner lowering indicator
Output
38
J/S left EPC
Output
19
NC
Input
39
NC
Input
20
Bucket cylinder horizon SW
Input
40
Bucket positioner down set SW
Input
10-422 b
–
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Transmission Controller System Electrical Circuit Diagram ★ Steering wheel specifications with lockup
WA500-6
10-423 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10-424 b
ELECTRICAL SYSTEM
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Transmission Controller Gearshifting Control Electronic Modulation Function •
To reduce the shocks made when the gear speed is changed (when the clutch is engaged), modulation control is applied.
•
The clutch oil pressure is controlled properly for the condition of the hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, gearshifting pattern, and transmission modulation data table saved in the transmission controller memory so that the transmission is set in any gear speed (including the lockup clutch) smoothly.
•
Modulation control is also performed for the clutch on the side to be turned off in order to reduce lowering the torque.
•
If an abnormal time lag is made in gearshifting, the learning function corrects the modulation automatically.
Display of Gearshift The transmission controller displays the state of the input signal related to the gearshift, sending it to the machine monitor via the network. ★ Directional indicators • •
• •
The directional indicators of the machine monitor display the signal input state of the directional lever, which is input to the transmission controller. When the lever is in the neutral position and there is no input signal to the transmission controller, the directional indicators go out completely. If two signals are input due to a problem, the two indicators may light up at the same time. If the directional lever is in the R state, the backup lamp relay is operated; the back lamp and backup buzzer are operated. If the machine has the right FNR switch (if equipped) and joystick steering (if equipped) installed with two systems of the FNR signal, see MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
★ Gear speed indicators • •
The gear speed indicators of the machine monitor display the signal input state of the gear speed lever, which is input to the transmission controller. When the lever is in the neutral position and there is no input signal to the transmission controller, the gear speed indicators go out completely. If two signals are input due to a problem, an indicator different from the lever position may light up because priority is given to the higher gear speed.
★ Display of actual gear speed •
The actual gear speed display of the machine monitor shows the state of the gear speed and travel direction, which is output from the transmission controller.
•
When the directional lever is in N, the monitor display is N. When the directional lever is in F or R, the monitor display is F or R + gear speed. This display is always N since no gear speed is output while the parking brake is ON.
Automatic Gearshifting Function Auto-shift (in which the gear speed is automatically determined depending on the travel speed) and manual shift (in which the speed is determined as the gear speed of the gearshift lever) are included in this function. •
In auto-shift, the auto-shift indicator of the machine monitor lights up. Shifting up/down and ON/OFF of the lockup clutch are changed with the engine power mode and selected shift mode.
•
There are two modes (H/L) in auto-shift whose gearshift points are different depending on the engine power mode.
•
In auto-shift, shifting up/down is controlled in accordance with the directional lever, gearshift lever, travel speed, accelerator pedal opening ratio, and data saved in the memory of the transmission controller according to the engine speed. For the gearshift point of each mode, see Transmission Controller System: Auto-Shift Points Table in this section.
WA500-6
10-425 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
★ Gearshift lever in the 1st to 4th (when steering option is selected) • •
The maximum gear speed (gear shifting range) used in the automatic gearshifting operation is limited. In the automatic gearshifting operation, the vehicle usually starts in the 2nd gear speed. If the gearshift lever is in 4th, the gear is shifted up and down between the 2nd gear speed and 4th gear speed. The vehicle starts in the 1st gear speed only when the kickdown function is used.
★ Directional lever in N position •
The gear speed of the transmission gearshift in the neutral position is changed in accordance with the travel speed, but the display is always N.
Shift Hold Function •
The shift hold function holds the current gear speed when the hold switch is pressed if the auto-shift mode is selected; it does not shift up even when the travel speed is increased. Even if the travel speed is decreased, the gear does not shift down.
•
While the shift hold function is operating, the shift hold indicator of the machine monitor lights up. When the shift hold switch is pressed again, the hold is released and the indicator goes out.
•
The hold is released automatically also by the directional lever, gearshift lever, and kickdown switch operation.
•
ON/OFF state of lockup is not held.
Kickdown Function ★ Kickdown in manual shift operation • • •
The kickdown switch operates only in the forward 2nd gear speed (F2) and the transmission is set in the forward 1st gear speed (F1). Operation of the kickdown switch is ignored in any gear speed other than (F2). After the actual gear speed becomes (F1) due to the kickdown switch operation, the kickdown function is released and the transmission is set in the gear speed of the lever when the directional lever is operated to a position other than forward or the gearshift lever is operated to a position other than the 2nd gear speed.
★ Kickdown in auto-shift operation • •
•
The kickdown function works regardless of the lever position if the directional lever is in a position other than N and the gearshift lever is in a position other than the 1st gear speed. After the transmission gear is shifted because of the kickdown switch operation, an ordinary gearshift is performed in accordance with the Auto-Shift Points table, after the time for the no-shift time is passed or when the directional lever is operated. The gear speed selected by the operation of the kickdown switch depends on the travel speed as shown in the following table. Gear Speed before Shifting
Output Shaft Speed [rpm] when Kickdown Switch = ON
2nd
<Reference> Travel Speed Conversion
All range
Gear Speed after Shifting
No-shift Time
1st
5 sec.
Below 824
12.5 km/h (7.8 mph)
1st
5 sec.
Min. 824
12.5 km/h (7.8 mph)
2nd
4 sec.
Below 824
12.5 km/h (7.8 mph)
1st
5 sec.
Min. 824
12.5 km/h (7.8 mph)
3rd
4 sec.
3rd
4th
10-426 b
2nd (lockup)
All range
2nd
*1
3rd (lockup)
All range
3rd
*1
4th (lockup)
All range
4th
*1
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
*1: When lockup is released due to the kickdown switch operation, lockup will not be ON again until the following conditions are satisfied: ★ Perform temporary operation to turn the torque converter lockup switch OFF ON. ★ The travel speed changes from below to above lockup ON speed as listed in the Auto-Shift Points table. Torque Converter Lockup Control Function •
ON/OFF operation of the lockup is performed automatically due to the ON operation of the torque converter lockup switch.
•
When the lockup clutch is ON, the lockup indicator of the machine monitor lights up.
•
Even when the manual shift is selected, if the torque converter lockup switch is ON, ON/OFF of the lockup is performed automatically by the transmission controller.
•
The operation gear speed of the lockup is shown in the following table. Lockup Operation Gear Speed (Lockup operates: ❍)
Travel Mode F1
F2
F3
F4
MANUAL
❍
❍
Auto H
❍
Auto L
❍
R1
R2
R3
R4
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
★ Lockup rotation •
For ON/OFF of lockup, see Transmission Controller System: Auto-Shift Points Table in this section.
★ Lockup protection function •
Lockup ON only operates when the moving direction of the machine and the position of the directional lever match. Determination of moving direction of the machine: • The machine is stopped when the transmission controller is started (key on) or the transmission output shaft speed is below 260 rpm. • While the machine is stopped and the transmission output shaft speed becomes 260 rpm or more, if the directional lever is in the F position, the machine is moving forward; if it is in the R position, it is moving backward. ★ The travel speed is approximately 4 km/h (2.5 mph) when the transmission output shaft speed is 260 rpm.
WA500-6
10-427 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Hunting Prevention Function •
The transmission controller prevents hunting by detecting hunting, which occurs between 2nd and 3rd when auto-shift is selected, with the controller.
•
If gearshifts 2nd to 3rd to 2nd to 3rd are performed within six seconds from the previous gearshift, hunting is thought to have occurred and the gear speed is selected from 2nd or 3rd, whichever operation time is longer. When the hunting prevention function operates, the shift point in hunting prevention stated in the Auto-Shift Points table is selected for the next automatic gearshifting operation.
•
The operation of the hunting prevention function ends when the next gearshift operation (including FR, kickdown operation, etc.) is performed. The gear is set to the ordinary shift point of the auto-shift.
•
When ON/OFF of 2nd lockup occurs consecutively within five seconds, the lockup is turned off and the speed is changed to lockup ON travel speed when the hunting prevention function operates.
•
The hunting prevention function operates when hunting occurs even in the manual shift.
Changing Shift Points •
The transmission controller can adjust the gearshift points of the L-mode in auto-shift.
•
If hunting occurs due to the conditions at a job site, the travel speed when shifted up/down can be changed by adjusting the gearshift points. ★ For information about the modification procedure, see MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Adjustment of Transmission L-Mode Shift Point in the Testing and Adjusting section.
4th Gear Speed Derating Function •
The transmission controller can limit the operation of the 4th gear speed by changing the optional setting. ★ For information about the modification procedure, see the 4th Gear Prohibition option in the Optional Device Installation Setting table in MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
Transmission Initial Learning and ECMV Current Adjustment •
The transmission controller can make an adjustment to correct dispersion between the transmission unit and ECMV solenoid.
•
If the adjustment is not performed, a gearshifting shock or a time lag may occur. ★ For the adjustment procedure, see the following information: • •
10-428 b
MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Setting Transmission Initial Learning MACHINE MONITOR SYSTEM: Service Mode: Adjustment Function (TUNING): Adjustment of Transmission ECMV Current in the Testing and Adjusting section.
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Auto-Shift Points Table The relationship among transmission output shaft speed, engine mode, shift switch, and gearshifting operation are shown in the following table. Unit: rpm Engine Mode and Shift Switch
Gearshifting operation
Power Mode
Economy Mode
Shift Switch H
Shift Switch L
Shift Switch H
Shift Switch L
F1 F2
395
395
362
362
F2 F2 (lockup)
560 – 660
560 – 660
540 – 632
540 – 632
F2 F2 (lockup) when hunting is prevented
692 – 824
692 – 824
659 – 744
659 – 744
F2 F3
632 – 922
501 – 922
573 – 896
481 – 896
F2 F3 when hunting is prevented
698 – 903
698 – 903
639 – 876
639 – 876
F3 F3 (lockup)
942 – 1120
942 – 1120
909 – 1054
909 – 1054
F3 F4
1166 – 1502
1120 – 1502
1080 – 1430
1034 – 1430
F4 F4 (lockup)
1614
1614
1548
1548
F4 (lockup) F4
1436
1436
1370
1370
F4 F3
1034 – 1436
988 – 1436
949 – 1370
903 – 1370
F3 (lockup) F3
850
850
817
817
F3 F2
501 – 850
329 – 850
441 – 817
270 – 817
F3 F2 when hunting is prevented
501 – 725
329 – 725
441 – 679
270 – 679
F2 (lockup) F2
514
514
494
494
★ The transmission output shaft speed of 1 rpm corresponds to 0.0145 km/h (0.009 mph). ★ The shifting down point of F4 F2 and F3 F2 is 66 rpm when the accelerator is idle.
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ELECTRICAL SYSTEM
Transmission Controller Protection Function Protection Function when Changing FR In order to protect the transmission, the controller limits changing F-R operation with the directional lever during high-speed travel. •
All range of auto modes (speed position switch at a position other than 1st gear speed) and manual mode (2nd, 3rd, and 4th)
•
In auto-shift mode: • • •
•
Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range) Range II: F-R is changed; transmission is set in 2nd gear speed; and the alarm is turned ON. Range III: F-R is changed and the alarm is turned ON. The gear speed of the transmission gearshift depends on the travel speed. The transmission is then shifted down to 2nd gear speed with reduction of the travel speed.
In manual-shift mode: • • •
Range I: Only F-R is changed. (Ordinary range) Range II: F-R is changed and the alarm is turned ON. Range III: F-R is changed and the alarm is turned ON. The gear speed of the transmission gearshift depends on the travel speed. The transmission is then shifted down to the speed position with reduction of the travel speed. ★ Two seconds immediately after the F-R changing operation, shifting up/down and kickdown switch operation is not accepted. If the shifting up/down operation is performed with the lever operation, the gearshift will be performed in two seconds. ★ In auto-shift, shifting up is not performed until the 2nd gear speed is obtained by speed reduction.
Transmission Output Shaft Speed before Gearshift (rpm)
Remarks (Travel speed conversion)
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A
B
C
856
922
1054
13 km/h (8.08 mph)
14 km/h (8.70 mph)
16 km/h (9.94 mph)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Protection Function in Shift-Down Operation •
In order to protect the engine and pump, the transmission controller performs shift-down protection in which operations are not accepted while shifting down. The alarm is turned ON while it is operating.
•
The operating conditions of the shift-down protection are shown in the following table.
•
The alarm turns ON until the gearshift position of the shift lever and the actual output gearshift match. Even when the travel speed does not decrease, performing the shift-up operation stops the alarm. Protection Condition
Condition for Resetting Protect
Target Gear Speed to Shift Down
Transmission Output Shaft Speed
Engine Speed
Transmission Output Shaft Speed
Engine Speed
To 3rd gear speed
Min. 1,721 rpm
–
Below 1,549 rpm
–
Min. 1,102 rpm
–
Below 861 rpm
–
Min. 895 rpm
Min. 1,620 rpm
Below 964 rpm
Below 1,440 rpm
Min. 895 rpm
–
Below 861 rpm
–
To 2nd gear speed To 1st gear speed
•
The shift-down protection is valid also in the kickdown operation in auto-shift. If the machine is traveling at a travel speed above the protect condition when the kickdown operation is performed, the kickdown operation is not accepted and the alarm goes ON for three seconds.
Protection Function in Lockup •
When the transmission output shaft speed is equivalent to the engine speed of 2,525 rpm or above, the lockup is released automatically to prevent engine overrun and the alarm goes off. For five seconds after it is released temporarily, the lockup stays OFF.
•
When five seconds have elapsed and the transmission output shaft speed is equivalent to the engine speed of below 2,375 rpm, lockup comes on again. (Function of engine overrun prevention)
★ Lockup OFF travel speed by function of engine overrun prevention (reference) Lockup Operation OFF Value (equivalent to engine speed of 2,525 rpm) WA500-6 Actual Gear Speed
WA500-6
Output Shaft Speed (rpm)
Reference Travel Speed km/h (mph)
F2
1137
17.3 (10.75)
F3
1908
29.0 (18.02)
F4
3250
49.3 (30.63)
R2
1281
19.4 (12.05)
R3
2151
32.6 (20.26)
R4
3661
55.6 (34.55)
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ELECTRICAL SYSTEM
Protection Function by Shift-Up •
When traveling in T/C, if the engine speed is 2,525 rpm or more, the transmission shifts up and the alarm turns ON. After shifting up, it does not shift down for three seconds.
•
After three seconds have elapsed and the engine speed drops below 2,375 rpm, the alarm stops and the shift control becomes the ordinary control.
•
When traveling in 4th gear speed, shift-up is not performed; only the alarm goes ON.
Warn Operation of Overrun Prevention Action Warning •
When the engine speed is 2,425 rpm or more, the overrun prevention action warning function operates.
•
The alarm is released when the engine speed goes below 2,325 rpm.
Neutralizer Function •
When the parking brake switch is ON (while the parking brake switch is operating), transmission output is maintained in neutral regardless of the state of the gearshift lever, to prevent dragging of the parking brake.
•
The parking brake switch circuit is a safety circuit and is not open when the key switch is changed from OFF to ON. While the key is on, the transmission is always in neutral regardless of the state of the lever.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Engine Control Engine Torque Curve Switching Function •
The transmission controller selects the engine power mode from the signal input of the engine power mode changing switch.
•
The controller sends torque curve information used in the engine controller to the monitor panel.
•
It also sends engine power mode information of power/economy to the monitor panel.
Maximum Travel Speed Limit For lower fuel consumption in load-and-carry operations, the maximum travel speed is limited by setting the maximum travel speed (select from three levels) and setting the upper limit to a throttle value in the F4 lockup state. Setting Information
Throttle Value Upper Limit
(1) (Default)
90%
(2)
100%
(3)
80%
Throttle Lock For improving the working efficiency, the engine speed is maintained at an arbitrary speed. •
The engine speed is set by pressing the accelerator pedal and the rpm set idle up/down switch.
•
When the right brake is pressed, throttle lock is temporarily released.
•
For lower fuel consumption in a setting with auto-deceleration function, the throttle lock function is temporarily released and the transmission follows the signal of the accelerator pedal if the following conditions are met: • • •
The transmission neutral continues for four seconds or the work equipment neutral state lasts for four seconds or longer. The throttle lock SET/ACCEL SW and throttle lock RESUME/DECEL SW are not operated. The travel speed is 5 km/h (3 mph) or less.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
ELECTRICAL SYSTEM
In the state where the throttle lock is temporarily released, if the transmission is set to a position other than neutral or the work equipment is in a state other than N, the throttle control state will resume automatically.
Component List
Throttle Lock Function Switch
Switch composition
Alternate 3-position switch
Switch theory
• ON (GND) • OFF (OPEN)
Function
• When this switch is pressed upward, “throttle lock auto deceleration function is disabled.” • When this switch is pressed downward, “throttle lock auto deceleration function is enabled.”
Throttle Lock SET/ACCEL Switch
Throttle lock RESUME/DECEL Switch
Momentary seesaw switch
• ON (GND) • OFF (OPEN)
• Function to set throttle stroke: Save the throttle stroke when it is ON (lock accelerator opening ratio) • Controls with input signal edge
Right Brake Pedal Operation (released) Switch (Left brake switch = OFF)
Throttle Lock Indicator Lamp
Momentary proximity switch
Lamp
• Brake operated (GND) • Brake not operated (OPEN)
• ON • Performed through electrical circuit
• Resume function: While the throttle lock function is released with the right brake pedal operation (release), press this switch and the When the right brake throttle lock pedal is pressed for Output is ON function is 0.5 sec. continually, when throttle lock resumed. the throttle lock ON/OFF switch is • Controls with input function is ON. signal edge temporarily released.
When acceleration When deceleration function switch is function switch is When this switch is pressed for 0.5 sec. pressed for 0.5 sec. pressed in the middle, continually, set continually, set the throttle lock throttle stroke rises throttle stroke lowers function is OFF. by the time the switch by the time the switch is pressed. is pressed.
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★ For a description of the throttle lock function, a sample time chart is shown below.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Transmission Cutoff Control •
The transmission cutoff control sets the transmission in neutral by detecting the brake pilot oil pressure with the pressure sensor when the left and right brake pedals are pressed.
•
This function enables cutoff at an optional position by saving the brake pedal pressing position where the transmission becomes neutral as the brake pilot oil pressure.
Contents of Transmission Cutoff Control
Outline
When transmission cutoff switch is ON and if pressure of left brake pressure sensor signal exceeds set pressure, this switch sets the transmission in neutral. (When the transmission cutoff operation condition is met) Gear changes by cutoff return modulation provided the pressure drops below the return pressure during cutoff or the condition for resetting transmission cutoff is met and the left brake operation switch is OFF. Operating condition at 1st and 2nd speed: •
Transmission cutoff control Operating condition
Operating condition at 3rd and 4th speed: •
Condition for resetting Settable condition
When transmission cutoff switch is ON and brake pilot pressure is > cutoff IN pressure.
When transmission cutoff switch is ON and accelerator opening is less than 30% (including 2nd speed low idle operating state) and the brake pilot pressure is > cutoff IN pressure.
{When transmission cutoff switch is OFF} or {Transmission cutoff pressure is < cutoff OUT pressure} Transmission cutoff switch is ON. (1) Press left brake pedal to the set position. (Setting is enabled without stepping on the brake.) (2) Press the transmission cutoff switch. (3) Transmission controller temporarily saves the pressure at the time the switch is pressed if it is within the setting-enabled range.
Setting method Setting of transmission cutoff point
If outside the range, the transmission controller temporarily saves the upper and lower limit pressure and transmits information for sounding the setting complete buzzer twice (pip, pip) over the network to the monitor. (4) At this time, the built-in indicator in the transmission cutoff switch blinks for 2.5 seconds. (5) After the indicator blinks for 2.5 seconds, the setting is saved (end of setting mode). (Set condition is still held after the key is turned off.) (1) During the 2.5 seconds in Step 4 (while the transmission cutoff switch built-in indicator is blinking), press the transmission cutoff switch again.
Resetting method
(2) Indicator stops blinking and cutoff point is set to default left brake pressure. Transmit to the monitor information for sounding the setting cancel buzzer over the network. (3) Set (default) value is saved (end of setting mode). (Set condition is still held after the key is turned off.)
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ELECTRICAL SYSTEM
Outputting Conditions for Buzzer, Indicator (main monitor), and Indicator in Transmission Cutoff Switch Indicator in Transmission Cutoff Switch
Buzzer Command (Communication Output)
Cutoff point
ON
Not displayed
Controlled with value saved last
2.5 seconds when transmission cutoff switch is ON and transmission cutoff set switch is ON or resetting (while sensor is normal) and setting method is (2) to (5).
Blinking (2.6 sec. or until reset)
When set switch is pressed, set completion buzzer sounds.
• Controls with previously saved value. • Saves the pressure that pressed the set switch.
When transmission cutoff switch is ON and pressure sensor is abnormal (see FMEA).
Remains turned out
Not displayed (error buzzer sounds).
• No control is made. • Saved value is not changed.
ON
Not displayed (monitor displays error).
• Controlled with value saved previous time. • Saved value is not changed.
When transmission cutoff switch is ON and transmission cutoff set switch is ON. Reset within 2.5 sec.
ON
Set cancel buzzer sounds when set switch is pressed.
• Controls with previously saved value. • Saves the default.
When transmission cutoff switch is OFF.
OFF
Not displayed
Output Conditions
When transmission cutoff switch is ON
When transmission cutoff switch is ON and set switch is abnormal (see FMEA).
Not controlled
★ During cutoff, actual transmission gear speed is indicated as N (neutral); FNR output number is N. ★ During lockup, lockup is cancelled to implement cutoff. ★ If cutoff is made after reaching 1st speed with the kickdown switch, the gear should return to 1st gear speed for both auto/ manual shift. Setting Enabled Range of Transmission Cutoff Point ★ Setting enabled range: 5.0 – 44.97 kg/cm² (71 – 640 psi) •
Add hysteresis of 2.04 kg/cm² (29 psi) to the cutoff IN (for neutral) pressure and OUT (reset) pressure. Example: When cutoff point is set to position of 5.0 kg/cm² (142 psi) of pressure sensor: Cutoff IN pressure: . . . . . . . . . . . . . . . . . . . . . . 5.0 kg/cm² (142 psi) Cutoff OUT pressure: . . . . . . . . . . . . . . . . . . . 7.95 kg/cm² (113 psi)
•
If the pressure sensor is set for under 5.0 kg/cm² (71 psi), the set value is 5.0 kg/cm² (71 psi).
•
If the pressure sensor is set for over 45.0 kg/cm² (640 psi), the set value is 45.0 kg/cm² (640 psi).
★ The default value is 15.0 kg/cm² (213 psi).
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
ECSS Function •
The ECSS is a system in which the controller automatically turns on and off the accumulator charged with high-pressure gas according to the travel condition and the lift arm operation condition.
•
This improves operator comfort and working efficiency by preventing spillage of material by absorbing the vertical movement of the work equipment, when the vehicle travels at high speed.
ECSS System Circuit
Operation of ECSS Since the ECSS is optional equipment, control cannot be performed unless the ECSS option is enabled in the optional setting of the machine monitor. ★ For information about the procedure to set the option, see the Optional Device Installation Setting table in MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section. ECSS Switch
Gear Speed
Output Shaft Speed
ECSS Output
OFF
All
0 to MAX
OFF
1st
0 to MAX
OFF
Condition A
OFF
Condition B
ON
ON 2nd to 4th
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
The transmission output shaft speed of 198 rpm corresponds to approximately 3 km/h (2 mph).
•
The transmission output shaft speed of 329 rpm corresponds to approximately 5 km/h (3 mph).
ELECTRICAL SYSTEM
Operation of Solenoid in ECSS ON/OFF •
Modulation control is performed for the ECSS solenoid with EPC output in switching ON/ OFF, reducing the lowering of the lift arm and occurrence of switching shocks.
•
The constant current when the ECSS solenoid is ON is 800 mA.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Economy Lamp Control of Economy Lamp The transmission controller lights up the economy lamp indicator on the machine monitor when operating in low fuel consumption, in order to prompt low fuel consumption operation to the operator. Lighting Condition of Economy Lamp When the engine power mode is the economy mode and the accelerator pedal opening ratio is 80% or less, the economy lamp is illuminated. Accelerator Opening Ratio
Power Mode
Economy Mode
Min. 80%
OFF
OFF
Max. 80%
OFF
Lighting
Turning Off Economy Lamp The economy lamp can be constantly kept off by using the optional setting of the monitor. ★ For instructions about changing the option setting, see the Optional Device Installation Setting table in MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
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ELECTRICAL SYSTEM
Cooling Fan Control Control of Fan •
Employment of the hydraulically driven cooling fan, as well as controlling its speed through control of the hydraulic pump swash plate, allows for reduction of horsepower loss and noises in a low temperature environment.
•
Engine speed and coolant temperature received by the engine controller and hydraulic oil temperature and torque converter oil temperature received by the machine monitor are sent to the transmission controller via the network.
•
Based on the received information, the transmission controller sends the signal current to the swash plate angle control EPC valve on the cooling fan pump so that the valve can control the swash plate angle in order to set the fan speed to a level suitable for the given temperature level and the engine speed.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Fan Speed in Accordance with Temperature The target fan speed is determined based on the data with the highest temperature among coolant temperature, hydraulic oil temperature, and torque converter oil temperature. ★ Fan speed
Protection Function •
In order to prevent overrun of the cooling fan motor, the protection function minimizes the swash plate angle of the cooling fan pump as the engine speed reaches 2,300 rpm or above.
•
If the transmission controller fails to recognize the engine speed and respective temperature data due to a failure on the network communication, this function sends a specific command current (677 mA) to the swash plate angle control EPC valve on the pump so that the pump may work functionally – equivalent to a fixed pump.
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ELECTRICAL SYSTEM
Control for Starting Engine The fan control is a different control from the ordinary temperature control when starting the engine. ★ When stopping the engine (key switch 1-stage on) • •
When the engine is stopped, the cooling fan pump EPC current of 677 mA is output. It is the same as a state where the engine speed cannot be recognized.
★ While cranking •
While cranking to start the engine and in order to improve engine start, the minimum swash plate is used for the cooling fan pump by setting the fan EPC current to 850 mA, reducing the torque necessary for starting the engine.
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ELECTRICAL SYSTEM
Fan Reverse Rotation Function As the fan reverse rotation switch is pressed for cleaning the radiator core, the cooling fan reverse rotation solenoid valve of the cooling fan motor is activated, rotating the fan in reverse. Standard Specification Fan Manual Reverse Rotation Function •
This function is used by the operator to reverse the fan rotation. By pressing the fan manual reverse switch, the turning direction of the fan is changed.
•
Changing from forward to reverse and reverse to forward is performed when the following conditions are satisfied. • •
•
The fan manual reverse switch is pressed. The engine speed is 500 rpm or lower.
The fan reverse indicator flashes when the state of the fan manual reverse switch and the rotation direction of the fan do not match. While the fan is rotating in the reverse direction, the fan reverse indicator illuminates. Reverse SOL Output before Switch Operation
Forward/Reverse Selector Switch Operation
OFF
From OFF to ON
OFF
From ON to OFF
ON
From OFF to ON
ON
Engine Speed
Reverse SOL Output
Fan Pump EPC Output
Monitor Indicator Lighting Logic
ON
MIN speed
From OFF to ON
OFF
Ordinary
From flashing to OFF
ON
MIN speed
From flashing to ON
From ON to OFF
OFF
Ordinary
From ON to OFF
OFF
From OFF to ON
OFF
Ordinary
From OFF to flashing
OFF
From ON to OFF
OFF
Ordinary
From flashing to OFF
Below 500 rpm
Min. 500 rpm ON
From OFF to ON
ON
MAX speed
From flashing to ON
ON
From ON to OFF
ON
MAX speed
From ON to flashing
Fan Reverse Rotation Function ★ This function is not used. Fan Speed in Reverse While it is operating in reverse, cleaning the radiator core is facilitated by increasing air flow by turning the fan at the maximum speed without outputting fan pump EPC current (output 0 mA).
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ELECTRICAL SYSTEM
Right FNR Switch Control (if equipped) This is optional equipment installed to the side of the work equipment lever separately from the standard FNR lever. It enables the operator to change travel direction with the right hand by arranging the directional selector switch. Change of Right FNR •
When using only the standard FNR lever, FNR lever input signal equals FNR recognition. When multiple switches are installed for the identical purpose of switching the travel direction, the selector switch is provided to select operation. ★ Switching of operation to the right FNR switch is made when the right FNR validity switch is turned ON. The operational priority is given to the FNR lever (standard FNR lever).
•
Switching condition to the right FNR switch turns the right FNR validity switch ON when the standard FNR lever is at N (neutral) and the right FNR switch is at N (neutral). Only at that time is the switching of the travel direction enabled with the right FNR switch. ★ When the travel direction is selectable with the right FNR switch, the right FNR indicator on the machine monitor is lit. ★ If either one of the switches is at other than N (neutral) and the right FNR validity switch ON-OFF is operated, the buzzer is actuated and the right FNR indicator flashes on the machine monitor.
•
Even if the right FNR switch is enabled, if the standard FNR lever is operated to other than N (F or R), the standard FNR lever has priority. As the result, the standard FNR lever controls the travel direction. Since the switching has not been made normally, the warning is actuated and the right FNR indicator on the machine monitor starts flashing. ★ The alarm is actuated and the right FNR indicator starts flashing. The alarm does not stop unless and until both the standard and the right FNR switches are set to N (neutral). The right FNR switch does not function to effect forwardreverse travel.
★ The following table outlines the above information.
Mode
Condition
FNR Recognition
Right FNR Valid/Invalid State
Monitor Operation (Reference)
<a> lever (Normal)
Lever: [F or N or R] Right SW: [N] Right FNR validity SW: [OFF]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp turns OFF. • Buzzer stops.
<b> seesaw SW (Normally [right switch])
Lever: [N] Right SW: [F or N or R] Right FNR validity SW: [ON]
Follow the right FNR seasaw SW
ON (Valid)
• Pilot lamp turns ON. • Buzzer stops.
<c> lever has priority (Emergency operation)
Lever: [F or R] Right SW: [F or N or R] Right FNR validity SW: [ON]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer sounding.
<d> lever SW error (Operation error)
Lever: [F or N or R] Right SW: [F or R] Right FNR validity SW: [OFF]
Follows the FNR lever (Right SW is disregarded)
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer sounding.
<e> switching error (Operation error)
Lever: [other than N] Right SW: [other than N] Right FNR validity SW: [OFF ON operation]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer sounding.
★ *SW = Switch
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Interlocking at Starting Engine (engine start inhibited) To prevent the machine from starting travel suddenly immediately upon engine start, the starting motor C terminal signal is cut by actuating the neutral safety through the work equipment controller in case the right FNR validity switch is at the ON position and the right FNR switch is at other than N (neutral) position. Setting of Right FNR Switch •
Since the right FNR switch is an optional device, it cannot exert any control unless the right FNR optional setting is enabled with the option setting on the machine monitor.
•
No simultaneous installation with the joystick steering is enabled.
★ For information about setting this option, see the Optional Device Installation Setting table in MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
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ELECTRICAL SYSTEM
Joystick Control Control of Joystick Steering The joystick is an optional device that enables turning of the machine (steering operation) and forward-reverse travel, shift-up/ -down by using the joystick lever provided in the left console. Since turning the machine is performed by the work equipment controller, see ELECTRICAL SYSTEM: Work Equipment Control System: Joystick Steering Control in this manual. Switching to the Joystick •
When using only the standard FNR lever, the FNR lever input signal equals FNR recognition. When multiple switches are installed for the identical purpose of switching the travel direction, the selector switch is provided to select operation. ★ Switching of operation to the FNR switch on the joystick knob is made only when the joystick validity switch is ON and the joystick lock lever is cancelled. The FNR lever (standard FNR lever) has complete priority for operation.
•
Switching conditions of the joystick to the FNR switch (hereinafter referred to as the joystick switch) are as follows: ★ Selection of the travel direction becomes enabled with the joystick switch by turning the joystick validity switch ON and canceling the joystick lock lever while the standard FNR lever is at N (neutral) and the joystick switch is at N (neutral). ★ When the travel direction is selectable with the joystick switch, the joystick indicator on the machine monitor is lit. ★ If either one of the switches is at other than N (neutral) and the joystick validity switch ON/OFF is operated, the alarm is actuated and the joystick indicator flashes on the machine monitor.
•
Even if the joystick switch is enabled, if the standard FNR lever is operated to other than N (F or R), the standard FNR lever has priority. As the result, the standard FNR lever controls the forward-reverse travel. Since the switching has not been done normally, the alarm is actuated and the joystick indicator on the machine monitor starts flashing. ★ Once the alarm is actuated and the joystick indicator starts flashing, the alarm does not stop unless and until both the standard FNR lever and the joystick switches are set to N (neutral). The joystick switch does not function to enable forward-reverse travel. ★ In the case where the joystick indicator is not lit, forward and reverse operation are disabled. Simultaneously the turning operation by the joystick is also disabled.
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★ The following table outlines the above information.
Condition
FNR Recognition
JS Valid/Invalid State
Monitor Operation (Reference)
<a> lever (Normal)
Lever: [F or N or R] JS SW: [N] JS validity SW: [OFF]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp turns OUT. • Buzzer stops.
<b> JS SW (Normal [JS])
Lever: [N] JS SW: [F or N or R] JS validity SW: [ON]
Follow the JS FNR SW
ON (Valid)
• Pilot lamp turns ON. • Buzzer stops.
<c> lever has priority (Emergency operation)
Lever: [F or R] JS SW: [F or N or R] JS validity SW: [ON]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer is sounding.
<d> lever SW error (Operation error)
Lever: [F or N or R] JS SW: [F or R] JS validity SW: [OFF]
Follows the FNR lever (JS SW disregarded)
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer is sounding.
<e> switching error (Operation error)
Lever: [other than N] Right SW: [other than N] Right FNR JS validity SW: [OFF ON operation]
Follows the FNR lever
OFF (Invalid)
• Pilot lamp is FLASHING. • Buzzer is sounding.
Mode
★ JS validity switch [ON] in the table indicates the state where JS validity switch [ON] and JS lock lever is cancelled. [OFF] indicate the state where JS validity switch [OFF] or JS lock lever locked. ★ *JS = Joystick steering system ★ * SW = Switch Joystick Shift-Up and Shift-Down Switch •
The joystick shift-up and shift-down switch performs shift-up and shift-down in the manual shift mode in the gear speed below the gear speed of the gearshift lever (not set to a gear speed above the gear speed lever position). If the current gear speed should exceed the gear speed lever position, the switch performs shift-down to the gear speed of the gear speed lever position same as the normal shift-down. ★ When shifting down during high-speed travel, the shift-down protection function operates and shifting down is performed after the travel speed has decreased.
•
In the case where the shift mode is in auto-shift mode (both H and L), the shift-up and shift-down switch of the joystick lever does not function and the range switch only by the gear speed lever.
•
When the shift-up and shift-down switch are operated at the same time, shift-down is effective.
•
After pressing the switch once, the next shift-up and shift-down switch operation is not accepted for 0.2 seconds.
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Interlocking at Starting Engine (engine start inhibited) •
To prevent the machine from starting travel suddenly upon engine start, the starting motor C terminal signal is cut by actuating the neutral safety relay through the work equipment controller in case the joystick validity switch is at the ON position, the joystick lock lever is in the open state, and the joystick FNR switch is at other than the N (neutral) position. The starting motor signal is cut if the joystick indicator is in the flashing state.
•
In case the joystick lever is operated when the joystick is in a valid state, the work equipment controller sends engine start inhibit information to actuate the neutral safety relay and cut the starting motor C terminal signal.
Joystick Setting •
Since the joystick is optional equipment, it does not work unless the joystick option setting is selected in the optional setting on the machine monitor.
•
The joystick cannot be simultaneously installed with the right FNR switch.
★ For information about setting this option, see the Optional Device Installation Setting table in MACHINE MONITOR SYSTEM: Service Mode: Optional Device Setting Function (OPTIONAL SELECT) in the Testing and Adjusting section.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Real-Time Monitor •
In the WA500-6, the state of the controller input and output signals can be checked using the real-time monitor function of the monitor.
•
The following table lists the display items and display contents in normal operation of the real-time monitor in relation to the transmission controller.
★ List of display contents of the real-time monitor No.
Check Item
ID No.
Display of Item Name
Contents of Display Data
Data Unit (and Range)
Remarks
1
Software part number
20201
VERSION
Output mass production software part number
Depends on the software part number
–
2
Software application version
20223
VERSION (APP)
Output software version (software logic part version)
Depends on the software version
–
3
Software application data 20224 version
VERSION (DATA)
Output software version (software data part version)
Depends on the software version
–
4
Engine mode
Output engine mode • 0: power mode 41600 ENGINE MODE for controlling engine • 2: economy mode output
–
• X1 [mA] (0 – 1000 [mA]) • When engine speed is below 500 rpm = 677 mA 5
ECMV output command value 41400 FAN EPC DIR (FAN pump)
Output to FAN EPC output command current value
• While cranking (C terminal operation) = 850 mA
–
• Switching fan reverse = 850 mA • Fan operating in reverse = 0 mA
6
Fan reverse switch input
93400
FAN REVERSE SW
Output fan reverse SW input state
• 1: ON (CLOSE) • 0: OFF
–
7
Torque converter inlet oil 41501 temperature
T/C IN OIL TEMP
–
–
Not used by this machine.
8
Torque converter inlet oil 41502 temperature
T/C IN OIL TEMP
–
–
Not used by this machine.
9
Torque converter 93500 T/C SPEED: IN input shaft speed
–
–
Not used by this machine.
10
Torque converter T/C TORQUE: output shaft 93501 OUT torque
–
–
Not used by this machine.
11
Transmission 31200 T/M SPEED: IN input shaft speed
Output transmission input shaft speed [PLS_AC_IN_0]
X1 [min-1] (0 – 32,767 [min-1])
–
10-450 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
ID No.
Display of Item Name
ELECTRICAL SYSTEM Contents of Display Data
Data Unit (and Range)
Remarks
• X1 [min-1] (0 – 32,767 [min1]) • 0 km/h = 0 rpm
12
Transmission output shaft speed
31400
T/M SPEED: OUT
Output output shaft speed [PLS_AC_IN_2]
• 10 km/h (6.2 mph) = 788 rpm • 20 km/h (12.4 mph) = 1,376 rpm
–
• 30 km/h (18.6 mph) = 2,063 rpm • 40 km/h (24.9 mph) = 2,751 rpm 13
Transmission output shaft speed
31404
T/M SPEED: OUT2
–
Converted value of Transmission the set oil pressure 14 cutoff operation 41203 T/M CUT SET (IN oil pressure) to setting transmission cutoff is displayed
15
16
Transmission cutoff (Left brake) pressure
Transmission cutoff (Left brake) pressure
–
Not used by this machine.
X10 [kg/cm²] (0 – 51 [kg/cm²])
Displayed value changes according to the cutoff set operation. • When the foot brake is released: 0 ±1 kg/cm²
Converted value of 41201 T/M CUT OFF P brake oil pressure is displayed
X10 [kg/cm²] (0 – 51 [kg/cm²])
• When foot brake is actuated: Displayed value changes according to the brake-actuating operation. • When the foot brake is released: 1.00 ±0.1 V
Input voltage value of 41202 T/M CUT OFF P brake oil pressure is displayed
• When the foot brake is actuated: Displayed value changes according to the brake-actuating operation.
Output torque converter speed ratio
X1 [%] (0 – 100 [%])
–
Output oil Transmission oil temperature value of 18 temperature 93600 T/M OIL TEMP transmission oil input temperature (A_IN_1)
X1 [°C] (0 – 150 [°C])
–
17
Torque converter 93700 speed ratio
TC SPEED RATIO
X1 [mV] (0.00 – 5.00 [V])
• X1 [mV] (0.00 – 5.00 [V]) Output input voltage Input voltage of value of transmission 19 transmission oil 93601 T/M OIL TEMP oil temperature temperature (A_IN_1)
• 4.72 V = 0°C (32°F) • 4.33 V = 30°C (86°F) • 3.55 V = 60°C (140°F)
–
• 2.20 V = 100°C (212°F) • 1.61 V = 120°C (248°F)
20
MOD/C oil pressure input
WA500-6
92400 MOD/C PRESS
–
–
Not used by this machine.
10-451 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD Contents of Display Data
Data Unit (and Range)
Remarks
92401 MOD/C PRESS
–
–
Not used by this machine.
MOD/C heat release value
92500
MOD/C Q
–
–
Not used by this machine.
MOD/C heat ratio
92501
MOD/C q
–
–
Not used by this machine.
No.
Check Item
ID No.
21
MOD/C oil pressure input voltage
22 23
Display of Item Name
ELECTRICAL SYSTEM
Throttle lock switch (pressed THROT LOCK 24 95500 upward) A (RPM set switch)
Output the state of input signal
Throttle lock switch (pressed downward) THROT LOCK 25 95501 (PRM set auto B deceleration switch)
Output the state of input signal
• 0: RPM set switch OFF • 1: PRM set switch ON
• 0: RPM set auto deceleration switch OFF • 1: RPM set auto deceleration switch ON
–
–
26
Throttle correction 95400 command output
Output throttle correction command output amount
X1 [%] (-100 – 100 [%])
–
27
Throttle opening Output throttle upper THROT LIMIT upper limit 44200 limit command output UP output amount
X0.1 [%] (0.0 – 100.0 [%])
–
28
Output throttle lower THROT LIMIT Throttle opening limit command output 44201 LO lower limit output amount
X0.1 [%] (0.0 – 100.0 [%])
–
THROTTLE MOD
Depends on accelerator pedal operation:
29
Accelerator mode
93801
THROTTLE MODE
• Accelerator pedal = 0 Depends on accelerator opening • Accelerator pedal partial ratio; output pressing (opened side) = 1 acceleration mode on • Accelerator pedal partial control pressing (pressed side) = 2
–
• Accelerator pedal pressing =3 30
Traction setting 94000 input value
TRACTION DIAL
–
–
Not used by this machine.
31
Traction setting 94001 input voltage
TRACTION DIAL
–
–
Not used by this machine.
Lockup changing 32 switch input 95000 LOCK UP SW signal
Output the state of input signal
ECMV output 33 command value 31602 (1st)
ECMV output to 1st clutch Output command current value
10-452 b
ECMV 1 DIR
• 0: Lockup changing switch OFF • 1: Lockup changing switch ON
X1 [mA] (0 – 1000 [mA])
–
–
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Display of Item Name
Contents of Display Data
Data Unit (and Range)
Remarks
ECMV 2 DIR
ECMV output to 2nd clutch Output command current value
X1 [mA] (0 – 1000 [mA])
–
ECMV 3 DIR
ECMV output to 3rd clutch Output command current value
X1 [mA] (0 – 1000 [mA])
–
X1 [mA] (0 – 1000 [mA])
–
ECMV F DIR
ECMV output to FWD clutch Output command current value
X1 [mA] (0 – 1000 [mA])
–
ECMV output 38 command value 31609 ECMV LU DIR (L/U)
ECMV output to L/U clutch Output command current value
X1 [mA] (0 – 1000 [mA])
–
ECMV output ECMV MOD/C 39 command value 31640 DIR (MOD/C)
–
–
Not used by this machine
X1 [mA] (0 – 1000 [mA])
–
No.
Check Item
ID No.
ECMV output 34 command value 31603 (2nd) ECMV output 35 command value 31604 (3rd)
ECMV output 36 command value 31605 (4th)
ECMV output 37 command value 31608 (FWD)
ECMV 4 DIR
ECMV output to 4th clutch Output command current value
ECMV output 40 command value 31606 (REV)
ECMV R DIR
ECMV output to REV clutch Output command current value
ECMV output 41 command value 93300 (ECSS)
ECSS V DIR
Output to ECSS valve Output command current value
X1 [mA] (0 – 1000 [mA])
–
FILL TIME 1
Output 1st clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55 [sec], No fill time: 0)
–
FILL TIME 2
Output 2nd clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55 [sec], No fill time: 0)
–
FILL TIME 3
Output 3rd clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55[sec], No fill time: 0)
–
FILL TIME 4
Output 4th clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55 [sec], No fill time: 0)
–
42
43
44
45
Fill time value (1st)
Fill time value (2nd)
Fill time value (3rd)
Fill time value (4th)
WA500-6
41802
41803
41804
41805
10-453 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
46
47
Check Item
Fill time value (FWD)
Fill time value (REV)
ID No.
41808
41806
ELECTRICAL SYSTEM
Display of Item Name
Contents of Display Data
Data Unit (and Range)
Remarks
FILL TIME F
Output FWD clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55 [sec], No fill time: 0)
–
FILL TIME R
Output REV clutch fill time value (State of gear change preceding immediately before)
X0.01 [sec] (0 – 2.55 [sec], No fill time: 0)
–
• 0*******: Engine mode selector SW OFF • 1*******: Engine mode selector SW ON • *00*****: (J/S shift-up/-down SW not operated) • *10*****: (J/S shift-up SW operated)
48
Input signal D_IN_0-7
40905
D-IN--0------7
Output the state of input signal
• D-IN0: Engine mode selector SW • D-IN1: J/S shift-up SW • D-IN2:
J/S shift-down SW • *01*****: (J/S shift-down SW operated) • D-IN3: Air conditioner • ***0****: compressor Air conditioner compressor operating stop • ***1****: Air conditioner compressor operating • ****00**: Manual shift mode • ****10**: Shift mode L • ****11**: Shift mode H • ******0*: Right FNR (J/S) selector SW OFF
• D-IN4: Shift mode L
• D-IN5: Shift mode H • D-IN6: J/S or right FNR valid SW • D-IN7: C terminal signal
• ******1*: Right FNR (J/S) selector SW ON • *******1: Cranking
10-454 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
ID No.
Display of Item Name
ELECTRICAL SYSTEM Contents of Display Data
Data Unit (and Range)
Remarks
• 10**0***: Transmission cutoff SW ON • 11**0***: Transmission cutoff SW AND • D-IN8: Transmission cutoff setting SW ON SW • **0*0***: Kickdown SW OFF • **1*0***: Kickdown SW ON • ***00***: Shift hold SW OFF • ***10***: Shift hold SW ON 49
Input signal D_IN_8-15
40906
D-IN--8-----15
Output the state of input signal
• ****00**: Throttle lock set SW OFF • ****01**: Throttle lock set SW ON • ****0*0*: Throttle lock resume SW OFF • ****0*1*: Throttle lock resume SW ON • ****0**0: Left brake pedal SW OFF
• D-IN9: Transmission cutoff point set SW • D-IN10: Kickdown SW • D-IN11: Shift hold SW • D-IN13: Throttle lock set SW • D-IN14: Throttle lock resume SW • D-IN15: Left brake pedal SW
• ****0**1: Left brake pedal SW ON • 1000****: Gear speed lever at 1st speed • 0100****: Gear speed lever at 2nd speed • 0010****: Gear speed lever at 3rd speed
50
Input signal D_IN_16-23
40907 D-IN-16-----23
Output the state of input signal
• 0001****: Gear speed lever at 4th speed • ****100*: Direction lever at F • ****010*: Direction lever at N • ****001*: Direction lever at R • *******0: Parking brake released • *******1: Parking brake operating
WA500-6
• D-IN16: Gear speed lever 1st speed • D-IN17: Gear speed lever 2nd speed • D-IN18: Gear speed lever 3rd speed • D-IN19: Gear speed lever 4th speed • D-IN20: Direction lever at F • D-IN21: Direction lever at N • D-IN22: Direction lever at R • D-IN23: Parking brake signal
10-455 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
ID No.
Display of Item Name
ELECTRICAL SYSTEM Contents of Display Data
Data Unit (and Range)
• 1******0: Right FNR (J/S FNR) F • 0101000*: Traveling at F1 • 0010100*: Traveling at R2 51
Input signal D_IN_24-31
40908 D-IN-24-----31
Output the state of input signal
• 0000010*: 3rd speed neutral • 0100001*: Traveling at F4 • 0******1: Right FNR (J/S FNR) R • 0******0: Right FNR (J/S FNR) N
52
Input signal D_IN_32-39 (Transmission controller does not have 33 – 39)
Remarks • D-IN24: Right FNR (J/S FNR) F • D-IN25: Fill SW at F • D-IN26: Fill SW at R • D-IN27: Fill SW at 1st • D-IN28: Fill SW at 2nd • D-IN29: Fill SW at 3rd • D-IN30: Fill SW at 4th • D-IN31: Right FNR (J/S FNR) at R
• 1*******: Right FNR (J/S FNR) at N 40942 D-IN-32-----39
Output the state of input signal
• 0*******: Right FNR (J/S FNR) at F • 0*******: Right FNR (J/S FNR) at R
D-IN32: Right FNR (J/SFNR) at N
• 0000**00: Fan reverse solenoid OFF • 0001**00: Fan reverse solenoid ON
53
Output signal D_OUT_0-7
40949
D-OUT 0-7
• ON/OFF output state of SOL_OUT0 to 7 • “0” is displayed when setting current output
• 000*0*00: Fan neutral solenoid OFF • 000*1*00: Fan neutral solenoid ON • 000**000: Low temperature bypass solenoid OFF
• D-OUT3: Fan reverse solenoid • D-OUT4: Fan neutral solenoid (if equipped) • D-OUT5: Low temperature bypass solenoid (optional)
• 000**100: Low temperature bypass solenoid ON
54
Output signal D_OUT_8-15
10-456 b
40950
D-OUT 8-15
• ON/OFF output state of SOL_OUT8 to 11B, SIG_OUT0 to 1 • “0” is displayed when setting current output
00000000
Not used by this machine.
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD No.
Check Item
55
Output signal D_OUT_16-23
56
Initial learning flag
WA500-6
ELECTRICAL SYSTEM
Display of Item Name
Contents of Display Data
Data Unit (and Range)
Remarks
40951
D-OUT 16-23
• ON/OFF output state of SIG_OUT2 to 3, HSW_OUT0 to 1, BATT_RY_OUT • “0” is displayed when setting current output
00000000
Not used by this machine.
94100
Output initial learning • 111111: (all clutches learned) flag state of trigger TRIG FR1234 time of each clutch • 000000: [F,R,1,2,3,4] (all clutches to be learned)
ID No.
16-bit data is displayed in the order of F, R, 1, 2, 3, and 4 on the monitor.
10-457 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Diagnosis ★ Troubleshooting function • • •
The transmission controller monitors the input and output signals constantly to troubleshoot the system. If any abnormality is detected by self-diagnosis, the information is transmitted through the network to the machine monitor. When an abnormality occurs, it can be confirmed on the machine monitor.
10-458 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
Input and Output Signals Pin Assignment
DEUTSCH-24P [CN-L02] Pin No.
Signal Name
Input and Output Signals
Pin No.
Signal Name
Input and Output Signals
1
T/C lock up SW.
Input
13
Throttle with auto decel
Input
2
Fan reverse SW.
Input
14
NC
Input
3
NC
Input
15
NC
Input
4
GND_SIG_D
16
PWR_OUT_SENS
Output
5
A/C compressor signal
Input
17
J/S shift up SW.
Input
6
Starting switch (IGN-C)
Input
18
Shift mode signal H
Input
7
E.C.S.S. SW.
Input
19
Throttle lock without auto decel
Input
8
LH brake press. sensor
Input
20
––
Input
9
T/M oil temp. sensor
Input
21
GND_SIG_A
10
GND_SIG_D
22
PWR_OUT_5V_0
Output
11
J/S shift down SW.
Input
23
Engine mode SW.
Input
12
SW enabling J/S RH FNR
Input
24
Shift mode signal L
Input
WA500-6
10-459 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
DEUTSCH-40P(1) [CN-L03] Pin No.
Signal Name
Input and Output Signals
Pin No.
Signal Name
Input and Output Signals
1
NC
Output
21
NC
Input and output
2
ECMV fill SW.:4th
Input
22
COMM_CAN_L_O
Input and output
3
ECMV fill SW.:3rd
Input
23
NC
Input and output
4
232C_RxD
Input
24
PWR_CTR_EXT
Input
5
Shift lever:4th
Input
25
Shift lever:2nd
Input
6
Parking brake signal
Input
26
Direction lever: N
Input
7
ECMV fill SW.:1st
Input
27
ECMV fill SW.: F
Input
8
NC
Output
28
J/S or RH FNR seesaw SW.: N
Input
9
NC
Output
29
GND_SIG_P
10
NC
Input
30
NC
11
NC
Output
31
NC
12
NC
32
COMM_CAN_H_O
Input and output
13
ECMV fill SW.:2nd
Input
33
NC
Input and output
14
232_TxD
Output
34
232C_GND
15
Shift lever:3rd
Input
35
Shift lever:1st
Input
16
Direction lever: R
Input
36
Direction lever: F
Input
17
ECMV fill SW.: R
Input
37
J/S or RH FNR seesaw SW.: F
Input
18
NC
Output
38
J/S or RH FNR seesaw SW.: R
Input
19
NC
Output
39
GND_SIG_P
20
Output speed sensor
Input
40
Input speed sensor
10-460 b
Input
Input
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRICAL SYSTEM
DEUTSCH-40P(2) [CN-L04]
Pin No.
Signal Name
Input and Output Signals
Pin No.
Signal Name
1
PWR_IN_BATT
Input
21
GND_PWR
2
PWR_IN_BRY
Input
22
PWR_IN_BRY
3
GND_ACT
23
GND_ACT
4
TM power hold relay
Output
24
PWR_CTR_KEY
Input
5
ECMV:F. clutch
Output
25
ECMV:1st clutch
Output
6
ECMV:2nd clutch
Output
26
ECMV:4th clutch
Output
7
NC
Output
27
Fan pump EPC
Output
8
Indicator with built-in TM cut off SW
Output
28
Fan pump neutral solenoid
Output
9
NC
Input
29
RESUME/DECEL SW
Input
10
TM cut off SW
Input
30
Kick down SW
Input
11
PWR_IN_BATT
Input
31
GND_PWR
12
PWR_IN_BRY
Input
32
GND_PWR
13
GND_ACT
33
GND_PWR
14
PWR_CTR_KEY
Input
34
PWR_OUT_5V_1
Output
15
ECMV:R. clutch
Output
35
ECMV: lock up clutch
Output
16
ECMV:3rd clutch
Output
36
NC
Output
17
E.C.S.S. solenoid
Output
37
Fan pump reverse solenoid
Output
18
Reverse lamp relay
Output
38
NC
Output
19
SET/ACCEL SW
Input
39
LH brake pedal SW
Input
20
TM cut off position set SW
Input
40
Shift hold SW
Input
WA500-6
Input and Output Signals
Input
10-461 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
ELECTRONIC TRANSMISSION CONTROL
10-462 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
1.
Brake valve
2.
Transmission cutoff switch
3.
Transmission cutoff set switch
4.
Relay
5.
Fuse box
6.
Transmission controller
7.
Parking brake switch
8.
Gearshift lever
9.
Directional lever
ELECTRONIC TRANSMISSION CONTROL
10. Speed sensor 11. Transmission control valve 12. Hold switch 13. Kickdown switch 14. Brake pressure sensor
Function No.
Function
1
Selection of travel direction and neutral
The travel direction can be changed by operating the directional lever.
2
Selection of gear speed
The gear speed can be changed by operating the gearshift lever.
3
Kickdown
The gear can be shifted down by pressing the kickdown switch without operating the gearshift lever. In the manual gear shift mode, the gear is shifted down to the 1st only while the transmission is in the forward 2nd. In the auto-shift mode, the gear is shifted down according to the gear speed and travel speed before the switch is pressed.
4
Hold
If the hold switch is pressed in the auto-shift mode, the current gear speed is held and is not shifted up even if the travel speed is increased. Even if the travel speed drops, the gear is not shifted down.
5
Transmission cutoff
While the transmission cutoff selector is ON, the transmission is set in neutral at the adjusted pressing distance of the brake pedal.
6
Transmission cutoff set
The pressing distance of the brake pedal to set the transmission in neutral with the transmission cutoff function can be adjusted.
7
Selection of transmission cutoff
The transmission cutoff function can be turned ON and OFF. While this function is OFF, the left brake pedal works as the ordinary brake (similar to the right brake pedal).
8
Neutralizer
While the parking brake is applied, the transmission is set in neutral. With this function, the machine does not travel while the parking brake is applied; in this manner, seizure of the parking brake is prevented.
9
Neutral safety
While the directional lever is not in neutral, the engine does not start even if the starting switch is operated; in this manner, an accident caused by sudden start of the machine is prevented.
10
Alarm
When the machine travels in reverse, the backup lamp and backup buzzer are turned ON to warn anybody in the vicinity of the machine.
WA500-6
Operation
10-463 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Combination Switch
Outline •
The directional lever has three positions; the gearshift lever switch has four positions.
•
The detent mechanism is not installed to each switch but installed to the body of the combination switch. Each switch is positioned with two pins and fixed to the body with three screws.
•
If each lever is set in a desired position, the switch connected by the shaft operates to supply the current only to the circuit of the desired position.
Function No.
Type
Operation
1
Directional lever switch
Selects the travel direction and neutral.
2
Gearshift lever switch
Selects a gear speed.
3
Gearshift lever stopper
Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4
Turn signal
Turn signal for LH and RH turns
5
Self-cancel
Returns the turn signal lever automatically to neutral when the steering wheel is returned after turning to the right or left.
6
Lamp switch
Selects the clearance lamp, head lamp, parking lamp, etc.
7
Dimmer switch
Selects main beam and low beam.
8
Hazard switch
Flashes turn signals to the left and right simultaneously.
9
Hazard pilot lamp
Flashes while the hazard lamp flashes.
10-464 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Operation •
Shaft (2) of directional and gearshift lever (1) of the combination switch is made one with magnet (3). As lever (1) moves, magnet (3) moves also.
•
Control switch (5), having Hall ICs (4) in it, is installed under magnet (3). Hall ICs (4) are arranged on the board for each position.
•
When the directional lever is set in the F position, magnet (3) comes directly above Hall IC (4) of the F position of the control switch. Magnet (3) magnetizes Hall IC (4) through the clearance and case (6).
•
Hall IC (4) is in the magnetism sensor circuit; it detects the magnetism of magnet (3) and sends the signal of the F position of the directional lever to the current amplifier circuit. The current amplifier circuit outputs the signal to operate the transmission valve.
WA500-6
10-465 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Engine Starting Circuit T
Function •
The neutral safety circuit is used to ensure safety when the engine is started. • • •
•
The engine cannot start while the directional lever is not in N (Neutral). The engine cannot start while the right FNR selector switch (if equipped) is ON or while the right FNR switch is not in N (Neutral). The engine cannot start while the joystick steering (if equipped) is ON or while either of the joystick steering lever FNR switch or joystick steering lever is not in N (Neutral).
The KOMTRAX engine cut circuit is used to prevent the engine from starting when the KOMTRAX receives an engine cut command issued through external operation.
10-466 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Operation •
Starting switch is turned to ON position. •
•
•
If the starting switch is turned to the ON position, terminals B and BR of the starting switch are closed. The current flows from the battery through the starting switch and battery relay coil to the ground; the battery relay contacts are closed. As a result, the power is supplied to each circuit of the machine. The current flows from terminal ACC of the starting switch into the engine controller power relay, operating it to provide the power supply for operation to the engine controller. The engine is ready to start.
Neutral safety circuit •
If the directional lever is set in the N (Neutral) position, the current flows from contact (N) of the directional lever through the exchange relay to the neutral safety relay coil, conducting terminal 3 of the neutral safety relay with terminal 5 of the same relay. • When the joystick steering (if equipped) is used, if the joystick steering armrest is tilted forward and the joystick steering selector switch is turned ON, the current flows from the joystick steering selector switch to the transmission controller to enable the controller. • At this time, if the joystick steering lever FNR switch is not in N (Neutral), the work equipment controller outputs the cutout current. The current flows to the lever relay coil, cutting terminal 3 of the lever relay out from terminal 6 of the same relay. • If the joystick steering lever is not in N (Neutral), the work equipment controller outputs the cutout current. The current flows to the lever relay coil, cutting terminal 3 of the lever relay out from terminal 6 of the same relay. ★ If the joystick steering system is installed, the joystick steering lock switch and joystick steering selector switch are installed instead of the right FNR selector switch indicated in the engine starting circuit diagram. The joystick steering lever FNR switch is installed instead of the right FNR switch. •
•
While the right FNR switch (if equipped) is used (the right FNR selector switch is ON), the current flows from the right FNR selector switch to the transmission controller to enable the controller. At this time, if the FNR switch is not in N (Neutral), the work equipment controller outputs the cutout current. The current flows to the lever relay coil, cutting terminal 3 of the lever relay out from terminal 6 of the same relay.
Starting switch is turned to Start position. •
• •
•
•
If the starting switch is turned to the Start position, the current flows through terminal B of the starting switch, terminal C of the same switch, terminal 3 of the KOMTRAX engine cut relay, terminal 6 of the same relay, terminal 3 of the neutral safety relay, terminal 5 of the same relay, terminal 3 of the lever relay, and terminal 6 of the same relay to the starting motor to start the engine. At the same time, the current flows from terminal C of the starting switch to the engine controller, where the engine speed and coolant temperature signals are processed to optimize the injection rate. When the directional lever is not in N (Neutral), or the right FNR switch is not in N (Neutral) (if the right FNR switch is used), or the joystick steering lever FNR switch is in N (Neutral), and the joystick steering lever is not in N (Neutral) (if the joystick steering is used), the neutral safety relay does not operate and the engine does not start. When the right FNR switch is not in N (Neutral) (if the right FNR switch is used), or the joystick steering lever FNR switch is in N (Neutral), and the joystick steering lever is not in N (Neutral) (if the joystick steering is used), the lever relay does not operate and the engine does not start. When the KOMTRAX controller receives an engine cut command issued through external operation, it grounds terminal 2 of the KOMTRAX engine cut relay to operate the relay. This cuts out the current from terminal 6 of the KOMTRAX engine cut relay to terminal 3 of the neutral safety relay, preventing the engine from starting.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Engine Stopping Circuit
Operation •
If the starting switch is set in the OFF position, the current of the ACC terminal is cut out and the ACC signal to the engine controller is cut out accordingly. The engine controller stops the fuel supply to the engine. As the fuel supply is stopped, the engine slows down and stops.
•
When the alternator stops generating electricity, the voltage supply from the R terminal of the alternator and the current from the BR terminal of the starting switch are cut out. The contact of the battery relay opens and the power supply provided to various circuits in the machine is cut out.
•
About 10 seconds after the starting switch is turned OFF, the current from the engine controller to the two engine controller cut relays is cut out. This turns the relay OFF and cuts out the engine controller operating power supply to prevent unexpected operation.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Preheating Circuit ★ Automatic preheating system
Outline •
The automatic preheating system is installed so that the engine will start easily in a cold district. This system reduces and sets the preheating time according to the engine coolant temperature when the starting switch is operated.
•
When the starting switch is set in the ON position, the current flows to the electrical intake air heater to preheat the intake air.
•
The engine controller determines the preheating time according to the coolant temperature detected by the engine coolant temperature sensor.
•
The preheater pilot lamp, on the main monitor, lights up during preheating. When the preheating is completed, the preheater pilot lamp goes out.
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10-469 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Operation •
When the starting switch is set in the ON position, the engine controller sends signals to operate the heater relay and closes the contact.
•
The current flows from the battery through the battery relay and heater relay to the electrical intake air heater for preheating.
•
When the preheating is completed, the current from the engine controller to the heater relay is cut out and the heater relay contact is opened.
•
During preheating, the current flows through the terminal (BR) of the starting terminal, and terminal 1 and terminal 2 of the preheating relay to the engine controller to energize the coil of the preheating relay. The preheater pilot lamp on the main monitor lights up. ★ When the preheating is completed, the preheater relay turns OFF and the preheater pilot lamp goes out.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Parking Brake Circuit Starting Switch Turned OFF
Operation •
If the starting switch is turned OFF, the contacts of the battery relay open and no current flows to the parking brake circuit.
•
While the starting switch is OFF, the current does not flow into the parking brake solenoid valve and the parking brake is kept applied, regardless of the position of the parking brake switch (whether it is ON (applied) or OFF (released)).
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10-471 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Starting Switch Turned ON ★ When the parking brake switch is turned ON (actuate) before the starting switch is turned ON .
Operation •
Since the parking brake selector switch is ON (actuate), the current flows through the battery relay, contact 6 of the parking brake selector switch, contact 5 of the same switch, and the parking brake safety relay coil to the chassis ground, closing terminal 3 and terminal 5 of the parking brake safety relay. The current from the battery relay keeps flowing into the parking brake relay coil to hold its contacts until the battery relay contacts open and the current does not flow into the parking brake circuit any longer.
•
At this time, the current does not flow into the parking brake solenoid and the parking brake is kept applied.
•
This signal is input to the transmission controller to keep the transmission in neutral and prevent the parking brake from dragging while the parking brake is applied.
•
After that, if the parking brake switch is turned OFF (released), the current flows through the battery relay, parking brake safety relay, contact 4 of the parking brake selector switch, contact 3 of the same switch, emergency brake switch, and the parking brake solenoid to the chassis ground, releasing the parking brake.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
★ When parking brake switch is turned OFF (released) before starting switch is turned ON
Operation •
While the starting switch is OFF, the current does not flow into the parking brake safety relay and its contacts are open.
•
Even if the starting switch is turned ON at this time, the current does not flow into the parking brake solenoid. The parking brake is not released automatically.
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10-473 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Main Brake Oil Pressure Lowers (emergency brake is applied)
Operation •
If the main brake oil pressure drops, the contacts of the emergency brake switch installed to the accumulator open. As a result, the current flowing into the parking brake solenoid valve is stopped and the oil in the parking brake cylinder is drained. The parking brake is applied.
•
In this case, however, unlike the case where the parking brake switch is turned ON (actuate), the transmission is not set in neutral since the parking brake release signal is flowing into the transmission controller.
•
Because of this operation, when the emergency brake is applied, the braking distance can be reduced by using the engine as a brake. Even if the emergency brake is applied, the machine can be moved.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Parking Brake Emergency Release Circuit
Operation •
When the vehicle stops due to engine trouble, the oil pressure from the transmission pump to the parking brake cylinder is cut out, triggering the parking brake. Under this condition, oil pressure in the main brake line is held in the accumulator.
•
When the emergency release switch is turned to ON (released), the buzzer sounds and the current flows to the emergency parking brake release solenoid valve. The oil pressure held in the accumulator of the main brake line flows into the parking brake cylinder, releasing the parking brake.
•
The emergency release switch must be in the OFF position during normal operation and after emergency release is completed.
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10-475 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Backup and Stop Lamp circuit Stop Lamp Circuit
Operation •
When the brake pedal is pressed, the contact of the stop lamp switch is closed to cause the current to flow to the stop lamp relay coil. This closes the contact of the relay to complete the circuit from the fuse through terminal 5 of the stop lamp relay, terminal 3 of the same relay, and the right and left stop lamps to the chassis ground. The right and left stop lamps light up.
•
When the brake pedal is released, the contact of the stop lamp switch is opened. This opens the contact of the stop lamp relay and the stop lamps go out.
•
Because the current flows through the stop lamp circuit when the battery relay operates, the stop lamps do not light up when the starting switch is in the OFF position.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Backup Lamp Circuit
Operation •
Because the current flows through the backup lamp circuit when the battery relay operates, the backup lamps do not light up and the backup buzzer does not sound when the starting switch is in the OFF position.
•
When the directional lever is in the R position When the directional lever is turned to the R position, the transmission controller sends a signal to the backup lamp relay to open its contact. This completes the circuit from the fuse through terminal 5 of the backup lamp relay, terminal 3 of the same relay, and right and left backup lamps to the chassis ground. The right and left backup lamps light up and the backup buzzer sounds.
•
When the right FNR switch is used Even if the directional lever is in N (Neutral), turning the right FNR switch to R causes the transmission controller to send the signal to operate the backup lamp relay. The right and left backup lamps light up and the backup buzzer sounds.
•
When the joystick steering is used When the right FNR switch is used and even if the directional lever is in N (Neutral), turning the joystick steering lever FNR switch to R causes the transmission controller to send the signal to operate the backup lamp relay. The right and left backup lamps light up and the backup buzzer sounds.
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10-477 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Small Lamp and Head Lamp Circuits
Operation •
Because the current flows through the small lamp and head lamp circuits when the battery relay operates, the small and head lamps do not light up when the starting switch is in the OFF position.
•
When the lighting switch is in the Small position When the lighting switch is turned to the Small position, the current flows through the switch and fuse to the front, rear, right, and left small lamps; the lamps light up. The small lamp signal is input to the main monitor and turns the main monitor night lamp on. The circuit supplies the current in the small lamp circuit to the working lamp switch, prohibiting the working lamp from lighting up when the small lamps are off.
•
When the lighting switch is in the Head position When the lighting switch is turned to the Head position, the current flows through the switch and fuse to the small lamp and head lamp circuits. The current flows from the head lamp through the dimmer switch (Hi/Lo selector switch) to the chassis ground. The high beam or low beam selected with the dimmer switch lights up. The high beam signal is input to the main monitor and turns on the high beam pilot lamp on the main monitor.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Working Lamp Circuit
Operation •
The current is supplied to the front and rear working lamp switches from the small lamp circuit.
•
When the working lamp switch is turned ON, the working lamp relay operates to close the contact. The current flows through the fuse, working lamp relay, and working lamp to the chassis ground.
•
The working lamp and the indicator in the working lamp switch light up.
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10-479 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Horn Circuit
Operation •
Because the current flows through the horn circuit when the battery relay operates, the horn does not sound when the starting switch is in the OFF position.
•
When the steering wheel horn switch is pressed The horn relay operates to close the relay contact. The current flows through the fuse, horn, and horn relay to the chassis ground; the horn sounds.
•
When the joystick steering horn switch is pressed The horn relay operates to close the relay contact. The current flows through the fuse, horn, and horn relay to the chassis ground; the horn sounds.
10-480 b
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Wiper and Window Washer Circuits
Operation Because the current flows through the wiper and window washer circuits when the battery relay operates, the wiper and window washer do not operate when the starting switch is in the OFF position. When the starting switch is turned OFF during operation, window washing and wiper action stop. ★ Front wiper circuit •
When the front wiper switch is in the Lo position The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 5 of the same switch to the front wiper motor (Lo). The wiper operates at the low speed.
•
When the front wiper switch is in the Hi position The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 4 of the same switch to the front wiper motor (Hi). The wiper operates at the high speed.
•
When the front wiper switch is in the INT (intermittent) position. The current flows through the fuse, terminal 7 of the front wiper switch, and terminal 2 of the same switch to the wiper relay; the relay contact closes. Then the current flows through the fuse, wiper relay, terminal 3 of the front wiper switch, and terminal 5 of the same switch to the front wiper motor (Lo). The wiper operates at the low speed. The wiper relay repeats the timer-controlled operation where the wiper makes reciprocating motions at intervals of four to six seconds.
WA500-6
10-481 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD •
ELECTRONIC TRANSMISSION CONTROL
When the washer switch is in the ON position The current flows through the fuse and front wiper switch to the washer motor; the washer operates. At the same time, the current flows to the wiper relay and operates the wiper 0.2 – 0.8 seconds after the washer switch is turned ON. The wiper relay moves the wiper two to four times after the washer switch is turned OFF. This operation occurs when the washer switch is turned OFF after it has been ON while the wiper makes more than one reciprocating motion.
•
When the front wiper switch is in the OFF position When the front wiper switch is turned OFF while the wiper is operating, contacts P1 and P2 of the front wiper motor close. The current flows through the fuse, contact P2 of the wiper motor, contact P1 of the same motor, the wiper relay, terminal 3 of the front wiper switch, and terminal 5 of the same switch to the front wiper motor (Lo). The wiper operates. When the wiper comes to the stop position, contacts P1 and P2 of the wiper motor open and the wiper stops.
★ Rear wiper circuit •
When the rear wiper switch is in the Lo position The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 9 of the same switch to the rear wiper motor; the rear wiper operates.
•
When the rear wiper switch is in the Washer position The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 10 of the same switch to the washer motor; the washer operates.
•
When the rear wiper switch is in the Washer or Lo position The current flows through the fuse, terminal 7 of the rear wiper switch, and terminal 9 of the same switch to the rear wiper motor; the rear wiper operates. The current also flows through the fuse, terminal 7 of the rear wiper switch, and terminal 10 of the same switch to the washer motor; the washer operates.
•
When the rear wiper switch is in the OFF position When the rear wiper switch is turned OFF while the wiper is operating, contacts P1 and P2 of the rear wiper motor close. The current flows through the fuse, contact P2 of the wiper motor, contact P1 of the same motor, terminal 8 of the rear wiper switch, and terminal 9 of the same switch to the rear wiper motor; the wiper operates. When the wiper comes to the stop position, contacts P1 and P2 of the wiper motor open and the wiper stops.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Relay
★ 1 = Case, 2 = Base
★ 1 = Case, 2 = Base
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10-483 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Sensors and Switches Input Shaft Speed Sensor Output Shaft Speed Sensor
1.
Magnet
2.
Locknut
3.
Harness
4.
Connector
Function •
The input shaft speed sensor is installed on the transmission unit input shaft; the output shaft speed sensor is installed in the output gear section at the transmission unit. These sensors emit pulse signals according to the gear rotation signal, which are detected by the transmission controller.
•
Signals are converted from pulse to the number of rotations (rpm) in the transmission controller and transmitted to the machine monitor over the network. The rpm is then converted into travel speed and displayed on the machine monitor.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Left Brake Pressure Sensor
1.
Sensor
2.
Lead wire
3.
Connector
Function •
Installed to the brake pilot circuit and detecting brake operating pressure, the left brake pressure sensor is used to set brake pressure for the transmission cutoff function and to operate the function.
★ The brake pressure of this sensor changes when either the right or left brake pedal is pressed.
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10-485 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Transmission Oil Temperature Sensor Torque Converter Oil Temperature Sensor Hydraulic Oil Temperature Sensor Axle Oil Temperature Sensor
1.
Thermistor
2.
Plug
3.
Harness
4.
Connector
Function •
The oil temperature sensors convert changes in temperature into changes in thermistor resistance; each controller detects temperature.
•
The transmission oil temperature sensor detects the internal temperature of the transmission case. The temperature data is used by the transmission controller to select the temperature table of electronic modulation in order to control modulation best matched to the oil temperature.
•
Data from the torque converter oil temperature sensor and hydraulic oil temperature sensor is detected by the machine monitor and indicated on the gauges. At the same time, the data is transmitted to the transmission controller via the network and used as the cooling fan control data.
•
The axle oil temperature sensor detects the internal oil temperature of the rear axle with the monitor and outputs a caution signal when the temperature rises to a high level.
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WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Kickdown Hold Switch
1.
Switch A (white wiring harness)
2.
Spring
3.
Harness
4.
Spring B (yellow wiring harness)
Function •
The kickdown hold switches are installed to the knob of the lift arm control lever. Switch A (1) works as the kickdown switch; switch B (4) works as the hold switch.
•
These switches are installed to the knob of the lift arm control lever when the load meter (if equipped) is installed. Switch A works as the cancel switch; switch B works as the subtotal switch.
•
Switch A (1) and switch B (4) are the automatic-reset type; their contacts are closed only while they are pressed.
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10-487 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Joystick Knob (if equipped)
1.
Horn switch:
Horn sounding switch
2.
Shift down switch:
Selects a gear speed (shift down)
3.
Shift up switch:
Selects a gear speed (shift up)
4.
Directional switch:
Selects the travel direction and neutral
Function •
The directional switch is held at a selected position. The transmission controller shifts gear according to the signal from the directional switch.
•
The shift-up/-down switch selects a circuit only while the switch is pressed. The transmission controller uses this signal for gearshifting operation accordingly.
•
The NC (normally close) side of the shift up/down switch is not connected to the controller.
•
The horn switch operates the relay and sounds the horn while it is pressed.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Right FNR Switch (if equipped)
Function •
The directional switch is held at a selected position.
•
The transmission controller shifts gear according to the signal from the directional switch.
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10-489 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Lift Arm Angle Sensor (if equipped)
1.
Oil seal
2.
Case
3.
Resistor assembly
4.
Brush
5.
Shaft
6.
Connector
Function •
The lift arm angle sensor is installed to the front frame.
•
When the lift arm angle changes, the shaft receives the sliding resistance through the link installed to the lift arm; the lift arm angle is detected from that sliding resistance.
•
The angle sensor is installed on a machine equipped with a load meter or electric work equipment lever.
10-490 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Loader Pump Pressure Sensor Lift Arm Cylinder Bottom Pressure Sensor Lift Arm Cylinder Head Pressure Sensor (Load Meter) (if equipped)
1.
Sensor
2.
Connector
Function •
The loader pump pressure sensor are installed to the inlet port circuit for the control valve.
•
These sensors convert pump discharge pressure to voltage and transmit to the governor pump controller.
Function (lift arm sensors) •
The lift arm sensors are installed on the bottom and rod pipes of the lift arm cylinder.
•
These sensors measure cylinder pressure for loaded/unloaded judgment and load weight calculation.
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10-491 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Operation •
When oil pressure led from the pressure input port applies pressure to the diaphragm of the oil pressure sensor, the diaphragm is deformed by deflection.
•
The gauge layer is installed opposite the diaphragm. Deflection of the diaphragm is converted into output voltage by the resistance of the gauge layer and is sent to the amplifier.
•
After amplifying the voltage, the amplifier transmits the voltage to the governor controller.
•
Relational expression of pressure P (kg/cm² {psi}) and output voltage (V): V = 0.82 {12} x P + 0.5
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Fuel Level Sensor
1.
Connector
2.
Float
3.
Arm
4.
Body
5.
Spring
6.
Contact
7.
Spacer
Function •
The fuel level sensor is installed to the side of the fuel tank.
•
The float moves up and down according to the fuel level. The float moves the variable resistor through the arm.
•
The voltage signal is sent to the machine monitor to indicate the fuel level.
•
When the machine monitor indicator reaches a specified position, the caution lamp is lit.
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10-493 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Parking Brake Pressure Switch Stop Lamp Pressure Switch
1.
Case
2.
Tube
3.
Connector
Function •
When the parking brake is released, oil pressure is fed to the brake piston. The oil pressure operates the pressure switch to turn out the parking brake pilot lamp on the machine monitor.
•
When the foot brake is pressed and the brake operating pressure is generated, the pressure switch contact is closed; the relay is operated; and the stop lamp illuminates.
10-494 b
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Air Cleaner Clogging Sensor
1.
Indicator
2.
Spring
3.
Adapter
Function •
The air cleaner clogging sensor is installed to the air cleaner outlet.
•
If the air cleaner is clogged and the pressure reaches the specified level (negative pressure), the caution lamp on the machine monitor lights up to indicate a warning.
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10-495 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Transmission Clogging Sensor
1.
Body
2.
Tube
3.
Connector
A.
Takeout port on low pressure side
B.
Takeout port on high pressure side
Function •
The clogging sensor is installed to the filter section.
•
If the filter is clogged and the pressure difference between the lower and higher sides reaches a specified level, the switch turns OFF; the maintenance caution lamp lights up. At the same time, a message appears on the character display to warn about the abnormal situation. Operating pressure: . . . . . . . . . . . . . . . . . . . . . 2.80 kg/cm² (40 psi) Principle of switching: . . . . . Differential pressure sliding piston type
10-496 b
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Steering Oil Pressure Sensor Switch
1.
Body
2.
Shaft
3.
Tube
4.
Connector
Function •
The steering oil pressure sensor switch detects the operation of the diverter valve spool, which is tripped to operate when the steering oil pressure drops.
•
If the steering oil pressure drops and the spool operates, the switch piston is turned OFF and the circuit opens.
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10-497 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Radiator Coolant Level Sensor
1.
Stopper
2.
Float
3.
Sensor
4.
Plug
5.
Tube
6.
Connector
Function •
The radiator coolant level sensor is installed on the coolant subtank.
•
If the coolant level drops below the specified level, the float lowers and the switch is turned OFF.
•
The caution lamp on the machine monitor lights up to indicate a warning.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Brake Accumulator Pressure Switch (front and rear)
1.
Case
2.
Tube
3.
Connector
Function •
If the brake accumulator oil pressure drops, the contact OPENs.
•
The caution lamp lights up on the machine monitor to warn about an abnormality.
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10-499 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Battery Electrolyte Level Sensor
1.
Body
2.
Connector
3.
Filter
4.
Packing
5.
Pin
Function •
The battery electrolyte level sensor is installed to the battery.
•
If the battery electrolyte level drops below the specified level, the sensor tip is exposed to air and a voltage signal change is generated.
•
The signal is sent to the machine monitor to warn about the abnormal situation.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Accelerator Pedal Sensor
1.
Pedal
2.
Connector
3.
Sensor
Function •
The accelerator pedal sensor is installed on the surface of the floor.
•
This sensor outputs the accelerator signal or idle validation signal, depending on the accelerator pedal pressing angle.
Accelerator Signal •
The magnitude of the accelerator pedal displacement detected by the sensor is output in variable voltage from No. 2 pin.
Idle Validation Signal •
This sensor detects the accelerator pedal operation.
•
As the accelerator pedal is released, it outputs the signal entered to No. 5 pin from No. 4 pin. As the accelerator pedal is pressed, it outputs the signal entered to No. 6. pin from No. 4 pin.
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10-501 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
Emergency Brake Pressure Switch (front) Emergency Brake Pressure Switch (rear)
1.
Case
2.
Tube
3.
Connector
Function •
When the brake accumulator pressure drops, the switch contact opens.
•
The circuit between the parking brake switch and parking brake solenoid is cut off.
•
The parking brake is tripped to operate.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ELECTRONIC TRANSMISSION CONTROL
MEMORANDUM
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10-503 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
KOMTRAX SYSTEM
KOMTRAX SYSTEM KOMTRAX Terminal System
•
The KOMTRAX terminal sends information about the machine by wireless communication. The KOMTRAX operator refers to this information in the office and can provide different services for the customer. ★ To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
•
The following information can be sent from the KOMTRAX terminal: • • • •
Operation history Service meter Location information Error history
10-504 b
WA500-6
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
KOMTRAX SYSTEM
KOMTRAX Terminal
1.
Communication antenna connector
2.
GPS antenna connector
3.
Machine harness connector (DEUTSCH-40P)
Outline •
The KOMTRAX terminal can acquire machine information with an intermachine network or input signals and transmit the information via a radio communication antenna. Equipped with a CPU (central processing unit), this terminal has radio communication and GPS functions.
•
Use of the KOMTRAX terminal is limited to countries where such communication is allowed.
•
The display monitor has a LED lamp and a 7-segment indicator lamp for testing and troubleshooting.
•
The information of the LED lamp and the 7-segment indicator lamp can be checked on the monitor panel by EMMS.
WA500-6
10-505 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
KOMTRAX SYSTEM
Input and Output Signals DEUTSCH-40P [CN-G01]
Pin No.
Signal Name
Input and Output
Pin No.
Signal Name
Input and Output
1
NC
–
21
Operation mode selection 1
Input
2
NC
–
22
Operation mode selection 2
Input
3
NC
–
23
NC
–
4
NC
–
24
NC
–
5
NC
–
25
NC
–
6
CAN shield GND
–
26
NC
–
7
CAN signal (L)
Input/output
27
Starting switch (C)
Input
8
CAN signal (H)
Input/output
28
Alternator (R)
Input
9
NC
–
29
NC
–
10
NC
–
30
NC
–
11
NC
–
31
NC
–
12
NC
–
32
NC
–
13
NC
–
33
NC
–
14
NC
–
34
NC
–
15
NC
–
35
NC
–
16
NC
–
36
Starting switch (ACC)
Input
17
NC
–
37
Power source (GND)
–
18
NC
–
38
Power source (GND)
–
19
NC
–
39
Constant power source (24 V)
Input
20
Immobilizing signal
Output
40
Constant power source (24 V)
Input
10-506 b
WA500-6
20
STANDARD VALUE TABLES
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Standard Service Value Table for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Standard Service Value Table for Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
WA500-6
20-1 b
STANDARD VALUE TABLES
STANDARD VALUE TABLES
12
STANDARD VALUE TABLES Standard Service Value Table for Engine
Item
Machine Model
WA500-6
Engine
SAA6D140E-5
Measurement Conditions
Unit
High idle Engine speed
Exhaust temperature Intake air pressure (Boost pressure)
Exhaust gas color
Engine coolant temperature: Within operating range
Low idle Engine speed set min. low idle (*1)
2,120 ±50
2,120 ±50
790 ±25
790 ±25
700 ±25
700 ±25
rpm
°C (°F)
Max. 650 (Max. 1202)
700 (Max. 1292)
At rated output
kg/cm² (psi)
Min. 1.18 (Min. 16.82)
0.91 (12.91)
% (Bosch index)
Max. 25 (Max. 2.5)
35 (3.5)
(Bosch index)
Max. 1.5
2.5
Max. 1.0
2.0
0.35 (0.014)
—
Exhaust valve
mm (in)
0.57 (0.022)
—
• At rated output • Engine coolant temperature: Min. 70°C (158°F)
kg/cm² (psi)
Max. 0.030 (0.426)
0.040 (0.569)
Min. 3.47 (Min. 49.31)
2.14 (30.46)
Min. 1.02 (Min. 14.50)
0.82 (11.60)
Engine coolant temperature: Within operating range
At sudden acceleration At rated output
Intake valve
Blow-by pressure
Service Limit Value
• All revolution ranges • Atmospheric temperature: 20°C (68°F)
At high idle Valve clearance
Standard Value for New Machine
Normal temperature
• At rated output • Engine oil temperature: Min. 80°C (176°F) Oil pressure • At low idle • Engine oil temperature: Min. 80°C (176°F)
SAE0W30EOS SAE5W40EOS SAE10W30DH SAE15W40DH SAE30DH
kg/cm² (psi)
Oil temperature
All engine speed ranges (Inside oil pan)
°C (°F)
90 – 110 (194 – 230)
120 (248)
Alternator belt tension
Deflection made by finger pressure of about 98 N (22.03 lbf)
mm (in)
13 – 16 (0.512 – 0.630)
13 – 16 (0.512 – 0.630)
★ *1: Denotes the low idle speed when the engine speed is decreased to the minimum speed with the RPM idle-up/ down selector switch.
20-2 b
WA500-6
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Standard Service Value Table for Chassis
Directional lever
Category
Machine Model
Gearshift lever
Operating effort
Service Limit Value
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
FORWARD, REVERSE N
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
1st 2nd
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
2nd 3rd
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
3rd 2nd
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
2nd 1st
5.9 ±2.9 (1.33 ±0.65)
5.9 ±2.9 (1.33 ±0.65)
HOLD RAISE (*2)
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
RAISE HOLD
Max. 15.2 (Max. 3.42)
Max. 22.9 (Max. 5.15)
HOLD LOWER (*2)
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
LOWER HOLD
—
—
Max. 18.6 (Max. 4.18)
Max. 28.4 (Max. 6.38)
FLOAT HOLD
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
HOLD DUMP
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
HOLD TILT (*2)
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
TILT HOLD
Max. 10.8 (Max. 2.43)
Max. 16.2 (Max. 3.64)
N FORWARD, REVERSE
Measurement Conditions
• Engine stopped • Measure at center of lever knob
Unit
N (lbf)
3rd 4th 4th 3rd
Stroke
Lift arm Operating effort
Work equipment control lever
Standard Value for New Machine
Item
Operating effort
WA500-6
LOWER FLOAT
Bucket
WA500-6
• Engine stopped • Measure at center of lever knob
• Engine speed: Low idle (*1) • Hydraulic oil temperature: Within operating range
N (lbf)
N (lbf)
20-3 b
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Lift arm
Service Limit Value
HOLD RAISE (*2)
40 ±10 (1.575 ±0.394)
40 ±15 (1.575 ±0.591)
HOLD LOWER (*2)
40 ±10 (1.575 ±0.394)
40 ±15 (1.575 ±0.591)
45 ±10 (1.727 ±0.394)
45 ±15 (1.772 ±0.591)
HOLD DUMP
40 ±10 (1.575 ±0.394)
40 ±15 (1.575 ±0.591)
HOLD TILT (*2)
40 ±10 (1.575 ±0.394)
40 ±15 (1.575 ±0.591)
Measurement Conditions
• Engine speed: Low idle (*1) • Hydraulic oil temperature: Within operating range
HOLD FLOAT
Bucket
Play
Steering wheel
Operating effort
Turns (Not including play) Low idle (*1)
Accelerator pedal
Operating time
High idle
Operating effort
Operating angle
Max. 40 (Max. 1.575)
50 – 100 (1.969 – 3.937)
• Flat, level, straight, dry, and paved road • Engine speed: Low idle (Bucket empty) (*1)
N (lbf)
9.8 ±2.0 (2.20 ±0.45)
Max. 19.6 (Max. 4.41)
• Engine speed: High idle • Left lock – right lock
Turns
4.0 ±0.3
Max. 4.5
Max. 6.0
Max. 7.0
Max. 3.5
Max. 4.0
Max. 58.8 (Max. 13.22)
Max. 107.9 (Max. 24.26)
52
—
17
—
Max. 363 ±39.2 (Max. 81.61 ±8.81)
Max. 520.3 (Max. 116.97)
53
—
16 (+1/0)
—
5 ±0.5 (0.197 ±0.020)
—
Max. 2.5 (Max. 0.098)
—
Max. 4.0 (Max. 0.158)
—
2 – 15 (0.079 – 0.591)
—
• Engine started • Hydraulic oil temperature: Within operating range • Left lock – right lock
sec.
• Engine started • Measure at 150 mm (5.91 in) from fulcrum of pedal.
N (lbf)
★ For measuring posture, see Fig. A at
Max. (a3)
end of this section. • Engine speed: Low idle (*1) • Hydraulic oil temperature: Within operating range
Brake pedal
★ For measuring posture, see Fig. B at Max. (a2)
mm (in)
mm (in)
Neutral (a1)
Neutral (a1)
Unit
• Engine stopped • Machine facing straight to front
Operating effort Operating angle
WA500-6 Standard Value for New Machine
Item
Stroke
Work equipment control lever
Category
Machine Model
end of this section. • Engine speed: Low idle (*1) • Hydraulic oil temperature: Within operating range
Play
deg.
N (lbf) deg. mm (in)
Tire
A Fitting of wheel lock ring B Clearance of wheel lock ring
20-4 b
★ For measuring posture, see Fig. C at
C
end of this section. • Tire inflation pressure: Specified pressure
mm (in)
WA500-6
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Category
Machine Model
WA500-6 Standard Value for New Machine
Service Limit Value
P-mode
1,840 ±100
1,840 ±200
E-mode
1,810 ±100
1,810 ±200
2,100 ±100
2,100 ±200
E-mode
2,000 ±100
2,000 ±200
P-mode
1,800 ±100
1,800 ±300
E-mode
1,765 ±100
1,765 ±300
Low idle (*1)
34.06 ±1.53 (484.43 ±21.76)
34.06 ±1.53 (484.43 ±21.76)
High idle
37.12 ± 1.53 (527.94 ±21.76)
37.12 ± 1.53 (527.94 ±21.76)
6.53 ±2.04 (92.82 ±29.01)
6.53 ±2.04 (92.82 ±29.01)
Torque converter outlet port oil pressure
3.98 ±1.02 (56.56 ±14.50)
3.98 ±1.02 (56.56 ±14.50)
Lubrication oil pressure
1.79 ±0.77 (25.38 ±10.88)
1.79 ±0.77 (25.38 ±10.88)
33.04 ±2.04 (469.92 ±29.01)
33.04 ±2.04 (469.92 ±29.01)
2nd
33.45 ±2.04 (475.72 ±29.01)
33.45 ±2.04 (475.72 ±29.01)
3rd
33.45 ±2.04 (475.72 ±29.01)
33.45 ±2.04 (475.72 ±29.01)
4th
32.53 ±2.04 (462.67 ±29.01)
32.53 ±2.04 (462.67 ±29.01)
Lockup
18.97 ±1.53 (269.77 ±21.76)
18.97 ±1.53 (269.77 ±21.76)
Forward
34.47 ±2.04 (490.23 ±29.01)
34.47 ±2.04 (490.23 ±29.01)
Reverse
34.06 ±1.53 (484.43 ±21.76)
34.06 ±1.53 (484.43 ±21.76)
249.83 (+12.03 ) -5.00
) 249.83 (+12.03 -5.00
(3553.43 (+171.14 )) -71.07
(3553.43 (+171.14 )) -71.07
37.93 (+2.04 ) 0
) 37.93 (+2.04 0
(539.54 (+29.01 )) 0
(539.54 (+29.01 )) 0
12.95 ±1.02 (184.20 ±14.50)
12.95 ±2.04 (184.20 ±29.01)
Item
Engine speed
Torque converter stall
Hydraulic stall
Torque converter stall + hydraulic stall
Measurement Conditions
• Engine coolant temperature: Within operating range • Torque converter oil temperature: Within operating range • Hydraulic oil temperature: Within operating range
Unit
P-mode rpm
Main relief pressure
Transmission, torque converter
Torque converter inlet oil pressure
High idle
1st kg/cm² (psi)
ECMV output (clutch) oil pressure
Steering
• Torque converter oil temperature: Within operating range • Engine speed: High idle
• Torque converter oil temperature: Within operating range • Engine speed: Hi idle • Manual switch: ON
Steering relief pressure
• Hydraulic oil temperature: Within operating range • Engine speed: High idle
Orbitrol basic pressure
• Hydraulic oil temperature: Within operating range • Engine speed: High idle • Steering wheel operation
LS pressure
• Hydraulic oil temperature: Within operating range • Engine speed: Low idle • Steering wheel: Stopped
WA500-6
kg/cm² (psi)
20-5 b
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Category
Machine Model Item
Accumulator
Charge cut-in pressure
Charge cut-out pressure
WA500-6
Measurement Conditions
Unit
• Point where brake oil pressure • Engine speed: Low warning lamp idle (*1) goes out kg/cm² • Hydraulic oil (psi) • Point where oil temperature: Within pressure is operating range going up and then starts to go down
Power train
(852.82 (+142.14 )) -71.07
99.93 (+9.99 ) 0
) 99.93 (+14.99 -5.00
(1421.37 (+142.14 )) 0
(1421.37 (+213.21 )) -71.07
12.5 ±0.6 (7.8 ±0.37) {14.2 ±0.7} (8.8 ±0.43)
12.5 ±0.6 (7.8 ±0.37) {14.2 ±0.7} (8.8 ±0.43)
3rd
22.3 ±1.1 (13.9 ±0.68) {23.4 ±1.2} (14.5 ±0.76)
22.3 ±1.1 (13.9 ±0.68) {23.4 ±1.2} (14.5 ±0.76)
34.9 ±1.7 (21.7 ±1.1) {38.8 ±1.9} (24.1 ±1.2)
34.9 ±1.7 (21.7 ±1.1) {38.8 ±1.9} (24.1 ±1.2)
1st
7.3 ±0.4 (4.5 ±0.25)
7.3 ±0.4 (4.5 ±0.25)
2nd
12.5 ±0.6 (7.8 ±0.37) {14.2 ±0.7} (8.8 ±0.43)
12.5 ±0.6 (7.8 ±0.37) {14.2 ±0.7} (8.8 ±0.43)
3rd
20.9 ±1.0 (13.0 ±0.62) {22.2 ±1.1} (13.8 ±0.68)
20.9 ±1.0 (13.0 ±0.62) {22.2 ±1.1} (13.8 ±0.68)
4th
32.1 ±1.6 (19.9 ±1.0) {36.7 ±1.8} (22.8 ±1.1)
32.1 ±1.6 (19.9 ±1.0) {36.7 ±1.8} (22.8 ±1.1)
1st
8.6 ±0.4 (5.3 ±0.25)
8.6 ±0.4 (5.3 ±0.25)
2nd
13.0 ±0.7 (8.1 ±0.43) {15.9 ±0.8} (9.9 ±0.5)
13.0 ±0.7 (8.1 ±0.43) {15.9 ±0.8} (9.9 ±0.5)
3rd
24.8 ±1.2 (15.4 ±0.75) {26.2 ±1.3} (16.3 ±0.81)
24.8 ±1.2 (15.4 ±0.75) {26.2 ±1.3} (16.3 ±0.81)
37.5 ±1.9 (23.3 ±1.2) {43.2 ±2.2} (26.8 ±1.4)
37.5 ±1.9 (23.3 ±1.2) {43.2 ±2.2} (26.8 ±1.4)
8.1 ±0.4 (5.0 ±0.2)
8.1 ±0.4 (5.0 ±0.2)
2nd
13.0 ±0.7 (8.1 ±0.43) {15.1 ±0.8} (9.4 ±0.50)
13.0 ±0.7 (8.1 ±0.43) {15.1 ±0.8} (9.4 ±0.50)
3rd
23.2 ±1.2 (14.4 ±0.75) {25.0 ±1.3} (15.5 ±0.81)
23.2 ±1.2 (14.4 ±0.75) {25.0 ±1.3} (15.5 ±0.81)
4th
35.0 ±1.8 (21.7 ±1.1) {41.0 ±2.1} (25.5 ±1.3)
35.0 ±1.8 (21.7 ±1.1) {41.0 ±2.1} (25.5 ±1.3)
REVERSE 1st
20-6 b
(852.82 (+71.07 )) 0
2nd
km/h (mph)
4th
E-mode • ( ): at lockup
) 59.96 (+9.99 -5.00
7.7 ±0.4 (4.8 ±0.25)
4th
P-mode • ( ): at lockup
59.96 (+5.00 ) 0
7.7 ±0.4 (4.8 ±0.25)
FORWARD
Travel speed (Bucket empty)
Service Limit Value
1st
P-mode • ( ): at lockup
E-mode • ( ): at lockup
Standard Value for New Machine
km/h (mph)
WA500-6
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Category
Machine Model Item
Brake oil pressure
Measurement Conditions
Unit
• Hydraulic oil temperature: Within operating range
Standard Value for New Machine
Service Limit Value
49.97 (+7.04 ) 0
) 49.97 (+8.97 -2.04
(710.68 (+100.08 ) 0
(710.68 (+127.63 ) -29.01
Max. 5.00 (Max. 71.07)
Max. 5.00 (Max. 71.07)
kg/cm² (psi)
Performance
• Tire inflation pressure: Specified pressure • Flat, level, straight, dry, and paved road • Braking initial speed: 20 km/h (12 mph), Braking delay: Within 0.1 sec. • Brake pedal pressing force: Specified pressing force 294 ±29.4 N (66.09 ±6.61 lbf) • Measure braking distance
m (ft)
Max. 4 (13.123)
Max. 4 (13.123)
Disc wear
• Measure with disc wear indicator
mm (in)
0 (0)
Max. 4.0 (0.157)
36.00 ±1.53 (511.98 ±21.76)
36.00 ±1.53 (511.98 ±21.76)
Min. 1.43 (Min. 20.31)
Min. 1.43 (Min. 20.31)
—
Holds in position
Holds in position
mm (in)
3.2 ±0.1 (0.126 ±0.004)
2.77 (0.109)
Wheel brake
Drop in brake pressure
• Engine stopped • Keep brake pedal depressed at 4.9 MPa (710.68 psi) and measure drop in oil pressure after 5 min.
Parking brake
Parking brake inlet pressure
When brake released When brake operated
Performance
• Torque converter oil temperature: Within kg/cm² operating range (psi) • Engine speed: Low idle (*1) • Tire inflation pressure: Specified pressure • Flat paved road with 1/5 (11° 20') grade. Dry, paved road surface • Machine at operating condition • For measuring posture, see Figs. D and E at end of this section.
Disc thickness
Work equipment EPC
WA500-6
EPC valve basic pressure (Orbitrol basic pressure)
• Hydraulic oil temperature: Within operating range • Engine speed: High idle
Lift arm RAISE, • EPC valve FLOAT; Bucket output DUMP, TILT, Lift • pressure arm LOWER •
Work equipment
Work equipment relief pressure
Unload pressure
LS differential pressure
WA500-6
Hydraulic oil temperature: Within operating range Engine speed: High idle Control lever operated fully
kg/cm² (psi)
• Hydraulic oil temperature: Within operating range • Engine speed: High idle • Hydraulic oil temperature: Within operating range • Engine speed: High idle • Work equipment control lever: Neutral • Hydraulic oil temperature: Within operating range • Engine speed: High idle • Lift arm lever: at half stroke
kg/cm² (psi)
37.93 (+2.04 ) 0
) 37.93 (+2.04 -2.04
(539.54 (+29.01 )) 0
(539.54 (+29.01 -29.01))
37.93 (+2.04 ) 0
) 37.93 (+2.04 -2.04
(539.54 (+29.01 )) 0
(539.54 (+29.01 -29.01))
) 37.93 (+2.04 0
) 37.93 (+2.04 -2.04
(539.54 (+29.01 )) 0
(539.54 (+29.01 -29.01))
339.57 (+14.99 ) -5.00
) 339.57 (+14.99 -5.00
(4829.76 (+213.21 )) -71.07
(4829.76 (+213.21 )) -71.07
23.05 ±1.02 (327.79 ±14.50)
23.05 ±2.04 (327.79 ±14.50)
13.97 ±1.02 (198.70 ±14.50)
13.97 ±2.04 (198.70 ±29.01)
20-7 b
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Category
Machine Model Item
Hydraulic drift
Hydraulic drive fan
Proximity switch
Work equipment
Work equipment speed
Lift arm RAISE
20-8 b
Lift arm LOWER
WA500-6 Standard Value for New Machine
Service Limit Value
P-mode
7.2 ±0.5
Max. 8.9
E-mode
8.1 ±0.5
Max. 9.7
P-mode
4.2 ±0.5
Max. 5.4
4.2 ±0.5
Max. 5.4
P-mode
2.5 ±0.3
Max. 3.4
E-mode
2.7 ±0.3
Max. 3.5
P-mode
1.8 ±0.3
Max. 2.6
E-mode
1.9 ±0.3
Max. 2.7
Max. 40 (Max. 1.575)
Max. 40 (Max. 1.575)
Max. 20 (Max. 0.787)
Max. 20 (Max. 0.787)
3–5 (0.118 – 0.197)
—
1,055 ±50
1,055 ±100
170 ±30
170 ±50
180.49 ±25.49 (2567.17 ±362.59)
180.49 ±25.49 (2567.17 ±362.59)
Measurement Conditions • Hydraulic oil temperature: Within operating range • Engine speed: High idle • Apply no load • For measuring posture, see Figs. F and G at end of this section.
Unit
E-mode sec.
• Hydraulic oil temperature: Within operating range • Engine speed: High idle Bucket • Apply no load tilt back Moving bucket • For measuring posture, see from level Figs. H and J at end of this position section. Bucket full stroke
Retraction of lift arm cylinder rod
Retraction of bucket cylinder rod
• Hydraulic oil temperature: Within operating range • Stop engine and leave for 5 minutes, then measure for 15 minutes. • Apply no load to bucket and set lift arm and bucket in level position. • For measuring posture, see Fig. K at end of this section.
Clearance of bucket positioner proximity switch
mm (in)
mm (in)
Max. fan speed
• Engine speed: High idle • Engine coolant temperature: Min. 95°C (Min. 203°F) • Hydraulic oil temperature: Min. 95°C (Min. 203°F) • Torque converter oil temperature: Min. 105°C (Min. 221°F)
Min. fan speed
• Engine speed: Low idle (*1) • Engine coolant temperature: Max. 75°C (Max. 167°F) • Hydraulic oil temperature: Max. 75°C (Max. 167°F) • Torque converter oil temperature: Max. 85°C (Max. 185°F) • Air conditioner OFF
Fan drive pressure
• Engine speed: High idle • Engine coolant temperature: Min. 95°C (Min. 203°F) • Hydraulic oil temperature: Min. 95°C (Min. 203°F) • Torque converter oil temperature: Min. 105°C (Min. 221°F)
rpm
kg/cm² (psi)
WA500-6
STANDARD VALUE TABLES
STANDARD VALUE TABLES
Hydraulic drive fan
Category
Machine Model
WA500-6
Measurement Conditions
Unit
Standard Value for New Machine
Service Limit Value
• Engine speed: High idle • Engine coolant temperature: Min. 95°C (Min. 203°F) Fan reverse solenoid output • Hydraulic oil temperature: pressure Min. 95°C (Min. 203°F) • Torque converter oil temperature: Min. 105°C (Min. 221°F)
kg/cm² (psi)
199.86 ±25.49 (2842.74 ±362.59)
199.86 ±25.49 (2842.74 ±362.59)
Item
★ *1: Denotes the low idle speed when the engine speed is decreased to the minimum speed with the RPM idle-up/down selector switch. ★ *2: The value before the detent
WA500-6
20-9 b
STANDARD VALUE TABLES
MACHINE POSTURE
MACHINE POSTURE (for performance measurement) ★ Fig. A
★ Fig. D
★ Fig. B
★ Fig. E
★ Fig. C
★ Fig. F
20-10 b
WA500-6
STANDARD VALUE TABLES
★ Fig. G
MACHINE POSTURE
★ Fig. K
★ Fig. H
★ Fig. J
WA500-6
20-11 b
STANDARD VALUE TABLES
MACHINE POSTURE
MEMORANDUM
20-12 b
WA500-6
30
TESTING AND ADJUSTING
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Tools for Testing, Adjusting, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Measuring Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 Measuring Exhaust Gas Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Using Handy Smoke Checker (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Using Smoke Meter (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Measuring Exhaust Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Testing Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Measuring Blow-By Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 Measuring Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 Measuring Intake Air (Boost) Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Handling Fuel System Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Releasing Residual Pressure in Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Testing Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27 Testing Fuel Return Rate and Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28 Bleeding Air from Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Testing Leakage in Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 Handling Reduced-Cylinder Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 Handling No-Injection Cranking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 Handling Controller Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 Alternator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 Air Conditioner Compressor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 TRANSMISSION SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38 DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 POWER TRAIN OIL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43 Transmission Main Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43 Torque Converter Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 Torque Converter Outlet Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 Lockup Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46 F (Forward) Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47 R (Reverse) Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48 1st Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 2nd Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 3rd Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51 4th Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 WA500-6
30-1 b
TESTING AND ADJUSTING
TABLE OF CONTENTS
Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54 Transmission Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54 Torque Converter Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54 FLUSHING TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55 Torque Converter and Transmission Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 30-55 WHEN TRANSMISSION VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 Moving Machine when Transmission Valve is Broken . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 Steering Stop Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 Measuring Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 Measuring Operating Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63 Measuring Operating Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64 Steering Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65 Measuring Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65 Measuring Pilot Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67 Measuring LS Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68 Adjusting Steering Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69 Bleeding Air From Steering Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70 HYDRAULIC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71 Measuring Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71 Measuring Fan Drive Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72 Measuring Fan Reverse Solenoid Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73 Bleeding Air from Hydraulic Drive Fan Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 Measuring Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 Measuring Brake Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77 Accumulator Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78 Testing Wheel Brake Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 Measuring Wear of Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83 Bleeding Air from Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 Bleeding Air from Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 Bleeding Air from Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86 Releasing Residual Pressure in Brake Accumulator Circuit . . . . . . . . . . . . . . . . . . . . . 30-87 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 Testing Parking Brake Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 Measuring Parking Brake Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89 Testing Wear of Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93 Releasing Parking Brake Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 Measuring Operating Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 Measuring Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95 PPC Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 Shutoff Valve Basic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 Shut-off Valve Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98 30-2 b
WA500-6
TESTING AND ADJUSTING
TABLE OF CONTENTS
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99 Preparation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99 Measuring Work Equipment Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99 Measuring Unload Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100 Measuring LS Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101 Adjusting Unload Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 Adjusting Work Equipment Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 Adjusting LS Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 Bleeding Air from Work Equipment Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 From Work Equipment Pump (piston pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 From Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 Releasing Residual Pressure in Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107 Between Respective Hydraulic Cylinders and Control Valve . . . . . . . . . . . . . . . . . 30-107 From ECSS (Travel Damper) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107 Moving Machine When Removing Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108 Bucket Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 Adjusting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109 Adjusting Bucket-Levelness Detecting Proximity Switch . . . . . . . . . . . . . . . . . . . 30-110 Adjusting Maximum Tilt-Detecting Proximity Switch . . . . . . . . . . . . . . . . . . . . . . 30-111 Position-Detecting Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112 Checking Proximity Switch Operation Pilot Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Procedure for Testing Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Using Digital-Type Circuit Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Using Analog-Type Circuit Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115 Preparation Work for Troubleshooting Electrical System . . . . . . . . . . . . . . . . . . . . . . . 30-116 Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 Transmission Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117 Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 KOMTRAX TERMINAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-119 Starting KOMTRAX Terminal Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-119 Station Opening Check in Machine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-119 Application for the Start of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123 KOMTRAX Terminal Indicator Lamps (if equipped) . . . . . . . . . . . . . . . . . . . . . . 30-124 MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127 Adjusting Replaced, Reassembled, or Added Sensors and Controllers . . . . . . . . . . . . 30-127 Adjustment for User’s Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128 Normal and Special Functions of Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129 Normal Functions: Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129 Special Functions: Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129 Functions and Flow of Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130 Operator Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133 Service Meter/Clock Display Function (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133 Load Meter Function (if equipped) (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133 Odometer Display Function (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133 Maintenance Monitoring Function (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 WA500-6
30-3 b
TESTING AND ADJUSTING
TABLE OF CONTENTS
Telephone Number Input Function (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 Language Selection Function (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 Monitor Brightness Adjustment Function (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 Time Adjustment Function (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135 Travel Speed/Engine Speed Display Selecting Function (9) . . . . . . . . . . . . . . . . . . 30-135 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10) . . . . . . 30-135 Action Code Display Function (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136 Failure Code Display Function (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136 Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138 Switching to Service Mode and Screen Display (1) . . . . . . . . . . . . . . . . . . . . . . . . 30-138 Electrical System Failure History Display Function (ELECTRIC FAULT) (2) . . . 30-140 Mechanical System Failure History Display Function (MACHINE FAULT) (3) . 30-142 Real-Time Monitoring Function (REAL-TIME MONITOR) (4) . . . . . . . . . . . . . . 30-143 Real-Time Monitoring Codes Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146 Cylinder Cutout Function (CYLINDER CUT-OUT) (5) . . . . . . . . . . . . . . . . . . . . 30-171 No-Injection Cranking Function (NO INJECTION) (6) . . . . . . . . . . . . . . . . . . . . . 30-172 Adjustment Function (TUNING) (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173 Maintenance Monitoring Function (MAINTENANCE MONITOR) (8) . . . . . . . . 30-204 Operating Information Display Function (OPERATION INFO) (9) . . . . . . . . . . . 30-209 Optional Device Selecting Function (OPTIONAL SELECT) (10) . . . . . . . . . . . . . 30-212 Machine Serial Number Input Function (MACHINE No. SET) (11) . . . . . . . . . . . 30-216 Model Selection Function (MACHINE WA500) (12) . . . . . . . . . . . . . . . . . . . . . . 30-217 Initialize Function (INITIALIZE) (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218 PM CLINIC INSPECTION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
30-4 b
WA500-6
TESTING AND ADJUSTING
TOOLS
TOOLS Tools for Testing, Adjusting, and Troubleshooting Testing and Adjusting Item Measuring exhaust gas color
Symbol
Part No.
Part Name
Qty
Remarks
1
799-201-9001
Handy smoke checker
1
Bosch index: Level 0 – 9
2
Commercially available
Smoke meter
1
–
A
Measuring exhaust temperature
B
799-101-1502
Digital thermometer
1
-99.9 – 1,299 °C (-147.82 – 2,370.20 °F)
Adjusting valve clearance
C
Commercially available
Clearance gauge
1
–
795-502-1590
Compression gauge
1
0 – 7 MPa (0 – 1,015.26 psi)
795-471-1330
Adapter
1
–
6261-71-6150
Gasket
1
–
799-201-1504
Blow-by checker
1
0 – 5 kPa (0 – 0.73 psi)
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-401-2320
Hydraulic tester
1
Pressure gauge: 1 MPa (145.04 psi)
799-201-2202
Boost gauge kit
1
-101 – 200 kPa (-14.65 – 29.01 psi)
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
2
799-401-2320
Hydraulic tester
1
Pressure gauge: 1 MPa (145.04 psi)
3
795-471-1450
Adapter
1
8 × 1.25 mm R1/8
1
6151-51-8490
Spacer
1
Inside diameter: 10 mm
2
6206-71-1770
Joint
1
Inside diameter of joint: 10 mm
3
Commercially available
Hose
1
5mm x 2 – 3 m
4
Commercially available
Hose
1
5mm x 2 – 3 m
5
Commercially available
Measuring cylinder
1
–
6
Commercially available
Stopwatch
1
–
1 Testing compression pressure
D 2
Measuring blow-by pressure
Measuring engine oil pressure
E
1 F
2 Measuring intake air (boost) pressure
G
1 Testing fuel pressure
Testing return rate and leakage
WA500-6
H
J
30-5 b
TESTING AND ADJUSTING Testing and Adjusting Item
TOOLS
Symbol
Part No.
Part Name
Qty
Remarks
K
79A-264-0021
Push-pull scale
1
0 – 294 N (0 – 66.09 lbf)
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
10 x 1.25 mm
07002-11023
O-ring
1
Pressure gauge: 1 MPa (145.04 psi)
Measuring directional lever (steering wheel specification)
1 Testing and adjusting power train oil pressure
L
2 Method of moving machine when transmission is broken
M
794-423-1190
Plug
1
20 x 1.5 mm
Testing and adjusting steering wheel
N
79A-264-0021
Push-pull scale
1
0 – 294 N (0 – 66.09 lbf)
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
3
799-401-3200
Adapter
1
Size 03
4
799-401-2701
Differential pressure gauge
1
–
1
799-205-1100
Tachometer kit
1
Digital display: 6 – 99999.9 rpm
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
799-401-3500
Adapter
1
Size 06
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.60, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
1
Testing steering oil pressure
Q 2
2 Testing hydraulic drive fan
R
3 4
1 Bleeding air from hydraulic drive fan circuit
S
2
30-6 b
WA500-6
TESTING AND ADJUSTING Testing and Adjusting Item Bleeding air from hydraulic drive fan circuit
Symbol
Part No.
Part Name
Qty
Remarks
3
799-401-3500
Adapter
1
Size 06
4
790-261-1130
Coupling
1
–
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
1
793-520-1821
Nipple
1
–
2
793-520-1810
Joint
1
–
3
385-101-78481
Bleeder screw
1
–
4
793-520-1831
Gauge assembly
1
G1/4 R1/8
Commercially available
Slide calipers
1
–
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
799-401-3100
Adapter
1
Size 02
Commercially available
Slide calipers
1
–
1
79A-264-0021
Push-pull scale
1
–
2
Commercially available
Scale
1
–
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-401-3200
Adapter
1
S
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
TOOLS
T
U
Measuring wear of wheel brake disc
V
1 Measuring parking brake oil pressure
W 2 3
Testing wear of parking brake disc Measuring and adjusting work equipment lever
Testing and adjusting work equipment PPC oil pressure
X
Y
1 Z
2
WA500-6
Size 03
30-7 b
TESTING AND ADJUSTING Testing and Adjusting Item
Symbol
TOOLS Part No.
Part Name
Qty
Remarks
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
3
799-401-2701
Differential pressure gauge
1
–
4
799-401-3200
Adapter
1
Size 03
799-101-1502
Digital thermometer
1
–
79A-264-0021
Push-pull scale
1
0 – 294 N (66.09 lbf)
79A-264-0091
Push-pull scale
1
0 – 490 N (110.16 lbf)
1
Measuring work equipment oil pressure
ZA 2
Measuring coolant and oil temperature
—
Measuring operating effort and pressing force
—
Measuring stroke and hydraulic lift
—
Commercially available
Scale
1
–
Measuring work equipment speed
—
Commercially available
Stopwatch
1
–
Measuring voltage and resistance
—
Commercially available
Circuit tester
‘
–
★ For the model names and part numbers of the T-adapters and boxes used for troubleshooting of the controllers, sensors, actuators, and wiring harnesses, see the T-Branch Box and T-Branch Adapter Table in the Troubleshooting section.
30-8 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
ENGINE COMPONENTS Remark See the Engine Shop Manual for additional information regarding testing and adjusting procedures.
Measuring Engine Speed WARNING!
Put chocks securely under the tires. Make sure that there is nobody near the machine.
★ Measure the engine speed under the following conditions. Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Torque converter oil temperature:. . . . . . . . .Within operating range
1.
Measure engine speed (low idle and high idle). A. Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. B. Select and display “ENG SPEED” from the monitoring items of the machine monitor. ★ Monitoring item: Code No. 01001: ENG SPEED (Engine speed) C. Start the engine; set it to the measurement condition; and measure the engine speed.
2.
Measure torque converter stall speed. A. Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. B. Select the two-item simultaneous monitoring (2 ITEMS) and enter the following code numbers directly. ★ Monitoring items: [1] Code No. 01001: ENG SPEED (Engine speed) [2] Code No. 40100: TC OIL TEMP (Torque converter oil temperature) C. Start the engine. D. Turn off the transmission cutoff switch and press the left brake pedal securely. E. Set the transmission auto-shift and manual shift selector switch in the MANUAL position. F.
Set the gearshift lever or gearshift switch to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
WA500-6
30-9 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
G. Release the parking brake. H. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position. WARNING!
I.
3.
Keep pressing the brake pedal securely.
While running the engine at high idle, press the accelerator pedal gradually. When the torque converter stalls, measure the engine speed. • Measure the stall speed two to three times. • Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does not exceed 120° C (248° F). • Measure the torque converter stall speed when the power mode and economy mode are turned on.
Measure hydraulic stall speed. A. Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. B. Select the two-item simultaneous monitoring (2 ITEMS) and then enter the following code numbers directly. ★ Monitoring items: [1] Code No. 01001: ENG SPEED (Engine speed) [2] Code No. 04401: HYD TEMP (Hydraulic oil temperature) C. Run the engine at high idle. D. Relieve the lift arm cylinder or bucket cylinder on the extraction side and measure the engine speed. • Measure the hydraulic stall speed when the power mode and economy mode are turned on.
4.
Measure torque converter stall and hydraulic stall (full stall) speed. A. Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. B. Select the two-item simultaneous monitoring (2 ITEMS) and then enter the following code numbers directly. ★ Monitoring items: [1] Code No. 01001: ENG SPEED (Engine speed) [2] Code No. 40100: TC OIL TEMP (Torque converter oil temperature) C. Start the engine. D. Turn off the transmission cutoff switch and press the left brake pedal securely.
30-10 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
E. Set the transmission auto-shift and manual shift selector switch in the MANUAL position. F.
Set the gearshift lever to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
G. Release the parking brake. H. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position. WARNING!
I.
Keep pressing the brake pedal securely
While running the engine at high idle, stall the torque converter and relieve the lift arm cylinder or bucket cylinder on the extraction side simultaneously. Measure the engine speed at this time. • Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does not exceed 120° C (248° F). • Measure the full stall speed when the power mode and economy mode are turned on.
WA500-6
30-11 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
Measuring Exhaust Gas Color Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
1
799-201-9001
Handy smoke checker
1
Bosch index: Level 0 – 9
2
Commercially available
Smoke meter
1
–
A
WARNING!
Be careful that you do not touch the hot exhaust stack when installing and removing the measuring instruments. Be sure to wear a protective mask to avoid breathing in the exhaust gas.
★ If an air source and an electric power source are not available in the field, use handy smoke checker A1. ★ When recording official data, use smoke meter A2. ★ Measure the exhaust gas color under the following condition. Engine coolant temperature: . . . . . . . . . . . .Within operating range
Using Handy Smoke Checker (A1) 1.
Stick a sheet of filter paper to smoke checker A1.
2.
Insert the exhaust gas intake pipe into the muffler (exhaust pipe).
3.
Start the engine and raise the engine coolant temperature to the operating range.
4.
Accelerate the engine suddenly and run it at high idle. Operate the handle of smoke checker A1 so that the filter paper absorbs the exhaust gas.
5.
Remove the filter paper and compare it with the attached scale to obtain a value.
6.
Remove the measurement tool after completing the measurement and confirm that the machine is back to normal condition.
Using Smoke Meter (A2) 1.
Insert the probe of smoke meter A2 into the outlet of the muffler (exhaust pipe) and use a clip to attach the probe to the exhaust pipe.
2.
Connect the probe hose, accelerator switch receptacle, and air hose to smoke meter A2. ★ Keep the pressure of the supplied compressed air at 15.3 kg/cm² (218 psi) or lower.
3.
Connect the power cable to a 100 V AC receptacle. ★ Confirm that the smoke meter power switch is in the OFF position before connecting the power cable to an outlet.
30-12 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
4.
Loosen the cap nut of the suction pump and fit the filter paper. • Fit the filter paper securely so that the exhaust gas does not leak.
5.
Turn on the power switch of smoke meter A2.
6.
Start the engine and keep it running until the engine coolant temperature reaches the operating range.
7.
Accelerate the engine suddenly or run it at high idle and press the accelerator pedal of smoke meter A2. Collect the exhaust gas in the filter paper.
8.
Put the polluted filter paper on non-polluted filter paper (more than ten sheets) in the filter paper holder and read the indicated value.
9.
After completing the work, remove the measurement tool and confirm that the machine is back to normal condition.
WA500-6
30-13 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
Measuring Exhaust Temperature Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
B
799-101-1502
Digital thermometer
1
-99.9 – 1,299 °C (-147.82 – 2,370.20 °F)
WARNING!
Make sure that the exhaust manifold is cool before you install and remove the measurement instruments.
★ Measure the exhaust gas temperature under the following conditions. Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Torque converter oil temperature:. . . . . . . . .Within operating range
1.
Open the engine left side cover.
2.
Remove exhaust temperature pickup plug (1) (R1/8) at the bottom of the exhaust manifold. ★ You may measure at either the front or rear plug.
3.
Install sensor [1] of digital thermometer B and connect them to meter [2]. ★ Be careful that the wiring harness of the digital thermometer does not touch a hot part during measurement.
4.
Procedure for periodic measurement done in preventive maintenance ★ To prevent the torque converter from overheating, increase the exhaust temperature once through full-stall operation (torque converter stall + hydraulic stall), and then measure the exhaust temperature while only the torque converter is stalled. A. Start the engine and raise the coolant temperature to the operating range. B. Turn off the transmission cutoff switch and press the left brake pedal securely. C. Set the transmission auto-shift and manual shift selector switch in the MANUAL position. D. Set the gearshift lever or gearshift switch to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
30-14 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
E. Release the parking brake. F.
While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position. WARNING!
Keep pressing the brake pedal securely.
G. Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the torque converter and relieve the lift arm cylinder or bucket cylinder on the extraction side simultaneously (full stall). • Increase the exhaust temperature to about 650°C (1202°F) (the state of (a) in the figure). • Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does not exceed 120°C (248°F). H. As the exhaust temperature reaches about 650°C (1202°F), release the hydraulic relief and then lower the exhaust temperature by stalling only the torque converter (the state of (b) in the figure). ★ The exhaust temperature starts lowering from the level of the full-stall operation. • Measure the exhaust temperature as it stabilizes (the state of (c) in the figure). • If the exhaust temperature rises instead of going down, set a higher full-stall temperature than the current one (650°C {1202°F}). 5.
Procedure for measuring the maximum exhaust temperature A. Operate the machine and measure the maximum exhaust temperature. ★ Use the PEAK mode of the thermometer (in which the maximum value can be saved). ★ The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). •
If any abnormal value is obtained, correct it by using the following calculation: Corrected value [°C] = Measured value + 2 x (20 – Outside air temperature)
6.
After completing the work, remove the measurement tool and confirm that the machine is back to normal condition.
WA500-6
30-15 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
Adjusting Valve Clearance Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
C
Commercially available
Clearance gauge
1
–
1.
Remove six cylinder head covers (1). ★ For details, see ENGINE AND COOLING SYSTEM: Cylinder Head in the Disassembly and Assembly section. ★ The shape of the engine shown in this photo is not identical with that of the SAA6D140E-5 engine installed in the WA500-6.
2.
Rotate the crankshaft forward to bring the stamped “1.6TOP” line (a) of the damper to pointer (2) and set the No. 1 cylinder to the compression top dead center. A. Rotate the crankshaft with the hexagonal part at the end of the water pump drive shaft. B. When the No. 1 cylinder is at the compression top dead center, you can use your hand to move the rocker arm of the No. 1 cylinder by the valve clearance. If the rocker arm cannot be moved, rotate the crankshaft one more turn.
3.
While fixing adjustment screw (3), loosen locknut (4). ★ After setting the No. 1 cylinder to the compression top dead center, adjust the valve clearance of the No. 1 cylinder.
4.
Insert clearance gauge C in the clearance between rocker arm (5) and crosshead (6). Adjust the valve clearance with adjustment screw (3). A. With the clearance gauge inserted, turn the adjustment screw so that a light force is sufficient to move the clearance gauge. ★ Valve clearance: Intake valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm Exhaust valve: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.57 mm
5.
While fixing adjustment screw (3), tighten locknut (4). Locknut: 45.1 – 51.0 N•m (33 – 38 lbf ft)
★ After tightening the locknut, check the valve clearance again.
30-16 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
6.
After adjusting the No. 1 cylinder, rotate the crankshaft forward by 120° and adjust the clearance of each cylinder according to the firing order. ★ Firing order: 1 – 5 – 3 – 6 – 2 – 4
7.
After finishing the adjustment, return the parts you removed. Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (22 – 25 lbf ft)
WA500-6
30-17 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
Testing Compression Pressure Special Tools Required Symbol 1 D
Part No.
Part Name
Qty
Remarks
795-502-1590
Compression gauge
1
0 – 7 MPa (0 – 1,015.26 psi)
795-471-1330
Adapter
1
–
6261-71-6150
Gasket
1
–
2
WARNING!
When measuring the compression pressure, be careful not to burn yourself on the exhaust manifold or muffler. Be careful not to get caught in a rotating part.
★ Measure the compression pressure after the engine is warmed up. Engine oil temperature: . . . . . . . . . . . . . . 40 – 60°C (104 – 140°F)
1.
Remove cylinder head cover (1) of the cylinder whose compression pressure you want to check. ★ For details, see ENGINE AND COOLING SYSTEM: Cylinder Head in the Disassembly and Assembly section. ★ The shape of the engine shown in this photo is not identical with that of the SAA6D140E-5 engine installed in the WA500-6.
2.
Set the target cylinder to be inspected to the compression top dead center and then remove rocker arm assembly (2). ★ See ENGINE COMPONENTS: Adjusting Valve Clearance in this section.
3.
Disconnect fuel high-pressure tube (3) and the injector wiring harness and remove injector (4). • Disconnect the terminal of the injector wiring harness on the injector side and the bracket on the rocker housing side and remove the injector wiring harness from the injector. ★ Loosen the two terminal nuts alternately. • Eliminate the slack of the injector wiring harness and press it against the injector body so that it does not interfere with the rocker arm. Nuts: 2 ±0.2 N•m (18±2 lbf in)
•
Pass a wire, etc. under the fuel path projected sideways and pull up the injector. ★ Do not pry up the injector top.
30-18 b
WA500-6
TESTING AND ADJUSTING 4.
ENGINE COMPONENTS
Install adapter D2 to the mounting hole on the injector and compression gauge D1. • Fit the gasket to the injector end. • Fix the adapter with the injector holder. Holder mounting bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
★ Apply a small amount of engine oil to the connecting parts of the adapter and gauge so that air does not leak easily. 5.
Install rocker arm assembly (2) and adjust the valve clearance. Rocker arm assembly mounting bolt: 93 – 103 N•m (69 – 76 lbf ft)
★ See ENGINE COMPONENTS: Adjusting Valve Clearance in this section. 6.
Set the mode to the no-injection cranking operation. ★ See MACHINE MONITOR SYSTEM: Service Mode: No-Injection Cranking Function (NO INECTION) in this section. WARNING!
Be sure to set the no-injection cranking mode, otherwise the engine may start and create a dangerous condition.
7.
Rotate the engine cranking with the starting motor and measure the compression pressure. • Read the pressure gauge pointer when it is stabilized.
8.
After finishing testing, remove the testing tools and return the parts you removed. A. Install the injector and fuel high-pressure tube according to the following procedure. i.
Use your hand to push in injector (11) to assemble holder (12) temporarily.
ii.
Tighten bolt (13) and washer (14) temporarily. Spherical portion of washer: Engine oil
iii. Tighten sleeve nut (15) of the fuel high-pressure tube temporarily. iv. Tighten bolt (13) permanently. Bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
v.
Tighten sleeve nut (15) permanently. Sleeve nut: 39.2 – 49.0 N•m (29 – 36 lbf ft)
WA500-6
30-19 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
B. Install the injector wiring harness according to the following procedure. i.
Install the injector wiring harness to the rocker arm housing and fix the connector side with the plate.
ii.
Fix the clamp in the intermediate position with the clip.
iii. Tighten the nut on the injector side. Nut: 2 ±0.2 N•m (18 ±2 lbf in)
iv. Secure the clamp and spacer with the bolt. Rocker arm assembly mounting bolt: 93 – 103 N•m (68.59 – 75.97 lbf ft)
C. Adjust the valve clearance. See ENGINE COMPONENTS: Adjusting Valve Clearance in this section. Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (22 – 25 lbf ft)
30-20 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
Measuring Blow-By Pressure Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
E
799-201-1504
Blow-by checker
1
0 – 5 kPa (0 – 0.73 psi)
★ Measure the blow-by pressure under the following conditions. Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Torque converter oil temperature: . . . . . . . .Within operating range
1.
Stop the engine. Install nozzle [1] and hose [2] of blow-by checker E to blow-by hose (1) and connect them to gauge [3].
2.
Start the engine and increase the engine coolant temperature to the operating range.
3.
Drain oil in the hose while running the engine at medium speed or higher. • Insert approximately half of the gauge and hose connection to the hose and then repeat opening the self-seal of the hose to drain the oil. ★ If Pm kit (A) is available, the air bleeding coupling (790-261-1130) in it may be used. • If oil is left in the hose, the gauge does not work. Be sure to drain the oil.
4.
Turn off the transmission cutoff switch and press the left brake pedal securely.
5.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
6.
Set the gearshift lever or gearshift switch to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Release the parking brake.
8.
While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position. WARNING!
WA500-6
Keep pressing the brake securely.
30-21 b
TESTING AND ADJUSTING 9.
ENGINE COMPONENTS
Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the torque converter and measure the blow-by pressure. ★ Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does not exceed 120°C (248°F). ★ Normally the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. ★ If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output. ★ Precaution for measuring blow-by pressure: The blow-by pressure may vary depending on the condition of the engine. If you determine that the measured value is abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, rapid deterioration speed of oil, etc. which are related to the abnormal blow-by pressure.
10. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-22 b
WA500-6
TESTING AND ADJUSTING
ENGINE COMPONENTS
Measuring Engine Oil Pressure Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
799-401-2320
Hydraulic tester (gauge)
1
1 F 2
Pressure gauge: 60 MPa (8,702.26 psi) Pressure gauge: 1 MPa (145.04 psi)
★ Measure the engine oil pressure under the following condition. Engine coolant temperature: . . . . . . . . . . . .Within operating range
1.
Open the engine right side cover.
2.
Remove engine oil pressure pickup plug (1) (R1/4) on the cylinder block.
3.
Install nipples [1] and [2] of hydraulic tester F and connect them to hydraulic tester F2. ★ Quick nipple (799-101-5210) is usable since the plug hole size is R1/4.
4.
Start the engine and raise the coolant temperature to the operating range.
5.
While running the engine at low or high idle speed, measure the engine oil pressure.
6.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition. Oil pressure pickup plug: 45 – 49 N•m (33 – 36 lbf ft)
WA500-6
30-23 b
TESTING AND ADJUSTING
ENGINE COMPONENTS
Measuring Intake Air (Boost) Pressure Special Tools Required Symbol G
2
Part No.
Part Name
Qty
Remarks
799-201-2202
Boost gauge kit
1
-101 – 200 kPa (-14.65 – 29.01 psi)
WARNING!
When installing and removing the measurement instruments, be careful that you do not touch a hot part of the engine.
★ Measure the intake air pressure (boost pressure) under the following conditions. Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Torque converter oil temperature: . . . . . . . .Within operating range
1.
Remove radiator top cover (1).
2.
Remove cover (2) between the engine and cooling.
3.
Remove exhaust temperature pickup plug (3) (R1/8) in the rear side of the air intake manifold.
30-24 b
WA500-6
TESTING AND ADJUSTING 4.
Install nipple [1] in boost gauge kit G and connect pressure gauge [2].
5.
Start the engine.
6.
Turn off the transmission cutoff switch and press the left brake pedal securely.
7.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
8.
Set the gearshift lever or gearshift switch to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
9.
Release the parking brake.
ENGINE COMPONENTS
10. While pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position. WARNING!
Keep pressing the brake pedal securely.
11. Press the accelerator pedal gradually to the high idle. While running the engine at high idle, stall the torque converter and measure the intake air pressure (boost pressure). ★ Do not stall the torque converter for more than 20 seconds. Be careful that the torque converter oil temperature does not exceed 120°C (248°F). 12. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-25 b
TESTING AND ADJUSTING
FUEL SYSTEM
FUEL SYSTEM Handling Fuel System Equipment Precautions for Testing and Maintaining Fuel System The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause problems. When testing and maintaining the fuel system, be very careful. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for Replacement of Fuel Filter Cartridge You must use a genuine Komatsu fuel filter cartridge. The fuel injection pump and nozzle of the common rail-type fuel injection system (CRI) consist of more precise parts than those used for the current pumps and nozzles. This system uses a special filter with a highly efficient filtering performance to prevent mixing of foreign substances. Substituting it with a non-genuine filter could cause problems in the fuel system. It is strictly prohibited to use a substitute part.
Releasing Residual Pressure in Fuel System Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: . . . . . Feed pump – Fuel filter – Supply pump High-pressure circuit: . . . . . Supply pump – Common rail – Injector
The pressure in both the low-pressure circuit and high-pressure circuit drops to a safety level automatically 30 seconds after the engine is stopped. ★ Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Observe the following warning. WARNING!
30-26 b
Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. Do not start the work immediately after stopping the engine since there is residual pressure in the fuel circuit.
WA500-6
TESTING AND ADJUSTING
FUEL SYSTEM
Testing Fuel Pressure Special Tools Required Symbol
Part No.
Part name
Qty
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
2
799-401-2320
Hydraulic tester
1
Pressure gauge: 1 MPa (145.04 psi)
3
795-471-1450
Adapter
1
8 × 1.25 mm R1/8
1 H
Remarks
★ Test only the fuel pressure in the low-pressure circuit (between the feed pump, fuel filter, and supply pump). WARNING!
You must not check the pressure check in the high pressure circuit between the supply pump, common rail, and injector because extremely high pressure is generated there.
1.
Open the engine right side cover.
2.
Remove fuel pressure pickup plug (1) on the fuel filter head.
3.
Install adapter H3 and 90° elbow [1] and nipple [2] of hydraulic tester H1. Connect them to hydraulic tester H2.
4.
Run the engine at high idle and measure the fuel pressure. ★ If the fuel pressure is in the following range, it is normal.
5.
Engine Speed
Fuel Pressure
High idle
1.53 – 3.06 kg/cm² (22 – 44 psi)
After completing the test, remove the testing tools and return the parts you removed.
WA500-6
30-27 b
TESTING AND ADJUSTING
FUEL SYSTEM
Testing Fuel Return Rate and Leakage ★ Engine with intake manifold equipped with return block Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
1
6151-51-8490
Spacer
1
Inside diameter: 10 mm
2
6206-71-1770
Joint
1
Inside diameter of joint: 10 mm
3
Commercially available
Hose
1
5mm x 2 – 3 m
4
Commercially available
Hose
1
5mm x 2 – 3 m
5
Commercially available
Measuring cylinder
1
–
6
Commercially available
Stopwatch
1
–
J
Required •
Container to hold the fuel which flows out during inspection: 20 l (5.28 gal)
30-28 b
WA500-6
TESTING AND ADJUSTING 1.
FUEL SYSTEM
Preparation work A. Open the engine right side cover. B. Remove tube (3) between common rail (1) and supply pump (2).
C. Insert spacer J1 to supply pump (2) side and tighten the currently removed joint bolt again. Connect the return pipe to the fuel tank again. ★ Be sure to provide a gasket for both ends of the spacer.
D. Insert joint J2 to common rail (1) side and tighten the removed joint bolt again. ★ Be sure to fit the gaskets to both ends of the joint. E. Connect inspection hose J3 to the tip of joint J2. Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off. ★ This completes the preparations needed for testing the leakage from the pressure limiter.
2.
Testing leakage from pressure limiter A. Lay test hose J3 so that it does not slacken and put its end in the oil pan. B. Set the mode that allows confirmation of the engine speed. Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. C. Start the engine and keep its speed to 1,600 rpm with no load.
WA500-6
30-29 b
TESTING AND ADJUSTING
FUEL SYSTEM
D. When the engine speed is stabilized, check the leakage amount per minute with measuring cylinder J5. ★ You may test for 20 seconds and judge by multiplying the result by 3. ★ If the leakage from the pressure limiter is in the following range, it is normal. Engine Speed (rpm)
Leakage (cc/min)
1,600
Max. 10
E. After finishing the test, stop the engine. 3.
Testing return rate from injector ★ Keep the hose on the pressure limiter side connected and keep its end in the oil pan while testing the return rate from the injector. A. Open the air cleaner inspection cover. B. Disconnect return hose (5) of return block (4) and connect inspection hose J4 instead. • Stop the return hose with a plug, etc. and fix it to the fuel tank. Plug: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07376-70315
•
Bind the connecting part of the test hose with a wire, etc. to prevent it from coming off.
C. Adjust the route of inspection hose J4 to remove its sag and insert the hose end into the oil pan (receiver). D. Set the mode that allows confirmation of the engine speed. ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REAL-TIME MONITOR) in this section. E. Stall the torque converter while the engine is run at high idle. As the engine speed is stabilized, measure the return rate per minute with measuring cylinder J5. ★ Refer to Measuring Engine Speed in this section for the torque converter stalling procedure. F.
When the engine speed is stabilized, check the leakage amount per minute with measuring cylinder J5. ★ You may test for 20 seconds and judge by multiplying the result by 3. ★ If the supply pump is not supplying fuel, the engine speed may not rise. In this case, also record the engine speed during the test.
30-30 b
WA500-6
TESTING AND ADJUSTING
FUEL SYSTEM
★ If the return rate (spill) from the injector is in the following range, it is normal. Rated Output Speed (rpm)
Limit of Return Rate (spill) (cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
G. After finishing the test, stop the engine. 4.
Work after finishing the test After completing the test, remove the testing tools and return the parts you removed.
WA500-6
30-31 b
TESTING AND ADJUSTING
FUEL SYSTEM
Bleeding Air from Fuel Circuit
★ If you use all the fuel or remove and install a fuel circuit part, you must bleed air from the fuel circuit. 1.
Open the engine right side cover.
2.
Remove fuel prefilter (1) and then fill the prefilter with fuel. • Fill the fuel filter with clean fuel and be careful that dirt does not get into the filter. • Confirm that the cap is installed to portion (a) (center hole) of the fuel prefilter and add fuel from portion (b) (peripheral holes). • After filling the fuel prefilter, remove the cap in portion (a). • If clean fuel is not available, do not remove the fuel prefilter but fill it with the fuel by operating priming pump (4). ★ Do not add fuel to fuel main filter (2).
30-32 b
WA500-6
TESTING AND ADJUSTING 3.
Install fuel prefilter (1) to the filter head. • Coat the packing surface of the fuel prefilter side with a small amount of engine oil. • Tighten the packing surface of the fuel prefilter by 3/4 of a turn after confirming that it is in contact against the sealing surface of the filter head.
4.
Remove air bleeding plug (3) on fuel main filter (2) and then operate priming pump (4). ★ Operate the priming pump until the fuel flows out of the plug hole and install the plug.
FUEL SYSTEM
Air bleeding plug: 7.8 – 9.8 N•m (69 – 87 lbf in)
5.
Loosen air bleeding plug (5) on fuel main filter (2) and then operate priming pump (4). ★ Operate the priming pump until the fuel flows out of the plug hole and install the plug. Air bleeding plug: 7.8 – 9.8 N•m (69 – 87 lbf in)
6.
Loosen air bleeder (6) of the fuel supply pump and operate priming pump (4) 90 – 100 times. ★ Operate the priming pump until the fuel flows out of the air bleeder and then tighten the air bleeder. Operate the priming pump several times more until it becomes heavy. Air bleeder: 4.9 – 6.9 N•m (43 – 61 lbf in)
7.
Start the engine cranking with the starting motor. ★ The air in the high-pressure circuit is bled automatically if the engine is cranked. ★ If the engine does not start, there may be air still in the low-pressure circuit. In this case, repeat this procedure from Step 3.
WA500-6
30-33 b
TESTING AND ADJUSTING
FUEL SYSTEM
Testing Leakage in Fuel System WARNING!
Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the engine is running, it can catch fire. This is dangerous. After testing the fuel system or removing its parts, test it for fuel leakage according to the following procedure
★ Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage. 1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at speeds below 1,000 rpm and stop it after its speed is stabilized.
3.
Inspect the fuel piping and devices for fuel leakage. ★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker. ★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.
4.
Run the engine at low idle.
5.
Inspect the fuel piping and devices for fuel leakage. ★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker. ★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.
6.
Run the engine at high idle.
7.
Inspect the fuel piping and devices for fuel leakage. ★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker. ★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.
8.
Run the engine at high idle and load it. ★ Stall the torque converter or relieve the hydraulic pump. ★ Refer to Measuring Engine Speed in this section.
9.
Inspect the fuel piping and devices for fuel leakage. ★ Check for fuel leakage mainly around the high-pressure circuit parts coated with the color checker. ★ If you detect fuel leakage, repeat the procedure from Step 1 after repairing the leakage.
★ If no fuel leakage is detected, the check is completed.
30-34 b
WA500-6
TESTING AND ADJUSTING
FUEL SYSTEM
Handling Reduced-Cylinder Mode Operation ★ Reduced-cylinder mode operation means to run the engine with the fuel injectors of one or more cylinders electrically disabled in order to reduce the number of effective cylinders. The purposes and effects of this operation are described below. 1.
This operation is used to determine which cylinder does not output power normally (or combustion in the cylinder is abnormal).
2.
If a cylinder is selected for the reduced-cylinder mode operation and the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has one or more defects. The possible defects are: • • • • •
3.
Leakage through cylinder head gasket Defective injection Defective piston, piston ring, or cylinder liner Defective valve mechanism (moving valve system) Defect in electrical system
Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced-cylinder mode operation easily using switches to determine the defective cylinder. The reduced-cylinder mode operation is set from the Service mode of the machine monitor. ★ For details, see MACHINE MONITOR SYSTEM: Service Mode: Cylinder Cutout Function (CYLINDER CUT-OUT) in this section.
Handling No-Injection Cranking Operation •
No-injection cranking means to crank the engine with the starting motor while all injectors are stopped electrically. ★ Use this method when a machine or engine has been stored for a long time. Implementing the no-injection cranking before starting the engine lubricates the engine parts and prevents the engine from seizing.
•
The no-injection cranking operation is set from the Service mode of the machine monitor. ★ For details, see MACHINE MONITOR SYSTEM: Service Mode: No-Injection Cranking Function (NO INJECTION) in this section.
Handling Controller Voltage Circuit 1.
When plugging or unplugging a connector between the engine controller and engine, be sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in (or connected to) a connector between the engine controller and engine for troubleshooting purposes, it is forbidden to start the engine. ★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
WA500-6
30-35 b
TESTING AND ADJUSTING
BELTS
BELTS Alternator Belt Tension This procedure describes how to test and adjust the alternator belt tension. Testing 1.
Open the engine right side cover.
2.
Using a finger, press the belt at midpoint between the alternator pulley and water pump pulley to check deflection (a). Pressing force: . . . . . . . . . . . . . . . . . . . . . . . . Approx. 98 N (22 lbf) Deflection (a): . . . . . . . . . . . . . . . . . . .13 – 16 mm (0.51 – 0.63 in)
Adjusting ★ If the deflection of the belt is abnormal, adjust it according to the following procedure. 1.
Remove two mounting bolts and then remove belt cover (1). ★ Remove the belt cover only when the belt is being replaced.
2.
Loosen two mounting bolts (3) of alternator (2) as well as lock bolt (4) of adjustment rod (5).
3.
Loosen the locknut of adjustment rod (5); slide alternator (2) using adjustment nut (6); then adjust the belt tension.
4.
While fixing adjustment screw (6), tighten the locknut of adjustment rod (5).
5.
Tighten lock bolt (4) of adjustment rod (5) and two mounting bolts (3) of alternator (2).
6.
Using two mounting bolts, install belt cover (1). • Check for breakage of the pulleys, wear of the V-grooves, contact of V belts and V-grooves, and contact of the belt covers and rotating parts. ★ The V belt must be replaced with a new one if it is stretched and its adjustment allowance is lost or when cuts or cracks are observed on the belt. • Whenever a V belt is replaced, test and adjust it again after operating the machine for an hour. • After tightening the bolt, make sure that the belt tension is normal by following the Testing procedure.
7.
After completing the adjustment, return the machine to the normal state.
30-36 b
WA500-6
TESTING AND ADJUSTING
BELTS
Air Conditioner Compressor Belt Tension This procedure describes how to test and adjust the air conditioner compressor belt tension. Testing 1.
Open the engine left side cover.
2.
Using a finger, press the belt at midpoint between the supply pump pulley and compressor pulley to check deflection (a). Pressing force: . . . . . . . . . . . . . . . . . . . . . . . . Approx. 59 N (13 lbf) Deflection (a): . . . . . . . . . . . . . . . . . . . . . . Approx. 10 mm (0.39 in)
Adjusting ★ If the deflection of the belt is abnormal, adjust it according to the following procedure. 1.
Loosen locknut (2); slide air conditioner compressor (4) along with the bracket using adjustment nut (3); and then adjust tension of air conditioner compressor belt (5).
2.
While fixing adjustment screw (3), tighten locknut (2).
3.
Tighten four mounting bolts (1) of the bracket. • Check for breakage of the pulleys, wear of the V-grooves, and contact of the V belts and V-grooves. ★ The V belt must be replaced with a new one if it is stretched and its adjustment allowance is lost or when cuts or cracks are observed on the belt. • Whenever a V belt is replaced, test and adjust it again after operating the machine for an hour. • After tightening the bolt, make sure that the belt tension is normal by following the Testing procedure.
4.
After completing the adjustment, return the machine to the normal state.
WA500-6
30-37 b
TESTING AND ADJUSTING
TRANSMISSION SPEED SENSOR
TRANSMISSION SPEED SENSOR Adjusting
1.
Transmission input shaft speed sensor A. Loosen locknut (2) of transmission input shaft speed sensor (1). B. Screw in transmission input shaft speed sensor (1) until its tip lightly contacts against the tooth tip of gear (3). ★ Before installing the sensor, check that its tip is free from steel chips and flaws. Threaded portion: Gasket sealant (LG-5)
C. From that position, return transmission input shaft speed sensor (1) by 1/2 – 1 turn. Clearance between speed sensor and gear: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 – 1.5 mm (0.03 – 0.06 in)
30-38 b
WA500-6
TESTING AND ADJUSTING
TRANSMISSION SPEED SENSOR
D. Fix speed sensor (1) with locknut (2). Locknut: 49.0 – 68.6 N•m (36 – 51 lbf ft)
2.
Transmission output shaft speed sensor A. Loosen locknut (5) of transmission output shaft speed sensor (4). B. Screw in transmission output shaft speed sensor (4) until its tip lightly contacts against the tooth tip of gear (6). ★ Before installing the sensor, check that its tip is free from steel chips and flaws. Threaded portion: Gasket sealant (LG-5)
C. From that position, return transmission output shaft speed sensor (4) by 1/2 – 1 turn. Clearance between speed sensor and gear: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.75 – 1.5 mm (0.03 – 0.06 in)
D. Fix speed sensor (4) with locknut (5). Locknut: 49.0 – 68.6 N•m (36 – 51 lbf ft)
WA500-6
30-39 b
TESTING AND ADJUSTING
DIRECTIONAL LEVER
DIRECTIONAL LEVER ★ Steering wheel specification Special Tools Required Symbol
K
1
Part No.
79A-264-0021
WARNING!
Part Name
Qty
Remarks
Push-pull scale
1
0 – 294 N (0 – 66.09 lbf)
Stop the machine on level ground; lower the work equipment to the ground; and set chocks securely under the tires.
Testing the Operating Effort 1.
Stop the engine.
2.
Install tool K or a spring balance to a point 10 mm (0.40 in) from the control lever end and pull it in the operating direction to measure the operating effort at that time.
3.
Measure the operating effort at each gear speed. ★ The shape of the lever shown in the photo is not identical with that on WA500-6.
Testing the Stroke 1.
Stop the engine.
2.
Make mark (a) on the center of the control lever knob.
3.
Move the knob in the operating direction and measure its stroke. ★ The shape of the lever shown in the photo is not identical with that on WA500-6.
30-40 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
POWER TRAIN OIL PRESSURES
WA500-6
30-41 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Special Tools Required Symbol
Part Number
Part Name
Qty
Remarks
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
10 x 1.25 mm
07002-11023
O-ring
1
Pressure gauge: 1 MPa (145.04 psi)
1 L 2
★ Oil pressure measuring point and measuring gauge No.
Measured oil pressure
Measuring Gauge kg/cm² (psi)
1
Main relief pressure
61.18 (870)
2
Torque converter relief pressure
25.49 (363)
3
Torque converter outlet pressure
10.20 (145)
4
Lockup clutch pressure
61.18 (870)
5
Transmission F clutch pressure
61.18 (870)
6
Transmission R clutch pressure
61.18 (870)
7
Transmission 1st clutch pressure
61.18 (870)
8
Transmission 2nd clutch pressure
61.18 (870)
9
Transmission 3rd clutch pressure
61.18 (870)
10
Transmission 4th clutch pressure
61.18 (870)
11
Lubrication pressure
10.20 (145)
WARNING!
Put chocks securely under the tires.
★ Measure the power train oil pressure under the following conditions. Engine coolant temperature: . . . . . . . . . . . Within operating range Torque converter oil temperature: . . . . . . . .Within operating range
1.
Remove rear frame left side cover (12) and right side cover (13).
30-42 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Measuring Transmission Main Relief Pressure 1.
Remove transmission main relief pressure pickup plug (1) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Start the engine and then maintain the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
4.
While running the engine at low idle and high idle, measure the transmission main relief pressure.
5.
After completing the measurement, remove the measuring instruments and return the parts you removed.
WA500-6
30-43 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Torque Converter Relief Pressure ★ Inlet pressure Required •
Container to hold the oil
1.
Remove torque converter relief pressure (inlet pressure) pickup plug (2) (10 x 1.25 mm). Make sure that the oil pan is in position before removing the plug to drain the oil.
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 25.49 kg/cm² (363 psi).
3.
Start the engine and then maintain the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
4.
While running the engine at high idle, measure the torque converter relief pressure (inlet pressure).
5.
After completing the measurement, remove the measuring instruments and return the parts you removed.
30-44 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Torque Converter Outlet Pressure 1.
Remove torque converter outlet pressure pickup plug (3) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 10.20 kg/cm² (145 psi).
3.
Start the engine and then maintain the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
4.
While running the engine at high idle, measure the torque converter outlet pressure.
5.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-45 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Lockup Clutch Pressure ★ Lockup clutch specification WARNING!
This measurement is done in the traveling condition. You must be aware of safety in the surrounding area.
1.
Remove lockup clutch pressure pickup plug (4) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 611.83 kg/cm² (870 psi).
3.
Turn the torque converter lockup switch ON.
4.
Set the transmission auto-shift and manual shift selector switch in the AUTO position.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever or gearshift switch to the 2nd position.
7.
Start traveling while setting the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position.
8.
Measure the lockup clutch oil pressure as the lockup pilot lamp comes on while continuing to travel with the engine at high idle.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-46 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
F (Forward) Clutch Pressure 1.
Remove the F (forward) clutch oil pressure pickup plug (5) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward). WARNING!
Keep pressing the brake pedal securely.
8.
Measure the F (forward) clutch oil pressure when the engine is run at high idle.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-47 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
R (Reverse) Clutch Pressure 1.
Remove the R (reverse) clutch oil pressure pickup plug (6) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the R (reverse). WARNING!
Keep pressing the brake pedal securely.
8.
Measure the R (reverse) clutch oil pressure when the engine is run at high idle.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-48 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
1st Clutch Pressure 1.
Remove the 1st clutch oil pressure pickup plug (7) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 1st speed while maintaining the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position once and then return it to N (Neutral) again. Keep pressing the brake pedal securely.
★ The above operation is required because moving the gearshift lever does not change the gear speed if the directional lever, joystick steering switch, or right directional switch is set at the N (neutral) position. 8.
While running the engine at high idle, measure the 1st clutch oil pressure.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-49 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
2nd Clutch Pressure 1.
Remove the 2nd clutch oil pressure pickup plug (8) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 2nd speed while maintaining the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position once and then return it to N (Neutral) again. Keep pressing the brake pedal securely.
★ The above operation is required because moving the gearshift lever does not change the gear speed if the directional lever, joystick steering switch, or right directional switch is set at the N (neutral) position. 8.
While running the engine at high idle, measure the 2nd clutch oil pressure.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-50 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
3rd Clutch Pressure 1.
Remove the 3rd clutch oil pressure pickup plug (9) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 3rd speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position once and then return it to N (Neutral) again. Keep pressing the brake pedal securely.
★ The above operation is required because moving the gearshift lever does not change the gear speed if the directional lever, joystick steering switch, or right directional switch is set at the N (neutral) position. 8.
While running the engine at high idle, measure the 3rd clutch oil pressure.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-51 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
4th Clutch Pressure 1.
Remove the 4th clutch oil pressure pickup plug (10) (10 x 1.25 mm).
2.
Connect nipple L2 and oil pressure gauge [1] in hydraulic tester L1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
3.
Set the transmission auto-shift and manual shift selector switch in the MANUAL position.
4.
Press the brake pedal.
5.
Start the engine and turn the parking brake switch OFF.
6.
Set the gearshift lever to the 4th speed while keeping the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
7.
Run the engine at low idle and while pressing the brake pedal, set the directional lever, joystick steering directional switch, or right directional switch to the F (forward) or R (reverse) position once and then return it to N (Neutral) again. Keep pressing the brake pedal securely.
★ The above operation is required because moving the gearshift lever does not change the gear speed if the directional lever, joystick steering switch, or right directional switch is set at the N (neutral) position. 8.
While running the engine at high idle, measure the 4th clutch oil pressure.
9.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-52 b
WA500-6
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Lubrication Pressure 1.
Remove the lubrication pressure pickup plug (11) (10 x 1.25 mm).
2.
Install elbow [2] and nipple [3] in hydraulic tester L1 and connect oil pressure gauge [1] to them. ★ Use an oil pressure gauge with capacity of 10.20 kg/cm² (145 psi).
3.
Start the engine and maintain the directional lever, joystick steering directional switch, or right directional switch at the N (Neutral) position.
4.
Measure the lubrication pressure as the engine is run at high idle.
5.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-53 b
TESTING AND ADJUSTING
POWER TRAIN OIL PRESSURES
Adjusting Transmission Main Relief Valve
WARNING!
Stop the engine before starting adjustment of the transmission main relief valve.
★ If the transmission main relief pressure is out of the specified range, adjust it according to the following procedure. 1.
Remove plug (13) from the transmission and torque converter relief valve (12).
2.
Remove inner spring (14) and outer spring (15).
3.
Adjust the main relief pressure by changing the number of shims (16). Standard shim thickness: . . . . . . . . . . 4.5 mm (0.5 mm x 9 pieces) Quantity of adjustment per shim: . . . . . . . . . . . 0.398 kg/cm² (6 psi)
Torque Converter Relief Valve ★ You cannot adjust the torque converter relief valve.
30-54 b
WA500-6
TESTING AND ADJUSTING
FLUSHING TRANSMISSION SYSTEM
FLUSHING TRANSMISSION SYSTEM Torque Converter and Transmission Hydraulic Circuit ★ Metal chips and dirt in the torque converter and transmission hydraulic circuit shorten the lives of these components and can cause internal breakage. Flush the hydraulic circuit to remove the metal chips and dirt. Required •
Container to hold the oil
1.
