Wa600 1 PDF

SEBM04260111
WA600-1
MACHINE MODEL SERIAL NO.
WA600- 1 IOOOlandup
. This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
. WA600-1 mount the S6D170-1 engine.

For details of the engine, see the 6D170-1 Series Engine Shop Manual.
0 1996 KOMAlbU
All Rights Reserved 00-l
96-04(02)03551 @
CONTENTS
10 ENGINE No. of page

12 TESTING AND ADJUSTING ........................... ............ 12-1
13 DISASSEMBLY AND ASSEMBLY ................................... 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ...................................... 21-I
22 TESTING AND ADJUSTING ........................................ 22-l
23 DISASSEMBLY AND ASSEMBLY ................................... 23-l
24 MAINTENANCE STANDARD ........................................ 24-l
40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION ...................................... 41-1
50 BRAKE AND AIR SYSTEM

51 STRUCTURE AND FUNCTION ...................................... 51-I
53 DISASSEMBLY AND ASSEMBLY ................................... 53-1
60 WORK EQUIPMENT SYSTEM

61 STRUCTURE AND FUNCTION ...................................... 61-1
80 ELECTRIC AND ELECTRONIC SYSTEM

81 STRUCTURE AND FUNCTION ...................................... 81-l
90 OTHERS
91 OTHERS .......................................................... 91-1
97 GEAR PUMP ...................................................... 97-l
00-2: WA600- 1
The affected pages are indicated by the use ofthe
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the
0 Pageto be newly added Add
table below.
111
Pages having no marks are those previously re-
vised or made aditions.
LIST OF REVISED PAGES
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0 00-I 0 12-16 @ 13-39 8 21-34 23-2-l @

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0 00-2-I : 13-40-I @I 21-36 @ 23-3
0 00-2-2 0 13-I 13-40-2 @ 21-37 23-4 :
0 00-2-3 @ 13-2 $ 13-41 0 21-38 @ 23-5
0 00-2-4 @I 13-42 @ 21-39 23-6 :
0 00-2-5 @ 13-3
13-4 $ 13-43 0 21-40 @ 23-7
0 00-3 13-44 0 21-41 23-8 g
0 00-4 13-5
13-6 : 21-I 21-42 23-9
0 00-5 21-2 21-43 @ 23-10 :
0 00-6 13-7
13-8 $ 21-3 0 21-44 23-11 @
0 00-7 21-4 21-45 @ 23-11-I @
0 00-8 13-9
13-10 : 21-5 21-46 23-12 @
0 00-9 13-11 @ 21-6 g 21-47 23-13 @
0 00-10 13-12 @ 21-7 @ 21-48 23-14 @
0 00-11 8 13-13 0 21-8 23-15 @
0 00-12 0 13-14 0 21-9 22-l 23-16 @
0 00-13 13-15 0 21-10 22-2 : 23-17 @
0 00-14 13-16 @ 21-11 23-18 @
0 00-15 13-17 @ 21-12 22-3
22-4 $ 23-19 0
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0 00-17 13-19 0 21-14 22-5
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0 00-19 0 13-20 @ 21-15 23-22 @
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13-22 @ 21-17 23-24 @
12-I 13-23 @ 21-18 22-9
22-10 $ 23-25 8
12-2 : 13-24 @ 21-19 22-11 @ 23-26 @
12-2-1 @I 13-25 @ 21-20 22-12 @ 23-27 @
13-26 @ 21-21 22-13 @ 23-28 8
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12-4 : 13-27 @ 21-22 0 22-14 @ 23-29 8
13-28 @ 21-23 22-15 0 23-29-l @
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23-39 0 23-94 0 24-4 0 41-33 43-3

23-40 @ 23-95 0 24-5 0 41-34 43-4
23-41 @ 23-96 8 24-6 0 41-35 43-5
23-42 @ 23-97 @ 24-7 0 0 41-36 43-5-l g
23-43 @ 23-97-l 8 24-8 43-5-2 8
23-44 @ 23-98 @ 24-9 0 42-1 43-5-3 @I
23-45 @ 23-99 0 24-10 42-2 43-6
23-46 @ 23-100 @ 24-11 42-3 43-7 g
23-47 @ 23-101 8 24-12 42-4 43-8
23-48 @ 23-102 @ 24-13 42-5 43-9 g
23-49 0 23-103 8 24-14 42-6 43-10 8
23-50 @ 23-103-I 8 24-15 42-7 43-11 0
23-51 @ 23-104 @ 24-16 42-8 43-12 8
23-52 @ 23-105 @ 24-17 42-8-l 43-13 8
23-53 @ 23-106 @ 24-18 42-8-2 43-14 0
23-54 @ 23-107 @ 24-19 42-8-3 43-15 0
23-55 @ 23-108 @ 24-20 42-8-4 43-16 8
23-56 @ 23-109 0 24-21 42-8-5 43-17 8
23-57 @ 23-110 @ 24-22 42-8-6 43-18 8
23-58 @ 23-111 @ 24-23 42-8-7 43-18-1 8
23-59 0 23-112 @ 24-24 42-8-8 43-19 0
23-60 @ 23-113 @ 42-8-9 43-20 @
23-61 @ 23-114 @ 0 41-I 42-9 43-21 @
23-62 @ 23-115 @ 41-2 42-11 43-22 @
23-63 @ 23-116 @I 41-3 42-12 43-24 8
23-64 @ 23-117 @ 41-3-1 42-13 43-25 8
23-65 @ 23-118 @ 41-4 42-15 43-26 @
23-66 @ 23-119 0 41-5 42-16 43-27 @
23-67 @ 23-120 8 41-6 42-17 43-28 @
23-68 @ 23-121 @ 41-7 42-18 43-29 0
23-69 @ 23-122 8 41-8 42-19 43-30 0
23-70 @ 23-123 8 41-9 42-20 43-31 0
23-71 @ 23-124 8 41-10 42-21 43-32 @
23-72 @ 23-125 8 41-11 42-22 43-33 0
23-73 @ 23-126 @ 41-12 42-23 43-34 0
23-74 @ ~ 23-127 @ 41-13 42-24 43-35 0
23-75 @ 23-128 @ 41-14 42-25 43-36 @
23-76 @ 23-129 0 41-15 42-26 43-37 0
23-77 @ 23-130 @ 41-16 42-27 43-38 @I
23-78 @ 23-131 @ 41-17 42-28 43-39 0
23-79 0 23-132 @ 41-18 42-29 43-40 0
23-80 @ 23-133 8 41-19 42-30 43-41 8
23-81 @ 23-134 8 41-20 42-31 43-42 8
23-82 @ 23-135 8 41-21 42-32 43-43 0
23-83 @ 23-136 @ 0 41-23 42-33 43-44 0
23-84 @ 23-137 @ 0 41-24 42-34 43-45 8
23-85 @ 23-138 @ 0 41-25 42-35 43-46 8
23-86 @ 23-139 0 0 41-26 42-36 43-47 8
23-87 @ 23-140 @ 0 41-27 42-37 43-48 8
23-88 @ 23-141 @ 0 41-28 42-38 43-49 8
23-90 0 0 41-29 42-39 43-50 8
23-91 0 24-l 0 41-30 43-51 8
23-92 0 24-2 @I 0 41-31 43-1 43-52 8
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43-54 8 52-8 43-38 @ 61-21 63-9-l @

43-55 8 52-9 43-39 @ 61-22 63-9-2 8
43-56 8 52-10 @ 43-39-l 0 61-23 63-10 8
43-57 8 52-11 0 43-40 0 61-24 @ 63-11 8
43-58 @I 52-12 @ 43-41 0 61-25 63-11-1 @
43-59 8 52-13 @ 43-42 @ 61-26 63-11-2 8
43-60 @ 52-14 @I 43-43 0 61-27 63-12 8
44-l @ 52-15 0 43-44 0 61-28 @ 63-12-1 @
44-2 @I 52-16 @I 43-45 0 61-29 63-12-2 8
44-3 52-17 @ 43-46 @ 61-30 63-12-3 8
44-3-I : 52-18 @ 63-12-4 @
44-3-2 0 52-19 0 54-l 62-l 63-12-5 @
44-4 52-20 @ 54-2 62-2 g 63-13 8
44-5 @ 54-3 62-2-l @I 63-14 8
44-6 53-l 54-4 62-2-2 @I 63-15 8
44-7 0 53-2 g 54-5 @I 62-3 63-16 8
44-8 53-3 54-6 62-4 g 63-16-1 8
44-9 g 53-4 g 54-7 62-5 63-16-2 8
44-10 0 53-5 54-8 62-5-l $ 63-18 8
53-5-l g 54-9 0 62-5-l @I 63-19 @
51-1 0 53-5-2 @ 62-6 @ 63-19-1 8
51-2 53-5-3 @ 0 61-1 0 62-7 63-19-2 8
51-2-1 : 53-5-4 @ 61-2 62-8 g 63-19-3 @
51-2-2 @I 53-7 0 61-3-1 : 62-8-l @ 63-19-4 8
51-3 53-8 61-3-2 @ 62-8-2 @ 63-20 8
51-4 g 53-9 g 61-4 62-9 @I 63-21 8
51-5 @ 53-10 0 61-5 g 62-10 @I 63-21-1 8
51-6 53-11 @ 61-5-1 @ 62-11 @ 63-22 8
51-7 53-12 @ 61-5-2 @ 62-12 @ 63-23 8
51-8 53-13 0 0 61-5-3 0 62-13 0 63-24 @
51-9 53-14 0 62-14 @I 63-25 8
51-10 53-15 0 61-6
61-6-1 g 62-15 @ 63-26 8
51-11 53-16 @ 61-7 @ 62-16 @ 63-27 8
51-12 53-17 0 61-7-1 0 62-17 @I 63-27-l @
51-13 53-18 @ 61-7-2 0 62-18 @ 63-27-2 @
51-14 53-19 0 61-8 @ 62-19 @ 63-28 @
51-15 @ 53-20 @ 61-9 62-20 @ 63-29 @
51-16 0 53-21 @ 61-10 0 63-30 @
51-17 0 53-22 @ 61-11 0 63-l 63-31 @
51-18 53-23 @I 61-12 0 63-l-l : 63-32 @
51-19 53-24 @ 61-13-1 @I 63-2 63-33 @
51-20 53-25 @ 61-13-2 0 63-3 g 63-34 8
51-21 53-26 @ 61-13-3 0 63-4 63-35 @
51-22 53-27 @ 61-13-4 0 63-5 g 63-36 @
51-23 @I 53-28 @ 61-13-5 @ 63-5-l @I 63-37 8
51-24 43-29 0 61-14 @ 63-5-2 @ 63-38 @
51-25 0 43-30 0 61-15 63-5-3 8 63-39 @
43-31 @ 61-15-1 @ 63-5-4 8 63-40 8
52-l 43-32 @ 61-15-2 0 63-6 63-41 @
52-2 g 43-33 0 61-16 63-7 g 63-42 @
52-3 43-34 @ 61-17 @ 63-7-l @ 63-42-l @
52-4 g 43-35 0 61-18 63-7-2 8 63-43 @
52-5 43-36 @ 61-19 @ 63-8 63-44 @I
52-7 43-37 @ 61-20 63-9 63-45 @
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Revisio Revisio Revisio Revisio Revision
number number number number lumber
63-46 @ 81-20 @ 82-15 @ 82-39-4 @ 82-59 0

81-21 @ 82-16 @ 82-39-5 @I 82-60 0
81-22 @I 82-17 @ 82-39-6 @ 82-61 @
64-1
64-2 g 81-22-1 @ 82-18 @ 82-39-7 @ 82-62 @
81-22-2 @I 82-18-1 @ 82-39-8 @ 82-63 @
64-3
64-4 g 81-22-3 0 82-18-2 @ 82-39-9 @I 82-64 @
81-23 @ 82-18-3 @I 82-39-10 @ 82-65 @
64-5
64-6 g 81-24 0 82-18-4 @ 82-39-l 1 @I 82-66 0
81-25 0 82-18-5 @ 82-39-12 @ 82-67 @
64-7
64-8 g 81-26 0 82-18-6 @ 82-39-13 @ 82-68 @
64-9 0 81-27 0 82-18-7 @ 82-39-14 @ 82-69 @
64-10 @ 81-28 @ 82-18-8 @ 82-39-15 @ 82-70 @I
64-11 0 81-29 82-18-9 @ 82-39-17 @ 82-71 0
64-12 @ 81-30 0 82-18-10 @ 82-39-18 @ 82-72 @
64-14 @ 81-31 0 82-19 @ 82-39-19 @I 82-73 @
64-15 0 81-32 82-19-1 @ 82-39-20 @ 82-74 @
64-16 0 81-33 @ 82-19-2 @ 82-39-21 @ 82-75 0
64-17 0 81-34 82-19-3 @ 82-39-22 @I 82-76 @
81-35 @ 82-19-4 @ 82-39-23 @I 82-77 @
l 81-1 0 81-36 @ 82-19-5 @ 82-39-24 @ 82-78 @
81-37 @ 82-19-6 @ 82-39-25 @ 82-79 0
81-3
81-6 : 81-38 @ 82-20 0 82-39-26 @ 82-80 @
81-6-1 @ 81-39 @ 82-21 @I 82-39-27 @I 82-81 @
81-6-2 @ 81-40 @ 82-21-1 @I 82-39-28 @I 82-82 @
81-6-3 0 81-41 @ 82-21-2 @ 82-39-29 @ 82-83 @
81-6-4 @ 81-42 0 82-21-3 @ 82-39-30 @I 82-84 @
81-6-5 0 81-43 0 82-21-4 @ 82-39-32 @I 82-85 @
0 81-6-7 @ 81-44 @ 82-22 @ 82-40 @ 82-86 @I
81-7 81-45 @ 82-23 @ 82-41 @ 82-87 @
81-8 g 81-46 @ 82-23-l @ 82-41-1 @ 82-88 @
81-8-1 0 81-47 @ 82-23-2 @ 82-41-2 @ 82-89 @
81-8-2 0 81-48 @ 82-24 @ 82-41-3 @ 82-90 @
81-9 82-25 @ 82-41-4 @ 82-91 @
81-10 g 82-l 82-25-l @ 82-42 @ 82-92 @
81-11 0 82-2-l : 82-26 @ 82-43 @ 82-93 0
81-12 0 82-2-2 @j 82-27 @ 82-43-l @ 82-94 @
81-13 @I 82-2-3 @ 82-27-l @ 82-43-2 @ 82-95 @
81-13-1 @ 82-2-4 @j 82-27-2 @ 82-43-3 @ 82-96 @
81-13-2 @ 82-2-5 @ 82-27-3 @I 82-44 @$ 82-97 @
81-13-3 @ 82-2-6 @ 82-28 @ 82-45 @ 82-98 @I
81-13-4 @ 82-2-7 @j 82-29 @ 82-46 @ 82-99 @
81-13-5 @ 82-3 82-30 @I 82-47 @ 82-100 @
81-13-6 @ 82-4 g 82-31 @I 82-48 @ 82-101 @
81-13-7 @I 82-5 82-32 @ 82-49 @ 82-102 @I
81-13-8 @ 82-6 g 82-33 @I 82-50 @ 82-103 @
81-13-9 @ 82-7 82-34 @ 82-51 @ 82-104 @
81-13-10 @ 82-8 g 82-35 @I 82-52 @ 82-105 @
81-14 @ 82-9 82-36 @ 82-53 @ 82-106 0
81-15 82-10 g 82-37 @ 82-54 @ 82-107 @
81-16 @ 82-11 @ 82-38 @ 82-55 @ 82-109 @$
81-17 @ 82-12 @ 82-39 @ 82-56 0 82-110 @J
81-18 @ 82-13 @ 82-39-2 @ 82-57 @ 82-111 @$
81-19 @ 82-14 @ 82-39-3 @ 82-58 0 82-112 @j
00-Z-4 WA600-1
0
Revisior Revision Revision Revision: Revision
82-113 @ 82-166 @$ 82-219 @ 97-107

82-114 @ 82-167 @B 82-220 @# 97-108
82-115 @ 82-168 @ 82-221 @ 97-109
82-116 @ 82-169 @ 82-222 @ 97-110
82-117 @Z$ 82-170 @$ 82-223 @# 97-111
82-118 @ 82-171 @ 97-112
82-119 @ 82-172 @$ 83-1 97-113
82-120 @I 82-173 @ 83-2 97-114
82-121 @ 82-174 @ 97-115
82-122 @J 82-175 @ 91-1 97-1'16
82-123 @ 82-176 @ 91-2 97-117
82-124 @ 82-177 @ 91-2-1 @
82-125 @ 82-178 @
82-126 @ 82-179 @ 91-3
91-4 :
82-127 @ 82-180 @#
82-128 @ 82-181 @ 91-5
91-6 g
82-129 @ 82-182 @$
82-130 @t 82-183 @0 91-7
91-8 g
82-131 @ 82-184 @I 91-9
82-132 @I 82-185 @# 91-10
82-133 @ 82-186 @I
82-134 @ 82-187 @ 93-l 8
82-135 @ 82-188 @C 93-2 0
82-136 @G 82-189 @
82-137 @t 82-190 @ 93-3
93-4 g
82-138 @ 82-191 @J 93-5 0
82-139 @ 82-192 @
82-140 @$ 82-193 @ 93-6
93-7 g
82-141 @I 82-194 @$
82-142 @ 82-195 @N 93-8
93-9 g
82-143 @ 82-196 @ 93-10 @
82-144 @ 82-197 @J 93-11 @
82-145 @J 82-198 @ 93-12 @I
82-146 @ 82-199 @ 93-13 8
82-147 @ 82-200 @ 93-14 8
82-148 @ 82-201 @B 93-15 8
82-149 @$ 82-202 @ 93-16 8
82-150 @t 82-203 @
82-151 @b 82-204 @ 97-l
82-152 @$ 82-205 @ 97-00 1
82-153 @t 82-206 @ 97-002
82-154 @ 82-207 @ 97-003
82-155 @b 82-208 @ 97-004
82-156 'I@ 82-209 @ 97-005
82-157 @ 82-210 @B 97-006
82-158 @ 82-211 @0 97-007
82-159 @ 82-212 @J 97-008
82-160 @ 82-213 @0 97-101
82-161 @ 82-214 @ 97-102
82-162 @ 82-215 @ 97-103
82-163 @ 82-216 @ 97-104
82-164 @I 82-217 @ 97-105
82-165 @# 82-218 @ 97-106
WA600-1 00-2-5
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service
and repair techniques recommended by Komatsu and described in this manual are both
effective and safe. Some of these techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the symbol A .IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed carefully.
If any dangerous situation arises or may possibly arise, first consider safety, and take the
necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, glasses, to lock all the control levers and hang warn-
cap and other clothes suited for welding ing signs on them.
work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11 When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits,’ first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a-hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
I I
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
I I
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
Safety necessary when performing
page number.
the work.
Example 1 (Chassis volume):
Special technical precautions
IO - 3
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item.
Caution necessary when se-
Example 2 (Engine volume): 63 kg Weight lecting hoisting wire, or when

working
etc.
posture is important,
rightenins 1 Places that require special at-

Unit number (I. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting)
Places to be coated with ad-
Consecutive page number for Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the
Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
1o-4 12-203
10-4-I -
k Added pages ---~~~~f~~:~
1O-4-2
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
will increase with the hanging angles. The
Rope diameter (mm) Allowable load (tons)
table below shows the variation of allow-
able load (kg) when hoisting is made with
10 1.0
two ropes, each of which is allowed to
11.2 1.4 sling up to 1000 kg vertically, at various
12.5 1.6 hanging angles.
When two ropes sling a load vertically, up
14 2.2
to 2000 kg of total weight can be sus-
16 2.8
pended. This weight becomes 1000 kg
18 3.6 when two ropes make a 120” hanging an-
20 4.4 gle. On the other hand, two ropes are
22.4 5.6 subjected to an excessive force as large
10.0 as 4000 kg if they sling a 2000 kg load at a

30
lifting angle of 150”.
40 18.0
50 28.0
60 40.0
* The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
2) Sling wire ropes from the middle portion

300 600 900 1200 1500
of the hook. Lifting angle (a) SAD00460
00-7
FOREWORD COATING MATERIALS
COATING IMATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Category Komatsu code Part No. 1 Q’w Container Main applications, features
LT-1A 7go-129-9030 1 150g Tube

- Used to prevent rubber gaskets, rubber cushions,
and cork plugs from coming out
* Used in places requiring an immediately effec-
20 9 Plastic tive, strong adhesive. Used for plastics (except
LT-1 S 790-129-9050
(x2) container polyethylene, polypropylene, tetrafluoroethylene,
and vinyl chloride), rubber, metal, and non-metal.
* Features: Resistance to heat, chemicals
Plastic
LT-2 09940-00030 50 g * Used for anti-loosening and sealant purposes for
container
Adhesive bolts and plugs.
* Used as adhesive or sealant for metal, glass, plastic
LT-3 Can
Plastic l Used as sealant for machined holes

LT-4
container
* Features: Resistance to heat, chemicals
Loctite 648-50 79A-129-9110 - . Used at joint portions subject to high tempera-
ture
l Used as adhesive or sealant for gaskets and
LG-1 Tube oackinas of Dower train case. etc.
l Features: Resistance to heat
l Used as sealant for flange surfaces and bolts at
high temperature locations, used to prevent sei-
LG-3 790-129-9070 1 Kg Can zure
l Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe
* Features: Resistance to water, oil
* Used as sealant for flange surface, thread
LG-4 790-l 29-9020 200 g Tube * Aiso possible to use as sealant for flanges with
Gasket sealant large clearance
- Used as sealant for mating surfaces of final drive
case, transmission case
* Used as sealant for various threads, pipe joints,
Plastic flanges
LG-5 790-129-9080 1 Kg . Used as sealant for tapered plugs, elbows, nip-
container
ples of hydraulic piping
. Features: Silicon based, resistance to heat, cold
LG-6 09940-00011 250 g Tube . Used as sealant for flange surface, thread
* Used as sealant for oil pan, final drive case, etc.
* Features: Silicon based, quick hardening type
LG-7 09920-00150 Tube - Used as sealant for flvwheel housina. intake mani-
fold, oil pan, thermostat housing, etc.
Rust preven- * Used as lubricant for sliding parts (to prevent
- Can
tion lubricant squeaking)
Molybdenum - Used to prevent seizure or scuffing of the thread
disulphide Iu- - Tube when press fitting or shrink fitting
bricant * Used as lubricant for linkaae. bearinas. etc.
* General purpose type
Lithium grease G2-LI SYG-400LI-A Various Various

SYG-IGOLI
. Used for normal temperature, light load bearing

at places in contact with water or steam
Calcium grease G2-CA Various
Molybdenum * Used for places with heavy load

disulphide SYG2-400M ,,04g&, )ellows type
grease
00-8
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in
section of DISASSEMBLY AND ASSEMBLY.
1 Kgm = 9.806 Nm
Thread diameter
of bolt
Width
across flats
T SAD00481 SAD00482
mm mm km Nm
6 IO 1.35+0.15 13.2k1.4
8 13 3.2 +0.3 31.422.9
IO 17 6.7 2 0.7 65.7 lr6.8
12 19 11.5fl.O 112k9.8
14 22 18.052.0 177219
16 24 28.513 279 f 29
18 27 3924 383-c39
20 30 56*6 549 f 58
22 32 76+8 745 278
24 36 94.5&10 927 i98
27 41 135215 132Ok 140

30 46 175-c20 1720+190
33 50 225k25 221O-c240
36 55 280 + 30 2750 5 290
39 60 335235 328Ok340
Ir This torque table does not apply to the bolts with which nylon packings or other
nonferrous metal washers are to be used, or which require tightening to otherwise
specified torque.
00-9
FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread diameter Width

Tightening torque
of bolt across fiats
mm mm kgm Nm
IO 14 6.720.7 65.7 + 6.8

12 17 II.521 112k9.8
16 22 28.523 279k-29
,Sealing surface
TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Thread diameter rNidth across flats

of nut part of nut part Tightening torque
mm mm kgm Nm
14 19 2.5kO.5 24.5 It 4.9
18 24 5+2 49 2 19.6
22 27 8*2 78.5 a 19.6
24 32 14+3 137.3k29.4
30 36 18k.3 176.5k29.4
33 41 20*5 196.1 k49
36 46 2525 245.2 rt 49
42 55 30+5 294.2 2 49
00-l 0
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Currer&rating
Number of Dia. of strands Cross section Applicable circuit
number (mm)
strands (mm) (mm?
0.85 11 0.32 0.88 2.4
2 26 0.32 2.09 3.1
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
CLASSIFICATION BY COLOR AND CODE
\Circuitz
Prior-
ity Classi-
fication
\
Pri_ Code
1
mav
t-Color
Code
2
t Color
Auxi_ Code
4 liary
Color
I-- White & Blue - Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
5
r-
Code
Color
WG
White & Green

-
-
-
-
RG
Red & Green Yellow

YL GB
& Blue Green & Black

LB
Blue & Black
- - - RL WV GL -
6
- - - Red & Blue Yellow &White Green & Blue -
00-l 1
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line down
from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by IO (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
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

IO 0.394 0.433 0.472 0.512 0.551 0.591 i 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
@ i
. ..5!!. . .. . . . . .1.969
.. .. .. . . . . .. . . .2.. .008 . . . . .. . . . .2. . .087
. . . . . .. .. . .2. . .047 . .. .. . . . . . .2.. . .126
.. . . . . . . ’12.1651 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
00-l 2
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l 3
Liter to U.S. Gallon

IL = 0.2642 U.S. Gal
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 16.567 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

18 = 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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-14
kgm to ft.lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
\
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
- -
00-l5
kg/cm2 to lb/in2
Ikg/cm' = 14.2233lb/in*
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 1 152 1 166 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 550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 835
130 1849 I'

863 I'
877 1892 1906 1920 1934 1949 1963 1977
140 1991 21
005 21020 2034 2048 2062 2077 2091 2105 2119
150 2134 2 148 2 162 2176 2190 2205 2219 2233 2247 2262
160 2276 2:290 2:304 2318 2333 2347 2361 2375 2389 2404
170 2418 2 432 2,446 2460 2475 2489 2503 2518 2532 2546
180 2560 2!574 2!589 2603 2617 2631 2646 2660 2674 2688
190 2702 2'717 2 731 2745 2759 2773 2788 2802 2816 2830
200 2845 2:859 21573 2887 2901 2916 2930 2944 2958 2973
210 2987 31001 31015 3030 3044 3058 3072 3086 3101 3115
220 3129 3 143 3 158 3172 3186 3200 3214 3229 3243 3257
230 3271 3:286 3:300 3314 3328 3343 3357 3371 3385 3399
240 3414 3 428 3,442 3456 3470 3485 3499 3513 3527 3542
00-l6
Temperature
Fahrenheit-Centigrade
Conversion ; a simple way to convert a Fahrenheit temperature reading intoa Centigrade tempera-
ture reading or vice versa isto enter the accompanying tablein the center or boldface column of figures.
These figuresrefer to the temperature in eitherFahrenheitor Centigrade degrees.
Ifitis desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
Ifit is desired to convert from Centigradeto Fahrenheit degrees,considerthe center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8"i=
“C “F “C “F “C “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-l 7
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
(Unit: kg)
Hydraulic pump (T/M lubrication+

Engine assembly 2750
T/C charging + Switch)
Radiator assembly 430 Steering cylinder (1 piece) 80
Torque converter assembly 160 Hydraulic tank 370 (430)
Transmission assembly 1400 Main control valve 90

I
Center drive shaft 60 Lift cylinder (1 piece) 420

I
Front drive shaft 60 Dump cylinder 520
I
Rear drive shaft 50 Engine hood 75
I
Front axle assembly 3200 Front frame 3400
Rear axle assembly 2900 Rear frame 2850
Front differential assembly 470 Bucket link (with bushing) 150

I
Rear differential assembly 480 Tilt lever (with bushing) 850
Planetary carrier assembly (1 piece) 120 Lift arm (with bushing) 3000
Wheel hub (1 piece) 200 Bucket with teeth 4100
Axle pivot (Rear axle)
Wheel (1 piece)
230
460
Counterweight I-.--
21 70 (Serial No.
10001-10068)
2314 (Serial No.