Flush the hydraulic circuit in the following cases. • When metal chips are circulated in the hydraulic circuit because of damage of the torque converter, transmission, or another hydraulic device. • When the torque converter or transmission is overhauled or repaired.
2.
Install the element for flushing. A. Remove cover (1) on the transmission oil filter installation position situated on the left side of the machine. B. Remove drain plugs (3) on two transmission oil filter cases (2) to drain the oil. ★ Make sure that the pan is in position before removing the plugs to drain the oil. C. Loosen the hexagonal portion (a) of two transmission oil filter cases (2) to remove the cases. ★ After removing each transmission oil filter case, clean inside the case as well as the removed parts, other than the filter. D. Remove two filter elements (4) and replace them with two flushing elements (424-16-11140). E. Install two transmission oil filter cases (2). Hexagonal portion (a) of transmission oil filter case: 58.8 – 78.5 N•m (43.37 – 57.90 lbf ft) Drain plug: 49 – 58.8 N•m (36.14 – 43.37 lbf ft)
WA500-6
30-55 b
TESTING AND ADJUSTING 3.
FLUSHING TRANSMISSION SYSTEM
Fill the transmission case with oil. • Add oil through oil filler (5) to the specified level. • Run the engine to circulate the oil through the system. • Check the oil level again. Transmission case: 76 l (20 gal) (Refill capacity)
4.
Flush the hydraulic circuit according to the following procedure. A. Start the engine and run it at low idle without operating the gearshift lever or directional lever for about 20 minutes. • Increase the engine speed to about 1,500 rpm at times. • If the engine coolant temperature gauge does not rise to the operating range because of low atmospheric temperature, continue the warm-up operation further. B. Operate or drive the machine for at least 20 minutes. ★ Use all the gear speeds (Forward, reverse, and 1st – 4th). C. Run the engine at low idle for about 20 minutes, similar to Step 4A.
5.
Replace the filter element. A. Replace element (4), used for flushing, with a new element (424-16-11140). ★ Follow the same procedure as described in Step 2. WARNING!
Using the flushing element for long periods causes premature clogging. Be sure to replace it with a new one.
B. Replace the current O-ring with a new one; coat it with a small amount of oil; and then install it. C. Add oil and check the oil level again. 6.
Replace the transmission last chance filter. A. Remove cover (6) on the left side of the rear frame.
B. Loosen hexagonal portion (b) of the transmission last chance filter case (7) to remove the case. ★ After removing the transmission oil filter case, clean inside the case as well as the removed parts, other than the filter. C. Remove filter element (8) and replace it with a new element (561-15-55670).
30-56 b
WA500-6
TESTING AND ADJUSTING
FLUSHING TRANSMISSION SYSTEM
D. Install transmission last chance filter case (7). E. Replace the current O-ring with a new one; coat it with a small amount of oil; and then install it. Hexagonal portion (b) of transmission oil filter case: 34.3 – 44.1 N•m (25 – 33 lbf ft)
WA500-6
30-57 b
TESTING AND ADJUSTING
WHEN TRANSMISSION VALVE FAILS
WHEN TRANSMISSION VALVE FAILS Moving Machine when Transmission Valve is Broken ★ Position of ECMV devices and connector numbers
★ Device for moving machine when transmission valve is broken Symbol
Part Number
Part Name
M
794-423-1190
Plug
★ Even if the machine is not movable because of a failure on the transmission valve portions (electrical system, solenoid valve, spool, etc.), install plug M to enable you to move the machine.
30-58 b
WARNING!
Installing plug M to the ECMV enables you to move the machine from a dangerous job site to a safe place for repair. This approach should be used only when the machine is not movable at any gear speed because of a failure on the transmission control valve. This method should not be used for any other purpose. When moving the machine using this method, follow the procedure and pay strict attention to safety.
WARNING!
Lower the work equipment completely to the ground; apply the parking brake; and put chocks under the tires so that the machine does not move.
WARNING!
Stop the engine.
WARNING!
When working while the oil temperature is still hot, be careful not to burn yourself.
WA500-6
TESTING AND ADJUSTING 1.
Remove cover (1) on the left side of the rear frame. ★ Remove mud and dirt from around the ECMV.
2.
Unplug the connector of the 2nd ECMV and the connector of the F or R ECMV.
WHEN TRANSMISSION VALVE FAILS
F ECMV (Forward) connector: . . . . . . . . . . . . . . . . .F.SW and F.PS R ECMV (Reverse) connector: . . . . . . . . . . . . . . . R.SW and R.PS 2nd ECMV (2nd speed) connector: . . . . . . . . . . . . 2.SW and 2.PS
★ Select either F ECMV or R ECMV, depending on the direction in which the machine is moving (Forward or Reverse). 3.
Remove two solenoids (2) on the 2nd ECMV and the F or R ECMV and install plug M. For forward travel: . . . . . . . . . . . . . . . F solenoid and 2nd solenoid For reverse travel: . . . . . . . . . . . . . . . R solenoid and 2nd solenoid
★ If an incorrect solenoid is removed, the transmission may break. Be careful and double-check before removing the solenoid. • Install each plug with its projection side toward the ECMV. Make sure that the O-ring is fitted to the mating face. • Be careful that mud or dirt does not enter the removed solenoids and valves. 4.
Press the brake pedal securely.
5.
Start the engine and release the parking brake gradually to start and move the machine. ★ If the parking brake cannot be released because of a problem in the electrical system, see BRAKE SYSTEM: Parking Brake: Releasing Parking Brake Manually in this section.
6.
WARNING!
Remove the chocks. If the engine is started, the transmission is engaged and the machine starts immediately. When starting the engine, check the moving direction of the machine and ensure that there is a safe perimeter around the machine.
WARNING!
Keep pressing the brake pedal.
WARNING!
After moving the machine, stop the engine; apply the parking brake; and put chocks under the tires.
After moving the machine, remove the devices and return the parts you removed.
WA500-6
30-59 b
TESTING AND ADJUSTING
STEERING SYSTEM
STEERING SYSTEM Steering Stop Valve Testing 1.
Straighten the front frame and rear frame.
2.
Make sure locknut (2) of stopper bolt (1) is not loosened.
3.
Start the engine and turn the steering wheel to the right and left. ★ Make sure that a clearance is maintained between the front frame stopper and rear frame stopper when the steering wheel is turned. WARNING!
•
•
Stop the engine before measuring the clearance.
If you cannot do the checkup because of a missing frame stopper or another missing item, do the necessary repair and then make sure clearance is provided on both sides. Measure clearance (a) between front frame (4) and rear frame (5) on both sides as the turning is stopped due to the contact of steering stop valve (3) and stopper bolt (1).
Standard clearance (a): . . . . . . . . . . . . . .36 ±5 mm (1.42 ±0.20 in)
30-60 b
WA500-6
TESTING AND ADJUSTING
STEERING SYSTEM
Adjusting ★ When clearance (a) between front frame (4) and rear frame (5) is out of the specified range, use the following procedure to adjust it. 1.
Loosen locknut (2) and then tighten stopper bolt (1) to set distance (b) to the minimum.
2.
Run the engine at low idle and then bring front frame (4) and rear frame (5) into contact with each other by turning the steering wheel slowly. WARNING!
Be careful that your body or arm does not get caught between the front and rear frames.
3.
Stop the engine and then loosen stop bolt (1) until it touches the contact surface of steering stop valve (3). ★ Be careful not to loosen the stopper bolt excessively. Excessive loosening can result in pushing spool (6) at the tip of steering stop valve (3).
4.
Start the engine and return the steering wheel slowly, at low idle, to set the machine in a straight travel path; then stop the engine.
5.
Rotate stopper bolt (1) 8.5 turns in the loosening direction and then fix it with locknut (2). ★ Adjust both the right and left side according to Steps 1 to 5.
6.
Start the engine; turn the machine; and then measure clearance (a) between front frame (4) and rear frame (5) as the turning is stopped due to the contact of steering stop valve (3) and stopper bolt (1). ★ Make sure clearance (a) is compliant with the standard dimension on both sides.
WA500-6
30-61 b
TESTING AND ADJUSTING
STEERING SYSTEM
Steering Wheel Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
N
79A-264-0021
Push-pull scale
1
0 – 294 N (0 – 66.09 lbf)
Measuring Play ★ Measurement conditions: Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopped Machine posture: . . . . . . . . . . . . . . . . . . . . Facing straight forward
1.
Move the steering wheel (1) two or three times lightly to the left and right; check that the steering mechanism is at the neutral position; then make mark (A) on the outside frame of the machine monitor.
2.
Turn the steering wheel to the right and make mark (B) at the position where the operating effort starts to become heavy.
3.
Turn the steering wheel to the left and make mark (C) at the point where the operating effort becomes heavy.
4.
Measure the distance in a straight line between marks (B) and (C).
30-62 b
WA500-6
TESTING AND ADJUSTING
STEERING SYSTEM
Measuring Operating Effort ★ Measurement conditions: Road surface: . . . . . . . . . . . . . . Flat, horizontal, dry paved surface Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature:. . . . . . . . . . . . . . .Within operating range Tire inflation pressure: . . . . . . . . . . . . . . . . . . . . Specified pressure Engine speed: . . . . . . . . . . . . . . . . . . . . . . Low idle (bucket empty)
1.
Install push-pull scale N on the steering wheel knob. ★ Be sure to install push-pull scale N at the center.
2.
Start the engine. ★ After starting the engine, raise the bucket approx. 400 mm (15.75 in) and release the frame lock lever.
3.
Pull push-pull scale N in the tangential direction and read the value when the steering wheel moves smoothly. ★ Do not use the value when the steering wheel starts to move. ★ The shape in the photo is not identical to that of the WA500-6.
4.
After finishing the work, remove the measuring instrument.
WA500-6
30-63 b
TESTING AND ADJUSTING
STEERING SYSTEM
Measuring Operating Time ★ Measurement conditions: Road surface: . . . . . . . . . . . . . . Flat, horizontal, dry paved surface Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Tire inflation pressure: . . . . . . . . . . . . . . . . . . . Specified pressure Engine speed: . . . . . . . . . . . . . . . . . . . . . . . Low idle and high idle
1.
Start the engine. ★ After starting the engine, raise the bucket approx. 400 mm (15.75 in) and release the frame lock lever.
2.
Turn the steering wheel to the left or right stroke end.
3.
Measure the time taken to operate the steering wheel to the right or left stroke end. ★ Turn the steering wheel smoothly at a speed of 60 rpm. Do not turn the steering wheel forcibly. ★ Carry out the measurements both at low idle and high idle, turning the machine both in the left and right direction. ★ The shape in the photo is not identical to that on the WA500-6.
4.
After finishing the work, remove the measuring instrument.
30-64 b
WA500-6
TESTING AND ADJUSTING
STEERING SYSTEM
Steering Oil Pressure Special Tools Required Symbol
Part Number
Part Name
Qty
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
3
799-401-3200
Adapter (Size 03)
1
Size 03
4
799-401-2701
Differential pressure gauge
1
–
1
Q
Remarks
2
★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature:. . . . . . . . . . . . . . .Within operating range
WARNING!
Loosen the oil filler cap of the hydraulic tank to release the internal pressure of the hydraulic tank. Operate the steering wheel two to three times to release the residual pressure from the piping.
WARNING!
Apply frame lock lever (1).
Measuring Steering Relief Pressure 1.
Remove steering circuit pressure pickup plug (2) (10 x 1.25 mm) on the right steering cylinder head side.
WA500-6
30-65 b
TESTING AND ADJUSTING
2.
Connect nipple Q2 and oil pressure gauge [1] in hydraulic tester Q1. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi).
3.
Run the engine at high idle and turn the steering wheel to the right. When the steering relief valve operates, measure the oil pressure. ★ When the gauge is connected to the steering circuit pressure pickup plug on the left side steering cylinder head, measure the pressure by turning the steering wheel counterclockwise.
4.
After completing the measurement, remove the measuring instruments and return the parts you removed.
30-66 b
STEERING SYSTEM
WA500-6
TESTING AND ADJUSTING
STEERING SYSTEM
Measuring Pilot Circuit Pressure 1.
Remove side covers (3) and (4) of the steering valve situated on the left side of the machine.
2.
Remove steering pilot circuit pressure hose (6) or (7) of steering valve assembly (5).
3.
Connect adapter Q3 and steering pilot circuit pressure hose (6) or (7).
4.
Connect nipple [2] and oil pressure gauge [1] in hydraulic tester Q1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
5.
While running the engine at high idle, measure the oil pressure as the steering wheel is turned. • When measuring at hose (6): Turn the steering wheel clockwise (or turn the joystick steering lever rightward). • When measuring at hose (7): Turn the steering wheel counterclockwise (or turn the joystick steering lever leftward).
6.
After completing the measurement, remove the measuring instruments and return the parts you removed.
WA500-6
30-67 b
TESTING AND ADJUSTING
STEERING SYSTEM
Measuring LS Circuit Pressure 1.
Remove side covers (3) and (4) of the steering valve situated on the left side of the machine.
2.
Remove steering LS circuit pressure hose (11) of steering valve assembly (5).
3.
Connect adapter Q3 and steering LS circuit pressure hose (11).
4.
Connect nipple [2] and oil pressure gauge [1] in hydraulic tester Q1. ★ Use the oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
5.
While running the engine at low idle, measure the oil pressure as the steering wheel is stopped.
6.
After completing the measurement, remove the measuring instruments and return the parts you removed.
30-68 b
WA500-6
TESTING AND ADJUSTING
STEERING SYSTEM
Adjusting Steering Relief Pressure
WARNING!
When adjusting the oil pressure, you must stop the engine.
★ If the steering relief pressure is abnormal, adjust steering relief valve (8) of steering valve assembly (5) by doing the following procedure.
1.
Loosen locknut (9) and turn adjustment screw (10) to adjust the pressure. ★ Adjustment screw: • Turned to the right, the pressure rises. • Turned to the left, the pressure lowers. ★ Quantity of adjustment of adjustment screw (per turn): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.53 kg/cm² (2596 psi) Locknut: 27 – 31 N•m (20 – 23 lbf ft)
WA500-6
30-69 b
TESTING AND ADJUSTING
STEERING SYSTEM
Bleeding Air From Steering Cylinder Circuit ★ Before starting the operation, make sure that you have the necessary quantity of hydraulic oil. ★ If the steering valve or the steering cylinder was removed and installed again, bleed the air from the steering circuit as described in this procedure. 1.
Run the engine at idle for approximately five minutes.
2.
Run the engine at low idle and steer the machine to the right and left four to five times. ★ Stop the piston rod about 100 mm (3.94 in) before the end of each stroke. Be careful not to relieve the circuit.
3.
Repeat Step 2 while running the engine at high idle.
4.
While running the engine at low idle, move the piston rod to the stroke end and relieve the circuit.
30-70 b
WA500-6
TESTING AND ADJUSTING
HYDRAULIC FAN
HYDRAULIC FAN Special Tools Required Symbol
Part Number
Part Name
Qty
Remarks
1
799-205-1100
Tachometer kit
1
Digital display: 6 – 99999.9 rpm
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
799-401-3500
Adapter (Size 06)
1
Size 06
2 R
3 4
WARNING!
Stop the machine on level ground; lower the work equipment to the ground; and set chocks securely under the tires.
WARNING!
When removing the oil pressure pickup plug and disconnecting the hose, loosen the oil filler cap of the hydraulic tank slowly to release the pressure inside the tank.
★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . . . . . Min. 95°C (203°F) Hydraulic oil temperature:. . . . . . . . . . . . . . . . . . Min. 95°C (203°F) Torque converter oil temperature:. . . . . . . . . . . Min. 105°C (221°F)
Measuring Fan Speed This procedure describes how to measure the fan speed. 1.
Set probe [2] to stand [1] of tachometer kit (R1) and stick reflective tape [3] to the fan. ★ See tachometer kit (R1) in the photo to the right.
2.
While running the engine at high idle and low idle, measure the fan speed.
3.
After completing the measurement, remove the measuring instruments and return the parts you removed.
WA500-6
30-71 b
TESTING AND ADJUSTING
HYDRAULIC FAN
Measuring Fan Drive Oil Pressure This procedure describes how to measure the fan drive oil pressure. 1.
Open the radiator grille (1).
2.
Remove fan net (2) at the center.
3.
Disconnect P port hose (4) of fan motor (3).
4.
Connect adapter R4 and hose (4).
5.
Connect nipple R3 (10 x 1.25 mm) and oil pressure gauge [1] in hydraulic tester R2. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi).
6.
While running the engine at high idle, measure the fan drive oil pressure.
7.
After completing the measurement, remove the measuring instruments and return the parts you removed.
30-72 b
WA500-6
TESTING AND ADJUSTING
HYDRAULIC FAN
Measuring Fan Reverse Solenoid Output Pressure 1.
Open radiator grille (1).
2.
Remove fan net (2) at the center.
3.
Remove fan reverse solenoid output pressure pickup plug (10 x 1.25 mm) (5) from fan motor (3).
4.
Connect nipple R3 (10 x 1.25 mm) and oil pressure gauge [1] in hydraulic tester R2. ★ Use an oil pressure gauge with capacity of 399.73 kg/cm² (5686 psi).
5.
Turn the cooling fan reverse switch ON.
6.
While running the engine at high idle, measure the fan reverse solenoid drive oil pressure. ★ Measure the fan forward and reverse drive oil pressures. When the fan is reversed, check that the solenoid operates and the specified oil pressure is applied.
7.
After completing the measurement, remove the measuring instruments and return the parts you removed. Fan reverse solenoid output pressure pickup plug: 9.8 – 12.7 N•m (87 – 112 lbf in)
WA500-6
30-73 b
TESTING AND ADJUSTING
HYDRAULIC FAN
Bleeding Air from Hydraulic Drive Fan Circuit Special Tools Required Symbol
Part Number
Part Name
Qty
Remarks
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.60, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
3
799-401-3500
Adapter (Size 06)
1
Size 06
4
790-261-1130
Coupling
1
–
1
S 2
★ Before starting the operation, make sure that you have the necessary amount of hydraulic oil. 1.
Bleeding air from fan pump A. Remove pump side cover (1) on the right side of the machine.
B. Stop the engine and then loosen air bleeder (3) of fan pump (2) to connect air bleeding hose [1]. C. As oil free from air starts to flow out of air bleeder (3), tighten air bleeder (3). Air bleeder: 7.8 – 9.8 N•m (69 – 87 lbf in)
D. Start the engine and run it at low idle for a minimum of five minutes.
30-74 b
WA500-6
TESTING AND ADJUSTING 2.
HYDRAULIC FAN
Bleeding air from fan motor circuit A. Open radiator grille (4). B. Remove fan net (5) at the center.
C. Disconnect P port hose (7) of fan motor (6).
D. Connect adapter S3 and hose (7). E. Connect nipple S2 (10 x 1.25 mm) and hose [1] in hydraulic tester S1.
F.
Connect air bleeder coupling S4 to the outlet end of the hose. ★ Put the outlet end of the hose in an oil receiver.
G. Run the engine. When the oil flows out of the outlet end of the hose, stop the engine. H. After completing the bleeding air procedure, remove the tools and return the parts you removed.
WA500-6
30-75 b
TESTING AND ADJUSTING
BRAKE SYSTEM
BRAKE SYSTEM Measuring Brake Pedal ★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle
Measuring Pressing Angle of Pedal 1.
Install push gauge [1] to the operator’s foot. ★ Set the push gauge at a point 150 mm (5.91 in) from the fulcrum of the pedal.
2.
While running the engine at low idle, measure pedal pressing angle (1).
3.
Apply angle gauge [2] to the brake pedal and measure pressing angle () between pressing angles (1) and (3) ( = 1 – 3). Operating effort at (2): . . . . . . . . . . 321 ±32.1 N (72.16 ±7.22 lbf)
30-76 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Measuring Brake Performance
★ Measurement conditions: Road: . . . . . . . . . . . . . . . . . . . . Flat, horizontal, dry, paved surface Braking initial speed: . . . . . . . . . . . . . . . . . . . . . .20 km/h (12 mph) Tire inflation pressure: . . . . . . . . . . . . . . . . . . . . Specified pressure Tire size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29.5-25-22PR Brake pedal pressing force: Specified pressing force: . . . . . . 294 ±29.4 N (66.09 ±6.61 lbf) Pressing time lag: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 second
Measurement Method 1.
Start the engine and drive the machine.
2.
Set the gearshift lever or gearshift switch to 4th position for run-up.
3.
When the travel speed reaches the braking initial speed (20 km/h (12 mph)), press the left brake pedal with the specified 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.
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.
WA500-6
30-77 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Accumulator Charge Pressure Special Tools Required Symbol
Part No.
Part Name
Qty
799-101-5002
Analog-type hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital-type hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
T
Remarks
★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
WARNING!
Stop the machine on level ground; lower the work equipment to the ground; and set chocks securely under the tires.
WARNING!
Stop the engine then depress the brake pedal at least 100 times to release the pressure inside the accumulator circuit.
Measuring 1.
Remove front cover (1) of the accumulator installation position situated on the right side of the machine.
2.
Connect oil pressure gauge [1] of hydraulic tester T to accumulator charge pressure measuring nipple (2). ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi).
30-78 b
WA500-6
TESTING AND ADJUSTING 3.
Measure the accumulator charge cut-in pressure. • Run the engine at low idle and then measure the oil pressure when the brake pressure caution lamp on the monitor panel goes out. Cut-in pressure: . . . . . . . . . . . .60.16 +5.1 0.0
4.
kg/cm² (856 +73 psi) 0.0
Measure the accumulator charge cutout pressure. ★ After the accumulator charge cut-in operation, measure the oil pressure when the indicator of the oil pressure gauge has risen and suddenly starts to drop. Cutout pressure: . . . . . . 99.93 +9.99 0.00
5.
BRAKE SYSTEM
kg/cm² (1,421 +142 psi) 0.0
After completing the work, remove the measuring instruments and return the parts you removed.
WA500-6
30-79 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Adjusting ★ When the accumulator charge cutout pressure is adjusted, the cutin pressure also changes in proportion to the ratio of the valve area. 1.
Remove cover (3) in the accumulator installation position.
2.
Loosen locknut (5) of accumulator charge valve (4) and turn adjustment screw (6) to adjust the pressure. ★ Adjustment screw: • Turned to the right, the pressure rises. • Turned to the left, the pressure lowers. Quantity of adjustment of adjustment screw (per turn): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.0 kg/cm² (811 psi) Locknut: 9.8 – 11.8 N•m (87 – 104 lbf in)
3.
After completing the measurement, check the accumulator charge cut-in and cutout pressures again following this procedure.
30-80 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Testing Wheel Brake Oil Pressure Special Tools Required Symbol
Part Number
Part Name
Qty
Remarks
1
793-520-1821
Nipple
1
–
2
793-520-1810
Joint
1
–
3
385-10178481
Bleeder screw
1
–
4
793-520-1831
Gauge assembly
1
G1/4 R1/8
U
WARNING!
Stop the machine on level ground; lower the work equipment to the ground; and set chocks securely under the tires. Apply the parking brake.
WARNING!
Even when the brake pedal is not usable due to problems with the brake-related equipment, high-pressure oil in the accumulator can erupt. It is mandatory to release pressure in the accumulator circuit by pressing the brake pedal at least 100 times while maintaining the engine at a stopped state.
★ Measure the oil pressure of the front brakes (right and left) and rear brakes (right and left) in a similar manner. ★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Measuring Wheel Brake Oil Pressure 1.
Remove cover (1).
2.
Remove bleeder screw (2).
WA500-6
30-81 b
TESTING AND ADJUSTING 3.
Install nipple U1, joint U2, bleeder screw U3, and gauge assembly U4.
4.
Connect hose [1] to bleeder screw U3 and then bleed air from the wheel brake circuit. ★ Refer to BRAKE SYSTEM: Bleeding Air from Brake Circuit in this section.
5.
Start the engine and measure the wheel brake oil pressure as the left brake pedal is pressed.
BRAKE SYSTEM
Drop in Wheel Brake Pressure 1.
Remove cover (1).
2.
Remove bleeder screw (2).
3.
Install nipple U1, joint U2, bleeder screw U3, and gauge assembly U4.
4.
Connect hose [1] to bleeder screw U3 and then bleed air from the brake circuit. ★ Refer to BRAKE SYSTEM: Bleeding Air from Brake Circuit in this section.
5.
Start the engine and accumulate pressure in the accumulator.
6.
Stop the engine and press the left brake to set the oil pressure to 60.16 kg/cm² (856 psi). Maintain this state for five minutes and then measure the pressure drop. • Do not move the brake pedal for five minutes. • After completing the measurement, remove the measuring instruments and return the currently removed parts to their original positions. Then bleed air from the wheel brake circuit. ★ Refer to BRAKE SYSTEM: Bleeding Air from Brake Circuit in this section.
30-82 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Measuring Wear of Brake Disc Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
V
Commercially available
Slide calipers
1
–
WARNING!
Stop the machine on level ground; lower the work equipment to the ground; and set chocks securely under the tires.
1.
Remove cap (1).
2.
Lightly press the brake pedal to the stroke end.
3.
While shaft (2) is pushed in, measure projection (x) from guide (3) using slide caliper V. ★ Keep pressing the brake pedal during measurement.
WA500-6
30-83 b
TESTING AND ADJUSTING
BRAKE SYSTEM
★ If the protrusion (x) in the figure is below 0, replace the disc. Wear (y): 4.0 – (x): . . . . . . . . . . . . . . . . . . . . Max. 4.0 mm (0.16 in)
4.
After testing, return cap (1). Cap (1): 29.4 – 39.2 N•m (22 – 29 lbf ft)
30-84 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Bleeding Air from Brake Circuit WARNING!
Stop the machine on level ground; lower the work equipment to the ground; and apply the parking brake.
WARNING!
Set chocks securely under the tires and support the lift arm with the fall-prevention rod.
★ After removing and installing a brake circuit part, bleed air from the brake circuit according to the following procedure. ★ Use the same procedure to bleed air from the front brake circuit and rear brake circuit.
Bleeding Air from Slack Adjuster WARNING!
Never bleed air while the engine is running since the drive shaft is rotating.
1.
Start the engine and increase the accumulator pressure. Check that the accumulator pressure is increased and stop the engine.
2.
Remove inspection cover (1) on the front side of the machine.
3.
Connect one end of the hose to bleeder screw (2) of the front slack adjuster and put the other end in an oil receiver.
4.
Press the brake pedal and loosen bleeder screw (2) about 1/2 turn to drain the oil. • Tighten bleeder screw (2) and then release the brake pedal slowly. ★ This work must be performed by two workers. One worker presses the brake pedal and the other drains the oil through the bleeder screw. • If the accumulator pressure decreases, start the engine to increase the pressure.
5.
Repeat the above procedure. When there are no bubbles in the oil flowing out of the hose, press the pedal fully and tighten the bleeder screw while the oil is flowing out. Bleeder screw: 7 – 9 N•m (62 – 80 lbf in)
6.
Following this same procedure, bleed air from rear slack adjuster (3).
WA500-6
30-85 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Bleeding Air from Brake Cylinder WARNING!
Never bleed air while the engine is running since the drive shaft is rotating.
1.
Remove cover (1).
2.
Connect one end of hose [1] to bleeder screw (2) and put the other end in an oil receiver.
3.
Press the brake pedal and loosen bleeder screw (2) about 1/2 turn to drain the oil. • Tighten bleeder screw (2) and then release the brake pedal slowly. ★ This work must be performed by two workers. One worker presses the brake pedal and the other drains the oil through the bleeder screw. • If the accumulator pressure decreases, start the engine to increase the pressure.
4.
Repeat the above procedure. When there are no bubbles in the oil flowing out of hose [1], press the pedal fully and tighten the bleeder screw while the oil is flowing out.
5.
Following this same procedure, bleed air from each brake cylinder. • Bleed air from the brake cylinders in order, from the one farthest from the brake valve. ★ Air bleeding order of cylinders: (1) Left rear brake cylinder (2) Right rear brake cylinder (3) Right front brake cylinder (4) Left front brake cylinder •
After bleeding air, carry out the brake performance test to check for any abnormality. ★ See BRAKE SYSTEM: Measuring Brake Performance in this section.
•
Drain oil again through each bleeder screw to see if there are any bubbles in the oil.
30-86 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Releasing Residual Pressure in Brake Accumulator Circuit WARNING!
Before disconnecting any of the following brake accumulator circuits, release residual pressure in those brake circuits.
★ Piping between accumulator charge valve and brake accumulator ★ Piping between accumulator charge valve and parking brake emergency release valve ★ Piping between brake accumulator and brake valve 1.
Stop the engine.
2.
Press the brake pedal at least 100 times to release the pressure from the brake accumulator circuit.
WA500-6
30-87 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Parking Brake Testing Parking Brake Performance ★ Measurement conditions: Tire inflation pressure: . . . . . . . . . . . . . . . . . . . Specified pressure Road: . . . . . . . . . . . . . . . . . . . . . 1/5 gradient (11° 20'), flat, and dry Machine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ready for operation
Measuring Method 1.
Start the engine and set the machine in the straight travel position. Drive up a slope of 1/5 gradient with no load in the bucket.
2.
Press the brake pedal to stop the machine; set the directional lever in the N position; and stop the engine.
3.
Turn the parking brake switch ON (to park) and then release the brake gradually. At this time, the machine must not move. ★ When the engine is stopped, the parking brake is turned ON (to park) automatically. ★ Measure the parking brake performance on an uphill and a downhill gradient.
30-88 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Measuring Parking Brake Oil Pressure Special Tools Required Symbol
Part Number
Part Name
Qty
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
799-401-3100
Adapter (Size 02)
1
Size 02
1 W
Remarks
2 3
WARNING!
Put chocks under the tires.
WARNING!
Install and remove the measuring instruments after the oil temperature drops completely.
★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Power train oil temperature: . . . . . . . . . . . . .Within operating range
Parking Brake Inlet Pressure 1.
Open rear frame left side cover (1).
2.
Remove parking brake inlet pressure pickup plug (10 x 1.25 mm) (2).
WA500-6
30-89 b
TESTING AND ADJUSTING 3.
Connect nipple W2 and oil pressure gauge [1] of hydraulic tester W1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
4.
While running the engine at low idle, measure the parking brake inlet pressure. WARNING!
BRAKE SYSTEM
Keep pressing the brake pedal for safety.
Measure the oil pressure both when the parking brake is ON and OFF. ★ If the parking brake solenoid valve output pressure is normal and the parking brake inlet pressure is abnormal, failure on the parking brake emergency release valve can be suspected. 5.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-90 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Parking Brake Emergency Release Valve Pilot Pressure ★ Transmission ECMV basic pressure 1.
Open rear frame left side cover (1).
2.
Disconnect parking brake emergency release valve pilot pressure hose (3).
3.
Install adapter W3 and connect parking brake pilot pressure hose (3).
4.
Connect nipple [2] and oil pressure gauge [1] in hydraulic tester W1. ★ Use the oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
5.
While running the engine at low idle, measure the parking brake pilot pressure. WARNING!
Keep pressing the brake pedal for safety.
★ Measure the oil pressure when the parking brake is OFF. 6.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
30-91 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Parking Brake Solenoid Valve Output Pressure 1.
Remove rear frame left side cover (1).
2.
Disconnect parking brake solenoid valve output pressure hose (4).
3.
Install adapter W3 and connect parking brake solenoid valve output pressure hose (5).
4.
Connect nipple [2] and oil pressure gauge [1] in hydraulic tester W1. ★ Use the oil pressure gauge with capacity of 61.18 kg/cm² (870 psi.
5.
Run the engine at low idle and measure output pressure of the parking brake solenoid valve. WARNING!
Keep pressing the brake pedal for safety.
★ Measure the oil pressure when the parking brake is OFF. ★ If the parking brake pilot pressure is normal and the parking brake solenoid valve output pressure is abnormal, failure on the check valve on the parking brake solenoid inlet side or failure on the parking brake solenoid can be suspected. 6.
After completing the measurement, remove the measurement tool after the measurement and make sure that the machine is back to normal condition.
30-92 b
WA500-6
TESTING AND ADJUSTING
BRAKE SYSTEM
Testing Wear of Parking Brake Disc Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
X
Commercially available
Slide calipers
1
–
★ If the parking brake does not work effectively, use this procedure to check the parking brake disc for wear. WARNING!
1.
Lower the work equipment to the ground and put chocks under the tires. When checking, stop the engine.
Drain the oil from the transmission case. Transmission case: 76 l (20 gal)
2.
Remove either of two plugs (1).
3.
Measure depth (a) from the end of cage (2) to piston (3) with slide calipers X. Depth at new disc (a): . . . . . . . . . . . . . . . . . . . . .28.9 mm (1.14 in) Wear limit depth (a): . . . . . . . . . . . . . . . . . . . . . .30.0 mm (1.18 in)
4.
If depth (a) exceeds the wear limit, remove parking brake disc (4) and measure its thickness (W). ★ Refer to POWER TRAIN: Parking Brake in the Disassembly and Assembly section. Service limit thickness (W):. . . . . . . . . . . . . . . . . 2.97 mm (0.12 in)
★ If the thickness of the parking brake disc is less than the service limit, replace the disc.
Refilling with Oil (Transmission Case) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
WA500-6
30-93 b
TESTING AND ADJUSTING
BRAKE SYSTEM
Releasing Parking Brake Manually ★ The parking brake is controlled hydraulically. If you cannot release the parking brake because of a problem with the transmission, emergency release solenoid valve, etc., you can move the machine by releasing the parking brake manually.
1.
WARNING!
Releasing the parking brake manually enables you to move the machine from a dangerous job site to a safe place. Use this method only in an emergency.
WARNING!
Lower the work equipment to the ground and put chocks under the tires to prevent the machine from moving.
WARNING!
When releasing the parking brake manually, stop the engine.
Drain the oil from the transmission case. Transmission case: 76 l (20 gal)
2.
Remove two plugs (1) (right and left).
3.
Prepare two cage mounting bolts (2) and tighten them alternately in plug (1) installation position. • Remove two bolts (2) on the diagonal positions. • Tighten two bolts (2) to push piston (3) and release the parking brake. • Tighten the two bolts gradually and evenly. (After they reach the seats, turn them four more turns.)
4.
After moving to a safe place, restore the machine to the original condition. Mounting bolt (2): . . . . . . . . . . . . . . . . . . . . . . . . . . Adhesive (LT-2) Mounting bolt (2): 98 – 123 N•m (72 – 91 lbf ft)
Refilling with Oil (Transmission Case) 1.
After releasing the parking brake manually, add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
30-94 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
WORK EQUIPMENT Control Lever Special Tools Required Symbol
Part No.
Part Name
Qty
Remarks
1
79A-264-0021
Push-pull scale
1
–
2
Commercially available
Scale
1
–
Y
WARNING!
Install the frame lock bar to the frame.
★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range Engine speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low idle
Measuring Operating Effort 1.
Install and fix tool Y1 to the work equipment control lever. • Install tool Y1 to the center of the knob. • Operate the work equipment control lever at the normal operating speed and measure the minimum effort necessary to operate the knob. ★ The shape in the photo is not identical with that of the WA500-6.
Measuring Stroke 1.
Operate the work equipment control lever and measure its stroke at each position. • Apply a mark to the lever knob and measure the stroke with scale Y2. • If the stroke is out of the standard range, check the linkage for play and the bushing for wear. ★ The shape in the photo is not identical with that of the WA500-6.
WA500-6
30-95 b
TESTING AND ADJUSTING
WORK EQUIPMENT
PPC Oil Pressure Special Tools Required Symbol
Part Number
Part Name
Qty
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-401-3200
Adapter (Size 03)
1
1 Z
2
Remarks
Size 03
WARNING!
Loosen the oil filler cap of the hydraulic oil tank slowly to release the pressure inside the tank.
WARNING!
Operate the work equipment control lever several times to release the remaining pressure from the PPC accumulator circuit.
★ Measurement condition: Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Shutoff Valve Basic Pressure 1.
Remove front cover (1) in the accumulator installation position situated on the right side of the machine.
30-96 b
WA500-6
TESTING AND ADJUSTING 2.
Disconnect hose (3) between the accumulator for PPC (2) and the shutoff valve. ★ Measurement at pickup plug (4) installation position is difficult.
3.
Connect adapter Z2 and hose (3).
4.
Connect nipple [2] and oil pressure gauge [1] of hydraulic tester Z1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
5.
Maintain the work equipment lock lever at the LOCK position.
6.
Start and run the engine at high idle and then measure the PPC oil pressure (shut-off valve basic pressure).
7.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
WA500-6
WORK EQUIPMENT
30-97 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Shut-off Valve Output Pressure 1.
Disconnect target PPC circuit hose (4) of measurement from the articulate on the right side of the machine.
2.
Connect adapter Z2 and hose (4).
3.
Connect nipple [2] and oil pressure gauge [1] of hydraulic tester Z1. ★ Use an oil pressure gauge with capacity of 61.18 kg/cm² (870 psi).
4.
Set the work equipment lock lever to the Free position.
5.
Start and run the engine at high idle and then measure the PPC oil pressure (shut-off valve output pressure).
6.
Do not operate the work equipment control lever.
7.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
★ You cannot adjust the PPC oil pressure.
30-98 D
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Oil Pressure Special Tools Required Symbol
Part Number
Part Name
Qty
799-101-5002
Hydraulic tester
1
Pressure gauge: 2.5, 6, 40, 60 MPa (362.59, 870.23, 5,801.51, 8,702.26 psi)
790-261-1204
Digital hydraulic tester
1
Pressure gauge: 60 MPa (8,702.26 psi)
799-101-5220
Nipple (10 x 1.25 mm)
1
Size: 10 x 1.25 mm
07002-11023
O-ring
1
–
3
799-401-2701
Differential pressure gauge
1
–
4
799-401-3200
Adapter (size 03)
1
Size 03
1
ZA
Remarks
2
Preparation Work 1.
Lower section (b) to the ground keeping (a) of bucket 30 – 50 mm (1.18 – 1.97 in) off the ground.
2.
After stopping the engine, lower bucket bottom (a) and (b) to the ground using the work equipment control lever. ★ Make sure the bucket is completely on the ground.
Measuring Work Equipment Relief Pressure 1.
Remove front frame left side cover (1).
2.
Disconnect hose (4) from union (3) of work equipment control valve (2).
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30-99 b
TESTING AND ADJUSTING 3.
Connect adapter ZA4 between union (3) and hose (4).
4.
Connect nipple [2] in hydraulic tester ZA1 and oil pressure gauge [1] of hydraulic tester ZA1. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi).
5.
Start the engine and raise the lift arm up about 400 mm (15.75 in). • Measure the oil pressure when the bucket is tilted back at high idle.
6.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition. WARNING!
WORK EQUIPMENT
After measuring the oil pressure, release pressure in the circuit and then remove the oil pressure gauge, nipple, and adapter using the same procedure as described in WORK EQUIPMENT: Oil Pressure: Preparation Work.
Measuring Unload Pressure 1.
Remove front frame left side cover (1).
2.
Disconnect hose (4) from union (3) of work equipment control valve (2).
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WA500-6
TESTING AND ADJUSTING 3.
Connect adapter ZA4 between union (3) and hose (4).
4.
Connect nipple [2] in hydraulic tester ZA1 and oil pressure gauge [1] of hydraulic tester ZA1. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi).
5.
Start and run the engine at high idle and then measure the oil pressure when all levers are set to neutral.
6.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition. WARNING!
WORK EQUIPMENT
After measuring the oil pressure, release pressure in the circuit and then remove the oil pressure gauge, nipple, and adapter using the same procedure as described in WORK EQUIPMENT: Oil Pressure: Preparation Work.
Measuring LS Differential Pressure ★ Before measuring LS differential pressure, make sure the work equipment relief oil pressure and work equipment PPC oil pressure are normal. ★ Determine the LS differential pressure by measuring the work pump discharge pressure and LS pressure (negative pressure of actuator) at the same time and calculating the difference between them. 1.
Remove front frame left side cover (1).
2.
Remove side cover (4) on the work equipment pump.
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30-101 b
TESTING AND ADJUSTING 3.
Disconnect hose (4) from union (3) of work equipment control valve (2).
4.
Connect adapter ZA4 between union (3) and hose (4).
5.
Connect nipple [2] in hydraulic tester ZA1 and oil pressure gauge [1] of hydraulic tester ZA1 or differential pressure gauge ZA3. ★ When using the differential oil pressure gauge, connect its high-pressure side. (Connect the low-pressure side to LS.)
WORK EQUIPMENT
The differential pressure gauge requires a 12 V power supply; connect a battery. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi). Since the differential pressure is 15.30 kg/cm² (218 psi) at maximum, the same gauge can be used throughout the measurement.
6.
Remove LS pressure pickup plug (10 x 1.25 mm) (6) from the work equipment pump.
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WA500-6
TESTING AND ADJUSTING 7.
WORK EQUIPMENT
Connect nipple ZA2 and oil pressure gauge [1] or differential pressure gauge ZA3 of hydraulic tester ZA1. ★ When using the differential oil pressure gauge, connect its low-pressure side. (Connect the high-pressure side to PS.) The differential pressure gauge requires a 12 V power supply; connect a battery. ★ Use an oil pressure gauge with capacity of 407.89 kg/cm² (5802 psi). Since the differential pressure is 15.3 kg/cm² (218 psi) at maximum, the same gauge can be used throughout the measurement.
8.
Start the engine and raise the lift arm upward about 400 mm (15.75 in).
9.
Start and run the engine at high idle and then measure the work equipment pump discharge pressure and LS pressure (actuator negative pressure) at the same time under the following condition. ★ When the lift arm lever is set to half stroke • •
Prevent the lift arm cylinder from turning to full stroke as long as measurement is continued. Calculation of LS differential pressure:
LS differential pressure = . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pump discharge pressure – LS pressure
10. After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition. WARNING!
WA500-6
After measuring the oil pressure, release pressure in the circuit and then remove the oil pressure gauge, nipple, and adapter using the same procedure as described in WORK EQUIPMENT: Oil Pressure: Preparation Work.
30-103 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Adjusting Unload Valve ★ Adjustment of the unload valve is not available.
Adjusting Work Equipment Relief Pressure 1.
Remove front frame right side cover (7).
2.
Loosen locknut (9) of main relief valve (8) of work equipment control valve (2) and then adjust the pressure by turning adjustment screw (10). ★ Adjustment screw: • When turned clockwise, the oil pressure increases. • When turned counterclockwise, the oil pressure decreases. Quantity of adjustment per turn of adjustment screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.97 kg/cm² (1820 psi) Locknut: 29.4 – 39.2 N•m (22 – 29 lbf ft)
3.
After completing the measurement, remove the measurement tool and make sure that the machine is back to normal condition.
30-104 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Adjusting LS Differential Pressure 1.
Loosen locknut (12) of LS valves (11) of work equipment pump assembly (5) and then adjust the pressure by turning adjustment screw (13). ★ Adjustment screw: • Turning the screw clockwise increases the pressure. • Turning it counterclockwise decreases the pressure. Quantity of adjustment per turn of adjustment screw: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.26 kg/cm² (189 psi) Locknut: 49 – 68.6 N•m (36 – 51 lbf ft)
2.
After the adjustment, measure the LS differential pressure again using the WORK EQUIPMENT: Oil Pressure: Measuring LS Differential Pressure procedure.
WA500-6
30-105 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Bleeding Air from Work Equipment Circuit From Work Equipment Pump (piston pump) 1.
Remove side cover (1) on the work equipment pump.
2.
Stop the engine and then loosen air bleeding plug (3) of work equipment pump (2) by 1/2 to 1 turn.
3.
As oil free from air starts to flow out of air bleeding plug (3) of work equipment pump (2), tighten air bleeding plug (3). Air bleeding plug (3): 34.3 – 44.1 N•m (25 – 33 lbf ft)
4.
Start the engine and run it at low idle for at least five minutes.
From Hydraulic Cylinder 1.
Start the engine and run it at low idle for at least five minutes.
2.
While running the engine at low idle, repeat raising and lowering of the lift arm four to five times. ★ Do not operate the piston rod beyond a position 100 mm (3.94 in) in front of the stroke end to prevent relieving.
3.
While running the engine at high idle, repeat raising and lowering of the lift arm four to five times. ★ Do not operate the piston rod beyond a position 100 mm (3.94 in) in front of the stroke end to prevent relieving.
4.
Operate the piston rod to the stroke end at low idle to relieve it.
5.
Repeat Steps 2 and 3 for the bucket and steering. ★ When a cylinder is replaced, this operation should be performed before connecting the piston rod.
30-106 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Releasing Residual Pressure in Hydraulic Circuit Between Respective Hydraulic Cylinders and Control Valve ★ When disconnecting the pipes between respective hydraulic cylinders and the work equipment, release the residual pressure in the circuit according to the following procedure. 1.
Stop the engine.
2.
Loosen the oil filler cap gradually to release the internal pressure of the hydraulic tank.
3.
Set the work equipment lock lever to the Free position.
4.
Turn the starting switch ON.
5.
Release the residual pressure using the work equipment control lever.
From ECSS (Travel Damper) Circuit WARNING!
When disconnecting the piping of the ECSS circuit (between the accumulator for the ECSS and the work equipment control valve), release the pressure of the accumulator for the ECSS according to the following procedure.
1.
Remove front frame left side cover (1).
2.
Loosen locknut (4) of ECSS pressure relief plug (3) on work equipment control valve (2).
3.
Loosen adjustment plug (5) 1/2 – 1 turn to release the accumulator pressure.
4.
After releasing the residual pressure, tighten plug (5) and locknut (4) securely in this order. • Loosen locknut (4) to the maximum before tightening plug (5). • After tightening plug (5), tighten locknut (4). Plug: 19.6 – 27.5 N•m (15 – 20 lbf ft) Locknut: 19.6 – 27.5 N•m (15 – 20 lbf ft)
WA500-6
30-107 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Moving Machine When Removing Operator Cab ★ It might be necessary to remove the operator cab to move a machine into a maintenance shop or to move a machine to a safe place after removing a damaged operator cab. In such cases, using the emergency parking brake release switch allows you to move the machine. ★ In this situation, the emergency parking brake release switch is used instead of the parking brake switch used on the machine. ★ The harness is prepared only for moving the machine into a maintenance shop or moving it from a work site to a safer place. It should not be used for any purpose other than this. WARNING!
Lower the work equipment to the ground; apply the parking brake; and put chocks under the tires so that the machine does not move.
1.
Remove operator cab assembly (1). ★ Refer to CAB AND ATTACHMENTS: Cab and Floor Frame in the Disassembly and Assembly section.
2.
Remove fuse box cover (2).
3.
Start the engine and set emergency parking brake release switch (3) to the release side to enable the machine to move to a maintenance shop or safe place. WARNING!
4.
Remove the chocks to move the machine.
After moving the machine, return the emergency parking brake release switch to the original position.
30-108 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Bucket Positioner ★ Measurement conditions: Engine coolant temperature: . . . . . . . . . . . .Within operating range Hydraulic oil temperature: . . . . . . . . . . . . . .Within operating range
Testing and Adjusting 1.
Stop the engine and make sure that clearance (a) between bucketlevelness detecting proximity switch (1) and detection bar (3), and between maximum tilt-detecting proximity switch (2) and detection bar (3) is within the standard value. Standard clearance (a): . . . . . . . . . . . . . .3 – 5 mm (0.12 – 0.20 in)
2.
Run the engine at high idle and check the operating position. (Measure three times and obtain the average.)
Adjusting Clearance 1.
Adjust switch nut (5) so that clearance (b) between the tip of switch protector (4) and switch (1) and sensing surface (2) conforms to the standard value. Then fix them to the adjusted positions. Standard clearance (b): . . . . . . . . . . .0.6 – 1.0 mm (0.02 – 0.04 in) Switch nut: 14.7 – 19.6 N•m (11 – 15 lbf ft)
2.
Use shims and the proximity switch bracket mounting bolt to adjust clearance (a) between proximity switch (1), sensing surface (2), and detection bar (3) to the standard range. Then fix them to the adjusted positions. Standard clearance (a): . . . . . . . . . . . . . 3 – 5 mm (0.12 – 0.20 in)
★ Using shims, adjust detection bar (3) so that clearance (a) conforms to the standard value along every stroke of the detection bar.
WA500-6
30-109 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Adjusting Bucket-Levelness Detecting Proximity Switch 1.
Start the engine and raise the bucket.
2.
Activate bucket-levelness detecting proximity switch (1) while operating the engine at 1,500 rpm.
3.
Lower the bucket to the ground.
4.
Make sure the bucket angle is set in the range of 0° – 1° downward to the ground. Repeat this three times and if the angle does not conform to the above angle, adjust it as described in Step 5.
5.
Loosen two mounting bolts of bucket-levelness detecting proximity switch bracket (6) to slide bracket (6) installing position and adjust it.
6.
Confirm three times that the bucket angle is set in the range of 0° – 1° downward to the ground.
30-110 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Adjusting Maximum Tilt-Detecting Proximity Switch 1.
Set height (c) of the pin center of the lift arm end to 1,000 mm (39.37 in) from the ground surface.
2.
Tilt the bucket to the maximum position.
3.
Loosen two mounting bolts of maximum tilt-detecting proximity switch bracket (7) to slide bracket (7) installing position and adjust it. ★ Set distance (d) from the end of detection bar (3) to the center line of proximity switch (2). Dimension: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 mm (1.97 in).
WA500-6
30-111 b
TESTING AND ADJUSTING
WORK EQUIPMENT
Position-Detecting Lever Testing ★ Make sure that clearance (a) between lift arm angle sensor (1) and detection lever (2) is within the standard value. Clearance (a): . . . . . . . . . . . . . . . . . . . 0.5 – 1 mm (0.02 – 0.04 in)
Adjusting ★ If clearance (a) does not conform to the standard value, adjust it according to the following procedure. 1.
Loosen bolt (3).
2.
Adjust position of detection bar (2) so that clearance (a) between lift arm angle sensor (1) and detection lever (2) becomes the standard value
3.
Tighten bolt (3).
30-112 b
WA500-6
TESTING AND ADJUSTING
WORK EQUIPMENT
Checking Proximity Switch Operation Pilot Lamp The proximity switch has a pilot lamp to indicate the operating condition of the switch. Use this pilot lamp to adjust the proximity switch. ★ A: Operation pilot lamp (Red)
Proximity Switch Bucket-levelness detecting proximity switch and maximum tiltdetecting proximity switch
WA500-6
Relative Position of Proximity Switch Sensing Surface and Sensing Object
Operation Pilot Lamp
Near
ON
Far
OFF
Remarks
Operates when center of switch is near.
30-113 b
TESTING AND ADJUSTING
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM Troubleshooting Procedure for Testing Diodes ★ Check an assembled-type diode (8 pins) and independent diode (2 pins) in the following manner. ★ The conductive directions of the assembled-type diode are indicated on the surface of the diode as shown in the figure.
★ The conductive directions of the single diode are indicated on the surface of the diode as shown in the figure.
Using Digital-Type Circuit Tester 1.
Switch the testing mode to diode range and confirm the indicated value. ★ Voltage of the battery inside is displayed with conventional circuit testers.
2.
Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of the diode. Confirm the indicated value.
3.
Determine acceptability of the diode from the indicated value. • Indicated value remains unchanged: Conduction is absent (Failure) • Indicated value changes: The diode has conductivity (Normal)★ ★ A value between 460 to 600 is indicated for silicon diodes.
30-114 b
WA500-6
TESTING AND ADJUSTING
ELECTRICAL SYSTEM
Using Analog-Type Circuit Tester 1.
Switch the testing mode to resistance range.
2.
Apply the leads of the tester as explained below and check the movement of the pointer. A. Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of the diode. B. Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side.
3.
Determine whether a specific diode is good by the way the pointer swings. •
With connection 2A above, the pointer does not move. It swings, however, when connection 2B is used. • Normal (however, magnitude of the pointer’s move (indicating the resistance value) varies depending on the given tester model and the measurement range selected).
•
The pointer swings with both connections 2A and 2B: •
•
Defective (Internal short circuit)
The pointer does not swing with both connections 2A and 2B: • Defective (Internal wire break)
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30-115 b
TESTING AND ADJUSTING
ELECTRICAL SYSTEM
Preparation Work for Troubleshooting Electrical System ★ When carrying out troubleshooting for an electric circuit related to the machine monitor, transmission controller, work equipment controller, or KOMTRAX terminal, expose the related connectors according to the following procedure. ★ Unplug and plug the connectors of special lock types according to the following procedure.
Machine Monitor 1.
Unplug the following connectors from cover (1). • L58 connector: Parking brake switch • L59 connector: ECSS switch • L65 connector: Machine monitor mode selector switch 2 • L66 connector: Machine monitor mode selector switch 1 • L67 connector: Front working lamp switch • L68 connector: Rear working lamp switch • L69 connector: Load meter mode selector switch (if equipped) • L70 connector: Load meter mode display switch (if equipped) • L72 connector: Beacon lamp switch (if equipped) ★ Pull the switches out of the cover and unplug the connectors. ★ Do not insert your hand through the bottom of the cover and try to forcibly unplug the connector. Forcibly unplugging a connector or switch may damage it.
2.
Remove interior covers (2).
3.
Remove cover (1).
30-116 b
WA500-6
TESTING AND ADJUSTING 4.
Remove bracket-mounting bolt (4) of machine monitor (3) and reverse the machine monitor. ★ Be careful not to pull the wiring harness forcibly.
5.
Connect diagnostic T-adapters to the following wiring connectors of machine monitor (3). • L51, L52, L53, L54, L55, L56, and L57 connectors
ELECTRICAL SYSTEM
Transmission Controller 1.
Remove covers (5) and (6) through the rear side of the operator seat.
2.
Connect diagnostic T-adapters to connectors L02, L03, and L04 of transmission controller (7). ★ When it is difficult to install or remove the connectors, do it after removing the transmission controller first. • Connectors are fixed with screws. Loosen the screws before unplugging the connectors. • When the connectors are returned to the original position, tighten the screw to the specified torque. Screw: 2.82 N•m (25 lbf in)
WA500-6
30-117 b
TESTING AND ADJUSTING
ELECTRICAL SYSTEM
Work Equipment Controller 1.
Remove covers (5) and (6) through the rear side of the operator seat.
2.
Connect diagnostic T-adapters to connectors L05, L06, and L07 of work equipment controller (8). ★ When it is difficult to install or remove the connectors, do it after removing the work equipment controller first. • Connectors are fixed with screws. Loosen the screws before unplugging the connectors. • When the connectors are returned to the original position, tighten the screw to the specified torque. Screw: 2.82 N•m (25 lbf in)
KOMTRAX Terminal 1.
Remove covers (5) and (6) through the rear side of the operator seat.
2.
Connect diagnostic T-adapter to connector L80 of KOMTRAX terminal (9). ★ When it is difficult to plug or unplug the connectors, do it after removing the KOMTRAX terminal. • Connectors are fixed with screws. Loosen the screws before unplugging the connectors. • When the connectors are returned to the original position, tighten the screw to the specified torque.. Screw: 2.2 – 2.8 N•m (20 – 25 lbf in)
30-118 b
WA500-6
TESTING AND ADJUSTING
KOMTRAX TERMINAL SYSTEM
KOMTRAX TERMINAL SYSTEM ★ Whether the KOMTRAX system is installed at the time of manufacture or retrofitted, you must do the following two actions before you can use the system: • •
Register the machine. Activate the KOMTRAX system.
Starting KOMTRAX Terminal Operations If the KOMTRAX Terminal Has Been Installed at the Plant Before Shipment ★ If the KOMTRAX terminal has been installed at the plant before shipment (as standard equipment), do the following procedure. 1.
Register the machine on the KOMTRAX web screen. • Notify the KOMTRAX operations administrator of model, part number, and serial number. ★ Refer to Global KOMTRAX Web Reference Manual (for Key Person) for the procedure.
2.
Activate the system • Activate the system by pressing APPLY on the KOMTRAX web screen. ★ Refer to Global KOMTRAX Web Reference Manual (for Key Person) for the procedure.
3.
Press the start button on the KOMTRAX web screen to start communication. ★ Refer to Global KOMTRAX Web Reference Manual (for Key Person) for the procedure.
★ The terminal is now ready to use. If the KOMTRAX Terminal is Retrofitted ★ When retrofitting the KOMTRAX terminal after shipment (retrofitted machine), do the Station Opening Check in Machine Side and the Application for the Start of Use procedures in this section. Remark During the communication and check, you should park the machine outside to enable frequent communication with the ORBCOMM satellite. The station opening check cannot be completed indoors where radio waves from the satellite are intercepted.
Station Opening Check in Machine Side ★ Complete Steps 3 to 5 within 60 seconds. If 60 seconds or more elapse, begin with Step 1 again. 1.
Turn OFF the starting switch and then, after making sure five seconds have elapsed, proceed to the next step.
2.
Visually check that check connectors 1 and 2 are connected. • Check connector 1: CHK0 • Check connector 2: CHK1
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30-119 b
TESTING AND ADJUSTING 3.
When about five seconds have elapsed after the starting switch was set to ACC, make sure that the 7-segment indicator lamp changes to hyphen “–” on the KOMTRAX terminal.
4.
Unplug inspection connector 1 and wait for about five seconds. ★ Make sure that the connector is unplugged.
5.
Replug inspection connector 1 and wait for about five seconds. ★ If the KOMTRAX terminal detects that the connector was unplugged and replugged, the dot on the 7-segment indicator lamp blinks a few times.
30-120 b
KOMTRAX TERMINAL SYSTEM
WA500-6
TESTING AND ADJUSTING 6.
KOMTRAX TERMINAL SYSTEM
Make sure that the 7-segment indicator lamp is indicated normally on the KOMTRAX terminal. ★ If so, the 7-segment indicator lamp indicates characters (d), (0), and (–) repeatedly for 30 seconds after Step 5 has ended. ★ Those characters, even if displayed normally, change to a character other than hyphen (–) after 30 seconds or more have elapsed. ★ The display may change to a character other than (0) even within 30 seconds.
• •
If [Normal] is indicated, proceed to the next step. If (–) remains displayed, do Steps 1 to 5 again.
7.
Turn the starting switch to the START position for about five seconds and make sure that the engine does not start. • If the engine starts, repeat the procedure from Step 1. • Do not return the starting switch to the OFF position.
8.
Turn the starting switch from the ACC position to the START position again and make sure that the engine starts.
9.
Make sure that the KOMTRAX terminal’s indicator lamps are normally turned on. • Move on to the next step if the display is [Normal]. (It takes from 90 seconds to 15 minutes before the display turns normal.) • If [GPS position data detection trouble] is indicated, check if the GPS antenna or cable appears abnormal. If there is an abnormality, repair it and start from Step 1 again. • If [Reception trouble] is indicated, check if the communication antenna or cable appears abnormal. If there is an abnormality, repair it then repeat from Step 1 again. • If [GPS position data detection trouble and reception trouble] is indicated, check if the GPS antenna/cable or communication antenna/cable appears abnormal. If there is an abnormality, repair it and start from Step 1 again.
WA500-6
30-121 b
TESTING AND ADJUSTING
KOMTRAX TERMINAL SYSTEM
★ If [Network trouble] is indicated, check the display of [LEDC4] (refer to KOMTRAX Terminal Indicator Lamps). If the CAN is not recognized, check the CAN harness of the KOMTRAX terminal. If there is any abnormality, repair it and start from Step 1 again. [A]: Normal [B]: GPS position data detection trouble [C]: Reception trouble [D]: GPS position data detection trouble and reception trouble [E]: Network trouble
10. Turn the starting switch OFF. 11. Make sure that the 7-segment indicator lamp displays normally after five seconds have elapsed. ★ When [Normal] appears, station opening check is completed. ★ If [Abnormal] appears, station opening check has not ended normally. Perform the procedure from Step 1 again. ★ If station opening check ends normally, it should not be rechecked.
30-122 b
WA500-6
TESTING AND ADJUSTING
KOMTRAX TERMINAL SYSTEM
Application for the Start of Use ★ Application for the start of use should be made only after the sign-up test is finished. 1.
Notify the KOMTRAX operations administrator of the following information about the machine that completed the station opening check in the machine side. A. Information (model, part number, and serial number) about the machine that completed the station opening check in the machine side B. Part number and serial number of KOMTRAX terminal C. Value of service meter when the KOMTRAX terminal was installed (in 0.1 hours)
2.
The KOMTRAX operations administrator will use a KOMTRAX client PC to register the machine. • Refer to Global KOMTRAX Web Reference Manual (for Key Person) for the procedure.
★ The terminal is now ready for use.
WA500-6
30-123 b
TESTING AND ADJUSTING
KOMTRAX TERMINAL SYSTEM
KOMTRAX Terminal Indicator Lamps (if equipped)
LED Lamps for CPU
7-Segment and Dot Displays for CPU
1.
LED-C1 (State of R or ACC signal)
7.
7-Segment (Number of unsent mails)
2.
LED-C2 (Starting output state)
8.
Dot (GPS positioning state)
3.
LED-C3 (State of S-NET or C signal)
4.
LED-C4 (CAN state)
5.
LED-C5 (Download write state)
6.
LED-C6 (Download write state)
In the KOMTRAX system, information and processing details are displayed on the LED on the upper surface of the KOMTRAX terminal. If a detect is suspected in the system, perform the following checks. •
Check antennas.
•
Check terminal LED displays.
Before using the KOMTRAX system, make sure that the application for starting its use is completed, as well as the station opening check in the machine side.
30-124 b
WA500-6
TESTING AND ADJUSTING
KOMTRAX TERMINAL SYSTEM
Checking Antennas ★ Before checking the LED displays, check that there is no abnormality around the communication antenna and GPS antenna. •
The communication antenna should not be off or damaged.
•
The communication antenna cable should not be broken and is normally connected to the KOMTRAX terminal.
•
The GPS antenna should not be off or damaged.
•
The GPS antenna cable should not be broken and is normally connected to the KOMTRAX terminal.
Checking Terminal LED Displays 1.
Meaning of CPU LED displays ★ The LED displays should be checked with the starting switch turned ON, starting switch at START, or with the engine started.
No.
1
2
3
4
5
LED
LED-C1
LED-C2
LED-C3
LED-C4
Name/Function
States of starting switch ACC signal and alternator R signal
State of engine control signal
States of S-NET connection and starting switch C signal
State of CAN connection
LED-C5
Display (*1)
Description
ON
Starting switch ACC signal: ON, Alternator R signal: ON
Fast blink
Starting switch ACC signal: OFF, Alternator R signal: ON
Slow blink
Starting switch ACC signal: ON, Alternator R signal: OFF
OFF
Starting switch ACC signal: OFF, Alternator R signal: OFF
ON
Engine control signal: ON
OFF
Engine control signal: OFF
ON
S-NET: Connected, Starting switch C signal: OFF
Fast blink
Starting switch C signal: ON
Slow blink
(Not used)
OFF
S-NET: Not connected, Starting switch C signal: OFF
ON
CAN: Connected (without fuel sensor)
Fast blink
CAN: Connected (with fuel sensor)
Slow blink
CAN: Not connected (with fuel sensor)
OFF
CAN: Not connected (without fuel sensor)
1-LED ON
Download write mode (system administrator only function)
2-LED OFF
Normal operation mode
Download write state 6
LED-C6
★ *1: Blink types and blink times Fast blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 1-second cycle Slow blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 4-second cycle
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KOMTRAX TERMINAL SYSTEM
Contents of 7-segment and dot displays for CPU ★ The LED display should be checked with the starting switch turned ON. No.
7
LED
7-segment
8
Dot
Name/Function
Number of unsent mails, satellite capture state
Display (*2)
Description
0 to 9 displayed
The number indicates the number of unsent mails (10 or more unsent mails are indicated by “9”). Light-on indicates that the machine is in the process of capturing the satellite.
0 to 9 fast blink
The number indicates the number of unsent mails (10 or more unsent mails are indicated by “9”). Fast blink indicates that the satellite is not captured.
ON
GPS positioning was completed. (The position can be confirmed.) *3
OFF
GPS positioning was not completed. (The position cannot be confirmed.) *3
GPS positioning status
★ *2: Blink types and blink times Fast blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 1-second cycle Slow blink: . . . . . . . . . . . . . . . . . . . .Blinks in about 4-second cycle
★ *3: Supplementary explanation of GPS positioning status • •
One or more minutes may pass until GPS positioning is completed after the starting switch is turned ON even in an outdoor service area. GPS positioning fails in a weak-signal or non-service area.
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MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM Adjusting Replaced, Reassembled, or Added Sensors and Controllers ★ If any of the following components or parts are replaced, disassembled, or assembled, initialize the sensors, solenoids, etc. using the machine monitor. ★ Adjust the items in alphabetical order (A) using the machine monitor. Replaced, Disassembled, Assembled, or Added Component or Option Machine monitor
Adjustment Item (Order) N, K, L, M, A, B, C
Transmission main body
E, D, F
Transmission controller
A, B, E, D, F
Transmission ECMV solenoid
E, D, F
Lift arm angle sensor
G, K, L, M
Work equipment control valve
I
Work equipment EPC solenoid
I
Work equipment electric lever
H
Work equipment controller
A, B, G, H, I
Work equipment bucket horizontal proximity switch
J
Bucket
J, K, L, M
Lift arm
B, G, J, K, L, M
Adding and removing an optional device
Adjustment Item
B
Contents of Adjustment
Section No.
A
Selection of model
12 (*1)
B
Selection of option
10 (*1)
C
Machine serial number input
11 (*1)
D
Adjustment of transmission ECMV current
7-1 (*1)
E
Reset of transmission initial learning
7-2 (*1)
F
Transmission initial learning
7-2 (*1)
G
Adjustment of work equipment controller lift arm angle
7-4 (*1)
H
Adjustment of work equipment EPC lever detent position
7-5, 7-6, 7-7 (*1)
I
Adjustment of work equipment EPC starting current
J
Adjustment of bucket positioner
K
Adjustment of load meter lift arm angle
L
No load calibration of load meter
— (*3)
M
Loaded calibration of load meter
— (*3)
7-5, 7-6, 7-7, 7-8 (*1) — (*2) 7-17, 7-18 (*1)
★ *1: Description No. in MACHINE MONITOR SYSTEM: Service Mode in this section ★ *2: See WORK EQUIPMENT: Bucket Positioner: Testing and Adjusting and WORK EQUIPMENT: Checking Proximity Switch Operation Pilot Lamp in this section. ★ *3: See the Operation manual provided with your load meter.
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Adjustment for User’s Needs ★ If the user indicates a problem or requests a solution for a problem, use the machine monitor to change or adjust the items shown in the following table. Contents of Remarks or Request
Adjustment Item
Want to change the display unit of the speedometer.
N
Want to use the short ton for the load meter weight display unit.
O
Want to turn off display of the economy lamp.
P
Want to suppress hunting.
Q
Want to change the gearshift travel speed in the auto-shift.
Q
Fine control is not available in the lift arm raise/lower operation or the response in this operation is poor.
R
Fine control is not available in the bucket tilt/dump operation or the shock dump effort is weak.
S
Large shocks result when stopping the lift arm raise/lower or a substantial overrun occurs at stopping.
T
Matching at loading to dump truck is poor.
U
Travel speed indication is too fast/slow.
V
Want to turn off the character display-based travel speed/engine speed indication.
W
Want the power mode to turn on as the starting switch is turned on. (Power mode priority)
X
Adjustment Item
Contents of Adjustment
Section No. (*)
N
Optional setting and selection of speed unit
10
O
Optional setting and selection of short ton switching
10
P
Optional setting and selection of economy lamp display
10
Q
Adjustment of sensor and adjustment of transmission L mode shift point
7-3
R
Adjustment of sensor and change of lift arm lever pattern
7-13
S
Adjustment of sensor and change of bucket lever pattern
7-14
T
Adjustment of sensor and adjustment of lift arm lower stop modulation
7-15
U
Adjustment of sensor and adjustment of pump cutoff pressure in lift arm raise
7-16
V
Optional setting and change of tire size
10
W
Optional setting and change of travel speed/engine speed display on character display and normal screen
10
X
Optional setting and change of power mode priority
10
★ *1: Section No. in MACHINE MONITOR SYSTEM: Service Mode in this section. ★ *2: Change of the display unit of the speedometer as well as the weight is not available when the specification is prepared for a country where the SI unit is employed.
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Normal and Special Functions of Machine Monitor The machine monitor (EMMS) is equipped with normal functions and special functions. Data items are displayed on the character display in the middle of the machine monitor. Depending on the internal setting of the machine monitor, the display items are divided into automatic display items and items displayed when the machine monitor switches are operated.
Normal Functions: Operator Mode Functions for which the content is normally displayed or which can be displayed and operated by the operator using the switches. ★ See the Operation & Maintenance Manual for details of the Operator mode.
Special Functions: Service Mode Functions which the serviceman can display and operate with the special switches to perform inspection, maintenance, and troubleshooting. Operator Mode Table
Service Mode Table
Section No. **
Operator Mode
Section No. **
Service Mode
1
Service meter/clock display function (*1)
1
Switch to Service mode and screen display
2
Load meter function (if equipped) (*1)
2
Electrical system failure history display function
3
Odometer display function
3
Mechanical system failure history display function
4
Maintenance monitoring function
4
Real-time monitoring function
5
Telephone No. input function
5
Cylinder cut-out function
6
Language selection function
6
No injection cranking function
7
Monitor brightness adjustment function
7
Adjustment function
8
Time adjustment function (*1)
8
Maintenance monitoring function
9
Travel speed/engine speed display selecting function
9
Operation information display function
10
Character display: Travel speed/engine speed display/non-display selecting function (*2)
10
Optional device selecting function
11
Action code display function
11
Machine serial number input function
12
Failure code display function
12
Model selection function
13
Initialize function
Appendix
Setting of machine monitor when monitor is exchanged
★ **: The number in this column correlates with an item number in the Operator Mode or the Service Mode function descriptions in this section. ★ *1: This display is not available when the load meter function is turned off through the OPT option in the Service mode. ★ *2: Not displayed if “Travel speed/Engine speed on character display” are turned off on the character display by selecting the OPT option in the Service mode.
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Functions and Flow of Service Mode Remark Some items may not be used, depending on the setting and specification, although they are displayed on the monitor (for details, see the text).
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Operator Mode ★ The Operator mode is described below. ★ For details of the Operator mode, see Section 10, Structure, Function and Maintenance Standard, or the Operation and Maintenance Manual. Remark The number after the function description correlates to the number in the Section No. column in the Operator Mode table located in Normal and Special Functions of Machine Monitor (page 30-129) in this section.
Service Meter/Clock Display Function (1) If the starting switch is turned ON, the service meter is displayed on the top line.
Load Meter Function (if equipped) (2) Press the [] switch on the ordinary Service Meter display screen to display the load meter function. ★ For more information, see EXPLANATION OF COMPONENTS: Meter Display Portion: Load Meter (if equipped) in the Operation section of the Operation & Maintenance Manual.
Odometer Display Function (3) •
Press the [] switch from the ordinary Service Meter display screen to display the odometer.
•
When the load meter option is selected, press the [<] switch to display the odometer.
★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
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MACHINE MONITOR SYSTEM
Maintenance Monitoring Function (4) •
Filter, oil replacement time display (automatic display) As the time approaches to replace the oil or filter, the machine monitor automatically displays this information to alert the operator.
•
Resetting replacement time (selection menu) When maintenance operation for oil or a filter is completed, the machine monitor allows you to reset the time interval through the switch operation. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
Telephone Number Input Function (5) Telephone numbers are entered through the switch operation. Modification or cancellation of the phone numbers in the machine monitor is also available through the switch operation. ★ When action code [E03] is displayed, a phone number is displayed along with [CALL]. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
Language Selection Function (6) Switch operation allows you to select a display language for the machine monitor. ★ The Service mode function is not included in the display selection function because it is always displayed in English. ★ Available languages: English, Japanese, German, French, Italian, Spanish, and Swedish. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
Monitor Brightness Adjustment Function (7) Brightness of the machine monitor is adjustable in seven levels through the switch operation. ★ Adjustment of brightness is available by two methods: adjustment of the monitor alone and separate adjustment of the monitor and liquid crystal. Remark The starting switch must be ON and the headlamps turned ON. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
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Time Adjustment Function (8) The time indicated by the clock of the machine monitor is adjustable. ★ This item can be changed only when the optional load meter function is selected. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
Travel Speed/Engine Speed Display Selecting Function (9) A unit to be used for the machine monitor speed display is selectable from km/h and MPH. It is also possible to turn the display of the travel speed and engine speed ON or OFF. ★ This function is available only when the RPM OPT option is selected. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
Travel Speed/Engine Speed Display/Non-Display Selecting Function (10) The travel speed or engine speed displayed on the character display of machine monitor can be turned ON and OFF. ★ This function is available only when the RPM/SPEED option is selected. ★ When the travel speed is displayed at the center of the machine monitor, the engine speed is displayed on the character display. When the engine speed is displayed at the center of the machine monitor, the travel speed is displayed on the character display. ★ For details, see OTHER FUNCTIONS OF MACHINE MONITOR in the Operation & Maintenance Manual.
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Action Code Display Function (11) If a problem occurs, the machine monitor displays an action code corresponding to the seriousness of the problem to alert the operator to take appropriate action. ★ The figure shows an example of the screen on which action code [E03] and [CALL + Telephone number] are alternately displayed. ★ When action code [E01] or [E02] is displayed, [CALL + Telephone number] is not displayed.
★ Action codes and actions alerted to operator Action Code
CALL + Telephone Number
Actions Recommended to Operator
E01
Not displayed
• Do necessary testing and/or servicing when the current work is completed or when the operator changes shift.
E02
Not displayed
• When an overrun-related item is displayed: Slow down the engine or machine speed. • When an overheat-related item is displayed: Stop the machine and run the engine at mid speed with no load.
E03
Displayed
• Stop the engine and machine immediately and contact a serviceman.
Failure Code Display Function (12) Pressing the [>] switch once while an action is displayed on the machine monitor displays the failure code corresponding to the failure currently warned. ★ The failure codes detected in the past are divided into failures of the electrical system and the mechanical system and are recorded as fault history. (For details, see Electrical System Failure History Display Function (ELECTRIC FAULT) and Mechanical System Failure History Display Function (MACHINE FAULT) in the Service Mode section.) ★ When two or more failures are involved, pressing the [>] switch displays further codes. ★ If the [>] switch is pressed again after it was pressed to display every involved failure code, the Service Meter display screen is restored. Pressing the [>] switch one more time displays the failure codes from the first. If the [>] switch is not touched for 60 seconds, the Action Code display screen is automatically displayed.
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★ The service code display function displays the following information. A: Failure code (location code + problem code) B: Controller code: • MON: Machine monitor • TM: Transmission controller • WRK: Work equipment controller • ENG: Engine controller C: The system where failure occurred ★ For details about a displayed failure code, see Failure Codes Table in the Troubleshooting section. ★ If any switch operation is not done for 60 seconds or longer on the Failure Code display screen, the Action Code display screen is automatically turned on.
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MACHINE MONITOR SYSTEM
Service Mode Remark The number after the function description correlates to the number in the Section No. column in the Service Mode table located in “Normal and Special Functions of Machine Monitor” on page 30-129.
Switching to Service Mode and Screen Display (1) Remark: The service meter is displayed in English, regardless of language selection in the Operator mode. When using the Service mode, perform the following special operation to switch the screen display. 1.
Checking screen display Make sure that the machine monitor is set to the Operator mode and any of “Service meter,” “Action code,” or “Failure code” is displayed on the screen.
2.
Displaying ID Input initial screen Hold down the [■] switch and [<] switch simultaneously for a minimum of five seconds to open the ID Input initial screen. ★ Holding down the two switches for five seconds or longer makes the entire screen blank. Once the screen is blank, release the buttons.
3.
Inputting and confirming ID Use the buttons to input the ID. • ID: 6491 A. Cursor (C) is positioned at the highest-order digit. Pressing the [<] and [>] switches changes the value of this digit in the range of 0 – 9. B. Press the [] switch when the intended value appears in order to select it. ★ The cursor moves to the 2nd digit. C. Set the value in the same order and then press the [] switch. • When you have entered a wrong value to a position except the highest-order digit, move to the highest-order digit using the [■] switch to repeat the procedure from the beginning. In this case, values that have been entered remain as they are until modified. When the cursor is at the highest-order digit, it can move to the higher layer using the [■] switch. (*1). ★ (*1): When the cursor is located at the leftmost position, pressing the switch restores the normal screen (Operator mode). ★ When the cursor is at a location other than the leftmost position, pressing the switch returns the cursor to the leftmost position. ★ If a switch operation is not done for 60 seconds or more from the ID Input screen, the normal screen is automatically turned on.
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TESTING AND ADJUSTING 4.
Displaying menu initial screen ★ After confirming the 4-digit ID, turn on the menu initial screen of the Service mode. ★ Once entered and confirmed, an ID remains effective until the starting switch is turned off.
5.
Selecting Service mode menu ★ Pressing the [<] and [>] switches from the menu screen displays the Service mode menus endlessly in the following order. ★ The menus are displayed in the field indicated with the [*] mark.
MACHINE MONITOR SYSTEM
[1] ELECTRIC FAULT: Electrical system failure history display function [2] MACHINE FAULT: Mechanical system failure history display function [3] REAL-TIME MONITOR: Real-time monitoring function [4] CYLINDER CUT-OUT: Cylinder cutout function [5] NO INJECTION: No injection cranking function [6] TUNING: Adjustment function [7] MAINTENANCE MONITOR: Maintenance monitoring function [8] OPERATION INFO: Operating information display function [9] OPTIONAL SELECT: Optional device selecting function [10] MACHINE No. SET: Machine serial number input function [11] MACHINE: Model selection function [12] INITIALIZE: Initialize function (function specialized for plant) 6.
Completion of mode and function Either of the following procedures ends a mode or function independent of the function selected and the layer in which it is used. A. When the operation is to be continued using another mode or function: Press the [■] switch to return to the mode screen or menu screen to be used next. ★ Note, however, that the [■] switch functions as an execution key on the [YES/NO] screen. ★ When the normal screen (Operator mode) is inadvertently turned on, repeat from Step 1 (input of the ID is not necessary). B. When ending an operation completely, turn the starting switch off from the current state.
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Electrical System Failure History Display Function (ELECTRIC FAULT) (2) The machine monitor records the past failures in the electrical system as failure codes. The failure codes are displayed from the following operations. 1.
Selecting the menu Select the ELECTRIC FAULT from the menu screen of the Service mode. ★ [**] field displays total number of the failure history currently recorded (up to 20 cases).
2.
Displaying failure history Press the [] button while the menu is selected to display the recorded failure history.
3.
Displayed problem data The electric system problem data display function displays the following information. A: Record number B: Failure code (Location code in four digits + Problem code in two digits) C: Number of occurrences (Number of occurrences of same code in past) D: Elapsed time 1 (Elapsed time on service meter from the first occurrence) E: Elapsed time 2 (Elapsed time on service meter from the last occurrence) ★ The code of a failure currently occurring is indicated by flashing. ★ For details of a displayed failure code, see the Failure Codes Table in the Troubleshooting section. ★ Note that part of the information displayed from the electrical system problem data display function and the failure code display function is not identical. ★ When the requested failure history is not recorded, [–] is indicated in the display space.
4.
Switching failure history display Pressing the [<] or [>] switch while a set of failure history is on the screen displays another set of recorded failure history.
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MACHINE MONITOR SYSTEM
Deleting individual failure history A. Press the [] switch while the target failure history of deletion is on the screen to turn on the CLEAR screen. B. Select YES or NO using the [<] or [>] switch. ★ The selected cursor starts to flash. • If YES is selected and the [■] switch is pressed, the information is deleted. • If NO is selected and the [■] switch is pressed, deletion is cancelled and the Maintenance Interval Change Item screen is restored. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. ★ You cannot delete information about the currently occurring failure.
6.
Deleting all problem data A. Press the [<] or [>] switch while the problem data is on the screen to display the ALL CLEAR menu screen. B. Press the [] switch to display the ALL CLEAR screen. C. Select YES or NO using the [<] or [>] switch. ★ The selected cursor starts to flash. • If YES is selected and the [■] switch is pressed, the information is deleted. • If NO is selected and the [■] switch is pressed, deletion is cancelled and the Maintenance Interval Change Item screen is restored. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. ★ You cannot delete information about the currently occurring failure.
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Mechanical System Failure History Display Function (MACHINE FAULT) (3) The machine monitor retains the data for problems that occurred in the mechanical system in the past as failure codes. The failure codes are displayed from the following operations. 1.
Selecting the menu ★ Select MACHINE FAULT from the menu screen of the Service mode. ★ [**] field displays total number of the failure history currently recorded.
2.
Displaying failure history Press the [] switch while the menu is selected to display the recorded failure history.
3.
Displayed failure history The mechanical system failure history display function displays the following information. A: Record number B: Failure code (Location code in four digits + Problem code in two digits) C: Number of occurrences (Number of occurrences of same code in past) D: Elapsed time 1 (Elapsed time on service meter from the first occurrence) E: Elapsed time 2 (Elapsed time on service meter from the last occurrence) ★ The code of a failure currently occurring is indicated by flashing. ★ For details of a displayed failure code, see the Failure Codes Table in the Troubleshooting section. ★ Note that part of the information displayed from the mechanical system failure history display function and the failure code display function is not identical. ★ When the requested failure history is not recorded, [–] is indicated in the display space.
4.
Switching failure history display Pressing the [<] or [>] switch while a set of failure history is on the screen displays another set of recorded failure history.
5.
Deleting failure history (Not available) You cannot delete the failure history of the mechanical system.
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Real-Time Monitoring Function (REAL-TIME MONITOR) (4) The machine monitor checks the state of the machine on a real-time basis by referencing signals from the sensors installed in various parts of the machine. The real-time monitoring function displays the following two types of information. •
1-item independent display (for each controller)
•
2- item simultaneous display (code input)
1.
Selecting the menu Select REAL-TIME MONITOR from the menu screen of the Service mode.
2.
Displaying submenu Press the [] switch while the menu is selected to display the Submenu initial screen.
3.
Selecting submenu ★ Press the [<] or [>] switch from the Submenu screen to display the submenus endlessly in the following order. ★ The submenus are displayed in the field indicated with the [*] mark. [1] MONITOR PANEL: Machine monitor system [2] TRANSMISSION: Transmission controller system [3] BOOM: Work equipment controller system [4] ENGINE: Engine controller system [5] 2 ITEMS: 2-item display
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TESTING AND ADJUSTING 4.
MACHINE MONITOR SYSTEM
Setting the 1-item individual monitoring A. Select the target controller system of monitoring from the Submenu screen. B. Press the [] switch while the submenu is selected to display the MONITOR PANEL screen.
C. Press the [<] or [>] switch to select a monitoring item. ★ The monitoring items are scrolled according to the internally set order. ★ Hold down the [] switch to turn on high-speed scrolling. ★ Holding and cancelling the monitoring data: Press the [] switch while the monitoring is in progress to hold the monitoring data; the [] mark starts to flash. Press the [] switch again to restore the active state.
D. Display data for 1-item individual monitoring The 1-item Individual Monitoring screen displays the following information. A: Item display B: Monitoring codes (5 digits) 1:
Monitoring data (including the unit used)
★ See the Real-Time Monitoring Codes Tables in this section for details.
5.
Setting 2-items simultaneous monitoring A. Select 2 ITEMS from the Submenu screen. B. Press the [] switch while the submenu is selected to display the Monitoring Code Input screen.
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TESTING AND ADJUSTING i.
This cursor (C) is located at the highest-order digit. Pressing the [<] or [>] switch changes the value of this digit in the range of 0 – 9.
ii.
Press the [] switch when the intended value appears in order to select it as the set value. ★ The cursor moves to the 2nd position.
MACHINE MONITOR SYSTEM
iii. Set the value in the same order and then press the [] switch. ★ When you have entered a wrong value in a position except the highest-order digit, you can move the cursor to the highest-order digit by using the [■] switch and repeating the procedure from the beginning. In this case, values that have been entered remain as they are until modified. When the cursor is at the highest-order digit, it can move to the higher layer by using the [■] switch.
C. As both monitoring codes are confirmed, the 2 ITEMS screen will be turned on. ★ Holding and cancelling the monitoring data Press the [] switch while the monitoring is in progress to hold the monitoring data; the [] mark starts to flash. Press the [] switch again to restore the active state.
D. Display data for 2-items simultaneous monitoring ★ The 2-items Simultaneous Monitoring screen displays the following information. A: Monitoring code 1 1: Monitoring data 1 (including the unit used) B: Monitoring code 2 2: Monitoring data 2 (including the unit used) ★ See the Real-Time Monitoring Codes Tables in this section for details.
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Real-Time Monitoring Codes Tables Monitor Panel [Mechanical Monitor System] Remark Table on this page corresponds to table on facing page. MONITOR PANEL [Mechanical Monitor System] Monitoring Items Display Item (*1) (*2) Part number of monitoring software VERSION Application version VERSION (APP) Data version VERSION (DATA)
1 2 3
Monitoring Codes 20200 20221 20222
4
01001
Engine speed
ENG SPEED
0 – 3000
5
40000
Travel speed
SPEED
0 – 50
6
04202
Fuel level
FUEL SENSOR
0 – 100
7
04207
Fuel level
FUEL SENSOR
0.00 – 5.00
8
04103
Engine coolant temperature
COOLANT TEMP
-40 – 210
9
40100
Torque converter oil temperature
TC OIL TEMP
24 – 131
10
40101
Torque converter oil temperature
TC OIL TEMP
0.00 – 5.00
11
04401
Hydraulic oil temperature
HYD TEMP
24 – 131
12
04404
Hydraulic oil temperature
HYD TEMP
0.00 – 5.00
13
30202
Rear brake oil temperature
R BRAKE OIL
24 – 131
14
30205
Rear brake oil temperature
R BRAKE OIL
0.00 – 5.00
15 16 17 18
04302 40200 40300 40301
Charge level Small lamp voltage Battery electrolyte level A Battery electrolyte level B
ALTERNATOR R SMALL LAMP BATTERY A BATTERY B
0.00 – 30.00 0.00 – 30.00 0.00 – 30.00 0.00 – 30.00
19
06001
Lift arm angle
BOOM ANG
-90 – 90
20
06003
Lift arm angle
BOOM ANG
0.00 – 5.00
No.
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Data Display Range (*3) Arabic numerals Arabic numerals Arabic numerals
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
MONITOR PANEL [Mechanical Monitor System] Unit Remarks No. Display Contents in Normal State (*4) (*5) 1 Depends on software part number Status display 2 Depends on application version Status display 3 Depends on data version Status display Low idle: 800 ±25 rpm High idle: 2000 ±50 rpm (P-mode) 4 1900 ±50 rpm (E-mode) rpm Torque converter stall: 1800 ±100 rpm (P-mode) 1730 ±100 rpm (E-mode) F1/R1: 6.7/7.3 km/h (4.2/4.5 mph) ±5% (P-mode, Torque converter) F2/R2: 11.7/12.8 km/h (7.3/8.0 mph) ±5% (P-mode, Torque converter) 5 km/h (mph) F3/R3: 20.3/22.0 km/h (12.6/13.7 mph) ±5% (P-mode, Torque converter) F4/R4: 33.8/37.0 km/h (21.0/23.0 mph) ±5% (P-mode, Torque converter) 6 0 – 100% % Gauge FULL (100%, 10 ): 0.32 V At disconnection or hot short Gauge 1/2 (50%, 32 ): 0.88 V in sensor: Gauge EMPTY 7 V Caution (61.3 ): 1.45 V At grounding fault in sensor: Gauge EMPTY (0%, 85 ): 1.81 V Gauge FULL Coolant temperature: Max. 100°C (212°F) 8 Depends on machine status (°C) °C (°F) Data acquired from engine controller 9 Depends on machine status (°C) °C (°F) Overheat 120°C (248°F) At disconnection or hot short in sensor: Gauge MIN Start of gauge red zone: 120°C (248°F): 1.62 V V 10 At grounding fault in sensor: 80°C (176°F): 2.91 V Gauge MAX Oil temperature of hydraulic 11 Depends on machine status (°C) °C (°F) tank Max. 100°C (212°F) At disconnection or hot short Start of gauge red zone:120°C (248°F): 1.62 V in sensor: Gauge MIN V 12 80°C (176°F): 2.91 V At grounding fault in sensor: Gauge MAX 13 Depends on machine status (°C) °C 120°C (248°F): 1.62 V V 14 80°C (176°F): 2.91 V 15 Depends on machine status (0.0 to 30 V) V 16 Depends on machine status (0.0 to 30 V) V 17 Min. 2 V V Only for optional setting 18 — V Not used in this machine. STD lift arm: Highest lift arm: 46.8 ±2.0 deg Lowest lift arm: -42.3 ±3.0 deg 19 Degree (°) Hi lift arm: Highest lift arm: 49.3 ±2.0 deg Lowest lift arm: -40.5 ±3.0 deg STD lift arm: Highest lift arm: 3.80 ±0.3 V Lowest lift arm: 1.33 ±0.5 V 20 V Hi lift arm: Highest lift arm: 3.87 ±0.3 V Lowest lift arm: 1.38 ±0.5 V
WA500-6
30-147 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
MONITOR PANEL [Mechanical Monitor System] No .
Monitoring Codes
21
40400
22
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
Lift arm bottom pressure
BOOM BTM PRESS
0.00 – 50.00
40402
Lift arm bottom pressure
BOOM BTM PRESS
0.00 – 5.00
23
40500
Lift arm head pressure
BOOM HEAD PRESS
0.00 – 50.00
24
40501
Lift arm head pressure
BOOM HEAD PRESS
0.00 – 5.00
25
40600
Calibration pressure
CAL PRESS
0.00 – 50.00
26
40800
Load meter calculated weight
MES LOAD
0.00 – 50.00
27
30802
Rotary switch setting state
SW1, SW2, SW3
F, F, F
28
30904
DIP switch setting state
SW5-1, SW5-2
ON/OFF, ON/OFF
29
30905
DIP switch setting state
SW5-3, SW5-4
ON/OFF, ON/OFF
30
30906
DIP switch setting state
SW6-1, SW6-2
ON/OFF, ON/OFF
31
30907
DIP switch setting state
SW6-3, SW6-4
ON/OFF, ON/OFF
32
40900
Input signal D_IN_0-7
D-IN--0------7
See attached table
33
40901
Input signal D_IN_8-15
D-IN--8------15
See attached table
34
40902
Input signal D_IN_16-23
D-IN--16------23
See attached table
35
40903
Input signal D_IN_24-31
D-IN--24------31
See attached table
36
40904
Input signal D_IN_32-39
D-IN--32------39
See attached table
37
40925
Output signal D_OUT_0-3
D-OUT--0--3
See attached table
*1: All items are displayed including those for which sensors are not provided depending on the given model or option. *2: Abbreviated expression is employed because of number of usable characters is restricted. *3: If a value is below (or above) the display range, it is displayed as the lowest (highest) value in the range. *4: SI units alone are employed whenever a unit is needed. *5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may be displayed on the machine monitor.
30-148 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
MONITOR PANEL [Mechanical Monitor System] No.
Display Contents in Normal State
21
Depends on machine status.
22
0 MPa: 0.5 V 10 MPa: 1.3 V 20 MPa: 1.1 V 50 MPa: 4.5 V
23
Depends on machine status.
24
0 MPa: 0.5 V 10 MPa: 1.3 V 20 MPa: 1.1 V 50 MPa: 4.5 V
25 26
– Load weight (t)
Unit (*4)
Remarks (*5)
MPa (psi)
Rated loading, high idle, lift arm control lever full, arm horizontal: Approx. 18 MPa (2611 psi)
V
–
MPa (psi)
Only for optional setting of load meter (Arm horizontal: Rated loading, high idle, lift arm control lever full: Approx. 0.5 MPa (73 psi)
V
Only for optional setting of load meter
MPa
Not used in this machine.
ton
Only for optional setting of load meter
27
–
Status display
Not used in this machine.
28
–
Status display
Not used in this machine.
29
–
Status display
Not used in this machine.
30
–
Status display
Not used in this machine.
31
–
Status display
Not used in this machine.
32
–
Status display
–
33
–
Status display
–
34
–
Status display
–
35
–
Status display
–
36
–
Status display
–
37
–
Status display
–
WA500-6
30-149 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
MON [Mechanical Monitor System] MON [Mechanical Monitor System] No.
1
2
3
Monitoring Codes
40900
40901
40902
30-150 b
Input/ Output Signal
Display Item
Description of ON/OFF Switch (Display: When ON = 1, when OFF = 0)
D-IN-0
Head lamp
Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1
Starting motor ACC
Starting switch Acc = ON (24 V)/OFF (OPEN)
D-IN-2
Starting switch C
Starting switch START = ON (24 V)/OFF (OPEN)
D-IN-3
–
–
D-IN-4
Auto grease A (Applicable for a machine equipped with optional auto-grease)
D-IN-5
Auto grease B (Applicable for a machine equipped with optional auto-grease)
D-IN-6
–
–
D-IN-7
–
–
D-IN-8
–
–
D-IN-9
–
–
D-IN-10
Load meter mode selector switch (A/B) (Applicable for a machine equipped with optional load meter)
Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-11
Load meter mode selector switch (+/–) (Applicable for a machine equipped with optional load meter)
Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-12
Turn signal right
Lighting of turn signal right lamp = ON (GND)/ OFF (OPEN)
D-IN-13
Turn signal left
Lighting of turn signal left lamp = ON (GND)/OFF (OPEN)
D-IN-14
[] switch
Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15
[■] switch
Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16
Brake oil pressure (front)
Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17
Brake oil pressure (rear)
Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18
–
–
D-IN-19
–
–
D-IN-20
Clogged air cleaner
D-IN-21
–
D-IN-22
Parking brake emergency release switch
Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-23
Load meter total weight display selector switch
Pressing of switch = ON (GND)/OFF (OPEN)
Operation Failed Tank empty Failed
D-IN-4 OFF OFF ON ON
D-IN-5 ON OFF OFF ON
No clogging = ON (GND)/OFF (OPEN) –
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM MON [Mechanical Monitor System]
No.
Monitoring Codes
Input/ Output Signal D-IN-24
Display Item Transmission filter clogging
D-IN-25
4
40903
–
5
40904
Parking brake
D-IN-27
Engine coolant level
D-IN-28
–
D-IN-29
Engine oil level
D-IN-30
Operation of emergency steering motor (Applicable to a machine equipped with the optional emergency steering)
WA500-6
Normal coolant level = ON (GND)/OFF (OPEN) –
Emergency steering operation = ON (GND)/OFF (OPEN) –
D-IN-32
Load meter subtotal switch (Load meter specifications)
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-33
Load meter cancel switch (Load meter specifications)
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-34
High beam (dimmer switch)
High beam = ON (GND)/OFF (OPEN)
D-IN-35
–
–
D-IN-36
Service switch
D-IN-37
> switch
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38
< switch
Pressing of switch = ON (GND)/OFF (OPEN)
D-OUT-0 40952
–
Normal oil level = ON (GND)/OFF (OPEN)
–
D-IN-39
6
No clogging = ON (GND)/OFF (OPEN) Parking brake operation = ON (GND)/OFF (OPEN)
D-IN-26
D-IN-31
Description of ON/OFF Switch (Display: When ON = 1, when OFF = 0)
ON = ON(GND)/OFF(OPEN)
– Alarm buzzer
– Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1
–
–
D-OUT-2
–
–
D-OUT-3
–
–
30-151 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Transmission [Transmission Controller System] Remark Table on this page corresponds to table on facing page. TRANSMISSION [Transmission Controller System] No.
Monitoring Codes
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
1
20201
Transmission controller ROM part number
2
20223
Application version
VERSION
Arabic numerals
VERSION APP
20223
3
20224
Data version
VERSION DATA
20224
4
41600
Selection of engine mode
ENGINE MODE
Arabic numerals
5
41400
Fan pump EPC current value (Command)
FAN EPC DIR
0 – 1000
6
93400
Fan reverse switch input
FAN REVERSE SW
Arabic numerals
7
41501
Torque converter inlet oil temperature
T/C IN OIL TEMP
–
8
41502
Torque converter inlet oil temperature
T/C IN OIL TEMP
–
9
93500
Torque converter input shaft speed
T/C SPEED:IN
–
10
93501
Torque converter output shaft torque
T/C TORQUE:OUT
–
11
31200
Transmission input shaft speed
T/M SPEED IN
0 – 32767
12
31400
Transmission output shaft speed
T/M SPEED:OUT
0 – 32767
13
31404
Transmission output shaft speed 2
T/M SPEED:OUT2
–
14
41203
Transmission cutoff operation setting
T/M CUT SET
0.00 – 5.00
15
41201
Transmission cutoff (left brake) pressure
T/M CUT OFF P
0.00 – 5.00
16
41202
Transmission cutoff (left brake) pressure
T/M CUT OFF P
0.00 – 5.00
17
93700
Torque converter speed ratio
TC SPEED RATIO
0 – 100
18
93600
Transmission oil temperature
T/M OIL TEMP
0 – 150
19
93601
Transmission oil temperature sensor input voltage
T/M OIL TEMP
0.00 – 5.00
20
92400
Modulation clutch oil pressure input
MOD/C PRESS
0.00 – 50.00
21
92401
Modulation clutch oil pressure input voltage
MOD/C PRESS
0.00 – 5.00
22
92500
Modulation clutch calorific value
MOD/C Q
0 – 25.5
23
92501
Modulation clutch calorific rate
MOD/C q
0 – 2.55
24
95500
Throttle lock switch (pressed up) (RPM set switch)
THROT LOCK A
Arabic numerals
30-152 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission controller system] No.
Display Contents in Normal State
Unit (*4)
Remarks (*5)
1
Depends on software part number
Status display
–
2
Depends on software version
Status display
–
3
Depends on software version
Status display
–
4
0: Power mode 2: Economy mode
Status display
–
5
0 – 1000 [mA] Engine speed below 500 rpm = 677 mA During cranking (Terminal C operation) = 850 mA During fan reverse switching = 850 mA During fan reverse operation = 0 mA
mA
–
6
1: ON (CLOSE) 0: OFF
Status display
– Not used in this machine.
7
–
°C
8
–
V
Not used in this machine.
9
–
rpm
Not used in this machine.
10
Nm
Not used in this machine.
11
0 – 32767 [min-1]
–
rpm
–
12
0 – 32767 [min-1] 0 km/h = 0 rpm 10 km/h (6 mph) = 788 rpm 20 km/h (12 mph) = 1376 rpm 30 km/h (19 mph) = 2063 rpm 40 km/h (25 mph) = 2751 rpm
rpm
–
rpm
Not used in this machine.
13
–
14
0.00 – 5.00 MPa (0.00 – 725 psi)
MPa (psi)
Cutoff set operation changes the displayed value.
15
0.00 – 5.00 MPa (0.00 – 725 psi)
MPa (psi)
As foot brake is released: 0.00 ±0.1 MPa Foot brake pressed: Brake pressing changes the displayed value.
16
0.00 – 5.00 [V]
V
As foot brake is released: 1.00 ± 0.1 V Foot brake pressed: Brake pressing changes the displayed value.
17
0 – 100 [%]
%
–
18
0 – 150°C (0 – 302°F)
°C (°F)
–
19
0.00 – 5.00 [V] 4.72 V = 0°C (0°F) 4.33 V = 30°C (86°F) 3.55 V = 60°C (140°F) 2.20 V = 100°C (212°F) 1.61 V = 120°C (248°F)
V
–
Not used in this machine.
20
–
MPa
21
–
V
22 23 24
0: PRM set switch OFF 1: PRM set switch ON
WA500-6
Not used in this machine.
–
100 J/cm
2
Not used in this machine.
–
0.1 kW/cm2
Not used in this machine.
Status display
–
30-153 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission Controller System] No.
Monitoring Codes
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
25
95501
Throttle lock switch (pressed downward) (RPM set auto-deceleration switch)
THROT LOCK B
Arabic numerals
26
95400
27
44200
Throttle correction command output
THROTTLE MOD
-100 – 100
Throttle opening upper limit output
THROT LIMIT UP
0 – 100.0
28
44201
Throttle opening lower limit output
THROT LIMIT LO
0 – 100.0
29
93801
Accelerator mode
THROTTLE MODE
Arabic numerals
30
94000
Traction setting input value
TRACTION DIAL
–
31
94001
Traction setting input voltage
TRACTION DIAL
–
32
95000
Lockup selector switch input signal
LOCK UP SW
Arabic numerals
33
31602
1st ECMV current value (Command)
ECMV 1 DIR
0 – 1000
34
31603
2nd ECMV current value (Command)
ECMV 2 DIR
0 – 1000
35
31604
3rd ECMV current value (Command)
ECMV 3 DIR
0 – 1000
36
31605
4th ECMV current value (Command)
ECMV 4 DIR
0 – 1000
37
31608
F (forward) ECMV current value (Command)
ECMV F DIR
0 – 1000
38
31609
Lockup clutch ECMV current value (Command)
ECMV LU DIR
0 – 1000
39
31640
Modulation clutch ECMV current value (Command)
ECMV MOD/C DIR
–
40
31606
R (reverse) ECMV current value (Command)
ECMV R DIR
0 – 1000
41
93300
ECSS (travel damper) solenoid valve current value (Command)
ECSS V DIR
0 – 1000
42
41802
1st fill time
FILL TIME 1
0 – 2.55 (When fill is not provided: 0)
43
41803
2nd fill time
FILL TIME 2
0 – 2.55 (When fill is not provided: 0)
44
41804
3rd fill time
FILL TIME 3
0 – 2.55 (When fill is not provided: 0)
45
41805
4th fill time
FILL TIME 4
0 – 2.55 (When fill is not provided: 0)
46
41808
F (forward) fill time
FILL TIME F
0 – 2.55 (When fill is not provided: 0)
47
41806
R (reverse) fill time
FILL TIME R
0 – 2.55 (When fill is not provided: 0)
48
40905
Input signal D_IN_0-7
D-IN--0------7
See attached table
49
40906
Input signal D_IN_8-15
D-IN--8-----15
See attached table
50
40907
Input signal D_IN_16-23
D-IN-16-----23
See attached table
30-154 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission Controller System] No.
Display Contents in Normal State
Unit (*4)
Remarks (*5)
Status display
–
25
0: PRM set auto deceleration switch OFF 1: PRM set auto deceleration switch ON
26
-100 – 100 [%]
%
–
27
0.0 – 100.0 [%]
%
–
28
0.0 – 100.0 [%]
%
–
29
Depends on accelerator pedal operation. Accelerator pedal released = 0 Accelerator pedal partial pressing (release side) = 1 Accelerator pedal partial pressing (pressing side) = 2 Accelerator pedal full pressing = 3
Status display
–
30
–
%
Not used in this machine.
31
–
V
Not used in this machine.
Status display
–
32
0: Lockup selector switch OFF 1: Lockup selector switch ON
33
0 – 1000 [mA]
mA
–
34
0 – 1000 [mA]
mA
–
35
0 – 1000 [mA]
mA
–
36
0 – 1000 [mA]
mA
–
37
0 – 1000 [mA]
mA
–
38
0 – 1000 [mA]
mA
39
–
–
mA
Not used in this machine.
40
0 – 1000 [mA]
mA
–
41
0 – 1000 [mA]
mA
–
42
0 – 2.55 [sec], When fill is not provided: 0
sec
–
43
0 – 2.55 [sec], When fill is not provided: 0
sec
–
44
0 – 2.55 [sec], When fill is not provided: 0
sec
–
45
0 – 2.55 [sec], When fill is not provided: 0
sec
–
46
0 – 2.55 [sec], When fill is not provided: 0
sec
–
47
0 – 2.55 [sec], When fill is not provided: 0
sec
–
48
–
Status display
–
49
–
Status display
–
50
–
Status display
–
WA500-6
30-155 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission Controller System] No.
Monitoring Codes
51
40908
52
40942
53
40949
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
Input signal D_IN_24-31
D-IN-24-----31
See attached table
Input signal D_IN_32-39
D-IN-32-----39
See attached table
Output signal D_OUT_0-7
D-OUT-0------7
See attached table
54
40950
Output signal D_OUT_8-15
D-OUT-8-----15
See attached table
55
40951
Output signal D_OUT_16-23
D-OUT-16----23
See attached table
56
94100
Clutch trigger initial learning flag
TRIG FR1234
0/1 (ON/OFF)
30-156 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission Controller System] No.
Display Contents in Normal State
Unit (*4)
Remarks (*5)
51
–
Status display
–
52
–
Status display
–
53
–
Status display
–
54
–
Status display
Not used in this machine.
55
–
Status display
Not used in this machine.
Status display
–
56
0: ON 1: OFF
*1: All items are displayed including those for which sensors are not provided depending on the given model or option. *2: Abbreviated expression is employed because number of usable characters is restricted. *3: If a value is below (or above) the display range, it is displayed as the lowest (highest) value in the range. *4: SI units alone are employed whenever a unit is needed. *5: An item that does not allow monitoring is indicated as “Not used in this machine” although its code and item name may be displayed on the machine monitor.
WA500-6
30-157 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Transmission [Transmission Controller System] TRANSMISSION [Transmission Controller System] No.
1
2
3
Monitoring Code
Input/ Output Signal
Display Item
D-IN-0
Engine mode selector switch
Engine mode selector switch (Power mode) = ON (GND)/OFF (OPEN)
D-IN-1
Joystick steering shift-up switch
Joystick shift-up switch = ON (GND)/OFF (OPEN)
D-IN-2
Joystick steering shift-down switch
Joystick shift-down switch = ON (GND)/OFF (OPEN)
D-IN-3
Air conditioner compressor operation
Air conditioner compressor operation = ON (GND)/OFF (OPEN)
D-IN-4
Shift mode L
40905
40906
40907
30-158 b
Description of ON/OFF Switch (Display: When ON = 1, when OFF = 2)
Shift mode D-IN-4 D-IN-5
Manual 0 0
L 1 0
H 1 1
D-IN-5
Shift mode L
D-IN-6
Joystick steering ON/OFF switch or right FNR ON/OFF switch
Joystick steering ON/OFF switch or right FNR ON/OFF switch = ON (24 V)/OFF (OPEN)
D-IN-7
Terminal C signal
Starting switch = ON (24 V)/OFF (OPEN)
D-IN-8
Transmission cutoff switch
Starting switch = ON (24 V)/OFF (OPEN)
D-IN-9
Transmission cutoff set switch
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-10
Kickdown switch
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-11
Shift hold switch
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-12
–
–
D-IN-13
RPM set idle-up/down selector switch (idleup)
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-14
RPM set idle-up/down switch (idle-down)
Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-15
Throttle lock release left brake pedal switch
Pressing left brake pedal = ON (GND)/OFF (OPEN)
D-IN-16
Gearshift lever 1st (1st speed)
• Gearshift lever 1st (1st speed) = ON (24 V)/OFF (OPEN)
D-IN-17
Gearshift lever 2nd (2nd speed)
• Gearshift lever 2nd (2nd speed) = ON (24 V)/OFF (OPEN)
D-IN-18
Gearshift lever 3rd (3rd speed)
• Gearshift lever 3rd (3rd speed) = ON (24 V)/OFF (OPEN)
D-IN-19
Gearshift lever 4th (4th speed)
• Gearshift lever 4th (4th speed) = ON (24 V)/OFF (OPEN)
D-IN-20
FNR (directional) lever F (Forward)
• FNR (directional) lever F (Forward) = ON (24 V)/OFF (OPEN)
D-IN-21
FNR (directional) lever N (Neutral)
• FNR (directional) lever N (Neutral) = ON (24 V)/OFF (OPEN)
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
TRANSMISSION [Transmission Controller System] No.
3
4
5
6
Monitoring Code
Input/ Output Signal
Display Item
D-IN-22
FNR (directional) lever R (Reverse)
• FNR (directional) lever R (Reverse) = ON (24 V)/OFF (OPEN)
D-IN-23
Parking brake signal
Parking brake = ON (24 V)/OFF (OPEN) [Travel] [Parking]
D-IN-24
Joystick steering FNR (directional) switch F (forward) or right FNR (directional) switch F (forward)
Joystick steering FNR (directional) switch F (forward) or right FNR (directional) switch F (forward) = ON (GND)/OFF (OPEN)
D-IN-25
ECMV fill switch F (forward)
ECMV fill switch F (forward) = ON (GND)/OFF (OPEN)
D-IN-26
ECMV fill switch R (reverse)
ECMV fill switch R (reverse) = ON (GND)/OFF (OPEN)
D-IN-27
ECMV fill switch 1st
ECMV fill switch 1st = ON (GND)/OFF (OPEN)
D-IN-28
ECMV fill switch 2nd
ECMV fill switch 2nd = ON (GND)/OFF (OPEN)
D-IN-29
ECMV fill switch 3rd
ECMV fill switch 3rd = ON (GND)/OFF (OPEN)
D-IN-30
ECMV fill switch 4th
ECMV fill switch 4th = ON (GND)/OFF (OPEN)
D-IN-31
Joystick steering FNR (directional) switch R (reverse) or right FNR (directional) switch R (reverse)
Joystick steering FNR (directional) switch R (reverse) or right FNR (directional) switch R (reverse) = ON (GND)/OFF (OPEN)
D-IN-32
Joystick steering FNR (directional) switch N (neutral) or right FNR (directional) switch N (neutral)
Joystick steering FNR (directional) switch N (neutral) or right FNR (directional) switch N (neutral) = ON (GND)/OFF (OPEN)
D-IN-33
–
–
D-IN-34
–
–
D-IN-35
–
–
D-IN-36
–
–
D-IN-37
–
–
D-IN-38
–
–
40907
40908
40942
40949
D-IN-39
–
–
D-OUT-0
–
–
D-OUT-1
–
–
D-OUT-2
–
–
D-OUT-3 Fan reverse solenoid
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-4 Fan neutral solenoid (if equipped)
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-5
WA500-6
Description of ON/OFF Switch (Display: When ON = 1, when OFF = 2)
Low temperature bypass solenoid (if equipped)
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-6
–
–
D-OUT-7
–
–
30-159 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] WRK [Work Equipment Controller System] No.
Monitoring Codes
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
VERSION
XXXXRYYY [3rd – 10th digits of part No. are displayed] Example: When the number is 7831-46-R110 “3146R110”
1
20202
Work equipment controller software version
2
20225
Application version
VERSION APP
Arabic numerals
3
20226
Data version
VERSION DATA
Arabic numerals
4
94700
Loader pump pressure
PUMP PRESS
0.00 – 50.00
5
94701
Loader pump pressure
PUMP PRESS
0.00 – 5.00
6
94500
Loader pump EPC current (Command)
PUMP EPC DIR
0 – 1000
7
94600
Pump delivery flow rate
PUMP FLOW
0 – 264
8
06002
Lift arm angle
BOOM ANG
-180.0 to +180.0
9
06005
Lift arm angle
BOOM ANG
0.00 – 5.00
10
94400
Frame angle
FRAME ANGLE
-180.0 to +180.0
11
42100
Lift arm lever operation frequency
BOOM LVR
0 – 256000 (In a thousand of times)
12
42000
Lever potentiometer voltage lift arm 1
BOOM POT1
0.00 – 5.00
13
42001
Lever potentiometer voltage lift arm 2
BOOM POT2
0.00 – 5.00
14
42101
Bucket lever operation frequency
BUCKET LVR
0 – 256000 (In a thousand of times)
15
42002
Lever potentiometer voltage bucket 1
BOOM POT1
0.00 – 5.00
30-160 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] No.
Display Contents in Normal State
Unit (*4)
Remarks (*5)
–
–
1
Depends on software part No.
2
Depends on application version No.
Status display
–
3
Depends on data version No.
Status display
–
4
Work equipment neutral: 2.0 ±2.0 MPa (290 ±290 psi) Work equipment relieved: 34.0 ±2.0 MPa (4931 ±290 psi)
MPa (psi)
–
5
Work equipment neutral: 0.70 ±0.2 V Work equipment relieved: 3.22 ±0.2 V
V
–
6
Low idle (800 rpm): 700 ±30 mA High idle (Min. 1,420 rpm): 200 ±10 mA Work equipment relieved: 700 ±10 mA Engine stop (below 500 rpm): 900 ±10 mA
mA
–
7
Work equipment neutral: 170 CC/R Work equipment relieved: 23 ±10 CC/R
cc/r
–
8
STD lift arm: Highest lift arm: 47.0 ±2.0 deg Lowest lift arm: -43.0 ±3.0 deg Hi lift arm: Highest lift arm: 50.0 ±2.0 deg Lowest lift arm: -43.0 ±3.0 deg
Degree (°)
–
9
STD lift arm: Highest lift arm: 3.80 ±0.3 V Lowest lift arm: 1.31 ±0.5 V Hi lift arm: Highest lift arm: 3.89 ±0.3 V Lowest lift arm: 1.31 ±0.5 V
V
–
10
No relevant function in WA500-5
Degree (°)
–
11
Depends on lever operation frequency.
–
–
12
Neutral 2.50 V ±0.10 V RAISE (Before detent) 3.89 V ±0.25 V RAISE (Detent position) 4.11 V ±0.25 V LOWER (Before detent) 1.11 V ±0.25 V FLOAT (Detent position) 0.89 V ±0.25 V
V
–
13
Neutral 2.50 V± 0.10 V RAISE (Before detent) 1.11 V ±0.25 V RAISE (Detent position) 0.89 V ±0.25 V LOWER (Before detent) 3.89 V ±0.25 V FLOAT (Detent position) 4.11 V ±0.25 V
V
–
14
Depends on lever operation frequency.
–
–
15
Neutral 2.50 V ±0.10 V TILT (Before detent) 3.89 V ±0.25 V TILT (Detent position) 4.11 V ±0.25 V Full dump 0.89 V ±0.20 V
V
–
WA500-6
30-161 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] No.
Monitoring Codes
16
42003
17
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
Lever potentiometer voltage bucket 2
BUCKET POT2
0.00 – 5.00
41900
Lift arm raise EPC current (Command)
RAISE EPC DIR
0 – 1000
18
41901
Lift arm lower EPC current (Command)
LOWER EPC DIR
0 – 1000
19
41902
Bucket tilt EPC current (Command)
TILT EPC DIR
0 – 1000
20
41903
Bucket dump EPC current (Command)
DUMP EPC DIR
0 – 1000
21
41908
AJSS EPC current (Command)
AJSS EPC DIR
–
22
41904
AJSS right EPC current (Command)
J/S EPC DIR RH
0 – 1000
23
41905
AJSS left EPC current (Command)
J/S EPC DIR LH
0 – 1000
24
42004
Lever potentiometer voltage AJSS 1
J/S POT1
0.00 – 5.00
25
42005
Lever potentiometer voltage AJSS 2
J/S POT2
0.00 – 5.00
26
41906
3-spool valve 1, ECMV and current value (Command)
3RD EPC1 DIR
0 – 1000
27
41907
3-spool valve 2, ECMV and current value (Command)
3RD EPC2 DIR
0 – 1000
28
42102
3-spool valve lever operation frequency
3RD LVR
0 – 256000 (In a thousand of times)
29
42006
Lever potentiometer voltage 3-spool valve 1
3RD POT1
0.00 – 5.00
30
42007
Lever potentiometer voltage 3-spool valve 2
3RD POT2
0.00 – 5.00
31
94300
AJSS lever operation angle
AJSS LEVER
–
32
94301
AJSS lever potentiometer voltage
AJSS LEVER
–
33
94401
AJSS frame potentiometer voltage
FRAME ANGLE
–
34
94800
AJSS steering deviation angle
S/T DEFLECTION
–
35
94900
Digging-in-progress flag
WORK FLAG
ON/OFF
36
40910
Input signal D_IN_0-7
D-IN--0------7
See attached table
37
40911
Input signal D_IN_8-15
D-IN--8-----15
See attached table
38
40912
Input signal D_IN_16-23
D-IN-16-----23
See attached table
39
40913
Input signal D_IN_24-31
D-IN-24-----31
See attached table
30-162 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work equipment controller system] Unit (*4)
Remarks (*5)
16
Neutral 2.50 V ±0.10 V TILT (Before detent) 1.11 V ±0.25 V TILT (Detent position) 0.89 V ±0.25 V Full dump 4.11 V ±0.20 V
V
–
17
Neutral 0 ±10 mA Max. 896 ±10 mA
mA
–
18
Neutral ±10 mA Before detent: 640 ±10 mA Float position: 1000 ±10 mA
mA
–
19
Neutral 0 ±10 mA Max. 930 ±10 mA
mA
–
20
Neutral 0 ±10 mA Max. 848 ±10 mA
mA
–
No.
Display contents in normal state
21
mA
Not used in this machine.
22
Neutral 0 ±10 mA Max. 850 ±10 mA
–
1 mA
–
23
Neutral 0 ±10 mA Max. 850 ±10 mA
1 mA
–
24
Neutral 2.50 V ±0.10 V Full steering to right 1.34 V ±0.25 V Full steering to left 3.66 V ±0.25 V
V
–
25
Neutral 2.50 V ± 0.10 V Full steering to right 1.34 V ±0.25 V Full steering to left 3.66 V ±0.25 V
V
–
26
Neutral 0 ±10 mA Max. 960 ±10 mA
1 mA
–
27
Neutral 0 ±10 mA Max. 960 ±10 mA
1 mA
–
28
Depends on lever operation frequency.
—
29
Neutral: 2.50 V ±0.10 V Retract: 4.11 V ±0.20 V Extract: 0.89 V ±0.20 V
0.01 V
–
30
Neutral: 2.50 V ±0.10 V Retract: 0.89 V ±0.20 V Extract: 4.11 V ±0.20 V
0.01 V
–
–
31
–
Degree (°)
Not used in this machine.
32
–
V
Not used in this machine.
33
–
V
Not used in this machine.
34
–
Degree (°)
Not used in this machine.
35
Digging: ON Others: OFF
Status display
–
36
–
Status display
–
37
–
Status display
–
38
–
Status display
–
39
–
Status display
–
WA500-6
30-163 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] No.
Monitoring Codes
40
40961
Input signal D_IN_32-39
41
40952
42
40953
43
40954
30-164 b
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
D-IN-32-----39
–
Output signal D_OUT_0-7
D-OUT-0------7
See attached table
Output signal D_OUT_8-15
D-OUT-8-----15
–
Output signal D_OUT_16-23
D-OUT-16----23
See attached table
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] No.
Display Contents in Normal State
Unit (*4)
Remarks (*5)
40
–
Status display
Not used in this machine.
41
–
Status display
–
42
–
Status display
Not used in this machine.
43
–
Status display
–
*1: All items are displayed including those for which sensors are not provided depending on the given model or option. *2: Abbreviated expression is employed because number of usable characters is restricted. *3: If a value is below (or above) the display range, it is displayed as the lowest (highest) value in the range. *4: SI units alone are employed whenever a unit is needed. *5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may be displayed on the machine monitor.
WA500-6
30-165 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
WRK [Work Equipment Controller System] WRK [Work Equipment Controller System] No.
1
2
3
4
Monitoring Codes
40910
Input/ Output Signal
Display Item
Description of ON/OFF Switch
D-IN-0
Semi-automatic digging lock mode switch
Pressing of switch ON = ON (24 V)/OFF (OPEN)
D-IN-1
Semi-automatic digging loose mode switch
Pressing of switch ON = ON (24 V)/OFF (OPEN)
D-IN-2
Joystick Hi/Lo selector switch
Pressing of switch ON = ON (24 V)/OFF (OPEN)
D-IN-3
–
–
D-IN-4
–
–
D-IN-5
–
–
D-IN-6
–
–
D-IN-8
Bucket full stroke proximity switch
Bucket dump ON = ON (24 V)/OFF (OPEN)
D-IN-9
Bucket tilt horizontal proximity switch
Bucket horizontal ON = ON (24 V)/OFF (OPEN)
D-IN-10
Remote positioner bucket angle set switch (facing upward)
Remote positioner bucket angle set switch (facing upward) = ON (GND)/OFF (OPEN)
D-IN-11
Remote positioner bucket angle set switch (facing downward)
Remote positioner bucket angle set switch (facing upward) = ON (GND)/OFF (OPEN)
D-IN-12
–
–
D-IN-13
–
–
D-IN-14
–
–
D-IN-15
–
–
D-IN-16
Work equipment neutral lock switch
Work equipment neutral lock switch (Working position) ON = (24 V)/OFF (OPEN)
D-IN-17
Starting motor C terminal signal
Starting switch = ON (24 V)/OFF (OPEN)
D-IN-18
–
–
D-IN-19
–
–
D-IN-20
–
–
D-IN-21
–
–
D-IN-22
–
–
D-IN-23
–
–
D-IN-24
–
–
D-IN-25
–
–
D-IN-26
–
–
D-IN-27
–
–
D-IN-28
Remote positioner raise/lower set switch (RAISE)
Remote positioner raise/lower set switch (RAISE) = ON (GND)/OFF (OPEN)
D-IN-29
Remote positioner raise/lower set switch (LOWER)
Remote positioner raise/lower set switch (LOWER) = ON (GND)/OFF (OPEN)
D-IN-30
–
–
D-IN-31
–
–
40911
40912
40913
30-166 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM WRK [Work Equipment Controller System]
No.
5
Monitoring Codes
40952
Input/ Output Signal
Work equipment neutral lock solenoid
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1
Lift arm raise detent solenoid
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-2
Lift arm float detent solenoid
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-3
Bucket tilt detent solenoid
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-4
–
–
D-OUT-5
–
–
D-OUT-6
–
–
D-OUT-8
7
40953
40954
WA500-6
Description of ON/OFF Switch
D-OUT-0
D-OUT-7
6
Display Item
– Joystick steering cut relay
– Output ON = ON (24 V)/OFF (OPEN)
D-OUT-9
–
–
D-OUT-10
–
–
D-OUT-11
–
–
D-OUT-12
–
–
D-OUT-13
–
–
D-OUT-14
–
–
D-OUT-15
–
–
D-OUT-16
–
–
D-OUT-17
–
–
D-OUT-18
Remote positioner top indicator ON
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-19
Remote positioner bottom indicator ON
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-20
Safety relay operation
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-21
–
–
D-OUT-22
–
–
D-OUT-23
–
–
30-167 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
ENG [Engine Controller System]
ENG [Engine controller system] Display Item (*2)
Data Display Range (*3)
Unit (*4)
Remarks (*5)
Hardware serial No.
ECM S/N
Arabic numerals
Status display
–
03200
Battery voltage
POWER SUPPLY
0.0 – 480.0
V
–
3
01002
Engine speed
ENG SPEED
0 – 4000
rpm
–
4
04104
Engine coolant temperature
COOLANT TEMP
-40 – 210
°C
–
5
04105
Engine coolant temperature sensor voltage
COOLANT TEMP
0.00 – 5.00
V
–
6
37200
Engine oil pressure sensor
ENG OIL PRESS
-99.9 – 999.9
kPa
–
7
37201
Engine oil pressure sensor voltage
ENG OIL PRESS
0.00 – 5.00
V
–
°C
Not equipped on WA500-6. Always displayed 600°C.
No.
Monitoring Code
1
20400
2
8
42700
Monitoring Items (*1)
Engine oil temperature
ENG OIL TEMP
-40 – 210
9
42702
Engine oil temperature sensor voltage
ENG OIL TEMP
0.00 – 5.00
V
Not equipped on WA500-6. Always displayed 0.00 V.
10
36400
Common rail pressure
RAIL PRESS
0 – 400
MPa
–
11
36402
Common rail pressure sensor voltage
RAIL PRESS
0.00 – 5.00
V
–
12
37400
Atmospheric pressure
AMBIENT PRESS
-99.9 – 999.9
kPa
–
13
37402
Atmospheric pressure sensor voltage
AMBIENT PRESS
0.00 – 5.00
V
–
°C
Not equipped on WA500-6. Always displayed 25°C. Not equipped on WA500-6. Always displayed 0.00 V.
14
18400
Air intake temperature
INTAKE TEMP
-50 – 200
15
18401
Air intake temperature sensor voltage
INTAKE TEMP
0.00 – 5.00
V
16
04204
Fuel temperature
FUEL TEMP
-40 – 210
°C
17
14201
Fuel temperature sensor voltage
FUEL TEMP
0.00 – 5.00
V
18
18500
Boost temperature
CHG TEMP
-50 – 200
°C
30-168 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM ENG [Engine controller system]
No.
Monitoring Code
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
Unit (*4)
Remarks (*5)
19
18501
Boost temperature sensor voltage
CHG TEMP
0.00 – 5.00
V
–
20
36500
Boost pressure
CHG PRESS-A
-99.9 – 999.9
kPa
–
21
36502
Boost pressure sensor voltage
CHG PRESS-A
0.00 – 5.00
V
–
kPa
Not equipped all models. Always displayed 0.0 kPa
22
17900
EGR valve differential pressure
EGR DIF PRESS
-99.9 – 999.9
EGR DIF PRESS
0.00 – 5.00
V
Not equipped all models. Always displayed 0.00 V.
EGR valve inlet pressure
EGR IN PRESSA
-99.9 – 999.9
kPa
–
18002
EGR valve inlet pressure sensor voltage
EGR IN PRESSA
0.00 – 5.00
V
–
26
18100
EGR valve position
EGR VALVE POS
0.00 – 99.99
mm
–
27
18101
EGR valve position sensor voltage
EGR VALVE POS
0.00 – 5.00
V
–
28
18700
Engine output torque
OUTPUT TORQUE
-24000 – 24000
Nm
–
29
36700
Equivalent torque
TORQUE RATIO
0 – 100
%
–
30
31706
Final accelerator position
FINAL THROTTLE
0 – 100
%
–
31
37300
Momentary fuel consumption
FUEL RATE
0.0 – 999.9
l/h
–
32
18600
Final injection volume command (in weight)
INJECT COMMAND
0 – 1000
mg
–
33
36300
Final injection timing command TFIN
INJECT TIMING
-180.0 – 180.0
CA
–
34
31701
Position of accelerator pedal
THROTTLE POS
0 – 100
%
–
35
31707
Accelerator pedal sensor voltage
THROTTLE POS
0.00 – 5.00
V
–
36
18200
Bypass valve position
BPS VALVE POS
0.00 – 99.99
mm
–
37
18202
Bypass valve position sensor voltage
BPS VALVE POS
0.00 – 5.00
V
–
38
18300
Idle validation signal
IVS 1
ON/OFF
Status display
–
39
18301
Idle validation signal
IVS 2
ON/OFF
Status display
–
40
18900
Engine controller internal temperature
ECM IN TEMP
-40 – 210
°C
–
23
17901
EGR valve differential pressure sensor voltage
24
18000
25
WA500-6
30-169 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM ENG [Engine controller system]
Monitoring Items (*1)
Display Item (*2)
Data Display Range (*3)
Unit (*4)
36200
Final common rail pressure command PFIN
PRESS COMMAND
0 – 400
MPa
42
17201
PCV valve close timing (BTDC standard)
PCV TIMING
180.0 – 180.0
CA
43
17500
Selection of engine mode
POWER MODE
0–4
Status display
00400
Name of selected model (upper 8 digits)
MACHINE ID (H)
Incoming value is displayed as is. (Lower 8 digits of 16 characters)
Status display
45
00401
Name of selected model (lower 8 digits)
MACHINE ID (L)
Incoming value is displayed as is. (Lower 8 digits of 16 characters)
Status display
46
20216
Build version
BUILD VER
Incoming value is displayed as is. (8 characters)
Status display
47
20217
Calibration data version
CAL VER
Incoming value is displayed as is. (8 characters)
Status display
No.
Monitoring Code
41
44
Remarks (*5)
*1: All items are displayed including those for which sensors are not provided depending on the given model or option. *2: Abbreviated expression is employed because number of characters usable is restricted. *3: If a value is below (or above) the display range, it is displayed as the lowest (highest) value in the range. *4: SI units alone are employed whenever a unit is needed. *5: An item that does not allow monitoring is indicated as “Not used in this machine” though its code and item name may be displayed on the machine monitor.
30-170 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Cylinder Cutout Function (CYLINDER CUT-OUT) (5) The engine reduced-cylinder function is used to set the injector of one or more cylinders electrically to the no-injection state and to turn on reduced-cylinder operation. When any engine cylinder is suspected of abnormal output (combustion), use this approach to pinpoint the failed cylinder. 1.
Selecting the menu Display the CYLINDER CUT-OUT screen from the menu screen of the Service mode.
2.
Displaying submenu Press the [] switch while the menu is selected to display the submenu. ★ The cylinder No. and engine speed (N): rpm are displayed on the upper line and the specified injection rate (Q): mg/stroke is displayed on the lower line.
3.
Selecting a cylinder to be reduced Using the [<] or [>] switch, select a cylinder to be reduced (from No. 1 – No. 6 cylinder) and then confirm this cylinder using the [] switch. ★ The cylinder to be reduced is selectable while the engine is running. ★ Any number of cylinders can be reduced – a single unit or two or more units. • [>] switch: Advances the cursor rightward • [<] switch: Advances the cursor leftward • [] switch: Confirms the cylinder to be reduced (the cursor starts flashing after the confirmation) • [■] switch: Restores the CYLINDER CUT-OUT screen
★ As the reduced-cylinder command is issued from the engine controller to the cylinder to be reduced, the bottom of the stopped cylinder number turns black.
WA500-6
30-171 b
TESTING AND ADJUSTING 4.
Determining which cylinder is abnormal ★ When a normal cylinder is cut out: The value (Q) increases and (N) is decreased by the quantity which is not injected. (They do not change, however, in the constant engine speed control mode.) The amount that (Q) and (N) change depends on the load condition. ★ When an abnormal cylinder is cut out: The values of (Q) and (N) do not change because the fuel has not been injected in the cutout cylinder since before it was cut out.
5.
Cancelling a reduced cylinder Using the [<] or [>] switch, select the currently stopped cylinder and then press the [] switch to cancel the reduced-cylinder command from the engine controller. The black display will disappear.
MACHINE MONITOR SYSTEM
No-Injection Cranking Function (NO INJECTION) (6) The machine monitor is equipped with a function capable of lubricating the engine through no-injection cranking. When a machine has been stored for a long time, this function is used to lubricate the engine prior to its restart in order to prevent wear or damage caused by lack of oil. ★ The no-injection cranking must be set up while the engine is stopped. 1.
Selecting menu Display the NO INJECTION screen from the menu screen of the Service mode.
2.
Pressing the [] switch sets up the no-injection cranking. ★ If the starting switch is turned to the START position while this screen is displayed, no injection cranking starts. ★ If this screen does not appear as the [] switch is pressed, you should suspect a communication error.
★ If the no-injection cranking is selected as the engine is running, the Engine Stop Instruction screen appears. ★ In such a case, stop the engine once and then do the setup again.
30-172 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Adjustment Function (TUNING) (7) The machine monitor implements the initial setting after disassembly or replacement of the transmission, or after replacement or addition of a sensor, EPC valve, or controller. Through the initial setting, the machine monitor corrects and adjusts the installation error or manufacturing variations of individual parts. ★ Adjustment function No.
Adjustment Item
7-1
Adjustment of transmission ECMV current
7-2
Setting of transmission initial learning
7-3
Adjustment of transmission L-mode shift point
7-4
Adjustment of lift arm angle sensor (Raise) (for EPC lever)
7-5
Adjustment of lift arm raise lever and variations in the dead zone of EPC
7-6
Adjustment of lift arm lower (float) lever and variations in the dead zone of EPC
7-7
Adjustment of bucket tilt lever and variations in the dead zone of EPC
7-8
Adjustment of bucket dump EPC starting current
7-9
Adjustment of 3-spool valve EPC cylinder extraction lever and variations in the dead zone of EPC (*1)
7-10
Adjustment of the 3-spool valve EPC cylinder retraction lever and variations in the dead zone of EPC (*1)
7-11
Adjustment of joystick steering right lever and variations at EPC starting point (*1)
7-12
Adjustment of joystick steering left lever and variations at EPC starting point (*1)
7-13
Modification of lift arm lever pattern
7-14
Modification of bucket lever pattern
7-15
Adjustment of lift arm lower stop modulation
7-16
Adjustment of pump cutoff pressure in lift arm raise
7-17
Adjustment of lift arm angle sensor (raise) (Machine with load meter)
7-18
Adjustment of lift arm angle sensor (lower) (Machine with load meter)
7-19
Modification of AJSS oil pressure command table pattern (*1)
7-20
Adjustment of speed limit (Machine with lockup clutch)
(*1): This item is not used.
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MACHINE MONITOR SYSTEM
Adjustment of Transmission ECMV Current (7-1) 1.
Preparations for transmission ECMV current adjustment A. Display the REAL-TIME MONITOR from the menu screen of the Service mode.
B. Press the [] switch to display the submenu and then select TRANSMISSION using the [<] or [>] switch (TRANSMISSION screen).
C. Press the [] switch to confirm the real-time monitoring of the transmission controller. ★ As the selection is confirmed, the application program version of the transmission controller is displayed. [20223]: . . . . . . . . . . . . . . . . . . . . . . ID number of display item [********]: . . . . . . . . . . . . . . . Display of data (program version)
D. Use the [<] or [>] switch, move the cursor to the T/M OIL TEMP screen. [93600]: . . . ID number of transmission control oil temperature [[********]: . . . . . Display of transmission control oil temperature
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TESTING AND ADJUSTING 2.
MACHINE MONITOR SYSTEM
Conformation of transmission oil temperature control A. Start the engine; press the brake pedal fully; and release the parking brake. B. Set the transmission shift mode to Manual; set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward); and shift lever or switch to 4th. C. Make sure from Step 1 that the transmission controlled oil temperature is 70 – 80°C (158 – 176°F). If it is out of this range, stall the torque converter and adjust the temperature to 70 – 80°C. D. Return the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) to N (neutral) and maintain it in that position. After three minutes, make sure the oil temperature is still in the 70 – 80°C (158 – 176°F) range. E. Let the oil move through the transmission by operating the FNR (directional) lever or joystick steering FNR (directional) switch, right FNR (directional) switch, or gearshift lever or switch as shown in the following table.
Operating Order
1
2
3
4
Gear speed
N2
F2
F1
F2
Holding time
Min. 2 sec.
Min. 2 sec.
Min. 2 sec.
Min. 2 sec.
Operating Order
5
6
7
8
Gear speed
F3
F4
F3
F2
Holding time
Min. 2 sec.
Min. 2 sec.
Min. 2 sec.
Min. 2 sec.
Operating Order
9
10
11
Gear speed
N2
R2
N2
Holding time
Min. 2 sec.
Min. 2 sec.
Min. 2 sec.
★ When doing this operation, the engine must be set to low idle, manual switch to ON, and lockup switch to OFF. ★ Make sure the machine is normal (failure is not detected). ★ When stalling the torque converter, be careful that it does not overheat. 3.
Adjustment of transmission ECMV current ★ There are six types of correction targets: F (forward), R (reverse), 1st, 2nd, 3rd, and 4th. As the engine is started, correction of all of these clutches is started automatically. ★ Since the learning operation requires the specified oil temperature, the oil temperature must be adjusted to the 70 – 80°C (158 – 176°F) range. A. Turn on the starting switch (engine is not started) and then display T/M OIL TEMP. Refer to Step 1 (Preparations for transmission ECMV current adjustment). B. Make sure that the transmission controlled oil temperature is in the 70 – 80°C (158 – 176°F) range when the engine is set to low idle; accelerator pedal to OFF; FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to N (neutral); and parking brake to ON.
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C. Display the TUNING from the menu screen of the Service mode.
D. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
E. Using the [<] or [>] switch from the submenu, select 02: ECMV TUNING. F.
Press the [] switch to confirm the adjustment item.
G. Using the [] switch, select AUTO from the Automatic Correction (AUTO) and Manual Correction (MANUAL) selection screen to confirm the automatic correction.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
★ Selecting ECMV TUNING AUTO displays IP in the character display, automatically starting transmission ECMV current adjustment.
Operating Order
1
2
3
4
5
6
7
8
IP
“IP F-1”
“IP F-2”
“IP F-3”
“IP F-4”
“IP R-1”
“IP R-2”
“IP R-3”
“IP R-4”
ECMV/ frequency
F/1st time
F/2nd time
F/3rd time
F/4th time
R/1st time
R/2nd time
R/3rd time
R/4th time
Operating Order
9
10
11
12
13
14
15
16
IP
“IP 1-1”
“IP 1-2”
“IP 1-3”
“IP 1-4”
“IP 2-1”
“IP 2-2”
“IP 2-3”
“IP 2-4”
2nd/3rd time
2nd/4th time
ECMV/ frequency
1st/1st time 1st/2nd time 1st/3rd time 1st/4th time 2nd/1st time 2nd/2nd time
Operating Order
17
18
19
20
21
22
23
24
IP
“IP 3-1”
“IP 3-2”
“IP 3-3”
“IP 3-4”
“IP 4-1”
“IP 4-2”
“IP 4-3”
“IP 4-4”
ECMV/ frequency 3rd/1st time 3rd/2nd time 3rd/3rd time 3rd/4th time 4th/1st time 4th/2nd time 4th/3rd time 4th/4th time
H. If the correction is completed normally, OK is displayed in the character display.
★ If the correction does not end normally, the code for an abnormal end is indicated. (The figure to the right shows an example of an operation in which the 1st time correction of the 3rd position has ended abnormally.)
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MACHINE MONITOR SYSTEM
★ Codes for abnormal end Reason
Code
Deviation from correction condition
1
Absence of fill
2
In excess of correction value
3
★ If abnormal end code “1” (NG1: Deviation from correction condition) is displayed, set the condition again by referring to Step 1 and repeating the correction. ★ If abnormal end code “2” (NG2: Absence of fill) is displayed, implement troubleshooting of the failure codes 15S❑LH and DXH❑KA. If the state is normal, repeat the operation starting from Step 1 and repeat the correction. (The value of ❑ depends on the applicable gear speed.) ★ If abnormal end code “3” (NG3: In excess of correction value) is displayed, execute the troubleshooting of failure code 15S❑L1. After making sure that the condition is normal, do Step 1 again. (The value of ❑ depends on the applicable gear speed.) I.
If the operation ended normally, turn the starting switch off. The corrected value will be stored on the transmission controller after three seconds. ★ When it is necessary to turn on the starting switch immediately after the adjustment, keep the starting switch, just in case, at the OFF position for a minimum of 10 seconds and then turn it on.
Setting of Transmission Initial Learning (7-2) When initializing all the past initial trigger learning data stored on the transmission controller, use the following procedure. 1.
Reset initial learning A. Turn the starting switch on. (Engine does not start.) B. Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to N (neutral). C. Display the TUNING screen from the menu screen of the Service mode.
D. Hold the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
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E. Press the [] switch to confirm the adjustment item. As the item is confirmed, the Initial Learning reset screen appears. ★ If the initial learning is not done, INITIAL STATUS is displayed.
★ When the initial learning is completed, TUNED is displayed. i.
When TUNED is displayed, press the [] switch to display the Initial Learning reset screen.
ii.
Press the [<] or [>] switch from the Initial Learning reset screen to move the cursor to the YES position and then press the [■] switch to reset the initial learning.
iii. When suspending the reset operation, select NO from the Initial Learning reset screen or press the [■] switch on the TUNED screen. 2.
Preparations for transmission initial learning A. Display the REAL-TIME MONITOR from the menu screen of the Service mode.
B. Press the [] switch to display the submenu; select 2 ITEMS using the [<] or [>] switch; and then confirm the selection using the [] switch. (SEL ITEMS 1, 2 screen).
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C. From the SEL ITEMS 1, 2 screen, enter ID number 93600 of the transmission control oil temperature and ID number 94100 for displaying the trigger learning. ★ Refer to Step 5 in MACHINE MONITOR SYSTEM: Service Mode: Real-Time Monitoring Function (REALTIME MONITOR).
D. Using the [] switch, confirm the 2 ITEMS display of the transmission control oil temperature and the trigger learning display. ★ Content of the trigger learning is displayed for each of F, R, 1st, 2nd, 3rd, and 4th clutch in the figure. • 0: Learning not done yet • 1: Learning completed 3.
Implementation of transmission initial learning ★ Before starting the transmission initial learning, be sure to implement the Adjustment of Transmission ECMV Current procedure and Step 1 in the Setting of Transmission Initial Learning procedure. Then start the initial learning according to the following procedure. ★ Implement the gearshift operation using actual travel, bench travel, or while pressing the wheel brake. WARNING!
When actual travel is used for the operation, be sure to choose a spacious area while paying reasonable care to the environment.
★ When executing the operation, the engine must be set to low idle, the manual switch to ON, and the lockup switch to OFF. A. Start the engine; press the brake pedal fully; and then release the parking brake. B. Set the transmission shift mode to Manual; set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward); and set the shift lever or switch to 4th. C. Make sure that the transmission control oil temperature is 70 – 80°C (158 – 176°F); refer to Step 2 (Preparations for transmission initial learning). If it is out of this range, stall the torque converter and adjust the temperature to 70 – 80°C (158 – 176°F). ★ If the initial learning is performed while the oil temperature is out of the specified range, time lags and gearshift shocks can result.
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MACHINE MONITOR SYSTEM
D. Perform the initial learning by operating the FNR (directional) lever, joystick steering FNR (directional) switch, right FNR (directional) switch, or gearshift lever or switch in the following manner. Operating Order
1
2
3
4
5
6
7
8
Gear speed
N2
F2
F1
F2
F3
F4
F3
F2
Holding time
Min. 6 sec.
Min. 6 sec.
Min. 6 sec.
Min. 4 sec.
Min. 4 sec.
Min. 4 sec.
Min. 4 sec.
Min. 4 sec.
Operating Order
9
10
11
Gear speed
N2
R2
N2
Holding Time
Min. 4 sec.
Min. 4 sec.
Min. 4 sec.
• Hold the gearshift lever in each gear speed for more than the specified time. ★ If the gearshift lever is operated before the specified time is reached, the initial learning is not completed (TUNED is not displayed). 4.
Conformation of completion of transmission initial learning A. Referring to Step 2 (Preparations for transmission initial learning), make sure 111111 is marked on ID number 94100, indicating that the initial learning is completed. B. Press the [■] switch to end confirmation of the initial learning.
Adjustment of Transmission L-Mode Shift Point (7-3) This function is used for modifying the shift point when the shift mode switch is at the L position, by adding a correction amount. ★ The factory default setting of the correction amount must be 0. ★ The shift point depends on the engine mode. When this function is used, however, the same correction value is applied independent of the engine mode. ★ Some of the shift points adjusted with the shift point adjustment function may not include the following shift patterns. • •
The shift point that is used when the hunting prevention function is turned on. The shift down point that is used when the accelerator is set to idle.
★ After a shift point adjustment is done, confirmation on the machine must be done. 1.
Clearing an adjusted shift point A. Display the TUNING screen from the menu screen of the Service mode.
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B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, select the 04: SHIFT rpm screen from the submenu. D. Press the [] switch to confirm the selection. ★ As the selection is confirmed, 0: ALL CLEAR is displayed in the lower space. E. Press the [] switch to confirm ALL CLEAR. ★ As all the stored values are cleared, the screen returns to the shift point adjustment item. ★ If the [■] switch is pressed instead of the [] switch, the stored value is not cleared and the screen returns to the adjustment items. 2.
Adjusting a shift point ★ This operation allows you to change a gearshift travel speed when L auto-shift mode is selected. ★ Gearshift patterns are changed as shown in the following table. No.
Gearshift Pattern to be Changed
0
ALL CLEAR
1
F2T/C F3T/C
2
F3 T/C F4 T/C
3
F4T/C F3T/C
4
F3 T/C F2 T/C
5
F3L/U ON
6
F3L/U OFF
7
F4L/U ON
8
F4L/U OFF
T/C: Torque converter travel L/U: Lockup travel (only for lockup specification) ★ Gearshift pattern change procedure As an example of a gearshift pattern change, this procedure describes how to change the gearshift travel speed pattern from F2T/C to F3T/C. (The same procedure is used for the other gearshift patterns, too.)
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MACHINE MONITOR SYSTEM
A. Select the 04: SHIFT rpm screen using the [] switch and then select 01: F2T/C F3T/C using the [<] or [>] switch.
B. Press the [] switch to confirm the selection. ★ As the selection is confirmed, the Shift Point Adjusting Value input screen appears. This screen displays the currently entered shift point adjusting value. ★ Adjusting Value input screen when Adjusting value = 0 C. Press the [<] or [>] switch to select a desired adjusting value. ★ When adjusting a shift point, 50 rpm of the transmission output shaft speed is used as a unit. ★ Adjusting the transmission output shaft speed by 50 rpm changes the travel speed by approximately 0.759 km/h (0.472 mph). ★ Selecting +50 rpm increases the speed by approximately 0.7 km/h (0.43 mph). ★ Selecting -50 rpm decreases the speed by approximately 0.7 km/h (0.43 mph). D. After selecting a desired setting data, press the [■] switch to end the setup procedure.
Adjustment of Lift Arm Angle Sensor (Raise) (7-4) ★ For EPC lever function This procedure is used for adjusting the lift arm angle of the work equipment. 1.
Display the TUNING screen from the menu screen of the Service mode.
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2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 05: RAISE ANGLE item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the RAISE ANGLE screen is displayed.
5.
Press the [] switch while the lift arm is being raised to the upper limit (cylinder stroke end). ★ The buzzer sounds twice to indicate the completion of the setting. ★ A 1-second beep indicates that the set lift arm angle voltage does not conform to the specified value. In this case, adjustment does not start.
6.
Press the [■] switch to end the adjustment mode. ★ If the [■] switch is pressed while the calibration is continued, the calibration currently taking place will be stopped even if it is not completed.
7.
When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitor.
8.
Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitor falls within the range in the following table and then do the sensor adjustment again. ★ Lift arm length by lift arm specification Lift Arm Specification A B
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Lift Arm Position Upper limit position (Stroke end of raised cylinder)
Voltage Range 3.80 ±0.3 V 3.87 ±0.3 V
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
★ Lift arm length by machine model Machine Model
A
B
WA500-6
3250 mm (127.95 in)
3636 mm (143.15 in)
Adjustment of Lift Arm Raise Lever and Variations in the Dead Zone of EPC (7-5) 1.
Adjusting variation correcting calibration of lift arm raise EPC lever This adjustment is needed when the electric (EPC) work equipment lever is used or when the work equipment controller was replaced. WARNING!
Before starting the adjustment, lower the lift arm to the ground and stop the engine.
A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 06: RAISE EPC item. D. Raise the lift arm EPC lever to a position just before the raise detent position and maintain the lever at this position. ★ Be careful that the raise detent operation does not start.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
E. Pressing the [] switch turns on the reading of lever voltage and then stores the read voltage, replacing the currently stored standard value. ★ The setting is complete as the 06: RAISE EPC screen is restored after the buzzer beeps (buzzer beeps twice). ★ If the lever output voltage at this point is below the standard value (off the design range), pressing the [] switch sounds the buzzer for one second and the screen remains unchanged as [] = SET, as shown in the figure. In this case, the adjustment is cancelled and the 06: RAISE EPC screen is restored. ★ If the [■] switch is pressed at this point, correction of variations in the work equipment EPC lever detent position is stopped even if it is not completed. 2.
Adjusting lift arm raise EPC starting current ★ Start the engine prior to the setup operation. A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 06: RAISE EPC item. D. Lower the lift arm by dumping the bucket and then lift the front wheel. E. Start raising the lift arm gradually while setting the engine to high idle (the machine body is lowered). F.
Return the lever through fine operation. As the lift arm is stopped, maintain the lever at that position (front wheel is floated).
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MACHINE MONITOR SYSTEM
G. Pressing the [] switch turns on reading of the commanded value of EPC and then stores the difference between it and the standard value as the offset value. ★ The setting is complete as the 06: RAISE EPC screen is restored after the buzzer beeps (buzzer beeps twice). ★ If the [] switch is pressed when the lever is at neutral, the adjusted value is cleared. In this case, the 06: RAISE EPC screen is restored after the buzzer beeps (buzzer beeps twice).
Adjustment of Lift Arm Lower (float) Lever and Variations in the Dead Zone of EPC (7-6) 1.
Adjusting variation correcting calibration of lift arm lower (float) EPC lever ★ This adjustment is required when the electric (EPC) work equipment lever is used or when the work equipment controller was replaced. WARNING!
Before starting the adjustment, lower the lift arm to the ground and stop the engine.
A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 07: LOWER EPC item. D. Stop the lift arm EPC lever in a position just before the float detent position and maintain the lever at this position. ★ Be careful that the float detent operation does not turn on.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
E. Pressing the [] switch turns on reading of lever voltage and then stores the read voltage, replacing the currently stored standard value. ★ The setting is complete as the 07: LOWER EPC screen is restored after the buzzer beeps twice. ★ If the lever output voltage at this point is below the standard value (off the design range), pressing the [] switch sounds the buzzer for one second and the screen remains unchanged as [] = SET, as shown in the figure. In this case, the adjustment is cancelled and the 07: LOWER EPC screen is restored. ★ If the [■] switch is pressed at this point, correction of variations in the work equipment EPC lever detent position is stopped even if it is not completed. 2.
Adjusting lift arm lower EPC starting current ★ Start the engine prior to the setup operation. A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 07: LOWER EPC item. D. Set the lift arm roughly horizontal without applying any load. E. Start lowering the lift arm gradually while maintaining the engine at high idle. F.
Return the lever through fine operation. As the lift arm is stopped, maintain the lever at that position.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
G. Pressing the [] switch turns on reading of the commanded value of EPC and then stores the difference between it and the standard value as the offset value. ★ The setting is complete as the 07: LOWER EPC screen is restored after the buzzer beeps twice. ★ If the [] switch is pressed when the lever is at neutral, the adjusted value is cleared. In this case, the 07: LOWER EPC screen is restored after the buzzer beeps twice.
Adjustment of Bucket Tilt Lever and Variations in the Dead Zone of EPC (7-7) 1.
Adjusting variation correcting calibration of bucket tilt EPC lever ★ This adjustment is required when the electric (EPC) work equipment lever is used or when the work equipment controller was replaced. WARNING!
Before starting the adjustment, lower the lift arm to the ground and stop the engine.
A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 08: TILT EPC item. D. Stop the bucket tilt lever in a position just before the tilt detent position and maintain the lever at this position. ★ Be careful that the tilt detent operation does not get turned on.
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E. Pressing the [] switch turns on reading of lever voltage and then stores the read voltage, replacing the currently stored standard value. ★ The setting is complete as the 08: TILT EPC screen is restored after the buzzer beeps twice. ★ If the lever output voltage at this point is below the standard value (off the design range), pressing the [] switch sounds the buzzer for one second and the screen remains unchanged as [] = SET, as shown in the figure. In this case, the adjustment is cancelled and 08: TILT EPC screen is restored. ★ If the [■] switch is pressed at this point, correction of variations in the work equipment EPC lever detent position is stopped even if it is not completed. 2.
Adjusting bucket tilt EPC starting current ★ Start the engine prior to the setup operation. A. Display the TUNING screen from the menu screen of the Service mode.
B. Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
C. Using the [<] or [>] switch, move the cursor to the 08: TILT EPC item. D. Lower the lift arm by dumping the bucket and then lift the front wheel. E. Start lowering the bucket gradually while maintaining the engine at high idle (the machine body is lowered). F.
Return the lever through fine operation. As the bucket is stopped, maintain the lever at that position.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
G. Pressing the [] switch turns on reading of the commanded value of EPC and then stores the difference between it and the standard value as the offset value. ★ The setting is complete as the 08: TILT EPC screen is restored after the buzzer beeps twice. ★ If the [] switch is pressed when the lever is at neutral, the adjusted value is cleared. In this case, the 08: TILT EPC screen is restored after the buzzer beeps twice.
Adjustment of Bucket Dump EPC Starting Current (7-8) ★ Start the engine prior to the setup operation. 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 09: DUMP EPC item.
4.
Set the bucket roughly horizontal without applying any load.
5.
Start dumping the bucket gradually while maintaining the engine at high idle.
6.
Return the lever through fine operation. As the bucket is stopped, maintain the lever at that position.
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TESTING AND ADJUSTING 7.
MACHINE MONITOR SYSTEM
Pressing the [] switch turns on reading of the commanded value of EPC and then stores the difference between it and the standard value as the offset value. ★ The setting is complete as the 09: DUMP EPC screen is restored after the buzzer beeps twice. ★ If the [] switch is pressed when the lever is at neutral, the adjusted value is cleared. In this case, the 09: DUMP EPC screen is restored after the buzzer beeps twice.
Adjustment of 3-Spool Valve EPC Cylinder Extraction Lever and Variations in the Dead Zone of EPC (7-9) ★ This item is not used. Adjustment of 3-Spool Valve EPC Cylinder Retraction Lever and Variations in the Dead Zone of EPC (7-10) ★ This item is not used. Adjustment of Joystick steering Right Lever and Variations at EPC Starting Point (7-11) ★ This item is not used. Adjustment of Joystick Steering Left Lever and Variations at EPC Starting Point (7-12) ★ This item is not used.
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Modification of Lift Arm Lever Pattern (7-13) This function is used to modify the fine-controllability and response of the lift arm by changing the data on the EPC output current to the lift arm lever stroke. ★ Characteristics of Tables 1 – 5 are summarized in the following table (factory-set table: 3).
★ Table number and function Table No.
Function
General
1
Fine control priority
• In the lowering operation, the lift arm is lowered at approximately 70% the speed of the floating speed. (Floating speed remains the same.) • In the raising operation, speed change becomes more drastic as the stroke grows larger.
2
Fine control priority
• In the lowering operation, the lift arm is lowered at approximately 85% the speed of the floating speed. (Floating speed remains the same.) • In the raising operation, controllability at fewer strokes is enhanced.
3
Standard
• This table allows compatibility between controllability and response in both the raise and lower operations.
4
Response priority
• Fewer and faster lever strokes enhance the response.
5
Response priority
• Response is further improved because the lever strokes are fewer and faster than that of No. 4. • This table allows a greater speed change at fewer strokes than others. If reasonable care is not exercised, there may be substantial shocks when stopping.
★ Normally, change to Tables No. 2 to No. 4 is made. When selecting the No. 1 or No. 5 table, thorough preliminary performance check and operator evaluation are required. ★ The maximum lowering speed is not available from the data of Tables No. 1 and No. 2. When measuring the lift arm lowering speed, Tables No. 3 – No. 5 must be used.
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TESTING AND ADJUSTING 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 14: BOOM TABLE item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the Lift Arm Lever Table adjustment screen is displayed.
5.
Select a desired table from No. 1 – No. 5 by using the [<] or [>] switch.
6.
Press the [■] switch to confirm the adjustment.
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MACHINE MONITOR SYSTEM
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Modification of Bucket Lever Pattern (7-14) This function is used to modify the fine controllability, response, and shock dump of the bucket by changing the data on the EPC output current to the bucket lever stroke. ★ Characteristics of Tables 1 – 3 are summarized in the following table (factory-set table: 2).
★ Table number and function Table No.
Function
1
Fine control priority
• In the dump and tilt operation, controllability at fewer strokes is enhanced.
2
Standard
• This table allows compatibility between controllability and response in both the dump and tilt operations.
3
Response priority
• Fewer and faster lever strokes enhance the response. • This table makes it easier to dump a load by swinging the bucket as well as shock dump and leveling of load at the tilt end.
WA500-6
General
30-195 b
TESTING AND ADJUSTING 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 15: BUCKET TBL item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the Bucket Lever adjustment screen is displayed.
5.
Select a desired table from No. 1 – No. 3 by using the [<] or [>] switch.
6.
Press the [■] switch to confirm the adjustment.
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MACHINE MONITOR SYSTEM
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Adjustment of Lift Arm Lower Stop Modulation (7-15) ★ When the lift arm lever is operated for a sudden stop, this function modifies the speed reduction rate of the stop modulation, which is prepared for alleviating shocks resulting from stopping, by applying the stop modulation to the EPC output current. ★ The modulation used for an automatic stop with the remote positioner or due to kickout does not depend on this data. ★ Before using this function to modify the modulation, you must do the Adjustment of Lift Arm Lever Pattern (7-13) procedure and perform the operator’s evaluation. ★ The stop modulation function acts the same way in both the raise and lower directions. ★ The data at delivery is set to 100% of the standard. Modulation Quantity
State
Remarks
0%
The stop modulation is not activated. The lift arm is stopped without delaying to the lever stroke.
Stopping shocks can result if the operator does not exercise reasonable care.
100%
It allows compatibility between delay in response at stop and stopping shocks.
200%
It alleviates stopping shocks that can result from the operator’s sudden stop operation.
1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
WA500-6
– The lift arm overruns the target stop position because its stopping is delayed even when the lever is set at neutral.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
3.
Using the [<] or [>] switch, move the cursor to the 16: LOWER STOP item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the LOWER STOP screen appears.
5.
Select a desired table from 0, 100, and 200 by using the [<] or [>] switch.
6.
Press the [■] switch to confirm the adjustment.
Adjustment of Pump Cutoff Pressure in Lift Arm Raise (7-16) This function modifies matching of the travel speed and work equipment speed at dump approach and hopper charge by changing the condition of the lift arm bottom pressure, which is used as a pump flow rate-restricting condition when lifting a given load. The following lists the pump flow rate-restricting conditions applicable to a load-lifting operation. ★ If the lift arm is operated under the following initial conditions, its speed is restricted to approximately 70% and the remaining torque is used for the travel. • • •
Lift arm angle > 0° (Horizontal) Bucket tilt end-detecting proximity switch signal = Present (Tilt end-detection available) Lift arm bottom pressure > 203.94 kg/cm² (2901 psi)
★ Modifying the lift arm bottom pressure changes the matching as shown in the table. • •
The following data shows, when the machine is loaded, the time required for the lift arm to reach the lift arm top when the raise operation is started simultaneously with start of the machine and the travel distance at that time. Decreasing the currently set pressure activates the cutoff earlier, thereby lengthening the lift arm rising time as well as extending the travel distance.
Working Mode
Economy
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Lift Arm Bottom Pressure during Rising kg/cm² (psi)
F1
F2
Distance
Time
Distance
Time
102 (1450)
16.5
11
25.1
11.2
204 (2901)
15.5
10.7
24.7
10.7
255 (3626)
15
10.2
24.5
10.6
WA500-6
TESTING AND ADJUSTING
Working Mode
Power
MACHINE MONITOR SYSTEM
Lift Arm Bottom Pressure during Rising kg/cm² (psi)
F1
F2
Distance
Time
Distance
Time
102 (1450)
17.8
10.7
26.7
11.1
204 (2901)
16.3
10.3
24.4
10.5
255 (3626)
15.3
9.8
24.2
10.2
★ The pressure at delivery is 204 kg/cm² (2901 psi). ★ Modifying the set value changes the lift arm rising time. ★ When measuring the lift arm rising time for troubleshooting purposes, be sure to return the current setting to 204 kg/cm² (2901 psi). 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 17: PUMP CUT item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the Pump Cutoff Pressure adjustment screen is displayed.
WA500-6
30-199 b
TESTING AND ADJUSTING 5.
Select a desired pressure in the range of 51 – 459 kg/cm² (725 – 6,527 psi) by using the [<] or [>] switch.
6.
Press the [■] switch to confirm the adjustment.
MACHINE MONITOR SYSTEM
Adjustment of Lift Arm Angle Sensor (raise) (machine with load meter) (7-17) 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 18: RAISE ANGLE item.
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WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the RAISE ANGLE screen appears.
5.
Press the [] switch after raising the lift arm to the upper limit position (cylinder stroke end). ★ The buzzer beeps twice to indicate the completion of the setting. ★ A 1-second beep indicates that the set lift arm angle voltage does not conform to the specified value. In this case, adjustment does not start.
6.
Press the [■] switch to end the adjustment mode. ★ If the [■] switch is pressed while the calibration is continued, the calibration currently underway will be stopped even if it is not completed.
7.
When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitoring. ★ Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitoring falls within the following range and then do the sensor adjustment again. Lift Arm Position
Voltage Range
Upper limit position (Stroke end of raised cylinder)
0.5 – 4.5 V
Adjustment of Lift Arm Angle Sensor (lower) (machine with load meter) (7-18) 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
WA500-6
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
3.
Using the [<] or [>] switch, move the cursor to the 19: LOWER ANGLE item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the LOWER ANGLE screen appears.
5.
Press the [] switch after lowering the lift arm to the lower limit position (cylinder stroke end). ★ The buzzer beeps twice to indicate completion of the setting. ★ A 1-second beep indicates that the set lift arm angle voltage does not conform to the specified value. In this case, adjustment does not start.
6.
Press the [■] switch twice to end the adjustment mode. ★ If the [■] switch is pressed while the calibration is continued, the calibration currently underway is stopped even if it is not completed.
7.
When the adjustment does not end successfully, check the lift arm angle sensor voltage from the real-time monitoring. ★ Adjust the lift arm angle sensor mounting position so that the voltage displayed on the real-time monitoring falls within the following range and then do the sensor adjustment again. Lift Arm Position
Voltage Range
Lower limit position (Stroke end of lowered cylinder)
0.5 – 4.5 V
Modification of AJSS Oil Pressure Command Table Pattern (7-19) ★ This item is not used. Adjustment of Speed Limit (machine with lockup clutch) (7-20) This speed limit adjusting function is used to enhance fuel consumption in the forward 4th lockup travel. •
First select the maximum travel speed (selected from three levels).
•
Set the upper limit of the throttle opening for F (forward), 4th, and L/U (lockup) to limit the maximum travel speed. ★ The throttle opening is limited to 90%, when delivered.
•
Select a restricted throttle opening from 80%, 90%, and 100% (no restriction). ★ The state in which F (forward), 4th, and L/U (lockup) are selected is the state in which F4 gearshift is completed and L/U is at the holding pressure.
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WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
★ When gearshift to a speed other than F4 is started or when L/U is cancelled, the upper limit value of this control becomes 100% (no restriction). ★ Setting at delivery is 90%. 1.
Display the TUNING screen from the menu screen of the Service mode.
2.
Hold down the [] switch for a minimum of five seconds to display the 01: TM TRIGGER screen.
3.
Using the [<] or [>] switch, move the cursor to the 22: SPEED LIMIT item.
4.
Press the [] switch to confirm the selection. ★ As the selection is confirmed, the Maximum Speed Limit adjustment screen is displayed.
5.
After making sure that 90% is displayed for the limit value, press the [■] switch to restore the original screen.
6.
When the displayed limit value is not 90%, select 90% using the [<] or [>] switch and then press the [] switch to confirm the setting change.
WA500-6
30-203 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Maintenance Monitoring Function (MAINTENANCE MONITOR) (8) The maintenance function provides the following capabilities for the maintenance of filters and oils. •
Change of maintenance interval time
•
Selection between enabling or disabling timer by item
•
Setting of a default value
•
Selection between enabling or disabling timer for items
1.
Changing maintenance interval time A. Display the MAINTENANCE MONITOR screen from the menu screen of the Service mode.
B. Press the [] switch to display the 41: FUEL P FILT screen. ★ The lower, left side of the display indicates the time remaining up to the replacement. ★ The lower, right side of the display indicates the cumulative replacement frequencies.
C. From the following table, choose the item for which the maintenance interval is to be changed and use the [<] or [>] switch to select it. ★ List of Maintenance Items ID No.
Indication of Items on the Character Display
Replacement Interval Time (H)
Fuel pre-filter
41
FUEL P FILT
500
Engine oil
01
ENG OIL
500
Engine oil filter
02
ENG OIL FILTER
500
Transmission oil filter
13
TRANSM FILTER
500
Fuel filter
03
FUEL FILT
1000
Transmission oil
12
TRANSM OIL
1000
Corrosion resistor
06
CORR-RESISTER
1000
Hydraulic tank breather element
05
HYD BREATHER
2000
Axle oil
15
AXLE OIL
2000
Hydraulic oil filter
04
HYD FILT
2000
Hydraulic oil
10
HYD OIL
2000
Item
30-204 b
WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
D. Use the [] switch to confirm the target items of the interval change. E. Maintenance interval time change procedure i.
This cursor (C) is located at the highest-order digit. Pressing the [<] or [>] switch changes the value of this digit in the range of 0 – 9.
ii.
Press the [] switch when the intended value appears to select it as the set value. ★ The cursor moves to the 2nd digit.
iii. Set the values up to the lowest-order digit in the same manner and then press the [] switch. ★ When the input interval time is within the setting range, the screen changes to the Check screen. ★ When the entered interval time is out of the setting range, the entered interval time does not replace the current value and the Input screen is restored. ★ The shortest interval time value is 50 hours. ★ When you have entered a wrong value in a position (except the highest-order digit), move to the highest order digit using the [■] switch and repeat the procedure from the beginning. In this case, the value that had been entered remains as it is until modified. When the cursor is at the highest-order digit, move to the higher layer using the [■] switch. F.
Use the [<] or [>] switch to select YES or NO. ★ The selected cursor starts flashing. • If YES is selected and the [■] switch is pressed, the information is deleted. • If NO is selected and the [■] switch is pressed, deletion is cancelled and the Maintenance Interval Change Item screen is restored. ★ By default, the cursor is set to NO (cancel) to prevent a resetting error. ★ When an interval time is changed, the timer remaining time is changed in the following manner: Timer remaining time = Interval time being set - Elapsed time from the last replacement
WA500-6
30-205 b
TESTING AND ADJUSTING 2.
MACHINE MONITOR SYSTEM
Selection between enabling or disabling timer by item A. Pressing the [<] or [>] switch from Step 1D, the Interval Time Change screen displays the Selection Between Enabling or Disabling Timer by Item screen. ★ When “Timer by item” is enabled, the order of display is ON OFF.
★ When “Timer by item” is disabled, the order of display becomes OFF ON. ★ The default display is ON.
B. Press the [] switch from this state. ★ If “Timer by item” is disabled, OFF is displayed in the upper column.
★ If “Timer by item” is enabled, ON is displayed in the upper column. C. Use the [<] or [>] switch to select YES or NO. ★ The selected cursor starts flashing. • If YES is selected and the [■] switch is pressed, the information is deleted. • If NO is selected and the [■] switch is pressed, deletion is cancelled and the Maintenance Interval Change Item screen is restored. ★ If the timer which has been stopped is activated, the interval time set before the timer was stopped is applied. The timer remaining time is reset. The number of resets before the timer was stopped is applied.
30-206 b
WA500-6
TESTING AND ADJUSTING 3.
MACHINE MONITOR SYSTEM
Changing set default value. A. Press the [] switch from the MAINTENANCE MONITOR screen of the Service mode to display the 01: ENG OIL screen.
B. Use the [<] or [>] switch to select the INITIALIZE screen. C. Press the [] switch from this state. D. Use the [<] or [>] switch to select YES or NO.
★ The selected cursor starts flashing. • If YES is selected and the [■] switch is pressed, the change is enabled. • If NO is selected and the [■] switch is pressed, the change is not implemented and the maintenance monitoring screen is restored. ★ If the default value setting is executed, all the currently changed interval times are returned to the default values. It is executed on every item independent of whether or not the function is enabled for a specific item. Timer remaining time = Default value - Elapsed time since the last replacement. ★ Executing the default value setting does not affect the reset frequency. It remains the same as before this operation was executed. ★ Set enable for enable or disable of individual items. 4.
Selection between timer stop for all items and enable by item A. Press the [] switch from the MAINTENANCE MONITOR screen of the Service mode to display the 01: ENG OIL screen.
WA500-6
30-207 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
B. Use the [<] or [>] switch to select the ALL ITEMS OFF OR ON screen.
C. Press the [] switch to display the ALL ITEMS OFF screen.
D. Press the [<] or [>] switch when selecting the ALL ITEMS ON screen.
E. Press the [] switch from the ALL ITEMS OFF screen or the ALL ITEMS ON screen. ★ When the [] switch is pressed from the ALL ITEMS OFF screen, OFF is displayed in the upper space.
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WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
★ When the [] switch is pressed from the ALL ITEMS ON screen, ON is displayed in the upper space. F.
Use the [<] or [>] switch to select YES or NO. ★ The selected cursor starts flashing. • If YES is selected and the [■] switch is pressed, the information is deleted. • If NO is selected and the [■] switch is pressed, deletion is cancelled and the Maintenance Interval Change Item screen is restored.
G. As the timer stop for all items is executed: • The timer function for all items is stopped and the MAINTENANCE MONITOR screen is restored. • Setting for individual items is also disabled. • If cancelled, the operation is cancelled and the MAINTENANCE MONITOR screen is restored. H. When timer enable for all items is executed: • Interval time being set for all items is executed to the set value before being disabled, independent of whether or not it is enabled or disabled for a specific item. • The timer remaining time is reset. (The reset frequency remains the same as before the resetting.) • The MAINTENANCE MONITOR screen is restored. • Setting for individual items is also enabled. • If cancelled, the operation is cancelled and the MAINTENANCE MONITOR screen is restored.
Operating Information Display Function (OPERATION INFO) (9) This is a fuel consumption-related function and displays the following information: •
Fuel consumption ratio and average fuel consumption
•
Cumulative fuel consumption and travel distance
•
Cumulative fuel consumption and elapsed time
•
Loaded volume and loading frequency (This display is available only if a load meter is installed.)
1.
Selecting menu Display the OPERATION INFO screen from the menu screen of the Service mode.
2.
Press the [] switch to display the Fuel Consumption Ratio and Average Fuel Consumption screen.
WA500-6
30-209 b
TESTING AND ADJUSTING 3.
MACHINE MONITOR SYSTEM
Use the [<] or [>] switch to select the item to be displayed (A to D in this step) on the Fuel Consumption Ratio and Average Fuel Consumption screen. A. Fuel Consumption Ratio and Average Fuel Consumption screen • The upper column displays fuel consumption [L/km or L/mile] per 1 km (or 1 mile) from the last resetting. ★ Above value is computed from the fuel consumption ratio and travel distance (odometer distance). ★ Counting is stopped at 99999.9, the upper limit. • The lower column displays the average fuel consumption [L/h] from the last resetting. ★ Counting is stopped at 99999.9, the upper limit. ★ Calculation is done only for the duration in which the engine is running. B. Cumulative fuel consumption and travel distance • The upper column displays the cumulative fuel consumption [L] from the last resetting. ★ Counting is stopped at 99999.9, the upper limit. • The lower column displays the travel distance [km or mile] from the last resetting. ★ The unit km or mile is selected depending on that used on the odometer. ★ Counting is stopped at 99999.9, the upper limit. ★ Calculation is done only for the duration in which the engine is running. C. Cumulative fuel consumption and elapsed time ★ The upper column displays the cumulative fuel consumption [L] from the last resetting. • Counting is stopped at 99999.9, the upper limit. ★ The lower column displays the elapsed time [h] from the last resetting. • Counting is stopped at 99999.9, the upper limit. ★ Calculation is done only for the duration in which the engine is running.
D. Loaded volume and loading frequency screen • The upper column displays the loaded volume [ton] from the last resetting. ★ Counting is stopped at 999999.9, the upper limit. • Short ton or metric ton depends on optional setting. • The lower column displays the loading frequency from the last resetting. ★ Counting starts stopped at 65000, the upper limit. ★ Calculation is done only for the duration in which the engine is run and the optional device is used.
30-210 b
WA500-6
TESTING AND ADJUSTING 4.
Deleting display data ★ Data on screens 3A to 3D allow deletion. • Select a desired item and then delete it using the [] switch. • Use the [■] switch when canceling deletion of data.
5.
Setting gain correction ★ Gain correction means the function of correcting gain to cumulative fuel consumption. ★ Gain correction is available only from the Fuel Consumption Ratio and Average Fuel Consumption screen.
MACHINE MONITOR SYSTEM
A. After deleting data (RESET screen), press the [<] or [>] switch to display the current set value. B. Pressing the [] switch displays the correction screen. ★ Default value: 0.0% ★ This setting allows you to correct the cumulative fuel consumption in the range of -50.0 to +50.0. C. Move the cursor to [+] or [–]. D. Pressing the [<] or [>] switch alternately displays [+] and [–]. E. Press the [] switch to confirm [+] or [–]. ★ The cursor moves to the highest-order digit of the set value. F.
Pressing the [<] or [>] switch changes the value of this digit in the range of 0 – 9.
G. Press the [] switch when the intended value appears in order to select it as the set value. ★ The cursor moves to the 2nd digit. H. Set the values up to the lowest digit in the same manner and then press the [] switch to confirm. ★ As the selection is confirmed, the preceding screen is restored. ★ If the [■] switch is pressed before you finish entering the selection, the cursor moves to the [+] and [–] position. In this case, the value remains unchanged. Pressing the [■] switch again restores the preceding screen. ★ If the value is not in the -50 to +50 range, pressing the [] switch at the lowest digit just moves the cursor to the [+] and [–] position and the value remains as it is.
WA500-6
30-211 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Optional Device Selecting Function (OPTIONAL SELECT) (10) Use this procedure for setting an option. ★ Set the option and turn the starting switch OFF. After the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again. The option is now effective. ★ Before setting an option, check that the machine model has been selected. (Select the machine model before setting the option.) Optional Device Installation Setting Table Item
Display in English
Item No.
Default
Description Select A or B according to the lift arm specifications. • Lift arm length = 3,250 mm: A • Lift arm length = 3,636 mm: B
Lift arm model
LIFT BOOM
1
A
Auto grease
AUTO GREASE
2
None
When an option is provided, select ADD.
Battery electrolyte level sensor
BAT LIQUID
3
None
When an option is provided, select ADD.
Transmission filter clogging sensor
TRANSM CLOG
4
None
When an option is provided, select ADD.
Printer
PRINTER
5
None
When an option is provided, select ADD.
Tire size
TIRE SIZE
6
0
Normally, 0% shall be maintained without modifying current setting.
Switching to short ton
SHORT TON
7
None
Only in specification which can display in mile, select ADD to display in short ton; select NO to display in metric ton.
Travel speed unit
SPEED (UNIT)
8
MPH
Only in specification which can display in mile, MPH and km/h are selectable.
Engine speed or travel speed display on character display and normal screen
RPM/SPEED
10
Provided
Normally, ADD shall be maintained without modifying current setting.
Load meter
LOAD METER
11
None
When an option is provided, select ADD.
Emergency steering
EMERG S/T
13
Provided
When an option is not provided, select NO ADD. When joystick steering or right FNR switch is installed, the setting applicable to each shall be implemented. • Set NON only for steering wheel. • Set J/S for joystick steering. • Set FNR SW for the right FNR (directional) switch.
Joystick steering or right FNR (directional) switch, or both are absent
J/S-FNR SW
14
NON
Display of economy lamp
ECO LAMP
–
Provided
Normally, ADD shall be maintained without modifying current setting.
ECSS (Travel damper)
E.C.S.S.
20
None
When an option is provided, select ADD.
Automatic reversing fan
AUTO RE FAN
21
None
Set NO ADD and never change.
Torque converter lockup
LOCK UP
22
None
When an option is provided, select ADD.
FORBID 4TH
23
None
Normally, NO ADD shall be maintained without modifying current setting.
4th gear prohibition
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WA500-6
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM Display in English
Item No.
Default
Throttle lock
THROT LOCK
24
None
When an option is provided, select ADD.
Power mode priority
P-MODE PRI
25
None
When an option is provided, select ADD. (Setting available: Power mode is introduced as starting switch is turned on.)
Very cold region specification
COLD SPEC
26
None
NO ADD; this must not be changed.
EPC 3-spool lever
EPC 3RD
31
None
When an option is provided, select ADD.
EPC lever
EPC LEVER
32
Provided
When an option is provided, select ADD.
Item
1.
Display the OPTIONAL SELECT screen from the menu screen of the Service mode.
2.
Hold down the [] switch for 5 seconds or longer.
3.
The 1: LIFT BOOM screen appears. ★ If the [■] switch is pressed, the screen returns to the OPTIONAL SELECT screen. ★ For optional setting, be sure to change or select the relevant items from the 1: LIFT BOOM screen. Also set each item sequentially on the next 2: AUTO GREASE screen and after.
WA500-6
Description
30-213 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Setting Options 1.
Changing or settling lift arm model option selection ★ Pressing the [] switch from the 1: LIFT BOOM screen interchanges A and B. ★ As A and B are interchanged, a sound (beep) is generated to indicate acceptance of the operation. •
Select the lift arm length for A and B from the following. Machine Model
A
B
WA500-6
3250 mm (128 in)
3636 mm (143 in)
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TESTING AND ADJUSTING 2.
MACHINE MONITOR SYSTEM
Option setting/not setting selection ★ Among the items included in the list of installed optional devices and their setting, the option setting/not setting selection applies to the following items. ★ If the options are not selected, the Option Non-Selection screen (NO ADD) is displayed.
★ If the options are selected, the Option Selected screen (ADD) is displayed. ★ The [] switch allows the alternate display of the Option NonSelection screen and the Option-Selected screen.
3.
Setting tire deflection option ★ Select the tire deflection option from the list of installed optional devices and their setting. ★ Pressing the [] switch sequentially displays [@@]% in the following order. ★ The display progresses from +00 through -10. Pressing the [] switch at this point returns the display to +00. Order No.1
No.2
No.3
No.4
No.5
No.6
No.7
@@
+02
+04
+06
+08
+10
+12
+00
Order No.8
No.9 No.10 No.11 No.12 No.13 No.14
@@
–4
–02
–6
–8
–10
–12
+00
★ As the display is switched, a sound (beep) is generated to indicate acceptance of the operation. 4.
Storing option selection A. If the option selection was changed, turn off the starting switch once to stop the controller operation completely. (After turning off the starting switch, wait for 15 seconds without doing any switch operation.) B. The specified option selection is enabled as the starting switch is turned on. ★ Whenever an option selection is made, turn off the starting switch once and then turn it on again in approximately 15 seconds.
WA500-6
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Machine Serial Number Input Function (MACHINE No. SET) (11) 1.
Display the MACHINE No. SET screen from the menu screen of the Service mode.
2.
Press the [] switch to display the MACHINE No. screen.
3.
Enter the serial number according to the following procedure. ★ The cursor is positioned at the highest-order digit. A. Pressing the [<] or [>] switch increases or decreases the value at the cursor position. Select a desired value using these switches. B. Press the [] switch to confirm the selection. ★ The cursor moves to the digit situated immediately on the right hand. C. Set the values up to the lowest digit in the same manner and then press the [] switch to confirm. ★ As the selection is confirmed, the preceding screen is restored. ★ Pressing the [■] switch while entry is taking place moves the cursor to the highest-order digit. In this case, repeat the entry from the highest-order digit. ★ If the [■] switch is pressed while the cursor is at the highest-order digit, the preceding screen is restored.
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TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Model Selection Function (MACHINE WA500) (12) ★ The machine model select function allows you to change the setting of the machine model by using the monitor. ★ Select a model first after initializing the machine monitor. ★ Selecting a model resets the optional setting. If a model is selected, perform all the optional settings in sequence from the beginning. 1.
Implementing the model change A. Display the MACHINE screen from the menu screen of the Service mode. ★ The currently selected machine model is displayed on the lower line. B. Hold down the [] switch for five seconds to display the Model Selection screen. C. Use the [<] and [>] switch to select the machine model. ★ Press the [■] switch to stop the model selection. ★ As the operation is stopped, a sound (beep) (indicating acceptance of the operation) is generated, restoring the MACHINE screen. D. Use the [] switch to confirm the selected model. ★ As the selection is confirmed, a sound (beep) (indicating acceptance of the operation) is generated, restoring the MACHINE screen. ★ Check that the desired machine model is displayed on the MACHINE screen.
2.
Storing model change A. When the model change is done, turn off the starting switch once to stop the controller operation completely. (After turning off the starting switch, wait for 15 seconds without doing any switch operation.) B. The model selected when the starting switch is turned on is validated. ★ Whenever a model change is done, turn off the starting switch once and then turn it on again in approximately 15 seconds.
WA500-6
30-217 b
TESTING AND ADJUSTING
MACHINE MONITOR SYSTEM
Initialize Function (INITIALIZE) (13) This function is used only in the factory. It is not used for service purposes.
30-218 b
WA500-6
TESTING AND ADJUSTING
PM CLINIC INSPECTION TABLES
PM CLINIC INSPECTION TABLES WA500-6 Serial No. A93001 and up WARNING!
When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel safely at a speed of more than 10 km/h (6 mph).
Hours inspection Work Order No.
Machine serial No.
#
Engine serial No.
SAA6D140E-5#
Service Meter
Inspector
Date of Service
Interview with Operator and Walk-around Inspection Problems before inspection: 1. 2. 3. 4. Maximum coolant temperature (During operation) Maximum HST oil temperature (During operation) Segment color
•
W = White
•
G = Green
•
R = Red
W G G G G R R 1 2 3 4 5 6 7
Segment color
Ambient temperature Max. °C (°F) Min. °C (°F) Altitude: m (yd)
G G G G G R R 1 2 3 4 5 6 7
★ Before starting the inspection, check that the machine does not move when the directional lever is placed in position. ★ If the machine is cold, warm it up fully. Item
Engine
Engine speed
Blow-by pressure
Condition
Unit
Standard Value for New Machine
Service Limit Value
Engine at low idle
650 – 700
650 – 700
Engine at high idle
2,100 – 2,200
2,100 – 2,200
1,740 – 1,940
1,640 – 2,040
Engine at high idle and work equipment relieved
2,000 – 2,200
1,900 – 2,300
Torque converter stalled + Work equipment relieved
1,700 – 1,900
1,500 – 2,100
Max. 2.94 (0.43)
3.92 (0.57)
Min. 0.34 (49.31)
0.21 (30.46)
Min. 0.10 (14.50)
0.08 (11.60)
Engine at high idle and torque converter stalled
Engine at high idle and torque converter stalled
SAE0W30EOS SAE5W40EOS Engine at high idle Lubricating oil SAE10W30DH pressure SAE15W40DH Engine at low idle SAE30DH
Good
Bad
rpm
kPa (psi)
MPa (psi)
Boost pressure
Engine at high idle and torque converter stalled
kPa (psi)
Min. 116 (16.82)
89 (12.91)
Exhaust temperature
• Engine at high idle and torque converter stalled • Outside temperature: 20°C (68°F)
°C (°F)
Max. 650 (Max. 1202)
700 (1292)
WA500-6
Measurement Result
30-219 b
TESTING AND ADJUSTING Item
PM CLINIC INSPECTION TABLES
Condition
Unit
Standard Value for New Machine
Service Limit Value
Measurement Result
Good
Bad
Measurement Result
Good
Bad
* When shifting transmission gear to forward/reverse position, apply brake securely. Main relief pressure
Engine at high idle
3.19 – 3.48 (462.67 – 504.73)
3.19 – 3.48 (462.67 – 504.73)
Engine at low idle
3.49 – 3.79 (506.18 – 549.69)
3.49 – 3.79 (506.18 – 549.69)
0.44 – 0.84 (63.82 – 121.83)
0.44 – 0.84 (63.82 – 121.83)
0.29 – 0.49 (42.06 – 71.07)
0.29 – 0.49 (42.06 – 71.07)
0.10 – 0.25 (14.50 – 36.26)
0.10 – 0.25 (14.50 – 36.26)
3.04 – 3.44 (440.91 – 498.93)
3.04 – 3.44 (440.91 – 498.93)
3.08 – 3.48 (446.72 – 504.73)
3.08 – 3.48 (446.72 – 504.73)
3.08 – 3.48 (446.72 – 504.73)
3.08 – 3.48 (446.72 – 504.73)
2.99 – 3.39 (433.66 – 491.68)
2.99 – 3.39 (433.66 – 491.68)
1.71 – 2.01 (248.01 – 291.53)
1.71 – 2.01 (248.01 – 291.53)
F
3.18 – 3.58 (461.22 – 519.24)
3.18 – 3.58 (461.22 – 519.24)
R
3.14 – 3.54 (455.42 – 513.43)
3.14 – 3.54 (455.42 – 513.43)
Unit
Standard Value for New Machine
Service Limit Value
MPa (psi)
24.5 – 25.5 (3553.43 – 3698.46)
23.5 – 25.5 (3553.43 – 3698.46)
3.38 – 3.68 (490.23 – 533.74)
3.38 – 3.68 (490.23 – 533.74)
Min. 0.14 (Min. 20.31)
Min. 0.14 (Min. 20.31)
TransmissiOn valve
Torque Engine at high converter inlet idle pressure Torque Engine at high converter outlet idle pressure Lubrication oil Engine at high pressure idle
MPa (psi)
1st 2nd 3rd ECMV output (clutch) pressure
4th Lockup
Item Steering
• Torque converter oil pressure: Within operating range • Transmission: Neutral
• Torque converter oil pressure: Within operating range • Engine at high idle • Manual switch: ON
Condition
* Secure frame with frame lock bar. Steering relief Engine at high idle pressure
Brake
• Torque converter oil temperature: Within operating Parking brake range inlet pressure • Engine at low idle
As brake is released When brake operated
MPa (psi)
• Tire inflation pressure: Specified pressure Parking brake • Test on flat and dry paved slope of performance 1/5 (11° 20'). • Set machine in operating state.
—
Holds in position
Holds in position
Parking brake disc thickness
mm (in)
3.1 – 3.3 (0.12 – 0.13)
2.77 (0.11)
5.88 – 6.37 (852.82 – 923.89)
5.39 – 6.86 (781.75 – 994.96)
9.8 – 10.78 (1421.37 – 1563.51)
9.31 – 11.27 (1350.30 – 1634.58)
Measure when brake oil pressure • Hydraulic oil warning lamp temperature: Within operating goes off. range Measure when • Engine at low brake oil Charge cut-out idle pressure starts pressure dropping after rising. Charge cut-in pressure
30-220 b
MPa (psi)
WA500-6
TESTING AND ADJUSTING Condition
Unit
Standard Value for New Machine
Service Limit Value
Brake oil pressure
• Hydraulic oil temperature: Within operating range • Engine at low idle
MPa (psi)
4.9 – 5.59 (710.68 – 810.76)
4.7 – 5.78 (681.68 – 838.32)
Drop in brake pressure
• Engine: Stopped • Measure lowering of oil pressure from 4.9 MPa (710.68 psi) in 5 minutes.
kPa (psi)
Max. 0.49 (Max. 0.071)
Max. 0.49 (Max. 0.071)
Wheel brake performance
• Tire inflation pressure: Specified pressure • Test on flat, level, straight, and dry paved road. • Braking initial speed: 20 km/h, Delay in pressing pedal: Max 0.1 sec • Brake pedal pressing force: Specified force, 294 ±29.4 N•m (lbf ft) • Measure braking distance.
m (ft)
Max. 4 (Max. 13.12)
Max. 4 (Max. 13.12)
mm (in)
0 (0)
Max. 5.5 (Max. 0.22)
32.8 – 34.8 (4757.24 – 5047.31)
31.8 – 34.8 (4612.20 – 5047.31)
1.27 – 1.47 (184.20 – 213.21)
1.17 – 1.57 (169.69 – 227.71)
Brake
Item
Work equipment
Wear of wheel Measure with disc wear indicator. brake disc Work equipment valve relief pressure
Bucket circuit relieved
Work equipment valve LS differential pressure
Work equipment control lever moved halfway
• P-mode Hydraulic oil temperature: Within operating range Lift arm speed • Engine at high idle Bucket tilt-back speed • Hydraulic oil temperature: Within Hydraulic drift operating of work range equipment • Engine: Stopped
Axle
PM CLINIC INSPECTION TABLES
Visual check of Front axle differential Rear axle drain plug
WA500-6
Rising time
6.7 – 7.5
Max. 8.9
3.7 – 4.7
Max. 5.4
2.2 – 2.8
Max. 3.4
Bucket at level time
1.5 – 2.1
Max. 2.6
Bucket cylinder
Max. 20
Max. 20
Max. 40 (Max. 1.57)
Max. 40 (Max. 1.57)
Lift cylinder
Good
Bad
MPa (psi)
Lowering time Bucket full stroke time
Measurement Result
Sec
mm/ 15 min. (in/ 15 min)
—
There must not be excessive metal powder.
30-221 b
TESTING AND ADJUSTING
PM CLINIC INSPECTION TABLES
Memo
30-222 b
WA500-6
40
TROUBLESHOOTING
TROUBLESHOOTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17 TROUBLESHOOTING EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20 Precautions when Handling Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20 Handling Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25 Points to Remember When Troubleshooting Electrical Circuits . . . . . . . . . . . . . . . . . . . 40-26 ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27 How to Read Electric Wire Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27 Type, Symbol, and Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28 Color Codes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-29 Circuits and Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30 Classification by Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30 HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31 CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-33 Categories and Method of Using Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . 40-34 Troubleshooting Individual Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-35 Chart Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37 Chart Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-37 Troubleshooting Individual Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38 CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40 Connection Tables for Connector PIN Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40 X-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40 SWP-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42 M-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44 S-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46 MIC-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48 AMP040-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50 AMP070-Type Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54 L-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54 PA-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55 Bendix (MS) Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55 KES1 (Automobile) Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56 F-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57 Connectors for Relay (Socket-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58 HD30 Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59 DT Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64 DTM Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66 DTHD Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66 WA500-6
40-1 b
TROUBLESHOOTING
TABLE OF CONTENTS
DTP Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67 DRC26 Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68 DRC12, 16 Series Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70 AMP Connectors for Pump Controller (CH700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-71 BOSCH Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72 SUMITOMO Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-73 CANNON Connector for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-74 AMP Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-75 FRAMATOME Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-76 PACKARD Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-78 DT Series Connectors for Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-79 T-BRANCH BOX and T-BRANCH ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80 MODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-85 INFORMATION IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-88 TROUBLESHOOTING BY FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90 Failure Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90 FUSE BOX AND SLOW-BLOW FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104 Connection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104 Fuse Box A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104 Fuse Box B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104 Slow-Blow Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-105 FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-106 1500LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-107 TORQFLOW Transmission: Double Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-107 15BONX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108 Transmission Filter: Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108 15SAL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . . 40-110 15SALH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112 ECMV F Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . . 40-112 15SBL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-114 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . . 40-114 15SBLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-116 ECMV R Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . . 40-116 15SEL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-118 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . . 40-118 15SELH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120 ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . . 40-120 15SFL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON . . . . . . . . . . . 40-122 15SFLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124 ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-124 15SGL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . 40-126 15SGLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128 ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-128 15SHL1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON . . . . . . . . . . . 40-130 15SHLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132 40-2 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF . . . . . . . . . . . 40-132 2F00MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134 Parking Brake: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134 2G42ZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136 Front Accumulator: Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136 2G43ZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138 Rear Accumulator: Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138 44K0L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140 Bucket Positioner: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140 AA1ANX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142 Air Cleaner: Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142 AB00L6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144 Alternator: Signal Disagrees with Operating State of Engine . . . . . . . . . . . . . . . . . . . . 40-144 AB00MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146 Alternator: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146 B@BAZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148 Engine: Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148 B@BAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150 Engine Oil: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150 B@BCNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152 Engine: Coolant: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152 B@BCZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154 Engine: Coolant: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154 B@C7NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156 Brake: Brake Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156 b@CENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158 Torque Converter Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158 B@CENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160 Torque Converter Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160 B@GAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162 Battery Electrolyte: Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162 B@HANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164 Hydraulic Oil: Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164 CA111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166 Abnormality in Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166 CA115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-169 Engine Ne or Bkup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-169 CA122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170 Charge Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170 CA123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172 Charge Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172 CA131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174 Throttle Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174 CA132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176 Throttle Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176 CA135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178 Engine Oil Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178 CA141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180 Engine Oil Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180 WA500-6
40-3 b
TROUBLESHOOTING CA144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182 Coolant Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182 CA145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184 Coolant Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184 CA153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186 Charge Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186 CA154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188 Charge Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188 CA187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-189 Sensor Power Supply 2 Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-189 CA221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190 Atmospheric Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190 CA222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192 Atmospheric Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192 CA227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194 Sensor Power Supply 2 High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194 CA234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196 Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196 CA238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198 Ne Speed Sensor Power Supply Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198 CA263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200 Fuel Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200 CA265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202 Fuel Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202 CA271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204 PCV1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204 CA272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206 PCV1 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206 CA273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208 PCV2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208 CA274 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210 PCV2 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210 CA322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212 Injector #1 (L/B #1) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212 CA323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214 Injector #5 (L/B #5) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214 CA324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216 Injector #3 (L/B #3) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216 CA325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218 Injector #6 (L/B #6) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218 CA331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220 Injector #2 (L/B #2) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220 CA332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222 Injector #4 (L/B #4) Open/Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222 CA342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224 Calibration Code Data Inconsistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224 CA351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225 Injectors Drive Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225 CA352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228 40-4 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
Sensor Power Supply 1 Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228 CA386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230 Sensor Power Supply 1 High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230 CA431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232 Idle Validation Switch Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232 CA432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234 Idle Validation Action Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234 CA441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-235 Battery Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-235 CA442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236 Battery Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236 CA449 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-237 Common Rail Pressure High Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-237 CA451 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238 Common Rail Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238 CA452 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240 Common Rail Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240 CA553 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241 Common Rail Pressure High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241 CA554 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242 Common Rail Pressure In-Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242 CA559 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244 Supply Pump Pressure Very Low Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244 Checksheet for No-Pressure Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246 CA689 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248 Engine Ne Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248 CA731 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250 Engine Bkup Speed Sensor Phase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250 CA757 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-251 All Continuous Data Lost Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-251 CA778 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252 Engine Bkup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252 CA1228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254 EGR Valve Servo Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254 CA1625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-255 EGR Valve Servo Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-255 CA1626 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256 Bypass Valve Solenoid Current High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256 CA1627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258 Bypass Valve Solenoid Drive Circuit Disconnection Error . . . . . . . . . . . . . . . . . . . . . 40-258 CA1628 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-259 Bypass Valve Servo Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-259 CA1629 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260 Bypass Valve Servo Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260 CA1631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262 Bypass Valve Lift Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262 CA1632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264 Bypass Valve Lift Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264 CA1633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-265 WA500-6
40-5 b
TROUBLESHOOTING KOMNET Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-265 CA1642 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266 Abnormally Low Signal in EGR Inlet Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 40-266 EGR Inlet Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-267 CA1653 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268 Abnormally High Signal in EGR Inlet Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . 40-268 EGR Inlet Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270 CA2185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272 Throttle Sensor Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272 CA2186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274 Throttle Sensor Power Supply Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274 CA2249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-275 Supply Pump Pressure Very Low Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-275 CA2271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276 EGR Valve Lift Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276 CA2272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278 EGR Valve Lift Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278 CA2351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280 EGR Valve Solenoid Operation Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280 CA2352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282 EGR Valve Solenoid Operation Disconnection Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282 CA2555 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-283 Intake Heater Relay Disconnection Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-283 CA2556 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284 Intake Heater Relay Short Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284 D160KZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286 Backup Lamp Relay: Disconnection or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286 D191KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288 Joystick Steering Neutral Safety Relay: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-288 D191KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290 Joystick Steering Neutral Safety Relay: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290 D192KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292 ECSS Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292 D192KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-293 ECSS Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-293 D192KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294 ECSS Solenoid Relay: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . 40-294 D193KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296 Joystick Steering Solenoid Cut Relay: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-296 D193KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298 Joystick Steering Solenoid Cut Relay: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298 D193KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300 Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line . . . . . . . 40-300 D5ZHKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302 Terminal C Signal: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302 D5ZHKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306 Terminal C Signal: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306 D5ZHKZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308 Terminal C Signal: Disconnection or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308 40-6 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
D5ZHL6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312 Terminal C Signal: Signal Does Not Match Engine Running or Stopped State . . . . . . 40-312 DA80L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314 Auto-Grease Controller: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314 DAF3KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316 Machine Monitor: Low Source Voltage (input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316 DAF5KP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318 Machine Monitor: Low Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318 DAFRKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322 Machine Monitor: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322 DAQ0KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324 Transmission Controller: Low Source Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324 DAQ0KT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326 Transmission Controller: Abnormality in Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326 DAQ2KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328 Transmission Controller Load Power Supply Line: Low Source Voltage (input) . . . . 40-328 DAQ9KQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330 Transmission Controller: Disagreement of Model Selection Signals . . . . . . . . . . . . . . 40-330 DAQRKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332 Transmission Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . 40-332 DAQRMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334 Transmission Controller Option Setting: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . 40-334 DB2RKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336 Engine Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336 DB90KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338 Work Equipment Controller: Low Source Voltage (input) . . . . . . . . . . . . . . . . . . . . . . 40-338 DB90KT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340 Work Equipment Controller: Abnormality in Controller . . . . . . . . . . . . . . . . . . . . . . . 40-340 DB92KK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342 Work Equipment Controller Load Power Supply Line: Low Source Voltage (input) . 40-342 DB95KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344 Work Equipment Controller Power Supply Output: Out-of-Input Signal Range . . . . . 40-344 DB99KQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-347 Work Equipment Controller: Disagreement of Model Selection Signals . . . . . . . . . . . 40-347 DB9RKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348 Work Equipment Controller: CAN Defective Communication . . . . . . . . . . . . . . . . . . 40-348 DB9RMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350 Work Equipment Controller Option Setting: Malfunction . . . . . . . . . . . . . . . . . . . . . . 40-350 DB9RMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352 Work Equipment Controller: CAN Communication Defective Operation . . . . . . . . . . 40-352 DD15LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354 Switch (Panel Switch 1 n): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-354 DD16LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356 Switch (Panel Switch 2 ‡): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-356 DD17LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358 Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-358 DD18LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-360 Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-360 DD1ALD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362 WA500-6
40-7 b
TROUBLESHOOTING Remote Positioner Raise/Lower Set Switch (raise): Switch Is Kept Pressed for Long Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362 DD1BLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-364 Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-364 DD1CLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-366 Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . 40-366 DD1FLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-368 Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long Time . . . 40-368 DD1GLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-370 Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long Time . . . . 40-370 DD1HLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-372 Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time . . . . . . . 40-372 DDA7L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-374 RPM Set ON/OFF Switch: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . 40-374 DDA8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-376 RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit . . . . . . . . . . . . . . . 40-376 DDA9KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-378 RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit . . . . . . . . . . . 40-378 DDB6L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-380 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . 40-380 DDD1LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-384 Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for Long Time . 40-384 DDE5MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386 Emergency Steering Drive Switch: Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386 DDK3KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388 Right FNR Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388 DDK3KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391 Right FNR Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391 DDK4KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-394 Joystick Steering FNR Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-394 DDK4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-397 Joystick Steering FNR Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-397 DDK5L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-400 Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree . . . . . . . . 40-400 DDK6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-402 FNR Lever Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-402 DDK6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-405 FNR Lever Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-405 DDT0L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-408 Shift Mode Selector Switch: ON/OFF Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . 40-408 DDT4LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-410 Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . 40-410 DDW9LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-412 Kickdown Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . . . . . . . . 40-412 DDWLLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-414 Hold Switch: Switch is Kept Pressed Down for Long Time . . . . . . . . . . . . . . . . . . . . . 40-414 DDY0LD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-416 Load Meter Cancel Switch: Switch is Kept Pressed for Long Time . . . . . . . . . . . . . . . 40-416 40-8 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
DF10KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-418 Transmission Shift Lever Switch: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-418 DF10KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-421 Transmission Shift Lever Switch: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-421 DGF1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-424 Transmission Oil Temperature Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-424 DGF1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-426 Transmission Oil Temperature Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-426 DGH2KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-428 Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . 40-428 DGR2KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430 Rear Brake Oil Temperature Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430 DGR2KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-432 Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . . . 40-432 DGT1KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-434 Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range . . . . . . . . . . . . 40-434 DH21KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-436 Work Equipment Pump Oil Pressure Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . 40-436 DH21KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-438 Work Equipment Pump Oil Pressure Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-438 DHPCKX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-440 Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . 40-440 DHPDKX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-442 Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . 40-442 DHT1KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-444 Left Brake Pressure Sensor: Out-of-Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-444 DHT2L6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-446 Transmission Filter Clogging Sensor: Signal Disagrees with Operating and Stopped States of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-446 DK59KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-448 Lift Arm EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . . . . . . . 40-448 DK59KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-451 Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . 40-451 DK59L8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-454 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . . . . . . . . 40-454 DK5AKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-458 Lift Arm EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . . . . . . . 40-458 DK5AKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-461 Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne . . . 40-461 DK5BKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-464 Bucket EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-464 DK5BKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-467 Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . . . 40-467 DK5BL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . . . . . . . . . 40-470 DK5CKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-473 Bucket EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-473 DK5CKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476 Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line . . . . . 40-476 WA500-6
40-9 b
TROUBLESHOOTING DK5DKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-479 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection . . . . . . 40-479 DK5DKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-482 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-482 DK5DL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-484 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-484 DK5EKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-488 3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection . . . . . . . 40-488 DK5EKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490 3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490 DK5FKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-492 Joystick Steering EPC Lever Potentiometer (Main): Disconnection . . . . . . . . . . . . . . . 40-492 DK5FKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-494 Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-494 DK5GKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-496 Joystick Steering EPC Lever Potentiometer (Sub): Disconnection . . . . . . . . . . . . . . . . 40-496 DK5GKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498 Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498 DK5FL8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-500 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree . . . . . . 40-500 DKA0KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-504 Lift Arm Angle Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-504 DKA0KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506 Lift Arm Angle Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506 DKA0KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510 Lift Arm Angle Sensor: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . 40-510 DKA0L0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512 Lift Arm Angle Sensor: Double Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512 DLF1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514 Transmission Input Shaft Speed Sensor: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-514 DLF1LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516 Transmission Input Shaft Speed Sensor: Speed Signals Disagree . . . . . . . . . . . . . . . . 40-516 DLT4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518 Transmission Input Shaft Speed Sensor: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-518 DLT4KX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520 Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range . . . . . . . . . . . . . 40-520 DT20KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522 Transmission Cutoff Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522 DUM1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-524 Remote Positioner Raise Set Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-524 DUM2KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-526 Remote Positioner Lower Set Indicator Lamp: Short Circuit . . . . . . . . . . . . . . . . . . . . 40-526 DV00KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528 Alarm Buzzer: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528 40-10 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
DW4PKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530 Lift Arm Raise EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530 DW4PKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-532 Lift Arm Raise EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-532 DW4PKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-534 Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . 40-534 DW4QKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536 Lift Arm Lower EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536 DW4QKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538 Lift Arm Lower EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538 DW4QKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-540 Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . 40-540 DW4RKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542 Bucket Tilt EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542 DW4RKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544 Bucket Tilt EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544 DW4RKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546 Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . 40-546 DW4SKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-548 Buck Dump EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-548 DW4SKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550 Bucket Dump EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550 DW4SKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-552 Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-552 DW7BKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-554 Fan Reverse Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-554 DW7BKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-556 Fan Reverse Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-556 DW7BKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-558 Fan Reverse Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . . . 40-558 DW7DKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-560 Hydraulic Drive Fan Neutral Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-560 DW7DKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-561 Hydraulic Drive Fan Neutral Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-561 DW7DKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-562 Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . 40-562 DWM1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-564 Work Equipment Neutral Lock Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-564 DWM1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-566 Work Equipment Neutral Lock Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-566 DWM1KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-568 Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line . . . . 40-568 DWN6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-570 Lift Arm Raise Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . 40-570 DWN6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-572 Lift Arm Raise Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-572 DWN6KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-574 Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line . . . . 40-574 DWN7KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-576 WA500-6
40-11 b
TROUBLESHOOTING Lift Arm Float Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . 40-576 DWN7KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-578 Lift Arm Float Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-578 DWN7KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580 Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line . . . . . 40-580 DWN8KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-582 Bucket Tilt Magnet Detent Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-582 DWN8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-584 Bucket Tilt Magnet Detent Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-584 DWN8KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-586 Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source . . . . . . . . . . . . . 40-586 DX16KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-588 Fan Pump EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-588 DX16KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-589 Fan Pump EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-589 DX16KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-590 Fan Pump EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . 40-590 DXA1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-591 Pump PC-EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-591 DXA1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-592 Pump PC-EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-592 DXH1KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-594 Lockup ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-594 DXH1KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-596 Lockup ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-596 DXH1KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-598 Lockup ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . . 40-598 DXH4KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-600 1st Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-600 DXH4KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-602 1st Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-602 DXH4KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-604 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-604 DXH5KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606 2nd Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606 DXH5KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608 2nd Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608 DXH5KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-610 DXH6KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612 3rd Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612 DXH6KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614 3rd Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614 DXH6KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-616 DXH7KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618 R Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618 DXH7KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620 R Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620 40-12 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
DXH7KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622 R Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . 40-622 DXH8KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624 F Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624 DXH8KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-626 F Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-626 DXH8KY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-628 F Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . . . 40-628 DXHHKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-630 4th Clutch ECMV Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-630 DXHHKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632 4th Clutch ECMV Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632 DXHHKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-634 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line . . . . . . . . . . . . . . 40-634 DXHJKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-636 3-Spool Valve Extract EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-636 DXHJKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-637 3-Spool Valve Extract EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-637 DXHJKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-638 3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-638 DXHKKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640 3-Spool Valve Retract EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640 DXHKKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-641 3-Spool Valve Retract EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-641 DXHKKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-642 3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-642 DXHLKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-644 Joystick Steering Right EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . 40-644 DXHLKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646 Joystick Steering Right EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646 DXHLKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-649 Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line . . . . . . 40-649 DXHMKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-652 Joystick Steering Left EPC Solenoid: Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-652 DXHMKB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-654 Joystick Steering Left EPC Solenoid: Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-654 DXHMKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-657 Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line . . . . . . . 40-657 TROUBLESHOOTING: E-MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-660 Troubleshooting Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-660 Information in Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-660 E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-662 Engine Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-662 E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-668 Wiper Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-668 E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-672 Windshield Washer Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-672 E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-676 Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or WA500-6
40-13 b
TROUBLESHOOTING Go Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-676 E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-684 Working Lamp Does Not Light Up or Go Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-684 E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-690 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off . . . . . . . . . . . . . . . . 40-690 E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-696 Brake Lamp Does Not Light or It Keeps Lighting Up . . . . . . . . . . . . . . . . . . . . . . . . . 40-696 E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-700 Backup Lamp Does Not Light or It Keeps Lighting Up . . . . . . . . . . . . . . . . . . . . . . . . 40-700 E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-702 Backup Buzzer Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . 40-702 E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-704 Horn Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-704 E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-708 Alarm Buzzer Does Not Sound or It Keeps Sounding . . . . . . . . . . . . . . . . . . . . . . . . . 40-708 E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-710 Air Conditioner Does Not Operate or Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-710 E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-714 KOMTRAX System Does Not Work Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-714 Lamp Display Section of KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . 40-716 TROUBLESHOOTING: H-MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-718 Troubleshooting Hydraulic and Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 40-718 Using Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-718 Failure Codes and Causes Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-720 H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-724 Machine Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-724 H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-726 Torque Converter Lockup is Not Switched OFF (Engine Stalls) . . . . . . . . . . . . . . . . . 40-726 H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-727 Torque Converter Lockup is Not Switched ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-727 H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-728 Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-728 H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-730 Large Shocks When Starting and Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-730 H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-731 Large Time Lag When Starting and Shifting Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-731 H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-732 Torque Converter Oil Temperature is High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-732 H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-733 Steering Does Not Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-733 H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-734 Steering Does Not Turn (Joystick Steering, if equipped) . . . . . . . . . . . . . . . . . . . . . . . 40-734 H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-735 Steering Response is Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-735 H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-736 Steering Turning Response is Poor (Joystick Steering, if Equipped) . . . . . . . . . . . . . . 40-736 H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-737 Steering is Heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-737 40-14 b
WA500-6
TROUBLESHOOTING
TABLE OF CONTENTS
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738 When Machine Turns, It Shakes or Jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-738 H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-739 When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped) . . . . . . . . . 40-739 H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-740 Wheel Brake Does Not Work or Does Not Work Well . . . . . . . . . . . . . . . . . . . . . . . . . 40-740 H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-741 Wheel Brake is Not Released or It Drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-741 H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-742 Parking Brake Does Not Work or Does Not Work Well . . . . . . . . . . . . . . . . . . . . . . . . 40-742 H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-743 Parking Brake is Not Released or It Drags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-743 H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-744 Lift Arm Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-744 H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-745 Lift Arm is Low or Rising Force is Insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-745 H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-746 When Rising, Lift Arm Starts to Move Slowly at a Specific Height . . . . . . . . . . . . . . . 40-746 H-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-746 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats) . . . . . . . . . . . . . . . . . . 40-746 H-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-746 Hydraulic Drifts of the Lift Arm Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-746 H-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-747 Lift Arm Wobbles During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-747 H-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-748 Bucket Does Not Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-748 H-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-749 Bucket Speed is Low or Tilting-Back Force Is Insufficient . . . . . . . . . . . . . . . . . . . . . 40-749 H-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-750 Bucket Starts to Operate Slowly in the Midst of Tilting Back . . . . . . . . . . . . . . . . . . . 40-750 H-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-750 Bucket Cylinder Cannot Hold Down the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-750 H-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-750 Hydraulic Drifts of the Bucket Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-750 H-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-751 Bucket Wobbles During Travel with Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-751 H-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-751 During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls . . . 40-751 H-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-751 Large Shocks When Work Equipment Starts and Stops . . . . . . . . . . . . . . . . . . . . . . . . 40-751 H-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-751 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves . . 40-751 H-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-752 ECSS Does Not Operate; Pitching and Bouncing Occur . . . . . . . . . . . . . . . . . . . . . . . 40-752
WA500-6
40-15 b
TROUBLESHOOTING
MEMORANDUM
40-16 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS 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. Do not allow any unauthorized person to come near the machine. WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns. Wait for the engine to cool down before starting to troubleshoot. 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, coolant, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The purpose 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 waste man hours, parts, or oil and grease. • It can also result in a loss of confidence by the user or operator. For this reason, when carrying out troubleshooting, it is necessary to do a thorough investigation first 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 other than 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 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?
WA500-6
40-17 b
TROUBLESHOOTING 3.
TROUBLESHOOTING POINTS
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 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. B. 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 pinpoint the position of the failure. 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 but 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.
40-18 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING EVENTS
TROUBLESHOOTING EVENTS
WA500-6
40-19 b
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
MAINTENANCE PRECAUTIONS To maintain the performance of the machine over a long period and to prevent failures or other troubles before they occur, correct operation, maintenance, inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it contains sections on handling electrical equipment and handling hydraulic equipment (particularly hydraulic oil).
Precautions when Handling Electrical Equipment 1.
Handling High-Voltage Circuits A. If the machine is equipped with an electronically-controlled engine, high voltage is used to control fuel injection, (110 130 V) for the fuel injector drive. • Never handle the engine wiring harness while the engine is running or tamper with or modify this circuit. ★ Severe injury may result due to the high voltage and amps in the circuit. • Always use caution when working around this circuit.
2.
Handling Wiring Harnesses and Connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed and reinstalled so they are likely to suffer deformation or damage. ★ It is necessary to be extremely careful when handling wiring harnesses.
3.
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 for several reasons: • The male connector is not properly inserted into the female connector. • One, or both, of the connectors is deformed. • The position of the connectors is not correctly aligned. • There is corrosion or oxidation of the contact surfaces.
40-20 b
WA500-6
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
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.
C. Disconnections in wiring • Crimping compression of the connectors to the wire may be loosened. • Soldering may be damaged. • Wiring may be broken. ★ Possible causes: • Wiring held and tugged and the connectors pulled apart. • Components lifted with a crane with the wiring still connected. • Heavy object hit the wiring. D. High pressure water entering a connector The connector is designed to make it difficult for water to enter (drip-proof structure). ★ If high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. ★ If water does enter, it is difficult for it to be drained. If water gets into the connector, the water will shortcircuit the pins. • 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; this will cause a defective contact. •
WA500-6
If there is oil, 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. Clean with air until all water and oil have been removed.
40-21 b
TROUBLESHOOTING 4.
MAINTENANCE PRECAUTIONS
Removing, Installing, and Drying Connectors and Wiring Harnesses A. Unplugging connectors i.
Hold the connectors when disconnecting. • When unplugging the connectors, hold the connectors and not the wires. • For connectors held by a screw, loosen the screw fully then hold the male connectors in one hand and the female connectors in the other hand and pull apart. • For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never try to pull connectors apart with one hand.
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 unplugging male and female connectors, release the lock and pull in parallel with both hands. • Never try to pull apart with one hand.
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.
40-22 b
WA500-6
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
B. Plugging 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. 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 of the boot. • 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; clean with properly filtered air. 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. Connecting DT-type connectors ★ Since the 8-pole DT and 12-pole DT-type connectors have two latches respectively, push them in until they click twice. • Male connector (1), female connector (2). • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
WA500-6
40-23 b
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
D. 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, unplug 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; avoid blowing with air. i.
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 deform or damage the connector.
ii.
Carry out a continuity test on the connector. • After drying, leave the wiring harness disconnected and carry out a continuity test to check the pins for any short circuits caused by water. • After completely drying the connector, spray it with contact restorer and reassemble.
40-24 b
WA500-6
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
Handling Electronic Control Unit 1.
The electronic control unit contains a microcomputer and electronic circuits. This control unit controls all of the electronic circuits on the machine. ★ Be extremely careful when handling the control unit.
2.
Do not open the cover of the control box unless necessary.
3.
Do not place objects on top of the control unit.
4.
Cover the control connectors with tape or a vinyl bag.
5.
Do not leave the control unit in a place where it is exposed to rain.
6.
Do not place the control unit on surfaces containing oil, water, or soil, or place it in any hot place, even for a short time. Do not immerse the control unit in oil, water, or soil. ★ Place it on a suitable dry stand.
7.
Precautions when carrying out arc welding. ★ When carrying out arc welding on the machine body, disconnect all wiring harness connectors connected to the control unit. Attach the arc welding ground as close to the welding point as possible.
WA500-6
40-25 b
TROUBLESHOOTING
MAINTENANCE PRECAUTIONS
Points to Remember When Troubleshooting Electrical Circuits 1.
Always turn the power OFF before plugging or unplugging connectors.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. • Plug and unplug the related connectors several times to check. • Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3.
Always plug any unplugged connectors before going on to the next step. ★ If power is turned ON with the connectors still unplugged, unnecessary abnormal displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably a defective contact in that circuit.
5.
When checking a single diode circuit: • Isolate the diode from the circuit. • Using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
6.
When checking a dual diode circuit: • Isolate the diode from the circuit. • Using a digital volt ohm meter, in the Ohms mode, check the polarity of the diode as shown in the illustration. Reversing the meter leads, you should have a reading in one direction only. ★ Electrical flow should be negative (-) to positive (+) only, red lead positive and black lead negative.
7.
Always be aware of what you are measuring: Voltage, Ohms, or Amps. Always use caution when measuring a circuit. • When measuring voltage, be sure the meter is set in the voltage range, AC or DC, and above the voltage value you are measuring. • When measuring ohms, be sure the circuit is dead (has no voltage in it) before you take any readings. Be sure the meter is set in the proper ohms range. • When measuring amps, be sure your meter is rated for the amount of amps you will be measuring. Failure to follow these procedures may damage your equipment or possibly cause injury. Always study the operator’s manual for the meter you are using.
40-26 b
WA500-6
TROUBLESHOOTING
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
How to Read Electric Wire Code ★ The information about the wires unique to each machine model is described in the Troubleshooting section. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example:
AEX
0.85
L ---
Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
Type, Symbol, and Material Table 1 ★ AV and AVS are different in only thickness and outside diameter of the cover. ★ AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
Type
Low-voltage wire for automobile
Thin-cover, lowvoltage wire for automobile
Heat-resistant, low-voltage wire for automobile
WA500-6
Symbol
Material
Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance
AV
AVS
AEX Insulator
Heat-resistant crosslinked polyethylene
Using Temperature Range °C (°F)
Example of Use
General wiring (Nominal No. 5 and above) -30 to +60°C (-22 to 140 °F) General wiring (Nominal No. 3 and below)
-50 to +110°C (-58 to 230°F)
General wiring in extremely cold district, wiring at hightemperature place
40-27 b
TROUBLESHOOTING
ELECTRIC WIRE CODE
Dimensions Table 2 Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of Strands/ Diameter of Strand
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
Sectional Area (mm2)
0.51
Cover D
Conductor 0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
–
AV
Standard
–
–
–
–
–
–
–
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
–
3.8
4.6
Nominal No.
8
15
20
30
40
50
60
85
100
Number of Strands/ Diameter of Strand
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
108/0.80 127/0.80 169/0.80 217/0.80
Sectional Area (mm2)
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
–
–
–
–
–
–
–
–
–
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Cover D
Conductor
★ A nominal No. with an “f” designation (for example, 1.25f) means flexible.
40-28 b
WA500-6
TROUBLESHOOTING
ELECTRIC WIRE CODE
Color Codes Table Table 3 Color Code
Color of Wire
Color Code
Color of Wire
B
Black
LgW
Light green & White
Br
Brown
LgY
Light green & Yellow
BrB
Brown & Black
LR
Blue & Red
BrR
Brown & Red
LW
Blue & White
BrW
Brown & White
LY
Blue & Yellow
BrY
Brown & Yellow
O
Orange
Ch
Charcoal
P
Pink
Dg
Dark green
R
Red
G
Green
RB
Red & Black
GB
Green & Black
RG
Red & Green
GL
Green & Blue
RL
Red & Blue
Gr
Gray
RW
Red & White
GR
Green & Red
RY
Red & Yellow
GW
Green & White
Sb
Sky Blue
GY
Green & Yellow
Y
Yellow
L
Blue
YB
Yellow & Black
LB
Blue & Black
YG
Yellow &Green
Lg
Light green
YL
Yellow & Blue
LgB
Light green & Black
YR
Yellow & Red
LgR
Light green & Red
YW
Yellow & White
Remark In a color code consisting of two colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
WA500-6
40-29 b
TROUBLESHOOTING
ELECTRIC WIRE CODE
Circuits and Color Codes Table 4 Type of Wire
AVS or AV
AEX
Charge
R
WG
–
–
–
–
R
–
Ground
B
–
–
–
–
–
B
–
Start
R
–
–
–
–
–
R
–
Light
RW
RB
RY
RG
RL
–
D
–
Instrument
Y
YR
YB
YG
YL
YW
Y
Gr
Signal
G
GW
GR
GY
GB
GL
G
Br
L
LW
LR
LY
LB
–
L
–
Br
BrW
BrR
BrY
BrB
–
–
–
Lg
LgR
LgY
LgB
LgW
–
–
–
O
–
–
–
–
–
–
–
Gr
–
–
–
–
–
–
–
P
–
–
–
–
–
–
–
Sb
–
–
–
–
–
–
–
Dg
–
–
–
–
–
–
–
Ch
–
–
–
–
–
–
–
Type of circuit
Others
Classification by Thickness Table 5 Copper Wire Nominal Number
Number of Strands
Diameter of CrossStrand (mm) section (mm)
Cable O.D. (mm)
Current Rating (A)
Applicable Circuit
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
40-30 b
WA500-6
TROUBLESHOOTING
HANDLING HYDRAULIC EQUIPMENT
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 in locations 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. It is desirable to use a unit exchange. ★ Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof 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. Be sure to follow the proper environmental regulation for 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. ★ 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; this is a more effective method.
WA500-6
40-31 b
TROUBLESHOOTING 5.
HANDLING HYDRAULIC EQUIPMENT
Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil; 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; 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. • 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. The filter is an extremely effective device.
40-32 b
WA500-6
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING Item
Lubricating oil and coolant
Electrical parts
Hydraulic and mechanical equipment
Check level and type of fuel
—
Add fuel
2.
Check for foreign matter in fuel
—
Clean or drain
3.
Check level and type of oil in engine oil pan
Between H and L
Add oil
4.
Check coolant level
Between FULL and LOW
Add coolant
5.
Check air cleaner for clogging
No red
Clean or replace
6.
Check level and type of hydraulic oil
Between H and L
Add oil
7.
Check level and type of transmission oil
In upper range of site gauge
Add oil
8.
Check engine oil filter for clogging
—
Replace
9.
Check hydraulic oil filter for clogging
—
Replace
10. Check transmission oil filter for clogging
—
Replace
11. Check battery terminal cables for looseness and corrosion
—
Retighten or replace
12. Check alternator terminal cables for looseness and corrosion
—
Retighten or replace
13. Check starting motor terminal cables for looseness and corrosion
—
Retighten or replace
14. Check operation of instruments
—
Repair or replace
15. Check for abnormal noise and smell
—
Repair
16. Check for oil leakage
—
Repair
17. Bleeding air
—
Bleed air
18. Check effect of brake
—
Repair or adjust
20 – 30 V
Charge or replace
Between U.L and L.L
Add or replace
21. Check wires for discoloration, burn, and removal of cover
—
Replace
22. Check for removed wire clamp and drooping wire
—
Repair
23. Check wiring for wetness (check connectors and terminals for wetness, in particular)
—
Disconnect and dry connectors
24. Check slow-blow fuses and fuses for disconnection and corrosion
—
Replace
25. Check alternator voltage (with engine at medium speed or higher)
After several-minute operation: 27.5 – 29.5 V
Repair or replace
26. Check operating sound of battery relay (Starting switch OFF ON)
—
Replace
20. Check battery electrolyte level
WA500-6
Remedy
1.
19. Check battery voltage (with engine stopped)
Electrical equipment
Criteria
40-33 b
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Categories and Method of Using Troubleshooting Charts Categories of Troubleshooting Codes ★ If the machine monitor displays a failure code, the name of the controller is also displayed at the same time. ★ The troubleshooting codes are categorized according to the name of each controller. (This may also include some failure codes for the electrical system that are not displayed.) ★ Failures of the hydraulic and mechanical systems that the machine monitor cannot display are categorized as H mode. Troubleshooting Code Display of code
Troubleshooting System Troubleshooting by failure code (code shown on monitor)
E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for Troubleshooting If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows. 1.
Failure code is displayed on machine monitor. ★ A failure code is displayed on the machine monitor at the same time as the problem occurs. ★ Each failure code flashes when the problem corresponding to it is detected. Even if a failure code lights up when the starting switch is turned ON, the problem corresponding to that failure code may not have been repaired. Certain problems can be detected by simply turning the starting switch ON. ★ Check the content of the display, then go to the applicable troubleshooting for the failure code.
2.
No failure code is displayed on the machine monitor but the failure is recorded in memory. ★ It is impossible to check the failure code display on the machine monitor when a problem occurs. ★ Each failure code flashes when the problem corresponding to it is detected. Even if a failure code lights up when the starting switch is turned ON, the problem corresponding to that failure code may not have been repaired. Some problems can be detected by simply turning the starting switch ON. ★ Use the Troubleshooting History display function in the Service mode of the machine monitor to check if there is a failure code. ★ If a failure code is recorded, it is probable that it is the cause; go to the applicable troubleshooting for the failure code.
3.
If no failure code is displayed and no failure history is recorded. ★ It is impossible to check the failure display on the machine monitor when a problem occurs, and there is also no failure code recorded in the Troubleshooting History display function in the Service mode of the machine monitor. ★ It is probable that a problem has occurred in the hydraulic, mechanical, or electrical system that the controller cannot detect. ★ In such a case, check the condition of the failure carefully and select the failure/phenomenon from the Mode chart in this section. Go to the applicable troubleshooting for the failure (E-mode, H-mode, or S-mode).
40-34 b
WA500-6
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Troubleshooting Individual Electrical Circuits
Tools and Procedures
★ This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow each step in the troubleshooting chart. Do not skip steps, jump ahead, or stop when a problem is found. It is important to complete all steps due to the fact that there may be several other problems causing the failure code. The chart is set up to start with the most likely problem first and progress down to the least likely.
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not write on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure; do not skip steps, jump ahead, or stop when a fault is found. It is important to complete all steps and record information for final analysis.
Action code
Failure code
Monitor display
Monitor display
Trouble
Problem that appears on machine
Contents of Trouble
State where the monitor panel or controller detects the trouble.
Action of Controller
Action taken by machine monitor or controller to protect the system or devices when engine controller detects trouble.
Problem That Appears On Machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above).
Related information
Information related to detected trouble or troubleshooting
Cause
<Described contents> • Standard value in normal state to judge assumed cause (good or not) • Remarks required to judge whether the cause is good
1
Possible causes of trouble is assumed to be detected. (The order number indicates a serial number, not a priority sequence.)
Possible causes and standard value in normal state
2
WA500-6
Standard value in normal state/Remarks on troubleshooting
<Phenomenon of defective wiring harness> • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to ground (earth) circuit comes in contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes in contact with the power (24 V) circuit. • Short circuit A harness of an independent circuit abnormally comes in contact with one of another circuit.
40-35 b
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING <Notes on troubleshooting>
3
Possible causes of trouble is assumed to be detected. (The order number indicates a serial number, not a priority sequence.)
Possible causes and standard value in normal state
4
(1) Method of indicating connector number and handling T-branch For troubleshooting, insert or connect T-branch adapter as shown below unless specifically specified. • When male or female is not indicated for a connector number, disconnect the connector and insert the T-branch adapter in both the male and female. • When male and female is indicated for a connector number, disconnect the connector, and insert the T-branch adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless specifically specified. • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.
Circuit Diagram
This is part of the circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Model - number of a pin) (color). • Connector No. and pin No. from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (): Roughly shows the location on the machine.
40-36 b
WA500-6
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Chart Use ★ Repair Shop Use • When using this chart in a repair shop environment where you have access to a copier, it is advisable to remove the pages of the fault codes displayed on the machine monitor and copy these pages. • After copying the needed pages, return the original pages to the Shop Manual for future use. • You can record your findings on the copied pages in the right-hand column of the chart for final analysis. • Do not write on the original chart in the Shop Manual. Complete all test procedures. ★ Road Service Use • When using this chart while on a road service call where a copier is not available, it is advisable to use a blank piece of paper and number it from #1 through the last number listed in conjunction with the Shop Manual. • Record your readings by each number on the paper for final analysis. • Do not write on the original chart in the Shop Manual. • Complete all test procedures.
Chart Tips • • • • • •
Check all fuses and fuse links first. If the system has a relay, replace the relay with a known good relay. Do not test the relay itself. For diode checking procedures, see Points to Remember when Troubleshooting Electrical Circuits. When checking Ohms in a system or component, always isolate the component you are checking; this will ensure that there are no additional circuits adding continuity to the component you are testing. Never measure Amps unless instructed in the testing procedure. Damage to the meter or injury may result. Never use a welder or a battery system of a higher voltage than the machine you are troubleshooting. The voltage of the welder or battery system must NOT EXCEED that of the machine to which you are trying to supply electricity. Damage to the machine’s electrical system may result.
WA500-6
40-37 b
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Troubleshooting Individual Hydraulic Circuits Like the electrical diagnostic procedures, it is important to complete all steps required in the testing procedures. This method is broken down into three steps: • • •
Question the operator Checks before troubleshooting Using the cross-reference tables.
1.
Question the operator The questions to ask the operator are given below the failure symptom. ★ If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the question and consult the table while proceeding to Steps 2 and 3 to find the true cause.
2.
Checks before troubleshooting Before starting the troubleshooting procedures or measuring any pressures, first check the listed basic items in the Checks Before Troubleshooting section. ★ These checks may avoid time wasted on unnecessary troubleshooting. ★ The items given in this procedure are the items which must be considered unique for that symptom before starting troubleshooting.
3.
Using the cross-reference table A. Operate the machine to check the symptom. ★ If it is not necessary to follow the troubleshooting checks in order, follow an order which is easiest to carry out troubleshooting.
B. Find the appropriate cause from the cause column. ★ If the symptom appears, the ❍ marks on that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or e.) ★ If there is only one ❍: Carry out the troubleshooting items (where the same cause is marked with ❍). Check if the symptom appears, then repair. ★ If there are two ❍: Go to Step C to narrow down the possible causes.
40-38 b
WA500-6
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
C. Operate the machine and check the troubleshooting items other than those in Step 1. ★ If the symptom appears, record that item for further reference. (In the chart on the right, the symptom appears again for item 5.) D. Find the appropriate chart for the cause from the cause column. ★ In the same way as in Step 2, if the symptom appears, the ❍ marks on that line indicate the possible causes. (For items No. 5 in the table on the right, the possible causes are b or e.) E. Narrow down the possible causes. ★ There are common causes among the causes located in Steps B and D. (One cause marked ❍ appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1 and 3. ★ The causes which are not common to both troubleshooting items (items which are not marked ❍ for both symptoms) are unlikely causes; it is advisable to ignore them. (In the example given on the right, the causes for troubleshooting Item 2 are c or e, and the cause for troubleshooting Item 5 are b or e, so cause e is common to both.) F.
Repeat the operations in Steps C, D, and E until one cause (one common cause) remains. If the cause cannot be narrowed down to one cause, narrow the causes down to a possible cause.
G. Remedy: If the causes are narrowed down to one common cause, take the action given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace
WA500-6
Repair
A: Adjust
C: Clean
40-39 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
CONNECTOR PIN NUMBERS Connection Tables for Connector PIN Numbers ★ The terms male and female refer to the pins. ★ The terms male housing and female housing refer to the mating portion of the housing. ★ Deutsch connectors have marks of pin numbers on the wiring harness side.
X-Type Connectors X-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
1
Part number: 08055-00181
Part number: 08055-00191
799-601-7010
2
799-601-7020
Part number: 08055-00282
Part number: 08055-00292
3
799-601-7030
Part number: 08055-00381
Part number: 08055-00391
4
799-601-7040
Part number: 08055-00481
40-40 b
Part number: 08055-00491
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS X-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
—
Terminal part number: 79A-222-3370 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
Terminal part number: 79A-222-3390 • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
—
—
Terminal part number: 79A-222-3380 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red
Terminal part number: 79A-222-3410 • Wire size: 2.0 • Quantity: 20 pieces • Grommet: red
—
WA500-6
40-41 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
SWP-Type Connectors SWP-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
6
799-601-7050
Part number: 08055-10681
Part number: 08055-10691
8
799-601-7060
Part number: 08055-10881
Part number: 08055-10891
12
799-601-7310
Part number: 08055-11281
40-42 b
T-adapter Part Number
Part number: 08055-11291
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS SWP-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
14
T-adapter Part Number
799-601-7070
Part number: 08055-11481
Part number: 08055-11491
16
799-601-7320
Part number: 08055-11681
Part number: 08055-11691
—
Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
Terminal part number: • Wire size: 0.85 • Quantity: 20 pieces • Grommet: black
—
—
Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red
Terminal part number: • Wire size: 1.25 • Quantity: 20 pieces • Grommet: red
—
WA500-6
40-43 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
M-Type Connectors M-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
1
Part number: 08056-00171
Part number: 08056-00181
799-601-7080
2
799-601-7090
Part number: 08056-00271
Part number: 08056-00281
3
799-601-7110
Part number: 08056-00371
Part number: 08056-00381
4
799-601-7120
Part number: 08056-00471
40-44 b
Part number: 08056-00481
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS M-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
6
799-601-7130
Part number: 08056-00671
Part number: 08056-00681
8
799-601-7340
Part number: 08056-00871
WA500-6
T-adapter Part Number
Part number: 08056-00881
40-45 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
S-Type Connectors S-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
8
799-601-7140
Part number: 08056-10871
Part number: 08056-10881
10 (white)
799-601-7150
Part number: 08056-11071
Part number: 08056-11081
12 (white)
799-601-7350
Part number: 08056-11271
Part number: 08056-11281
16 (white)
799-601-7330
Part number: 08056-11671
40-46 b
T-adapter Part Number
Part number: 08056-11681
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS S-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
10 (blue)
—
—
—
12 (blue)
799-601-7160
Part number: 08056-11272
Part number: 08056-11282
16 (blue)
799-601-7170
Part number: 08056-11672
WA500-6
T-adapter Part Number
Part number: 08056-11682
40-47 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
MIC-Type Connectors MIC-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
T-adapter Part Number
7
Body part number: 79A-222-2640 (Quantity: 5 pieces)
Body part number: 79A-222-2630 (Quantity: 5 pieces)
—
11
Body part number: 79A-222-2680 (Quantity: 5 pieces)
Body part number: 79A-222-2670 (Quantity: 5 pieces)
—
5
799-601-2710
Body part number: 79A-222-2620 (Quantity: 5 pieces)
Body part number: 79A-222-2610 (Quantity: 5 pieces)
9
799-601-2950
Body part number: 79A-222-2660 (Quantity: 5 pieces)
Body part number: 79A-222-2650 (Quantity: 5 pieces)
13
799-601-2720
Body part number: 79A-222-2710 (Quantity: 2 pieces)
40-48 b
Body part number: 79A-222-2690 (Quantity: 2 pieces)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS MIC-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
17
799-601-2730
Body part number: 79A-222-2730 (Quantity: 2 pieces)
Body part number: 79A-222-2720 (Quantity: 2 pieces)
21
WA500-6
T-adapter Part Number
799-601-2740
Body part number: 79A-222-2750 (Quantity: 2 pieces)
Body part number: 79A-222-2740 (Quantity: 2 pieces)
Terminal part number: 79A-222-2770 (Quantity: 50 pieces)
Terminal part number: 79A-222-2760 (Quantity: 50 pieces)
40-49 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
AMP040-Type Connectors AMP040-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
8
799-601-7180
—
Housing part number: 79A-222-3430 (Quantity: 5 pieces)
12
799-601-7190
—
Housing part number: 79A-222-3440 (Quantity: 5 pieces)
16
799-601-7210
—
40-50 b
T-adapter Part Number
Housing part number: 79A-222-3450 (Quantity: 5 pieces)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS AMP040-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
20
T-adapter Part Number
799-601-7220
—
Housing part number: 79A-222-3460 (Quantity: 5 pieces)
★ Terminal part number: 79A-222-3470 (no relation to number of pins)
WA500-6
40-51 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
AMP070-Type Connectors AMP070-Type Connectors Number of Pins
Male (Female housing)
Female (Male housing)
10
–
—
—
10
799-601-7510
—
Part number: 7821-92-7330
12
799-601-7520
—
40-52 b
T-adapter Part Number
Part number: 7821-92-7340
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS AMP070-Type Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
14
T-adapter Part Number
799-601-7530
—
Part number: 7821-92-7350
18
799-601-7540
—
Part number: 7821-92-7360
20
799-601-7550
Part number: 7821-92-7370
WA500-6
40-53 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
AMP Connector Oil Pressure Sensor Number of Pins
Sensor Side (plug)
Harness Side (receptacle)
T-adapter Part Number
799-601-9420 Kits: 799-601-4101 799-601-4201
3
—
—
L-Type Connector L-Type Connector Number of Pins
Male (Female housing)
Female (Male housing)
2
—
—
40-54 b
T-adapter Part Number
—
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
PA-Type Connector PA-Type Connector Number of Pins
Male (Female housing)
Female (Male housing)
9
T-adapter Part Number
—
—
—
Bendix (MS) Connector BENDIX (MS) Connector Number of Pins
Male (Female housing)
Female (Male housing)
10
799-601-3460
—
WA500-6
T-adapter Part Number
—
40-55 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
KES1 (Automobile) Connectors KES1 (Automobile) Connectors Number of Pins
Male (Female housing)
Female (Male housing)
2
—
Part number: 08027-10210 (Natural color) 08027-10220 (Black)
Part number: 08027-10260 (Natural color) 08027-10270 (Black)
3
—
Part number: 08027-10310
Part number: 08027-10360
4
—
Part number: 08027-10410 (Natural color) 08027-10420 (Black)
40-56 b
T-adapter Part Number
Part number: 08027-10460 (Natural color) 08027-10470 (Black)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS KES1 (Automobile) Connectors
Number of Pins
Male (Female housing)
Female (Male housing)
6
T-adapter Part Number
—
Part number: 08027-10610 (Natural color) 08027-10620 (Black)
Part number: 08027-10660 (Natural color) 08027-10670 (Black)
8
—
Part number: 08027-10810 (Natural color) 08027-10820 (Black)
Part number: 08027-10860 (Natural color) 08027-10870 (Black)
F-Type Connector F-Type Connector Number of Pins
Male (Female housing)
Female (Male housing)
4
—
—
WA500-6
T-adapter Part Number
—
40-57 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
Connectors for Relay (Socket-Type) Connectors for Relay (Socket-Type) Number of Pins
Male (Female housing)
Female (Male housing)
5
799-601-7360
—
—
6
799-601-7370
—
40-58 b
T-adapter Part Number
—
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
HD30 Series Connectors ★ The pin No. is also marked on the connector (electric wire insertion end). HD30 Series Connectors Type (shell size code)
Body (Plug)
Body (Receptacle)
Pin (Male terminal)
Socket (Female terminal)
T-adapter Part Number
799-601-9210
18-8 (1)
Part number: 08191-11201, 08191-11202 08191-11205, 08191-11206
Part number: 08191-14101, 08191-14102 08191-14105, 08191-14106
Socket (Female terminal)
Pin (Male terminal)
799-601-9210
Part number: 08191-11201, 08191-12202 08191-11205, 08191-12206
Part number: 08191-13101, 08191-13102 08191-13105, 08191-13106
Pin (Male terminal)
Socket (Female terminal)
799-601-9220
18-14 (2)
Part number: 08191-21201, 08191-12202 08191-21205, 08191-12206
Part number: 08191-24101, 08191-24102 08191-24105, 08191-24106
Socket (Female terminal)
Pin (Male terminal)
799-601-9220
Part number: 08191-22201, 08191-22202 08191-22205, 08191-22206
WA500-6
Part number: 08191-23101, 08191-23102 08191-23105, 08191-23106
40-59 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS HD30 Series Connectors
Type (shell size code)
Body (Plug)
Body (Receptacle)
Pin (Male terminal)
Socket (Female terminal)
T-adapter Part Number
799-601-9230
18-20 (3)
Part number: 08191-31201, 08191-31202
Part number: 08191-34101, 08191-34102
Socket (Female terminal)
Pin (Male terminal)
799-601-9230
Part number: 08191-32201, 08191-32202
Part number: 08191-33101, 08191-33102
Pin (Male terminal)
Socket (Female terminal)
799-601-9240
18-21 (4)
Part number: 08191-41201, 08191-42202
Part number: 08191-44101, 08191-44102
Socket (Female terminal)
Pin (Male terminal)
799-601-9240
Part number: 08191-42201, 08191-42202
40-60 b
Part number: 08191-43101, 08191-43102
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS HD30 Series Connectors
Type (shell size code)
Body (Plug)
Body (Receptacle)
Pin (Male terminal)
Socket (Female terminal)
T-adapter Part Number
799-601-9250
24-9 (5)
Part number: 08191-51201, 08191-51202
Part number: 08191-54101, 08191-54102
Socket (Female terminal)
Pin (Male terminal)
799-601-9250
Part number: 08191-52201, 08191-52202
Part number: 08191-53101, 08191-53102
Pin (Male terminal)
Socket (Female terminal)
799-601-9260
24-16 (6)
Part number: 08191-61201, 08191-62202 08191-61205, 08191-62206
Part number: 08191-64101, 08191-64102 08191-64105, 08191-64106
Socket (Female terminal)
Pin (Male terminal)
799-601-9260
Part number: 08191-62201, 08191-62202 08191-62205, 08191-62206
WA500-6
Part number: 08191-63101, 08191-63102 08191-63105, 08191-63106
40-61 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS HD30 Series Connectors
Type (shell size code)
Body (Plug)
Body (Receptacle)
Pin (Male terminal)
Socket (Female terminal)
T-adapter Part Number
799-601-9270
24-21 (7)
Part number: 08191-71201, 08191-71202 08191-71205, 08191-71206
Part number: 08191-74101, 08191-74102 08191-74105, 08191-74106
Socket (Female terminal)
Pin (Male terminal)
799-601-9270
Part number: 08191-72201, 08191-72202 08191-72205, 08191-72206
Part number: 08191-73101, 08191-73102 08191-73105, 08191-73106
Pin (Male terminal)
Socket (Female terminal)
799-601-9280
24-23 (8)
Part number: 08191-81201, 08191-81202, 08191-81203, 08191-81204, 08191-81205, 08191-80206
Part number: 08191-84101, 08191-84102, 08191-84103, 18191-84104, 08191-84105, 08191-84106
Socket (Female terminal)
Pin (Male terminal)
799-601-9280
Part number: 08191-82201, 08191-82202, 08191-82203, 08191-82204, 08191-82205, 08191-82206
40-62 b
Part number: 08191-83101, 08191-83102, 08191-83103, 18191-83104, 08191-83105, 08191-83106
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS HD30 Series Connectors
Type (shell size code)
Body (Plug)
Body (Receptacle)
Pin (Male terminal)
Socket (Female terminal)
T-adapter Part Number
799-601-9290
24-31 (9)
Part number: 08191-91203, 08191-91204 08191-91205, 08191-91206
Part number: 08191-94103, 08191-94104 08191-94105, 08191-94106
Socket (Female terminal)
Pin (Male terminal)
799-601-9290
Part number: 08191-92203, 08191-92204 08191-92205, 08191-92206
WA500-6
Part number: 08191-93103, 08191-93104 08191-93105, 08191-93106
40-63 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DT Series Connectors ★ The pin No. is also marked on the connector (electric wire insertion end). DT Series Connectors Number of Pins
Body (plug)
Body (receptacle)
799-601-9020 799-601-9890
2
Part number: 08192-12200 (normal type) 08192-22200 (fine wire type)
Part number: 08192-12100 (normal type) 08192-22100 (fine wire type)
799-601-9030 799-601-9890
3
Part number: 08192-13200 (normal type) 08192-2A200 (fine wire type)
Part number: 08192-13100 (normal type) 08192-23100 (fine wire type)
799-601-9040 799-601-9890
4
Part number: 08192-14200 (normal type) 08192-24200 (fine wire type)
40-64 b
T-adapter Part Number
Part number: 08192-14100 (normal type) 08192-24100 (fine wire type)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS DT Series Connectors
Number of Pins
Body (plug)
Body (receptacle)
6
799-601-9050
Part number: 08192-16200 (normal type) 08192-26200 (fine wire type)
Part number: 08192-16100 (normal type) 08192-26100 (fine wire type)
8GR: 799-601-9060 8B: 799-601-9070 8G: 799-601-9080 8BR: 799-601-9090
8
Part number: 08192-1820 ❏ (normal type) 08192-2820 ❏ (fine wire type)
Part number: 08192-1810 ❏ (normal type) 08192-2810 ❏ (fine wire type)
12GR: 799-601-9110 12B: 799-601-9120 12G: 799-601-9130 12BR: 799-601-9140
12
Part number: 08192-1920 ❏ (normal type) 08192-2920 ❏ (fine wire type)
WA500-6
T-adapter Part Number
Part number: 08192-1910 ❏ (normal type) 08192-2910 ❏ (fine wire type)
40-65 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DTM Series Connectors ★ The pin No. is also marked on the connector (electric wire insertion end). DTM Series Connector Number of Pins
Body (plug)
Body (receptacle)
T-adapter Part Number
799-601-9010 799-601-9890
2
Part number: 08192-02200
Part number: 08192-02100
DTHD Series Connectors ★ The pin No. is also marked on the connector (electric wire insertion end). DTHD Series Connector Number of Pins
Body (plug)
Body (receptacle)
2
—
Part number: 08192-31200 (Contact size #12) 08192-41200 (Contact size #8) 08192-51200 (Contact size #4)
40-66 b
T-adapter Part Number
Part number: 08192-31100 (Contact size #12) 08192-41100 (Contact size #8) 08192-51100 (Contact size #4)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DTP Series Connectors The pin No. is also marked on the connector (electric wire insertion end). DTP Series Connectors Number of Pins
Body (plug)
Body (receptacle)
Pin (female terminal)
Socket (male terminal)
2
—
—
—
799-601-4260
4
Part No: 6261-81-2810
WA500-6
T-adapter Part Number
—
40-67 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DRC26 Series Connectors ★ The pin No. is also marked on the connector (electric wire insertion end). DRC26 Series Connectors Number of Pins
Male pin (Female housing)
Female pin (Male housing)
799-601-9360 Kit: 799-601-9300
24
–
Part number: 08194-01101
799-601-9350 Kit: 799-601-9300
40 (A)
–
Part number: 08194-02101
799-601-9350 Kit: 799-601-9300
40 (B)
–
Part number: 08194-02102
799-601-4211 Kit: 799-601-4101
50
–
40-68 b
T-adapter Part Number
Part number: 08194-03103
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS DRC26 Series Connectors
Number of Pins
Male pin (Female housing)
Female pin (Male housing)
T-adapter Part Number
799-601-4220 Kit: 799-601-4101
60 -05 ❈
–
Part number: 08194-04104
❈ -05: Key position Socket Part Number
60 -06 ❈
799-601-4390
–
–
❈ -06: Key position
WA500-6
40-69 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DRC12, 16 Series Connectors The pin No. is also marked on the connector (electric wire insertion end). DRC12, 16 Series Connectors Number of Pins
DRC12: Male pin (female housing)
DRC16: Female pin (male housing)
24 (A) ❈ (B) (C)
T-adapter Part Number
–
–
–
40 (A) ❈ (B) (C)
–
–
Seal (S) Part number: 17A-06-41830
70 (A) ❈ (B) (C)
–
–
Seal (S) Part number: 17A-06-41840
❈ (A), (B), (C): Key position
40-70 b
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
AMP Connectors for Pump Controller (CH700) ★ PC200/220-8, PC270-8, PC300-8, PC400-8, PC128/138US-8, etc. AMP Connectors for Pump Controller Number of Pins
Controller side (plug)
T-adapter Part Number
– 81
Harness side (receptacle)
Part number: 7880-70-9040 Controller side (plug)
40
799-601-4280
– Harness side (receptacle)
Part number: 7880-70-9010
WA500-6
40-71 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
BOSCH Connectors for Engine BOSCH Connectors for Engine Number of Pins
Boost (air intake) pressure and temperature sensor (95 engine) Sensor side (plug)
T-adapter Part Number
Harness side (receptacle)
4
799-601-4380
–
–
Common rail (fuel) pressure sensor (95, 107, 114 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4190 Kit: 799-601-4101 799-601-4201
3
–
–
Fuel supply pump (95, 107 engine) and fuel injector (95 engine) Valve side (plug)
Harness side (receptacle)
799-601-4340 Kit: 799-601-4101 799-601-4201
2
–
40-72 b
–
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
SUMITOMO Connectors for Engine SUMITOMO Connectors for Engine Number of Pins
T-adapter Part Number Boost (air intake) pressure and temperature sensor (107,114 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4230 Kit: 799-601-4101 799-601-4201
4
–
–
Boost (air intake) pressure sensor (125, 170,12V140 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4250 Kit: 799-601-4101 799-601-4201
3
–
–
G sensor (fuel supply pump speed sensor) (125, 140, 170, 12V140 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4330 Kit: 799-601-4101 799-601-4201
3
–
WA500-6
–
40-73 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS SUMITOMO Connectors for Engine
Number of Pins
T-adapter Part Number PCV (125, 140, 170, 12V140 engine) Valve side (plug)
Harness side (receptacle)
799-601-9430 Kit: 799-601-4101 799-601-4201
2
–
–
CANNON Connector for Engine CANNON Connector for Engine Number of Pins
Boost (air intake) pressure sensor (140 engine)
Sensor side (plug)
Harness side (receptacle)
799-601-4110 Kit: 799-601-4101 799-601-4201
4
✩ Without pin (4)
40-74 b
T-adapter Part Number
✩ Without pin (4)
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
AMP Connectors for Engine AMP Connectors for Engine Number of Pins
Common rail (fuel) pressure sensor (125, 140, 170, 12V140 engine) Sensor side (plug)
T-adapter Part Number
Harness side (receptacle)
799-601-9420 Kit: 799-601-4101 799-601-4201
3
–
–
Ambient pressure sensor (95, 125, 140, 170, 12V140 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4240 Kit: 799-601-4101 799-601-4201
3
–
WA500-6
–
40-75 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
FRAMATOME Connectors for Engine FRAMATOME Connectors for Engine Number of Pins
T-adapter Part Number Ambient pressure sensor (107,114 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4140 Kit: 799-601-4101 799-601-4201
3
–
–
NE speed sensor (95, 107, 125, 140, 170,12V140 engine) and CAM sensor (95, 107, 114 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4130 Kit: 799-601-4101 799-601-4201
3
–
– EGR gas pressure sensor (125, 140 engine)
Sensor side (plug)
Harness side (receptacle)
799-601-4180 Kit: 799-601-4101 799-601-4201
3
–
40-76 b
–
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS FRAMATOME Connectors for Engine
Number of Pins
T-adapter Part Number Lubrication oil pressure sensor (125, 140, 170, 12V140 engine) Sensor side (plug)
Harness side (receptacle)
799-601-4150 Kit: 799-601-4101 799-601-4201
3
–
– Hydraulic switch (95, 107, 114 engine)
Switch side (plug)
Harness side (receptacle)
799-601-4160 Kit: 799-601-4101 799-601-4201
2
✩ Without pin (2)
WA500-6
✩ Without pin (2)
40-77 b
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
PACKARD Connectors for Engine PACKARD Connectors for Engine Number of Pins
Temperature sensor of coolant, fuel and lubricating oil (95, 107, 114, 125, 140, 170, 12V140 engine) Sensor side (plug)
T-adapter Part Number
Harness side (receptacle)
795-799-5530 Kit: 799-601-4101 799-601-4201
2
✩ Non-polarity
–
Boost (air intake) temperature sensor (125, 140, 170, 12V140 engine) Sensor side (plug)
Harness side (receptacle)
795-799-5540 Kit: 799-601-4101 799-601-4201
2
✩ Non-polarity
40-78 b
–
WA500-6
TROUBLESHOOTING
CONNECTOR PIN NUMBERS
DT Series Connectors for Engine DT Series Connectors for Engine WIF (water-in-fuel) sensor (107, 114 engine) Number of Pins
Body (plug)
Body (receptacle)
Pin (female terminal)
Socket (male terminal)
799-601-9020 Kit: 799-601-41011 799-601-42011
2
Part No: 08192-12200 (normal type) 08192-22200 (fine wire type) Number of Pins
Part No: 08192-12100 (normal type) 08192-22100 (fine wire type)
EGR (bypass valve stroke sensor (125, 140, 170 engine) Body (plug)
Body (receptacle)
T-adapter Part Number
799-601-9040 Kit: 799-601-41011 799-601-42011
4
Part No: 08192-14200 (normal type) 08192-24200 (fine wire type)
WA500-6
T-adapter Part Number
Part No: 08192-14100 (normal type) 08192-24100 (fine wire type)
40-79 b
TROUBLESHOOTING
T-BRANCH BOX and T-BRANCH ADAPTER TABLE
T-BRANCH BOX and T-BRANCH ADAPTER TABLE ★ The part numbers of the T-branch boxes or T-branch adapters are shown in the columns. ★ The part numbers of the wiring harness checker assemblies are shown in the lines.
●
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
●
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
●
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
●
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
●
799-601-3470 Case
–
799-601-2710 Adapter for MIC
5
MIC-5P
● ●
●
799-601-2720 Adapter for MIC
13
MIC-13P
● ●
●
799-601-2730 Adapter for MIC
17
MIC-17P
● ● ●
● ●
●
799-601-2740 Adapter for MIC
21
MIC-21P
● ● ●
● ●
●
799-601-2950 Adapter for MIC
9
MIC-9P
● ● ●
●
799-601-2750 Adapter for ECONO
2
ECONO2P
● ●
799-601-2760 Adapter for ECONO
3
ECONO3P
● ●
799-601-2770 Adapter for ECONO
4
ECONO4P
● ●
799-601-2780 Adapter for ECONO
8
ECONO8P
● ●
799-601-2790 Adapter for ECONO
12
ECONO12P ● ●
799-601-2810 Adapter for DLI
8
DLI-8P
● ●
799-601-2820 Adapter for DLI
12
DLI-12P
● ●
799-601-2830 Adapter for DLI
16
DLI-16P
● ●
40-80 b
Out of Kit
MS-24P
799-601-4201
24
799-601-4101
799-601-3410 Adapter for BENDIX (MS)
799-601-9300
●
799-601-9200
–
799-601-9100
799-601-3380 Plate for MS (14 pins)
799-601-9000
●
799-601-8000
37
● ●
799-601-7500
799-601-3200 T-branch box (For MS)
799-601-7400
●
799-601-7100
37
●
799-601-7000
799-601-3100 T-branch box (For MS)
●
799-601-2800
21
ID Symbol
799-601-2700
799-601-2600 T-branch box (For ECONO)
Part No.
799-601-2500
Connector Type or Part Name
No. of Pins
T-branch Adapter Kit
●
●
WA500-6
TROUBLESHOOTING
T-BRANCH BOX and T-BRANCH ADAPTER TABLE
●
799-601-7010 Adapter for X (T-branch)
1
––
●
●
799-601-7020 Adapter for X
2
X2P
● ● ●
●
799-601-7030 Adapter for X
3
X3P
● ● ●
●
799-601-7040 Adapter for X
4
X4P
● ● ●
●
799-601-7050 Adapter for SWP
6
SW6P
● ● ●
799-601-7060 Adapter for SWP
8
SW8P
● ● ●
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-branch)
1
–
799-601-7090 Adapter for M
2
799-601-7110 Adapter for M
●
●
● ●
● ●
●
●
M2P
● ● ●
●
3
M3P
● ● ●
●
799-601-7120 Adapter for M
4
M4P
● ● ●
●
799-601-7130 Adapter for M
6
M6P
● ● ●
●
799-601-7340 Adapter for M
8
M8P
799-601-7140 Adapter for S
8
S8P
● ● ●
●
799-601-7150 Adapter for S (white)
10
S10P
● ● ●
●
799-601-7160 Adapter for S (blue)
12
S12P
● ● ●
799-601-7170 Adapter for S (blue)
16
S16P
● ● ●
799-601-7330 Adapter for S (white)
16
S16PW
799-601-7350 Adapter for S (white)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
●
799-601-7190 Adapter for AMP040
12
A12P
●
●
799-601-7210 Adapter for AMP040
16
A16P
● ● ●
●
799-601-7220 Adapter for AMP040
20
A20P
● ● ●
●
799-601-7230 Short connector for X
2
–
● ● ●
●
799-601-7240 Case
–
–
● ●
799-601-7270 Case
–
–
WA500-6
Out of Kit
–
799-601-4201
–
799-601-4101
799-601-4360 Case
799-601-9300
●
799-601-9200
–
799-601-9100
60
799-601-9000
799-601-4350 T-box (for DRC 60, ECONO)
799-601-8000
–
799-601-7500
–
799-601-7400
799-601-2850 Case
799-601-7100
ECONO12P ● ●
799-601-7000
12
799-601-2800
799-601-2840 Extension cable (ECONO type)
Connector Type or Part Name
799-601-2700
ID Symbol
Part No.
799-601-2500
No. of Pins
T-branch Adapter Kit
●
● ● ●
●
40-81 b
TROUBLESHOOTING
T-BRANCH BOX and T-BRANCH ADAPTER TABLE
18
07-18
●
799-601-7550 Adapter for 070
20
07-20
●
799-601-7360 Adapter for relay
5
REL-5P
●
799-601-7370 Adapter for relay
6
REL-6P
●
799-601-7380 Adapter for JFC
2
–
●
799-601-9010 Adapter for DTM
2
DTM2
●
●
799-601-9020 Adapter for DT
2
DT2
●
●
799-601-9030 Adapter for DT
3
DT3
●
●
799-601-9040 Adapter for DT
4
DT4
●
●
799-601-9050 Adapter for DT
6
DT6
●
●
799-601-9060 Adapter for DT (gray)
8
DT8GR
●
●
799-601-9070 Adapter for DT (black)
8
DT8B
●
●
799-601-9080 Adapter for DT (green)
8
DT8G
●
●
799-601-9090 Adapter for DT (brown)
8
DT8BR
●
●
799-601-9110 Adapter for DT (gray)
12
DT12GR
●
●
799-601-9120 Adapter for DT (black)
12
DT12B
●
●
799-601-9130 Adapter for DT (green)
12
DT12G
●
●
799-601-9140 Adapter for DT (brown)
12
DT12BR
●
●
799-601-9210 Adapter for HD30-18
8
D18-8
● ●
799-601-9220 Adapter for HD30-18
14
D18-14
● ●
799-601-9230 Adapter for HD30-18
20
D18-20
● ●
799-601-9240 Adapter for HD30-18
21
D18-21
● ●
799-601-9250 Adapter for HD30-24
9
D24-9
● ●
799-601-9260 Adapter for HD30-24
16
D24-16
● ●
799-601-9270 Adapter for HD30-24
21
D24-21
● ●
799-601-9280 Adapter for HD30-24
23
D24-23
● ●
799-601-9290 Adapter for HD30-24
31
D24-31
● ●
–
● ●
●
–
● ●
●
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
40-82 b
24
Out of Kit
799-601-7540 Adapter for 070
799-601-4201
●
799-601-4101
07-14
799-601-9300
14
799-601-9200
799-601-7530 Adapter for 070
799-601-9100
●
799-601-9000
07-12
799-601-8000
12
799-601-7500
799-601-7520 Adapter for 070
799-601-7400
●
799-601-7100
07-10
799-601-7000
10
799-601-2800
799-601-7510 Adapter for 070
Connector Type or Part Name
799-601-2700
ID Symbol
Part No.
799-601-2500
No. of Pins
T-branch Adapter Kit
● ●
● ●
WA500-6
TROUBLESHOOTING
T-BRANCH BOX and T-BRANCH ADAPTER TABLE
●
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
● ●
2
P
● ●
799-601-9440* Socket for engine (CRI-T2)
3
1, 2, 3
●
795-799-5520* Socket for engine (HPI-T2)
2
S
●
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
● ●
2
A
● ●
795-799-5460 Cable for engine (HPI-T2)
3
–
●
795-799-5470 Cable for engine (HPI-T2)
3
–
●
795-799-5480 Cable for engine (HPI-T2)
3
–
●
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
● ●
799-601-4130
Adapter for engine (CRI-T3) NE, CAM
3
FCIN
● ●
799-601-4140
Adapter for engine (CRI-T3) Atmospheric pressure
3
FCIG
● ●
3
FCIB
● ●
2
4160
● ●
3
4180
● ●
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Adapter for engine (HPI-T2) Adapter for engine (CRI-T3) TIM
799-601-4150 Adapter for engine (CRI-T3) POIL 799-601-4160
Adapter for engine (CRI-T3) Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA
● ●
●
799-601-4190*
Socket for engine (CRI-T3) Common rail pressure
3
1,2,3L
● ●
799-601-4230*
Socket for engine (CRI-T3) Air intake pressure/temperature
4
1,2,3,4C
● ●
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
● ●
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
● ●
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3G
● ●
WA500-6
Out of Kit
DRC-24
799-601-4201
24
799-601-4101
799-601-9360 Adapter for DRC
799-601-9300 ●
799-601-9200
DRC-40
799-601-9100
40
799-601-9000
799-601-9350 Adapter for DRC
799-601-8000
–
799-601-7500
–
799-601-7400
799-601-9340 Case
799-601-7100
–
799-601-7000
–
799-601-2800
799-601-9330 Case
799-601-2700
ID Symbol
Connector Type or Part Name
Part No.
799-601-2500
No. of Pins
T-branch Adapter Kit
40-83 b
TROUBLESHOOTING
T-BRANCH BOX and T-BRANCH ADAPTER TABLE
50
DRC50
●
799-601-4220 Adapter for controller (ENG)
60
DRC60
●
799-601-4390* Socket for controller (95 ENG)
60
–
●
799-601-4280 Box for controller (PUMP)
121
–
●
799-601-9720 Adapter for controller (HST)
16
HST16A
●
799-601-9710 Adapter for controller (HST)
16
HST16B
●
799-601-9370 Adapter for controller (HST)
26
HST26A
●
799-601-9890 Multi-adapter for DT2 – 4 and DTM2
2,3, 4
–
●
Out of Kit
799-601-4211 Adapter for controller (ENG)
799-601-4201
● ●
799-601-4101
DTP4
799-601-9300
4
799-601-9200
799-601-4260 Adapter for controller (ENG)
799-601-9100
1,2,3,4T
799-601-9000
4
799-601-8000
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
799-601-7500
799-601-4380*
799-601-7400
2, PA
799-601-7100
2
799-601-7000
Socket for engine (CRI-T3) Pump actuator
799-601-2800
799-601-4340*
799-601-2700
ID Symbol
Part No.
799-601-2500
Connector Type or Part Name
No. of Pins
T-branch Adapter Kit
● ● ●
★ Shows socket, not adapter.
40-84 b
WA500-6
TROUBLESHOOTING
MODE CHART
MODE CHART Troubleshooting Mode No.
Failure or Possible Phenomena
Code Display
E-mode
H-mode
S-mode
Problems Related to Action Codes and Failure Codes 1
Action codes are displayed on machine monitor.
2
If failure code display function is checked, failure codes are displayed.
Check failure code ●
Engine-related Problems (S-mode, see Engine Shop Manual also) 3
Engine does not start easily.
4 5
Engine does not crank. Engine does not start.
6
E-1
S-1
E-1
S-2 a)
Engine cranks but exhaust smoke does not come out.
S-2 b)
Exhaust smoke comes out but engine does not start. (Fuel is injected.)
S-2 c)
7
Engine does not pick up smoothly.
S-3
8
Engine stops during operation.
9
Engine does not run smoothly (engine hunts).
H-2
S-4 S-5
10 Engine output is insufficient (lacks power).
S-6
11 Exhaust gas color is black (incomplete combustion).
S-7
12 Oil consumption is excessive (exhaust smoke is blue).
S-8
13 Engine oil is contaminated quickly.
S-9
14 Fuel consumption is excessive.
S-10
15 Coolant contains oil (blows back or reduces).
S-11
16 Engine oil pressure drops.
S-12
17 Engine oil level rises (water or fuel is mixed in oil).
S-13
18 Coolant temperature is too high (overheating).
S-14
19 Abnormal sound is heard.
S-15
20 Vibration is excessive.
S-16 Power Train-related Problems
21 Machine does not start.
H-1
22
Torque converter lockup is not switched (engine stalls). [machine with lockup clutch (if equipped)]
H-2
23
Torque converter lockup is not switched. [machine with lockup clutch (if equipped)]
H-3
24
Travel speed is slow; thrusting force is weak; uphill traveling power is weak; and gear is not shifted.
H-4
25 Shocks are large at the time of starting and shifting gear.
WA500-6
H-5
40-85 b
TROUBLESHOOTING
MODE CHART Troubleshooting Mode
No.
Failure or Possible Phenomena
Code Display
E-mode
H-mode
26 Time lag is large at the time of starting and shifting gear.
H-6
27 Torque converter oil temperature is high.
H-7
S-mode
Steering-related Problems 28 Machine cannot be steered. 29
H-8
Machine cannot be steered. [machine with joystick steering (if equipped)]
H-9
30 Steering response is low. 31
H-10
Turning, response of steering is poor. [machine with joystick steering (if equipped)]
H-11
32 Steering is heavy.
H-12
33 When machine turns, it shakes or makes large shocks.
H-13
When machine turns, it shakes or makes large shocks. [machine with joystick steering (if equipped)]
H-14
34
Brake-related Problems 35 The wheel brake does not work or does not work well.
H-15
36 The wheel brake is not released or it drags.
H-16
37 The parking brake does not work or does not work well.
H-17
38
Parking brake cannot be reset or it drags (including emergency release system).
H-18
Work Equipment-related Problems 39 Lift arm does not rise.
H-19
40 Lift arm speed is low or rising force of lift arm is insufficient.
H-20
41 When rising, the lift arm starts to move slowly at a specific height.
H-21
42 Bucket cannot be held with lift arm cylinder (bucket floats).
H-22
43 Hydraulic drifts of the lift arm occur often.
H-23
44 The lift arm wobbles during operation.
H-24
45 Bucket does not tilt back.
H-25
46 Bucket speed is low or tilting back force is insufficient.
H-26
47 The bucket starts to operate slowly in the midst of tilting back.
H-27
48 The bucket cylinder cannot hold down the bucket.
H-28
49 Hydraulic drifts of the bucket occur often.
H-29
50
The bucket wobbles during travel with cargo (work equipment valve is set to HOLD).
40-86 b
H-30
WA500-6
TROUBLESHOOTING
MODE CHART Troubleshooting Mode
No.
51
Failure or Possible Phenomena
Code Display
E-mode
Engine speed lowers remarkably or engine stalls during work equipment control.
S-mode
H-31
52 Large shocks are made when work equipment starts and stops. 53
H-mode
H-32
When work equipment circuit is relieved singly, other work equipment moves.
H-33
54 ECSS does not operate; pitching or bouncing occurs.
H-34
Additional Problems 55 Wiper does not operate.
E-2
56 Windshield washer does not operate.
E-3
57
Headlamp, clearance lamp, tail lamp, and license plate lamp do not light up or go off.
E-4
58 Working lamp does not light up or go off.
E-5
59 Turn signal lamp and hazard lamp do not light up or go off.
E-6
60 Brake lamp does not light or it keeps lighting up.
E-7
61 Backup lamp does not light or it keeps lighting up.
E-8
62 Backup buzzer does not sound or it keeps sounding.
E-9
63 Horn does not sound or it keeps sounding.
E-10
64 Alarm buzzer does not sound or it keeps sounding.
E-11
65 Air conditioner does not operate or stop.
E-12
66 KOMTRAX system does not work properly.
E-13
WA500-6
40-87 b
TROUBLESHOOTING
INFORMATION IN TESTING PROCEDURES
INFORMATION IN TESTING PROCEDURES
Tools and Procedures
★ The testing table and the related circuit diagrams contain the following information. Read all information and each step carefully; if necessary, redo each step in a test procedure to confirm the fault.
• • • •
Digital Volt Ohm Meter. T-adapter kit. Do not write on original page of service manual. Remove this page from the service manual and make a copy for recording information while performing these tests. If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure. Follow each step throughout this procedure; do not skip steps, jump ahead, or stop when a fault is found. It is important to complete all steps and record information for final analysis.
Action code
Failure code
Monitor display
Monitor display
Trouble
Problem that appears on machine
Contents of Trouble
State where the monitor panel or controller detects the trouble.
Action of Controller
Action taken by machine monitor or controller to protect the system or devices when engine controller detects trouble.
Problem That Appears On Machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above).
Related information
Information related to detected trouble or troubleshooting
Cause
<Described contents> • Standard value in normal state to judge assumed cause (good or not) • Remarks required to judge whether the cause is good
1
Possible causes of trouble is assumed to be detected. (The order number indicates a serial number, not a priority sequence.)
Possible causes and standard value in normal state
2
40-88 b
Standard value in normal state/Remarks on troubleshooting
<Phenomenon of defective wiring harness> • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Grounding fault A harness not connected to ground (earth) circuit comes in contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes in contact with the power (24 V) circuit. • Short circuit A harness of an independent circuit abnormally comes in contact with one of another circuit.
WA500-6
TROUBLESHOOTING
INFORMATION IN TESTING PROCEDURES <Notes on troubleshooting>
3
Possible causes of trouble is assumed to be detected. (The order number indicates a serial number, not a priority sequence.)
Possible causes and standard value in normal state
4
(1) Method of indicating connector number and handling T-branch For troubleshooting, insert or connect T-branch adapter as shown below unless specifically specified. • When male or female is not indicated for a connector number, disconnect the connector and insert the T-branch adapter in both the male and female. • When male and female is indicated for a connector number, disconnect the connector, and insert the T-branch adapter in only either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless specifically specified. • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.
Circuit Diagram
This is part of the circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Model - number of a pin) (color). • Connector No. and pin No. from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (): Roughly shows the location on the machine.
WA500-6
40-89 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
TROUBLESHOOTING BY FAILURE CODE Failure Code Table Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
1500L0
TORQFLOW transmission
Double meshing
TM
E03
Electrical system
15B0NX
Transmission filter
Clogging
MON
E01
Mechanical system
15SAL1
ECMV F clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SALH
ECMV F clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
15SBL1
ECMV R clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SBLH
ECMV R clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
15SEL1
ECMV 1st clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SELH
ECMV 1st clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
15SFL1
ECMV 2nd clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SFLH
ECMV 2nd clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
15SGL1
ECMV 3rd clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SGLH
ECMV 3rd clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
15SHL1
ECMV 4th clutch
When command current is OFF, fill signal is ON
TM
E03
Electrical system
15SHLH
ECMV 4th clutch
When command current is ON, fill signal is OFF
TM
E01
Electrical system
2F00MA
Parking brake
Malfunction
MON
E03
Electrical system
2G42ZG
Front accumulator
Low oil pressure
MON
E03
Mechanical system
2G43ZG
Rear accumulator
Low oil pressure
MON
E03
Mechanical system
44K0L4
Bucket positioner
ON/OFF signals disagree
WRK
E01
Electrical system
AA1ANX
Air cleaner
Clogging
MON
E01
Mechanical system
AB00L6
Alternator
Signal does not match engine running or stopped state
MON
E03
Electrical system
40-90 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
AB00MA
Alternator
Malfunction
MON
E03
Mechanical system
B@BAZG
Engine oil
Low oil pressure
ENG
E03
Mechanical system
B@BAZK
Engine oil
Low level
MON
E01
Mechanical system
B@BCNS
Coolant
Overheating
ENG
E02
Mechanical system
B@BCZK
Coolant
Low level
MON
E01
Mechanical system
B@C7NS
Brake oil
Overheating
MON
E02
Mechanical system
b@CENS
Torque converter oil
Overheating
MON
E02
Mechanical system
B@CENS
Torque converter oil
Overheating
MON
E02
Mechanical system
B@GAZK
Battery electrolyte
Low level
MON
E01
Mechanical system
B@HANS
Hydraulic oil
Overheating
MON
E02
Mechanical system
CA111
Abnormality in engine controller
—
ENG
E03
Electrical system
CA115
Engine Ne or Bkup speed sensor error
—
ENG
E03
Electrical system
CA122
Charge pressure sensor high error
—
ENG
E03
Electrical system
CA123
Charge pressure sensor low error
—
ENG
E03
Electrical system
CA131
Throttle sensor high error
—
ENG
E03
Electrical system
CA132
Throttle sensor low error
—
ENG
E03
Electrical system
CA135
Engine oil pressure sensor high error
—
ENG
E01
Electrical system
CA141
Engine oil pressure sensor low error
—
ENG
E01
Electrical system
CA144
Coolant temperature sensor high error
—
ENG
E01
Electrical system
CA145
Coolant temperature sensor low error
—
ENG
E01
Electrical system
CA153
Charge temperature sensor high error
—
ENG
E01
Electrical system
CA154
Charge temperature sensor low error
—
ENG
E01
Electrical system
WA500-6
40-91 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
CA187
Sensor power supply 2 voltage low error
—
ENG
E03
Electrical system
CA221
Atmospheric pressure sensor high error
—
ENG
E01
Electrical system
CA222
Atmospheric pressure sensor low error
—
ENG
E01
Electrical system
CA227
Sensor power supply 2 high error
—
ENG
E03
Electrical system
CA234
Engine overspeed
—
ENG
E02
Mechanical system
CA238
Ne speed sensor power supply error
—
ENG
E03
Electrical system
CA263
Fuel temperature sensor high error
—
ENG
E01
Electrical system
CA265
Fuel temperature sensor low error
—
ENG
E01
Electrical system
CA271
PCV1 short circuit
—
ENG
E03
Electrical system
CA272
PCV1 disconnection
—
ENG
E03
Electrical system
CA273
PCV2 short circuit
—
ENG
E03
Electrical system
CA274
PCV2 disconnection
—
ENG
E03
Electrical system
CA322
Injector #1 (L/B #1) open/short error
—
ENG
E03
Electrical system
CA323
Injector #5 (L/B #5) open/short error
—
ENG
E03
Electrical system
CA324
Injector #3 (L/B #3) open/short error
—
ENG
E03
Electrical system
CA325
Injector #6 (L/B #6) open/short error
—
ENG
E03
Electrical system
CA331
Injector #2 (L/B #2) open/short error
—
ENG
E03
Electrical system
CA332
Injector #4 (L/B #4) open/short error
—
ENG
E03
Electrical system
CA342
Engine controller data inconsistency
—
ENG
E03
Electrical system
CA351
Injector drive circuit error
—
ENG
E03
Electrical system
CA352
Sensor power supply 1 voltage low error
—
ENG
E03
Electrical system
CA386
Sensor power supply 1 high error
—
ENG
E03
Electrical system
40-92 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
CA431
Idle validation switch error
—
ENG
E01
Electrical system
CA432
Idle validation action error
—
ENG
E03
Electrical system
CA441
Battery voltage low error
—
ENG
E03
Electrical system
CA442
Battery voltage high error
—
ENG
E03
Electrical system
CA449
Common rail pressure high error 2
—
ENG
E03
Electrical system
CA451
Common rail pressure sensor high error
—
ENG
E03
Electrical system
CA452
Common rail pressure sensor low error
—
ENG
E03
Electrical system
CA553
Common rail pressure high error 1
—
ENG
E03
Electrical system
CA554
Common rail pressure sensor inrange error
—
ENG
E03
Electrical system
CA559
Supply pump pressure very low error 1
—
ENG
E03
Electrical system
CA689
Engine Ne speed sensor error
—
ENG
E03
Electrical system
CA731
Engine Bkup speed sensor phase error
—
ENG
E03
Electrical system
CA757
All continuous data lost error
—
ENG
E03
Electrical system
CA778
Engine Bkup speed sensor error
—
ENG
E03
Electrical system
CA1228
EGR valve servo error 1
—
ENG
E03
Electrical system
CA1625
EGR valve servo error 2
—
ENG
E03
Electrical system
CA1626
Bypass valve solenoid current high error
—
ENG
E03
Electrical system
CA1627
Bypass valve solenoid drive circuit disconnection error
—
ENG
E03
Electrical system
CA1628
Bypass valve servo error 1
—
ENG
E03
Electrical system
CA1629
Bypass valve servo error 2
—
ENG
E03
Electrical system
CA1631 Bypass valve lift sensor high error
—
ENG
E03
Electrical system
CA1632
—
ENG
E03
Electrical system
Bypass valve lift sensor low error
WA500-6
40-93 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
CA1633
KOMNET datalink timeout error
—
ENG
E03
Electrical system
CA1642
• EGR inlet pressure sensor low error • Abnormally low signal in EGR inlet pressure sensor
—
ENG
E03
Electrical system
CA1653
• EGR inlet pressure sensor high error • Abnormally high signal in EGR inlet pressure sensor
—
ENG
E03
Electrical system
CA2185
Throttle sensor supply voltage high error
—
ENG
E03
Electrical system
CA2186
Throttle sensor power supply low error
—
ENG
E03
Electrical system
CA2249
Supply pump pressure very low error 2
—
ENG
E03
Electrical system
CA2271
EGR valve lift sensor high error
—
ENG
E03
Electrical system
CA2272
EGR valve lift sensor low error
—
ENG
E03
Electrical system
CA2351
EGR valve solenoid operation short circuit error
—
ENG
E03
Electrical system
CA2352
EGR valve solenoid operation disconnection error
—
ENG
E03
Electrical system
CA2555
Intake heater relay voltage low error
—
ENG
E01
Electrical system
CA2556
Intake heater relay voltage high error
—
ENG
E01
Electrical system
D160KZ
Backup lamp relay
Disconnection or short circuit
TM
E01
Electrical system
D191KA
Joystick steering neutral safety relay
Disconnection
WRK
E01
Electrical system
D191KB
Joystick steering neutral safety relay
Short circuit
WRK
E01
Electrical system
D192KA
ECSS (travel damper) solenoid
Disconnection
TM
E01
Electrical system
D192KB
ECSS (travel damper) solenoid
Short circuit
TM
E01
Electrical system
D192KY
ECSS (travel damper) solenoid
Short circuit with power supply line
TM
E01
Electrical system
D193KA
Joystick steering solenoid cut relay
Disconnection
WRK
E03
Electrical system
D193KB
Joystick steering solenoid cut relay
Short circuit
WRK
E03
Electrical system
40-94 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
D193KY
Joystick steering solenoid cut relay
Short circuit with power supply line
WRK
E03
Electrical system
D5ZHKA
Terminal C signal
Disconnection
TM
E01
Electrical system
D5ZHKB
Terminal C signal
Short circuit
TM
E01
Electrical system
D5ZHKZ
Terminal C signal
Disconnection or short circuit
WRK
E01
Electrical system
D5ZHL6
Terminal C signal
Signal does not match engine running or stopped state
MON
E01
Electrical system
DA80L4
Auto grease controller
ON/OFF signals disagree
MON
—
Electrical system
DAF3KK
Machine monitor
Low source voltage (input)
MON
E03
Electrical system
DAF5KP
Machine monitor
Low output voltage
MON
E01
Electrical system
DAFRKR
CAN communication with machine monitor
Defective communication (Abnormality in target component system)
TM
E03
Electrical system
DAQ0KK
Transmission controller
Low source voltage
TM
E03
Electrical system
DAQ0KT
Transmission controller
Abnormality in controller
TM
E01
Electrical system
DAQ2KK
Transmission controller load power supply line
Low source voltage (input)
TM
E03
Electrical system
DAQ9KQ
Transmission controller model selection wiring harness
Disagreement of model selection signals
MON
E03
—
DAQRKR
CAN communication with transmission controller
Defective communication (Abnormality in target component system)
MON
E03
Electrical system
DAQRMA
CAN communication with transmission controller
Malfunction
MON
E03
—
TM
E03
Electrical system
CAN communication with engine Defective communication (Abnormality controller in target component system)
DB2RKR DB90KK
Work equipment controller
Low source voltage (input)
WRK
E03
Electrical system
DB90KT
Work equipment controller
Abnormality in controller
WRK
E01
Electrical system
DB92KK
Work equipment controller load power supply line
Low source voltage (input)
WRK
E03
Electrical system
DB95KX
Work equipment controller power supply output
Out-of-input signal range
WRK
E03
Electrical system
DB99KQ
Work equipment controller model selection wiring harness
Disagreement of model selection signals
MON
E03
—
DB9RKR
CAN communication with work equipment controller
Defective communication (Abnormality in target component system)
TM
E03
Electrical system
WA500-6
40-95 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DB9RMA
CAN communication with work equipment controller
Malfunction
MON
E03
—
DB9RMC
CAN communication with work equipment controller
Defective operation
WRK
E03
Electrical system
DD15LD
■ switch (Panel switch 1)
Switch is kept pressed for long time
MON
E01
Electrical system
DD16LD
switch (Panel switch 2)
Switch is kept pressed for long time
MON
E01
Electrical system
DD17LD
< switch (Panel switch 3)
Switch is kept pressed for long time
MON
E01
Electrical system
DD18LD
> switch (Panel switch 4)
Switch is kept pressed for long time
MON
E01
Electrical system
DD1ALD
Remote positioner raise/lower set switch (RAISE)
Switch is kept pressed for long time
WRK
E01
Electrical system
DD1BLD
Remote positioner raise/lower set switch (LOWER)
Switch is kept pressed for long time
WRK
E01
Electrical system
DD1CLD
Load meter subtotal switch
Switch is kept pressed for long time
MON
E01
Electrical system
DD1FLD
Load meter mode selector switch (A/B)
Switch is kept pressed for long time
MON
E01
Electrical system
DD1GLD
Load meter mode selector switch (+/–)
Switch is kept pressed for long time
MON
E01
Electrical system
DD1HLD
Load meter display selector switch
Switch is kept pressed for long time
MON
E01
Electrical system
DDA7L4
RPM set ON/OFF switch
ON/OFF signals disagree
TM
E01
Electrical system
DDA8KB
RPM set idle-up/down switch (idle-up)
Short circuit
TM
E01
Electrical system
DDA9KB
RPM set idle-up/down switch (idle-down)
Short circuit
TM
E01
Electrical system
DDB6L4
Turn parking brake switch (Neutralizer)
ON/OFF signals disagree
TM
E03
Electrical system
DDD1LD
Remote positioner bucket angle set switch
Switch is kept pressed for long time
WRK
E01
Electrical system
DDE5MA Emergency steering drive switch
Malfunction
MON
E01
Electrical system
DDK3KA
Right FNR switch
Disconnection
TM
E03
Electrical system
DDK3KB
Right FNR switch
Short circuit
TM
E03
Electrical system
DDK4KA
Joystick steering FNR switch
Disconnection
TM
E03
Electrical system
DDK4KB
Joystick steering FNR switch
Short circuit
TM
E03
Electrical system
40-96 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DDK5L4
Joystick steering shift-up/down selector switch
ON/OFF signals disagree
TM
E01
Electrical system
DDK6KA
FNR lever switch
Disconnection
TM
E03
Electrical system
DDK6KB
FNR lever switch
Short circuit
TM
E03
Electrical system
DDT0L4
Shift mode selector switch
ON/OFF signals disagree
TM
E01
Electrical system
DDT4LD
Transmission cut-off set switch
Switch is kept pressed for long time
TM
E01
Electrical system
DDW9LD
Kick-down switch
Switch is kept pressed for long time
TM
E01
Electrical system
DDWLLD
Hold switch
Switch is kept pressed for long time
TM
E01
Electrical system
DDY0LD
Load meter cancel switch
Switch is kept pressed for long time
MON
E01
Electrical system
DF10KA
Transmission shift lever switch
Disconnection
TM
E01
Electrical system
DF10KB
Transmission shift lever switch
Short circuit
TM
E01
Electrical system
DGF1KA
Transmission oil temperature sensor
Disconnection
TM
E01
Electrical system
DGF1KB
Transmission oil temperature sensor
Short circuit
TM
E01
Electrical system
DGH2KX
Hydraulic oil temperature sensor
Out-of-input signal range
MON
E01
Electrical system
DGR2KA
Rear brake oil temperature sensor
Disconnection
MON
E01
Electrical system
DGR2KX
Rear brake oil temperature sensor
Out-of-input signal range
MON
E01
Electrical system
DGT1KX
Torque converter oil temperature sensor
Out-of-input signal range
MON
E01
Electrical system
DH21KA
Oil pressure sensor of work equipment pump
Disconnection
WRK
E01
Electrical system
DH21KB
Oil pressure sensor of work equipment pump
Short circuit
WRK
E01
Electrical system
DHPCKX
Lift arm cylinder bottom pressure sensor
Out-of-input signal range
MON
E01
Electrical system
DHPDKX
Lift arm cylinder head pressure sensor
Out-of-inputsignal range
MON
E01
Electrical system
DHT1KX
Left brake pressure sensor
Out-of-input signal range
TM
E01
Electrical system
DHT2L6
Transmission filter clogging sensor
Signal does not match engine running or stopped state
MON
E01
Electrical system
WA500-6
40-97 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DK59KA
Lift arm EPC lever potentiometer (Main)
Disconnection
WRK
E03
Electrical system
DK59KY
Lift arm EPC lever potentiometer (Main)
Short circuit with power supply line
WRK
E03
Electrical system
DK59L8
Lift arm EPC lever potentiometer (Main)
Analog signals disagree
WRK
E03
Electrical system
DK5AKA
Lift arm EPC lever potentiometer (Sub)
Disconnection
WRK
E03
Electrical system
DK5AKY
Lift arm EPC lever potentiometer (Sub)
Short circuit with power supply line
WRK
E03
Electrical system
DK5BKA
Bucket EPC lever potentiometer (Main)
Disconnection
WRK
E03
Electrical system
DK5BKY
Bucket EPC lever potentiometer (Main)
Short circuit with power supply line
WRK
E03
Electrical system
DK5BL8
Bucket EPC lever potentiometer (Main)
Analog signals disagree
WRK
E03
Electrical system
DK5CKA
Bucket EPC lever potentiometer (Sub)
Disconnection
WRK
E03
Electrical system
DK5CKY
Bucket EPC lever potentiometer (Sub)
Short circuit with power supply line
WRK
E03
Electrical system
DK5DKA
3rd valve (attachment) EPC lever potentiometer (Main)
Disconnection
WRK
E03
Electrical system
DK5DKY
3rd valve (attachment) EPC lever potentiometer (Main)
Short circuit with power supply line
WRK
E03
Electrical system
DK5DL8
3rd valve (attachment) EPC lever potentiometer (Main)
Analog signals disagree
WRK
E03
Electrical system
DK5EKA
3rd valve (attachment) EPC lever potentiometer (Sub)
Disconnection
WRK
E03
Electrical system
DK5EKY
3rd valve (attachment) EPC lever potentiometer (Sub)
Short circuit with power supply line
WRK
E03
Electrical system
DK5FKA
Joystick steering EPC lever potentiometer (Main)
Disconnection
WRK
E03
Electrical system
DK5FKY
Joystick steering EPC lever potentiometer (Main)
Short circuit with power supply line
WRK
E03
Electrical system
DK5GKA
Joystick steering EPC lever potentiometer (Sub)
Disconnection
WRK
E03
Electrical system
DK5GKY
Joystick steering EPC lever potentiometer (Sub)
Short circuit with power supply line
WRK
E03
Electrical system
DK5FL8
Joystick steering EPC lever potentiometer (Main)
Analog signals disagree
WRK
E03
Electrical system
DKA0KA
Lift arm angle sensor
Disconnection
WRK
E01
Electrical system
DKA0KX
Lift arm angle sensor
Out-of-input signal range
MON
E01
Electrical system
40-98 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DKA0KY
Lift arm angle sensor
Short circuit with power supply line
WRK
E01
Electrical system
DKA0L0
Lift arm angle sensor
Double meshing
WRK
E01
Electrical system
DLF1KA
Transmission input shaft speed sensor
Disconnection
TM
E01
Electrical system
DLF1LC
Transmission input shaft speed sensor
Speed signals disagree
TM
E01
Electrical system
DLT4KB
Transmission output shaft speed sensor
Short circuit
TM
E03
Electrical system
DLT4KX
Transmission output shaft speed sensor
Out-of-input signal range
TM
E03
Electrical system
DT20KB
Transmission cut-off indicator lamp
Short circuit
TM
E01
Electrical system
DUM1KB
Remote positioner raise set indicator lamp
Short circuit
WRK
—
—
DUM2KB
Remote positioner lower set indicator lamp
Short circuit
WRK
—
—
DV00KB
Alarm buzzer
Short circuit
MON
E01
Electrical system
DW4PKA
Lift arm raise EPC solenoid
Disconnection
WRK
E03
Electrical system
DW4PKB
Lift arm raise EPC solenoid
Short circuit
WRK
E03
Electrical system
DW4PKY
Lift arm raise EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DW4QKA
Lift arm lower EPC solenoid
Disconnection
WRK
E03
Electrical system
DW4QKB
Lift arm lower EPC solenoid
Short circuit
WRK
E03
Electrical system
DW4QKY
Lift arm lower EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DW4RKA
Bucket tilt EPC solenoid
Disconnection
WRK
E03
Electrical system
DW4RKB
Bucket tilt EPC solenoid
Short circuit
WRK
E03
Electrical system
DW4RKY
Bucket tilt EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DW4SKA
Bucket dump EPC solenoid
Disconnection
WRK
E03
Electrical system
DW4SKB
Bucket dump EPC solenoid
Short circuit
WRK
E03
Electrical system
DW4SKY
Bucket dump EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
WA500-6
40-99 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DW7BKA
Fan reverse solenoid
Disconnection
TM
E01
Electrical system
DW7BKB
Fan reverse solenoid
Short circuit
TM
E01
Electrical system
DW7BKY
Fan reverse solenoid
Short circuit with power supply line
TM
E01
Electrical system
DW7DKA
Hydraulic drive fan neutral solenoid
Disconnection
TM
E01
Electrical system
DW7DKB
Hydraulic drive fan neutral solenoid
Short circuit
TM
E01
Electrical system
DW7DKY
Hydraulic drive fan neutral solenoid
Short circuit with power supply line
TM
E01
Electrical system
DWM1KA
Work equipment neutral lock EPC solenoid
Disconnection
WRK
E01
Electrical system
DWM1KB
Work equipment neutral lock EPC solenoid
Short circuit
WRK
E01
Electrical system
DWM1KY
Work equipment neutral lock EPC solenoid
Short circuit with power supply line
WRK
E01
Electrical system
DWN6KA
Lift arm raise magnet detent solenoid
Disconnection
WRK
E01
Electrical system
DWN6KB
Lift arm raise magnet detent solenoid
Short circuit
WRK
E01
Electrical system
DWN6KY
Lift arm raise magnet detent solenoid
Short circuit with power supply line
WRK
E01
Electrical system
DWN7KA
Lift arm float magnet detent solenoid
Disconnection
WRK
E01
Electrical system
DWN7KB
Lift arm float magnet detent solenoid
Short circuit
WRK
E01
Electrical system
DWN7KY
Lift arm float magnet detent solenoid
Short circuit with power supply line
WRK
E01
Electrical system
DWN8KA Bucket tilt magnet detent solenoid
Disconnection
WRK
E01
Electrical system
DWN8KB Bucket tilt magnet detent solenoid
Short circuit
WRK
E01
Electrical system
DWN8KY Bucket tilt magnet detent solenoid
Short circuit with power supply line
WRK
E01
Electrical system
DX16KA
Fan pump EPC solenoid
Disconnection
TM
E01
Electrical system
DX16KB
Fan pump EPC solenoid
Short circuit
TM
E01
Electrical system
DX16KY
Fan pump EPC solenoid
Short circuit with power supply line
TM
E01
Electrical system
DXA1KA
Pump PC-EPC solenoid
Disconnection
WRK
E01
Electrical system
40-100 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DXA1KB
Pump PC-EPC solenoid
Short circuit
WRK
E01
Electrical system
DXH1KA
Lockup ECMV solenoid
Disconnection
TM
E01
Electrical system
DXH1KB
Lockup ECMV solenoid
Short circuit
TM
E01
Electrical system
DXH1KY
Lockup ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXH4KA
1st clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXH4KB
1st clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXH4KY
1st clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXH5KA
2nd clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXH5KB
2nd clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXH5KY
2nd clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXH6KA
3rd clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXH6KB
3rd clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXH6KY
3rd clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXH7KA
R clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXH7KB
R clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXH7KY
R clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXH8KA
F clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXH8KB
F clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXH8KY
F clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
DXHHKA
4th clutch ECMV solenoid
Disconnection
TM
E03
Electrical system
DXHHKB
4th clutch ECMV solenoid
Short circuit
TM
E03
Electrical system
DXHHKY
4th clutch ECMV solenoid
Short circuit with power supply line
TM
E03
Electrical system
WA500-6
40-101 b
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
Failure Code
Problem Part
Trouble
Controller
Action Code
Category of Record
DXHJKA
3rd valve extract EPC solenoid
Disconnection
WRK
E03
Electrical system
DXHJKB
3rd valve extract EPC solenoid
Short circuit
WRK
E03
Electrical system
DXHJKY
3rd valve extract EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DXHKKA
3rd valve retract EPC solenoid
Disconnection
WRK
E03
Electrical system
DXHKKB
3rd valve retract EPC solenoid
Short circuit
WRK
E03
Electrical system
DXHKKY
3rd valve retract EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DXHLKA
Joystick steering right EPC solenoid
Disconnection
WRK
E03
Electrical system
DXHLKB
Joystick steering right EPC solenoid
Short circuit
WRK
E03
Electrical system
DXHLKY
Joystick steering right EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
DXHMKA
Joystick steering left EPC solenoid
Disconnection
WRK
E03
Electrical system
DXHMKB
Joystick steering left EPC solenoid
Short circuit
WRK
E03
Electrical system
DXHMKY
Joystick steering left EPC solenoid
Short circuit with power supply line
WRK
E03
Electrical system
40-102 b
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE
★ Failure codes: • Failure codes are listed in alphabetical order and start from the smallest number. • A failure code in parentheses is not recorded in the failure history for either the electrical system or mechanical system. ★ Applicable controller: Applicable controller indicates in which controller system the failure has occurred. MON: Machine monitor system ENG: Engine controller system TM : Transmission controller system ★ Action codes: Action codes indicate what is displayed in the Operator mode when a failure is detected. ★ History classification: History classification indicates in which system a failure has been recorded (either electrical or mechanical in the failure history display function). Remark Optional equipment is also included in the table.
WA500-6
40-103 b
TROUBLESHOOTING
FUSE BOX AND SLOW-BLOW FUSES
FUSE BOX AND SLOW-BLOW FUSES Connection Table ★ This connection table indicates the devices to which the power of the fuse box and slow blow fuse is supplied. • A switch power supply device supplies power while the starting switch is in the ON position. • A constant power supply device supplies power while the starting switch is in the OFF and ON positions. ★ When carrying out troubleshooting related to the electrical system, you should check the fuse box and slow-blow fuse to see if the power is supplied normally.
Fuse Box A Power Supply (Power Source)
Fuse No.
Fuse Capacity
Switch power supply Starting switch ACC
1
5A
Engine controller circuit
2
10 A
Starting switch terminal B circuit
3
30 A
Engine controller cut circuit
4
10 A
Hazard lamp circuit
5
10 A
Radio, auto-grease circuit
6
10 A
Transmission controller (B) circuit
7
10 A
Work equipment controller (B) circuit
8
10 A
Machine monitor (B) circuit
9
10 A
Horn circuit
10
20 A
Air conditioner circuit
Constant power supply slow-blow fuse SBF1 (50 A)
Switch power supply slow-blow fuse CBF2 (80 A)
Description
11
5A
Air conditioner compressor circuit
12
20 A
Rear glass heater circuit
13
10 A
Radio, auto-grease circuit
14
20 A
Air suspension seat, 12 V converter circuit
15
10 A
KOMTRAX circuit
Fuse No.
Fuse Capacity
1
10 A
Turn signal lamp circuit
2
10 A
Back-up lamp and brake lamp circuit
3
20 A
Front working lamp circuit
4
20 A
Rear working lamp circuit
5
10 A
Transmission controller (A) circuit
6
10 A
Parking brake circuit
7
10 A
Work equipment controller (A) circuit
8
10 A
Machine monitor (A) circuit
Fuse Box B Power Supply (Power Source)
Switch power supply slow-blow fuse SBF2 (120 A)
Description
9
20 A
Wiper and washer circuit
10
10 A
Spare
11
20 A
Main lamp circuit
Switch power supply lamp switch
12
10 A
Clearance lamp (right) circuit
13
10 A
Clearance lamp (left) circuit
Switch power supply head lamp relay
14
10 A
Headlamp (right) circuit
15
10 A
Headlamp (left) circuit
40-104 b
WA500-6
TROUBLESHOOTING
FUSE BOX AND SLOW-BLOW FUSES
Slow-Blow Fuses Power Supply (Power Source)
Constant power supply
Slow-blow Fuse No.
SBF1
Fuse Capacity
Description
50 A
Starting switch B terminal circuit, engine controller cut circuit, hazard lamp circuit, radio, auto-grease circuit, transmission controller (B) circuit, work equipment controller (B) circuit, machine monitor (B) circuit
80 A
Horn circuit, air conditioner circuit, air conditioner compressor circuit, rear glass heater circuit, radio, auto-grease circuit, air suspension seat, 12 V converter circuit, KOMTRAX circuit
120 A
Turn signal lamp circuit, backup lamp, brake lamp circuit, front working lamp circuit, rear working lamp circuit, transmission controller (A) circuit, parking brake circuit, work equipment controller (A) circuit, machine monitor (A) circuit, wiper, washer circuit, spare, main lamp circuit
250 A
Heater relay circuit
SBF2 Switch power supply
SBF3
WA500-6
40-105 b
TROUBLESHOOTING
FAILURE CODES
FAILURE CODES Remark Where applicable, the Failure Code table is on the left-hand page and the related diagram is on the right-hand page.
40-106 b
WA500-6
TROUBLESHOOTING
1500LO
1500LO TORQFLOW Transmission: Double Meshing Action Code
Failure Code
E03
1500LOG
Trouble
TORQFLOW transmission: Double meshing (Transmission controller system)
Contents of trouble
• A combination for double meshing is input as a fill signal.
Action of machine monitor
• Turns the centralized warning lamp and warning buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission may be broken. • The machine cannot travel.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Causes Possible causes and standard value in normal state
WA500-6
1
Standard value in normal state/Remarks on troubleshooting
See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1], and [15SHL1].
40-107 b
TROUBLESHOOTING
15BONX
15BONX Transmission Filter: Clogging Action Code
Failure Code
E01
15B0NX
Trouble
Transmission filter: Clogging (Machine monitor system)
Contents of trouble
• Transmission filter clogging sensor circuit is OPEN. (When torque converter oil temperature is above 50°C (122°F), engine is running and option is set) • Trouble detected while engine is stopped is maintained even after engine is started.
Action of controller
• Turns the transmission filter clogging caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The transmission filter clogging caution lamp illuminates. • The transmission may be broken.
Related information
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the monitoring function (Code: 40903, D-IN-24). • Method of reproducing failure code: Start engine. Cause 1 Transmission filter clogging
Standard value in normal state/Remarks on troubleshooting The transmission filter may be clogged. Check it directly.
★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission clogging sensor (Internal 2 disconnection or short circuit)
without turning starting switch ON. • Disconnect connector R12 R12 (male)
Transmission oil filter
Resistance
Normal
Max. 1
Clogging
Min. 1 M
Between (1) and (2)
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection or 3 defective contact of connector)
without turning starting switch ON. Wiring harness between L53 (female) (5) – R12 (female) (1)
Resistance Max. 1
Wiring harness between R12 (male) (2) – chassis ground
Resistance Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 4 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L53 (female) (5) – R12 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective machine monitor
40-108 b
L53 (female)
Transmission oil filter
Resistance
Between (5) – chassis ground
Normal
Max. 1
Clogging
Min. 1 M
WA500-6
TROUBLESHOOTING
15BONX
Related Circuit Diagram
WA500-6
40-109 b
TROUBLESHOOTING
15SAL1
15SAL1 ECMV F Clutch: When Command Current is OFF, Fill Signal is ON Action Code
Failure Code
E03
15SAL1
Trouble
ECMV F clutch: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not released.
Action of controller
• Judges that the F ECMV fill switch signal is turned ON. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• F travel is enabled, but R travel is disabled.
Related information
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function (Code: 31608, ECMV F DIR). • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code: 40908, D-IN-25). • Method of reproducing failure code: Start engine. Cause
Standard value in normal state/Remarks on troubleshooting
Abnormal F (forward) 1 clutch oil pressure (There is There is no pressure in position other than F. residual pressure)
★ Prepare with starting switch OFF, then start engine and carry out
Defective F ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling.
F.SW (male)
Between (1) – chassis ground Grounding fault in wiring harness 3 (Contact with ground circuit)
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (27) – F.SW (female) (1) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 4
Defective transmission controller L03
Between (27) – chassis ground
40-110 b
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Voltage
F (Forward)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SAL1
Related Circuit Diagram
WA500-6
40-111 b
TROUBLESHOOTING
15SALH
15SALH ECMV F Clutch: When Command Current is ON, Fill Signal is OFF Action Code
Failure Code
E01
15SALH
Trouble
ECMV F clutch: When command current is ON, fill signal is OFF. (Transmission controller system)
Contents of trouble
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
Action of controller
• Judges that the F ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• When the travel direction is changed, a shock or a time lag may be made.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function (Code: 31608, ECMV F DIR). • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code: 40908, D-IN-25). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch F (forward)
Cause Abnormal F (forward) clutch oil pressure 1 (There is no pressure while command is ON.)
Standard value in normal state/Remarks on troubleshooting
Oil pressure is normal in F.
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 2
Defective F ECMV fill switch (Internal disconnection) F.SW (male)
Between (1) – chassis ground Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
40-112 b
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (27) – F.SW (female) (1)
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
15SALH Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 4
Defective transmission controller L03
Between (27) – chassis ground
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Voltage
F (Forward)
Max. 1 V
Other than above
8 – 10 V
Related Circuit Diagram
WA500-6
40-113 b
TROUBLESHOOTING
15SBL1
15SBL1 ECMV R Clutch: When Command Current is OFF, Fill Signal is ON Action Code
Failure Code
E03
15SBL1
Trouble
ECMV R clutch: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input and clutch is not released.
Action of controller
• Judges that the R ECMV fill switch signal is turned ON. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel in the R position, but cannot travel in the F position.
Related information
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring function (Code: 31606, ECMV R DIR). • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code: 40908, D-IN-26). • Method of reproducing failure code: Start engine.
Cause Abnormal R (reverse) clutch oil pressure 1 (There is residual pressure.)
Standard value in normal state/Remarks on troubleshooting
There is no pressure in position other than R.
★ Prepare with starting switch OFF, then start engine and carry out
Defective R ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling.
R.SW (male)
Between (1) – chassis ground Grounding fault in wiring harness 3 (Contact with ground circuit)
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Resistance
R (Reverse)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (17) – R.SW (female) (1) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 4
Defective transmission controller L03
Between (17) – chassis ground
40-114 b
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Voltage
R (Reverse)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SBL1
Related Circuit Diagram
WA500-6
40-115 b
TROUBLESHOOTING
15SBLH
15SBLH ECMV R Clutch: When Command Current is ON, Fill Signal is OFF Action code
Failure code
E01
15SBLH
Trouble
ECMV R clutch: When command current is ON, fill signal is OFF (Transmission controller system)
Contents of trouble
• When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input. • Engine speed is below 500 rpm and clutch does not mesh.
Action of controller
• Judges that the R ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• When the travel direction is changed, a shock or a time lag may occur.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring function (Code: 31606, ECMV R DIR). • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code: 40908, D-IN-26). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch R (reverse)
Cause
Standard value in normal state/Remarks on troubleshooting
Abnormal R (reverse) clutch oil pressure 1 Oil pressure is normal in R. (There is no pressure while command is ON.)
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 2
Defective R ECMV fill switch (Internal short circuit) R.SW (male)
Between (1) – chassis ground Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
40-116 b
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Resistance
R (Reverse)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (17) – R.SW (female) (1)
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
15SBLH Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 4
Defective transmission controller L03
Between (17) – chassis ground
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Voltage
R (Reverse)
Max. 1 V
Other than above
8 – 10 V
Related Circuit Diagram
WA500-6
40-117 b
TROUBLESHOOTING
15SEL1
15SEL1 ECMV 1st Clutch: When Command Current is OFF, Fill Signal is ON Action Code
Failure Code
E03
15SEL1
Trouble
ECMV 1st clutch: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is not released.
Action of controller
• Judges that the 1st ECMV fill switch signal is turned ON. • Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
Related information
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code: 40908, D-IN-27). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
Abnormal 1st clutch oil 1 pressure There is no pressure in position other than 1st. (There is residual pressure.)
★ Prepare with starting switch OFF, then start engine and carry out
Defective 1st ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 1.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
1st (1st speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L03 (female) (7) – (Contact with ground circuit) Resistance Min. 1 M 1.SW (female) (1) and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out
4
40-118 b
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (7) – chassis ground
1st (1st speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SEL1
Related Circuit Diagram
WA500-6
40-119 b
TROUBLESHOOTING
15SELH
15SELH ECMV 1st Clutch: When Command Current is ON, Fill Signal is OFF Action Code
Failure Code
E01
15SELH
Trouble
ECMV 1st clutch: When command current is ON, fill signal is OFF. (Transmission controller system)
Contents of trouble
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
Action of controller
• Judges that the 1st ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The machine may not travel at 1st. • When the 1st gear speed is changed, a shock or a time lag may occur.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code: 40908, D-IN-27). • Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse) + Shift lever 1st
Cause Abnormal 1st clutch oil pressure 1 (There is no pressure while command is ON.)
Standard value in normal state/Remarks on troubleshooting
Oil pressure is normal in 1st.
★ Prepare with starting switch OFF, then start engine and carry out
Defective 1st ECMV fill 2 switch (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 1.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
1st (1st speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (7) – 1.SW (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then start engine and carry out
4
40-120 b
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (7) – chassis ground
1st (1st speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SELH
Related Circuit Diagram
WA500-6
40-121 b
TROUBLESHOOTING
15SFL1
15SFL1 ECMV 2nd Clutch: When Command Current is OFF, FIll Signal is ON Action Code
Failure Code
E03
15SFL1
Trouble
ECMV 2nd clutch: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch is not released.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Judges that the 2nd ECMV fill switch signal is turned ON. • Holds 1st, 3rd, and 4th proportional solenoid outputs OFF. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
Related information
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603, ECMV 2 DIR). • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code: 40908, D-IN-28). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
Abnormal 2nd clutch oil 1 pressure There is no pressure in position other than 2nd. (There is residual pressure.)
★ Prepare with starting switch OFF, then start engine and carry out
Defective 2nd ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
2.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
2nd (2nd speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L03 (female) (13) – (Contact with ground circuit) Resistance Min. 1 M 2.SW (female) (1) and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out
4
40-122 b
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling.
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (13) – chassis ground
2nd (2nd speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SFL1
Related Circuit Diagram
WA500-6
40-123 b
TROUBLESHOOTING
15SFLH
15SFLH ECMV 2nd Clutch: When Command Current is ON, Fill Signal is OFF Action Code
Failure Code
E01
15SFLH
Trouble
ECMV 2nd clutch: When command current is ON, fill signal is OFF. (Transmission controller system)
Contents of trouble
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
Action of controller
• Judges that the 2nd ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The machine may not travel at 2nd. • When the 2nd gear speed is changed, a shock or a time lag may occur.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603, ECMV 2 DIR). • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code: 40908, D-IN-28). • Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse) + Shift lever 2nd
Cause Abnormal 2nd clutch oil pressure 1 (There is no pressure while command is ON.)
Standard value in normal state/Remarks on troubleshooting
Oil pressure is normal in 2nd.
★ Prepare with starting switch OFF, then start engine and carry out
Defective 2nd ECMV fill 2 switch (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 2.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
2nd (2nd speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (13) – 2.SW (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then start engine and carry out
4
40-124 b
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (13) – chassis ground
2nd (2nd speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SFLH
Related Circuit Diagram
WA500-6
40-125 b
TROUBLESHOOTING
15SGL1
15SGL1 ECMV 3rd Clutch: When Command Current is OFF, Fill Signal is ON Action Code
Failure Code
E03
15SGL1
Trouble
ECMV 3rd: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is not released.
Action of controller
• Judges that the 3rd ECMV fill switch signal is turned ON. • Holds 1st, 2nd, and 4th proportional solenoid outputs OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
Related information
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604, ECMV 3 DIR). • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code: 40908, D-IN-29). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
Abnormal 3rd clutch oil 1 pressure There is no pressure in position other than 3rd. (There is residual pressure.)
★ Prepare with starting switch OFF, then start engine and carry out
Defective 3rd ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
3.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
3rd (3rd speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L03 (female) (3) – (Contact with ground circuit) Resistance Min. 1 M 3.SW (female) (1) and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out
4
40-126 b
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling.
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (3) – chassis ground
3rd (3rd speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SGL1
Related Circuit Diagram
WA500-6
40-127 b
TROUBLESHOOTING
15SGLH
15SGLH ECMV 3rd Clutch: When Command Current is ON, Fill Signal is OFF Action Code
Failure Code
E01
15SGLH
Trouble
ECMV 3rd clutch: When command current is ON, fill signal is OFF. (Transmission controller system)
Contents of trouble
• When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input. • Engine speed is below 500 rpm and clutch does not mesh.
Action of controller
• Judges that the 3rd ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The machine may not travel at 3rd. • When the 3rd gear speed is changed, a shock or a time lag may occur.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604, ECMV 3 DIR). • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code: 40908, D-IN-29). • Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse) + Shift lever 3rd
Cause Abnormal 3rd clutch oil pressure 1 (There is no pressure while command is ON)
Standard value in normal state/Remarks on troubleshooting
Oil pressure is normal in 3rd.
★ Prepare with starting switch OFF, then start engine and carry out
Defective 3rd ECMV fill 2 switch (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 3.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
3rd (3rd speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (3) – 3.SW (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then start engine and carry out
4
40-128 b
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (3) – chassis ground
3rd (3rd speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SGLH
Related Circuit Diagram
WA500-6
40-129 b
TROUBLESHOOTING
15SHL1
15SHL1 ECMV 4th Clutch: When Command Current is OFF, Fill Signal is ON Action Code
Failure Code
E03
15SHL1
Trouble
ECMV 4th: When command current is OFF, fill signal is ON. (Transmission controller system)
Contents of trouble
• When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is not released.
Action of controller
• Judges that the 4th ECMV fill switch signal is turned ON. • Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
Related information
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function (Code: 31605, ECMV 4 DIR). • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code: 40908, D-IN-30). • Method of reproducing failure code: Start engine.
Cause Abnormal 4th clutch oil 1 pressure (There is residual pressure)
Standard value in normal state/Remarks on troubleshooting There is no pressure in position other than 4th.
★ Prepare with starting switch OFF, then start engine and carry out
Defective 4th ECMV fill 2 switch (Internal short circuit)
Possible causes and standard value in normal state
4.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
4th (4th speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L03 (female) (2) – (Contact with ground circuit) Resistance Min. 1 M 4.SW (female) (1) and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out
4
40-130 b
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling.
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto-shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (2) – chassis ground
4th (4th speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SHL1
Related Circuit Diagram
WA500-6
40-131 b
TROUBLESHOOTING
15SHLH
15SHLH ECMV 4th Clutch: When Command Current is ON, Fill Signal is OFF Action Code
Failure Code
E01
15SHLH
Trouble
ECMV 4th: When command current is ON, fill signal is OFF. (Transmission controller system)
Contents of trouble
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
Action of controller
• Judges that the 4th ECMV fill switch signal is turned OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The machine may not travel at 4th. • When the 4th gear speed is changed, a shock or a time lag may occur.
Related information
• This failure code may be displayed just after transmission oil was changed. • The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function (Code: 31605, ECMV 4). • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code: 40908, D-IN-30). • Method of reproducing failure code: Engine started + Manual/auto-shift selector switch to MANUAL + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse) + Shift lever 4th
Cause Abnormal 4th clutch oil pressure 1 (There is no pressure while command is ON)
Standard value in normal state/Remarks on troubleshooting
Oil pressure is normal in 4th.
★ Prepare with starting switch OFF, then start engine and carry out
Defective 4th ECMV fill 2 switch (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. 4.SW (male)
Shift lever
Resistance
Between (1) – chassis ground
4th (4th speed)
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (2) – 4.SW (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then start engine and carry out
4
40-132 b
Defective transmission controller
troubleshooting. • Turn transmission cutoff switch OFF. • Turn parking brake switch OFF. • Keep pressing brake pedal to prevent machine from traveling. • Set the auto shift and manual shift selector switch in the MANUAL position. • Set the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to F (forward) or R (reverse). L03
Shift lever
Voltage
Between (2) – chassis ground
4th (4th speed)
Max. 1 V
Other than above
8 – 10 V
WA500-6
TROUBLESHOOTING
15SHLH
Related Circuit Diagram
WA500-6
40-133 b
TROUBLESHOOTING
2F00MA
2F00MA Parking Brake: Malfunction Action Code
Failure Code
E03
2F00MA
Trouble
Parking brake: Malfunction (Machine monitor system)
Contents of trouble
• While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• While parking brake lamp is lighting up, actual gear speed is not neutral.
Related information
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring function (Code: 40903 D-IN-26). • Method of reproducing failure code: Turn starting switch ON; turn parking brake switch OFF; and perform forward or reverse travel operation.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out Defective parking brake 1 indicator switch (Internal disconnection)
troubleshooting. • Disconnect connector PB.SW. PB.SW (male) Between (1) and (2)
Parking brake
Resistance
Released
Max. 1
Operates
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L54 (female) (1) – PB.SW (female) (1)
Resistance
Max. 1
Wiring harness between PB.SW (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3 Defective machine monitor
L54 Between (1) – chassis ground
40-134 b
Parking brake oil pressure
Voltage
Released
Max. 1 V
Operates
20 – 30 V
WA500-6
TROUBLESHOOTING
2F00MA
Related Circuit Diagram
WA500-6
40-135 b
TROUBLESHOOTING
2G42ZG
2G42ZG Front Accumulator: Low Oil Pressure Action Code
Failure Code
E03
2G42ZG
Trouble
Front accumulator: Low oil pressure (Machine monitor system)
Contents of trouble
• After engine is started, pressure increases to set pressure and then front brake accumulator pressure sensor circuit is OPEN.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The front brake accumulator oil pressure lowers. • The brake may not work.
Related information
• The input state (ON/OFF) from the front brake oil pressure sensor can be checked with the monitoring function (Code: 40902, D-IN-16). • Method of reproducing failure code: Turn starting switch ON.