10069 and UD)
Tire (1 piece) 1000 Fuel tank 400
Steering valve 45 Battery (1 piece) 60
Hydraulic pump (Work equipment +

55 Operator’s seat 40
Steering + POC(PPC) valve) I
Floor frame 100 (120)
( ): Serial No. 10881 and up.
WA600- 1 00-l 9
0
TABLE OF OIL AND COOLANT QUANTITIES
RESERVOIR
Engine oil pan
Brake
I See NOTE (4) each 110 ) each 110
Add antifreeze
NOTE:
ASTM: American Society of Testing and Material
SAE: Society of Automative Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
(1) When fuel sulphur content is less than 0.5%. (2) When starting the engine in an atmospheric tem-
change oil in the oil pan every periodic mainte- perature of lower than O”C, be sure to use engine
nance hours described in this manual. oil of SAEl OW, even though an atmospheric tem-
Change oil according to the following table if fuel perature goes up to 10°C more or less in the day
sulphur content is above 0.5%. time.
(31 Use API classification CD as engine oil and if API
I
Change interval of oil classification CC, reduce the engine oil change in-
Fuel sulphur content
in engine oil pan terval to half.
I
(4) For axle oil, use only recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
* It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
00-20 WAiOO- 1
0
ENGINE -
12 TESTING AND ADJUSTING
Standard value table ... . . 12. 2

Tool list for testing and adjusting . 12. 3
valve . . . 12.
. 12. 8
Testing and adjusting alternator drive belt
tension . . 12. 9
Measuring exhaust gas color . . 12-10
12-11
. 12-13
Measuring accelerator pedal operating force
and operating angle . . . ... 12-14
Measuring accelerator pedal . . .
* The
WA600-1 12-1
0
STANDARD VALUE TABLE
Engine KOMATSU S6D170-1
Condition Unit Standard value Permissible value
rpm 2,100 - 2.200 2,100 - 2,200

rpm 630 - 680 630 - 680
rpm 2,000 2,000
0°C rpm Min. 80

Necessary starting speed
-20°C (using starting aid) rpm Min. 80
Intake resistance All speed mmH,O Max. 300 635
Intake pressure All speed mmlig Max. 950 710
Exhaust temperature All speed (intake air temp. 20°C) “C Max. 650 Max. 650
At abrupt acceleration Bosch index Max. 6.0 7.0

Exhaust gas color
At high idling Bosch index Max. 2.0 3.0
mm 0.4
mm 1.0
kg/cm’ Min. 29 20
Blow-by pressure At high idling mmH,O Max. 300 600

I
At high idling kg/cm’ 3.0 - 5.0 2.0
Oil pressure
(Engine water temperature SAE30 Min. 1.5 0.7
green range) At low idling kg/cm *
SAEIOW Min. 1 .O 0.7
Oil temperature Whole speed range (inside oil pan) OC 80- 110 120
At continuous rated horsepower

Oil consumption ratio % Max. 0.5 1 .o
(proportion to fuel consumption)
Fuel injection pressure Nozzle tester kg/cm’ 225 + 10 205
Fuel injection timing Before top dead center degree 42 i 1 42 t 1
Valve cracking pressure kg/cm’ 0.75 f 0.1 0.75 i 0.1

Radiator pressure valve
(Differential pressure)
Fan speed / Engine speed: At rated speed rpm 1170 - 1230 1170- 1230
Alternator belt tension Deflection when pushing with - mm 15 -

(Drive pulley--Alternator) finger force approx. 6 kg
12-2 WA600-1
(8
Engine KOMATSU S6D170-1
1t
I tern Condition Unit Standard value Permissible value
Serial No. 10001 and up (D spec.)

Operating force Serial No. 10001-10880 kg 6.5 Max. 10.0
(except D spec.1
-
Operating angle 01 degree cyz 45, cIz 30 -
I 19 ! _
I-
L,
I
L*
Cable length X 426F251
_
Serial No. 10881 and up
Operating force (except D spec.)
I
Operating angle degree.
t-F-j-+
Stopper height mm 45 * 5” ._
I
WA600- 1 12-2-l
m
TOOL LIST FOR TESTING AND ADJUSTING
NO. Testing and measuring item Tool Name Part No. Remarks
1 Engine speed Tachometer 799-203-8000 Digital display 60-19999 rpm
2 Battery specific gravity 1 .lOO - 1.300

Battery coolant tester 795-500-l 000’
3 Coolant freezing temperature -5 - -50°C
Water temperature, oil temper-

4 o-200°C
ature, intake temperature
Thermistor
799-l 01-6000
temperature gauge
5 Exhaust temperature 0 - looo”c
I I
6 Lubricating oil pressure 0 - 10 kg/cm2

I I
I I
‘I Fuel pressure
I
0 - 20 kg/cm’
799-203-2002 0 - 1500 mmHg
0 - 1000 mmH:O
10 Intake resistance j -1000 - 0 mmH,O

I
Compression gauge 795-502-I 204
Compression pressure 0 - 70 kg/cm’
Adapter 795-502-l 350
Blow-by pressure Blow-by checker 799-201-1503 0 - 500 mmH,O
795-125-1340 0.4, 1 .O mm
Discoloration 0 to 70% standard color

799-210-9001
(Discoloration %x l/l0 = Bosch index)
Water content 0.1%. 0.2%

799-201-6000
in standard sample
16 Coolant quality Water quality tester 799-202-7001 PH. nitrous acid ion concentration
I
17 Leakage from cooling system Cap tester 799-202-9001 0 - 2 kg/cm’
I
Fuel injection pressure Commercially
18 Nozzle tester 0 - 300 kg/cm2
Nozzle injection condition available
Commercially
19 Electrical circuit Tester Current, voltage, resistance
available
-
20 Accelerator pedal force Push-pull scale 79A-262-0020 Commercially available 0 - 25 kg
n! When carrying
and block the tires.
out testing, adjusting or troubleshooting, stop the machine on level ground, insert the safety pins
A When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
A When checking
the water is hot.
the water
Boiling
level in the radiator
water may spurt out.
wait for the water to cool. Do not remove the radiator cap while
Av Be careful not to get caught in rotating parts.
WA600- 1 12-3
@
ADJUSTING VALVE CLEARANCE
* Condition: Engine is cold.

* Adjust clearance between crosshead and rocker lever
as follows.
Unit: mm
Intake valve Exhaust valve
Cold 0.4 1 .O
Special tool
I Part No. I Part Name Q’ty
A 795-l 25-1340 Feeler gauge 1
1. Remove cylinder head cover.

2. Rotate the crankshaft in the normal direction to
align pointer (1) with the 1.6 TOP mark on crank-
shaft pulley. When rotating, check the movement
of the valves. When the pointer is in line with the
1.6 TOP mark, No.1 cylinder should be at compres- Alternator drive pully
sion top dead center.

* The barring method is as follows.
Screw bolts (01010-31240) into the tap holes
(4-M12x 1.75) on the front face of the alternator
drive pulley as shown in the figure, then use a bar
to rotate.
F41E01112
3. When No.1 cylinder is at compression top dead
center, adjust the valve marked 0.
When No.6 cylinder is at compression top dead
center, adjust the valves marked 0.
Cylinder No. 1 2 3 4 5 6
8; Intakevalve ‘. ‘a ‘0 ‘a ‘0 ‘0
Exhaust valve 0 0 l 0 l 0
4. To adjust, insert tool A between rocker lever (2)

and crosshead (3) and turn adjustment screw (4)
until clearance is a sliding fit. Then tighten lock nut
(5) to hold adjustment screw in position.
w Lock nut: 6.0 f 1 .O kgm
* After tightening the lock nut, check the clear-

ance again.
5. Next, rotate crankshaft one turn in the normal di-
rection and adjust the valve clearance of the remain-
ing valves marked 0.
* After adjusting No.1 cylinder at compression top
dead center, it is also possible to turn crankshaft
120’ each time and adjust the valve clearance of
each cylinder according to the firing order.
- Firing prder: l-5-3-6-2-4
F42601011-K
12-4 WA600- 1
0
MEASURING COMPRESSION PRESSURE
* Measurement condition
* Engine oil temperature: 40 to 6O’C
* Engine valve clearance: Standard value
- Engine speed: 210 to 250 rpm
Unit: kg/cm2
Item Standard value Permissible value
Compression pressure Min. 29 20
Special tools
Part No. Part Name a’ty
A 795-502-l 204 Compression gauge 1
795-502-l 350 Adapter 1

A,
+ If performance tests or troubleshooting shows that

the piston, piston ring or cylinder liner may be worn,
measure the compression pressure.
7 When measuring the compression pressure,

Q
be careful not to touch the exhaust manifold or
muffler, or to get caught in rotating parts.
1. Adjust valve clearance.

* For details, see ADJUSTING VALVE CLEAR-
426POO6
ANCE.
2. Warm up engine (oil temperature 40 to GO’C).
3. Remove nozzle holder assembly.
* For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4. Install tool A and Al in mount of nozzle holder
assembly.
5. Disconnect fuel CUT-OFF solenoid valve connector.
Crank engine with starting motor and measure com-
pression pressure.
* Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
* When measuring the compression pressure, meas-
ure the engine speed to confirm that it is within
the specified range.
* Installing the nozzle holder assembly after measuring

the compression pressure.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
WA600- 1 12-5
0
TESTING AND ADJUSTING FUEL INJECTION TIMING
- Coolant temperature: Inside operating range.
Unit: degree
item Standard value Permissible value
Fuel injection B.T.D.C. 42 42 f 1

timing
TESTING FUEL INJECTION TIMING
1. Disconnect fuel injection pipe (1) of No. 1 cylinder.
2. Remove delivery valve holder (21, then remove

delivery valve (3) and spring (4), and install deliv-
ery valve holder (2) again.
3. Place accelerator pedal at FULL position.
4. Operate priming pump and rotate crankshaft

slowly in normal direction. Check point where
fuel stops flowing from delivery valve holder (2).
5. Check that 42’ I.J. line on pulley and pointer (5)

are aligned at point where fuel stops flowing.
* BEYOND injection timing line:
Timing RETARDED
* BEFORE injection timing line:
Timing ADVANCED 426F253
* If the test shows that the fuel injection timing is
12-6 WA600- 1
0
ADJUSTING FUEL INJECTION TIMING BY
DELIVERY CHECK
1. Turn crankshaft back 40 to 50” from top dead

center.
2. Rotate crankshaft to align 42’ I.J. line on crank-
shaft pulley and pointer correctly.
3. Loosen nut (6) on the injection pump mount
bracket, then loosen 4 mounting bolts (7) of injec-
tion pump.
4. Move injection pump to outwards, then move injec-
tion pump to cylinder block little by little by
operating priming pump until no fuel flows out of
the delivery valve holder.
5. Tighten 4 mounting bolts (7) of injection pump.
6. Tighten nut (6) on injection pump mounting
bracket.
* After tightening the nut, check again that the
fuel stops flowing from the delivery valve holder
at the point where the pointer is aligned with
the line on the crankshaft pulley.
7. Remove delivery valve holder (2), assemble delivery
valve (3) and spring (4). then install delivery valve
holder (2) again.
m Delivery holder: 11.5 + 0.5 kgm
8. Connect~fuel injection pipe (1).
m Sleeve nut: 2.2 ? 0.2 kgm
WA600- 1 12-7
0
MEASURING BLOW-.BY PRESSURE
* Coolant temperature: Inside operating range.
- Engine valve clearance: Standard value.
- Engine oil temperature: Min. 60°C
Unit: mmH,O
Blow-by
Max. 300 Max. 600
pressure
Special tool
A 799-201-I 503 Blow-by checker 1
Q ) When taking measurements,

the exhaust manifold
be careful not to touch
or muffler, or to get caught
in rotating parts.
1. Measuring blow-by
1) When measuring the blow-by, warm the engine
up thoroughly.
2) Stop engine and install adapter of blow-by
checker on engine breather hose (I ).
3) Connect adapter and tool A (0 to 500 mmH,O)
with hose.
4) Run the engine at high idling and measure the
blow-by pressure.
2. Precautions when measuring blow-by

* The blow-by should be measured with the
engine running at rated output.
+ When measuring in the field, a similar value
can be obtained at stall speed.
- If it is impossible to check at rated output
or stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
* Blow-by may vary greatly according to the

condition of the engine, so if there is any ab-
normality in the reading, check for any prob-
lem related to defective blow-by, such as ex-
cessive oil consumption, defective exhaust
gas color, or early deterioration or contami-
nation of the oil.
12-8 WA600- 1
0
TESTING AND ADJUSTING ALTERNATOR DRIVE BELT
TENSION
Unit: mm
Deflection of belt 15
* Testing alternator belt tension

Check the amount of alternator belt deflection when
pushed with a force of approx. 6 kg at a point mid-
way between the alternator pulley and drive pulley.
Use a scale to measure the amount of the V-belt
deflection.
* Adjusting alternator belt tension

Loosen alternator mount bolt (2) and bolt (I) of
adjusting plate.
Use a bar @ , rise alternator assembly and ad-
just tension of belt, and tighten bolt (1) of adjust-
ing plate as first, tighten alternator mount bolt (2).
After adjusting belt tension, check again that
deflection of belt is within standard value.
Alternator pulley
\\
15 mm
%
Drive pulley
197F404
WA600-1 12-9
0
MEASURING EXHAUST GAS COLOR
* Coolant temperature: Inside operating range
* Valve clearance: Standard value
Special tools
* For tests in the field where there is no air or electric-

ity available, use A-l ; for tests in a repair shop, use
A-2.
Measuring with A-l
When measuring the exhaust color, be careful

n! not to-touch the exhaust pipe.
* Measure the exhaust color when the engine is warm

(oil temperature 60°C).
1) Fit the filter paper in tool A-l _
2) Insert the exhaust gas suction port into the ex-
haust pipe, accelerate the engine suddenly, and
operate the handle to catch the exhaust gas on the
filter paper.
3) Remove the filter paper and compare withy the
scale provided to judge the condition.
Measuring with A-2
When measuring the exhaust color, be careful

n! not to touch the exhaust pipe.
* Measure the exhaust color, when the engine is warm

(oil temperature 60°C).
1) Insert the probe (A) in the outlet of exhaust pipe
(1) and secure it to the exhaust pipe with a clip.
2) Connect the probe hose, accelerator switch plug
and air hose to tool A-2.
* The pressure of the air supply should be under
15 kg/cm2.
3) Connect the power cord to an AClOOV socket.
* Check that the power switch is OFF before
connecting the cord.
4) Loosen the cap nut of the suction pump and insert
the filter paper.
* Fit the filter paper securely so that the exhaust
gas does not leak.
5) Turn the power switch ON.
6) Accelerate the engine suddenly. At the same time,
depress the accelerator pedal, operate the relief
valve and catch the exhaust gas color on the filter
paper.
7) Lay the filter paper used to catch the exhaust gas
color on top of unused filter papers (IO sheets or
more) inside the filter paper holder, and read the
indicated value.
12-10 WA600- 1
0
MEASEURING ENGINE OIL PRESSURE AND TEMPERATURE
MEASURING ENGINE OIL PRESSURE
. Coolant temperature: Inside operating range.
Unit: kg/cm*
Oil pressure
3.0 - 5.0 2.0
High idling
I
I
/
Low idling Min. 1.5 0.7
Special tool
Part No. Part Name Q’ty
Engine pressure
A 799-203-2002 1
measuring kit
A When measuring,
rotating parts.
be careful not to get caught in
A Install
gauge with
and remove the
the engine stopped.
plug and oil pressure
* Measure the engine oil pressure when the oil tem-

perature is at the specified temperature.
1. Remove plug (1).
2. Install oil pressure gauge A (20 kg/cm’).
3. Start engine and measure oil pressure.
MEASURING OIL TEMPERATURE
. Coolant temperature: Inside operating range
Oil temperature 80 - 110°C 120°C
Special tool
Part No. Part Name a’ty
A 799-l 01-6000 Thermister temp. gauge 1
1. Remove dipstick (1).
2. Insert sensor of thermistor temperature gauge in

dipstick guide.
Connect sensor to thermistor temperature gauge A
and measure temperature of oil in oil pan.
426PO16 426PO! 7
WA600- 1 12-11
@
ADJUSTING FUEL CUT SOLENOID
Serial No. 10001-10342
1. Adjust rod (I) while pulling rod (5) in the running

direction so that there is clearance of 0.4 f 0.1 mm
between stop lever (2) and stopper (3), then tighten
lock nuts (4) and (5) temporarily.
2. Turn on the engine starting key and confirm that
clearance between stop lever and stopper is 0.4 +
0.1 mm. If clearance is not within standard value,
adjust rod again.
3. After turning on and off the key two or three times,
reconfirm that solenoid works smoothly and engine
runs or stops completely.
4. Tighten lock nuts (4) and (5).
-m
Stop lever
426F254
12-12 WA600- 1
0
ADJUSTMENT OF ENGINE STOP MOTOR CABLE
1. Temporarily install a ball joint (to connect to the

fuel injection pump) to the cable of the engine stop
motor.
2. Pull the stop lever of the fuel injection pump to the
ENGINE STOP position (no fuel injection), tem-
porarily fit ball joint (2) to the stop lever, then with
the stop lever contacting stopper (4) at the STOP
side, temporarily install the cable to bracket (1)
with locknut (6).
* The engine stop motor is delivered with the cable
in the pulled position.
* When stop lever (3) is in the lever FREE posi-
tion, it is at the operating position (spring
built-in).
3. From this condition, turn cable locknut (6) of
bracket (1) two turns (in the direction to push the
stop lever further against stopper (4) on the STOP
side, to push the stop lever firmly against the
stopper.
* The two turns are absorbed by the loose spring
mechanism inside the motor.
4. Tighten all parts.
5. Turn the engine starting switch ON/OFF repeatedly
and check that the engine stop motor work smooth-
ly.
i The engine stop motor has limit switches built in
at both ends of the cable stroke. 6162F642
* Check that there is no clearance between stop
lever (3) at stoppers (4) and (5) when the engine
starting switch is turned ON and OFF.
- Stroke of engine stop motor: 35 mm
- Stroke of fuel injection pump stop lever:
30 mm
WA600- 1 12-13
8
MEASURING ACCELERATOR PEDAL OPERATING FORCE
AND OPERATING ANGLE
Serial No. 10001-10880 (except D spec.)
OPERATING FORCE
1. Measuring procedure a
1) Put push-pull scale A in contact with the ac-
celerator pedal at point 150 mm from pedal
fulcrum “a”.
* The center of push-pull scale A must be in
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direc- 426F255
tion of operation and measure the maximum

value when pushing from idling to the end of
the pedal travel (high idling).
Testing and adjusting

1) Stop the engine.
2) Disconnect the cable (1) at the bottom of the
accelerator pedal, and check that the linkage
(2) move smoothly.
3) Connect the cable at the bottom of the pedal,
then disconnect at the connection for lever (3).
and check that the cable (1) moves smoothly.
4) Leave the cable (1) disconnect, and check that
the lever (3) moves smoothly.
* When carrying out this inspection, adjust
or replace parts as necessary. Measure the
operating force again and check that it is
within the standard value.
12-14
9
OPERATING ANGLE OF ACCELERATOR PEDAL
\
1. Measuring procedure
I) Stop the engine.
2) Mekure the operating angle o1 , lyz, put the
angle gauge A in contact with the accelerator
pedal it is operated from low-idling and high
idling.
426F256
2. Adjusting procedure
1) Remove cover under cab, then open cover of

engine right side.
2) Loosen nut (4) and adjust so that installed

length X of the cable (1) is within the standard
value.
3) Loosen nut (2) and adjust bolt so that installed

height L1 of accelerator pedal stopper is
4) Loosen nut (3) and adjust bolt so that installed
height Lz of accelerator pedal stopper is
5) Adjust the length of the rod (6) so ‘that the

injection pump governor lever contacts the
high idling stopper (5) when the pedal is de-
pressed (high idling).
WA600-1 12-15
0
MEASURING ACCELERATOR PEDAL
Serial No. 10881 and up (except D spec.)
OPERATING FORCE OF PEDAL
1. Set push-pull scale @ at a position 150 mm from

fulcrum “a” of the pedal.
* Make sure that the center of push-pull scale @
contacts the point 150 mm from the pedal
fulcrum. Top surface of f
2. Start the engine, and measure the maximum reading

when depressing the pedal from the idling position
to the end of its travel (high idling).
Testing
1. Stop the engine.
2. Disconnect cable (1) at the bottom of the accelera-
tor pedal, and check that there is no stiffness in
plate (2) under the pedal.
3. Connect the cable to the bottom of the pedal, then

disconnect it again at the connection with lever (3),
and check that there is no stiffness in cable (I).
4. With cable (1) disconnected, check that there is no
stiffness in lever (3).
* Carry out the above inspection, and if neces-
sary, adjust or replace parts, then measure the
operating force again to confirm that it is within
the standard value.
426FOllOl
12-16 WA600-1
@
ACCELERATOR PEDAL ENGINE
1. Measuring
1) Stop the engine.
2) Put angle meter (A) in contact with the accelera-
tor pedal, and measure pedal angles or and cy2 at
low idling and high idling.
Top surface of f
___ .-
U41901002
2. Adjusting
1) Remove the cover under the cab, then open the
right engine side cover.
2) Loosen nut (1) so that installed height L of the
accelerator pedal stopper is 45 + 5 mm, then
adjust bolt (2).
3) Adjust rod (6) so that the clearance between the

injection pump governor lever and high idling
stopper (5) is clearance a when the accelerator
pedal is depressed (high idling).
Clearance a: 0.2 mm
Check that the injection pump governor lever is

in contact with the low idling stopper when the
accelerator pedal is released (low idling).
Adjust the travel of the governor lever with rod

(6) or the cable.
421P01014
After carrying out the above adjustments, meas-
ure all parts again to confirm that they are within
the standard value.
WA600-1 12-17
@
ENGINE
13 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR TURBOCHARGER

Removal _ . 13- 2 Removal . . . . 13- 8
Installation . . .. 13- 2 Installation .. .. .. . 13- 8
ALTERNATOR AIR COMPRESSOR
Removal .... . . .. . 13- 3 Removal . .. . . . 13- 9
Installation .. . .. .. .. . . 13- 3 Installation .. .. . . 13- 9
OIL COOLER CYLINDER HEAD
Removal . . . . . . . . 13- 4 Removal . .. . . 13-10
Installation . _ .. . . . 13- 4 Installation .. . 13-15
FUEL INJECTION PUMP RADIATOR
Removal . . . . .. . 13- 5 Removal . . 13-21
Installation . . . .. . .. 13- 5 Installation . .. .. . 13-24
WATER PUMP ENGINE
Removal . . . . .. .. . . . 13- 6 Removal . . . 13-27
Installation . . .. 13- 6 Installation . . 13-35
NOZZLE HOLDER FUEL TANK
Removal _ .. . 13- 7 Removal . . . . . 13-41
Installation . .. .. . . 13- 7 Installation .. 13-43
* To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to
the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing
the filters, check that the oil container and area around the filler of the hydraulic tank are clean.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and
circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and
assembled, also carry out thorough flushing of the hydraulic circuits.
* After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any
hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always% bleed
the air as follows after completion of installation.
* Air bleeding procedure
1) Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times
without going to the end of this stroke. (Stop approx. 100 mm before the end of the stroke.)
2) Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine
and bleed the air from the plugs at the top of the hydraulic tank filter.
3) Raise the engine speed and repeat Step 2) to bleed the air. Repeat this procedure until no more air comes
out from the plug.
4) After completing bleeding the air, tighten the plugs.
$ZZl Plug: 1.15+0.15kgm
* If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
5) Check the level of the oil inside the hydraulic tank, add oil if necessary, then tighten the oil filler cap.
* Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap,
then open the pressurizing valve. (Serial No. 10868 and up)
* After repair or long storage, follow the same procedure.
WA600- 1
%’
REMOVAL OF STARTING MOTOR ASSEMBLY (Upper)
A Disconnect the cable from

minal of the battery.
the negative (-) ter-
1. Remove left side cover (1).

2. Open left engine side cover.
3. Disconnect wire (2).
4. Disconnect connector (3).
5. Remove starting motor assembly (4).
INSTALLATION OF STARTING
MOTOR ASSEMBLY (Upper)
1. Fit gasket and install starting motor assembly (4).

2. Connect connector (3).
3. Connect wire (2).
4. Close left engine side cover.
5. Install left side cover (1).
6. Connect cable to negative (-) terminal of battery.
REMOVAL OF STARTING MOTOR

ASSEMBLY (Lower)
1. Remove starting motor assembly (upper).
2. Disconnect wire (5).
3. Disconnect connector (6).
4. Remove starting motor assembly (7).
INSTALLATION OF STARTING
MOTOR ASSEMBLY (Lower)
1. Fit gasket and install starting motor assembly (7).

2. Connect connector (6).
3. Connect wire (5).
4. Install starting motor assembly (upper).
13-2
0
REMOVAL OF ALTERNATOR ASSEMBLY
n! Disconnect the cable from the negative (-)

minal of the battery.
ter-
1. Open left side cover.

2. Disconnect wires (I), (2) and (3).
3. Remove bolt (5) of adjustment plate (4), then loos-
en mounting bolt and nut (6).
4. Move alternator assembly towards lower to loosen
belt tension, then remove belt (7).
5. Remove mounting bolt and nut, then remove alter-
nator assembly (8).
INSTALLATION OF
ALTERNATOR ASSEMBLY
1. Install alternator assembly (81, then partially
tighten mounting bolt and nut (6).
2. Fit belt (7) in pulley groove and install.
3. Partially tighten bolt (5) of adjustment plate (4).
4. Insert a bar @ between alternator assembly and
cylinder block, raise alternator assembly and adjust
tension of belt.
* For details, see TESTING AND ADJUSTING.
5. Tighten bolt of adjustment plate, mounting bolt and
nut.
6. Connect wires (3). (2) and (1).
7. Close left side cover.
8. Connect cable to negative (-) terminal of battery.
WA600- 1
REMOVAL OF OIL COOLER ASSEMBLY

2. Loosen drain valves (1) and (2), and drain cooling
water.
* If the coolant contains antifreeze, dispose of it
correctly.
3. Remove connector pipe (3) for hydraulic oil cooler.
4. Disconnect heater hose (4).
5. Disconnect air hoses (5) and (6), then remove
bracket (7).
6. Remove turbocharger drain tube (8).
7. Disconnect oil cooler drain hose (9).
8. Remove muffler drain tube (10).
9. Remove clamp, and remove water tube (11).
IO. Disconnect water pipe (12) for compressor.
11. Remove mounting bolts (13), then remove oil cool-
er assembly (14).
INSTALLATION OF OIL
COOLER ASSEMBLY
1. Fit gasket, and install oil cooler assembly (14); then

tighten mounting bolts (13).
2. Connect water pipe (12) for compressor.
3. Fit gasket and O-ring, and install water tube (II),
then secure with clamp.
4. Install muffler drain tube (IO),, then secure with
clamp.
5. Connect oil cooler drain hose (9).
6. Fit gaskets on .both end, and install turbocharger
drain tube (8).
7. Install bracket, then connect air hoses (6) and (5).
8. Connect heater hose (4).
9. Fit gasket, then install connector pipe (3) for
hydraulic oil cooler.
10. Tighten drain valves (2) and (1).
11. Add water through water filler to the specified
level.
* Run the engine to circulate the water through
the system. Then check the water level again.
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY
1. Open right side cover.

2. Disconnect fuel control rod (1) and fuel cut sole-
noid rod (2).
3. Disconnect fuel supply hose (3).
4. Remove clamp, and disconnect fuel hoses (4) and
(5).
5. Disconnect fuel injection pipes (6).
6. Remove lubricating tubes (7) and (8).
7. Remove 2 nuts (9). remove bolts.
8. Remove 4 mounting bolts (IO), then pull out fuel
injection pump assembly (11) to rearwards.
Fuel injection pump assembly: 30 kg
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
1. Set fuel injection pump assembly (11) on bracket,

align spline of coupling (12). then install.
2. Align match marks, and tighten 4 fuel injection
pump mounting bolts (11) and 2 nuts (9).
3. Fit gaskets and install lubrication tubes (8) and (7).
4. Connect 6 fuel injection pipes (6).
m Sleeve nut: 2.25 + 0.25 kgm
5. Connect fuel supply hose (3).

6. Connect fuel cut solenoid rod (2) and fuel control
rod (1).
* Bend cotter pin securely.
* Bleed air from fuel pipings.
* To adjust fuel cut solenoid, see TESTING AND
ADJUSTING FUEL CUTSOLENOID.
* To adjust fuel injection timing, see TESTING
AND ADJUSTING FUEL INJECTION TIMING.
8. Close right engine side cover.
426P21
WA600- 1
REMOVAL OF WATER PUMP ASSEMBLY
1. Loosen drain valves (1) and (2), then drain cooling

water.
* If coolant contains antifreeze, dispose of it
correctly.
3. Remove connector (3) for hydraulic oil cooler.
4. Remove clamp, and remove water tube (4).
5. Disconnect water pump inlet tube (5).
6. Remove bracket (6) mounting bolts.
7. Remove mounting bolts (7), and remove water
pump assembly (8).
INSTALLATION OF WATER
PUMP ASSEMBLY
1. Fit gasket, and align spline of drive shaft, install

water pump assembly (8), then tighten mounting
bolts (7).
2. Tighten bracket (6) mounting bolts, secure water
pump assembly.
3. Fit gasket, then connect water pump inlet tube (5).
426P217
4. Fit gasket and O-ring on both end, install water tube
(4), then secure with clamp.
5. Fit O-ring, and install connector (3) for hydraulic
oil cooler.
6. Tighten drain valves (2) and (11, and add water
through water filler to the specified level.
* Run the engine to circulate the water through
the system. Then check the water level again.
426P218
13-6
0
REMOVAL OF NOZZLE HOLDER ASSEMBLY
1. Remove exhaust pipe, then remove hood.

* When remove No.3 to No.6 nozzle holder, re-
move intake connector (1) and pipe (2).
2. Disconnect fuel injection pipes (3).
3. Loose.n sleeve nut (4), and disconnect spill tube (5).
then remove connection (6).
4. Remove cylinder head cover (7).
5. Remove nozzle holder assembly (8).
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
1. Install nozzle holder assembly (8).
B Nozzle holder mounting bolt:

2.75 + 0.25 kgm
* Tighten nozzle holder mounting bolts evenly.
2. Fit gasket, install cylinder head cover (7).
w Cylinder head cover mounting bolt:

3.25 * 0.25 kgm
3. Fit connection (6), connect spill tube (5), then
tighten sleeve nut (4).
4. Connect fuel injection pipes (3).
m Sleeve nut: 2.25 f 0.25 kgm
* When install No.3 to No.6 nozzle holder, fit

gasket and O-ring, install pipe (2) and intake
connector (1).
5. Install hood and exhaust pipe.
WA600- 1
REMOVAL OF TURBOCHARGER ASSEMBLY
1. Remove exhaust pipe and hood.

3. Remove intake connector (1).
4. Loosen hose clamp (2), then remove pipe (3).
5. Disconnect muffler drain tube (4).
6. Remove coupling (5) mounting bolts and muffler
mounting bolts, then lift off muffler assembly (6). ,
PI kg Muffler assembly: 70 kg
7. Disconnect turbocharger lubricating hose (7).

8. Disconnect turbocharger drain tube (8).
9. Remove turbocharger assembly (9).
Turbocharger assembly: 30 kg
INSTALLATION OF
TURBOCHARGER ASSEMBLY
1. Fit gasket, and align intake connector, then install

turbocharger assembly (9).
&?Y Connector O-ring: Grease (G2-LI)
2. Fit gasket, and connect turbocharger drain tube (8).

3. Connect turbocharger lubricating hose (7).
4. Set muffler assembly (6) in mounting position,
tighten coupling (5) mounting bolts and muffler
mounting bolts.
5. Connect muffler drain tube (4).
6. Fit gasket, and install pipe (3), then tighten hose
clamp (2).
7. Fit gasket and O-ring on both end, install intake
connector (1).
9. Install hood and exhaust pipe.
13-8
0
REMOVAL OF AIR COMPRESSOR ASSEMBLY
* Drain air from air tank.
1. Open right engine side cover.

2. Loosen drain valve (1) and drain cooling water.
* If coolant contains antifreeze, dispose of it cor-
rectly .
3. Disconnect air tubes (2), (3) and (4).
.4. Remove water pipe (5), then disconnect water pipe
(6).
5. Remove 5 mounting bolts (7), then remove com-
pressor assembly (8).
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
1. Fit O-ring, and install compressor assembly (8),

then tighten 5 mounting bolts (7).
2. Fit gasket, and connect water pipe (6). then install
water pipe (5).
3. Fit gaskets, then connect air tubes (4), (3) and (2).
4. Tighten drain valve (1).
5. Add water through water filler to specified level.
* Run engine to circulate water through system.
Then check water level again.
6. Close right engine side cover.
WA600- 1
REMOVAL OF CYLINDER HEAD ASSEMBLY
1. Draining water
1) Loosen drain valve (1) of radiator and drain
coolant.
2) Loosen drain valve (2) of engine oil cooler and
drain coolant from cylinder block.
* If the coolant contains antifreeze, dispose of
it correctly.
2. Hood, side cover

1) Remove exhaust pipe and hood.
2) Open left and right engine side covers.
3) Remove air cleaner duct case (3).
3. Intake connector, pipe

1) Remove intake connector (4).
2) Loosen hose clamp (5). remove pipe (6).
!26P236 :
--
4. Drain tube, muffler assembly

1) Disconnect muffler drain tube (7).
2) Remove coupling (8) mounting bolts and muffler
mounting bolts, then lift off muffler assembly (9).
Muffler assembly: 70 kg
5. Turbocharger piping
I) Disconnect turbocharger lubricating hose (IO).
2) Remove turbocharger drain tube (II).
,,,,,
426P239
6. Turbocharger assembly
Remove mounting bolts (12). then remove turbo-
charger assembly (13).
Turbocharger assembly: 30 kg
7. Clamp, exhaust manifold assembly

1) Remove clamps (14), (15) and (16).
2) Sling exhaust manifold assembly (17), and re-
move mounting bolts (18). then lift off exhaust
manifold assembly (17).
elkg Exhaust manifold assembly: 50 kg
8. Air tube
Remove compressor inlet tube (I 9).
WA600- 1
9. Clamp, tube
1) Disconnect clamp (20) of fuel hose.
2) Remove tubes (21) and (22).
3) Remove clamp, then remove water tube (23).
10. Hose
Disconnect hose (24).
11. Fuel filter assembly

Remove fuel filter assembly (25) together with
bracket. then move to frame end.
12. Fuel injection pipe

Remove clamp (26). then remove fuel injection
pipes (27).
13. Mechanical tube, intake manifold assembly

1) Disconnect tube (28) of mechanical pump.
2) Leave 2 or 3 mounting bolts (29). and sling in-
take manifold assembly, remove mounting bolts,
then lift off intake manifold assembly (30).
Intake manifold assembly: 45 kg
13 -12
a
* When remove No.6 cylinder head, remove follow-
ing parts.
i) ‘Remove pipe (31).
ii) Disconnect water temperature gauge wire (32)
at connector.
iii) Disconnect heater hose (33).
14. Connection, head cover

1) Disconnect spill hose (34), then remove connec-
tion (35).
2) Remove mounting bolts (36), then remove head
cover (37).
15. Rocker arm assembly

Remove mounting bolts (38), then remove rocker
arm assemblies (39).
* To prevent press on push rod when installing,
loosen locknut (40) and turn adjustment screw
(41) 2 to 3 turns before removing rocker arm
assemblies.
16. Push rod

Remove push rods (42).
WA600- 1
17. Nozzle holder assembly
Remove mounting bolts (43), remove nozzle holder
assemblies (44).
18. Crosshead
Remove crossheads (45).
19. Rocker arm housing

1) Remove pin (46), using a bar, twist pipe (47) to
move it to side.
2) Remove mounting bolts (48). then remove
rocker arm housing (49).
20. Cylinder head assembly

1) Remove mounting bolts (50).
2) Using eye bolts @ (thread dia. = 12 mm, pitch
= 1.75 mm), remove cylinder head assembly
(51).
Cylinder head assembly: 40 kg
WA600- 1
INSTALLATION OF CYLINDER HEAD ASSEMBLY
Special tool
Part number Part name Q’ty

I I I
A 795-l 25-1340 Feeler gauge 1
* Remove all carbon and dirt from the contact surfaces

of the cylinder block and cylinder head. Remove all
burrs and damage, and clean out all dirt from inside
the cylinder block.
1. Cylinder head assembly

1) Set gasket (52) on cylinder block.
2) Using eyebolts 0 (thread dia. = .I2 mm, pitch =
1.75 mm), install cylinder head assembly (51).
3) Tighten mounting bolts (50).
* Coat the thread of the mounting bolts and the
contact surface of the washers with antifric-
tion compound.
& Mounting bolt, washer:

Antifriction compound (LM-P)
* First tighten the mounting bolts 2 to 3 turns

by hand, then tighten as shown in the diagram
below.
m Cylinder head bolt:
Unit: kgm
Order Target Range
1st 8.0 6.5 - 9.5
2nd 23.5 22.0 - 25.0
3rd I 39.0 I 37.5 - 40.5 ~~
4th 50.5 49.0 - 52.0
426F301
2. Rocker arm housing

1) Set rocker arm housing (49) in position and
tighten with mounting bolts (48).
w Mounting bolt: 10.5 + 0.5 kgm
2) Fit O-ring to pipe then using a bar, lever pipe

(47) to side and secure with pin (46).
WA600- 1
3. Crosshead
Install crosshead (45).
* Adjust crosshead as follows.
i) Loosen locknut, then loosen adjustment
screw.
ii) Press down lightly on top of crosshead, and
screw in adjustment screw.
iii)When adjustment screw contacts valve stem,
tighten a further 20”.
iv) Tighten locknut to hold in this position.
m Locknut: 4 +_0.5 kgm
4. Nozzle holder assembly

* Check that there is no dirt or dust inside nozzle
holder sleeve.
Install nozzle holder assembly (44) and tighten with
bolts (43).
* Tighten the nozzle holder mounting bolts uni-
formly in turn.
m Mounting bolt: 2.75 + 0.25 kgm
5. Push rod
Install push rod (42).
6. Rocker arm
Set rocker arm assembly (39) in position and tight-
en with mounting bolts (38).
* Check that the ball of the adjustment screw is
fitted properly into the socket of the push rod.
* Clean the oil hole of the bolt before installing.
w Mounting bolt: 10.0 f 0.5 kgm

7. Adjustment of valve clearance
Adjust valve clearance.
For details, see 12 TESTING AND ADJUSTING.
8. Head cover, connection

1) Fit gasket, and install head cover (37). then
w Mounting bolt: 3.25 * 0.25 kgm
2) Install connection (35), then connect spill hose

(34).
9. Intake manifold, mechanical tube

1) Sling intake manifold assembly (29), and set in
mounting position.
2) Fit gasket, tighten mounting bolts (30).
m Mounting bolt: 6 F 0.5 kgm
3) Connect tube (28) of mechanical pump.
* When installing No.6 cylinder head assembly,

install following parts.
i) Connect heater hose (33).
ii) Connect water temperature gauge wire (32) at
connector.
iii) Install pipe (31 ).
WA600- 1
IO. Fuel injection pipe
Install fuel injection pipes (27), and tighten sleeve
nuts, then secure with clamps (26).
w Sleeve nut: 2.25 f 0.25 kgm
11. Fuel filter ajsembly

Install fuel filter assembly (25) together with
bracket.
12. Hose
Connect hose (24).
13. Tube, clamp

1) Fit gasket, install water tube (23) then secure
with clamp.
2) Install tubes (22) and (21).
3) Connect clamp (20) of fuel hose.
14. Air tube

Fit gasket, then install compressor inlet tube (19).
15. Exhaust manifold, clamp
1) Sling exhaust manifold assembly (17). set on
cylinder head.
2) Fit gasket, and tighten mounting bolts (18).
* Fit gasket with protruding surface on outside.
w Mounting bolt: 11 f 1.5 kgm
3) Install clamps (16). (15) and (14).
16. Turbocharger assembly

Fit gasket, set turbocharger assembly (13) in mount-
ing position, then tighten mounting bolts (12).
* Fit gasket with “TOP” mark facing up.
17. Turbocharger piping

1) Fit gasket, then install turbocharger drain tube
(11).
2) Connect turbocharger Iu bricating hose (IO).
18. Muffler assembly, drain tube

1) Sling muffler assembly (9), and set in mounting
position, then tighten coupling (8) mounting
bolts and muffler mounting bolts.
2) Connect muffler drain tube (7).
WA600- 1
19. Pipe, intake connector
1) Install pipe (6), then tighten hose clamp (5).
2) Fit gasket, then install intake connector (4).
20. Side cover, hood

1) Install air cleaner duct case (3).
* Tighten with air cleaner duct case and hood.
2) Close left and right engine side covers.
3) install hood and exhaust pipe.
21. Refilling with water

1) Tighten drain valve (2) of engine oil cooler.
2) Tighten drain valve (I) of radiator, and add water
through water filler (52) to specified level.
+ Run engine to circulate water through system.
Then check water level again.
426P267
WA600- 1
REMOVAL OF RADIATOR
Stop the machine on level ground and install

A! the safety bar on the frame. Lower the bucket
to the ground and stop the engine. Then apply
the parking brake and put blocks under the
whee’ls to prevent the machine from moving.
Loosen the oil filler cap slowly to release the
Q! pressure inside the hydraulic

ate the steering wheel
tank.
and the control
Then oper-
levers
several times to release the remaining pressure
in the hydraulic piping.
1. Draining water
Loosen drain valve (1) and drain coolant.
correctly.
b
& Coolant: 135Q
2. Radiator grill
Remove radiator grill (2), then open engine inspec-
tion panel (3).
3. Radiator guard
1) Sling hood (4). remove radiator guard mounting
bolts.
* Remove door catch of engine inspection
panel.
* Be careful not to sling too much.
426P270
2) Disconnect electric wirings (5) and (6) from

connector.
* Move connector to radiator end, after discon-
nect radiator water level sensor wiring.
WA600- 1 13-21
0
3) Remove radiator guard (7) mounting bolts, move
radiator guard to rearwards.
(Approx. 50 mm)
42617273
4) Lift off radiator guard (7).

* Raise about 200 mm, then lift off to rear-
wards.
4kg Radiator guard: 190 kg
426P274
4. Fan guard, support

1) Remove radiator support (8).
* Remove clamp of hose (9).
2) Remove fan guard (10) from radiator.
5. Radiator hose
1) Disconnect coolant drain hose (11) from radia-
tor.
2) Loosen radiator end clamp of lower hose (12).
426P277 426P278
13-22 WA600- 1
0
6. Cooler piping
Disconnect hydraulic oil cooler hoses (17) and (18)
from radiator end tube.
7. Radiator
Sling radiator (19), and remove mounting bolts,
then lift off radiator.
* Raise radiator a little, check that lower hose and
upper hose are removed, then lift off.
t Be careful no that fan does not interfere with
radiator core.
..5 kg Radiator: 422 kg
426P281
WA600- 1
INSTALLATION OF RADIATOR
1. Radiator
Install radiator assembly (19).
* Check that lower hose and upper hose are set in
kY
mounting position. ) :”
* Tighten mounting bolts temporarily, then tighten
them fully after installing support.
426P281
2. Cooler piping
Connect hydraulic oil cooler hoses (17) and (18) to
radiator end tube.
w Cooler hose: 20 * 5.0 kgm

(Width across flats: 41 mm)
2) Tighten radiator end clamp of lower hose (12).

3) Connect coolant drain hose (11).
426P277
13iif4 WA600- 1
1) Install fan guard (IO) to radiator.
* install fan guard so that clearance between fan
and fan guard at left and right, and top and
bottom are same.
2) install radiator support (8).
* Tighten clamp of hose (9).
* Tighten radiator mounting bolts fully.
5. Radiator guard
I) Raise radiator guard (7) and set on 50 mm rear
of mounting position.
426P274
2) Sling hood (4), move radiator guard (7) to

mounting position, then tighten mounting bolts.
+ Tighten fully’after installing hood.
* Be careful not to sling too much.
426P282
3) Connect electric wirings (5) and (6) to connec-

tor.
WA600- 1
6. Radiator grill
Install radiator grill (21, then close engine inspection
panel (3).
WA600- 1
REMOVAL OF ENGINE
Serial No. 10868-10880 (Except D spec.)
Serial No. 10868 and UD ID soec.)
A Stop the machine
the safety bar on the frame.
on level ground and install
Lower the bucket
wheels to prevent the machine from moving.
* Disconnect the cable from the negative (-) terminal

of the batterv.
*A& Loosen the oil filler cap slowly to release the

4 pressure inside the hydraulic tank. Then oper-
ate the steering wheel and the control levers
426FO1201
* Before loosening the oil filler cap, close pres- Serial No, 10881 and up (Except D spec.1
surizing valve (1A).
(Serial No. 10868 and up)
426W7302 426FO1202
,, XI
1. Draining water
Loosen drain valve (1) and drain coolant.
correctly.
:
- Coolant: 135 R
2. Cover
Remove engine inspection cover (2).
* Remove left and right covers.
WA600-1
Serial No. 10001-I 0880
Except D spec.)
$rFiaeJS). 10001 and up
3. Hood
1) Disconnect POC hoses (3), (4) and (5) from POC
relief valve. [Serial No. 10001 - 10880 (Except
D spec.), Serial No. 10001 and up (D spec.)]
* Mark with tag to show installing position.
2) Remove lower mounting bolts of cover (6).
* Disconnect hose (7) at bulkhead, remove
clamp, then pull out to engine end.
3) Sling hood (8), then remove mounting bolts.

* Loosen band of air cleaner duct, when lift up
hood a little, pull out duct from duct case.
* Set lifting tool on hood so that bulkhead end
raisefirst.
Hood: 260 kg
‘ 426P288
4. Radiator guard
1) Disconnect electric wirings (9) and (10) from
connector.
* Move connector to radiator end, after discon-
necting radiator water level sensor wiring.
2) Lift off radiator guard (11).

* Raise about 200 mm, then lift off to rear-
ward.
Radiator guard: 190 kg
426P291
3) Lift off engine inspection cover (12).
Cover: 270 kg /
426P292

1) Remove radiator support (13).
2) Remove fan guard (15) from radiator.
6. Radiator hose
1) Disconnect coolant drain hose (16).
2) Loosen radiator end clamp of lower hose (17).
426P294 426P295
3) Loosen tube (19) end clamp of upper hose (18).

* Disconnect hoses (20) and (21).
WA600-1 13$?9
i/
7. Cooler piping
Disconnect hydraulic oil cooler hoses (22) and (23)
from radiator end tube.
8. Radiator
Remove radiator (24).
* Raise radiator a little, check that lower hose and
upper hose are removed, then lift off. 24
* Be careful so that fan does not interfere radiator -
core.
Radiator: 422 kg
426P298
9. Hydraulic piping
Disconnect following pipings from hydraulic pump.
- Hoses (25) and (26) between hydraulic tank and
hydraulic pump.
* Loosen clamps, push hoses (25) and (26) in to
lower.
* Hoses (27) and (28) between hydraulic pump
and steering valve.
- Branch hose (29).
* Tube (30) between transmission and hydraulic
pump.
Loosen clamp of hose (31) at tube (30) end,
then pull out to forward.
Loosen clamp of tube (30).
Be careful not to damage O-ring.
Remove clamp of POC hose. [Serial No.
10001 - 10880 (Except D spec.), Serial No.
10001 and up (D spec.)]
Remove clamp of PPC hose (Serial No. 10881
and up (Except D spec.)]
Tube (32) between hydraulic tank and

hydraulic pump.
WA600-1
1320
Tube (33) between hydraulic pump and trans-
mission.
* Disconnect hose (34) from torque converter
PTO case.
Tube (35) between hydraulic pump and torque
converter filter.
* Loosen clamp of tube.
Tube (36) between hydraulic pump and steering
valve.
Hose (37) between torque converter oil cooler
and hydraulic pump.
10. Torque converter piping

1) Disconnect tube (38) between torque converter
oil cooler and torque converter from torque
converter.
2) Disconnect hoses (39) and (40) between trans..
mission and torque converter from torque con-
verter.
3) Disconnect tube (41) between transmission and

torque converter from torque converter.
* Remove brackets (42) and (43) from torque
converter.
11. Drive shaft

Remove drive shaft (44) from torque converter.
* Make match marks before disconnecting coupl-
ing.
* Push torque converter end coupling in to torque
converter, then disconnect coupling.
Drive shaft: 30 kg
WA600-1
12. Electric wiring
Disconnect following electric wirings.
- Wiring (45) for starting motor.
- Wiring (46) for chassis ground.
* Main breaker wiring (47).
* Remove clamp for wiring.
* Wirings (48) and (49) for engine.
t Mark with tag to show installing position.
13. Air hose

Disconnect air hoses (50) and (51) from tube.
14. Fuel hose

Disconnect fuel hoses (52) and (53) from fuel tank
and fuel pump.
* Remove clamp of fuel hose (53).
426P309
15. Fuel control cable

F Serial No. 10001 - 10880 (Except D spec.)
! Serial No. 10001 and up (D spec.) 1
Disconnect fuel control cable (54) from bracket and
lever.
* After disconnecting, move cable to forward.
+ Remove clamp of hose (55).
WA600-1
’3G32
.,
Sene! No. 10881 and up (Except D spec.)
15A. Fuel control cable
b ‘J
[Serial No. 10881 and up (Except D spec.)]
Disconnect fuel control cable (54) from bracket
and lever together with plate (54A).
* After disconnecting, move the cable forward.
16. Drain valve

Remove engine oil drain valve (56) from fuel tank.
17. Engine
1) Remove PTO lubricating hose mounting elbow
(57).
* Remove the elbow to prevent interference
with the lifting tool.
* Record mounting angle of elbow before
removing.
2) Loosen engine end clamps of torque converter oil

cooler hoses (58) and (59).
WA600-1
3) Sling engine, remove front mounting bolts (60)
and rear mounting bolts (61).
426P375
4) Lift off engine (62).

* Raise engine until torque converter oil cooler
hose come off, and move to rearward then lift
off.
* Be careful to lift off hydraulic pump.
t Check that each hose and electric wirings are
disconnected.
Engine: 3100 kg
13-34 WA600-1
CR
INSTALLATION OF ENGINE
1. Engine
1) Set engine (62) in mounting position.
* When installing rubber, coat with water or
rubber grease, then install. Do not use other
than specified coating.
* Set torque converter oil cooler hoses in
mounting position.
426P316
2) Tighten front mounting bolts (60) and rear

mounting bolts (61).
m Mounting bolt (60) and (61):

94.5 + 10.5 kgm
* Set engine in position, then tighten mounting

bolts fully so that clearace “a” between engine
damper and trunnion support is the specified
value.
Standard clearance “a” : 7 mm 426P315
F42601012
3) Tighten engine end clamp of torque converter oil

cooler hoses (58) and (59). 426P3 73
4) Install PTO lubricating hose mounting elbow

(57).
* Align mounting angle then install.
WA600- 1
2. Drain valve
Install engine oil drain valve (5‘6) to fuel tank.

Serial No. 10001 and uo ID COACI
Serial No. 10001 - 10880 (Except D spec.)
[ Serial No. 10001 and up (D spec.) 1
Connect fuel control cable (54) to lever and
bracket.
* Install clamp of hose (55).
* Adjusting of length of cable, see 12 TESTING
AND ADJUSTING.
Serial No. 10881 and up (Except D spec.)

3A. Fuel control cable
Connect fuel control cable (54) and plate (54A) to
bracket and lever.
* Install clamp of hose (55).
* Adjusting of length of cable, see 12 TESTING
AND ADJUSTING.
4. Fuel hose
Connect fuel hoses (52) and (53) to fuel tank and
fuel pump.
* Install clamp of fuel hose (53).
426P309
WA600-1
5. Air hose
Connect air hoses (50) and (51) to tube.
* Check air leakage from connection of piping.
6. Electric wiring
Connect following wirings.
* Wirings (48) and (49) for engine.
- Main breaker wiring (47).
* Install clamp for wiring.
- Wiring (46) for chassis ground.
- Wiring (45) for starting motor.
7. Drive shaft _
Align match marks, instal! drive shaft (44).
* When connecting drive shaft, clean contact sur-
face of spider and coupling.
m Mounting bolt: 11.5 i: 1 .O kgm

1) Connect tube (41) between transmission and
torque converter to torque converter.
* Install brackets (42) and (43).
WA600-1
2) Connect hoses (39) and (40) between transmis-
sion and torque converter to torque converter.
3) Connect tube (38) between torque converter oil
cooler and torque converter to torque converter.
9. Hydraulic piping
Connect following pipings to hydraulic pump.
* Hose (37) between torque converter oil cooler
and hydraulic pump.
- Tube (36) between hydraulic pump and steering
valve.
* Tube (35) between hydraulic pump and torque
converter filter.
* Tighten clamp of tube.
- Tube (33) between hydraulic pump and trans-
mission.
* Connect hose (34) to torque converter PTO
case.
- Tube (32) between hydraulic tank and hydraulic
pump.
* Connect tube (32) first surely.
- Tube (30) between transmission and hydraulic
pump.
Tighten clamp of hose (31).
Tighten clamp of tube (30).
Be careful not to damage O-ring.
Install clamp of POC hose. [Serial No. 10001
- 10880 (Except D spec.), Serial No. 10001
and up (D spec.)]
Install clamp of PPC hose. [Serial No. 10881
and up (Except D spec.)]
* Hose (27) and (28) between hydraulic pump and
steering valve.
- Branch hose (29).
* Hose (25) and (26) between hydraulic tank and

hydraulic pump.
* Connecting hoses (25) and (26), tighten lower
clamp, then tighten mounting bolts.
IO. Radiator
Set radiator (24) in mounting position.
* Check that upper hose and lower hose are set in
mounting position.
* Tighten mounting bolts temporarily, tighten
mounting’bolts fully after installing support.
w Mounting bolt: 28.5 ? 3.0 kgm
426P298
11. Oil cooler piping

Connect hydraulic oil cooler hoses (22) and (23) to
radiator and tube.
w Cooler hose: 20 + 5.0 kgm

12. Radiator hose

1) Tighten tube (19) end clamp of upper hose (18).
* Connect hoses (20) and (21).
2) Tighten radiator end clamp of lower hose (17).

3) Connect coolant drain hose (16) to radiator.
1’1
4 : . -’ .
426P294 426P295
<.
WA600-1
13g9
1) Install fan guard (15) to radiator.
* Install fan guard so that clearance between fan
and fan guard at top and bottom, and left and
right are same.
2) Install radiator support (13).
* Tighten radiator mounting bolts fully.
14. Radiator guard

1) Install engine inspection cover (12).
* Install left and right inspection covers.
* Check that covers are closed securely.
2) install radiator guard (11).