Cause 1
Standard value in normal state/Remarks on troubleshooting
The front brake accumulator Check the front brake accumulator oil pressure. (See Testing and adjusting.) oil pressure lowers.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. B05 (male) Defective front brake oil 2 pressure sensor (Internal disconnection) Between (1) and (2)
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact)
Front brake accumulator oil pressure
Resistance
Normal brake pressure Min. 60 kg/cm² (Min. 853 psi)
Max. 1
Low brake pressure Max. 40 kg/cm² (Max. 569 psi)
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L53 (female) (1) – B05 (female) (1)
Resistance
Max. 1
Wiring harness between B05 (female) (2) – GND Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L53 (female) 4 Defective machine monitor Wiring harness between (1) – chassis ground
40-136 b
Front brake accumulator oil pressure
Resistance
Normal brake pressure Min. 60 kg/cm² (Min. 853 psi)
Max. 1
Low brake pressure Max. 40 kg/cm² (Max. 569 psi)
Min. 1 M
WA500-6
TROUBLESHOOTING
2G42ZG
Related Circuit Diagram
WA500-6
40-137 b
TROUBLESHOOTING
2G43ZG
2G43ZG Rear Accumulator: Low Oil Pressure Action Code
Failure Code
E03
2G43ZG
Trouble
Rear accumulator: Low oil pressure (Machine monitor system)
Contents of trouble
• After engine is started, pressure increases to set pressure and then rear brake accumulator pressure sensor circuit is OPEN.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Low rear brake accumulator oil pressure • The brake may not work.
Related information
• The input state (ON/OFF) from the rear brake oil pressure sensor can be checked with the monitoring function (Code: 40902, D-IN-17). • Method of reproducing failure code: Turn starting switch ON.
Cause 1
Standard value in normal state/Remarks on troubleshooting
Low rear brake accumulator Check the rear brake accumulator oil pressure. (See Testing and adjusting.) oil pressure
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. B04 (male) Defective rear brake oil 2 pressure sensor (Internal disconnection) Between (1) and (2)
Possible causes and standard value in normal state
Rear brake accumulator oil pressure
Resistance
Normal brake pressure Min. 60 kg/cm² (Min. 853 psi)
Max. 1
Low brake pressure Max. 40 kg/cm² (Max. 569 psi)
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 3 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L53 (female) (7) – B04 (female) (1)
Resistance Max. 1
Wiring harness between B04 (female) (2) and GND
Resistance Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L53 (female) 4 Defective machine monitor Wiring harness between (7) – chassis ground
40-138 b
Rear brake accumulator oil pressure
Resistance
Normal brake pressure Min. 60 kg/cm² (Min. 853 psi)
Max. 1
Low brake pressure Max. 40 kg/cm² (Max. 569 psi)
Min. 1 M
WA500-6
TROUBLESHOOTING
2G43ZG
Related Circuit Diagram
WA500-6
40-139 b
TROUBLESHOOTING
44K0L4
44K0L4 Bucket Positioner: ON/OFF Signals Disagree Action Code
Failure Code
E01
44K0L4
Trouble
Bucket positioner: ON/OFF signals disagree (Work equipment controller system)
Contents of trouble
• The signals input from the bucket proximity switch are combined impossibly. • After bucket level-over signal ON and full stroke signal OFF were continued for three seconds, full stroke signal ON was detected for one second. • After bucket level-over signal ON and full stroke signal OFF were continued for three seconds, bucket level-over signal OFF was detected for one second. • If cause of failure disappears, system resets itself.
Action of controller
• Judged to be below bucket level.
Problem that appears on machine
• Bucket leveler does not function.
Related information
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with the monitoring function (Code: 40911, D-IN-8). • The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the monitoring function (Code: 40911, D-IN-9). • Method of reproducing failure code: Start engine + Slowly full-tilt bucket Full dump
Cause
Standard value in normal state/Remarks on troubleshootin
★ Prepare with starting switch OFF, then turn starting switch ON and Defective bucket cylinder level proximity switch 1 (Internal disconnection or short circuit)
carry out troubleshooting. F11
Position of bucket
Voltage
Between (A) and (C)
Constant
20 – 30 V
Below horizontal
Max. 1 V
Above horizontal
8 – 10 V
Between (B) and (C)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Defective bucket cylinder full stroke proximity switch 2 (Internal disconnection or short circuit)
F12 Between (A) and (C) Between (B) and (C)
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
Position of bucket
Voltage
Constant
20 – 30 V
Tilt full stroke
8 – 10 V
Other than tilt full stroke
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F12 (female) (B) – L07 Resistance (female) (10)
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 4 harness (Contact with ground circuit) Wiring harness between F11 (female) (B) – L07 Resistance Min. 1 M (female) (20) and chassis ground
40-140 b
WA500-6
TROUBLESHOOTING
44K0L4 Cause
Standard value in normal state/Remarks on troubleshootin
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
5
Defective work equipment controller
L07
Position of bucket
Voltage
Between (20) – chassis ground
Below horizontal
Max. 1 V
Above horizontal
8 – 10 V
Tilt full stroke
8 – 10 V
Other than tilt full stroke
Max. 1 V
Between (10) – chassis ground
Related Circuit Diagram
WA500-6
40-141 b
TROUBLESHOOTING
AA1ANX
AA1ANX Air Cleaner: Clogging Action Code
Failure Code
E01
AA1ANX
Air cleaner: Clogging (Machine monitor system)
Trouble
Contents of trouble
• The air cleaner clogging sensor circuit is OPEN (at engine running).
Action of controller
• Turns the air cleaner clogging caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The engine does not start or pick up easily; its output is insufficient; and its exhaust gas color is black.
Related information
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring function (Code: 40902, D-IN-20). • Method of reproducing failure code: Start engine.
Cause 1 Clogged air cleaner
Standard value in normal state/Remarks on troubleshooting The air cleaner may be clogged. Check it directly.
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. Defective dust indicator 2 (Internal short circuit)
Failure code AA1ANX
E15 (female) Replace dust indicator.
Dust indicator
If condition becomes normal, dust indicator is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective dust indicator relay (L107) (Internal 3 ★ disconnection or short circuit)
Possible causes and standard value in normal state
L107 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then start engine and carry out troubleshooting.
If dust indicator relay (L107) is replaced with a relay of the same type (5-pin type) and the condition becomes normal, the exchanged relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness (Disconnection or 4 defective contact of connector)
Grounding fault in wiring 5 harness (Contact with ground circuit)
without turning starting switch ON. Wiring harness between L53 (female) (3) – L107 (female) (3)
Resistance
Max. 1
Wiring harness between L107 (female) (6) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L107 (female) (2) – E15 (female) (1) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. L53 6 Defective machine monitor Between (3) – chassis ground
40-142 b
Dust indicator
Voltage
Normal (Air cleaner is normal.)
20 – 30 V
Defective (Air cleaner is clogged.)
Max. 1 V
WA500-6
TROUBLESHOOTING
AA1ANX
Related Circuit Diagram
WA500-6
40-143 b
TROUBLESHOOTING
AB00L6
AB00L6 Alternator: Signal Disagrees with Operating State of Engine Action code
Failure code
E03
AB00L6
Trouble
Alternator: Signal does not match engine running or stopped state (Machine monitor system)
Contents of trouble
• When engine is stopped, alternator terminal R input voltage is above 12 V.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Turns charge circuit abnormality caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• After engine start operation, after the starting switch is turned ON, the service meter advances.
Related information
• The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302, ALTERNATOR R). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 1
Possible causes and standard value in normal state
Defective alternator (Internal defect)
Alternator
Engine
Voltage
Wiring harness between terminal R (E03) – chassis ground
Start (Throttle: Above 1/2)
27.5 – 29.5 V
Holds in position
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON Hot short in wiring harness 2 (Contact with 24 V circuit)
and carry out troubleshooting. Wiring harness between alternator terminal R (E03) – L52 (female) (18), – D02 (female) (3), – circuit branch
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3 Defective machine monitor
L52 Between (18) – chassis ground
40-144 b
Engine
Voltage
Start (Throttle: Above 1/2)
27.5 – 29.5 V
Holds in position
Max. 1 V
WA500-6
TROUBLESHOOTING
AB00L6
Related Circuit Diagram
WA500-6
40-145 b
TROUBLESHOOTING
AB00MA
AB00MA Alternator: Malfunction Action Code
Failure Code
E03
AB00MA
Trouble
Alternator: Malfunction (Machine monitor system)
Contents of trouble
• While the engine is running, the alternator terminal R input voltage is below 5 V.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Turns charge circuit abnormality caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Deteriorated battery, lack of charge.
Related information
• The input state (voltage) from the alternator can be checked with the monitoring function (Code: 04302, ALTERNATOR R). • Method of reproducing failure code: Start engine.
Cause 1 Deteriorated battery
Standard value in normal state/Remarks on troubleshooting The battery may be deteriorated. Check it directly.
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 2
Possible causes and standard value in normal state
Defective alternator (Internal defect)
Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
Alternator
Engine
Voltage
Wiring harness between terminal R (E03) – chassis ground
Start (Throttle: Above 1/2)
27.5 – 29.5 V
Holds in position
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between alternator terminal R (E03) – L52 (female) (18)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring 4 harness Wiring harness between alternator terminal R (Contact with ground circuit) (E03) – L52 (female) (18), – D02 (female) (3), Resistance Min. 1 M – circuit branch and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 5 Defective machine monitor
L52 Between (18) – chassis ground
40-146 b
Engine
Voltage
Start (Throttle: Above 1/2)
27.5 – 29.5 V
Holds in position
Max. 1 V
WA500-6
TROUBLESHOOTING
AB00MA
Related Circuit Diagram
WA500-6
40-147 b
TROUBLESHOOTING
B@BAZG
B@BAZG Engine: Low Engine Oil Pressure Action Code
Failure Code
E03
B@BAZG
Trouble
Low engine oil pressure (Engine controller system)
Contents of trouble
• When engine speed was below 500 rpm for 15 seconds or more, engine oil pressure became lower than operating range.
Action of controller
• Limit output for travel (limit injection rate and engine speed). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output lowers.
Related information
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37200 ENG OIL PRESS). • The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37201 ENG OIL PRESS). • Method of reproducing failure code: Start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 2
Defective oil pressure sensor (Internal defect)
POIL Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for another cause of trouble before judgment
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – POIL (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – POIL (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (13) – POIL (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) – POIL (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between ENG (female) (47) – POIL (female) (2) and chassis ground
Resistance Min. 1 M
Wiring harness between ENG (female) (13) – POIL (female) (3) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 5 Defective engine controller
ENG Between (37) and (47)
40-148 b
Voltage Power supply
4.75 – 5.25 V
WA500-6
TROUBLESHOOTING
B@BAZG
Related Circuit Diagram
WA500-6
40-149 b
TROUBLESHOOTING
B@BAZK
B@BAZK Engine Oil: Low Level Action Code
Failure Code
E01
B@BAZK
Trouble
Engine oil: Low level (Machine monitor system)
Contents of trouble
• The engine oil level OPEN sensor circuit was detected for a minimum of two seconds (when engine stopped). (However, no error is detected for five minutes after the engine stopped.) • Error detected while engine is stopped is maintained until it is reset even after engine is started.
Action of controller
• Turns the engine oil level caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• The engine oil level sensor is connected between the target pin and chassis ground of the machine monitor. • The input state (ON/OFF) from target pin – ground circuit of the machine monitor can be checked with the monitoring function (Code: 40903, D-IN-29). • Method of reproducing failure code: Turn starting switch ON.
Cause
Possible causes and standard value in normal state
Disconnection in wiring harness 1 (Disconnection or defective contact)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L54 (female) (11) – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2 Defective machine monitor
L54 (female) Wiring harness between (11) – chassis ground
40-150 b
Resistance Max. 1
Resistance Normal
Max. 1
Disconnection
Min. 1 M
WA500-6
TROUBLESHOOTING
B@BAZK
Related Circuit Diagram
WA500-6
40-151 b
TROUBLESHOOTING
B@BCNS
B@BCNS Engine: Coolant: Overheating Action Code
Failure Code
E02
B@BCNS
Trouble
Coolant: Overheating (Engine controller system)
Contents of trouble
• When engine speed was below 500 rpm for three seconds or more, coolant temperature exceeded operating range.
Action of controller
• Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output lowers.
Related information
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring function (Code: 04104 COOLANT TEMP). • The input state (voltage) from the coolant temperature sensor can be checked with the monitoring function (Code: 04105 COOLANT TEMP). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective coolant 1 temperature sensor (Internal defect)
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
without turning starting switch ON. TWTR (male)
Coolant temperature
Resistance
Between (A) and (B)
10 – 100°C (50 – 212F)
0.6 – 20 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (15) – TWTR (female) (A)
Resistance
Max. 1
Wiring harness between ENG (female) (38) – TWTR (female) (B)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective engine controller
40-152 b
ENG (female)
Coolant temperature
Resistance
Between (15) and (38)
10 – 100°C (50 – 212F
0.6 – 20 k
WA500-6
TROUBLESHOOTING
B@BCNS
Related Circuit Diagram
WA500-6
40-153 b
TROUBLESHOOTING
B@BCZK
B@BCZK Engine: Coolant: Low Level Action Code
Failure Code
E01
B@BCZK
Trouble
Coolant: Low level (Machine monitor system)
Contents of trouble
• The coolant level sensor circuit is OPEN (detected time 30 seconds).
Action of controller
• Turns the coolant level caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The coolant level is low. The engine overheats (the engine may be broken).
Related information
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function (Code: 40903, D-IN-27). • Method of reproducing failure code: Turn starting switch ON.
Cause 1 Low coolant level
Standard value in normal state/Remarks on troubleshooting The coolant level may be low. Check it directly.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective coolant level 2 sensor (Internal ground fault)
R13 (male)
Between (1) and (2)
Sub-tank
Resistance
Below low level (Abnormal)
Max. 1
Above low level (Normal)
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L54 (female) (10) – R13 (female) (1)
Resistance
Max. 1
Wiring harness between L116 (female) (6) – GND
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 4 harness (Contact with ground circuit) Wiring harness between L116 (female) (2) – Resistance Min. 1 M R13 (female) (1) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L54 (female) 5 Defective machine monitor Wiring harness between (10) – chassis ground
40-154 b
Subtank
Resistance
Below low level (Abnormal)
Min. 1 M
Above low level (Normal)
Max. 1
WA500-6
TROUBLESHOOTING
B@BCZK
Related Circuit Diagram
WA500-6
40-155 b
TROUBLESHOOTING
B@C7NS
B@C7NS Brake: Brake Oil: Overheating Action Code
Failure Code
E02
B@C7NS
Brake oil: Overheating (Machine monitor system)
Trouble
Contents of trouble
• Brake oil temperature was above 130°C (266°F) for five seconds. • When travel speed was above 35 km/h (22 mph), brake oil temperature (125°C (257°F) and higher), was detected continuously for five seconds.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Brake oil temperature caution lamp lights up • The brake may be damaged.
Related information
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30202 R BRAKE OIL). • The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30205 R BRAKE OIL). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Brake may overheat because brake was operated improperly during 1 Defective brake operation
travel.
★ Instruct the operator on how to operate the machine properly when traveling.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective rear brake oil 2 temperature sensor (Internal defect)
R17 (male)
Between (1) and (2)
Rear brake oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L55 (female)
3 Defective machine monitor
Wiring harness between (8) – chassis ground
Rear brake oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
★ Also refer to Parts and Service News AA10025A
40-156 b
WA500-6
TROUBLESHOOTING
B@C7NS
Related Circuit Diagram
WA500-6
40-157 b
TROUBLESHOOTING
b@CENS
b@CENS Torque Converter Oil: Overheating Action Code
Failure Code
E02
b@CENS
Trouble
Torque converter oil: Overheating (Machine monitor system)
Contents of trouble
• The torque converter oil temperature is above 120°C (248°F).
Action of controller
• If cause of failure disappears, system resets itself. (A temperature of 120°C (248°F) and lower was detected continuously for one second.)
Problem that appears on machine
• The torque converter oil temperature caution lamp is turned ON. If the machine is used in this state, the torque converter may be damaged.
Related information
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40100 TC OIL TEMP). • The input state (voltage) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40101 TC OIL TEMP). • Method of reproducing failure code: Turn starting switch ON.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Overheating of torque converter oil
Torque converter oil may overheat due to torque converter stall, etc. (See Troubleshooting Hydraulic and Mechanical Systems (H-mode) in this section.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective torque converter 2 oil temperature sensor (Internal defect)
T05 (male)
Between (1) and (2)
Torque converter oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (2) – chassis ground
40-158 b
Torque converter oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
b@CENS
Related Circuit Diagram
WA500-6
40-159 b
TROUBLESHOOTING
B@CENS
B@CENS Torque Converter Oil: Overheating Action Code
Failure Code
E02
B@CENS
Trouble
Torque converter oil: Overheating (Machine monitor system)
Contents of trouble
• The torque converter oil temperature is above 130°C (266°F).
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself. A temperature of 130°C (266°F) and lower was detected continuously for one second.
Problem that appears on machine
• The torque converter oil temperature caution lamp is turned ON. If the machine is used in this state, the torque converter may be broken.
Related information
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40100 TC OIL TEMP). • The input state (voltage) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40101 TC OIL TEMP). • Method of reproducing failure code: Turn starting switch ON.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Overheating of torque converter oil
Torque converter oil may overheat due to torque converter stall, etc. (See Troubleshooting Hydraulic and Mechanical Systems (H-mode) in this section.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective torque converter 2 oil temperature sensor (Internal defect)
T05 (male)
Between (1) and (2)
Torque converter oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (2) – chassis ground
40-160 b
Torque converter oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
B@CENS
Related Circuit Diagram
WA500-6
40-161 b
TROUBLESHOOTING
B@GAZK
B@GAZK Battery Electrolyte: Low Level Action Code
Failure Code
E01
B@GAZK
Trouble
Battery electrolyte: Low level (Machine monitor system)
Contents of trouble
• The electrolyte level sensor (if equipped) voltage is below 2 V (continuously for 10 seconds).
Action of controller
• Turns the electrolyte level caution lamp ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Turns the electrolyte level caution lamp ON. • The electrolyte level is low. • Engine may not start easily.
Related information
• The input state (voltage) from the electrolyte level sensor can be checked with the monitoring function (Code: 40300, BATTERY A). • Method of reproducing failure code: Turn starting switch ON.
Cause 1 The electrolyte level is low
Standard value in normal state/Remarks on troubleshooting The electrolyte level may be low. Check it directly.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective electrolyte level 2 sensor (Internal disconnection)
R18 (male) Between (1) – chassis ground
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact)
Battery electrolyte level
Voltage
Normal
Min. 2 V
Insufficient level (Low level)
Max. 2 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L55 (female) (5) – R18 (female) (1)
Resistance Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective machine monitor
L55 (female) Wiring harness between (5) – chassis ground
40-162 b
Battery electrolyte level
Voltage
Normal
Min. 2 V
Insufficient level (low level)
Max. 2 V
WA500-6
TROUBLESHOOTING
B@GAZK
Related Circuit Diagram
WA500-6
40-163 b
TROUBLESHOOTING
B@HANS
B@HANS Hydraulic Oil: Overheating Action Code
Failure Code
E02
B@HANS
Trouble
Hydraulic oil: Overheating (Machine monitor system)
Contents of trouble
• The hydraulic oil temperature is above 100°C (212°F). Detected time: 10 seconds
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The hydraulic oil overheat warning is turned ON. If the machine is used in this state, the pump and cylinder seals may be broken.
Related information
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the monitoring function (Code: 04401 HYD TEMP). • The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitoring function (Code: 04404 HYD TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause 1
Standard value in normal state/Remarks on troubleshooting
Overheating of hydraulic oil The hydraulic oil may be overheating.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective hydraulic oil 2 temperature sensor (Internal defect) Possible causes and standard value in normal state
Hydraulic oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
T03 (male)
Between (1) and (2)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L55 (female) Wiring harness between (7) – chassis ground
40-164 b
Hydraulic oil temperature
Voltage
25°C (77°F) (Normal temperature)
4.4 – 4.6 V
100°C (212°F)
2.1 – 2.3 V
WA500-6
TROUBLESHOOTING
B@HANS
Related Circuit Diagram
WA500-6
40-165 b
TROUBLESHOOTING
CA111
CA111 Abnormality in Engine Controller Action Code
Failure Code
E03
CA111
Trouble
Abnormality in engine controller (Engine controller system)
Contents of trouble
• Internal defect occurred in controller.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Operations are continued, but engine may stop during operations or may not start in stopped state.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1
Defective fuse No. 3 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt, the circuit probably has a grounding fault. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control cut relay 1 (L117) 2 (Internal disconnection or short circuit)
L117 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If engine control cut relay 1 (L117) is replaced with a relay of the same type and the condition becomes normal, engine control cut relay 1 is defective.
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control cut relay 2 (L119) 3 (Internal disconnection or short circuit)
L119 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If engine control cut relay 2 (L119) is replaced with a relay of the same type and the condition becomes normal, engine control cut relay 2 is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
40-166 b
Defective diode (D01) (Internal disconnection)
D01 (male)
Diode range
Between (1) and (2)
Measure at (1) in diode range.
Between (3) and (2)
Measure at (3) in diode range.
Continuity
Continuity
WA500-6
TROUBLESHOOTING
CA111 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection in wiring or defective contact in connector)
Wiring harness between LS4 (female) (2) – D01 (female) (1)
Resistance Max. 1
Wiring harness between D01 (female) (2) – L117 (female) (1), – L119 (female) (1)
Resistance Max. 1
Wiring harness between L117 (female) (2), – Resistance Max. 1 L119 (female) (2) – E18 (female) (33) Wiring harness between fuse No. 3 of fuse box A – L117 (female) (5), – L119 (female) (5)
Resistance Max. 1
Wiring harness between L117 (female) (3) – E19 (female) (3)
Resistance Max. 1
Wiring harness between L119 (female) (3) – E19 (female) (4)
Resistance Max. 1
Wiring harness between E19 (female) (1), (2) – chassis ground
Resistance Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON.
Ground fault in wiring harness 6 (Short circuit with GND circuit)
Wiring harness between LS4 (female) (2) – D01 (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between D01 (female) (2) – L117 (female) (1), – L119 (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between L117 (female) (2), – Resistance Min. 1 M L119 (female) (2) – E18 (female) (33) and chassis ground Wiring harness between fuse No. 3 of fuse box A – L117 (female) (5), – L119 (female) (5) and chassis ground
Resistance Min. 1 M
Wiring harness between L117 (female) (3) – E19 (female) (3) and chassis ground
Resistance Min. 1 M
Wiring harness between L119 (female) (3) – E19 (female) (4) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7 Defective engine controller
WA500-6
E19
Voltage
Between (1), (2) – (3), (4)
20 – 30 V
40-167 b
TROUBLESHOOTING
CA111
Related Circuit Diagram
40-168 b
WA500-6
TROUBLESHOOTING
CA115
CA115 Engine Ne or Bkup Speed Sensor Error Action Code
Failure Code
E03
CA115
Trouble
Engine Ne or Bkup speed sensor error (Engine controller system)
Contents of trouble
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
Action of controller
• Stops the engine. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• The engine does not start (if engine has been stopped). • Engine stops (if engine has been running).
Related information
• Method of reproducing failure code: Start engine.
Cause
Possible causes and standard value in normal state
1
Defective Ne speed sensor system
Carry out troubleshooting for failure code [CA689].
2
Defective Bkup speed sensor system
Carry out troubleshooting for failure code [CA778].
3
Defective installation of Ne speed sensor
Ne speed sensor may be installed incorrectly. Check it directly. (Defective installation of sensor itself, internal defect of flywheel, etc.)
4
Defective installation of Bkup speed sensor
Bkup speed sensor may be installed incorrectly. Check it directly. (Defective installation of sensor itself, internal defect of supply pump, etc.)
5
Defective sensor connection (Improper connection)
Ne and Bkup speed sensors may be connected incorrectly (improper connection). Check them directly.
6 Defective engine controller
WA500-6
Standard value in normal state/Remarks on troubleshooting
If causes 1 – 5 are not the cause of the problem, the engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
40-169 b
TROUBLESHOOTING
CA122
CA122 Charge Pressure Sensor High Error Action Code
Failure Code
E03
CA122
Trouble
Charge pressure sensor high error (Engine controller system)
Contents of trouble
• Charge pressure sensor (boost pressure sensor) circuit is abnormally high.
Action of controller
• Sets charge pressure (boost pressure) to fixed value (4.1 kg/cm² [58 psi]), and continues operation. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine does not accelerate smoothly.
Related information
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36500 CHG PRESS-A). • The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36502 CHG PRESS-A). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective power supply system of charge pressure 1 sensor (boost pressure sensor)
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective charge pressure sensor (boost pressure 2 sensor) (Internal defect)
Possible causes and standard value in normal state
PIM Between (1) and (3)
Voltage Power supply
4.75 – 5.25 V
Charge pressure sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – PIM (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – PIM (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (44) – PIM (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-170 b
Wiring harness between ENG (female) (37) – PIM (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – PIM (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (44) – PIM (female) (3) and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA122 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – PIM (female) (1) and between ENG (female) (47) – PIM (female) (2)
Possible causes and standard value in normal state
Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (37) – harness) PIM (female) (1) and between ENG (female) (44) – PIM (female) (3) Wiring harness between ENG (female) (47) – PIM (female) (2) and between ENG (female) (44) – PIM (female) (3)
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG Between (37) and (47)
Voltage Power supply
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-171 b
TROUBLESHOOTING
CA123
CA123 Charge Pressure Sensor Low Error Action Code
Failure Code
E03
CA123
Trouble
Charge pressure sensor low error (Engine controller system)
Contents of trouble
• Charge pressure sensor (boost pressure sensor) circuit is abnormally low.
Action of controller
• Sets charge pressure (boost pressure) to fixed value (4.1 kg/cm² [58 psi]) and continues operation. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine does not accelerate smoothly.
Related information
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36500 CHG PRESS-A). • The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with the monitoring function (Code: 36502 CHG PRESS-A). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-172 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA122].
WA500-6
TROUBLESHOOTING
CA123
MEMORANDUM
WA500-6
40-173 b
TROUBLESHOOTING
CA131
CA131 Throttle Sensor High Error Action Code
Failure Code
E03
CA131
Trouble
Throttle sensor high error (Engine controller system)
Contents of trouble
• Throttle sensor circuit is abnormally high.
Action of controller
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• The engine does not reach full throttle.
Related information
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the monitoring function (Code: 31701 THROTTLE POS). • The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code: 31707 THROTTLE POS). • Method of reproducing failure code: Turn starting switch ON.
Cause 1
Defective throttle sensor power supply system
Standard value in normal state/Remarks on troubleshooting If failure code [CA2185] or [CA2186] is also indicated, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective accelerator pedal 2 (Internal defect)
L15
Accelerator pedal
Voltage
Between (1) and (3)
All range (Power supply)
4.75 – 5.25 V
When released
(13 ±2% of power supply)
When pressed
(77 ±2% of power supply)
Between (2) and (3)
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision. Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between E18 (female) (22) – L15 (female) (1)
Resistance
Max. 1
Wiring harness between E18 (female) (9) – L15 (female) (2)
Resistance
Max. 1
Wiring harness between E18 (female) (23) – L15 (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between E18 (female) (22) – Grounding fault in wiring L15 (female) (1) and chassis ground 4 harness (Contact with ground circuit) Wiring harness between E18 (female) (9) – L15 (female) (2) and chassis ground Wiring harness between E18 (female) (23) – L15 (female) (3) and chassis ground
40-174 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA131 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
E18
Accelerator pedal
Voltage
Between (22) and (23)
All range (Power supply)
4.75 – 5.25 V
When released
(13 ±2% of power supply)
When pressed
(77 ±2% of power supply)
Between (9) and (23)
Related Circuit Diagram
WA500-6
40-175 b
TROUBLESHOOTING
CA132
CA132 Throttle Sensor Low Error Action Code
Failure Code
E03
CA132
Trouble
Throttle sensor low error (Engine controller system)
Contents of trouble
• Throttle sensor circuit is abnormally low.
Action of controller
• Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• The engine does not reach full throttle.
Related information
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the monitoring function (Code: 31707 THROTTLE POS). • The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code: 31701 THROTTLE POS). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-176 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA131].
WA500-6
TROUBLESHOOTING
CA132
Related Circuit Diagram
WA500-6
40-177 b
TROUBLESHOOTING
CA135
CA135 Engine Oil Pressure Sensor High Error Action Code
Failure Code
E01
CA135
Trouble
Engine oil pressure sensor high error (Engine controller system)
Contents of trouble
• Engine oil pressure sensor circuit is abnormally high.
Action of controller
• Sets engine oil pressure to default (2.5 kg/cm² {36 psi}), and continues operation.
Problem that appears on machine
—
Related information
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37200 ENG OIL PRESS). • The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37201 ENG OIL PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective power supply If failure code [CA187] or [CA227] is also indicated, carry out 1 system of engine oil pressure troubleshooting for it first. sensor
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective engine oil pressure 2 sensor (Internal defect)
POIL Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – POIL (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – POIL (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (13) – POIL (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-178 b
Wiring harness between ENG (female) (37) – POIL (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – POIL (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (13) – POIL (female) (3) and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA135 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – POIL (female) (1) and between ENG (female) (47) – POIL (female) (2)
Possible causes and standard value in normal state
Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (37) harness) – POIL (female) (1) and between ENG (female) (13) – POIL (female) (3) Wiring harness between ENG (female) (47) – POIL (female) (2) and between ENG (female) (13) – POIL (female) (3)
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG Between (37) and (47)
Voltage Power supply
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-179 b
TROUBLESHOOTING
CA141
CA141 Engine Oil Pressure Sensor Low Error Action Code
Failure Code
E01
CA141
Trouble
Engine oil pressure sensor low error (Engine controller system)
Contents of trouble
• Engine oil pressure sensor circuit is abnormally low.
Action of controller
• Sets engine oil pressure to default (2.5 kg/cm² {36 psi}), and continues operation.
Problem that appears on machine
—
Related information
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37200 ENG OIL PRESS). • The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring function (Code: 37201 ENG OIL PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-180 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA135].
WA500-6
TROUBLESHOOTING
CA141
MEMORANDUM
WA500-6
40-181 b
TROUBLESHOOTING
CA144
CA144 Coolant Temperature Sensor High Error Action Code
Failure Code
E01
CA144
Trouble
Coolant temperature sensor high error (Engine controller system)
Contents of trouble
• Coolant temperature sensor circuit is abnormally high.
Action of controller
• Sets coolant temperature to fixed value (90°C [194°F]) and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring function (Code: 04104 COOLANT TEMP). • The input state (voltage) from the coolant temperature sensor can be checked with the monitoring function (Code: 04105 COOLANT TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without Defective coolant 1 temperature sensor (Internal defect)
Possible causes and standard value in normal state
turning starting switch ON. TWTR (male)
Coolant temperature
Resistance
Between (A) and (B)
10 – 100°C (50 – 212°F)
0.6 – 20 k
★ Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between ENG (female) (15) – 2 (Disconnection in wiring or Resistance Max. 1 TWTR (female) (A) defective contact in Wiring harness between ENG (female) (38) – connector) Resistance Max. 1 TWTR (female) (B) Ground fault in wiring harness 3 (Short circuit with GND circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (15) – TWTR (female) (A) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine 4 controller
40-182 b
ENG (female)
Coolant temperature
Resistance
Between (15) and (38)
10 – 100°C (50 – 212°F)
0.6 – 20 k
WA500-6
TROUBLESHOOTING
CA144
Related Circuit Diagram
WA500-6
40-183 b
TROUBLESHOOTING
CA145
CA145 Coolant Temperature Sensor Low Error Action Code
Failure Code
E01
CA145
Trouble
Coolant temperature sensor low error (Engine controller system)
Contents of trouble
• Coolant temperature sensor circuit is abnormally low.
Action of controller
• Sets coolant temperature to fixed value (90°C [194°F]) and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the coolant temperature sensor can be checked with the monitoring function (Code: 04104 COOLANT TEMP). • The input state (voltage) from the coolant temperature sensor can be checked with the monitoring function (Code: 04105 COOLANT TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-184 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA144].
WA500-6
TROUBLESHOOTING
CA145
MEMORANDUM
WA500-6
40-185 b
TROUBLESHOOTING
CA153
CA153 Charge Temperature Sensor High Error Action Code
Failure Code
E01
CA153
Trouble
Charge temperature sensor high error (Engine controller system)
Contents of trouble
• Charge temperature sensor (boost temperature sensor) circuit is abnormally high.
Action of controller
• Sets charge temperature (boost temperature) to fixed value (70°C [158°F]) and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: 18500 CHG TEMP). • The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: 18501 CHG TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective charge temperature sensor (boost 1 temperature sensor) (Internal defect)
Possible causes and standard value in normal state
TIM (male)
Charge temperature (Boost temperature)
Resistance
Between (A) and (B)
10 – 100°C (50 – 212°F)
0.5 – 20 k
Between (A) and chassis ground
In all range
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness Wiring harness between ENG (female) (23) – 2 (Disconnection in wiring or Resistance Max. 1 TIM (female) (A) defective contact in Wiring harness between ENG (female) (47) – connector) Resistance Max. 1 TIM (female) (B) Ground fault in wiring harness 3 (Short circuit with GND circuit)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (23) – TIM (female) (A) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
40-186 b
ENG (female)
Charge temperature (Boost temperature)
Resistance
Between (23) and (47)
10 – 100°C (50 – 212°F)
0.5 – 20 k
WA500-6
TROUBLESHOOTING
CA153
Related Circuit Diagram
WA500-6
40-187 b
TROUBLESHOOTING
CA154
CA154 Charge Temperature Sensor Low Error Action Code
Failure Code
E01
CA154
Trouble
Charge temperature sensor low error (Engine controller system)
Contents of trouble
• Charge temperature sensor (boost temperature sensor) circuit is abnormally low.
Action of controller
• Sets charge temperature (boost temperature) to fixed value (70°C [158°F]) and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: 18500 CHG TEMP). • The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be checked with the monitoring function (Code: 18501 CHG TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-188 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA153].
WA500-6
TROUBLESHOOTING
CA187
CA187 Sensor Power Supply 2 Low Error
Action Code
Failure Code
E03
CA187
Trouble
Sensor power supply 2 voltage low error (Engine controller system)
Contents of trouble
• Sensor power supply 2 (5 V) circuit is abnormally low.
Action of controller
• Bkup speed sensor operates with signal from Ne speed sensor. • Engine oil pressure sensor sets engine oil pressure to default (2.5 kg/cm² {36 psi}) and continues operation. • Atmospheric pressure sensor sets atmospheric pressure to default (0.53 kg/cm² {8 psi}) and continues operation. • Charge pressure sensor sets charge pressure to fixed value (4.1 kg/cm² {58 psi}) and continues operation. • EGR inlet pressure sensor sets EGR inlet pressure to default (1.04 kg/cm² {14 psi}) and limits output to continue operation. • EGR valve lift sensor limits output and closes EGR and bypass valves. • Bypass valve lift sensor limits output and closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA227].
40-189 b
TROUBLESHOOTING
CA221
CA221 Atmospheric Pressure Sensor High Error Action Code
Failure Code
E01
CA221
Trouble
Atmospheric pressure sensor high error (Engine controller system)
Contents of trouble
• Atmospheric pressure sensor circuit is abnormally high.
Action of controller
• Sets atmospheric pressure to default (0.53 kg/cm² {8 psi}) and continues operation.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the monitoring function (Code: 37400 AMBIENT PRESS). • The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring function (Code: 37402 AMBIENT PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause Defective power supply 1 system of atmospheric pressure sensor
Standard value in normal state/Remarks on troubleshooting If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. PAMB Defective atmospheric 2 pressure sensor (Internal defect)
Voltage
Between (1) and (3)
Power supply
4.75 – 5.25 V
Between (2) and (3)
Signal
0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision. Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – PAMB (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (38) – PAMB (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (3) – PAMB (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-190 b
Wiring harness between ENG (female) (37) – PAMB (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (38) – PAMB (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (3) – PAMB (female) (3) and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA221 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – PAMB (female) (1) and between ENG (female) (38) – PAMB (female) (2)
Possible causes and standard value in normal state
Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (37) – harness) PAMB (female) (1) and between ENG (female) (3) – PAMB (female) (3) Wiring harness between ENG (female) (38) – PAMB (female) (2) and between ENG (female) (3) – PAMB (female) (3)
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (38)
4.75 – 5.25 V
Between (3) and (38)
0.3 – 4.7 V
Related Circuit Diagram
WA500-6
40-191 b
TROUBLESHOOTING
CA222
CA222 Atmospheric Pressure Sensor Low Error Action Code
Failure Code
E01
CA222
Trouble
Atmospheric pressure sensor low error (Engine controller system)
Contents of trouble
• Atmospheric pressure sensor circuit is abnormally low.
Action of controller
• Sets atmospheric pressure to default (0.53 kg/cm² {8 psi}), and continues operation.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with the monitoring function (Code: 37400 AMBIENT PRESS). • The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring function (Code: 37402 AMBIENT PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-192 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA221].
WA500-6
TROUBLESHOOTING
CA222
MEMORANDUM
WA500-6
40-193 b
TROUBLESHOOTING
CA227
CA227 Sensor Power Supply 2 High Error Action Code
Failure Code
E03
CA227
Trouble
Sensor power supply 2 high error (Engine controller system)
Contents of trouble
• Sensor power supply 2 (5 V) circuit is abnormally high.
Action of controller
• Bkup speed sensor operates with signal from Ne speed sensor. • Engine oil pressure sensor sets engine oil pressure to default (2.5 kg/cm² {36 psi}) and continues operation. • Atmospheric pressure sensor sets atmospheric pressure to default (0.53 kg/cm² {8 psi}) and continues operation. • Charge pressure sensor (boost pressure sensor) sets charge pressure to fixed value (4.1 kg/cm² {58 psi}) and continues operation. • EGR inlet pressure sensor sets EGR inlet pressure to default (1.04 kg/cm² {15 psi}) and limits output to continue operation. • EGR and bypass valve lift sensors limit output and close EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defect in related system
Standard value in normal state/Remarks on troubleshooting If another code is displayed, carry out troubleshooting for it.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Defective sensor (Internal defect)
Possible causes and standard value in normal state Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Disconnect device suggested on the right. At this time, if failure code is not indicated, the device is defective.
Bkup speed sensor system
G connector
Oil pressure sensor
POIL connector
Charge pressure sensor
PIM connector
Atmospheric pressure sensor
PAMB connector
EGR inlet pressure sensor
PEVA connector
EGR valve lift sensor
SEGR connector
Bypass valve position sensor
SBP connector
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – each sensor (female)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – each sensor (female)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-194 b
without turning starting switch ON. Wiring harness between ENG (female) (37) – each sensor (female) and chassis ground
Resistance Min. 1 M
Wiring harness between ENG (female) (47) – each sensor (female) and chassis ground
Resistance Min. 1 M
WA500-6
TROUBLESHOOTING
CA227 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON. Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (37) – harness) each sensor (female) and between ENG (female) (47) – each sensor (female)
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (47)
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-195 b
TROUBLESHOOTING
CA234
CA234 Engine Overspeed Action Code
Failure Code
E02
CA234
Trouble
Engine overspeed (Engine controller system)
Contents of trouble
• Engine speed exceeded operating range.
Action of controller
• Reduces fuel injection rate until engine speed lowers to operating range. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine speed changes.
Related information
• Engine speed can be checked by monitoring function (Code: 01002 ENG SPEED). • Method of reproducing failure code: Start engine and keep running at high idle.
Cause Possible causes and standard value in normal state
40-196 b
Standard value in normal state/Remarks on troubleshooting
1 Defect in related system
If another code is displayed, carry out troubleshooting for it.
2 Usage is improper.
Improper use of the machine. Instruct the operator on how to use the machine properly.
3 Defective engine controller
If causes 1 and 2 are not the cause of the problem, the engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
WA500-6
TROUBLESHOOTING
CA234
MEMORANDUM
WA500-6
40-197 b
TROUBLESHOOTING
CA238
CA238 Ne Speed Sensor Power Supply Error Action Code
Failure Code
E03
CA238
Trouble
Ne speed sensor power supply error (Engine controller system)
Contents of trouble
• Error occurred in Ne speed sensor power supply (5 V) circuit.
Action of controller
• Controls with signal from Bkup speed sensor. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine stops during operations (when engine Bkup speed sensor is also defective). • Engine cannot be started during operations (when engine Bkup speed sensor is also defective).
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective Ne speed sensor (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
Disconnect device suggested on the right. At this time, if failure code is not indicated, the device is defective.
Ne speed sensor
NE connector
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENGINE (female) (16) – NE (female) (1)
Resistance Max. 1
Wiring harness between ENGINE (female) (48) – NE (female) (2)
Resistance Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
without turning starting switch ON. Wiring harness between ENG (female) (16) – NE (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between ENG (female) (48) – NE (female) (2) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring 4 harness (with another wiring Wiring harness between ENG (female) (16) – harness) NE (female) (1) and between ENG (female) (48) Resistance Min. 1 M – NE (female) (2) ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
40-198 b
ENG
Voltage
Between (16) and (48)
4.75 – 5.25 V
WA500-6
TROUBLESHOOTING
CA238
Related Circuit Diagram
WA500-6
40-199 b
TROUBLESHOOTING
CA263
CA263 Fuel Temperature Sensor High Error Action Code
Failure Code
E01
CA263
Trouble
Fuel temperature sensor high error (Engine controller system)
Contents of trouble
• Fuel temperature sensor circuit is abnormally high.
Action of controller
• Sets fuel temperature to fixed value (95°C [203°F]), and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring function (Code: 04204 FUEL TEMP). • The input state (voltage) from the fuel temperature sensor can be checked with the monitoring function (Code: 14201 FUEL TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fuel temperature 1 sensor (Internal defect)
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
TFUEL (male)
Fuel temperature
Resistance
Between (A) and (B)
10 – 100°C (50 – 212°F)
0.6 – 20 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (30) – TFUEL (female) (A)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – TFUEL (female) (B)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
without turning starting switch ON. Wiring harness between ENG (female) (30) – TFUEL (female) (A) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller
40-200 b
ENG (female)
Fuel temperature
Resistance
Between (30) and (47)
10 – 100°C (50 – 212°F)
0.6 – 20 k
WA500-6
TROUBLESHOOTING
CA263
Related Circuit Diagram
WA500-6
40-201 b
TROUBLESHOOTING
CA265
CA265 Fuel Temperature Sensor Low Error Action Code
Failure Code
E01
CA265
Trouble
Fuel temperature sensor low error (Engine controller system)
Contents of trouble
• Fuel temperature sensor circuit is abnormally low.
Action of controller
• Sets fuel temperature to fixed value (95°C [203°F]) and continues operation.
Problem that appears on machine
—
Related information
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring function (Code: 04204 FUEL TEMP). • The input state (voltage) from the fuel temperature sensor can be checked with the monitoring function (Code: 14201 FUEL TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-202 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA263].
WA500-6
TROUBLESHOOTING
CA265
MEMORANDUM
WA500-6
40-203 b
TROUBLESHOOTING
CA271
CA271 PCV1 Short Circuit Action Code
Failure Code
E03
CA271
Trouble
PCV1 short circuit (Engine controller system)
Contents of trouble
• Short circuit was detected in supply pump PCV1 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump 1 PCV1 (Internal short circuit)
PCV1 (male)
Resistance
Between (1) and (2)
2.3 – 5.3
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON. Grounding fault in wiring Wiring harness between ENG (female) (4) – 2 harness PCV1 (female) (1) and chassis ground (Contact with ground circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting 3
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between ENG (female) (4) – PCV1 (female) (1) and chassis ground
Voltage
Max. 1 V
Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
40-204 b
ENG (female)
Resistance
Between (4) and (5)
2.3 – 5.3
Between (4), (5) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA271
Related Circuit Diagram
WA500-6
40-205 b
TROUBLESHOOTING
CA272
CA272 PCV1 Disconnection Action Code
Failure Code
E03
CA272
Trouble
PCV1 disconnection (Engine controller system)
Contents of trouble
• Disconnection was detected in supply pump PCV1 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump 1 PCV1 (Internal disconnection)
PCV1 (male)
Resistance
Between (1) and (2)
2.3 – 5.3
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between ENG (female) (4) – PCV1 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (5) – PCV1 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between ENG (female) (4) – 3 harness PCV1 (female) (1) and chassis ground (Contact with ground circuit) Wiring harness between ENG (female) (5) – PCV1 (female) (2) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
40-206 b
ENG (female)
Resistance
Between (4) and (5)
2.3 – 5.3
Between (4), (5) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA272
Related Circuit Diagram
WA500-6
40-207 b
TROUBLESHOOTING
CA273
CA273 PCV2 Short Circuit Action Code
Failure Code
E03
CA273
Trouble
PCV2 short circuit (Engine controller system)
Contents of trouble
• Short circuit was detected in supply pump PCV2 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective supply pump 1 PCV2 (Internal short circuit)
PCV2 (male)
Resistance
Between (1) and (2)
2.3 – 5.3
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON. Grounding fault in wiring Wiring harness between ENG (female) (9) – 2 harness PCV2 (female) (1) and chassis ground (Contact with ground circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting 3
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between ENG (female) (9) – PCV2 (female) (1) and chassis ground
Voltage
Max. 1 V
Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
40-208 b
ENG (female)
Resistance
Between (9) and (10)
2.3 – 5.3
Between (9), (10) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA273
Related Circuit Diagram
WA500-6
40-209 b
TROUBLESHOOTING
CA274
CA274 PCV2 Disconnection Action Code
Failure Code
E03
CA274
Trouble
PCV2 disconnection (Engine controller system)
Contents of trouble
• Disconnection was detected in supply pump PCV2 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn the starting switch ON.
Cause Defective supply pump 1 PCV2 (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PCV2 (male)
Resistance
Between (1) and (2)
2.3 – 5.3
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 2 (Disconnection or defective contact of connector) Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between ENG (female) (9) – PCV2 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (10) – PCV2 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between ENG (female) (9) 3 harness – PCV2 (female) (1) and chassis ground (Contact with ground circuit) Wiring harness between ENG (female) (10) – PCV2 (female) (2) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4 Defective engine controller
40-210 b
ENG (female)
Resistance
Between (9) and (10)
2.3 – 5.3
Between (9), (10) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA274
Related Circuit Diagram
WA500-6
40-211 b
TROUBLESHOOTING
CA322
CA322 Injector #1 (L/B #1) Open/Short Error Action Code
Failure Code
E03
CA322
Trouble
Injector #1 (L/B #1) open/short error (Engine controller system)
Contents of trouble
• Disconnection or short circuit was detected in injector #1 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not stabilize.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #1 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN1 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (45) – CN1 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (53) – CN1 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (45) – CN1 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (53) – CN1 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #2 or #3.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-212 b
ENG (female)
Resistance
Between (45) and (53)
0.4 – 1.1
Between (45), (53) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA322
Related Circuit Diagram
WA500-6
40-213 b
TROUBLESHOOTING
CA323
CA323 Injector #5 (L/B #5) Open/Short Error Action Code
Failure Code
E03
CA323
Trouble
Injector #5 (L/B #5) open/short error (Engine controller system)
Contents of trouble
• Disconnection or short circuit was detected in injector #5 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not stabilize.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #5 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN5 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (46) – CN5 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (60) – CN5 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (46) – CN5 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (60) – CN5 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #4 or #6.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-214 b
ENG (female)
Resistance
Between (46) and (60)
0.4 – 1.1
Between (46), (60) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA323
Related Circuit Diagram
WA500-6
40-215 b
TROUBLESHOOTING
CA324
CA324 Injector #3 (L/B #3) Open/Short Error Action Code
Failure Code
E03
CA324
Injector #3 (L/B #3) open/short error (Engine controller system)
Trouble
Contents of trouble
• Disconnection or short circuit was detected in injector #3 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not become stable.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #3 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN3 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (55) – CN3 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (52) – CN3 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (55) – CN3 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (52) – CN3 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #1 or #2.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-216 b
ENG (female)
Resistance
Between (55) and (52)
0.4 – 1.1
Between (55), (52) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA324
Related Circuit Diagram
WA500-6
40-217 b
TROUBLESHOOTING
CA325
CA325 Injector #6 (L/B #6) Open/Short Error Action Code
Failure Code
E03
CA325
Injector #6 (L/B #6) open/short error (Engine controller system)
Trouble
Contents of trouble
• Disconnection or short circuit was detected in injector #6 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not become stable.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #6 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN6 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (57) – CN6 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (59) – CN6 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (57) – CN6 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (59) – CN6 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #4 or #5.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-218 b
ENG (female)
Resistance
Between (57) and (59)
0.4 – 1.1
Between (57), (59) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA325
Related Circuit Diagram
WA500-6
40-219 b
TROUBLESHOOTING
CA331
CA331 Injector #2 (L/B #2) Open/Short Error Action Code
Failure Code
E03
CA331
Injector #2 (L/B #2) open/short error (Engine controller system)
Trouble
Contents of trouble
• Disconnection or short circuit was detected in injector #2 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not become stable.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #2 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN2 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (54) – CN2 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (51) – CN2 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (54) – CN2 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (51) – CN2 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #1 or #3.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-220 b
ENG (female)
Resistance
Between (54) and (51)
0.4 – 1.1
Between (54), (51) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA331
Related Circuit Diagram
WA500-6
40-221 b
TROUBLESHOOTING
CA332
CA332 Injector #4 (L/B #4) Open/Short Error Action Code
Failure Code
E03
CA332
Injector #4 (L/B #4) open/short error (Engine controller system)
Trouble
Contents of trouble
• Disconnection or short circuit was detected in injector #4 circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops. • Speed does not become stable.
Related information
• Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Defective injector #4 (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
CN4 (male)
Resistance
Between (1) and (2)
0.4 – 1.1
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (56) – CN4 (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (58) – CN4 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 3 (Short circuit with GND circuit)
4
Defective injector or wiring harness of another cylinder
without turning starting switch ON. Wiring harness between ENG (female) (56) – CN4 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (58) – CN4 (female) (2) and chassis ground
Resistance
Min. 1 M
• If a failure code of problems in multiple injectors is displayed, carry out troubleshooting for it. • Carry out troubleshooting for a short circuit in circuit #5 or #6.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-222 b
ENG (female)
Resistance
Between (56) and (58)
0.4 – 1.1
Between (56), (58) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
CA332
Related Circuit Diagram
WA500-6
40-223 b
TROUBLESHOOTING
CA342
CA342 Calibration Code Data Inconsistency Action Code
Failure Code
E03
CA342
Trouble
Engine controller data inconsistency (Engine controller system)
Contents of trouble
• Data inconsistency occurred in engine controller.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped state.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-224 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA111].
WA500-6
TROUBLESHOOTING
CA351
CA351 Injectors Drive Circuit Error Action Code
Failure Code
E03
CA351
Trouble
Injector drive circuit error (Engine controller system)
Contents of trouble
• Error was detected in injector drive circuit.
Action of controller
• Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Start engine.
Cause 1
Defective fuse No. 3 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt, the circuit probably has a grounding fault. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control cut relay 1 (L117) 2 (Internal disconnection or short circuit)
L117 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If engine control cut relay 1 (L117) is replaced with a relay of the same type and the condition becomes normal, engine control cut relay 1 is defective.
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective engine control cut relay 2 (L119) 3 (Internal disconnection or short circuit)
L119 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If engine control cut relay 2 (L119) is replaced with a relay of the same type and the condition becomes normal, engine control cut relay 2 is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
WA500-6
Defective diode (D01) (Internal disconnection)
D01 (male)
Diode range
Between (1) and (2)
Measure at (1) in diode range.
Between (3) and (2)
Measure at (3) in diode range.
Continuity
Continue
40-225 b
TROUBLESHOOTING
CA351 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection in wiring or defective contact in connector)
Wiring harness between LS4 (female) (2) – D01 (female) (1)
Resistance
Max. 1
Wiring harness between D01 (female) (2) – L117 (female) (1), – L119 (female) (1)
Resistance
Max. 1
Wiring harness between L117 (female) (2), – L119 (female) (2) – E18 (female) (33)
Resistance
Max. 1
Wiring harness between fuse No. 3 of fuse box A – L117 (female) (5), – L119 (female) (5)
Resistance
Max. 1
Wiring harness between L117 (female) (3) – E19 (female) (3)
Resistance
Max. 1
Wiring harness between L119 (female) (3) – E19 (female) (4)
Resistance
Max. 1
Wiring harness between E19 (female) (1), (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON.
Ground fault in wiring harness 6 (Short circuit with GND circuit)
Wiring harness between LS4 (female) (2) – D01 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between D01 (female) (2) – L117 (female) (1), – L119 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between L117 (female) (2), – L119 (female) (2) – E18 (female) (33) and chassis ground
Resistance
Min. 1 M
Wiring harness between fuse No. 3 of fuse box A – L117 (female) (5), – L119 (female) (5) and chassis ground
Resistance
Min. 1 M
Wiring harness between L117 (female) (3) – E19 (female) (3) and chassis ground
Resistance
Min. 1 M
Wiring harness between L119 (female) (3) – E19 (female) (4) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7 Defective engine controller
40-226 b
E19
Voltage
Between (1), (2) – (3), (4)
20 – 30 V
WA500-6
TROUBLESHOOTING
CA351
Related Circuit Diagram
WA500-6
40-227 b
TROUBLESHOOTING
CA352
CA352 Sensor Power Supply 1 Low Error Action Code
Failure Code
E03
CA352
Trouble
Sensor power supply 1 low error (Engine controller system)
Contents of trouble
• Sensor power supply 1 (5 V) circuit is abnormally low.
Action of controller
• Common rail pressure sensor: Limits output for travel (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-228 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA386].
WA500-6
TROUBLESHOOTING
CA352
MEMORANDUM
WA500-6
40-229 b
TROUBLESHOOTING
CA386
CA386 Sensor Power Supply 1 High Error Action Code
Failure Code
E03
CA386
Trouble
Sensor power supply 1 high error (Engine controller system)
Contents of trouble
• Sensor power supply 1 (5 V) circuit is abnormally high.
Action of controller
• Common rail pressure sensor: Limits output for travel (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defect in related system
Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, carry out troubleshooting for it.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Defective sensor (Internal defect)
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
Disconnect device suggested on the right. At this time, if failure code is not indicated, the device is defective.
Common rail pressure sensor
PFUEL
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance Max. 1
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Ground fault in wiring harness 4 (Short circuit with GND circuit)
without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between ENG (female) (47) – PFUEL (female) (3) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (33) – harness) Resistance Min. 1 M PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3) ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 6 Defective engine controller
40-230 b
ENG
Voltage
Between (33) and (47)
4.75 – 5.25 V
WA500-6
TROUBLESHOOTING
CA386
Related Circuit Diagram
WA500-6
40-231 b
TROUBLESHOOTING
CA431
CA431 Idle Validation Switch Error Action Code
Failure Code
E01
CA431
Trouble
Idle validation switch error (Engine controller system)
Contents of trouble
• Error was detected in idle validation switch circuit.
Action of controller
• Operates at position of throttle of throttle sensor.
Problem that appears on machine
Related information
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function (Code: 18300 IVS 1). • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function (Code: 18301 IVS 2). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
1
Defective accelerator pedal (Internal defect)
L15
Signal name
Voltage
Between (5) and (4)
Signal 1
Between (6) and (4)
Signal 2
See Figure 1 on next page.
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between E18 (female) (32) – L15 (female) (4)
Resistance
Max. 1
Wiring harness between E18 (female) (11) – L15 (female) (5)
Resistance
Max. 1
Wiring harness between E18 (female) (1) – L15 (female) (6)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 3 (Short circuit with GND circuit)
Wiring harness between E18 (female) (32) – L15 (female) (4) and chassis ground
Resistance
Min. 1 M
Wiring harness between E18 (female) (11) – L15 (female) (5) and chassis ground
Resistance
Min. 1 M
Wiring harness between E18 (female) (1) – L15 (female) (6) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
4
Wiring harness between E18 (female) (32) – Hot short in wiring harness L15 (female) (4) and chassis ground (Contact with 24 V circuit) Wiring harness between E18 (female) (11) – L15 (female) (5) and chassis ground Wiring harness between E18 (female) (1) – L15 (female) (6) and chassis ground
40-232 b
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
CA431 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. 5 Defective engine controller
E18
Signal name
Voltage
Between (11) and (32)
Signal 1
Between (1) and (32)
Signal 2
See Figure 1 on this page.
Related Circuit Diagram
WA500-6
40-233 b
TROUBLESHOOTING
CA432
CA432 Idle Validation Action Error Action Code
Failure Code
E03
CA432
Trouble
Idle validation action error (Engine controller system)
Contents of trouble
• Signals disagree between idle validation switch and throttle sensor (inconsistent).
Action of controller
• Idle validation switch with accelerator pedal OFF, throttle sensor with accelerator pedal ON: Control the position of throttle to 0% when accelerator pedal is OFF and to 50% when it is ON. • 2) Idle validation switch with accelerator pedal ON, throttle sensor with accelerator pedal OFF: Control the position of throttle to 0% (fix to low idle). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
—
Related information
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function (Code: 18300 IVS 1). • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring function (Code: 18301 IVS 2). • Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-234 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA431].
WA500-6
TROUBLESHOOTING
CA441
CA441 Battery Voltage Low Error Action Code
Failure Code
E03
CA441
Trouble
Battery voltage low error (Engine controller system)
Contents of trouble
• Low voltage was detected in battery voltage circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped state.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA111].
40-235 b
TROUBLESHOOTING
CA442
CA442 Battery Voltage High Error Action Code
Failure Code
E03
CA442
Trouble
Battery voltage high error (Engine controller system)
Contents of trouble
• High voltage was detected in battery voltage circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Normal operation is continued; however, the machine may stop during travel or may not start in stopped state.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-236 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA111].
WA500-6
TROUBLESHOOTING
CA449
CA449 Common Rail Pressure High Error 2 Action Code
Failure Code
E03
CA449
Trouble
Common rail pressure high error 2 (Engine controller system)
Contents of trouble
• There is high pressure error (level 2) in common rail pressure sensor circuit.
Action of controller
• Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Start engine.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA553].
40-237 b
TROUBLESHOOTING
CA451
CA451 Common Rail Pressure Sensor High Error Action Code
Failure Code
E03
CA451
Trouble
Common rail pressure sensor high error (Engine controller system)
Contents of trouble
• Common rail pressure sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause Defective common rail 1 pressure sensor power system
Standard value in normal state/Remarks on troubleshooting If failure code [CA352] or [CA386] is also indicated, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. PFUEL Defective common rail 2 pressure sensor (Internal defect)
Voltage
Between (1) and (3)
Power supply
4.75 – 5.25 V
Between (2) and (3)
Signal
0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision. Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (33) – PFUEL (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (25) – PFUEL (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – PFUEL (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with GND circuit)
40-238 b
Wiring harness between ENG (female) (33) – PFUEL (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (25) – PFUEL (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – PFUEL (female) (3) and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA451 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (33) – PFUEL (female) (1) and between ENG (female) (25) – PFUEL (female) (2)
Possible causes and standard value in normal state
Short circuit in wiring 5 harness (with another wiring Wiring harness between ENG (female) (33) – harness) PFUEL (female) (1) and between ENG (female) (47) – PFUEL (female) (3) Wiring harness between ENG (female) (25) – PFUEL (female) (2) and between ENG (female) (47) – PFUEL (female) (3)
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (33) and (47)
4.75 – 5.25 V
Between (25) and (47)
0.25 – 4.6 V
Related Circuit Diagram
WA500-6
40-239 b
TROUBLESHOOTING
CA452
CA452 Common Rail Pressure Sensor Low Error Action Code
Failure Code
E03
CA452
Trouble
Common rail pressure sensor low error (Engine controller system)
Contents of trouble
• Common rail pressure sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-240 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA451].
WA500-6
TROUBLESHOOTING
CA553
CA553 Common Rail Pressure High Error 1 Action Code
Failure Code
E03
CA553
Trouble
Common rail pressure high error 1 (Engine controller system)
Contents of trouble
• There is high pressure error (level 1) in common rail pressure sensor circuit.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
—
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
If another code is displayed, carry out troubleshooting for it.
2 Use of improper fuel
Fuel used may be improper. Check it directly. (Viscosity is high.)
3 Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Defective electrical system of Electrical system of common rail pressure sensor may be defective. Carry common rail pressure sensor out troubleshooting for failure code [CA451].
Defective mechanical system Mechanical system of common rail pressure sensor may be defective. 4 of common rail pressure Check it directly. sensor 5 Defective overflow valve
Spring damage, seat wear, or overflow valve ball is stuck is suspected. Check it directly.
6 Clogged overflow pipe
Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter
Pressure limiter may be damaged mechanically. Check it directly.
40-241 b
TROUBLESHOOTING
CA554
CA554 Common Rail Pressure In-Range Error Action Code
Failure Code
E03
CA554
Trouble
Common rail pressure sensor in-range error (Engine controller system)
Contents of trouble
• In-range error occurred in common rail pressure sensor circuit.
Action of controller
• Limits output and continues operation (limits common rail pressure). • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-242 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA451].
WA500-6
TROUBLESHOOTING
CA554
MEMORANDUM
WA500-6
40-243 b
TROUBLESHOOTING
CA559
CA559 Supply Pump Pressure Very Low Error 1 Action Code
Failure Code
E03
CA559
Trouble
Supply pump pressure very low error 1 (Engine controller system)
Contents of trouble
• There is no-pressure feed error (level 1) in supply pump.
Action of controller
• Limits common rail pressure. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
1 Defect in related system
If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel
Fuel used may be incorrect. Check it directly.
3
Defect in low pressure circuit parts
★ For more information on troubleshooting, see Note 1. ★ To check pressure in fuel low pressure circuit, see FUEL SYSTEM: Testing Fuel Pressure in Testing and Adjusting section. Pressure in fuel low-pressure circuit (high idle or rated load (stall load))
4 Clogged fuel filter, strainer
Possible causes and standard value in normal state
Min. 1.5 kg/cm² (22 psi)
★ For more information on troubleshooting, see Note 2.
5
Defective electrical system of Electrical system of supply pump PCV may be defective. Carry out supply pump PCV troubleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
6
Defective common rail pressure sensor
Mechanical system of common rail pressure sensor may be defective. Check whether wiring harness is damaged.
★ For check of leakage through pressure limiter, see FUEL SYSTEM: 7 Defective pressure limiter
Testing Fuel Return Rate and Leakage in Testing and Adjusting section. Leakage through pressure limiter
Max. 10 cc/min Rated load (stall load)
★ For check of limited return rate (spill) from injector, see FUEL SYSTEM: Testing Fuel Return Rate and Leakage in Testing and Adjusting section.
8 Defective injector
9 Defective supply pump
Rated load (stall load)
Limited return (spill) rate from injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 – 8 are not the cause of the problem, supply pump may be defective.
Using Checksheet ★ While carrying out troubleshooting, record troubleshooting results on the Checksheet for No-Pressure Feed.
40-244 b
WA500-6
TROUBLESHOOTING
CA559
Note 1 When low-pressure circuit is defective, check the following: • • • • • • •
Fuel level Clogged fuel tank breather Stuck or worn feed pump, clogged filter Leaked or clogged low-pressure fuel pipe Bypass valve malfunction, defective assembly of other parts (See Fig.1.) Clogged fuel filter Fuel in oil pan (fuel leakage in head cover)
Figure 1 Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3) • • •
Overflow valve (1): Spring is seen through both holes. Bypass valve (2): Spring is seen through hole on nut side. Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2 Check, clean, and replace the filters and strainers according to the following procedure. 1.
Gauze filter: Disassemble and check. If clogged, clean.
2.
Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter also.
3.
Fuel filter: If the problem is not solved by performing Steps 1 and 2, replace the fuel filter.
WA500-6
40-245 b
TROUBLESHOOTING
CA559
Checksheet for No-Pressure Feed Machine model
Working No.
Model serial No.
#
Checked on
Engine
/
/
Service meter
Engine serial No.
#
h
Worker name
A. Visual check
Good
Bad
Good
Bad
Standard value Measured Good (Reference value) value
Bad
1 Fuel leakage to outside 2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) 3 Checking error and failure codes
/
/
/
/
Checking monitoring information Code
01002
31701
Display item
Engine speed
Position of accelerator pedal
Check conditions
Unit
Low idle
rpm
625 ± 5
High idle
rpm
2,150 ±50
Full stall (P-mode)
rpm
1,800 ±100
Low idle
%
0
High idle
%
100
36200
Common rail pressure command
Rating or equivalent
kg/cm² (psi)
36400
Common rail fuel pressure
Rating or equivalent
kg/cm² (psi)
36300
Injection timing command
4
Low idle
CA
—
—
—
High idle
CA
—
—
—
Rating or equivalent
CA
—
—
—
kg/cm² (psi)
Min. 1.50 (Min. 21)
—
—
36500
Boost pressure
Rating or equivalent
04104
Engine coolant temperature
Low idle
°C
—
—
—
04204
Fuel temperature
Low idle
°C
—
—
—
40-246 b
WA500-6
TROUBLESHOOTING
CA559
Checking cylinder cut-out operation (Engine speed) Function
Cut-out cylinder
Check conditions
Standard value Measured Good (Reference value) value
Bad
Cylinder 1
Low idle
rpm
—
—
—
Cylinder 2
Low idle
rpm
—
—
—
Cylinder Cylinder 3 cut-out function Cylinder 4
Low idle
rpm
—
—
—
Low idle
rpm
—
—
—
Cylinder 5
Low idle
rpm
—
—
—
Cylinder 6
Low idle
rpm
—
—
—
5
C. Checking fuel circuit pressure 6
Unit
Pressure in fuel low-pressure circuit
Check conditions
Unit
High idle or rated load (stall load)
kg/cm² (psi)
Standard value Measured Good (Reference value) value
Bad
Min. 1.5 (Min. 22)
D. Checking strainer, filter
Good
Bad
Standard value Measured Good (Reference value) value
Bad
7 Visual check of strainer 8 Visual check of gauze filter 9 Visual check of fuel filter 10 Visual check of bypass valve
E. Checking leakage and fuel return rate
11 Leakage through pressure limiter
12 Return rate from injector
WA500-6
Check conditions
Unit
No load (stall load), full stall, or relief
cc/min
Max. 10
Rating or equivalent <by model> 1,600 rpm
cc/min
960
Rating or equivalent <by model> 1,700 rpm
cc/min
1,020
Rating or equivalent <by model> 1,800 rpm
cc/min
1,080
Rating or equivalent <by model> 1,900 rpm
cc/min
1,140
Rating or equivalent <by model> 2,000 rpm
cc/min
1,200
Speed:
Return rate:
40-247 b
TROUBLESHOOTING
CA689
CA689 Engine Ne Speed Sensor Error Action Code
Failure Code
E03
CA689
Trouble
Engine Ne speed sensor error (Engine controller system)
Contents of trouble
• Error was detected in engine Ne speed sensor circuit.
Action of controller
• Operates the engine with signal from engine Bkup speed sensor. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine stops during operations (when engine Bkup speed sensor is also defective). • Engine cannot be started during stop (when engine Bkup speed sensor is also defective).
Related information
• Method of reproducing failure code: Start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooti
Defective sensor power supply system
If failure code [CA238] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENGINE (female) (16) – NE (female) (1)
Resistance
Max. 1
Wiring harness between ENGINE (female) (48) – NE (female) (2)
Resistance
Max. 1
Wiring harness between ENGINE (female) (27) – NE (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Ground fault in wiring harness 3 (Short circuit with GND circuit)
Wiring harness between ENG (female) (16) – NE (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (48) – NE (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (27) – NE (female) (3) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (16) – NE (female) (1) and between ENG (female) (48) – NE (female) (2)
Short circuit in wiring 4 harness (with another wiring Wiring harness between ENG (female) (16) – harness) NE (female) (1) and between ENG (female) (27) – NE (female) (3) Wiring harness between ENG (female) (48) – NE (female) (2) and between ENG (female) (27) – NE (female) (3) Defective installation of 5 sensor or defective speed sensor parts
40-248 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Installation of Ne speed sensor (clearance error) may be incorrect or speed sensor parts (fly wheel) may be defective. Check it directly.
WA500-6
TROUBLESHOOTING
Possible causes and standard value in normal state
CA689 Cause
Standard value in normal state/Remarks on troubleshooti
Defective engine Ne speed sensor
If causes 1 – 4 are not the cause of the problem, engine Ne speed sensor may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
7 Defective engine controller
If causes 1 – 4 are not the cause of the problem, engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
6
Related Circuit Diagram
WA500-6
40-249 b
TROUBLESHOOTING
CA731
CA731 Engine Bkup Speed Sensor Phase Error Action Code
Failure Code
E03
CA731
Trouble
Engine Bkup speed sensor phase error (Engine controller system)
Contents of trouble
• There is phase error in engine Bkup speed sensor circuit.
Action of controller
• Controls the engine with signal from engine Ne speed sensor. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine stops during operations (when engine Ne speed sensor is also defective). • Engine cannot be started during stop (when engine Ne speed sensor is also defective).
Related information
• Method of reproducing failure code: Start engine.
Possible causes and standard value in normal state
40-250 b
Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective engine Ne speed sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
2
Defective engine Bkup speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
WA500-6
TROUBLESHOOTING
CA757
CA757 All Continuous Data Lost Error Action Code
Failure Code
E03
CA757
Trouble
All continuous data lost error (Engine controller system)
Contents of trouble
• All data in engine controller are lost.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Operations are continued but engine may stop during operations or may not start in stopped state.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA111].
40-251 b
TROUBLESHOOTING
CA778
CA778 Engine Bkup Speed Sensor Error Action Code
Failure Code
E03
CA778
Trouble
Engine Bkup speed sensor error (Engine controller system)
Contents of trouble
• Error was detected in engine Bkup speed sensor circuit.
Action of controller
• Operates the engine with signal from engine Ne speed sensor. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine stops during operations (when engine Ne speed sensor is also defective). • Engine cannot be started during stop (when engine Ne speed sensor is also defective).
Related information
• Method of reproducing failure code: Start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – G (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – G (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (26) – G (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Ground fault in wiring harness 3 (Short circuit with GND circuit)
Wiring harness between ENG (female) (37) – G (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – G (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (26) – G (female) (3) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – G (female) (1) and between ENG (female) (47) – G (female) (2)
Short circuit in wiring 4 harness (with another wiring Wiring harness between ENG (female) (37) – harness) G (female) (1) and between ENG (female) (26) – G (female) (3) Wiring harness between ENG (female) (47) – G (female) (2) and between ENG (female) (26) – G (female) (3)
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Defective engine Bkup speed sensor
If causes 1 – 4 are not the cause of the problem, engine Bkup speed sensor may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
6 Defective engine controller
If causes 1 – 4 are not the cause of the problem, engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
5
40-252 b
Resistance
WA500-6
TROUBLESHOOTING
CA778
Related Circuit Diagram
WA500-6
40-253 b
TROUBLESHOOTING
CA1228
CA1228 EGR Valve Servo Error 1 Action Code
Failure Code
E03
CA1228
Trouble
EGR valve servo error 1 (Engine controller system)
Contents of trouble
• There is servo error (level 1) of EGR valve.
Action of controller
• Performs open control. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defect in related system
Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, carry out troubleshooting for it.
★ For check of EGR valve oil pressure,see Item 5. 2 Defective EGR valve oil pressure system
Engine
EGR valve oil pressure
Low idle
Min. 1.18 MPa (171 psi)
High idle
Min. 1.43 MPa (207 psi)
If EGR valve oil pressure is abnormal,proceed to No.3 and No.4 below.
★ To check engine oil pressure, see ENGINE COMPONENTS: Measuring Engine Oil Pressure in the Testing and Adjusting section.
Possible causes and standard value in normal state
40-254 b
3
Defective engine oil pressure system (main circuit)
Engine
Engine oil pressure
Low idle
0.08 MPa (12 psi)
High idle
0.21 MPa (31 psi)
If engine oil pressure is not normal, carry out troubleshooting (S-mode) for the mechanical system. ★ See S-12: Oil Pressure Drops in the Engine Shop Manual. 4
Defective EGR valve oil pump
Oil pump or relief valve for EGR valve circuit may be defective. Check it directly.
5
Defective EGR valve oil pressure supply piping
Oil pressure supply piping for EGR valve circuit may be defective. Check it directly.
6
Defective EGR valve oil pressure return piping
Oil pressure return piping for EGR valve circuit may be defective. Check it directly.
7 Defective EGR valve
EGR valve may be damaged mechanically. Check it directly.
8 Defective engine controller
If causes 1 – 7 are not the cause of the problem, engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
WA500-6
TROUBLESHOOTING
CA1625
CA1625 EGR Valve Servo Error 2 Action Code
Failure Code
E03
CA1625
Trouble
EGR valve servo error 2 (Engine controller system)
Contents of trouble
• There is servo error (level 2) of EGR valve.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1228].
40-255 b
TROUBLESHOOTING
CA1626
CA1626 Bypass Valve Solenoid Current High Error Action Code
Failure Code
E03
CA1626
Trouble
Bypass valve solenoid current high error (Engine controller system)
Contents of trouble
• High current was detected in drive circuit of bypass valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting 1
Defective bypass valve solenoid (Internal defect)
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
without turning starting switch ON. BP (male)
Resistance
Between (1) and (2)
10 – 21
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (31) – BP (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (11) – BP (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Ground fault in wiring harness 3 (Short circuit with GND circuit)
without turning starting switch ON. Wiring harness between ENG (female) (31) – BP (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (11) – BP (female) (2) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between ENG (female) (31) – BP (female) (1) and chassis ground
Voltage
Max. 1 V
Wiring harness between ENG (female) (11) – BP (female) (2) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-256 b
ENG (female)
Resistance
Between (31) and (11)
10 – 21
WA500-6
TROUBLESHOOTING
CA1626
Related Circuit Diagram
WA500-6
40-257 b
TROUBLESHOOTING
CA1627
CA1627 Bypass Valve Solenoid Drive Circuit Disconnection Error Action Code
Failure Code
E03
CA1627
Trouble
Bypass valve solenoid drive circuit disconnection error (Engine controller system)
Contents of trouble
• Disconnection error was detected in drive circuit of bypass valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-258 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1626].
WA500-6
TROUBLESHOOTING
CA1628
CA1628 Bypass Valve Servo Error 1 Action Code
Failure Code
E03
CA1628
Trouble
Bypass valve servo error 1 (Engine controller system)
Contents of trouble
• There is servo error (level 1) of bypass valve.
Action of controller
• Performs open control. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn starting switch ON.
Cause 1 Defect in related system
Standard value in normal state/Remarks on troubleshooting If another failure code is displayed, carry out troubleshooting for it.
★ For check of EGR valve oil pressure,see Item 5. 2 Defective EGR valve oil pressure system
Engine
EGR valve oil pressure
Low idle
Min. 1.18 MPa (171 psi)
High idle
Min. 1.43 MPa (207 psi)
If EGR valve oil pressure is abnormal,proceed to No.3 and No.4 below.
★ For check of engine oil pressure, see ENGINE COMPONENTS: Measuring Engine Oil Pressure in the Testing and Adjusting section.
Possible causes and standard value in normal state
WA500-6
3
Defective engine oil pressure system (main circuit)
Engine
Engine oil pressure
Low idle
0.08 MPa (11.60 psi)
High idle
0.21 MPa (30.46 psi)
If engine oil pressure is not normal, carry out troubleshooting (S-mode) for the mechanical system. ★ See S-12: Oil Pressure Drops in the Engine Shop Manual. 4
Defective bypass valve oil pump
Oil pump or relief valve for bypass valve circuit may be defective. Check it directly.
5
Defective bypass valve oil pressure supply piping
Oil pressure supply piping for bypass valve circuit may be defective. Check it directly.
6
Defective bypass valve oil pressure return piping
Oil pressure return piping for bypass valve circuit may be defective. Check it directly.
7 Defective bypass valve
Bypass valve may be damaged mechanically. Check it directly.
8 Defective engine controller
If causes 1 – 7 are not the cause of the problem, engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
40-259 b
TROUBLESHOOTING
CA1629
CA1629 Bypass Valve Servo Error 2 Action Code
Failure Code
E03
CA1629
Trouble
Bypass valve servo error 2 (Engine controller system)
Contents of trouble
• There is servo error (level 2) of bypass valve.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-260 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1628].
WA500-6
TROUBLESHOOTING
CA1629
MEMORANDUM
WA500-6
40-261 b
TROUBLESHOOTING
CA1631
CA1631 Bypass Valve Lift Sensor High Error Action Code
Failure Code
E03
CA1631
Trouble
Bypass valve lift sensor high error (Engine controller system)
Contents of trouble
• Bypass valve lift sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring function (Code: 18200 BPS VALVE POS). • The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring function (Code: 18202 BPS VALVE POS). • Method of reproducing failure code: Start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective bypass valve lift 2 sensor (Internal defect)
SBP Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – SBP (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (38) – SBP (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring 4 harness (Short circuit with GND circuit)
40-262 b
Wiring harness between ENG (female) (37) – SBP (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (38) – SBP (female) (2) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (29) – SBP (female) (3), (4) and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA1631 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness of ENG (female) (37) – SBP (female) (1) and between ENG (female) (38) – SBP (female) (2)
Possible causes and standard value in normal state
Short circuit in wiring 5 harness (with another wiring Between wiring harness of ENG (female) (37) – harness) SBP (female) (1) and between ENG (female) (29) – SBP (female) (3), (4) Between wiring harness of ENG (female) (38) – SBP (female) (2) and between ENG (female) (29) – SBP (female) (3), (4)
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (38)
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-263 b
TROUBLESHOOTING
CA1632
CA1632 Bypass Valve Lift Sensor Low Error Action Code
Failure Code
E03
CA1632
Trouble
Bypass valve lift sensor low error (Engine controller system)
Contents of trouble
• Bypass valve lift sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring function (Code: 18200 BPS VALVE POS). • The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring function (Code: 18202 BPS VALVE POS). • Method of reproducing failure code: Start engine.
Cause Possible causes and standard value in normal state
40-264 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1631].
WA500-6
TROUBLESHOOTING
CA1633
CA1633 KOMNET Datalink Timeout Error Action Code
Failure Code
E03
CA1633
Trouble
KOMNET datalink timeout error (Engine controller system)
Contents of trouble
• There is an error in KOMNET communication circuit with applicable machine.
Action of controller
• Operates in default mode or holds the state set when error occurred. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine Related information
—
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
1
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [DB2RKR].
40-265 b
TROUBLESHOOTING
CA1642
CA1642 Abnormally Low Signal in EGR Inlet Pressure Sensor
Action Code
Failure Code
E03
CA1642
Trouble
Abnormally low signal in EGR inlet pressure sensor (Engine controller system)
Contents of trouble
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally low.
Action of controller
• Sets EGR valve inlet pressure to default (1.04 kg/cm² {15 psi}) and continues operation. • Limits engine output and continues operation.
Problem that appears on machine
• Engine output drops.
Related information
–
Cause Possible causes and standard value in normal state
40-266 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1653].
WA500-6
TROUBLESHOOTING
CA1642
EGR Inlet Pressure Sensor Low Error
Action Code
Failure Code
E03
CA1642
Trouble
EGR inlet pressure sensor low error (Engine controller system)
Contents of trouble
• EGR inlet pressure sensor circuit is abnormally low.
Action of controller
• Sets EGR inlet pressure to default (1.02 kg/cm² {15 psi}) and continues operation. • Limits engine output and continues operation. • Turns the centralized warning lamp and alarm buzzer on.
Problem that appears on machine
• Engine output drops.
Related information
• The inlet state (EGR inlet pressure) from the EGR inlet pressure sensor can be checked with the monitoring function (Code: 18000 EGR IN PRESS-A). • The input state (voltage) from the EGR inlet pressure sensor can be checked with the monitoring function (Code: 18002 EGR IN PRESS-A). • Method of reproducing failure: Start engine.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA1653].
40-267 b
TROUBLESHOOTING
CA1653
CA1653 Abnormally High Signal in EGR Inlet Pressure Sensor ★ Also refer to Parts And Service News AA09117. Action Code
Failure Code
E03
CA1653
Trouble
Abnormally high signal in EGR inlet pressure sensor (Engine controller system)
Contents of trouble
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally high.
Action of controller
• Sets EGR inlet pressure to default (1.04 kg/cm² {15 psi}) and continues operation. • Limits output and continues operation.
Problem that appears on machine
• Engine output drops.
Related information
• Condition of EGR valve inlet pressure sensor signal can be checked with the monitoring function (Code: ENGINE - EGR IN PRESS-A - 18001).
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective EGR valve inlet 2 pressure sensor (Internal defect)
PEVA Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
EGR inlet pressure sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection in wiring or defective contact in connector)
Wiring harness between ENG (female) (37) – PEVA (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – PEVA (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (20) – PEVA (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring harness – PEVA (female) (1) and chassis ground. 4 (Short circuit with GND Wiring harness between ENG (female) (47) circuit) – PEVA (female) (2) and chassis ground. Wiring harness between ENG (female) (20) – PEVA (female) (3) and chassis ground.
40-268 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA1653 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (47) – PEVA (female) (2)
5 Possible causes and standard value in normal state
Resistance
Min. 1 M
Short circuit in wiring harness (with another wiring harness) Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – PEVA (female) (2) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (47)
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-269 b
TROUBLESHOOTING
CA1653
EGR Inlet Pressure Sensor High Error Action Code
Failure Code
E03
CA1653
Trouble
EGR inlet pressure sensor high error (Engine controller system)
Contents of trouble
• EGR inlet pressure sensor circuit is abnormally high.
Action of controller
• Sets EGR inlet pressure to default (1.02 kg/cm² {15 psi}) and continues operation. • Limits output and continues operation. • Turns the centralized warning lamp and alarm buzzer on.
Problem that appears on machine
• Engine output drops.
Related information
• The inlet state (EGR inlet pressure) from the EGR inlet pressure sensor can be checked with the monitoring function (Code: 18000 EGR IN PRESS-A). • The inlet state (voltage) from the EGR inlet pressure sensor can be checked with the monitoring function (Code: 18002 EGR IN PRESS-A). • Method of reproducing failure: Start engine.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective EGR inlet pressure 2 sensor (Internal defect)
PEVA Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
EGR inlet pressure sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between ENG (female) (37) – PEVA (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – PEVA (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (20) – PEVA (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring harness – PEVA (female) (1) and chassis ground 4 (Contact with ground circuit) Wiring harness between ENG (female) (47) – PEVA (female) (2) and chassis ground Wiring harness between ENG (female) (20) – PEVA (female) (3) and chassis ground
40-270 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
CA1653 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (47) – PEVA (female) (2)
5 Possible causes and standard value in normal state
Resistance
Min. 1 M
Short circuit in wiring harness (with another wiring harness) Wiring harness between ENG (female) (37) – PEVA (female) (1) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – PEVA (female) (2) and between ENG (female) (20) – PEVA (female) (3)
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (47)
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-271 b
TROUBLESHOOTING
CA2185
CA2185 Throttle Sensor Supply Voltage High Error Action Code
Failure Code
E03
CA2185
Trouble
Throttle sensor supply voltage high error (Engine controller system)
Contents of trouble
• Voltage of throttle sensor power supply (5V) circuit is high.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine continues normal operation but may not run at full throttle.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 1
Defective accelerator pedal Disconnect device suggested on the right. (Internal defect) At this time, if failure code is not indicated, the device is defective.
Accelerator pedal
L15 connector
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 2 (Disconnection or defective contact in connector) Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between E18 (female) (22) – L15 (female) (1)
Resistance
Max. 1
Wiring harness between E18 (female) (23) – L15 (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Ground fault in wiring harness Wiring harness between E18 (female) (22) – (Contact with ground circuit) L15 (female) (1) and chassis ground
Resistance Min. 1 M
Wiring harness between E18 (female) (23) – L15 (female) (3) and chassis ground
Resistance Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting 4
without turning starting switch ON. Short circuit in wiring harness (with another wiring harness) Wiring harness between E18 (female) (22) – L15 (female) (1) and between E18 (female) (23) – L15 (female) (3)
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective engine controller
40-272 b
E18
Voltage
Between (22) and (23)
4.75 – 5.25 V
WA500-6
TROUBLESHOOTING
CA2185
Related Circuit Diagram
WA500-6
40-273 b
TROUBLESHOOTING
CA2186
CA2186 Throttle Sensor Power Supply Low Error Action Code
Failure Code
E03
CA2186
Trouble
Throttle sensor power supply low error (Engine controller system)
Contents of trouble
• Voltage of throttle sensor power supply (5V) circuit is low.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine continues normal operation but may not run at full throttle.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
40-274 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA2185].
WA500-6
TROUBLESHOOTING
CA2249
CA2249 Supply Pump Pressure Very Low Error 2 Action Code
Failure Code
E03
CA2249
Trouble
Supply pump pressure very low error 2 (Engine controller system)
Contents of trouble
• There is a no-pressure feed error (level 2) in supply pump.
Action of controller
• Limits common rail pressure. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with the monitoring function (Code: 36400 RAIL PRESS). • The input state (voltage) from the common rail pressure sensor can be checked with the monitoring function (Code: 36402 RAIL PRESS). • Method of reproducing failure code: Start engine.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA559].
40-275 b
TROUBLESHOOTING
CA2271
CA2271 EGR Valve Lift Sensor High Error Action Code
Failure Code
E03
CA2271
Trouble
EGR valve lift sensor high error (Engine controller system)
Contents of trouble
• EGR valve lift sensor circuit is abnormally high.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring function (Code: 18100 EGR VALVE POS). • The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function (Code: 18101 EGR VALVE POS). • Method of reproducing failure code: Start engine.
1
Causes
Standard value in normal state/Remarks on troubleshooting
Defective sensor power supply system
If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. Defective EGR valve lift 2 sensor (Internal defect)
SEGR Between (1) and (2)
Voltage Power supply
4.75 – 5.25 V
Sensor voltage is measured with wiring harness connected. If voltage is abnormal, check wiring harness and controller for another cause of the problem before making a decision.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between ENG (female) (37) – SEGR (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (47) – SEGR (female) (2)
Resistance
Max. 1
Wiring harness between ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between ENG (female) (37) Ground fault in wiring harness – SEGR (female) (1) and chassis ground 4 (Contact with ground circuit) Wiring harness between ENG (female) (47)
Resistance
Min. 1 M
Resistance
Min. 1 M
Wiring harness between ENG (female) (19) Resistance – SEGR (female) (3), (4) and chassis ground
Min. 1 M
– SEGR (female) (2) and chassis ground
40-276 b
WA500-6
TROUBLESHOOTING
CA2271 Causes
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning staring switch ON. Wiring harness between ENG (female) (37) – SEGR (female) (1) and ENG (female) (19) – SEGR (female) (3), (4)
5 Possible causes and standard value in normal state
Resistance
Min. 1 M
Short circuit in wiring harness (with another wiring harness) Wiring harness between ENG (female) (37) – SEGR (female) (1) and ENG (female) (47) – SEGR (female) (2)
Resistance
Min. 1 M
Wiring harness between ENG (female) (47) – SEGR (female) (2) and ENG (female) (19) – SEGR (female) (3), (4)
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON or start engine and carry out troubleshooting. 6 Defective engine controller
ENG
Voltage
Between (37) and (47)
4.75 – 5.25 V
Related Circuit Diagram
WA500-6
40-277 b
TROUBLESHOOTING
CA2272
CA2272 EGR Valve Lift Sensor Low Error Action Code
Failure Code
E03
CA2272
Trouble
EGR valve lift sensor low error (Engine controller system)
Contents of trouble
• EGR valve lift sensor circuit is abnormally low.
Action of controller
• Limits output and continues operation. • Closes EGR valve. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring function (Code: 18100 EGR VALVE POS). • The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function (Code: 18101 EGR VALVE POS). • Method of reproducing failure code: Start engine.
Cause Possible causes and standard value in normal state
40-278 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA2271].
WA500-6
TROUBLESHOOTING
CA2272
MEMORANDUM
WA500-6
40-279 b
TROUBLESHOOTING
CA2351
CA2351 EGR Valve Solenoid Operation Short Circuit Action Code
Failure Code
E03
CA2351
Trouble
EGR valve solenoid operation short circuit error (Engine controller system)
Contents of trouble
• Short circuit was detected in drive circuit of EGR valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting 1
Defective EGR valve solenoid (Internal defect)
without turning starting switch ON. EGR (male)
Resistance
Between (1) and (2)
10 – 21
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between ENG (female) (22) – EGR (female) (1)
Resistance
Max. 1
Wiring harness between ENG (female) (11) – EGR (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Ground fault in wiring harness Wiring harness between ENG (female) (22) 3 (Contact with ground circuit) – EGR (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between ENG (female) (11) – EGR (female) (2) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between ENG (female) (22) – EGR (female) (1) and chassis ground
Voltage
Max. 1 V
Wiring harness between ENG (female) (11) – EGR (female) (2) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5 Defective engine controller
40-280 b
ENG (female)
Resistance
Between (22) and (11)
10 – 21
WA500-6
TROUBLESHOOTING
CA2351
Related Circuit Diagram
WA500-6
40-281 b
TROUBLESHOOTING
CA2352
CA2352 EGR Valve Solenoid Operation Disconnection Error Action Code
Failure Code
E03
CA2352
Trouble
EGR valve solenoid operation disconnection error (Engine controller system)
Contents of trouble
• Disconnection error was detected in drive circuit of EGR valve solenoid.
Action of controller
• Limits output and continues operation. • Closes EGR and bypass valves. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Engine output drops.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-282 b
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA2351].
WA500-6
TROUBLESHOOTING
CA2555
CA2555 Intake Heater Relay Disconnection Error Action Code
Failure Code
E01
CA2555
Trouble
Intake heater relay voltage low error (Engine controller system)
Contents of trouble
• Disconnection error was detected in intake air heater relay circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Engine does not start easily at low temperature.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Carry out troubleshooting for failure code [CA2556].
40-283 b
TROUBLESHOOTING
CA2556
CA2556 Intake Heater Relay Short Circuit Error Action Code
Failure Code
E01
CA2556
Trouble
Intake heater relay short circuit error (Engine controller system)
Contents of trouble
• Short circuit was detected in intake heater relay circuit.
Action of controller
• None in particular.
Problem that appears on machine
• Engine does not start easily at low temperature.
Related information
• Method of reproducing failure code: Turn starting switch ON while engine coolant temperature below 5°C (41°F).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting 1
Defective intake heater relay (Internal defect)
without turning starting switch ON. L106 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 2 (Disconnection or defective contact in connector) Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between E18 (female) (40) – L106 (female) (1)
Resistance
Max. 1
Wiring harness between E18 (female) (42) – L106 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Ground fault in wiring harness Wiring harness between E18 (female) (40) – (Contact with ground circuit) L106 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between E18 (female) (42) – L106 (female) (2) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4 Defective engine controller
40-284 b
E18
Heater relay
Voltage
Between (40) and (42)
Operating condition
20 – 30 V
Stop condition
Max. 1 V
WA500-6
TROUBLESHOOTING
CA2556
Related Circuit Diagram
WA500-6
40-285 b
TROUBLESHOOTING
D160KZ
D160KZ Backup Lamp Relay: Disconnection or Short Circuit Action Code
Failure Code
E01
D160KZ
Backup lamp relay: Disconnection or short circuit (Transmission controller system)
Trouble
Contents of trouble
• Since the backup lamp relay output system is shorted, signals are not output to the backup relay.
Action of controller
• Turns the output to the backup lamp relay OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Backup lamp does not light up. • Backup buzzer does not sound.
Related information
• Method of reproducing failure code: Turn starting switch ON and set FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective backup lamp relay 1 (L101) ★ (Internal short circuit)
L101 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Replace backup lamp relay (L101) with another one of same type. If condition becomes normal at this time, backup lamp relay is defective. Possible causes and standard value in normal state
Grounding fault in wiring harness 2 (Disconnection or defective contact of connector)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L04 (female) (18) – L101 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
3
Defective transmission controller
L04
Between (18) and chassis ground
40-286 b
FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch
Voltage
R (Reverse)
20 – 30 V
Other than above
Max. 1 V
WA500-6
TROUBLESHOOTING
D160KZ
Related Circuit Diagram
WA500-6
40-287 b
TROUBLESHOOTING
D191KA
D191KA Joystick Steering Neutral Safety Relay: Disconnection Action Code
Failure Code
E01
D191KA
Trouble
Joystick steering neutral safety relay: Disconnection (Work equipment controller system)
Contents of trouble
• Signals are not output to neutral safety relay due to disconnection of joystick steering neutral safety relay output system.
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• While operating the joystick steering, engine can be started. Steering moves immediately after engine started. • Engine can be started while joystick or right FNR switch is not in N (neutral).
Related information
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted (initial setting). • The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function (Code: 40954, D-OUT-20). • Machine with joystick steering only • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering (engine stopped state).
Cause Defective joystick steering 1 neutral safety relay (L104) (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L104 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L07 (female) (4) – L104 (female) (1)
Resistance
Max. 1
Wiring harness between L104 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and Defective work equipment 3 controller
40-288 b
carry out troubleshooting. • Operate the joystick steering lever. L07
Voltage
Between (4) and chassis ground
20 – 30 V
WA500-6
TROUBLESHOOTING
D191KA
Related Circuit Diagram
WA500-6
40-289 b
TROUBLESHOOTING
D191KB
D191KB Joystick Steering Neutral Safety Relay: Short Circuit Action Code
Failure Code
E01
D191KB
Trouble
Joystick steering neutral safety relay: Short circuit (Work equipment controller system)
Contents of trouble
• Signals are not output to joystick steering neutral safety relay due to grounding fault in joystick steering neutral safety relay output system.
Action of controller
• Turns the output to the joystick steering neutral safety relay OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• While operating the joystick steering, engine can be started. Steering moves immediately after engine started. • Engine can be started while joystick or right FNR switch is not in N (neutral).
Related information
• The neutral safety relay does not operate when the joystick steering neutral position is not adjusted (initial setting). • Work equipment controller does not output signals to joystick steering neutral safety relay while outputting a failure code. • The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function (Code: 40954, D-OUT-20). • Machine with joystick steering only • Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine stopped state).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective joystick steering 1 neutral safety relay (L104) (Internal short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. L104 (male)
Resistance
Between (1) and (2)
200 – 400
Between (1) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (4) – Resistance Min. 1 M L104 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and Defective work equipment 3 controller
40-290 b
carry out troubleshooting. • Operate the joystick steering lever. L07
Voltage
Between (4) and chassis ground
20 – 30 V
WA500-6
TROUBLESHOOTING
D191KB
Related Circuit Diagram
WA500-6
40-291 b
TROUBLESHOOTING
D192KA
D192KA ECSS Solenoid: Disconnection Action Code
Failure Code
E01
D192KA
Trouble
ECSS (travel damper) solenoid: Disconnection (Transmission controller system)
Contents of trouble
• Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is turned ON.
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The ECSS does not operate.
Related information
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code: 93300 ECSS V DIR). • Applicable only to ECSS specification machines (if equipped). • Method of reproducing failure code: Turn the starting switch and ECSS switch ON, and travel at a speed other than 1st.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting 1
Defective ECSS solenoid (Internal disconnection)
without turning starting switch ON. F24 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L04 (female) (17) – F24 (female) (1)
Resistance
Max. 1
Wiring harness between F24 (female) (2) – L04 (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission 3 controller
without turning starting switch ON. L04 (female)
Resistance
Wiring harness between (17) and (3)
5 – 15
Related Circuit Diagram
40-292 b
WA500-6
TROUBLESHOOTING
D192KB
D192KB ECSS Solenoid: Short Circuit Action Code
Failure Code
E01
D192KB
Trouble
ECSS (travel damper) solenoid: Short circuit (Transmission controller system)
Contents of trouble
• Since the ECSS solenoid system is shorted with the chassis ground, abnormal current flows when ECCS solenoid output is ON.
Action of controller
• Turns the output to the ECSS solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The ECSS does not operate. • The wiring harness or controller may be burnt out.
Related information
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code: 93300 ECSS V DIR). • Applicable only to ECSS specification machines (if equipped). • Method of reproducing failure code: Turn starting switch ON + ECSS switch ON + non-1st speed
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Possible causes and standard value in normal state
Defective ECSS solenoid (Internal short circuit)
F24 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (17) – Resistance Min. 1 M F24 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Defective transmission controller
L04 (female)
Resistance
Between (17) and (3)
5 – 15
Between (17), (3) and chassis ground
Min. 1 M
Related Circuit Diagram
WA500-6
40-293 b
TROUBLESHOOTING
D192KY
D192KY ECSS Solenoid Relay: Short Circuit with Power Supply Line Action Code
Failure Code
E01
D192KY
Trouble
ECSS (travel damper) solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied when ECSS solenoid output was turned OFF.
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• ECCS keeps operating.
Related information
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code: 93300 ECSS V DIR). • Applicable only to ECSS specification machines (if equipped). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Possible causes and standard value in normal state
Defective ECSS solenoid (Internal short circuit)
F24 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (17) – F24 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-294 b
Defective transmission controller
L04 (female)
Resistance
Between (17) and (3)
5 – 15
Between (17), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
D192KY
Related Circuit Diagram
WA500-6
40-295 b
TROUBLESHOOTING
D193KA
D193KA Joystick Steering Solenoid Cut Relay: Disconnection Action Code
Failure Code
E03
D193KA
Trouble
Joystick steering solenoid cut relay: Disconnection (Work equipment controller system)
Contents of trouble
• Signals are not output to joystick steering solenoid cut relay due to disconnection of joystick steering solenoid cut relay output system.
Action of controller
• Stops outputting the signal to the joystick steering left-right EPC solenoid. • Turns the output to the joystick steering cut relay OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The operator cannot operate the joystick steering.
Related information
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring function (Code: 40953, D-OUT-8). • Machine with joystick steering only • Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine stopped state).
Cause Defective joystick steering 1 neutral cut relay (L118) (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L118 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L07 (female) (26) – L118 (female) (1)
Resistance
Max. 1
Wiring harness between L118 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and 3
40-296 b
Defective work equipment controller
carry out troubleshooting. • Operate the joystick steering lever. L07
Voltage
Between (26) and chassis ground
20 – 30 V
WA500-6
TROUBLESHOOTING
D193KA
Related Circuit Diagram
WA500-6
40-297 b
TROUBLESHOOTING
D193KB
D193KB Joystick Steering Solenoid Cut Relay: Short Circuit Action Code
Failure Code
E03
D193KB
Trouble
Joystick steering solenoid cut relay: Short circuit (Work equipment controller system)
Contents of trouble
• Signals are not output to joystick steering solenoid cut relay due to grounding fault in joystick steering solenoid cut relay output system.
Action of controller
• Stops the output to the joystick steering left-right EPC solenoid. • Turns the output to the joystick steering cut relay OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The operator cannot operate the joystick steering.
Related information
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring function (Code: 40953, D-OUT-8). • Machine with joystick steering only • Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine stopped state).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective joystick steering 1 cut relay (L118) (Internal short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. L118 (male)
Resistance
Between (1) and (2)
200 – 400
Between (1) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting 2
without turning starting switch ON. Ground fault in wiring harness (Contact with ground circuit) Wiring harness between L07 (female) (26) – L118 (female) (1) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and 3
40-298 b
Defective work equipment controller
carry out troubleshooting. • Operate the joystick steering lever. L07
Voltage
Between (26) and chassis ground
20 – 30 V
WA500-6
TROUBLESHOOTING
D193KB
Related Circuit Diagram
WA500-6
40-299 b
TROUBLESHOOTING
D193KY
D193KY Joystick Steering Solenoid Cut Relay: Short Circuit with Power Supply Line Action Code
Failure Code
E03
D193KY
Trouble
Joystick steering solenoid cut relay: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Signals are not output to joystick steering solenoid cut relay due to hot short circuit in joystick steering solenoid cut relay output system.
Action of controller
• Stops the output to the joystick steering left-right EPC solenoid. • Stops the output to the joystick steering cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The operator cannot operate the joystick steering.
Related information
• The output state (ON/OFF) to the joystick steering solenoid cut relay can be checked with the monitoring function (Code: 40953, D-OUT-8). • Machine with joystick steering only • Method of reproducing failure code: Turn the starting switch ON and joystick steering operation (engine stopped state).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering 1 cut relay (L118) (Internal short circuit)
Possible causes and standard value in normal state
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Ground fault in wiring harness 2 (Contact with ground circuit) Wiring harness between L07 (female) (26) – Voltage Max. 1 V L118 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and 3
40-300 b
Defective work equipment controller
carry out troubleshooting. • Operate the joystick steering lever. L07
Voltage
Between (26) and chassis ground
20 – 30 V
WA500-6
TROUBLESHOOTING
D193KY
Related Circuit Diagram
WA500-6
40-301 b
TROUBLESHOOTING
D5ZHKA
D5ZHKA Terminal C Signal: Disconnection Action Code
Failure Code
E01
D5ZHKA
Trouble
Terminal C signal: Disconnection (Transmission controller system)
Contents of trouble
• Terminal C system is disconnected or shorted with the chassis ground. (Engine speed is above 500 rpm and no starting switch terminal C signal has been input.)
Action of controller
• None in particular. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Engine does not start easily.
Related information
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with the monitoring function (Code: 40905, D-IN-7). • Method of reproducing failure code: START position of starting switch
Cause 1
Defective fuse No. 2 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON, OFF or START and carry out troubleshooting Defective starting switch 2 (Internal disconnection)
LS4 Between (1) and (3)
Starting switch
Resistance
START
Max. 1
OFF, ON
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between LS4 (female) (3) – L120 (female) (3)
Resistance
Max. 1
Wiring harness between L120 (female) (6) – L103 (female) (5)
Resistance
Max. 1
Wiring harness between L103 (female) (3) – L104 (female) (6)
Resistance
Max. 1
Wiring harness between L104 (female) (3) – L02 (female) (6)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LS4 (female) (3) – L120 (female) (3), – circuit branch end and chassis ground Grounding fault in wiring Wiring harness between L120 (female) (6) – 4 harness L103 (female) (5) and chassis ground (Contact with ground circuit) Wiring harness between L103 (female) (3) – L104 (female) (6), – circuit branch end and chassis ground Wiring harness between L104 (female) (3) – L02 (female) (6), – circuit branch end and chassis ground
40-302 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
D5ZHKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON, OFF Possible causes and standard value in normal state
WA500-6
or START and carry out troubleshooting Defective transmission 5 controller
L02
Starting switch
Voltage
Between (6) and chassis ground
START
20 – 30 V
OFF, ON
Max. 1 V
40-303 b
TROUBLESHOOTING
D5ZHKA
Related Circuit Diagram
40-304 b
WA500-6
TROUBLESHOOTING
D5ZHKA
MEMORANDUM
WA500-6
40-305 b
TROUBLESHOOTING
D5ZHKB
D5ZHKB Terminal C Signal: Short Circuit Action Code
Failure Code
E01
D5ZHKB
Trouble
Terminal C signal: Short circuit (Transmission controller system)
Contents of trouble
• Terminal C system is shorted with the power source. (Engine speed is above 500 rpm and starting switch terminal C signal has been input.)
Action of controller
• Engine start assistance is not working. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Engine does not start easily.
Related information
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with the monitoring function (Code: 40905, D-IN-7). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON, OFF or START and carry out troubleshooting Defective starting switch 1 (Internal disconnection)
LS4 Between (1) and (3)
Starting switch
Resistance
START
Max. 1
OFF, ON
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting after engine starts and during engine operation
Possible causes and standard value in normal state
2
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between LS4 (female) (3) – L120 (female) (3), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L120 (female) (6) – L103 (female) (5) and chassis ground
Voltage
Max. 1 V
Wiring harness between L103 (female) (3) – L104 (female) (6), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L104 (female) (3) – L02 (female) (6), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON, OFF, or START and carry out troubleshooting Defective transmission 3 controller
40-306 b
L02
Starting switch
Voltage
Between (6) and chassis ground
START
20 – 30 V
OFF, ON
Max. 1 V
WA500-6
TROUBLESHOOTING
D5ZHKB
Related Circuit Diagram
WA500-6
40-307 b
TROUBLESHOOTING
D5ZHKZ
D5ZHKZ Terminal C Signal: Disconnection or Short Circuit Action Code
Failure Code
E01
D5ZHKZ
Trouble
Terminal C signal: Disconnection or short circuit (Work equipment controller system)
Contents of trouble
• Terminal C system is disconnected. (Engine speed is above 500 rpm and no starting switch terminal C signal has been input.)
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Engine starts when work equipment control lever is not at Neutral (disconnection). • While engine is stopped, residual pressure in work equipment cannot be released (short circuit).
Related information
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be checked with the monitoring function (Code: 40912, D-IN-17). • Method of reproducing failure code: Set the starting switch to START position.
Cause 1
Defective fuse No. 2 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON, OFF or START and carry out troubleshooting Defective starting switch 2 (Internal disconnection)
LS4 Between (1) and (3)
Starting switch
Resistance
START
Max. 1
OFF, ON
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector) Possible causes and standard value in normal state
Wiring harness between LS4 (female) (3) – L120 (female) (3)
Resistance
Max. 1
Wiring harness between L120 (female) (6) – L103 (female) (5)
Resistance
Max. 1
Wiring harness between L103 (female) (3) – L06 (female) (25)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LS4 (female) (3) – L120 (female) (3), – circuit branch end and chassis ground
Grounding fault in wiring 4 harness (Contact with ground circuit) Wiring harness between L120 (female) (6) – L103 (female) (5) and chassis ground Wiring harness between L103 (female) (3) – L06 (female) (25), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
40-308 b
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between LS4 (3) – L120 (3)
Voltage
Max. 1 V
Wiring harness between L120 (6) – L103 (5) and chassis ground
Voltage
Max. 1 V
Wiring harness between L103 (5) – L06 (25)
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
D5ZHKZ Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON, OFF Possible causes and standard value in normal state
WA500-6
or START and carry out troubleshooting Defective work equipment 6 controller
L06
Starting switch
Voltage
Between (25) and chassis ground
START
20 – 30 V
OFF, ON
Max. 1 V
40-309 b
TROUBLESHOOTING
D5ZHKZ
Related Circuit Diagram
40-310 b
WA500-6
TROUBLESHOOTING
D5ZHKZ
MEMORANDUM
WA500-6
40-311 b
TROUBLESHOOTING
D5ZHL6
D5ZHL6 Terminal C Signal: Signal Does Not Match Engine Running or Stopped State Action Code E01
Failure Code D5ZHL6
Trouble
Terminal C signal: Signal does not match engine running or stopped state (Machine monitor system)
Contents of trouble
• Terminal C system is disconnected or shorted with the chassis ground. (Engine speed is above 500 rpm and alternator terminal R voltage has been checked.)
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The engine does not start.
Related information
• The input state (ON/OFF) from starting switch terminal C to machine monitor can be checked with the monitoring function (Code: 40900, D-IN-2). • Method of reproducing failure code: Set the starting switch to START position.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON, OFF, or START and carry out troubleshooting Defective starting switch 1 (Internal disconnection)
LS4
Starting switch
Voltage
Between (3) and chassis ground
START
20 – 30 V
OFF, ON
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between LS4 (female) (3) – L120 (female) (3)
Resistance
Max. 1
Wiring harness between L120 (female) (6) – L103 (female) (5)
Resistance
Max. 1
Wiring harness between L103 (female) (3) – L104 (female) (6)
Resistance
Max. 1
Wiring harness between L104 (female) (3) – L52 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between LS4 (female) (3) – L120 (female) (3), – circuit branch end and chassis ground Grounding fault in wiring Wiring harness between L120 (female) (6) – 3 harness L103 (female) (5) and chassis ground (Contact with ground circuit) Wiring harness between L103 (female) (3) – L104 (female) (6), – circuit branch end and chassis ground Wiring harness between L104 (female) (3) – L52 (female) (2), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON, OFF or START and carry out troubleshooting 4 Defective machine monitor
40-312 b
L52
Starting switch
Voltage
Between (2) and chassis ground
START
20 – 30 V
OFF, ON
Max. 1 V
WA500-6
TROUBLESHOOTING
D5ZHL6
Related Circuit Diagram
WA500-6
40-313 b
TROUBLESHOOTING
DA80L4
DA80L4 Auto-Grease Controller: ON/OFF Signals Disagree Action Code
Failure Code
—
DA80L4
Trouble
Auto-grease controller: ON/OFF signals disagree (Machine monitor system)
Contents of trouble
• Both auto-grease sensor input circuits A and B are in the same signal (+24 V).
Action of controller
• None in particular. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Auto-grease does not work. • Auto-grease lamp goes off.
Related information
• The input state (ON/OFF) from the auto-grease controller can be checked with the monitoring function (Code: 40900, D-IN-4, D-IN-5). • Applicable only to machines equipped with auto-grease function (if equipped). • Method of reproducing failure code: Turn the starting switch ON (auto-grease install).
Cause Defective auto grease controller 1 (Internal disconnection or short circuit)
2
Hot short in wiring harness (Contact with 24 V circuit)
Standard value in normal state/Remarks on troubleshooting
Refer to and carry out troubleshootings for auto-grease system.
★ Fill up grease to the tank. ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Wiring harness between L52 (female) (3) R38 (female) (2) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Auto- grease Possible causes and standard value in normal state
Operating
3 Defective machine monitor
Abnormal
Tank empty
Abnormal
40-314 b
L52
Real-time monitor (Code: 40900)
Between (3) – ground (0 V)
D-IN-4 0
Between (12) – ground (24 V)
D-IN-5 1
Between (3) – ground (0 V)
D-IN-4 0
Between (12) – ground (0 V)
D-IN-5 0
Between (3) – ground (24 V)
D-IN-4 1
Between (12) – ground (0 V)
D-IN-5 0
Between (3) – ground (24 V)
D-IN-4 1
Between (12) – ground (24 V)
D-IN-5 1
Auto-grease lamp
ON
Blink (2 Hz)
Blink (1 Hz)
OFF
WA500-6
TROUBLESHOOTING
DA80L4
Related Circuit Diagram
WA500-6
40-315 b
TROUBLESHOOTING
DAF3KK
DAF3KK Machine Monitor: Low Source Voltage (input) Action Code
Failure Code
E03
DAF3KK
Trouble
Machine monitor: Low source voltage (input) (Machine monitor system)
Contents of trouble
• When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of the constant power supply (power supply for operation) is below 17 V.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The service meter reading is abnormal; the odometer does not advance; and failure history data is not saved.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause 1
Defective fuse No. 8 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between LR1 (male) (1) – fuse No. 8 of fuse box A
Resistance
Max. 1
Wiring harness between fuse No. 8 of fuse box A – L51 (female) (4), (5)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring 3 harness Wiring harness between fuse No. 8 of fuse (Contact with ground circuit) box A – L51 (female) (4), (5) and chassis ground 4 Defective machine monitor
40-316 b
Resistance
Min. 1 M
If machine monitor is replaced and condition becomes normal, machine monitor is defective.
WA500-6
TROUBLESHOOTING
DAF3KK
Related Circuit Diagram
WA500-6
40-317 b
TROUBLESHOOTING
DAF5KP
DAF5KP Machine Monitor: Low Output Voltage Action Code
Failure Code
E01
DAF5KP
Trouble
Machine monitor: Low output voltage (Machine monitor system)
Contents of trouble
• When the voltage of the switch power supply (power supply for operation) of the machine monitor is above 17 V, the voltage of the sensor is below 5 V.
Action of controller
• None in particular. • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that appears on machine
• Machine monitor does not display load.
Related information
• Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshootin
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L51 (female) (16) – JF3 (female) (1) and chassis ground
Grounding fault in wiring Wiring harness between JF3 (female) (2) – 1 harness F13 (female) (C) and chassis ground (Contact with ground circuit) Wiring harness between JF3 (female) (7) – F14 (female) (B) and chassis ground Wiring harness between JF3 (female) (8) – F15 (female) (B) and chassis ground Possible causes and standard value in normal state
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
Defective lift arm angle sensor ★ (Internal short circuit)
F13 (male)
Resistance
Between (C) and (A)
5 k ±20%
Between (A), (B), (C) and chassis ground
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. F13
Lift arm cylinder
Voltage
Between (C) and (A)
Constant
4.85 – 5.15 V
Constant
0.83 – 4.17 V
At max. length
3.50 – 4.17 V
At min. length
0.83 – 1.88 V
Between (B) and (A)
40-318 b
Resistance
WA500-6
TROUBLESHOOTING
DAF5KP Cause
Standard value in normal state/Remarks on troubleshootin
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective lift arm bottom 3 pressure sensor (Internal short circuit)
F14 (male)
Resistance
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. F14 (male)
Lift arm bottom pressure
Voltage
Between (C) and (B)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
When released
0.50 – 0.90 V
When relieved
3.02 – 3.42 V
Between (C) and (A)
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON.
Defective lift arm rod pressure ★ 4 sensor (Internal short circuit)
F15 (male)
Resistance
Between (A), (B), (C) and chassis ground
Min. 1 M
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. F15 (male)
Lift arm rod pressure
Voltage
Between (C) and (B)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
When released
0.50 – 0.90 V
When relieved
3.02 – 3.42 V
Between (C) and (A)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective machine monitor
WA500-6
L51
Lift arm cylinder
Voltage
Between (16) and chassis ground
Constant
4.85 – 5.15 V
40-319 b
TROUBLESHOOTING
DAF5KP
Related Circuit Diagram
40-320 b
WA500-6
TROUBLESHOOTING
DAF5KP
MEMORANDUM
WA500-6
40-321 b
TROUBLESHOOTING
DAFRKR
DAFRKR Machine Monitor: CAN Defective Communication Action Code
Failure Code
E03
DAFRKR
Trouble
CAN communication with machine monitor: Defective communication (Abnormality in target component system) (Transmission controller system)
Contents of trouble
• Communication via CAN signal line between the machine monitor and transmission controller is defective.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Uses CAN information that was sent from machine monitor before the occurrence of the error. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The monitor does not display normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 1 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L56 (female) (3) – L03 (female) (32)
Resistance
Max. 1
Wiring harness between L56 (female) (8) – L03 (female) (22)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L56 (female) (3) – 2 harness L03 (female) (32) and chassis ground (Contact with ground circuit) Wiring harness between L56 (female) (8) – L03 (female) (22) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. 3
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L56 (female) (3) – L03 (female) (32) and chassis ground
Voltage
Max. 1 V
Wiring harness between L56 (female) (8) – L03 (female) (22) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between L56 (female) Resistance Min. 1 M (3) – (8) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
Defective end point resistance
CAN1 (male)
Resistance
Between (A) and (B)
120 ±12
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
40-322 b
E21 (male)
Resistance
Between (A) and (B)
120 ±12
WA500-6
TROUBLESHOOTING
Possible causes and standard value in normal state
DAFRKR Cause
Standard value in normal state/Remarks on troubleshooting
6 Defective machine monitor
If causes 1 – 5 are not the cause of the problem, the machine monitor may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
Related Circuit Diagram
WA500-6
40-323 b
TROUBLESHOOTING
DAQ0KK
DAQ0KK Transmission Controller: Low Source Voltage Action Code
Failure Code
E03
DAQ0KK
Trouble
Transmission controller: Low source voltage (Transmission controller system)
Contents of trouble
• Voltage of constant power supply (battery direct power supply) of the transmission controller is low. • Voltage of constant power supply (battery direct power supply) is below 18 V and engine speed is above 500 rpm.
Action of controller
• Cannot sense the input signals normally. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine cannot operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective slow blow fuse (SBF1)
If the slow blow fuse is shut down, the circuit probably has a grounding fault, etc. (See cause 4.)
2
Defective fuse No.6 of fuse box A
If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between battery relay BTR1 D03 – slow blow fuse SBF1 R01
Resistance
Max. 1
Wiring harness between slow blow fuse SBF1 R02 – fuse No.6 of fuse box A
Resistance
Max. 1
Wiring harness between fuse No.6 of fuse box A – L04 (female) (1), (11)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between battery relay BTR1 D03 – slow blow fuse SBF1 R01 and chassis ground
Grounding fault in wiring 4 harness Wiring harness between slow blow fuse (Contact with ground circuit) SBF1 R02 – fuse No.6 of fuse box A and chassis ground
Wiring harness between fuse No.6 of fuse box A – L04 (female) (1), (11), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective transmission 5 controller
40-324 b
carry out troubleshooting. L04
Voltage
Between (1), (11) and (21), (31), (32), (33)
20 – 30 V
WA500-6
TROUBLESHOOTING
DAQ0KK
Related Circuit Diagram
WA500-6
40-325 b
TROUBLESHOOTING
DAQ0KT
DAQ0KT Transmission Controller: Abnormality in Controller Action Code
Failure Code
E01
DAQ0KT
Trouble
Transmission controller: Abnormality in controller (Transmission controller system)
Contents of trouble
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal. • Just after starting switch was turned OFF, battery direct power source was lost and finishing operation was not carried out normally.
Action of controller
• Sets the internal adjustment values to the default values. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The feel of the transmission gear shift may be bad.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-326 b
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission controller
Since problem is in system, troubleshooting cannot be carried out. If there is not any visible problem in machine, controller may be used as it is after initial setting and adjustment.
WA500-6
TROUBLESHOOTING
DAQ0KT
MEMORANDUM
WA500-6
40-327 b
TROUBLESHOOTING
DAQ2KK
DAQ2KK Transmission Controller Load Power Supply Line: Low Source Voltage (input) Action Code E03
Failure Code DAQ2KK
Trouble
Transmission controller load power supply line: Low source voltage (input) (Transmission controller system)
Contents of trouble
• The voltage of the 24 V solenoid power supply system is low. • Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power supply) above 20 V, and solenoid power supply below 18 V
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Does not display failure codes that may be falsely detected due to low 24 V solenoid source voltage. • Even if cause of failure disappears, system does not reset itself until directional lever, joystick steering FNR (directional) switch, or directional selector switch is set to N (Neutral).
Problem that appears on machine
• Transmission is stuck in Neutral. • The fan rotates forward if reversed.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fan motor relay (L114) 1 (Internal disconnection or short circuit)
L114 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If fan motor relay (L114) is replaced with a relay of the same type (5-pin type) and the condition becomes normal, the fan motor relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L04 (female) (2), (12), (22) – L114 (female) (5)
Resistance
Max. 1
Wiring harness between L114 (female) (3) – fuse No.6 of fuse box A
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L04 (female) (2), Grounding fault in wiring (12), (22) – L114 (female) (5) and chassis 3 harness ground (Contact with ground circuit) Wiring harness between L114 (female) (3) – fuse No. 6 of fuse box A, – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective transmission 4 controller
40-328 b
carry out troubleshooting. L04
Voltage
Between (2), (12), (22) and (21), (31), (32), (33)
20 – 30 V
WA500-6
TROUBLESHOOTING
DAQ2KK
Related Circuit Diagram
WA500-6
40-329 b
TROUBLESHOOTING
DAQ9KQ
DAQ9KQ Transmission Controller: Disagreement of Model Selection Signals Action Code E03
Failure Code DAQ9KQ
Trouble
Transmission controller model selection: Disagreement of model selection signals (Machine monitor system)
Contents of trouble
• The transmission controller model is mistaken for another one.
Action of controller
• Operates on the assumption that the controller model which has been used before occurrence of the failure code is still used. • Turns the centralized warning lamp and alarm buzzer ON. • Does not display failure codes which may be falsely detected.
Problem that appears on machine
• If machine travels in this state, transmission may be broken.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Improper machine monitor 1 model selection
• Select the model using the machine monitor and Service mode adjustment function. • See MACHINE MONITOR SYSTEM: Service Mode: Model Selection Function in the Testing and Adjusting section.
2 Transmission controller
40-330 b
Check controller part number. If it is wrong, replace controller.
WA500-6
TROUBLESHOOTING
DAQ9KQ
MEMORANDUM
WA500-6
40-331 b
TROUBLESHOOTING
DAQRKR
DAQRKR Transmission Controller: CAN Defective Communication Action Code E03
Failure Code DAQRKR
Trouble
CAN communication with transmission controller: Defective communication (Abnormality in target component system) (Machine monitor system)
Contents of trouble
• Machine monitor cannot get information from transmission controller.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Uses CAN information that was sent from transmission controller before the occurrence of the error. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The monitor does not display normally.
Related information
• Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then disconnect CAN1 and E21 Defective CAN terminal 1 resistor
and carry out troubleshooting. Between CAN1 (male) (A) – (B)
Resistance
120
Between E21 (male) (A) – (B)
Resistance
120
★ Prepare with starting switch OFF, then disconnect CAN1, E21, L56, L03, L06 and E18 and carry out troubleshooting.
Possible causes and standard value in normal state
40-332 b
Disconnection in wiring harness 2 (Disconnection in wiring or defective contact in connector)
Wiring harness between L56 (female) (8), (3) – E21 (female) (A), (B)
Resistance
Max. 1
Wiring harness between L56 (female) (8), (3) – L03 (female) (32), (22)
Resistance
Max. 1
Wiring harness between L56 (female) (8), (3) – L06 (female) (32), (22)
Resistance
Max. 1
Wiring harness between L56 (female) (8), (3) – E18 (female) (46), (47)
Resistance
Max. 1
Wiring harness between L56 (female) (8), (3) – CAN1 (female) (A), (B)
Resistance
Max. 1
Wiring harness between L56 (female) (8), (3) – L80 (female) (7), (8)
Resistance
Max. 1
Wiring harness between E18 (female) (46), (47) – CAN1 (female) (A), (B) or E21 (female) (A), (B)
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DAQRKR Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then disconnect CAN1, E21, L56, L03, L06 and E18 and carry out troubleshooting.
Possible causes and standard value in normal state
Ground fault in wiring 3 harness (Contact with GND circuit)
Defective machine monitor, engine controller, 4 transmission controller, or work equipment controller
Wiring harness between L56 (female) (3) – E21 (female) (A)
Resistance
Min. 1 M
Wiring harness between L56 (female) (3) – L03 (female) (32)
Resistance
Min. 1 M
Wiring harness between L56 (female) (3) – E18 (female) (46)
Resistance
Min. 1 M
Wiring harness between L56 (female) (3) – CAN1 (female) (A)
Resistance
Min. 1 M
Wiring harness between L56 (female) (3) – L80 (female) (3)
Resistance
Min. 1 M
Wiring harness between E18 (female) (46) – CAN1 (female) (A) – E21 (female) (A)
Resistance
Min. 1 M
If causes 1 – 3 are not detected, machine monitor, engine controller, transmission controller, or work equipment controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
Related Circuit Diagram
WA500-6
40-333 b
TROUBLESHOOTING
DAQRMA
DAQRMA Transmission Controller Option Setting: Malfunction Action Code
Failure Code
E03
DAQRMA
Trouble
Transmission controller option setting: Malfunction (Machine monitor – transmission controller)
Contents of trouble
• Optional setting of the machine monitor disagrees with its recognition in the transmission controller.
Action of controller
• The transmission controller complies with its optional setting recognition. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Optional components do not operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-334 b
Standard value in normal state/Remarks on troubleshooting
1 Defective machine monitor
Since problem is in system, troubleshooting cannot be carried out.
Defective transmission controller
Since problem is in system, troubleshooting cannot be carried out.
2
WA500-6
TROUBLESHOOTING
DAQRMA
MEMORANDUM
WA500-6
40-335 b
TROUBLESHOOTING
DB2RKR
DB2RKR Engine Controller: CAN Defective Communication Action Code
Failure Code
E03
DB2RKR
Trouble
CAN communication with engine controller: Defective communication (Abnormality in target component system) (Transmission controller system)
Contents of trouble
• Communication via CAN signal line between the transmission controller and engine controller is defective.
Action of controller
• Uses CAN information that was sent from engine controller before the occurrence of the error. • Keeps recognizing engine speed at 2,100 rpm. • Holds recognized position of accelerator at 80%. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The monitor does not display normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 1 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between E18 (female) (47) – L03 (female) (22)
Resistance
Max. 1
Wiring harness between E18 (female) (46) – L03 (female) (32)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between E18 (female) (47) – 2 harness L03 (female) (22) and chassis ground (Contact with ground circuit) Wiring harness between E18 (female) (46) – L03 (female) (32) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. 3
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between E18 (female) (47) – L03 (female) (22) and chassis ground
Voltage
Max. 1 V
Wiring harness between E18 (female) (46) – L03 (female) (32) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between E18 (female) (46) – Resistance Min. 1 M (47) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
Defective end point resistance
CAN1 (male)
Resistance
Between (A) and (B)
120 ±12
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
40-336 b
E21 (male)
Resistance
Between (A) and (B)
120 ±12
WA500-6
TROUBLESHOOTING
Possible causes and standard value in normal state
DB2RKR Cause
Standard value in normal state/Remarks on troubleshooting
6 Defective engine controller
If causes 1 – 5 are not the cause of the problem, the engine controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
Related Circuit Diagram
WA500-6
40-337 b
TROUBLESHOOTING
DB90KK
DB90KK Work Equipment Controller: Low Source Voltage (input) Action Code
Failure Code
E03
DB90KK
Trouble
Work equipment controller: Low source voltage (input) (Work equipment controller system)
Contents of trouble
• Voltage of work equipment controller UNSW power supply (battery direct power supply) is low. • Voltage of constant power supply (battery direct power supply) is 18 V or less.
Action of controller
• Does not display failure codes other than this code if voltage of constant power supply (battery direct power supply) remains under 18 V for more than two seconds. • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work equipment lever are set to N (Neutral). • Turns the centralized warning lamp and alarm buzzer ON. • Cannot operate normally since it cannot sense the input signals properly.
Problem that appears on machine
• The machine cannot operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective slow blow fuse (SBF1)
If the slow blow fuse is shut down, the circuit probably has a grounding fault, etc. (See cause 4.)
2
Defective fuse No.7 of fuse box A
If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between battery relay BTR1 D03 – slow blow fuse SBF1 R01
Resistance
Max. 1
Wiring harness between slow blow fuse SBF1 R02 – fuse No.7 of fuse box A
Resistance
Max. 1
Wiring harness between fuse No.7 of fuse box A – L07 (female) (1), (11)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between battery relay BTR1 D03 – slow blow fuse SBF1 R01 and chassis ground
Grounding fault in wiring 4 harness Wiring harness between slow blow fuse (Contact with ground circuit) SBF1 R02 – fuse No.7 of fuse box A and chassis ground
Wiring harness between fuse No.7 of fuse box A – L07 (female) (1), (11) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
40-338 b
Defective work equipment controller
L07
Voltage
Between (1), (11) and (21), (31), (32), (33)
20 – 30 V
WA500-6
TROUBLESHOOTING
DB90KK
Related Circuit Diagram
WA500-6
40-339 b
TROUBLESHOOTING
DB90KT
DB90KT Work Equipment Controller: Abnormality in Controller Action Code
Failure Code
E01
DB90KT
Trouble
Work equipment controller: Abnormality in controller (Work equipment controller system)
Contents of trouble
• The information in the ROM (non-volatile memory) of the work equipment controller system is abnormal.
Action of controller
• Sets the internal adjustment values to the default values. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The machine may falsely detect errors. • Performance degrades since the machine is controlled with improper data.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes and standard value in normal state
40-340 b
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective work equipment controller
• Since problem is in system, troubleshooting cannot be carried out. • Replace the work equipment controller.
WA500-6
TROUBLESHOOTING
DB90KT
MEMORANDUM
WA500-6
40-341 b
TROUBLESHOOTING
DB92KK
DB92KK Work Equipment Controller Load Power Supply Line: Low Source Voltage (input) Action Code
Failure Code
E03
DB92KK
Trouble
Work equipment controller load power supply line: Low source voltage (input) (Work equipment controller system)
Contents of trouble
• The voltage of the 24V solenoid power supply system is low. • Detection conditions: Terminal C input turned OFF, constant power supply (battery direct power supply) above 20 V, and solenoid power supply below 18 V
Action of controller
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.) • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering lever and work equipment lever are set to N (Neutral).
Problem that appears on machine
• Work equipment does not move.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
1
Defective slow blow fuse (SBF2)
If the slow blow fuse is shut down, the circuit probably has a grounding fault, etc. (See cause 4.)
2
Defective fuse No. 7 of fuse box B
If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between battery relay BTR1 D04 – slow blow fuse SBF2 R03
Resistance
Max. 1
Wiring harness between slow blow fuse SBF2 R05 – fuse No.7 of fuse box B
Resistance
Max. 1
Wiring harness between fuse No.7 of fuse box B – L07 (female) (2), (12), (22)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery relay BTR1 D04 – slow blow fuse SBF2 R03 and chassis ground
Grounding fault in wiring 4 harness Wiring harness between slow blow fuse (Contact with ground circuit) SBF2 R05 – fuse No.7 of fuse box B and chassis ground
Wiring harness between fuse No.7 of fuse box B – L07 (female) (2), (12), (22), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5
40-342 b
Defective work equipment controller
L07
Voltage
Between (2), (12), (22) and (21), (31), (32), (33)
20 – 30 V
WA500-6
TROUBLESHOOTING
DB92KK
Related Circuit Diagram
WA500-6
40-343 b
TROUBLESHOOTING
DB95KX
DB95KX Work Equipment Controller Power Supply Output: Out-of-Input Signal Range Action Code E03
Failure Code DB95KX
Trouble
Work equipment controller power supply output: Out-of-input signal range (Work equipment controller system)
Contents of trouble
• Normal voltage output of 5 V sensor power supply system is out of range (outside 4.7 – 5.3 V).
Action of controller
• Cannot sense the input signals normally due to abnormal potentiometer signal. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The operator cannot operate the work equipment (all stop). • The following potentiometer errors occur.
Related information
• Method of reproducing failure code: Turn starting switch ON. • See failure code DH21KA for open circuit in wiring harness.
Cause Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective joystick steering lever potentiometer 1 (Internal disconnection or short circuit)
without turning starting switch ON.
JS3 (male)
Resistance
Between (4) and (1)
4 – 6 k
Between (1), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Defective 3-spool valve EPC lever potentiometer 2 (Internal disconnection or short circuit)
without turning starting switch ON. S25 (male)
Resistance
Between (4) and (1)
2.5 – 3.9 k
Between (1), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Defective lift arm EPC lever potentiometer 3 (Internal disconnection or short circuit)
without turning starting switch ON. S03 (male)
Resistance
Between (4) and (1)
2.5 – 3.9 k
Between (1), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Defective bucket EPC lever potentiometer 4 (Internal disconnection or short circuit)
40-344 b
without turning starting switch ON. S02 (male)
Resistance
Between (4) and (1)
2.5 – 3.9 k
Between (1), (4) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DB95KX Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective oil pressure sensor 5 of work equipment pump
Possible causes and standard value in normal state
F16 (male)
Resistance
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine, tilt the bucket and carry out troubleshooting. F16
Work equipment
Voltage
Between (B) and (A)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
When bucket tilt relieved
3.02 – 3.42 V
Between (C) and (A)
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 6 harness (Contact with ground circuit) Wiring harness between L05 (female) (22) – Resistance Min. 1 M chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and 7
WA500-6
Defective work equipment controller
carry out troubleshooting. L05
Voltage
Between (22) and (21)
4.85 – 5.15 V
40-345 b
TROUBLESHOOTING
DB95KX
Related Circuit Diagram
40-346 b
WA500-6
TROUBLESHOOTING
DB99KQ
DB99KQ Work Equipment Controller: Disagreement of Model Selection Signals Action Code E03
Failure Code DB99KQ
Trouble
Work equipment controller model selection: Disagreement of model selection signals (Machine monitor system)
Contents of trouble
• Work equipment controller model is mistaken for another one.
Action of controller
• Operates on the assumption that the controller model which has been used before occurrence of the failure code is still used. • Does not display failure codes which may be false detected. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Work equipment may not operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Improper machine monitor 1 model selection
• Set the model with the service mode adjustment function of the machine monitor. • See Machine Monitor System: Service Mode: Model Selection Function in the Testing and Adjusting section.
2 Work equipment controller
• Check if work equipment controller has the correct part number. • If the part number is not correct, replace it.
40-347 b
TROUBLESHOOTING
DB9RKR
DB9RKR Work Equipment Controller: CAN Defective Communication Action Code
Failure Code
E03
DB9RKR
Trouble
CAN communication with work equipment controller: Defective communication (Abnormality in target component system) (Transmission controller system)
Contents of trouble
• Communication via CAN signal line between the work equipment controller and transmission controller is defective.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Uses CAN information that was sent from work equipment controller before the occurrence of the error. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 1 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L06 (female) (22) – L03 (female) (22)
Resistance
Max. 1
Wiring harness between L06 (female) (32) – L03 (female) (32)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L06 (female) (22) – 2 harness L03 (female) (22) and chassis ground (Contact with ground circuit) Wiring harness between L06 (female) (32) – L03 (female) (32) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. 3
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L06 (female) (22) – L03 (female) (22) and chassis ground
Voltage
Max. 1 V
Wiring harness between L06 (female) (32) – L03 (female) (32) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Short circuit in wiring harness 4 (with another wiring harness) Wiring harness between L06 (female) (22) – Resistance Min. 1 M (32) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
Defective end point resistance
CAN1 (male)
Resistance
Between (A) and (B)
120 ±12
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
40-348 b
E21 (male)
Resistance
Between (A) and (B)
120 ±12
WA500-6
TROUBLESHOOTING
Possible causes and standard value in normal state
6
DB9RKR Cause
Standard value in normal state/Remarks on troubleshooting
Defective work equipment controller
If causes 1 – 5 are not the cause of the problem, the work equipment controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
Related Circuit Diagram
WA500-6
40-349 b
TROUBLESHOOTING
DB9RMA
DB9RMA Work Equipment Controller Option Setting: Malfunction Action Code
Failure Code
E03
DB9RMA
Trouble
Work equipment controller option setting: Malfunction (Machine monitor system)
Contents of trouble
• Optional setting of the machine monitor disagrees with its recognition in the work equipment controller.
Action of controller
• The work equipment controller complies with its optional setting recognition. • Turns the centralized warning lamp and alarm buzzer ON.
Problem that appears on machine
• Optional components do not operate normally.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause Possible causes and standard value in normal state
40-350 b
Standard value in normal state/Remarks on troubleshooting
Defective work equipment controller
Since trouble is in system, troubleshooting cannot be carried out.
2 Defective machine monitor
Since trouble is in system, troubleshooting cannot be carried out.
1
WA500-6
TROUBLESHOOTING
DB9RMA
MEMORANDUM
WA500-6
40-351 b
TROUBLESHOOTING
DB9RMC
DB9RMC Work Equipment Controller: CAN Communication Defective Operation Action code
Failure code
E03
DB9RMC
Trouble
CAN communication with work equipment controller: Defective operation (Work equipment controller system)
Contents of trouble
• Communication via CAN signal line between the work equipment controller and transmission controller is defective. • The travel speed signal cannot be transmitted from the transmission controller. • The engine start prohibition signal cannot be transmitted from the transmission controller. • If cause of failure disappears, system resets itself.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Judges that the travel speed is at 0 km/h. • Uses CAN information that was sent from transmission controller before the occurrence of the error.
Problem that appears on machine
• The operator cannot use semi-automatic digging occasionally or cannot use it at any time. • The engine can start when the joystick steering lever is not in neutral. • Swing speed increases because joystick steering cannot sense travel speed properly.
Related information
• Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 1 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L06 (female) (22) – L03 (female) (22)
Resistance
Max. 1
Wiring harness between L06 (female) (32) – L03 (female) (32)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L06 (female) (22) – 2 harness L03 (female) (22) and chassis ground (Contact with ground circuit) Wiring harness between L06 (female) (32) – L03 (female) (32) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. Hot short in wiring harness 3 (Contact with 24 V circuit)
Wiring harness between L06 (female) (22) – L03 (female) (22) and chassis ground
Voltage
Max. 1 V
Wiring harness between L06 (female) (32) – L03 (female) (32) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting 4
without turning starting switch ON. Short circuit in wiring harness (with another wiring harness) Wiring harness between L06 (female) (22) – (32)
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5
Defective end point resistance
CAN1 (male)
Resistance
Between (A) and (B)
120 ±12
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
40-352 b
E21 (male)
Resistance
Between (A) and (B)
120 ±12
WA500-6
TROUBLESHOOTING
Possible causes and standard value in normal state
6
DB9RMC Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission controller
If causes 1 – 5 are not the cause of the problem, the transmission controller may be defective. (Since problem is in system, troubleshooting cannot be carried out.)
Related Circuit Diagram
WA500-6
40-353 b
TROUBLESHOOTING
DD15LD
DD15LD Switch (Panel Switch 1 ■): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD15LD
Trouble
■ Switch (Panel switch 1): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the machine monitor mode selector switch 1 ■ (panel switch 1) is kept CLOSED continuously for more than one minute.
Action of controller
• None in particular.
Problem that appears on machine
• The operator cannot operate the monitor (cannot enter the Service mode). • Character display may not display letters.
Related information
• The input state (ON/OFF) from the machine monitor mode selector switch 1 ■ (panel switch 1) can be checked with the monitoring function (Code: 40901 D-IN-15). • The operator may not be able to use the monitoring function because of the ■ switch problem. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective ■ switch 1 (Panel switch 1) (Internal short circuit)
L66 (male) Between (4) and (5)
Possible causes and standard value in normal state
■ switch (Panel switch 1)
Resistance
ON
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L52 (female) (17) and L66 (female) (4) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L52 Between (17) and chassis ground
40-354 b
■ switch (Panel switch 1)
Voltage
ON
20 – 30 V
Other than above
Max. 1 V
WA500-6
TROUBLESHOOTING
DD15LD
Related Circuit Diagram
WA500-6
40-355 b
TROUBLESHOOTING
DD16LD
DD16LD Switch (Panel Switch 2 ): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD16LD
Trouble
Switch (Panel switch 2): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the machine monitor mode selector switch 2 (panel switch 2) is kept CLOSED continuously for more than one minute.
Action of controller
• None in particular.
Problem that appears on machine
• The operator cannot operate the monitor. • Character display may not display letters.
Related information
• The input state (ON/OFF) from the machine monitor mode selector switch 2 (panel switch 2) can be checked with the monitoring function (Code: 40901 D-IN-14). • The operator may not be able to use the monitoring function because of the switch problem. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective switch 1 (Panel switch 2) (Internal short circuit)
L66 (male) Between (5) and (6)
Possible causes and standard value in normal state
switch (Panel switch 2)
Resistance
ON
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L52 (female) (8) and L66 (female) (6) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L52 Between (8) and chassis ground
40-356 b
switch (Panel switch 2)
Voltage
ON
20 – 30 V
Other than above
Max. 1 V
WA500-6
TROUBLESHOOTING
DD16LD
Related Circuit Diagram
WA500-6
40-357 b
TROUBLESHOOTING
DD17LD
DD17LD Switch (Panel Switch 3 <): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD17LD
Trouble
< Switch (Panel switch 3): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the machine monitor mode selector switch 3 < (panel switch 3) is kept CLOSED continuously for more than one minute.
Action of controller
• None in particular.
Problem that appears on machine
• The operator cannot operate the monitor. • Character display may not display letters.
Related information
• The input state (ON/OFF) from the machine monitor mode selector switch 3 < (panel switch 3) can be checked with the monitoring function (Code: 40904 D-IN-38). • The operator may not be able to use the monitoring function because of the < switch problem. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective < switch 1 (Panel switch 3) (Internal short circuit)
L65 (female) Between (4) and (5)
Possible causes and standard value in normal state
< switch (Panel switch 3)
Resistance
ON
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L54 (female) (7) Resistance Min. 1 M and L65 (female) (4) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L54 (female) Between (7) and chassis ground
40-358 b
< switch (Panel switch 3)
Voltage
ON
Max. 1 V
Other than above
20 – 30 V
WA500-6
TROUBLESHOOTING
DD17LD
Related Circuit Diagram
WA500-6
40-359 b
TROUBLESHOOTING
DD18LD
DD18LD Switch (Panel Switch 4 >): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD18LD
Trouble
> Switch (Panel switch 4): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the machine monitor mode selector switch 4 > (panel switch 4) is kept CLOSED continuously for more than one minute.
Action of controller
• None in particular. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The operator cannot operate the monitor.
Related information
• The input state (ON/OFF) from the machine monitor mode selector switch 4 > (panel switch 4) can be checked with the monitoring function (Code: 40904 D-IN-37). • The operator may not be able to use the monitoring function because of the > switch problem. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective > switch 1 (Panel switch 4) (Internal short circuit)
L65 (female) Between (5) and (6)
Possible causes and standard value in normal state
> switch (Panel switch 4)
Resistance
ON
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L54 (female) (15) Resistance Min. 1 M and L65 (female) (6) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L54 (female) Between (15) and chassis ground
40-360 b
> switch (Panel switch 4)
Voltage
ON
Max. 1 V
Other than above
20 – 30 V
WA500-6
TROUBLESHOOTING
DD18LD
Related Circuit Diagram
WA500-6
40-361 b
TROUBLESHOOTING
DD1ALD
DD1ALD Remote Positioner Raise/Lower Set Switch (raise): Switch Is Kept Pressed for Long Time Action Code
Failure Code
E01
DD1ALD
Trouble
Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time (Work equipment controller system)
Contents of trouble
• Since the remote positioner raise/lower set switch (raise) system has a grounding fault, operator cannot set raising.
Action of controller
• Stops setting the lift arm raise set position. • Stops the remote raise stop operation. • Turns the lift arm raise set indicator OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The operator cannot set the lift arm raise set position. • The remote positioner raise stop control does not operate.
Related information
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked with the monitoring function (Code: 40913 D-IN-28). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Remote positioner S13 (male) Defective remote positioner raise/lower set switch 1 raise/lower set switch (raise) Raise (Internal short circuit) Between (5) and (6) Other than above Possible causes and standard value in normal state
Between (5), (6) and chassis ground
Constant
Resistance Max. 1 Min. 1 M Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L06 (female) (13) – (Contact with ground circuit) Resistance Min. 1 M S13 (female) (6) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L06 (male) Between (13) and chassis ground
40-362 b
Remote positioner raise/lower set switch
Voltage
Raise
Max. 1 V
Other than above
7 – 10 V
WA500-6
TROUBLESHOOTING
DD1ALD
Related Circuit Diagram
WA500-6
40-363 b
TROUBLESHOOTING
DD1BLD
DD1BLD Remote Positioner Raise/Lower Set Switch (lower): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD1BLD
Trouble
Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time (Work equipment controller system)
Contents of trouble
• Since the remote positioner raise/lower set switch (lower) system has a grounding fault, operator cannot set lowering.
Action of controller
• Stops setting the lift arm lower set position. • Stops the remote lower stop operation. • Turns the lift arm lower set indicator OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The operator cannot set the lower set position. • The remote positioner lower stop control does not operate.
Related information
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked with the monitoring function (Code: 40913 D-IN-29). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective remote positioner 1 raise/lower set switch (Internal short circuit)
Possible causes and standard value in normal state
S13 (male) Between (4) and (5) Between (4), (5) and chassis ground
Remote positioner raise/lower set switch
Resistance
Lower
Max. 1
Other than above
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L06 (female) (3) – (Contact with ground circuit) Resistance Min. 1 M S13 (female) (4) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L06 (male) Between (3) and chassis ground
40-364 b
Remote positioner raise/lower set switch
Voltage
Lower
Max. 1 V
Other than above
7 – 10 V
WA500-6
TROUBLESHOOTING
DD1BLD
Related Circuit Diagram
WA500-6
40-365 b
TROUBLESHOOTING
DD1CLD
DD1CLD Load Meter Subtotal Switch: Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD1CLD
Trouble
Load meter subtotal switch: Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The load meter subtotal switch may not operate because of grounding fault in load meter subtotal switch system.
Action of controller
• None in particular.
Problem that appears on machine
• The total amount of load cannot be set to 0 on the screen. • Data cannot be output to printer (if equipped).
Related information
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring function (Code: 40904 D-IN-32). • Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective load meter subtotal 1 switch (Internal short circuit)
Possible causes and standard value in normal state
S08 (male)
Load meter subtotal switch ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (3) and (4) Between (3), (4) and chassis ground
Resistance
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L54 (female) (4) – (Contact with ground circuit) Resistance Min. 1 M S08 (female) (3) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L54 (male) Between (4) and chassis ground
40-366 b
Load meter subtotal switch
Voltage
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DD1CLD
Related Circuit Diagram
WA500-6
40-367 b
TROUBLESHOOTING
DD1FLD
DD1FLD Load Meter Mode Selector Switch (A/B): Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD1FLD
Trouble
Load meter mode selector switch (A/B): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the load meter mode selector switch (A/B) is kept CLOSED continuously for more than one minute
Action of controller
• None in particular.
Problem that appears on machine
• The working object cannot be changed. • Character display may not display letters.
Related information
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the monitoring function (Code: 40901 D-IN-10). • Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective load meter mode 1 selector switch (A/B) (Internal short circuit)
Possible causes and standard value in normal state
L69 (male)
Load meter mode selector switch (A/B)
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (5) and (6) Between (5), (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and 2
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L52 (female) (6) and L69 (female) (6) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L52 (female) Between (6) and chassis ground
40-368 b
Load meter mode selector switch (A/B)
Voltage
ON
20 – 30 V
OFF
Max. 1 V
WA500-6
TROUBLESHOOTING
DD1FLD
Related Circuit Diagram
WA500-6
40-369 b
TROUBLESHOOTING
DD1GLD
DD1GLD Load Meter Mode Selector Switch (+/-): Switch is Kept Pressed for Long Time Action Code E01
Failure Code DD1GLD
Trouble
Load meter mode selector switch (+/–): Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The input circuit of the load meter mode selector switch (+/–) is kept CLOSED continuously for more than one minute.
Action of controller
• None in particular.
Problem that appears on machine
• The operator cannot use settings of load meter addition mode. • Character display may not display letters.
Related information
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the monitoring function (Code: 40901 D-IN-11). • Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective load meter mode 1 selector switch (+/–) (Internal short circuit)
Possible causes and standard value in normal state
L69 (male)
Load meter mode selector switch (+/–)
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (4) and (5) Between (4), (5) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L52 (female) (15) and L69 (female) (4) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L52 (female) Between (15) and chassis ground
40-370 b
Load meter mode selector switch (+/–)
Voltage
ON
20 – 30 V
OFF
Max. 1 V
WA500-6
TROUBLESHOOTING
DD1GLD
Related Circuit Diagram
WA500-6
40-371 b
TROUBLESHOOTING
DD1HLD
DD1HLD Load Meter Display Selector Switch: Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DD1HLD
Trouble
Load meter display selector switch: Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The load meter display selector switch does not operate because of grounding fault in the load meter display selector switch system.
Action of controller
• None in particular.
Problem that appears on machine
• Unable to display cumulative data. • Character display may not display letters.
Related information
• The input state (weight) from the load meter display selector switch can be checked with the monitoring function (Code: 40902 D-IN-23). • Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective load meter display 1 selector switch (Internal short circuit)
Possible causes and standard value in normal state
L70 (male)
Load meter display selector switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (5) and (6) Between (5), (6) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L53 (female) (10) Resistance Min. 1 M and L70 (female) (6) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L53 (male) Between (10) and chassis ground
40-372 b
Load meter display selector switch
Voltage
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DD1HLD
Related Circuit Diagram
WA500-6
40-373 b
TROUBLESHOOTING
DDA7L4
DDA7L4 RPM Set ON/OFF Switch: ON/OFF Signals Disagree Action Code
Failure Code
E01
DDA7L4
Trouble
RPM set ON/OFF switch: ON/OFF signals disagree (Transmission controller system)
Contents of trouble
• RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system.
Action of controller
• Turns RPM set function OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• RPM setting is disabled.
Related information
• The input state (ON/OFF) from the RPM set ON/OFF switch (pressed upward) can be checked with the monitoring function (Code: 95500 THROT LOCK A). • The input state (ON/OFF) from the RPM set ON/OFF switch (pressed downward) can be checked with the monitoring function (Code: 95501 THROT LOCK B). • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S11 (male)
1
Defective RPM set ON/OFF switch (Internal short circuit)
RPM set ON/OFF switch
Resistance
ON , OFF
Min. 1 M
ON
Max. 1
ON
Max. 1
ON , OFF
Min. 1 M
Constant
Min. 1 M
Between (4) and (5)
Between (5) and (6) Between (4), (5), (6) and chassis ground Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L02 (female) (13) – S11 (female) (4) and chassis ground
Voltage
Max. 1 V
Wiring harness between L02 (female) (19) – S11 (female) (6) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L02 3 Defective machine monitor
Between (13) and chassis ground Between (19) and chassis ground
40-374 b
RPM set ON/OFF switch
Voltage
ON , OFF
Max. 1 V
ON
20 – 30 V
ON
20 – 30 V
ON , OFF
Max. 1 V
WA500-6
TROUBLESHOOTING
DDA7L4
Related Circuit Diagram
WA500-6
40-375 b
TROUBLESHOOTING
DDA8KB
DDA8KB RPM Set Idle UP/DOWN Selector Switch (idle UP): Short Circuit Action Code
Failure Code
E01
DDA8KB
Trouble
RPM set idle UP/DOWN selector switch (idle UP): Short circuit (Transmission controller system)
Contents of trouble
• Idle-up switch is misjudged to be ON due to ground fault in RPM set idle UP/DOWN selector switch (idle UP) system.
Action of controller
• Turns RPM set function OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• RPM setting is disabled.
Related information
• The input state (ON/OFF) from the RPM set idle UP/DOWN selector switch can be checked with the monitoring function (Code: 40906 D-IN-13, D-IN-14). • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and operate the RPM set idle UP/DOWN selector switch (idle UP)
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S12 (male) Defective RPM set idle UP/ 1 DOWN selector switch (Internal short circuit)
Between (4) and (5)
Between (5) and (6)
Possible causes and standard value in normal state
Between (4), (5), (6) and chassis ground
RPM set idle UP/ DOWN selector switch
Resistance
Idle UP position or neutral
Min. 1 M
Idle DOWN position
Max. 1
Idle UP position
Max. 1
Idle DOWN position or neutral
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (19) – Resistance Min. 1 M S12 (female) (6) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L04 3
Defective transmission controller
Between (29) and chassis ground Between (19) and chassis ground
40-376 b
RPM set idle UP/ DOWN selector switch
Voltage
Idle UP position or neutral
20 – 30 V
Idle DOWN position
Max. 1 V
Idle UP position
Max. 1 V
Idle DOWN position or neutral
20 – 30 V
WA500-6
TROUBLESHOOTING
DDA8KB
Related Circuit Diagram
WA500-6
40-377 b
TROUBLESHOOTING
DDA9KB
DDA9KB RPM Set Idle UP/DOWN Selector Switch (idle DOWN): Short Circuit Action Code
Failure Code
E01
DDA9KB
Trouble
RPM set idle UP/DOWN selector switch (idle-down): Short circuit (Transmission controller system)
Contents of trouble
• Idle DOWN switch is misjudged to be ON due to ground fault in RPM set idle UP/DOWN switch (idle DOWN) system.
Action of controller
• Turns RPM set function OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• RPM setting is disabled.
Related information
• The input state (ON/OFF) from the RPM set idle UP/DOWN selector switch can be checked with the monitoring function (Code: 40906 D-IN-13, D-IN-14). • Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON and operate the RPM set idle UP/DOWN selector switch (idle DOWN).
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S12 (male) Defective RPM set idle UP/ 1 DOWN selector switch (Internal short circuit)
Between (4) and (5)
Between (5) and (6)
Possible causes and standard value in normal state
Between (4), (5), (6) and chassis ground
RPM set idle UP/ DOWN selector switch
Resistance
Idle UP position or neutral
Min. 1 M
Idle DOWN position
Max. 1
Idle UP position
Max. 1
Idle DOWN position or neutral
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (29) – Resistance Min. 1 M S12 (female) (4) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L04 3
Defective transmission controller
Between (29) and chassis ground Between (19) and chassis ground
40-378 b
RPM set idle UP/ DOWN selector switch
Voltage
Idle UP position or neutral
20 – 30 V
Idle DOWN position
Max. 1 V
Idle UP position
Max. 1 V
Idle DOWN position or neutral
20 – 30 V
WA500-6
TROUBLESHOOTING
DDA9KB
Related Circuit Diagram
WA500-6
40-379 b
TROUBLESHOOTING
DDB6L4
DDB6L4 Parking Brake Switch (Neutralizer): ON/OFF Signals Disagree Action Code
Failure Code
E03
DDB6L4
Trouble
Parking brake switch (Neutralizer): ON/OFF signals disagree (Transmission controller system)
Contents of trouble
• Controller outputs a failure signal when all the following conditions are satisfied: • Parking brake switch signal ON (neutralizer signal OPEN) • Parking brake released (by CAN communication from the machine monitor) • Hydraulic oil temperature under 25°C (77°F)
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Forward-reverse cannot be operated, or parking brake indicator lamp remains turned off.
Related information
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked with the monitoring function (Code: 40903 D-IN-26). • The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function (Code: 40907 D-IN-23). • If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out-of-input signal range) is displayed, carry out troubleshooting for it first. • If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnormality in target component system) is displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Turn the starting switch and parking brake switch ON. • If emergency parking brake reset switch is turned ON (set to release position) while parking brake switch is ON (set to parking position), this error may be detected.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. PB.SW (male) Defective parking brake 1 indicator switch (Internal disconnection) Between (1) and (2) Possible causes and standard value in normal state
Parking brake oil pressure
Resistance
When parking brake is released, Min. 6.2 kg/cm² (Min. 89 psi)
Max. 1
When parking brake applied, Max. 3.5 kg/cm² (Max. 49 psi)
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L58 (male) Defective parking brake 2 switch (Internal disconnection)
Between (3) and (4) Between (5) and (6) Between (3) and (6)
40-380 b
Parking brake switch
Resistance
ON
Min. 1 M
OFF
Max. 1
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
WA500-6
TROUBLESHOOTING
DDB6L4 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact) Possible causes and standard value in normal state
Wiring harness between L54 (female) (1) – PB.SW (female) (1)
Resistance
Max. 1
Wiring harness between PB.SW (female) (2) – chassis ground
Resistance
Max. 1
Wiring harness between L58 (female) (3) – L03 (female) (6)
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L03 Defective transmission 4 controller Between (6) and chassis ground
WA500-6
Parking brake switch
Voltage
ON
Max. 1 V
Turn starting switch ON and then turn parking brake switch ON and OFF.
20 – 30 V
40-381 b
TROUBLESHOOTING
DDB6L4
Related Circuit Diagram
40-382 b
WA500-6
TROUBLESHOOTING
DDB6L4
MEMORANDUM
WA500-6
40-383 b
TROUBLESHOOTING
DDD1LD
DDD1LD Remote Positioner Bucket Angle Set Switch: Switch is Kept Pressed for Long Time Action Code E01
Failure Code DDD1LD
Trouble
Remote positioner bucket angle set switch: Switch is kept pressed for long time (Work equipment controller system)
Contents of trouble
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket angle set switch system. • Detected continuous operation for 30 seconds and longer.
Action of controller
• Judged that remote positioner bucket angle set switch is turned ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Remote positioner raise set signal: Setting is changed to upward by 1° (degree) and the monitor displays the changed angle. • Remote positioner lower set signal: Setting is changed to downward by 1° (degree) and the monitor displays the changed angle. • Cannot be changed to upward or downward.
Related information
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with the monitoring function (Code: 40911 D-IN-10, D-IN-11). • Only for load meter (if equipped) • Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S14 (male) Defective remote positioner 1 bucket angle set switch (Internal short circuit)
Between (4) and (5) Between (5) and (6) Between (4), (5), (6) and chassis ground
Possible causes and standard value in normal state
Remote positioner bucket angle set switch
Resistance
Downward ON
Max. 1
OFF
Min. 1 M
Upward ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L07 (female) (30) – 2 harness S14 (female) (6) and chassis ground (Contact with ground circuit) Wiring harness between L07 (female) (40) – S14 (female) (4) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Remote positioner bucket angle set switch
Voltage
Between (40) and chassis ground
Downward ON
Max. 1 V
OFF
7 – 10 V
Between (30) and chassis ground
Upward ON
Max. 1 V
OFF
7 – 10 V
L07 (female) Defective work equipment 3 controller
40-384 b
WA500-6
TROUBLESHOOTING
DDD1LD
Related Circuit Diagram
WA500-6
40-385 b
TROUBLESHOOTING
DDE5MA
DDE5MA Emergency Steering Drive Switch: Malfunction Action Code
Failure Code
E01
DDE5MA
Trouble
Emergency steering drive switch: Malfunction (Machine monitor system)
Contents of trouble
• When engine stopped, steering pump pressure detected because of ground fault in the emergency steering drive switch system.