* Tighten mounting bolts fully after installing
each hood.
426P291
3) Connect electric wirings (9) and (10) to connec-

tor.
13$0
j_, WA600-1
15. Hood
1) Install hood (8).
* Insert duct in,duct case and tighten band of
duct at 20 mm in front of hood mounting
position.
426”288
Serial No. 10001-10880
(Except D spec.)
Sgial NO. 10001 and ua
2) Tighten cover (6) lower mounting bolts. (D swc.)
* Connect hose (7) to bulkhead, then tighten
clamp.
3) Connect POC hoses (3), (4) and (5) to POC relief
valve. [Serial No. 10001 - 10880 (Except D
spec.), Serial No. 10001 and up (D spec.)]
16. Cover
Install engine inspection cover (2).
* Install left and right covers.
17. Refilling with oil and coolant

1) Add oil through oil filler to specified level
%z Hydraulic oil: Approx. 1011

Serial No. 10881 and up (Exe Serial No. 10001 and up CD spec.)
WA600-1
Serial No. 10868 and up (D sped.)
* Tighten the oil filler cap, then open pressuriz-
ing valve (1A). (Serial No. 10868 and up)
426FO1201
Serial No. 10881 (Except D spec.)
1A
426FO1202
2) Add transmission oil through oil filler to speci-

fied level.
Transmission oil: Approx. 52
3) Tighten drain valve, and add coolant through

water filler (65) to specified level.
Gi?
* Run
Coolant:
engine
135P
to circulate oil and coolant

through system. Then check oil and water
level again.
REMOVAL OF FUEL TANK
n! Stop the machine on level ground and install

the safety bar on the frame. Lower the bucket
1. Draining fuel
Loosen drain valve (1) and drain fuel.
:
- Fuel: 61OQ
2. Drain valve
426P320
Remove engine oil drain valve (2) and coolant drain /
valve (3) from the fuel tank.
3. Cover
Remove battery box side cover (4).
* Remove mounting bolts of step (5) and battery
box.
* Remove cover (5) surely, because fuel tank lift-
ing hooks locate in side battery box.
4. Fuel hose
Disconnect fuel hoses (6) and (7) from fuel tank.
54
426P323
5. Electric wiring
Disconnect wiring (8) for fuel unit from connector.
* Remove clamp (9).
WA600- 1
6. Fuel tank
1) Remove U-clamp (IO), then remove bracket (11).
* Remove connectors (12) and (13) and clamp
(14).
2) Remove bracket (15) from frame.

3) Remove grease tube clamp (16).
4) Sling fuel tank (17), and remove mounting bolts,

then lift off.
* Set lifting, tool on steps and lifting hooks,
then taking care of balance, lift off fuel tank
quietly.
* Check that fuel is drained completely.
* Lay a pallet below fuel tank. Aligning fuel
tank, set blocks under machine, then pull out
full tank.
[m Fuel tank: 400 kg
13g2 WA600- 1
INSTALLATION OF FUEL TANK
1. Fuel tank
1) Put fuel tank on pallet, then insert under mount-
ing position.
2) Install fuel tank (17).
* When raising fuel tank, keep it horizontal and
set in mounting position.
* Tighten mounting bolts diagonally.

3) Install grease tube clamp (16).

4) install bracket (15) on frame.
* Be careful not to bend hose
P326
5) install bracket (II), then install U-clamp (10).

* InStall connectors (12) and (13) and clamp
(14).
2. Electric wiring
Connect wiring (8) for fuel unit.
* Install clamp (9).
WA600- 1
3. Fuel hose
Connect fuel hoses (6) and (7) to fuel tank.
* Install hose without twisting.
426P323
4. Cover
Install battery box side cover (4).
* Install mounting bolts of step (5) and battery box.
5. Drain valve
Install engine oil drain valve (2) and coolant drain
valve (3) to fuel tank.
6. Refilling with fuel

Tighten drain valve, and add fuel through fuel
filler (18).
Fuel: 61OQ
13-44 WA600- 1
0
POWER TRAIN.
21 STRUCTURE AND FUNCTION
Genera!. ............ . .................... 21- 2

- Location of components ................ 21- 2
- Powertrain ............................ 21- 3
- Hydraulic circuit schematics for
powertrain ............................ 21- 4
- Hydraulic circuit diagram for power train 21- 5
Transmission mount ...................... 2 I- 6
Torque converter and transmission piping ... 21- 7
Torque converter oil cooler................ 2 I- 8
Torque converter oil filter .................. 2 I- 9
Lubrication bypass valve. .................. 21-I 0
Pilot oil filter .............................. 21-I 1
Torque converter ......................... 21-l 2
Torque converter regulator valve ........... 21-I 4
Torque converter relief valve ............... 21-l 6
Transmission ............................. 21-l 8
Transmission control valve ................ 21-23
- Upper valve ........................... 21-24
. Lower valve ........................... 21-25
. Main relief valve ........................ 2 1-26
. Priority valve ........................... 2 l-27
- Modulating valve and quick return valve . . 21-28
. Reducing valve ......................... 21-30
. Accumulator valve ..................... 2 1-3 1
. Pilot reducing valve ..................... 2 1-33
Transmission solenoid valve ............... 2 l-34
Emergency manual spool .................. 21-36
Transfer ................................. 21-37
Driveshaft ............................... 21-38
Center support ........................... 21-39
Axle mount .............................. -21-40
Axle and differential ....................... 21-42
Final drive ................................ 21-47
Tire and wheel ............................ 21-48
WA600- 1 21-l
GENERAL
l LOCATION OF COMPONENTS
15 16 18 20
426FOO3
OUTLINE
- The motive force from engine (1) is transmitted from The output shaft of transmission (6) transmits the
the flywheel through the ring gear to torque con- motive force through the gear of transfer (7) to the
verter (4). The torque converter uses oil as a medium output shaft of the transfer.
to convert the transmitted torque to match the varia- At the front, the motive force is transmitted through
tion in the load. It transmits this motive force to the center drive shaft (17), center support (16), and front
input shaft of transmission (6). drive shaft (15) to front differential (14).
- In addition, the motive power of the engine passes At the rear, the motive force is transmitted from rear
through the pump drive gear and is sent to the two drive shaft (18) to rear differential (19).
triple pumps (3) and (24), and drives each of the The motive force transmitted to front differential
pumps. (14) and rear differential (19) is transmitted to the
- In transmission (6), solenoid valves are used to oper- sun gear shaft (axle shaft) of final drives (11) and
ate the direction spool and speed spool of the trans- (23).
mission valve. In this way, the six hydraulically The motive force of the sun gear is reduced by a
operated clutches are actuated to select FORWARD planetary mechanism, and passes through the plane-
and REVERSE speeds. The speed selection is carried tary hub to front wheel (10) and rear wheel (22).
out manually.
21-2 WA600- 1
l POWER TRAIN
7 8
426FOO4
Engine lS6D170) 8. Emergency steering 17. Center drive shaft

2. PTO Pump (If equipped)
18. Rear drive shaft
3. 9. Parking brake
Triple pump (SAR(41125 t 19. Rear differential
(31100 + (3)lOO) 10. Front wheel
20. Rear axle
(for transmission and PTO
Front final drive
lubrication, torque converter 21. Rear brake
charging and switch) 12. Front brake
22. Rear wheel
4. Torque converter 13. Front axle
23. Rear final drive
5. Upper drive shaft 14. Front differential
24. Triple pump (SAR(41250 t
6. Transmission 15. Front drive shaft (4)125 + (11201
7. (for hydraulic, steering
Transfer 1s. Center support
and POC(PPClI
WA600- 1 21-3
@
. HYDRAULIC CIRCUIT SCHEMATICS FOR POWER TRAIN
Engine running, gear shift levers at Neutral.
2 1 426FO36
21-4 WA600- 1
. HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
.;_+_i--,
30 kg/cm>
18
I
I i
Ill I ICJ I Ill I / r--
=__LL_-,
r----l
426F037A
1. Transmission case 14. Quick return valve 27. 2nd spool
2. PTO case 15. Torque converter 28. 1St spool
3. Strainer 16. Torque converter relief valve 29. Emergency manual spool
4. Transmission and PTO lubrication 17. Torque converter regulator valve 30. Solenoid valve
pump ISAR(4)-125)
18. Oil cooler 31. Reverse clutch
5. Torque converter charging pump
(SAR(3)-100) 19. Lubrication valve 32. Forward clutch
6. Switch pump (SAR(3)-100) 20. Transmission lubrication 33. 4th clutch
7. PTO lubrication 21. Lubrication bypass valve 34. 3rd clutch
8. Oil filter (3 pcs) 22. Reducing valve 35. 2nd clutch
9. Transmission main relief valve 23. Reverse spool 36. Accumulator valve
10. Pilot oil filter 24. Forward spool 37. 1st clutch
11. Pilot reducing valve 25. 4th spool

12. Priority valve 26. 3rd spool
13. Modulating valve
WA600- 1 21-5
0
TRANSMISSION MOUNT
TP Section A-A
r+; Section B-B
View Z
426FOO7-1
1. Transmission OUTLINE
2. Torque converter
* The transmission is mounted separately from the
3. Transmission mount
torque converter and engine.
4. Rubber * Both front and rear have rubber mounts.
21-6 WA600- 1
0
TORQUE CONVERTER AND TRANSMISSION PIPING
426FOO8
1. Transmission 6. Oil cooler
2. Lubrication bypass valve 7. PTO case
3. Transmission control valve 8. Torque converter
4. Torque converter charging pump 9. Torque converter oil filter
5. Radiator
WA600- 1 21-7
0
TORQUE CONVERTER OIL COOLER
OUTLINE
- The oil which comes out from the torque converter

outlet port is at a high temperature because of the
energy used in transmitting the motive force. This
torque converter oil passes through oil cooler port A
and enters the oil cooler. Here it is cooled by the
engine cooling water. The oil then flows out from oil
outlet port B, flows lubrication pump.
n - To radiator
View Y View Z
426FO35
1. Torque converter oil cooler
A. Inlet port
B. Outlet port
21-8 WA600- 1
TORQUE CONVERTER OIL FILTER
1. Relief valve
2. Element
3. Center bolt
4. Drain plug
5. Clogged sensor
A. Inlet port
B. Outlet port
Filtration area: 8,900 cm*x 3

Relief pressure: 3.25 kg/cm*
(Bypass pressure)
Section X-X
View Z 426FOO9
To transmission
‘control valve
OPERATION
. The oil from the torque converter charging pump

(6) enters the filter inlet port A and passes from the
outside of element (2) tb the inside. It then flows
to the outlet port B.
423FOlO
TO transmission
control valve
. If the element (2) is clogged with dirt, or the oil
temperature is low, the pressure at the inlet port A
rises. When this happens, the oil from the inlet port
A opens relief valve (1) and flows directly to the
outlet port B. This prevents damage to the pump or
element (2).
423FOll
WA600- 1 21-9
LUBRICATION BYPASS VALVE
FUNCTION
- When traveling in 4th gear, the transmission gears

are rotating at high speed. Because of this, the
churning resistance of the transmission lubrication
oil increases. To reduce this power loss,only enough
oil to lubricate the gears at 4th speed is kept. All
the rest of the oil is bypassed to the transmission
case.
OPERATION
. 4th clutch not being operated From quick return valve From oil cooler
When the 4th clutch is not being operated, there is
no hydraulic pressure at port a of spool (I). As a
result, spool (1) is pushed to the left by the spring.
The oil from the torque converter is stopped by
spool (l), so all the oil is used for lubricating the
transmission.
426FO32
. 4th clutch being operated

From quick return valve
When oil flows to the 4th clutch, pressure oil flows From oil cooler
from 4th spool (2) to port a of spool (2). When
pressure oil enters port a, it pushed back the spring
and moves spool (2) to the right. The oil from the
torque converter flows to the transmission lubri-
cation system and drain port b.
F
re
valve
426FO33
21-10 WA600- 1
PILOT OIL FILTER
OUT
4
Section A - A
;I
1. Oil filter head
2. Element
3. Case
Specification:
Filtration area: 370 cm*
WA600- 1 21-11
TORQUE. CONVERTER
View Z
426FOlO
1. Regulator valve
2. Coupling
3. Housing
4. Torque converter relief valve

pressure pick-up (PT l/8)
5. Torque converter outlet oil

temperature pick-up
6. Regulator pressure pick-up

(PT l/8)
2 7. Stator
8. Turbine
9. Drive case
10. Pump
11. Shaft
A. Inlet port
B. Outlet port
Specifications
Model: TCA452A
Type: s-element, single stage, single phase
Stall torque ratio: 2.60
tj
S-ion X-X
426FOll
WA600- 1
Flow of motive force
* The torque converter is installed between the engine

and transmission. The motive force from the fly-
wheel enters drive case (9). Drive case (9) and pump
(IO) are fixed with bolts. They are rotated directly
by the rotation of the engine.
The motive force of pump (IO) uses oil to rotate
turbine (8). This transmits motive force to transmis-
sion input shaft.
426FO12
Flow of oil
- The oil pressure is adjusted by the torque converter

relief valve and then enters inlet port A, passes
through the oil passage in housing (3) and flows to
pump (IO). In pump (10) centrifugal force is applied.
The oil enters turbine (8) and the energy of the oil is
transmitted to the turbine.
Turbine (8) is fixed to torque converter shaft (1 l), so
the motive force is transmitted to the torque con-
verter shaft (I 1).
The oil from turbine (8) is sent to stator (7) and again
enters the pump. However, part of the oil passes
from the stator through outlet port B and housing (3)
oil port and is sent to the regulator valve (1).
7’
‘11
426FO13
WA600- 1 21-13
TORQUE CONVERTER REGULATOR VALVE
-LuI
Section X-X
426FO14
1. Torque converter relief valve pressure pick up (PT l/8) A. Torque converter inlet port
2. Regulator valve pressure tap (PT l/8) 8. Torque converter outlet port
3. Torque converter outlet oil temperature pick up
4. Regulator spool
5. Spring
6. Valve body
7. Poppet
21-14 WA600- 1
FUNCTION
- The torque converter regulator valve is installed in the

output circuit of the torque converter to regulate the
hydraulic’ pressure inside the torque converter to the
specified pressure.
OPERATION
- The oil from the torque converter flows from port A

to port B. However, the hydraulic pressure at port B
is lower than the tension of spring (5). so spool (4)
does not move.
426FO15
- When the hydraulic pressure at port B becomes higher

than the tension of spring (5), it pushes spool (4) in
the direction of the arrow, and the oil at port A flows
to port c.
TOoil
cooler
From *
torque
converter
426FO16
WA600- 1 21-15
TORQUE CONVERTER RELIEF VALVE
FUNCTION
. The torque converter relief valve acts to maintain

the pressure of the oil entering the torque converter
To eath
at a constant pressure. It drains the oil if it goes transmission Spool
above the specified pressure. /
4 fj
OP‘ERATION
. The oil from the pump passes through main relief

valve (1). It then enters port A and flows to the
torque converter.
transmission converter
lubrication ,.eg,,lator
TIC: Torque converter
426FO3O
. If the oil at port A goes above the specified pres-

To eath
sure, it passes through orifice “a” of torque con-
verter relief valve (2) and enters port B. It then
moves torque converter relief valve (2) to the left.
As a result, the oil from port A is drained, and the
oil flowing to the torque converter is maintained
at the specified pressure.
To torque
transmission converter
T/C: Torque converter

t!!J 426FO31
21-16 WA600- 1
TRANSMISSION
Sactim A - A
Oil level: (Engine stopped1
Oil level: (Engine idling)
I Section B - B
426FO17
1. Coupling 6. Transmission control valve
2. Lubrication bypass valve 7. Oil filler
3. Transmission 8. Drain plug
4. Transfer 9. Strainer
5. Coupling
WA600- 1 21-17
10. Input shaft
11. Sun gear (Teeth 32)
12. Planetary gear (Teeth 29)
13. Reverse clutch
14. Ring gear (Teeth 112)
17. Forward clutch
21. 4th clutch
24. 2nd clutch
25. Hub
26. 3rd clutch
28. Planetary gear (Teeth 21 i
30 1st clutch
31 Ring gear (Teeth 95)
34. Output shaft
35. Carrier
36. Carrier
37. Carrier
38. Carrier
Reverse clutch Forward clutch 4th clutch 2nd clutch 3rd clutch 1 st clutch
426FO18
No.5 No.6
21-18 WA600- 1
Section C - C
OUTLINE
Speed range Clutch combination
The transmission consists of a 4-FORWARD, 4- Fl. No.2, No.6
REVERSE speed planetary gear transmission, trans- F2 No.2, No.4
fer, and transmission control valve. F3 No.2, No.5
In the transmission, the motive force of the input F4 No.2, No.3
shaft is changed by the combination of Forward or RI No.1, No.6
Reverse clutch with lst, 2nd, 3rd or 4th clutch to R2 No.1, No.4
give FORWARD 1 - 4 or REVERSE 1 - 4 speed, R3 No.1, No.5
and is transmitted to the output shaft. Rd No.1 No.3
OPERATION OF CLUTCH
. Engaged
The oil sent from the transmission control valve

passes through the oil passage inside the transmis-
sion. When it reaches the rear of piston (21, it
moves the piston (2).
When the piston (2) moves, disc (4) and Plate (5)
are pressed together. Ring gear (6) is meshed with
disc (4), so the rotation is topped.
423FO18
. Disengages
When the supply of oil from the transmission con-

trol valve is shut off, the pressure of the oil acting
on the rear of piston (2) is reduced. The piston is
then pushed back to the right by return spring (3).
and disc (4) and plate (5) are separated. Ring gear
(6) then rotates freely, and no motive force is
transmitted.
423FO19
WA600- 1 21-19
FORWARD IST
(Power pass)
I
36
Reverse Forward
clutch clutch 4th clutch 2nd clutch 3rd clutch
I. I I I. I. I.
I 7 I 7 I 7 1 . I’
No.1 No.2 No.3 Nd.4 No.5 No.6
426FO19
- In 1st FORWARD, Forward clutch (17) and 1st . Ring gear (18) is held in position by Forward clutch
clutch (30) are engaged. The motive force trans- so the rotation of planetary gear (19) rotates carries
mitted from the torque converter by input shaft (10) (36), which is on the inside of ring gear (18). This
is transmitted to output shaft (34). carrier (36) rotates carrier (37) through ring gear
* Forward clutch (17) is actuated by the hydraulic (23). Ring gear (31) is held by 1st clutch (30), so the
pressure applied to the clutch piston, and it locks ring rotation of sun gear (33) is transmitted to carrier (38)
gear (18) in position. 1st clutch (30) is actuated by through planetary gear (31) and rotate output shaft
the hydraulic pressure applied to the clutch piston (34).
and holds gear (31) in position.
* The motive force from the torque converter is trans-
mitted to the input shaft (IO). The rotation of the
input shaft (IO) is transmitted to planetary gear (19)
through sun gear (16).
21-20 WA600- 1
FORWARD 1ST
(Hydraulic circuit schematics)
Solenoid valve
Main relief valve
Torque converter
regulator valve
Oil cooler
Transmission and
PTO lubrication
w-w
(SAR(4)-125)
Torque converter
charging pump
(SAL=?(B)-100)
Oil filter (3 PCS)
Pilot reducing valve
FORWARD spool
1Stspool
12. Spring
13. Spring
14. Priority valve
426FO34
15. Quick return valve
16. Modulating valve
piston
17. Modulating piston
18. FORWARD clutch
19. 1st clutch
WA600- 1 21-21
OPERATION
When the directional and speed control levers are The other oil line flows from priority valve (14) to
moved to FORWARD lst, solenoid valves (1) and (2) quick return valve (15). It then flows through orifice
are opened. “a”, and directional and speed spools (11) and (IO), and
The oil from the pump is divided into three lines, but flows to the FORWARD clutch and 1st clutch. When
when the gears are being changed, the oil flows main- it starts to flow to the clutch, it passes through orifice
ly to each clutch. “a” and creates a difference in pressure between port
In one of the three lines, the oil passes from main C and port D. Quick return valve (15) moves to the
relief valve (3) through the torque converter. It right, and the oil at the rear of modulating valve
then lubricates the transmission and returns to the piston (16) flows to drain circuit E. When each clutch
transfer case. is filled with oil, the difference in pressure between
. One of the two oil lines flows from the pilot reducing port C and port D disappears. The valve is pushed
valve through the orifice of each speed spool to the back to the left by the difference in area of the
solenoid valve. However, solenoid valves (I) and (2) valves, and drain circuit E is closed:
of FORWARD spool (IO) and 1st spool (11) are open, At this point, each clutch is filled with oil, but the oil
so the oil passing through the orifice flows to the has not reached the specified pressure. The oil at
drain circuit. As a result, a difference in pressure is port D flows through orifice “b” and reaches the
created between port A and port B, and this over- back of modulating piston (16). The piston (16)
comes the force of springs (12) and (13). The port to moves to the right and the clutch pressure rises slow-
the clutch is then connected. ly. When the modulating piston reaches the end of its
stroke, the clutch pressure reaches the specified level,
and the clutch is completely engaged.
21-22 WA600- 1
0 .
TRANSMISSION CONTROL VALVE
426FO24
1. Pilot reducing pick-up 9. Priority pressure pick-up
2. Lower valve 10. Reducing pressure pick-up
3. Upper valve 11. Modulating pressure pick-up
4. Main relief valve 12. Accumulator pressure pick-up
5. Pilot oil filter 13. Transmission solenoid valve (See page 21-35)
6. Torque converter relief pressure pick-up 14. Emergency manual spool
7. Transmission lubricating pressure pick-up 15. Connector
8. Main relief pressure pick-up
WA600- 1 21-23
UPPER VALVE
l-
1 valve valve
OUTLINE
SectionC -C 426F02$A-K
The oil from the torque converter charging pump The other oil line flows to the modulating valve (6)
enters port A of main relief valve, and passes and quick return valve (5). The action of the modu-
through the priority valve (7) via by main relief lating valve (6) and quick return valve (5) raises the
valve (3). It is then divided into three lines; there clutch pressure smoothly. This reduces the shock
are; to the clutch pistons, to the pilot reducing valve when actuating the FORWARD, REVERSE and lst,
(9) and main relief valve. The priority valve (7) acts 2nd, 3rd, and 4th speed clutches to change gear.
to control the three lines so that the pilot reducing The accumulator valve (11) controls the oil flow at
valve (4) is the priority circuit. the 2nd clutch and reduces the filling time when
The oil flowing to the pilot reducing valve (4) con- shifting from 2nd to 1st or 3rd gear.
trols the pilot pressure used to actuate the direc- The lubrication valve (15) controls the lubrication
tional and speed spools. The oil regulated by the oil inside the transmission.
pilot reducing valve (4) presses through the orifice
in each spool and fills the spool.
21-24 WA$OO- 1
0
LOWER VALVE
16
425FO28
Section B - B
1. Piston 7. Priority valve 13. FORWARD spool
2. Torque converter relief valve 8. Housing 14. Reducing valve
3, Main relief valve 9. 1st spool 15. Lubrication valve
4. Pilot reducing valve 10. 2nd spool 16. REVERSE spool
5. Quick return valve 11. Accumulator (for 2nd) 17. 4th spool
6. Modulating valve 12. Pilot filter 18. 3rd spool
WA600- 1 21-25
MAIN RELIEF VALVE
Function
. The main relief valve acts to supply the necessary oil
to the clutch when shifting gear. When the gears
are not being shifted, it sends all of the oil directly
to the torque converter.
Operation
. The oil from the pump passes through the oil filter
and enters port A of main relief valve (I).
. Until the specified pressure is reached, the oil flows
to the priority valve.
To torque convener
regulhtor valve
426FO27
. When the pressure goes above the specified level, oil

passes through the orifice in relief valve (1). pushes
poppet (21, and moves relief valve (1) to the left.
The oil is relieved to the torque converter, so the
specified pressure is maintained.
* Specified pressure: 30 kg/cm2
To torq& converter
426FO28
regulator valve
21-26 WA600- 1
PRIORITY VALVE
Function
. The .priority valve (1) controls the minimum pres-
sure of the pilot reducing valve (2). In addition, the
priority valve (I) gives the oil flow to the pilot
reducing valve (2) priority over the other circuit.
Operation
. The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
To modulating valve To each transmission spool
IZ) To main relief valve
425FO35
The oil entering port A flows from orifice “a” of

priority valve (I) to port D. The hydraulic pressure
and force of poppet spring (3) push back spring (4)
and move priority valve (I) to the right.
When this happens, port A and port C are connect-
ed, and the oil flows from port C to the clutch
spool.
To modulating valve To each transmission spool
425FO36
WA600- 1 21-27
MODULATING VALVE AND QUICK RETURN VALVE
Function
(kg/cm’ 1 C
. The modulating valve and quick return valve act 40- Shifting gear
together to raise the transmission clutch pressure
slowly. In this way, they reduce the shock when
30
shifting gear, and prevent the generation of peak
torque in the power train. As a result, operator
s 20
fatigue is reduced, and at the same time, operator D
comfort and the durability of the power train are E
increased. 8 10
0- 1 .o
0 0.5
Time (second)
1) Immediately after shifting gear (Point A on Fig. 426FO29)
pilot
ucing valve
425 F037
Operation
. The oil sent from the pump flows from priority sure between port B and port C. The quick return
valve (I) through port A, passes through modulating valve moves to the right and the oil flows to clutch
valve (2). and enters port B of quick return valve (5). In addition, when quick return valve (3) moves
(3). The oil passes through orifice “a” of quick to the right, drain port D is opened, and the pres-
return valve (3) and flows to the clutch piston, surized oil at the rear of piston (4) flows to the
which has been actuated. However when it passes drain circuit.
through orifice “a” it creates a difference in pres-
21-28 WA600- 1
2) Clutch pressure rising (Point B on Fig. 426FO29) Operation
. AS the pressure at the clutch piston rises, the pres-
sure at port C also rises. Quick return valve (3) is
pushed back to the left and drain port D is closed.
The oil from the pump flows from port C to the
clutch piston and at the same time it flows from
orifice “b” through quick return valve (3) and
enters port E.
The oil at port E acts on the modulating piston (4).
It pushes back spring (6) and moves piston (4)
to the right.
At the same time, pressurized oil also passes thorugh
the orifice and enters poppet (7) of modulating
valve (2). It moves modulating valve (2) to the left
and some of the oil at port A flows to port G.
To solenoid valve
425FO38
3) Completion of rise in clutch pressure Operation

(Point C on Fig. 426FO29) . The oil entering port E continues to push piston (4).
When the piston reaches the end of its stroke, the
rise in pressure stops. When this happens, the pres-
sure reaches the set pressure of the modulating
valve. In addition, port F and port G are closed
by piston (4).
To solenoid valve
, pilot reducing
“B
425FO39
WA600- 1 21-29
REDUCING VALVE
Function
. The reducing valve is in the circuit between the
quick return valve and the 2nd spool. It reduces the
pressure applied to the 2nd clutch.
The maximum pressure in the main circuit is kept to
the specified level by the main relief pressure.
Operation
. The oil from the quick return valve enters port A
and then flows from port 6 to 2nd
. When the circuit to the 2nd clutch is filled with oil

and the hydraulic pressure rises, the oil from port B
which flows through orifice a to port C pushes
From pilot
poppet (3). The reaction to this compresses spring reducing valve
(4) and moves reducing spool (1) to the left. 425FO40
As a result, port A and port B are closed, and the oil
stops flowing.
The hydraulic pressure at this point is 17 kg/cm2.
From pilot
reducing valve
425FO41
21-30
ACCUMULATOR VALVE
Function
. The accumulator valve acts to escape slowly when
shifting from 2nd to 1st. This allows the clutch to
be engaged smoothly when shifting from 2nd to 1st.
1. Shiftirig to 2nd
* When shifting to 2nd gear, the oil from the pump

passes through the reducing valve and enters pot-t
A of the 2nd spool (5). When the 2nd spool
moves, port A and port B are connected and the
oil flows to port C.
The oil at port C flows from check valve (2) and
orifice “a” to port D. From reducing valve
From pilot reducing valve 423FO39
- As the pressure of the oil entering port D rises,

the oil continues to push piston (3) to the left
until stops.
At the same time, oil is sent to the clutch piston
and actuates 2nd clutch (4).
From reducing valve
423FO40
From pilot reducing valve
WA600- 1 21-37
2. Shifting from 2nd to 1st
- The oil from the clutch piston of 2nd clutch (4)

enters port D and acts on the rear of the check
valve (2). The oil from port D passes through
orifice “a” and flows to the drain circuit. In
this way the shock when shifting gears can be
reduced.
From reducing valve
From pilot reducing valve 423FO41
21-32 WA600-
PILOT REDUCING VALVE
Function
. The pilot reducing valve acts to control the pressure
needed to actuate the transmission spools.
Operation
. The oil from the pump passes through the pilot
filter and enters port A of pilot reducing valve (1).
The oil passes through port B and enters through
the orifice of transmission spool (2) to fill the inside
of port C.
relief valve
425 F033
. When the pressure inside port C rises, pressurized

oil flows from orifice “a” of pilot reducing valve (1)
and goes to port D.
As a result, pilot reducing valve (1) moves to the
right, and port A and B are shut off, so the pres-
surized oil at port C is . . d at the same
pressure.
,@gTo main relief valve
425FO34
WA600- 1 21-33
TRANSMISSION SOLENOID VALVE
Forward
3rd
2nd
A-A
1. 1st solenoid valve 6. REVERSE solenoid valve Actuation table solenoid valve
2. 2nd solenoid valve 7. Body and
3. 3rd solenoid valve 8. Emergency manual spool
4. 4th solenoid valve 9. Connector
5. FORWARD solenoid valve
STRUCTURE
. The valve installed to

with
When the lever speed control lever
operated, the valve actuated and moves
spool inside the transmission
WA600- 1
FUNCTION
. There is one solenoid valve installed for each direc-
tional and speed spool in the transmission valve.
When the directional lever and speed control levers
in the operator’s compartment are operated, the
solenoid valve is actuated, and oil is drained to
actuate the directional and speed spools.
OPERATION
1) Solenoid valve OFF
The oil of spool (1) enters port A. However, valve
(2) shuts off the oil, so directional and speed spool
(1) does not move.
From quick return valve
reducing valve 2 * 1
423FO31
2) Solenoid valve ON
When the directional and gear shift lever are operat-
ed, the solenoid valve is pulled up.
The oil from directional and speed spool (1) enters
port A and flows from port B to the drain circuit.
Therefore, port A becomes the low pressure circuit,
and directional and speed spool (1) is actuated.
A B
423FO32
WA600- 1 21-35
EMERGENCY MANUAL SPOOL
FUNCTION
If there is any failure in the electrical circuit of the
transmission control system, and the solenoid valve
does not work, the emergency manual spool is used.
This spool is attached to each directional and speed
spool and is used to operate the transmission valve
mechanically. (It is used to drive the machine to a
place where it can be repaired.)
* Particular attention must be paid for when
using this spool.
OPERATION
1. When solenoid valve is normal: From quick
(Emergency manual spool is at normal position) return valve
When the solenoid valve is working normally, the

spool is maintained in this position.
Oil from directional and speed spool (1) enters port
A, but it is shut off by solenoid valve (2).
423FO44
2. When solenoid valve is abnormal:
a. Clutch in disengaged position
(Emergency manual spool is pushed to the left)
Emergency manual spool (3) is pushed to the
left, and the oil at port A is shut off regardless
of the action of solenoid valve (2). The oil
cannot flow to port B, so the clutch is not
actuated.
From
reduc
423FO45
b. Clutch in engaged position
(Emergency manual spool is pulled to the right)
When emergency manual spool (3) is pulled to From quick
the right, the oil at port A is drained to port B
regardless of the operation of solenoid valve
(2). As a result, the clutch is actuated.
reducing valve
423FO46
21-36 WA&OO- 1
0
TRANSFER
OUTLINE
. The transfer is installed at the power output end of

the transmission and is secured to the transmission
case by’bolts.
TRANSMISSION PATH
. Output shaft (1) of the transmission is coupled to

transfer input gear (2) by a spline. The motive force
is transmitted to output gear (4) through idler gear
(3) and output shaft (5). 1. Transmission output shaft
Part of the power transmitted to the output shaft is 2. Transfer input gear (teeth 46)
transmitted to the front axle through the center 3. Transfer idler gear (teeth 39)
drive shaft and front drive shaft. The rest of the 4. Idler gear
power is transmitted to the rear axle through the 5. Output shaft
rear drive shaft. 6. Rear coupling

7. Strainer
8. Output gear (teeth 43)
9. Front coupling
From
C transmission
output shaft
To
front
426FO38
WA600- 1 21-37
DRIVE SHAFT
OUTLINE
. The motive force from the engine passes through . When the body is articulated, or when there is shock
the torque converter, upper drive shaft (5), trans- from the road surface during traveling, or when
mission and transfer. Part of this motive force there is shock during operations, the axle in front
passes through rear drive shaft (4) and goes to the and behind the engine and transmission change
rear axle; the rest of the motive force passes through position.
center drive shaft (3), center support (2) and front To allow the motive force to be transmitted without
drive shaft (1) and is sent to the front axle. In addi- damage to parts of the machine when there is shock
tion to transmitting the motive force, the drive or when the components move position, the drive
shafts have the following purposes. shafts have a universal joint and a sliding joint.
This allows them to handle changes in angle and
length.
426FO40
1. Front drive shaft 4. Rear drive shaft
2. Center support 5. Upper drive shaft
3. Center drive shaft
WA600- 1
CENTER SUPPORT
Section A - A
426FO41
1. Front coupling FUNCTION

. The center support is installed to the front frame
2. Case
between the center drive shaft and the front drive
3. Grease nipple
shaft.
4. Rear coupling . With the articulating frame, this part is constantly
twisting from side to side, so there is liable to be
large stress on the drive shaft. Therefore, the center
support is used to transmit the power smoothly, to
reduce the stress on the drive shafts, and in this way
improve the durability of the drive shafts.
WA600- 1
AXLE MOUNT
----- Tzz=
426FO48
__I ,
Section B-6 Section A-A F42601013- 1
21-40 WA600- 1
8
View Y
View Z
426FO49
1. Front axle Front axle
2. Rear axle
. The front axle (1) receives the force directly during
operations, so it is fixed directly to the front frame
3. Front frame
(3) by axle mounting bolts (5).
4. Rear frame
6. Axle mounting bolt Rear axle

. The rear axle (2) has a structure which allows the
center of the rear axle to float, so that all tires can
be. in contact with the ground when traveling over
soft ground.
WA600- 1 21-41
AXLE AND DIFFERENTIAL
. The motive force from the engine passes through * Inside the axles, the motive force passes from the
the damper, torque ‘converter, transmission, trans- bevel pinion to the bevel gear and is sent at right
fer, and drive shafts, and is then sent to the front angles. At the same time, the speed is reduced and
and rear axles. passes through the front differential (1) to the axle
shaft. The motive force of the axle shaft is further
reduced by a planetary-gear-type final drive (4) and
is sent to the wheels.
FRONT AXLE
426FO42
1. Front differential
2. Front axle
3. Brake (See page 51-I 8)
4. Final drive (See page 21-47)
5. Spring cylinder
6. Parking brake
\ View Z
21-42 1
FRONT DIFFERENTIAL
L-J
LJ
SectionY - Y
426FO43
1. Pinion (Differential) (Teeth 15) 4. Bevel gear (Teeth 43)
2. Bevel pinion (Teeth 8) 5. Side gear (Differential) (Teeth 22)
3. Shaft
WA600- 1 21-43
0
REAR AXLE
ii
1. Rear differential
2. Rear axle
426FO44
View Z
3. Brake (See page 51-18)
4. Final drive (See page 21-47)
5. Drain plug
21-44 WA600- 1
REAR DIFFERENTIAL
SectionY- Y
Section X - X
426FO45
1. Bevel pinion (Teeth 8) 4. Shaft
2. Bevel gear (Teeth 43) 6. Side gear (Differential) (Teeth 22)
3. Pinion (Differential) (Teeth 15)
WA600- 1 21-45
0
OUTLINE
. The motive force from the drive shaft passesthrough
bevel pinion (1) and is transmitted to the bevel gear
(5). The bevel gear changes the direction of the
motive force by 90”, and at the same time reduces
the speed. It then transmits the motive force
through the differential (4) to the sun gear shaft (2).
423FO59
When driving straight forward

. When the machine is driven straight forward, the
rotating speed of the left and right wheels is the
same, so the pinion gear (4) inside the differential
assembly (6) is sent through the pinion gear (4)‘and
the side gear (3) and is transmitted equally to the
left and right sun gear shafts (2).
423FO60
When turning
. When turning, the rotating speed of the left and
right wheels is different, so the pinion gear (4) and
side gear (3) inside the differential assembly rotate
in accordance with the difference between the
rotating speed of the left and right wheels. The
motive force of the carrier (6) is then transmitted
to the sun gear shafts (2).
423FO61
21-46 WA600- 1
FINAL DRIVE
OUTLINE OPERATION
* To gain a large drive force, the final drive uses a plan- - The motive force transmitted from the differential
etary gear system to reduce the speed and send drive through axle shaft (1) to sun gear (2) is transmitted
force to the tires. to planetary gear (5). The planetary gear rotates
around the inside of a fixed ring gear (3) and in this
way transmits rotation at a reduced speed to the
planetary carrier (4). This motive force is then sent
to the wheels (5) which are installed to the planetary
carriers (4).
426FO46
1. Axle shaft 4. Planetary carrier
2. Sun gear (Teeth 19) 5. Wheel
3. Ring gear (Teeth 71) 6. Planetary gear (Teeth 25)
WA600- 1 21-47
TIRE AND WHEEL
OUTLINE
The to absorb the shock from the ground SPECIFICATIONS

surface to the machine, and at the same time they . Tire type: 35/65-33-24PR
must rotate in contact with the ground to gain the
. TRA code: L4
power which drives the machine.
Various types of tires are available to suit the pur- * Nominal size of wheel: 28.00 x 33 WTB
pose. Therefore it is very important to select the . Normal inflation pressure: 4.0 kg/cm2
correct tires for the type of work and bucket
capacity.
426FO50
1. Tire
2. Rim
3. Air valve
4. Lock ring
5. Side ring
21-48 WA600- 1
POWER TRAIN.
Standard value table .. .. 22- 2

Tool list for testing and adjusting 22- 3
Measuring engine stall speed . 22- 4
Measuring oil pressure of torque
converter and transmission .. . 22- 6
Measuring speed lever . . 22. 8
Method for operation of emergency
manual spool .. ...... 22- 9
Tire and wheel ... . . . 22-10
Troubleshooting . . . .. 22-11
* The following precautions are necessary when using the Standard Value Tables to make judgements during trouble-
shooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values based on the
standard values for the machine when shipped from the plant, and on the results of various test.
Therefore, they should be used as reference in combination with repair and operating records when making
judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do not use
these values alone to make simple judgements.
WA600- 1 22-1
is)
Testing and measuring iterr Measurement condition Unit Standard value Permissible value
Shift lever operating force - Torque converter oil

and travel temperature: 60 - 80°C
* Directional lever operat-
- Engine speed: Engine stop
ing force
N-F kg 0.3 - 0.9 Max. 1.4
N-R 0.3 - 0.9 Max. 1.4
* Speed lever operating
force
1st - 2nd kg 0.3 - 0.9 Max. 1.4
2nd - 3rd 0.3 - 0.9 Max. 1.4
3rd - 4th 0.3 - 0.9 Max. 1.4
* Directional lever travel
N-F mm 32-42 27 -47
N-R 32-42 27 - 47
- Speed lever
Ist-2nd-3rd-4th mm 32 - 42 27 - 47
Engine stall speed . Coolant temperature:

Inside operating range -
- Low idling wm 630 - 680
- High idling * Torque converter oil
2100 - 2200 -
temperature: 60 - 80°C
- Torque converter stall 1920 - 2070 1820 - 2220
- Hydraulic oil temperature:
- Hydraulic stall 45 - 55°C 1790 - 1990 1690 - 2090
- Full stall 1420 - 1620 1220 - 1820
Oil pressure of torque . Torque converter oil

converter and transmission temperature: 60 - 80°C
- Pilot reducing pressure - Coolant temperature: g/cm2 9.8- 11.8 9.8 - 11.8
Inside operating range
* Modulating pressure
(except F2, R2) It high idling: 29-32 29 - 32
- Reducing valve pressure

(for F2, R2) It high idling: 16-19 16-19
- Lubrication oil pressure l-3 1-3

* Torque converter outlet 1.8 - 2.4 1.8 - 2.4
pressure
Tire and wheel * Tire inflation pressure:

Specified pressure
* Fitting of wheel lock ring
(A) mm Max. 2.5 -
(5) Max. 4.0 -
- Clearance of wheel lock
ring
(C) 2- 15 -
Q-ring
F42301008
423F309A
WA600- 1
2$2
TOOL LIST FOR TESTING A-ND ADJUSTING
No. Testing and measuring item Tool Name Part No. Remarks
1 Engine speed Tachometer 799-203-8000 Digital display 60 - 19999 rpm
2 Oil temperature Thermistor kit 799-l 01-6000 0 - looo”c

I I I
3 Oil pressure Hydraulic tester 799-l 01-5000 0 - 25 kg/cm’

0 - 50 kg/cm*
I I ! I
Pedal and lever
4 Push-pull gauge 79A-262-0200 0 - 25 kg
operating force
5 Measuring clearance Feeler gauge Commercially available 0.1 - 3.0 mm
A When carrying
on the frame,
out testing,
lower the bucket
adjusting or troubleshotting,
to the ground,
stop the machine
and stop the engine.
on level ground, install the safety bar
Then apply the parking brake and block the tires.
A Do not allow unauthorized persons near the machine.
When measuring the engine speed, one worker should measure the engine speed while the other sits in the OP-
A
erator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.
A Be careful not to get caught in rotating parts.
WA600- 1 22-3
0
MEASURING ENGINE STALL SPEED
Coolant temperature: operating range.
- Hydraulic oil temperature: 45 - 55’C
- Torque converter oil temperature: 60 - 80°C
Special tools
A / 799-203-8000 Tachometer I 1
B 799-l 01-6000 Thermistor kit 1
Check that the low idling and high idling speeds are
Before measuring the rpm at each stall, install tool A
on output port (1) of tachometer.
Check that the engine speeds are the standard value.
If any item is outside the permitted range, check
for any looseness for play in the linkage.
A Block the tires
1. Measuring torque converter stall

1) Start engine and run at low idling.
2) Put the directional lever in FORWARD or
REVERSE, and speed control lever (3) in the
highest speed range.
3) Using the brake, stop the machine and measure
the engine speed when the engine reaches accel-
erator pedal depress fully.
* Turn the transmission cut-off selector
switch (2) to OFF, and use the left brake.
(Check that the pilot lamp is OFF).
* Do not run at stall speed for more than 20
seconds, and do not let the torque converter
oil temperature rise above 120°C.
22-4
@
2. Measuring hydraulic stall
1) Start engine and run at high idling.
2) Operate the dump (5) or lift control lever to
move the cylinder to the end of its stroke and
actuate the relief valve of the main control valve.
3) Measure the engine speed at this point.
* Do not run the engine at stall speed for
more than 20 seconds, and operate the
control lever quickly.
3. Measuring full stall

Measure the engine speed when torque converter
stall and hydraulic stall are reached at the same
time.
* Measure full stall when both the torque con-
verter and hydraulic stall speeds are normal.
If either stall speed is abnormal, remove the ab-
normality and measure the stall speed again.
WA600- 1 22-5
!,p
\...I
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND
TRANSMISSION
* Measurement conditions
- Coolant temperature: Inside operating range
- Torque converter oil temperature: 60 to 80°C
Special tool
I Part No. I
A 1 799-l 01-5000 Hydraulic tester I 1
A Apply the parking brake and block the tires.
Measuring procedure
* The follo\;ving preparatory work is necessary before
measuring any oil pressure.
- Remove cover (I) on rear side of the cab.
* Turn the transmission cut-off selector switch (2)
to OFF and use the left brake. (Check that the
pilot lamp is OFF.)
* Remove the plug from the measuring port of the
transmission valve.
- Install hydraulic tester A to the measuring port,
pull the gauge to the operator’s compartment,
then start the engine and measure the pressure.
* Check that there is no leakage of oil from any joints.
P3
Pl
426F257.1
22-6 WA600-1
@I
1. Measuring pilot reducing pressure
1) Measuring port (P5).
2) Put the directional lever in neutral, and measure
the pressure when the speed control lever is
operated.
2. Measuring modulating pressure

1) Measuring port (Pl).
2) Put the directional lever in neutral, and measure
the pressure when the speed control lever is
operated.
* Measure pressure except F2 and R2.
Torque converter relief pressure

2) Start the engine and measure the pressure at.
high idling.
Measuring lubrication valve pressure

2) Start the engine and measure the pressure at
high idling.
Measuring reducing valve pressure

high idling and low idling.
6. Torque converter outlet pressure

high idling and low idling.
426FO1103
WA600-1 22-7
0
MEASURING SPEED LEVER
- Engine speed: Stopped
* Put marks a for dimension A and dimension B of the

control levers.
- Dimension A (directional lever, N position):
72.5 mm
. Dimension B (speed lever, 2 position): 91 mm
A Put blocks under the wheels to stop the ma-

chine from moving.
426FO1102
MEASURING OPERATING FORCE OF

LEVER
1. Stop the engine.
2. Install push-pull scale @

a of lever (I), measure
the force when lever is in the
of operation.
Carry out measurement in speed range.
TRAVEL OF
1. Stop engine.
2. the travel marked portion of con-

lever (1) moved in direction of
22-8 WA600- 1
0
METHOD FOR OPERATION OF EMERGENCY MANUAL
SPOOL
OUTLINE
. The transmission valve is controlled electrically.

Therefore, the emergency manual spool is installed
to enable the machine to be moved if there is any
failure in the electrical system, or in the solenoid
valve and spool.
a The
failure
emergency manual spool is for use when
in the transmission control prevents the
t
machine from being moved. It allows the

PO44
machine to be moved from a dangerous place to
a place where repairs can be carried out safety.
The emergency manual spool must never be
used except when the transmission control has
broken down.
When operating the emergency manual spool,

B
follow the correct order of operation exactly,
and pay full attention to safety when moving
the machine.
To prevent the machine from moving, lower the

L5
bucket to the ground, apply the parking brake,
and block the wheels. Check that the pressure
inside the air tank is above the specified pres-
sure.
1. Open cover (1) on rear side of cab.
2. Remove lock plate (2) of the emergency manual

spool (3) of the transmission valve.
t Simply loosen the mounting bolts to remove
the lock plate.
3. Decide the direction to move the machine (forward

or in reverse), then move the emergency manual
spool to the operating position.
Fow.&d 4th 3rd 2nd
spool spool spool spool SD001
FORWARD: Rotate FORWARD clutch spool and
1st spool counterclockwise, and pull 425F204
out approx. 10 mm to the operating
position.
REVERSE: Rotate REVERSE clutch spool and

1st spool counterclockwise, and pull
out approx. 10 mm to the operating
position.
421 F203
WA600- 1 22-9
4. Check that the area around the machine is safe,
remove the blocks from under the wheels.
5. Sit in the operator’s seat, and depress the left brake

pedal fully.
6. Start the engine, release the parking brake, then re-

lease the brake pedal gradually to start the machine.
LI When the engine is started, the transmission is

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

the parking brake, and block the wheels.
8. Return the emergency manual spool to the neutral

position, and install the lock plate.
TIRE AND WHEEL

- Tire
Unit: kg/cm’
Permissible
Item
value
A Max. 2.5
Fitting of wheel
lock ring
B Max. 4.0 -
Clearance of C 2-15
wheel lock ring
O-ring
I
F42301008
Measuring procedure
1. Fitting of wheel
Measure distances A and B at four places around
the circumference.
2. Clearance of wheel lock ring

Measure dimension C.
423F309
22-10 WA600- 1
0
TROUBLESHOOTING
Precautions when troubleshooting .. . . . . . . . 22-12

Method of reading troubleshooting table . . . . . . 22-14
Preventing recurrence of trouble . . . . . . . . . . . Z-16
Method of locating main problem points when
troubleshooting transmission system . . _. . . 22-17
Troubleshooting . . . . . . _. . . . . .
table . .. . _ 22-18
1. Machine does not move . . . . . . . . . . .. . . 22-18
2. Machine lacks power or speed . . . . . . .. . . 22-20
3. Excessive timing lag when starting
machine or shifting gear . . . _. . . . . _ . . 22-21
4. Torque converter oil temperature
too high . . . . . . . . . . . . . . . . . . . . . . . . 22-22
WA600- 1 22-11
0
PRECAUTIONS WHEN TROUBLESHOOTING
1. SAFETY
* Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied,
B
and that the tires are blocked.
* When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
* Be careful not to get burned by hot parts or to get caught in rotating parts.
- Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wir-
ing.
* Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure,
and connect all measuring tools correctly.
2. METHODS FOR TROUBLESHOOTING

* Just because a failure occurs, do not immediately start to disassemble the machine.
If the machine is disassembled before making the proper checks.
- The machine may be disassembled in such a way that the problem cannot be located, so the cause of the
problem will be unknown.
As a result,
* The customer and operator will lose confidence in you.
- Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems, use the following procedure when troubleshooting.
1. Ask the customer and operator the following questions about the breakdown.
a. Have there been any other problems apart from the one reported?
b. Was there anything usual before the machine broke down?
c. Did the breakdown occur suddenly, or had there been signs of trouble before?
d. What was the machine doing when the breakdown occurred?
e. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?
f. Had the same kind of failure occurred before?
2. Check the following items which can be checked simply by visual checks, etc.
a. Check oil level.
b. Check for leakage of oil from piping or hydraulic equipment.
c. Check travel of control levers.
d. Check stroke of spool in control valves.
3. Reenact the failure and check the condition of the machine (particular conditions at the time of failure).
a. Ask the user or operator if the decision about the failure was made based on measured values, or by com-
parison, or by feeling.
b. Compare extent of failure with standard values.
- Check safety before carrying out any check.
- Did not make any check or measurement that will make the conditon worse.
4. Try to locate the possible causes for the failure.
The transmission system consists of the transmission itself, the transmission control valve, and the transmis-
sion electric control.
In particular, when trouble occurs in the transmission system, the probable location of the failure can be
divided as follows.
- Transmission itself, or transmission control valve.
+ Transmission electric control.
To decide which of the two is the location of the failure, go to page 22-l 7.
22-l 2 WA600- 1
0
5. Carry out troubleshooting using the troubleshooting charts.
There are the following two types of troubleshooting charts.
1. TROUBLESHOOTING TABLE . . . . _ . . . . . . . 22 POWER TRAIN,
42 STEERING SYSTEM,
52 BRAKE AND AIR SYSTEM,
62 WORK EQUIPMENT SYSTEM
2. TROUBLESHOOTING FLOW CHART. . . . . . . 82 ELECTRIC AND ELECTRONIC SYSTEM
The troubleshooting charts consist of:
1) Items which can be checked easily.
2) Items which are likely to be the cause of such failures.
Follow these charts to carry out troubleshooting.
At the same time, do not forget the following points.
- Check related items.
- Check that there are no other failures or breakdowns.
* For details of troubleshooting tables, see page 22-14.
6.
3.
- Carry out the various testing and adjusting while observing the items on quality control given in “Testing and
Adjusting”.
part.
- When installing or assembling, clean off all dust and dirt and repair any scratches or dents.
Remove all grease or oil before coating with gasket sealant.
22-13
0
METHOD OF READING TROUBLESHOOTING TABLE
DESCRIPTION OF SYMBOLS USED IN TROUBLESHOOTING TABLE
The following symbols are used in the “Remedy”

column to indicate the method of eliminating the
cause of a fault.
X: Replace; A: Repair;
A: Adjusting; C: Clean
METHOD OF READING TROUBLESHOOT-

ING TABLE
The symbol 0 in the table is inserted only for causes

which can be diagnosed. If a cause cannot be diag-
nosed, the corresponding box is left blank.
If the result of problems 1 using the troubleshooting

table shown at right is abnormal, the cause of the
trouble can be assumed to lie between “a” and “d”.
Because it is not possible to make a problems regard-
ing”e”, it is necessary to perform the next problems
(owing to the possibility of a multiple fault).
If the result of problems 1 is normal, the cause of the
fault does not lie between “a” and ‘Id”. In such a
case, before diagnosing the cause as “e”, however,
carry out a check by means of problems 2 or 5.
If now the result of problems 1 is abnormal and the
result or problems 2 normal, the cause is one of “a”,
“b” or “d”. In addition, if the result of problems 3 is
abnormal, the cause will be narrowed down to one of
“b” or “d”. To determine which of “b” or “d” is the
actual cause, perform problems 4.
If the result of problems is abnormal, blacken out the
corresponding 0 in the table and then perform the
Not necessary
next problems on these causes in order to narrow the problems
likely causes.
Example 1 :
Problem 1 + Abnormal
From the table of ex-
Problem 2 + Normal Example 2
Problem 3 + Abnormal ’ ample ” the cauSeOf
the fault is “b”.
Problem 4 + Normal
Example 2: Not
Problem 1 + Normal
ample 2, the cause of
Problem 2 -+ Abnormal the fault is ,,e,,
* In example 2, it is evident that the cause is “8”

without carrying out problems 2, however pro-
blem 2 is performed by way of an additional
check.
22z4 WA600- 1
Example 3:
Problem 1 + Abnormal From the table of ex-
Problem 2 + Abnormal ample 3, the cause is
Problem 3 + Normal one of “a”, “c” and
’
e
I, I,
Continue problems

Problem 4 -+ Normal
ample 3-1, the cause is
Problem 5 + Normal
“C‘I.
Example 4:
Problem 1 + Abnormal
ample 4, the cause is
Problem 2 + Noraml
one of “a”, “b” or “d”.
Cont;nue problems
4
Problem 3 -+ Abnormal From the table of ex-
Problem 4 --f Abnormal ample 4-1, the cause is
Problem 5 + Normal “a” or “d”.
As can be seen from the above examples, it is not neces-

sary to perform all of the problems.
Also, looking at a particular cause, no matter how many
l marks there are in the column corresponding to that
cause, it will cease to be an actual cause if there is even
one 0 mark is the same column.
WA600- 1 22-15
0
PREVENTING RECURRENCE OF TROUBLE
The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equip-
ment. It is not able to establish the root cause of the damage or failure, however.
Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not
mention what action should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while
referring to the following items.
Regarding the method of checking and adjusting each part or piece of equipment, refer to “Testing and adjusting” in
the Shop Manual.
HYDRAULIC EQUIPMENT
1. Oil checks 3) Oil cleaning and replacement

. The fundamental cause of almost all faults occurr- - If a large amount of metal particles or other
ing in hydraulic equipment is the inclusion of water, foreign matter is discovered in the oil, either
air or other foreign matter in the oil. Accordingly, wash the oil using an oil refresher or replace it.
it is necessary to check the oil to see whether or * If the oil is contaminated by water, it is
not it contains any of the above substances, and not possible to remove the water by means
then take appropriate action. of an oil refresher.
1) Oil checks * When washing the oil, also wash or replace
. Check for water ingress the strainer and replace the filter.
Check the oil for possible water ingress by
means of a diesel engine oil checker or a hot 2. Cleaning fragments of damaged parts
plate. - If a part becomes damaged, fragments may pass
- Check for ingress of other foreign matter into the oil line. It is thus necessary to wash the oil.
Remove the drain plug and filter, then check - In addition, disassemble and wash such parts as
the bottom of the tank and also the filter to valves and cylinders which are liable to collect
see if any foreign matter has collected there. metal fragments and other foreign matter, thus
Check the degree of contamination by means helping to prevent a recurrence of faults due to
of a contamination checker. such fragments becoming lodged in various parts
. Viscosity check of the engine or hydraulic equipment.
Check the viscosity of the oil using a visco-
meter in order to confirm whether or not the
oil is satisfactory.
2) Check of ingress point
If, as a result of the above checks, it is dis-
covered that the oil is contaminated by water
or other foreign matter, it is necessary to find
out where the contamination is occurring and
also the take steps to prevent it.
Water: Oil storage tank, breather, etc.
Stand: Oil replenishing or replacing meth-
od, etc.
Rubber: Cylirrder packing, etc.
Metal: Wear or damage to hydraulic
equipment such as pump and
motor, as well as transmission
and torque converter, etc.
WA600- 1
22G’6
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN
TROUBLESHOOTING TRANSMISSION SYSTEM
The problem points in the transmission system can be broadly divided into the following two areas.
1. Transmission itself and transmission control valve.
2. Transmission electric control.
Use the following method to decide which of the two areas has the problems.
Problem: Machine will not start.