Action of controller
• None in particular.
Problem that appears on machine Related information
— • The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring function (Code: 40903 D-IN-30). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. • Relieve the steering circuit. Defective emergency steering 1 drive switch (Internal defect)
T04 (male) Between (1) and (2)
Possible causes and standard value in normal state
Between (1), (2) and chassis ground
Steering relief oil pressure
Resistance
Low
Min. 1 M
Normal
Max. 1
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L54 (female) (3) – Resistance Min. 1 M T04 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. • Relieve the steering circuit. 3 Defective machine monitor
L54 (female) Between (3) and chassis ground
40-386 b
Steering relief oil pressure
Voltage
Low
20 – 30 V
Normal
Max. 1 V
WA500-6
TROUBLESHOOTING
DDE5MA
Related Circuit Diagram
WA500-6
40-387 b
TROUBLESHOOTING
DDK3KA
DDK3KA Right FNR Switch: Disconnection Action Code
Failure Code
E03
DDK3KA
Trouble
Right FNR switch: Disconnection (Transmission controller system)
Contents of trouble
• Right FNR (directional) switch signal cannot be recognized due to disconnection or hot short circuit in right FNR (directional) switch input signal system.
Action of controller
• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with directional lever. • Shift lever position pilot lamp turns out.
Related information
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942 D-IN-32). • Only for right FNR (directional) switch (If equipped) • Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch ON + Operate right FNR (directional) switch.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S09 (male)
Defective right FNR (directional) switch 1 (Internal disconnection or short circuit)
Between (1) and (2) Between (1) and (3) Between (1) and (4)
Possible causes and standard value in normal state
Between (1), (2), (3), (4) and chassis ground
Right FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
N (Neutral).
Max. 1
Other than above
Min. 1 M
R (Reverse)
Max. 1
Other than above
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
40-388 b
Wiring harness between L03 (female) (28) – S09 (female) (3)
Resistance
Max. 1
Wiring harness between L03 (female) (37) – S09 (female) (2)
Resistance
Max. 1
Wiring harness between L03 (female) (38) – S09 (female) (4)
Resistance
Max. 1
Wiring harness between S09 (female) (1) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DDK3KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 3 (Contact with 24 V circuit)
Wiring harness between L03(female) (28) – S09 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (37) – S09 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (38) – S09 (female) (4) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes and standard value in normal state
carry out troubleshooting. • Directional selector ON/OFF switch ON L03 4
Defective transmission controller
Voltage
Between (37) and chassis ground
F (Forward)
Max. 1 V
Other than above
7 – 10 V
Between (28) and chassis ground
N (Neutral).
Max. 1 V
Other than above
7 – 10 V
R (Reverse)
Max. 1 V
Other than above
7 – 10 V
Between (38) and chassis ground
WA500-6
Right FNR (directional) switch
40-389 b
TROUBLESHOOTING
DDK3KA
Related Circuit Diagram
40-390 b
WA500-6
TROUBLESHOOTING
DDK3KB
DDK3KB Right FNR Switch: Short Circuit Action Code
Failure Code
E03
DDK3KB
Trouble
Right FNR switch: Short circuit (Transmission controller system)
Contents of trouble
• Multiple right FNR (directional) switch signals are input due to grounding fault in right FNR (directional) switch input signal system.
Action of controller
• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with directional lever. • Multiple shift lever position pilot lamps light up.
Related information
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32). • Only for right FNR (directional) switch (If equipped) • Method of reproducing failure code: Turn the starting switch and directional selector ON/OFF switch ON + Operate right FNR (directional) switch.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S09 (male) Between (1) and (2) Defective right FNR 1 (directional) switch (Internal short circuit) Possible causes and standard value in normal state
Between (1) and (3) Between (1) and (4) Between (1), (2), (3), (4) and chassis ground
Right FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
N (Neutral).
Max. 1
Other than above
Min. 1 M
R (Reverse)
Max. 1
Other than above
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (28) – S09 (female) (3) and chassis ground
Grounding fault in wiring 2 harness (Contact with ground circuit) Wiring harness between L03 (female) (37) – S09 (female) (2) and chassis ground Wiring harness between L03 (female) (38) – S09 (female) (4) and chassis ground
WA500-6
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
40-391 b
TROUBLESHOOTING
DDK3KB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Directional selector ON/OFF switch ON L03 Possible causes and standard value in normal state
3
Defective transmission controller
Between (37) and chassis ground Between (28) and chassis ground Between (38) and chassis ground
40-392 b
Right FNR (directional) switch
Voltage
F (Forward)
Max. 1 V
Other than above
7 – 10 V
N (Neutral).
Max. 1 V
Other than above
7 – 10 V
R (Reverse)
Max. 1 V
Other than above
7 – 10 V
WA500-6
TROUBLESHOOTING
DDK3KB
Related Circuit Diagram
WA500-6
40-393 b
TROUBLESHOOTING
DDK4KA
DDK4KA Joystick Steering FNR Switch: Disconnection Action Code
Failure Code
E03
DDK4KA
Trouble
Joystick steering FNR switch: Disconnection (Transmission controller system)
Contents of trouble
• Joystick steering FNR (directional) switch signal is not input due to disconnection or hot short circuit in joystick steering FNR (directional) switch input signal system.
Action of controller
• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with directional lever. • Shift lever position pilot lamp turns out.
Related information
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or D-IN-32). • Only for joystick steering (If equipped) • Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Operate joystick steering FNR (directional) switch.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JL2 (male)
Defective joystick steering FNR (directional) switch 1 (Internal disconnection or short circuit)
Between (1) and (2) Between (1) and (3) Between (1) and (4)
Possible causes and standard value in normal state
Between (1), (2), (3), (4) and chassis ground
Joystick steering FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
N (Neutral).
Max. 1
Other than above
Min. 1 M
R (Reverse)
Max. 1 z
Other than above
Min. 1 Mz
Constant
Min. 1 Mz
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
40-394 b
Wiring harness between L03 (female) (28) – JL2 (female) (3)
Resistance
Max. 1
Wiring harness between L03 (female) (37) – JL2 (female) (2)
Resistance
Max. 1
Wiring harness between L03 (female) (38) – JL2 (female) (4)
Resistance
Max. 1
Wiring harness between JL2 (female) (1) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DDK4KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 3 (Contact with 24 V circuit)
Wiring harness between L03 (female) (28) – JL2 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (37) – JL2 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (38) – JL2 (female) (4) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes and standard value in normal state
carry out troubleshooting. • Joystick selector ON/OFF switch ON. L03 4
Defective transmission controller
Voltage
Between (37) and chassis ground
F (Forward)
Max. 1 V
Other than above
7 – 10 V
Between (28) and chassis ground
N (Neutral).
Max. 1 V
Other than above
7 – 10 V
R (Reverse)
Max. 1 V
Other than above
7 – 10 V
Between (38) and chassis ground
WA500-6
Joystick steering FNR (directional) switch
40-395 b
TROUBLESHOOTING
DDK4KA
Related Circuit Diagram
40-396 b
WA500-6
TROUBLESHOOTING
DDK4KB
DDK4KB Joystick Steering FNR Switch: Short Circuit Action Code
Failure Code
E03
DDK4KB
Joystick steering FNR switch: Short circuit (Transmission controller system)
Trouble
Contents of trouble
• Multiple signals are input due to grounding fault in joystick steering FNR (directional) switch input signal system.
Action of controller
• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with directional lever. • Multiple shift lever position pilot lamps light up.
Related information
• The input signal (ON/OFF) from the right FNR (directional) or joystick steering FNR (directional) switch can be checked with the monitoring function (Code: 40908 D-IN-24, D-IN-31 or Code: 40942 D-IN-32). • Only for joystick steering (If equipped) • Method of reproducing failure code: Turn the starting switch and joystick ON/OFF switch ON + Operate joystick steering FNR (directional) switch.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JL2 (male) Between (1) and (2) Defective joystick steering 1 FNR (directional) switch (Internal short circuit) Possible causes and standard value in normal state
Between (1) and (3) Between (1) and (4) Between (1), (2), (3), (4) and chassis ground
Joystick steering FNR (directional) switch
Resistance
F (Forward)
Max. 1
Other than above
Min. 1 M
N (Neutral).
Max. 1
Other than above
Min. 1 M
R (Reverse)
Max. 1
Other than above
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L03 (female) (28) – JL2 (female) (3) and chassis ground
Grounding fault in wiring 2 harness (Contact with ground circuit) Wiring harness between L03 (female) (37) – JL2 (female) (2) and chassis ground Wiring harness between L03 (female) (38) – JL2 (female) (4) and chassis ground
WA500-6
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
40-397 b
TROUBLESHOOTING
DDK4KB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Joystick ON/OFF switch ON L03 Possible causes and standard value in normal state
3
Defective transmission controller
Between (37) and chassis ground Between (28) and chassis ground Between (38) and chassis ground
40-398 b
Joystick steering FNR (directional) switch
Voltage
F (Forward)
Max. 1 V
Other than above
7 – 10 V
N (Neutral).
Max. 1 V
Other than above
7 – 10 V
R (Reverse)
Max. 1 V
Other than above
7 – 10 V
WA500-6
TROUBLESHOOTING
DDK4KB
Related Circuit Diagram
WA500-6
40-399 b
TROUBLESHOOTING
DDK5L4
DDK5L4 Joystick Steering with Shift UP/DOWN Switch: ON/OFF Signals Disagree Action Code
Failure Code
E01
DDK5L4
Trouble
Joystick steering shift UP/DOWN switch: ON/OFF signals disagree (Transmission controller system)
Contents of trouble
• Multiple signals are input due to grounding fault in joystick steering shift UP/DOWN switch system.
Action of controller
• Turns the joystick steering shift UP/DOWN function OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Shift UP/DOWN cannot be performed by joystick steering.
Related information
• The input signal (ON/OFF) from the joystick steering shift UP/DOWN switch can be checked with the monitoring function (Code: 40905 D-IN-1 or D-IN-2). • Method of reproducing failure code: Turn the starting switch ON + Joystick ON/OFF switch ON + Joystick steering shift UP/DOWN switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JL2 (male) Between (1) and (5) Defective joystick steering 1 shift UP/DOWN switch (Internal short circuit)
Between (1) and (6) Between (1) and (7) Between (1) and (8)
Possible causes and standard value in normal state
Between (5), (6), (7), (8) and chassis ground
Joystick steering shift UP/DOWN switch
Resistance
Shift DOWN ON
Min. 1 M
Shift DOWN OFF
Max. 1
Shift DOWN ON
Max. 1
Shift DOWN OFF
Min. 1 M
Shift UP ON
Min. 1 M
Shift UP OFF
Max. 1
Shift UP ON
Max. 1
Shift UP OFF
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L02 (female) (11) – 2 harness JL2 (female) (6) and chassis ground (Contact with ground circuit) Wiring harness between L02 (female) (17) – JL2 (female) (8) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Joystick ON/OFF switch ON Defective transmission 3 controller
40-400 b
L02
Joystick steering shift UP/DOWN switch
Resistance
Between (11) and chassis ground
Shift DOWN ON
Max. 1
Shift DOWN OFF
Min. 1 M
Between (17) and chassis ground
Shift UP ON
Max. 1
Shift UP OFF
Min. 1 M
WA500-6
TROUBLESHOOTING
DDK5L4
Related Circuit Diagram
WA500-6
40-401 b
TROUBLESHOOTING
DDK6KA
DDK6KA FNR Lever Switch: Disconnection Action Code
Failure Code
E03
DDK6KA
Trouble
FNR lever switch: Disconnection (Transmission controller system)
Contents of trouble
• Since the FNR (directional) lever switch signal system is disconnected or in ground fault, all the lever signals are not input.
Action of controller
• Sets to Neutral when joystick steering ON/OFF switch is OFF. • When joystick steering ON/OFF switch is ON: • Follows right FNR switch or joystick steering FNR switch. • Assumes FNR lever switch to be set to Neutral for control operation. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with right FNR switch or joystick FNR switch. • Shift lever position pilot lamp turns out.
Related information
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22). • Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.
Cause 1
Defective fuse No.5 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective FNR (directional) lever switch 2 (Internal disconnection or short circuit)
L63
FNR (directional) lever
Voltage
Between (1) and (10)
Constant
20 – 30 V
Between (2) and (10) Between (3) and (10)
Possible causes and standard value in normal state
Between (4) and (10)
N (Neutral).
20 – 30 V
Other than above
Max. 1 V
F (Forward)
20 – 30 V
Other than above
Max. 1 V
R (Reverse)
20 – 30 V
Other than above
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
40-402 b
Wiring harness between fuse No. 5 of fuse box B – L63 (female) (1)
Resistance
Max. 1
Wiring harness between L03 (female) (16) – L63 (female) (4)
Resistance
Max. 1
Wiring harness between L03 (female) (26) – L63 (female) (3)
Resistance
Max. 1
Wiring harness between L03 (female) (36) – L63 (female) (2)
Resistance
Max. 1
Wiring harness between L63 (female) (10) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DDK6KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 5 of fuse Resistance box B – L63 (female) (1) and chassis ground
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Grounding fault in wiring Wiring harness between L03 (female) (16) – 4 harness L63 (female) (4) and chassis ground (Contact with ground circuit) Wiring harness between L03 (female) (26) – L63 (female) (3) and chassis ground Wiring harness between L03 (female) (36) – L63 (female) (2) and chassis ground
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L03
5
Defective transmission controller
Voltage
Between (26) and chassis ground
N (Neutral).
20 – 30 V
Other than above
Max. 1 V
Between (36) and chassis ground
F (Forward)
20 – 30 V
Other than above
Max. 1 V
R (Reverse)
20 – 30 V
Other than above
Max. 1 V
Between (16) and chassis ground
WA500-6
FNR (directional) lever
40-403 b
TROUBLESHOOTING
DDK6KA
Related Circuit Diagram
40-404 b
WA500-6
TROUBLESHOOTING
DDK6KB
DDK6KB FNR Lever Switch: Short Circuit Action Code
Failure Code
E03
DDK6KB
Trouble
FNR lever switch: Short circuit (Transmission controller system)
Contents of trouble
• FNR (directional) lever switch signals are input due to hot short circuit in FNR (directional) lever switch signal system.
Action of controller
• Sets to neutral. • Turns the centralized warning lamp and alarm buzzer ON. • Follows right FNR (directional) switch or joystick steering FNR (directional) switch when joystick steering ON/OFF switch is turned ON OFF ON. • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to N (Neutral).
Problem that appears on machine
• Machine cannot be moved with FNR switch. • Machine can be moved with right FNR switch or joystick FNR switch. • Multiple shift lever position pilot lamps light up.
Related information
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22). • Only for steering wheel specification (Standard) • Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective FNR (directional) 1 lever switch (Internal short circuit)
L63
FNR (directional) lever
Voltage
Between (1) and (10)
Constant
20 – 30 V
F (Forward)
20 – 30 V
Other than above
Max. 1 V
Between (2) and (10) Between (3) and (10)
Possible causes and standard value in normal state
Between (4) and (10)
N (Neutral).
20 – 30 V
Other than above
Max. 1 V
R (Reverse)
20 – 30 V
Other than above
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L03 (female) (16) – L63 (female) (4) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (26) – L63 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (36) – L63 (female) (2) and chassis ground
Voltage
Max. 1 V
40-405 b
TROUBLESHOOTING
DDK6KB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Defective transmission 3 controller
L03
FNR (directional) lever
Voltage
Between (26) and chassis ground
N (Neutral).
20 – 30 V
Other than above
Max. 1 V
F (Forward)
20 – 30 V
Other than above
Max. 1 V
R (Reverse)
20 – 30 V
Other than above
Max. 1 V
Between (36) and chassis ground Between (16) and chassis ground
40-406 b
WA500-6
TROUBLESHOOTING
DDK6KB
Related Circuit Diagram
WA500-6
40-407 b
TROUBLESHOOTING
DDT0L4
DDT0L4 Shift Mode Selector Switch: ON/OFF Signals Disagree Action Code
Failure Code
E01
DDT0L4
Trouble
Shift mode selector switch: ON/OFF signals disagree (Transmission controller system)
Contents of trouble
• The signals input from the transmission manual/auto-shift selector switch are combined in an impossible manner.
Action of controller
• Selects the manual shift mode. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The position of the transmission manual/auto-shift selector switch does not match the shift mode during auto-shift.
Related information
• The input state (H/L) from the transmission manual/auto-shift selector switch can be checked with the monitoring function (Code: 40905 D-IN-4, D-IN-5). • The operator can check the current shift mode with the automatic shift pilot lamp. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S16 (male)
Defective transmission manual/auto-shift selector 1 switch (Internal defect).
Between (2) and (4)
Between (1) and (2)
Between (1) and (4)
Possible causes and standard value in normal state
Shift mode
Resistance
Manual shift
Min. 1 M
Auto shift (L)
Min. 1 M
Auto shift (H)
Max. 1
Manual shift
Min. 1 M
Auto shift (L)
Max. 1
Auto shift (H)
Max. 1
Manual shift
Min. 1 M
Auto shift (L)
Min. 1 M
Auto shift (H)
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L02 (female) (18) – S16 (female) (4)
Resistance
Max. 1
Wiring harness between L02 (female) (24) – S16 (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L02 (female) (18) – 3 harness S16 (female) (4) and chassis ground (Contact with ground circuit) Wiring harness between L02 (female) (24) – S16 (female) (2) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
40-408 b
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L02 (female) (18) – S16 (female) (4) and chassis ground
Voltage
Max. 1 V
Wiring harness between L02 (female) (24) – S16 (female) (2) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
DDT0L4 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Defective transmission 5 controller
L02
Shift mode
Voltage
Manual shift
Max. 1 V
Between (18) and chassis ground
Auto shift (L)
Max. 1 V
Auto shift (H)
20 – 30 V
Manual shift
Max. 1 V
Auto shift (L)
20 – 30 V
Auto shift (H)
20 – 30 V
Between (24) and chassis ground
Related Circuit Diagram
WA500-6
40-409 b
TROUBLESHOOTING
DDT4LD
DDT4LD Transmission Cutoff Set Switch: Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DDT4LD
Trouble
Transmission cutoff set switch: Switch is kept pressed for long time (Transmission controller system)
Contents of trouble
• Transmission cutoff is not performed normally due to grounding fault in transmission cutoff set switch system.
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• Transmission cutoff is performed at unintended position.
Related information
• The input state (ON/OFF) from the transmission cutoff set switch can be checked with the monitoring function (Code: 40906 D-IN-9). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission cut-off 1 set switch (Internal short circuit)
Possible causes and standard value in normal state
S19 (male)
Transmission cut-off set switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (5) and (6) Between (5), (6) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (20) – Resistance Min. 1 M S19 (female) (6) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective transmission controller
L04 (female) Between (20) and chassis ground
40-410 b
Transmission cut-off set switch
Resistance
ON
Max. 1
OFF
Min. 1 M
WA500-6
TROUBLESHOOTING
DDT4LD
Related Circuit Diagram
WA500-6
40-411 b
TROUBLESHOOTING
DDW9LD
DDW9LD Kickdown Switch: Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DDW9LD
Trouble
Kickdown switch: Switch is kept pressed for long time (Transmission controller system)
Contents of trouble
• The kickdown does not function due to grounding fault in kickdown switch system.
Action of controller
• Turns the kickdown ON when a grounding fault is detected then does not control the kickdown. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• When ground fault occurs, kickdown is turned ON once but is not turned ON again.
Related information
• The input state (ON/OFF) from the kickdown switch can be checked with the monitoring function (Code: 40906 D-IN-10). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S07 (male) 1
Possible causes and standard value in normal state
Defective kickdown switch (Internal short circuit)
Kickdown switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (1) and (2) Between (1), (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (30) – Resistance Min. 1 M S07 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 3 controller
40-412 b
L04
Kickdown switch
Voltage
Between (30) and chassis ground
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DDW9LD
Related Circuit Diagram
WA500-6
40-413 b
TROUBLESHOOTING
DDWLLD
DDWLLD Hold Switch: Switch is Kept Pressed Down for Long Time Action Code
Failure Code
E01
DDWLLD
Trouble
Hold switch: Switch is kept pressed for long time (Transmission controller system)
Contents of trouble
• Since the hold switch system is in ground fault, the hold switch does not function.
Action of controller
• Holds once when a grounding fault occurs then does not control holding. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• When ground fault occurs, turn the hold switch once.
Related information
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code: 40906 D-IN-11). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S07 (male) 1
Possible causes and standard value in normal state
Defective hold switch (Internal short circuit)
Hold switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (3) and (4) Between (3), (4) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (40) – Resistance Min. 1 M S07 (female) (3) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective transmission 3 controller
40-414 b
L04
Hold switch
Voltage
Between (40) and chassis ground
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DDWLLD
Related Circuit Diagram
WA500-6
40-415 b
TROUBLESHOOTING
DDY0LD
DDY0LD Load Meter Cancel Switch: Switch is Kept Pressed for Long Time Action Code
Failure Code
E01
DDY0LD
Trouble
Load meter cancel switch: Switch is kept pressed for long time (Machine monitor system)
Contents of trouble
• The load meter cancel switch is in ground fault and load meter cancel switch does not function.
Action of controller
• None in particular.
Problem that appears on machine
• Unable to cancel calculated load weight.
Related information
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring function (Code: 40904 D-IN-33). • Only for load meter (if equipped) • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S08 (male) 1
Possible causes and standard value in normal state
Defective load meter cancel switch (Internal short circuit)
Load meter cancel switch ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (1) and (2) Between (1), (2) and chassis ground
Resistance
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L54 (female) (13) – (Contact with ground circuit) Resistance Min. 1 M S08 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3 Defective machine monitor
L54 (male) Between (13) and chassis ground
40-416 b
Load meter cancel switch
Voltage
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DDY0LD
Related Circuit Diagram
WA500-6
40-417 b
TROUBLESHOOTING
DF10KA
DF10KA Transmission Shift Lever Switch: Disconnection Action Code
Failure Code
E01
DF10KA
Trouble
Transmission shift lever switch: Disconnection (Transmission controller system)
Contents of trouble
• Since the transmission shift lever switch input signal system is disconnected or in ground fault, the signal is not input.
Action of controller
• Fixed to the shift range before the abnormality occurred. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The transmission is not set to the selected gear speed. • Shift indicator displays the shift range before the abnormality occurred.
Related information
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19). • Method of reproducing failure code: Turn the starting switch ON and operate shift lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L63 Between (1) and (10) Defective transmission shift 1 lever switch (Internal disconnection)
Between (5) and (10) Between (6) and (10) Between (7) and (10) Between (8) and (10)
Possible causes and standard value in normal state
Voltage
Constant
20 – 30 V
1st (1st speed)
20 – 30 V
Other than above
Max. 1 V
2nd (2nd speed)
20 – 30 V
Other than above
Max. 1 V
3rd (3rd speed)
20 – 30 V
Other than above
Max. 1 V
4th (4th speed)
20 – 30 V
Other than above
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
40-418 b
Shift range
Wiring harness between fuse No. 5 of fuse box B – L63 (female) (1)
Resistance
Max. 1
Wiring harness between L03 (female) (5) – L63 (female) (8)
Resistance
Max. 1
Wiring harness between L03 (female) (15) – L63 (female) (7)
Resistance
Max. 1
Wiring harness between L03 (female) (25) – L63 (female) (6)
Resistance
Max. 1
Wiring harness between L03 (female) (35) – L63 (female) (5)
Resistance
Max. 1
Wiring harness between L63 (female) (10) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DF10KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 5 of fuse Resistance box B – L63 (female) (1) and chassis ground Wiring harness between L03 (female) (5) – Grounding fault in wiring L63 (female) (8) and chassis ground 3 harness (Contact with ground circuit) Wiring harness between L03 (female) (15) – L63 (female) (7) and chassis ground
Possible causes and standard value in normal state
Resistance
Min. 1 M
Resistance
Min. 1 M
Wiring harness between L03 (female) (25) – L63 (female) (6) and chassis ground
Resistance
Min. 1 M
Wiring harness between L03 (female) (35) – L63 (female) (5) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective transmission 4 controller
L03
Shift range
Voltage
Between (35) and chassis ground
1st (1st speed)
20 – 30 V
Between (25) and chassis ground Between (15) and chassis ground Between (5) and chassis ground
WA500-6
Min. 1 M
Other than above
Max. 1 V
2nd (2nd speed)
20 – 30 V
Other than above
Max. 1 V
3rd (3rd speed)
20 – 30 V
Other than above
Max. 1 V
4th (4th speed)
20 – 30 V
Other than above
Max. 1 V
40-419 b
TROUBLESHOOTING
DF10KA
Related Circuit Diagram
40-420 b
WA500-6
TROUBLESHOOTING
DF10KB
DF10KB Transmission Shift Lever Switch: Short Circuit Action Code
Failure Code
E01
DF10KB
Trouble
Transmission shift lever switch: Short circuit (Transmission controller system)
Contents of trouble
• Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmission shift lever switch signals are input.
Action of controller
• Uses the shift range input to the higher gear speed. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The relevant gear speed is not set. (The transmission does not shift into 1st or 2nd even if the transmission shift lever is used.) • Shift indicator indicates the shift range input to the higher gear speed.
Related information
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19). • Method of reproducing failure code: Turn the starting switch ON and operate shift lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L63 Between (5) and (10) Defective transmission shift 1 lever switch (Internal short circuit)
Between (6) and (10) Between (7) and (10)
Possible causes and standard value in normal state
Between (8) and (10)
Shift range
Voltage
1st (1st speed)
20 – 30 V
Other than above
Max. 1 V
2nd (2nd speed)
20 – 30 V
Other than above
Max. 1 V
3rd (3rd speed)
20 – 30 V
Other than above
Max. 1 V
4th (4th speed)
20 – 30 V
Other than above
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L03 (female) (5) – L63 (female) (8) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (15) – L63 (female) (7) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (25) – L63 (female) (6) and chassis ground
Voltage
Max. 1 V
Wiring harness between L03 (female) (35) – L63 (female) (5) and chassis ground
Voltage
Max. 1 V
40-421 b
TROUBLESHOOTING
DF10KB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
Defective transmission 3 controller
L03
Shift range
Voltage
Between (35) and chassis ground
1st (1st speed)
20 – 30 V
Other than above
Max. 1 V
2nd (2nd speed)
20 – 30 V
Other than above
Max. 1 V
3rd (3rd speed)
20 – 30 V
Between (25) and chassis ground Between (15) and chassis ground Between (5) and chassis ground
40-422 b
Other than above
Max. 1 V
4th (4th speed)
20 – 30 V
Other than above
Max. 1 V
WA500-6
TROUBLESHOOTING
DF10KB
Related Circuit Diagram
WA500-6
40-423 b
TROUBLESHOOTING
DGF1KA
DGF1KA Transmission Oil Temperature Sensor: Disconnection Action Code
Failure Code
E01
DGF1KA
Trouble
Transmission oil temperature sensor: Disconnection (Transmission controller system)
Contents of trouble
• Due to disconnection in transmission oil temperature sensor signal system, the signal level is higher than normal range. • Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15°C [59°F]); torque converter oil temperature sensor signal voltage: Min. 3.7 V (Max. 5.5°C [41.9°F]).
Action of controller
• Cannot judge transmission oil temperature normally. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Gear shift shock may occur.
Related information
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with the monitoring function (Code: 93600 T/M OIL TEMP). • The input state (voltage) from the transmission oil temperature sensor can be checked with the monitoring function (Code: 93601 T/M OIL TEMP). • The input state (oil temperature) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40100 TC OIL TEMP). • The input state (voltage) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40101 TC OIL TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission oil temperature sensor 1 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
TM.T (male)
Transmission oil temperature
25°C Between (1) and (2) (Normal temperature) 100°C
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L02 (female) (9) – TM.T (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Defective transmission controller
L02 (female)
Transmission oil temperature
25°C (Normal temperature) Between (9) and (21) 100°C
40-424 b
Resistance 35 – 50 k 3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGF1KA
Related Circuit Diagram
WA500-6
40-425 b
TROUBLESHOOTING
DGF1KB
DGF1KB Transmission Oil Temperature Sensor: Short Circuit Action Code
Failure Code
E01
DGF1KB
Trouble
Transmission oil temperature sensor: Short circuit (Transmission controller system)
Contents of trouble
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower than normal range. • Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of controller
• Judges that the transmission oil temperature is higher. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Gear shift shock may occur.
Related information
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with the monitoring function (Code: 93600 T/M OIL TEMP). • The input state (voltage) from the transmission oil temperature sensor can be checked with the monitoring function (Code: 93601 T/M OIL TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission oil 1 temperature sensor (Internal short circuit)
Possible causes and standard value in normal state
TM.T (male)
Transmission oil temperature
25°C (77°F) (Normal temperature) Between (1) and (2) 100°C (212°F)
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L02 (female) (9) – (Contact with ground circuit) Resistance Min. 1 M TM.T (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-426 b
Defective transmission controller
L02 (female)
Transmission oil temperature
25°C (77°F) Between (9) and (21) (Normal temperature) 100°C (212°F)
Resistance 35 – 50 k 3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGF1KB
Related Circuit Diagram
WA500-6
40-427 b
TROUBLESHOOTING
DGH2KX
DGH2KX Hydraulic Oil Temperature Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DGH2KX
Trouble
Hydraulic oil temperature sensor: Out-of-input signal range (Machine monitor system)
Contents of trouble
• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower than normal range. • Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• The hydraulic oil temperature gauge reads MAX position.
Related information
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the monitoring function (Code: 04401 HYD TEMP). • The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitoring function (Code: 04404 HYD TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission oil 1 temperature sensor (Internal short circuit)
Possible causes and standard value in normal state
T03 (male)
Hydraulic oil temperature
25°C Between (1) and (2) (Normal temperature) 100°C
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L55 (female) (7) – Resistance Min. 1 M T03 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (7) and chassis ground
40-428 b
Hydraulic oil temperature
Resistance
25°C (Normal temperature)
35 – 50 k
100°C
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGH2KX
Related Circuit Design
WA500-6
40-429 b
TROUBLESHOOTING
DGR2KA
DGR2KA Rear Brake Oil Temperature Sensor: Disconnection Action CCode
Failure Code
E01
DGR2KA
Trouble
Rear brake oil temperature sensor: Disconnection (Machine monitor system)
Contents of trouble
• Rear brake oil temperature sensor signal system disconnection.
Action of controller
• Judges that the rear brake oil temperature is lower. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30202 R BRAKE OIL). • The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30205 R BRAKE OIL). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective rear brake oil 1 temperature sensor (Internal disconnection)
R17 (male)
Rear brake oil temperature
25°C (77°F) Between (1) and (2) (Normal temperature) 100°C (212°F)
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L55 (female) (8) – R17 (female) (1)
Resistance
Max. 1
Wiring harness between R17 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (8) and chassis ground
40-430 b
Rear brake oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGR2KA
Related Circuit Diagram
WA500-6
40-431 b
TROUBLESHOOTING
DGR2KX
DGR2KX Rear Brake Oil Pressure Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DGR2KX
Trouble
Rear brake oil temperature sensor: Out-of-input signal range (Machine monitor system)
Contents of trouble
• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower than normal range. • Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C [302°F])
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30202 R BRAKE OIL). • The input state (voltage) from the rear brake oil temperature sensor can be checked with the monitoring function (Code: 30205 R BRAKE OIL). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective rear brake oil 1 temperature sensor (Internal short circuit)
Possible causes and standard value in normal state
R17 (male)
Rear brake oil temperature
25°C (77°F) Between (1) and (2) (Normal temperature) 100°C (212°F)
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L55 (female) (8) – Resistance Min. 1 M R17 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (8) and chassis ground
40-432 b
Rear brake oil temperature
Resistance
25°C (77°F) (Normal temperature)
35 – 50 k
100°C (212°F)
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGR2KX
Related Circuit Diagram
WA500-6
40-433 b
TROUBLESHOOTING
DGT1KX
DGT1KX Torque Converter Oil Temperature Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DGT1KX
Trouble
Torque converter oil temperature sensor: Out-of-input signal range (Machine monitor system)
Contents of trouble
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower than normal range. (Transmission oil temperature voltage: max. 0.97 V; min. 150°C [302°F])
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• The torque converter oil temperature gauge reads MAX position.
Related information
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40100 TC OIL TEMP). • The input state (voltage) from the torque converter oil temperature sensor can be checked with the monitoring function (Code: 40101 TC OIL TEMP). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective torque converter 1 oil temperature sensor (Internal short circuit)
Possible causes and standard value in normal state
T05 (male)
Torque converter oil temperature
25°C (F) Between (1) and (2) (Normal temperature) 100°C (212F)
Resistance 35 – 50 k 3.1 – 4.5 k
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L55 (female) (2) – Resistance Max. 1 T05 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3 Defective machine monitor
L55 (female) Between (2) and chassis ground
40-434 b
Torque converter oil temperature
Resistance
25°C (F) (Normal temperature)
35 – 50 k
100°C (212F)
3.1 – 4.5 k
WA500-6
TROUBLESHOOTING
DGT1KX
Related Circuit Diagram
WA500-6
40-435 b
TROUBLESHOOTING
DH21KA
DH21KA Work Equipment Pump Oil Pressure Sensor: Disconnection Action Code
Failure Code
E01
DH21KA
Trouble
Work equipment pump oil pressure sensor: Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the signal voltage is lower than normal range. (Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of controller
• Judges that work equipment pump oil pressure reads 0. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Remote positioner inaccuracy of stopping • When work equipment is relieved, cut-off does not function
Related information
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked with the monitoring function (Code: 94700 PUMP PRESS). • The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the monitoring function (Code: 94701 PUMP PRESS). • Method of reproducing failure code: Start engine and relieve bucket tilt.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective work equipment pump oil pressure sensor 1 (Internal disconnection or short circuit)
F16 (male)
Resistance
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine, tilt the bucket and carry out troubleshooting. F16
Work equipment
Voltage
Between (B) and (A)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
When bucket tilt relieved
3.02 – 3.42 V
Between (C) and (A) Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
Wiring harness between L05 (female) (2) – F16 (female) (C)
Resistance
Max. 1
Wiring harness between L05 (female) (21) – F16 (female) (A)
Resistance
Max. 1
Wiring harness between L05 (female) (22) – F16 (female) (B)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (2) – 3 harness F16 (female) (C) and chassis ground (Contact with ground circuit) Wiring harness between L05 (female) (22) F16 (female) (B) and chassis ground
40-436 b
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
DH21KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine, tilt the bucket and carry out troubleshooting. Possible causes and standard value in normal state
4 Work equipment controller
L05
Work equipment
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
When bucket tilt relieved
3.02 – 3.42 V
Between (2) and (21)
Related Circuit Diagram
WA500-6
40-437 b
TROUBLESHOOTING
DH21KB
DH21KB Work Equipment Pump Oil Pressure Sensor: Short Circuit Action Code
Failure Code
E01
DH21KB
Trouble
Work equipment pump oil pressure sensor: Short circuit (Work equipment controller system)
Contents of trouble
• Due to a hot short circuit in the work equipment pump oil pressure sensor signal system, the signal voltage is higher than normal range. (Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of controller
• Judges that work equipment pump oil pressure is higher. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Remote positioner inaccurate stopping • When work equipment is relieved, cutoff does not function
Related information
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked with the monitoring function (Code: 94700 PUMP PRESS). • The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the monitoring function (Code: 94701 PUMP PRESS). • Method of reproducing failure code: Start engine and relieve bucket tilt.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective work equipment 1 pump oil pressure sensor (Internal short circuit)
F16 (male)
Resistance
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine, tilt the bucket and carry out troubleshooting. F16
Bucket
Voltage
Between (B) and (A)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
When bucket tilt relieved
3.02 – 3.42 V
Between (C) and (A) Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L05 (female) (2) – F16 (female) (C) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – F16 (female) (B) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine, tilt the bucket and carry out troubleshooting.
3
Defective work equipment controller
L05
Bucket
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
When bucket tilt relieved
3.02 – 3.42 V
Between (2) and (21)
40-438 b
WA500-6
TROUBLESHOOTING
DH21KB
Related Circuit Diagram
WA500-6
40-439 b
TROUBLESHOOTING
DHPCKX
DHPCKX Lift Arm Cylinder Bottom Pressure Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DHPCKX
Trouble
Lift arm cylinder bottom pressure sensor: Out-of-input signal range (Machine monitor system)
Contents of trouble
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bottom pressure sensor voltage is lower than normal range. (Lift arm cylinder bottom pressure sensor signal voltage: Less than 0.3 V) • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bottom pressure sensor voltage is higher than normal range. (Lift arm cylinder bottom pressure sensor signal voltage: Min. 4.7 V)
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• Machine monitor does not display load.
Related information
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with the monitoring function (Code: 40400 BOOM BTM PRESS). • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the monitoring function (Code: 40402 BOOM BTM PRESS). • Only for load meter (if equipped) • Method of reproducing failure code: Start engine and perform lift arm lever operation.
Standard value in normal state/Remarks on troubleshooting
★ Replace sensor and check if error is reset. ★ Prepare with starting switch OFF; then start engine; raise the lift arm; and carry out troubleshooting. 1
Defective lift arm cylinder bottom pressure sensor
F14
Lift arm
Voltage
Between (B) and (A)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
Lift arm bottom relief
3.02 – 3.42 V
Between (C) and (A)
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between L51 (female) (16) – Disconnection in wiring F14 (female) (B) harness 2 (Disconnection in wiring Wiring harness between L55 (female) (9) – harness or defective contact) F14 (female) (C) Wiring harness between F14 (female) (A) – chassis ground
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring 3 harness (Contact with ground circuit)
40-440 b
Wiring harness between L51 (female) (16) – F14 (female) (B), – circuit branch end and chassis ground
Resistance
Min. 1 M
Wiring harness between L55 (female) (9) – F14 (female) (C), – circuit branch end and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
DHPCKX Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 4 (Contact with 24 V circuit)
Possible causes and standard value in normal state
Wiring harness between L51 (female) (16) – F14 (female) (B), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L55 (female) (9) – F14 (female) (C), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine, raise the lift arm and carry out troubleshooting.
5 Defective machine monitor
L51, L55
Lift arm
Voltage
Between L51 (16) and chassis ground
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
Lift arm bottom relief
3.02 – 3.42 V
Between L55 (9) and chassis ground
Related Circuit Diagram
WA500-6
40-441 b
TROUBLESHOOTING
DHPDKX
DHPDKX Lift Arm Cylinder Head Pressure Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DHPDKX
Trouble
Lift arm cylinder bottom head pressure sensor: Out-of-input signal range (Machine monitor system)
Contents of trouble
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head pressure sensor voltage is lower than normal range. (Lift arm cylinder head pressure sensor signal voltage: Less than 0.3 V) • Due to a hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head pressure sensor voltage is higher than normal range. (Lift arm cylinder head pressure sensor signal voltage: Min. 4.7 V)
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• Machine monitor does not display load.
Related information
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the monitoring function (Code: 40500 BOOM HEAD PRESS). • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the monitoring function (Code: 40501 BOOM HEAD PRESS). • Only for load meter (if equipped) • Method of reproducing failure code: Start engine and perform lift arm lever operation.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Replace sensor and check if error is reset. ★ Prepare with starting switch OFF; start engine; lower the lift arm; and carry out troubleshooting. 1
Defective lift arm cylinder head pressure sensor
F15 (male)
Lift arm
Voltage
Between (B) and (A)
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
Lift arm head relief
3.02 – 3.42 V
Between (C) and (A)
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between L51 (female) (16) – Disconnection in wiring F15 (female) (B) harness 2 (Disconnection in wiring Wiring harness between L55 (female) (4) – harness or defective contact) F15 (female) (C) Wiring harness between F15 (female) (A) – chassis ground
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L51 (female) (16) – Grounding fault in wiring F15 (female) (B), – circuit branch end and 3 harness chassis ground (Contact with ground circuit) Wiring harness between L55 (female) (4) – F15 (female) (C), – circuit branch end and chassis ground
40-442 b
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
DHPDKX Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 4 (Contact with 24 V circuit) Possible causes and standard value in normal state
Wiring harness between L51 (female) (16) – F15 (female) (B), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L55 (female) (4) – F15 (female) (C), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine, raise the lift arm and carry out troubleshooting.
5 Defective machine monitor
L51, L55
Lift arm
Voltage
Between L51 (16) and chassis ground
Constant
4.85 – 5.15 V
Constant
0.50 – 4.50 V
Neutral
0.50 – 0.90 V
Lift arm head relief
3.02 – 3.42 V
Between L55 (4) and chassis ground
Related Circuit Diagram
WA500-6
40-443 b
TROUBLESHOOTING
DHT1KX
DHT1KX Left Brake Pressure Sensor: Out-of-Input Signal Action Code
Failure Code
E01
DHT1KX
Trouble
Left brake pressure sensor: Out-of-input signal range (Transmission controller system)
Contents of trouble
• Due to grounding fault in left brake pressure sensor signal system, the signal level is lower than normal range.
Action of controller
• Turns the transmission cutoff function OFF. • Disables the change of transmission cutoff setting. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral), or the transmission cutoff switch is turned OFF.
Problem that appears on machine
• The transmission cutoff indicator goes off.
Related information
• Left brake pressure sensor input voltage: Max. 0.3 V • The input state (oil pressure) from the left brake pressure sensor can be checked with the monitoring function (Code: 41201 T/M CUT OFF P). • The input state (voltage) from the left brake pressure sensor can be checked with the monitoring function (Code: 41202 T/M CUT OFF P). • Method of reproducing failure code: Turn the starting switch and transmission cutoff switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Turn transmission cutoff switch ON. Defective left brake pressure 1 sensor (Internal short circuit)
B01
Between (C) and (A)
Possible causes and standard value in normal state
Brake
Voltage
When brake released
0.9 – 1.1 V
When left brake pressed
1.1 – 5.1 V
When right brake pressed
1.1 – 5.1 V
Other than above
0.9 – 5.1 V
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L02 (female) (8) – B01 Resistance Min. 1 M (female) (C) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L02 3
Defective transmission controller Between (8) and (21)
40-444 b
Brake
Voltage
When brake released
0.9 – 1.1 V
When left brake pressed
1.1 – 5.1 V
When right brake pressed
1.1 – 5.1 V
Other than above
0.9 – 5.1 V
WA500-6
TROUBLESHOOTING
DHT1KX
Related Circuit Diagram
WA500-6
40-445 b
TROUBLESHOOTING
DHT2L6
DHT2L6 Transmission Filter Clogging Sensor: Signal Disagrees with Operating and Stopped States of Engine Action Code
Failure Code
E01
DHT2L6
Trouble
Transmission filter clogging sensor: Signal disagrees with operating and stopped states of engine (Machine monitor system)
Contents of trouble
• Due to disconnection or hot short circuit in transmission filter clogging sensor signal, transmission filter clogging sensor signal voltage does not agree with the engine operation or stopping in normal condition.
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• The transmission filter clogging caution lamp does not light up.
Related information
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the monitoring function (Code: 40903 D-IN-24). • Method of reproducing failure code: Start engine and drive the machine in high idle.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out Defective transmission filter 1 clogging sensor (Internal disconnection)
troubleshooting. R12 (male) Between (1) and (2)
Transmission filter
Resistance
Normal
Max. 1
Clogging
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L53 (female) (5) – R12 (female) (1)
Resistance
Max. 1
Wiring harness between R12 (male) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 3 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L53 (female) (5) – R12 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4 Defective machine monitor
40-446 b
L53 (female)
Transmission filter
Resistance
Between (5) and chassis ground
Normal
Max. 1
Clogging
Min. 1 M
WA500-6
TROUBLESHOOTING
DHT2L6
Related Circuit Diagram
WA500-6
40-447 b
TROUBLESHOOTING
DK59KA
DK59KA Lift Arm EPC Lever Potentiometer (Main): Disconnection Action Code
Failure Code
E03
DK59KA
Trouble
Lift arm EPC lever potentiometer (Main): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer system, the signal voltage is lower than normal range. (Lift arm EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
Action of controller
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N (Neutral).
Problem that appears on machine
—
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S03 (male)
Resistance
Between (1) and (4)
3.2 ± 0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective lift arm EPC lever potentiometer 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S03 Between (4) and (1)
Between (3) and (1)
Lift arm EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Lower operation (Before detent)
0.86 – 1.36 V
Float operation
0.64 – 1.14 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (19) – Disconnection in wiring S03 (female) (3) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S03 (female) (1) Wiring harness between L05 (female) (22) – S03 (female) (4)
40-448 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DK59KA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (19) – 3 harness S03 (female) (3) and chassis ground (Contact with ground circuit) Between L05 (female) (22) – S03 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state 4
L05
Lift arm EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Lower operation (Before detent)
0.86 – 1.36 V
Float operation
0.64 – 1.14 V
Defective work equipment controller Between (19) and (21)
WA500-6
40-449 b
TROUBLESHOOTING
DK59KA
Related Circuit Diagram
40-450 b
WA500-6
TROUBLESHOOTING
DK59KY
DK59KY Lift Arm EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line Action Code
Failure Code
E03
DK59KY
Trouble
Lift arm EPC lever potentiometer (Main): Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is higher than normal range. (Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
Action of controller
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N (Neutral).
Problem that appears on machine
Related information
— • The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42000 BOOM POT1). • The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42001 BOOM POT2). • Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S03
Resistance
Between (1) and (4)
3.2 ± 0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective lift arm EPC lever 1 potentiometer (Internal short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S03
Lift arm EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Lower operation (Before detent)
0.86 – 1.36 V
Float operation
0.64 – 1.14 V
Between (3) and (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L05 (female) (19) – S03 (female) (3) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S03 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
40-451 b
TROUBLESHOOTING
DK59KY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state
3
L05
Lift arm EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Defective work equipment controller Between (19) and (21)
40-452 b
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Lower operation (Before detent)
0.86 – 1.36 V
Float operation
0.64 – 1.14 V
WA500-6
TROUBLESHOOTING
DK59KY
Related Circuit Diagram
WA500-6
40-453 b
TROUBLESHOOTING
DK59L8
DK59L8 Lift Arm EPC Lever Potentiometer (Main): Analog Signals Disagree Action Code
Failure Code
E03
DK59L8
Trouble
Lift arm EPC lever potentiometer (Main): Analog signals disagree (Work equipment controller system)
Contents of trouble
• Lift arm EPC lever potentiometer (Main and Sub) input signals disagree with each other. (Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (Lift arm EPC lever potentiometer signal voltage (Total of Main and Sub): Min. 5.3 V)
Action of controller
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as the regular potentiometer. • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality ±5%. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N (Neutral).
Problem that appears on machine
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to neutral. • If both Main and Sub potentiometers are abnormal, lift arm does not move.
Related information
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42000 BOOM POT1). • The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42001 BOOM POT2). • Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S03 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
Defective lift arm EPC lever potentiometer 1 (Internal disconnection or short circuit)
carry out troubleshooting. • Work equipment lock lever: Lock S03
Lift arm EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Float operation
0.64 – 1.14 V
Lower operation (Before detent)
0.86 – 1.36 V
Between (3) and (1)
40-454 b
WA500-6
TROUBLESHOOTING
DK59L8 Cause
Defective lift arm EPC lever potentiometer 1 (Internal disconnection or short circuit)
Standard value in normal state/Remarks on troubleshooting
Between (2) and (1)
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (13) – S03 (female) (2)
Disconnection in wiring harness Wiring harness between L05 (female) (19) – 2 (Disconnection in wiring S03 (female) (3) harness or defective contact) Wiring harness between L05 (female) (21) – S03 (female) (1)
Possible causes and standard value in normal state
Wiring harness between L05 (female) (22) – S03 (female) (4)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (13) – Grounding fault in wiring S03 (female) (2) and chassis ground 3 harness (Contact with ground circuit) Wiring harness between L05 (female) (19) – S03 (female) (3) and chassis ground
Resistance Min. 1 M Resistance Min. 1 M
Between L05 (female) (22) – S03 (female) (4), – Resistance Min. 1 M circuit branch end and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 4 (Contact with 24 V circuit)
WA500-6
Wiring harness between L05 (female) (13) – S03 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (19) – S03 (female) (3) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S03 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
40-455 b
TROUBLESHOOTING
DK59L8 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state
Defective work equipment 5 controller
L05
Lift arm EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Between (19) and (21)
Between (13) and (21)
40-456 b
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
3.64 – 4.14 V
Raise operation (Detent position)
3.86 – 4.36 V
Float operation
0.64 – 1.14 V
Lower operation (Before detent)
0.86 – 1.36 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
WA500-6
TROUBLESHOOTING
DK59L8
Related Circuit Diagram
WA500-6
40-457 b
TROUBLESHOOTING
DK5AKA
DK5AKA Lift Arm EPC Lever Potentiometer (Sub): Disconnection Action Code
Failure Code
E03
DK5AKA
Trouble
Lift arm EPC lever potentiometer (Sub): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is lower than normal range. (Lift arm EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
Action of controller
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• —
Related information
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42000 BOOM POT1). • The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42001 BOOM POT2). • Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S03 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective lift arm EPC lever potentiometer 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S03 (male) Between (4) and (1)
Between (2) and (1)
Lift arm EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (13) – Disconnection in wiring S03 (female) (2) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S03 (female) (1) Wiring harness between L05 (female) (22) – S03 (female) (4)
40-458 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DK5AKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (13) – 3 harness S03 (female) (2) and chassis ground (Contact with ground circuit) Between L05 (female) (22) – S03 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state 4
L05
Lift arm EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
Defective work equipment controller Between (13) and (21)
WA500-6
40-459 b
TROUBLESHOOTING
DK5AKA
Related Circuit Diagram
40-460 b
WA500-6
TROUBLESHOOTING
DK5AKY
DK5AKY Lift Arm EPC Lever Potentiometer (Sub): Short Circuit with Power Supply LIne Action Code
Failure Code
E03
DK5AKY
Trouble
Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is higher than normal range. (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
Action of controller
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N (Neutral).
Problem that appears on machine
Related information
— • The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42000 BOOM POT1). • The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42001 BOOM POT2). • Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S03 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective lift arm EPC lever 1 potentiometer (Internal short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S03 (male)
Lift arm EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
Between (2) and (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L05 (female) (13) – S03 (female) (2) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S03 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
40-461 b
TROUBLESHOOTING
DK5AKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state
3
L05
Lift arm EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Defective work equipment controller Between (13) and (21)
40-462 b
Lever in neutral
2.40 – 2.60 V
Raise operation (Before detent)
0.86 – 1.36 V
Raise operation (Detent position)
0.64 – 1.14 V
Lower operation (Before detent)
3.64 – 4.14 V
Float operation
3.86 – 4.36 V
WA500-6
TROUBLESHOOTING
DK5AKY
Related Circuit Diagram
WA500-6
40-463 b
TROUBLESHOOTING
DK5BKA
DK5BKA Bucket EPC Lever Potentiometer (Main): Disconnection Action Code
Failure Code
E03
DK5BKA
Trouble
Bucket EPC lever potentiometer (Main): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the signal voltage is lower than normal range. (Bucket EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
Action of controller
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N (Neutral).
Problem that appears on machine
Related information
— • The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42002 BUCKET POT1). • The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42003 BUCKET POT2). • Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S02 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective bucket EPC lever potentiometer 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S02
Bucket EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Between (3) and (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (7) – Disconnection in wiring S02 (female) (3) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S02 (female) (1) Wiring harness between L05 (female) (22) – S02 (female) (4)
40-464 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DK5BKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (7) – 3 harness S02 (female) (3) and chassis ground (Contact with ground circuit) Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state Defective work equipment 4 controller
L05
Bucket EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Between (7) and (21)
WA500-6
40-465 b
TROUBLESHOOTING
DK5BKA
Related Circuit Diagram
40-466 b
WA500-6
TROUBLESHOOTING
DK5BKY
DK5BKY Bucket EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line Action Code
Failure Code
E03
DK5BKY
Trouble
Bucket EPC lever potentiometer (Main): Short circuit with power supply line (Work equipment controller system).
Contents of trouble
• Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is higher than normal range. (Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
Action of controller
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42002 BUCKET POT1). • The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42003 BUCKET POT2). • Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S02 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective bucket EPC lever 1 potentiometer (Internal short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S02
Bucket EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Between (3) and (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)
WA500-6
Wiring harness between L05 (female) (7) – S02 (female) (3) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
40-467 b
TROUBLESHOOTING
DK5BKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state
Defective work equipment 3 controller
L05
Bucket EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Between (7) and (21)
40-468 b
WA500-6
TROUBLESHOOTING
DK5BKY
Related Circuit Diagram
WA500-6
40-469 b
TROUBLESHOOTING
DK5BL8
DK5BL8 Bucket EPC Lever Potentiometer (Main): Analog Signals Disagree Action Code
Failure Code
E03
DK5BL8
Trouble
Bucket EPC lever potentiometer (Main): Analog signals disagree (Work equipment controller system)
Contents of trouble
• Bucket EPC lever potentiometer (Main and Sub) input signals disagree with each other. (Bucket EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (Bucket EPC lever potentiometer signal voltage (Total of Main and Sub): Min 5.3 V)
Action of controller
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as the regular potentiometer. • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality ±5%. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N (Neutral).
Problem that appears on machine
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to neutral. • If both Main and Sub potentiometers are abnormal, bucket does not move.
Related information
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42002 BUCKET POT1). • The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42003 BUCKET POT2). • Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S02 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock Possible causes and standard value in normal state
Defective bucket EPC lever potentiometer 1 (Internal disconnection or short circuit)
S02
Bucket EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.64 – 1.14 V
Full dump operation
3.86 – 4.36 V
Between (3) and (1)
Between (2) and (1)
40-470 b
WA500-6
TROUBLESHOOTING
DK5BL8 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (1) – S02 (female) (2)
Disconnection in wiring harness Wiring harness between L05 (female) (7) – 2 (Disconnection in wiring S02 (female) (3) harness or defective contact) Wiring harness between L05 (female) (21) – S02 (female) (1) Wiring harness between L05 (female) (22) – S02 (female) (4)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (1) – Grounding fault in wiring S02 (female) (2) and chassis ground 3 harness (Contact with ground circuit) Wiring harness between L05 (female) (7) – S02 (female) (3) and chassis ground Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Hot short in wiring harness 4 (Contact with 24 V circuit)
Wiring harness between L05 (female) (1) – S02 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (7) – S02 (female) (3) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Defective work equipment 5 controller
L05
Bucket EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
3.64 – 4.14 V
Tilt operation (Detent position)
3.86 – 4.36 V
Full dump operation
0.64 – 1.14 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.61 – 1.14 V
Full dump operation
3.96 – 4.36 V
Between (7) and (21)
Between (1) and (21)
WA500-6
40-471 b
TROUBLESHOOTING
DK5BL8
Related Circuit Diagram
40-472 b
WA500-6
TROUBLESHOOTING
DK5CKA
DK5CKA Bucket EPC Lever Potentiometer (Sub): Disconnection Action Code
Failure Code
E03
DK5CKA
Trouble
Bucket EPC lever potentiometer (Sub): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system, (Sub) signal voltage is lower than normal range. (Bucket EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
Action of controller
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42002 BUCKET POT1). • The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42003 BUCKET POT2). • Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective bucket EPC lever potentiometer 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
S02 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock S02
Bucket EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.64 – 1.14 V
Full dump operation
3.96 – 4.36 V
Between (2) and (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S02 (female) (1) Wiring harness between L05 (female) (1) – S02 (female) (2)
Wiring harness between L05 (female) (22) – S02 (female) (4)
WA500-6
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
40-473 b
TROUBLESHOOTING
DK5CKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (1) – 3 harness S02 (female) (2) and chassis ground (Contact with ground circuit) Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state Defective work equipment 4 controller
L05
Bucket EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.64 – 1.14 V
Full dump operation
3.86 – 4.36 V
Between (1) and (21)
40-474 b
WA500-6
TROUBLESHOOTING
DK5CKA
Related Circuit Diagram
WA500-6
40-475 b
TROUBLESHOOTING
DK5CKY
DK5CKY Bucket EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line Action Code
Failure Code
E03
DK5CKY
Trouble
Bucket EPC lever potentiometer (Sub): Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system, (Sub) signal voltage is lower than normal range. (Bucket EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
Action of controller
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N (Neutral).
Problem that appears on machine
Related information
— • The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42002 BUCKET POT1). • The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42003 BUCKET POT2). • Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S02 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Defective bucket EPC lever 1 potentiometer (Internal short circuit) Possible causes and standard value in normal state
carry out troubleshooting. • Work equipment lock lever: Lock S02
Bucket EPC lever
Voltage
Between (4) and (1)
Constant
4.85 -5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.64 – 1.14 V
Full dump operation
3.86 – 4.36 V
Between (2) and (1)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)
40-476 b
Wiring harness between L05 (female) (1) – S02 (female) (2) and chassis ground
Voltage
Max. 1 V
Between L05 (female) (22) – S02 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
DK5CKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state
Defective work equipment 3 controller
L05
Bucket EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Tilt operation (Before detent)
0.86 – 1.36 V
Tilt operation (Detent position)
0.64 – 1.14 V
Full dump operation
3.86 – 4.36 V
Between (1) and (21)
WA500-6
40-477 b
TROUBLESHOOTING
DK5CKY
Related Circuit Diagram
40-478 b
WA500-6
TROUBLESHOOTING
DK5DKA
DK5DKA 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Disconnection Action Code E03
Failure Code DK5DKA
Trouble
3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer (Main), the signal voltage is lower than normal range. (3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
Action of controller
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting of the machine monitor.) • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42006 3RD POT1). • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42007 3RD POT2). • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal disconnection or short circuit)
S25 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock S25 (male) Between (4) and (1)
Between (3) and (1)
WA500-6
3-spool valve (attachment) EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.86 – 4.36 V
Full retraction operation
0.64 – 1.14 V
40-479 b
TROUBLESHOOTING
DK5DKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (20) – Disconnection in wiring S25 (female) (3) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S25 (female) (1) Wiring harness between L05 (female) (22) – S25 (female) (4)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Grounding fault in wiring Wiring harness between L05 (female) (20) – 3 harness S25 (female) (3) and chassis ground (Contact with ground circuit) Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground
Resistance Min. 1 M
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
4
Defective work equipment controller
L05
3-spool valve (attachment) EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.86 – 4.36 V
Full retraction operation
0.64 – 1.14 V
Between (20) and (21)
40-480 b
WA500-6
TROUBLESHOOTING
DK5DKA
Related Circuit Diagram
WA500-6
40-481 b
TROUBLESHOOTING
DK5DKY
DK5DKY 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line Action Code E03
Failure Code DK5DKY
Trouble
3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Main) system the signal voltage is higher than normal range. (3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 4.7 V)
Action of controller
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting of the machine monitor.) • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42006 3RD POT1). • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42007 3RD POT2). • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S25 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal short circuit)
carry out troubleshooting. • Work equipment lock lever: Lock S25 (male) Between (4) and (1)
Between (3) and (1)
40-482 b
3-spool valve (attachment) EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.86 – 4.36 V
Full retraction operation
0.64 – 1.14 V
WA500-6
TROUBLESHOOTING
DK5DKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L05 (female) (20) – S25 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state 3
Defective work equipment controller
L05
3-spool valve (attachment) EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.64 – 4.36 V
Full retraction operation
0.64 – 1.14 V
Between (20) and (21)
Related Circuit Diagram
WA500-6
40-483 b
TROUBLESHOOTING
DK5DL8
DK5DL8 3-Spool Valve (Attachment) EPC Lever Potentiometer (Main): Analog Signals Disagree Action Code E03
Failure Code DK5DL8
Trouble
3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree (Work equipment controller system)
Contents of trouble
• The 3-spool valve (attachment) EPC lever potentiometer (Main and Sub) input signals disagree with each other. (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and Sub): Max. 4.7 V) or (3-spool valve (attachment) EPC lever potentiometer signal voltage (Total of Main and Sub): Min. 5.3 V)
Action of controller
• Operates with either Main or Sub potentiometer, whichever detects a position within neutrality ±5% as the regular potentiometer. • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality ±5%. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC lever is set to N (Neutral).
Problem that appears on machine
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to neutral. • If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not move.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting of the machine monitor.) • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42006 3RD POT1). • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42007 3RD POT2). • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal disconnection or short circuit)
S25 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock S25 (male)
3-spool valve (attachment) EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.86 – 4.36 V
Full retraction operation
0.64 – 1.14 V
Between (3) and (1)
40-484 b
WA500-6
TROUBLESHOOTING
DK5DL8 Cause
Standard value in normal state/Remarks on troubleshooting
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal disconnection or short circuit)
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
Between (2) and (1)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (14) – S25 (female) (2) Disconnection in wiring harness Wiring harness between L05 (female) (20) – 2 (Disconnection in wiring S25 (female) (3) harness or defective contact) Wiring harness between L05 (female) (21) – S25 (female) (1) Wiring harness between L05 (female) (22) – S25 (female) (4)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (14) – S25 (female) (2) and chassis ground Grounding fault in wiring 3 harness Wiring harness between L05 (female) (20) – (Contact with ground circuit) S25 (female) (3) and chassis ground Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground Possible causes and standard value in normal state
Resistance Min. 1 M Resistance Min. 1 M
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Hot short in wiring harness 4 (Contact with 24 V circuit)
Wiring harness between L05 (female) (14) – S25 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (20) – S25 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
5
Defective work equipment controller
L05
3-spool valve (attachment) EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
3.86 – 4.36 V
Full retraction operation
0.64 – 1.14 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
Between (20) and (21)
Between (14) and (21)
WA500-6
40-485 b
TROUBLESHOOTING
DK5DL8
Related Circuit Diagram
40-486 b
WA500-6
TROUBLESHOOTING
DK5DL8
MEMORANDUM
WA500-6
40-487 b
TROUBLESHOOTING
DK5EKA
DK5EKA 3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Disconnection Action Code E03
Failure Code DK5EKA
Trouble
3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer (Sub), the signal voltage is lower than normal range. (3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
Action of controller
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting of the machine monitor.) • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42006 3RD POT1). • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42007 3RD POT2). • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal disconnection or short circuit)
S25 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock S25 Between (4) and (1)
Between (2) and (1)
40-488 b
3-spool valve (attachment) EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
WA500-6
TROUBLESHOOTING
DK5EKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (14) – Disconnection in wiring S25 (female) (2) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (21) – harness or defective contact) S25 (female) (1) Wiring harness between L05 (female) (22) – S25 (female) (4)
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Grounding fault in wiring Wiring harness between L05 (female) (14) – 3 harness S25 (female) (2) and chassis ground (Contact with ground circuit) Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
4
Defective work equipment controller
L05
3-spool valve (attachment) EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
Between (14) and (21)
Related Circuit Diagram
WA500-6
40-489 b
TROUBLESHOOTING
DK5EKY
DK5EKY 3-Spool Valve (Attachment) EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line Action Code E03
Failure Code DK5EKY
Trouble
3-spool valve (attachment) EPC lever potentiometer (Sub): Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the 3-spool valve (attachment) EPC lever potentiometer (Sub) system, the signal voltage is higher than normal range. (3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V)
Action of controller
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select “None” in the 3-spool valve (attachment) optional setting on the optional setting of the machine monitor.) • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42006 3RD POT1). • The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42007 3RD POT2). • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attachment) lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S25 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
Defective 3-spool valve (attachment) EPC lever 1 potentiometer (Internal short circuit)
carry out troubleshooting. • Work equipment lock lever: Lock S25 Between (4) and (1)
Between (2) and (1)
40-490 b
3-spool valve (attachment) EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
WA500-6
TROUBLESHOOTING
DK5EKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 2
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L05 (female) (14) – S25 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – S25 (female) (4), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Work equipment lock lever: Lock
Possible causes and standard value in normal state 3
Defective work equipment controller
L05
3-spool valve (attachment) EPC lever
Voltage
Between (22) and (21)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full extension operation
0.64 – 1.14 V
Full retraction operation
3.86 – 4.36 V
Between (14) and (21)
Related Circuit Diagram
WA500-6
40-491 b
TROUBLESHOOTING
DK5FKA
DK5FKA Joystick Steering EPC Lever Potentiometer (Main): Disconnection Action Code
Failure Code
E03
DK5FKA
Trouble
Joystick steering EPC lever potentiometer (Main): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system (main), the signal voltage is lower than normal range. (Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 0.3 V)
Action of controller
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• This failure code is not displayed when joystick steering ON/OFF switch is OFF. • The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42004, J/S POT1). • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42005, J/S POT2). • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective joystick steering EPC lever potentiometer 1 (Internal disconnection or short circuit)
JS3 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. JS3 (male)
Possible causes and standard value in normal state
Between (4) and (1) Between (3) and (1)
Joystick steering EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 2 (Disconnection in wiring Wiring harness between L05 (female) (22) – harness or defective contact) JS3 (female) (4) Wiring harness between L05 (female) (9) – JS3 (female) (3)
Wiring harness between JS3 (female) (1) – chassis ground
40-492 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DK5FKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (9) – 3 harness JS3 (female) (3) and chassis ground (Contact with ground circuit) Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes and standard value in normal state
carry out troubleshooting.
4
Defective work equipment controller
L05
Joystick steering EPC lever
Voltage
Between (22) and chassis ground
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
Between (9) and chassis ground
Related Circuit Diagram
WA500-6
40-493 b
TROUBLESHOOTING
DK5FKY
DK5FKY Joystick Steering EPC Lever Potentiometer (Main): Short Circuit with Power Supply Line Action Code E03
Failure Code DK5FKY
Trouble
Joystick steering EPC lever potentiometer (Main): Short circuit with the power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal voltage is higher than normal range. (Joystick steering EPC lever potentiometer (Main) signal voltage: Max. 4.7 V)
Action of controller
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• This failure code is not displayed when joy stick steering ON/OFF switch is OFF. • The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42004, J/S POT1). • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42005, J/S POT2). • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective joystick steering 1 EPC lever potentiometer (Internal short circuit) Possible causes and standard value in normal state
JS3 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. JS3 (male) Between (4) and (1) Between (3) and (1)
Joystick steering EPC lever
Voltage
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)
40-494 b
Wiring harness between L05 (female) (9) – JS3 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
DK5FKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
3
Defective work equipment controller
L05
Joystick steering EPC lever
Voltage
Between (22) and chassis ground
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
Between (9) and chassis ground
Related Circuit Diagram
WA500-6
40-495 b
TROUBLESHOOTING
DK5GKA
DK5GKA Joystick Steering EPC Lever Potentiometer (Sub): Disconnection Action Code
Failure Code
E03
DK5GKA
Trouble
Joystick steering EPC lever potentiometer (Sub): Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer system (Sub), the signal voltage is lower than normal range. (Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V)
Action of controller
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • If cause of failure disappears, system resets itself.
Problem that appears on machine
—
Related information
• This failure code is not displayed when joystick steering ON/OFF switch is OFF. • The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42004, J/S POT1). • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42005, J/S POT2). • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective joystick steering EPC lever potentiometer 1 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
JS3 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. JS3 (male)
Joystick steering EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Between (2) and (1)
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (3) – Disconnection in wiring JS3 (female) (2) harness 2 (Disconnection in wiring Wiring harness between L05 (female) (22) – harness or defective contact) JS3 (female) (4) Wiring harness between JS3 (female) (1) – chassis ground
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Grounding fault in wiring Wiring harness between L05 (female) (3) – 3 harness JS3 (female) (2) and chassis ground (Contact with ground circuit) Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground
40-496 b
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
DK5GKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
4
Defective work equipment controller
L05
Joystick steering EPC lever
Voltage
Between (22) and chassis ground
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
Between (3) and chassis ground
Related Circuit Diagram
WA500-6
40-497 b
TROUBLESHOOTING
DK5GKY
DK5GKY Joystick Steering EPC Lever Potentiometer (Sub): Short Circuit with Power Supply Line Action Code E03
Failure Code DK5GKY
Trouble
Joystick steering EPC lever potentiometer (Sub): Short circuit with the power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal voltage is higher than normal range. (Joystick steering EPC lever potentiometer (Sub) signal voltage: Max. 4.7 V)
Action of controller
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to N (Neutral).
Problem that appears on machine
—
Related information
• This failure code is not displayed when joystick steering ON/OFF switch is OFF. • The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42004, J/S POT1). • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42005, J/S POT2). • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective joystick steering EPC lever potentiometer 1 (Internal disconnection or short circuit)
JS3 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. JS3 (male)
Joystick steering EPC lever
Voltage
Between (4) and (1) Between (2) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)
40-498 b
Wiring harness between L05 (female) (3) – JS3 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
DK5GKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
3
Defective work equipment controller
L05
Joystick steering EPC lever
Voltage
Between (22) and chassis ground
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
Between (3) and chassis ground
Related Circuit Diagram
WA500-6
40-499 b
TROUBLESHOOTING
DK5FL8
DK5FL8 Joystick Steering EPC Lever Potentiometer (Main): Analog Signals Disagree Action Code
Failure Code
E03
DK5FL8
Trouble
Joystick steering EPC lever potentiometer (Main): Analog signals disagree (Work equipment controller system)
Contents of trouble
• Joystick steering EPC lever potentiometer (Main and Sub) input signals disagree with each other. (Joystick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joystick steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
Action of controller
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5% as the regular potentiometer. • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality ±5%. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until joystick steering EPC lever is set to N (Neutral).
Problem that appears on machine
• If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steering EPC lever is set to neutral. • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.
Related information
• This failure code is not displayed when joystick steering ON/OFF switch is OFF. • The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked with the monitoring function (Code: 42004, J/S POT1). • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked with the monitoring function (Code: 42005, J/S POT2). • Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JS3 (male)
Resistance
Between (1) and (4)
3.2 ±0.64 k
Between (1), (2), (3), (4) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
Defective joystick steering EPC lever potentiometer 1 (Internal disconnection or short circuit)
carry out troubleshooting. JS3 (male)
Joystick steering EPC lever
Voltage
Between (4) and (1)
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Between (3) and (1)
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
Between (2) and (1)
40-500 b
WA500-6
TROUBLESHOOTING
DK5FL8 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (3) – JS3 Resistance (female) (2)
Disconnection in wiring harness Wiring harness between L05 (female) (9) – JS3 2 Resistance (Disconnection in wiring (female) (3) harness or defective contact) Wiring harness between L05 (female) (22) – Resistance JS3 (female) (4) Wiring harness between JS3 (female) (1) – chassis ground
Resistance
Max. 1 Max. 1 Max. 1 Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L05 (female) (3) – JS3 Resistance Min. 1 M Grounding fault in wiring (female) (2) and chassis ground 3 harness (Contact with ground circuit) Wiring harness between L05 (female) (9) – JS3 Resistance Min. 1 M (female) (3) and chassis ground Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground Possible causes and standard value in normal state
Resistance Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 4 (Contact with 24 V circuit)
Wiring harness between L05 (female) (3) – JS3 (female) (2) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (9) – JS3 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L05 (female) (22) – JS3 (female) (4) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective work equipment 5 controller
L05
Joystick steering EPC lever
Voltage
Between (22) and chassis ground
Constant
4.85 – 5.15 V
Lever in neutral
2.40 – 2.60 V
Full steering to left
1.09 – 1.59 V
Full steering to right
3.41 – 3.91 V
Between (9) and chassis ground
Between (3) and chassis ground
WA500-6
Lever in neutral
2.40 – 2.60 V
Full steering to left
3.41 – 3.91 V
Full steering to right
1.09 – 1.59 V
40-501 b
TROUBLESHOOTING
DK5FL8
Related Circuit Diagram
40-502 b
WA500-6
TROUBLESHOOTING
DK5FL8
MEMORANDUM
WA500-6
40-503 b
TROUBLESHOOTING
DKA0KA
DKA0KA Lift Arm Angle Sensor: Disconnection Action Code
Failure Code
E01
DKA0KA
Trouble
Lift arm angle sensor: Disconnection (Work equipment controller system)
Contents of trouble
• Due to disconnection or grounding fault in lift arm angle sensor system, the signal voltage is lower than normal range. (Lift arm angle sensor signal: Max. 0.3 V)
Action of controller
• Judges that lift arm is at the lowest position. • Resets the remote positioner function. • Resets semi-auto digging function. • No PC control while the lift arm is rising. • When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the remote positioner lower setting is OFF, usually operates the lift arm float detent. • Turns the lift arm raise detent OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Remote positioner malfunction (Not stop) • Faulty semi-auto digging operation (Not operate) • No PC control while the lift arm is rising
Related information
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code: 06002 BOOM ANG). • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function (Code: 06005 BOOM ANG). • If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Turn starting switch ON.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective lift arm angle sensor 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
F13 (male)
Resistance
Between (A) and (C)
5 k ±20%
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. F13
Lift arm position
Voltage
Between (C) and (A)
Constant
4.85 – 5.15 V
Constant
1.00 – 4.00 V
Between (B) and (A)
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F13 (female) (A) – Disconnection in wiring chassis ground harness 2 (Disconnection in wiring Wiring harness between F13 (female) (B) – harness or defective contact) L05 (female) (8) Wiring harness between F13 (female) (C) – L51 (female) (16)
40-504 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DKA0KA
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Wiring harness between F13 (female) (B) – Grounding fault in wiring L05 (female) (8), L55 (female) (10) and 3 harness chassis ground (Contact with ground circuit) Wiring harness between F13 (female) (C) – L51 (female) (16), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 4
Defective work equipment controller
L05 Between (8) and chassis ground
Lift arm position
Voltage
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
Related Circuit Diagram
WA500-6
40-505 b
TROUBLESHOOTING
DKA0KX
DKA0KX Lift Arm Angle Sensor: Out-of-Input Signal Range Action Code
Failure Code
E01
DKA0KX
Trouble
Lift arm angle sensor: Out of input signal range (Machine monitor system)
Contents of trouble
• Due to grounding fault in lift arm angle sensor system, the signal voltage is not input. (Lift arm angle sensor signal voltage: Max. 1 V) • Due to disconnection or hot short circuit in lift arm angle sensor system, the signal voltage is higher than normal level. (Lift arm angle sensor signal voltage: Min. 4 V)
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine
• Machine monitor does not display load.
Related information
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code: 06001 BOOM ANG). • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function (Code: 06003 BOOM ANG). • If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshooting for it first. • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective lift arm angle sensor 1 (Internal disconnection or short circuit) Possible causes and standard value in normal state
F13 (male)
Resistance
Between (A) and (C)
5 k ±20%
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. F13
Lift arm position
Voltage
Between (C) and (A)
Constant
4.85 – 5.15 V
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
Between (B) and (A)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F13 (female) (A) – Disconnection in wiring chassis ground harness 2 (Disconnection in wiring Wiring harness between F13 (female) (B) – harness or defective contact) L55 (female) (10) Wiring harness between F13 (female) (C) – L51 (female) (16)
40-506 b
Resistance
Max. 1
Resistance
Max. 1
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DKA0KX Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between F13 (female) (B) – Grounding fault in wiring L05 (female) (8), L55 (female) (10) and 3 harness chassis ground (Contact with ground circuit) Wiring harness between F13 (female) (C) – L51 (female) (16), – circuit branch end and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Possible causes and standard value in normal state
carry out troubleshooting. (Lift arm lower position)
4
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between F13 (female) (B) – L05 (female) (8), L55 (female) (10) and chassis ground
Voltage
Max. 1 V
Wiring harness between F13 (female) (C) – L51 (female) (16), – circuit branch end and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. L55 5 Defective machine monitor Between (10) and chassis ground
WA500-6
Lift arm position
Voltage
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
40-507 b
TROUBLESHOOTING
DKA0KX
Related Circuit Diagram
40-508 b
WA500-6
TROUBLESHOOTING
DKA0KX
MEMORANDUM
WA500-6
40-509 b
TROUBLESHOOTING
DKA0KY
DKA0KY Lift Arm Angle Sensor: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DKA0KY
Trouble
Lift arm angle sensor: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Due to hot short in lift arm angle sensor system, the signal voltage is higher than normal range. (Lift arm angle sensor signal: Min. 4.7 V)
Action of controller
• Judges that lift arm is at the highest position. • Resets the remote positioner function. • Resets semi-auto digging function. • No PC control while the lift arm is rising. • When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the remote positioner lower setting is OFF, usually operates the lift arm float detent. • Turns the lift arm raise detent OFF. • Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neutral).
Problem that appears on machine
• Remote positioner malfunction • Faulty semi-auto digging operation • No PC control while the lift arm is rising
Related information
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code: 06002 BOOM ANG). • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function (Code: 06005 BOOM ANG). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective lift arm angle 1 sensor (Internal short circuit) Possible causes and standard value in normal state
F13 (male)
Resistance
Between (A) and (C)
5 k ±20%
Between (A), (B), (C) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. F13
Lift arm position
Voltage
Between (C) and (A)
Constant
4.85 – 5.15 V
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
Between (B) and (A)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Hot short in wiring harness 2 (Contact with 24 V circuit)
40-510 b
Wiring harness between F13 (female) (B) – L05 (female) (8), L55 (female) (10) and chassis ground
Voltage
Max. 1 V
Wiring harness between F13 (female) (C) – L51 (female) (16), – circuit branch end and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
DKA0KY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then start engine and carry out Possible causes and standard value in normal state
troubleshooting. 3
Defective work equipment controller
L05
Lift arm position
Voltage
Constant
1.00 – 4.00 V
Between (8) and chassis ground
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
Related Circuit Diagram
WA500-6
40-511 b
TROUBLESHOOTING
DKA0L0
DKA0L0 Lift Arm Angle Sensor: Double Meshing Action code
Failure code
E01 Contents of trouble
Action of controller
DKA0L0
Trouble
Lift arm angle sensor: Double meshing (Work equipment controller system)
• Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly. (Lift arm angle upper limit + 5° and above or lift arm angle lower limit + 5° or above) • • • •
Resets the remote positioner function. Resets semi-auto digging function. No PC control while the lift arm is rising. When the remote positioner lower setting is ON, turns OFF the lift arm float detent; when the remote positioner lower setting is OFF, usually operates the lift arm float detent. • Turns the lift arm raise detent OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Remote positioner malfunction (Not stop) • Faulty semi-auto digging operation (Not operate) • No PC control while the lift arm is rising
Related information
• This failure code may be displayed when the initial setting of the lift arm angle sensor failed. • The input state (angle) from the lift arm angle sensor can be checked with the monitoring function (Code: 06002 BOOM ANG). • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function (Code: 06005 BOOM ANG). • Method of reproducing failure code: Start engine and set the lift arm to raise or lower stroke end.
1
Cause
Standard value in normal state/Remarks on troubleshooting
Defective lift arm angle sensor adjustment
★ Adjustment of lift arm angle sensor may be defective. Check it directly (see the Testing and Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Possible causes and standard value in normal state
Defective lift arm angle ★ sensor (Internal short circuit)
F13 (male)
Resistance
Between (A) and (C)
5 k ±20%
Between (A), (B), (C) and chassis ground
Min. 1 M
Prepare with starting switch OFF, then start engine and carry out troubleshooting. F13
Lift arm position
Voltage
Between (C) and (A)
Constant
4.85 – 5.15 V
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
Between (B) and (A)
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. 3
Defective work equipment controller
L05 Between (8) and chassis ground
40-512 b
Lift arm position
Voltage
Constant
1.00 – 4.00 V
Raise stroke end
3.50 – 4.00 V
Lower stroke end
1.00 – 1.88 V
WA500-6
TROUBLESHOOTING
DKA0L0
Related Circuit Diagram
WA500-6
40-513 b
TROUBLESHOOTING
DLF1KA
DLF1KA Transmission Input Shaft Speed Sensor: Disconnection Action Code
Failure Code
E01
DLF1KA
Trouble
Transmission input shaft speed sensor: Disconnection (Transmission controller system)
Contents of trouble
• Due to disconnection or hot short circuit in the transmission input shaft speed sensor system, the signal voltage is higher than normal range. (Transmission input shaft speed sensor signal: Min. 1.5 V) • Signal from the transmission input shaft speed sensor: 0 rpm
Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine Related information
— • The input state (speed) from the transmission input shaft speed sensor can be checked with the monitoring function (Code: 31200 T/M SPEED IN). • Method of reproducing failure code: Start engine and drive the machine.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission input The transmission input shaft speed sensor adjustment may be defective. 1 shaft speed sensor Check it directly (see Transmission Speed Sensor in the Testing and adjustment Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission input shaft speed sensor 2 (Internal disconnection or short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. REV OUT1 (male)
Resistance
Between (1) and (2)
500 – 1,000
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness Wiring harness between L03 (female) (39) – 3 Resistance Max. 1 (Disconnection in wiring REV OUT1 (female) (2) harness or defective contact) Wiring harness between L03 (female) (40) – Resistance Max. 1 REV OUT1 (female) (1) ★ Prepare with starting switch OFF, then turn starting switch ON and 4
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L03 (female) (40) – REV OUT1 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5
40-514 b
Defective transmission controller
L03 (female)
Resistance
Between (39) and (40)
500 – 1,000
Between (39), (40) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DLF1KA
Related Circuit Diagram
WA500-6
40-515 b
TROUBLESHOOTING
DLF1LC
DLF1LC Transmission Input Shaft Speed Sensor: Speed Signals Disagree Action Code
Failure Code
E01
DLF1LC
Trouble
Transmission input shaft speed sensor: Speed signals disagree (Transmission controller system)
• Due to grounding fault in the transmission input shaft speed sensor, the transmission input shaft speed sensor signal voltage is lower than normal range. • This failure code appears under the following conditions. ([A] or [B])
[A]
Contents of trouble
• Transmission output shaft speed sensor and transmission input shaft speed obtained from reduction ratio: Min. 200 rpm • Signal from transmission input shaft speed sensor: 0 rpm • Transmission input shaft speed sensor signal line: Disconnection is not detected.
[B] • Difference between actual transmission output shaft speed and output shaft speed obtained from input shaft speed sensor and reduction ratio is larger than 200 rpm. • Output shaft speed is sensed. • Input shaft speed is sensed. Action of controller
• If cause of failure disappears, system resets itself.
Problem that appears on machine Related information
— • The input state (speed) from the transmission input shaft speed sensor can be checked with the monitoring function (Code: 31200, T/M SPEED IN). • Method of reproducing failure code: Start engine and drive the machine. • This error may be detected when engine stalls.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission input The transmission input shaft speed sensor adjustment may be defective. 1 shaft speed sensor Check it directly (see Transmission Speed Sensor in the Testing and Adjusting section). adjustment
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission input 2 shaft speed sensor (Internal short circuit) Possible causes and standard value in normal state
REV OUT1 (male)
Resistance
Between (1) and (2)
500 – 1,000
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L03 (female) (40) – (Contact with ground circuit) Resistance Min. 1 M REV OUT1 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4
40-516 b
Defective transmission controller
L03 (female)
Resistance
Between (39) and (40)
500 – 1,000
Between (39), (40) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DLF1LC
Related Circuit Diagram
WA500-6
40-517 b
TROUBLESHOOTING
DLT4KB
DLT4KB Transmission Input Shaft Speed Sensor: Short Circuit Action Code
Failure Code
E03
DLT4KB
Trouble
Transmission output shaft speed sensor: Short circuit (Transmission controller system)
Contents of trouble
• Due to grounding fault in the transmission output shaft speed sensor system, transmission output shaft speed sensor signal voltage is lower than normal range. • This failure code appears under the following conditions ([A] or [B]). [A] • Transmission input shaft speed sensor and transmission output shaft speed obtained from reduction ratio: Min. 200 rpm • Transmission output shaft speed sensor: 0 rpm • Transmission output shaft speed sensor signal line: Disconnection is not detected. [B] • Difference between actual transmission output shaft speed and output shaft speed obtained from input shaft speed sensor and reduction ratio is larger than 200 rpm. • Output shaft speed is sensed. • Input shaft speed is sensed.
Action of controller
• In the auto-shift mode, changes the shift mode to the manual mode. • In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the manual mode. • In the manual shift mode, performs the normal control. • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control operation. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Does not change to auto-shift mode (changes to manual shift mode). • No travel speed limit function • No transmission protection function • Gear shifting shocks occur.
Related information
• The input state (speed) from the transmission output shaft speed sensor can be checked with the monitoring function (Code: 31400, T/M SPEED OUT). • Method of reproducing failure code: Start engine and drive the machine. • This error may be detected when engine stalls.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission 1 output shaft speed sensor adjustment
The transmission output shaft speed sensor adjustment may be defective. Check it directly (see Transmission Speed Sensor in the Testing and Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Defective transmission 2 output shaft speed sensor (Internal short circuit)
REV OUT2 (male)
Resistance
Between (1) and (2)
500 – 1,000
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness (Contact with ground circuit) Wiring harness between L03 (female) (20) – Resistance Min. 1 M REV OUT2 (female) (1) and chassis ground
40-518 b
WA500-6
TROUBLESHOOTING
DLT4KB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. 4
Defective transmission controller
L03 (female)
Resistance
Between (20) and (29)
500 – 1,000
Between (20), (29) and chassis ground
Min. 1 M
Related Circuit Diagram
WA500-6
40-519 b
TROUBLESHOOTING
DLT4KX
DLT4KX Transmission Output Shaft Speed Sensor: Out-of-Input Signal Range Action Code
Failure Code
E03
DLT4KX
Trouble
Transmission output shaft speed sensor: Out of input signal range (Transmission controller system)
Contents of trouble
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor system, the signal voltage is higher than normal range. (Transmission output shaft speed sensor signal: Min. 1.5 V) • Signal from the transmission output shaft speed sensor: 0 rpm
Action of controller
• In the auto-shift mode, changes the shift mode to the manual mode. • In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the manual mode. • In the manual shift mode, performs the normal control. • Obtains the output shaft speed from the input shaft speed and gear speed reduction ratio for control operation. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Does not change to auto-shift mode (changes to manual shift mode). • No travel speed limit function • No transmission protection function • Gear shifting shocks occur.
Related information
• The input state (speed) from the transmission output shaft speed sensor can be checked with the monitoring function (Code: 31400, T/M SPEED OUT). • Method of reproducing failure code: Start engine and drive the machine.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective transmission 1 output shaft speed sensor adjustment
The transmission input shaft speed sensor adjustment may be defective. Check it directly (see Transmission Speed Sensor in the Testing and Adjusting section).
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective transmission 2 output shaft speed sensor (Internal short circuit)
REV OUT2 (male)
Resistance
Between (1) and (2)
500 – 1,000
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Disconnection in wiring harness Wiring harness between L03 (female) (20) – 3 (Disconnection in wiring REV OUT2 (female) (1) harness or defective contact) Wiring harness between L03 (female) (29) – REV OUT2 (female) (2)
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 4 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L03 (female) (20) – REV OUT2 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 5
40-520 b
Defective transmission controller
L03 (female)
Resistance
Between (20) and (29)
500 – 1,000
Between (20), (29) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DLT4KX
Related Circuit Diagram
WA500-6
40-521 b
TROUBLESHOOTING
DT20KB
DT20KB Transmission Cutoff Indicator Lamp: Short Circuit Action Code
Failure Code
E01
DT20KB
Trouble
Transmission cutoff indicator lamp: Short circuit (Transmission controller system)
Contents of trouble
• Due to grounding fault in transmission cutoff indicator lamp system, the signal is not output to the indicator lamp.
Action of controller
• Turns the transmission cutoff indicator lamp output OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission cutoff indicator lamp does not light up.
Related information
• Method of reproducing failure code: Start engine and turn the transmission cutoff switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission cutoff indicator lamp (light-emitting 1 diode) (Internal short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. S10 (male)
Resistance
Between (2) and (1)
Min. 1 M (No continuity)
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (8) – (Contact with ground circuit) Resistance Min. 1 M S10 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective transmission controller
L04 Between (8) and chassis ground
40-522 b
Transmission cutoff switch
Voltage
ON
Max. 1 V
OFF
20 – 30 V
WA500-6
TROUBLESHOOTING
DT20KB
Related Circuit Diagram
WA500-6
40-523 b
TROUBLESHOOTING
DUM1KB
DUM1KB Remote Positioner Raise Set Indicator Lamp: Short Circuit Action Code
Failure Code
—
DUM1KB
Trouble
Remote positioner raise set indicator lamp: Short circuit (Work equipment controller system)
Contents of trouble
• Since the remote positioner raise set indicator lamp system is shorted with the chassis ground, the signal is not output to the indicator lamp.
Action of controller
• Turns off the remote positioner raise set indicator output. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The remote positioner raise set indicator lamp does not light up.
Related information
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the monitoring function (Code: 40954 D-OUT-18). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective remote positioner raise set indicator lamp 1 (light-emitting diode) (Internal short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. (See Electrical System Troubleshooting: Procedure for Testing Diodes in the Testing and Adjusting section.) S13 (male)
Resistance
Between (2) and (1)
Min. 1 M (No continuity)
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (8) – Resistance Min. 1 M S13 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (8) and chassis ground
40-524 b
Remote positioner raise
Voltage
In use
20 – 30 V
Not in use
Max. 1 V
WA500-6
TROUBLESHOOTING
DUM1KB
Related Circuit Diagram
WA500-6
40-525 b
TROUBLESHOOTING
DUM2KB
DUM2KB Remote Positioner Lower Set Indicator Lamp: Short Circuit Action Code
Failure Code
—
DUM2KB
Trouble
Remote positioner lower set indicator lamp: Short circuit (Work equipment controller system)
Contents of trouble
• Since the remote positioner lower set indicator lamp system is shorted with the chassis ground, the signal is not output to the indicator lamp.
Action of controller
• Turns off the remote positioner lower set indicator output. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The remote positioner lower set indicator lamp does not light up.
Related information
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the monitoring function (Code: 40954 D-OUT-19). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting Defective remote positioner lower set indicator lamp 1 (light-emitting diode) (Internal short circuit)
Possible causes and standard value in normal state
without turning starting switch ON. (See Electrical System Troubleshooting: Procedure for Testing Diodes in the Testing and Adjusting section.) S13 (male)
Resistance
Between (2) and (3)
Min. 1 M (No continuity)
Between (2), (3) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (18) – Resistance Min. 1 M S13 (female) (3) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (18) and chassis ground
40-526 b
Remote positioner lower
Voltage
In use
20 – 30 V
Not in use
Max. 1 V
WA500-6
TROUBLESHOOTING
DUM2KB
Related Circuit Diagram
WA500-6
40-527 b
TROUBLESHOOTING
DV00KB
DV00KB Alarm Buzzer: Short Circuit Action code
Failure code
E01
DV00KB
Trouble
Alarm buzzer: Short circuit (Machine monitor system)
Contents of trouble
• The alarm buzzer output circuit is shorted with the power supply line.
Action of controller
• Stops alarm buzzer output. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Alarm buzzer does not sound.
Related information
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code: 40295, D-OUT-0). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF; disconnect L51 and L20; turn 1 Hot short in wiring harness
Possible causes and standard value in normal state
starting switch ON; and carry out troubleshooting. Wiring harness between L51 (female) (14) – L20 (female) (2) and chassis ground
Voltage
Min. 5 V
★ Prepare with starting switch OFF, then turn starting switch ON
2 Defective alarm buzzer
and carry out troubleshooting. (Remove buzzer and connect +24 V to L20 (male) (1) and connect GND to L20 (male) (2)) Alarm buzzer sounds.
Alarm buzzer is normal.
Alarm buzzer does not sound.
Alarm buzzer is abnormal.
★ Check alarm buzzer unit. 3 Defective machine monitor
40-528 b
If results of 1 and 2 are normal, machine monitor is defective.
WA500-6
TROUBLESHOOTING
DV00KB
Related Circuit Diagram
WA500-6
40-529 b
TROUBLESHOOTING
DW4PKA
DW4PKA Lift Arm Raise EPC Solenoid: Disconnection Action Code
Failure Code
E03
DW4PKA
Trouble
Lift arm raise EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when the lift arm raise EPC solenoid output is ON.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Lift arm does not rise.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • Method of reproducing failure code: Engine started + lift arm raise
Cause Defective lift arm raise EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F07 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness Wiring harness between L07 (female) (6) – 2 Resistance Max. 1 (Disconnection in wiring F07 (female) (1) harness or defective contact) Wiring harness between L07 (female) (3) – Resistance Max. 1 F07 (female) (2) ★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-530 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (6) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DW4PKA
Related Circuit Diagram
WA500-6
40-531 b
TROUBLESHOOTING
DW4PKB
DW4PKB Lift Arm Raise EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DW4PKB
Trouble
Lift arm raise EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the lift arm raise EPC solenoid signal system was shorted with the chassis ground, abnormal current flowed when the lift arm raise EPC solenoid output was ON.
Action of controller
• Stops outputting the signal to the lift arm raise EPC solenoid. • Stops outputting the signal to the lift arm raise detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Lift arm does not rise.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • Method of reproducing failure code: Engine started + lift arm raise
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm raise EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F07 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (6) – Resistance Min. 1 M F07 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-532 b
Defective work equipment controller
L07 (female)
Resistance
Between (6) and (3)
5 – 15
Between (6), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4PKB
Related Circuit Diagram
WA500-6
40-533 b
TROUBLESHOOTING
DW4PKY
DW4PKY Lift Arm Raise EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DW4PKY
Trouble
Lift arm raise EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the lift arm raise EPC solenoid signal system was shorted with the power source, abnormal voltage was applied when the lift arm raise EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work. • The lift arm raise EPC solenoid may be burnt out.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906 3RD EPC1 DIR). • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm raise EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F07 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (6) – F07 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-534 b
Defective work equipment controller
L07 (female)
Resistance
Between (6) and (3)
5 – 15
Between (6), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4PKY
Related Circuit Diagram
WA500-6
40-535 b
TROUBLESHOOTING
DW4QKA
DW4QKA Lift Arm Lower EPC Solenoid: Disconnection Action Code
Failure Code
E03
DW4QKA
Trouble
Lift arm lower EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when the lift arm lower EPC solenoid output is ON.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Lift arm does not lower.
Related information
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • Method of reproducing failure code: Start engine and lower the lift arm.
Cause Defective lift arm lower EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F08 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness Wiring harness between L07 (female) (16) – 2 Resistance Max. 1 (Disconnection in wiring F08 (female) (1) harness or defective contact) Wiring harness between L07 (female) (3) – Resistance Max. 1 F08 (female) (2) ★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-536 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (16) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DW4QKA
Related Circuit Diagram
WA500-6
40-537 b
TROUBLESHOOTING
DW4QKB
DW4QKB Lift Arm Lower EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DW4QKB
Trouble
Lift arm lower EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the lift arm lower EPC solenoid signal system was shorted with the chassis ground, abnormal current flowed when the lift arm lower EPC solenoid output was ON.
Action of controller
• Stops outputting the signal to the lift arm lower EPC solenoid. • Stops outputting the signal to the lift arm float detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Lift arm does not lower.
Related information
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • Method of reproducing failure code: Start engine and lower the lift arm.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm lower EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F08 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (16) – Resistance Min. 1 M F08 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-538 b
Defective work equipment controller
L07 (female)
Resistance
Between (16) and (3)
5 – 15
Between (16), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4QKB
Related Circuit Diagram
WA500-6
40-539 b
TROUBLESHOOTING
DW4QKY
DW4QKY Lift Arm Lower EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DW4QKY
Trouble
Lift arm lower EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the lift arm lower EPC solenoid signal system was shorted with the power source, abnormal voltage was applied when the lift arm lower EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work. • The lift arm lower EPC solenoid may be burnt out.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906, 3RD EPC1 DIR). • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm lower EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F08 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (16) – F08 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-540 b
Defective work equipment controller
L07 (female)
Resistance
Between (16) and (3)
5 – 15
Between (16), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4QKY
Related Circuit Diagram
WA500-6
40-541 b
TROUBLESHOOTING
DW4RKA
DW4RKA Bucket Tilt EPC Solenoid: Disconnection Action Code
Failure Code
E03
DW4RKA
Trouble
Bucket tilt EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the bucket tilt EPC solenoid output signal system is disconnected, no current flows when the bucket tilt EPC solenoid output is ON.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Bucket does not tilt.
Related information
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • Method of reproducing failure code: Start engine and tilt the bucket.
Cause Defective bucket tilt EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F09 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness Wiring harness between L07 (female) (5) – 2 Resistance Max. 1 (Disconnection in wiring F09 (female) (1) harness or defective contact) Wiring harness between L07 (female) (13) – Resistance Max. 1 F09 (female) (2) ★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-542 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (5) and (13)
5 – 15
WA500-6
TROUBLESHOOTING
DW4RKA
Related Circuit Diagram
WA500-6
40-543 b
TROUBLESHOOTING
DW4RKB
DW4RKB Bucket Tilt EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DW4RKB
Trouble
Bucket tilt EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the bucket tilt EPC solenoid signal system was shorted with the chassis ground, abnormal current flowed when the bucket tilt EPC solenoid output was ON.
Action of controller
• Stops outputting the signal to the bucket tilt EPC solenoid. • Stops outputting the signal to the bucket tilt detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Bucket does not tilt.
Related information
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • Method of reproducing failure code: Start engine and tilt the bucket.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket tilt EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F09 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (5) – Resistance Min. 1 M F09 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-544 b
Defective work equipment controller
L07 (female)
Resistance
Between (5) and (13)
5 – 15
Between (5), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4RKB
Related Circuit Diagram
WA500-6
40-545 b
TROUBLESHOOTING
DW4RKY
DW4RKY Bucket Tilt EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DW4RKY
Trouble
Bucket tilt EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the bucket tilt EPC solenoid signal system was shorted with the power source, abnormal voltage was applied when the bucket tilt EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work. • The bucket tilt EPC solenoid may be burnt out.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906, 3RD EPC1 DIR). • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket tilt EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F09 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (5) – F09 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-546 b
Defective work equipment controller
L07 (female)
Resistance
Between (5) and (13)
5 – 15
Between (5), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4RKY
Related Circuit Diagram
WA500-6
40-547 b
TROUBLESHOOTING
DW4SKA
DW4SKA Buck Dump EPC Solenoid: Disconnection Action Code
Failure Code
E03
DW4SKA
Trouble
Bucket dump EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when the bucket dump EPC solenoid output is ON.
Action of controller
• Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Bucket does not dump.
Related information
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • Method of reproducing failure code: Start engine and dump the bucket.
Cause Defective bucket dump EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F10 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness Wiring harness between L07 (female) (15) – 2 Resistance Max. 1 (Disconnection in wiring F10 (female) (1) harness or defective contact) Wiring harness between L07 (female) (13) – Resistance Max. 1 F10 (female) (2) ★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-548 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (15) and (13)
5 – 15
WA500-6
TROUBLESHOOTING
DW4SKA
Related Circuit Diagram
WA500-6
40-549 b
TROUBLESHOOTING
DW4SKB
DW4SKB Bucket Dump EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DW4SKB
Trouble
Bucket dump EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the bucket dump EPC solenoid signal system was shorted with the chassis ground, abnormal current flowed when the bucket dump EPC solenoid output was ON.
Action of controller
• Stops outputting the signal to the bucket dump EPC solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Bucket does not dump. • The wiring harness or controller may be burnt out.
Related information
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • Method of reproducing failure code: Start engine and dump the bucket.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket dump EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F10 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (15) – Resistance Min. 1 M F10 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-550 b
Defective work equipment controller
L07 (female)
Resistance
Between (15) and (13)
5 – 15
Between (15), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4SKB
Related Circuit Diagram
WA500-6
40-551 b
TROUBLESHOOTING
DW4SKY
DW4SKY Bucket Dump EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DW4SKY
Trouble
Bucket dump EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the bucket dump EPC solenoid signal system was shorted with the power source, abnormal voltage was applied when the bucket dump EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• When the work equipment neutral lock solenoid is turned ON, all the work equipment does not work. • The bucket dump EPC solenoid may be burnt out.
Related information
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring function (Code: 41900 RAISE EPC DIR). • The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring function (Code: 41901 LOWER EPC DIR). • The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function (Code: 41902 TILT EPC DIR). • The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring function (Code: 41903 DUMP EPC DIR). • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906, 3RD EPC1 DIR). • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket dump EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
F10 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (15) – F10 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-552 b
Defective work equipment controller
L07 (female)
Resistance
Between (15) and (13)
5 – 15
Between (15), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DW4SKY
Related Circuit Diagram
WA500-6
40-553 b
TROUBLESHOOTING
DW7BKA
DW7BKA Fan Reverse Solenoid: Disconnection Action Code
Failure Code
E01
DW7BKA
Trouble
Fan reverse solenoid: Disconnection (Transmission controller system)
Contents of trouble
• Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse solenoid output is ON.
Action of controller
• Disables the automatic fan reverse function (if equipped). • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (if equipped) specification. • Fan cannot be reversed.
Related information
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function (Code: 40949, D-OUT-3). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting 1
Defective fan reverse solenoid (Internal disconnection)
without turning starting switch ON. G09 (male)
Resistance
Between (1) and (2)
35 – 45
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L04 (female) (37) – G09 (female) (1)
Resistance
Max. 1
Wiring harness between G09 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-554 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (37) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DW7BKA
Related Circuit Diagram
WA500-6
40-555 b
TROUBLESHOOTING
DW7BKB
DW7BKB Fan Reverse Solenoid: Short Circuit Action Code
Failure Code
E01
DW7BKB
Trouble
Fan reverse solenoid: Short circuit (Transmission controller system)
Contents of trouble
• Since the fan reverse solenoid system was shorted with the chassis ground, abnormal current flowed when the fan reverse solenoid output was ON.
Action of controller
• Turns the output to the fan reverse solenoid OFF. • Disables the automatic fan reverse function (if equipped). • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The fan cannot turn in reverse when the fan reverse switch is operated. • The automatic fan reverse function is disabled in the case of automatic fan reverse function (if equipped) specification.
Related information
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function (Code: 40949, D-OUT-3). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Possible causes and standard value in normal state
Defective fan reverse solenoid (Internal short circuit)
G09 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (37) – (Contact with ground circuit) Resistance Min. 1 M G09 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission 3 controller
40-556 b
without turning starting switch ON. L04 (female)
Resistance
Between (37) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DW7BKB
Related Circuit Diagram
WA500-6
40-557 b
TROUBLESHOOTING
DW7BKY
DW7BKY Fan Reverse Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DW7BKY
Trouble
Fan reverse solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was applied when the fan reverse switch output was OFF.
Action of controller
• Disables the automatic fan reverse function (if equipped). • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (if equipped) specification. • The fan does not rotate normally. • The machine may overheat.
Related information
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function (Code: 40949, D-OUT-3). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1
Possible causes and standard value in normal state
Defective fan reverse solenoid (Internal short circuit)
G09 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (37) – G09 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting Defective transmission 3 controller
40-558 b
without turning starting switch ON. L04 (female)
Resistance
Between (37) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DW7BKY
Related Circuit Diagram
WA500-6
40-559 b
TROUBLESHOOTING
DW7DKA
DW7DKA Hydraulic Drive Fan Neutral Solenoid: Disconnection Action Code
Failure Code
E01
DW7DKA
Trouble
Hydraulic drive fan neutral solenoid: Disconnection (Transmission controller system)
Contents of trouble
• A hydraulic drive fan neutral solenoid error was detected.
Action of controller
• None in particular
Problem that appears on machine Related information
—
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
Cause Possible causes and standard value in normal state
40-560 b
1
Standard value in normal state/Remarks on troubleshooting
Optional setting may be incorrect. ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function in the Testing and Adjusting section and check that AUTO RE FAN is set to None.
WA500-6
TROUBLESHOOTING
DW7DKB
DW7DKB Hydraulic Drive Fan Neutral Solenoid: Short Circuit Action Code
Failure Code
E01
DW7DKB
Trouble
Hydraulic drive fan neutral solenoid: Short circuit (Transmission controller system)
Contents of trouble
• A hydraulic drive fan neutral solenoid error was detected.
Action of controller
• None in particular
Problem that appears on machine Related information
—
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
Cause Possible causes and standard value in normal state
WA500-6
Standard value in normal state/Remarks on troubleshooting
Optional setting may be improper. 1 ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function in the Testing and Adjusting section and check that AUTO RE FAN is set to None.
40-561 b
TROUBLESHOOTING
DW7DKY
DW7DKY Hydraulic Drive Fan Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DW7DKY
Trouble
Hydraulic drive fan neutral solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• A hydraulic drive fan neutral solenoid error was detected.
Action of controller
• None in particular
Problem that appears on machine Related information
—
• The hydraulic drive fan neutral solenoid is not set in the WA500-6.
Cause Possible causes and standard value in normal state
40-562 b
1
Standard value in normal state/Remarks on troubleshooting
Optional setting may be improper. ★ Refer to MACHINE MONITOR SYSTEM: Service Mode: Optional Device Selecting Function in the Testing and Adjusting section and check that AUTO RE FAN is set to None.
WA500-6
TROUBLESHOOTING
DW7DKY
MEMORANDUM
WA500-6
40-563 b
TROUBLESHOOTING
DWM1KA
DWM1KA Work Equipment Neutral Lock Solenoid: Disconnection Action Code
Failure Code
E01
DWM1KA
Trouble
Work equipment neutral lock solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the work equipment neutral lock solenoid system is disconnected, no current flows when the work equipment neutral lock solenoid output is ON.
Action of controller
• Stops outputting the signal to each work equipment solenoid according to an input signal from the work equipment lock lever. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Each work equipment solenoid lock normally works according to an input signal from the work equipment lock lever.
Related information
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the monitoring function (Code: 40952, D-OUT-0). • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock lever to the LOCK position.
Cause Defective work equipment 1 neutral lock solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. B02 (male)
Resistance
Between (1) and (2)
35 – 45
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Disconnection in wiring harness Wiring harness between L07 (female) (7) – 2 (Disconnection in wiring B02 (female) (1) harness or defective contact) Wiring harness between B02 (female) (2) – chassis ground
Resistance
Max. 1
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-564 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (7) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DWM1KA
Related Circuit Diagram
WA500-6
40-565 b
TROUBLESHOOTING
DWM1KB
DWM1KB Work Equipment Neutral Lock Solenoid: Short Circuit Action Code
Failure Code
E01
DWM1KB
Trouble
Work equipment neutral lock solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the work equipment neutral lock solenoid system is shorted with the chassis ground, no current flows when the work equipment neutral lock solenoid output is ON.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to each work equipment solenoid according to an input signal from the work equipment lock lever. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Each work equipment solenoid lock normally works according to an input signal from the work equipment lock lever. • The wiring harness or controller may be burnt out.
Related information
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the monitoring function (Code: 40952, D-OUT-0). • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock lever to the LOCK position.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective work equipment 1 neutral lock solenoid (Internal short circuit)
B02 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
2
Defective diode (B03) (Internal short circuit)
B03 (male)
Diode range
Continuity
Between (2) and (1)
Measured from side (2)
Continue
Between (1) and (2)
Measured from side (1)
No continuity
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L07 (female) (7) – (Contact with ground circuit) Resistance Min. 1 M B02 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting 4
40-566 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (7) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DWM1KB
Related Circuit Diagram
WA500-6
40-567 b
TROUBLESHOOTING
DWM1KY
DWM1KY Work Equipment Neutral Lock Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DWM1KY
Trouble
Work equipment neutral lock solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the work equipment neutral lock solenoid system was shorted with the power source, abnormal voltage was applied when the work equipment neutral lock solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to each work equipment solenoid according to an input signal from the work equipment lock lever. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• All work equipment does not move.
Related information
• The work equipment can be operated by disconnecting the connector of the work equipment neutral lock solenoid. • The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the monitoring function (Code: 40952, D-OUT-0). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective work equipment 1 neutral lock solenoid (Internal short circuit)
B02 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
2
Defective diode (B03) (Internal short circuit)
B03 (male)
Diode range
Continuity
Between (2) and (1)
Measured from side (2).
Continue
Between (1) and (2)
Measured from side (1).
No continuity
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 3 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (7) – B02 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting Defective work equipment 4 controller
40-568 b
without turning starting switch ON. L07 (female)
Resistance
Between (7) and chassis ground
35 – 45
WA500-6
TROUBLESHOOTING
DWM1KY
Related Circuit Diagram
WA500-6
40-569 b
TROUBLESHOOTING
DWN6KA
DWN6KA Lift Arm Raise Magnet Detent Solenoid: Disconnection Action Code
Failure Code
E01
DWN6KA
Trouble
Lift arm raise magnet detent solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current flows when the lift arm raise magnet detent solenoid output is ON.
Action of controller
• Keeps normal output condition to the lift arm raise magnet detent solenoid. • Stops outputting the signal to the remote positioner raise stop lamp. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The lift arm remote positioner raise does not function. • The lift arm is not held at the lift arm raise detent position.
Related information
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-1). • Method of reproducing failure code: Engine started + lift arm raise detent
Cause Defective lift arm raise 1 magnet detent solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S05 (male)
Resistance
Between (1) and (2)
35 – 45
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L07 (female) (17) – S05 (female) (1)
Resistance
Max. 1
Wiring harness between S05 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (17) and chassis ground
40-570 b
Lift arm lever
Voltage
Neutral
Max. 1 V
Raise detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN6KA
Related Circuit Diagram
WA500-6
40-571 b
TROUBLESHOOTING
DWN6KB
DWN6KB Lift Arm Raise Magnet Detent Solenoid: Short Circuit Action Code
Failure Code
E01
DWN6KB
Trouble
Lift arm raise magnet detent solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the lift arm raise magnet detent solenoid power supply system was shorted with the chassis ground, abnormal current flowed when the lift arm raise magnet detent solenoid output was ON.
Action of controller
• Stops outputting the signal to the lift arm raise magnet detent solenoid. • Stops outputting the signal to the remote positioner raise stop lamp. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The lift arm remote positioner raise does not function. • The lift arm is not held at the lift arm raise detent position.
Related information
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-1). • Method of reproducing failure code: Engine started + lift arm raise detent
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm raise magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S05 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (17) – Resistance Min. 1 M S05 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (17) and chassis ground
40-572 b
Lift arm lever
Voltage
Neutral
Max. 1 V
Raise detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN6KB
Related Circuit Diagram
WA500-6
40-573 b
TROUBLESHOOTING
DWN6KY
DWN6KY Lift Arm Raise Magnet Detent Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DWN6KY
Trouble
Lift arm raise magnet detent solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the lift arm raise magnet detent solenoid power supply system was shorted with the power source, abnormal voltage was applied when the lift arm raise magnet detent solenoid output was ON.
Action of controller
• Stops outputting the signal to the lift arm raise magnet detent solenoid. • Stops outputting the signal to the remote positioner raise stop lamp. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be manually released). • If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the suction power of the magnet (lever control is deteriorated).
Related information
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-1). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm raise magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S05 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (17) – S05 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (17) and chassis ground
40-574 b
Lift arm lever
Voltage
Neutral
Max. 1 V
Raise detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN6KY
Related Circuit Diagram
WA500-6
40-575 b
TROUBLESHOOTING
DWN7KA
DWN7KA Lift Arm Float Magnet Detent Solenoid: Disconnection Action Code
Failure Code
E01
DWN7KA
Trouble
Lift arm float magnet detent solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the lift arm float magnet detent solenoid power supply system is disconnected, no current flows when the lift arm float magnet detent solenoid output is ON.
Action of controller
• Keeps normal output condition to the lift arm float magnet detent solenoid. • Stops outputting the signal to the remote positioner lower stop lamp. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The lift arm remote positioner lower does not function. • The lift arm is not held at the lift arm float detent position.
Related information
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-2). • Method of reproducing failure code: Start engine and perform lift arm float detent operation.
Cause Defective lift arm float magnet 1 detent solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S06 (male)
Resistance
Between (1) and (2)
35 – 45
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L07 (female) (27) – S06 (female) (1)
Resistance
Max. 1
Wiring harness between S06 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective work equipment 3 controller
40-576 b
L07
Lift arm lever
Voltage
Between (27) and chassis ground
Neutral
Max. 1 V
Float detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN7KA
Related Circuit Diagram
WA500-6
40-577 b
TROUBLESHOOTING
DWN7KB
DWN7KB Lift Arm Float Magnet Detent Solenoid: Short Circuit Action Code
Failure Code
E01
DWN7KB
Trouble
Lift arm float magnet detent solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the lift arm float magnet detent solenoid power supply system was shorted with the chassis ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
Action of controller
• Stops outputting the signal to the lift arm float magnet detent solenoid. • Stops outputting the signal to the remote positioner lower stop lamp. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The lift arm remote positioner lower does not function. • The lift arm is not held at the lift arm float detent position.
Related information
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-2). • Method of reproducing failure code: Start engine and perform lift arm float detent operation.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm float magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S06 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (27) – Resistance Min. 1 M S06 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective work equipment 3 controller
40-578 b
L07
Lift arm lever
Voltage
Between (27) and chassis ground
Neutral
Max. 1 V
Float detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN7KB
Related Circuit Diagram
WA500-6
40-579 b
TROUBLESHOOTING
DWN7KY
DWN7KY Lift Arm Float Magnet Detent Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DWN7KY
Trouble
Lift arm float magnet detent solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the lift arm float magnet detent solenoid power supply system was shorted with the power source, abnormal voltage was applied when the lift arm float magnet detent solenoid output was OFF.
Action of controller
• Stops outputting the signal to the lift arm float magnet detent solenoid. • Stops outputting the signal to the remote positioner lower stop lamp. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• If you perform lift arm float detent operation, detent condition is not automatically released (can be manually released). • If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the suction power of the magnet (lever control is deteriorated).
Related information
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-2). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lift arm float magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S06 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (27) – S06 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective work equipment 3 controller
40-580 b
L07
Lift arm lever
Voltage
Between (27) and chassis ground
Neutral
Max. 1 V
Float detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN7KY
Related Circuit Diagram
WA500-6
40-581 b
TROUBLESHOOTING
DWN8KA
DWN8KA Bucket Tilt Magnet Detent Solenoid: Disconnection Action Code
Failure Code
E01
DWN8KA
Trouble
Bucket tilt magnet detent solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows when the bucket tilt magnet detent solenoid output is ON.
Action of controller
• Keeps normal output condition to the bucket tilt magnet detent solenoid. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• Bucket leveler does not work. • The bucket is not held at the bucket tilt detent position.
Related information
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). • Method of reproducing failure code: Engine started + bucket tilt detent
Cause Defective bucket tilt magnet 1 detent solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. S04 (male)
Resistance
Between (1) and (2)
35 – 45
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact)
without turning starting switch ON. Wiring harness between L07 (female) (37) – S04 (female) (1)
Resistance
Max. 1
Wiring harness between S04 (female) (2) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (37) and chassis ground
40-582 b
Bucket lever
Voltage
Neutral
Max. 1 V
Bucket detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN8KA
Related Circuit Diagram
WA500-6
40-583 b
TROUBLESHOOTING
DWN8KB
DWN8KB Bucket Tilt Magnet Detent Solenoid: Short Circuit Action Code
Failure Code
E01
DWN8KB
Trouble
Bucket tilt magnet detent solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the bucket tilt magnet detent solenoid power supply system was shorted with the chassis ground, abnormal current flowed when the bucket tilt magnet detent solenoid output was ON.
Action of controller
• Stops outputting the signal to the bucket tilt magnet detent solenoid. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Bucket leveler does not work. • The bucket is not held at the bucket tilt detent position.
Related information
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). • Method of reproducing failure code: Engine started + bucket tilt detent
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket tilt magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S04 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (37) – Resistance Min. 1 M S04 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (37) and chassis ground
40-584 b
Bucket lever
Voltage
Neutral
Max. 1 V
Bucket detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN8KB
Related Circuit Diagram
WA500-6
40-585 b
TROUBLESHOOTING
DWN8KY
DWN8KY Bucket Tilt Magnet Detent Solenoid: Shorted with the Power Source Action Code
Failure Code
E01
DWN8KY
Trouble
Bucket tilt magnet detent solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the bucket tilt magnet detent solenoid power supply system was shorted with the power source, abnormal voltage was applied when the bucket tilt magnet detent solenoid output was OFF.
Action of controller
• Stops outputting the signal to the bucket tilt magnet detent solenoid. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be manually released). • If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the suction power of the magnet (lever control is deteriorated).
Related information
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective bucket tilt magnet 1 detent solenoid (Internal short circuit)
Possible causes and standard value in normal state
S04 (male)
Resistance
Between (1) and (2)
35 – 45
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (37) – S04 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 3
Defective work equipment controller
L07 Between (37) and chassis ground
40-586 b
Bucket lever
Voltage
Neutral
Max. 1 V
Bucket detent operation
20 – 30 V
WA500-6
TROUBLESHOOTING
DWN8KY
Related Circuit Diagram
WA500-6
40-587 b
TROUBLESHOOTING
DX16KA
DX16KA Fan Pump EPC Solenoid: Disconnection Action Code
Failure Code
E01
DX16KA
Trouble
Fan pump EPC solenoid: Disconnection (Transmission controller system)
Contents of trouble
• Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC solenoid output is ON.
Action of controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The fan speed is set to the maximum.
Related information
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function (Code: 41400 FAN EPC DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause Defective fan pump EPC 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. T02 (male)
Resistance
Between (1) and (2)
5 – 10
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L04 (female) (23) – T02 (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (27) – T02 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (27) and (23)
5 – 10
Related Circuit Diagram
40-588 b
WA500-6
TROUBLESHOOTING
DX16KB
DX16KB Fan Pump EPC Solenoid: Short Circuit Action Code
Failure Code
E01
DX16KB
Trouble
Fan pump EPC solenoid: Short circuit (Transmission controller system)
Contents of trouble
• Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current flowed when the fan pump EPC solenoid output was ON.
Action of controller
• Turns the output to the fan pump EPC solenoid OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The fan speed is set to the maximum.
Related information
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function (Code: 41400 FAN EPC DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fan pump EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
T02 (male)
Resistance
Between (1) and (2)
5 – 10
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (27) – Resistance Min. 1 M T02 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Defective transmission controller
L04 (female)
Resistance
Between (23) and (27)
5 – 10
Between (23), (27) and chassis ground
Min. 1 M
Related Circuit Diagram
WA500-6
40-589 b
TROUBLESHOOTING
DX16KY
DX16KY Fan Pump EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E01
DX16KY
Trouble
Fan pump EPC solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was applied when the fan pump EPC solenoid output was OFF.
Action of controller
• Turns the output to the fan pump EPC solenoid OFF. • If cause of failure disappears, system resets itself.
Problem that appears on machine
• The fan speed is set to the minimum.
Related information
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function (Code: 41400 FAN EPC DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective fan pump EPC 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
T02 (male)
Resistance
Between (1) and (2)
5 – 10
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (27) – T02 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
Defective transmission controller
L04 (female)
Resistance
Between (23) and (27)
5 – 10
Between (23), (27) and chassis ground
Min. 1 M
Related Circuit Diagram
40-590 b
WA500-6
TROUBLESHOOTING
DXA1KA
DXA1KA Pump PC-EPC Solenoid: Disconnection Action Code
Failure Code
E01
DXA1KA
Trouble
Pump PC-EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader pump PC-EPC solenoid output is ON.
Action of controller
• Keeps normal output condition to the loader pump PC-EPC solenoid. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Fuel consumption may become poor when engine speed is low. • The engine may stop. • Engine acceleration performance is deteriorated. • The lift arm may increase speed suddenly.
Related information
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring function (Code: 94500 PUMP EPC DIR). • Method of reproducing failure code: Start engine.
Cause Defective loader pump PC1 EPC solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. T01 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L07 (female) (23) – T01 (female) (2)
Resistance
Max. 1
Wiring harness between L07 (female) (36) – T01 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (23) and (36)
5 – 15
Related Circuit Diagram
WA500-6
40-591 b
TROUBLESHOOTING
DXA1KB
DXA1KB Pump PC-EPC Solenoid: Short Circuit Action Code
Failure Code
E01
DXA1KB
Trouble
Pump PC-EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal current flowed when the loader pump PC-EPC solenoid output was ON.
Action of controller
• Stops outputting the signal to the loader pump PC-EPC solenoid. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Fuel consumption may become poor when engine speed is low. • Engine acceleration performance is deteriorated. • The lift arm may increase speed suddenly. • The wiring harness or controller may be burnt out.
Related information
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring function (Code: 94500 PUMP EPC DIR). • Method of reproducing failure code: Start engine.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective loader pump 1 PC-EPC solenoid (Internal short circuit)
Possible causes and standard value in normal state
T01 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (36) – Resistance Min. 1 M T01 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-592 b
Defective work equipment controller
L07 (female)
Resistance
Between (23) and (36)
5 – 15
Between (23), (36) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXA1KB
Related Circuit Diagram
WA500-6
40-593 b
TROUBLESHOOTING
DXH1KA
DXH1KA Lockup ECMV Solenoid: Disconnection Action Code
Failure Code
E01
DXH1KA
Trouble
Lockup ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid output is ON.
Action of controller
• Stops outputting the signal to the lockup ECMV solenoid. • Determines that the lockup fill switch is OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Torque converter lockup is not turned on.
Related information
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function (Code: 31609 ECMV LU DIR). • Method of reproducing failure code: Start engine; turn the torque convertor lockup switch ON; and drive the machine.
Cause Defective lockup ECMV 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. LC.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (23) – LC.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (35) – LC.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-594 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (23) and (35)
5 – 15
WA500-6
TROUBLESHOOTING
DXH1KA
Related Circuit Diagram
WA500-6
40-595 b
TROUBLESHOOTING
DXH1KB
DXH1KB Lockup ECMV Solenoid: Short Circuit Action Code
Failure Code
E01
DXH1KB
Trouble
Lockup ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed when the lockup solenoid output was ON.
Action of controller
• Stops outputting the signal to the lockup ECMV solenoid. • Determines that the lockup fill switch is OFF. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Torque converter lockup is not turned on.
Related information
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function (Code: 31609 ECMV LU DIR). • Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lockup ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
LC.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (35) – Resistance Max. 1 LC.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-596 b
Defective transmission controller
L04 (female)
Resistance
Between (23) and (35)
5 – 15
Between (23), (35) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH1KB
Related Circuit Diagram
WA500-6
40-597 b
TROUBLESHOOTING
DXH1KY
DXH1KY Lockup ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH1KY
Trouble
Lockup ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was applied when the lockup ECMV solenoid output was OFF.
Action of controller
• Keeps the transmission in neutral. • Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch to N (neutral). • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (neutral). • The lockup clutch is always in the meshed state. • When fault occurs, shock and sound may be made by sudden engagement and engine may stall.
Related information
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function (Code: 31609 ECMV LU DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lockup ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
LC.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and 2
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (35) – LC.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-598 b
Defective transmission controller
L04 (female)
Resistance
Between (23) and (35)
5 – 15
Between (23), (35) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH1KY
Related Circuit Diagram
WA500-6
40-599 b
TROUBLESHOOTING
DXH4KA
DXH4KA 1st Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXH4KA
Trouble
1st clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the 1st clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 1st (the machine can travel in any gear speed other than 1st).
Related information
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). • Method of reproducing failure code: Turn starting switch to START; set the transmission manual/autoshift selector switch in the MANUAL position; and select 1st using the shift down switch or move the gear shift lever to 1st.
Cause Defective 1st clutch ECMV 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact in connector)
without turning starting switch ON. Wiring harness between L04 (female) (13) – 1.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (25) – 1.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-600 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (25) and (13)
5 – 15
WA500-6
TROUBLESHOOTING
DXH4KA
Related Circuit Diagram
WA500-6
40-601 b
TROUBLESHOOTING
DXH4KB
DXH4KB 1st Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXH4KB
Trouble
1st clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when 1st clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the 1st clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 1st (the machine can travel in any gear speed other than 1st).
Related information
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). • Method of reproducing failure code: Turn starting switch to START; set the transmission manual/autoshift selector switch in the MANUAL position; and select 1st using the shift down switch or move the gear shift lever to 1st.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
1.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (25) – (Contact with ground circuit) Resistance Min. 1 M 1.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-602 b
Defective transmission controller
L04 (female)
Resistance
Between (25) and (13)
5 – 15
Between (25), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH4KB
Related Circuit Diagram
WA500-6
40-603 b
TROUBLESHOOTING
DXH4KY
DXH4KY 1st Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH4KY
Trouble
1st clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage was applied when 1st clutch ECMV solenoid output was OFF.
Action of controller
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids. • Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed clutch output is OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
Related information
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602 ECMV 1 DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 1st clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
1.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (25) – 1.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-604 b
Defective transmission controller
L04 (female)
Resistance
Between (25) and (13)
5 – 15
Between (25), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH4KY
Related Circuit Diagram
WA500-6
40-605 b
TROUBLESHOOTING
DXH5KA
DXH5KA 2nd Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXH5KA
Trouble
2nd clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the 2nd clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 2nd (the machine can travel in any gear speed other than 2nd).
Related information
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603 ECMV 2 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 2nd using the shift down switch or move the gear shift lever to 2nd.
Cause Defective 2nd clutch ECMV 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 2.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (6) – 2.PS (female) (1)
Resistance
Max. 1
Wiring harness between L04 (female) (3) – 2.PS (female) (2)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-606 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (6) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DXH5KA
Related Circuit Diagram
WA500-6
40-607 b
TROUBLESHOOTING
DXH5KB
DXH5KB 2nd Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXH5KB
Trouble
2nd clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when 2nd clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the 2nd clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 2nd (the machine can travel in any gear speed other than 2nd).
Related information
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603 ECMV 2 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 2nd using the shift down switch or move the gear shift lever to 2nd.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
2.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (6) – (Contact with ground circuit) Resistance Min. 1 M 2.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-608 b
Defective transmission controller
L04 (female)
Resistance
Between (6) and (3)
5 – 15
Between (6), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH5KB
Related Circuit Diagram
WA500-6
40-609 b
TROUBLESHOOTING
DXH5KY
DXH5KY 2nd Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH5KY
Trouble
2nd clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage was applied when 2nd clutch ECMV solenoid output was OFF.
Action of controller
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids. • Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed clutch output is OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
Related information
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603 ECMV 2 DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 2nd clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
2.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (6) – 2.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-610 b
Defective transmission controller
L04 (female)
Resistance
Between (6) and (3)
5 – 15
Between (6), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH5KY
Related Circuit Diagram
WA500-6
40-611 b
TROUBLESHOOTING
DXH6KA
DXH6KA 3rd Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXH6KA
Trouble
3rd clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the 3rd clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 3rd (the machine can travel in any gear speed other than 3rd).
Related information
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604 ECMV 3 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 3rd using the shift down switch or move the gear shift lever to 3rd.
Cause Defective 3rd clutch ECMV 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (3) – 3.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (16) – 3.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-612 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (16) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DXH6KA
Related Circuit Diagram
WA500-6
40-613 b
TROUBLESHOOTING
DXH6KB
DXH6KB 3rd Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXH6KB
Trouble
3rd clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when 3rd clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the 3rd clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 3rd (the machine can travel in any gear speed other than 3rd).
Related information
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604 ECMV 3 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 3rd using the shift down switch or move the gear shift lever to 3rd.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
3.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (16) – (Contact with ground circuit) Resistance Min. 1 M 3.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-614 b
Defective transmission controller
L04 (female)
Resistance
Between (16) and (3)
5 – 15
Between (16), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH6KB
Related Circuit Diagram
WA500-6
40-615 b
TROUBLESHOOTING
DXH6KY
DXH6KY 3rd Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH6KY
Trouble
3rd clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage was applied when 3rd clutch ECMV solenoid output was OFF.
Action of controller
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids. • Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed clutch output is OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
Related information
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604 ECMV 3 DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 3rd clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
3.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (16) – 3.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-616 b
Defective transmission controller
L04 (female)
Resistance
Between (16) and (3)
5 – 15
Between (16), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH6KY
Related Circuit Diagram
WA500-6
40-617 b
TROUBLESHOOTING
DXH7KA
DXH7KA R Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXH7KA
Trouble
R clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R (Reverse) clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
Related information
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring function (Code: 31606 ECMV R DIR). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch R (reverse)
Cause Defective R (Reverse) clutch 1 ECMV solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (13) – R.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (15) – R.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-618 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (15) and (13)
5 – 15
WA500-6
TROUBLESHOOTING
DXH7KA
Related Circuit Diagram
WA500-6
40-619 b
TROUBLESHOOTING
DXH7KB
DXH7KB R Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXH7KB
Trouble
R clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the R (Reverse) clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when R (Reverse) clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
Related information
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring function (Code: 31606 ECMV R DIR). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch R (reverse)
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective R (Reverse) clutch 1 ECMV solenoid (Internal short circuit)
Possible causes and standard value in normal state
R.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (15) – Resistance Min. 1 M R.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-620 b
Defective transmission controller
L04 (female)
Resistance
Between (15) and (13)
5 – 15
Between (15), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH7KB
Related Circuit Diagram
WA500-6
40-621 b
TROUBLESHOOTING
DXH7KY
DXH7KY R Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH7KY
Trouble
R clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal voltage was applied when the R (Reverse) ECMV solenoid output was OFF.
Action of controller
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional switch is in R (Reverse). • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward). • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel only at R (reverse).
Related information
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the monitoring function (Code: 31606 ECMV R DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective R (Reverse) clutch 1 ECMV solenoid (Internal short circuit)
Possible causes and standard value in normal state
R.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harness 2 (Contact with 24 V circuit)
without turning starting switch ON. Wiring harness between L04 (female) (15) – R.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-622 b
Defective transmission controller
L04 (female)
Resistance
Between (15) and (13)
5 – 15
Between (15), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH7KY
Related Circuit Diagram
WA500-6
40-623 b
TROUBLESHOOTING
DXH8KA
DXH8KA F Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXH8KA
Trouble
F clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (Forward) clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
Related information
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function (Code: 31608 ECMV F DIR). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch F (forward)
Cause Defective F (Forward) clutch 1 ECMV solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (3) – F.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (5) – F.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-624 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (5) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DXH8KA
Related Circuit Diagram
WA500-6
40-625 b
TROUBLESHOOTING
DXH8KB
DXH8KB F Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXH8KB
Trouble
F clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the F (Forward) clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when F (Forward) clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
Related information
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function (Code: 31608 ECMV F DIR). • Method of reproducing failure code: Engine started + FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch F (forward)
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective F (Forward) clutch 1 ECMV solenoid (Internal short circuit)
Possible causes and standard value in normal state
F.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L04 (female) (5) – Resistance Min. 1 M F.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-626 b
Defective transmission controller
L04 (female)
Resistance
Between (5) and (3)
5 – 15
Between (5), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH8KB
Related Circuit Diagram
WA500-6
40-627 b
TROUBLESHOOTING
DXH8KY
DXH8KY F Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXH8KY
Trouble
F clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage was applied when the F (Forward) ECMV solenoid output was OFF.
Action of controller
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional switch is in F (Forward). • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse). • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The machine can travel only at F (forward).
Related information
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring function (Code: 31608 ECMV F DIR). • Method of reproducing failure code: Turn starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective F (Forward) clutch 1 ECMV solenoid (Internal short circuit)
Possible causes and standard value in normal state
F.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Hot short in wiring harness 2 (Contact with 24 V circuit)
without turning starting switch ON. Wiring harness between L04 (female) (5) – F.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-628 b
Defective transmission controller
L04 (female)
Resistance
Between (5) and (3)
5 – 15
Between (5), (3) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXH8KY
Related Circuit Diagram
WA500-6
40-629 b
TROUBLESHOOTING
DXHHKA
DXHHKA 4th Clutch ECMV Solenoid: Disconnection Action Code
Failure Code
E03
DXHHKA
Trouble
4th clutch ECMV solenoid: Disconnection (Transmission controller system)
Contents of trouble
• When the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV solenoid output is ON.
Action of controller
• Stops outputting the signal to the 4th clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 4th (the machine can travel in any gear speed other than 4th).
Related information
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function (Code: 31605 ECMV 4 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 4th using the shift down switch or move the gear shift lever to 4th.
Cause Defective 4th clutch ECMV 1 solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 4.PS (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection or defective contact of connector)
without turning starting switch ON. Wiring harness between L04 (female) (13) – 4.PS (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (26) – 4.PS (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-630 b
Defective transmission controller
without turning starting switch ON. L04 (female)
Resistance
Between (26) and (13)
5 – 15
WA500-6
TROUBLESHOOTING
DXHHKA
Related Circuit Diagram
WA500-6
40-631 b
TROUBLESHOOTING
DXHHKB
DXHHKB 4th Clutch ECMV Solenoid: Short Circuit Action Code
Failure Code
E03
DXHHKB
Trouble
4th clutch ECMV solenoid: Short circuit (Transmission controller system)
Contents of trouble
• When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal current flowed when 4th clutch ECMV solenoid output was ON.
Action of controller
• Stops outputting the signal to the 4th clutch ECMV solenoid. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The transmission does not shift into 4th (the machine can travel in any gear speed other than 4th).
Related information
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function (Code: 31605 ECMV 4 DIR). • Method of reproducing failure code: Turn starting switch START; set the transmission manual/auto-shift selector switch in the MANUAL position; and select 4th using the shift down switch or move the gear shift lever to 4th.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 4th clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
4.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness Wiring harness between L04 (female) (26) – (Contact with ground circuit) Resistance Min. 1 M 4.PS (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-632 b
Defective transmission controller
L04 (female)
Resistance
Between (26) and (13)
5 – 15
Between (26), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXHHKB
Related Circuit Diagram
WA500-6
40-633 b
TROUBLESHOOTING
DXHHKY
DXHHKY 4th Clutch ECMV Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXHHKY
Trouble
4th clutch ECMV solenoid: Short circuit with power supply line (Transmission controller system)
Contents of trouble
• When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage was applied when 4th clutch ECMV solenoid output was OFF.
Action of controller
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids. • Stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the speed clutch output is OFF. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joystick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that appears on machine
• The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
Related information
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring function (Code: 31605 ECMV 4 DIR). • Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective 4th clutch ECMV 1 solenoid (Internal short circuit)
Possible causes and standard value in normal state
4.PS (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L04 (female) (26) – 4.PS (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 3
40-634 b
Defective transmission controller
L04 (female)
Resistance
Between (26) and (13)
5 – 15
Between (26), (13) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
DXHHKY
Related Circuit Diagram
WA500-6
40-635 b
TROUBLESHOOTING
DXHJKA
DXHJKA 3-Spool Valve Extract EPC Solenoid: Disconnection Action Code
Failure Code
E03
DXHJKA
Trouble
3-spool valve extract EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system is disconnected, no current flows when the 3-spool valve (attachment) extract EPC solenoid output is ON.
Action of controller
• Continues outputting. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not extracted.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906 3RD EPC1 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
Cause Defective 3-spool valve (attachment) extract EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection in wiring harness and defective contact)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F21 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L07 (female) (3) – F21 (female) (2)
Resistance
Max. 1
Wiring harness between L07 (female) (25) – F21 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (25) and (3)
5 – 15
Related Circuit Diagram
40-636 b
WA500-6
TROUBLESHOOTING
DXHJKB
DXHJKB 3-Spool Valve Extract EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DXHJKB
Trouble
3-spool valve extract EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the chassis ground, abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid output was ON.
Action of controller
• The output to the 3-spool valve (attachment) extract EPC solenoid is stopped. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not extracted. • The wiring harness or controller may be burnt out.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906 3RD EPC1 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
Cause Defective 3-spool valve (attachment) extract EPC 1 solenoid (Internal disconnection) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F21 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (25) – Resistance Min. 1 M F21 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (25) and (3)
5 – 15
Related Circuit Diagram
WA500-6
40-637 b
TROUBLESHOOTING
DXHJKY
DXHJKY 3-Spool Valve Extract EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXHJKY
Trouble
3-spool valve extract EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the power source, abnormal voltage was applied when the 3-spool valve (attachment) extract EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not extracted. • The 3-spool valve (attachment) extract EPC solenoid may be burnt out.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked with the monitoring function (Code: 41906 3RD EPC1 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Turn starting switch ON.
Cause Defective 3-spool valve (attachment) extract EPC 1 solenoid (Internal disconnection) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F21 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 2 (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L07 (female) (25) – F21 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-638 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (25) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DXHJKY
Related Circuit Diagram
WA500-6
40-639 b
TROUBLESHOOTING
DXHKKA
DXHKKA 3-Spool Valve Retract EPC Solenoid: Disconnection Action Code
Failure Code
E03
DXHKKA
Trouble
3-spool valve retract EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
Action of controller
• Continues outputting. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not retracted.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
Cause Defective 3-spool valve (attachment) retract EPC 1 solenoid (Internal disconnection)
Possible causes and standard value in normal state
Disconnection in wiring harness 2 (Disconnection in wiring harness and defective contact)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F22 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L07 (female) (3) – F22 (female) (2)
Resistance
Max. 1
Wiring harness between L07 (female) (35) – F22 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (35) and (3)
5 – 15
Related Circuit Diagram
40-640 b
WA500-6
TROUBLESHOOTING
DXHKKB
DXHKKB 3-Spool Valve Retract EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DXHKKB
Trouble
3-spool valve retract EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the chassis ground, abnormal current flowed when the 3-spool valve (attachment) retract EPC solenoid output was ON.
Action of controller
• The output to the 3-spool valve (attachment) retract EPC solenoid is stopped. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not retracted. • The wiring harness or controller may be burnt out.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
Cause Defective 3-spool valve (attachment) retract EPC 1 solenoid (Internal short circuit) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F22 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 2 harness (Contact with ground circuit) Wiring harness between L07 (female) (35) – Resistance Min. 1 M F22 (female) (1) and chassis ground ★ Prepare with starting switch OFF, then carry out troubleshooting 3
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (35) and (3)
5 – 15
Related Circuit Diagram
WA500-6
40-641 b
TROUBLESHOOTING
DXHKKY
DXHKKY 3-Spool Valve Retract EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXHKKY
Trouble
3-spool valve retract EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the power source, abnormal voltage was applied when the 3-spool valve (attachment) retract EPC solenoid output was OFF.
Action of controller
• Turns the output to the work equipment neutral lock solenoid ON. • Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment) extract/retract EPC solenoid. • Stops outputting the signal to all work equipment detent. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• The 3-spool valve (attachment) cylinder is not retracted. • The 3-spool valve (attachment) retract EPC solenoid may be burnt out.
Related information
• When the 3-spool valve (attachment) is not installed, this failure code is not displayed. (If this failure code is displayed, select None in the EPC 3-spool lever setting on the optional setting of the machine monitor.) • The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked with the monitoring function (Code: 41907 3RD EPC2 DIR). • 3-spool valve (attachment)-equipped model specification only • Method of reproducing failure code: Start engine.
Cause Defective 3-spool valve (attachment) retract EPC 1 solenoid (Internal short circuit) Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. F22 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then turn starting switch ON Hot short in wiring harness 2 (Contact with 24 V circuit)
and carry out troubleshooting. Wiring harness between L07 (female) (35) – F22 (female) (1) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting 3
40-642 b
Defective work equipment controller
without turning starting switch ON. L07 (female)
Resistance
Between (35) and (3)
5 – 15
WA500-6
TROUBLESHOOTING
DXHKKY
Related Circuit Diagram
WA500-6
40-643 b
TROUBLESHOOTING
DXHLKA
DXHLKA Joystick Steering Right EPC Solenoid: Disconnection Action Code
Failure Code
E03
DXHLKA
Trouble
Joystick steering right EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joystick steering right EPC solenoid output is ON.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring function (Code: 41904 J/S EPC DIR RH). • Method of reproducing failure code: Start engine and operate joystick steering to right. • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function (Code: 40953, D-OUT-8). • If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed, carry out troubleshooting for joystick steering solenoid cut relay system first.
Cause
1
Defective joystick steering right EPC solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JS5 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
2
Defective joystick cutoff relay (L118) (Internal disconnection)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
40-644 b
Disconnection in wiring harness (Disconnection or defective contact of connector)
Wiring harness between L07 (female) (28) – JS5 (female) (1)
Resistance
Max. 1
Wiring harness between JS5 (female) (2) – L118 (female) (5)
Resistance
Max. 1
Wiring harness between L118 (female) (3) – L07 (female) (23)
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DXHLKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
4
Defective work equipment controller
L07 (female)
Between (28) and (23)
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at right stroke end
5 – 10 V
Related Circuit Diagram
WA500-6
40-645 b
TROUBLESHOOTING
DXHLKB
DXHLKB Joystick Steering Right EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DXHLKB
Trouble
Joystick steering right EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the joystick steering right EPC solenoid system is short with the chassis ground, no current flows when the joystick steering right EPC solenoid output is ON.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring function (Code: 41904 J/S EPC DIR RH). • Method of reproducing failure code: Start engine and operate joystick steering to right. • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function (Code: 40953, D-OUT-8). • If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed, carry out troubleshooting for joystick steering solenoid cut relay system first.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering 1 right EPC solenoid (Internal short circuit)
JS5 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Defective joystick cutoff relay 2 (L118) ★ (Internal short circuit)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L07 (female) (28) – (Contact with ground circuit) Resistance Min. 1 M JS5 (female) (1) and chassis ground
40-646 b
WA500-6
TROUBLESHOOTING
DXHLKB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
4
Defective work equipment controller
L07 (female)
Resistance
Between (23), (28) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between L07 (28) – (23)
WA500-6
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at right stroke end
5 – 10 V
40-647 b
TROUBLESHOOTING
DXHLKB
Related Circuit Diagram
40-648 b
WA500-6
TROUBLESHOOTING
DXHLKY
DXHLKY Joystick Steering Right EPC Solenoid: Short Circuit with Power Supply Line Action Code E03
Failure Code DXHLKY
Joystick steering right EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Trouble
Contents of trouble
• Since the joystick steering right EPC solenoid system was shorted with the power source, abnormal voltage was applied when the joystick steering right EPC solenoid output was OFF.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering right EPC solenoid can be checked with the monitoring function (Code: 41904 J/S EPC DIR RH). • Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering 1 right EPC solenoid (Internal short circuit)
JS5 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Defective joystick cutoff relay 2 (L118) ★ (Internal short circuit)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 3 (Contact with 24 V circuit)
WA500-6
carry out troubleshooting. Wiring harness between L07 (female) (28) – JS5 (female) (1) and chassis ground
Voltage
Max. 1 V
40-649 b
TROUBLESHOOTING
DXHLKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
4
Defective work equipment controller
L07 (female)
Resistance
Between (23), (28) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between L07 (28) – (23)
40-650 b
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at right stroke end
5 – 10 V
WA500-6
TROUBLESHOOTING
DXHLKY
Related Circuit Diagram
WA500-6
40-651 b
TROUBLESHOOTING
DXHMKA
DXHMKA Joystick Steering Left EPC Solenoid: Disconnection Action Code
Failure Code
E03
DXHMKA
Trouble
Joystick steering left EPC solenoid: Disconnection (Work equipment controller system)
Contents of trouble
• Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joystick steering left EPC solenoid output is ON.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring function (Code: 41905 J/S EPC DIR RH). • Method of reproducing failure code: Start engine and operate joystick steering to left. • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function (Code: 40953, D-OUT-8). • If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed, carry out troubleshooting for joystick steering solenoid cut relay system first.
Cause Defective joystick steering 1 left EPC solenoid (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. JS6 (male)
Resistance
Between (1) and (2)
5 – 15
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Defective joystick cutoff relay 2 (L118) ★ (Internal disconnection)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact of connector)
40-652 b
Wiring harness between L07 (female) (38) – JS6 (female) (1)
Resistance
Max. 1
Wiring harness between JS6 (female) (2) – L118 (female) (5)
Resistance
Max. 1
Wiring harness between L118 (female) (3) – L07 (female) (23)
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
DXHMKA Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Defective work equipment 4 controller
L07 (female)
Between L07 (38) – (23)
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at left stroke end
5 – 10 V
Related Circuit Diagram
WA500-6
40-653 b
TROUBLESHOOTING
DXHMKB
DXHMKB Joystick Steering Left EPC Solenoid: Short Circuit Action Code
Failure Code
E03
DXHMKB
Trouble
Joystick steering left EPC solenoid: Short circuit (Work equipment controller system)
Contents of trouble
• Since the joystick steering left EPC solenoid system is short with the chassis ground, no current flows when the joystick steering left EPC solenoid output is ON.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring function (Code: 41905 J/S EPC DIR RH). • Method of reproducing failure code: Start engine and operate joystick steering to left. • Output state (ON/OFF) to joystick steering solenoid cut relay can be checked with monitoring function (Code: 40953, D-OUT-8). • If failure code of joystick steering solenoid cut relay system (D193KA, D193KB, or D193KY) is displayed, carry out troubleshooting for joystick steering solenoid cut relay system first.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering 1 left EPC solenoid (Internal short circuit)
JS6 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Defective joystick cutoff relay 2 (L118) ★ (Internal short circuit)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting Grounding fault in wiring without turning starting switch ON. 3 harness Wiring harness between L07 (female) (38) – (Contact with ground circuit) Resistance Min. 1 M JS6 (female) (1) and chassis ground
40-654 b
WA500-6
TROUBLESHOOTING
DXHMKB Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
4
Defective work equipment controller
L07 (female)
Resistance
Between (23), (38) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Between L07 (38) – (23)
WA500-6
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at left stroke end
5 – 10 V
40-655 b
TROUBLESHOOTING
DXHMKB
Related Circuit Diagram
40-656 b
WA500-6
TROUBLESHOOTING
DXHMKY
DXHMKY Joystick Steering Left EPC Solenoid: Short Circuit with Power Supply Line Action Code
Failure Code
E03
DXHMKY
Trouble
Joystick steering left EPC solenoid: Short circuit with power supply line (Work equipment controller system)
Contents of trouble
• Since the joystick steering left EPC solenoid system was shorted with the power source, abnormal voltage was applied when the joystick steering left EPC solenoid output was OFF.
Action of controller
• Stops the output to the joystick steering right and left EPC solenoids. • Stops the output to the joystick steering solenoid cut relay. • Turns the centralized warning lamp and alarm buzzer ON. • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that appears on machine
• Joystick steering is inoperable (operable in handle mode).
Related information
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitoring function (Code: 41905 J/S EPC DIR RH). • Method of reproducing failure code: Turn the starting switch ON.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering 1 left EPC solenoid (Internal short circuit)
JS6 (male)
Resistance
Between (1) and (2)
5 – 15
Between (1), (2) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Defective joystick cutoff relay 2 (L118) ★ (Internal short circuit)
L118 (male)
Resistance
Between (1) and (2)
200 – 400
Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
If joystick cutoff relay (L118) is replaced with a relay of the same type and the condition becomes normal, the joystick cutoff relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and Hot short in wiring harness 3 (Contact with 24 V circuit)
WA500-6
carry out troubleshooting. Wiring harness between L07 (female) (38) – JS6 (female) (1) and chassis ground
Voltage
Max. 1 V
40-657 b
TROUBLESHOOTING
DXHMKY Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
L07 (female)
Resistance
Between (23), (38) and chassis ground
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and 4
Defective work equipment controller
carry out troubleshooting.
Between L07 (38) – (23)
Joystick lever operation
Voltage
Joystick lever in neutral
Max. 1 V
Joystick lever at right stroke end
40-658 b
5 – 10 V
WA500-6
TROUBLESHOOTING
DXHMKY
Related Circuit Diagram
WA500-6
40-659 b
TROUBLESHOOTING
TROUBLESHOOTING: E-MODE
TROUBLESHOOTING: E-MODE Troubleshooting Electrical System Information in Troubleshooting Table The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Related information
Problem that appears on machine Information related to detected trouble or troubleshooting Cause
1
Possible causes and standard value in normal state
40-660 b
Standard value in normal state/Remarks on troubleshooting <Described contents> • Standard value in normal state required to judge the assumed cause (good or not) • Remarks required to judge whether the cause is good
<Phenomenon of defective harness> • Disconnection in wiring The connector connection is defective or wiring harness is disconnected. • Ground fault A harness not connected to the ground (earth) circuit comes into contact with the ground (earth) circuit. • Hot short circuit A harness not connected to the power (24 V) circuit comes into 2 contact with the power (24 V) circuit. • Short circuit Causes by which a problem is A harness of an independent circuit abnormally comes into contact assumed to be detected with one of another circuit. (The order number indicates a serial number, not a priority sequence.) <Notes on troubleshooting> (1) Method of indicating connector numbers and handling of T-adapter For troubleshooting, insert or connect T-adapter shown below 3 unless especially specified. • When male or female is not indicated for a connector number, disconnect the connector and insert the T-adapters in both the male and female. • When male or female is indicated for a connector number, unplug the connector and insert the T-adapter in either the male or female. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (–) leads as shown below unless especially specified. 4 • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (–) lead to a pin or harness indicated in the rear.
WA500-6
TROUBLESHOOTING
TROUBLESHOOTING: E-MODE
Related Circuit Diagram
This is the excerpted circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – No. of pins) (Color). • “Connector No. and pin No.” from each branching/merging point: indicate the ends of branch or source of merging within the parts of the same wiring harness.
WA500-6
40-661 b
TROUBLESHOOTING
E-1
E-1 Engine Does Not Start Contents of trouble
• The engine does not start.
Related information
• The engine does not start because the starting motor does not run due to problems in the starting motor system and starting switch terminal C signal system. • Check that No. 2 fuse of fuse box A is normal. (If it is broken, check the related wiring harness for a grounding fault.) • The input state (ON/OFF) from starting switch terminal C to the machine monitor can be checked with the monitoring function (Code: 40900, D-IN-7). • The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with the monitoring function (Code: 40905, D-IN-7). • The input state (ON/OFF) from starting switch terminal C to work equipment controller can be checked with the monitoring function (Code: 40912, D-IN-17). • If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK4KA], [DDK4KB], [DDK6KA], or [DDK6KB] is displayed, carry out troubleshooting for it first.
Cause 1 Defective battery Defective battery relay (BTR1) 2 (Internal disconnection or short circuit) 3
Defective fuse No.5 of fuse box B
Standard value in normal state/Remarks on troubleshooting Specific gravity
Min. 1.26
Voltage
Min. 25 V
• The battery is normal if any operating sound is heard at the battery relay contact when operating the starting switch. • Operate the starting switch OFFONOFF. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 15.)
★ Prepare with starting switch OFF (with wiring harness connected), then turn starting switch to START and carry out troubleshooting. Starting motor
Possible causes and standard value in normal state
Defective starting motor 4 (Internal defect)
Voltage
Between terminals B and E
Power supply input
20 – 30 V
Between terminals R and E
Battery input
Max. 1 V
Between terminals C and E
Starting input
20 – 30 V
If the starting motor does not run even if power supply input, battery input, and starting input is normal, the starting motor is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and Defective alternator 5 (Internal short circuit)
carry out troubleshooting. Wiring harness between alternator terminal R (E03) and chassis ground
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then keep starting switch OFF and turn it to START and carry out troubleshooting in each case. Defective starting switch 6 (Internal disconnection)
LS4 Between (1) and (3)
40-662 b
Position of switch
Resistance
OFF
Min. 1 M
START
Max. 1
WA500-6
TROUBLESHOOTING
E-1 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and Defective FNR (directional) lever switch 7 (Internal disconnection or short circuit)
carry out troubleshooting. L63
FNR (directional) lever
Voltage
Between (1) and (10) Between (3) and (10)
Constant
20 – 30 V
N (Neutral)
20 – 30 V
Other than above
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective joystick steering FNR (directional) switch 8 (Internal disconnection or short circuit)
Defective right FNR (directional) switch 9 (Internal disconnection or short circuit)
Joystick steering FNR (directional) switch
Resistance
N (Neutral)
Max. 1
Other than above
Min. 1 M
Between (1), (3) – chassis ground
Constant
Min. 1 M
S09 (male)
Right FNR (directional) switch
Resistance
N (Neutral)
Max. 1
Other than above
Min. 1 M
Constant
Min. 1 M
JL2 (male) Between (1) and (3)
Between (1) and (3) Between (1), (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON.
Defective diode (D02, D03, 10 D04) (Internal disconnection)
D02 (male)
Diode range
Between (1) and (2)
Measure at (1) in diode range
Between (3) and (2)
Measure at (3) in diode range
Continuity
Continue
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D03 (male)
Diode range
Continuity
Between (2) and (1)
Measure at (2) in diode range
Continue
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. D04 (male)
Diode range
Continuity
Between (2) and (1)
Measure at (2) in diode range
Continue
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective neutral safety relay 11 (L103) (Internal defect)
L103 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. If neutral safety relay (L103) is replaced with a relay of the same type and the condition becomes normal, the neutral safety relay is defective.
WA500-6
40-663 b
TROUBLESHOOTING
E-1 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective lever neutral cutoff 12 relay (L104) (Internal defect)
L104 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. If lever neutral cutoff relay (L104) is replaced with a relay of the same type and the condition becomes normal, the lever neutral cutoff relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective KOMTRAX engine 13 cut relay (L120) (Internal defect)
L120 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch to START and carry out troubleshooting. If KOMTRAX engine cut relay (L120) is replaced with a relay of the same type and the condition becomes normal, the KOMTRAX engine cut relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery relay BTR1 D04 Resistance Max. 1 – starting motor terminal B (E08)
Possible causes and standard value in normal state
Wiring harness between starting motor terminal E – chassis ground
Resistance Max. 1
Wiring harness between LS4 (female) (3) – L120 Resistance Max. 1 (female) (3)
Disconnection in wiring harness 14 (Disconnection or defective contact in connector)
Wiring harness between L120 (female) (6) – L103 (female) (5)
Resistance Max. 1
Wiring harness between L104 (female) (6) – L103 (female) (3), – L06 (female) (25)
Resistance Max. 1
Wiring harness between L63 (female) (3) – L03 (female) (26), – L103 (female) (1)
Resistance Max. 1
Wiring harness between JL2 (female) (3) – S09 (female) (3), – L03 (female) (28)
Resistance Max. 1
Wiring harness between L104 (female) (3) – D04 Resistance Max. 1 (female) (2) Wiring harness between D04 (female) (2) –D03 (female) (2)
Resistance Max. 1
Wiring harness between D04 (female) (1) -D03 (female) (1)
Resistance Max. 1
Wiring harness between D03 (female) (1) – E01 Resistance Max. 1 (female) (1) Wiring harness between L07 (female) (4) – L104 Resistance Max. 1 (female) (1) Wiring harness between L103 (female) (2), L104 Resistance Max. 1 (female) (2) – chassis ground
40-664 b
WA500-6
TROUBLESHOOTING
E-1 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between battery relay BTR1 D04 Resistance Min. 1 M – starting motor terminal B (E08) and chassis ground Wiring harness between LS4 (female) (3) – L120 Resistance Min. 1 M (female) (3), – circuit branch end and chassis ground Wiring harness between L120 (female) (6) -L103 Resistance Min. 1 M (female) (5) and chassis ground
15
Wiring harness between L104 (female) (6) – L103 (female) (3), – L06 (female) (25), – circuit branch end and chassis ground
Resistance Min. 1 M
Wiring harness between L63 (female) (3) – L03 Ground fault in wiring harness (female) (26), – L103 (female) (1), – circuit (Short circuit with ground circuit) branch end
Resistance Min. 1 M
Wiring harness between JL2 (female) (3), S09 (female) (3) – L03 (female) (28)
Resistance Min. 1 M
Wiring harness between L104 (female) (3) – D04 (female) (2), – circuit branch end and chassis Resistance Min. 1 M ground
Possible causes and standard value in normal state
Wiring harness between D04 (female) (2) – D03 Resistance Min. 1 M (female) (2) and chassis ground Wiring harness between D04 (female) (1) – D03 Resistance Min. 1 M (female) (1) and chassis ground Wiring harness between D03 (female) (1) – E01 Resistance Min. 1 M (female) (1) and chassis ground Wiring harness between L07 (female) (4) – L104 Resistance Min. 1 M (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and 16
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between alternator terminal R – E01 (female) (2), – L80 (female) (28), – L52 (female) (18), – circuit branch end
Voltage
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective work equipment 17 controller
WA500-6
L07
Joystick lever
Voltage
Between (4) and chassis ground
Neutral
Max. 1 V
Other than above
20 – 30 V
40-665 b
TROUBLESHOOTING
E-1
Related Circuit Diagrams
40-666 b
WA500-6
TROUBLESHOOTING
E-1
MEMORANDUM
WA500-6
40-667 b
TROUBLESHOOTING
E-2
E-2 Wiper Does Not Operate Contents of trouble
(1) Front wiper does not operate.
Related information
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
Cause 1
Defective fuse No. 9 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Defective front wiper motor (Internal defect)
C12
Front wiper switch
Voltage
Between (6) and (3)
Constant
20 – 30 V
Between (2) and (3)
Lo
20 – 30 V
Between (1) and (3)
Hi
20 – 30 V
If wiper switch is turned OFF while wiper is operating, voltage is applied between C12 (5) and chassis ground until wiper motor stops.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
3
Defective wiper timer (relay) (Internal defect)
L21
Front wiper switch
Voltage
Between (3) and (1)
Constant
20 – 30 V
Between (4) and (1)
INT
20 – 30 V
Between (2) and (1)
Washer side
20 – 30 V
INT (If wiper switch is Between (5) and (1) set in INT, voltage is output intermittently.)
Repeat 20 to 30 V 0 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L22
Voltage
Between (7) and chassis ground
20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting 4
Defective front wiper switch (Internal defect)
without turning starting switch ON. L22
Front wiper switch
Resistance
Between (7) and (5)
Lo
Max. 1
Between (7) and (4)
Hi
Max. 1
Between (7) and (2)
INT
Max. 1
Between (3) and (5)
INT
Max. 1
Other than above
40-668 b
Min. 1 M
WA500-6
TROUBLESHOOTING
E-2 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between L22 (female) (3) – L21 (female) (5)
Resistance
Max. 1
Wiring harness between L22 (female) (5) – C12 (female) (2)
Resistance
Max. 1
Wiring harness between L22 (female) (7) – Resistance fuse No. 9 of fuse box B, – circuit branch end
Max. 1
Wiring harness between L22 (female) (4) – C12 (female) (1)
Resistance
Max. 1
Wiring harness between C12 (female) (3) and chassis ground
Resistance
Max. 1
Wiring harness between L21 (female) (1) and chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L22 (female) (3) L21 (female) (5) and chassis ground 6
Wiring harness between L22 (female) (5) – Ground fault in wiring harness C12 (female) (2) and chassis ground (Short circuit with ground circuit) Wiring harness between L22 (female) (7) – fuse No. 9 of fuse box B, – circuit branch end and chassis ground Wiring harness between L22 (female) (4) – C12 (female) (1) and chassis ground
WA500-6
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
40-669 b
TROUBLESHOOTING
Contents of trouble
E-2
(2) Rear wiper does not operate.
Related information
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective rear wiper motor 1 (Internal defect)
C15
Rear wiper switch
Voltage
Between (1) and (4)
Constant
20 – 30 V
Between (2) and (4)
ON
20 – 30 V
If wiper switch is turned OFF while wiper is operating, voltage is applied between C15 (1) and chassis ground until wiper motor stops.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
2
Defective rear wiper switch (Internal defect)
Possible causes and standard value in normal state
L22
Voltage
Between (7) and chassis ground
20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L22
Rear wiper switch
Resistance
Between (7) and (9)
ON
Max. 1
Between (8) and (9)
OFF
Max. 1
Other than above
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Wiring harness between L22 (female) (7) – C15 (female) (1)
Resistance
Max. 1
Wiring harness between L22 (female) (8) – C15 (female) (3)
Resistance
Max. 1
Wiring harness between L22 (female) (9) – C15 (female) (2)
Resistance
Max. 1
Wiring harness between C15 (female) (4) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L22 (female) (7) – Ground fault in wiring harness C15 (female)(1), – circuit branch end 4 (Short circuit with ground circuit) Wiring harness between L22 (female) (8) – C15 (female) (3) and chassis ground Wiring harness between L22 (female) (9) – C15 (female) (2) and chassis ground
40-670 b
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
E-2
Related Circuit Diagram
WA500-6
40-671 b
TROUBLESHOOTING
E-3
E-3 Windshield Washer Does Not Operate Contents of trouble
Windshield washer does not operate. • Since the windshield washer motor, switch, timer (for front only), or wiring harness is defective, the windshield washer does not operate. • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not operate normally, carry out troubleshooting for E-2: Wiper Does Not Operate first.)
Related information
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and 1
Defective front washer motor (Internal defect)
carry out troubleshooting. B09
Voltage
Between (1) and (2)
20 – 30 V
★ Prepare with starting switch OFF, then turn starting switch ON and 2
Defective rear washer motor (Internal defect)
carry out troubleshooting. B11
Voltage
Between (1) and (2)
20 – 30 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L22
Voltage
Between (7) and chassis ground
20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting Defective front wiper switch 3 (Internal defect)
without turning starting switch ON. L22 (male)
Possible causes and standard value in normal state
Front wiper washer switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (7) and (6) Between (7), (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L22
Voltage
Between (7) and chassis ground
20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective rear wiper switch 4 (Internal defect)
L22 (male) Between (7) and (10) Between (7), (10) and chassis ground
Rear wiper washer switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L22 (male)
40-672 b
Rear wiper washer switch
Resistance
WA500-6
TROUBLESHOOTING
E-3 Cause
4
Defective rear wiper switch (Internal defect)
Standard value in normal state/Remarks on troubleshooting Between (7) and (9), (10)
ON
Max. 1
Between (7), (9), (10) and chassis ground
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective wiper timer (relay) 5 (for front wiper only)
L21 (male)
Front wiper washer switch
Voltage
Between (3) and (1)
Constant
20 – 30 V
Between (2) and (1)
ON
20 – 30 V
Between (5) and (1) 0.2 – 0.8 sec after ON
20 – 30 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 6 (Disconnection or defective contact in connector)
Wiring harness between L22 (female) (6) – B09 (female) (1), L21 (female) (2)
Resistance
Max. 1
Wiring harness between L22 (female) (7) – fuse No. 9 of fuse box B
Resistance
Max. 1
Wiring harness between L22 (female) (10) – B11 (female) (1)
Resistance
Max. 1
Wiring harness between B09 (female) (2), – B11 (female) (2) – chassis ground
Resistance
Max. 1
Wiring harness between L21 (female) (1) and chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L22 (female) (6) – B09 (female) (1), L21 (female) (2) and Ground fault in wiring harness chassis ground 7 (Short circuit with ground circuit) Wiring harness between L22 (female) (7) – fuse No. 9 of fuse box B and chassis ground Wiring harness between L22 (female) (10) – B11 (female) (1) and chassis ground
WA500-6
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
40-673 b
TROUBLESHOOTING
E-3
Related Circuit Diagram
40-674 b
WA500-6
TROUBLESHOOTING
E-3
MEMORANDUM
WA500-6
40-675 b
TROUBLESHOOTING
E-4
E-4 Headlamp, Clearance Lamp, Tail Lamp, and License Lamp Do Not Light Up or Go Off Contents of trouble
(1) None of headlamp, clearance lamp, tail lamp, and license lamp lights up. • Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the lamps lights up. • Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp light up. • Headlamp at HEAD position: Above lamps and headlamp light up. • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked with the monitoring function (Code: 40200, SMALL LAMP). • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with the monitoring function (Code: 40900 D-IN-0). • The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked with the monitoring function (Code: 40904 D-IN-34).
Related information
Cause 1
Defective fuse No. 11 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L61 (male) Defective lamp switch 2 (Internal disconnection or short circuit)
Between (1) and (5)
Between (1) and (2)
Possible causes and standard value in normal state
Between (1), (2), (5) and chassis ground Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Lamp switch
Resistance
OFF
Min. 1 M
SMALL or HEAD
Max. 1
OFF
Min. 1 M
SMALL
Min. 1 M
HEAD
Max. 1
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 11 of fuse box B – L61 (female) (1)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting 4
40-676 b
without turning starting switch ON. Ground fault in wiring harness (Short circuit with ground circuit) Wiring harness between fuse No. 11 of fuse box B – L61 (female) (1), – circuit branch end and chassis ground
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
Contents of trouble
Related information
E-4
(2) Either of headlamp low or high beams does not light up or go off. • The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective. • When the clearance lamp, tail lamp, and license lamp light up and go off normally. • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with the monitoring function (Code: 40900 D-IN-0). • The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked with the monitoring function (Code: 40904 D-IN-34).
Cause Defective fuse No. 14 or 1 No. 15 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective head lamp relay 2 (L115)
L115 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If head lamp relay (L115) is replaced with a relay of the same type and the condition becomes normal, the head lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
L61 (male) Defective lamp switch 3 (Internal disconnection or short circuit)
Between (1) and (2) Between (1), (2) and chassis ground
Headlamp switch
Resistance
OFF
Min. 1 M
SMALL
Min. 1 M
HEAD
Max. 1
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L61 (male) Defective dimmer switch 4 (Internal disconnection or short circuit)
Between (6) and (3) Between (6) and (4) Between (3), (4) and chassis ground
WA500-6
Dimmer switch
Resistance
Low
Min. 1 M
High
Max. 1
Low
Max. 1
High
Min. 1 M
Constant
Min. 1 M
40-677 b
TROUBLESHOOTING
E-4 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
Wiring harness between L61 (female) (2) – L115 (female) (1)
Resistance
Max. 1
Wiring harness between L115 (female) (2) – chassis ground
Resistance
Max. 1
Wiring harness between fuse No. 11 of fuse box B – L115 (female) (3)
Resistance
Max. 1
Wiring harness between L115 (female) (5) – fuse No. 14 or No. 15 of fuse box B
Resistance
Max. 1
Wiring harness between fuse No. 14 of fuse box B – right HEAD (female) (B)
Resistance
Max. 1
Wiring harness between fuse No. 15 of fuse box B – left HEAD (female) (B)
Resistance
Max. 1
Wiring harness between L61 (female) (6) and chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
6
Wiring harness between L61 (female) (2) – L115 (female) (1), – circuit branch end and chassis ground
Resistance
Min. 1 M
Wiring harness between L115 (female) (5) – Ground fault in wiring harness fuse No. 14 or No. 15 of fuse box B and (Short circuit with ground circuit) chassis ground
Resistance
Min. 1 M
Wiring harness between fuse No. 14 of fuse box B – right HEAD (female) (B) and chassis ground
Resistance
Min. 1 M
Wiring harness between fuse No. 15 of fuse box B – left HEAD (female) (B) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Headlamp switch is OFF.
7
40-678 b
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L61 (female) (2) – L115 (female) (1), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L115 (female) (5) – fuse No. 14 or No. 15 of fuse box B and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 14 of fuse box B – right HEAD (female) (B) and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 15 of fuse box B – left HEAD (female) (B) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
Contents of trouble
Related information
E-4
(3) Headlamp low beam does not light up or go off. • The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the chassis ground. • When the high beam lights up (goes off) normally. • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with the monitoring function (Code: 40900 D-IN-0). • The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked with the monitoring function (Code: 40904 D-IN-34).
Cause 1 Broken bulb
Standard value in normal state/Remarks on troubleshooting If a specific headlamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L61 (male) Defective dimmer switch 2 (Internal disconnection or short circuit)
Between (6) and (3) Between (6) and (4)
Possible causes and standard value in normal state
Between (3), (4) and chassis ground Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Dimmer switch
Resistance
Low
Min. 1 M
High
Max. 1
Low
Max. 1
High
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between HEAD (female) (A) – L61 (female) (4)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with ground circuit) Wiring harness between HEAD (female) (A) Resistance Min. 1 M – L61 (female) (4) and chassis ground
WA500-6
40-679 b
TROUBLESHOOTING
Contents of trouble
Related information
E-4
(4) Headlamp high beam does not light up or go off. • The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the chassis ground. • When the low beam lights up (goes off) normally. • The input state (ON/OFF) from the lamp switch (head lamp) to the machine monitor can be checked with the monitoring function (Code: 40900 D-IN-0). • The input state (ON/OFF) from the dimmer switch (high beam) to the machine monitor can be checked with the monitoring function (Code: 40904 D-IN-34).
Cause 1 Broken bulb
Standard value in normal state/Remarks on troubleshooting If a specific headlamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L61 (male) Defective dimmer switch 2 (Internal disconnection or short circuit)
Between (6) and (3) Between (6) and (4)
Possible causes and standard value in normal state
Between (3), (4) and chassis ground Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
Dimmer switch
Resistance
Low
Min. 1 M
High
Max. 1
Low
Max. 1
High
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between HEAD (female) (C) – L61 (female) (3)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Ground fault in wiring harness 4 (Short circuit with ground circuit) Wiring harness between HEAD (female) (C) – L61 (female) (3), – circuit branch end and chassis ground
40-680 b
Resistance
Min. 1 M
WA500-6
TROUBLESHOOTING
Contents of trouble
E-4
(5) Clearance lamp does not light up or go off. (6) Tail lamp does not light up or go off. • The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective. • When the headlamp and turn signal lamp light up. • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked with the monitoring function (Code: 40200, SMALL LAMP).
Related information
Cause 1 Broken bulb 2
Defective fuse No. 12 or No. 13 of fuse box B
Standard value in normal state/Remarks on troubleshooting If a specific lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L61 (male) Defective lamp switch 3 (Internal disconnection or short circuit)
Between (1) and (5)
Between (1) and (2) Between (1), (2), (5) and chassis ground
Headlamp switch
Resistance
OFF
Min. 1 M
SMALL or HEAD
Max. 1
OFF
Min. 1 M
SMALL
Min. 1 M
HEAD
Max. 1
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Disconnection in wiring harness 4 (Disconnection or defective contact in connector)
Wiring harness between L61 (female) (5) – fuse No. 12 or No. 13 of fuse box B
Resistance
Max. 1
Wiring harness between fuse No. 12 of fuse box B – right COMBI (female) (A)
Resistance
Max. 1
Wiring harness between fuse No. 12 of fuse box B – G01 (female) (6)
Resistance
Max. 1
Wiring harness between fuse No. 13 of fuse box B – left COMBI (female) (A)
Resistance
Max. 1
Wiring harness between fuse No. 13 of fuse box B – G02 (female) (6)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 12 of fuse box B – right COMBI (female) (A) and chassis ground 5
Resistance
Min. 1 M
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse Resistance (Short circuit with ground circuit) box B – G01 (female) (6) and chassis ground
Min. 1 M
Wiring harness between fuse No. 13 of fuse box B – left COMBI (female) (A) and chassis ground
WA500-6
Resistance
Min. 1 M
Wiring harness between fuse No. 13 of fuse Resistance box B – G02 (female) (6) and chassis ground
Min. 1 M
40-681 b
TROUBLESHOOTING
E-4 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Headlamp switch is OFF.
Possible causes and standard value in normal state
40-682 b
Hot short in wiring harness 6 (Contact with 24 V circuit)
Wiring harness between L61 (female) (5) – fuse No. 12 or No. 13 of fuse box B and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 12 of fuse box B – right COMBI (female) (A) and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 12 of fuse box B – G01 (female) (6) and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 13 of fuse box B – left COMBI (female) (A) and chassis ground
Voltage
Max. 1 V
Wiring harness between fuse No. 13 of fuse box B – G02 (female) (6) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
E-4
Related Circuit Diagram
WA500-6
40-683 b
TROUBLESHOOTING
E-5
E-5 Working Lamp Does Not Light Up or Go Off Contents of trouble
(1) Either of front working lamp or rear working lamp does not light up • The working lamp system power supply wiring harness is disconnected or shorted with the chassis ground. • If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.
Related information
Possible causes and standard value in normal state
Contents of trouble
Cause
Standard value in normal state/Remarks on troubleshooting
Disconnection in wiring harness 1 (Disconnection or defective contact in connector)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L61 (female) (5) – S67 (female) (5), S68 (female) (5)
Resistance
Max. 1
(2) Front working lamp does not light up or go off. • The switch, lamp, or wiring harness of the front working lamp system is defective. • When the rear working lamp lights up (goes off). • If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.
Related information
Cause 1 Broken bulb 2
Defective fuse No. 3 of fuse box B
Standard value in normal state/Remarks on troubleshooting If a specific working lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3 Possible causes and standard value in normal state
Defective front working lamp relay (L109)
L109 (male)
Resistance
Between (5) and (6)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If front working lamp relay (L109) is replaced with a relay of the same type and the condition becomes normal, the front working lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective front working lamp switch 4 (Internal disconnection or short circuit)
S67 (male) Between (5) and (6) Between (5), (6) and chassis ground
40-684 b
Front working lamp switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
WA500-6
TROUBLESHOOTING
E-5 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
Wiring harness between L61 (female) (5) and S67 (female) (5)
Resistance
Max. 1
Wiring harness between S67 (female) (6) and L109 (female) (5)
Resistance
Max. 1
Wiring harness between L109 (female) (6) – chassis ground
Resistance
Max. 1
Wiring harness between fuse No. 3 of fuse box B – L109 (female) (2), (4)
Resistance
Max. 1
Wiring harness between L109 (female) (1) – C04 (female) (1), C05 (female) (1)
Resistance
Max. 1
Wiring harness between C04 (female) (2), C05 (female) (2) – chassis ground
Resistance
Max. 1
Wiring harness between L109 (female) (3) – RS1 (female) (1), RS2 (female) (1)
Resistance
Max. 1
Wiring harness between RS1 (female) (1), RS2 (female) (1) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between S67 (female) (6) – L109 (female) (5) and chassis ground Wiring harness between fuse No. 3 of fuse box B – L109 (female) (2), (4) and chassis Ground fault in wiring harness 6 ground (Short circuit with ground circuit) Wiring harness between L109 (female) (1) – C04 (female) (1), C05 (female) (1), – circuit branch end and chassis ground Wiring harness between L109 (female) (3) – RS1 (female) (1), RS2 (female) (1) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Front working lamp switch OFF.
Hot short in wiring harness 7 (Contact with 24 V circuit)
WA500-6
Wiring harness between S67 (female) (6) – L109 (female) (5) and chassis ground
Voltage
Max. 1 V
Wiring harness between L109 (female) (1) – C04 (female) (1), C05 (female) (1), – circuit branch end and chassis ground
Voltage
Max. 1 V
Wiring harness between L109 (female) (3) – RS1 (female) (1), – RS1 (female) (1) and chassis ground
Voltage
Max. 1 V
40-685 b
TROUBLESHOOTING
Contents of trouble
E-5
(3) Rear working lamp does not light up or go off. • The switch, lamp, or wiring harness of the rear working lamp system is defective. • When the front working lamp and side working lamp (OPT) light up (goes off). • If the clearance lamp does not light up or go off, carry out troubleshooting for the clearance lamp first.
Related information
Cause 1 Broken bulb 2
Defective fuse No. 4 of fuse box B
Standard value in normal state/Remarks on troubleshooting If a specific working lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (Se cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3
Defective rear working lamp relay (L110)
L110 (male)
Resistance
Between (5) and (6)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If rear working lamp relay (L110) is replaced with a relay of the same type and the condition becomes normal, the rear working lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Possible causes and standard value in normal state
Defective rear working lamp switch 4 (Internal disconnection or short circuit)
S68 (male) Between (5) and (6) Between (5), (6) and chassis ground
Front working lamp switch
Resistance
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
40-686 b
Wiring harness between L61 (female) (5) and S68 (female) (5)
Resistance
Max. 1
Wiring harness between S68 (female) (6) and L110 (female) (5)
Resistance
Max. 1
Wiring harness between L110 (female) (6) – chassis ground
Resistance
Max. 1
Wiring harness between fuse No. 4 of fuse box B – L110 (female) (2)
Resistance
Max. 1
Wiring harness between L110 (female) (1) – G03 (female) (1), G04 (female) (1)
Resistance
Max. 1
Wiring harness between G03 (female) (2) or G04 (female) (2) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-5 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between S68 (female) (6) – L110 (female) (5) and chassis ground 6
Ground fault in wiring harness Wiring harness between fuse No. 4 of fuse (Short circuit with ground circuit) box B – L110 (female) (2), – circuit branch
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
end and chassis ground Wiring harness between L110 (female) (1) – G03 (female) (1), G04 (female) (1) and chassis ground
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • Front working lamp switch OFF. 7
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between S68 (female) (6) – L110 (female) (5) and chassis ground
Voltage
Max. 1 V
Wiring harness between L110 (female) (1) – G03 (female) (1), G04 (female) (1) and chassis ground
Voltage
Max. 1 V
40-687 b
TROUBLESHOOTING
E-5
Related Circuit Diagram
40-688 b
WA500-6
TROUBLESHOOTING
E-5
MEMORANDUM
WA500-6
40-689 b
TROUBLESHOOTING
E-6
E-6 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off Contents of trouble
Related information
(1) Either of turn signal lamp or hazard lamp does not light up or go off. • The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective. • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12). • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to machine monitor can be checked with the monitoring function (Code: 40901, D-IN-13).
Cause Defective fuse No. 4 of fuse 1 box A and fuse No. 1 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Defective hazard relay (L113)
L113 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Possible causes and standard value in normal state
If hazard relay (L113) is replaced with a relay of the same type and the condition becomes normal, the hazard relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
Defective flasher unit 3 (Internal disconnection or short circuit)
L19 (male)
Voltage
Between (3) and (1)
20 – 30 V
Between (4) and (1)
Repeat 20 to 30 V 0 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
40-690 b
L19 (male)
Resistance
Between (3), (4) and chassis ground
Min. 1 M
WA500-6
TROUBLESHOOTING
E-6 Cause
Standard value in normal state/Remarks on troubleshooting L62 (male)
Between (2) and (3)
Defective turn signal lamp and hazard lamp switches 4 (Internal disconnection or short circuit)
Between (2) and (4)
Between (1) and (5)
Between (1), (2), (4), (5) and chassis ground
Possible causes and standard value in normal state
Turn signal lamp and hazard lamp switches
Resistance
Turn signal lever: Left
Min. 1 M
Turn signal lever: Neutral
Min. 1 M
Turn signal lever: Right
Max. 1
Hazard lamp switch: ON
Max. 1
Turn signal lever: Left
Max. 1
Turn signal lever: Neutral
Min. 1 M
Turn signal lever: Right
Min. 1 M
Hazard lamp switch: ON
Max. 1
Hazard lamp switch: ON
Max. 1
Hazard lamp switch: OFF
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
Wiring harness between L113 (female) (3) – L19 (female) (3)
Resistance
Max. 1
Wiring harness between L19 (female) (4) – L62 (female) (2)
Resistance
Max. 1
Wiring harness between L19 (female) (1) – chassis ground
Resistance
Max. 1
Wiring harness between L62 (female) (5) and chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 6
Ground fault in wiring harness Wiring harness between L113 (female) (3) – (Short circuit with ground circuit) L19 (female) (3) and chassis ground
Resistance
Min. 1 M
Wiring harness between L19 (female) (4) – L62 (female) (2) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L113 (female) (3) – L19 (female) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between L19 (female) (4) – L62 (female) (2) and chassis ground
Voltage
Max. 1 V
40-691 b
TROUBLESHOOTING
E-6
Contents of trouble
(2) Turn signal lamp does not light up or go off.
Related information
• The switch, lamp, or wiring harness of the turn signal lamp system is defective. When the hazard lamp blinks. • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (right turn signal lamp) to machine monitor can be checked with the monitoring function (Code: 40901, D-IN-12). • The input state (ON/OFF) from turn signal lamp and hazard lamp switch (left turn signal lamp) to machine monitor can be checked with the monitoring function (Code: 40901, D-IN-13).
Cause 1 Broken bulb
Standard value in normal state/Remarks on troubleshooting If a specific turn signal lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. L62 (male)
Between (2) and (3) Defective turn signal lamp and hazard lamp switches 2 (Internal disconnection or short circuit) Between (2) and (4) Possible causes and standard value in normal state
Between (2), (3), (4) and chassis ground
Turn signal lamp and hazard lamp switches
Resistance
Turn signal lever: Left
Min. 1 M
Turn signal lever: Neutral
Min. 1 M
Turn signal lever: Right
Max. 1
Hazard lamp switch: ON
Max. 1
Turn signal lever: Left
Max. 1
Turn signal lever: Neutral
Min. 1 M
Turn signal lever: Right
Min. 1 M
Hazard lamp switch: ON
Max. 1
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 3 (Disconnection or defective contact in connector)
40-692 b
Wiring harness between L62 (female) (3) – Resistance G01 (female) (1), – right COMBI (female) (C)
Max. 1
Wiring harness between L62 (female) (4) – G02 (female) (1), – left COMBI (female) (C)
Resistance
Max. 1
Wiring harness between G01 (female) (4) – chassis ground
Resistance
Max. 1
Wiring harness between G02 (female) (4) – chassis ground
Resistance
Max. 1
Wiring harness between right COMBI (female) (B) – chassis ground
Resistance
Max. 1
Wiring harness between left COMBI (female) (B) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-6 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between L62 (female) (3) – Ground fault in wiring harness G01 (female) (1), – right COMBI (female) (C) 4 (Short circuit with ground circuit) and chassis ground
Resistance
Min. 1 M
Wiring harness between L62 (female) (4) – G02 (female) (1), – left COMBI (female) (C) and chassis ground
Resistance
Min. 1 M
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5
Contents of trouble
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L62 (female) (3) – G01 (female) (1), – right COMBI (female) (C) and chassis ground
Voltage
Max. 1 V
Wiring harness between L62 (female) (4) – G02 (female) (1), – left COMBI (female) (C) and chassis ground
Voltage
Max. 1 V
(3) Hazard lamp does not light up or go off.
Related information
• The switch or lamp of the hazard lamp is defective. • When the turn signal lamp flashes normally.
Cause 1
Defective fuse No.4 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2 Defective hazard relay (L113)
L113 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If hazard relay (L113) is replaced with a relay of the same type and the condition becomes normal, the hazard relay is defective.
Possible causes and standard value in normal state
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective hazard lamp switch 3 (Internal disconnection or short circuit)
L62 (male)
Hazard lamp switch
Between (2) and (3), (4)
ON
Max. 1
OFF
Min. 1 M
ON
Max. 1
OFF
Min. 1 M
Constant
Min. 1 M
Between (1) and (5) Between (1), (2), (3), (4), (5) and chassis ground
WA500-6
Resistance
40-693 b
TROUBLESHOOTING
E-6 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Disconnection in wiring harness 4 (Disconnection or defective contact in connector)
Wiring harness between fuse No. 4 of fuse box A – L113 (female) (1), (5)
Resistance
Max. 1
Wiring harness between L113 (female) (2) – L62 (female) (1)
Resistance
Max. 1
Wiring harness between L62 (female) (5) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 4 of fuse Ground fault in wiring harness 5 box A – L113 (female) (1), (5) and chassis (Short circuit with ground circuit) ground
Resistance
Min. 1 M
Wiring harness between L113 (female) (2) – L62 (female) (1) and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. • The harnesses in the following two systems are shorted with the power source simultaneously. 6
40-694 b
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L62 (female) (3) – G01 (female) (1), – right COMBI (female) (C) and chassis ground
Voltage
Max. 1 V
Wiring harness between L62 (female) (4) – G02 (female) (1), – left COMBI (female) (C) and chassis ground
Voltage
Max. 1 V
WA500-6
TROUBLESHOOTING
E-6
Related Circuit Diagram
WA500-6
40-695 b
TROUBLESHOOTING
E-7
E-7 Brake Lamp Does Not Light or It Keeps Lighting Up Contents of trouble
Brake lamp does not light or it keeps lighting up.
Related information
• The lamp or wiring harness of the brake lamp system is abnormal.
Cause 1 Broken bulb 2
Defective fuse No. 2 of fuse box B
Standard value in normal state/Remarks on troubleshooting If a specific brake lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 6.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective brake lamp relay (L102) 3 (Internal disconnection or short circuit)
L102 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If brake lamp relay (L102) is replaced with a relay of the same type and the condition becomes normal, the brake lamp relay is defective.
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Possible causes and standard value in normal state
Defective brake lamp switch 4 (Internal disconnection or short circuit)
L16 (male) Between (1) and (2) Between (1), (2) and chassis ground
Brake pedal
Resistance
Pressed
Max. 1
Released
Min. 1 M
Constant
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 5 (Disconnection or defective contact in connector)
40-696 b
Wiring harness between fuse No. 2 of fuse Resistance box B – L102 (female) (2), – L16 (female) (1)
Max. 1
Wiring harness between L16 (female) (2) – L102 (female) (5)
Resistance
Max. 1
Wiring harness between L102 (female) (6) – chassis ground
Resistance
Max. 1
Wiring harness between L102 (female) (1) – G01 (female) (5), – G02 (female) (5)
Resistance
Max. 1
Wiring harness between G01 (female) (4), G02 (female) (4) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-7 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 2 of fuse box B – L102 (female) (2), – L16 (female) Ground fault in wiring harness (1), – circuit branch end and chassis ground 6 (Short circuit with ground Wiring harness between L16 (female) (2) – circuit) L102 (female) (5) and chassis ground Possible causes and standard value in normal state
Wiring harness between L102 (female) (1) – G01 (female) (5), – G02 (female) (5) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 7
WA500-6
Hot short in wiring harness (Contact with 24 V circuit)
Wiring harness between L16 (female) (2) – L102 (female) (5) and chassis ground
Voltage
Max. 1 V
Wiring harness between L102 (female) (1) – G01 (female) (5), – G02 (female) (5) and chassis ground
Voltage
Max. 1 V
40-697 b
TROUBLESHOOTING
E-7
Related Circuit Diagram
40-698 b
WA500-6
TROUBLESHOOTING
E-7
MEMORANDUM
WA500-6
40-699 b
TROUBLESHOOTING
E-8
E-8 Backup Lamp Does Not Light or It Keeps Lighting Up Contents of trouble
Backup lamp does not light or it keeps lighting up.
Related information
• The transmission controller monitors the primary circuit of the backup lamp relay for problems. • (If a disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code [D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)
Cause 1 Broken bulb 2
Defective fuse No. 2 of fuse box B
Standard value in normal state/Remarks on troubleshooting If a specific backup lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly. If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective backup lamp relay (L101) 3 (Internal disconnection or short circuit)
L101 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If backup lamp relay (L101) is replaced with a relay of the same type and the condition becomes normal, the backup lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
without turning starting switch ON.
Disconnection in wiring harness 4 (Disconnection or defective contact in connector)
40-700 b
Wiring harness between fuse No. 2 of fuse box B – L101 (female) (5)
Resistance
Max. 1
Wiring harness between L101 (female) (3) – G01 (female) (2), – G02 (female) (2)
Resistance
Max. 1
Wiring harness between L04 (female) (18) – L101 (female) (1) • If any abnormality is detected, failure code [D160KA] is displayed.
Resistance
Max. 1
Wiring harness between L101 (female) (2) – chassis ground • If any abnormality is detected, failure code [D160KA] is displayed.
Resistance
Max. 1
Wiring harness between G01 (female) (4) – chassis ground
Resistance
Max. 1
Wiring harness between G02 (female) (4) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-8 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Possible causes and standard value in normal state
Wiring harness between fuse No. 2 of fuse box B – L101 (female) (5) and chassis Ground fault in wiring harness ground (Short circuit with ground circuit) Wiring harness between L101 (female) (3) – Ground fault in wiring harness G01 (female) (2), – G02 (female) (2) and (Short circuit with ground circuit) chassis ground Wiring harness between L04 (female) (18) – L101 (female) (1) and chassis ground • If any abnormality is detected, failure code [D160KZ] is displayed.
Resistance
Min. 1 M
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and 6
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L101 (female) (3) – G01 (female) (2), – G02 (female) (2), – circuit branch end and chassis ground
Voltage
Max. 1 V
Related Circuit Diagram
WA500-6
40-701 b
TROUBLESHOOTING
E-9
E-9 Backup Buzzer Does Not Sound or It Keeps Sounding Contents of trouble
Backup buzzer does not sound or it keeps sounding. • The transmission controller monitors the primary circuit of the backup lamp relay for problems. • (If disconnection or short circuit occurs in the primary side of the backup lamp relay, failure code [D160KA] or [D160KZ] is displayed. Carry out troubleshooting for it first.)
Related information
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and Defective backup buzzer 1 (Internal disconnection or short circuit)
carry out troubleshooting. G06
Gearshift lever
Voltage
R
20 – 30 V
Other than R
Max. 1 V
Between (1) and (2) 2
Defective fuse No. 2 of fuse box B
If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 5.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective backup lamp relay (L101) 3 (Internal disconnection or short circuit) Possible causes and standard value in normal state
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If backup lamp relay (L101) is replaced with a relay of the same type and the condition becomes normal, the backup lamp relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 4 (Disconnection or defective contact in connector)
40-702 b
L101 (male)
Wiring harness between fuse No. 2 of fuse box B – L101 (female) (5)
Resistance
Max. 1
Wiring harness between L101 (female) (3) – G06 (female) (1)
Resistance
Max. 1
Wiring harness between L04 (female) (18) – L101 (female) (1) • If any abnormality is detected, failure code [D160KA] is displayed.
Resistance
Max. 1
Wiring harness between L101 (female) (2) – chassis ground • If any abnormality is detected, failure code [D160KA] is displayed.
Resistance
Max. 1
Wiring harness between G06 (female) (2) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-9 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 2 of fuse box B – L101 (female) (5) and chassis ground
5 Possible causes and standard value in normal state
Resistance
Min. 1 M
Ground fault in wiring harness (Short circuit with ground circuit) Wiring harness between L101 (female) (3) – G06 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between L04 (female) (18) – L101 (female) (1) and chassis ground • If any abnormality is detected, failure code [D160KZ] is displayed.
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and 6
Hot short in wiring harness (Contact with 24 V circuit)
carry out troubleshooting. Wiring harness between L101 (female) (3) – G06 (female) (1), – circuit branch end and chassis ground
Voltage
Max. 1 V
Related Circuit Diagram
WA500-6
40-703 b
TROUBLESHOOTING
E-10
E-10 Horn Does Not Sound or It Keeps Sounding Contents of trouble
Horn does not sound or it keeps sounding (steering wheel specification).
Related information
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
Cause 1
Defective fuse No. 9 of fuse box A
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 7.)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Defective horn relay (L108) 2 (Internal disconnection or short circuit)
L108 (male)
Resistance
Between (1) and (2)
200 – 400
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. If horn relay (L108) is replaced with a relay of the same type and the condition becomes normal, the horn relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes and standard value in normal state
Defective steering wheel horn switch 3 (Internal disconnection or short circuit)
without turning starting switch ON. L64 (male) Between (1) and chassis ground
Steering wheel horn switch
Resistance
ON
Max. 1
OFF
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting Defective joystick lever horn switch 4 (Internal disconnection or short circuit)
without turning starting switch ON. JL2 (male) Between (9) and (10)
Joystick lever horn switch
Resistance
ON
Max. 1
OFF
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. (Disconnect connector and measure on female side.) Defective horn 5 (Internal disconnection or short circuit)
40-704 b
F03, F05
Horn switch
Voltage
Between F03 (2) and (1)
OFF
Max. 1 V
ON
20 – 30 V
Between F05 (2) and (1)
OFF
Max. 1 V
ON
20 – 30 V
WA500-6
TROUBLESHOOTING
E-10 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness 6 (Disconnection or defective contact in connector)
Possible causes and standard value in normal state
Wiring harness between fuse No. 9 of fuse box A – L108 (female) (1), – F03 (female) (2), – F05 (female) (2)
Resistance
Max. 1
Wiring harness between L108 (female) (2) – L64 (female) (1)
Resistance
Max. 1
Wiring harness between L108 (female) (2) – JL2 (female) (9)
Resistance
Max. 1
Wiring harness between L108 (female) (3) – chassis ground
Resistance
Max. 1
Wiring harness between L108 (female) (5) – F03 (female) (1), – F05 (female) (1)
Resistance
Max. 1
Wiring harness between steering wheel horn switch – chassis ground
Resistance
Max. 1
Wiring harness between JL2 (female) (10) – chassis ground
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
7
WA500-6
Wiring harness between fuse No. 9 of fuse box A – L108 (female) (1), – F03 (female) (2), – F05 (female) (2) and chassis ground
Resistance
Min. 1 M
Ground fault in wiring harness Wiring harness between L108 (female) (2) – (Short circuit with ground circuit) L64 (female) (1) and chassis ground
Resistance
Min. 1 M
Wiring harness between L108 (female) (2) – JL2 (female) (9) and chassis ground
Resistance
Min. 1 M
Wiring harness between L108 (female) (5) – F03 (female) (1), F05 (female) (1) and chassis ground
Resistance
Min. 1 M
40-705 b
TROUBLESHOOTING
E-10
Related Circuit Diagram
40-706 b
WA500-6
TROUBLESHOOTING
E-10
MEMORANDUM
WA500-6
40-707 b
TROUBLESHOOTING
E-11
E-11 Alarm Buzzer Does Not Sound or It Keeps Sounding Contents of trouble
Alarm buzzer does not sound or it keeps sounding. • The alarm buzzer output circuit is disconnected or shorted with the chassis ground. • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the monitoring function (Code: 40952, D-OUT-0). • If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.
Related information
Cause 1
Defective fuse No. 8 of fuse box B
Standard value in normal state/Remarks on troubleshooting If the fuse is burnt out, the circuit probably has a grounding fault, etc. (See cause 4.)
★ Prepare with starting switch OFF, then turn starting switch ON and 2
Defective alarm buzzer (Internal short circuit)
carry out troubleshooting. • Check two seconds after starting switch is turned ON. L20 (female) Ground (2)
Alarm buzzer
Normal/Defective
Sounds
Buzzer is normal
Does not sound.
Buzzer is defective
★ Prepare with starting switch OFF, then carry out troubleshooting Disconnection in wiring harness 3 (Disconnection or defective contact in connector) Possible causes and standard value in normal state
without turning starting switch ON. Wiring harness between fuse No. 8 of fuse box B – L20 (female) (1)
Resistance
Max. 1
Wiring harness between L20 (female) (2) – L51 (female) (14)
Resistance
Max. 1
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 8 of fuse Ground fault in wiring harness 4 box B – L20 (female) (1), – circuit branch end (Short circuit with ground circuit) and chassis ground Wiring harness between L20 (female) (2) – L51 (female) (14) and chassis ground
Resistance
Min. 1 M
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. L51 5 Defective machine monitor Between (14) and chassis ground
40-708 b
Starting switch
Voltage
For two sec after ON (Alarm buzzer sounds)
20 – 30 V
For three sec from two sec after ON (Alarm buzzer does not sound)
Max. 1 V
WA500-6
TROUBLESHOOTING
E-11
Related Circuit Diagram
WA500-6
40-709 b
TROUBLESHOOTING
E-12
E-12 Air Conditioner Does Not Operate or Stop Contents of trouble Related information
Air conditioner does not operate or stop. • The following is troubleshooting for only the power supply or ground circuit between the air conditioner and operator's cab. For troubleshooting the air conditioner unit, see the Shop Manual for the air conditioner.
Cause
Standard value in normal state/Remarks on troubleshooting
Defective fuse No. 10 or No.11 of fuse box A and fuse 5A or If the fuse is burnt out, the circuit probably has a grounding fault, etc. 1 15A in main circuit in air (See cause 2.) conditioner unit
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 10 of fuse box A is broken. Wiring harness between fuse No. 10 of fuse box A – fuse 5A of main circuit in air conditioner unit, – fuse 15 A in air conditioner unit and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse No. 11 of fuse box A is broken.
Grounding fault in power 2 supply wiring harness (Contact with ground circuit)
Wiring harness between fuse No. 11 of fuse box A – compressor clutch relay and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse 5 A of main circuit in air conditioner unit is broken.
Possible causes and standard value in normal state
Wiring harness between fuse 5 A of main circuit in air conditioner unit – C48 (female) (7), – pressure switch, – primary side of blower OFF relay and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. • When fuse 15 A in air conditioner unit is broken Wiring harness between fuse 15A in air conditioner unit – blower OFF relay and chassis ground
Resistance
Min. 1 M
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. C48 Disconnection in air conditioner control panel power supply or ground wire 3 harness (Disconnection or defective contact in connector)
40-710 b
Between (7) and (1)
Starting switch
Voltage
ON
20 – 30 V
OFF
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between fuse No. 10 of fuse box A – C48 (female) (7)
Resistance
Max. 1
Wiring harness between C48 (female) (1) – chassis ground
Resistance
Max. 1
WA500-6
TROUBLESHOOTING
E-12 Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Blower OFF relay, pressure switch Between blower OFF relay (15 A fuse line) – chassis ground Between blower OFF relay (5 A fuse line of main circuit) – chassis ground Possible causes and standard value in normal state
Disconnection in relay wiring harness 4 (Disconnection or defective contact in connector)
Between pressure switch (5 A fuse line of main circuit) – chassis ground
Starting switch
Voltage
ON
20 – 30 V
OFF
Max. 1 V
ON
20 – 30 V
OFF
Max. 1 V
ON
20 – 30 V
OFF
Max. 1 V
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
WA500-6
Wiring harness between fuse No. 10 of fuse box A – blower OFF relay (15 A fuse line side)
Resistance
Max. 1
Wiring harness between fuse No. 10 of fuse box A – blower OFF relay (5 A fuse line side of main circuit)
Resistance
Max. 1
Wiring harness between fuse No. 10 of fuse box A – pressure switch (5 A fuse line side of main circuit)
Resistance
Max. 1
Wiring harness between pressure switch – compressor clutch relay
Resistance
Max. 1
40-711 b
TROUBLESHOOTING
E-12
Related Circuit Diagram
40-712 b
WA500-6
TROUBLESHOOTING
E-12
MEMORANDUM
WA500-6
40-713 b
TROUBLESHOOTING
E-13
E-13 KOMTRAX System Does Not Work Properly Trouble Related information
KOMTRAX system does not work properly. • If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine system, carry out the following troubleshooting. • A defect in the KOMTRAX system, if any, does not appear as a defective phenomenon.
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. 1 Defective power supply
L80
Signal
Voltage
Between (39), (40) and (37), (38)
Constant power supply
20 – 30V
Turn the starting switch ON, then start engine and carry out troubleshooting.
Defective starting switch 2 ACC signal and alternator R signal
LED(6)
Normal state
LED-C1
ON
★ Prepare with starting switch OFF, then start engine and carry out troubleshooting. L80
Signal
Voltage
Between (36) and (37), (38)
Starting switch ACC
20 – 30V
Between (28) and (37), (38)
Alternator R
20 – 30V
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes and standard value in normal state
carry out troubleshooting.
3
Defective starting switch C signal
L80
Signal
Voltage
Between (27) and (37), (38)
Starting switch C
Max. 1 V
★ Prepare with starting switch OFF, then turn starting switch START and carry out troubleshooting. L80
Signal
Voltage
Between (27) and (37), (38)
Starting switch C
20 – 30V
Turn the starting switch ON, and carry out troubleshooting.
Defective CAN connection 4 state
LED(4)
Normal state
LED-C4
ON
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. L80 (female)
Signal
Resistance
Between (7) and (8)
CAN
40 – 80
Turn the starting switch ON, and carry out troubleshooting. 5 Number of unsent mails
40-714 b
LED(7)
Normal state
7 segments
0–9
WA500-6
TROUBLESHOOTING
E-13 Cause
Standard value in normal state/Remarks on troubleshooting Turn the starting switch ON, and carry out troubleshooting.
Possible causes and standard value in normal state
WA500-6
6
Defective GPS positioning status
LED(8)
Normal state
Dot
ON
One or more minutes may pass before GPS positioning is completed after the starting switch has been turned ON even in an outdoor service area.
40-715 b
TROUBLESHOOTING
E-13
Lamp Display Section of KOMTRAX Terminal CPU LEDs See graphic to the right. 1.
LED-C1 (R signal and ACC signal status)
2.
LED-C2 (engine control signal status)
3.
LED-C3 (S-NET, C signal status)
4.
LED-C4 (CAN status)
5.
LED-C5 (download writing condition)
6.
LED-C6 (download writing condition)
7-Segment and Dot Displays for CPU 7.
7 segments (number of unsent mail messages)
8.
Dot (GPS positioning state)
L80 Connector See graphic to the right.
40-716 b
WA500-6
TROUBLESHOOTING
E-13
MEMORANDUM
WA500-6
40-717 b
TROUBLESHOOTING
TROUBLESHOOTING: H-MODE
TROUBLESHOOTING: H-MODE Troubleshooting Hydraulic and Mechanical Systems Using Troubleshooting Chart This troubleshooting chart, like the other troubleshooting charts (YES/NO type), determines the location of the problem occurring on the machine and categorizes the problem under one of the main components, such as the steering system or work equipment hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly. Step 1. Ask operator questions The questions to ask the operator are given under the problem. If the answer to the question matches the content given, the cause given after the arrow is the probable cause. Keeping the content of the questions in mind, read the matrix and proceed with Steps 2 and 3 to pinpoint the correct cause. Example: Steering wheel does not turn ★ Ask the operator and check the following points. • Did the problem suddenly start? • Related equipment broken • Was the steering wheel heavy before the problem started? • Wear of related parts, defective seal Step 2. Checks before troubleshooting Before measuring the oil pressure or starting the troubleshooting, confirm the checks before starting items, check for leakage of oil, or for loose bolts. This will prevent wasting time when troubleshooting. Before starting the actual troubleshooting, it is very important to determine the condition of the machine by checking the items given in Checks Before Troubleshooting. Example: Checks before starting troubleshooting • • •
Is oil level and type of oil in hydraulic tank correct? Is there any oil leakage from steering valve or demand valve? Is steering linkage adjusted properly?
Step 3. Method of reading matrix 1.
Operate the machine when carrying out troubleshooting of the items in the Diagnosis column. If any problems occur as the result of the troubleshooting, put a check against the items. ★ When carrying out the troubleshooting, check the easier items first. ★ It is not necessary to follow the numerical order. ★ Marks and Remedies in Remedy line • X: Replace • : Repair • A: Adjust • C: Clean
40-718 b
No.
Remedy Diagnosis
1
Steering does not turn in both directions (left and right)
2
Steering turns only in one direction (left or right)
3
Steering is heavy when turned in both directions (left and right)
4
Steering wheel is heavy in one direction (left or right)
5
Work equipment moves
WA500-6
TROUBLESHOOTING 2.
Find the matching cause in the Cause column. If a problem is found, the ❍ marks on the same line as the troubleshooting are the causes. ★ In Diagnosis item 2 in the diagram on the right, the cause is (c) or (e). ★ When there is one ❍ mark: • Carry out troubleshooting for the other items marked with ❍ in the same Cause column to check if the problem occurs, then make repairs. ★ When there are two ❍ marks: • Go to Step (3) to narrow down the cause.
3.
Operate the machine and carry out troubleshooting of the items not checked in Step 1. • Operate the machine in the same way as in Step 1 and if any problem occurs, put a check against the item. ★ In Troubleshooting item 5 in the diagram to the right, the problem was repeated.
4.
Find the matching cause in the Cause column. • In the same way as in Step 2, if a problem is found, the ❍ marks on the same line for the troubleshooting item are the causes. ★ In Diagnosis item 5 in the diagram to the right the cause is (b) or (e).
5.
Narrow down the causes. Of the causes found in Steps 2 and 4, there are common items (❍ marks on the line for each Diagnosis item and in the same Cause column) that have causes common with the problem items found when troubleshooting in Steps 1 and 3.
TROUBLESHOOTING: H-MODE
★ The items that are not common (items that do not have ❍ marks in the same cause common to each other) are probably not the cause, so they can be eliminated. ★ The causes for Diagnosis item 2 in the diagram to the right are (c) or (e), and the causes in Diagnosis item 5 are (b) or (e). Cause (e) is the common cause. 6.
Repeat the operation in Steps 3, 4, and 5 until the cause is narrowed down to one item (one common item). ★ If cause items are two or more, continue until you get a minimum number of items.
7.
Remedy • After narrowing down the common causes, take the action given in the remedy line.
WA500-6
40-719 b
TROUBLESHOOTING
TROUBLESHOOTING: H-MODE
Internal breakage of torque converter
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
Drop of transmission main relief valve set pressure
Defective torque converter charging pump
Machine does not start.
Defective operation of torque converter relief valve
Clogging or air intake on torque converter charging pump suction side
Defective engine
Failure mode
Clogged or broken torque converter oil cooler
Clogging of torque converter charging pump strainer
❍
Part that can cause failure
Defective regulator valve
PTO is defective
Failure Codes and Causes Table
❍
❍
Power train
Torque converter lockup is not switched off (engine stalls). [Machine with lockup clutch (if equipped)] ❍
Torque converter lockup is not switched on. [Machine with lockup clutch (if equipped)] Travel speed is slow; thrusting force is weak; uphill traveling power is weak; gear is not shifted.
❍
Shocks are large when starting and shifting gear. Time lag is large when starting and shifting gear.
Steering
Torque converter oil temperature is high.
❍
Steering does not turn.
❍
Steering does not turn. [Machine with joystick steering (if equipped)]
❍
Steering response is poor.
❍
Turning response of steering is poor. [Machine with joystick steering (if equipped)]
❍
❍
❍
❍
❍ ❍ ❍
❍
❍
❍
Steering is heavy. When machine turns, it shakes or makes large shocks. When machine turns, it shakes or makes large shocks. [Machine with joystick steering (if equipped)]
Brake
Wheel brake does not work or does not work well.
❍
Wheel brake is not released or it drags. Parking brake does not work or does not work well. Parking brake is not released or it drags (including emergency release system). Lift arm does not rise.
❍
Lift arm speed is low or rising force of lift arm is insufficient. When rising, lift arm starts to move slowly at specific height. Lift arm cylinder cannot hold bucket down (bucket floats). Hydraulic drifts of lift arm occur often. Work equipment
Lift arm wobbles during operation. Bucket does not tilt back.
❍
Bucket speed is low or tilting back force is insufficient. Bucket starts to operate slowly in midst of tilting back. Bucket cylinder cannot hold bucket down. Hydraulic drifts of the bucket occur often. The bucket wobbles during travel with cargo. (The work equipment valve is set to HOLD.) Engine speed lowers remarkably or engine stalls during work equipment control.
❍
Large shocks are made when work equipment starts and stops. When work equipment circuit is relieved singly, other work equipment moves. ECSS does not operate and pitching and bouncing occur.
40-720 b
WA500-6
❍ ❍ ❍
❍ ❍ ❍
WA500-6 ❍ ❍ ❍ ❍
❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍
❍ ❍ ❍
❍
❍ ❍ ❍
❍ ❍
❍ ❍
❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
❍
❍ ❍
❍
❍ ❍ ❍
Troubleshooting No.
Defective brake valve
Air in wheel brake circuit
Clogging or air intake on brake pump suction side
Defective brake pump
Seized wheel brake disc plate
Wear of wheel brake disc
Internal breakage of wheel brake
Defective operation of brake piston
Defective seal of brake piston
Defective steering wheel or steering shaft
Defective actuation of rotary valve
Defective joystick steering solenoid valve
Clogging of joystick steering solenoid valve line filter
Defective seal of steering cylinder piston
Defective safety-suction valve
Defective steering spool of steering valve
Defective demand spool
Defective steering main relief valve
Defective steering stop valve
Defective Orbitrol
Defective steering pump servo
Defective steering pump
Clogging or air intake on steering pump suction side
Defective seal of work equipment and steering system hydraulic pump shaft
Defective transmission output shaft speed sensor
Defective transmission oil temperature sensor
Clogging of transmission breather
Defective seal of relevant clutch shaft
Relevant clutch piston seal is defective
Defective clutch piston
Wear or seizure of relevant clutch disc
Internal breakage of transmission
Defect of transmission controller system
Defective operation of relevant ECMV
Clogging of last chance filter
TROUBLESHOOTING TROUBLESHOOTING: H-MODE
H-1
H-2
H-3
H-4
H-5
H-6
H-7
❍ ❍
H-8
H-9
❍ ❍ H-10
❍ ❍ H-11
❍ H-12
❍ H-13
❍ H-14
❍ ❍ ❍ ❍ H-15
❍ H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
H-29
H-30
H-31
H-32
H-33
H-34
40-721 b
❍
❍
❍
❍
❍
❍
Defective operation of parking brake piston
Defective operation of parking brake solenoid valve
❍
Defective parking brake spring
Defective parking brake emergency release valve
Machine does not start.
Defective operation of check valve (between last chance filter and parking brake solenoid)
Defective axle oil
Defective slack adjuster
Failure mode
Defective operation of wheel brake emergency switch
Part that can cause failure
Defective accumulator charge valve
TROUBLESHOOTING: H-MODE
Gas leakage from accumulator, defective seal of piston
TROUBLESHOOTING
❍
❍
Power train
Torque converter lockup is not switched off (engine stalls). [Machine with lockup clutch (if equipped)] Torque converter lockup is not switched on. [Machine with lockup clutch (if equipped)] Travel speed is slow; thrusting force is weak; uphill traveling power is weak; gear is not shifted. Shocks are large when starting and shifting gear. Time lag is large when starting and shifting gear.
Steering
Torque converter oil temperature is high. Steering does not turn.
❍
Steering does not turn. [Machine with joystick steering (if equipped)]
❍
Steering response is poor.
❍
Turning response of steering is poor. [Machine with joystick steering (if equipped)]
❍
Steering is heavy.
❍
When machine turns, it shakes or makes large shocks.
❍
When machine turns, it shakes or makes large shocks. [Machine with joystick steering (if equipped)]
❍ ❍
Brake
Wheel brake does not work or does not work well.
Parking brake does not work or does not work well. Parking brake is not released or it drags (including emergency release system).
❍
❍
❍
❍
Wheel brake is not released or it drags.
❍
Lift arm does not rise. Lift arm speed is low or rising force of lift arm is insufficient. When rising, lift arm starts to move slowly at a specific height. Lift arm cylinder cannot hold bucket down (bucket floats). Hydraulic drifts of lift arm occur often. Work equipment
Lift arm wobbles during operation. Bucket does not tilt back. Bucket speed is low or tilting-back force is insufficient. Bucket starts to operate slowly in midst of tilting back. Bucket cylinder cannot hold bucket down. Hydraulic drifts of bucket occur often. Bucket wobbles during travel with cargo. (Work equipment valve is set to HOLD.) Engine speed lowers remarkably or engine stalls during work equipment control. Large shocks are made when work equipment starts and stops. When work equipment circuit is relieved singly, other work equipment moves. ECSS does not operate and pitching and bouncing occur.
40-722 b
❍
WA500-6
❍
WA500-6
❍
❍ ❍
❍
❍
❍
❍
❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ H-26
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
H-27
❍
❍
❍
❍
❍
❍
❍
❍
H-28
❍
❍
❍ ❍
❍
❍ ❍
❍
❍
❍ ❍ H-20
❍ ❍ H-21
❍ H-22
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍ ❍ ❍
❍
Troubleshooting No.
Defective ECSS charge valve
Defective ECSS solenoid valve
Clearance error of pin or bush of working equipment linkage
Defect in electrical system of lift arm or bucket EPC lever
Defective stroke of bucket EPC lever
Defective stroke of lift arm EPC lever
Defective seal of bucket cylinder piston
Defective seal of lift arm cylinder piston
Defective bucket cylinder
Defective lift arm cylinder
Defective safety-suction valve on bucket bottom side of work equipment valve
Defective safety-suction valve on bucket head side of work equipment valve
Defective lift arm load check valve of work equipment valve
Defective bucket spool of work equipment valve
Defective lift arm spool of work equipment valve
Defective work equipment unload valve
Defective work equipment main relief valve
Defective work equipment valve body
Defective work equipment pump servo
Defective work equipment pump
Defective work equipment controller
Clogging or air intake on work equipment pump suction side
Defective harness of parking brake switch line
Seizure of parking brake disc and plate
Wear of parking brake disc
The parking brake piston seal is defective
TROUBLESHOOTING TROUBLESHOOTING: H-MODE
H-1
H-2
❍ H-3
H-4
❍ H-5
H-6
H-7
H-8
H-9
H-10
H-12
H-11
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-23
H-24
H-25
H-29
H-30
H-31
H-32
H-33
H-34
40-723 b
TROUBLESHOOTING
H-1
H-1 Machine Does Not Start Ask the operator about the following: • DId the machine suddenly not start? Seizure of clutch, breakage of parts • Did the machine cause any abnormal noise at the time and where?
Parking brake emergency release valve
h
i
j
k
l
m
n
o
p
q
Internal breakage of transmission
Wear or seizure of relevant clutch
Relevant clutch piston seal is defective
The relevant clutch shaft seal is defective
x
* *
x
*
❍
❍
❍
❍
❍
2
The machine does not start at specific gear speeds.
3
When the transmission oil temperature is low, the charging pump or the transmission filter causes an abnormal noise(s).
4
When the transmission oil temperature rises, the machine does not start.
❍
5
Metal (aluminum, copper, iron, etc.) powders are stuck to the transmission filter or the strainer.
❍
❍
❍
❍
7
❍ ❍
❍
❍
When the ECMV The oil pressure is low at output (Clutch) oil specific gear speeds. pressure is measured The oil pressure does not 10 become stable as the gauge fluctuates.
❍
❍
❍
❍
❍
❍
❍
❍
❍
x
x
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍
❍ ❍
9
11
❍
x
❍
❍
❍
❍
x
❍
The oil pressure is low at all ❍ ❍ ❍ ❍ gear speeds.
8
❍
Parking brake piston seal is defective
x
Defective operation of parking brake solenoid valve
x
Defective operation of spool of parking brake emergency release valve
x
Defective operation of check valve (between last chance filter and parking brake solenoid)
x
The machine does not start at all gear speeds.
The speed is higher at all When the stall speed gear speeds. of the torque converter The speed is higher at is measured specific gear speeds.
ECMV Defective operation of relevant ECMV
x
1
6
Main relief valve Clogging of last chance filter
❍
Set pressure drop of main relief valve
❍
Defective operation of torque converter relief valve
❍
Internal breakage of torque converter
Remedy x C x
Parking brake
Check valve
g
Transmission
f
Torque converter e
Torque converter charging pump d
Charging pump is defective
Diagnosis
c
Clogging or air intake on suction side
No.
b
Clogging of strainer
* Proceed to Defective Clutch and ECMV Specifying Method (Check by Failure Code) on next page.
a
PTO is defective
Checks before troubleshooting • Does the machine monitor function normally? • Has the machine monitor displayed any failure code of the electrical system? • Are the transmission oil level and the oil type appropriate? • Did you smell deteriorated or burnt transmission oil? • Have the transmission filter and strainer been clogged? • Can you find any damage or oil leak from appearances? • Has the drive shaft been broken? • Have the wheel brake and the parking brake been locked?
Cause
❍
❍
❍
❍
When the torque converter relief (Inlet) oil pressure ❍ ❍ ❍ ❍ ❍ ❍ is measured, the oil pressure is low.
40-724 b
WA500-6
TROUBLESHOOTING
H-1
Defective Clutch and ECMV Specifying Method (Check by Failure Code) ★ To check the failure code display, see Normal and Special Functions of Machine Monitor in the Testing and Adjusting section. • When replacing the ECMV for diagnosis, remove mud and dust around the ECMV completely and clean it. Then tighten the mounting bolt with the specified torque. • For the following diagnoses, start the engine and select the manual mode.
1
2
3
4
5
6
c
d
e
f
g h
i
j
k
l
Wear or seizure of 1st clutch disc or wear of piston seal
Wear or seizure of 2nd clutch disc or wear of piston seal
Wear or seizure of 3rd clutch disc or wear of piston seal
Wear or seizure of 4th clutch disc or wear of piston seal
Defective operation of F clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of 2nd clutch ECMV (Fill switch)
Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
1st
2nd
3rd
4th
❍
❍
● ❍
In the manual mode F1
●
F2
●
F3
●
F4
●
❍
● ● ● ●
R1
●
R2
●
R3
●
R4
●
● ● ●
Diagnosis
●
Remedy Failure Code
x
x
x
x
x
x
x
x
x
x
x
x
15SAL1 ❍
(1)
The code is not displayed at R1-R4 but is displayed at F1-F4
(2)
When the failure code is 15SAL1 after the diagnosis in (1), the failure code is not displayed when the F fill switch connector (CN-F.SW) is disconnected. 15SALH When the failure code is 15SALH, the failure code is not displayed when the ECMV is replaced with any one other than F clutch ECMV.
(1)
The code is not displayed at F1-F4 but is displayed at R1-R4.
(2)
When the failure code is 15SBL1 after the diagnosis in (1), the failure code is not displayed when the R fill switch connector (CN-R.SW) is disconnected. 15SBLH When the failure code is 15SBLH, the failure code is not displayed when the ECMV is replaced with any one other than R clutch ECMV.
(1)
The code is not displayed at F2, F3, and F4 but is displayed at F1.
(2)
When the failure code is 15SEL1 after the diagnosis in (1), the failure code is not displayed when the 1st fill switch connector (CN-1.SW) is disconnected. 15SELH When the failure code is 15SELH, the failure code is not displayed when the ECMV is replaced with any one other than the 1st clutch ECMV.
(1)
The code is not displayed at F1, F3, and F4 but is displayed at F2.
15SFL1
(2)
When the failure code is 15SFL1 after the diagnosis in (1), the failure code is not displayed when the 2nd fill switch connector (CN-2.SW) is disconnected. When the failure code is 15SFLH, the failure code is not displayed when the ECMV is replaced with any one other than the 2nd clutch ECMV.
15SFLH
(1)
The code is not displayed at F1, F2, and F4 but is displayed at F3.
15SGL1
(2)
When the failure code is 15SGL1 after the diagnosis in (1), the failure code is not displayed when the 3rd fill switch connector (CN-3.SW) is disconnected. 15SGLH When the failure code is 15SGLH, the failure code is not displayed when the ECMV is replaced with any one other than the 3rd clutch ECMV.
(1)
The code is not displayed at F1, F2, and F3 but is displayed at F4.
(2)
When the failure code is 15SHL1 after the diagnosis in (1), the failure code is not displayed when the 4th fill switch connector (CN-4.SW) is disconnected. 15SHLH When the failure code is 15SHLH, the failure code is not displayed when the ECMV is replaced with any one other than the 4th clutch ECMV.
WA500-6
b
Wear or seizure of R clutch disc or wear of piston seal
R
• When the gear speed is N in the manual mode, the clutch of the gear speed (marked with ❍), to which the gear shift lever is set, is ON. • Even if the gear shift lever is used when the gear speed is N, the clutch position cannot be changed.
No.
a
Clutch F
In the automatic mode
Gear Speed
N
ECMV
Wear or seizure of F clutch disc or wear of piston seal
Table of Applicable Clutches
Cause Transmission
15SBL1
15SEL1
15SHL1
❍ ❍ ❍
❍ ❍ ❍
❍ ❍ ❍
❍ ❍ ❍
❍ ❍ ❍
❍ ❍
40-725 b
TROUBLESHOOTING
H-2
H-2 Torque Converter Lockup is Not Switched OFF (Engine Stalls) Machine with lockup clutch (if equipped)
Remedy Diagnosis
1
Lockup oil pressure does not drop to 0.
2
Lockup cannot be turned off even when the lockup oil pressure is 0.
40-726 b
a
b
Wear or seizure of lockup clutch disc
No.
Cause Defective operation of lockup clutch ECMV
Checks before troubleshooting • Is the oil level in the transmission case appropriate?
x
x
❍ ❍
WA500-6
TROUBLESHOOTING
H-3
H-3 Torque Converter Lockup is Not Switched ON Machine with lockup clutch (if equipped) Ask the operator about the following: • Has the lockup suddenly started not to turn on? Seizure or breakage inside torque converter • Did any abnormal noise occur at the time? Breakage of parts
x
x
x
❍
❍
Defective seal of lockup clutch shaft
g
Clogging of last chance filter
f
x
x
C
x
❍
❍
❍
❍
1
Main relief oil pressure is low.
2
Main relief oil pressure is normal but lockup oil pressure is low or 0.
3
Main relief oil pressure and oil pressure is normal but lockup oil pressure is low or 0.
4
Time to lockup actuation takes long.
WA500-6
e
Crack on lockup clutch case
Transmission controller self-diagnosis code
d
Wear or seizure of lockup clutch disc
Remedy No. Diagnosis
c
Defective seal of lockup clutch piston
Check for abnormality • Main relief oil pressure • Lockup oil pressure • Travel speed
b
Defective operation of lockup clutch ECMV
Checks before troubleshooting • Is the oil level in the transmission case appropriate? • Is there any external oil leakage?
a Drop of transmission main relief valve set pressure
Cause
15SJLH
❍ ❍
40-727 b
TROUBLESHOOTING
H-4
H-4 Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, Gear is Not Shifted
Diagnosis
g
h
i
j
k
l
m n
o
Breakage of oil cooler and piping (after torque converter outlet)
Oil leak inside torque converter
Internal breakage of torque converter
Defective operation of torque converter relief valve
Drop of main relief valve set pressure
Clogging of last chance filter
Defective operation of relevant ECMV
Internal breakage of transmission
Defective seal of relevant clutch piston
Defective seal of relevant clutch shaft
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
1
An abnormality occurs at all gear speeds.
2
An abnormality occurs at specific gear speeds.
3
When the transmission oil temperature is low, the charging pump or the transmission filter causes an abnormal noise.
4
The torque converter oil temperature is abnormally high. ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
5
The transmission oil level rises and falls.
6
Metal (aluminum, copper, iron, etc.) powders are stuck to the transmission filter or the strainer.
7
The engine low idle and high idle speeds are measured and are abnormal.
8 9
When the stall speed of the The speed is high. torque converter is The speed is low. measured
40-728 b
q
r
Defective seal of parking brake piston
Defective seal of work equipment and steering system hydraulic pump shaft (Mixing of hydraulic oil in transmission case)
s
❍
x
❍ ❍
❍
❍
❍
❍
❍
❍
* x * x x x ❍
Others
p
Clogging of breather
Transmission
ECMV
Remedy ❍ x x x x x x x x x x x
Parking brake
f
Main relief valve
e
Clogging of oil cooler and piping (after torque converter outlet)
Torque converter
Regulator valve
Torque converter oil cooler
d
Defective operation of regulator valve
Torque converter charging pump c
Note Engine degradation
No.
b
Charging pump is defective
proceed to Troubleshooting of Engine (S-mode). * Proceed to “Defective Clutch and ECMV Specifying Method (Check by Failure Code)” on page -725.
a
Clogging or air intake on pump suction side
★ When the inspection result is Engine Degradation,
Cause
Clogging of strainer
Ask the operator about the following: • Has the abnormality occurred suddenly? Breakage of related equipment • Did any abnormal noise occur at the time and where? • Have any abnormal signs occurred gradually? Wear of related equipment, defective seal Check for abnormality • Execute digging and measure traveling speeds on level ground and on a slope to check whether the abnormality actually occurs or is simply the operator's opinion. Checks before troubleshooting • Is any failure code of the electrical system displayed on the machine monitor? • Are the transmission oil level and the oil type appropriate? • Are the transmission filter and strainer clogged? • Is any external oil leak found on the mating faces of pipings and valves around the torque converter and the transmission? • Is the wheel brake or the parking brake being dragged? • Are the tire air pressure and the tread shape appropriate? • Is the operating method correct?
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍
❍ ❍ ❍
❍
❍
❍
❍
❍ ❍ ❍ ❍
❍
❍
❍
❍ ❍ ❍
WA500-6
No.
12
15 Diagnosis
10 The oil pressure drops as the oil temperature rises.
11 The oil pressure is low at all ❍ ❍ ❍ gear speeds.
When the ECMV output (clutch) oil pressure is measured
13 The oil pressure does not become stable as the gauge fluctuates.
When the oil pressure at the torque converter outlet is measured, the oil pressure is low. (No. 14 is normal.)
WA500-6 f g h i j k l m n o
Remedy ❍ x x x x x x x x x x x
❍ ❍ ❍
❍ ❍
The oil pressure is low at specific gear speeds.
When the torque converter relief (inlet) oil pressure is 14 measured, the oil pressure is low. (No. 11 - 13 are normal.) ❍
Charging pump is defective Defective operation of regulator valve Clogging of oil cooler and piping (after torque converter outlet) Breakage of oil cooler and piping (after torque converter outlet) Oil leak inside torque converter Internal breakage of torque converter Defective operation of torque converter relief valve Drop of main relief valve set pressure Clogging of last chance filter Defective operation of relevant ECMV Internal breakage of transmission Defective seal of relevant clutch piston Defective seal of relevant clutch shaft
q r
* x * x x x ❍
❍ ❍
x
Note Engine degradation
p
Defective seal of work equipment and steering system hydraulic pump shaft (Mixing of hydraulic oil in transmission case)
e
Defective seal of parking brake piston
d
Clogging of breather
c
Others
Parking brake
Transmission
ECMV
Main relief valve
Torque converter
Regulator valve Torque converter oil cooler
b
Clogging or air intake on pump suction side
Torque converter charging pump
a
Clogging of strainer
TROUBLESHOOTING H-4
Cause
s
❍ ❍
❍ ❍ ❍ ❍
❍ ❍
❍ ❍ ❍
❍
40-729 b
TROUBLESHOOTING
H-5
H-5 Large Shocks When Starting and Shifting Gears
1
Shocks are large at all gear speeds.
2
Shocks are large at specific gear speeds.
3
When the ECMV output The oil pressure is low at all gear speeds. (clutch) oil pressure is The oil pressure is low at specific gear speeds. measured The oil pressure is high at all gear speeds.
4 5
Parking brake
Sensor
i
j
k
l
Defective return (release) of relevant clutch piston
Defective seal of relevant clutch shaft
Parking brake piston seal is defective
Defective transmission oil temperature sensor
x x
**
ECMV
Transmission h
Relevant clutch piston seal is defective
Main relief valve Clogging of last chance filter
Defective operation of main relief valve
Remedy C x x x x x
g
Defect of transmission controller system
Diagnosis
f
Defective operation of relevant ECMV ★
No.
Charging pump is defective
Checks before troubleshooting • Is any failure code of the electrical system displayed on the machine monitor? • Are the transmission oil level and the oil type appropriate? • Are the transmission filter and strainer clogged? • Is any external oil leak found on the mating faces of pipings and valves around the torque converter and the transmission? • Is the engine speed high at the time of low idle? • Is play of each drive shaft large?
a b c d e
Clogging or air intake on pump suction side
Checks before troubleshooting • Did any of the following abnormal phenomena occur at the same time: • Traveling speed is slow. • Braking is weak. • Uphill travelling power is weak. • Gear is not shifted. Execute H-4
Torque converter charging pump
Cause
Clogging of strainer
Ask the operator about the following: • Did shocks suddenly become large? Breakage of related equipment • Did any abnormal noise occur at the time and where? • Did shocks gradually become large? Wear of related equipment, defective seal
* ** * *
❍ ❍ ❍ ❍ ❍
❍ ❍
❍
❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍
❍ ❍
❍
❍
❍
❍
★: Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes of pressure control valve spool *:
Proceed to “Defective Clutch and ECMV Specifying Method (Check by Failure Code)” on page -725.
**: See Troubleshooting by Failure Code in this section.
40-730 b
WA500-6
TROUBLESHOOTING
H-6
H-6 Large Time Lag When Starting and Shifting Gear Cause Parking brake
Sensor
b
c
d
e
f
g
h
i
j
Clogging of strainer
Clogging or air intake on pump suction side
Charging pump is defective
Drop of main relief valve set pressure
Clogging of last chance filter
Defective operation of relevant ECMV ★
Relevant clutch piston seal is defective
Defective seal of relevant clutch shaft
Parking brake piston seal is defective
Defective transmission oil temperature sensor
Remedy C x
x
x
*
*
x
x
**
• Did any of the following abnormal phenomena occur at the same time: • Traveling speed is slow. • Braking is weak. • Uphill travelling power is weak. • Gear is not shifted. Execute H-4 Checks before troubleshooting • Is any failure code of the electrical system displayed on the machine monitor? • Are the transmission oil level and the oil type appropriate? • Are the transmission filter and strainer clogged? • Is any external oil leak found on the mating faces of pipings and valves around the torque converter and the transmission?
Diagnosis
x
x
ECMV
❍ ❍ ❍ ❍ ❍
1
Time lag is large at all gear speeds.
2
Time lag is large at specific gear speeds.
3
When the transmission oil temperature is low, any abnormal noise occurs from the ❍ ❍ charging pump or the transmission filter.
4
The torque converter oil temperature is heated abnormally high.
❍ ❍ ❍
5
When the ECMV output (Clutch) The oil pressure is low at all gear speeds. oil pressure is measured The oil pressure is low at specific gear speeds.
❍ ❍ ❍ ❍
6
Transmission
a
Check for abnormality
No.
Main relief valve
Torque converter charging pump
Ask the operator about the following: • Did the time lag suddenly become large? Breakage of related equipment • Did any abnormal noise occur at the time and where? • Has the time lag gradually become large? Wear of related equipment, defective seal
❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes of pressure control valve spool. *:
Proceed to “Defective Clutch and ECMV Specifying Method (Check by Failure Code)” on page -725.
**: See Troubleshooting by Failure Code in this section.
WA500-6
40-731 b
TROUBLESHOOTING
H-7
H-7
Troubleshooting of Engine (S-mode).
No.
Remedy C x x x
Diagnosis
1
When the transmission oil temperature is low, the charging pump or the ❍ ❍ transmission filter causes an abnormal noise.
2
Traveling speed, braking force, and uphill traveling power do not occur ❍ ❍ ❍ at all gear speeds.
3
Traveling speed, braking force, and uphill traveling power do not occur at specific gear speeds.
4
The transmission oil level rises and falls.
5
Metal powders (aluminum, copper, iron, etc.) are stuck to the transmission filter and the strainer.
6
The engine low idle and high idle speeds are measured and are abnormal.
7
When the stall speed of the torque converter is measured, the speed is ❍ ❍ ❍ high.
9
When the ECMV output The oil pressure is low at all gear speeds. (Clutch) oil pressure is The oil pressure is low at specific gear 10 measured speeds. 11
The oil pressure does not become stable as the gauge vibrates.
12
When the torque converter relief (Inlet) oil pressure is measured, the oil pressure is low. (No. 9 - 11 are normal.)
13
When the oil pressure at the torque converter outlet is measured, the oil pressure is low. (No. 12 is normal.)
40-732 b
Others
Transmission
Main relief valve
Torque converter
f g h i
j
k
l
x
x
C x x x x x
x
❍
❍
❍ ❍ ❍ ❍
❍
❍
❍ ❍
❍
❍
The oil pressure drops as the oil temperature rises.
8
e
Note Engine degradation
★ When the inspection result is Engine Degradation, proceed to
d
Defective seal of work equipment and steering system hydraulic pump shaft (Mixing of hydraulic oil in transmission case)
Checks before troubleshooting • Are the coolant level in the radiator and the belt tension appropriate? • Are the oil level in the transmission and the oil type appropriate? • Are the transmission filter and strainer clogged?
Torque converter oil cooler
a b c
Breakage of oil cooler and piping (After torque converter outlet) Oil leak inside torque converter Internal breakage of torque converter Drop of main relief valve set pressure Internal breakage of transmission Clogging of breather
Check for abnormality • Measure the torque converter oil temperature to find if the oil temperature is really high. The torque converter oil temperature gauge is defective.
Cause
Clogging of strainer Clogging or air intake on pump suction side Charging pump is defective Clogging of oil cooler and piping (After torque converter outlet)
Ask the operator about the following: • Does the oil temperature rise when the torque converter stalls and does the temperature fall at the time of no load? Selection of improper gear speed • Did any abnormal noise occur at the time and where? • Does the oil temperature rise only at the time of lifting? Improvement of operating method
Torque converter charging pump
Torque Converter Oil Temperature is High
❍
❍ ❍
❍
❍
❍
❍
❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍
❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍
WA500-6
TROUBLESHOOTING
H-8
H-8 Steering Does Not Turn
Orbitrol
Stop valve
d
e
f
g
h
i
j
k
Defective brake pump
Defective accumulator charge valve
Defective Orbitrol
Defective stop valve
Defective actuation of demand spool
Defective actuation of steering spool
Defective safety-suction valve
Defect in steering cylinder (defective piston seal)
x
x
x
x
x
x
x
x
x
Remedy x
❍ ❍ ❍ ❍ ❍ ❍
1
Steering does not turn in both directions (left and right).
2
Steering turns only in one direction (left or right).
3
Steering is heavy when turned in both directions (left and right).
4
Steering wheel is heavy in one direction (left or right).
5
Work equipment moves.
6
Work equipment does not move.
❍ ❍
7
Abnormal noise comes from around PTO.
❍
8
Abnormal noise comes from around hydraulic tank.
9 10 11 12 13
❍ ❍ ❍
❍ ❍ ❍
❍ ❍
❍ ❍
❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
Oil pressure is low or there is no pressure in both When steering relief directions (left and right). pressure is measured Oil pressure is low or there is no pressure in one direction (left or right).
❍ ❍ ❍ ❍ ❍ ❍
When Orbitrol output pressure is measured, oil pressure is found to be low or there is no oil pressure.
❍ ❍
❍ ❍ ❍
When Orbitrol basic Oil pressure is low. pressure is measured There is no oil pressure.
❍ ❍
❍ ❍
❍ ❍
❍
WA500-6
Steering valve
Charge valve c
Defective steering pump
Diagnosis
b
Clogging or air intake on pump suction side
No.
a
Defective PTO
Checks before troubleshooting • Is oil level in hydraulic tank correct? Is the type of oil correct? • Is the steering shaft broken? • Is the steering stop valve properly adjusted? • Has the lock bar been removed from the frame?
Hydraulic cylinder
Cause Hydraulic pump
Ask the operator about the following: • Did the problem suddenly start? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where?
❍ ❍ ❍
❍ ❍
40-733 b
TROUBLESHOOTING
H-9
H-9 Steering Does Not Turn (Joystick Steering, if equipped) Joystick steering solenoid valve
Rotary valve
e
f
g
h
i
j
k
l
Defective accumulator charge valve
Clogged line filter
Defective joystick steering solenoid valve
Defective actuation of rotary valve
Defective actuation of demand spool
Defective actuation of steering spool
Defective safety-suction valve
Defect in steering cylinder (defective piston seal)
x
x
C x x x
x
x
x
x
x
Remedy x
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
1
Steering does not turn in both directions (left and right).
2
Steering turns only in one direction (left or right).
3
Joystick steering is heavy when turned in both directions (left and right).
4
Joystick steering is heavy in one direction (left or right).
5
Work equipment moves.
6
Work equipment does not move.
❍ ❍
7
Abnormal noise comes from around PTO.
❍
8
Abnormal noise comes from around hydraulic tank.
9 10 11 12 13
Steering valve
Charge valve d
Hydraulic pump c
Defective brake pump
Diagnosis
b
Defective steering pump
No.
a
Clogging or air intake on pump suction side
Checks before troubleshooting • Is oil level in hydraulic tank correct? Is the type of oil correct? • Is the steering shaft broken? • Has the lock bar been removed from the frame? • Are the steering mode switch and steering operations correct?
❍ ❍
❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍
Oil pressure is low or there is no pressure in both When steering relief directions (left and right). pressure is measured Oil pressure is low or there is no pressure in one direction (left or right).
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
When joystick steering solenoid valve output pressure is measured, oil pressure is found to be low.
❍ ❍
❍ ❍ ❍ ❍ ❍
When Orbitrol basic Oil pressure is low. pressure is measured There is no oil pressure.
❍ ❍
❍ ❍
❍ ❍
❍
40-734 b
Hydraulic cylinder
Cause
PTO is defective
Ask the operator about the following: • Did the problem suddenly start? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where?
❍ ❍
WA500-6
TROUBLESHOOTING
H-10
H-10 Steering Response is Poor
e
f
g
h
i
j
k
l
m
Defective steering pump
Defective steering pump servo
Defective accumulator charge valve
Defective Orbitrol
Defective stop valve
Defective actuation of demand spool
Defective main relief valve
Defective steering spool
Defective safety-suction valve
Defect in steering cylinder (defective piston seal)
x
x
x
x
x
x
x
x
x
Remedy x
Turning response of steering wheel is poor in both directions (left and right).
2
Turning response of steering wheel is poor in one direction (left or right).
3
Steering wheel is heavy in both directions (left and right).
4
Steering wheel is heavy in one direction (left or right).
5
Work equipment moves.
6
Work equipment does not move.
❍ ❍ ❍
7
Abnormal noise comes from around PTO.
❍
8
Abnormal noise comes from around hydraulic tank.
10
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
x
❍ ❍ ❍
x ❍
❍
❍ ❍
❍ ❍
❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍
Oil pressure is low or there is no pressure in ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ When steering relief both directions (left and right). pressure is measured Oil pressure is low or there is no pressure in one ❍ direction (left or right).
11 When Orbitrol output pressure is measured, oil pressure is low.
❍ ❍ ❍
❍ ❍
When Orbitrol basic pressure is measured, oil pressure is low or there is 12 no pressure.
❍ ❍ ❍
❍
13 When steering pump servo assembly is replaced, oil pressure is normal.
Hydraulic cylinder
Orbitrol
Stop valve
d
1
9
Steering valve
Charge valve
c
Defective brake pump
Diagnosis
b
Clogging or air intake on pump suction side
No.
a
PTO is defective
Checks before troubleshooting • Is oil level in hydraulic tank correct? Is the type of oil correct?
Cause Hydraulic pump
Ask the operator about the following: • Did the problem suddenly start? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where? • Did the problem gradually appear? Wear of related parts, defective seal
❍ ❍
❍
★ There is a close connection between the steering circuit and the work equipment circuit. If any abnormality is present in the steering, check the operation of the work equipment also.
WA500-6
40-735 b
TROUBLESHOOTING
H-11
H-11 Steering Turning Response is Poor (Joystick Steering, if Equipped)
No.
Defective accumulator charge valve
Clogged line filter
Defective joystick steering solenoid valve
Defective rotary valve
Defective actuation of demand spool
Defective main relief valve
Defective actuation of steering spool
Turning response of steering wheel is poor in both directions (left and right).
2
Turning response of steering wheel is poor in one direction (left or right).
3
Steering wheel is heavy in both directions (left and right).
4
Work equipment moves.
5
Work equipment does not move.
❍ ❍ ❍
6
Abnormal noise comes from around PTO.
❍
7
Abnormal noise comes from around hydraulic tank.
9 10
When steering relief pressure is measured
Defective safety-suction valve
Remedy C x x x x x x x x x x x x x
Diagnosis
1
8
Hydraulic cylinder
Rotary valve
l m n Defect in steering cylinder (defective piston seal)
Joystick steering solenoid valve
k
Steering valve
Charge valve
j
Defective steering pump servo
i
Defective steering pump
g h
Defective brake pump
f
Clogging or air intake on pump suction side
a b c d e
PTO is defective
Checks before troubleshooting • Is oil level in hydraulic tank correct? Is the type of oil correct?
Cause Steering pump
Ask the operator about the following: • Did the problem suddenly start? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where? • Did the problem gradually appear? Wear of related parts, defective seal
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍
Oil pressure is low or there is no pressure in both directions (left and right).
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
Oil pressure is low or there is no pressure in one direction (left or right).
When joystick steering solenoid valve output pressure is measured, oil pressure is low.
11 When steering pump servo assembly is replaced, oil pressure is normal.
❍
❍ ❍
❍ ❍ ❍
❍ ❍ ❍ ❍ ❍
★ There is a close connection between the steering circuit and the work equipment circuit. If any abnormality is present in the steering, check the operation of the work equipment also.
40-736 b
WA500-6
TROUBLESHOOTING
H-12
H-12 Steering is Heavy Hydraulic pump
Charge valve
Orbitrol
Stop valve
Steering valve
Others
a
b
c
d
e
f
Defective accumulator charge valve
Defective Orbitrol
Defective stop valve
Defective actuation of steering spool
Defective actuation of steering wheel or steering shaft
Cause
Defective brake pump
Check for abnormality • Is the steering difficult to turn? See H-8 or H-9.
Remedy x
x
x
x
x
x
• Measure the operating effort and turning speed. Check the Standard Value table in Section 20 to see if the values are abnormal. Ask the operator about the following: • Did the problem suddenly start? Breakage of related equipment • Was there previously any symptom that could lead to heavy steering? Wear of related equipment, defective seal Checks before troubleshooting • Is oil level in hydraulic tank correct? Is the type of oil correct? • Is the tire inflation pressure correct?
No.
Diagnosis
1
Steering is heavy when turned in both directions (left and right).
2
Steering wheel is heavy in one direction (left or right).
3
Steering is heavy even when joint between steering shaft and Orbitrol is disconnected.
❍ ❍ ❍ ❍
❍ ❍ ❍ ❍
5
Oil pressure is low or there is no pressure in both directions (left and When steering relief right). pressure is measured Oil pressure is low or there is no pressure in one direction (left or right).
6
When Orbitrol output pressure is measured, oil pressure is low.
❍ ❍ ❍
4
7 8
Oil pressure is low.
When Orbitrol basic pressure is measured There is no oil pressure.
WA500-6
❍ ❍
❍ ❍ ❍
❍ ❍ ❍
40-737 b
TROUBLESHOOTING
H-13
H-13 When Machine Turns, It Shakes or Jerks
Charge valve
Orbitrol
Stop valve
a
b
c
d
e
f
g
h
i
Defective accumulator charge valve
Defective Orbitrol
Defective stop valve
Defective actuation of demand spool
Defective main relief valve
Defective actuation of steering spool
Defective safety-suction valve
Defect in steering cylinder (defective piston seal)
Remedy x
x
x
x
x
x
x
x
No.
Diagnosis
1
When machine turns, it shakes or jerks in both directions (left and right).
2
When machine turns, it shakes or jerks in one direction (left or right).
3
During operations or when traveling (steering is neutral), the machine shakes or jerks.
4
Machine jerks or there is excessive shock when steering is operated to end of its stroke.
5
Work equipment also jerks.
6 7 8 9
❍ ❍ ❍
❍ ❍
❍ ❍ ❍
When Orbitrol output Oil pressure is unstable in both directions (left and right). pressure is measured Oil pressure is unstable in one direction (left or right).
❍ ❍ ❍
40-738 b
❍ ❍ ❍
❍ ❍ ❍
❍ ❍ Q
10 When Orbitrol basic pressure is measured, oil pressure is unstable.
E
❍
When steering relief pressure is measured Oil pressure is unstable in one direction (left or right).
Oil pressure is unstable in both directions (left and right).
Cylinder
Checks before troubleshooting • Is the steering wheel play correct? • Is there any abnormality in the connection between the steering shaft and the Orbitrol? • Is the tire inflation pressure correct?
Steering valve
Hydraulic pump
Cause
Defective brake pump
Check for abnormality • Is the steering difficult to turn? See H-8. • Is there any abnormal noise from around the steering equipment?
❍ ❍ ❍ ❍
❍ ❍
❍ ❍ ❍
WA500-6
TROUBLESHOOTING
H-14
H-14 When Machine Turns, It Shakes or Jerks (Joystick Steering, if Equipped)
Charge valve
Joystick steering solenoid valve
Rotary valve
a
b
c
d
e
f
g
h
i
Defective accumulator charge valve
Defective operation in joystick steering solenoid valve
Defective actuation of rotary valve
Defective actuation of demand spool
Defective main relief valve
Defective actuation of steering spool
Defective safety-suction valve
Defect in steering cylinder (defective piston seal)
Remedy x
x
x
x
x
x
x
No.
Diagnosis
x
Cylinder
Checks before troubleshooting • Has the machine monitor displayed any failure code? See Troubleshooting by Failure Code in this section. • Is the steering play proper? • Is there any abnormality in the connection between the steering shaft and the Orbitrol? • Is the tire inflation pressure correct?
Steering valve
Hydraulic pump
Cause
Defective brake pump
Check for abnormality • Is the steering difficult to turn? See H-9. • Is there any abnormal noise from around the steering equipment?
❍ ❍ ❍ ❍ ❍ ❍ ❍
1
When machine turns, it shakes or jerks in both directions (left and right).
2
When machine turns, it shakes or jerks in one direction (left or right).
3
During operations or when traveling (steering is neutral), the machine shakes or jerks.
4
Work equipment also jerks.
❍ ❍
5
When steering relief Oil pressure is unstable in both directions (left and right). pressure is measured Oil pressure is unstable in one direction (left or right).
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
8
When Orbitrol output Oil pressure is unstable in both directions (left and right). pressure is measured Oil pressure is unstable in one direction (left or right).
9
When Orbitrol basic pressure is measured, oil pressure is unstable.
❍ ❍
6 7
WA500-6
❍ ❍
❍ ❍ ❍ ❍ ❍
40-739 b
TROUBLESHOOTING
H-15
H-15 Wheel Brake Does Not Work or Does Not Work Well Accumulator
Brake valve
Slack adjuster
c
d
e
f
g h
i
j
k
l
m
Defective brake pump
Defective accumulator charge valve
Gas leakage from accumulator, defective seal of piston
Defective brake valve
Defective slack adjuster
Brake piston seal is defective
x
x
When the brake pedal is pressed, only a little resistance is felt.
2
When the brake pedal is pressed, a heavy resistance is felt.
3
To get the specified braking force, extremely strong leg power is required.
4
When the brake works, an abnormal noise occurs from the brake.
5
Work equipment and steering wheel does not move.
6
Work equipment and steering wheel move slowly.
7
Abnormal noise comes from around PTO.
8
Abnormal noise comes from around hydraulic tank or brake pump.
9
A lot of metal powders are mixed in the oil when it is drained from the axle case.
10
When the accumulator charge pressure is measured, the oil pressure is low.
11 The brake does not work immediately when the engine is stopped.
x
❍ ❍ ❍ ❍
15 When wear of brake disc is measured, the amount of wear is large. 16 Air is discharged when the air is bled from the brake system.
40-740 b
Others
x x
x
x
x
❍
❍
❍
❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍
13 When brake pressure is measured, the oil pressure is low. When brake piston pressure effect is measured, the pressure effect is large.
x x
❍ ❍ ❍
12 The brake works after some time lag.
14
Improper axle oil
1
Air in brake circuit
Remedy x
Wear of brake disc
Diagnosis
Internal breakage of brake
No.
Defective operation of brake piston
Checks before troubleshooting • Is oil level and type of oil in hydraulic tank correct? • Is the play of brake pedal appropriate? • Has oil leaked from brake piping? Is tube deformed? • Are the tire air pressure and the tread state appropriate?
Wheel brake
Charge valve
b
Brake pump a
Air intake on suction side
Ask the operator about the following: • Has the brake suddenly not worked? Breakage of related equipment • Did any abnormal noise occur at the time and where? • Has the brake gradually not worked? Wear of related equipment, defective seal
Cause
PTO is defective
Check for abnormality • Test the effectiveness of the brake. Refer to BRAKE SYSTEM: Measuring Brake Performance in the Testing and Adjusting section to check whether the abnormality actually occurs or is the operator's opinion.
❍
❍ ❍ ❍ ❍
WA500-6
TROUBLESHOOTING
H-16
H-16 Wheel Brake is Not Released or It Drags
Seizure of brake disc plate
Wheel brake e
Remedy x
x
x
x
❍
❍
❍
1
The machine does not travel at all.
2
The machine travels a little.
3
When residual pressure in the brake accumulator circuit is released using only the brake pedal, the brake is released.
4
When air bleeder at wheel is opened, oil leaks out and the brake is released.
5
When air bleeder is opened, large amount of oil flows out.
6
When wear of brake disc is measured and the brake pedal is released, the piston returns.
7
When wear of brake disc is measured and the brake pedal is released, the piston does not return.
WA500-6
d Defective operation of brake piston
Diagnosis
c Defective operation of slack adjuster
No.
a
Defective brake valve
Checks before troubleshooting • Has the brake pedal returned completely? • Is the parking brake turned ON?
Slack adjuster
Cause Brake valve
Ask the operator about the following: • Was the brake locked suddenly? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where?
❍
❍ ❍ ❍ ❍ ❍
❍
40-741 b
TROUBLESHOOTING
H-17
H-17 Parking Brake Does Not Work or Does Not Work Well
No.
Remedy Diagnosis
1
The parking brake is not applied even if the engine stops.
2
When wear of parking brake disc is checked, the disc thickness is lower than standard value.
3 4 5 6
When the parking brake inlet pressure is measured
Valve
a
b
c
d
e
Defective parking brake emergency release valve
Defective parking brake spring
Defective operation of parking brake piston
Wear of parking brake disc
x
x
x
x
x
❍
❍
❍ ❍
With the parking brake switch ON, there is no oil pressure. (Normal) With the parking brake switch ON, there is oil pressure.
With the parking brake switch ON, there is no oil pressure. When the parking brake solenoid (Normal) valve output pressure is measured With the parking brake switch ON, there is oil pressure.
40-742 b
Solenoid
Checks before troubleshooting • Is the parking brake emergency release switch turned ON? • Has the mechanical release of parking brake been performed?
Parking brake
Cause
Defective parking brake solenoid valve
Ask the operator about the following: • Has the brake suddenly not worked? Breakage of related equipment • Did the machine cause any abnormal noise at the time and where? • Has the brake gradually not worked? Wear of related equipment, defective seal
❍ ❍
❍
❍
❍
❍
❍
❍
WA500-6
TROUBLESHOOTING
H-18
H-18 Parking Brake is Not Released or It Drags (Includes Emergency Release System)
d
e Defective operation of wheel brake emergency brake switch
Seizure of parking brake disc and plate
x
x
x
x
The parking brake is released when the emergency release switch is turned ON. (The parking brake switch does not release the brake.)
❍
❍
2
The parking brake is released when the parking brake is manually released. (The parking brake switch and emergency release switch do not release the brake.)
❍
❍
❍
❍
3 5
When the parking brake inlet pressure is measured (while operating the parking switch)
Oil pressure is normal. Oil pressure is low.
When the parking brake output pressure is measured Oil pressure is normal. (while operating the emergency release switch) Oil pressure is low.
❍
7
When the parking brake solenoid valve output pressure is measured, the oil pressure is low.
❍
8
When the wheel brake piping oil pressure is measured, the oil pressure is lower than the emergency brake working pressure (37 ±5 kg/cm² [522 ±71 psi]).
6
Wheel
Valve c
1
4
Parking brake
Solenoid
b
Defective seal of parking brake piston
Remedy Diagnosis
a
Defective parking brake emergency release valve
No.
Cause
Defective parking brake solenoid valve
Check of abnormality • Is there any abnormality in the power train system? See H-1, H-4, H-5, and H-6 (power train hydraulic system).
❍ ❍
❍
❍
❍
❍
❍
★ If any abnormality is present when releasing the parking brake, check the operation of the power train also because the power train main relief pressure is used as the parking brake release pressure. (The emergency release circuit uses the wheel brake circuit oil pressure.)
WA500-6
40-743 b
TROUBLESHOOTING
H-19
H-19 Lift Arm Does Not Rise
Bypass valve
Cylinder
b
c
d
e
f
g
h
i
j
Clogging or air intake on pump suction side
PTO is defective
Defective work equipment pump servo
Defective work equipment pump
Defective operation of main relief valve
Defective operation of unload valve
Defective operation of lift arm load check valve
Internal breakage of valve body (lift arm spool)
Defective operation of spool
Damaged lift arm cylinder piston seal
Diagnosis
Work equipment valve
a
Remedy C
x
x
x
x
x
x
x
x
x
Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is the stroke of the lift arm control lever correct? • Is the engine speed correct? • Has the machine monitor displayed any failure code? See Troubleshooting by Failure Code in this section.
No.
Cause Tank – Work equipment pump
Ask the operator about the following: • Did the bucket stop suddenly? Seizure or breakage of each component • Was there an abnormal sound when the lift arm stopped? From what part? • Has the speed dropped? Wear of parts and fatigue of springs
❍ ❍ ❍ ❍ ❍
1
Bucket does not move and lift arm does not rise.
2
Lift arm can raise chassis but does not rise.
❍
❍
3
Bucket moves but lift arm does not rise.
❍
❍
4
Lift arm can rise when not loaded but cannot when loaded.
❍
❍ ❍ ❍ ❍
5
Work equipment pump is making abnormal sounds.
❍
❍
6
Hydraulic drifts of the lift arm cylinder occur often.
7
When lift arm and bucket are operated simultaneously, lift arm does not rise.
8
When work equipment pump and servo assembly are replaced, lift arm moves normally.
40-744 b
❍ ❍ ❍ ❍ ❍ ❍
WA500-6
TROUBLESHOOTING
H-20
H-20 Lift Arm is Low or Rising Force is Insufficient Cause
e
f
g
h
i
Defective operation and defective adjustment of main relief valve
Defective operation of unload valve
Defective operation of ECSS charge valve
Defective operation of lift arm load check valve
Internal wear or breakage of valve body (lift arm spool)
Damaged lift arm cylinder piston seal
Cylinder
d
Remedy C x
x
x
x
1
Tilting force and speed of bucket are abnormal and rising speed of lift arm is low.
2
Tilting force and speed of bucket are normal and rising speed of lift arm is low.
3
After oil temperature rises, rising speed lowers more in Step 1.
4
Work equipment pump is making abnormal sounds.
5
Hydraulic drift of the cylinder is large.
6
Relief oil pressure of work equipment relief valve is low.
7
When work equipment pump and servo assembly are replaced, lift arm moves normally.
WA500-6
Work equipment valve c
Defective work equipment pump
Diagnosis
b
Defective work equipment pump servo
No.
a
Clogging or air intake on pump suction side
Check of abnormality • The problems with the rising force and rising speed are strongly related to each other. The rising speed lowers first. Measure the lift arm rising speed while it is loaded. Check the Standard Value table in Section 20 to see if the values are correct.
Tank – Work equipment pump
Checks before troubleshooting • Is the stroke of the lift arm control lever correct? • Is the engine speed correct?
A x x
x
C x
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
❍ ❍
❍
40-745 b
TROUBLESHOOTING
H-21
H-21 When Rising, Lift Arm Starts to Move Slowly at a Specific Height Check before troubleshooting •
Deformation of appearance of lift arm cylinder
Cause • Expansion of lift arm cylinder tube or internal damage ★ For other abnormal phenomena during lift arm rise, see H-20: Lift Arm is Low or Rising Force is Insufficient.
H-22 Lift Arm Cylinder Cannot Hold Down Bucket (Bucket Floats) See H-20: Lift Arm is Low or Rising Force is Insufficient. Check before troubleshooting •
Is the stroke of the lift arm control lever appropriate?
Cause • •
Defective seat of suction valve on the lift arm cylinder head side of work equipment valve Oil leak from lift arm cylinder piston seal
H-23 Hydraulic Drifts of the Lift Arm Occur Often Ask the operator about the following: • •
Have hydraulic drifts suddenly started to occur often? Waste pinched in valve or damage of parts Have hydraulic drifts gradually started to occur often? Wear of parts
Check before troubleshooting •
Is the lift arm spool at the neutral holding position? The spool detent is defective.
Check for abnormality •
Check the hydraulic drift of the lift arm in the Standard Value table.
Cause • • •
Oil leakage in lift arm cylinder Imperfect fitting of load check valve on bottom side Imperfect fitting of lift arm spool
40-746 b
WA500-6
TROUBLESHOOTING
H-24
H-24 Lift Arm Wobbles During Operation The bucket and the lift arm move up and down as the topography changes during digging or leveling with the lift arm control lever in the HOLD position. Diagnosis and Cause First check the hydraulic drift and see if the lift arm cylinder can lift the machine. 1.
When the hydraulic drift is more than the standard value, see H-23: Hydraulic Drifts of Lift Arm Occur Often.
2.
When the lift arm cylinder cannot lift the machine, see H-20: Lift Arm Speed is Low or Rising Force is Insufficient.
3.
When the lift arm cylinder starts to lift the machine after the lift arm is operated several times with the normal hydraulic drift and after the lift arm cylinder operates to full stroke The cause is vacuum generated inside the cylinder. ★ Frequent hydraulic drifts The suction valve on the lift arm cylinder rod side is defective.
WA500-6
40-747 b
TROUBLESHOOTING
H-25
H-25 Bucket Does Not Tilt Back Cause
d
e
f
g
h
i
j
Defective work equipment pump
Defective operation of main relief valve
Defective operation of unload valve
Defective operation of bucket bottom safety valve (Suction safety valve)
Defective operation of bucket bottom suction valve (Suction safety valve)
Internal breakage of valve body (bucket spool)
Damaged bucket cylinder piston seal
Remedy C x
x
x
x
x
x
C x x
x
❍ ❍ ❍ ❍ ❍
1
Lift arm does not move and bucket does not tilt back.
2
Bucket can raise chassis but does not tilt back.
3
Lift arm moves but bucket does not tilt back.
4
Bucket can tilt back when not loaded but cannot when used for digging or scooping. ❍
5
Work equipment pump is making abnormal sound.
6
Hydraulic drift of bucket cylinder is large.
7
When lift arm and bucket are operated simultaneously, bucket does not tilt back.
8
When work equipment pump and servo assembly is replaced, bucket moves normally.
40-748 b
Cylinder
c
Defective work equipment pump servo
Diagnosis
b
PTO is defective
No.
a
Clogging or air intake on pump suction side
Checks before troubleshooting • Is the oil level in the hydraulic tank correct? • Is the stroke of the bucket control lever correct? • Is the engine speed correct? • Has the machine monitor displayed any failure code? See Troubleshooting by Failure Code in this section.
Work equipment valve
Tank – Work equipment pump
Ask the operator about the following: • Did the bucket stop suddenly? Seizure or breakage of each component • Was there an abnormal sound when the bucket stopped? From what part? • Has the speed dropped? Wear of parts and fatigue of springs
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
❍
❍ ❍ ❍ ❍ ❍ ❍ ❍
WA500-6
TROUBLESHOOTING
H-26
H-26 Bucket Speed is Low or Tilting-Back Force Is Insufficient Cause
e
f
g
h
i
j
k
Defective operation and defective adjustment of main relief valve
Defective operation of unload valve
Defective operation of ECSS charge valve
Defective operation of bucket bottom safety valve (Suction safety valve)
Defective operation of bucket bottom suction valve (Suction safety valve)
Internal wear or breakage of valve body (bucket spool)
Damaged bucket cylinder piston seal
x
x
C x x x
Remedy C x x
A x
1
Rising force and speed of lift arm are abnormal and tilting-back force and speed of ❍ ❍ ❍ ❍ ❍ ❍ bucket are low.
2
Rising force and speed of lift arm are normal and tilting-back force and speed of bucket are low.
3
After oil temperature rises, tilting back speed lowers more in Step 1.
4
Work equipment pump is making abnormal sounds.
5
Hydraulic drift of the cylinder is large.
6
Relief oil pressure of relief valve of work equipment valve is low.
7
When work equipment pump and servo assembly are replaced, bucket moves normally.
WA500-6
Cylinder
Work equipment valve c
Defective work equipment pump
Diagnosis
b
Defective work equipment pump servo
No.
a
Clogging or air intake on pump suction side
Check of abnormality • Check by actual operation that the tilting back force is insufficient. • Measure the operating speed of the bucket and check it in the Standard Value table.
Tank – Work equipment pump
Checks before troubleshooting • Is the stroke of the bucket control lever correct? • Is the engine speed correct?
x
❍ ❍ ❍ ❍ ❍ ❍
❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
40-749 b
TROUBLESHOOTING
H-27
H-27 Bucket Starts to Operate Slowly in the Midst of Tilting Back Check before troubleshooting •
Deformation of appearance of bucket cylinder
Cause • •
Expansion of bucket cylinder tube or internal damage For other abnormal phenomena during bucket operation, see H-26: Bucket Speed is Low or Tilting-Back Force is Insufficient.
H-28 Bucket Cylinder Cannot Hold Down the Bucket See H-26: Bucket Speed is Low or Tilting-Back Force is Insufficient. Check before troubleshooting •
Is the stroke of the bucket control lever appropriate?
Cause • •
Defective seat of suction valve (with suction valve) on the bucket cylinder head side of work equipment valve Oil leak from bucket cylinder piston seal
H-29 Hydraulic Drifts of the Bucket Occur Often Ask the operator about the following: • •
Have hydraulic drifts suddenly started to occur often? Waste pinched in valve or damage of parts Have hydraulic drifts gradually started to occur often? Wear of parts
Check before troubleshooting •
Is the bucket spool at the neutral position? The spool detent is defective.
Check for abnormality •
Refer to the Standard Value table and check if the hydraulic drift of the bucket occurs often.
Cause • • •
Oil leak in bucket cylinder Improper adhesion of safety valve (with suction valve) on the bottom side Improper oil tight of bucket spool
40-750 b
WA500-6
TROUBLESHOOTING
H-30
H-30 Bucket Wobbles During Travel with Load (The work equipment valve is set to HOLD.) Cause • •
Defective seal of bucket cylinder piston Defective operation of safety valve (with suction valve) on bucket cylinder head side. For other abnormal phenomena, refer to diagnoses for relevant abnormal phenomena.
H-31 During Operation of Machine, Engine Speed Drops Remarkably or Engine Stalls Check before troubleshooting •
Is the working equipment main relief pressure normal?
Cause • • • •
Defective work equipment pump servo Defective working equipment pump unit Defective working equipment pump servo EPC input voltage Defective engine system
H-32 Large Shocks When Work Equipment Starts and Stops Cause • •
Defective operation of control valve spool Defective working equipment electric lever system See Troubleshooting by Failure Code in this section.
H-33 When Work Equipment Circuit is Relieved Singly, Other Work Equipment Moves Cause •
Pressure is not released properly from main spool of moving equipment Replace main spool.
WA500-6
40-751 b
TROUBLESHOOTING
H-34
H-34 ECSS Does Not Operate; Pitching and Bouncing Occur
The ECSS actuation speed (5 km/h [3 mph]) largely fluctuates.
2
The ECSS does not operate under no load.
3
When the ECSS operates under load, the lift arm lowers to the maximum distance (30 cm [11.8 in] or more).
4
The ECSS does not operate at all.
40-752 b
Controller
Sensor
c
d
x
Defective transmission output shaft speed sensor
1
b
Defective operation of work equipment controller
Remedy Diagnosis
Accumulator
No.
a
Gas leakage from accumulator, defective seal
Checks before troubleshooting • Is the state of ECSS switch correct?
Solenoid valve
Cause
Defective ECSS solenoid valve
Ask the operator about the following: • Did pitching and bouncing occur suddenly? Breakage of related equipment • Did any abnormal noise occur at the time and where? • Has pitching and bouncing occurred gradually? Wear of related equipment, defective seal
x
x
A x
❍
❍
❍
❍ ❍
❍
❍
❍
❍
WA500-6
50
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6 Removal and Installation of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6 Disassembly and Assembly of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8 COATING MATERIALS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10 SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14 SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19 CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26 Stripping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26 Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26 Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27 Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28 Insertion of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29 Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30 Crimping Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31 Insertion of Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32 ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44 Air Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46 Cooling Fan and Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-49 Radiator Guard and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-53 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56 Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60 Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-65 WA500-6
50-1 b
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85 Engine Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89 Engine Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99 Torque Converter and Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-106 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112 Input Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-118 Torque Converter (Lockup Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131 Torque Converter (Without Lockup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-148 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-156 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-156 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-175 Transfer and Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-196 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-197 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-207 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-219 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-219 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-221 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-222 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-222 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-224 Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-225 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-225 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-226 Differential (with Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-227 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-227 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-233 Differential (without Limited Slip Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-245 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-245 50-2 b
WA500-6
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-251 Final Drive (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-264 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-269 Brakes (Front and Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-269 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-269 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-272 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-276 Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-280 Brake Accumulator Charge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-281 UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-282 Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-282 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-283 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-287 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-292 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-292 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-292 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-296 Cooling Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-297 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-297 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-298 Fan Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-299 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-299 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-300 Work Equipment Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-301 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-301 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-303 Steering, Torque Converter Charge, and EPC Pump Assembly . . . . . . . . . . . . . . . . . . 50-304 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-304 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-305 Work Equipment Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-306 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-306 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-309 Work Equipment Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-310 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-310 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-314 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-314 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-317 Lift Arm and Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-319 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-319 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-323 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-328 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-328 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-329 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-330 Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-330 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-330 WA500-6
50-3 b
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-334 Counterweight (Large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-336 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-336 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-337 Counterweight (Small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-338 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-338 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-338 CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-339 Cab (Separate Cab and Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-339 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-339 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-346 Cab and Floor Frame (Cab-Floor Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-347 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-352 Cab Glass (Stuck Glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-353 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-354 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-355 Operator Seat (Upper Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-363 Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-363 Seat Pad and Backrest Upholstery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-363 Mechanical Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-364 Armrests (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-365 Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-366 Backrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-368 Seat Angle and Seat Depth Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-369 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-371 Slide Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-372 Operator Seat (Suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-373 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-373 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-373 Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-374 Bowden Pull Wire and Handle (Vertical Shock Absorber Adjustment) . . . . . . . . . 50-376 Vertical Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-380 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-382 Height Level Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-386 Compressed-Air Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-392 Bowden Pull Wires and Handle (Height Adjustment) . . . . . . . . . . . . . . . . . . . . . . . 50-396 Pneumatic Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-400 Air Tank for Additional Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-402 Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-404 Suspension System (Upper Part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-406 Suspension System (Lower Part) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-410 Swinging Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-414 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-418 Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-418 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-418 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-418 Transmission Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-419 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-419 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-419 50-4 b
WA500-6
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
Work Equipment Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-420 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-420 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-420 KOMTRAX Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-421 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-421 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-421 Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-422 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-422 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-426
WA500-6
50-5 b
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL Removal and Installation of Assemblies Special Tools • • 1.
The special tools necessary for the removal and installation work are indicated by the symbols A1, ••• X1. Their part numbers, part names, and quantity are described in the Special Tools List table. The following information is also described in the table. Necessity ■: Special tools that cannot be substituted and should always be used (installed). ●: Special tools that will be useful, if available, and can be substituted with commercially available tools.
2.
Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number. R: Tools with upgraded part numbers. They are remodeled from tools already available for other models. Blank: Tools already available for other models. They can be used without any modification.
3.
Circle mark O in sketch column: • The sketch of the special tool is presented in Sketches of Special Tools in this section. • Part No. of special tools starting with 79*T-***-**** means that these tools are not available from Komatsu. The tools are made locally.
Removal •
•
•
The Removal section contains procedures and precautions for implementing the work, expertise, and the amount of oil or coolant to be drained. General tools that are necessary for removal are indicated by [1], [2], etc. Their part numbers, part names, and quantity are not described. Various symbols used in the Removal section are explained and listed in the table to the right.
Indicates safety-related precautions that must be followed when implementing the work. ★
Technique or precautions for work.
[*1]
Indicates that there are instructions or precautions for installing parts. Indicates the amount of oil or coolant to be drained.
Indicates the weight of part or component.
50-6 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
Installation • •
•
•
Except where otherwise instructed, installation of parts is done in the reverse order of removal. Instructions and precautions for installing parts are shown with the [*1] mark in the Installation section, identifying the step for which the instructions are intended. General tools necessary for the installation work are indicated by [1], [2], etc. Their part numbers, part names, and quantity are not described. Marks shown in the Installation section are listed and explained in the table to the right.
Sketches of Special Tools •
Special tools are illustrated for the convenience of local manufacture.
WA500-6
Precautions related to safety in execution of work. ★
Mark provides guidance or precautions when doing the procedure.
Type of coating material.
Tightening torque.
Quantity of oil or coolant to be added.
50-7 b
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
12 Disassembly and Assembly of Assemblies Special Tools • • 1.
The special tools necessary for the disassembly and assembly work are indicated by the symbols A1, ••• X1. Their part numbers, part names, and quantity are described in the Special Tools List table. The following information is also described in the table. Necessity ■: Special tools that cannot be substituted and should always be used (installed). ●: Special tools that will be useful, if available, and can be substituted with commercially available tools.
2.
Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number. R: Tools with upgraded part numbers. They are remodeled from tools already available for other models. Blank: Tools already available for other models. They can be used without any modification.
3.
Circle mark O in sketch column: • The sketch of the special tool is presented in Sketches of Special Tools in this section. • Part No. of special tools starting with 79*T-***-**** means that these tools are not available from Komatsu. The tools are made locally.
Remark General tools that are necessary for removal or installation are described as [1], [2], etc. Their part names, part numbers, and quantities are not described. Disassembly •
•
•
The Disassembly section describes the work procedures, precautions, and expertise for carrying out disassembly procedures, and the quantity of the oil and coolant drained. General tools that are necessary for the disassembly work are indicated by [1], [2], etc. Their part numbers, part names, and quantity are not described. The meaning of the symbols used in the Disassembly section are explained and listed in the table to the right.
50-8 b
Indicates safety-related precautions that must be followed when implementing the work. ★
Technique or precautions for work. Indicates the quantity of oil or coolant to be drained.
WA500-6
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
Assembly •
•
•
The Assembly section describes the work procedures, precautions, and expertise for carrying out assembly procedures, and the quantity of the oil and coolant added. General tools necessary for the assembly work are indicated by [1], [2], etc. Their part numbers, part names, and quantity are not described. The meaning of the symbols used in the Assembly section are listed and explained in the table to the right.
Precautions related execution of work. ★
to
safety
in
Mark provides guidance or precautions when doing the procedure.
Type of coating material.
Sketches of Special Tools •
Special tools are illustrated for the convenience of local manufacture.
Tightening torque.
Quantity of oil or coolant to be added.
WA500-6
50-9 b
DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
COATING MATERIALS LIST ★ The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed in the following table. ★ For coating materials not listed in the table, use the equivalent of products shown in this manual. Category Komatsu Code
Adhesive
LT-1A
Container
Main Features and Applications
790-129-9030
150 g
Tube
• Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
• Features: Resistance to heat and chemicals. • Used to fix and seal bolts and plugs.
LT-3
790-129-9060 (Set of adhesive and hardener)
Adhesive: 1 kg Hardener: 500 g
Can
• Used to stick and seal metal, glass, and plastics.
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-129-9120
75 g
Tube
50 g
Polyethylene container
• Quick-setting adhesive. • Setting time: Within 5 sec. to 3 min. • Used mainly to stick metals, rubbers, plastics, and woods.
2g
Polyethylene container
• Quick-setting adhesive. • Quick-setting type (max. strength is obtained after 30 minutes). • Used mainly to stick rubbers, plastics, and metals. • Features: Resistance to heat and chemicals. • Used for fitted portions used at high temperatures.
Aron-alpha 201
Gasket sealant
Qty
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
ThreeBond 1735
790-129-9140
790-129-9130
• Used to seal plugs. • Heat-resistant seal used to repair engines.
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
• Used to stick or seal gaskets and packings of power train case, etc.
1 kg
Polyethylene container
• Used to seal various threaded portions, pipe joints, and flanges. • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-5
LG-6
50-10 b
Part Number
790-129-9080
790-129-9020
200 g
WA500-6
DISASSEMBLY AND ASSEMBLY Category Komatsu Code
LG-7
Gasket sealant
LG-8 ThreeBond 1207B
Part Number
790-129-9070
419-15-18131
COATING MATERIALS LIST Qty
1 kg
100 g
Container
Main Features and Applications
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat- and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
LG-9 ThreeBond 1206D
790-129-9310
200 g
Tube
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case, etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
Can
• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins, and bolts of various links, etc.
–
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
09940-00040
200 g
Molybdenum disulfide lubricant
LM-P
Grease
Seizure prevention compound
–
LC-G NEVER-SEEZ
09995-00250
–
SYG2-400LI SYG2-350LI G2-LI SYG2-400LI-A G0-LI SYG2-160LI *For cold district SYGA-160CNLI SYG0-400LI-A (*) SYG0-160CNLI (*)
WA500-6
190 g
50-11 b
DISASSEMBLY AND ASSEMBLY
Grease
Category Komatsu Code
Molybdenum disulfide grease LM-G (G2-M)
SYG2-400M SYG2-400M-A SYGA-16CNM
Hyper White Grease G2-T, G0-T (*) *For cold district
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
Biogrease SYG2-400B G2-B, G2-BT (*) SYGA-16CNB *For use at high SYG2-400BT (*) temperature and SYGA-16CNBT (*) under high load
G2-S ThreeBond 1855
G2-U-S ENS grease
50-12 b
Part Number
–
427-12-11871
COATING MATERIALS LIST Qty
Container
Main Features and Applications
400 g x 10 400 g x 20 16 kg
Bellows-type container Can
• Used for parts under heavy load. ★ Caution: • Do not apply grease to rolling bearings like swing circle bearings, etc., and spline. • The grease should be applied to work equipment pins at their assembly only, not applied for greasing afterwards.
400 g
Bellows-type container Can
• Seizure resistance, heat resistance, and water resistance higher than molybdenum disulfide grease. • Not conspicuous on machine since it is white in color.
Bellows-type container Can
• Since this grease is decomposed by natural bacteria in a short period, it has less effects on microorganisms, animals, and plants.
Tube
• Feature: Silicone grease with wideusing temperature range, high resistance to thermal-oxidative degradation, and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing, and oil seal in damper. ★ Caution: Do not mix with lithium grease.
16 kg
400 g 16 kg
200 g
2 kg
WA500-6
DISASSEMBLY AND ASSEMBLY
Part Number
SUNSTAR PAINT PRIMER 580 SUPER
SUNSTAR PAINT PRIMER 435-95
Main Features and Applications
20 ml
Glass container
• Used as primer for cab side. (Using limit: Four months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: Four months after date of manufacture)
20 ml
Glass container
417-926-3910
22M-54-27230
• Used as primer for painted surface on cab side. (Using limit: Four months after date of manufacture)
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: Four months after date of manufacture) Adhesive for cab glass
22M-54-27240
• Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: Four months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
Sika Japan Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: Six months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
• Used as adhesive for glass. (Using limit: Six months after date of manufacture)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
WA500-6
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220
333 ml
Cartridge
Adhesive for cab glass
Adhesive Caulking material
Container
SUNSTAR GLASS PRIMER 435-41
Adhesive
Primer
SUNSTAR GLASS PRIMER 580 SUPER
Qty
Adhesive for cab glass
Category Komatsu Code
COATING MATERIALS LIST
• Used as adhesive for glass. “S” is used for high-temperature season and “W” for lowtemperature season. (Using limit: Four months after date of manufacture)
• Used to seal joints of glass parts. (Using limit: Four months after date of manufacture) • Used to seal front window. • (Using limit: Six months after date of manufacture) • Used to seal joint of glass. • Translucent white seal • (Using limit: 12 months after date of manufacture)
50-13 b
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
SPECIAL TOOLS LIST ★ Tools with part number 79*T-***-**** are not available from Komatsu; these items are manufactured locally. ★ Necessity: ■ Cannot be substituted; should always be installed (used). ●
Extremely useful if available; can be substituted with commercially available tools.
★ 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; can be used without any modification.
Work item
Symbol
Part No.
795-630-5500 Removal of fuel supply pump
1
Angle tightening of head bolt
Removal and installation of engine front seal and engine rear seal
• Bolt
■ 2
01643-31032
• Washer
■ 2 ■ 1
3
795-931-1100
Seal puller
■ 1
795T-521-1111 Push tool
■ 1 N ❍
01050-31655
Bolt
■ 3
01050-31635
Bolt
■ 3
Removal of oil seal
Press-fitting of engine front seal
795T-521-1150 Push tool
■ 1 N ❍ Press-fitting of engine front seal
01050-31635
■ 3
5 Bolt
795T-421-1260 Push tool
■ 1 N ❍
01050-31640
Bolt
■ 4
01643-31645
Washer
■ 8
795T-421-1240 Push tool
■ 1 N ❍
01050-31645
Bolt
■ 4
01643-31645
Washer
■ 4
(sleeve type)
Press-fitting of engine rear seal (standard type)
795T-421-1231 Push tool
Press-fitting of engine rear seal (sleeve type) ■ 1 N ❍
01050-31645
Bolt
■ 4
01643-31645
Washer
■ 8
1
795-101-2102
Puller (294 kN {30 ton})
■ 1
Removal of turbine boss
2
793-613-1210
Wrench
■ 1
Removal and installation of pump nut
8
50-14 b
01010-81090
Wrench
6
Nature of Work, Remarks
■ 1
790-331-1110
7
Disassembly and assembly of torque converter assembly
Standard puller
2
4
A
Part Name
Necessity Qty New/Remodel Sketch
★ Tools marked ❍ in the Sketch column are tools for which sketches are provided in Sketches of Special Tools in this section.
F
WA500-6
Work item
SPECIAL TOOLS LIST
Symbol
Part No.
Necessity Qty New/Remodel Sketch
DISASSEMBLY AND ASSEMBLY
Nature of Work, Remarks
1
799-301-1500
Oil leak tester
■ 1
Operation check of clutch piston
796-514-2000
Remover
■ 1
796-515-2140
Adapter
1
790-201-1702
Push tool kit
1
Part Name
2 Disassembly and assembly of transmission
790-201-1741
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
■ 1
790-101-2501
Push puller
■ 1
790-101-2610
• Leg
1
790-101-2660
• Adapter
1
790-101-2510
• Block
1
790-101-2560
• Nut
1
01643-32060
Washer
■ 2
790-101-2102
Puller (294 kN {30 ton})
■ 2
790-101-1102
Pump
■ 6
790-101-2501
Push puller
■ 1
790-101-2540
• Washer
1
790-101-2620
• Leg
2
790-101-2510
• Block
1
790-101-2660
• Adapter
2
790-101-2560
• Nut
2
791-112-1180
• Nut
1
3
4
G
Disassembly and assembly of transfer assembly
5
Press-fitting of No. 3 and No. 4 carrier bushings
Removal of output shaft
791-520-4140
WA500-6
Removal of No. 3 planetary gear shaft
Screw
Press-fitting of output shaft bearing
■ 1
793T-615-1630 Adapter
■ 1 N ❍
793T-615-1640 Push tool
■ 1 N ❍
01643-32060
Washer
■ 2
790-101-2102
Puller (294 kN {30 ton})
■ 1
790-101-1102
Pump
■ 1
6
793-615-1140
Spline wrench
■ 1
Preload adjustment on intermediate shaft bearing
7
796-720-3800
Wrench assembly
■ 1
Preload adjustment on input shaft bearing
50-15 b
Work item
Symbol
1 Disassembly and assembly of differential assembly
SPECIAL TOOLS LIST
Part No.
Part Name
790-501-5000
Repair stand
■ 1
790-901-4110
Bracket
■ 1
793T-622-2120 Plate
■ 1 N ❍
792-103-0901
Wrench
■ 1
1
792-525-1000
Micrometer
■ 1
2
793T-822-1310 Adapter
■ 1 N ❍
792T-422-1220 Plate
■ 1 N ❍
790-101-5421
Grip
■ 1
01010-81240
Bolt
■ 1
6 7
2
3
Disassembly and assembly of final drive assembly
H
Necessity Qty New/Remodel Sketch
DISASSEMBLY AND ASSEMBLY
793T-622-2210 Fixture
■ 3 N ❍
792-520-2110
Installer
■ 1
791-580-1600
Push tool
■ 1
791-580-1610
• Plate
1
791-580-1620
• Arm
4
791-580-1640
• Plate
1
791-580-1650
• Plate
4
01010-51425
• Bolt
8
01541-21670
• Nut
4
01640-21426
• Washer
4
4
Disassembly and assembly of brake assembly
50-16 b
792-530-1630
Stud
■ 4
792-520-2110
Installer
■ 1
793T-622-2310 Plate
■ 1 N ❍
793T-622-2320 Arm
■ 4 N ❍
791-580-1640
Plate
■ 1
792-530-1630
Stud
■ 4
01010-61425
Bolt
■ 4
01640-21426
Washer
■ 4
01580-01613
Nut
■ 4
5
Nature of Work, Remarks
Removal and installation of differential
Bearing preload adjustment –
Press-fitting of outer drum oil seal
Removal and installation of wheel hub and brake, disassembly and assembly of brake
Installation of floating seal (gear side)
Installation of floating seal (hub side)
WA500-6
Work item
Symbol
Press-fitting of upper hinge pin
SPECIAL TOOLS LIST
Part No.
Part Name
793-520-2630
Bar
■ 2
–
2
793-520-2640
Push puller
■ 1
–
3
793-520-2550
Guide
■ 1
–
4
790-101-2300
Push puller
■ 1
–
5
790-101-2310
• Block
1
–
6
02215-11622
• Nut
2
–
7
790-101-2102
Puller (294 kN {30 ton})
■ 1
–
8
790-101-1102
Pump
■ 1
–
1
793-520-2530
Guide
■ 1
–
2
01010-31480
Bolt
■ 2
–
3
01643-31445
Washer
■ 2
–
4
793-520-2640
Push puller
■ 1
–
5
790-101-2102
Puller (294 kN {30 ton})
■ 1
–
6
790-101-1102
Pump
■ 1
–
1
790-502-1003
Repair stand
■ 1
–
2
790-101-1102
Pump
1
–
790-102-4300
Wrench assembly
■ 1
790-102-4310
Pin
■ 2
790-302-1290
Socket (Width across flats: 60 mm)
■ 1
Removal and installation of steering cylinder nut
1
790-201-1500
Push tool kit
■ 1
Press-fitting of dust seal
2
790-201-1590
• Plate
■ 1
Steering cylinder
4 3
790-201-1680
• Plate
1
Bucket cylinder
4 790-101-5021
• Grip
1
5 01010-50816
• Bolt
1
1 790-201-1702
Push tool kit
K
2
1
2
3
Disassembly and assembly of hydraulic cylinder assembly
U
Nature of Work, Remarks
1
1
Press-fitting of lower hinge pin
Necessity Qty New/Remodel Sketch
DISASSEMBLY AND ASSEMBLY
Removal and installation of piston
All cylinders ■ 1
Press-fitting of roll bushing
2 790-201-1781
• Push tool
1
Steering cylinder
5 3 790-201-1871
• Push tool
1
Bucket cylinder
4 790-101-5021
• Grip
1
5 01010-50816
• Bolt
1
All cylinders
WA500-6
50-17 b
Work item
Disassembly and assembly of hydraulic cylinder assembly
Operator's cab glass
Nature of Work, Remarks
1 790-720-1000
Expander
■ 1
Expansion of piston ring
2 796-720-1660
Ring
■ 1
3 07281-01159
Clamp
■ 1
Ring
■ 1
5 07281-01589
Clamp
■ 1
6 796-720-1690
Ring
■ 1
7 07281-01919
Clamp
■ 1
1
793-498-1120
Clear plate
■ 2
2 2
793-498-1130
Plate
■ 2
3
793-498-1110
Magnet
■ 2
793-498-1210
Lifter (Suction cup)
■ 2
Symbol
Part No.
U 6 4 796-720-1680
Part Name
X 3
50-18 b
SPECIAL TOOLS LIST Necessity Qty New/Remodel Sketch
DISASSEMBLY AND ASSEMBLY
Steering cylinder
Lift arm cylinder
Bucket cylinder
Installation of operator's cab glass
WA500-6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. A4 Push Tool
A5 Push Tool
WA500-6
50-19 b
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. A6 Push Tool
A7 Push Tool
50-20 b
WA500-6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. A8 Push Tool
G5 Adapter
WA500-6
50-21 b
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. G5 Push Tool
H1 Plate
50-22 b
WA500-6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. H2 Plate
H3 Fixture
WA500-6
50-23 b
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. H5 Plate
H5 Arm
50-24 b
WA500-6
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Remark Komatsu does not accept any responsibility for special tools manufactured according to these sketches. H6 Adapter
WA500-6
50-25 b
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
CONNECTOR REPAIR PROCEDURES These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
Stripping Insulation After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or corroded sections of the wire being repaired referring to the table below. Deutsch Terminal Part Number
Wire Gauge Range
Strip Length: mm (in)
0460 - 202 - 20141 0462 - 201 - 20141
20 AWG 20 AWG
3.96 - 5.53 (0.156 - 0.218) 3.96 - 5.53 (0.156 - 0.218)
0460 - 202 - 16141 0462 - 201 - 16141
16, 18 and 20 AWG 16, 18 and 20 AWG
6.35 - 7.92 (0.250 - 0.312) 6.35 - 7.92 (0.250 - 0.312)
0460 - 215 - 16141 0462 - 209 - 16141
14 AWG 14 AWG
6.35 - 7.92 (0.250 - 0.312) 6.35 - 7.92 (0.250 - 0.312)
0460 - 204 - 12141 0462 - 203 - 12141
12 and 14 AWG 12 and 14 AWG
5.64 - 7.21 (0.222 - 0.284) 5.64 - 7.21 (0.222 - 0.284)
0460 - 204 - 08141 0462 - 203 - 08141
8 and 10 AWG 8 and 10 AWG
10.92 - 12.47 (0.430 - 0.492) 10.92 - 12.47 (0.430 - 0.492)
0460 - 204 - 0490 0462 - 203 - 04141
6 AWG 6 AWG
10.92 - 12.47 (0.430 - 0.492) 10.92 - 12.47 (0.430 - 0.492)
Using wire insulation strippers, remove only the measured amount of insulation from the wire according to the size contact terminal listed in the "Strip Length" above.
Wire Inspection After stripping insulation from wire, inspect wire strands for: • Corrosion, straightness and uniformity • Broken or nicked wire strands are unexcitable and may cause high resistance in the circuit. • Do not twist or wrap the wire strands as this may cause wire strand breakage during the crimping process.
50-26 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Contact Terminal Removal (HD30 Type) 1.
Obtain the correct removal tool according to the wire size used in the connector.
2.
With the rear insert part of the connector facing you, snap the removal tool over the wire of the contact terminal you will be removing.
Remark Using a removal tool that is too large or too small will hinder wire removal and may damage the connector or removal tool. Always use the correct removal tool size for the wire gauge you are servicing. 3.
In a straight line, carefully slide the removal tool along the wire and into the grommet until a contact resistance is felt.
Remark Do not pull on the wire or twist the tool when inserting removal tool into the grommet. Damage to the tool or connector may result.
4.
Once tool is fully inserted into the connector, carefully pull the removal tool and contact terminal-wire out of the connector.
5.
If contact terminal-wire will not come out, remove tool and reinsert removal tool again.
WA500-6
50-27 b
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Crimping Contact Terminal (HD30 Type) 1.
After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
50-28 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Insertion of Contact Terminal (HD30 Type) 1.
Grasp contact terminal approximately 25 mm (1 in) behind the crimped barrel.
2.
Hold connector with rear grommet facing you.
3.
Insert completed contact terminal straight into connector grommet until a positive stop is felt.
4.
Once contact terminal is in connector, a slight tug will confirm that the contact terminal is properly locked in place.
5.
For unused wire cavities, insert enviroN•mental sealing.
WA500-6
sealing
plugs for full
50-29 b
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Contact Terminal Removal (DT Type) 1.
Remove the wedge lock using needle nose pliers or a hooked shaped wire.
2.
Pull the wedge lock straight out and save for reinstallation.
3.
To remove the contact terminal gently pull the wire backwards while at the same time releasing the locking finger by pushing it away from the terminal with a small screwdriver.
4.
Hold the rear seal grommet in place and pull the contact terminal out of the connector.
50-30 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Crimping Contact Terminal (DT Type) 1.
After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool #HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
WA500-6
50-31 b
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
Insertion of Contact Terminal (DT Type) 1.
Grasp the crimped contact terminal approximately 25mm (1in) behind the crimped barrel.
2.
Hold the connector with the rear grommet facing you and insert the completed wire into the connector.
3.
Push the contact terminal straight into the connector until a "click" is felt. A slight tug will confirm that the contact terminal is properly locked in place.
4.
Once all contact terminals are in place, insert the wedge lock with the arrow pointing toward exterior locking mechanism. The wedge lock will snap into place. Rectangular wedges are not oriented and may fit either way.
Remark As the connector receptacle is shown - use the same procedures for a plug.
50-32 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
MEMORANDUM
WA500-6
50-33 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
ENGINE AND COOLING SYSTEM Engine WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
WARNING!
Immediately after stopping the engine, the coolant is VERY HOT and the pressure inside the radiator is high. Removing the cap and draining the coolant under this condition could cause burns. Allow the engine to cool down and then turn the cap slowly to release the pressure.
WARNING!
When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it.
Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the engine hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
4.
Set jack [1] under the transmission.
50-34 b
WA500-6
DISASSEMBLY AND ASSEMBLY 5.
Remove two breather tube support U-bolts (1).
6.
Disconnect wiring harness clamp (2).
7.
Remove bracket (3).
8.
Remove cover (4).
9.
Remove rear breather tube (5).
ENGINE AND COOLING SYSTEM
10. Remove right and left covers (6). 11. Remove partition plate (7).
12. Loosen the clamp and remove air connector and hose assembly (8). 13. Loosen the clamp and remove tube (9) between the turbocharger and air aftercooler. [*1] 14. Loosen hose clamps (10) between the air cleaner and turbocharger and remove air cleaner band (11) and air cleaner assembly (12). [*2]
WA500-6
50-35 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
15. Remove air cleaner bracket (13).
16. Disconnect heater hose (14). 17. Remove partition rubber plates (15) and (16). ★ Disconnect partition rubber plate (16) and move it to the right.
18. Remove hose clamps (17); disconnect hoses (18); and remove prefilter assembly (19).
19. Disconnect connector E16 (20). 20. Remove the air compressor belt; remove and move air compressor assembly (21) outward. [*3] 21. Disconnect fuel supply hose (22).
50-36 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
22. Disconnect hose (23); remove the clamp and fuel return tube (24). [*4]
23. Disconnect fan drive motor hoses (25). 24. Remove fan drive motor tube clamp (26) and hose clamp (27) between the torque converter cooler and pump. 25. Remove fan pump tube (28).
26. Disconnect fuel tank breather (29) and remove crossbar (30).
27. Remove cover (31) and disconnect engine drain valve (32).
WA500-6
50-37 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
28. Remove the two clamps and disconnect aeration hose (33). 29. Loosen four hose clamps (34) and remove tube, hose, and block assembly (35).
30. Disconnect air bleeder hose (36). 31. Loosen clamps (37) and (38); remove water pump tubes (39) and (40). [*5] 32. Loosen clamp (41); remove engine oil cooler tube (42).
[*6]
33. Disconnect heater cable (42). 34. Disconnect starting motor cable (43). 35. Disconnect wiring harness connectors ER1 (44), ER2 (45), and ER3 (46). 36. Disconnect wiring harness connectors JE1 (47), JE2 (48), E11 (49), and E17 (50).
37. Remove the U-bolt and bracket (51).
50-38 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
38. Remove right and left engine front mounting bolts (52).
[*7]
39. Remove right and left engine rear mounting bolts (53).
[*8]
40. Sling the engine assembly and remove mounting bolt (54).
[*9]
41. Lift off engine assembly (55). ★ Before lifting off the engine assembly, check that all the wiring harnesses and pipe clamps are disconnected. Engine assembly: 1,900 kg (4,189 lbs)
WA500-6
50-39 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Hose clamp: 10.5 N•m (93 lbf in)
[*2] Hose clamp: 10.5 N•m (93 lbf in)
★ When installing clamp (10), direct it down. [*3] Adjust the air conditioner compressor belt tension. ★ For details, see BELTS: Air Conditioner Compressor Belt Tension in the Testing and Adjusting section. [*4] Tube joint bolt: 24.5 – 34.3 N•m (18 – 25 lbf ft)
[*5], [*6] Hose clamp: 10.5 N•m (93 lbf in)
[*7], [*8] Mounting bolt: 662 – 829 N•m (488 – 611 lbf ft)
[*9] Engine and transmission coupling bolt: 98 – 123 N•m (72 – 91 lbf ft)
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
50-40 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Bleeding Air 1.
Bleed air from the brake circuit. ★ See BRAKE SYSTEM: Bleeding Air from Brake Circuit in the Testing and Adjusting section.
2.
Bleed air from the fan drive motor circuit. ★ Se HYDRAULIC FAN: Bleeding Air from Hydraulic Drive Fan Circuit in the Testing and Adjusting section.
WA500-6
50-41 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Radiator WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Immediately after stopping the engine, the coolant is VERY HOT and the pressure inside the radiator is high. Removing the cap and draining the coolant under this condition could cause burns. Allow the engine to cool down and then turn the cap slowly to release the pressure.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required •
Container to hold the coolant
Removal 1.
Drain the coolant. Radiator: 90 l (24 gal)
2.
Remove rear top hood (1).
3.
Remove rubber cover (2) and covers (3), (4), and (5).
50-42 b
WA500-6
DISASSEMBLY AND ASSEMBLY 4.
Remove the four clamps and aeration hoses (6) and (7).
5.
Disconnect hose (8) from the bracket.
6.
Remove the two clamps; disconnect hose (9) from the reservoir tank.
7.
Remove the clamp; disconnect hose (10) from the tube.
8.
Disconnect air bleeder hose (11).
9.
Remove the four clamps; move hose (12) toward the engine.
ENGINE AND COOLING SYSTEM
10. Remove air bleeder hose clamps (13) and right and left partition plates (14).
11. Remove EGR cover (15). 12. Remove engine outlet tube fixing bracket (16).
13. Remove bracket (17). 14. Loosen four hose clamps (18); remove the tube bolts on the engine side and tube and hose assembly (19). [*1]
WA500-6
50-43 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
15. Remove eight radiator mounting bolts and 12 bracket mounting bolts; lift off bracket (20). Bracket: 30 kg (66 lbs)
16. Lift off radiator assembly (21) slowly. Radiator assembly (1 piece): 30 kg (66 lbs)
★ Remove the other radiator assembly in the same manner.
Installation ★ Carry out installation in the reverse order of removal. [*1] Hose clamp: 10.5 N•m (93 lbf in)
50-44 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Air Aftercooler WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
2.
Remove four partition plates (1).
3.
Loosen clamp (2); remove hose and air intake connector (3). [*1]
4.
Loosen clamps (4) and (5); remove pipe (6).
5.
Remove two reservoir tank hose clamps (7).
6.
Remove the two bolts; move receiver tank assembly (8) outward.
WA500-6
[*2]
50-45 b
DISASSEMBLY AND ASSEMBLY 7.
ENGINE AND COOLING SYSTEM
Sling air aftercooler assembly (9); remove its six mounting bolts; and lift it off. Air aftercooler assembly: 30 kg (66 lbs)
Installation ★ Carry out installation in the reverse order of removal. [*1] Hose clamp: 10.5 N•m (93 lbf in)
[*2] Hose clamp: 10.5 N•m (93 lbf in)
★ When installing clamp (4), direct it down.
50-46 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Cooling Fan and Fan Motor WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
WARNING!
The parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work.
WARNING!
When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it.
Required •
Container to hold the hydraulic oil
Removal 1.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
2.
Remove the two mounting bolts and open grille (1).
3.
Remove fan guard (2).
4.
Disconnect motor hoses (3), (4), and (5).
WA500-6
50-47 b
DISASSEMBLY AND ASSEMBLY 5.
Remove cover (6).
6.
Remove the three wiring harness clamps; disconnect wiring harness connector G09 (7).
7.
Remove the three support mounting bolts; open motor, fan, fan guard, and support assembly (8). [*1]
8.
Remove lock plate (9) and nut (10).
9.
Sling fan (11). Using the puller [1], disconnect and remove the fan from the motor.
ENGINE AND COOLING SYSTEM
[*2]
Fan: 40 kg (88 lbs)
10. Remove mounting bolt (12); remove fan motor assembly (13). [*3]
50-48 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Support mounting bolt: 235 – 285 N•m (173 – 210 lbf ft)
[*2] Fan mounting nut: 132.3 – 156.8 N•m (98 – 116 lbf ft)
★ When setting the bolt holes of the nut lock plate, do not rotate the nut in the loosening direction but rotate it in the tightening direction. [*3] Fan motor assembly mounting bolt (12): 98 – 123 N•m (72 – 91 lbf ft)
• •
Loosen bracket mounting bolts (14). Adjust the clearance between fan (11) and the shroud to more than 5.5 mm (0.217 in) all around the periphery. Mounting bolt (14): 245 – 309 N•m (181 – 228 lbf ft)
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air Bleed air from the fan drive motor circuit. ★ See HYDRAULIC FAN: Bleeding Air from Hydraulic Drive Fan Circuit in the Testing and Adjusting section.
WA500-6
50-49 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Radiator Guard and Cooling Fan WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
WARNING!
The parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work.
WARNING!
When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it.
Required •
Container to hold the hydraulic oil
Removal 1.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
2.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
3.
Remove right and left door locks (1).
4.
Remove open-close lock (2) of the grille.
5.
Lift off grille (3). Grille: 28 kg (62 lbs)
50-50 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
6.
Remove fan guard (4).
7.
Remove wiring harness connector GR1 (5).
8.
Remove wiring harness cover (6).
9.
Disconnect wiring harness connector G09 (7); remove the three clamps.
10. Disconnect fan motor hoses (8), (9), and (10). 11. Remove fan motor hose clamps (11), (12), and (13). ★ The wiring harness clamp is also fixed with hose clamp (11). ★ Move the disconnected hoses to the rear of the counterweight. 12. Remove the three mounting bolts of support (14).
WA500-6
[*1]
50-51 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
13. Remove reservoir tank bracket (15). 14. Remove eight mounting bolts (16) of the right and left side hood and guard.
15. Remove the two radiator support mounting bolts (17) from the front. [*2]
16. Remove the eight radiator guard mounting bolts (18) from the right and left.
17. While slinging radiator guard and cooling fan motor assembly (19) slowly, move it toward the rear to remove it. Radiator guard and cooling fan motor assembly: 320 kg (706 lbs)
50-52 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Support mounting bolt: 235 – 285 N•m (173 – 210 lbf ft)
[*2] Radiator support mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air Bleed air from the fan drive motor circuit. ★ See HYDRAULIC FAN: Bleeding Air from Hydraulic Drive Fan Circuit in the Testing and Adjusting section.
WA500-6
50-53 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Fuel Tank WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
WARNING!
Do not bring any fire or spark close to the machine.
Required •
Container to hold the fuel
Removal 1.
Drain the fuel. Fuel tank (when full): 473 l (125 gal)
2.
Remove right and left steps (1) and covers (2).
3.
Disconnect fuel drain valve (3) from the frame.
4.
Disconnect fuel tank breather (4) from the frame.
5.
Disconnect the three clamps of radiator drain hose (5).
6.
Disconnect wiring harness connector R16 (6).
50-54 b
WA500-6
DISASSEMBLY AND ASSEMBLY 7.
Remove the two bolts; move receiver tank assembly (7) outward.
8.
Disconnect fuel return hose (8) of the fuel tank from the tube.
9.
Disconnect fuel supply hose (9) of the fuel tank from the tube; disconnect the two clamps.
ENGINE AND COOLING SYSTEM
10. Disconnect hoses (10) between the fuel tank and water separator from the water separator; disconnect the clamp.
11. Sling fuel tank assembly (11) with the nylon sling; support its front bottom with jack [1]; and remove the four mounting bolts. [*1]. 12. While adjusting the jack height so that the bottom of fuel tank assembly (11) is parallel with the ground, lower the crane slowly. ★ Check that all the wiring harnesses, pipings, etc. are disconnected. Fuel tank assembly (Empty): 230 kg (507 lbs)
WA500-6
50-55 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
13. Place fuel tank assembly (11) on a palette truck [2], etc. and pull it out of the machine.
Installation ★ Carry out installation in the reverse order of removal. [*1] Reduce the clearance between the fuel tank and rear frame to below 0.5 mm (0.020 in) with shims. Fuel tank mounting bolt: 785 – 980 N•m (579 – 723 lbf ft)
50-56 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Engine Hood WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove rear hood (1).
2.
Lift off front hood, muffler, and precleaner assembly (2). Front hood, muffler, and precleaner assembly: 70 kg (154 lbs)
3.
Remove right and left side panels (3).
WA500-6
50-57 b
DISASSEMBLY AND ASSEMBLY 4.
Disconnect air conditioner hose clamp (4).
5.
Disconnect six reservoir hose clamps (5).
6.
Remove rubber cover (6).
7.
Remove partition covers (7), (8), and (9).
8.
Remove covers (10) and (11).
9.
Remove support (12).
ENGINE AND COOLING SYSTEM
10. Remove covers (13) and (14).
50-58 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
11. Disconnect torque converter cooler air bleeder hose clamps (15). 12. Disconnect reservoir tank bracket (16). 13. Disconnect bracket (17) of the pipe between the turbocharger and aftercooler.
14. Disconnect dust indicator (18) and block together.
15. Remove right and left intermediate covers (19).
16. Disconnect right and left gas springs (20) and rods (21).
WA500-6
50-59 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
17. Sling right and left side hood and door assemblies (22); remove their mounting bolts; and lift them off. Right and left side hood and door assemblies: 80 kg (176 lbs)
18. Remove cover and support assembly (23).
Installation ★ Carry out installation in the reverse order of removal.
50-60 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Fuel Supply Pump
795-630-5500 A
1
Standard puller
■
1
01010-81090
• Bolt
■
2
01643-31032
• Washer
■
2
Sketch
Part Name
New/Remodel
Part No.
Qty
Symbol
Necessity
Special Tools
Nature of Work, Remarks
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Open the inspection door of the right side hood.
2.
Remove the partition plates (1) and (2).
3.
Disconnect connector E16 (3).
4.
Remove the air conditioner compressor belt (4); disconnect the wiring harness clamp. [*1]
5.
Remove air conditioner compressor assembly (5) and bracket (6) together and move them outward.
WA500-6
50-61 b
DISASSEMBLY AND ASSEMBLY 6.
Disconnect wiring harness clamps (7) and (8); remove fuel prefilter (9) and bracket (10) together; and move them outward.
7.
Remove fuel tube (11); disconnect fuel tube (12) and fuel main filter head assembly (13). [*2]
8.
Remove engine oil filler bracket (14).
9.
Disconnect fuel supply hose (15). [*3]
ENGINE AND COOLING SYSTEM
10. Disconnect clamps (16), (17), (18), (19), and (20); remove oil tubes (21), (22), (23), and (24). [*4] 11. Remove fuel tubes (25) and (26).
50-62 b
[*5]
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
12. Remove the wiring harness clamp; unplug connectors PCV1 (27), PCV2 (28), and G (29). 13. Remove bracket (30).
14. Remove bracket (31) and clamps (32), (33), and (34). 15. Remove two high-pressure pipes (35).
[*6]
[*7]
16. Remove cover (36).
17. Rotate the crankshaft forward and set intermediate point (a) between stamps 2/5 TOP and 3/4 TOP on damper (37) to pointer (38). ★ At this time, check that the drive gear forcing tap is set to the bolt hole at the top of cover (36). (If the drive gear forcing tap is not set in this manner, rotate the crankshaft one more turn.) ★ At this point, the pump shaft key is at 15° to the right from the top.
WA500-6
50-63 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
18. Remove nut (37). [*8] ★ Be careful not to drop the removed parts into the case.
19. Install tool A1 and tighten center bolt to remove gear (39). ★ Keep tool A1 installed until the gear is installed again.
20. Remove four fuel supply pump mounting bolts (40) and fuel supply pump assembly (41). [*9]
50-64 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Adjust the air conditioner compressor belt tension. ★ For details, see BELTS: Air Conditioner Compressor Belt Tension in the Testing and Adjusting section. [*2] Joint bolt of fuel tubes (11) and (12): Supply pump side: 14.8 – 19.6 N•m (11 – 15 lbf ft) Filter side: 24.5 – 34.3 N•m (18 – 25 lbf ft)
[*3] Joint bolt of fuel supply hose (15): 14.8 – 19.6 N•m (11 – 15 lbf ft)
[*4] Sleeve nut of oil tube (22): 43 – 47 N•m (32 – 35 lbf ft) Sleeve nut of oil tube (21): 34.3 – 44.1 N•m (25 – 33 lbf ft)
[*5] Joint bolt of fuel tubes (25) and (26): 7.9 – 12.7 N•m (70 – 112 lbf in) Mounting bolt of tube clamps (17), (18), and (19): 9.8 ±1.0 N•m (87 ±9 lbf in)
[*6], [*7] 1.
Finger-tighten tube (35) first and then tighten it permanently. High-pressure pipe sleeve nut: Supply pump side: 39.2 – 49.0 N•m (29 – 36 lbf ft) Common rail side: 39.2 – 58.8 N•m (29– 43 lbf ft)
2.
Finger-tighten tube clamps (32), (33), and (34) first and then tighten them permanently. Tube clamp mounting bolt: 9.8 ±1.0 N•m (87 ±9 lbf in)
3.
Direct the notch of the scatter prevention cover on the supply pump side toward the block and direct that on the common rail side down.
WA500-6
50-65 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*8], [9] 1.
Remove the center screw of tool A1.
2.
Leave tool A1 installed to the gear and set the key of fuel supply pump (41) up.
3.
Insert the supply pump along the gear groove.
4.
Tighten fuel supply pump assembly mounting bolts (40). Supply pump mounting bolt: Adhesive (LT-2)
5.
Remove tool A1.
6.
Tighten the timing gear nut. Nut: 176 – 196 N•m (130 – 145 lbf ft)
WARNING!
Check that each high-pressure pipe is at least 10 mm (0.394 in) from the wiring harnesses around it.
Bleeding Air Bleed air from the fuel circuit. ★ For details, see FUEL SYSTEM: Bleeding Air from Fuel Circuit in the Testing and Adjusting section. Checking for Fuel Leakage Check the fuel circuit for leakage. ★ For details, see FUEL SYSTEM: Testing Leakage in Fuel Circuit in the Testing and Adjusting section.
50-66 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Cylinder Head
A
2
790-331-1110
Wrench (angle)
●
1
Sketch
Part Name
New/Remodel
Part No.
Qty
Symbol
Necessity
Special Tool
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
WARNING!
Immediately after stopping the engine, the coolant is VERY HOT and the pressure inside the radiator is high. Removing the cap and draining the coolant under this condition could cause burns. Allow the engine to cool down and then turn the cap slowly to release the pressure.
Required •
Container to hold the coolant
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
3.
Remove partition plates (1), (2), (3) and (4).
4.
Remove tube (5) between the turbocharger and air aftercooler. [*1]
5.
Remove EGR covers (6), (7), (8), (9), and (10).
WA500-6
50-67 b
DISASSEMBLY AND ASSEMBLY 6.
Loosen hose clamps (11) between the air cleaner and turbocharger; remove air cleaner fixing bands (12) and air cleaner assembly (13). [*2]
7.
Remove the muffler fixing band and four mounting bolts; lift off muffler assembly (14).
ENGINE AND COOLING SYSTEM
Muffler assembly: 50 kg (110 lbs)
8.
Remove cover (15).
9.
Remove fuel prefilter assembly (16) and head together and move them outward.
50-68 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
10. Disconnect supply pump connectors PCV1 (18), PCV2 (19), and G (20); remove the wiring harness clamp. 11. Disconnect air compressor connector E16 (21); remove the wiring harness clamp.
12. Disconnect EGR valve connectors SBP (22), BP (23), SEGR (24), and EGR (25); remove the wiring harness clamp. 13. Disconnect electrical intake air heater wiring harness (26); remove the wiring harness clamp.
14. Disconnect EGR gas pressure sensor connector (27) and wiring harness clamp. ★ If machine is equipped.
15. Disconnect fuel tube (28); remove fuel filter and bracket assembly (29). [*3] 16. Disconnect two tubes (30); remove corrosion resistor and bracket assembly (31). ★ If machine is equipped.
WA500-6
50-69 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
17. Remove oil tubes (32) and oil filter and bracket assembly (33). ★ Make match marks on these tubes since their tops, bottoms, inlets, and outlets are indistinguishable from each other. 18. Disconnect fuel return tube (34). [*4]
19. Remove muffler bracket (35). 20. Remove air cleaner bracket (36). 21. Remove blow-by breather (37).
22. Remove air connector (38) and electrical intake air heater. 23. Remove bracket (39), clamps (40), and EGR tubes (41) and (42). [*5]
24. Remove clamps (43), (44), (45), (46), and (47) and brackets (48), (49), (50), (51), and (52).
50-70 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
25. Remove upper bypass valve assembly (53) and the tube together. [*6]
26. Remove tubes (54) and (55).
27. Remove lower bypass valve assembly (56) and the tube together. [*7]
28. Remove bypass valve assembly mounting plate (57). 29. Remove blow-by tube (58).
WA500-6
50-71 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
30. Remove oil filter assembly mounting bracket (59).
31. Lift off air intake connector assembly (60) and joint housing together. Air intake connector assembly: 35 kg (77 lbs)
32. Unplug connectors TIM (61), PIM (62), and TFUEL (63).
33. Remove bracket (64). 34. Remove ten high-pressure pipe clamps (65) and seven brackets (66). [*8]
50-72 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
35. Remove six high-pressure pipe clamps (67); remove brackets (68). [*9] 36. Remove spill pipe (69).
[*10]
37. Remove six wiring harness clamps (70); unplug six injector connectors (71) and move them toward the hydraulic tank.
• •
Insert flat-head screwdriver [3] in shoulder (a). While pressing stopper (b), move the screwdriver in direction (X). Connector (c) is disconnected. ★ (d): Fuel injector wiring side
38. Remove four tube clamps (72) and turbocharger lubrication tube (73). [*11]
WA500-6
50-73 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
39. Sling air intake manifold assembly (74); remove its mounting bolts; and lift it off. [*12] ★ The two high-pressure pipe brackets are mounted together. Air intake manifold assembly: 50 kg (110 lbs)
40. Unplug connector (75); remove dust indicator hose (76). 41. Remove connector (77) and bracket (78).
[*13]
42. Remove stay (79) and bracket (80).
43. Remove bracket (81) and EGR cooler inlet tube (82).
[*14]
44. Disconnect turbocharger drain tube (83).
50-74 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
45. Sling exhaust manifold and turbocharger assembly (84); remove its mounting bolts; and lift it off. [*15] Exhaust manifold and turbocharger assembly: 65 kg (143 lbs)
46. Remove air bleeding tube (85).
[*16]
47. Remove the scatter prevention cover and high-pressure pipes (86). [17]
48. Remove head cover (87).
WA500-6
[*18]
50-75 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
49. Remove the three mounting bolts and rocker arm and shaft assembly (88). [*19] ★ Loosen locknut (89) and then loosen adjustment screw (90) two to three turns so that an excessive force is not applied to the push rod when the rocker arm is installed.
50. Remove push rods (91).
[*20]
51. Remove crossheads (92).
[*21]
52. Remove two nuts (93) from the solenoid valve of the fuel injector. [*22] ★ Loosen the nuts alternately. 53. Pull out spring clamp (94). 54. Disconnect clamp (95). 55. Remove the fixing bolt and holder of connector (96); push in the connector; and remove the injector wiring harness. [*23] 56. Loosen mounting bolt (98) of holder (97).
[*24]
57. Insert a small L-bar under the connector of the fuel injector and pry out fuel injector assembly (99) slowly. [*25] ★ Do not grip the solenoid valve at the top of the injector with pliers (or any other tool) to pull off the injector.
58. Remove mounting bolts (100), auxiliary bolts, and cylinder head assembly (101). [*26] 59. Remove cylinder head gasket. [*27]
50-76 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Tube hose clamp: 10.5 N•m (93 lbf in)
★
When installing the clamp, direct it down.
[*2] Air cleaner hose clamp: 8.8 ±0.5 N•m (78 ±4 lbf in)
[*3] Tube joint bolt: 24.5 – 34.3 N•m (18 – 25 lbf ft)
[*4] Tube joint bolt: 24.5 – 34.3 N•m (18 – 25 lbf ft)
[*5] Tube joint bolt: 24.5 – 34.3 N•m (18 – 25 lbf ft) Tube sleeve nut: Centralized housing bracket side: 54 – 93 N•m (40 – 69 lbf ft) Front cover side: 24 – 27 N•m (18 – 20 lbf ft)
[*6], [*7] EGR valve mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
[*8] Bracket mounting bolt: 9.8 ±1.0 N•m (87 ±9 lbf in) High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (87 ±9 lbf in)
[*9] High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (87 ±9 lbf in)
WA500-6
50-77 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*10] Spill pipe joint bolt: 9.8 – 12.7 N•m (87 – 112 lbf in)
[*11] Lubrication tube joint bolt: 24.5 – 34.3 N•m (18 – 25 lbf ft)
[*12] 1.
Install the gasket with the UP mark up.
2.