Machine will only travel in one direction. (FORWARD or REVERSE)
Cause Remedy
2 YES
c Replace transmission control
Does machine move valve
Y ES if screw of
emergency spool -
1 forForRa”dlstis
pushed in?
Isvoltage and c Go to TroubleshootIng for
resistance of F or R NO transmission
solenoid correct? (See page 22-18 - 22-22)
1) Voltage 20 - 30V.
2) &s;z~nce approx.
Go to Troubleshooting for
electrical system of
transmission
(See page 82-38 - 82-43)
Problem: Machine will not move in certain speed ranges
Replacetransmission
control valve
YES
transmission
solenoid for problem LSee page 22-l 8 - 22-22)
speed range correct?
1)Voltage 20 - 30V.
2) Resistance approx.
electrical system of
transmission
(See page 82-38 - 82-43)
WA600- 1 22-17
0
TROUBLESHOOTING TABLE
1. Machine does not move.
Ask the operator the following points.

* Did the machine suddenly stop moving?
Yes = Component seized or damaged.
* Was there any abnormal noise when the ma-
chine stopped moving?
Yes = Comoonant broken.
Checks before troubleshooting

- Is oil level in transmission case correct?
- Is monitor display normal?
* Is drive shaft broken?
NO.
Remedy
A X A
x x
Problems X
I I I I I I I
Machine will not move when T/C oil temperature rises.
Transmission
7 Indicator fluctuates violently. 0
8 Pilot pressure defective 0
Note 1: If the solenoid valve and hydraulic pressure

are normal, the “I” in the Causes column in-
dicates that the valve spool does not work.
Note 2: If the transmission clutch pressure is low,
but the cause cannot be found in the above
table, a possible cause is cracks in the valve
or transmission.
22-18 WA600- 1
0
The following symbols are used to indicate the action
to be taken when a cause of failure is located.
WA600- 1 22-19
0
2. Machine lacks power or speed

* Is oil level in transmission case correct?
- Is there any leakage of oil from joints of piping
or valves?
- Is parking brake or brake locked?
Checking for abnormalities

- Engine high idling speed
- Torque converter stall speed
* Machine travel speed
- Transmission clutch pressure
- Pressure at outlet port of pump
- Pilot reducing pressure
1 Abnormal noise from between pump and filter.

lolo!
I I I
~I I I I I
1 I I I 1 /
2 Torque converter stall speed too high. 0 0 0 0 0
3 Torque converter stall speed too low 0
Transmission Low at every speed range

4 (Item 2 abnormal) 0 0 0
modulating
pressure
5 too low Indicator fluctuates violently. 0
i
6 Pilot reducing pressure too low (Items 4 and 5 normal) 0
Relief pressure at torque converter inlet port too low

7 0
(Item 4 and 7 normal)
Iron or aluminium particles stuck to strainer of

8 0
transmission case.
9 Modulating pressure drops when oil temperature rises. 0

22-20 WA600- 1
ii)
3. Excessive time lag when starting machine or shift-
ing gear

* Is there any leakage of oil from joints of piping
or valves?
I /a/b/C/d/ejf/g/h
A A
No. A x A x x x
Problems X X
1 Abnormal noise between pump and filter 0
2 Excessive time lag in every speed range 0 0 0 0 0
3 Machine moves normally in certain speed ranges. 0 0 0
Transmission modulating pressure too low

4 in every speed range 0 0 0 0
5 As in Item 4: indicator fluctuates violently 0
Torque converter oil temperature is above operating

6 range. 0 0
WA600- 1 22-21
0
4. Torque converter oil temperature too high
Ask the operator the following points.

- Does not torque converter oil temperature go
up during torque converter stall, and down when
the torque converter is not stalled?
Yes = Normal (Incorrect selection of gear speed)
Checking before troubleshooting

* Is filter clogged?
Checking for abnormalities

* If the oil temperature is normal but the oil
temperature gauge is outside the operating
range, the oil temperature gauge is defective.
1 Pump makes abnormal noise when oil temperature is low. 0
2 High idling and low idling speeds are too low. 0
3 Hydraulic pressure at inlet port of torque converter too low 0
4 Transmission modulating pressure too low 0 0

X : Repalce A: Repair
A : Adjust C : Clean
22-22 WA600-1
0
POWER TRAIN
HYDRAULIC PUMP REAR DIFFERENTIAL

Removal .......... : ‘23-2-2
23- 2 Removal . _ . . _ . . . . . . ... ... . . . 23- 98
Installation ........ lnstallaion . . . . . . . . . . ... ... . . . 23-101
TORQUE CONVERTER DIFFERENTIAL GEAR
Removal .......... .... .. 23- 4 Disassembly . . . . . . _ . ... . . . 23-l 04
lnstallaion ......... .... ... .. 23- 8 Assembly _. . _. . . . . ... . . . 23-l 08
Disassembly ....... .... ... .. 23-12 FRONT AXLE
Assembly ......... .... .. 23-18 Removal . _. . _. . . . . ... ... . . . 23-l 14
TRANSMISSION lnstallaion _. . _. ...., ... ... . . . 23-l 16
Removal .......... .... .. 23-24 REAR AXLE
lnstallaion ......... .... ... .. 23-30 Removal . . . . . . . . . . . ... ... . . . 23-118
Disassembly .................. ... .. 23-36 lnstallaion . , . . . . . ... ... . . . 23-l 22
Assembly .................... .. 23-51 CENTER SUPPORT
TRANSFER Removal . . . . . . . . _ . ... ... ... 23-126
Disassembly .................. . . 23-67 lnstallaion _. . _. . _. _. ... ... ... 23-l 27
Assembly .................... . . 23-76 Disassembly . . . . . . . . . . ... 23-l 28
TRANSMISSION CONTROL VALVE Assembly _. . . . . . . . ... 23-130
Removal ..................... . . 23-87 DRIVE SHAFT
lnstallaion .................... . . 23-88 Disassembly . . _ . . _ . ... . . . 23-l 32
Disassembly and assembly ..... . . 23-90 Assembly . . . . _. . _. . . . . . 23-l 34
FRONT DIFFERENTIAL FINAL DRIVE
Removal ..... .... . ....... . . 23-94 Disassembly . . . . . . _ . 23-l 36
lnstallaion . . _. . . . 23-96 Assembly _. . _. . . . _. 23-l 39
hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed
- Air bleeding procedure
1) Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders4 - 5 times
out from the plug.
m Plug: 1.15 20.15 kgm
WA600- 1
2&1
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
(Transmission lubricating + Torque converter charging + Switch pump)
Serial No. 10868 and UP (D spec.)
A Stop the machine
Lower the bucket
“A& Loosen the oil filler cap slowly to release the

* Before loosening the oil filler cap, close pres-
426FO1201
surizing valve (1A). (Serial No. 10868 and up)
Serial No. 10881 and UD (Exceot D met.)
426FOl202
1. Cover
Open bulkhead inspection cover, then remove cover
(1) and support (2).
2. Hydraulic piping
Disconnect following pipings from hydraulic pump.
mission.
* Disconnect hose (4) from torque converter
PTO case.
* Tube (5) between hydraulic pump and torque
converter filter.
* Loosen clamp of tube,
* Tube (6) between hydraulic pump and steering
halve.
- Hose (7) between torque converter oil cooler and
hydraulic pump.
2%$2 WA600-1
Tube (8) between transmission and hydraulic
pump.
* Loosen clamp of hose (9) at tube (8) end,
then pull out to forward.
* Loosen clamp of tube (8).
* Be careful not to damage O-ring.
Tube (IO) between hydraulic tank and hydraulic
pump.
3. Hydraulic pump
Sling hydraulic pump (1 I), remove mounting bolts,
then lift off.
* When removing hydraulic pump, be careful not
to damage O-ring.
Hydraulic pump: 48 kg
WA600-1
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
(Transmission lubricating + Torque converter charging + Switch pump)
1. Hydraulic pump
install hydraulic pump (11).
* Insert O-ring in groove securely.
2. Hydraulic piping
Connect following piping to hydraulic pump.
- Tube (10) between hydraulic tank and hydraulic
pump.
* Connect tube (IO) first surely.
pump.
* Tighten clamp of tube (8).
- Hose (7) between torque converter oil cooler and
hydraulic pump.
* Tube (6) between hydraulic pump and steering
valve.
- Tube (5) between hydraulic pump and torque
converter filter.
mission.
* Connect hose (4) to torque converter PTO
case.
3. Cover
Install cover (I) and support (2), and close bulkhead
inspection cover, then install left engine inspection
cover.
23-2-2
@
Serial No. 10001-10880
(Except D spec.)
Serial No. 10001 and up Serial No. 10881 and up
(Except D spec.)
4. Refilling with oil
1) Add hydraulic oil through oil filler to specified
level.
ing valve (IA). (Serial No. 10868 and up)

Serial No. 10868 and up (0 spec.)
426FO1201
426FO1202

fied level.
t Run engine to circulate oil through system.

Then check oil level again.
426P318A
WA600- 1
2z3
REMOVAL OF TORQUE CONVERTER ASSEMBLY
Serial No. 10868-l 0880 (Except D spec.)
A Serial No. 10868 and up (D spec.)
A Stop the machine on level ground and ‘install
*A& Loosen the oil filler cap slowly to release the

426FO1201
surizing valve (IA). (Serial No. 10868 and up)
!pt D spec
Front of
machine
426FO1202
1. Cover
Remove engine inspection covers (1).
426P334
Serial No. 10001-10880
(Except D spec.)
Serial No. 10001 and UP
(D spec.)
2. Hood
1) Disconnect POC hoses (21, (3) and (4) from POC
D spec.), 10001 and up (D spec.)]
* Mark with tag to show mounting position.
2) Remove cover (5) lower mounting bolts.
* Disconnect hose (6) at bulkhead, remove
clamp, then pull out to engine end.
2zjY4
i, WA600- 1
3) Sling hood (7), remove mounting bolts, then
lift off.
* Loosen band of air cleaner duct, when lift up
hood a little, pull out duct from duct case.
* Set lifting tool on hood so that bulkhead end
raise first.
Hood: 260 kg
426P337
Air cleaner
Sling air cleaner (8), and remove mounting bolts,
then lift off.
* Disconnect hose of air duct from duct.
* Raise air cleaner a little, then disconnect air
cleaner from turbocharger.
* Be careful not to damage O-ring inserted turbo-
charger connection.
Air cleaner: 30 kg
426P338
Hydraulic pump
(Work equipment + Steering + POC pump)
Serial No. 10001 - 10880 (Escept D spec.)
[ Serial No. 10001 and up (D spec.) I
(Work equipment + Steering + PPC pump)
[Serial No. 10881 and up (Except D spec.]
1) Disconnect following pipings from hydraulic

pump.
* Hose (9) between hydraulic tank and hydrau-
lic pump.
- Hose (IO) between hydraulic tank and steer-
ing valve.
* Loosen all clamp of hoses (9) and (IO),
push down hoses fully, then remove pump
mounting bolts.
. Hose (11) between hydraulic pump and

steering valve.
- Hose (12) between hydraulic pump and
steering valve.
- Branch hose (13).
* Remove clamp of POC (PPC) hose (14).
WA600-1
2) Sling hydraulic pump (15), and remove mount-
ing bolts, then lift off.
* Taking care of balance, set lifting tool.
426P34.l
5. Hydraulic pump
(Transmission lubricating + Torque converter charg-
ing + Switch pump)
1) Disconnect following piping from pump.
Tube (16) between transmission and hydraulic
pump.
* Loosen clamp of hose (17) at tube (16)
end, then pull out to forward.
* Remove clamp of tube (16).
Tube (18) between hydraulic tank and hy-
draulic pump.
mission.
* Disconnect hose (20) from torque con-
verter PTO case.
. Tube (21) between hydraulic pump and
torque converter filter.
Tube (22) between hydraulic pump and steer-
ing valve.
Hose (23) between torque converter oil cooler
and hydraulic pump.
2) Sling hydraulic pump (24), remove mounting

bolts, then lift off.
Disconnect following pipings from torque converter.
- Tube (25) between torque converter oil cool and
torque converter.
- Hoses (26) and (27) between transmission and
torque converter.
7. Drive shaft
Sling drive shaft (28). remove mounting bolts, then
lift off.
ing.
* Push in torque converter end coupling to torque
converter. Then disconnect coupling.
Drive shaft: 30 kg
8. Torque converter
1) Remove brackets (29) and (30).
* Remove bracket (32) of tube (31).
2) Sling torque converter, remove mounting bolts.

Using forcing screw 0, disconnect from case.
* Disconnect torque converter oil temperature
sensor wiring (.33) from connector.
3) Lift off torque converter (34).

* Be careful not to interfere with pipings when
lifting off torque converter.
Torque converter: 155 kg
WA600- 1
INSTALLATION OF TORQUE CONVERTER ASSEMBLY
1. Torque converter
1) Install torque converter (34).
* Adjust height sufficiently not to damage
O-ring, then install quietly.
2) Tighten mounting bolts, then connect torque

converter oil temperature sensor wiring (33).
m Mounting bolt: 11.5 +_ 1 .O kgm
3) Install brackets (29) and (30).

* Install bracket (32) of tube (31 I.
2. Drive shaft
Align match marks, install drive shaft (28).
* When connecting drive shaft, clean contact sur-
face of spider and coupling.
B Mounting bolt: 11.5 i 1 .O kgm

Connect following pipings to torque converter.
* Hoses (26) and (27) between transmission and
torque converter.
* Tube (25) between torque converter oil cooler
and torque converter.
4. Hydraulic pump
ing + Switch pump)
1) Install hydraulic pump (24).
2) Connect following hydraulic pipings to hydraulic

pump.
* Hose (23) between torque converter oil cooler
and hydraulic pump.
* Tube (22) between hydraulic pump and steer-
ing valve.
- Tube (21) between hydraulic pump and
* Tube (19) between hydraulic pump and trans-
mission.
* Connect hose (20) to torque converter
PTO case.
- Tube (18) between hydraulic tank and hy-
draulic pump.
* Connect hose 118) first surely.
pump.
* Install clamp of tube (16).
* Be careful not to damage O-ring of tube
(16) installing surface.
WA600- 1
5. Hydraulic pump
1
! Serial No. 10001 and up (D spec.)
(Work equipment + Steering + PPC Pump)

2) Connect following hydraulic pipings to hydraulic

pump.
- Hose (12) between hydraulic pump and steer-
ing valve.
- Branch hose (13).
- Hose (11) between hydraulic pump andsteer-
ing valve.
* Install clamp of POC (PPC) hose (14).
* Hose (10) between hydraulic tank and steer-

ing valve.
- Hose (9) between hydraulic tank and hydrau-
lic pump.
* Connection of hoses (9) and (lo), tighten
lower clamp, then tighten mounting bolts.
6. Air cleaner
Install air cleaner (8).
* Connect hose of air duct to duct.
+ Be careful not to damage O-ring of turbocharger
connection.
7. Hood
1) Install hood (7).
* Insert duct in duct case and tighten band of
duct at 20 mm in front of hood mounting
position.
426P337
2) Tighten cover (5) lower mounting bolts.

* Connect hose (6) to bulkhead, then install
clamp.
3) Connect POC hoses (2), (3) and (4) to POC
D spec.), Serial No. 10001 and up (D spec.)l
8. Cover
Install engine inspection cover (1).
426P334
Serial No. 10001-10880
(Except D spec.)
ID spec.) (Excem D wet.)
1) Add hydraulic oil through oil filler to specified
level.
Hydraulic oil: Approx. 10 Q
WA600- 1 23-11
0
* Tighten the oil filler cap, then open pre’ssuriz-
‘4
426FO1201
426POlt02 426FO1202
*\,

fied level.
-7
Transmwon oil
Transmission oil: Approx. 5L?
%i#
+ Run engine to circulate oil through system.
23-&l
\ -’
__I
WA600- 1
DISASSEMBLY OF TORQUE CONVERTER ASSEiVlBLY
Special tools
A 790-501-5000 Unit repair stand 1
A, 790-901-4110 Bracket 1
A2 793-310-2190 Plate 1
Preparatory work
* Using eyebolts, raise torque converter (1) and set on
tool A.
Torque converter: 160 kg
1. Torque converter valve assembly

Remove torque converter valve assembly (2).
2. Flange
Remove flange (3).
3. Drive case, turbine assembly

* Come out remain oil, so prepare oil pan.
1) Remove inspection cover (4).
2) Leave 2 bolts on diagonally, remove mounting
bolts (5).
3) Turn over tool A to set drive case facing upper.
Remove 2 remain bolts (5).
4) Remove 6 mounting bolts (6), using forcing

screw, remove cover (7).
23G2
ii WA600- 1
5) Using eyebolts 0 (thread dia. = 10 mm, pitch =
1.5 mm), lift off drive case, turbine assembly (8).
6) Disassemble drive case, turbine assembly as fol-

lows.
i) Remove snap ring (9), then remove spacer
(10).
426P358 426P359
ii) Using puller @ , remove turbine (11) from

drive case (12).
426P360
iii) Remove snap ring (13), then remove bearing

(14) from turbine (11).
iv) Remove bearing (15) from drive case (12).
426P361 426P362
WA600- 1 23-13
4. Inner race
Remove snap ring (16), then using puller @ , re-
move inner race (17).
5. Spacer
Remove snap ring (18), then remove spacer (19).
6. Stator
Remove stator (20).
7. Spacer
Remove 2 spacers (21).
8. Retainer
1) Turn tool A 90”. remove 12 mounting bolts (22),
then remove retainer (23).
2) Remove oil seal (24) from retainer (23).
426P370
WA600- 1
23G4
j._
./
9. Shaft, bearing assembly
1) Using 3 bolts @ (thread dia. = 10 mm, pitch =
1.5 mm, length = 20 mm), lock shaft (25) to
housing temporarily.
2) Remove shaft, bearing assembly (26).
3) Disassemble shaft, bearing assembly as follows.

i) Remove snap ring (27), then remove plate
(28).
426P373 426P374
ii) Using push tool @ (inner dia. = 80 mm), re-

move bearing (29).
WA600- 1
IO. Pump assembly
1) Remove 2 plugs (30), using pin (thread dia. = 8
mm, length = more than 200 mm), tap out inner
race, then remove pump assembly (31).
426F302
2) Disassemble pump assembly as follow.

i) Remove 12 mounting bolts (32). using forcing
screws, remove retainer (33).
426P378 426P379
ii) Remove guide (34) from pump (35).
iii)Using push tool @ (outer dia. = 105 mm),

remove bearing (36).
11. Stator shaft assembly
1) Remove 3 bolts @ , remove stator shaft assem-
bly (37).
2) Remove bushing (38) from stator shaft (39).
426Q385
WA600- 1
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
Special tools
A, 1 790-9014111 ( Bracket I 1
A2 ( 793-310-2190 Plate 1
Preparatory work
Clean all parts and check for dirt or damage before
assembly.
Set torque converter housing (40) on tool A, rotate
tool A to set valve installing surface of housing facing
top.
Stator shaft assembly

1) Fit seal ring, using push tool @ (outer dia. = 75
mm), press fit bushing (38) to stator shaft (39).
* Coat seal ring with grease, and make protru-
sion from shaft uniform.
426P387
2) Fit O-ring, press fit stator shaft assembly (37) to

housing.
3) Lock stator shaft assembly (37) with bolts @
(thread dia. = 10 mm, pitch = 1.5 mm, length =
20 mm) temporarily.
4) Install plug (30).
m Plug: 0.5 IO.1 kgm
426P389
2. Shaft, bearing assembly

1) Assemble shaft, bearing assembly as follow.
i) Using push tool (8) (inner dia. = 70 mm),
install bearing (29).
ii) Fit plate (28), then install snap ring (27)
426P374 426P373
2) Fit seal ring, install shaft, bearing assembly (26).

* Coat seal ring with grease, and make protru-
sion from shaft uniform.
3. Retainer
1) Using push tool @ (outer dia. = 120 mm), press
fit oil seal (24) to retainer (23).
/f2l, Oil seal press fitting surface:

Gasket sealant (LG-4)
a Oil seal lip: Grease (G2-LI)

‘:
‘*.
* Coat oil seal press fitting surface with gasket .
.
sealant thinly, wipe it up when overflowed.
.
d
’ - - 426P393 426P376
2) Remove 3 bolts @ , fit O-ring, then install

retainer (23) with 12 mounting bolts (22).
a Mounting bolt: Adhesive (LT-2)
42W394
WA600- 1
4. Pump assembly
1) Assemble pump assembly as follow. 36
i) Using push tool @ (outer dia. = 150 mm), \
press fit bearing (36) to guide (34).
426P396
ii) Set guide (34) on pump (35).

33
iii) Press fit retainer (33). then tighten 12 mount- 32 35
ing bolts (32). \ /
6 Mounting bolt: Adhesive (LT-2)
-m Mounting bolt: 7.0 + 0.5 kgm
2) Set pump assembly (31) on spline of stator shaft.

3) Using push tool @ (inner dia. = 90 mm), press
fit bearing part.
5. Spacer
Install 2 spacers (21).
WA&OO- 1
23ifo
6. Stator
Install stator (20) on stator shaft.
7. Spacer
Fit spacer (IS), install snap ring (18).
8. Inner race
1) Using push tool 0 (inner dia. = 75 mm), press
fit inner race (17).
2) Install snap ring (16).
9. Drive case, turbine assembly

C -
1) Assemble drive case, turbine assembly as follows. 8. . .
i) Using push tool @ , (outer dia. = 130 mm),
press fit bearing (15) to drive case (12).
426P362
ii) Using push tool @ (outer dia. = 120 mm),
press fit bearing (14) to turbine (11).
iii) Install snap ring (13).
426P361
iv) Using push tool @ (outer dia. = 70 mm),

press fit turbine (11) to bearing part of drive
case (12).
v) Fit spacer (lo), install snap ring (9).
426P359 426P358
2) Using eyebolts @ (thread dia. = 10 mm, pitch =

1.5 mm), set drive case, turbine assembly (8) to
stator shaft. Then align with pump mounting
holes.
3) Tighten 2 bolts (5) temporarily on diagonally.
WA600- 1
2?g22
,’
4) install cover (7), then tighten 6 mounting bolts
(6).
6 Mounting bolt: Adhesive (LT-2)
e Mounting bolt: 7.0 * 0.5 kgm
5) Turn tool A 90”, tighten 30 mounting bolts (5).
& Mounting bolt: Adhesive (LT-2)
6) Install inspection cover (4).
10. Flange
Install flange (3).
11. Torque converter valve assembly

Fit O-rings, install valve assembly (2).
WA600- 1
REMOVAL OF TRANSMISSION
Serial No. 10868--10880 (Except D spec.)
Serial No, 10868 and up (D spec.)
A Stop the machine
Lower the bucket
1A
Q&Loosen the oil filler cap slowly to release the

426FO1201
+ Before loosening the oil filler cap, close pres-
1A
I
426F01202
1. Cover
1) Remove transmission inspection cover (1) and
bar (2), then remove cab rear cover (3).
WA600- 1
Serial No, 10001-10880 (Except D spec.)
Serial No. 10001 and up CD spec.)
2) Remove electric wiring (43 for wind shield wash-
er from connector, then disconnect hoses (5) and
3) Remove plate (7).

* Rubber is inserted in contact surface of cab.
Be careful not to damage rubber when remov-
ing.
WA600- 1
2. Hydraulic pump
i Serial No. 10001 and up (D spec.) I
pump.
lic pump.
lic pump.
* Loosen clamps of hoses (8) and (9). then
push in to lower.
* Hose (10) between hydraulic pump and steer-

ing valve.
- Branch hose (11).
ing valve.
- Tube (13) between hydraulic pump and POC
(PPC) strainer.
3) Sling hydraulic pump (14), remove mounting

* When removing hydraulic pump, be careful
not to damage O-ring.
& Hydraulic pump: 51 kg
3. Hydraulic pump
ing + Switch pump)
pump.
. Tube (15) between hydraulic pump and trans-
mission.
* Disconnect hose (16) from torque convert-
er PTO case.
* Tube (17) between hydraulic pump and
* Tube (18) between hydraulic pump and steer-
ing valve.
- Hose (19) between torque converter oil cooler
and hydraulic pump.
23-26 WA600-1
9
* Tube (20) between transmission and hydraulic
pump.
* Loosen clamp of hose (21) at tube (20)
end, then pull out to forward.
* Loosen clamp of tube (20).
* Be careful not to damage O-ring when re-
moving.
- Tube (22) between hydraulic tank and hy-
draulic pump.
2) Sling hydraulic pump (23). remove mounting

* Be careful not to damage O-ring when remov-
ing hydraulic pump.
4. Upper drive shaft

Sling upper drive shaft (24), remove mounting
ing.
* Push in torque converter end coupling to torque
converter. Then disconnect coupling.
* Remove clamp of fuel control cable, move to
frame end.
Upper drive shaft: 30 kg
5 Torque converter piping

1) Loosen transmission end hose clamp, then re-
move tube (25) between transmission and
hydraulic pump.
* Remove clamp of tube.
* Remove clamp of hose (26), then disconnect
hose from transmission.
WA600- 1
21 Loosen clamp of hose (27) between torque con-
verter and transmission, move hose to transmis-
sion end.
* Disconnect hose (28) from tube.
3) Remove clamp (31) of tubes (29) and (30) be-

tween transmission and torque converter oil
cooler, then disconnect tubes from transmission.
* Move tubes to engine end after disconnecting.
4) Remove transmission lubricating tubes (32) and
(33) from transmission.
* Remove tube (33) after removing tube in fore-
ground.
5) Remove tube (34) between torque converter
filter and transmission from filter end tube.
* Remove bracket of trunnion, then remove
tube together with bracket.
6. Rear drive shaft

Sling rear drive shaft (35) with lever block, remove
mounting bolts, then lift off.
* Set lifting tool between transmission and trun-
nion.
Rear drive shaft: 47 kg

Sling drive shaft (36). remove mounting bolts, then
lift off.
* Remove drive shaft guard bar.
* Pull in drive shaft to front frame end, then pull
out it to right side machine.
b Center drive shaft: 56 kg
23-28
0
8. Electric wiring
1) Disconnect wiring (37) for speedometer sensor
from connector.
* Remove clamp from transmission.
2) Disconnect wiring (38) for transmission solenoid
valve from connector.
* Be careful not to deform thread part of case
when disconnecting connector.
9. Grease hose
Disconnect trunnion lubricating hose (39) from
trunnion.
* Remove clamp (40).
10. Trunnion
1) Sling transmission (41).
Set lifting tool as short as possible.
2) Remove mounting bolts (43) of front mount

bracket (42).
426P426
WA600-1 23-29
3) Remove trunnion (44) mounting bolts,’ raise
transmission (41) about 50 mm, then remove
trunnion.
* Be careful not to lose shims inserted between
frame and trunnion. Check numbers of shims
and thickness, and keep in a safe place.
* Since there is only a narrow space, remove
trunnion carefully.
Trunnion: 25 kg
11. Transmission
1) Remove hose (45) between transmission and
torque converter.
2) Remove mounting bracket (42).

* Be careful not to lose pin inserted transmis-
sion.
426P429
3) Move transmission (41) to engine end, then lift

off slowly.
* Be careful not to hit wet air tank when lifting
off.
* Be careful not to break cab glass.
* Be careful not to interfere speedometer
sensor with plate of lower cab.
,
‘-. kgm-1 Transmission: 1400 kg
23-;:-’ WA600-1
INSTALLATION OF TRANSMISSION
Special tools
A 790-438-I 120 Centering tool 1
1. Transmission
1) Set transmission (41) at 100 mm in front of
mounting position.
* Be careful to cab glass.
2) Install mount bracket (42) to transmission.

* Check that pin is inserted in transmission
securely.
w Mounting bolt: 28.5 ? 3.0 kgm
3) Install hose (45) between transmission and

torque converter to transmission end tube.
* Push in hose (45) until hose does not inter-
fere transmission end tube.
* Insert hose clamp previously.
2. Trunnion
Set trunnion (44) in mounting position, insert shim,
then set transmission (41) in mounting position.
* Standard shim thickness: 1.5 mm
* Align holes, tighten mounting bolts temporarily.
Shim
426F303
23go WA600- 1
2) Tighten front mount bracket (42) mounting
bolts (43) temporarily.
3. Adjusting position
Install tool A and dial gauge @ to transmission,
rotating transmission end coupling, measure runout,
then adjust position with shim.
* Adjust runout with shim inserting between trun-
nion and frame.
* After adjusting shims, tighten mounting bolts
fully.
* Standard face runout: Max. 0.1 mm
* Remove lifting tool after decided position.
w Trunnion mounting bolt: 18.0 + 2.0 kgm

426F361
B Front bracket mounting bolt:
28.5 + 3.0 kgm
4. Grease hose
Connect trunnion lubricating hose (39) to trunnion.
5. Electric wiring
1) Connect wiring (38) for transmission solenoid
valve to connector.
* Be careful not to deform thread part case
when connecting.
2) Connect wiring (37) for speedometer sensor.
* Install clamp to transmission.
WA600- 1
Install center drive shaft (36).
l Install guard bar after installing drive shaft.
7. Rear drive shaft

Using lever block @ , install rear drive shaft (35).
* Tighten rear differential end first.

1) Install tube (34) between torque converter filter
and transmission to filter end tube.
* Install bracket of trunnion.
2) Install transmission lubricating tubes (32) and
(33) to transmission.
* Install foreground tube of tube (33).
w Tube (33): 18.0 f 5.0 kgm

3) Connect tubes (29) and (30) between transmis-

sion and torque converter, then install clamp
(31).
* If do not remove clamp, there is a possibility

of damage of O-ring. Be careful when install-
ing.
4) Install hose (27) between torque converter and
transmission.
* Connect hose (27) to tube.
5) Install tube (25) between transmission and
torque converter charging pump, then tighten
transmission end hose clamp.
* Install clamp of tube.
* Install clamp of hose (26). then connect to
transmission.
9. Upper drive shaft

Install upper drive shaft (24).
* Align match marks of coupling.
* Install clamp of fuel control cable to transmis-
sion.
m Mounting bolt: 11.5 ? 1 .O kgm
10. Hydraulic pump

ing + Switch pump)
* insert O-ring in groove securely.
2) Connect following pipings to hydraulic pump.

* Tube (22) between hydraulic tank and hy-
draulic pump.
* Connect tube (22) surely first.
pump.
WA600- 1
Hose (19) between torque converter oil
cooler and hydraulic pump.
Tube (18) between hydraulic pump and steer-
ing valve.
Tube (17) between hydraulic pump and
mission.
* Connect hose (16) to torque converter
PTO case.
11. Hydraulic pump

2) Connect following pipings to hydraulic pump.

- Tube (13) between POC (PPC) pump and POC
(PPC) strainer.
* Connect tube (13) surely .first.
* Hose (12) between hydraulic pump and steer-
ing valve.
* Branch hose (11).
- Hose (IO) between hydraulic pump and steer-
ing valve.

lic pump.
lic pump.
* Connecting hoses (8) and (9), tighten lower
clamp, then tighten mounting bolts.
23-34 WA600- 1
0
12. Cover
1) Install plate (7).
* Coat cab mounting surface of plate with
soapy water, set in mounting position from
lower.
Serial No. 10001-10880 (Except 0 sPeC.1

Serial No. 10001 and up (D sPeC.)
- e
2) Connect electric wiring (4) for wind shield wash-
er, and connect hoses (5) and (6) to connector.
* Install clamp of electric wiring.
3) Install cab rear cover (3). then install transmis-

sion inspection cover (I) and bar (2).
WA600-1
Serial No. 10001-10880

1) Add hydraulic oil through oil filler to speci-
fied level.
Hydraulic oil: Approx. 1011

Q
(ExceptD spec.)
szerial NO. 10868 and up
1A
426FOl201
Serial No. 10881 and ua (Except D spec.)
426FO1202

fied level.
Iii8 Transmission oil: 3OP
* Run engine to circulate oil through system

23-z-5- 1
3:
DISASSEMBLY OF TRANSMISSION
Special tool
A 1 799-301-l 500 1 Leak tester I 1
1. Control valve assembly

1) Remove tubes (I), (2) and (3).
Long bolt
A
2) Remove 11 mounting bolts.
* Different length of bolts are used. Check bolt
length then remove.
* Do not remove bolts which do not indicate in
diagram.
1.5 mm), lift off control valve assembly (4).
Control valve assembly: 70 kg
@ Mounting bolt
l Mounting eye bolt
426F304
2. Sleeve
Using eyebolt @ (thread dia. = 16 mm, pitch = 2.0
mm), remove sleeve (5).
3. Lubricating pipe
Remove 4 mounting bolts, remove lubricating pipe
(6).
426P437
WA600- 1
2326
4. Coupling, cage assembly
1) Using eyebolts, raise transmission, transfer case
assembly. Set it on block @ with transfer case
facing down.
&I kg Transmission, transfer case assembly:

1350 kg
* Be careful not to damage lubricating tube on case

lower end.
2) Remove mounting bolts (8). then remove plate

(9).
3) Remove 8 mounting bolts, and using forcing
screw, pull out coupling, cage assembly (10)
from transmission case.
4) Using eyebolts (thread dia. = 12 mm, pitch =
1.75 mm), lift off coupling, cage assembly (IO).
re kg Coupling, cage assembly: 30 kg
5) Disassemble coupling, cage assembly as follows.

i) Set coupling, cage assembly on press, using
push tool @ (outer dia. = 90 mm), remove
coupling (11).
ii) Remove snap ring (12).

iii)Set cage on press, using push tool @ (outer
dia. = 120 mm), remove bearing (13).
WA600- 1
iv) Remove oil seal (14).
4268445
5. Collar
Remove collar (15) from shaft.
6. Transmission case
* Bolt fitted plate (16) is 5 mm longer than
others, distinguish it from other and keep it.

1.75 mm), sling transmission case (17).
2s
+!?I Transmission case: 115 kg
3) Using forcing screw, remove transmission case

(17). then lift off.
7. Tie bolt
* Using tool A, check operating condition of pis-
ton before disassembling.
* Referring to DISASSEMBLY OF TRANSFER
ASSEMBLY, remove tie bolts leaving 2 tie bolts,
so that assembly can be removed
from transfer case.
Remove 17 tie bolts (18).

18
* There are 2 short bolts in 17 tie bolts. Mark 2
short bolts to distinguish.
**,** J
,
,L I 426P450
* d
8. Housing, carrier assembly

2.0 mm), lift off housing, carrier assembly (19).
&l H ousing, carrier assembly: 55 kg
* Be careful not to screw in eyebolt until lower

housing.
426P451
2) Disassemble housing, carrier assembly as follows.

i) Remove snap ring (20).
ii) Set housing, carrier assembly on press, using
push tool @ (outer dia. = 135 mm), remove
carrier assembly (22) from housing (21).
42EP452
WA600- 1
iii) Remove snap ring (23).
iv) Set housing on press, using push tool @
(outer dia. = 155 mm), remove bearing (24).
v) Remove collar (25).
vi) Pull out roll pin, remove pin (26), then re-
move thrust washer (27), planetary gear (28)
and needle bearing (29).
is
426P457
426F305
9. Guide pin
Remove guide pin (30).
10. Spring
Remove spring (31).
2320 WA600- 1
11. Plate, disc, spring
Remove plate (32), disc (33) and spring (34).
12. Ring gear

Remove ring gear (35).
13. No.1 piston, housing

2.0 mm), lift off piston, housing (36).
& kg Piston, housing: 30 kg
2) Remove piston (38) from housing (37).
426F306
14. Spring
Remove spring (39).
15. Disc, plate, spring

Remove disc (40), plate (41) and spring (42).
16. No.2 piston, housing, No.3 piston

1) Remove snap ring (43).
2.0 mm), lift of No.2 piston, housing, No.3 pis-
ton assembly (44) together with ring gear, plate.
No.2 piston, housing, No.3 piston ring

gear, plate: 65 kg
WA600- 1
3) Disassemble piston, housing as follows.
i) Remove plate (46) and ring gear (47) and
(48).
ii) Remove No.2 piston (50) and No.3 piston
(51) from housing (49).
426P466 426P467
iii) Remove snap ring (52) of ring gear (47).
426P468
17. Spring
Remove spring (53).

Remove disc (54), plate (55) and spring (56).
19. Collar
Remove collar (57).
20. Housing
Using eyebolts @ (thread dia. = 14 mm, pitch =
2 mm), lift off housing (58).
Housing: 25 kg
21. Shaft, carrier assembly
1) Using bolt (8) and collar (9). lift off shaft, carrier
assembly (59).
Shaft, carrier assembly: 50 kg
2) Disassemble shaft, carrier assembly as follows.

i) Set shaft, carrier assembly on press, remove
shaft (61) from carrier assembly (60).
426F307
ii) Remove sun gear (62) from carrier assembly.

iv) Remove sun gear (64) from carrier assembly.
426P477
WA600- -I 23-43
0
v) Using push tool 0 (outer dia. = 100 mm),
remove sun gear (65).
vi) Using push tool @? (outer dia. = 85 mm),

vii) Pull out roll pin from carrier (67), rekove

pin (68). then remove thrust washers (69).
planetary gears (70) and needle bearings (71).
roll pin
with pin (dia. = 5 mm)
AAll pin
426F306
22. Collar 72
Remove collar (72).
426P482
WA600- 1
23if4
23. Rotating clutch assembly
1) Remove snap ring (73).
1.75 mm), lift off rotating clutch assembly (74).
Rotating clutch assembly: 75 kg
3) Disassemble rotating clutch assembly as follows.

i) Remove 22 mounting bolts (75).
ii) Using forcing screw, remove case (76).
426P485 -426P486
iii) Remove hub (77).

iv) Using puller @ and push tool @ (outer
dia. = 115 mm), remove bearing (78).
v) Remove disc (79), spring (80) and plate (81).

88 79
81
426P489
WA600- 1
23645
Be careful to remove spring, because spring is
1 installed with 217 kg tension.
vi) Using push tool @ (inner dia. = 180 mm),

compress belleville spring, and remove snap
ring.
vii) Release press slowly, then remove snap ring
(82) and belleville spring (83).
viii) Remove piston (84).

ix)Using push tool @ (outer dia. = 105 mm),

2.0 mm), lift off housing, carrier assembly (86).
A._
1 Housing, carrier assembly: 55 kg
i-
/+‘?:
426P494
2) Disassemble housing, carrier assembly as follows.

i) Remove snap ring (87).
remove carrier assembly (88).
426P495
23-46 WA600- 1
,-.
I2/
iii)Pull out roll pin, remove pin (89), then re-
move thrust washers (90). planetary gear (91)
and needle bearing (92).
--G
\
89
426P497
426F309
iv) Remove 3 mounting bolts, then using forcing

screw, remove collar (93).
426P498
v) Remove snap ring (94).

vi) Using push tool 0 (outer dia. = 165 mm),
426P499
25. Guide pin

Remove
98
96
Spring
Remove spring (97).

Remove @kc (98), plate (99) and spring (100).
1
):;
_ _ 426P501 426P532
WA600- ‘I 23-47
p
28. Sun gear
Remove snap ring (101). then remove sun gear
(102).

1) Using pin (thread dia. = 8 mm, length = more
than 95 mm), insert pin in hole of shaft, then lift
off shaft, carrier assembly (103).
Shaft, carrier assembly: 50 kg
2) Disassemble shaft, carrier assembly as follows.

i) Remove 3 mounting bolts, remove plate
(104).
ii) Remove snap ring (105). then remove ring
gear (106).
iii) Remove snap ring (107).

iv) Using push tool @ (inner dia. = 210 mm),
remove carrier assembly (108).
vi) Remove snap ring (109).
vii) Using push tool @ (inner dia. = 105 mm),
remove sun gear (110).
viii) Remove snap ring (11 I), then using push tool
(outer dia. = 130 mm), remove bearing (112).
426F310
ix) Using push tool (outer dia. = 95 mm), remove

collar (113).
Stand
426F311
x) Pull out roll pin, remove pin (114) then re-

move thrust washers (115), planetary gear
(116) and needle bearing (117).
26P513 426P5 I4
WA600- 1
23if9
2.0 mm), lift off No.5 piston, housing (118).
kg
LE?zl No.5 piston, housing: 40 kg
2) Remove piston (120) from housing (119).
119
426F312
31. Spring
Remove spring (121).
l/21
Remove disc (122). plate (123) and spring (124).
33. Ring gear

Remove ring gear (125).

1zll
\
2.0 mm), lift off No.6 piston, housing (126).
12,”
kg
ET?? No.6 piston, housing: 40 kg
2) Remove piston (128) from housing (127). &
426F313
WA600- 1
2320
ASSEMBLY OF TRANSMISSION
Special tool
A 799-301-I 500 Leak tester
* Caution for assembling

- Coat rotating and sliding surface of each parts with
engine oil (EOIO-CD) before assembling.
- Coat seal ring with grease (G2-LI), assemble seal
ring uniformly without inclimation.
- Coat outer and inner install surface of bearing with
adhesive (Threebond 13738) before assembling,
* Align notch of discs.
- Check that snap ring is inserted in groove securely.
Preparatory work
Clean all parts and check for dirt or damage before
assembling.

1) Fit seal ring, install piston (128) in housing.
* Install seal ring with seal ring groove facing
housing end as shown in diagram.
2) Fit O-ring to transfer case, using eyebolts @
(thread dia. = 14 mm, pitch = 2.0 mm), align
dowel pin, then install No.6 piston, housing
assembly (126).
127
426F314
2. Guide pin
Install guide pin (96).
* Length of guide pin: 150 mm
3. Ring gear
Install ring gear (125).
WA600- 1 23-5 1
Install disc (122). plate (123) and spring (124).
* Spring (124) is different from others. Install it 124 123 122
carefully.
* Free height of spring (124): 8 mm
5. Spring
Install spring (121).
426F315
6. No.5 piston, housing 120 Sealring
1) Fit sealing, install piston (120) in housing (119).

* Referring to Step l-l ), install seal ring.
2.0 mm), align dowel pin, install No.5 piston,
housing (118).
* Checking spring through clearance between
housing and transfer case, install No.5 piston,
housing not to fall down spring (121).
119
426F316
3) Using bolt @ (thread dia. = 14 mm, pitch =

2.0 mm, length = 200 mm) and nut, insert dowel
pin of housing.
426P524

1) Assemble shaft, carrier assembly as follows.
i) Fit seal ring, assemble needle bearing (117),
planetary gear (116) and thrust washer (115),
then install roll pin A.
426P514
23-52
0
ii) Expand fit collar (113).
426P526

press fit bearing (112).
iv) Install snap ring (111).
v) Install snap ring (109) on shaft.

vi) Using push tool @ (inner dia. = 105 mm),
press fit sun gear (110).
vii) Using push tool @ (inner dia. = 90 mm),

press fit carrier assembly (108).
viii) Install snap ring (107).
WA600- 1
ix)Assemble ring gear (106), then install snap
ring (105).
x) Assemble sun gear (102), then install snap ring
(101).
426P531
xi) Install plate (104).
426P532
2) Insert pin in hole of shaft, install shaft, carrier

assembly (103).
* Align planetary gear with ring gear, then in-
stall.
426P533

Install disc (98), plate (99) and spring (100). Then
remove bolt @ . 1ntl 9!I 48
9. Spring
kx ;
426F3! 7
23-54 WA600- 1
@I
IO. Housing, carrier assembly
1) Assemble housing, carrier assembly as follows.
i) Using push tool @ (outer dia. = 175 mm),
ii) Install snap ring (94).
426P537
iii) Install collar (93), then tighten 3 mounting

bolts.
m Mounting bolt: 1.4 f 0.1 kgm
6 V groove of outer circumference of

collar: Gasket sealant (LG-1)
iv) Assemble needle bearing (92), planetary gear

(91), thrust washer (90) and pin (89). then
install roll pin.
89 Roll pin
/ /
426P497
426F318
v) Using push tool @ (inner dia. = 135 mm),

press fit carrier assembly (88).
vi) Install snap ring (87).
WA600- 1
2.0 mm), install housing, carrier assembly (86).
11. Rotating clutch assembly

1) Assemble rotating clutch assembly as follows.
i) Fit seal ring, using push tool @ (outer dia.
= 125 mm), press fit bearing (85).
ii) Fit seal ring, install piston (84).
426P492
iii)Set belleville spring (83) and snap ring (82) in

mounting position.
iv) Using push tool @ (inner dia. = 180 mm),
compress belleville spring with press, install
snap ring (82).

vi) Install hub (77).
426P543
23F WA600- 1
vii) Disc, plate, spring
426F319
viii) Install case (76), then tighten mounting bolts

(75).
m Mounting bolt: 11.5 * 1 .O kgm
426P545

1.75 mm), install rotating clutch assembly (74).
* Push in rotating clutch assembly until snap
ring groove of shaft come out.
12. Collar 72
Fit seal ring, install collar (72).
.*”
426P548
WA600- 1
13. Housing
2.0 mm), install housing (58).
14. Collar
Install collar (57).
15. Guide pin

Install guide pin (30).
* Length of guide pin: 255 mm

Install disc (54), plate (55) and spring (56).
17. Spring
426F320
18. No.2 piston, housing, No.3 piston

1) Fit seal ring, install No.2 piston (50) and No.3
piston (51) in housing (49).
* Referring to Step l-1 1, install seal ring.
2 mm), install No.2 piston, housing, No.3 piston
(44).
* Be careful not to fall No.3 piston when in-
stalling.
426P467
23$8
_i WA600- 1
1) Assemble shaft, carrier assembly as follows.
i) Assemble needle bearing (71), planetary gear
(70). thrust washer (69) and pin (68), then in-
stall roll pin.
68
/
68
426P481
Rdll pin
426F321
ii) Using push tool @ (inner dia. = 95 mm),

press fit sun gear (65).
iv) Install sun gear (64).
426P477
v) Using push tool @ (outer dia. = 105 mm),

vi) Install sun gear (62).
r 426P476
WA600- 1
vii) Install seal ring on shaft (61).
viii) Using push tool @ (inner dia. = 75 mm),
press fit shaft (61) in carrier assembly (60).
2) Using bolt (8) and collar (9), install shaft, carrier

assembly (59).
3) Press fit bearing part while tapping shaft.
20. Ring gear

426P561
21. Ring gear

Fit snap ring (52). then install ring gear (47).
22. Plate
Aligning roll pin, assemble plate (46), then install
_,.
snap ring (43). 46
23. Disc, plate, snap ring

Install disc (40), plate (41) and spring (42).
24. Spring
426F322

1) Fit seal ring, install piston (38) in housing.
* Referring to Step 1-l ), install seal ring.
-
2) Using eyebolts a (thread dia. = 14 mm, pitch =
2,0 mm), install No.1 piston, housing (36).
26. Ring gear

426P567d
WA600- 1
28. Spring

1) Assemble housing, carrier assembly as follows.
i) Assemble needle bearing (29), planetary gear
(28). thrust washer (27) and pin (26). then
install roll pin.
426F324
26 Roll pin
is
426P457
426F325
ii) Fit seal ring, aligning dowel pin, install collar

(25).
426P569
” - - i-
iii) Fit seal ring in housing, using push tool @J

(outer dia. = 185 mm), install bearing (24).
iv) Install snap ring (23).
426P454
23&62 WA600- 1
press fit carrier assembly (22) in housing (21).
vi) Install snap ring (20).
426P572

2.0 mm), aligning dowel pin, install housing, car-
rier assembly (19).
30. Tie bolt

Install 17 tie bolts (18).
w Tie bolt: 17 f 1 kgm
* When remove transmission assembly from trans-

fer assembly, see ASSEMBLY OF TRANSFER
ASSEMBLY.
31. Checking operation of piston

Using tool A, check operation and stroke of piston.
* Air pressure: 3 - 5 kg/cm2
* Piston stroke mm
Piston Stroke
No. 1 I 4.0
WA600- 1 23-63
3,
1) Fit O-ring on transfer case. Using eyebolts @
(thread dia. = 12 mm, pitch = 1.75 mm), sling
transmission case (17).
2) Aligning dowel pin, install transmission case (17).
* Bolt fitted plate (16) is 5 mm longer than
others.
* Install bolt length 60 mm on ( -Xl portion.
33. Collar
install collar (15).

I) Assemble coupling, cage assembly as follows.
i) Using push tool @ (outer dia. = 145 mm),
press fit oil seal (14).
&& Oil seal lip: Grease (G2-LI)

iii) Install snap ring (12).
iv) Using push tool @ (outer dia. = 90 mm), in-
stall coupling (11).

1.75 mm), install coupling, housing assembly
(10).
3) Fit O-ring, and install collar (9), then tighten
mounting bolts (8).
w Mounting bolt: 28.5 + 3 kgm
35. Lubricating pipe

1) Using eyebolts, sling transmission, transfer assem-
bly (71, then set it on block @
IF 426P438
2) Install lubricating pipe (6).
WA600- 1
36. Sleeve
Fit O-ring, install sleeve (5).
Long bolt

1) Fit O-ring, using eyebolts @ (thread dia. = 10
mm, pitch = 1.5 mm), install control I valve assem-
bly (4).
2) Install 11 mounting bolts.
* Check bolt length, then install.
0 Mounting bolt
. Mounnng eye bolt
426F304
3) Install tubes (3), (2) and (1).
WA600- 1
DISASSEMBLY OF TRANSFER ASSEMBLY
Special tool
A 799-301-l 500 Leak tester 1
Control valve assembly

1) Remove tubes (I), (2) and (3).
Long hoi t

* Different length of bolts are used. Check bolt
length then remove.
* Do not remove bolts which do not indicate in
diagram.
1.5 mm), lift off control valve assembly (4).
Control valve assembly: 70 kg
0 Mounttng bolt
. Mounting eye bolt
426F304
Sleeve
Using eyebolt @ (thread dia. = 16 mm, pitch = 2.0
mm), remove sleeve (5).
3. Lubricating pipe
Remove 4 mounting bolts, remove lubricating pipe
(6).
4. Oil filler
Remove oil filler (7).
5. Shaft mounting bolt

Loosen shaft mounting bolts (8).
426P588
WA600- 1
23iif7
6. Strainer assembly
I) Using eyebolts, raise transmission, transfer case
assembly (9). then set it on block @ with trans-
fer case facing down.
Transmission, transfer assembly:

1350 kg
2) Remove cover (IO).

* Remove bolts while pushing cover with hand,
since cover come out by spring tension.
3) Remove spring (II) and strainer (12), then re-
move flange (13).

I) Remove mounting bolts (14). then remove plate
(15).
2) Remove 8 mounting bolts, using forcing screw,
remove coupling, cage assembly (16).
8. Collar
Remove collar (I 7) from shaft.
WA600- 1
23668
* The bolt mounting plate (18) is 5 mm longer
than the other bolts, so keep it separately in a
safe place.
2) Using eyebolts and lifting bolts @ (thread dia.

= 12 mm, pitch = 1.75 mm), raise transmission
case (19) temporarily.
3) Using forcing screws, lift off transmission case
(19).
10. Tie bolts

* Using tool A, check the operating condition of
the piston before disassembling.
-. _ 426P598
Remove 15 tie bolts (20) not marked(%).
426P5;9
WA600- 1
11. Transmission assembly
2.0 mm), lift off transmission assembly (21).
42eP600, 1
12. Cage assembly

1) Remove 4 mounting bolts, then using forcing
screws, remove cage assembly (22).
2) Remove outer race (23) from cage (24).
426P602
13. No.1 gear assembly

1) Remove gear assembly (25).
2) Using puller, remove 2 bearings (26) from gear
(27).
426F326
14. Cage assembly

1) Remove mounting bolts, then using forcing
screws, remove fitting part of cage.
1.5 mm), lift off cage assembly (28).
* The cage is thick, so lift it up straight.
23-70 WA600- 1
9;
30 29
426P605

1) Remove No.3 gear assembly (31).
2) Using puller, remove bearing (32) from gear.
426F327
16. Coupling
Remove coupling (33).
17. Cage assembly

1) Remove cage assembly (34).
2) Remove oil seal (35) from cage (36).
426F328
426P608
WA600- 1
2S71
L,
18. Shaft assembly
1) Remove mounting bolts (9) and plate (37), then
remove shaft assembly (38).
2) Remove snap ring (39), then remove inner race

(40) from shaft (41).
19. Rearing
Remove bearing (42) from transfer case.
426P612
20. Cage assembly

screws, remove cage assembly (43) and shim
(44).
* Check the number and thickness of the shims,
and keep in a safe place.
426P614
WA600- 1
2322
21. Cage assembly
(48).
426P616
22. Cage assembly

(52).
53
426P618

1) Remove No.2 gear assembly (55). 56
2) Using puller, remove bearing (56) from gear
(57).
426P619 426F329
24. Outer race

Remove outer race (58) from transfer case.
Wli600- 1
screws @ (thread dia. = 12 mm, pitch = 1.75
mm), remove coupling and cage assembly (59).
2) Disassemble coupling and cage assembly as

follows.
i) Remove mounting bolts (60), then using push
tool @ (outside diameter: 125 mm), re-
move coupling and bearing assembly (61), and
shim (62) from cage assembly (63).
* Check the number and thickness of the
shims, and keep in a safe place.
ii) Remove collar (64) and outer race (65) from

66
cage (66).
64
426P624
iii)tJsing push tool @ (outside diameter: 105

mm), remove coupling (67).
iv) Remove bearings (68) and (69) and outer race
(70), then remove oil seal (71) from cage (72).
426F330
WA600- 1
23z4
26. No.4 gear, collar
Remove No.4 gear (73) and collar (74) from trans-
fer case.
426F331
WA600- 1
ASSEMBLY OF TRANSFER ASSEMBLY
Special tools required
I Part number I Part name Q’ty
A 1 799-301-1500 1 Leak tester I 1

B 796-730-2140 Wrench 1
Preparatory work
- Clean all parts, and check for dirt or damage before
assembling.
1. Cage assembly
1) Using push tool @ (outside diameter: 190 mm),
press fit outer race (45) in cage (46).
426F332
426P614
2) Fit O-ring and install cage assembly (43) and

shim (44).
* Standard shim thickness: 2 mm
426F333
2. Cage assembly
press fit outer race (49) in cage (50). 49
5
426F334
426P616
WA600- 1
2326
2) Fit O-ring and install cage assembly (47) and
shim (48).
426F335

1) Turn over transfer case.
2) Using push tool @ (inside diameter: 105 mm),
press fit 2 bearings (26) on gear (27).
3) Install gear assembly (25).
4. Case assemblv
1) Using push tool @(outside diameter: 190 mm),
426P602
426F337
2) Fit O-ring and install cage assembly (22).
WA600- 1
23z7
5. Adjusting bearing preload of No.1 gear
Set tool 6 in position, then using torque wrench, Torque wrench
measure preload.
* Standard value for preload: 0.01 - 0.1 kgm
* If the measurement is not within the standard
value, adjust with shim (44).
426F338
6. No.4 gear, cdlar

Set No.4 gear (73) and collar (74) inside transfer
case.
426F331

install bearing (32) on gear.
2) Install No.3 gear assembly (31).
8. Cage assembly
426F339 426P631
WA600- 1
23z8
2) Fit O-ring, then using eyebolts @ (thread dia. =
10 mm, pitch = 1.5 mm), raise cage assembly
(28) and install.