Tighten the air intake manifold assembly mounting bolts in the order of [1] – [24] as shown in this figure. Air intake manifold mounting bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
[*13] Connector hose clamp: 8.8 ±0.5 N•m (78 ±4 lbf in)
[*14] EGR cooler mounting bolt: 44.1 – 53.9 N•m (33 – 40 lbf ft) Bracket mounting bolt: 44.1 – 53.9 N•m (32 – 40 lbf ft)
[*15] 1.
Apply heat-resistant sealant to the fitting parts of the exhaust manifold (between ports No. 2 and No. 3 and between ports No. 4 and No. 5). Fitting parts: Heat-resistant sealant (HOLTZ MH705)
2.
Tighten the three bolts of [1] – [3] shown in the figure temporarily in the numeric order and then tighten other bolts [4] – [24] temporarily in the numeric order.
3.
Tighten all bolts [1] – [24] to the specified torque in the numeric order. Threads of mounting bolt: Anti-seizure compound (LC-G)
Exhaust manifold mounting bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
50-78 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*16] Air bleeding tube joint bolt: 9.8 – 12.7 N•m (87 – 112 lbf in)
[*17] WARNING!
Before installing the high-pressure pipe, check it for defects. If there are any defects, it can cause fuel leakage. If the high-pressure pipe has defects, replace it.
1.
Check the high-pressure pipe for the following defects: • Check the taper seal of the connecting part (part (a): part of 2 mm (0.079 in) from the end) for visible lengthwise slit (b) and dent (c). • Check part (d) (end of the taper seal: part at 2 mm (0.079 in) from the end) for stepped-type wear (fatigue) which you can feel with your nail.
2.
Fit the O-ring to the sleeve of high-pressure pipe (86). While setting the sleeve to the injector connector, tighten the sleeve nut temporarily. Tighten the sleeve nut on the common rail side temporarily also. O-ring: Engine oil (EO30-DH)
3.
Tighten the high-pressure pipe sleeve nut permanently with a spanner-type torque wrench. Sleeve nut: 39.2 – 49 N•m (29 – 36 lbf ft)
4.
Check that the O-ring is not projected from the sleeve.
5.
Install the scatter prevention cover on the injector side with the notch down and that on the common rail side with the notch directed toward the cylinder block.
[*18] Head cover mounting bolt: 29.4 – 34.3 N•m (22 – 25 lbf ft)
★ Tighten the bolts temporarily; these bolts are also used to fix the wiring harness clamp. [*19] •
Before tightening the mounting bolts, check that the adjustment screw ball is fitted in the push rod socket. Rocker arm and shaft assembly mounting bolt: 93 – 103 N•m (69 – 76 lbf ft)
•
For adjustment of the valve clearance. ★ See ENGINE COMPONENTS: Adjusting Valve Clearance in the Testing and Adjusting section.
WA500-6
50-79 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*20] Check that the push rod is in the cam follower. [*21] Adjust the crosshead according to the following procedure. 1.
Loosen the locknut and return the adjustment screw.
2.
While holding the crosshead top lightly, tighten the adjustment screw.
3.
After the adjustment screw touches the valve stem, tighten it 20° more.
4.
Tighten the locknut. Locknut: 58.7 ±5.9 N•m (43 ±4 lbf ft)
[*22] 1.
Take up the slack of the wiring harness and press it against the injector so that it does not interfere with the rocker arm.
2.
Tighten the nuts alternately. Wiring harness terminal nut: 2.0 ±0.2 N•m (18 ±2 lbf in)
[*23] Since the injector wiring harness fitted with the O-ring is difficult to insert from inside, install it according to the following procedure. 1.
Remove O-ring (102) from connector (96) and pass the wiring harness out from inside of the cylinder head and then fit the O-ring. O-ring: Engine oil (EO30-DH)
2.
Install holder (103) to connector (96) and push the connector into the position where the O-ring is fitted.
3.
Fix the holder with mounting bolt (104).
50-80 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*24], [*25] Install the injector assembly according to the following procedure. 1.
Check that there is no dirt in the injector sleeve.
2.
Install gasket (105) and O-ring (106) to fuel injector (99). O-ring: Engine oil (EO30-DH)
3.
Insert holder (97) in the fuel injector and insert the injector connector, directing it toward the high-pressure pipe insertion hole.
4.
Install the spherical washer to bolt (98) and tighten holder (97) temporarily. Spherical washer: Engine oil (EO30-DH)
5.
Insert high-pressure pipe sleeve (107) through the high-pressure pipe insertion part, setting it to injector connector (108) and tighten it temporarily. ★ Tighten the sleeve nut on the common rail side also and be careful that the high-pressure pipe does not slant.
6.
Tighten holder (97) permanently. ★ While pulling the high-pressure pipe in the opposite direction to the injector, tighten the bolt. Holder mounting bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
★ After tightening the holder, remove the high-pressure pipe. [*26] 1.
Check the cylinder head mounting bolts for the following items. If they are out of the standard, do not use them but replace them. • Number of tightening times must be five or less (number of punch marks denoting the number of tightening times must be five or less). • Usable limit length of bolt stem (e): Short bolt: . . . . . . . . . . . . . . . . . . . . . . . . .170.8 mm (6.724 in) Long bolt: . . . . . . . . . . . . . . . . . . . . . . . . .205.8 mm (8.102 in) Cylinder head mounting bolt: Molybdenum disulfide grease (LM-P)
WA500-6
50-81 b
DISASSEMBLY AND ASSEMBLY 2.
ENGINE AND COOLING SYSTEM
Tighten the mounting bolts in the order of 1 – 6 as shown in the figure. 1st time: . . . . . . . . . . . . . . . . . . . . 137 – 157 N•m (101 – 116 lbf ft) 2nd time: . . . . . . . . . . . . . . . . . . . . 284 – 294 N•m (210 – 217 lbf ft)
3rd time: . . . . . . . . Using tool A2, tighten the bolts by 90° (+30°/0).
When not using tool A2, make marks (a) and (b) on each bolt and cylinder head with paint, and then tighten the bolts by 90° (+30°/0). 3.
After tightening bolts 1 – 6, tighten bolt 7. Bolt 7: . . . . . . . . . . . . . . . . . . . . . . . . . 66.6 ±7.4 N•m (49 ±6 lbf ft)
[*27] •
•
Check that there is no dirt or foreign matter on the cylinder head mounting face and in the cylinder, and then set the gasket to the cylinder head. When fitting the gasket, check that the grommets are fitted correctly.
Refilling with Coolant 1.
Add coolant to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Bleeding Air 1.
Bleed air from the fuel system. ★ For details, see FUEL SYSTEM: Bleeding Air from Fuel Circuit in the Testing and Adjusting section.
2.
Before starting the engine, check that the wiring harnesses. WARNING!
50-82 b
The wiring harnesses must be at least 10 mm (0.394 in) from each high-pressure pipe.
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Fuel Injector Removal WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
1.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
2.
Remove the muffler fixing band and four mounting bolts; lift off muffler assembly (1). Muffler assembly: 50 kg (110 lbs)
3.
Loosen hose clamps (2) between the air cleaner and turbocharger; remove the air cleaner fixing band and air cleaner assembly (3). [*1]
4.
Remove air cleaner bracket (4) and muffler bracket (5).
5.
Remove the EGR gas pressure sensor tube. ★ For details, see Step 26 in the Removal procedure for the cylinder head (ENGINE AND COOLING SYSTEM: Cylinder Head: Removal in this section). ★ Perform this only for the removal and installation of the No. 1 fuel injector assembly. ★ If machine is equipped.
WA500-6
50-83 b
DISASSEMBLY AND ASSEMBLY 6.
ENGINE AND COOLING SYSTEM
Remove the wiring harness clamp and unplug connector (10). ★ Unplug the injector connector according to the following procedure. A. Apply flat-head screwdriver [1] to the shoulder (part (a)). B. While pressing stopper (1a), move flat-head screwdriver [1] in direction (X) to unplug the connector.
7.
Remove the high-pressure pipe clamp.
8.
Remove the scatter prevention cover.
9.
Loosen the high-pressure pipe sleeve nut and pull out highpressure pipe sleeve (11). [*2]
10. Remove cylinder head cover (12).
[*3]
11. Remove the three mounting bolts and rocker arm and shaft assembly (13). [*4] • Loosen the locknut (14) and then loosen the adjustment screw (15) fully so that an excessive force is not applied to the push rod when the rocker arm is installed.
12. Remove two nuts (16) from the solenoid valve of the fuel injector. [*5] ★ Loosen nuts (16) alternately. 13. Remove wiring harness clamp (17). 14. Remove the mounting bolts of holder (19) and then remove fuel injector (20) and holder (18) together. [*6] ★ Insert a small L-bar under the connector of the fuel injector and pry out the fuel injector assembly (20) slowly. ★ Do not grip the solenoid valve at the top of the injector with pliers (or any other tool) to pull off the injector.
50-84 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Air cleaner hose clamp: 8.8 ±0.5 N•m (78 ±4 lbf in)
[*2] WARNING!
1.
Before installing the high-pressure pipe, check it for defects. If there are any defects, it can cause fuel leakage. If the high-pressure pipe has defects, replace it.
Check the high-pressure pipe for the following defects: • Check the taper seal of the connecting part (part (a): part of 2 mm (0.079 in) from the end) for visible lengthwise slit (b) and dent (c). • Check part (d) (end of the taper seal: part at 2 mm (0.079 in) from the end) for stepped-type wear (fatigue) which you can feel with your nail. High-pressure pipe sleeve O-ring: Engine oil (EO30-DH)
High-pressure pipe sleeve nut: 39.2 – 49 N•m (29 – 36 lbf ft) High-pressure pipe clamp mounting bolt: 9.8 ±1.0 N•m (87 ±9 lbf in)
[*3] Cylinder head cover mounting bolt: 29.4 – 34.3 N•m (22 – 25 lbf ft)
[*4] ★ Before tightening the mounting bolts, check that the adjustment screw ball is fitted in the push rod socket. Rocker arm mounting bolt: 93 – 103 N•m (69 – 76 lbf ft)
★ For adjustment of the valve clearance, see ENGINE COMPONENTS: Adjusting Valve Clearance in the Testing and Adjusting section. [*5] 2.
Take up the slack of the wiring harness and press it against the injector.
3.
Tighten the nuts alternately. Terminal nut: 2.0 ±0.2 N•m (18 ±2 lbf in)
WA500-6
50-85 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
[*6] Install the injector assembly according to the following procedure. 1.
Check that there is no dirt in the injector sleeve.
2.
Install gasket (21) and O-ring (22) to fuel injector (20). O-ring: Engine oil (EO30-DH)
3.
Insert holder (18) in the fuel injector and insert the injector connector (24), directing it toward the high pressure pipe insertion.
4.
Install the spherical washer to bolt (19) and temporarily tighten holder (18). Spherical washer: Engine oil (EO30-DH)
5.
Insert high-pressure pipe sleeve (23) through the high-pressure pipe insertion part, setting it to injector connector (24); tighten it temporarily. ★ Tighten the sleeve nut on the common rail side also and be careful that the high-pressure pipe does not slant.
6.
Tighten holder (19) permanently. ★ While pulling the high-pressure pipe in the opposite direction to the injector, tighten the bolt. Holder mounting bolt: 58.8 – 73.5 N•m (43 – 54 lbf ft)
★ After tightening the holder, remove the high-pressure pipe.
50-86 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Engine Front Seal
3
Seal puller
■
1
795T-521-1111
Push tool
■
1
4
01050-31655
Bolt
■
3
01050-31635
Bolt
■
3
795T-521-1150
Push tool
■
1
01050-31635
Bolt
■
3
Part Name
A
5
Sketch
795-931-1100
Part No.
New/Remodel
Qty
Symbol
Necessity
Special Tools
Nature of Work, Remarks
Removal of oil seal N
❍ Press-fitting of engine front seal
N
❍
Press-fitting of engine front seal (sleeve type)
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove right and left partition covers (1) and cover mounting supports.
2.
Remove damper (2).
WA500-6
50-87 b
DISASSEMBLY AND ASSEMBLY 3.
ENGINE AND COOLING SYSTEM
Remove front seal (3) from housing (4) according to the following procedure. ★ Be careful during the removal procedure not to damage the front seal (3) installation position on housing (4) and the seal contact face on crankshaft (5). A. Before removing the seal, slightly drive the front seal in once to free it if it is stuck. B. When front seal (3) is fixed too hard to the housing (4), do the following procedure. • Drill a through hole of approximately 3 mm (0.118 in) diameter on front seal (3). • Replace the tip of tool A3 with a drill type one. • Insert the top end of tool A3 into the drilled hole and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly in order not to tilt the front seal.) C. Remove the metal powders completely.
D. When the sleeve is attached, cut sleeve (6) using a chisel and hammer to remove it. ★ Be careful not to damage crankshaft (5).
50-88 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation 1.
Check the seal by checking the wear of the shaft. Replace the seal with the standard seal or sleeved seal. ★ If the shaft is worn to the degree of luster (if wear that you feel with your finger is less than 10 mm (0.394 in)) and does not have any flaw, install standard seal A. In other cases, install sleeved seal B. • (7): Plastic inside cylinder (also used as installation guide) • (6): Sleeve.
2.
Do not remove installation guide (7) from front seal (3) before installing the front seal.
3.
Handle front seal (3) and sleeve (6) as an assembly and never separate them from each other.
Procedure for Installing Standard Seal 1.
Before installing the seal, check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing. ★ When installing the seal, do not apply oil or grease to the shaft and seal lip. Wipe off the oil from the shaft. ★ Never remove inside plastic cylinder (7) of the replacement seal before installing the seal.
2.
Set large inside diameter side (b) of plastic inside cylinder (7) to the end of crankshaft (5). ★ Be careful not to mistake the direction of the plastic inside cylinder.
WA500-6
50-89 b
DISASSEMBLY AND ASSEMBLY 3.
Push the metal ring of front seal (3) evenly as if you are passing over the large inside diameter side of plastic inside cylinder (7).
4.
After pushing in the seal, remove plastic inside cylinder (7). ★ When removing the inside cylinder, be careful not to damage the seal lip.
5.
Using tool A4, tighten the three bolts evenly to press-fit seal (3) until the end of tool A4 reaches the end of crankshaft (5).
ENGINE AND COOLING SYSTEM
A. Tighten tool A4 first until the 55-mm bolts stop; replace the 55-mm bolts with the 35-mm bolts; and tighten them. Seal driving distance (a) from crankshaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 – 10.1 mm (0.358 – 0.398 in)
B. When press-fitting the seal, be careful not to damage the lip of the seal with the tool set, etc. C. After press-fitting the seal, remove the red sealant layer from its periphery. Procedure for installing sleeved seal ★ When installing the front seal, do not apply oil or grease to the shaft, inside cylinder surface of sleeve (6), and the seal lip. 1.
Set sleeve (6) and front seal (3) assembly to tool A5 (for fitting the sleeved seal). Sleeve (6) inside cylinder surface: Gasket sealant (LG-7)
2.
Set the sleeve of the front seal to the end of crankshaft (5) and tighten the three bolts evenly to press-fit the sleeve and front seal assembly (9) until the end of tool A5 reaches the end of crankshaft (5). ★ Tighten tool A5 (for press-fitting the sleeved seal) until the 35-mm bolt stops.
50-90 b
WA500-6
DISASSEMBLY AND ASSEMBLY 3.
Remove tool A5 (for press-fitting the sleeved seal) and install tool A4 (for press-fitting the seal).
4.
Tighten the 35-mm bolts of tool A4 evenly to press-fit seal and sleeve assembly (9) until the end of tool A4 reaches the end of crankshaft (5).
ENGINE AND COOLING SYSTEM
Seal driving distance (a) from crankshaft: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 – 10.1 mm (0.358 – 0.398 in)
★ When press-fitting the seal, be careful not to damage the lip of the seal with the tool set, etc. ★ After press-fitting the seal, remove the red sealant layer from its periphery. 5.
Install damper (2).
WA500-6
50-91 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Engine Rear Seal
790-331-1110
Wrench
■
1
3
795-931-1100
Seal puller
■
1
795T-421-1260
Push tool
■
1
01050-31640
Bolt
■
4
01643-31645
Washer
■
8
795T-421-1240
Push tool
■
1
01050-31645
Bolt
■
4
01643-31645
Washer
■
4
795T-421-1231
Push tool
■
1
01050-31645
Bolt
■
4
01643-31645
Washer
■
8
Part No.
6
A 7
8
Part Name
Sketch
Qty
2
Symbol
New/Remodel
Necessity
Special Tools
Nature of Work, Remarks
Removal of oil seal N
❍ Press-fitting of engine rear seal (standard type)
N
❍
N
❍
Press-fitting of engine rear seal (sleeve type)
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove the engine assembly. ★ For details, see ENGINE AND COOLING SYSTEM: Engine in this section.
2.
Remove ring gear (1).
50-92 b
WA500-6
DISASSEMBLY AND ASSEMBLY 3.
Install eyebolt [1] to flywheel (2) and sling it. Remove bolts (3) and flywheel (2).
4.
While moving flywheel (2) toward this side, lift it off. WARNING!
ENGINE AND COOLING SYSTEM
Since the socket part of the flywheel is shallow, it may fall suddenly. Be careful not to catch your fingers in the flywheel.
Flywheel: 60 kg (132 lbs)
5.
Remove rear seal (4) from flywheel housing (5) according to the following procedure. ★ Be careful not to damage rear seal (4) installation position on flywheel housing (5) and the seal contact face on crankshaft (5).
Remark If you have a standard seal, do Steps A, B, and F. If you have the sleeved seal, do Steps C, D, E, and F. ★ Seals (illustrated in figure to the right) • Left: Standard seal • Right: Sleeved seal A. Before removing the seal, slightly drive the rear seal in once to free it if it is stuck. B. When rear seal (4) is fixed too hard to the flywheel housing (5), do the following procedure. ★ Tool A3 (illustrated in figure to the right) i.
Drill a through hole of approximately 3 mm (0.118 in) diameter on rear seal (4).
ii.
Replace the tip of tool A3 with a drill-type one (DT).
iii. Insert the top end of tool A3 into the drilled hole and remove the front seal by the impact of slide hammer (SH). (Apply the slide hammer evenly in order not to tilt the rear seal.) iv. Go to Step F.
WA500-6
50-93 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
C. Cut and remove sleeve (7) using a chisel and hammer. D. Replace the tip of tool A3 with a puller-type one (PT). E. Hitch the end of tool A3 to the metal ring of rear seal (4) and pull out the seal using impacts of slide hammer (DH). F.
Remove the metal powders completely. ★ Be careful not to damage crankshaft (6).
50-94 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Installation ★ Carry out the following installation in the reverse order of removal. 1.
Check the Teflon seal (laydown lip seal) by checking the wear of the shaft. Replace the seal with a standard seal or sleeved seal. ★ If the shaft is worn to the degree of luster (if wear that you feel with your finger is less than 10 mm (0.394 in)) and does not have any flaw, install standard seal A. In other cases, install sleeved seal B. ★ Seals (illustrated in the figure to the right) • Left: Standard seal • Right: Sleeved seal • (8): Plastic inside cylinder (also used as installation guide) • (7): Sleeve ★ Do not remove plastic inside cylinder (8) from rear seal (4) before installing the rear seal.
2.
Handle rear seal (4) and sleeve (7) as an assembly and never separate them from each other.
3.
Clean, degrease, and dry the contact surface against the flywheel housing.
4.
Clean, degrease, and dry the seal lip surface (periphery of the crankshaft).
5.
Check that the end corners and lip sliding surfaces of the crankshaft are free from flaw, burr, and rust of the housing.
WA500-6
50-95 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Procedure for Installing Standard Seal ★ When installing rear seal (4), do not apply oil or grease to the shaft and seal lip. 1.
Set large inside diameter side (b) of guide (8) of rear seal (4) to the end of crankshaft (6). ★ Be extremely careful not to mistake the direction of the plastic inside cylinder.
2.
Push the metal ring of rear seal (4) evenly. ★ Hit the metal ring of the rear seal evenly with a plastic hammer. ★ Do not hit it too hard.
3.
After pushing in the seal, remove guide (8). ★ When removing the inside cylinder, be careful not to damage the seal lip.
4.
Tighten the four bolts evenly to press-fit rear seal (4) until the end of tool A6 (for press-fitting the seal) reaches the end of crankshaft (6). A. Tighten tool A6 (for press-fitting the seal) first until the bolt without a washer stops and then tighten the bolt with two washers. ★ When press-fitting the seal, be careful not to damage the lip with the tool set, etc. B. After press-fitting the seal, remove the red sealant layer from its periphery.
50-96 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Procedure for Installing Sleeved Seal ★ When installing the rear seal, do not apply oil or grease to the shaft, inside cylinder surface (C) of the sleeve (7), and seal lip. 1.
Set sleeve and rear seal assembly (9) to tool A7 (for fitting the sleeved seal). Sleeve inside cylinder surface (C): Gasket sealant (LG-7)
2.
Set sleeve (7) of the rear seal to the end of crankshaft (6) and tighten the four bolts evenly to press-fit sleeve and rear seal assembly (9) until the end of tool A7 reaches the end of crankshaft (6). ★ Tighten tool A7 (for press-fitting the sleeved seal) until the bolt with a washer stops.
3.
Remove tool A7 (for press-fitting the sleeved seal) and install tool A8 (for press-fitting the seal).
4.
Tighten the four bolts evenly to press-fit sleeve and rear seal assembly (9) until the end of tool A8 reaches the end of crankshaft (6). A. Tighten tool A8 (for press-fitting the seal) first until the bolt without a washer stops and then tighten the bolt with two washers. B. After press-fitting the seal, remove the red sealant layer from its periphery. Rear seal driving depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2 ±0.2 mm (0.520 ±0.008 in)
C. When installing, set the dowel pin of the crankshaft to the dowel hole of the flywheel.
WA500-6
50-97 b
DISASSEMBLY AND ASSEMBLY
ENGINE AND COOLING SYSTEM
Flywheel 1.
Using eyebolt [1] (12 mm, P = 1.75), sling flywheel (2); install it to the crankshaft; and tighten bolts (3). ★ If there are five punch marks on a bolt, do not use that bolt but replace it. Threads and seat of bolt: Engine oil SAE No. 30
2.
Tighten the flywheel mounting bolts according to the following procedure. ★ First time Flywheel mounting bolts: 118 ±4.9 N•m (87 ±4 lbf ft)
★ 2nd time: ★ When using tool A2 (see Special Tools): • Retighten each bolt by 90° (+30°/0) in the order of [1] – [8]. ★ When not using tool A2: • Make marks on each bolt and flywheel with paint then retighten each bolt by 90° (+30°/0) in the order of [1] – [8]. 3.
After tightening, make one punch mark (9) on each bolt head to indicate the number of tightening times.
4.
After installing the flywheel, measure the facial runout and radial runout with tool [2]. Radial runout: . . . . . . . . . . . . . . . . . Maximum 0.13 mm (0.005 in) Facial runout: . . . . . . . . . . . . . . . . . . Maximum 0.20 mm (0.008 in)
50-98 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
POWER TRAIN Torque Converter and Transmission Assembly WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
The parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work.
WARNING!
When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it.
WARNING!
Immediately after stopping the engine, the coolant is VERY HOT and the pressure inside the radiator is high. Removing the cap and draining the coolant under this condition could cause burns. Allow the engine to cool down and then turn the cap slowly to release the pressure.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required • • •
Container to hold the coolant Container to hold the hydraulic oil Container to hold the transmission oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Drain the transmission oil. Transmission oil: 76 l (20 gal)
4.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
5.
Remove the cab and floor frame assembly. ★ For details, see CAB AND ITS ATTACHMENTS: Cab and Floor Frame in this section.
6.
Remove the hydraulic tank assembly. ★ For details, see HYDRAULIC SYSTEM: Hydraulic Tank in this section.
WA500-6
50-99 b
DISASSEMBLY AND ASSEMBLY 7.
Remove the right and left mudguard seats.
8.
Remove cover (1).
9.
Remove guard (2).
POWER TRAIN
10. Sling center drive shaft (3); remove its mounting bolts (4); and lift it off. [*1] ★ Before removing the drive shaft, make a match mark on the coupling. Center drive shaft: 50 kg (110 lbs)
11. Support rear drive shaft (5) with transmission jack [1]; remove its mounting bolts (6); and lift it off. [*2] ★ Before removing the drive shaft, make a match mark on the coupling. Rear drive shaft: 45 kg (99 lbs)
12. Remove bracket (7) and transmission oil feed tube (8). 13. Disconnect hoses (9) and (10) at transmission oil filter side. ★ Disconnect two clamps, also. 14. Disconnect hose (11).
50-100 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
15. Disconnect parking brake hose (12).
16. Unplug wiring harness connectors RJ1 (13) and RJ2 (14); remove the two wiring harness clamps. 17. Disconnect hoses (15) and (16). 18. Disconnect tube (17).
19. Lift off transmission filter and bracket assembly (18). Transmission filter and bracket assembly: 45 kg (99 lbs)
20. Loosen hose clamp (19) and remove U-bolt (20) and transmission suction tube (21).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
21. Disconnect wiring harness bracket (22).
22. Disconnect work equipment pump hoses (23), (24), and (25). 23. Disconnect hose clamp (26). 24. Disconnect hose (27) and remove brackets (28) and (29) and work equipment pump outlet tube (30).
25. Unplug wiring harness connector RT1 (31). 26. Remove wiring harness clamps (32) and bracket (33).
27. Remove pump inlet tube (34). 28. Disconnect pump outlet hoses (35) and (36).
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29. Disconnect hose (37).
30. Remove pump inlet tube (38). 31. Disconnect pump inlet tube (39). 32. Disconnect pump outlet hoses (40), (41), and (42). 33. Disconnect hose (43) and remove bracket (44).
34. Sling torque converter charging and EPC pump assembly (45) and remove its mounting bolts. ★ At this time, leave two bolts installed. Torque converter charging and EPC pump assembly: 30 kg (66 lbs)
35. Remove tube (46).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
36. Disconnect hose (47). 37. Remove U-bolts (48) and bracket (49).
38. Remove U-bolt (50) and disconnect oil cooler tube (51).
39. Sling the torque converter and transmission assembly; loosen lock bolts (52); and remove right and left mounting brackets (53). [*3]
40. Remove connecting bolts (54) of the engine and torque converter and transmission assembly. [*4]
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
41. Remove torque converter and transmission assembly (55). ★ Check that all the wiring harness and pipings are disconnected from the machine and be careful that the assembly does not interfere with the machine. Torque converter and transmission assembly: 1,950 kg (4,299 lbs)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Installation ★ Carry out installation in the reverse order of removal. [*1] Center drive shaft mounting bolt: 107 – 127 N•m (79 – 94 lbf ft)
[*2] Rear drive shaft mounting bolt: 107 – 127 N•m (79 – 94 lbf ft)
★ Tighten the drive shaft (5) according to the following procedure. 1.
Check that the seats of the mating yoke and drive shaft spider are free from rust, foreign matter (masking material), bruises, etc.
2.
Set the keyway of the yoke vertically; place the drive shaft on the bottom of the yoke socket; and fit the key in the keyway.
3.
Insert the four upper and lower bolts and finger-tighten them until the seats of the spider and yoke are fitted. • At this time, if the keyway and socket of the yoke are tight and the spider is not fitted easily, drive in the spider with a plastic or copper hammer. (Do not use a steel hammer which can damage the cross bearing.) • If the spider is not fitted perfectly at this time, it will float and its seat will be parted from the yoke when the other parts are tightened. Tighten the spider securely.
4.
Tighten the bolts in the diagonal order.
[*3] Bracket (53) mounting bolt: 235 – 285 N•m (173 – 210 lbf ft) Transmission mounting bolt: 662 – 829 N•m (488 – 611 lbf ft)
1.
Adjust the clearance between bracket (53) and lock adjustment bolt (52) to 1.0 – 1.5 mm (0.039 – 0.059 in).
2.
Tighten the locknut. Threaded part of lock adjustment bolt: Adhesive (LT-2)
[*4] Connecting bolt of engine and torque converter and transmission assembly: 98 – 123 N•m (72 – 91 lbf ft)
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Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Refilling with Oil (Transmission) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air Bleed air from the circuit. ★ For details, see these procedures in the Testing and Adjusting section. • FUEL SYSTEM: Bleeding Air from Fuel Circuit • HYDRAULIC SYSTEM: Bleeding Air from Hydraulic Drive Fan Circuit
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Power Train WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
The parts and oil are at high temperature immediately after the engine is stopped and may cause burns. Wait for the temperature to go down before starting the work.
WARNING!
When removing the oil filler cap, turn it slowly to release the internal pressure and then remove it.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required •
Container to hold the transmission oil
Preparation 1.
Set torque converter and transmission assembly (1). Torque converter and transmission assembly: 1,700 kg (3,748 lbs) (with lockup) 1,650 kg (3,638 lbs) (without lockup)
2.
Loosen drain valve to drain the oil. Transmission case: 76 l (20 gal)
3.
Remove right and left transmission mounts (3).
4.
Disconnect each ECMV of transmission control valve and remove wiring harness (4).
5.
Remove hoses (5) and (6) and pipes (7), (8), (9), (10), and (11).
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DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Remove transmission control valve (12) and lubricating oil relief valve (13). [*1] ★ The three bolts marked with * are used to clamp other parts also.
★ Lockup specification (figure to the right)
★ Without lockup specification (figure to the right)
7.
Remove pipes (14) and (15), block (16), and heater plug (17).
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DISASSEMBLY AND ASSEMBLY 8.
Remove torque converter regulator valve (19).
9.
Remove pipe (20).
POWER TRAIN
Disassembly 1.
Set torque converter and transmission assembly (1). Torque converter and transmission assembly: 1,700 kg (3,748 lbs) (with lockup) 1,650 kg (3,638 lbs) (without lockup)
2.
Torque converter assembly A. Remove two upper mounting bolts (2a) and 15 lower mounting bolts (2b). B. Lift off torque converter assembly (3). Torque converter assembly: 460 kg (1,014 lbs) (with lockup) 420 kg (926 lbs) (without lockup)
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DISASSEMBLY AND ASSEMBLY 3.
POWER TRAIN
Input transfer A. Remove 13 mounting bolts (4). [*4] B. Lift off input transfer (5). Input transfer: 140 kg (309 lbs)
4.
Transmission assembly
A. Remove four upper mounting bolts (6a) and eight lower mounting bolts (6b); disconnect the case by using forcing screws. [*5] B. Sling transmission assembly (7) and lift it off from transfer assembly (8). Transmission assembly: 550 kg (1,213 lbs)
Transfer assembly: 440 kg (970 lbs)
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Assembly ★ Carry out assembly in the reverse order of disassembly. ★ Before fitting the O-ring, apply grease (G2-LI) to it. [*1] Install the transmission control valve by using guide bolts [1]. ★ The three bolts marked with * are used to clamp other parts also.
★ Lockup specification (figure to the right)
★ Without lockup specification (figure to the right)
[*2] Joint bolt A: 24.5 – 34.3 N•m (18 – 25 lbf ft) Joint bolt B: 34.3 – 44.1 N•m (25 – 33 lbf ft) Joint bolt C: 19.6 – 29.4 N•m (15 – 22 lbf ft)
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[*3] (Only lockup specification)
Input shaft seal ring: Grease (G2-LI)
★ Project the seal ring evenly from the shaft. ★ Be careful when handling the seal ring. It may break if it is pushed forcibly. Torque converter mounting bolts (2a), (2b): 98 – 122.5 N•m (73 – 90 lbf ft) [*4] Input transfer mounting bolt (4): 98 – 122.5 N•m (73 – 90 lbf ft)
[*5] Transmission mounting bolts (6a), (6b): 98 – 122.5 N•m (73 – 90 lbf ft)
Transmission shaft (Spline): Grease (LM-G)
Refilling with Oil Transmission case: 76 l (20 gal) Power train oil (TO30)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Input Transfer Disassembly 1.
Disconnect the input transfer assembly from the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
2.
Input shaft A. Remove input shaft speed sensor (1) and input shaft (2).
B. Remove seal rings (3) from input shaft (2). ★ Lockup specification
★ Without lockup specification (figure to the right)
3.
Bearing cage assembly (drive gear side) A. Remove six mounting bolts (4). B. Using forcing screw [1], remove bearing cage (5) and shim (6). ★ Check the thickness and quantity of the shims at each position and keep the shims.
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C. Remove outer race (7) from bearing cage (5).
4.
Drive gear assembly A. Remove drive gear assembly (8).
B. Remove bearings (9) and (10) from drive gear assembly (8).
5.
Outer race (drive gear side) ★ Using puller [2], remove outer race (19) from the case.
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DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Bearing cage assembly (driven gear side) A. Reverse input transfer case (11). B. Remove six mounting bolts (12). C. Using forcing screws [3], remove bearing cage (13) and shim (14). ★ Check the thickness and quantity of the shims at each position and keep the shims.
D. Remove outer race (15) from bearing cage (13).
7.
Driven gear assembly A. Remove driven gear assembly (16).
B. Remove bearings assembly (16).
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(17)
and
(18)
from
driven
gear
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DISASSEMBLY AND ASSEMBLY 8.
POWER TRAIN
Outer race ★ Using puller [4], remove outer race (20) from the case.
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Assembly 1.
Outer race (driven gear side) ★ Using push tool [1] (outside diameter: 124 mm [4.882 in]), press-fit outer race (20) to the case.
2.
Driven gear assembly A. Using push tool [2], press-fit bearings (17) and (18) to driven gear (21).
B. Install driven gear assembly (16).
3.
Bearing cage assembly (driven gear side) A. Using push tool [3] (outside diameter: 124 mm [4.882 in]), press-fit outer race (15) to bearing cage (13).
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B. Adjust the shim of bearing cage (13) according to the following procedure. i.
Install bearing cage (13) without setting any shim and tighten mounting bolts (12). Mounting bolt: 4.8 ±0.98 N•m (43 ±9 lbf in)
★ After installing the bearing, drop 6 cc of transmission oil (TO30) onto it and rotate it ten turns. ii.
Rotate driven gear (21) 20 turns.
iii. Check the tightening torque of mounting bolts (12) again. Mounting bolt: 4.8 ±0.98 N•m (43 ±9 lbf in)
iv. If the tightening torque has changed, repeat Steps Bi and Bii. v.
Using thickness gauge [4], measure the clearance of bearing cage (13) at the three places marked with (*). Obtain shim thickness (b) from average clearance (a). ★ Check that the bearing is not leaning. ★ If the dispersion of the above measured values is larger than 0.15 mm (0.006 in), check if the bearing is fitted fully or check for another cause and then set the bearing normally. Shim thickness (b): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a + (0.15 to 0.20) mm [0.006 – 0.008 in] Standard shim thickness: . . . . . . . . . . . .1.0 mm (0.039 in) Standard clearance: . . .0.60 – 1.80 mm (0.024 – 0.071 in)
vi. Install shim (14) of the thickness obtained by the above procedure and tighten mounting bolts (12). Mounting bolt: 98.0 – 122.5 N•m (72 – 90 lbf ft)
vii. Install input shaft (2) to driven gear (21) and measure the rotation torque. Rotation torque: 1.47 – 2.45 N•m (13 – 22 lbf in)
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DISASSEMBLY AND ASSEMBLY 4.
Outer race (drive gear side) ★ Using push tool [5] (outside diameter: 139 mm [5.472 in]), press-fit outer race (19) to the case.
5.
Drive gear assembly
POWER TRAIN
A. Using push tool [6], press-fit bearings (9) and (10) to drive gear (22).
B. Install drive gear assembly (8).
6.
Bearing cage assembly (drive gear side) A. Using push tool [7] (outside diameter: 149 mm [5.866 in]), press-fit outer race (7) to bearing cage (5).
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B. Adjust the shim of bearing cage (5) according to the following procedure. ★ Since the shim adjustment and torque measurement are carried out on the drive gear independently, remove the drive gear. i.
Install bearing cage (5) without setting any shim and tighten mounting bolts (4). Mounting bolt: 4.8 ±0.98 N•m (43 ±9 lbf in)
★ After installing the bearing, drop 6 cc of transmission oil (TO30) onto it and rotate it ten turns. ii.
Rotate drive gear (22) 20 turns.
iii. Check the tightening torque of mounting bolts (4) again. Mounting bolt: 4.8 ±0.98 N•m (43 ±9 lbf in)
iv. If the tightening torque has changed, repeat Steps Bi and Bii. v.
Using thickness gauge [8], measure the clearance of bearing cage (5) at the three places marked with (*). Obtain shim thickness (d) from average clearance (c). ★ Check that the bearing is not leaning. ★ If the dispersion of the above measured values is larger than 0.15 mm (0.006 in), check if the bearing is fitted fully or check for another cause and then set the bearing normally. Shim thickness (d):. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (c) + (0.15 to 0.20) mm [0.006 – 0.008 in] Standard shim thickness: . . . . . . . . . . .1.0 mm (0.039 in) Standard clearance: . . .0.40 – 1.60 mm (0.016 – 0.063 in)
vi. Install shim (6) of the thickness obtained by the above procedure and tighten mounting bolts (4). Mounting bolt: 98.0 – 122.5 N•m (72 – 90 lbf ft)
vii. Install input shaft (2) to drive gear (22) and measure the rotation torque. Rotation torque: 1.47 – 2.45 N•m (13 – 22 lbf in)
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DISASSEMBLY AND ASSEMBLY 7.
POWER TRAIN
Input shaft A. Install seal ring (3) to input shaft (2). Seal ring: Grease (G2-LI)
Input shaft (Spline): Grease (LM-G)
★ Lockup specification (figure to the right) ★ Without lockup specification (figure to the right) B. Install input shaft (2). C. Install input shaft speed sensor (1). ★ Finger-tighten input shaft speed sensor (1) to the end and then return it by 1/2 turn and lock it with locknut (1a). Locknut: Gasket sealant (LG-5)
Locknut: 49 – 68.6 N•m (36 – 51 lbf ft)
8.
Connect the input transfer assembly to the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
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Torque Converter (Lockup Specification)
Part Name
Qty
1
790-101-2102
Puller (294 kN {30 ton})
■
1
Removal of turbine boss
2
793-613-1210
Wrench
■
1
Removal and installation of pump nut
Symbol
F
Sketch
Part No.
Necessity
New/Remodel
Special Tools
Nature of Work, Remarks
Disassembly 1.
Disconnect the torque converter assembly from the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
2.
Torque converter assembly A. Set torque converter assembly (1) on the block. B. Remove 12 mounting bolts (2).
3.
Housing A. Using eyebolts [1], sling housing (3). B. Using forcing screws [2], remove housing (3).
4.
Pilot A. Remove eight mounting bolts (4). B. Using forcing screws [3], remove pilot (65).
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DISASSEMBLY AND ASSEMBLY 5.
POWER TRAIN
Torque converter assembly A. Remove 16 mounting bolts (5) from the lower part. B. Using eyebolts [4], remove torque converter assembly (6). Torque converter assembly: 180 kg (397 lbs)
★ Steps 6 – 11 are disassembly procedures for the torque converter. 6.
Turbine assembly A. Remove 36 lower mounting bolts (7). ★ Leave the two bolts on the right and left sides. B. Remove the left two bolts and turbine assembly (8), using eyebolts [5].
7.
Snap ring and spacer • Remove snap ring (9) and spacer (10).
8.
Turbine boss assembly A. Using tool F1 and push tool [6] (outside diameter: 104 mm [4.095 in]), remove turbine boss assembly (11).
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B. Remove snap ring (12). C. Remove 20 mounting bolts (13) and turbine (14).
9.
Drive case assembly A. Remove 30 mounting bolts (15). B. Using eyebolts [7], remove piston housing (16).
C. Remove piston (17) and bearing (18) from piston housing (16). ★ Do not remove dowel pin (64) since it is a complete part. D. Remove piston rings (19a) and (19b).
E. Remove disc (20).
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10. Stator assembly A. Remove stator assembly (21).
B. Remove snap ring (22) from stator assembly (21). C. Remove race (23) from stator assembly (21).
D. Remove freewheel (24) from race (23). ★ When removing the freewheel, be careful with ball (25).
11. Pump assembly A. Install the bolts to the pump case and lock them with bar [8]. B. Using tool F2, remove nut (26).
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C. Remove spacer (27). ★ When removing the spacer, be careful with ball (28).
D. Using push tool [9], remove stator shaft (29).
E. Remove inner race (30).
F.
Remove 16 mounting bolts (31) and gear (32).
G. Remove bearing (33).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
H. Remove inner race (34) and seal ring (35) from stator shaft (29).
12. PTO gear A assembly A. Remove eight mounting bolts (36). B. Using forcing screws [10], disconnect PTO gear A assembly (37).
C. Using eyebolts [11], remove PTO gear A assembly (37).
D. Remove snap ring (38a) and spacer (39). E. Remove gear (40) and bearing (41). F.
Remove snap ring (38b) and bearing (57).
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G. Remove snap ring (42) and outer race (43) on the case side.
13. PTO gear B assembly A. Remove eight mounting bolts (44). B. Using forcing screws [12], disconnect PTO gear B assembly.
C. Using eyebolts [13], remove PTO gear B assembly (45).
D. Remove snap ring (46a) and spacer (47). E. Remove gear (48) and bearing (49). F.
Remove snap ring (46b) and bearing (58).
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DISASSEMBLY AND ASSEMBLY
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G. Remove snap ring (50) and outer race (51) on the case side.
14. Idler gear A. Remove mounting bolt (52). B. Using forcing screw [14], pull the shaft out and down, and remove gear (53).
C. Remove bearings (54a) and (54b) from gear (53).
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POWER TRAIN
Assembly 1.
Idler gear A. Install bearings (54a) and (54b) to gear (53).
B. Set gear (53) to the case. C. Fit the O-ring to shaft (55) and press-fit them. O-ring: Grease (G2-LI)
D. Reverse the case and install mounting bolt (52). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 153 – 190 N•m (113 – 140 lbf ft)
2.
PTO gear B assembly A. Install snap ring (50) to the case. B. Using push tool [1] (outside diameter: 99 mm [3.898 in]), press-fit outer race (51) on the case side. C. Using push tool [2] (inside diameter: 56 mm [2.205 in]), press-fit bearing (49) to the gear.
D. Using push tool [4] (outside diameter: 124 mm [4.882 in]), press-fit bearing (58) to the cover. E. Install snap ring (46b).
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DISASSEMBLY AND ASSEMBLY F.
POWER TRAIN
Using push tool [5] (inside diameter: 71 mm [2.795 in]), press-fit cover assembly (59) to gear (48).
G. Install spacer (47) and snap ring (46a).
H. Fit the O-ring; install PTO gear B assembly (45) using eyebolts [13]. O-ring: Grease (G2-LI)
3.
PTO gear A assembly A. Install snap ring (42) to the case. B. Using push tool [6] (outside diameter: 99 mm [3.898 in]), press-fit outer race (43) on the case side. C. Using push tool [7] (inside diameter: 56 mm [2.205 in]), press-fit bearing (41) to the gear.
D. Using push tool [8] (outside diameter: 149 mm [5.866 in]), press-fit bearing (57) to the cover. E. Install snap ring (38b).
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DISASSEMBLY AND ASSEMBLY F.
POWER TRAIN
Using push tool [9] (inside diameter: 71 mm [2.795 in]), press fit cover assembly (60) to gear (40).
G. Install spacer (39) and snap ring (38a).
H. Fit the O-ring; install PTO gear A assembly (37) using eyebolts [11]. O-ring: Grease (G2-LI)
★ Steps 4 – 10 are assembly procedures for the torque converter. 4.
Pump assembly A. Using push tool [10] (outside diameter: 215 mm [8.465 in]), press-fit bearing (33) to gear (32).
★ After press-fitting bearing (33), measure dimension (a) at four places on the periphery and check that the error is not larger than 0.05 mm (0.002 in).
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B. Install gear (32) to the pump case and tighten 16 bolts (31). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
C. Using push tool [11] (inside diameter: 121 mm [4.764 in]), press-fit inner race (34) to stator shaft (29). D. Install seal ring (35). Seal ring: Grease (G2-LI)
E. Install pump case (61) to stator shaft (29).
F.
Using push tool [12] (inside diameter: 121 mm [4.764 in]), press-fit inner race (66) to stator shaft (29).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Match the product Nos. (c) and match symbols “A” (d) of the inner and outer races of bearing (33); use those races as an assembly.
G. Install spacer (27). ★ When installing, set ball (28) correctly.
H. Install the bolts to the pump case and lock them with bar [8]. I.
Using tool F2, tighten nut (26). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 441 – 490 N•m (325 – 361 lbf ft)
★ After tightening nut (26), drop 6 cc of TO30 or TO10 onto the bearing and rotate the bearing ten turns. Check the tightening torque for nut (26) again. Mounting bolt: 441 – 490 N•m (325 – 361 lbf ft)
5.
Stator assembly A. Install freewheel (24) to race (23). ★ When inserting freewheel (24), use your hand. Do not use a hammer or other tool. ★ When inserting the freewheel, be careful with ball (25).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ When installing the one-way clutch, direct arrow (b) of the free rotation direction on the front face of the cage toward the input side (turbine side). Clockwise: . . . . . . . . . . . . . . . . . . . . . . . . . . .Free rotation Counterclockwise: . . . . . . . . . . . . . . . . . . . . . . . . . Locked
★ Do not remove the sprag (d). • When inserting, be careful that drag clip (c) on the periphery of the one-way clutch is not hitched in the ball groove.
B. Install stator assembly (21).
6.
Turbine assembly A. Install snap ring (12). B. Install turbine (14) to the turbine boss and tighten 20 mounting bolts (13). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
7.
Drive case assembly A. Using eyebolts [13], install drive case (63) to turbine boss assembly (11).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Apply tool [14] (outside diameter: 150 mm [5.906 in], height: 129 mm [5.079 in]) to the bottom of turbine boss assembly (11) to hold the latter. ★ This secures a space for installing the disc to drive case (63).
C. Install disc (20).
8.
Piston housing assembly A. Install seal ring (19a) to piston housing complete (16). ★ Do not remove dowel pin (64) since it is a complete part. Periphery of seal ring: Grease (G2-LI)
B. Install seal ring (19b) to piston (17). ★ Set pressure receiving side (e) of the seal ring in the arrow direction as shown in the figure. Periphery of seal ring: Grease (G2-LI)
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POWER TRAIN
C. Using eyebolts [15], install piston housing (16). D. Tighten 30 mounting bolts (15). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
E. Using push tool [16] (outside diameter: 179 mm [7.047 in]), press-fit bearing (18).
★ After press-fitting bearing (18), measure dimension (e) at four places on the periphery and check that the error is not larger than 0.05 mm (0.002 in).
9.
Snap ring and spacer ★ Install spacer (10) and snap ring (9).
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POWER TRAIN
10. Turbine assembly A. Using eyebolts [5], install turbine assembly (8). B. Tighten 36 lower mounting bolts (7). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 49 – 58.8 N•m (36 – 43 lbf ft) Drain plug (2 pieces): 9.8 – 12.7 N•m (87 – 112 lbf in)
11. Pilot ★ Install pilot (65) and tighten eight mounting bolts (4). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 98 – 122.5 N•m (72 – 90 lbf ft)
12. Torque converter assembly A. Set torque converter case (66).
B. Install guide bolt [17] to stator shaft (29). C. Using eyebolts [18] and positioning with guide bolt [17], install torque converter assembly (6). Torque converter assembly: 180 kg (397 lbs)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Tighten 16 mounting bolts (5) from the underside. Mounting bolt: Adhesive (LT-2)
13. Housing A. Fit the O-ring and install housing (3), using eyebolts [19]. B. Tighten 12 mounting bolts (2). O-ring: Grease (G2-LI)
Mounting bolt: 98 – 122.5 N•m (72 – 90 lbf ft)
14. Connect the torque converter assembly to the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Torque Converter (Without Lockup)
Part Name
Qty
1
790-101-2102
Puller (294 kN {30 ton})
■
1
Removal of turbine boss
2
793-613-1210
Wrench
■
1
Removal and installation of pump nut
Symbol
F
Sketch
Part No.
Necessity
New/Remodel
Special Tools
Nature of Work, Remarks
Disassembly 1.
Disconnect the torque converter assembly from the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
2.
Housing A. Set torque converter assembly (1) on the block. B. Remove 12 mounting bolts (2). C. Remove housing (3).
3.
Pilot A. Remove eight mounting bolts (4). B. Remove pilot (5).
4.
Torque converter assembly A. Remove 16 mounting bolts (6) from the lower part. B. Remove torque converter assembly (8) from case (7). Torque converter assembly: 150 kg (331 lbs)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Steps 5 – 10 are disassembly procedures for the torque converter. 5.
Turbine assembly A. Remove 36 lower mounting bolts (9). ★ Leave the two bolts on the right and left sides. B. Remove the last two bolts and lift off turbine assembly (10).
6.
Snap ring and spacer ★ Remove snap ring (11) and spacer (12).
7.
Turbine boss assembly A. Using tool F1 and push tool [1] (outside diameter: 104 mm [4.095 in]), remove turbine boss assembly (13).
B. Remove snap ring (14). C. Remove 20 mounting bolts (15) and turbine (16).
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WA500-6
DISASSEMBLY AND ASSEMBLY 8.
Drive case assembly ★ Remove bearing (17) from drive case (63).
9.
Stator
POWER TRAIN
A. Remove snap ring (18). B. Remove stator (19).
10. Pump assembly A. Install the bolts to the pump case and lock them with bar [2]. B. Using tool F2, remove nut (20).
C. Remove spacer (21). ★ When removing the spacer, be careful with ball (22).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Using push tool [3], remove stator shaft (23).
E. Remove inner race (24).
F.
Remove 16 mounting bolts (25) and gear (26).
G. Remove bearing (27).
H. Remove inner race (28) and seal ring (29) from stator shaft (23). I.
Remove collar (52).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
11. PTO gear A assembly A. Remove eight mounting bolts (30). B. Using forcing assembly (31).
screws [4], disconnect PTO gear A
C. Using eyebolts [5], remove PTO gear A assembly (31).
D. Remove snap ring (32a) and spacer (33). E. Remove gear (34) and bearing (35). F.
Remove snap ring (32b) and bearing (36).
G. Remove snap ring (37) and outer race (38) on the case side.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
12. PTO gear B assembly A. Remove eight mounting bolts (39). B. Using forcing screws [6], disconnect PTO gear B assembly.
C. Using eyebolts [7], remove PTO gear B assembly (40).
D. Remove snap ring (41a) and spacer (42). E. Remove gear (43) and bearing (44). F.
Remove snap ring (41b) and bearing (45).
G. Remove snap ring (46) and outer race (47) on the case side.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
13. Idler gear A. Remove mounting bolt (48). B. Using forcing screw [8], pull the shaft out and down and remove gear (49).
C. Remove bearings (50a) and (50b) from gear (49).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
Idler gear A. Install bearings (50a) and (50b) to gear (49).
B. Set gear (49) to the case. C. Fit the O-ring to shaft (51) and press-fit them. O-ring: Grease (G2-LI)
D. Reverse the case and install mounting bolt (48). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 153 – 190 N•m (113 – 140 lbf ft)
2.
PTO gear B assembly A. Install snap ring (46) to the case. B. Using push tool [1] (outside diameter: 99 mm [3.898 in]]), press-fit outer race (47) on the case side. C. Using push tool [2] (inside diameter: 56 mm [2.205 in]), press-fit bearing (44) to the gear.
D. Using push tool [3] (outside diameter: 124 mm [4.882 in]), press-fit bearing (45) to the cover. E. Install snap ring (41b).
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DISASSEMBLY AND ASSEMBLY F.
POWER TRAIN
Using push tool [4] (inside diameter: 71 mm [2.795 in]), press-fit cover assembly (52) to gear (43).
G. Install spacer (42) and snap ring (41a).
H. Fit the O-ring and install PTO gear B assembly (40), using eyebolts [7]. O-ring: Grease (G2-LI)
3.
PTO gear A assembly A. Install snap ring (37) to the case. B. Using push tool [5] (outside diameter: 99 mm [3.898 in]), press-fit outer race (38) on the case side. C. Using push tool [6] (inside diameter: 56 mm [2.205 in]), press-fit bearing (35) to the gear.
D. Using push tool [8] (outside diameter: 149 mm [5.866 in]), press-fit bearing (36) to the cover. E. Install snap ring (32b).
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50-149 b
DISASSEMBLY AND ASSEMBLY F.
POWER TRAIN
Using push tool [9] (inside diameter: 71 mm [2.795 in]), press-fit cover assembly (53) to gear (34).
G. Install spacer (33) and snap ring (32a).
H. Fit the O-ring and install PTO gear A assembly (31), using eyebolts [5]. O-ring: Grease (G2-LI)
★ Steps 4 – 10 are assembly procedures for the torque converter. 4.
Pump assembly A. Using push tool [10] (outside diameter: 215 mm [8.465 in]), press-fit bearing (27) to gear (26).
★ After press-fitting bearing (27), measure dimension (a) at four places on the periphery and check that the error is not larger than 0.05 mm (0.002 in).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Install gear (26) to the pump case and tighten 16 bolts (25). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
C. Using push tool [11] (inside diameter: 121 mm [4.764 in]), press-fit inner race (28) to stator shaft (23). D. Install seal ring (29). Seal ring: Grease (G2-LI)
E. Install collar (52).
F.
Install pump case (54) to stator shaft (23).
G. Using push tool [12] (inside diameter: 121 mm [4.764 in]), press-fit inner race (55) to stator shaft (23).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Match the product Nos. (c) and match symbols “A” (d) of the inner and outer races of bearing (27); use those races as an assembly.
H. Install spacer (21). ★ When installing, set ball (22) correctly.
I.
Install the bolts to the pump case and lock them with bar [2].
J.
Using tool F2, tighten nut (20). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 441 – 490 N•m (325 – 361 lbf ft)
K. After tightening nut (20), drop 6 cc of TO30 or TO10 onto the bearing and rotate the bearing ten turns. Check the tightening torque again. Mounting bolt: 441 – 490 N•m (325 – 361 lbf ft)
5.
Stator A. Install stator (19). B. Install snap ring (18).
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WA500-6
DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Turbine assembly A. Install snap ring (14). B. Install turbine (16) to the turbine boss and tighten 20 mounting bolts (15). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
7.
Drive case assembly A. Install drive case (63) to turbine boss assembly (13).
B. Using push tool [13] (outside diameter: 179 mm [7.047 in]), press-fit bearing (17) to drive case (63).
★ After press-fitting bearing (17), measure dimension (e) at four places on the periphery and check that the error is not larger than 0.05 mm (0.002 in).
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50-153 b
DISASSEMBLY AND ASSEMBLY 8.
Snap ring and spacer ★ Install spacer (12) and snap ring (11).
9.
Turbine assembly
POWER TRAIN
A. Sling and install turbine assembly (10). B. Tighten 36 lower mounting bolts (9). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 49 – 58.8 N•m (36 – 43 lbf ft) Drain plug (2 pieces): 9.8 – 12.7 N•m (87 – 112 lbf in)
10. Pilot ★ Install pilot (5) and tighten eight mounting bolts (4). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 98 – 122.5 N•m (72 – 90 lbf ft)
11. Torque converter assembly A. Set torque converter case (56).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Install guide bolt [14] to stator shaft (23). C. Positioning with guide bolt [14], install torque converter assembly (8) to case (7). Torque converter assembly: 150 kg (331 lbs)
D. Tighten 16 mounting bolts (6) from the underside. Mounting bolt: Adhesive (LT-2)
12. Housing A. Fit the O-ring to housing (3). B. Sling housing (3) and install it to torque converter assembly (1). C. Tighten 12 mounting bolts (2). O-ring: Grease (G2-LI)
Mounting bolt: 98 – 122.5 N•m (72 – 90 lbf ft)
13. Connect the torque converter assembly to the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
WA500-6
50-155 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Transmission
1
Oil leak tester
■
1
769-514-2000
Remover
■
1
796-515-2140
Adapter
1
790-201-1702
Push tool kit
1
Part Name
2 G
Nature of Work, Remarks
Operation check of clutch piston Removal of No. 3 planetary gear shaft
790-201-1741
• Push tool
1
790-101-5021
• Grip
1
01010-50816
• Bolt
3 ■
Sketch
799-301-1500
Part No.
New/Remodel
Qty
Symbol
Necessity
Special Tools
Press-fitting of No. 3 and No. 4 carrier bushings
1
Disassembly 1.
Disconnect the transmission assembly from the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
2.
Sleeves ★ Using forcing screw [1], remove five sleeves (1).
3.
Transmission assembly A. Remove six mounting bolts (3) from the lower output shaft side of transmission assembly (2).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Set transmission assembly (2) on block [2]. C. Remove 18 mounting bolts (4) from the upper input shaft side.
D. Remove two tie bolts (6). E. Install eyebolts [3] to the holes of the removed tie bolts and remove transmission assembly (5). ★ Do not use an impact wrench to loosen the tie bolts because it could damage the cushion sleeve and cause the tie bolts to seize. Transmission assembly: 410 kg (904 lbs)
4.
Check clutch piston operation. ★ Using tool G, check the operating condition of the piston before disassembling the transmission.
5.
Input shaft and No. 1 carrier housing assembly A. Remove 13 other tie bolts (6). ★ Do not use an impact wrench to loosen the tie bolts because it can damage the cushion sleeve. B. Using eyebolt [4], remove the input shaft and No. 1 carrier housing assembly (7).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Disassemble No. 1 carrier housing assembly according to the following procedure. i.
Remove snap ring (9).
ii.
Remove No. 2 sun gear (10).
iii. Support housing (11) and push out input shaft (12) with push tool [5].
iv. Remove snap ring (13) on the inner race side.
v.
Support housing (11) and push out No. 1 carrier assembly (14) with push tool [6] (inside diameter: 91 mm [3.583 in]).
vi. Remove spacer (15).
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
vii. Remove snap ring (16). viii. Remove bearing (17). ix. Remove seal ring (18) from housing (11).
D. Disassemble No. 1 carrier assembly (14) according to the following procedure. i.
Remove spacer (21) and seal ring (22).
ii.
Remove snap ring (19) and No. 1 ring gear (20).
iii. Using a round rod, drive pin (24) into shaft (23). iv. Remove shaft (23) from No. 1 carrier (14). v.
Remove pin (24) from shaft (23). ★ Be careful not to lose pin (24).
vi. Remove two thrust washers (25), needle roller bearing (26), and planetary gear (27).
vii. Remove sun gear (28) and spacer (29).
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50-159 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
viii. Using push tool [7] (outside diameter: 64 mm [2.520 in]), remove the spacer and bearing assembly (30). ix. Remove snap ring (31). x.
Using push tool [8], remove bearing (32).
xi. Remove snap ring (33) from No. 1 carrier (14). xii. Using push tool [9], remove bearing (34).
6.
No. 1 spring ★ Remove ten No. 1 springs (35).
7.
No. 1 plate, spring and No. 1 disc ★ Remove seven No. 1 discs (36), 35 springs (37), and six No. 1 plates (38).
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WA500-6
DISASSEMBLY AND ASSEMBLY 8.
POWER TRAIN
Guide pin and piston A. Remove five guide pins (39) and piston (40).
B. Remove seal ring (41) from piston (40).
9.
No. 1 and No. 2 piston housing assembly A. Using eyebolts [10], remove No. 1 and No. 2 piston housing assembly (42). ★ When disconnecting the dowel pin, drive it out with a copper hammer. ★ When slinging the housing assembly, be careful that the No. 2 piston does not fall.
B. Remove seal rings (43) and (44) from No. 1 and No. 2 piston housing (42).
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50-161 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Remove 15 cushion sleeves (166) from No. 2 piston housing (42).
★ When removing cushion sleeve (166) from No. 2 piston housing (42), check slit position (A).
10. No. 2 piston A. Remove No. 2 piston (45).
B. Remove seal ring (46) from No. 2 piston (45).
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
11. No. 2 spring ★ Remove ten No. 2 springs (47).
12. No. 2 disc, spring and No. 2 plate ★ Remove seven No. 2 discs (48), 35 springs (49), and six No. 2 plates (50).
13. No. 2 carrier and housing assembly A. Using eyebolts [11], remove the No. 2 carrier and housing assembly (51). B. Remove snap ring (52) on the bearing inner race side.
C. Support No. 2 housing assembly (53) and push out No. 2 carrier assembly (54) with push tool [12] and the press. ★ Push the No. 2 carrier.
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50-163 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Disassemble No. 2 housing assembly (55) according to the following procedure. i.
Remove snap ring (56).
ii.
Support No. 2 housing assembly (55) and push out bearing (57) with push tool [13] (outside diameter: 179 mm [7.047 in]) and the press.
iii. Remove seal ring (58) from No. 2 housing (55).
E. Disassemble No. 2 carrier assembly (54) according to the following procedure. i.
Remove spacer (59).
ii.
Remove ring gear (61).
iii. Insert rods in four snap ring removing holes (a) of ring gear (64) and push out snap ring (63). iv. Remove No. 2 carrier assembly (62) from ring gear (64).
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WA500-6
DISASSEMBLY AND ASSEMBLY v.
POWER TRAIN
Remove pin (65) and shaft (66) from No. 2 carrier (62). ★ Be careful not to lose pin (65).
vi. Remove two thrust washers (67), bearing (68), and planetary gear (69).
needle
roller
14. Guide pin and plate ★ Remove five guide pins (70) and upper plate (71).
15. No. 3 spring ★ Remove ten No. 3 springs (72). 16. No. 3 disc, spring and No. 3 plate ★ Remove four No. 3 discs (74), 20 springs (73), and three No. 3 plates (75).
17. Plate ★ Remove lower plate (76).
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50-165 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
18. No. 3 ring gear ★ Remove No. 3 ring gear (77). 19. No. 3 and No. 4 housing and piston assembly • Using eyebolts [13], remove No. 3 and No. 4 housing and piston assembly (78). • When disconnecting the dowel pin, drive it out with a copper hammer.
20. No. 3 piston assembly A. Remove No. 3 piston assembly (79) and seal rings (80) and (81) from No. 3 and No. 4 housing (78). B. Remove No. 4 piston assembly (82) and seal rings (83) and (84) from No. 3 and No. 4 housing (78).
21. Plate ★ Remove upper plate (85).
22. No. 4 spring ★ Remove ten No. 4 springs (86). 23. No. 4 disc, spring and No. 4 plate ★ Remove three No. 4 discs (88), 15 springs (87), and two No. 4 plates (89).
50-166 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
24. Plate ★ Remove lower plate (90).
25. No. 3 and No. 4 carrier assembly A. Using eyebolts [14], temporarily sling No. 3 and No. 4 carrier assembly (91). B. Using bar [15], push up No. 3 and No. 4 carrier assembly (91) to remove it.
C. Disassemble No. 3 and No. 4 carrier assembly (91) according to the following procedure. i.
Using tool G2, pull out No. 3 shaft (92). ★ Be careful not to lose ball (93).
ii.
Remove two thrust washers (94), needle roller bearing (95), and planetary gear (96).
★ When No. 3 and No. 4 carrier assembly (91) is disassembled, bearing (104) comes out to the end of planetary gear (96). Be careful that bearing (104) does not contact the thrust washer.
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50-167 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iii. Using a round rod, drive pin (97) into No. 4 shaft (98). iv. Using round rod [16], drive out No. 4 shaft (98) from the No. 3 shaft carrier side.
v.
Remove two thrust washers (101), needle roller bearing (102), and No. 4 planetary gear (103).
vi. Using push tool [17], push out bearing (104) with the press.
vii. Remove seal ring (106) from No. 3 and No. 4 carrier (105). viii. Remove bushing (107).
50-168 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
26. No. 4 sun gear A. Remove snap ring (108) and spacer (109). B. Remove No. 4 sun gear (110).
C. Remove seal ring (111) from spacer (109).
27. No. 4 ring gear A. Remove four mounting bolts (112) and cover (113). B. Remove No. 4 ring gear (114).
28. No. 5 housing and No. 5 piston assembly A. Using eyebolts [17], remove No. 5 housing assembly (115). ★ When slinging the housing, be careful that the No. 5 piston does not fall. B. Using eyebolts (17a), remove No. 5 piston (116) from No. 5 housing assembly (115).
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50-169 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Remove seal ring (117) from No. 5 piston (116). D. Remove seal ring (118) from No. 5 housing (115).
29. No. 5 plate ★ Remove No. 5 upper plate (119).
30. No. 5 spring ★ Remove ten No. 5 springs (120). 31. Remove three No. 5 discs (121), 15 springs (122), and two No. 5 plates (123). 32. Remove five guide pins (124).
33. Remove No. 5 ring gear (125). 34. Remove No. 5 plate (126). 35. Remove bearing (127).
50-170 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
36. No. 5 sun gear A. Remove spacer (160) and No. 5 sun gear (161). B. Remove bearing (127) and seal ring (162) from spacer (160).
37. No. 5 carrier assembly A. Remove 11 mounting bolts (128). B. Using eyebolts [18], remove No. 5 carrier assembly (129). ★ When disconnecting the dowel pin, drive it out with a copper hammer.
C. Disassemble No. 5 carrier assembly (129) according to the following procedure. i.
Remove snap ring (130).
ii.
Remove shaft (131), ball (132), and plug (133) from No. 5 carrier assembly (129). ★ Be careful not to lose ball (132).
iii. Remove four thrust washers (134), needle roller bearing (135), and planetary gear (136).
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50-171 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
38. No. 6 plate ★ Remove No. 6 upper plate (137).
39. No. 6 spring ★ Remove ten No. 6 springs (138). 40. Remove four No. 6 discs (139), 20 springs (140), and three No. 6 plates (141). 41. Remove 5 guide pins (142).
42. No. 6 piston A. Remove No. 6 piston (143).
B. Remove seal ring (144) from No. 6 piston (143). C. Remove seal ring (146) from No. 6 housing (145).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
43. No. 6 hub ★ Remove No. 6 hub (147).
44. Output shaft A. Remove snap ring (148). B. Support the cage and drive out output shaft (149) with push tool [19] and a hammer. ★ Place a receiver to receive the shaft which will fall down.
C. Remove bearing (150) from output shaft (149).
45. Cage assembly A. Remove snap ring (151).
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50-173 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Support No. 6 housing assembly (152) and push out cage assembly (153) with push tool [20] (outside diameter: 139 mm [5.472 in]) and the press.
C. Remove seal ring (154) from cage assembly (153).
46. No. 6 housing assembly A. Remove snap ring (155) from No. 6 housing assembly (152).
B. Using push tool [21], remove bearing (157), bushing (158), and ball (159) from housing (156). ★ Be careful not to lose ball (159).
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
No. 6 housing assembly A. Using push tool [1] (outside diameter: 189 mm [7.441 in]), press-fit bearing (157) to No. 6 housing (156). B. Using push tool [2] (outside diameter: 199 mm [7.835 in]), press-fit bushing (158) and ball (159) to No. 6 housing (156).
C. Install snap ring (155) to No. 6 housing (152).
2.
Cage assembly A. Install two seal rings (154) to cage (153). Seal ring: Grease (G2-LI)
B. Using push tool [3] (inside diameter: 141 mm [5.551 in]), press-fit No. 6 housing assembly (152) to cage assembly (153). ★ Press the inner race of bearing (157).
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50-175 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Install snap ring (151).
3.
Output shaft A. Using push tool [4] (inside diameter: 71 mm [2.795 in]), press-fit bearing (150) to output shaft (149). B. Set No. 6 housing assembly (152) to tool [5]. C. Using push tool [4] (inside diameter: 71 mm [2.795 in]), press-fit output shaft and bearing assembly (149). ★ Press bearing (150) of the output shaft.
4.
Seal ring A. Install seal ring (146) to No. 6 housing assembly (145). B. Install seal ring (144) to No. 6 piston assembly (143). Seal ring: Grease (G2-LI)
★ Set groove (a) of the seal ring in pressure-receiving direction (b).
50-176 b
WA500-6
DISASSEMBLY AND ASSEMBLY 5.
Guide pin ★ Install five guide pins (142).
6.
No. 6 pin ★ Install No. 6 piston (143).
7.
No. 6 hub ★ Install No. 6 hub (147).
8.
No. 6 plate, spring and No. 6 disc ★ Install three No. 6 plates (141), 20 springs (140), and four No. 6 discs (139).
9.
No. 6 spring ★ Install ten No. 6 springs (138).
POWER TRAIN
10. No. 6 plate ★ Install No. 6 upper plate (137).
11. No. 5 carrier assembly A. Assemble No. 5 carrier assembly (129) according to the following procedure. i.
Install needle roller bearing (135) to planetary gear (136).
ii.
Fit two thrust washers (134) each to both sides of planetary gear (136) and set them to the No. 5 carrier. • Align each part with the shaft hole.
iii. Fit plug (133) and ball (132) to shaft (131) and install them. ★ Check that the planetary gear rotates smoothly.
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50-177 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iv. Install snap ring (130) to No. 5 carrier assembly (129).
B. Using eyebolts [18] and setting the dowel pin, install No. 5 carrier assembly (129). C. Install 11 mounting bolts (128). ★ Drive in the dowel pin with a copper hammer. Mounting bolt: Adhesive (LT-2)
Mounting bolt: 157 – 177 N•m (116 – 131 lbf ft)
12. No. 5 sun gear A. Install No. 5 sun gear (161). B. Install bearing (127) and seal ring (162) to spacer (160).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
13. Install the bearing and spacer assembly (127). 14. Install No. 5 plate (126). 15. Install No. 5 ring gear (125).
16. Install five guide pins (124). 17. Install two No. 5 plates (123), three No. 5 discs (121), and 15 springs (122) alternately. 18. Install ten No. 5 springs (120).
19. No. 5 plate ★ Install No. 5 upper plate (119).
20. Install No. 5 housing and No. 5 piston assembly. A. Install seal ring (117) to No. 5 piston (116). B. Install seal ring (118) to No. 5 housing (115). Seal ring: Grease (G2-LI)
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50-179 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Set groove (c) of the seal ring in pressure-receiving direction (d).
C. Using eyebolt [7], install No. 5 housing (115) and No. 5 piston (116). ★ While installing, use your hand to support No. 5 piston (116) to prevent it from falling.
21. No. 4 ring gear A. Install snap ring (163). B. Install No. 4 ring gear (114).
C. Install cover (113). D. Install four mounting bolts (112). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
22. No. 4 sun gear and spacer A. Install seal ring (111) to spacer (109). Seal ring: Grease (G2-LI)
B. Install No. 4 sun gear (110). C. Install spacer (109). D. Install snap ring (108).
23. Plate ★ Install lower plate (90).
24. No. 4 plate, spring and No. 4 disc ★ Install two No. 4 plates (89), 15 springs (87), and three No. 4 discs (88). 25. No. 4 spring ★ Install ten No. 4 springs (86).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
26. Plate ★ Install upper plate (85).
27. No. 3 piston and No. 4 piston assembly A. Install seal rings (81) and (84) to No. 3 and No. 4 housing (78). B. Install seal ring (80) to No. 3 piston (79) and then install them to No. 3 and No. 4 housing (78). C. Install seal ring (83) to No. 4 piston (82) and then install them to No. 3 and No. 4 housing (78). Seal ring: Grease (G2-LI)
★ Set groove (e) of the seal ring in pressure-receiving direction (f).
28. No. 3 and No. 4 housing assembly A. Using eyebolts [8], install No. 3 and No. 4 housing assembly (78). ★ While installing, use your hand to support No. 4 piston (80) to prevent it from falling. B. Drive in the dowel pin with a copper hammer.
50-182 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
29. No. 3 and No. 4 carrier assembly Assemble the No. 3 and No. 4 carrier assembly according to the following procedure. A. Install seal ring (106) to No. 3 and No. 4 carrier (164). Seal ring: Grease (G2-LI)
B. Using push tool G3, press-fit bushing (107) to No. 3 and No. 4 carrier (164).
C. Using push tool [9], press-fit bearing (104) to No. 3 and No. 4 carrier (164).
D. Install needle roller bearing (102) to planetary gear (103). E. Fit two thrust washers (101) to both sides of planetary gear (103) and set them to the No. 3 and No. 4 carrier. ★ Align each part with the shaft hole. F.
While setting the pin holes, install shaft (98).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
G. Install pin (97).
★ If pin (97) was removed from carrier (164), remove the burrs from edge (g) with sandpaper. ★ Do not apply sandpaper to inside surface (h).
H. Install needle roller bearing (95) to planetary gear (96). I.
Put two thrust washers (94) to both sides of the planetary gear and set them to the No. 3 and No. 4 carriers.
J.
Install shaft (92) and ball (93). ★ Check that the planetary gear rotates smoothly.
K. Install No. 3 and No. 4 carrier assembly (129). ★ Apply push tool [10] to No. 3 and No. 4 carrier assembly (129) and press-fit the bearing inner race to the output shaft.
50-184 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
30. Guide pin ★ Install 5 guide pins (70). 31. No. 3 ring gear ★ Install No. 3 ring gear (77).
32. Plate ★ Install lower plate (76).
33. No. 3 plate, spring and No. 3 disc ★ Install three No. 3 plates (75), 20 spring (73), and four No. 3 discs (74). 34. No. 3 spring ★ Install ten No. 3 springs (72).
35. Plate ★ Install upper plate (71).
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50-185 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
36. No. 2 carrier and housing assembly A. Assemble the No. 2 carrier assembly according to the following procedure. i.
Set snap ring (63) to No. 2 carrier assembly (62) and install ring gear (64).
ii.
Install snap ring (63) to the groove of ring gear (64) securely.
iii. Install needle roller bearing (68) to planetary gear (69). iv. Fit two thrust washers (67) to both sides of planetary gear (69) and set them to the No. 2 and No. 4 carrier (62). ★ Align each part with the shaft hole. v.
While setting the pin holes, install shaft (66).
vi. Install pin (65). ★ Check that the planetary gear rotates smoothly.
★ If pin (65) was removed from carrier (62), remove the burrs from edge (m) with sandpaper. ★ Do not apply sandpaper to inside surface (n).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
vii. Install spacer (59) and ring gear (61) to the No. 2 carrier assembly.
B. Assemble the No. 2 housing assembly according to the following procedure. i.
Install seal ring (58) to No. 2 housing (55). Seal ring: Grease (G2-LI)
ii.
Support No. 2 housing assembly (55) and press-fit bearing (57) with push tool [12].
iii. Install snap ring (56).
iv. Support No. 2 carrier assembly (165) and press-fit No. 2 housing (54) with push tool [13]. ★ Press-fit the bearing inner race. v.
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Install snap ring (52).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Using eyebolts [14], install No. 2 carrier and housing assembly (51).
37. No. 2 disc, spring and No. 2 plate A. Install six No. 2 plates (50), seven No. 2 discs (48), and 35 springs (49) alternately. B. Install ten springs (47).
38. No. 1 and No. 2 piston housing assembly Assemble No. 1 and No. 2 piston housing assembly according to the following procedure. A. Install seal rings (43) and (44) to No. 1 and No. 2 piston housing (42). Seal ring: Grease (G2-LI)
B. Install seal ring (41) to No. 1 piston (40). Seal ring: Grease (G2-LI)
C. Install seal ring (46) to No. 2 piston (45). Seal ring: Grease (G2-LI)
D. Install No. 1 piston (40) and No. 2 piston (45) to No. 1 and No. 2 piston housing (42). ★ Set groove (j) of the seal ring in pressure-receiving direction (k).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
E. Install 15 cushion sleeves (166) to No. 2 piston housing (42).
★ When installing cushion sleeve (166) to No. 2 piston housing (42), set slit (A) to the position which you checked when you removed it.
39. Using eyebolts [15], install No. 1 and No. 2 piston housing assembly (42). ★ While installing, use your hand to support No. 2 piston (45) to prevent it from falling. ★ Drive in the dowel pin with a copper hammer.
40. No. 1 carrier assembly Assemble the No. 1 carrier assembly according to the following procedure. A. Using push tool [16], press-fit bearing (34) to No. 1 carrier (14). B. Install snap ring (33) to No. 1 carrier (14).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Install needle roller bearing (26) to planetary gear (27). D. Fit two thrust washers (25) to both sides of planetary gear (27) and set them to the No. 1 carrier (14). ★ Align each part with the shaft hole. E. While setting the pin holes, install shaft (23).
F.
Install pin (24). ★ Check that the planetary gear rotates smoothly.
★ If pin (24) was removed from carrier (14), remove the burrs from edge (r) with sandpaper. ★ Do not apply sandpaper to inside surface (s).
G. Set No. 1 ring gear (20) to No. 1 carrier assembly (14) and install snap ring (19).
50-190 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
41. Input shaft ★ Support No. 1 carrier (14) and press-fit input shaft (12) with push tool [22].
42. Spacer and sun gear ★ Install spacer (29) and sun gear (28). 43. Bearing and spacer A. Using push tool [18] (inside diameter: 66 mm [2.598 in]), press-fit bearing (32) to spacer (30).
B. Using push tool [19] (inside diameter: 66 mm [2.598 in]), press-fit spacer (30). C. Install snap ring (31) to spacer (30). ★ After assembling, check that the bearing rotates lightly.
44. No. 2 sun gear A. Install No. 2 sun gear (10). B. Install snap ring (9). 45. Input shaft and No. 1 carrier assembly ★ Using eyebolts [20], install the input shaft and No. 1 carrier assembly (167).
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50-191 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
46. Guide pin ★ Install five guide pins (39).
47. No. 1 plate, spring and No. 1 disc ★ Install six No. 1 plates (38), 35 springs (37), and seven No. 1 discs (36) alternately. 48. No. 1 spring ★ Install ten No. 1 springs (35).
49. No. 1 housing A. Install seal ring (18) to No. 1 housing (11). Seal ring: Grease (G2-LI)
B. Using push tool [23] (outside diameter: 149 mm [5.866 in]), press-fit bearing (17).
C. Install snap ring (16) to fix bearing (17).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Using eyebolts [24], install No. 1 housing (11).
E. Install eyebolt [25] to the input shaft; sling the input shaft; and install snap ring (13).
F.
Install 13 tie bolts (6). ★ Do not install two tie bolts (6a) to install the eyebolts. • Finger tighten the tie bolts until they reach the tap hole. • Make sure that the bolts do not damage the cushion sleeves. • Use an impact wrench after the threads are engaged perfectly. ★ Do not degrease the threads of the tie bolts. Mounting bolt: 157 – 177 N•m (116 – 131 lbf ft)
50. Check operation and stroke of clutch piston ★ Using tool G, check the operation and stroke of the clutch piston. Air pressure: . . . . . . . . . . . . . . 2.96 – 5.0 kg/cm² (42 – 71 psi)
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Piston
Stroke (mm)
No. 1
7
No. 2
7
No. 3
4.2
No. 4
3
No. 5
3
No. 6
4
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
51. Transmission assembly A. Install dowel pin (168) from the output shaft side. B. Install the eyebolts to the bolt holes marked with (*).
C. Set transmission case (169) on block [26]. D. Using eyebolts [27], install transmission assembly (5).
E. Set dowel pin (168) and install the transmission assembly. F.
Install six lower mounting bolts (3) and 18 upper mounting bolts (4). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
Shaft (Spline): Grease (LM-G)
G. Install two tie bolts (170) which were removed to install the eyebolts. • Finger tighten the tie bolts until they reach the tap hole. • Make sure that the bolts do not damage the cushion sleeves. • Use an impact wrench after the threads are engaged perfectly. ★ Do not degrease the threads of the tie bolts. Mounting bolt: 157 – 177 N•m (116 – 131 lbf ft)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
52. Sleeve ★ Using forcing screw [1], install 5 sleeves (1). 53. Couple the transmission assembly with the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
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50-195 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Transfer and Parking Brake Assembly
4
G
5
■
1
790-101-2501
Push puller
790-101-2610
• Leg
1
790-101-2660
• Adapter
1
790-101-2510
• Block
1
790-101-2560
• Nut
1
01643-32060
Washer
■
2
790-101-2102
Puller (294 kN {30 ton})
■
2
790-101-1102
Pump
■
6
790-101-2501
Push puller
■
1
790-101-2540
• Washer
1
790-101-2620
• Leg
2
790-101-2510
• Block
1
790-101-2660
• Adapter
2
790-101-2560
• Nut
2
791-112-1180
• Nut
1
Sketch
Part Name
New/Remodel
Part No.
Qty
Symbol
Necessity
Special Tools
Nature of Work, Remarks
Removal of output shaft
Press-fitting of output shaft bearing
791-520-4140
Screw
■
1
793T-615-1630
Adapter
■
1
N
❍
793T-615-1640
Push tool
■
1
N
❍
01643-32060
Washer
■
2
790-101-2102
Puller (294 kN {30 ton})
■
1
790-101-1102
Pump
■
1
6
793-615-1140
Spline wrench
■
1
Preload adjustment on intermediate shaft bearing
7
796-720-3800
Wrench assembly
■
1
Preload adjustment on input shaft bearing
50-196 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Disassembly 1.
Disconnect the transfer and parking brake assembly from the power train unit. ★ For details, see POWER TRAIN: Power Train in this section.
2.
Remove strainer (1) and drain valve (2).
3.
Remove speed sensor (3).
4.
Input shaft bearing cage assembly A. Remove six mounting bolts (4). B. Using forcing screws [1], remove bearing cage assembly (5).
C. Remove shim (6). ★ Check the thickness and quantity of the shims at each position; keep these shims.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Using push tool [2], remove outer race (7) from bearing cage assembly (5).
5.
Input shaft gear assembly A. Remove input shaft gear assembly (8). B. Remove bearings (10) and (11) from input shaft gear assembly (8).
6.
Outer race (input shaft side) ★ Remove outer race (12) from the case.
7.
Cover (input shaft side) A. Reverse the transfer case. B. Remove three mounting bolts (13) and cover (14).
50-198 b
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DISASSEMBLY AND ASSEMBLY 8.
POWER TRAIN
Intermediate shaft bearing cage assembly A. Remove eight mounting bolts (15). B. Using forcing screws [3], remove bearing cage assembly (16).
C. Remove shim (17). ★ Check the thickness and quantity of the shims at each position; keep these shims.
D. Remove outer race (18) and O-ring (86) from bearing cage assembly (16).
9.
Intermediate shaft gear assembly A. Remove intermediate shaft gear assembly (19). B. Remove bearings (20) and (21) from intermediate shaft gear assembly (19).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
10. Outer race (intermediate shaft side) ★ Remove outer race (22) from the case.
★ Steps 11 – 22 are disassembly procedures for the parking brake. 11. Parking brake emergency release valve A. Reverse the case. B. Remove mounting bolts (32) and parking brake emergency release valve (33).
C. Remove O-ring (87) from the mating face. D. Using forcing screw [4], remove sleeve (34). E. Remove O-rings (88) from sleeve (34).
12. Coupling (rear side) • Remove bolt (35), holder (36), and coupling (37).
50-200 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
13. Parking brake assembly A. Remove 12 mounting bolts (38). ★ Do not remove four hexagon socket head bolts (39). B. Using forcing screws [5], disconnect parking brake assembly (40).
C. Remove the forcing screws used in the Step 13B from parking brake assembly (40) and lift off the parking brake assembly, using eyebolts [6]. D. Remove O-ring (89).
14. Cover assembly A. Remove mounting bolts (41) and remove oil seal (43), dust seal (44), and O-ring (45) from cage (42).
B. Install stopper bolts [7] and remove four hexagon socket head bolts (39). C. Loosen stopper bolts [7] gradually to disconnect cover assembly (46) from the case. ★ The cover assembly is lifted up from the case about 21 mm (0.827 in) by the spring.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Lift off cover assembly (46).
E. Remove bearing (47), dowel pin (48), and O-ring (90) from cover assembly (46).
15. Spring ★ Remove 18 outer springs (49) and 18 inner springs (50).
16. Spacer assembly A. Remove spacer assembly (51). B. Using push tool [8], remove inner race (53) from spacer (52).
50-202 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
17. Piston A. Using eyebolts [9], lift off piston (54). B. Remove seal rings (55) and (56).
18. Gear ★ Remove gear (77).
19. Plate A. Reverse the housing. B. Remove four mounting bolts (57) and plate (58).
20. Snap ring and end plate ★ Remove snap ring (59) and end plate (60).
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50-203 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
21. Plate, disc, and wave spring ★ Remove five plates (61), five discs (62), and five wave springs (63) alternately.
22. End plate A. Remove end plate (64).
B. Remove snap ring (91).
23. Coupling (front side) ★ Remove bolt (23), holder (24), and coupling (25).
50-204 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
24. Seal cage A. Remove four bolts (80) and seal cage (81). B. Remove shim (82). ★ Check the thickness and quantity of the shims; keep these shims.
C. Remove O-ring (29), oil seal (87), and dust seal (84) from seal cage (81).
25. Output shaft ★ Using tool G4, remove output shaft (65).
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50-205 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
26. Output shaft bearing cage assembly A. Remove six mounting bolts (66). B. Using forcing assembly (67).
screws
[10],
remove
bearing
cage
C. Using push tool [11], remove outer races (68a) and (68b), collar (68c), and bearings (68d) and (68e) from bearing cage (69). ★ Since the two bearings are not interchangeable, keep them and their respective cages as sets. 27. Output shaft gear A. Remove output shaft gear (70) and spacer (71). B. Remove three mounting bolts (72) and oil plate (73).
50-206 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
Outer race (intermediate shaft side) ★ Using push tool [1] (outside diameter: 179 mm [7.047 in]), press-fit outer race (22) to the case.
2.
Intermediate shaft gear assembly A. Press-fit bearings (20) and (21) to intermediate shaft gear assembly (19).
B. Install intermediate shaft gear assembly (19). Bearing: Grease (LM-G)
3.
Bearing cage assembly (intermediate shaft gear side) A. Using push tool [2] (outside diameter: 179 mm [7.047 in]), press-fit outer race (18) to bearing cage (16). B. Fit O-ring (86). O-ring: Grease (G2-LI)
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50-207 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Install intermediate shaft bearing cage assembly (16) without setting any shim. D. Adjusting preload on intermediate shaft bearing Adjust the shim of bearing cage (16) according to the following procedure. i.
Install bearing cage (16) without setting shim (17) and tighten the mounting bolts to 4.9 N•m (43 lbf in). ★ After installing the bearing, drop 6 cc of transmission oil (TO30) onto it and rotate it about ten turns.
ii.
Rotate intermediate shaft gear (19) 20 turns and check the tightening torque of 4.9 N•m (43 lbf in) for the mounting bolts again.
iii. If the tightening torque has changed, repeat Steps Di and Dii. iv. If the tightening torque has not changed, set shim (17) and tighten the mounting bolts to the specified torque. Shim standard thickness: . . . . . . . . . . . . 1 mm (0.039 in)
v.
Using tool G6 and the torque wrench, measure the rotation torque of intermediate shaft gear (19). Rotation torque: 0.49 – 0.98 N•m (4 – 9 lbf in) Standard shim thickness: . . . . . . . . . . . . 1 mm (0.039 in) Standard clearance: . .0.63 – 1.37 mm (0.025 – 0.054 in)
★ Check that the gear has no play. vi. After adjusting the preload, remove intermediate shaft gear (19) and bearing cage (16) (since the preload on each gear must be adjusted independently). 4.
Cover (input shaft side) ★ Fit the O-ring; install cover (14); and tighten the mounting bolts (13). O-ring: Grease (G2-LI)
5.
Outer race (input shaft side) A. Reverse the case. B. Using push tool [3] (outside diameter: 159 mm [6.260 in]), press-fit outer race (12) to the case.
50-208 b
WA500-6
DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Input shaft gear assembly A. Press-fit bearings (10) and (11) to input shaft gear (8).
B. Install input shaft gear (8). Bearing: Grease (LM-G)
7.
Bearing cage assembly (input shaft gear side) A. Using push tool [4] (outside diameter: 159 mm [6.260 in]), press-fit outer race (7) to bearing cage (5).
B. Install input shaft bearing cage assembly (5) without setting the shim. C. Adjusting preload on input shaft bearing Adjust the shim of bearing cage (5) according to the following procedure. i.
WA500-6
Install bearing cage (5) without setting shim (6) and tighten the mounting bolts to 4.9 N•m (43 lbf in). ★ After installing the bearing, drop 6 cc of transmission oil (TO30) onto it and rotate it about ten turns.
50-209 b
DISASSEMBLY AND ASSEMBLY ii.
POWER TRAIN
Rotate input shaft gear (8) 20 turns and check the tightening torque of 4.9 N•m (43.37 lbf in) for the mounting bolts again.
iii. If the tightening torque has changed, repeat Steps Ci and Cii. iv. If the tightening torque has not changed, set shim (6) and tighten the mounting bolts to the specified torque. v.
Using tool G7 and the torque wrench, measure the rotation torque of input shaft gear (8). Rotation torque: 0.49 – 0.98 N•m (4 – 9 lbf in) Standard shim thickness: . . . . . . . . . . . . 2 mm (0.079 in) Standard clearance: . .1.61 – 2.39 mm (0.063 – 0.094 in)
★ Check that the gear has no play. 8.
Output shaft gear assembly A. Put spacer (71), output shaft gear (70), and oil plate (73) in the case. B. Tighten three mounting bolts (72). Mounting bolt: Adhesive (LT-2)
9.
Outer race and output shaft A. Using push tool [5], press-fit outer race (68a) to bearing cage (69). B. Install output shaft (65) and support it on block [6].
10. Output shaft bearing cage assembly ★ Fit the O-ring and install bearing cage assembly (69). O-ring: Grease (G2-LI)
50-210 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
11. Output shaft bearing A. Using tool G5, press-fit bearing (68d). B. Install collar (68c). C. Press-fit bearing (68e) in the same manner.
12. Outer race • Using push tool [6], press-fit outer race (68b). • After installing the bearing, drop 6 cc of transmission oil (TO30) onto it and rotate it about ten turns.
13. Seal cage A. Using the push tool, press-fit oil seal (83) and dust seal (84) to seal cage (81). Oil seal: Grease (G2-LI)
Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)
★ Apply the gasket sealant thinly over the inside surface of the housing hole and wipe off the projected part. Dust seal: Grease (G2-LI)
WA500-6
50-211 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Adjust the shim according to the following procedure. i.
Fit the O-ring and install seal cage (81) without setting the shim. ★ Do not tighten the mounting bolts. O-ring: Grease (G2-LI)
ii.
Rotate the shaft about 20 turns.
iii. Using thickness gauges, measure clearance (a) between the seal cage (81) and fitting surface. Shim thickness (b): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(a) – (0.05 to 0.10) mm [(a) - 0.0020 – 0.0039 in)]
iv. Set shim (82) of thickness (b), obtained by the above procedure, and tighten bolts (80). Standard shim thickness: . . . . . . . . . . .0.5 mm (0.020 in) Standard clearance: . .0.48 – 1.32 mm (0.019 – 0.052 in)
14. Coupling (front side) ★ Fit the O-ring and install coupling (25), holder (24), and bolt (23). O-ring: Grease (G2-LI)
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
15. Intermediate shaft gear assembly ★ Refer to Step 2 and install the intermediate shaft gear assembly which was removed. ★ Steps 16 – 29 are assembly procedures for the parking brake. 16. Cover ★ Assemble the cover assembly according to the following procedure. A. Using push tool [1] (outside diameter: 189 mm [7.441 in]), press-fit bearing (47) to cover (46). B. Install two dowel pins (48).
50-212 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
17. Spacer assembly A. Using push tool [2] (inside diameter: 106 mm [4.173 in]), press-fit inner race (53) to spacer (52). B. Install spacer assembly (51) to cover assembly (46).
18. Spring A. Install 18 outer springs (49) and 18 inner springs (50). B. Install O-ring (90). O-ring: Grease (G2-LI)
19. Piston A. Install seal rings (55) and (56) to piston (54). ★ Set groove (c) of the seal ring as shown in the figure. Seal ring: Grease (G2-LI)
B. Install piston (54) to cover assembly (46).
20. Plug A. Remove two plugs (74). B. Install the washers to two parking brake assembly mounting bolts and tighten them into the plug holes. ★ Tighten the bolts gradually and alternately. ★ Pull the piston by tightening the bolts.
WA500-6
50-213 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
21. Housing A. Install housing (75) to cover (46).
B. Install four hexagon socket head bolts (76).
22. Gear ★ Install gear (77).
23. Plate, disc, and wave spring A. Install snap ring (91). B. Install end plate (64).
50-214 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Alternately install five discs (62), five wave springs (63), and five plates (61).
24. Snap ring and end plate ★ Install end plate (60) and fix it with snap ring (59).
25. Plate A. Install plate (58) and tighten four mounting bolts (57). Mounting bolt: Adhesive (LT-2)
B. Reverse the parking brake assembly. C. Remove the two bolts used to install the spring and install plugs (74). Plug: Gasket sealant (LG-5)
WA500-6
50-215 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
26. Seal cage A. Press-fit oil seal (43) and dust seal (44) to seal cage (42). ★ Apply the gasket sealant thinly over the inside surface of the oil seal fitting part of the cover and wipe off the projected part. Oil seal: Grease (G2-LI) Oil seal fitting surface: Gasket sealant (THREEBOND 1110B) Dust seal: Grease (G2-LI)
B. Install seal cage (42) and tighten four mounting bolts (41).
27. Parking brake assembly A. Fit O-ring (89). O-ring: Grease (G2-LI)
B. Using eyebolts [6], install parking brake assembly (40).
C. Install 12 mounting bolts (38). Mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
50-216 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
28. Sleeve A. Fit O-ring (88) to sleeve (34). O-ring: Grease (G2-LI)
B. Using forcing screw [4], install sleeve (34).
C. Fit O-ring (87) and install parking brake emergency release valve (33). O-ring: Grease (G2-LI)
29. Coupling (rear side) A. Fit the O-ring and install coupling (37), holder (36), and bolt (35). B. Set coupling (37) to the position of the coupling on the opposite side. O-ring: Grease (G2-LI)
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
30. Speed sensor A. Tighten speed sensor (3) until it touches the gear lightly and then return it by 1/2 - 1 turn to make clearance (d). Clearance (d): . . . . . . . . . . .0.75 – 1.5 mm (0.030 – 0.059 in)
B. Tighten locknut (85). Locknut: 49.0 – 68. 6 N•m (36 – 51 lbf ft)
WA500-6
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
31. Install strainer (1) and drain valve (2). 32. Connect the transfer and parking brake assembly to the power train unit. ★ For details, see POWER TRAIN: Power Train in this section
50-218 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Front Axle WARNING!
Stop the machine on level ground and lower the bucket to the ground.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Start the engine; dump the bucket gradually to raise the machine body; and set stands [1] securely under the front frame. WARNING!
2.
Apply the parking brake and lock the rear tires with chocks.
Install a nylon sling around front tire and wheel assembly (1); sling it; remove its mounting bolts; and lift it off. Remove both the right and left tires. [*1] Front tire and wheel assembly: 830 kg (1,830 lbs)
3.
Remove front frame front cover (2).
WA500-6
50-219 b
DISASSEMBLY AND ASSEMBLY 4.
Disconnect brake hose (3).
5.
Remove the mounting bolts and disconnect front drive shaft (4). [*2] ★ When disconnecting the drive shaft, make a match mark between it and the coupling.
6.
Sling front axle assembly (5); remove its eight mounting bolts (6); and lift it off. [*3]
POWER TRAIN
Front axle assembly: 2,300 kg (5,071 lbs)
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Installation ★ Carry out installation in the reverse order of removal. [*1] Front tire mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
[*2] Drive shaft mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
[*3] Front axle mounting bolt: 2,450 – 3,038 N•m (1,807 – 2,241 lbf ft)
Bleeding Air Bleed air from the brake circuit. ★ For details, see BRAKE SYSTEM: Bleeding Air from Brake Circuit in the Testing and Adjusting section.
WA500-6
50-221 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Rear Axle WARNING!
Stop the machine on level ground and lower the bucket to the ground.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Start the engine; dump the bucket gradually to raise the machine body; and set stands [1] securely under the front end of the rear frame.
2.
Tilt the bucket slowly until the front tires are fully lowered to the ground and the rear tires are floating.
3.
Set jack [2] under the counterweight to support the rear end of the rear frame. WARNING!
4.
Apply the parking brake and lock the front tires with chocks.
Install a nylon sling around rear tire and wheel assembly (1); sling it; remove its mounting bolts; and lift it off. Remove both the right and left tires. [*1] Rear tire and wheel assembly: 830 kg (1,830 lbs)
50-222 b
WA500-6
DISASSEMBLY AND ASSEMBLY 5.
Disconnect brake hoses (2) and (3).
6.
Unplug wiring harness connector R17 (4) and remove the two wiring harness clamps.
7.
Disconnect grease tubes (5) and (6)
8.
Disconnect rear drive shaft (7).
9.
Sling rear axle assembly (8) and support rear support (9) with jack [3].
POWER TRAIN
[*2]
10. Remove support mounting bolts (10); disconnect the support and rear axle assembly from the machine; and lower the jack and crane slowly to remove the assembly. [*3] 11. Sling the left (right) side of the axle housing; support the other side with a jack or a forklift; and pull out the rear axle and support assembly to the side of the machine. Rear axle and support assembly: 2,400 kg (5,291 lbs)
WA500-6
50-223 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Installation ★ Carry out installation in the reverse order of removal. [*1] Rear tire mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
[*2] Drive shaft mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
[*3] Axle (support) mounting bolt: 1,519 – 1,911 N•m (1,120 – 1,410 lbf ft)
Bleeding Air ★ Bleed air from the brake circuit. ★ For details, see BRAKE SYSTEM: Bleeding Air from Brake Circuit in the Testing and Adjusting section.
50-224 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Front Differential ★ This section describes the removal and installation procedures for the front differential assembly. Remove and install the rear differential assembly in the same manner. WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal
Required •
Container to hold the axle oil
Removal 1.
Remove the front axle assembly. ★ For details, see POWER TRAIN: Front Axle in this section.
2.
Remove plug (1) and drain the axle oil. [*1] ★ Set the drain plug at the bottom. Axle oil: Front: Approximately 98 l (26 gal) Rear: Approximately 85 l (23 gal)
3.
Remove seven bolts (2).
[*2]
4.
Remove cover (3).
5.
Using forcing screw [1], pull out drive shaft (4). • Pull out the drive shaft by about 200 mm (8 in). • Pull out the drive shaft on the opposite side in the same manner.
6.
Remove 18 mounting bolts (5). [*3]
7.
Using eyebolts [2], remove front differential assembly (6).
[*4]
Front differential assembly: Without LSD* specification: . . . . . . . . . . . . . . . . . . 370 kg (816 lbs) LSD specification: . . . . . . . . . . . . . . . . . . . . . . . . . 400 kg (882 lbs)
* LSD: Limited Slip Differential ★ Remove the O-ring from the mating face of the housing.
WA500-6
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Installation ★ Carry out installation in the reverse order of removal. [*1] Plug (1): 58.8 – 78.4 N•m (43 – 58 lbf ft)
[*2] Mounting bolt (2): 98 – 123 N•m (72 – 91 lbf ft)
[*3] Mounting bolt (5): 490 – 608 N•m (361 – 448 lbf ft)
[*4] Adjusting Clearance Adjustment Bolt 1.
Tighten clearance adjustment bolt (7) to cap (9) and then return it by 20 – 30° to make clearance (a). Clearance (a): . . . . . . . . . . . . . .0.08 – 0.13 mm (0.003 – 0.005 in)
2.
Tighten nut (8). Nut (8): 343 – 441 N•m (253 – 325 lbf ft)
Refilling with Oil Axle oil: Front: 98 l (26 gal) Rear: 85 l (23 gal)
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Differential (with Limited Slip Differential)
Repair stand
■
1
790-901-4110
Bracket
■
1
793T-622-2120 Plate
■
1
792-103-0901
Wrench
■
1
1
792-525-1000
Micrometer
■
1
2
793T-822-1310 Adapter
■
1
Part No.
1
Part Name
H 6 7
Sketch
Qty
790-501-5000
Symbol
New/Remodel
Necessity
Special Tools
Nature of Work, Remarks
Removal and installation of differential N
❍ Bearing preload adjustment
N
❍
–
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Disassembly 1.
Set differential assembly (1) to tool H1. Differential assembly: 430 kg (948 lbs)
2.
Differential gear and case assembly ★ Perform the following work on the right and left sides in a similar manner. A. Remove mounting bolts (2) and remove lock (3).
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Loosen nut (4) with a bar until you can rotate it with your fingers. C. Sling the differential gear and case assembly. D. Remove mounting bolts (5) and cap (6). ★ Make marks on the right and left caps. E. Remove nut (4).
F.
Using sling [1], remove differential gear and case assembly (7). ★ Be careful not to drop bearing outer race (8). Differential gear and case assembly: 210 kg (463 lbs)
3.
Gear case cover A A. Remove 24 mounting bolts (9). B. Remove gear case cover A (10). C. Remove bearing (11).
D. Remove thrust plate (12) and dowel pin (13) from gear case cover A (10).
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DISASSEMBLY AND ASSEMBLY 4.
Disc and plate ★ Remove three discs (14) and four plates (15).
5.
Pressure ring A ★ Remove pressure ring A (16).
6.
Side gear A ★ Remove side gear A (17).
7.
Cross shaft and pinion gear ★ Remove cross shaft (18) and pinion gear (19) together.
WA500-6
POWER TRAIN
50-229 b
DISASSEMBLY AND ASSEMBLY 8.
Side gear B ★ Remove side gear B (20).
9.
Pressure ring B ★ Remove pressure ring B (21).
POWER TRAIN
10. Disc and plate ★ Remove four plates (22) and three discs (23).
11. Gear case cover B A. Remove thrust plate (25) and dowel pin (26) from gear case cover B (24).
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Reverse the gear case and remove bearing (27). C. Remove 20 mounting bolts (28). D. Remove gear case cover B (29) from bevel gear (30).
12. Coupling A. Remove mounting bolt (31) and holder (32). B. Remove shim (33), O-ring (34), and coupling (35).
13. Pinion assembly A. Remove 18 mounting bolts (36). B. Using forcing screws [2], disconnect pinion assembly (37).
C. Using eyebolts [3], remove pinion assembly (37). Pinion assembly: 95 kg (209 lbs)
D. Remove shim (38). ★ Check the thickness and quantity of the shim.
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
E. Remove differential carrier (47) from tool H1. Differential carrier assembly: 85 kg (187 lbs)
F.
Disassemble the pinion assembly according to the following procedure. i.
Using tool [4] (inside diameter: 321 mm [12.638 in]), support pinion case (39).
ii.
Using push tool [5], pull out pinion shaft (40).
iii. Using puller [6] (294 kN [30 ton]), pull out bearing (41).
iv. Remove dust seal (42), oil seal (43), and bearing (44). v.
50-232 b
Remove bearing outer race (45).
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
Bevel gear assembly A. Using push tool [10] (inside diameter: 131 mm [5.158 in]), press-fit bearing (27) to gear case cover B (29). ★ Press-fit the inner race of the bearing.
B. Install gear case cover B (29) to bevel gear (30). C. Tighten 20 mounting bolts (28). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 490 – 608 N•m (361 – 448 lbf ft)
2.
Gear case cover B A. Install dowel pin (26) to gear case cover B (24). B. Install thrust plate (25).
3.
Disc and plate • Install three discs (23) and four plates (22) alternately. Both sides of plate and disc: AXO80
WA500-6
50-233 b
DISASSEMBLY AND ASSEMBLY 4.
Pressure ring B ★ Install pressure ring B (21).
5.
Side gear B
POWER TRAIN
A. Install side gear B (20). B. Mesh the internal teeth of the disc with the gear spaces.
6.
Cross shaft and pinion gear ★ Install cross shaft (18) and pinion gear (19) together.
7.
Side gear A ★ Install side gear A (17).
50-234 b
WA500-6
DISASSEMBLY AND ASSEMBLY 8.
Pressure ring A ★ Install pressure ring A (16).
9.
Disc and plate
POWER TRAIN
A. Install four plates (15) and three discs (14) alternately. ★ When installing, mesh the internal teeth of the disc with the gear spaces. Both sides of plate and disc: AXO80
B. Adjusting clearance between plate and disc (adjusting internal clearance of LSD) i.
Using depth gauge [1], measure level difference (A2) between the case and washer.
ii.
Using depth gauge [1], measure level difference (A1) of the cover. Clearance (A): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 – A1 = 0.2 to 0.8 mm (0.008 – 0.031 in)
★ Measure the clearance at four places equally spaced on the periphery and obtain the average. iii. If the clearance is out of the standard range, adjust it by using plates of different thickness. Part No. 425-22-37450: . . . . . . . . . . . . .3.4 mm (0.134 in) Part No. 425-22-37460: . . . . . . . . . . . . .3.5 mm (0.138 in)
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50-235 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Be sure to use plates of the same thickness for the lower side (see the table). ★ When assembling the plates and discs, minimize the clearance.
Combination of Plates
Standard (Before adjustment)
After adjustment (Sample 1)
After adjustment (Sample 2)
Flange Cover Flange Cover Flange Cover side side side side side side 425–22–37450 (3.4 mm)
2
2
1
1
4
4
425–22–37460 (3.5 mm)
2
2
3
3
0
0
C. Adjusting clearance between thrust washer and cover i.
Install thrust washer (12) to cover (10) temporarily.
ii.
Using depth gauge [1], measure level difference (B1) between the cover and washer.
iii. Using depth gauge [1], measure level difference (B2) between the case and washer. Clearance (B): . . . . . . . . . . . . . . . . . . . . (B2 – B1) + (A/2)
★ Measure the bottom side in the same manner. ★ Measure the clearance at four places equally spaced on the periphery and obtain the average. iv. If the clearance is out of the standard range, adjust it by using plates of different thickness. Part No. 425-22-37390: . . . . . . . . . . . .3.75 mm (0.148 in) Part No. 425-22-37380: . . . . . . . . . . . . .4.0 mm (0.158 in) Part No. 425-22-37370: . . . . . . . . . . . .4.25 mm (0.167 in)
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
10. Gear case cover A A. Using push tool [11] (inside diameter: 131 mm [5.158 in]), press-fit bearing (11) to gear case cover (A) (10). ★ Press-fit the inner race of the bearing.
B. Install dowel pin (13) and thrust plate (12) to gear case cover A (10). ★ When installing, apply grease (G2-LI) thinly to the thrust plate to prevent it from falling.
C. Install gear case cover A (10). D. Tighten 24 mounting bolts (9). Mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
E. Measuring differential rotation torque i.
Using the bearing, cap, and nut, install the differential gear and case assembly temporarily to the differential carrier.
ii.
Fix either side gear of the differential gear case assembly with shaft [1]. (Stop the rotation of the side gear.)
iii. Measure the rotation torque of the side gear on the opposite side with torque wrench [2]. ★ Set the case so that it can rotate freely. ★ You can use a measuring instrument which satisfies the measurement condition and can be fixed to the side gear. Differential rotation torque: Maximum 34 N•m (25 lbf ft)
WA500-6
50-237 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
11. Differential gear and carrier assembly ★ Perform the following work on the right and left sides in the same manner. A. Set differential carrier (47) to tool H1. Differential carrier assembly: 85 kg (187 lbs)
B. Using sling [1], install differential gear and case assembly (7). ★ Be careful not to drop bearing outer race (8). Differential gear and case assembly: 210 kg (463 lbs)
C. Install nut (4) to the threaded part on the differential carrier side. D. Install cap (6) and tighten mounting bolts (5). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 1,520 – 1,910 N•m (1,121 – 1,409 lbf ft)
★ Set the match mark on cap (6). ★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate it about ten turns. ★ Before tightening mounting bolts (5), rotate the bevel gear 20 – 30 turns to run in the bearing. E. Adjust the differential bearing preload according to the following procedure. i.
50-238 b
Install tool H7-2 to the threaded portions (A) of the right and left cap tops. ★ Tighten until there is no play.
WA500-6
DISASSEMBLY AND ASSEMBLY ii.
POWER TRAIN
Using tool H7-1, measure dimension (L).
iii. Add 0.31 ±0.11 mm (0.012 ±0.004 in) to measured value (L) and set the scale of tool H7-1 to the obtained value. ★ The added dimension is the deflection of the case made by providing a preload.
iv. Using tool H6, tighten nut (4). ★ Using tool H6, tighten adjustment nut (4) so that the increase is 0.31 ±0.11 mm (0.012 ±0.004 in).
v.
Put push-pull scale [13] to the tip of bevel gear (30) and measure the starting force. Starting force: . . . . . . . . . . . . . . . 14.7 – 44.1 N (3 – 10 lbf)
★ If the starting force is out of the above range, repeat Step 11Eiii and adjust again.
★ Precautions for adjusting starting torque • If the nut is tightened too much for starting force adjustment or the starting force is adjusted defectively, return the nut to the condition before the adjustment. • At this time, hit the cap and the bevel gear lightly with a plastic hammer while rotating the bevel gear. • At this time, check that there is no clearance in part (c) and adjust the preload again.
WA500-6
50-239 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
12. Pinion assembly A. Assemble the pinion assembly according to the following procedure. i.
Using push tool [6] (inside diameter: 101 mm [3.976 in]), press-fit bearing (41) to pinion shaft (40).
ii.
Press-fit bearing (44) and bearing outer race (45) to pinion case (46). ★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate it about ten turns.
iii. Using push tool [7] (inside diameter: 76 mm [2.992 in]), press-fit pinion case (46) to pinion shaft (40). ★ Press-fit the inner race of bearing (44).
iv. Install dust seal (42) and oil seal (43). ★ Using the jig, press-fit the oil seal so that its height (a) is 14 ±0.5 mm (0.551 ±0.020 in). ★ Install the dust seal so that its height (b) is the same as the oil seal. ★ Apply the gasket sealant thinly over the inside surface of the oil seal fitting part of the pinion case and wipe off the projected part. Oil seal: Grease (G2-LI)
Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)
Dust seal: Grease (G2-LI)
50-240 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Coupling i.
Install coupling (35).
ii.
Install O-ring (34) and shim (33) which was removed during disassembly.
iii. Install holder (32) and tighten mounting bolts (31). ★ While rotating the pinion shaft 20 – 30 turns, tighten mounting bolts (31) gradually. O-ring: Grease (G2-LI)
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
C. Adjust the preload on the pinion shaft according to the following procedure. i.
Install measuring bolt [8] to pinion assembly (37).
ii.
Using push-pull scale [9], measure starting torque (a). Starting torque (a): 49.0 – 127.4 N•m (36 – 94 lbf ft) ★ If the measured value is out of the above range, adjust it by increasing or decreasing the shims.
D. Install shim (38) removed during the disassembly procedure. Shim adjustment allowance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.71 – 2.21 mm (0.028 – 0.087 in)
E. Fit the O-ring and install pinion assembly (37). O-ring: Grease (G2-LI)
Pinion assembly: 110 kg (243 lbs)
F.
Tighten 18 mounting bolts (36). Mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
WA500-6
50-241 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
13. Adjusting tooth contact and backlash ★ Adjust the backlash and tooth contact simultaneously. A. Adjust the backlash according to the following procedure. i.
Move the bevel gear with adjustment nuts (4a) and (4b). ★ Rotate adjustment nuts (4a) and (4b) by the same amount, in the same direction, so that the adjusted preload on the bearing does not change.
ii.
Apply dial gauge [14] perpendicularly to the tooth surface on the reverse side at the outer end of the bevel gear.
iii. Adjust adjustment nut (4) so that dial gauge [14] indicates the following range (backlash). Standard backlash: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.36 – 0.51 mm (0.014 – 0.020 in)
★ Adjust the backlash at three to four places and measure it with the pinion gear fixed.
•
When backlash is less than standard range: Loosen the adjustment nut on the bevel gear side and tighten the adjustment nut on the opposite side by the same angle (to move the bevel gear in direction (A)).
•
When the backlash is above standard range: Loosen the adjustment nut on the opposite side and tighten the adjustment nut on the bevel gear side by the same angle (to move the bevel gear in direction (B)).
B. Checking tooth contact
i.
Apply red lead thinly to the surface of the pinion gear and turn the bevel gear in the forward and reverse directions, and then check the tooth contact pattern on the bevel gear.
ii.
The center of the tooth contact must be at the middle of the tooth height and at a point about 33% of the tooth length (x) from small end (C). The tooth contact width must be 30 – 60% of the tooth length (y). Check that there is no strong contact at tip (A), bottom (B), small end (C), or large end (D). ★ If the tooth contact is adjusted in this way, the teeth come in contact with each other correctly when they are loaded.
50-242 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iii. Adjusting tooth contact • If the tooth contact pattern is not correct, adjust it according to the following procedure. • After adjusting the tooth contact, check the backlash again. ★ If bevel pinion is too far from bevel gear • The tooth contact pattern is illustrated in the figure. • Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). • Move the bevel gear in direction (D). ★ If bevel pinion is too close to bevel gear • The tooth contact pattern is illustrated in the figure. • Increase the shims of the bevel pinion to move the bevel pinion in direction (E). • Move the bevel gear in direction (F).
★ If bevel gear is too close to bevel pinion • The tooth contact pattern is illustrated in the figure. • Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). • Move the bevel gear in direction (D).
★ If bevel gear is too far from bevel pinion • The tooth contact pattern is illustrated in the figure. • Increase the shims of the bevel pinion to move the bevel pinion in direction (E). • Move the bevel gear in direction (F).
WA500-6
50-243 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
14. Lock ★ After finishing all adjustments, install lock (3) and tighten mounting bolts (2). Mounting bolt: 27 – 34 N•m (20 – 25 lbf ft)
15. Differential assembly ★ Remove differential assembly (1) from tool H1. Differential assembly: 430 kg (948 lbs)
50-244 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Differential (without Limited Slip Differential)
Repair stand
■
1
790-901-4110
Bracket
■
1
793T-622-2120 Plate
■
1
792-103-0901
Wrench
■
1
1
792-525-1000
Micrometer
■
1
2
793T-822-1310 Adapter
■
1
Part No.
1
Part Name
H 6 7
Sketch
Qty
790-501-5000
Symbol
New/Remodel
Necessity
Special Tools
Nature of Work, Remarks
Removal and installation of differential N
❍ Bearing preload adjustment
N
❍
–
Disassembly 1.
Set differential assembly (1) to tool H1. Differential assembly: 390 kg (860 lbs)
2.
Differential gear and case assembly ★ Perform the following work on the right and left sides in a similar manner. A. Remove mounting bolts (2) and remove lock (3).
WA500-6
50-245 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Loosen nut (4) with a bar until you can rotate it with your fingers. C. Sling the differential gear and case assembly. D. Remove mounting bolts (5) and cap (6). ★ Make distinctive marks on the right and left caps. E. Remove nut (4).
F.
Using sling [1], remove differential gear and case assembly (7). ★ Be careful not to drop bearing outer race (8). Differential gear and case assembly: 180 kg (397 lbs)
3.
Gear case cover A A. Remove eight mounting bolts (9). B. Remove gear case cover A (10). C. Remove bearing (11).
D. Remove dowel pin (13) from gear case cover A (10).
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WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
E. Remove thrust plate (12).
4.
Side gear A ★ Remove side gear A (14).
5.
Cross shaft and pinion gear ★ Remove cross shaft (15), pinion gear (16), and washer (17) together.
6.
Side gear B ★ Remove side gear B (18).
WA500-6
50-247 b
DISASSEMBLY AND ASSEMBLY 7.
POWER TRAIN
Gear case cover B A. Remove thrust plate (20) and dowel pin (21) from gear case cover B (19).
B. Remove bearing (22). C. Remove 20 mounting bolts (23). D. Remove gear case cover B (24) from bevel gear (25).
8.
Coupling A. Remove mounting bolt (31) and holder (32). B. Remove shim (33), O-ring (34), and coupling (35).
9.
Pinion assembly A. Remove 18 mounting bolts (36). B. Using forcing screws [2], disconnect pinion assembly (37).
50-248 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Using eyebolts [3], remove pinion assembly (37). Pinion assembly: 95 kg (209 lbs)
D. Remove shim (38). ★ Check the thickness and quantity of the shim.
E. Remove differential carrier (47) from tool H1. Differential carrier assembly: 85 kg (187 lbs)
F.
Disassemble the pinion assembly according to the following procedure. i.
Using tool [4] (inside diameter: 321 mm [12.638 in]), support pinion case (39).
ii.
Using push tool [5], pull out pinion shaft (40).
iii. Using puller [6] (294 kN [30 ton]), pull out bearing (41).
WA500-6
50-249 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iv. Remove dust seal (42), oil seal (43), and bearing (44). v.
50-250 b
Remove bearing outer race (45).
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
Bevel gear assembly A. Using push tool [10] (inside diameter: 131 mm [5.158 in]), press-fit bearing (22) to gear case cover B (24). ★ Press-fit the inner race of the bearing.
B. Install gear case cover B (24) to bevel gear (25). C. Tighten 20 mounting bolts (23). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 490 – 608 N•m (361 – 448 lbf ft)
2.
Gear case cover B A. Install dowel pin (21) to gear case cover B (19). B. Install thrust plate (20).
3.
Side gear B • Install side gear B (18).
WA500-6
50-251 b
DISASSEMBLY AND ASSEMBLY 4.
Cross shaft and pinion gear ★ Install cross shaft (15), pinion gear (16), and washer (17) together.
5.
Side gear A ★ Install side gear A (14).
6.
Gear case cover A
POWER TRAIN
A. Using push tool [11] (inside diameter: 131 mm [5.158 in]), press-fit bearing (11) to gear case cover (A) (10). ★ Press-fit the inner race of the bearing.
B. Install dowel pin (13) and thrust plate (12) to gear case cover A (10). ★ When installing, apply grease (G2-LI) thinly to the thrust plate to prevent it from falling.
50-252 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Install gear case cover A (10). D. Tighten eight mounting bolts (9). Mounting bolt: 490 – 608 N•m (361.40 – 448.44 lbf ft)
7.
Differential gear and carrier assembly ★ Perform the following work on the right and left sides in the same manner. A. Set differential carrier (47) to tool H1. Differential carrier assembly: 85 kg (187 lbs)
B. Using sling [1], install differential gear and case assembly (7). ★ Be careful not to drop bearing outer race (8). Differential gear and case assembly: 180 kg (397 lbs)
C. Install nut (4) to the threaded part on the differential carrier side. D. Install cap (6) and tighten mounting bolts (5). Mounting bolt: Adhesive (LT-2)
Mounting bolt: 1,520 – 1,910 N•m (1,121 – 1,409 lbf ft)
★ Set the match mark on cap (6). ★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate it about ten turns. ★ Before tightening mounting bolts (5), rotate the bevel gear 20 – 30 turns to run in the bearing.
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50-253 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
E. Adjust the differential bearing preload according to the following procedure. i.
Install tool H7-2 to the threaded portions (A) of the right and left cap tops. ★ Tighten until there is no play.
ii.
Using tool H7-1, measure dimension (L).
iii. Add 0.31 ±0.11 mm (0.012 ±0.004 in) to measured value (L) and set the scale of tool H7-1 to the obtained value. ★ The added dimension is the deflection of the case made by providing a preload.
iv. Using tool H6, tighten nut (4). ★ Using tool H6, tighten adjustment nut (4) so that the increase is 0.31 ±0.11 mm (0.012 ±0.004 in).
v.
Put push-pull scale [13] to the tip of bevel gear (30) and measure the starting force. Starting force: . . . . . . . . . . . . . . . 14.7 – 44.1 N (3 – 10 lbf)
★ If the starting force is out of the above range, repeat Step 7Eiv and adjust again.
50-254 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ Precautions for adjusting starting torque • If the nut is tightened too much for starting force adjustment or the starting force is adjusted defectively, return the nut to the condition before the adjustment. • At this time, hit the cap and the bevel gear lightly with a plastic hammer while rotating it. • At this time, check that there is no clearance in part (c) and adjust the preload again.
8.
Pinion assembly A. Assemble the pinion assembly according to the following procedure. i.
Using push tool [6] (inside diameter: 101 mm [3.976 in]), press-fit bearing (41) to pinion shaft (40).
ii.
Press-fit bearing (44) and bearing outer race (45) to pinion case (46). ★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate it about ten turns.
iii. Using push tool [7] (inside diameter: 76 mm [2.992 in]), press-fit pinion case (46) to pinion shaft (40). ★ Press-fit the inner race of bearing (44).
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50-255 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iv. Install dust seal (42) and oil seal (43). ★ Apply the gasket sealant thinly over the inside surface of the oil seal fitting part of the pinion case and wipe off the projected part. Oil seal: Grease (G2-LI)
Oil seal fitting surface: Gasket sealant (THREEBOND 1110B)
Dust seal: Grease (G2-LI)
B. Coupling i.
Install coupling (35).
ii.
Install O-ring (34) and shim (33) which was removed during disassembly.
iii. Install holder (32) and tighten mounting bolts (31). ★ While rotating the pinion shaft 20 – 30 turns, tighten mounting bolts (31) gradually. O-ring: Grease (G2-LI)
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 824 – 1,030 N•m (608 – 760 lbf ft)
C. Adjust the preload on the pinion shaft according to the following procedure. i.
Install measuring bolt [8] to pinion assembly (37).
ii.
Using push-pull scale [9], measure starting torque (a). Starting torque (a): 49.0 – 127.4 N•m (36 – 94 lbf ft) ★ If the measured value is out of the above range, adjust it by increasing or decreasing the shims.
50-256 b
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DISASSEMBLY AND ASSEMBLY
POWER TRAIN
D. Install shim (38) removed during the disassembly procedure. Shim adjustment allowance: 0.71 – 2.21 mm (0.028 – 0.087 in)
E. Fit the O-ring and install pinion assembly (37). O-ring: Grease (G2-LI)
Pinion assembly: 110 kg (243 lbs)
F.
Tighten 18 mounting bolts (36). Mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
9.
Adjusting tooth contact and backlash ★ Adjust the backlash and tooth contact simultaneously. A. Adjust the backlash according to the following procedure. i.
Move the bevel gear with adjustment nuts (4a) and (4b). ★ Rotate adjustment nuts (4a) and (4b) by the same amount, in the same direction, so that the adjusted preload on the bearing does not change.
ii.
Apply dial gauge [14] perpendicularly to the tooth surface on the reverse side at the outer end of the bevel gear.
iii. Adjust adjustment nut (4) so that dial gauge [14] indicates the following range (backlash). ★ Adjust the backlash at three to four places and measure it with the pinion gear fixed. Standard backlash: . . .0.36 – 0.51 mm (0.014 – 0.020 in)
•
When backlash is less than standard range: Loosen the adjustment nut on the bevel gear side and tighten the adjustment nut on the opposite side by the same angle (to move the bevel gear in direction (A)).
•
When the backlash is above standard range: Loosen the adjustment nut on the opposite side and tighten the adjustment nut on the bevel gear side by the same angle (to move the bevel gear in direction (B)).
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50-257 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Checking tooth contact i.
Apply red lead thinly to the surface of the pinion gear and turn the bevel gear in the forward and reverse directions, and then check the tooth contact pattern on the bevel gear.
ii.
The center of the tooth contact must be at the middle of the tooth height and at a point about 33% of the tooth length (x) from small end (C). The tooth contact width must be 30 – 60% of the tooth length (y). Check that there is no strong contact at tip (A), bottom (B), small end (C), or large end (D). ★ If the tooth contact is adjusted in this way, the teeth come in contact with each other correctly when they are loaded.
iii. Adjusting tooth contact • If the tooth contact pattern is not correct, adjust it according to the following procedure. • After adjusting the tooth contact, check the backlash again. ★ If bevel pinion is too far from bevel gear • The tooth contact pattern is illustrated in the figure. • Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). • Move the bevel gear in direction (D). ★ If bevel pinion is too close to bevel gear • The tooth contact pattern is illustrated in the figure. • Increase the shims of the bevel pinion to move the bevel pinion in direction (E). • Move the bevel gear in direction (F).
★ If bevel gear is too close to bevel pinion • The tooth contact pattern is illustrated in the figure. • Decrease the shims of the bevel pinion to move the bevel pinion in direction (C). • Move the bevel gear in direction (D).
50-258 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
★ If bevel gear is too far from bevel pinion • The tooth contact pattern is illustrated in the figure. • Increase the shims of the bevel pinion to move the bevel pinion in direction (E). • Move the bevel gear in direction (F).
10. Lock ★ After completing all adjustments, install lock (3) and tighten mounting bolts (2). Mounting bolt: 27 – 34 N•m (20 – 25 lbf ft)
11. Differential assembly ★ Remove differential assembly (1) from tool H1. Differential assembly: 390 kg (860 lbs)
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50-259 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Final Drive (Front and Rear)
793T-622-2210
Fixture
Sketch
3
Part Name
New/Remodel
H
Part No.
Qty
Symbol
Necessity
Special Tools
Nature of Work, Remarks
■
3
N
❍
Removal and installation of wheel hub and brake, disassembly and assembly of brake
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required •
Container to hold the oil
Disassembly 1.
Tire wheel assembly A. Raise the machine body with the work equipment or a jack and set a stand under the axle. B. Using a sling, sling tire wheel assembly (1); remove the hub mounting bolts; and lift off the tire wheel assembly. Tire wheel assembly: 850 kg (1,874 lbs)
2.
Draining oil A. Remove drain plug (2) and drain the oil. B. Set the drain plug at the bottom. Axle oil Front: Approximately 98 l (26 gal) Rear: Approximately 85 l (23 gal)
3.
Cover ★ Remove seven bolts (3) and cover (4).
50-260 b
WA500-6
DISASSEMBLY AND ASSEMBLY 4.
POWER TRAIN
Drive shaft A. Using forcing screw [2], pull out drive shaft (5). B. Using sling [3], remove drive shaft (5). C. Remove spacer (6), sun gear (7), and snap ring (8) from drive shaft (5).
5.
Planetary carrier assembly A. Remove three hexagonal head bolts (9). B. Using forcing screws [4], disconnect planetary carrier assembly (10) from the wheel hub. C. Using sling [5], remove planetary carrier assembly (10). Planetary carrier assembly: 110 kg (243 lbs)
D. Disassemble the planetary carrier assembly according to the following procedure. i.
WA500-6
Using a press, pull out shaft (11) and remove planetary gear (12), ball (13), and bearing (14). ★ Be careful not to lose ball (13). • Write a number on the case. Arrange and keep the removed parts separate to prevent them from mixing with other parts. • Since the bearing has been fitted to the mating part, make a distinctive mark on it.
50-261 b
DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Ring gear A. Using tools H3, fix wheel hub (15) and brake housing (16). • Install tools H3 to three places at regular intervals. • Keep tools H3 installed until Step 6 is finished.
B. Remove eight mounting bolts (17). C. Remove retainer (18) and shim (19). ★ Check the thickness and quantity of the shim.
D. Using sling [9], remove ring gear assembly (20).
E. Disassemble the ring gear assembly according to the following procedure. i.
Remove 12 mounting bolts (21) and six lock plates (22).
ii.
Using sling [6], remove ring gear hub (23).
50-262 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
iii. Remove bearing (24) from ring gear hub (23).
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50-263 b
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
Assembly 1.
Ring gear A. Assemble the ring gear assembly according to the following procedure. i.
Using push tool [7] (inside diameter: 221 mm [8.701 in]), press-fit bearing (24) to ring gear hub (23). ★ After press-fitting the bearing, check that there is no clearance between it and the hub.
ii.
Before installing, measure thickness (a) of retainer (18). ★ Measure the thickness at two places and obtain the average.
iii. Using sling [6], install ring gear hub (23). iv. Install six lock plates (22) and tighten 12 mounting bolts (21). ★ Install each lock plate (22) with the wider end in. ★ Degrease the bolt holes thoroughly. Mounting bolt: Adhesive (LT-2)
Mounting bolt: 27 – 34 N•m (20 – 25 lbf ft)
B.
Using sling [9], install ring gear assembly (20). ★ Drop 6 cc of axle oil (AXO80) onto the bearing and rotate it about ten turns.
50-264 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
C. Adjustment procedure for wheel bearing i.
Install retainer (18) and tighten three mounting bolts (17) temporarily without setting the shim.
ii.
Remove tool H3 which has been fixing wheel hub (15) and brake housing (16).
iii. While rotating wheel hub (15) 20 – 30 turns, tighten mounting bolts (17) alternately and evenly to the following torque. Mounting bolt: 62.7 ±4.9 N•m (46 ±4 lbf ft)
iv. Insert depth micrometer [10] or a dial gauge in the measurement hole of retainer (18) and measure distance (b) between retainer (18) and tube (26) to obtain shim thickness (C). ★ Measure the distance at two places and obtain the average. Shim thickness (C): . . . . . (b – a) + 0.3 mm (0.012 in)
★ Dimension (a) was measured in Step 1.
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50-265 b
DISASSEMBLY AND ASSEMBLY v.
POWER TRAIN
Install tool H3 and fix wheel hub (15) and brake housing (16) again.
vi. Remove retainer (18) and install shim (19) of the thickness obtained in Step Civ. ★ Assemble the shims so that the number of them are minimized. vii. Install retainer (18) again and tighten eight mounting bolts (17) alternately and evenly to the following torque. Mounting bolt: Adhesive (LT-2)
Mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
viii. Remove tool H3 which has been fixing wheel hub (15) and brake housing (16).
2.
Planetary carrier A. Assemble the planetary carrier assembly according to the following procedure. i.
Set planetary gear (12) and bearing (14) to the carrier case.
ii.
Fit ball (13) to shaft (11) and press-fit them to the carrier case. • Press-fit shaft (11) with the ball hole out. Stop before the hole and adjust the hole. • After press-fitting the shaft, check that the planetary gear rotates lightly.
50-266 b
WA500-6
DISASSEMBLY AND ASSEMBLY
POWER TRAIN
B. Using sling [5], install planetary carrier assembly (10). • Using guide bolt [4], set the bolt holes. Planetary carrier assembly: 110 kg (243 lbs)
C. Tighten three hexagon head bolts (9). Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
3.
Drive shaft A. Install snap ring (8), sun gear (7), and spacer (6) to drive shaft (5). B. Using sling [1], install drive shaft (5). C. Using guide bolt [2], set the spline at the end of drive shaft (5) and push it in. ★ If the sun gear does not mesh with the planetary gear, use your hand to rotate the wheel hub to mesh those gears.
4.
Cover A. Fit the O-ring; install cover (4); and tighten seven bolts (3). O-ring: Grease (G2-LI)
Mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
B. Install drain plug (2). ★ Set the drain plug at the bottom. Drain plug (2): 58.8 – 78.4 N•m (43 – 58 lbf ft)
5.
Refilling with oil A. Remove level plug (27). B. Remove oil filler plug (28) and add oil to the specified level. Axle oil Front: 98 l (26 gal) Rear: 85 l (23 gal)
C. Install level plug (27) and oil filler plug (28). Level plug (27): 127.4 – 176.4 N•m (94 – 130 lbf ft) Oil filler plug (28): 127.4 – 176.4 N•m (94 – 130 lbf ft)
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50-267 b
DISASSEMBLY AND ASSEMBLY 6.
POWER TRAIN
Tire wheel assembly A. Using the sling, set tire wheel assembly (1) to the wheel hub and tighten the hub mounting bolts temporarily. Tire wheel assembly: 850 kg (1,874 lbs)
B. Raise the machine body with the work equipment or the jack; remove the stand under the axle; and lower the tire to the ground. C. Tighten the hub mounting bolts to the specified torque. Hub mounting bolt: 824 – 1,034 N•m (608 – 763 lbf ft)
50-268 b
WA500-6
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
BRAKE SYSTEM Brakes (Front and Rear) WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
793T-622-2210
Fixture
Sketch
3
Part Name
New/Remodel
H
Part No.
Qty
Symbol
Necessity
Special Tools
Nature of Work, Remarks
■
3
N
❍
Removal and installation of wheel hub and brake, disassembly and assembly of brake
Removal 1.
Remove the final drive assembly. ★ For details, see POWER TRAIN: Final Drive (Front and Rear) in this section.
2.
Leave tool H3 (used to fix the wheel hub and brake housing), installed for the above work, in position.
3.
Disconnect brake tube (1). [*1]
WA500-6
50-269 b
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
4.
Remove cover (2).
5.
Remove brake disc wear indicator (3).
6.
Remove 15 mounting bolts (6). [*3]
7.
Using sling [1], remove brake and wheel hub assembly (7).
[*2]
Brake and wheel hub assembly: 350 kg (772 lbs)
8.
Remove eight O-rings (16) from brake piston assembly (15).
9.
Remove bearing (9) and retainer (10) from axle (8).
50-270 b
[*4]
WA500-6
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Brake tube: 84 – 132 N•m (62 – 97 lbf ft)
[*2] Adjustment Procedure for Brake Disc Wear Indicator 1.
Apply oil pressure of 5.39 – 5.88 MPa (781.75 – 852.82 psi) to the brake oil port.
2.
Remove cap (11) and loosen nut (13).
3.
Push in shaft (12) fully and rotate guide (14) to reduce its projection distance (a) to 0.
4.
Tighten nut (13). Nut: 58.8 – 78.4 N•m (43 – 58 lbf ft)
5.
Install cap (11). Cap: 29.4 – 39.2 N•m (22 – 29 lbf ft)
[*3] Mounting bolt (6): 548.8 ±58.8 N•m (405 ±43 lbf ft)
[*4] Brake and wheel hub assembly •
When installing the bearing, drop 6 cc of the axle oil (AXO80) on it.
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50-271 b
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
Disassembly
Sketch
3
New/Remodel
2
Qty
Symbol
Necessity
Special Tools
792T-422-1220
Plate
■
1
N
❍
790-101-5421
Grip
■
1
01010-81240
Bolt
■
1
793T-622-2210
Fixture
■
3
792-520-2110
Installer
■
1
791-580-1600
Push tool
■
1
791-580-1610
Plate
1
791-580-1620
Arm
4
791-580-1640
Plate
1
791-580-1650
Plate
4
01010-51425
Bolt
8
01541-21670
Nut
4
01640-21426
Washer
4
792-530-1630
Stud
■
4
792-520-2110
Installer
■
1
793T-622-2310
Plate
■
1
N
❍
793T-622-2320
Arm
■
4
N
❍
791-580-1640
Plate
■
1
792-530-1630
Stud
■
4
01010-61425
Bolt
■
4
01640-21426
Washer
■
4
01580-01613
Nut
■
4
Part No.
Part Name
Press-fitting of outer drum oil seal
N
❍
5
1.
Remove the brake assembly. ★ For details, see BRAKE SYSTEM: Brakes (Front and Rear) in this section.
2.
Remove tool H3 (used to fix the wheel hub and brake housing) installed for the above work.
50-272 b
Removal and installation of wheel hub and brake, disassembly and assembly of brake
Installation of floating seal (gear side)
4 H
Nature of Work, Remarks
Installation of floating seal (hub side)
WA500-6
DISASSEMBLY AND ASSEMBLY 3.
BRAKE SYSTEM
Cylinder assembly A. Remove 24 mounting bolts (1). B. Using forcing screws [1], disconnect cylinder assembly (2). C. Using eyebolts [2], remove cylinder assembly (2).
D. Disassemble the cylinder assembly according to the following procedure. i.
Install eyebolt [3]; push in the head of shaft (3) with bar [4]; and remove pin (5) from the underside.
ii.
Remove shaft (3) and spring (4).
iii. Reverse cylinder assembly (2) and remove piston (6).
iv. Remove nine mounting bolts (7) and inner cylinder (8).
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50-273 b
DISASSEMBLY AND ASSEMBLY v.
BRAKE SYSTEM
Remove seal ring (9) from piston (6).
vi. Remove seal ring (10) from inner cylinder (8).
4.
Plate and disc A. Remove eight discs (13), nine plates (14), and bottom plate (15). B. Before removing, make match marks between the inner gear and discs and between the outer gear and plates. ★ Since the discs are made of soft material, be careful not to scratch them. C. Remove the discs and plates alternately.
5.
Outer gear A. Using sling [5], remove outer gear (16).
B. Remove oil seal (17) and floating seal (18) from outer gear (16).
50-274 b
WA500-6
DISASSEMBLY AND ASSEMBLY 6.
BRAKE SYSTEM
Wheel hub A. Remove bearing outer races (19) and (20).
B. Remove six mounting bolts (22) then remove seal cage (23) and O-ring (25) from wheel hub (21). C. Remove floating seal (24) from seal cage (23).
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50-275 b
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
Assembly 1.
Wheel hub A. Using push tool [6] (outside diameter: 313 mm [12.323 in]), press-fit outer race (20) to wheel hub (21). B. Using push tool [7] (outside diameter: 189 mm [7.441 in]), press-fit outer race (19) to wheel hub (21).
C. Install O-ring (25) and seal cage (23) to wheel hub (21). O-ring: Grease (G2-LI)
D. Tighten six mounting bolts (22). Mounting bolt: 59 – 74 N•m (44 – 55 lbf ft)
E. Using tool H5, install floating seal (24) to wheel hub (21). i.
Fit the O-ring to the floating seal. ★ Be careful not to twist the O-ring of the floating seal. Tighten tool H5 evenly.
ii.
Use alcohol to remove all the white powder protecting the surface of O-ring (24a).
iii. Thoroughly degrease the floating seal and O-ring contact surface of the wheel hub. iv. After press-fitting O-ring (24a) of the floating seal, measure height (t) at four places on the periphery and check that its dispersion is not larger than 1 mm (0.039 in). v.
50-276 b
Apply axle oil to the seal surface of floating seal (24b) to prevent dirt from sticking.
WA500-6
DISASSEMBLY AND ASSEMBLY 2.
BRAKE SYSTEM
Outer gear A. Using tool H2, install oil seal (17) to outer gear (16). Seal lip surface: Grease (G2-LI)
B. Using tool H4, install floating seal (18) to outer gear (16). i.
Fit the O-ring to the floating seal. ★ Be careful not to twist the O-ring of the floating seal. Tighten tool H4 evenly.
ii.
Use alcohol to remove all of the white powder protecting the surface of O-ring (18a).
iii. Thoroughly degrease the floating seal and O-ring contact surface of the wheel hub. iv. After press-fitting O-ring (18a) of the floating seal, measure height (t) at four places on the periphery and check that its dispersion is not larger than 1 mm (0.039 in). v.
Apply axle oil to the seal surface of floating seal (18b) to prevent dirt from sticking.
C. Using sling [5], install outer gear (16).
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50-277 b
DISASSEMBLY AND ASSEMBLY 3.
BRAKE SYSTEM
Plate and disc A. Install bottom plate (15). B. Install nine plates (14) and eight discs (13) alternately. • Match the match marks made between the inner gear and discs and between the outer gear and plates. ★ Since the discs are made of soft material, be careful not to scratch them.
4.
Cylinder assembly A. Assemble the cylinder assembly according to the following procedure. i.
Install seal rings (10) and (11) to inner cylinder (8). Seal ring: Grease (G2-LI)
ii.
Install seal ring (9) to piston (6). Seal ring: Grease (G2-LI)
iii. Install inner cylinder (8). iv. Tighten nine mounting bolts (7). Mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
v.
50-278 b
Install piston (6) to cylinder assembly (2).
WA500-6
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
vi. Reverse cylinder assembly (2). vii. Install shaft (3) and spring (4). viii. Install eyebolt [3]; push in the head of shaft (3) with bar [4]; and install pin (5) from underside.
B. Fit the O-ring and install cylinder assembly (2), using eyebolts [2]. O-ring: Grease (G2-LI)
C. Tighten 24 mounting bolts (1). Mounting bolt: 157 – 196 N•m (116 – 145 lbf ft)
5.
Install tool H3 (to fix the wheel hub and brake housing).
6.
Install the brake assembly. ★ For details, see BRAKE SYSTEM: Brakes (Front and Rear) in this section.
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50-279 b
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
Slack Adjuster ★ Only the precautions for assembling the slack adjuster are described in this section. Assembly of Slack Adjuster Assembly
Valve and outside of spring (a): Grease (G2-LI)
Threaded part of plug (b): CEMEDINE 366 or equivalent
Threaded part of plug (b): CEMEDINE 366 or equivalent
Torque Values Designation
N•m
lbf ft
A
60 – 75
44 – 55
C
10 – 20
8 – 15
D
50 – 65
37 – 48
Designation
N•m
lbf in
B
7–9
62 – 80
50-280 b
WA500-6
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
Brake Accumulator Charge Valve ★ Only the precautions for assembling the brake accumulator charge valve assembly are described in this section. Assembly of Brake Accumulator Charge Valve Assembly
Plug (1): THREEBOND 1305 or equivalent
Plug (2): Adhesive (LT-2)
Torque Values Designation
N•m
lbf ft
lbf in
AA
29.4 – 39.2
22 – 29
–
BB
3.14 – 3.92
–
28 – 35
Plug (3): Adhesive (LT-2)
Plug (4): THREEBOND 1305 or equivalent
Torque Values Designation
N•m
lbf ft
lbf in
AA
30.4 – 37.3
22 – 28
–
BB
78.5 – 88.3
58 – 65
–
CC
53.9 – 68.6
40 – 51
–
DD
9.8 – 11.8
–
87 – 104
WA500-6
50-281 b
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
UNDERCARRIAGE AND FRAME Center Hinge Pin
Qty
1
793-520-2630
Bar
■
2
–
2
793-520-2640
Push tool
■
1
–
3
793-520-2650
Guide
■
1
–
4
790-101-2300
Push puller
■
1
–
5
790-101-2102
• Block
1
–
6
02215-11622
• Nut
2
–
7
790-101-2102
Puller 294 kN {30 ton}
■
1
–
8
790-101-1102
Pump
■
1
–
1
793-520-2530
Guide
■
1
–
2
01010-31480
Bolt
■
2
–
3
01643-31445
Washer
■
2
–
4
793-520-2640
Push puller
■
1
–
5
790-101-2102
Puller 294 kN {30 ton}
■
1
–
6
790-101-1102
Pump
■
1
–
Symbol
Part No.
Part Name
1
K
2
Sketch
Necessity
New/Remodel
Special Tools
Nature of Work, Remarks
WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant cools down before draining the coolant.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
50-282 b
WA500-6
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
Removal Precautions for Handling Refrigerant WARNING!
Collect refrigerant (R134a) beforehand.
WARNING!
If the refrigerant (R134a) gets into your eyes, it may cause blindness. You must wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be done by a qualified person.
WARNING!
If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled and then drain the coolant.
★ Ask professional traders to collect and fill the refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. Required • •
Container to hold the hydraulic oil Container to hold the coolant
1.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
2.
Drain the coolant. Coolant: 90 l (24 gal)
3.
Remove the operator cab and floor frame assembly. ★ For details, see CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
4.
Set jacks [1] under the right and left of the rear frame.
5.
Set jack [2] under the front frame.
6.
Set jack [3] under the rear counterweight.
WA500-6
50-283 b
DISASSEMBLY AND ASSEMBLY 7.
Remove guard (1).
8.
Sling center drive shaft (2); remove its mounting bolts; and lift it off. [*1] ★ Before removing the drive shaft, make a match mark between it and the coupling.
UNDERCARRIAGE AND FRAME
Center drive shaft: 50 kg (110 lbs)
9.
Unplug wiring harness connectors JF1 (3), JF2 (4), and JF3 (5); remove wiring harness clamps (6) and (7).
10. Disconnect hoses (8), (9), (10), (11), and (12).
11. Disconnect hoses (13), (14), (15), (16), and (17).
50-284 b
WA500-6
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
12. Disconnect right and left steering hoses (18). 13. Remove right and left bolts (19) and pull out right and left cylinder bottom pins (20). [*2] • After removing the pins, retract the cylinder piston rods. • Check the quantity and thickness of the shims on the frame.
14. Remove bolts (21) and (22) and retainer (22); pull out the lower hinge pin. [*3] ★ After removing the bolts, pull out the pin while adjusting the height of the front frame and rear frame with the jacks.
15. Remove four bolts (24) and plate (25).
[*4]
16. Remove six bolts (26), four bolts (27), and retainer (28); pull out the hinge pin. [*5] • After removing the bolts, pull out the pin while adjusting the height of the front frame and rear frame with the jacks. • Check the quantity and thickness of the shims between retainer (28) and the frame.
17. Remove bushing (29) from the frame.
WA500-6
50-285 b
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
18. Pull front frame (30) forward slowly to disconnect it from rear frame (31). ★ When disconnecting the front frame, balance it carefully. • Check that all the pipings and wiring harnesses are disconnected. • Move the front frame about 100 mm (3.937 in) each time.
19. Remove bushing (32) and the collar from the rear frame.
20. Remove bolts (33) and retainer (34) from the front frame. [*6] ★ Check the quantity and thickness of the shims between the retainer and frame. 21. Remove dust seal (35) from the retainer. [*7] 22. Remove dust seal (36) from the frame. [*8] 23. Remove bearing (37) from the frame. [*9]
24. Remove bolts (38) and retainer (39) from the front frame. [*10] ★ Check the quantity and thickness of the shims between the retainer and frame. 25. Remove dust seal (40) from the retainer. [*11] 26. Remove bushing (41) and dust seal (42) from the front frame. [*12] 27. Remove bearing (43) from the frame. [*13]
50-286 b
WA500-6
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
Installation ★ Carry out installation in the reverse order of removal. [*1] Drive shaft mounting bolt: 107 – 127 N•m (79 – 94 lbf ft)
★ Tighten the drive shaft according to the following procedure. 1.
Check that the seats of the mating yoke and drive shaft spider are free from rust, foreign matter (masking material), damage, etc.
2.
Set the keyway of the yoke vertically; place the drive shaft on the bottom of the yoke socket; and fit the key in the keyway.
3.
Insert the four upper and lower bolts and finger tighten them until the seats of the spider and yoke are fitted. ★ At this time, if the keyway and socket of the yoke are tight and the spider is not fitted easily, drive in the spider with a plastic or copper hammer. ★ Do not use a steel hammer which can damage the cross bearing. ★ If the spider is not fitted perfectly at this time, it will float and its seat will be parted from the yoke when the other parts are tightened. ★ Tighten the spider securely.
4.
Tighten the bolts in the diagonal order.
[*2] Adjust the shim so that clearances (a) and (b) between the cylinder and mounting face of the frame are 0.5 mm (0.020 in) or less. [*3] ★ Install the lower hinge pin according to the following procedure. 1.
Install bushing (32) and collar (44) to the frame.
2.
Align the front frame and rear frame. WARNING!
3.
When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
Fit retainer (23) to hinge pin (45); insert them in the pin hole; and tighten bolts (22). Periphery of hinge pin: Grease (G2-LI) Threaded part of retainer mounting bolt: Adhesive (LOCTITE 262) Retainer mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
Threaded part of pin mounting bolt: Adhesive (LOCTITE 262)
Retainer mounting bolt: 343 – 426 N•m (253 – 314 lbf ft)
WA500-6
50-287 b
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
[*4], [*5] ★ Install the upper hinge pin according to the following procedure. 1.
Measure the thickness of retainer (28) in advance at three places of the Ø6.5 hole of the retainer.
2.
Install bushing (29) to the upper hinge.
3.
Temporarily install retainer (28) to hinge pin (46) with bolts (27) and insert hinge pin (46) in the pin hole. Periphery of hinge pin: Grease (G2-LI)
4.
Tighten bolts (27) to the specified torque. ★ While tightening the bolts, check each one.
5.
After tightening the bolts to the specified torque, measure the clearance between the retainer and rear frame at three places of the Ø6.5 hole.
6.
Select shims so that their total thickness is 0.08 – 0.18 mm (0.003 – 0.007 in) less than the measured clearance.
7.
Remove the retainer; install shim (47); and tighten the retainer mounting bolts to the specified torque. Threaded part of retainer (26) mounting bolt: Adhesive (LOCTITE 262)
Retainer (26) mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
Threaded part of pin mounting bolt (27): Adhesive (LOCTITE 262)
Pin mounting bolt (27): 343 – 426 N•m (253 – 314 lbf ft)
Threaded part of pin mounting bolt (24): Adhesive (LOCTITE 262)
Pin mounting bolt (24): 343 – 426 N•m (253 – 314 lbf ft)
50-288 b
WA500-6
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
[*6], [*7], [*8], [*9] ★ Assemble the lower hinge according to the following procedure. 1.
Using push tool K2, press-fit bearing (37) to the frame. ★ Be careful that the bearing does not lean. • Since the clearance of the bearing is adjusted properly, do not change the combination of it and the spacer. When the bearing must be replaced, replace it and the spacer as a set. • Fill the inside of the bearing with grease.
2.
Press-fit dust seal (35) to retainer (34). ★ Press-fit the dust seal with the lip side out. Lip of dust seal: Grease (G2-LI)
3.
Evenly tighten the six mounting bolts of retainer (34) at intervals of 60°. Mounting bolt (when adjusting shim): 34.3 N•m (25 lbf ft) ±10%
4.
Select shims so that their total thickness is 0.08 – 0.18 mm (0.003 – 0.007 in) less than clearance (a) between the retainer and hinge, measured at four places on the periphery.
5.
Tighten the mounting bolts to the specified torque. Threaded part of retainer mounting bolt: Adhesive (LT-2)
Retainer mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
6.
Press-fit dust seal (36). ★ Press-fit the dust seal with the lip side out. Lip of dust seal: Grease (G2-LI)
WA500-6
50-289 b
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
[*10], [*11], [*12], [*13] ★ Assemble the upper hinge pin according to the following procedure. 1.
Using push tool K1, press-fit bearing (43) to the frame. ★ Be careful that the bearing does not lean. • Since the clearance of the bearing is adjusted properly, do not change the combination of it and the spacer. When the bearing must be replaced, replace it and the spacer as a set. • Fill the inside of the bearing with grease.
2.
Press-fit dust seal (40) to retainer (39). ★ Press-fit the dust seal with the lip side out. Lip of dust seal: Grease (G2-LI)
3.
Evenly tighten the six mounting bolts of retainer (38) at intervals of 60°. Mounting bolt (when adjusting shim): 34.3 Nm (25 lbf ft) ± 10%
4.
Select shims so that their total thickness is 0.08 – 0.18 mm (0.003 – 0.007 in) less than clearance (a) between the retainer and hinge, measured at four places on the periphery.
5.
Tighten the mounting bolts to the specified torque. Threaded part of retainer mounting bolt: Adhesive (LT-2)
Retainer mounting bolt: 245 – 309 N•m (181 – 228 lbf ft)
6.
Press fit dust seal (42). ★ Press fit the dust seal with the lip side out. Lip of dust seal: Grease (G2-LI)
7.
Install bushing (41).
50-290 b
WA500-6
DISASSEMBLY AND ASSEMBLY
UNDERCARRIAGE AND FRAME
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the brake circuit. ★ For details, see BRAKE SYSTEM: Bleeding Air from Wheel Brake Circuit in the Testing and Adjusting section.
WA500-6
50-291 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM Hydraulic Tank WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Precautions for Handling Refrigerant WARNING!
Collect refrigerant (R134a) beforehand.
WARNING!
If the refrigerant (R134a) gets into your eyes, it may cause blindness. You must wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be done by a qualified person.
WARNING!
If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled, and then drain the coolant.
★ Ask professional traders to collect and fill the refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
50-292 b
WA500-6
DISASSEMBLY AND ASSEMBLY 4.
Remove the operator cab and floor frame. ★ For details, see the CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
5.
Loosen hose clamps (1) between the air cleaner and turbocharger; remove air cleaner fixing bands (2) and air cleaner assembly (3). [*1]
6.
Remove air cleaner bracket (4).
7.
Disconnect heater hose (5).
8.
Remove partition rubber plates (6) and (7). ★ Disconnect and move partition rubber plate (7).
9.
Remove clamps (9) of transmission breather (8) and move the breather aside. [*2]
HYDRAULIC SYSTEM
10. Disconnect hose clamps (10) and (11) fixed together with the hydraulic tank.
WA500-6
50-293 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
11. Disconnect all of air conditioner and reservoir tank hose clamps (12) fixed together with the hydraulic tank.
12. Disconnect hoses (13), (14), (15), (16), (17), and (18) and all of the hose clamps fixed together with the hydraulic tank.
13. Disconnect flange (19). 14. Disconnect hoses (20), (21), and (22). ★ Disconnect the hoses on the opposite side of the block from the pump and motor.
15. Loosen hose clamps (23). 16. Disconnect hoses (24) and (25). 17. Remove tube (26). 18. Disconnect heater hose clamps (27). ★ Disconnect all of the heater hose clamps fixed together with the hydraulic tank.
50-294 b
WA500-6
DISASSEMBLY AND ASSEMBLY 19. Remove eight hydraulic tank mounting bolts (29).
HYDRAULIC SYSTEM [*3]
20. Lift off hydraulic tank (30). ★ Before lifting off the tank, check that all the pipings are disconnected. Hydraulic tank assembly: 480 kg (1,058 lbs)
WA500-6
50-295 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Hose clamp: 10.5 N•m (93 lbf in)
[*2]
Threaded part of hose clamp mounting bolt: Adhesive (LT-2)
Hose clamp mounting bolt: 10.1 N•m (89 lbf in)
[*3] ★ Adjust the clearance between the hydraulic tank and rear frame to 0.5 mm (0.020 in) or less with the shim. Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Charging Air Conditioner with Refrigerant ★ Charge the air conditioner circuit with refrigerant (R134a) through the compressor. Bleeding Air ★ Bleed air from the brake circuit. ★ For details, see BRAKE SYSTEM: Bleeding Air from Wheel Brake Circuit in the Testing and Adjusting section.
50-296 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Cooling Pump WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the hood. ★ For details, see ENGINE AND COOLING SYSTEM: Engine Hood in this section.
4.
Remove the operator cab and floor frame. ★ For details, see the CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
5.
Remove the hydraulic tank. ★ For details, see the HYDRAULIC SYSTEM: Hydraulic Tank in this section.
6.
Disconnect pump inlet tube (1) and outlet hose (2).
7.
Remove the two mounting bolts and cooling pump assembly (3). [*1]
WA500-6
50-297 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Pump mounting bolt: 235 – 285 N•m (173 – 210 lbf ft)
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
50-298 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Fan Pump WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the hood. ★ For details, see the ENGINE AND COOLING SYSTEM: Engine Hood in this section.
4.
Remove the operator cab and floor frame. ★ For details, see the CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
5.
Remove the hydraulic tank. ★ For details, see the HYDRAULIC SYSTEM: Hydraulic Tank in this section.
6.
Disconnect wiring harness connector T02 (1) and remove the wiring harness clamp.
7.
Remove pump inlet tube (2).
8.
Disconnect pump outlet hose (3) and hose (4).
9.
Remove three pump mounting bolts and lift off fan pump assembly (5).
[*1]
Fan pump assembly: 25 kg (55 lbs)
WA500-6
50-299 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Pump mounting bolt: 98 – 123 N•m (72 – 91 lbf ft)
★ Check that the clearance between the shroud and fan is even (standard clearance: 6 mm [0.236 in]). If it is uneven, loosen the mounting bolts of the fan motor mounting bracket and adjust it. Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
50-300 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Work Equipment Pump WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the hood. ★ For details, see the ENGINE AND COOLING SYSTEM: Engine Hood in this section.
4.
Remove the operator cab and floor frame. ★ For details, see the CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
5.
Remove the hydraulic tank. ★ For details, see the HYDRAULIC SYSTEM: Hydraulic Tank in this section.
6.
Remove side cover (1) on the right of the transmission.
WA500-6
50-301 b
DISASSEMBLY AND ASSEMBLY 7.
Disconnect hose (2), (3), (4), and (5).
8.
Disconnect pump inlet tube (6).
9.
Remove the tube fixing U-bolt and pump outlet tube (7).
HYDRAULIC SYSTEM
10. Remove the two pump mounting bolts and lift off work equipment pump assembly (8). [*1] Work equipment pump assembly: 110 kg (243 lbs)
50-302 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Pump mounting bolt: 455 – 565 N•m (336 – 417 lbf ft)
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
WA500-6
50-303 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Steering, Torque Converter Charge, and EPC Pump Assembly WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required • •
Container to hold the coolant Container to hold the hydraulic oil
Removal 1.
Drain the coolant. Coolant: 90 l (24 gal)
2.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
3.
Remove the hood. ★ For details, see the ENGINE AND COOLING SYSTEM: Engine Hood in this section.
4.
Remove the operator cab and floor frame. ★ For details, see the CAB AND ATTACHMENTS: Cab and Floor Frame in this section.
5.
Remove the hydraulic tank. ★ For details, see the HYDRAULIC SYSTEM: Hydraulic Tank in this section.
6.
Disconnect pump inlet tubes (1), (2), and (3).
7.
Disconnect pump outlet hoses (4), (5), and (6).
8.
Disconnect hoses (7), (8), (9), and (10).
9.
Remove the two pump mounting bolts and lift off steering-torque converter charge-EPC pump assembly (11). [*1] Steering-torque converter charge-EPC pump assembly: 60 kg (132 lbs)
50-304 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. [*1] Pump mounting bolt: 235 – 285 N•m (173 – 210 lbf ft)
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
WA500-6
50-305 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Work Equipment Valve WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required •
Container to hold the hydraulic oil
Removal 1.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
2.
Remove cover (1).
3.
Remove right and left round covers (2).
4.
Remove bracket (3).
5.
Disconnect hose (4).
6.
Remove accumulator fixing clamps (5) and (6).
50-306 b
WA500-6
DISASSEMBLY AND ASSEMBLY 7.
HYDRAULIC SYSTEM
Remove the two accumulator mounting bolts and lift off accumulator assembly (7). Accumulator assembly: 130 kg (287 lbs)
8.
Remove bracket (8).
9.
Disconnect brake hose (9).
10. Disconnect hoses (10), (11), (12), and (13).
11. Unplug wiring harness connectors F24 (14), F07 (15), and F10 (16). 12. Remove bracket (17). 13. Unplug wiring harness connectors F08 (18), F09 (19), and F16 (20).
WA500-6
50-307 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
14. Remove hoses (21) and (22) and brackets (23) and (24).
15. Remove tubes (25) and (26). 16. Disconnect tubes (27) and (28). 17. Disconnect hoses (29), (30), (31), (32), and (33).
18. Remove four work equipment valve assembly mounting bolts (34).
19. Set a wooden block and steel plate [1] to the frame. Sling work equipment valve assembly (35) and pull it out to this side to remove it. Work equipment valve assembly: 160 kg (353 lbs)
50-308 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
WA500-6
50-309 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Work Equipment Control Valve Assembly Disassembly and Assembly ★ Only the precautions for assembling the work equipment control valve assembly are described in this section. Assembly • •
When assembling, apply engine oil to the spool sliding surfaces. When slinging the work equipment control valve assembly, use tap holes (a). ★ Valve mating face Valve mating face (b): SEALEND 242 or equivalent
50-310 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
★ Plate mounting bolt (1) and cover mounting bolts (2) Torque Values Designation
Description
N•m
lbf ft
A
Plate mounting bolt (1)
156.8 – 196.0
116 – 145
B
Cover mounting bolt (2)
156.8 – 176.5
116 – 130
•
Tighten the mounting bolts in the order illustrated in the figure.
★ Plugs • Thoroughly degrease and dry the plugs and threaded parts of the valve mounting holes with denatured alcohol, etc. • Do not apply oil pressure for two hours after installing the plugs. Lift arm spool plug (3): LOCTITE No. 638
Bucket spool plug (4): LOCTITE No. 638
WA500-6
50-311 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
★ ECSS valve • Loosen locknut (6) and tighten plug (5) to the specified torque. • Tighten locknut (6) to the specified torque. • Check that no clearance is made at parts (c) on the seat surface (to prevent oil from flowing in through the seat of plug (5)). Torque Values Designation
Description
N•m
lbf ft
Plug (5)
19.6 – 27.5
15 – 20
Locknut (6)
19.6 – 27.5
15 – 20
B
★ O-ring on valve mounting face • Before assembling the entire work equipment control valve assembly, check that the O-ring of each valve is fitted to the groove securely. • Check O-ring (7) in particular since it is not circular.
50-312 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
★ Main relief valve assembly After installing main relief valve assembly (8) to the work equipment control valve, adjust the main relief valve. ★ For details, see WORK EQUIPMENT: Oil Pressure: Adjusting Work Equipment Relief Pressure in the Testing and Adjusting section. Torque Value Designation
Description
N•m
lbf ft
A
Locknut (9)
49 – 58.5
36 – 43
WA500-6
50-313 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Steering Cylinder
Qty
■
1
–
1
–
■
1
Removal and installation of steering cylinder nut
Push tool kit
■
1
Press-fitting of dust seal
790-201-1590
• Plate
■
1
Steering cylinder
4
790-101-5021
• Grip
1
5
01010-50816
• Bolt
1
1
790-201-1702
Push tool kit
2
790-201-1781
• Push tool
4
790-101-5021
• Grip
1
5
01010-50816
• Bolt
1
1
790-720-1000
Expander
■
1
2
796-720-1660
Ring
■
1
3
07281-01159
Clamp
■
1
790-330-1100
Wrench assembly
■
1
Symbol
Part No.
Part Name
1
790-502-1003 or 790-502-2000
Repair stand
2
790-101-1102
Pump
790-302-1290
Socket (Width across flats: 60 mm [2.36 in])
1
790-201-1500
2
1
3
4
Sketch
Necessity
New/Remodel
Special Tools
Nature of Work, Remarks
All cylinders
U
5
■
1
Press-fitting of roll bushing
■
1
Steering cylinder All cylinders
6
7
Expansion of piston ring Steering cylinder –
Required •
Container to hold the engine oil
Disassembly 1.
Set cylinder assembly (1) to tool U1.
2.
Using tool U7, remove cylinder head (2) from the cylinder.
50-314 b
WA500-6
DISASSEMBLY AND ASSEMBLY 3.
Pull cylinder head and piston rod assembly (3) out of cylinder (4) and lift it off. ★ Since oil flows out when the piston rod assembly is pulled out of the cylinder, make sure that there is a container to catch the oil.
4.
Remove cylinder (4) from tool U1.
5.
Set the cylinder head and piston rod assembly to tool U1 and loosen nut (5) with torque multiplier [1] and socket U3.
HYDRAULIC SYSTEM
Torque multiplier [1]: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 times Width across flats of socket U3: . . . . . . . . . . . . . 60 mm (2.362 in)
6.
Remove nut (5) and then remove piston assembly (6) and cylinder head assembly (7) from rod (8).
7.
Disassembly of piston assembly A. Remove wear ring (9). B. Remove piston ring (10) from piston (11).
WA500-6
50-315 b
DISASSEMBLY AND ASSEMBLY 8.
HYDRAULIC SYSTEM
Disassembly of cylinder head assembly A. Remove snap ring (16) and 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).
50-316 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Assembly ★ When assembling, coat the sliding surfaces of each part with engine oil and be careful not to damage the rod packings, dust seals, and O-rings. 1.
Assembly of cylinder head assembly A. Using U5, press-fit bushing (23) to cylinder head (24). ★ When press-fitting, be extremely careful not to deform the bushing. B. Install buffer ring (19). C. Install rod packing (18). ★ Pay attention to the installed directions of rod packing (18) and buffer ring (19). D. Using the 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 insert the backup ring forcibly; warm it in water at 50 – 60°C (122 – 140°F) and then insert it. 2.
Assembly of piston assembly A. Using tool U6-1, expand piston ring (10). ★ Set the piston ring to the tool and rotate the handle of the tool eight to ten turns to expand the piston ring. B. Remove piston ring (10) from tool U6-1 and install it to piston (11).
C. Install tool U6-2 to the piston ring and shrink the piston ring with clamp U6-3. D. Install wear ring (9).
WA500-6
50-317 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
3.
Set piston rod (8) to tool U1.
4.
Install cylinder head assembly (7) and piston assembly (6) to the rod and install nut (5).
5.
Using torque multiplier [1] and socket U3, tighten nut (5). ★ Piston nut Power of torque multiplier [1]
16 times
Width across flats of nut (5)
60 mm (2.362 in)
Tightening torque for nut
1,764.0 ±176.4 N•m (1,301 ±130 lbf ft)
6.
Remove piston rod and head assembly (3) from tool U1.
7.
Set cylinder (4) to tool U1.
8.
Sling piston rod and head assembly (3) and install it to cylinder (4).
9.
Using tool U2, tighten cylinder head nut (2). Cylinder head nut: 785 ±78.5 N•m (579 ±58 lbf ft)
10. Remove the cylinder assembly from tool U1.
50-318 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Lift Arm and Bucket Cylinder
■
1
–
1
–
Sketch
Part Name
Qty
Part No.
Necessity
Symbol
New/Remodel
Special Tools
Nature of Work, Remarks
1
790-502-1003
Repair stand
2
790-101-1102
Pump
790-102-4300
Wrench assembly
■
1
790-102-4310
Pin
■
2
1
790-201-1500
Push tool kit
■
1
Press-fitting of dust seal
3
790-201-1680
• Plate
1
Bucket cylinder
4
790-101-5021
• Grip
1
5
01010-50816
• Bolt
1
1
790-201-1702
Push tool kit
3
790-201-1871
4
1
2
Removal and installation of piston
4 All cylinders U
❖
1
Press-fitting of roll bushing
• Push tool
1
Bucket cylinder
790-101-5021
• Grip
1
5
01010-50816
• Bolt
1
1
790-720-1000
Expander
■
1
4
796-720-1680
Ring
■
1
5
07281-01589
Clamp
■
1
6
796-720-1690
Ring
■
1
7
07281-01919
Clamp
■
1
5 All cylinders
6
Expansion of piston ring Lift arm cylinder
Bucket cylinder
Required •
Container to hold the engine oil
Disassembly 1.
Set cylinder assembly (1) to tool U1.
2.
Remove mounting bolt (2) of the cylinder head.
WA500-6
50-319 b
DISASSEMBLY AND ASSEMBLY 3.
Set the cylinder to tool U1. Pull cylinder head and piston rod assembly (3) out of cylinder (4) and lift it off. ★ Since oil flows out when the piston rod assembly is pulled out of the cylinder, make sure that you have a container to catch the oil.
4.
Disassemble the piston rod assembly. ★ Set piston rod assembly (3) to tool U1.
5.
Remove piston assembly lock screw (5).
HYDRAULIC SYSTEM
Screw size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 × Pitch 1.75
★ If screw (5) is caulked so that you cannot remove it, tighten it temporarily and cut the threads on it with tap [1] and then remove it.
50-320 b
WA500-6
DISASSEMBLY AND ASSEMBLY 6.
Using tool U2, remove piston assembly (6). ★ When not using tool U2, loosen the piston assembly by using the drilled holes (DH) (Ø10: two places).
7.
Remove cylinder head assembly (7) from piston rod assembly (9).
8.
Disassembly of piston assembly
HYDRAULIC SYSTEM
A. Remove guard rings (11). B. Remove wear rings (12). C. Remove piston ring (13). D. Remove the O-ring and backup ring (14).
9.
Disassembly of cylinder assembly A. Remove O-ring (15) and backup ring (16). B. Remove the snap ring and dust seal (17).
WA500-6
50-321 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
C. Remove rod packing (18). D. Remove buffer ring (21). E. Remove bushing (19).
50-322 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Assembly ★ When assembling, coat the sliding surfaces of each part with engine oil and be careful not to damage the U-packings, dust seals, and O-rings. 1.
Assemble the cylinder head assembly according to the following procedure. A. Using push tool U4, press-fit bushing (19) to cylinder head (20). ★ When press-fitting, be extremely careful not to deform the bushing. B. Install rod packing (18). ★ Pay attention to the installed directions of the rod packing. C. Install buffer ring (21). ★ Pay attention to the installed directions of the buffer ring. D. Install backup ring (16) and O-ring (15) in order. ★ Do not insert the backup ring forcibly; warm it in water at 50 – 60°C (122 – 140 °F) and then insert it.
E. Using push tool U5, install dust seal (17) to the cylinder head and fix it with snap ring (22).
WA500-6
50-323 b
DISASSEMBLY AND ASSEMBLY
2.
HYDRAULIC SYSTEM
Assemble the piston assembly according to the following procedure. A. Using tool U6-1, expand piston ring (13). ★ Set the piston ring to the tool and rotate the handle of the tool eight to ten turns to expand the piston ring. B. Remove the piston ring from tool U6-1 and install it to piston (10).
C. Install tool U6-4 and shrink the piston ring with clamp U6-5.
D. Install wear ring (12) to the piston. E. Install guard ring (11) to the piston. F.
Install the O-ring and backup ring (14) to the piston.
50-324 b
WA500-6
DISASSEMBLY AND ASSEMBLY 3.
Install cylinder head assembly (7) to piston rod (9).
4.
Piston rod assembly
HYDRAULIC SYSTEM
A. Set piston rod assembly (3) to tool U1.
B. Assemble piston assembly (6) according to the following procedure. ★ When reusing piston rod assembly (3) and piston assembly (6): • Clean the piston rod and piston thoroughly and remove chips, dirt, etc. • Screw in piston assembly (6). Then, using tool U2, tighten piston assembly (6) until the screw holes (H) are aligned. • Remove burrs from the threaded parts with a file, etc.
★ When either or both of the rod and piston are new: • Screw in piston assembly (6) until it touches rod end [part B]. Then using tool U2, tighten the piston assembly to the specified torque.
WA500-6
50-325 b
DISASSEMBLY AND ASSEMBLY i.
HYDRAULIC SYSTEM
Make a screw hole to install screw (5). ★ Make a hole horizontally with a drill at the V-groove of the threaded part of piston (6) and rod (3). ★ Threading dimensions (mm [in]) Diameter of Depth of Tap Tap to be Tap Drill Hole Drill Hole Used 10.3 27 12 × 7.5 [0.40] [1.06] [0.47 x 0.30]
ii.
Tapping Depth 20 [0.79]
After making the hole, remove all the chips and dirt and clean thoroughly.
iii. Tighten screw (5). Threaded part (b) of screw: Adhesive (LT-2)
Screw: 58.9 – 73.6 N•m (43 – 54 lbf ft)
iv. Caulk four points (a) of the threaded part with a punch.
C. Remove piston rod assembly (3) from tool U1.
50-326 b
WA500-6
DISASSEMBLY AND ASSEMBLY 5.
HYDRAULIC SYSTEM
Set cylinder (4) to tool U1 and sling cylinder head and piston rod assembly (3); install it to the cylinder.
A. Tighten cylinder head mounting bolt (2). Cylinder head mounting bolt (2): Lift arm: 529.7 ±78.5 N•m(391 ±58 lbf ft) Bucket: 892 ±137 N•m (658 ±101 lbf ft)
B. Remove cylinder assembly (1) from tool U1.
WA500-6
50-327 b
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Steering Valve WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Required •
Container to hold the hydraulic oil
Removal 1.
Drain the hydraulic oil. Hydraulic oil: 337 l (89 gal)
2.
Remove guard and seat (1).
3.
Remove plate (2).
4.
Remove toolbox (3).
5.
Remove covers (4), (5), and (6).
6.
Disconnect hoses (7), (8), (9), (10), (11), (12), and (13).
7.
Disconnect tube (14).
8.
Sling steering valve assembly (15); remove its four mounting bolts; and lift it off. Steering valve assembly: 35 kg (77 lbs)
50-328 b
WA500-6
DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
Installation ★ Carry out installation in the reverse order of removal. Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the appropriate circuit. For details, see these procedures in the Testing and Adjusting section. • Brake System: Bleeding Air from Wheel Brake Circuit • Work Equipment: Bleeding Air from Work Equipment Circuit • Steering System: Bleeding Air from Steering Cylinder Circuit • Fuel System: Bleeding Air from Fuel Circuit
WA500-6
50-329 b
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
WORK EQUIPMENT Work Equipment Removal WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
1.
Sling the bucket link and remove pin (1). [*1] ★ Using a lever block, fix the bucket link to the bellcrank. ★ If any shim is inserted, check the quantity and thickness.
2.
Remove right and left bucket hinge pins (2). [*2] ★ If any shim is inserted, check the quantity and thickness.
3.
Disconnect the bucket from the lift arm by moving the machine in reverse or sling the bucket with a crane. Bucket: 3,150 kg (6,945 lbs)
4.
Disconnect grease hose (4).
5.
Sling bucket cylinder (5); pull out pin (6); and disconnect the bucket cylinder from the bellcrank. ★ After disconnecting the bucket cylinder, start the engine and retract the piston rod.
50-330 b
WA500-6
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
6.
Fix bucket cylinder (5) to the frame with a nylon sling, etc.
7.
Set stand [1] under the lift arm end and release the residual pressure in the hydraulic piping.
8.
Sling lift arm cylinder (7) and remove pin (8). • Remove the other lift arm cylinder pin in the same manner. • After disconnecting the lift arm cylinder, start the engine and retract the piston rod.
9.
Remove coves (9) and (10).
10. Disconnect wiring harness connector F13 (11) and remove the three wiring harness clamps. 11. Remove lift arm angle sensor assembly (12).
WA500-6
[*3]
50-331 b
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12. Disconnect right and left grease tubes (13).
13. Sling lift arm, bellcrank, and bucket link assembly (14); pull out right and left pins (15); and lift off the assembly. [*4] ★ When slinging the assembly, insert block [2] in the bellcrank. ★ If any shim is inserted, check the quantity and thickness. Lift arm, bellcrank and bucket link assembly: 3,250 kg (7,165 lbs)
14. Sling bucket link assembly (16); pull out pin (17); and remove the assembly from the bellcrank. Bucket link: 160 kg (353 lbs)
15. Sling bellcrank (18); pull out pin (19); and remove the bellcrank from the lift arm. Bellcrank: 800 kg (1,764 lbs)
50-332 b
WA500-6
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
16. Remove dust seal (21) and bushing (22) from lift arm (20). [*5]
17. Remove dust seal (23) and bushing (24) from bellcrank (18).
18. Remove dust seal (25) and bushing (26) from bucket link (16).
WA500-6
50-333 b
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
Installation ★ Carry out installation in the reverse order of removal.
WARNING!
When aligning the pin holes, use a bar. Never insert your fingers in the pin holes.
WARNING!
When starting the engine, check that the directional lever is in neutral and the parking brake is applied.
[*1] 1.
Sling bucket link (16) and install cord rings (27) while aligning the holes for pin (1).
2.
Insert a shim so that clearances (a) on the right and left sides are the same.
3.
Install pin (1) and lock it with the bolt. ★ Be careful that the cord ring does not get caught. Clearance (a): . . . . . . . . . . . . . . . . . . Maximum 1.5 mm (0.059 in)
[*2] 1.
Operate the control lever to align the holes for bucket mounting pin (2) and install cord rings (28).
2.
Insert a shim so that clearances (b) on the right and left sides are the same.
3.
Install mounting pin (2) and lock it with the bolt. ★ Be careful that the cord ring does not get caught. Clearance (b): . . . . . . . . . . . . . . . . . . Maximum 1.5 mm (0.059 in)
[*3] ★ Adjust the lift arm angle sensor assembly. For details, see WORK EQUIPMENT: Bucket Positioner in the Testing and Adjusting section. [*4] 1.
Sling the assembly of the lift arm, bellcrank, and bucket link and set it to the lift arm mounting hole of the front frame.
2.
Insert a shim so that clearances (c) on the right and left sides are the same.
3.
Install pin (15) and lock it with the bolt. ★ Be careful that the cord ring does not get caught. Clearance (c): . . . . . . . . . . . . . . . Maximum 1.0 mm (0.039 in)
★ After installing the pin, set a stand under the lift arm end.
50-334 b
WA500-6
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
[*5] 1.
Press-fit the respective bushings to the bucket link, bellcrank, and lift arm with puller [3] and install the dust seals. Bushing: Grease (G2-LI)
★ The figure to the right shows the lift arm. 2.
Supply grease to each pin.
WA500-6
50-335 b
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
Counterweight (Large) WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove the radiator guard assembly. ★ For details, see the ENGINE AND COOLING SYSTEM: Radiator Guard and Cooling Fan in this section.
2.
Disconnect wiring harness connector R18 (1) (when removing only the left-hand battery).
3.
Disconnect right and left battery cables (2) and (3).
4.
Remove right and left battery holders (4).
5.
Lift off right and left batteries (5). Battery: 65 kg (143 lbs)
6.
Remove right and left battery box covers (6) and (7).
50-336 b
WA500-6
DISASSEMBLY AND ASSEMBLY 7.
WORK EQUIPMENT
Sling counterweight assembly (8); remove its four mounting bolts; and lift it off. [*1] Counterweight: 2,550 kg (5,622 lbs)
Installation ★ Carry out installation in the reverse order of removal. [*1] Counterweight mounting bolt: 1,372 – 1,764 N•m (1,012 – 1,301 lbf ft)
WA500-6
50-337 b
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
Counterweight (Small) WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Operate the work equipment control lever two to three times to release the residual pressure in the work equipment circuit.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove the right and left batteries and right and left battery covers. ★ For details, see the WORK EQUIPMENT: Counterweight (Large) in this section.
2.
Sling counterweight assembly (2); remove its four mounting bolts (1); and lift it off. [*1] Counterweight: 900 kg (1,984 lbs)
Installation ★ Carry out installation in the reverse order of removal. [*1] Counterweight mounting bolt: 785 – 980 N•m (579 – 723 lbf ft)
50-338 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
CAB AND ITS ATTACHMENTS Cab (Separate Cab and Floor) WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove floor skirt cover (1) and right and left covers (2).
2.
Open the external air filter cover and remove filter (3) and filter box (4).
3.
Remove brake combination box front cover (5).
WA500-6
50-339 b
DISASSEMBLY AND ASSEMBLY 4.
Remove upper cover (6) of the steering valve cover.
5.
Remove right and left covers (7) under the hydraulic tank.
6.
Disconnect tipping protection wire (8).
7.
Disconnect heater hose clamp (9).
50-340 b
CAB AND ITS ATTACHMENTS
WA500-6
DISASSEMBLY AND ASSEMBLY 8.
Disconnect reservoir tank and subtank hose clamps (10).
9.
Remove front step (11).
CAB AND ITS ATTACHMENTS
10. Remove air conditioner pipe and heater hose fixing plate (12).
11. Remove the floor mat. 12. Remove rear wiper motor cover (13). 13. Remove rear cover (14). 14. Remove lunchbox (15).
WA500-6
50-341 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
15. Unplug rear windshield wiper wiring harness connector C15 (16). 16. Disconnect rear window washer hose (17). 17. Disconnect KOMTRAX wiring harnesses (18). 18. Remove the five mounting bolts and disconnect rear controller box (19) from the rear side of the cab.
19. Remove the four mounting bolts and disconnect right console (20).
20. Remove right and left pillar covers (21) and (22).
21. Disconnect internal temperature sensor connector (23). 22. Disconnect parking brake switch (24). 23. Disconnect switch connectors (25) L59, (26) L65, L66, L69, L70, (27) L67, L68, L72 (if equipped), and (28) C10. 24. Remove the ten mounting bolts and monitor dashboard cover (29).
50-342 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
25. Remove right and left covers (30) and (31) on the front side of the cab.
26. Disconnect six wiring harness clamps (32). 27. Remove wiring harness protection cover (33).
28. Unplug wiring harness connectors (34) AL1, (35) CL1, (36) CL2, and (37) CL15.
29. Remove four bolts (38) marked with ★. 30. Remove two screws (39) marked with ●. 31. Unplug wiper motor wiring harness connector (40) C12.
WA500-6
50-343 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
32. Disconnect window washer hose (41).
33. Disconnect hose (42) of the cooler and heater hoses from the air conditioner unit.
34. Remove the four mounting bolts and disconnect air conditioner unit assembly (43) from the cab.
35. Disconnect internal air filter (44) from the floor.
50-344 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
36. Remove the cab mounting bolts. [*1] ★ Remove the bolts marked with ★ and ● from the underside of the floor. ★ Remove the bolts marked with ▲ from the top of the floor.
37. Lift off cab (45). ★ When removing the cab, check that all the wiring harnesses and pipings are disconnected. Be extremely careful that the cab does not interfere with another part. [*2] Cab assembly: 750 kg (1,654 lbs)
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Installation ★ Carry out installation in the reverse order of removal. [*1] Cab mounting bolt: (M20): 490 – 608 N•m (361 – 448 lbf ft) Cab mounting bolt: (M12): 98 – 123 N•m (72 – 91 lbf ft)
[*2] ★ Replace seal (46) between the cab and floor frame. • Stick the seal along the periphery of the floor frame top. • Remove oil, grease, dust, etc. from the sticking surface. • Do not cut the bent parts of the seal but stick them as they are. Bend each part by 10 – 20 mm (0.394 – 0.787 in). ★ If the cab is not sealed perfectly, the pressurized performance of the cab drops and the noise in the cab increases.
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Cab and Floor Frame (Cab-Floor Unit) ★ The cab of this machine forms one unit with the floor frame. WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Precautions for Handling Refrigerant WARNING!
Collect refrigerant (R134a) beforehand.
WARNING!
If the refrigerant (R134a) gets in your eyes, it may cause blindness. You must wear protective glasses when collecting or filling the refrigerant. Collecting and filling work must be conducted by a qualified person.
WARNING!
If you disconnect the heater hose when the coolant temperature in the radiator is high, you may be scalded. Wait until the coolant temperature drops before disconnecting the heater hose.
Required •
Container to hold the coolant
1.
Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. ★ Have professional traders collect and fill the refrigerant (R134a). ★ Never release the refrigerant (R134a) into the atmosphere. ★ Refrigerant quanity: 1,250 ±50 g
2.
Drain the coolant. Coolant: 90 l (24 gal)
3.
Remove right and left side panels (1).
4.
Remove cover (2).
5.
Remove box (3).
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DISASSEMBLY AND ASSEMBLY 6.
Remove the bolts from the rear part of cover (4).
7.
Remove the bolts from the front part of cover (5).
8.
Remove cover (6).
9.
Remove toolbox (7).
CAB AND ITS ATTACHMENTS
10. Disconnect air conditioner hoses (8) and (9). [*1] 11. Disconnect hose bracket (10).
12. Disconnect brake hoses (11) and (12). 13. Disconnect steering hose (13).
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14. Unplug wiring harness connectors LR1 (14), LR4 (15), LS2 (16), LR3 (17), LR2 (18), LR6 (19), and LR5 (20).
15. Disconnect wiring harness connector bracket (21) from the frame. 16. Disconnect wiring harness clamps (22) and (23).
17. Unplug wiring harness connectors FL1 (24) and RT1 (25). 18. Disconnect wiring harness clamps (26) and (27) from the bracket.
19. Disconnect heater hoses (28) and (29).
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20. Disconnect hoses (30) and (31).
21. Disconnect window washer hoses (32).
22. Disconnect steering hoses (33) and (34). 23. Disconnect brake booster hoses (35), (36), (37), and (38).
24. Remove rear windshield wiper motor cover (39). 25. Remove cover (40). 26. Remove lunchbox (41).
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27. Disconnect ground wire (42) from the floor frame.
28. Remove four front and rear rubber caps (43). 29. Remove four front and rear nuts (44).
[*2]
30. Lift off cab and floor frame assembly (45). ★ Before removing the assembly, check that all the wiring harnesses and pipings are disconnected. Cab and floor frame assembly: 1,200 kg (2,646 lbs)
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Installation ★ Carry out installation in the reverse order of removal. [*1] ★ When installing the air conditioner circuit hoses, be careful that dirt, dust, or water does not enter them. 1.
Before connecting each air conditioner hose, check that the O-rings are fitted to the joints.
2.
Check that each O-ring is not damaged or deteriorated.
3.
Tighten each nut with two spanners. Threaded part of refrigerant piping: ND-OIL8
Threaded part of hose (M16 x 1.5): 12 – 15 N•m (106 – 133 lbf in) Threaded part of hose (M24 x 1.5): 30 – 35 N•m (22 – 26 lbf ft)
Filling with Air Conditioner Gas ★ Fill the air conditioner circuit with refrigerant (R134a). Air conditioner gas: 1,250 ±50 g
[*2] Floor frame mounting nut: 1,177 – 1,471 N•m (868 – 1,085 lbf ft)
Refilling with Coolant 1.
Add coolant through the coolant filler to the specified level.
2.
Run the engine to circulate the coolant through the system.
3.
Check the coolant level again.
Refilling with Oil (Hydraulic Tank) 1.
Add oil through the oil filler to the specified level.
2.
Run the engine to circulate the oil through the system.
3.
Check the oil level again.
Bleeding Air ★ Bleed air from the brake circuit. ★ For details, see BRAKE SYSTEM: Bleeding Air from Wheel Brake Circuit in the Testing and Adjusting section.
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Cab Glass (Stuck Glass) ★ This is the procedure for replacing the stuck glass.
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1.
Front glass
2.
Right door glass
3.
Right window glass
4.
Rear window glass
5.
Left window glass
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793-498-1120
Clear plate
■
2
2
2
793-498-1130
Plate
■
2
3
793-498-1110
Magnet
■
2
793-498-1210
Lifter (Suction cup)
■
2
Part No.
Part Name
X 3
Sketch
Qty
1
Symbol
New/Remodel
Necessity
Special Tools
Nature of Work, Remarks
Installation of operator's cab glass
Removal ★ All sides of each glass of the cab of this machine are stuck. ★ Remove the window glass to be replaced according to the following procedure. 1.
Using seal cutter [1], cut the adhesive between broken window glass (1) and cab (2).
★ If the glass is narrow, you can cut the adhesive by inserting a fine wire [2] (piano wire, etc.) in the adhesive and gripping both of its ends with pliers [3] (or holding the ends by winding them onto something) and cutting the adhesive with the wire.
★ If the window glass is broken finely, you can remove the glass with a knife [4] and a screwdriver. (If the screwdriver is applied directly to the normal window glass, the glass will break.) ★ When using a knife [4], insert a screwdriver in the cut to widen it and move the knife forward. 2.
Remove the window glass.
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Installation 1.
Using scraper [5], remove the remaining adhesive from the sticking surface. ★ Do not scratch the paint.
2.
Remove oil, dust, dirt, etc. from the sticking surfaces of cab (2) and window glass (3) with white gasoline. ★ If the sticking surfaces are not cleaned well, the glass may not stick correctly. ★ Clean all the black part on the back side of the window glass. ★ After cleaning the sticking surfaces, leave them to dry for at least five minutes.
3.
If paint was flaked off when the adhesive was removed with the scraper, coat the bare part with paint. ★ If the glass is installed without repairing the bare part, that part will rust. ★ Do not apply paint to a part which will be coated with primer.
4.
Stick double-sided adhesive tape (4) along the inside edge of the glass-sticking section. Size of double-sided adhesive tape:. . . 7 × 4.8 mm (0.28 x 0.19 in)
★ When sticking the double-sided adhesive tape, do not touch the cleaned surface for as long as possible. ★ Do not remove the release tape of the double-sided adhesive tape on the glass-sticking side before sticking the glass.
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★ Be careful that the corner (part (b)) of the double-sided adhesive tape does not float.
★ When sticking the double-sided adhesive tape around a side or a rear window glass, start at the center of the top and make a clearance of about 5 mm (0.20 in) at end joint (c).
5.
Position the replacement glass. A. Stick X2-2 (thin steel sheet) to tool X2-1 (spacer) with adhesive. Spacer thickness (t): . . . . . . . . . . . . . . . . . . . . 5 mm (0.197 in)
B. Set tool X2-3 (magnet) to tools X2-1 and X2-2 and set them to the two lower places of the window glass-sticking part of cab (2).
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C. Using tool X3 (suction cup), place window glass (3) on tool X2-1 (5 mm (0.20 in) spacer) and match it to the cab.
D. Check the clearance between window glass (3) and cab (2) on both sides and adjust it evenly. E. Stick tape [6] between window glass (3) and cab (2) and draw positioning line (a) on the tape. F.
6.
Cut the tape between window glass (3) and cab (2) with a knife and then remove the window glass. ★ Do not remove the tapes left on the window glass and cab before installing the window glass.
Apply primer. ★ The using limit of primer (5) is four months after the date of manufacture. Do not use primer (5) after this limit. ★ Use the primer within two hours after unpacking it. ★ Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) A. Stir the primers for paint and glass sufficiently before using them. ★ If the primer has been stored in a refrigerator, leave it at room temperature for at least half a day before stirring it. (If the primer is unpacked just after being taken out of the refrigerator, water will condense. Leave the primer at room temperature for a sufficient time.) B. When reusing primer brush (6), wash it in white gasoline. ★ After washing the brush, check it again for dirt and foreign matter. ★ Prepare respective brushes for the paint primer and glass primer.
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C. Evenly apply paint primer (7) to the parts on the outside of the double-sided adhesive tape, on cab (2), which will be coated with the adhesive. Paint primer: SUNSTAR PAINT PRIMER 580 SUPER
★ Do not apply the primer more than two times. (If it is applied more than two times, its performance is reduced.)
★ Parts to be coated with primer: Apply the primer all over dimension (d) on the outside of the double-sided adhesive tape. Dimension to apply primer (d): . . . . . . . . 23 mm (0.91 in)
★ After applying the primer, leave it for at least five minutes (within eight hours) to dry. ★ If the glass primer is applied by mistake, wipe it off with white gasoline. (If the wrong primer is applied, the glass will not stick.)
D. Evenly apply glass primer (8) to the black part of window glass (3) to be stuck. Glass primer: SUNSTAR GLASS PRIMER 580 SUPER
★ Do not apply the primer more than two times. (If it is applied more than two times, its performance is reduced.) ★ Parts to be coated with primer: Apply the primer to the sticking surface of window glass (3) and all over dimension (d) on double-sided adhesive tape (4) and cab (2). Dimension to apply primer (d): . . . . . . . . . 23 mm (0.91 in)
★ Do not apply the primer to the border, about 5 mm (0.20 in) wide, between the black part and transparent part of the glass. ★ After applying the primer, leave it for at least five minutes (within eight hours) to dry. ★ If the paint primer is applied by mistake, wipe it off with white gasoline. (If the wrong primer is applied, the glass will not stick.)
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DISASSEMBLY AND ASSEMBLY 7.
CAB AND ITS ATTACHMENTS
Apply adhesive. A. Use either of the two types of adhesive. Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER “S”
Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER “W”
★ The using limit of the adhesive is four months after the date of manufacture. Do not use the adhesive after this limit. ★ Keep the adhesive in a dark place where the temperature is below 25°C (77°F). ★ Never heat the adhesive higher than 30°C (86°F). ★ When reusing the adhesive, remove all the hardened parts from the nozzle tip. B. Break aluminum seal (10) of the outlet of adhesive cartridge (9) and install the nozzle. C. Cut the tip of the adhesive nozzle (11) so that dimensions (f) and (g) are as follows. Dimension (f): . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.394 in) Dimension (g): . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in)
D. Put the adhesive cartridge (9) in caulking gun [7]. ★ An electric caulking gun is more efficient.
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E. Remove release tape (13) of the double-sided adhesive tape on the glass side.
F.
Apply adhesive (12) to the outside of double-sided adhesive tape (4) of the cab. ★ Before applying the adhesive, check that the primer is applied to the surface to which the adhesive will be applied.
★ Apply adhesive (12) to dimensions (h) and (j) of doublesided adhesive tape (4) of cab (2). Dimension (h): . . . . . . . . . . . . . . . . . . . . 10 mm (0.394 in)
★ Apply adhesive (12) wider than double-sided adhesive tape (4). ★ Apply the adhesive evenly.
8.
Install window glass (3). ★ If the glass is positioned incorrectly, the adhesive must be removed and cleaned and then the primer and adhesive must be applied again. Position the glass carefully when sticking it. A. Similarly to Step 5, match tools X2-1, X2-2, and X2-3 and set them to the two lower places of the window glass-sticking part of cab (2).
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B. Using tool X3, raise and place window glass (3) on tool X2-1 (5-mm spacer) and stick it to the cab. ★ Match the lines of the match tapes stuck in Step 5. ★ Stick the glass within ten minutes after applying the adhesive. ★ Before sticking the glass, check that the primer is applied to the surface to which the glass will be stuck.
★ Check that clearance (k) between the front side of the front glass and right and left side glasses is even. Clearance (k): . . . . . . . . . . . . . . . . . . . . . 5 mm (0.197 in)
C. After sticking window glass (3), press it evenly. ★ Press all over the window glass just enough so that the window glass sticks to the double-sided adhesive tape. ★ Do not press too hard on the window glass. 9.
Cure the stuck window glass for a certain time. Curing time before removing tool X2-1 (5 mm (0.20 in) spacer) (at temperature of 20°C (68°F) and humidity of 60%): . . . . . . 10 hours Curing time before operating machine: . . . . . . . . . . . . . . . . . 1 day
10. If the front glass and both front side glasses are replaced, seal them. A. Stick masking tapes (14) along the parts to be sealed as shown in the figures. ★ Stick the masking tapes to both the inside and outside of the cab.
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B. Fill the glass joints with caulking material (15). ★ The usable period of the following caulking material is four months after the date of manufacture. Do not use the caulking material after its usable period. Caulking material: SUNSTAR PENGUINE SEAL NO. 2505
C. Use cardboard [8], etc. to remove the caulking material projecting from the joint. D. Remove the masking tapes from the window glass. 11. Remove the primer and adhesive from the cab and window glass. ★ Using white gasoline, wipe off the adhesive before it dries. ★ When cleaning the glass, do not hit it or push on it.
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Operator Seat (Upper Seat) ★ Manufactured by Grammer. Remark Although the machine with joystick steering is not equipped with the left armrest, its operator seat is also disassembled and assembled according to the following procedure.
Storage Box Removal 1.
Open the storage box (1).
2.
Remove the hook (3).
3.
Undo the screws (2) and remove the storage box (1).
Installation 1.
Set the storage box (1) and fix it with the screws (2).
2.
Install the hook (3).
Seat Pad and Backrest Upholstery Removal 1.
Remove the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
2.
Undo the four screws (1) and remove the backrest upholstery (2).
3.
Undo the five screws (4) and remove the seat pad (5).
4.
Unplug the connectors (3) and (6).
Installation 1.
Plug in the connectors (3) and (6).
2.
Install the seat pad (5) and fix it with the five screws (4).
3.
Install the backrest upholstery (2) and fix it with the four screws (1).
4.
Install the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Mechanical Lumbar Support Removal 1.
Remove the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
2.
Remove the backrest upholstery. See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
3.
Drill off the rivets (1); loosen the spring steel sheets (2) from the L-bar (3); and remove them.
4.
Unhook the L-bars (3) from the catch element (4).
5.
Undo the hexagon socket screw (5) and remove the adjusting knob (6) with the toothed wheel (7).
6.
Drill off the rivet (8); remove the wrap spring brake element (9) and the catch element (4).
Installation 1.
Install the wrap spring brake element (9) and the catch element (4); fix them with the rivets (8).
2.
Install the adjusting knob (6) and the toothed wheel (7); tighten the hexagon socket screw (5).
3.
Install the catch element (4) to the L-bars (3); fix with the rivets (1).
4.
Install the two spring steel sheets (2) to the L-bar (3); fix with the rivets (1).
5.
Install the backrest upholstery. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
6.
Install the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
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DISASSEMBLY AND ASSEMBLY
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Armrests (if equipped) Removal 1.
Remove the cover (1).
2.
Unscrew the hexagon nuts (2) and remove the nuts and washers (3).
3.
Remove the armrests (4).
Installation 1.
Set the armrests (4).
2.
Put the washers (3) and tighten hexagon nuts (2). Hexagon nuts: 25 N•m (18.44 lbf ft)
3.
Install the cover (1).
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Backrest
Removal 1.
Detach the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
2.
Remove the backrest upholstery. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
3.
Remove the armrests. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Armrests (if equipped) in this section.
4.
Disassemble the backrest. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Backrest Adjustment in this section.
5.
Unscrew the hexagon nut (5); remove the washers (6) and (7).
6.
Remove the hexagon bolt (11) and the washer (10).
7.
Press the backrest (1) slightly to the left and move it upwards to take it off.
8.
Remove the bearing (8) and the torsion spring (9) from the backrest (1).
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Installation 1.
Install the bearing (8) and the torsion spring (9) to the backrest (1). ★ Oil the bearing point (Q) on the backrest (1) for the bearing (8) with acid-free multiple-purpose lubricant. ★ Insert the bearing (B/8) into the upper hole on the backrest support on the right side (figure B/4).
2.
Press the backrest (1) slightly to the left and install it. ★ The large cylindrical stamping on the backrest adjustment (figure C/2) must engage into the large positional bore hole on the backrest support on the left side (figure C/3). ★ The integral catch on the backrest (figure A/1) must engage into the torsion spring (figure A/9).
3.
Put the washer (10) and tighten the hexagon bolt (11).
4.
Put the washers (6) and (7) and tighten the hexagon nut. Hexagon nuts: 25 N•m (18 lbf ft)
5.
Assemble the backrest adjustment. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Backrest Adjustment in this section.
6.
Install the armrests. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Armrests (if equipped) in this section.
7.
Install the backrest upholstery. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
8.
Install the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
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CAB AND ITS ATTACHMENTS
Backrest Adjustment Disassembly 1.
Remove the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
2.
Remove the backrest upholstery. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
3.
Remove the armrests. See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Armrests (if equipped) in this section.
4.
Fold the backrest (1) forwards.
5.
Unscrew three flat-headed screws (2); remove the adaptor plate (3) and the flat-headed screw (4).
6.
Remove the lever (5) and handle (6).
Assembly 1.
Fold the backrest (1) forwards.
2.
Install the handle (6) and the lever (5).
3.
Tighten the three flat-headed screws (4); install the adaptor plate (3); and tighten the flat-headed screw (2). ★ The lifter of the flat-headed screw (4) must engage into the nut of the adaptor plate (3). Flat-headed screw: 12 N•m (106 lbf in)
4.
Install the armrests. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Armrests (if equipped) in this section.
5.
Install the backrest upholstery. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
6.
Install the storage box. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Storage Box in this section.
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Seat Angle and Seat Depth Adjuster Disassembly 1.
Remove the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
2.
Remove the switch (if equipped). A. Disconnect the spring (1). B. Tilt the switch-plate (2) forwards and remove it. C. Drill off the rivet (3) and remove the seat switch (4).
3.
Remove the flexible support plate (7).
A. Press the spring plate (5) (P position) inwards (arrow) and operate the lever for seat angle adjustment (6). B. Pull the flexible support plate (7) backwards and remove it. 4.
Remove the plate (15). A. Drill off the rivet and remove the spring steel sheet (5). B. Unscrew the hexagon socket screws (8); remove the cover (9), the levers for seat angle and seat depth adjustment (6) and (10), the linkage rod (11), and the locking lever (12). C. Remove the spring (13). D. Turn the lever (14) clockwise until it snaps in; pull the plate (15) to the very front and remove it.
5.
Remove the covers on the right and left side. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Covers in this section.
6.
Unscrew the nut (16); remove the lever (14) and the screw (17).
7.
Drill off the rivet (18); remove the spring steel sheets (19).
8.
Drill off the rivet (20); remove the locating element (21).
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Assembly 1.
Install the locating element (21); fix it with the rivet (20).
2.
Install the spring steel sheets (19); fix it with the rivet (18).
3.
Set the lever (14) and the screw (17); fix with nut (16).
4.
Install the covers on the right and left side. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Covers in this section.
5.
Assemble the plate (15). A. Turn the lever (14) clockwise until it snaps in; install the plate (15). B. Install the spring (13) to hook (a) of the lever (14) and hook (b) of the plate (15). C. Install the cover (9), the levers for seat angle and seat depth adjustment (6) and (10), the linkage rod (11), and the locking lever (12); tighten the hexagon socket screws (8). D. Install the spring steel sheet (5) and fix it with the rivet.
6.
Install the flexible support plate. A. Press the spring plate (5) (P position) inwards (arrow); operate the lever for seat angle adjustment (6). B. Swivel the flexible support plate (7) upwards and install it.
7.
Install the end hook of the linkage rod (11) to position (c) of the lever (10) and the other side of the hook of the linkage rod (11) to the port (d) of the lever (14).
8.
Install the switch (4) (if equipped). A. Install the seat switch (4) and fix it with rivet (3). B. Tilt switch-plate (2) forwards and install it. C. Install the spring (1).
9.
Install the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
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CAB AND ITS ATTACHMENTS
Covers Removal 1.
Remove the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
2.
Remove spring (1) and switch-plate (2) (if equipped).
3.
Remove the flexible support plate. A. Press the spring sheet inwards (arrow) and operate the lever for seat angle adjustment (3). B. Pull the flexible support plate (4) backwards and remove it.
4.
Remove the spring (5).
5.
Turn the lever (6) clockwise until it snaps in; pull the plate (7) to the extreme front and remove it.
6.
Drill off the rivet (8) and remove the washers (9).
7.
Unhook the covers (10) by pulling them forwards; remove them in an upward direction.
Installation 1.
Install the covers (10) on right and left side.
2.
Install the washers (9) and fix them with the rivet (8).
3.
Turn the lever (6) clockwise until it snaps in, then install the plate (7).
4.
Remove the spring (5). ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster in this section.
5.
Install the flexible support plate (4). ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster in this section.
6.
Install spring (1) and switch-plate (2). ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Angle and Seat Depth Adjuster in this section.
7.
Install the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section
WA500-6
50-371 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Slide Rails Removal 1.
Remove the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
2.
Push the seat top assembly (1) as far back as possible.
3.
Unscrew the hexagon socket screws (2) and remove the nuts (3).
4.
Push the seat top assembly (1) as far forward as possible.
5.
Unscrew the hexagon socket screws (4); remove the washers (5) and nuts (6).
6.
Remove the seat top assembly (1) and remove the washers (7).
7.
Disconnect the bellows from the upper part of the suspension system and lay it down.
8.
Unscrew the hexagon socket screws (8) and remove the nuts (9).
9.
Remove the slide rails (10).
Installation 1.
Install the slide rails (10).
2.
Put the nuts (9) and tighten the hexagon socket screws (8). ★ Replace the hexagon socket screws (8) with new ones. Hexagon socket screws: 25 N•m (18 lbf ft)
3.
Install the bellows to the upper part of the suspension system.
4.
Put the washers (7) and install the seat top assembly (1).
5.
Put the washers (5) and nuts (6), then tighten the hexagon socket screws (4). ★ Replace the hexagon socket screws (4) with new ones. Hexagon socket screws: 25 N•m (18 lbf ft)
6.
Push the seat top assembly (1) as far forward as possible.
7.
Put the nuts (3) and tighten the hexagon socket screws (2). ★ Replace the hexagon socket screws (2) with new ones. Hexagon socket screws: 25 N•m (18 lbf ft)
8.
Push the seat top assembly (1) as far back as possible.
9.
Install the seat pad. ★ See CAB AND ATTACHMENTS: Operator Seat (Upper Seat): Seat Pad and Backrest Upholstery in this section.
50-372 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Operator Seat (Suspension) Top Cover Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Pull the connecting cable (3) inwards through the upper cover (2).
3.
Remove the two bellows pins (1) and take the upper cover (2) off.
Installation 1.
Install the connecting cable (3) inwards through the upper cover (2).
2.
Install the upper cover (2) and fix it with the two bellows pins (1).
3.
Install the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
Front Cover Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Bore out two rivet heads and drive out blind rivets (1); remove the front cover (2).
Installation 1.
Install the front cover (2) and fix it with the two rivets (1).
2.
Install the top cover. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Install the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-373 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Bellows Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the bellows (2) from the upper part of the suspension (1). A. Take bellows pins (4) off on the front. B. Take bellows pins (3) off on the left side of the top. C. Remove two bellows pins (4) on the back; take two bellows pins (3) off the upper part of the suspension system (1). D. Take three bellows pins (3) on the right side off the upper part of the suspension (1); pull the bellows (2) over the handle for vertical shock absorber adjustment (9).
3.
Remove the bellows (2) from the lower part of the suspension (6). A. Take three bellows pins (3) on the front side off the lower part of the suspension (6). B. Release two bellows pins (3) on the left side from the lower part of the suspension (6). C. Release four bellows pins (3) on the back side from the lower part of the suspension (6). D. Remove a cable tie (10) on the right side from the connecting cable; take two bellows pins (3) off the lower part of the suspension (6) (if equipped).
4.
Lift the bellows (2) over the lower part of the suspension (6) and remove the bellows (2) in a downward direction.
5.
Remove the wire insert (5) from the bellows (2).
Installation 1.
Install the wire insert (5) to the bellows (2).
2.
Install the bellows (2).
3.
Fix the bellows (2) with pins (3) to the lower part of the suspension (6) in the reverse order of their removal.
4.
Fix the connecting cable with the cable tie (10) (if equipped).
5.
Fix the bellows (2) with pins (3) to the upper part of the suspension (1) in the reverse order of their removal.
6.
Install the upper part of the seat. ★ Refer to CAB AND ATTACHMENTS: Operator Seat (Upper Seat) in this section.
50-374 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
MEMORANDUM
WA500-6
50-375 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Bowden Pull Wire and Handle (Vertical Shock Absorber Adjustment)
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Screw out Torx screw (2).
6.
Pull the handle for vertical shock absorber adjustment (1) off the upper part of the suspension (4).
7.
Remove the Bowden pull wire (5) from the handle for vertical shock absorber adjustment (1).
8.
Push the Bowden pull wire (5) off the bearing for Bowden pull wire (6).
9.
Bore out the rivet head and drive out the blind rivet (7); remove the bearing for Bowden pull wire (6).
50-376 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
10. Mark the points where the Bowden pull wire (5) is fastened with the swinging structure (14) with the cable tie (8); take the cable tie (8) off. 11. Pull the fixation (12) off the vertical shock absorber (13). 12. Take the Bowden pull wire (5) off the bearing (9). 13. Remove the fixation (12) from the fork (11). 14. Take the Bowden pull wire (5) off the fork (11); remove the fork (11) and compression spring (10). 15. Mark the location of the mounting hole for the Bowden pull wire (5) in the upper part of the suspension (4); pull the Bowden pull wire (5) out of the upper part of the suspension (4); and then remove it.
WA500-6
50-377 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Put the Bowden pull wire (5) to the upper part of the suspension (4) through the location of the mounting hole marked before removing the Bowden pull wire (5).
3.
Install the fork (11) and compression spring (10) and take the Bowden pull wire (5) to the fork (11).
4.
Install the fixation (12) to the fork (11).
5.
Take the Bowden pull wire (5) to the bearing (9).
6.
Put the fixation (12) to the vertical shock absorber (13).
7.
Install the Bowden pull wire (5) and fix it with the cable tie (8) at the marked points. ★ Install the Bowden pull wire according to the marking.
8.
Install the bearing for Bowden pull wire (6) and fix it with the rivet (7).
9.
Install the Bowden pull wire (5) to the bearing for Bowden pull wire (6).
10. Install the Bowden pull wire (5) to the handle for vertical shock absorber adjustment (1).
50-378 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
11. Install the handle for vertical shock absorber adjustment (1) to the upper part of the suspension (4). 12. Tighten Torx screw (2). Torx screw: 2.25 N•m (20 lbf in)
13. Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section. 14. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section. 15. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-379 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Vertical Shock Absorber Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Remove circlip (8) from stud (6).
6.
Pull the stud (6) out of swinging structure (7) and vertical shock absorber (4).
7.
Take fixation (2) and bearing (1) off vertical shock absorber (4).
8.
Remove circlip (5) from stud (3).
9.
Pull stud (3) out of swinging structure (7) and vertical shock absorber (4).
10. Remove vertical shock absorber (4) in an upward direction.
50-380 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Install vertical shock absorber (4). ★ When re-installing vertical shock absorber (4), make sure the labeling is on top.
3.
Assemble vertical shock absorber (4) to swinging structure (7) and put stud (3).
4.
Install circlip (5) to stud (3). ★ Apply acid-free multi-purpose lubricant to the entire external surface (F) of stud (3).
5.
Install fixation (2) and bearing (1) to vertical shock absorber (4).
6.
Assemble vertical shock absorber (4) to swinging structure (7) and put stud (6). ★ Apply acid-free multi-purpose lubricant to the entire external surface (F) of stud (6).
7.
Install circlip (8) to stud (6).
8.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
9.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
10. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-381 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Compressor
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Mark the points where compressor cable (5) is fastened with six cable ties (6); remove cable ties (6).
6.
Unplug right-angle plug (10) from height level control unit (1).
7.
Disconnect the electric connector of flat plug (11).
8.
Mark the points where compressed-air hose (7) is fastened with cable tie (12); remove cable tie (12).
9.
Mark the points where compressor (3) is fastened with two cable ties (4); remove cable ties (4).
50-382 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
10. Pull fitting (8) out of the spike of compressor (3) and push it backwards off compressed-air hose (7). 11. Pull compressed-air hose (7) off compressor (3). ★ Do not use a screwdriver to lift compressed-air hose (7) off the spike of compressor (3). ★ Heat compressed-air hose (7) at the head of compressor (3) (for example, using a hot-air blower) and then pull it off in one move. 12. Pull out compressor cable (5) in a downward direction and remove compressor (3) to the front. 13. Remove support (9) from the lower part of suspension (2).
WA500-6
50-383 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Install support (9) to the lower part of suspension (2).
3.
Install compressor (3) to support (9).
4.
Install compressed-air hose (7) and fix it with cable tie (4) at the marked points. ★ Loosely apply cable tie (4) until the locking head of cable tie (4) is located slightly over the front curve of compressor (3) and while compressor (3) can be still moved. ★ Align compressor (3) and use the pliers to tighten the locking head of cable tie (4) to 310 N•m (229 lbf ft) in the direction shown (arrow).
5.
Put fitting (8) to compressed-air hose (7).
6.
Install them to the spike of compressor (3).
7.
Fix compressor (3) with cable ties (4) at marked points. ★ Fix the cable tie according to the marking.
8.
Fix compressed-air hose (7) with cable tie (12) at the marked points.
9.
Connect the electric connector of flat plug (11).
50-384 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
10. Connect right-angle plug (10) to height level control unit (1). 11. Install compressor cable (5) and fix it with cable tie (6) at the marked points. ★ Tie back any excess length of compressor cable (5). 12. Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section. 13. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section. 14. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-385 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Height Level Controller
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Loosen up two circlips (17) from stud (18) and then remove them.
6.
Knock out stud (18) from the lower part of suspension (15) and then remove it. ★ Firmly hold webbing (5) and let it carefully roll back to the rewinder on the height level controller (1).
7.
Remove two buffers (16) from the loop of webbing (5).
8.
Mark the points where air input hoses (10) and (11) are fastened with five cable ties (12); remove cable ties (12).
50-386 b
WA500-6
DISASSEMBLY AND ASSEMBLY 9.
CAB AND ITS ATTACHMENTS
Pull air input hoses (10) and (11) off the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section.
10. Mark the place where the cable is fastened with right-angle plugs (13) and (14) and the cable tie; remove the cable tie. 11. Mark the place where Bowden pull wire (19) is fastened with the cable tie; remove the cable tie. 12. Unhook Bowden pull wires (3) and (19) from height level control (1). 13. Mark and then unplug the right-angle plugs (13) and (14) from height level control unit (1). 14. Remove two hexagon nuts (4) from the thread of height level control (1). 15. Remove plate (7), loop of webbing (5), and edge protection strip (6). 16. Remove height level control (1) from the upper part of suspension (8). 17. Undo Torx screw (9); take the attachment for Bowden pull wire (2) off the height level valve (1). ★ To do this, first release the two catchers on the backside of the attachment for Bowden pull wire (2) and take the attachment for Bowden pull wire (2) off the height level valve (1). 18. Pull Bowden pull wire (3) out of the attachment for Bowden pull wire (2). 19. Remove the height level controller in an upward direction.
WA500-6
50-387 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Install the height level controller.
3.
Install Bowden pull wire (3) to the attachment for Bowden pull wire (2).
4.
Install the attachment for Bowden pull wire (2) to height level controller (1).
5.
Tighten Torx screw (9) to height level controller (1). ★ Finger-tighten Torx screw (9).
6.
Install height level control (1) to the upper part of suspension (8).
7.
Install plate (7), loop of webbing (5), and edge protection strip (6).
8.
Install two hexagon nuts (4) to the thread of height level controller (1).
9.
Connect right-angle plugs (13) and (14) to height level controller (1) at the marked point.
10. Install Bowden pull wires (3) and (19) to height level controller (1). 11. Install Bowden pull wire (19) and fix it with the cable tie at the marked points.
50-388 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
12. Install right-angle plugs (13) and (14) and fix them with the cable tie at the marked points. 13. Install air input hoses (10) and (11) to the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section. 14. Fix air input hoses (10) and (11) with five cable ties (12) at the marked points. 15. Install two buffers (16) to the loop of webbing (5). 16. Install stud (18) to the lower part of suspension (15). 17. Install two circlips (17) to stud (18); then remove them. 18. Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section. 19. Install the top cover. ★ Refer to the Operator Seat (Suspension): Top Cover in this section. 20. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-389 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Adjustment
1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Loosen self-tapping screw (9) a half turn.
6.
Adjust micro switch (3). A. Adjust the clearance between cam switch (5) and cam disc (7) by turning crosshead screw (8). Specified clearance (A) = . . . . . . . . . . . . . . .0.5 mm (0.020 in)
B. Turn the crosshead screw (8) to the left; cam switch (5) is moving towards cam disc (7).
50-390 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
C. Turn crosshead screw (8) to the right; cam switch (5) is moving away from cam disc (7). ★ When cam switch (5) seats on cam disc (7) under pressure, compressor (11) turns too early and runs during the compression and expansion of the seat suspension. 7.
Adjust the output level (2). A. Adjust the clearance between valve lever (6) and cam disc (7) by turning crosshead screw (10). ★ Specified value: The valve lever (6) must seat on the cam disc without pressure (7). B. Turn crosshead screw (10) to the left; valve lever (6) is moving towards cam disc (7). This increases the pressure on valve tappets (4) at output valve (2) and the air escapes output valve (2) earlier. C. Turn crosshead screw (10) to the right; valve lever (6) is moving away from cam disc (7). This decreases the pressure on valve tappets (4) at output valve (2) and the air escapes output valve (2) later.
8.
Tighten self-tapping screw (9) after the adjustment has been completed.
9.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
10. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section. 11. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-391 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Compressed-Air Hoses ★ Do not disconnect the hose more than one or two times. Always check the hose for damage before connecting it.
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Mark the points where compressed-air hose (11) is fastened with cable tie (12); remove cable tie (12).
6.
Pull compressed-air hose (11) off pneumatic spring (9). ★ When pulling the hoses out, the retaining ring of quick coupling (13) must first be completely pressed back (for example, using flat pliers) to avoid marks.
7.
Pull compressed-air hose (11) off compressor (5) and remove it. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section.
50-392 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
8.
Pull the compressed-air hose with angle (8) off pneumatic spring (9) and then off air tank (10). ★ When pulling the hoses out, the retaining ring of quick coupling (13) must first be completely pressed back (for example, using flat pliers) to avoid marks.
9.
Mark the points where the compressed-air hose with angle (8) is fastened with cable ties (6), (7), and (12); remove cable ties (6), (7), and (12).
10. Remove the air hose with angle (8). 11. Mark the points where air input hoses (3) and (4) are fastened with cable ties (2) and (6); remove cable ties (2) and (6). 12. Pull air input hoses (3) and (4) out of pneumatic spring (9). 13. Remove height level controller (1) with air input hoses (3) and (4). ★ To ensure tightness, air input hoses (3) and (4) cannot be removed from height level control (1).
WA500-6
50-393 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation
★ Always replace a damaged (marks) hose with a new one. It is possible to cut the damaged part off (about 12 mm [0.472 in]) using special tools (14) only once. After cutting off this piece, the blue marking should be (arrow) set back by the length of the cutoff piece. 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Install height level controller (1) with air input hoses (3) and (4). ★ Cut air input hose (3) or (4) off at the leaky area and connect new air input hose (3) or (4) to an appropriate adapter. Subsequently, cut the excess length off.
3.
Install air input hoses (3) and (4) to pneumatic spring (9).
4.
Fix air input hoses (3) and (4) with cable ties (2) and (6) at the marked points.
5.
Install the compressed-air hose with angle (8) to pneumatic spring (9) and then off air tank (10). ★ To avoid kinking, always install the compressed-air hose with angle (8) first on pneumatic spring (9). ★ Apply pressure to insert the air hose with angle (8) into pneumatic spring (9) and air tank (10) up to the blue marking.
6.
Fix the compressed air hose with angle (8) with cable ties (6), (7), and (12) at the marked points. ★ Do not fix cable tie (12) at the angle.
50-394 b
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DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
7.
Install compressed-air hose (11) to compressor (5). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section.
8.
Install compressed-air hose (11) to pneumatic spring (9).
9.
Fix the compressed-air hose with cable tie (12) at the marked points.
10. Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section. 11. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section. 12. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section. Hydrostatic test ★ After the installation of a compressed-air hose, you must perform the hydraulic test of the suspension. • Apply a 60 kg (132 lbs) load to the suspension for 24 hours. • The lowering within this time must not exceed 15 mm (0.591 in). ★ The compressed-air hoses are locked after they are connected.
WA500-6
50-395 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Bowden Pull Wires and Handle (Height Adjustment) Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Mark the points where Bowden pull wire (1) is fastened with two cable ties (3); remove cable ties (3).
5.
Mark the points where Bowden pull wire (6) is fastened with two cable ties (8); remove cable ties (8).
6.
Take Bowden pull wire (1) off the height level controller and pull it out of the holder for the Bowden pull wire. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.) ★ To release the tension of Bowden pull wire (1), press the handle for height adjustment (5) upwards.
7.
Take Bowden pull wire (6) off the height level controller. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section. ★ To release the tension of Bowden pull wire (6), press the handle for height adjustment (5) upwards.
8.
Undo the three crosshead screws (7).
9.
Take Bowden pull wires (1) and (6) off the holder for Bowden pull wire (4); pull the wires out of the upper part of suspension (2).
10. Remove holder (4) for the Bowden pull wire. 11. Replace handle (5), if required. A. Handle (5) and the holder for Bowden pull wire (4) are wedged into the two latching noses (arrow) at the lower part of the holder for Bowden pull wire (4). Carefully separate the parts. B. To remove the handle, use a screwdriver to bend open handle (5) between handle (5) and the holder for Bowden pull wire (4) so that the two latching noses are released from handle (5). C. Take handle (5) off the holder for Bowden pull wire (4).
50-396 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Install handle (5) to holder (4), if removed. ★ When handle (5) is deformed, replace it.
2.
Install Bowden pull wires (1) and (6) to the holder for Bowden wire (4). ★ Adjust the new Bowden pull wire to the length of the old one (excess length of the wire).
3.
Install holder (4) to the upper part of suspension (2) and tighten three crosshead screws (7).
4.
Install Bowden pull wire (6) to the height level controller. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
5.
Install Bowden pull wire (1) to the height level controller. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
6.
Fix Bowden pull wire (6) with two cable ties (8) at the marked points. ★ Loosely fix the Bowden pull wire with the cable ties at the marked points and make sure it is not distorted.
7.
Fix Bowden pull wire (1) with two cable ties (3) at the marked points. ★ Loosely fix the Bowden pull wire with the cable ties at the marked points and make sure it is not distorted.
8.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
9.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
10. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-397 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Checking and Adjusting
★ When checking and adjustment is performed during removal and installation, skip Steps 1 and 2 in the Checking procedure. Checking 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Operate the handle for height adjustment (2) several times in both directions and check the following: • Bowden pull wires (1) and (3) for easy-running • Bowden wire lever (10), valve lever (14), and valve tappets (13) at the output valve (12) for smoothness of running
4.
Check the neutral position of the handle for seat height adjustment (2) and the tensile force of the retracting spring (11) on height level valve (4): • The retracting spring (11) must fix the handle for seat height adjustment (2) in the neutral position. • The retracting spring (11) must tightly pull Bowden pull wires (1 and 3) and keep Bowden wire lever (10) in the neutral position.
5.
Check the clearance between Bowden wire lever (10) and the holder for Bowden wire end cap (9). ★ Specified value: Distance (A) between 1 and 3.5 mm (0.039 – 0.138 in) (with the handle for height adjustment (2) in the up position) ★ When the specified value exceeds 3.5 mm (0.138 in), the suspension cannot be lifted above the middle position.
50-398 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Adjustment 1.
Adjustment of the Bowden pull wire (3) A. Loosen counternut (6) and adjust the clearance between Bowden wire lever (10) and the holder for Bowden wire end cap (9) using locknut (5). ★ Turn locknut (5) inwards; the Bowden pull wire gets longer. ★ Turn locknut (5) outwards; the Bowden pull wire gets shorter. ★ Specified value: Clearance (A) between 1 and 3.5 mm (0.039 – 0.138 in) B. Secure locknut (5) with counternut (6) and make sure not to distort Bowden pull wire (3). C. Operate the handle for seat height adjustment (2) several times and check the specified value. D. Repeat the adjustment, if necessary.
2.
Adjustment of Bowden pull wire (1) A. Loosen counternut (7) and adjust the tension of Bowden pull wire (1) on height valve (4) using locknut (8). ★ Turn locknut (8) inwards; the Bowden pull wire gets longer. ★ Turn locknut (8) outwards; the Bowden pull wire gets shorter. ★ Specified value: Bowden wire (8) must be tightened, but not distorted, on the suspension device on height level valve (4). B. Secure locknut (8) with counternut (7) and make sure not to distort Bowden pull wire (1). C. Operate the handle for seat height adjustment (2) several times and check the specified value. D. Repeat the adjustment, if necessary.
WA500-6
50-399 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Pneumatic Spring
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Remove the two air input hoses, compressed-air hose, and air input hose with angle from the pneumatic spring (6). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section.
5.
Undo countersunk screw (3) from pneumatic spring (6) and remove it together with washer (4).
6.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
7.
Turn the spring system by 180° and place it onto upper part (1).
8.
Undo countersunk screw (7) from pneumatic spring (6).
9.
Slightly compress pneumatic spring (6) and remove it from swinging structure (5) and lower part of suspension (2).
50-400 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Turn the spring system by 180° and place it onto upper part (1).
3.
Slightly compress pneumatic spring (6) and install pneumatic spring (6) to swinging structure (5) and lower part of suspension (2).
4.
Tighten countersunk screw (7) to pneumatic spring (6). Countersunk screw (6): 6 N•m (53 lbf in)
5.
Turn the spring system by 180° and place it onto upper part (1).
6.
Put washer (4) to pneumatic spring (6) and tighten countersunk screw (3). Countersunk screw (6): 6 N•m (53 lbf in)
7.
Install the two air input hoses, compressed-air hose, and air input hose with angle to the pneumatic spring (6). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section.
8.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
9.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
10. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-401 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Air Tank for Additional Air Supply
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Remove the air hose with angle (4) from air tank (3). ★ Refer to the Operator Seat (Suspension): Compressed-Air Hoses removal procedure in this section.
6.
Remove air tank (3) from bracket (2) and clamp (5).
7.
Take clamp (5) off bracket (6) in a downward direction, if required. ★ To do this, use a screwdriver to press through the hole (arrow) in the bracket against the catchers (arrow) of clamp (5) and pull clamp (5) out in a downward direction.
50-402 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Install clamp (5) to bracket (6), if removed. ★ Replace the clamp with a new one, if required.
3.
Install air tank (3) to bracket (2) and clamp (5).
4.
Install the air hose with angle (4) to air tank (3). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section.
5.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
6.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
7.
Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-403 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Cable Harness
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
5.
Mark the points where the cable of machine power connector (3) is fastened with cable tie (8) on the upper part of suspension (7); remove cable tie (8).
6.
Mark places where the cable harness of connector plug (2) and the cable harness of machine power connector (3) are fastened with cable ties (5); remove cable ties (5).
7.
Unplug the electric connection (flat plug) of compressor cable (4) to the cable harness of connector plug (2) and the cable harness of machine power connector (3).
8.
Disconnect right-angle plug (6) from height level control unit (1).
50-404 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Connect right-angle plug (6) to height level control unit (1).
3.
Plug the electric connection (flat plug) of compressor cable (4) to the cable harness of connector plug (2) and the cable harness of machine power connector (3).
4.
Fix the cable harness of connector plug (2) and the cable harness of machine power connector (3) with cable ties (5) at the marked points. ★ Run cable harnesses (2) and (3) and fix them with cable ties (5) so that they are neither squeezed nor otherwise damaged.
5.
Fix the cable of machine power connector (3) with cable tie (8) on the upper part of suspension (7) at the marked points.
6.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
7.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
8.
Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-405 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Suspension System (Upper Part)
Disassembly 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Take the Bowden pull wire and handle off the upper part of suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) in this section. ★ The Bowden pull wire does not need to be taken off the vertical shock absorber.
5.
Remove the vertical shock absorber from the upper part of suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Vertical Shock Absorber in this section.
6.
Remove the height level controller from the upper part of suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section. ★ Air input hoses do not need to be taken off the pneumatic spring.
50-406 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
7.
Remove Bowden pull wires and handle for height adjustment. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Height Adjustment) in this section.
8.
Move the suspension system to the highest position. WARNING!
9.
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
Bore out two rivet heads and drive out blind rivets (10); remove stops (9).
10. Push the upper part of suspension (1) forwards until the cutouts (arrow) on the left and right sides at guiding rails (2) are located at the same height with front rollers (8) of swinging structure (7). 11. Remove the upper part of suspension (1) on the front side over rollers (8) and back rollers (6) of swinging structure (7).
WA500-6
50-407 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Assembly 1.
Move the suspension system to the highest position. WARNING!
Risk of crushing! Secure the suspension between the swinging structure and lower part of the suspension system with suitable spacers.
2.
Push the upper part of suspension (1) forwards until the cutouts (arrow) on the left and right sides at guiding rails (2) are located at the same height with front rollers (8) of swinging structure (7).
3.
Install the upper part of suspension (1) on back rollers (6) and front rollers (8) of swinging structure (7). ★ Apply acid-free multi-purpose lubricant to side surfaces (F) of two guiding rails (2) of rollers (6).
4.
Install stops (9) and fix with two rivets (10).
5.
Install Bowden pull wires and handle for height adjustment. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Height Adjustment) in this section.
6.
Install the height level controller to the upper part of suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
7.
Install the vertical shock absorber to the upper part of suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Vertical Shock Absorber in this section.
8.
Install the Bowden pull wire and handle to the upper part of the suspension (1). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) in this section.
50-408 b
WA500-6
DISASSEMBLY AND ASSEMBLY 9.
CAB AND ITS ATTACHMENTS
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
10. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section. 11. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-409 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Suspension System (Lower Part)
Disassembly 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Remove the compressor from the lower part of suspension (7). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section ★ Compressor cable and compressed-air hose do not need to be removed. ★ Protect the compressor against shocks (impacts) by fixing it on the swinging structure with adhesive tape.
5.
Remove the webbing from the lower part of suspension (7). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
6.
Undo the countersunk screw from the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Pneumatic Spring in this section.
7.
Remove the two cable ties for the vehicle power connector cable on the lower part of suspension (7). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Cable Harness in this section.
8.
Unscrew the two hexagon nuts (11); remove washers (10) and countersunk screws (9).
50-410 b
WA500-6
DISASSEMBLY AND ASSEMBLY 9.
CAB AND ITS ATTACHMENTS
Undo two corrugated-head screws (5) and take the U-shaped profiles (6) off guiding rail (8).
10. Push the upper part of suspension (1) with swinging structure (3) backwards until the two fixed bearings (4) on swinging structure (3) can be taken out through the cutouts (arrows) of guiding rails (8) on the upper part of suspension (1). 11. Lift the upper part of suspension (1) with swinging structure (3) out and pull it out together with two rollers (2) from guiding rails (8) by turning it sideways.
WA500-6
50-411 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Assembly 1.
Install the upper part of suspension (1) with swinging structure (3) together with two rollers (2) to guiding rails (8). ★ Apply acid-free multi-purpose lubricant to the bearing surface at side (F) of two guiding rails (8) of rollers (2).
2.
Install the U-shaped profile (6) to guiding rail (8) and tighten two corrugated-head screws (5).
3.
Put the countersunk screws (9) and washers (10); tighten two hexagon nuts (11).
4.
Install the two cable ties for the machine power connector cable on the lower part of suspension (7). ★ Refer to the Operator Seat (Suspension): Cable Harness installation procedure in this section.
5.
Tighten the countersunk screw to the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Pneumatic Spring in this section.
6.
Install the webbing to the lower part of suspension (7). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
7.
Install the compressor to the lower part of suspension (7). ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section
8.
Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section
9.
Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Cover in this section
50-412 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
10. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-413 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Swinging Structure
Removal 1.
Remove the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
2.
Remove the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Top Cover in this section.
3.
Take the bellows off. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section.
4.
Take the Bowden pull wire for vertical shock absorber adjustment off the vertical shock absorber. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) in this section.
5.
Take the vertical shock absorber off the swinging structure. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Vertical Shock Absorber in this section.
6.
Remove the compressor. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section.
7.
Take the webbing off the lower part of the suspension. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section.
50-414 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
8.
Remove the cable tie for the air input hoses of the height level control and pull the air input hoses off the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section.
9.
Take the Bowden pull wires for height level adjustment off the height level valve. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bowden Pull Wires and Handle (Height Adjustment) in this section.
10. Remove the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Pneumatic Spring in this section. 11. Remove the air tank for additional air supply. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Air Tank for Additional Air Supply in this section. 12. Remove the cable harness. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Cable Harness in this section. 13. Take the upper part of the suspension off the swinging structure. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Suspension System (Upper Part) in this section. 14. Take the lower part of the suspension off the swinging structure. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Suspension System (Lower Part) in this section. 15. Take four rollers (5), two rollers (6), two fixed bearings (9), and four felt rings (4) off the swinging structure (1). 16. Pull the tube piece (8) out of the fixed bearing (9). 17. Remove the two buffers (7) from the swinging structure (1). 18. Remove the edge protection strip (2) from the swinging structure (1).
WA500-6
50-415 b
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
Installation 1.
Check: maximum clearance (A) or (B) between rollers (5) and the guiding rails of the lower part of suspension (11) or upper part of suspension (10) over the complete adjustment length.
2.
Place the washer compensating for clearance (2) between roller (5 or 6) and the axle of swinging structure (1), if necessary. ★ Clearance spacers (with thickness of 0.2 mm and 0.5 mm) are included in the wear parts set.
3.
Install edge protection strip (2) to swinging structure (1).
4.
Install the two buffers (7) to swinging structure (1).
5.
Put tube piece (8) to fixed bearing (9).
6.
Install four rollers (5), two rollers (6), two fixed bearings (9), and four felt rings (4) to swinging structure (1).
7.
Install the lower part of the suspension to the swinging structure. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Suspension System (Lower Part) in this section.
8.
Install the upper part of the suspension to the swinging structure. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Suspension System (Upper Part) in this section.
9.
Install the cable harness. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Cable Harness in this section.
10. Install the air tank for additional air supply.
50-416 b
WA500-6
DISASSEMBLY AND ASSEMBLY
CAB AND ITS ATTACHMENTS
★ Refer to the Operator Seat (Suspension): Air Tank for Additional Air Supply in this section. 11. Install the pneumatic spring. ★ Refer to the Operator Seat (Suspension): Pneumatic Spring in this section. 12. Install the Bowden pull wires for height level adjustment to the height level valve. ★ Refer to the Operator Seat (Suspension): Bowden Pull Wires and Handle (Height Adjustment) n this section. 13. Install the cable tie for the air input hoses of the height level controller and pull the air input hoses to the pneumatic spring. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressed-Air Hoses in this section. 14. Install the webbing to the lower part of the suspension. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Height Level Controller in this section. 15. Install the compressor. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Compressor in this section. 16. Install the vertical shock absorber to the swinging structure. ★ Refer to the Operator Seat (Suspension): Vertical Shock Absorber in this section. 17. Install the Bowden pull wire for vertical shock absorber adjustment to the vertical shock absorber. ★ Refer to the Operator Seat (Suspension): Bowden Pull Wires and Handle (Vertical Shock Absorber Adjustment) in this section. 18. Install the bellows. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Bellows in this section 19. Install the top cover. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Suspension): Cover in this section 20. Install the upper part of the seat. ★ Refer to CAB AND ITS ATTACHMENTS: Operator Seat (Upper Seat) in this section.
WA500-6
50-417 b
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM Engine Controller WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove the right side panel.
2.
Open the right side door.
3.
Remove cover (1).
4.
Disconnect wiring harness connectors E18 (2), (3) and E19 (4). [*1]
5.
Remove engine controller assembly (5).
Installation ★ Carry out installation in the reverse order of removal. [*1] ★ When installing each heavy-duty wire connector, check that it is locked. Connectors (2) and (3): 2.54 – 3.01 N•m (23 – 27 lbf in)
50-418 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
Transmission Controller WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove cover (a).
2.
Disconnect wiring harness clamps (1) and (2).
3.
Unplug wiring harness connectors L04 (3), L03 (4), and L02 (5). [*1]
4.
Remove transmission controller assembly (6).
Installation ★ Carry out installation in the reverse order of removal. [*1] ★ Before plugging each connector, check that its inside is free from dirt, dust, and water. ★ When installing each heavy-duty wire connector, check that it is locked. (When it is locked, it clicks.) Connectors (3), (4) and (5): 2.54 – 3.01 Nm (23 – 27 lbf in)
WA500-6
50-419 b
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
Work Equipment Controller WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove cover (a).
2.
Disconnect wiring harness clamps (1) and (2).
3.
Unplug wiring harness connectors L05 (3), L06 (4), and L07 (5). [*1]
4.
Remove work equipment controller assembly (6).
Installation ★ Carry out installation in the reverse order of removal. [*1] ★ Before connecting each connector, check that its inside is free from dirt, dust, and water. ★ When installing each heavy-duty wire connector, check that it is locked. (When it is locked, it clicks.) Connectors (3), (4), and (5): 2.54 – 3.01 N•m (23 – 27 lbf in)
50-420 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
KOMTRAX Terminal WARNING!
Disconnect the cable from the negative (-) battery terminal.
Removal 1.
Remove cover (a).
2.
Disconnect connector L80 (1). ★ A failure code will be recorded if the antenna wire is disconnected before the connector L80 is disconnected.
3.
Disconnect GPS wire (2) and antenna wire (3).
4.
Remove four mounting bolts (4) and remove KOMTRAX terminal assembly (5).
Installation ★ Carry out installation in the reverse order of removal.
WA500-6
50-421 b
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
Air Conditioner Unit Removal WARNING!
Stop the machine on level ground and set the lock bar to the frame to lock the front and rear frames.
WARNING!
Lower the work equipment to the ground; stop the engine; apply the parking brake; and put chocks under the tires.
WARNING!
If the radiator coolant temperature is high, you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant. Wait until the coolant has cooled and then drain the coolant.
WARNING!
Disconnect the cable from the negative (-) battery terminal.
Precautions for Handling Refrigerant WARNING!
If the refrigerant (R134a) gets in your eyes, it may cause blindness. You must wear protective glasses.
WARNING!
You must wear protective glasses, gloves, and a working suit when collecting or filling the refrigerant.
WARNING!
Collecting and filling work must be conducted by a qualified person.
★ Ask professional traders to collect and fill the refrigerant (R134a). ★ Never release the refrigerant (R134a) to the atmosphere. 1.
Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. Air conditioner gas: 1,250 ±50 g
2.
Remove covers (1) and (2).
3.
Remove filter (3) and filter cover (4).
50-422 b
WA500-6
DISASSEMBLY AND ASSEMBLY 4.
Unplug wiring harness connector (5).
5.
Remove blower assembly (6).
6.
Remove front windshield wiper (7).
7.
Remove left side cover (8).
8.
Remove door lock (9), ashtray (10), holder (11), and right side cover (12).
9.
Remove cover (13).
ELECTRICAL SYSTEM
10. Unplug the cigarette lighter wiring harness connector.
WA500-6
50-423 b
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
11. Unplug the seven wiring harness connectors and remove monitor assembly (14).
12. Unplug wiring harness connector C12 (15) and remove wiper motor (16). 13. Disconnect wiper washer hose (17).
14. Remove ducts (18) and (19).
15. Remove four mounting bolts (20) and disconnect steering wheel stand (21) from the bracket. 16. Disconnect two wiring harness clamps (22). 17. Remove bracket (23).
50-424 b
WA500-6
DISASSEMBLY AND ASSEMBLY
ELECTRICAL SYSTEM
18. Remove covers (24) and (25).
19. Disconnect heater hose (26). 20. Unplug wiring harness connector (27). 21. Disconnect drain hose (28).
22. Disconnect air conditioner pipes (29) and (30) and clamps (31) and (32). [*1]
23. Disconnect drain hose (33). 24. Unplug wiring harness connectors L17 (34), C50 (35), C49 (36), and AL1 (37). 25. Remove the mounting bolts and disconnect fuse (38).
WA500-6
50-425 b
DISASSEMBLY AND ASSEMBLY 26. Remove air conditioner unit assembly (39).
ELECTRICAL SYSTEM [*2]
Installation ★ Carry out installation in the reverse order of removal. [*1] • • •
When installing the air conditioner circuit hoses, be careful that dirt, dust, water, etc. does not enter them. Before connecting each air conditioner hose, check that the O-rings are fitted to its joints. Check that each O-ring is not damaged or deteriorated. O-ring: ND-OIL8 or equivalent
Filling Air Conditioner Gas ★ Fill the air conditioner circuit with refrigerant (R134a). Air conditioner gas: 1,250 ±50 g
[*2] Air conditioner unit mounting bolt: 8 – 12 N•m (71 – 106 lbf in)
50-426 b
WA500-6
60
AIR CONDITIONER
PRECAUTIONS FOR REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4 Basic Flow of Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-4 CIRCUIT DIAGRAM AND CONNECTOR PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-6 SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11 DETAIL OF AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-13 Parts and Connectors Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15 Testing with Self-Diagnosis Function (Control Panel Display) . . . . . . . . . . . . . . . . . . . 60-19 Testing Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22 Testing Vent (Mode) Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23 Testing Fresh/Recirc Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26 Testing Inside and Outside Air Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28 Testing Evaporator Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30 Testing Sunlight Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31 Testing Relays 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-32 TROUBLESHOOTING CHART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-33 TROUBLESHOOTING CHART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-34 INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-37 TROUBLESHOOTING FOR POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-38 Air Conditioner Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-38 TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM . . . . . . . . . . . 60-41 Air is Not Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41 TROUBLESHOOTING FOR BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-44 No Air Comes Out or Air Flow is Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-44 TROUBLESHOOTING TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50 TROUBLESHOOTING VENT (MODE) CHANGEOVER . . . . . . . . . . . . . . . . . . . . . . . . . 60-53 Machine Equipped With Automatic Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-53 TROUBLESHOOTING FRESH/RECIRC AIR CHANGEOVER . . . . . . . . . . . . . . . . . . . . 60-56 Machine Equipped With Automatic Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-56 TROUBLESHOOTING WITH GAUGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-58 CONNECTION OF SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60 HANDLING OF COMPRESSOR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61
WA500-6
60-1 D
AIR CONDITIONER 12
MEMORANDUM
60-2 D
WA500-6
AIR CONDITIONER
PRECAUTIONS FOR REFRIGERANT
12
PRECAUTIONS FOR REFRIGERANT WARNING! Collect the refrigerant (air conditioner gas:R134a) from air conditioner circuit before disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or air conditioner condenser and so on.
★ Ask a qualified person for collecting, adding and filling operations of refrigerant (R134a). ★ Never release refrigerant (R134a) into the atmosphere. WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on safety glasses, gloves and working suits with long sleeves while you are collecting the refrigerant (R134a) or filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted by a qualified person. Refrigerant (R134a) refilling level: 1,250 ±50 g (44 ±1.76 oz)
WA500-6
60-3 D
AIR CONDITIONER
TROUBLESHOOTING PROCEDURE
12
TROUBLESHOOTING PROCEDURE The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function, you can inspect the operation of sensor and actuators in the system. If a troubled section is detected, every part of that section must be inspected. 1.
After basic check, find the troubled section according to the detected trouble of the air conditioner.
2.
Find the troubled section with the self-diagnosis function (see "Inspection with Self-diagnosis"). If the air conditioner unit or control panel does not operate at all, check that the power supplied to the control panel is normal. If any part of the air conditioner unit or control panel operates, the power supply does not need to be checked.
3.
After finding out the troubled section, inspect the component parts in that section and repair the troubled part.
Basic Flow of Troubleshooting
60-4 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING PROCEDURE
*1: By LCD blink on air conditioner control panel (failure code may be displayed on the temperature display area in the case of auto air conditioner). *2: Simple checking of refrigerant volume by sight glass. Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with the inspection. A. If a continuous stream of bubbles can be seen, the system contains insufficient refrigerant. B. If the bubbles can be seen intermittently, the refrigerant volume is sufficient. C. If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no refrigerant at all. The above should be treated as general guidelines as certain exceptions do exist. See "Troubleshooting with Gauge Pressure" and use gauge pressure to determine whether or not the condition is normal. S: Sight glass condition R: Receiver drier internal condition LR: Liquid refrigerant
*3: If any refrigerant is leaking, the compressor oil circulating within the air conditioner circuit will definitely be leaking from the same point. In such a case, retighten in accordance with the table of retightening torques from "Precautions for Disconnecting and Connecting Air Conditioner Piping." *4: Start the engine and perform the check with the air conditioner switch set to ON.
WA500-6
60-5 D
AIR CONDITIONER
CIRCUIT DIAGRAM AND CONNECTOR PINS
12
CIRCUIT DIAGRAM AND CONNECTOR PINS Manual Air Conditioner
60-6 D
WA500-6
AIR CONDITIONER
CIRCUIT DIAGRAM AND CONNECTOR PINS
12 Manual Air Conditioner
WA500-6
60-7 D
AIR CONDITIONER
CIRCUIT DIAGRAM AND CONNECTOR PINS
12 Auto Air Conditioner
60-8 D
WA500-6
AIR CONDITIONER
CIRCUIT DIAGRAM AND CONNECTOR PINS
12 Auto Air Conditioner
★ W/L and WL are the same.
WA500-6
60-9 D
AIR CONDITIONER
CIRCUIT DIAGRAM AND CONNECTOR PINS
12 Fuse parts number:
T-adapter number
5A: 08041-00500
DT-2: 799-601-9020
15A: 08041-01500
DT-3: 799-601-9030
20A: 08041-02000
DT-6: 799-601-9050 DT-8: 799-601-9070 DT-12: 799-601-7110 (GRAY) or 9720 (BLACK)
60-10 D
WA500-6
AIR CONDITIONER
SYSTEM DIAGRAM
12
SYSTEM DIAGRAM Manual Air Conditioner
WA500-6
60-11 D
AIR CONDITIONER
SYSTEM DIAGRAM
12 Auto Air Conditioner
60-12 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12
DETAIL OF AIR CONDITIONER UNIT Manual Air Conditioner
1. Evaporator
AMA: Air mix actuator
2. Evaporator temperature sensor
BR: Blower off relay
3. Sensor holder
BA: Blower amplifier
4. Heater core
CR: Compressor relay
5. Pressure switch 6. Fuse
P: Top position of the sensor *: To blower harness under floor
WA500-6
60-13 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
Auto Air Conditioner ★ Auto air conditioner has mode actuator (MA)
1. Evaporator
AMA: Air mix actuator
2. Evaporator temperature sensor
BR: Blower off relay
3. Sensor holder
BA: Blower amplifier
4. Heater core
CR: Compressor relay
5. Pressure switch
MA: Mode actuator
6. Fuse P: Top position of the sensor *: To blower harness under floor
60-14 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
Parts and Connectors Layout ★ Fuses are installed at two places in the air conditioner unit (wiring harness) and in the fuse box at the left rear of the operator's seat (duplicated). 1.
Open the fuse box cover at the left rear of the operator's seat. (See the fuse locations in Troubleshooting.) • No. 8 of fuse box 2: 20A For power supply of blower (fan) and air conditioner unit • No. 9 of fuse box 2: 5A For air conditioner compressor • Fuse part Nos. 5A: 08041-00500 20A:08041-02000
2.
Remove covers (1) and (2) • A/C U: Air conditioner unit • B/I U: Blower intake unit
3.
Two 5A fuses and one 15A fuse are on the left of the air conditioner unit (A/C U). ★ Identify the 5A fuse by its wiring harness color. (See the circuit diagram.) Fuse part Nos. 5A:08041-00500 15A:08041-01500
4.
Machine wiring harness connectors C49, C50 and AL1 are on the left of the air conditioner unit. [3] – [8] Are symbols in the circuit diagram.
5.
Pressure switch (PRESS SW) connector [11] is installed on the air conditioner hose on the right of air conditioner unit (A/C U).
WA500-6
60-15 D
AIR CONDITIONER 6.
Remove left side cover (3).
7.
Take out filter (4) and remove box (5).
8.
Connectors [19] and [20] are connected to the blower intake unit (B/I U) under the left of the operator's cab. D: Recirc/Fresh changeover damper Connectors [23] and [24] (see the circuit diagram) are in the blower intake unit. You cannot access them unless the blower intake unit is disassembled.
DETAIL OF AIR CONDITIONER UNIT
9.
Intermediate connector FL1 is at the lower left side of the floor frame. ★ Connector FL1 is DRC-70 and must be handled with care. • How to unplug connector FL1 Unplug the connector straight slowly and check the seal for breakage, peeling and sticking foreign matter. ★ If the seal is damaged, replace it. • How to plug in connector FL1 A. Check that the seal is correctly installed to the plug. B. Check that the key is positioned to be matched to the groove of the receptacle (key is not positioned oppositely). C. Set the plug connector to the receptacle straight (since the seal is projected) and fit it a little, while checking that the seal is not rolled up. D. Tighten the hexagon bolt at the center of the connector two to three turns.
60-16 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
E. Fit the plug connector to the end and adjust it so that the clearance between it and the fitted receptacle will be even when seen from each direction. F.
Tighten the lock bolt to the specified torque. Hexagon lock bolt: 2.8 ±0.3 N•m (24.7 ±2.65 lbf in)
★ If the lock bolt is tightened too tight, it will break and cannot lock. Be careful. 10. Connectors C47 and C48 are on the back side of the air conditioner control panel (CP). ★ The figure of control panel (CP) is for manual air conditioner, but connectors are common to auto air conditioner.
11. Remove right side plate (6). 12. Remove right side cover (7) (mounting bolts are located at the top and bottom of each cover, that is in the center portion of the machine).
WA500-6
60-17 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
13. Connector E10 is for air conditioner compressor (ACC). RD: Receiver drier
14. Unplug connectors S01 (9), S02 (10), C17(11) and C21 (12) in the lower right side of the front cover.
15. Unplug connectors S31 (13), S32 (14), L07 (15) and L08 (16) in the lower left side of the front cover. 16. Disconnect connector C10 inside cigarette lighter (17). 17. Disconnect front cover (18).
18. Connector C60 is below sunlight sensor (SLS). Sunlight sensor connector (C60) (machine equipped with automatic air conditioner)
60-18 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing with Self-Diagnosis Function (Control Panel Display) Manual Air Conditioner
Outline The self-diagnosis system checks the following three items and shows the failed part by blinking the symbol on the air conditioner control panel (CP). ★ Once a problem is detected, indication of the problem is not reset even if it is repaired. The indication can be reset (blinking of the LCD can be stopped) by turning the starting switch OFF. 1.
HOT mark (1) blinks The drive line of the temperature control air mix actuator has a problem (disconnection, short circuit, etc.) or opening and closing of the temperature control air mix actuator do not reach the target value (locking of the damper is detected since the input voltage of potentiometer is low or limiter input are not received). ★ Action of control panel: Stopping output to the air mix actuator ★ Problem: Temperature control switch (4) does not work. ★ Even if the link comes off and the damper does not rotate, the self-diagnosis assumes that the air mix actuator is normal if it rotates normally. ★ See "Testing temperature control."
2.
Fresh/Recirc mark (2) blinks Opening and closing of the Fresh/Recirc changeover damper does not reach the target value (locking of the damper is detected since the limiter input is not received). ★ Action of control panel: Stopping output to the Fresh/Recirc changeover damper. ★ Problem: Fresh/Recirc selector switch (5) does not work. ★ Even if the lever comes off and the damper does not rotate, the self-diagnosis assumes that the Fresh/Recirc changeover actuator is normal if it rotates normally. ★ See "Testing Fresh/Recirc Changeover."
3.
There is a problem (disconnection, short circuit, etc.) in evaporator temperature sensor input circuit ··· A/C mark (3) blinks. ★ Problem: Air conditioner does not work. ★ See "Testing Evaporator Temperature Sensor." ★ Resetting control panel: Turn starting switch OFF.
WA500-6
60-19 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Auto Air Conditioner Outline The self-diagnosis system checks the following six items and shows the failed part by blinking the symbol or displaying not number but alphabet at temperature display area on the air conditioner control panel (CP). ★ Once a problem is detected, indication of the problem is not reset even if it is repaired. The indication can be reset (blinking of the LCD can be stopped) by turning the starting switch OFF. 1.
Display of "HL, E" (1) at temperature display area The drive line of the temperature control air mix actuator has a problem (disconnection, short circuit, etc.) or opening and closing of the temperature control air mix actuator do not reach the target value (locking of the damper is detected since the potentiometer input and limiter input are not received). ★ Action of control panel: Stopping output to the air mix actuator ★ Problem: Temperature control switch does not work. ★ Even if the link comes off and the damper does not rotate, the self-diagnosis assumes that the air mix actuator is normal if it rotates normally. ★ See "Testing Temperature Control."
2.
Man-shaped mark (2) blinks The drive line of the vent (mode) change over actuator has a problem (disconnection, short circuit, etc.) or opening and closing of the vent (mode) changeover actuator do not reach the target value (locking of the damper is detected since the potentiometer input and limiter input are not received). ★ Action of control panel: Stopping output to the mode actuator ★ Problem: Defroster switch (3) and mode switch (4) does not work. ★ Even if the link comes off and the damper does not rotate, the self-diagnosis assumes that the mode actuator is normal if it rotates normally. ★ See "Testing Vent (Mode) Changeover."
3.
Fresh/Recirc mark (5) blinks Opening and closing of the Fresh/Recirc changeover damper do not reach the target value (locking of the damper is detected since the limiter input is not received). ★ Action of control panel: Stopping output to the Fresh/Recirc changeover damper. ★ Problem: Fresh/Recirc selector switch (6) does not work. ★ Even if the lever comes off and the damper does not rotate, the self-diagnosis assumes that the Fresh/Recirc changeover actuator is normal if it rotates normally. ★ See "Testing Fresh/Recirc Changeover."
60-20 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 4. A/C mark (7) blinks and display of "E" (8) at decimal point first of temperature display area. There is a problem (disconnection, short circuit, etc.) in evaporation sensor input circuit. ★ Problem: Air conditioner does not work. ★ See "Testing Evaporator Temperature Sensor." ★ Resetting control panel: Turn starting switch OFF. 5.
Display of "E" (8) at decimal point first of temperature display area. There is a problem (disconnection, short circuit, etc.) in outside air temperature sensor input circuit. ★ Problem: Auto air conditioner is controlled without outside air temperature sensor. ★ See "Testing Inside Air Temp. Sensor and Outside Air Temp. Sensor." ★ Resetting control panel: Turn starting switch OFF.
6.
Display of "HL.*" (9) at temperature display area. There is a problem (disconnection, short circuit, etc.) in inside air temperature sensor input circuit. ★ Problem: Auto air conditioner does not work. ★ See "Testing Inside Air Temp. Sensor and Outside Air Temp. Sensor." ★ Resetting control panel: Turn starting switch OFF.
WA500-6
60-21 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Temperature Control Outline •
Temperature is controlled by mixing ratio of the air from the heater and from the evaporator by changing the damper angle in the air mix section. The damper angle is set to eight different levels by the air mix actuator through the link and rod. Check the link visually. ★ To reset the self-diagnosis system (stop blinking of the LCD), the starting switch must be turned OFF. While the LCD is blinking, no signals are output to the air mix actuator since the self-diagnosis system has detected a problem. 1.
Remove cover (1). A/C U: Air conditioner unit
2.
Check contacts of connectors C47, C50 (See the connector locations) and [15] (for disconnection).
3.
If the HOT mark blinks or "HL, E" is displayed on temperature indicator (see "Testing with Self-diagnosis Function"), check if links (2) – (4) have stopped halfway. If the links have stopped, remove the cause (hitch, interference, foreign matter, etc.) and repair.
4.
Turn the power of the air conditioner OFF and then turn the starting switch OFF (resetting of problem).
5.
Turn the starting switch ON and then turn the power of the air conditioner ON.
6.
Operate the temperature control switch (see the self-diagnosis) and check that link (2) moves to the eight steps normally together with links (3) and (4) between COOL MAX and HOT MAX. ★ If the above parts do not move smoothly, clean them and apply grease to the links. Link: Grease, G2-LI
★ The figure of control panel (CP) is for manual air conditioner, but links for temperature control are common to auto air conditioner. • AMA: Air mix actuator • BA: Blower amplifier ★ For electric problems, see "Troubleshooting for Temperature Control."
60-22 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Vent (Mode) Changeover ★ Auto air conditioner equipped only. Outline •
Vent (modes) are changed over to defroster, foot and face by changing the three damper angles. The damper angle is set by the mode actuator through the link and rod. Check the link visually. ★ To reset the self-diagnosis system (stop blinking "man-shaped mark" on the LCD), the starting switch must be turned OFF. While "man-shaped mark" on the LCD is blinking, no signals are output to the mode actuator since the self-diagnosis system has detected a problem. 1.
Remove cover (1). A/C U: Air conditioner unit
2.
Check contacts of connectors C47, C50 (See the connector locations), [16] and (2) (for disconnection).
3.
If the man-shaped mark blinks (see the self-diagnosis), check if links (3) – (5) have stopped halfway with operation of mode switch and defroster switch. If the links have stopped, remove the cause (hitch, interference, foreign matter, etc.) and repair.
4.
Turn the power of the air conditioner OFF and then turn the starting switch OFF (resetting of problem).
5.
Turn the starting switch ON and then turn the power of the air conditioner ON.
6.
Operate the mode switch and defroster switch (see the self-diagnosis) and check that links (3) – (5) move normally together. ★ If the above parts do not move smoothly, clean them and apply grease to the links. Link: Grease, G2-LI •
MA: Mode actuator
WA500-6
60-23 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 ★ The position of link (4) is following. • FACE
•
FACE/FOOT
•
FOOT
•
FOOT/DEF
60-24 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
• DEF ★ For electric problems, see "Troubleshooting for Vent (Mode) Changeover."
WA500-6
60-25 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Fresh/Recirc Changeover Outline Recirculated air or fresh air is selected by changing the damper angle 90° in the intake section of the blower intake unit. The damper angle is changed by the Fresh/Recirc changeover actuator through the link and rod. Check the opening and closing operations of the damper visually. ★ The self-diagnosis system checks only the motor for locking (it does not check for disconnection and short circuit). ★ To reset the self-diagnosis system (stop blinking of the LCD), the starting switch must be turned OFF, (while the LCD is blinking, no signals are output to the Fresh/Recirc changeover actuator since the self-diagnosis system has detected a problem). 1.
Remove cover (1).
2.
Remove fresh air filter (2).
3.
Remove box (3).
4.
If the self-diagnosis result is abnormal, check Fresh/Recirc changeover damper (D) has topped halfway. If the damper has stopped, remove the cause (hitch, interference, foreign matter, etc.) and repair. For check after repair, see Step 5 below. When disassembling, see Step 7 below.
• • 5.
If the self-diagnosis result is normal, turn the power of the air conditioner ON and operate the Fresh/Recirc selector switch to see if Fresh/Recirc changeover damper (D) opens and closes normally.
6.
If Fresh/Recirc changeover damper (D) does not open or close, check along wiring harness and check blower intake unit (B/I U) connectors [19] and [20] for disconnection.
7.
When connectors [19] and [20] are connected securely. A. Remove the blower intake unit (B/I U). B. Referring to Structure and function or Parts book, disassemble blower intake unit (B/I U) (only the blower side). C. Check lever (5) between damper (D) and damper actuator (4) to see if it has come off and repair it if necessary. D. Check connector [23] (damper actuator connector) (for disconnection). E. Assemble the blower unit and plug in connectors [20] and [23].
60-26 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
F.
Turn starting switch ON, turn the power of the air conditioner ON, and perform Step 4. (After checking, assemble and install the blower intake unit (B/I U). ★ For electric problems, see "Troubleshooting for FRESH/RECIRC Air Changeover." ★ Manual Air Conditioner * To Blower
★ Auto Air Conditioner * To Blower
WA500-6
60-27 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Inside and Outside Air Temp Sensor ★ Auto air conditioner equipped machine only. • If an error is detected by the self-diagnosis, perform these tests. • To reset the self-diagnosis system (detection of trouble), the starting switch must be turned OFF. 1.
See "Testing Fresh/Recirc Changeover," remove cover (1), fresh air filter (2) and box (3). Inside air temperature sensor (ITS)
2.
Check contacts of connectors [20] and [21] (for disconnection).
3.
Turn the starting switch OFF and unplug connectors [21].
4.
Measure the resistance between the terminals of connector [26] (on the inside air temp. sensor (ITS) side). Normal resistance: 0° C (32° F):7.2 k 25° C (77° F):2.2 k IU: Intake unit BU: Blower unit D: FRESH/RECIRC air changeover damper FA: FRESH air RA: RECIRC air ★ If an error is detected by the self-diagnosis and the inside air temp sensor (ITS) is normal, the control panel or wiring harness is abnormal.
5.
Turn the starting switch OFF and disconnect connector C48 ([2]) (see the circuit diagram and arrangement of connector pins) from the control panel. Between terminals (6) (RG) and (2) (W) of connector [2]. Normal resistance: 7.2 k (at 0° C)(32° F) 2.2 k (at 25° C)(77° F) ★ If the result of Step 5 above is normal, the control panel is abnormal. If the former is abnormal, the wiring harness is abnormal. • Outside air temperature sensor (OTS) ★ See left figure
6.
Check contacts of connectors [20] and [22] (for disconnection).
7.
Turn the starting switch OFF and unplug connectors [22].
8.
Measure the resistance between the terminals of connector [22] (on the outside air temp. sensor (OTS) side). Normal resistance: 7.2 k (at 0° C)(32° F) 2.2 k (at 25° C)(77° F) ★ If an error is detected by the self-diagnosis and the outside air temp. sensor (OTS) is normal, the control panel or wiring harness is abnormal.
60-28 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 9. Turn the starting switch OFF and unplug connector C48 ([2]) (See the circuit diagram and connector locations) from the control panel. Between terminals (4) (BrW) and (2) (W) of connector [2]. Normal resistance: 7.2 k (at 0°C)(32°F) 2.2 k (at 25°C)(77°F) ★ If the result of Step 9. above is normal, the control panel is abnormal. If the former is abnormal, the wiring harness is abnormal.
WA500-6
60-29 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Evaporator Temperature Sensor • •
If an error is detected by the self-diagnosis, perform these tests. To reset the self-diagnosis system (detection of trouble), the starting switch must be turned OFF.
1.
Remove cover (1). A/C U: Air conditioner unit
2.
Check contacts of connectors [18] and [26] (for disconnection).
3.
Turn the starting switch OFF and unplug connectors [18] and [26].
4.
Measure the resistance between the terminals of connector [26] (on the evaporator temperature sensor side). Normal resistance: 7.2 k (at 0°C)(32°F) 2.2 k (at 25°C)(77°F) • If the result is abnormal, remove the air conditioner unit (See Disassembly and Assembly, "Removal and Installation of Air Conditioner Unit") and replace the evaporator temperature sensor (3) from evaporator (2) (See the disassembly drawing in Structure and Function). ★ Precautions for exchanging evaporator temperature sensor (installed position (P) of evaporator temperature sensor) With the flange outlet (OUT) of the evaporator on the right side, install the evaporator temperature sensor so that its top will be 100 ±5 mm (3.9 ±0.2 in) above the fin top face and its body will be at the center (P) of the 8th stage of the fins. (Insert and attach the sensor holder (4) to the 10th and 11th stages of the fins.) ★ If an error is detected by the self-diagnosis and the evaporator temperature sensor is normal, the control panel or wiring harness is abnormal.
5.
Turn the starting switch OFF and disconnect connector C48 ([2]) (see the circuit diagram and arrangement of connector pins) from the control panel. Between terminals (5) (GY) and (2) (W) of connector [2]. Normal resistance: 7.2 k (at 0° C)(32° F) 2.2 k (at 25° C)(77° F) ★ If the result of Step 5 above is normal, the control panel is abnormal. If the former is abnormal, the wiring harness is abnormal.
60-30 D
WA500-6
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Sunlight Sensor ★ Auto air conditioner equipped machine only. • When sunlight is strong, control panel compensates air mix actuator and lower the blowing out target temperature. ★ If sunlight sensor (S) is measured with resistance range of tester, sunlight sensor may be destroyed, so measure it with voltage range of tester. 1.
Disconnect connector C10 inside cigarette lighter (1).
2.
Remove cover (2) and inspect the connector C60 for the sunlight sensor (S). (Check whether the connector has been partially disconnected.)
3.
Disconnect connector C60, and using a tester set to the voltage range, measure the voltage between the male side terminals on the sunlight sensor (S). • Approximate voltage of sunlight sensor unit 0.45 V: Direct sunlight 0.35 V: Cloudy 0.2 V: Indoors
4.
Disconnect connector C48 from the air conditioner control panel in line with item 10 from "Parts and Connectors Layout."
5.
Ensure that the female terminals of the connector C60 (harness side) are not being shorted. (If the terminals are shorted, the harness is defective.)
6.
Confirm whether the condition between the female terminal of the connector C60 (harness side) (2) (LgR) and the terminal of connector C48 (harness side) (15) (LgR) is 1 or less. If not, the wiring harness is defective.
7.
Confirm whether the condition between the female terminal of connector C60 (harness side) (1) (RB) and the terminal of connector C48 (harness side) (13) (RB) is 1 or less. If this is not the case, the harness is defective.
8.
Connect all the connectors.
9.
Turn the starting switch to ON position, and if target temperature does not change when the sunlight sensor is exposed to the sunlight at auto air conditioner, replace the air conditioner control panel.
WA500-6
60-31 D
AIR CONDITIONER
DETAIL OF AIR CONDITIONER UNIT
12 Testing Relays 1 • •
If the air conditioner compressor is normal (air is cooled) and air comes out, the relays are normal. Accordingly, skip these relay tests. Listen closely to each relay to check its operation by sound.
There are two relays • •
Blower-off relay: Used to turn the fan motor ON and OFF. Compressor relay: Used to turn the air conditioner compressor (clutch) ON and OFF.
1.
Remove cover (1). A/C U: Air conditioner unit
2.
Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON. If the blower-off relay is normal, it is turned ON. Check its click.
3.
Turn the air conditioner switch ON. If the compressor relay is normal, it is turned ON. Check its click. ★ Control panel does not turn the compressor relay ON in the following cases. i. When the evaporator temperature is below 3° C (37.4° F) (depending on the input voltage from the evaporator temperature sensor). ii. When the pressure switch detects abnormality (it is turned OFF). ★ If the fan sound is so loud that you cannot hear the sound of the compressor relay, perform the following. iii. Turn the main power of the air conditioner OFF and disconnect the battery ground wire. iv. Disconnect connector [12]. v. Connect the battery ground wire and check the compressor relay.
4.
If either relay seems to be abnormal, perform the following procedure. A. Turn the main power of the air conditioner OFF and disconnect the battery ground wire. B. Remove the relay mounting screws and exchange the bloweroff relay (BR) and compressor relay (CR). C. Connect the battery ground wire and perform Steps 2 and 3 above and see if the conditions of the relays are reversed. •
Checking relay unit i. The resistance of the coil between terminals (1) and (2) is 320 . ii. Without voltage (DC20 – 30 V) applied between terminals (1) and (2), terminals (3) and (4) are disconnected from each other. iii. With the voltage (DC20 – 30 V) applied between terminals (1) and (2), terminals (3) and (4) are connected to each other.
60-32 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING CHART 1
12
TROUBLESHOOTING CHART 1 ★ The numbers in the boxes are the item numbers in the troubleshooting table. 1.
Cooling trouble
2.
Heating trouble
WA500-6
60-33 D
AIR CONDITIONER
TROUBLESHOOTING CHART 2
TROUBLESHOOTING CHART 2 1.
Blower fan motor does not revolve or its speed is different from set value. ★ See "Troubleshooting for Blower Motor System (No air comes out or air flow is abnormal)." Possible cause
Check method
Remedy
Defective BLOWER OFF relay
See "Testing relays"
Disconnection of wire or defective connection
Check connector of blower fan motor for disconnection. See Repair broken parts and "Troubleshooting for Blower Motor System" and "Parts and connect correctly Connectors Layout."
Defective blower motor
Check two lead wires of motor with circuit tester. If there is not continuity, motor is defective. See "Troubleshooting for Blower Motor System" and "Parts and Connectors Layout."
Replace
Defective BLOWER amplifier (AMP)
Move fan switches in sequence and check fan speed.
Replace
2.
Replace
Blower fan motor is normal but air flow is insufficient at cool. Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging.
Repair
Air leakage
Check duct joints for defective duct seal and disconnection of duct.
Replace
Obstruction on suction side of evaporator
Check evaporator for stain and obstruction.
Remove obstruction and clean
Defective evaporator temperature sensor, defective contact of evaporator temperature sensor or defective expansion valve
Evaporator is frozen. Check sensor clip. Check sensor for dirt. Check the frost on the hose near pressure switch (when freezing advances furthermore).
Repair or replace (Evaporator temperature sensor and expansion valve are in air conditioner unit)
3.
Low/high pressure Possible cause
Insufficient refrigerant
Overcharged with refrigerant
Judgment by pressure at inlet/ outlet of compressor
60-34 D
Check method If R134a is used as refrigerant, its quantity cannot be checked through sight glass. Accordingly, check by connecting gauge manifold. Purpose of sight glass is to check refrigerant flow. Normal pressure range Low pressure: Approximately1.3 - 2.0 kg/cm² (18 - 29 psi) High pressure: Appoximately 15 - 17 kg/cm² (213 - 241 psi) These values are for following condition, however. Temperature in cab: 30 - 35° C (86 - 95° F) Engine speed: Appoximately 1500 rpm
Remedy Repair leaking part, then charge with proper quantity of refrigerant again Collect refrigerant, then charge with proper quantity of refrigerant again
See Troubleshooting with gauge pressure
WA500-6
AIR CONDITIONER
TROUBLESHOOTING CHART 2
12 4. Compressor does not revolve at all or its speed is low. ★ See "Troubleshooting for Compressor System (Air is not cooled)." Troubled part
Possible cause
Compressor belt
Loosened compressor belt
Vibration amplitude of belt is large
Adjust tension
Trouble in compressor
Slip of belt
Repair or replace
Insufficient compressor oil or seizure in the compressor
Heating of compressor
See "Handling compressor oil"
Low battery voltage
Slip of clutch
Charge battery
Disconnection or short circuit in coil
Inspect with circuit tester
Replace
Disconnection in wiring or defective connection of ground wire
Check ground wire and connections. See "Troubleshooting for compressor system."
Repair
Relay
Defective compressor relay
See “Testing Relay.”
Replace
Refrigerant pressure
Low/high pressure (Operation of pressure switch)
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure
Pressure switch
Defective pressure switch
See "Troubleshooting for Compressor System."
Replace
Compressor
Check method
Magnet clutch
5.
Remedy
Blower fan motor is normal but air flow is insufficient. Possible cause
Check method
Remedy
Large duct resistance
Check duct for crushing and filter for clogging.
Repair
Air leakage through duct joints
Check duct joints for defective duct seal and disconnection of duct.
Repair
Clogging of heater core fins
Check heater core fins for clogging.
Repair
6.
Check of hot water. Possible cause
Check method
Remedy
Low engine coolant temperature
Warm up engine, and then check engine coolant temperature.
Find out cause
Low engine coolant level
Check coolant level in radiator.
Add coolant
Insufficient circulation of engine coolant
Check engine coolant piping for clogging (hose, pipe, and core).
Bleed air and repair
Contrary connection of IN and OUT Check the destination of heater hoses. heater hoses
7.
Repair
Fan rotation speed. Possible cause
Fan rotation speed is low (Defective fan motor EPC or hydraulic system)
WA500-6
Check method See "Testing and Adjusting Hydraulic Drive Fan" in chapter 30 "Testing and Adjusting" of shop manual.
Remedy Repair
60-35 D
AIR CONDITIONER
TROUBLESHOOTING CHART 2
12 8. Other items Possible cause
Check method
Temperature cannot be adjusted
See "Testing Temperature Control" and "Troubleshooting for Temperature Control."
Vent (mode) can not be changed over (machine equipped with automatic air conditioner)
See "Testing Vent (Mode) Changeover" and "Troubleshooting for Vent (Mode) Air Changeover."
Fresh/Recirc cannot be changed over
See "Testing Fresh/Recirc Air Changeover" and "Troubleshooting for Fresh/Recirc Air Changeover."
Excessive compressor oil
See "Handling Compressor Oil."
Water leakage into the cab
Clogging of drain hole
60-36 D
Remedy
Common to cooling and heating
Cooling only
WA500-6
AIR CONDITIONER
INFORMATION IN TROUBLESHOOTING TABLE
12
INFORMATION IN TROUBLESHOOTING TABLE ★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Problem
Problem on machine
Related information
Information related to detected failure or troubleshooting
Cause 1 Probable causes of trouble 2 (Perform troubleshooting according to these.)
Possible causes and standard value in normal state 3 Defective
Standard value in normal state/Remarks on troubleshooting <Information described>
• Procedure • Measuring location ★ "Between A - B" means "Measure voltage or resistance and so on between A and B." • Standard value in normal condition to judge probable causes • Remarks required for judgement <Notes on troubleshooting> (1) Pin number description sequence and tester lead handling. For troubleshooting, connect the plus (+) and minus (-) tester leads as shown below unless otherwise specified. •
Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus(-) lead to a pin or harness indicated in the rear. (2) Example of troubleshooting by inspection of multiple items ★ Normal in 1 but abnormal in 2 At this time " - defective" shown at left is applied ★ If a wiring harness is burnt, replace it. <Defective wiring harness> • •
• •
Open circuit Connector is connected imperfectly or wiring harness is disconnected. Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. Hot short circuit A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit accidentally. Short circuit An independent wire in the harness abnormally comes into contact with another wire (defective insulation in connector or others).
Related Circuit Diagram This is the excerpted circuit diagram related to troubleshooting • Indicates connector No., and pin No. • See "Circuit Diagram and Arrangement of Connector Pins" and "Parts and Connector Locations" for Connector Location, • The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown,Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
★ When there are two colors Example: WY: Yellow line on white background
★ ★ ★ ★
The number before the wire color indicates the wire size. N.C.: Normally closed (Normally ON) [1], [2], are numbers of unlabeled connectors. Arrow (): Roughly indicates their mounting place on the machine
WA500-6
60-37 D
AIR CONDITIONER
TROUBLESHOOTING FOR POWER
TROUBLESHOOTING FOR POWER Air Conditioner Does Not Operate Problem Indication of problem on machine Related information
Air conditioner does not operate due to power supply system failure. • When main power of control panel is turned ON and switch is pressed, no LCD on control panel lights up. • No air comes out (blower motor does not rotate). • Referring to "Parts and connectors layout," check fuse No. 8 (20A) in the fuse box 2 and 5A fuse in air conditioner unit (wiring harness) for breakage. • Air conditioner ground wire is grounded together with that of machine wiring harness for machine electric components. • For each connector, see "Parts and Connectors Layout."
Cause
1
Defective (ground)
wiring
Standard value in normal state/Remarks on troubleshooting Turn starting switch OFF. Disconnect battery ground cable. Disconnect connector C48 ([2]) from control panel and carry out troubleshooting with starting switch kept OFF Between [2]-(1) (black) on wiring harness side ResisMax. 1 of connector C48 and ground tance
1. 2. harness 3.
★ If any fuse referred to in the related information is broken, replace 1. 2. 3.
2
Between [2]-(1) (black) and (7) Defective wiring harness or (YW) on wiring harness side of defective air mix actuator connector C48 Between [1]-(10) (BW) and (22) (red) on wiring harness side of connector C47
Possible causes and standard value in normal state
Resistance
Min. 1 M
A
Resistance
Approx. 4 k (Potentiometer resistance)
B
★ If check result of cause 2-A is abnormal, find out abnormal wiring
3
60-38 D
it. Turn starting switch OFF. Disconnect battery ground cable. Disconnect connectors C47 ([1]) and C48 ([2]) from control panel and carry out troubleshooting with starting switch kept OFF.
Ground fault in wiring harness (Contact with GND circuit)
harness. 1) – 3.) See cause 2. 4) Disconnect connector C49 ([3]) and carry out troubleshooting with starting switch kept OFF. ★ If check result of C below is abnormal: Wiring harness between air conditioner unit and control panel is abnormal. Between [2]-(1) (black) and (7) Resis(YW) on wiring harness side of Min. 1 M C tance connector C48
★ If check result of cause 2-A is abnormal and check result of C above is normal, find out abnormal wiring harness. 1) – 3) See cause 2. 4) Connect connector C49 ([3]). 5) Disconnect connector AL1 and carry out troubleshooting with starting switch kept OFF. ★ If check result of D below is abnormal: Wiring harness in air conditioner unit is abnormal. Between [2]-(1) (black) and (7) Resis(YW) on wiring harness side of Min. 1 M D tance connector C48
WA500-6
AIR CONDITIONER
TROUBLESHOOTING FOR POWER Cause
Standard value in normal state/Remarks on troubleshooting
★ If check result of cause 2-A is abnormal and check results of C and D are normal, machine wiring harness is abnormal. Check for confirmation. 1)– 2) See cause 2. 3) Disconnect connector AL1 and connect T-adapter to connector [7] on machine wiring harness side. 4) Carry out troubleshooting with starting switch kept OFF.
3
Ground fault in wiring harness (Contact with GND circuit)
Possible causes and standard value in normal state 4
Defective relay (Short circuit in relay coil)
Between [7]-(1) (green) and (5) Resisblack on machine wiring harness tance side of connector AL1
Max. 1
★ If check result of cause 2-B is abnormal, check to see if wiring harness is cause. 1)– 3) See cause 2. 4) Disconnect connector [15] and carry out troubleshooting with starting switch kept OFF. ★ If check results of cause 2-B and E below are abnormal, disconnect connector [5] and check again in the same way to find abnormal wiring harness. Between [11]-(10) (BW) and (22) Resis(red) on wiring harness side of Min. 1 M E tance connector C47 1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect relay connectors [12] and [14] and carry out troubleshooting with starting switch kept OFF. ★ See Testing relays. Between blower-off relay (1) – (2) Between compressor relay (1) – (2)
Resistance Resistance
320 320
★ If any fuse referred to in the related information is broken, replace it.
5
Defective control panel
1) Turn starting switch OFF. 2) Disconnect battery ground cable. 3) Disconnect connectors C47 ([1]) and C48 ([2]) from control panel. 4) Connect battery ground cable, turn starting switch ON, and carry out troubleshooting.
★ Leave control panel disconnected. Between [2]-(7) (YW) and (1) (black) on wiring harness side of connector C48 6 7
WA500-6
Resistance
20 - 30 V
Defective air mix actuator (Short circuit in potentiometer resistor) Disconnection in wiring harness
60-39 D
AIR CONDITIONER
TROUBLESHOOTING FOR POWER
12 Related Circuit Diagram
★ Manual air conditioner does not have sunlight sensor, inside air temperature sensor or outside air temperature sensor.
60-40 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM
12
TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM Air is Not Cooled Problem Indication of problem on machine
Air is not cooled due to compressor system failure. When main power of control panel is turned ON and air conditioner switch is pressed, LCD on control panel lights up but air is not cooled. Air conditioner compressor does not operate.
• •
Check if "A/C mark" or "HOT mark" is blinking and "HL. E" or "**. E" is displayed at the temperature indicator with self-diagnosis function on the control panel. Then, see "Testing with Self-Diagnosis Function" and repair abnormality by self-diagnosis. (*: Any character or number.) Referring to "Parts and Connectors Layout," check fuse No. 9 (5A) in the fuse box 2 for breakage. Pressure switch is turned OFF when refrigerant pressure is abnormally low or high (see Structure and Function). Referring to "Testing Temperature Control," check angle of air mix damper (link section). Air conditioner may not be turned ON even when ambient temperature is below 3° C (37.4° F) (Normal). For each connector, see "Parts and Connectors Layout."
•
Related information
• • • • •
Cause
1
Defective wiring harness (ground)
Standard value in normal state/Remarks on troubleshooting 1. Turn starting switch OFF. 2. Disconnect connector E10 from air conditioner compressor and carry out troubleshooting with starting switch kept OFF. Between [9]-(2) (black) on wiring Resisharness side of connector E10 and Max. 1 tance ground 1. 2.
2
Possible causes and standard value in normal state
Defective air conditioner compressor
Turn starting switch to OFF position. Disconnect the connector E10 from the air-conditioner compressor and connect a T-adapter at the male side. ★ Ensure connection of air conditioner compressor ground cable terminal. Between connector E10 (male) Resis(1) and the machine ground Approximately 15 (i.e., air conditioner compressor tance coil resistance).
★ If no fuse referred to in related information is broken, skip all checks for cause 3. 1) Turn starting switch OFF. 2) Disconnect connector E10 from air conditioner compressor and carry out troubleshooting with starting switch kept OFF. Between [9]-(1) and (2) on wiring harness side of connector E10 3
WA500-6
Resistance
Min. 1
A
Ground fault in wiring harness ★ (Contact with GND circuit)
If check result of A above is abnormal, find out abnormal wiring harness. 1) Turn starting switch OFF. 2) Disconnect battery ground terminal. 3) Disconnect connector E10 from air conditioner compressor. 4) Disconnect connector AL1 and carry out troubleshooting with starting switch kept OFF. Between [9]-(1) and (2) on Resiswiring harness side of connector Min. 1 B tance E10
60-41 D
AIR CONDITIONER
TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM Cause
Standard value in normal state/Remarks on troubleshooting
★ If check result of A above is abnormal and check result of B above
3
4 Possible causes and standard value in normal state
is normal, perform following procedure. 1) – 4) See above. ★ If check result C below is abnormal: Machine wiring harness between fuse and air conditioner unit is abnormal. Between [7]-(3) (white) and (5) Resis(black) on wiring harness side of Max. 1 C tance Ground fault in wiring harness connector AL1 ★ If check result of A above is abnormal and check result of B and C (Contact with GND circuit) above are normal, perform following procedure. 1) – 4) See above. ★ If check result D below is abnormal: Wiring harness in air conditioner unit is abnormal. Between [8]-(3) (red) and (5) Resis(black) on air conditioner unit wiring Max. 1 D tance harness side of connector AL1 1) Turn starting switch OFF. 2) Disconnect battery ground terminal. 3) Replace blower-off relay with compressor relay. ★ See check of relay. Defective compressor relay 4) Connect battery ground terminal. 5) Turn starting switch ON. (Relay is not turned ON) 6) Turn main power of control panel ON and press air conditioner switch. If air conditioner compressor operates and air does not come out, original compressor relay is defective.
★ If check result of A above is abnormal, find out abnormal wiring
5
Defective pressure switch
harness. Turn starting switch OFF. Disconnect battery ground terminal. Disconnect connector E10 from air conditioner compressor. Disconnect connector AL1 and carry out troubleshooting with starting switch kept OFF. Between (1) and (2) on pressure ResisMin. 1 switch side of connector tance When replacing pressure switch, collect refrigerant in advance.
1) 2) 3) 4)
1) 2) 3) 4)
60-42 D
6
Defective control panel
Turn starting switch OFF. Disconnect battery ground terminal. Disconnect connectors C47 ([1]) from control panel. Connect battery ground terminal and turn starting switch ON. ★ Leave only connector C48 connected to control panel. 5) Turn main power of control panel ON and press air conditioner switch. Between (15) on control panel side Voltage Max. 1 V of connector C47 and ground
7
Disconnection in wiring harness
Refer to circuit diagram, check wiring harness for disconnection.
8
Lowering of fan rotation speed (wind speed at condenser)
See "Testing Hydraulic Drive Fan" in chapter 30 "Testing and Adjusting" of shop manual. Fan rotation speed at engine low idle Min. 500 rpm
WA500-6
AIR CONDITIONER
TROUBLESHOOTING COMPRESSOR AND REFRIGERANT SYSTEM
12 Related Circuit Diagram
WA500-6
60-43 D
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR
12
TROUBLESHOOTING FOR BLOWER MOTOR No Air Comes Out or Air Flow is Abnormal Problem Indication of problem on machine
No air comes out or air flow is abnormal due to blower motor system failure. When main power of control panel is turned ON, LCD on control panel lights up but air does not come out. Air flow does not match fan switch setting of control panel.
• • • • •
This trouble cannot be checked with self-diagnosis function. Referring to "Parts and Connectors Layout," check 15 A fuse in air conditioner unit for breakage. If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. In this case, the probable causes are as follows. 1) Defective compressor relay, (stuck closed). See "Testing Relays." 2) Evaporator temperature sensor mounting clip may have come off. 3) Expansion valve may not be adjusted correctly. Remove and disassemble air conditioner unit. If air comes out, fuse and relay are normal and wiring harness is seldom abnormal. If air flow is also abnormal in heating mode, replace blower amplifier first. For each connector and relay, see "Parts and Connectors Layout." Since blower intake unit is independent (under cab), disconnect it first.
Related information • • • •
Manual Air Conditioner Cause
Standard value in normal state/Remarks on troubleshooting Turn starting switch OFF. Disconnect connector [20] from under cab and connect T-adapter to it. 3. Carry out troubleshooting with connector [19] disconnected and starting switch kept OFF. Between wiring harness (1) (R/W) and (3) (orange) of connector [20] (on blower motor side) There is no continuity 1. Turn starting switch OFF. 2. Disconnect the connector [20] from under cab and insert T-adapter (Connect connectors [19] and [20]). 3. Turn starting switch ON, turn main power of control panel ON, set fan switch to HI-MAX, and carry out troubleshooting. ★ If following voltage is not applied, go to cause 4. 1. 2.
1
Defective blower (fan) motor or defective wiring harness in blower intake unit
Between wiring harness (1) (R/W) and (3) (orange) of connector [20] (on blower motor side)
Possible causes and standard value in normal state
Voltage
20 - 30 V
★ If check result of cause 1 is abnormal (continuity is broken or motor
2
Defective wiring harness in blower intake unit
does not rotate while voltage is normal), perform following procedure. 1) Turn starting switch OFF. 2) Remove blower intake unit. 3) Referring to Structure and Function, disassemble blower intake unit. (Disconnect connector [24]) Orange line between connectors [20] and [24]
Resistance
Max. 1
RW line between connectors [20] and [24] Between (1) (RW) and (3) (orange) of connector [20]
Resistance Resistance
Max. 1 Min. 1 M
★ If check result of cause 1 is abnormal (continuity is broken or motor 3
Defective blower (fan) motor
★
60-44 D
does not rotate while voltage is normal) and check result of cause 2 is normal, blower (fan) motor is defective. If blower (fan) motor coil is burnt and broken because of short circuit, fuse (15A) is also broken.
WA500-6
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR Cause
Standard value in normal state/Remarks on troubleshooting
★ If no fuse referred to in the related information is broken, skip all checks for cause 4. Turn starting switch OFF. Disconnect battery ground terminal. Unplug connectors AL1, [12], [19] and [13]. Connect T-adapter to connector [19] and [8] on air conditioner unit side of AL1 and carry out troubleshooting with starting switch kept OFF. Defective wiring harness Between [8]-(5) on air conditioner unit Resis4 (Contact with GND circuit side of connector AL1 and (3) of Min. 1 M tance connector [12] or another line) Between [8]-(5) on air conditioner unit Resisside of connector AL1 and (4) of Min. 1 M tance connector [12] ResisBetween (2) and (3) of connector [12] Min. 1 M tance ResisBetween (1) and (3) of connector [19] Min. 1 M tance Referring to check of relay, check if turn ON sound Click is heard of blower-off relay is heard. 4. 5. 6. 7.
★ If "click is not heard" in above troubleshooting, perform following
Defective blower-off relay, 5 etc. (Relay is not turned ON)
1) 2) 3)
★ 4) 5) 6)
Possible causes and standard value in normal state
procedure. Turn starting switch OFF. Disconnect battery ground terminal. Replace blower-off relay with compressor relay. See check of relay. Connect battery ground cable. Turn starting switch ON. Turn main power of control panel ON.
★ If air comes out, original blower-off relay is defective. ★ If check result of cause 5 is abnormal but relay is normal, go to cause 7. 1) 2) 3) 4)
Turn starting switch OFF. Insert T-adapter between connectors [13] and [25]. Turn starting switch ON. Turn main power of control panel ON. ★ Check about 10 V between terminals (B) and (C) (base voltage) of blower amplifier input connector [13]. Between (A) and (C) of connector [13] Voltage Max. 10 V 1) – 4) See above. 5) Operate fan switch on control panel from LO to HI. ★ Between terminals (B) and (C) (base voltage) of blower amplifier input connector [13]. Between (A) and (C) of connector [13] Voltage Change is 10 V less
6 Defective blower amplifier
WA500-6
★ If blower amplifier is normal, all of following are normal. Reverse is not always satisfied, however (amplifier cannot be checked by checking each unit). 1) Turn starting switch OFF. 2) Disconnect connector [13]. 3) Connect T-adapter to connector [25] and carry out troubleshooting (Leave connector [13] disconnected). ResisBetween (B) and (C) of connector [25] 4.7 K±5% tance No continuity Between (A) (+) and (C) (–) of connector [25] * Measure at diode range No continuity Between (A) (–) and (C) (+) of connector [25] * Measure at diode range
60-45 D
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR Cause
Possible causes and standard value in normal state
7
Defective control panel
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Unplug connector C49 and insert T-adapter (since there is not T-adapter for connector C47). 3) Turn starting switch ON. 4) Turn main power of control panel ON (turn blower-OFF relay ON (Output = GND) to apply voltage of about 10 V to gate of blower amplifier). Between (6) and (11) of connector C49 Between (5) and (11) of connector C49
8
Disconnection in wiring harness
Voltage
Max. 1 V
Voltage
Approximately 10 V
Referring to circuit diagram, check wiring harness for disconnection.
Related Circuit Diagram, Manual Air Conditioner
60-46 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR
Auto Air Conditioner Cause
Standard value in normal state/Remarks on troubleshooting Turn starting switch OFF. Unplug connector [20] from under cab and connect T-adapter to it. 3. Carry out troubleshooting with connector [19] disconnected and starting switch kept OFF. Between wiring harness (8) (R/W) and (5) (orange) of connector [20] (on blower motor side) There is no continuity 1. Turn starting switch OFF. 2. Unplug connector [20] from under cab and insert T-adapter (plug in connectors [19] and [20]). 3. Turn starting switch ON. Turn main power of control panel ON. Set fan switch to HI-MAX, and carry out troubleshooting. ★ If following voltage is not applied, go to cause 4. 1. 2.
1
Defective blower (fan) motor or defective wiring harness in blower intake unit
Between wiring harness (8) (R/W) and (5) (orange) of connector [20] (on blower motor side)
Possible causes and standard value in normal state
Voltage
20 - 30 V
★ If check result of cause 1 is abnormal (continuity is broken or motor
2
Defective wiring harness in blower intake unit
does not rotate while voltage is normal), perform following procedure. 1) Turn starting switch OFF. 2) Remove blower intake unit. 3) Referring to Structure and function, disassemble blower intake unit. (Unplug connector [24]) Orange line between connectors [20] and [24]
Resistance
Max. 1
RW line between connectors [20] and [24] Between (1) (RW) and (3) (orange) of connector [20]
Resistance Resistance
Max. 1 Min. 1 M
★ If check result of cause 1 is abnormal (continuity is broken or motor 3
Defective blower (fan) motor
★
WA500-6
does not rotate while voltage is normal) and check result of cause 2 is normal, blower (fan) motor is defective. If blower (fan) motor coil is burnt and broken because of short circuit, fuse (15A) is also broken.
60-47 D
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR Cause
Standard value in normal state/Remarks on troubleshooting
★ If no fuse referred to in the related information is broken, skip all checks for cause 4. Turn starting switch OFF. Disconnect battery ground terminal. Unplug connectors AL1, [12], [19] and [13]. Connect T-adapter to connector [19] and [8] on air conditioner unit side of AL1 and carry out troubleshooting with starting switch kept OFF. Defective wiring harness Between [8]-(5) on air conditioner unit Resis4 (Contact with GND circuit side of connector AL1 and (3) of Min. 1 M tance connector [12] or another line) Between [8]-(5) on air conditioner unit Resisside of connector AL1 and (4) of Min. 1 M tance connector [12] ResisBetween (2) and (3) of connector [12] Min. 1 M tance ResisBetween (5) and (8) of connector [19] Min. 1 M tance Referring to check of relay, check if turn ON sound Click is heard of blower-off relay is heard. 1. 2. 3. 4.
★ If "click is not heard" in above troubleshooting, perform following
Defective blower-off relay, 5 etc. (Relay is not turned ON)
1) 2) 3)
★ 4) 5) 6)
Possible causes and standard value in normal state
procedure. Turn starting switch OFF. Disconnect battery ground terminal. Replace blower-off relay with compressor relay. See check of relay. Connect battery ground cable. Turn starting switch ON. Turn main power of control panel ON.
★ If air comes out, original blower-off relay is defective. ★ If check result of cause 5 is abnormal but relay is normal, go to cause 7. 1) 2) 3) 4)
Turn starting switch OFF. Insert T-adapter between connectors [13] and [25]. Turn starting switch ON. Turn main power of control panel ON. ★ Check about 10 V between terminals (B) and (C) (base voltage) of blower amplifier input connector [13]. Between (A) and (C) of connector [13] Voltage Max. 10 V 1) – 4) See above. 5) Operate fan switch on control panel from LO to HI. ★ Between terminals (B) and (C) (base voltage) of blower amplifier input connector [13]. Between (A) and (C) of connector [13] Voltage Change is 10 V less 6 Defective blower amplifier
60-48 D
★ If blower amplifier is normal, all of following are normal. Reverse is not always satisfied, however (amplifier cannot be checked by checking each unit). 1) Turn starting switch OFF. 2) Unplug connector [13]. 3) Connect T-adapter to connector [25] and carry out troubleshooting (Leave connector [13] unplugged). ResisBetween (B) and (C) of connector [25] 4.7 K±5% tance No continuity Between (A) (+) and (C) (–) of connector [25] * Measure at diode range No continuity Between (A) (–) and (C) (+) of connector [25] * Measure at diode range
WA500-6
AIR CONDITIONER
TROUBLESHOOTING FOR BLOWER MOTOR Cause
Possible causes and standard value in normal state
7
Defective control panel
Standard value in normal state/Remarks on troubleshooting 1) Turn starting switch OFF. 2) Unplug connector C49 and insert T-adapter (since there is not T-adapter for connector C47). 3) Turn starting switch ON. 4) Turn main power of control panel ON (turn blower-OFF relay ON (Output = GND) to apply voltage of about 10 V to gate of blower amplifier). Between (6) and (11) of connector C49 Between (5) and (11) of connector C49
8
Disconnection in wiring harness
Voltage
Max. 1 V
Voltage
Approximately 10 V
Referring to circuit diagram, check wiring harness for disconnection.
Related Circuit Diagram, Auto Air Conditioner
WA500-6
60-49 D
AIR CONDITIONER
TROUBLESHOOTING TEMPERATURE CONTROL
TROUBLESHOOTING TEMPERATURE CONTROL Problem Indication of problem on machine
Temperature cannot be controlled When temperature control switch on control panel is operated, temperature does not change.
★ Temperature control means “Air Mix” of cooled air and hot air. •
When main power of control panel is turned ON, HOT mark (LCD) on the control panel blinks or “HLE” is displayed on the temperature display area. (See "Testing with Self-Diagnosis Function.") Self-diagnosis system checks air mix actuator for disconnection and short circuit and checks contacts (LIMIT terminal) in air mix actuator each time main power of control panel is turned ON. Even if link is disconnected (See "Testing Temperature Control," self-diagnosis system assumes that temperature control system is normal, if air mix actuator rotates when switch is operated. Operating angle of air mix actuator (COOL-MAX – HOT-MAX) is 90°. Referring to "Testing temperature control," check that there is not mechanical trouble (disconnection or interference of link, etc.). To replace air mix actuator, link section must be removed. (See parts book and Structure and Function.) For each connector and relay, see "Parts and connectors layout."
• Related information
• • • • •
Cause
1
Defective blower (fan) motor or defective wiring harness in blower intake unit
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Since there is no T-adapter for connector [15], check with connectors C49 and C50. 1) Turn starting switch OFF. 2) Unplug connectors C49 and C50 and connect T-adapter to connectors [4] and [6] (on air conditioner unit side). 3) In the case of "Auto air conditioner" equipped machine, disconnect mode actuator connector [16] 4) Carry out troubleshooting with connectors [3] and [5] (on control panel side) disconnected and starting switch kept OFF. Between (1)of connector (4) and ResisApproximately 110 (12) of connector [6] tance (Motor coil) Between (1) and (10) of ResisApproximately 4 k connector [6] tance Approximately 500 Between (7) and (10) of Resis(COOL-MAX) – connector [6] tance Approximately 3.5 k (HOT-MAX)
★ Contact input cannot be checked with removed unit (see related information).
★ If check result of cause 1 is abnormal (continuity is broken or 2
Defective wiring harness in air conditioner unit
3
Defective air mix actuator
4
Defective wiring harness (extended) between control panel and air conditioner unit
resistance is abnormal), perform following procedure. 1) Turn starting switch OFF. 2) Unplug connectors C49, C50 and [15] and connect T-adapter to connectors [4] and [6] (on air conditioner unit side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
★ If check result of cause 1 is abnormal (continuity is broken or resistance is abnormal) and check result of cause 2 is normal, air mix actuator is defective. 1) Turn starting switch OFF. 2) Unplug connectors C47, C49 and C50 and connect T-adapter to connectors [3] and [5] (on extended wiring harness side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
60-50 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING TEMPERATURE CONTROL
12 Cause
Standard value in normal state/Remarks on troubleshooting
★ Contact input cannot be checked with removed unit (see related information). Turn starting switch OFF. Unplug connectors C49 and C50 and insert T-adapter (since there is no T-adapter for connector C47). 3) Turn starting switch ON. 4) Turn main power of control panel ON. 5) Press temperature control switch and check if voltage is applied in about three seconds (while damper is moving). (Voltage stops when damper stops.) ★ Polarities (+, –) in changing from COOL to HOT are reverse to those in changing from HOT to COOL. Approximately 24 V Between connector C49 (1) (+) and C50 (2) (–) (For about 3 seconds Voltage ★ COOL HOT after temperature control switch is pressed) Between connector C49 (1) (–) Approximately 24 V and C50 (2) (+) (For about 3 seconds Voltage ★ COOL HOT after temperature control switch is pressed) 1) Turn starting switch OFF. 2) Disconnect connector C50 and insert T-adapter (since there is not T-adapter for connector C47). 3) Turn starting switch ON. 4) Turn main power of control panel ON. Between connector C50 (1) (+) and Voltage 5V (10) (–) 1) 2)
Possible causes and standard value in normal state
5
Defective control panel
★ If self-diagnosis system does not blink LCD, output to actuator is not stopped, thus control unit can be checked. 1)– 4) See above. 5) Measure each time you press temperature control switch. (Measure eight times in total from COOL-MAX to HOT-MAX.) ★ If damper rotates, potentiometer resistance changes and voltage changes consequently. Between (7) and (10) of Change between Voltage connector C5 0 and 5 V
WA500-6
60-51 D
AIR CONDITIONER
TROUBLESHOOTING TEMPERATURE CONTROL
12 Related Schematic Diagram
60-52 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING VENT (MODE) CHANGEOVER
12
TROUBLESHOOTING VENT (MODE) CHANGEOVER Machine Equipped With Automatic Air Conditioner Problem Indication of problem on machine
Vent (mode) cannot be controlled When mode selector switch or defroster switch on control panel is operated, vent (mode) does not change. •
When main power of control panel is turned ON, man-shaped mark (LCD) on the control panel blinks or “HLE” is displayed on the temperature display area. (See "Testing with Self-Diagnosis Function.") Self-diagnosis system checks mode actuator for disconnection and short circuit and checks contacts (LIMIT terminal) in mode actuator each time main power of control panel is turned ON. Even if link is disconnected (see "Testing vent (mode) changeover," self-diagnosis system assumes that vent (mode) changeover is normal, if mode actuator rotates when switch is operated. Referring to "Testing Vent (Mode) Changeover," check that there is not mechanical trouble (disconnection or interference of link, etc.). To replace mode actuator, link section must be removed. (See parts book and Structure and Function.) For each connector and relay, see "Parts and connectors layout."
• Related information
• • • •
Cause
1
Defective mode actuator or defective wiring harness in air conditioner unit
Possible causes and standard value in normal state
Standard value in normal state/Remarks on troubleshooting Since there is no T-adapter for connector [16], check with connectors C49 and C50. 1) Turn starting switch OFF. 2) Unplug connectors C49 and C50 and connect T-adapter to connectors [4] and [6] (on air conditioner unit side). 3) In the case of "Auto air conditioner" equipped machine, disconnect mode actuator connector [16]. 4) Carry out troubleshooting with connectors [3] and [5] (on control panel side) disconnected and starting switch kept OFF. Between (2)of connector (4) and (8) ResisApproximately 110 of connector [6] tance (Motor coil) Between (1) and (10) of ResisApproximately 4 k connector [6] tance Between (11) and (10) of ResisApproximately connector [6] tance 500 3.5 k
★ Contact input cannot be checked with removed unit (See related information).
★ If check result of cause 1 is abnormal (continuity is broken or 2
Defective wiring harness in air conditioner unit
3
Defective mode actuator
4
Defective wiring harness (extended) between control panel and air conditioner unit
resistance is abnormal), perform following procedure. 1) Turn starting switch OFF. 2) Unplug connectors C49, C50 and [16] and connect T-adapter to connectors [4] and [6] (on air conditioner unit side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
★ If check result of cause 1 is abnormal (continuity is broken or resistance is abnormal) and check result of cause 2 is normal, air mode actuator is defective. 1) Turn starting switch OFF. 2) Unplug connectors C47, C49 and C50 and connect T-adapter to connectors [3] and [5] (on extended wiring harness side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
WA500-6
60-53 D
AIR CONDITIONER
TROUBLESHOOTING VENT (MODE) CHANGEOVER
12 Cause
Standard value in normal state/Remarks on troubleshooting
★ If self-diagnosis system does not blink LCD, output to actuator is 1) 2) 3) 4) 5)
★
Possible causes and standard value in normal state
5
Defective control panel
not stopped, thus control unit can be checked. Turn starting switch OFF. Unplug connectors C49 and C50 and insert T-adapter (since there is no T-adapter for connector C47). Turn starting switch ON. Turn main power of control panel ON. Press mode switch and check if voltage is applied in about 3 seconds (while damper is moving). (Voltage stops when damper stops.) Polarities (+, –) are reversed by pushing the mode switch.
Between connector C49 (2) (+) and C50 (8) (–) ★ FACE FACE/FOOT FOOT/DEF DEF
Voltage
Approximately 24 V (For about 3 seconds after switch is pressed)
Between connector C49 (2) (–) and C50 (8) (+) ★ DEF FOOT/DEF FOOT FACE/FOOT FACE
Voltage
Approximately 24 V (For about 3 seconds after is pressed)
1) Turn starting switch OFF. 2) Disconnect connector C50 and insert T-adapter (since there is no T-adapter for connector C47). 3) Turn starting switch ON. 4) Turn main power of control panel ON. Between connector C50 (1) (+) and (10) (–)
Voltage
5V
★ If self-diagnosis system does not blink LCD, output to actuator is not stopped, thus control unit can be checked. 1)– 4) See above. 5) Measure each time you press mode selector switch or defroster switch. (Measure five times in total.) ★ If damper rotates, potentiometer resistance changes and voltage changes consequently. Between (11) and (10) of Change between Voltage connector C5 0 and 5 V
60-54 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING VENT (MODE) CHANGEOVER
12 Related Schematic Diagram
WA500-6
60-55 D
AIR CONDITIONER
TROUBLESHOOTING FRESH/RECIRC AIR CHANGEOVER
12
TROUBLESHOOTING FRESH/RECIRC AIR CHANGEOVER Machine Equipped With Automatic Air Conditioner Problem Indication of problem on machine
Fresh/Recirc cannot be changed over. When Fresh/Recirc switch on control panel is operated, recirculated or fresh air does not change over (Fresh/ Recirc changeover damper does not rotate). • •
★ Related information
• • • • •
When main power of control panel is turned ON, Fresh/Recirc mode LCD blinks. (See "Testing with Self-Diagnosis Function.") Self-diagnosis system checks contacts (LIMIT terminal) in Fresh/Recirc changeover actuator each time main power of control panel is turned ON. Since self-diagnosis system does not check Fresh/Recirc changeover actuator line for disconnection and short circuit, it does not indicate all troubles of Fresh/Recirc changeover actuator by blinking LCD. Referring to "Testing Fresh/Recirc Changeover," check that there is not mechanical trouble (removal or interference of lever, etc.). Operating angle of Fresh/Recirc changeover actuator is 90°. To replace Fresh/Recirc changeover actuator, blower intake unit must be removed and disassembled. (See "Testing Fresh/Recirc Changeover.") Resistance (Potentiometer) in Fresh/Recirc changeover actuator is not used. For each connector and relay, see "Parts and Connectors Layout." Cause
1
Standard value in normal state/Remarks on troubleshooting
Since there is no T-adapter for connector [23], check with connectors C49. 1) Turn starting switch OFF. Defective Recirc/Fresh 2) Unplug connector C49 and connect T-adapter to connector [4] changeover actuator or (on air conditioner unit side). defective wiring harness in air Between (3) and (7) of connector [4] ResisApproximately 110 conditioner unit or defective tance (Motor coil) wiring harness in blower intake Between (3) and (8) of connector [4] There is one way unit ★ Measure in diode range continuity. (Because one internal ★ Check continuity on both directions by switch is OFF.) changing polarity of tester probes.
★ If check result of cause 1 is abnormal (continuity is broken or
Possible causes and standard value in normal state
2
Defective wiring harness in air conditioner unit
resistance is abnormal), perform following procedure. 1) Turn starting switch OFF. 2) Unplug connectors C49 and [19] and connect T-adapter to connectors [4] and [19] (on air conditioner unit side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
★ If check result of cause 1 is abnormal (continuity is broken or
3
Defective wiring harness in blower intake unit
4
Defective Fresh/Recirc changeover actuator
5
Defective wiring harness (extended) between control panel and air conditioner unit
resistance is abnormal) and check result of cause 2 is normal, perform following procedure. 1) Turn starting switch OFF. 2) Referring to "Testing Recirc/Fresh Changeover," remove and disassemble blower intake unit. 3) Carry out troubleshooting with connector [23] disconnected. Referring to circuit diagram, check wiring harness for defect.
★ If check result of cause 1 is abnormal (continuity is broken or resistance is abnormal) and check results of causes 2 and 3 are normal, Fresh/Recirc changeover actuator is defective. 1) Turn starting switch OFF. 2) Unplug connectors C47, C48 and C49 and connect T-adapter to connector [3] (on extended wiring harness side) and carry out troubleshooting. Referring to circuit diagram, check wiring harness for defect.
60-56 D
WA500-6
AIR CONDITIONER
TROUBLESHOOTING FRESH/RECIRC AIR CHANGEOVER Cause
Standard value in normal state/Remarks on troubleshooting
★ If self-diagnosis system does not blink LCD, output to actuator is 1) 2)
Possible causes and standard value in normal state
3) 4) 5) 6
Defective control panel
★
not stopped, thus control unit can be checked. Turn starting switch OFF. Unplug connector C49 and insert T-adapter (since there is no T-adapter for connector C47 and C48). Turn starting switch ON. Turn main power of control panel ON. Press Recirc/Fresh selector switch and check if voltage is applied in about three seconds (while damper is moving). (Voltage stops when damper stops.) Polarities (+, –) in changing from Recirc to Fresh are reverse to those in changing from Fresh to Recirc.
Between (7) and (8) of connector Voltage C49
Approximately 24 V (for about 3 seconds after Recirc/Fresh selector switch is pressed)
Related Circuit Diagram
WA500-6
60-57 D
AIR CONDITIONER
TROUBLESHOOTING WITH GAUGE PRESSURE
12
TROUBLESHOOTING WITH GAUGE PRESSURE Referring to "Connection of Service Tool," carry out troubleshooting by reading the high and low gauge pressures of the cooling cycle. ★ The gauge pressure varies greatly with the weather condition and operating condition of the machine. Take care. • High pressure is too high: Above approximately 25 kg/cm² (355.6 psi) • High pressure is too low: Below approximately 10 kg/cm² (142.2 psi) • Low pressure is too high: Above approximately 3 kg/cm² (42.6 psi) • Low pressure is too low: Below approximately 0.5 kg/cm² (7.1 psi) • (Dual) pressure switch on high pressure side protects air conditioner circuit with OFF:
• Dual Pressure Switch ★ Normally "ON," abnormal pressure "OFF" for compressor
Refer to diagram: LA: 2 kg/cm² (28.4 psi) LB: 0.2 kg/cm² (2.8 psi) HA: 32 kg/cm² (455 psi) HB: 6 kg/cm² (85.3 psi)
Indicated gauge pressure Pressure is normal
Pressure is normal Both high pressure and low pressure are too low Low pressure becomes vacuum
60-58 D
Cause
Check method
Remedy
Air conditioner cycle is operating normally. If there is any trouble (cooling trouble), there is another cause. High pressure: Approximately 15 – 17 kg/cm² (213.4 – 241.8 psi) Low pressure: Approximately 1.3 – 2.0 kg/cm² (18.5 – 28.4 psi) Insufficient refrigerant
Bubble can be seen in the sight glass (*1, *3)
Clogging of receiver drier
There is a temperature difference between inlet and outlet pipes of receiver drier. Tank is frosty
Clogging of expansion valve
Expansion valve is frosty
Gas leakage at heat sensing tube of expansion valve
Low pressure gauge becomes vacuum
Defective evaporator sensor or defective contact of sensor (removal of mounting clip)
Evaporator is frozen. Air flow is down by freezing (at cool max. and HI speed of fan, later it becomes not too cold.)
Clogging or flattening or piping
Piping between receiver drier and compressor is clogged or flattened. If clogged completely, low gauge pressure becomes vacuum
—
Collect refrigerant, then fill up with proper quantity of refrigerant again (*2) Replace (*2) Clean or replace (*2) Replace (*2) Repair or replace Replace receiver drier. Collect refrigerant, then fill up with proper quantity of refrigerant again (*2) Clean or replace (*2)
WA500-6
AIR CONDITIONER
TROUBLESHOOTING WITH GAUGE PRESSURE
12 Indicated gauge pressure
Both high pressure and low pressure are too high
High pressure is too high and low pressure is too low High pressure is too low and low pressure is too high
Cause
Check method
Remedy
Filling too much with refrigerant
Connect gauge manifold
Collect refrigerant, then fill up with proper quantity of refrigerant again (*2)
Defective cooling of condenser
Stain of condenser, clogging or crushing of fins, or defective revolution of cooling fan
Collect refrigerant, then fill up with proper quantity of refrigerant again (*2)
Defective adjustment of expansion valve (Valve is opened too wide)
Bubble can be seen in the sight glass (*3)
Replace
Air in cycle
Bubble can be seen in the sight glass (*3)
Clogging or flattening of piping between compressor and condenser
There is a remarkable temperature difference between before and after clogged part.
Defective compressor (Compression trouble of compressor)
Both high pressure and low pressure are balanced while compressor is in operation. Compressor has seized and is extremely hot.
(*2) Evacuate and then fill up with proper quantity of refrigerant again (*2) Clean inside of cycle or replace (*2)
Replace (*2)
*1. If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are stained with oil. Increase tightening of the joints or replace parts. WARNING! *2. When replacing a cooling cycle part, see "Caution About Refrigerant" and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant again. *3. Sight glass (SG) is on the receiver drier (RD).
WA500-6
60-59 D
AIR CONDITIONER
CONNECTION OF SERVICE TOOL
12
CONNECTION OF SERVICE TOOL Symbol
Part No.
Part name
X
799-703-1200
Service tool kit
★ Use the service tool kit for R134a Service Tool Kit 1. Gauge manifold 2. High pressure charging hose (red) 3. Low pressure charging hose (blue) 4. Quick joint (Hi) (Large diameter) 5. Quick joint (Lo) (Small diameter) a. The thread is rough. So be careful not to loosen.
60-60 D
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1.
Close the high-pressure valve (HI) and low pressure valve (LO) of gauge manifold (1).
2.
Connect red charging hose (2) to the (HI) side and blue charging hose (3) to the (LO) side.
3. 4.
Connect quick joints (4) and (5) to each hose. Connect the quick joints to the service valves of the high and low-pressure pipings.
WA500-6
AIR CONDITIONER
HANDLING OF COMPRESSOR OIL
HANDLING OF COMPRESSOR OIL 1.
Control of compressor oil (SANDEN: SP-10: For R134a) Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can cause the following troubles.
Condition
Contents
Insufficiency of oil
Lubrication trouble and seizure of compressor
Excess of oil
Cooling trouble (Excessive oil sticks to parts and lower heat exchange performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant. 2.
Adding compressor oil WARNING! Since refrigerant is dangerous and bad for environment, collect the refrigerant before disconnecting the air conditioner hose. See "Caution About Refrigerant." WARNING! If refrigerant gets in your eyes, you may lose your sight. Wear protective goggles.
★ If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized. Be sure to use the specified oil for R134a (SANDEN: SP-10). ★ Oil for R134a absorbs moisture very easily. Accordingly, fit the cap immediately after using oil to stop the atmosphere. Store the oil can in a dry and ventilated place. ★ Precautions for using oil. Oil for R134a (SP-10 in particular) may dissolve acrylic resin and polystyrene (excluding baked polystyrene paint film). Accordingly, do not apply oil to those plastics. Check compressor oil in the following cases, and then add new oil if necessary. • When much refrigerant is discharged because of leakage. • When the compressor is troubled and replaced. • When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced. Quantity of oil to be added when cycle part is replaced. Air conditioner part
Quantity to be added (cm3) {in3}
Air conditioner unit, evaporator
Approximately 40 cm3 (2.441 in3)
Condenser
Approximately 40 cm3 (2.441 in3)
Receiver drier
Approximately 20 cm3 (1.220 in3)
Each hose (Cab – M24 Joint – Compressor)
Approximately 30 cm3 (1.831 in3)
Each hose (Cab – M16 Joint – Receiver drier – Condenser – Compressor)
Approximately 15 cm3 (0.915 in3)
WA500-6
60-61 D
AIR CONDITIONER
HANDLING OF COMPRESSOR OIL
12 3. Compressor replacement • In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil. Flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (135 cc){8.238 in3} filled in it. • Other cases New compressor has 135 cc (8.238 in3) compressor oil in it. So drain excessive compressor oil before installing new compressor in the following. i. Prepare an oil pan and drain oil from old compressor. ii. Measure the quantity of the drained oil with a graduated cylinder, and note the quantity or mark the level. iii. Drain below-mentioned quantity of oil from new compressor. WARNING! Drain Compressor Oil: 135 cc (8.238 in3)
The drain quantity = 135 cc (8.238 in3) – "the noted quantity." Example: If drained oil quantity from removed compressor is 30 cc (1.83 in3), drain oil of 135 – 30 cc = 105 cc from new one (8.238 - 1.83 in3 = 6.41 in3). 4.
Applying compressor oil for O-ring When connecting a pipe or hose, apply oil (SP-10) to its O-ring to prevent refrigerant leakage. WARNING! When discarding a can which still has some oil in it, make a hole in it to discharge gas and oil.
60-62 D
WA500-6
90
DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 Power Train Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 Without Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 With Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5 Brake Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7 Without Forced Brake Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7 With Forced Brake Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 Work Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 Air Conditioner Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 Electrical Circuit Diagram (1/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 Electrical Circuit Diagram (2/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17 Electrical Circuit Diagram (3/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 Electrical Circuit Diagram (4/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21 Electrical Circuit Diagram (5/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 Electrical Circuit Diagram (6/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25 Electrical Circuit Diagram (7/7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27 Connector List and Stereogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31 Engine and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
WA500-6
90-1 b
DIAGRAMS AND SCHEMATICS
90-2 b
WA500-6