1) Turn over transfer case, and remove inspection
cover (75).
2) Set tool B in position, then using torque wrench,
measure preload.
* Move so that the teeth of No.4 gear do not
Nd.3 gear
contact.
426F340 426F341
10. Outer race

Using push tool @ (outside diameter: 190 mm),
press fit outer race (58) in transfer case.
*
426P634
426F342

press fit 2 bearings (56) on gear (57).
2) Install No.2 gear assembly (55).
426P635
WA600- 1
23679
12. Cage assembly
1) Using push tool @(outside diameter: 190 mm),
426P618
2) Fit O-ring and install shim (52) and cage assem-

bly (51).
426F344

1) Set tool B on No.3 gear, then using torque Torque
52 wrench B
wrench, measure preload.
2) Install inspection cover (75).
* Check that there is no play in any gear.
426F345

.Prncc
null0
1) Assemble coupling and cage assembly as follows. n /
Using push tool 0 (outside diameter: 155
mm), install oil seal (71) to cage (72).
& Oil seal press-fitting surface:

Gasket sealant (Three Bond 11OB)
& Lip of oil seal: Grease (G2-LI)
Coat the oil seal press-fitting surface on the

cage side thinly with gasket sealant, and wipe
off any sealant which is squeezed out.
426F346
23-80 WA600- 1
ii) Using push tool @ (outside diameter: 185
mm), press fit outer race (65) in cage (66).
iii)Assemble bearing (68), collar (64) and bearing
(69), then using push tool @ (outside dia-
meter: 185 mm), press fit outer race (70) in
cage (66).
426F347 426F348
iv) Fit O-ring and install cage assembly (76) to

cage assembly (77), then using feeler gauge,
measure clearance S.
v) Install shim (62).
Standard shim thickness =

Clearance S + (0.05 - 0.10 mm)
426F349
vi) Using push tool @ (outside diameter: 125

mm), press fit coupling (67) in cage assembly
67 Plate
(78).
2) Fit O-ring and install cage and coupling assembly

(59) to transfer case.
426F350
15. No.4 gear, collar

Turn over transfer case, and set No.4 gear (73) and
collar (74) in position.
73’
426F351
WA600- 1
2321
16. Bearing
Using push tool @ (outside diameter: 145 mm),
press fit bearing (42) in transfer case.
17. Shaft assembly

press fit inner race (40) on shaft (41), then install
snap ring (39).
2) Align spline, and assemble shaft assembly (38).

then install plate (37), and tighten mounting
bolts (9).
m Mounting bolt: 95 + 10 kgm
18. Cage assembly

1) Using push tool @ (outside diameter: 135
mm), install oil seal (35) to cage (36).
F?IYEx Oil seal press-fitting surface:

Gasket sealant (Three Bond 110B)
a Lip of oil seal: Grease (G2-LI)
* Coat the oil seal press-fitting surface on the

cage side thinly with gasket sealant, and wipe
off any sealant which is squeezed out.
2) Install cage assembly (34) to transfer case.
426F354
23if2 WA600- 1
19. Coupling
Align spline of shaft and install coupling (33).
* install so that it is in the same position as the
front output coupling.
20. Transmission assembly

1) Fit O-ring to cage (24).
2) Fit seal ring, then using eyebolts @ (thread dia.
= 14 mm, pitch = 2.0 mm), raise transmission
assembly (21), align dowel pin, and install.
* Be careful to install the seal ring uniformly
and not to one side.
21. Tie bolts

Install 15 tie bolts (20).
w Tie bolt: 17 + 1 kgm
22. Checking of operation of piston

Using tool A, check operation of piston and stroke
* Air pressure: 3 - 5 kgm
* Piston stroke:
mm
Piston 1 Stroke
No. 1 1 4.0
1) Fit O-ring to transfer case, then using eyebolts
4 thread dia = 12 mm, pitch = 1.75 mm),
s?gltransmission case (19).
2) Align dowel pin, and install transmission case
(19).
t The bolt holding plate (18) is 5 mm longer
than the other bolts, so check before install-
ing.
* Install the 60 mm bolt in the place marked
%.
426P648
24. Collar

1.75 mm), raise coupling and cage assembly (16)
and install.
2) Fit O-ring and install plate (15), then tighten
w Mounting bolt: 28.5 +_3.0 kgm
26. Strainer assembly

1) Fit flange (13). and install strainer (12) and
spring (11).
2) Install cover (10).
23684
27. Shaft mounting bolts
1) Using lifting hook, raise torqflow transmission
and transfer assembly (9), and put on block @
2) Tighten shaft mounting bolts (8).
w Mounting bolt: 95 + 10 kgm
28. Oil supply pipe

Install oil supply pipe (7).
29. Lubrication tube

Fit gasket and install lubrication tube (6), then
tighten joint bolt.
426P588
30. Sleeve
Fit O-ring and install sleeve (5).
Longbolt
1) Fit O-ring, and using eyebolts @ (thread dia. =
10 mm, pitch = 1.5 mm), raise control valve as-
sembly (4) and install.
2) Tighten 11 mounting bolts.
m Mounting bolt: 5 2 0.5 kgm
* Check the length of the bolt before installing.
. Mount,ng eye bo,~
426F304
WA600- 1
23k85
3) install
tubes (3).(2) and (1).
1
\
2326 WA600- 1
\I
REMOVAL OF TRANSMISSION CONTROL VALVE

the safety bar on the frame. Lower the work r
equipment to the ground and stop the engine.
Then apply the parking brake and put blocks
unde’r the wheels to prevent the machine from
moving.
F
* Disconnect the cable from the negative (-) terminal
of the battery.
1. Cover
Remove platform cover (1).
2. Hydraulic piping
Remove lubrication hydraulic tubes (2) and (3).
* Remove the nut of tube (4) to remove tube (3).
3. Electric wiring
Disconnect the following electric wiring.
* Disconnect wire (5) for transmission solenoid
valve from transmission.
* Disconnect wire (6) for speedometer sensor from
connector.
* Remove the clamp of fuel cable (7).
4. Transmission valve
Using eyebolts, lift off transmission valve (8).
Transmission valve: 65 kg
WA600- 1
INSTALLATION OF TRANSMISSION CONTROL VALVE
1. Transmission valve
Set retainer valve (8) in mounting position, then
tighten mounting bolts.
* Align the positions of the holes in the mounting
face gasket correctly.
+ Tighten the mounting bolts on opposite sides in
turn to prevent the valve from being deformed.
2. Electrical wiring
Connect the following electrical wiring.
- Connect wiring (6) for speedometer sensor to
connector.
* Connect wiring (5) for transmission solenoid
valve to transmission.
* When connecting the connectors, be careful
not to deform the thread case.
* Install the clamp of fuel cable (7).
3. Hydraulic piping
Install lubrication hydraulic tubes (2) and (3).
* Tighten the nut of tube (4).
* Check that the O-ring is fitted in the groove.
+ Tube (4) joint (width across flats: 36 mm)
4. Cover
Install platform cover (1).
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF SPEED VALVE ASSEMBLY
2b 423F421
WA600- 1
DISASSEMBLY OF SPEED VALVE ASSEMBLY
Remove solenoid valve assembly (1)
Remove stopper (2). spring (3) and valve (4).
Remove valves (5) and (6). and shim (7).
Remove spring (8). then remove shim (9). valves (ll),

(12) and (13). and spring (14) as a set.
5. Remove covers (15) and (16).
6. Remove spacer (17).
7. Remove spring (18) and valve (19).
8. Remove plug (20), then remove collar (21) and spring

(22).
ASSEMBLY OF SPEED VALVE ASSEMBLY
1. Assemble spring (22) in collar (21), install in body (23),

then fit O-ring and install plug (20).
2. Assemble spring (18) in valve (19) and install.
3. Install spacer (17).
4. Fit gasket and install covers (16) and (15).
5. Assemble valve (12), spring (14), valve (13), shim (9)

and spring (8) in valve (11) and install in body.
6. Assemble shim (7) in valve (6), and install in body.
7. Install valve (5).
8. Install valve (4), spring (3) and stopper (2).
9. Fit gasket and install solenoid valve assembly (1).
WA600- 1
DISASSEMBLY AND ASSEMBLY OF MODULATING VALVE ASSEMBLY
@b@ /’
D &I
0
0
0
0
425F271A
WA600- 1
DISASSEMBLY OF MODULATING VALVE DISASSEMBLY OF MAIN RELIEF VALVE
ASSEMBLY ASSEMBLY
1. Remove cover (1) and (2). 1. Remove plug (37), then remove washer (46), springs
(38) and (39).
2. Remove guide (3), then remove spring (4), shim (5).
2. Assemble and install shim (40), valves (41) and (42).
valves (6), (7) and (9) and spring (8) as a set.
spring (43) and valve (44).
3. Remove valves (IO), (12) and (13) and spring (11)

as a set.
4. Remove stopper (14). then remove quick return

valve (15).
5. Remove spacer (16).

ASSEMBLY OF MAIN RELIEF VALVE
6. Remove cover (17).
ASSEMBLY
7. Remove guide (18), spring (19), shim (20), valves
1. Install together with valve (44), spring (43). valves
(21). (22) and (24) and spring (23) as a set.
(42) and (41) in valve body (45).
8. Remove valve (25). shim (26) and springs (27) and * Standard shim width : 1.5 mm
(28).
2. Assemble springs (39) and (38) in valve body.
9. Remove plug (29), then remove spring (30), shim
(31), valves (32), (33) and (35) and spring (34) as
3. Fit O-ring, washer (46) and tighten plug (37).
a set.
ASSEMBLY OF MODULATING VALVE

ASSEMBLY
1. Assemble spring (34), valves (35), (33), (32) and

shim (31). and spring (30), fit O-ring, then tighten
plug (29).
m Plug: ll.O? 1.5 kgm
2. Assemble shim (26) and springs (27) and (28) in

valve (25) and install in valve body.
* Standard shim width: 3 mm
3. Assemble valve (22) to valve (21), then assemble

spring (23), valve (24), shim (20), and spring (19) in
valve body and install guide (18).
4. Fit O-ring and install cover (17).
5. Install spacer (16).
6. Assemble quick return valve (15), fit O-ring, and

install stopper (14).
7. Assemble valve (12). spring (ll), and valve (IO) in

425F272A
valve (13) and install in valve body.
8. Assemble valves (9) and (7), spring (8), shim (5),

and spring (4), and install guide (3).
9. Fit O-ring and gasket and install covers (2) and (1).
WA600- 1 2323
REMOVAL OF FRONT DIFFERENTIAL
,+, Stop the machine on level ground and install

/:\ the safety bar on the frame. Lower the work
under the wheels to prevent the machine from
moving.
- Remove the front axle.

For details, see 23 REMOVAL OF FRONT AXLE.
I. Draining oil
Remove drain plugs (I) and (2), and drain axle oil.
4
& Axleoil: IIOQ
426P655 426P656
2. Covers
Remove mounting bolts, then remove left and right
covers (3).
42613657
3. Axle shaft
Using forcing screws, pull out axle shaft (4).
* Pull out the axle shaft about 200 mm.
2384
i
7. Differential
Using forcing screws, disconnect differential (9)
from housing. Then set lifting tool in position, and
using bar @ to maintain balance, remove differen-
tial.
+ After removing the mounting bolts, install one
guide bolt each on the left and right.
* Be careful not to damage the O-ring at the con-
tact face.
Front differential: 470 kg
WA600- 1
INSTALLATION OF FRONT DIFFERENTIAL
1. Differential
Raise differential (9). set in mounting position,
then tighten mounting bolts.
Use bar @to maintain the balance when setting
in the mounting position.
Install one guide bolt each on the left and right
in the housing.
Check that there is an O-ring assembled in the
contact face.
& Mounting bolt: Thread tightener (LT-2)

IA. Adjusting shaft shim

* Adjust the shaft shim when the differential
assembly or axle housing have been replaced.
1) Tighten the mounting bolts of shaft (12) uni-

formly, and measure clearance a between the
axle housing and shaft.
* Do not assemble any shim.
D Mounting bolt: 0.4 f 0.1 kgm

(when measuring clearance)
426FO1204
2) Select a shim of 0.1 + 0.05 mm larger than the

measured value of clearance a, then assemble the
shim.
* Shim thickness =
Clearance a + (0.1 + 0.05 mm)
w Mounting bolt: 11.5 * 1 .O kgm
426FO1205
2. Bracket
Set bracket (8) in mounting position, and tighten
mounting bolts.
m Mounting bolt: 28.5 ? 3.0 kgm
WA600-
23696 1
3. Disc
Set disc (7) in mounting position, and tighten
mounting bolts.
B Mounting bolt: 56.0 + 6.0 kgm

5. Axle shaft
Install axle shaft (4).
* If the axle shaft cannot be inserted, rotate the
coupling lightly by hand. Never try to force it
in.
6. Cover
Install cover (3).
t Insert the O-ring securely in the housing groove.
* Be careful not to get the O-ring caught.
m Mounting bolt: 1 1.5 + 1 .O kgm
426P657
WA600-1
Remove level plug, and add oil through oil fillers
(10) and (11) to the specified level.
* Position with the drain plug directly below the
final drive level plug when adding oil.
Axle oil: 1109
8. Bleeding air from brake system

Bleed air from brake system.
* For details, see 52 TESTING AND ADJUSTING.
- Install the front axle.

For details, see 23 INSTALLATION OF FRONT
AXLE.
23-97-1 WA600-1
cc
REMOVAL OF REAR DIFFERENTIAL
A Stop
the safety
the machine on level ground
bar on the frame.
and ‘install
Lower the bucket
Put blocks
chine from
under
moving,
the front
and
wheels to prevent
apply the parking
the ma-
brake
rf/-__
t
securely.
Jack up the bottom of the rear frame and set block
@ under the counterweight.
Set block @ between the top of the rear axle hous-
ing and the frame.
Tire, wheel
Sling left and right wheels (l), remove mounting
nuts, then lift off.
Tire, wheel: 1450 kg
426P667
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
* Fit a lever block on the upper drive shaft and
sling the rear drive shaft.
& Rear drive shaft: 47 kg
3. Brake piping
1) Disconnect tube (3) between brake chamber
and slack adjuster from slack adjuster.
2) Remove tubes (4) and (5) between slack adjuster
and right and left wheel cylinders.
* When lifting off the axle, there is danger that
the brake tube may be damaged, so always
remove it.
669.-
23-98 WA600- 1
0
4. Grease tubes
1) Disconnect grease tubes (6) and (7) from rear
axle support.
2) Disconnect grease tube (8) from front axle sup-
port.
5. Rear axle, support assembly

1) Secure axle support (9) and rear axle (10) with
chains.
2) Remove mounting bolt, then using hoist and

garage jack to maintain balance, lower rear axle
and support.
Rear axle, support: 3270 kg
3) Pull out rear axle and support (11) from under

the machine.
* Support both ends of the axle with jacks.
6. Front support
Remove front support (12) from rear axle.
*, Be careful not to damage the seal.
Front support: 140 kg
WA600- 1
7. Draining oil
Remove drain plugs (13) and (14), and drain oil
from axle assembly.
:
u Axle oil: 1lOQ
/
13 426P676 426P677
8. Axle shaft
1) Remove cover (15).
_$ 426P678
:*\ ,Q&
2) Using forcing screw@, pull out axle shaft (16).

* Pull out axle shaft about 200 mm.
9. Differential
Using eyebolts, lift off rear differential (17).
kg Rear differential: 480 kg

CT???
* Remove O-ring from contact surface.
WA600- 1
23ioo
INSTALLATION OF REAR DIFFERENTIAL
1. Rear differential
Raise differential (17), set in mounting position,
* Install the differential raising it horizontally.
* Check that there is an O-ring fitted to the mount-
ing face of the differential.
Mounting bolt: Thread tightener (LT-2)
Mounting bolt: 56 + 6 kgm

IA. Adjusting shaft shim

* Adjust the shaft shim when the differential Axle housing
\
assembly or axle housing have been replaced.
1) Tighten the mounting bolts of shaft (20) uni-
formly, and measure clearance a between the
axle housing and shaft.
* Do not assemble any shim.

(when measuring clearance)
426FO1210
2) Select a shim of 0.1 f. 0.05 mm larger than the

measured value of clearance a, then assemble the
shim.
* Shim thickness =
Clearance a + (0.1 + 0.05 mm)
Clearancea
B Mounting bolt: 11.5 f 1 .O kgm
426FO1211
2. Axle shaft
1) Using forcing screw 0, push in axle shaft (16).
* If the axle shaft cannot be inserted, rotate the
differential coupling lightly. tiever try to
force the shaft in.
WA600-1
2) Fit O-ring on cover (15) and install cover.
* Make sure that the O-ring is not caught when
installing.
m Mounting bolt: 11.5 + 1 .O kgm
426P678
3. Front support
Lift up front support (12) and insert on the rear
axle mount.
* Be careful not to damage seal with the coupling.
& Rear axle mount: Grease (G2-LI)
4. Rear axle, support

1) Pull rear axle and support (11) under machine.
* Secure the rear axle and axle support with a
chain.
2) Using hoist and jack to maintain balance, set in
mounting position, then tighten mounting bolts
of axle support.
* Always tighten the mounting bolts for the
front support on opposite sides in turn.
w Mounting bolt: 250 f 30 kgm

5. Grease tube
1) Connect grease tube (8) to front axle support
position.
2) Connect grease tubes (6) and (7) to rear axle
support.
23-102
(9
Brake piping
1) Install tubes (4) and (5) between slack adjuster
and right and left wheel cylinder.
2) Connect tube (3) between brake chamber and
slack adjuster to slack adjuster.
7. Drive shaft
Connect rear drive shaft (2) to rear axle.
* When connecting the drive shaft, clean the con-
tact surfaces before installing.
w Mounting bolt: 18 2 2 kgm
8. Tire, wheel
Set right and left tires and wheels (1) in mounting
position, then tighten mounting nut.
w Mounting nut: 94.5 + 10.5 kgm

(Width across fiats: 36 mm)
426P667
9. Lowering machine
1) Jack up machine, and remove block @) under
counterweight.
2) Remove block @from rear axle housing.
WA600-1
Tighten drain plug and add axle oil through oil filler
to the specified level (18) and (19).
* Set the machine so that the drain plug of the
final drive is at the bottom when refilling with
oil.
sir Axle oil: 11012
11. Bleeding air from brakes

Bleed air from brakes, then check operation of
brakes.
* For details of bleeding air, see 52 TESTING
AND ADJUSTING.
23-103-l WA600- 1
co
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
Al 790-901-4110 Brat ket 1
A2 793-310-2190 Plate 1
Preparatory work
Set differential assembly (1) on special tools A, A, and
A,.
Differential assembly: 468 kg
1. Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) from case.
426P685
3) Screw in forcing screws @ (thread dia. = 16

mm, pitch = 2.0 mm), disconnect pinion assem-
bly (4), and lift off using eyebolts @ (thread
dia. = 16 mm, pitch = 2.0 mm).
* Check number of shims (5).
23-104
0
2. Differential gear case assembly
1) Remove left and right locks (6), and with a bar,
turn nut (7) until it becomes loose.
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential gear case

assembly (10).
WA600- 1 23-105
0
FINE DISASSEMBLY OF PINION
ASSEMBLY
3. Bearing, collar, cage

1) Support cage (11). push shaft with press and take
out pinion.
2) Remove bearing (12) and collar from cage.
426P692
3) Remove outer races (13) and (14) from cage.
426P693 426P694
4. Pinion, bearing
1) Remove snap ring (15), then remove bearing
(16).
2) Remove bearing (17).
23-106
0
FINE DISASSEMBLY OF DIFFERENTIAL
GEAR CASE ASSEMBLY
5. Bevel gear (large)

Remove mounting bolts, using eyebolts @ (thread
dia. = 20 mm, pitch = 2.5 mm), lift off bevel gear
(18).
426P696
6. Bevel gear (small)

Remove thrust plate (19) and bevel Sear (20).
7. Pinion gear, cross shaft

Remove pinion gear (211, cross shaft (221, and
washer (23) as one unit.
8. Bevel gear (small) 26

Remove bevel gear (24) and thrust plate.
9. Bearing
Remove bearing (26) from case (25).
426P699 426P700
WA600- 1 23-107
0
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY
Special tools
Differential
B 792-525-l 100 1
micrometer
Bl 792-525-l 230 Adapter 1
FINE ASSEMBLY OF DIFFERENTIAL

GEAR CASE ASSEMBLY
3. Pinion gear, cross shaft

Assemble pinion gear (21) and washer (23) with
19 7n
cross shaft (22).
* Align washer groove with dowel pin of case and
install.
4. Bevel gear (small)

Install bevel gear (20) and thrust (19).
5. Bevel gear (large)

2.5 mm), lift and install bevel gear (18).
* Align pin hole of thrust and dowel pin on case
side and install.
426P696
23- 108 WA600- 1

0
FINE ASSEMBLY OF PINION ASSEMBLY
6. Bearing
1) Using press fit kit @ (Inner diameter: 90 mm),
install pinion bearing (17).
2) Using press fit kit (@ (Inner diameter: 65 mm),
& Rotating surface of bearing:

Engine oil (E030-CD)
7. Cage
1) Install outer races (14) and (13).
426P694 426P693
2) Install cage (11) to pinion assembly.
8. Collar
9. Bearing
Using press fit kit @ (Inner diameter: 90 mm),
WA600- 1 23-109
0
3) Install oil seal (3) to case.
a lip of oil seal: Grease (G2-LI)
4) Fit O-ring to case, and install case (2).
6 Mounting bolt: Thread tightener (LT-2)
5) Install coupling (28), fit O-ring and tighten

holder.
m Mounting bolt: 94 f 10 kgm
* Fit the balancer @ to bolt hole of coupling,

and measure the rotating torque.
* Rotating torque: Max. 9.3 kg
11. Differential gear assembly

Sling differential gear assembly (10) and install
case.
WA600- 1
12. Nut, cap
1) Align nut (7) with differential case groove and
install.
2) Install cap (8) and tighten bolt (9).
& Mounting bolt: Thread tightener (LT-2) 9.
m Mounting bolt: 175 * 20 kgm
* Check match marks on bearing cap before

installing.
* Rotate bevel gear 20 - 30 times to settle in,
then tighten bolt.
i 426P689
* Bearing pre-load adjustment steps are as follows:

1) Install tool B1 to cap on both sides.
2) Measure clearance “a” between tool B, with
tool B.
I 425F290
3) Add 0.47 f 0.09 mm to measurement dimension

and set scale on tool B.
* The added dimension becomes the amount of
bending of the case, given before pre-load and
given after pre-load.
4) Tighten adjusting nut with bar until increased
amount becomes 0.47 ? 0.09 mm.
WA600- 1 23-111
i-x
i_/
2
* Caution for pre-load adjustment
When adjusting nut is overtightened, in case the
amount of increased bending surpasses the stand-
ard measurement, return adjusting nut to posi-
tion before adjusting. Then, while rotating bevel
gear, lightly tap bearing cap and bevel gear with
plastic hammer, and check that there is no clear-
ance in portion b.
426F355
13. Adjusting tooth contact, backlash

Adjust the backlash, and at the same time adjust
tooth contact.
I) Adjust backlash as follows:
Movement of bevel gear is done with adjusting
nut (7). At this time, so as not to change pre-
load pressurization of bearing, turn nuts on
both sides, the same amount each, in same
direction. ,
Put dial gauge @ in vertical contact with
forward and reverse sides of outer edge of
bevel gear tooth face, and while turning ad-
426F356
justing nut, adjust until gauge meter fluctua-
tion becomes 0.33 to 0.46 mm.
* Measure at 3 or 4 places, and keep the
pinion gear fixed when measuring.
2) Adjust tooth contact as follows:
i) Adjust bevel pinion by adjusting shims be-
tween differential case and bearing cage.
ii) Adjusting tooth contact
For details, see ADJUSTING TOOTH CON-
TACT.
WA600- 1
23-k’
2
3) Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act
as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
Tooth contact Cause Procedure for adjustment
The tooth contact pattern should Adjust the pinion gear by adjusting the shims at the
start from about 5 mm from the cage. Adjust the bevel gear in the same way as when
toe of the bevel gear and cover adjusting backlash.
about 50% of the length of the
tooth.
It should be in the center of the
tooth height.
2OBF514
Pinion gear is too far from 1. Reduce shims at pinion gear to bring closer to bevel
bevel gear. gear.
2. Move bevel gear further away
from pinion gear and adjust
backlash correct1.y.
2OBF515
2OBF519
Pinion gear is too close to 1. Increase shims at pinion gear to move away from
bevel gear. bevel gear.
2. Move bevel gear closer to pinion 2
gear and adjust backlash c
correctly.
? _j 2OBF520
Bevel gear is too close to pinion 1. Reduce shims at pinion gear to bring closer to bevel
gear. gear.
2. Move bevel gear further away 2
from pinion gear and adjust *
backlash correctly.
f ._; 2OBF519
Bevel gear is too far from 1. Increase shims at pinion gear to move away from
pinion gear. bevel gear.
2. Move bevel gear closer to pinion
gear and adjust backlash
correctly.
2OBF520
* When adjusting the driven gear, do not change the pre-load of the bearing. Turn the left and right adjusting nut,
the same amount each (check by the number of notches), in the sanre direction.
WA600- 1
REMOVAL OF FRONT AXLE
Qt Stop
the
the
safety
machine
bar on the
on level
frame.
ground
Lower
and install
the work
moving.
- Block the rear tires and apply the parking brake

securely.
. Insert block @ between the top face (1) of the rear
axle housing and frame (2).
. Jack up the machine and set blocks @ under the

front frame on the left and right.
426P714
1. Tires, wheels
Sling left.and right tires and wheels (3). remove
mounting nuts, then lift off.
w Tire, wheel: 1450 kg
2. Drive shaft
Using lever block @ , lift off front drive shaft
(4).
* Make match marks on the drive shaft coupling to
act as a guide when assembling.
* Move the drive shaft towards the front differen-
tial, then move the center support end to the side
and remove the pilot portion at the differential
end.
B Front drive shaft: 57 kg

3. Brake hoses
Disconnect brake hoses (5) and (6) from connection
of tube.
* Fit covers after disconnecting the piping.
4. Air hose
Disconnect air hose (7) from parking brake cham-
ber.
* Check that the parking brake works.
5. Front axle
1) Sling one end of front axle housing (8) and fit a
jack at other end.
2) Fit jack under differential case.
* Be careful not to damage the side face of the
parking brake cover.
3) Remove mounting bolts, then using hoist and
jack, maintain balance and lower axle.
* Be careful not to let the slack adjuster at the
top face of the axle housing hit the frame.
6 kg Front axle: 3140 kg
4) Pull out front axle from chassis.
WA600- 1 23-115
0
INSTALLATION OF FRONT AXLE
1. Front axle
1) Pull front axle under machine body.
2) Fit lifting tool to front axle (8), set jack under
differential case, and maintain balance while
setting in mounting position.
3) Tighten mounting bolts of front axle.

2. Air hose
Connect air hose (7) to parking brake chamber.
3. Brake hoses
Connect brake hoses (5) and (6) to tube.
* Wipe the connection clean with a cloth.
4. Drive shaft
Using lever block @ , set front drive shaft (4) in
mounting position, then tighten mounting bolts.
* Install the differential end of the drive shaft
first.
23-116
@
5. Tires, wheels
1) Set left and right tires and wheels (3) in mount.
ing position, then install mounting nuts.
m Mounting nut: 94.5 f 10.5 kgm

(Width across fiats: 36 mm)
2) Jack up machine, and remove block @ from

under front frame.
426P774
3) Remove block @ between top face (1) of rear

I
axle housing and frame (2).
i
Bleed air from brake system, then check operation
of brakes.
AND ADJUSTING.
WA600- 1
23-A1
7
REMQVAL OF REAR AXLE

Qv the safety bar on the frame. Lower the bucket
* Put blocks under the front wheels to prevent the

machine from moving, and apply the parking brake
securely.
. Jack up the machine, put block @ under the rear
frame, and put a stand @ under the counterweight.
1. Tire, wheel
Sling left and right wheels (I), remove mounting
nuts, then lift off.
Tire, wheel: 1450 kg
426P667
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
Rear drive shaft: 47 kg
3. Brake piping
1) Disconnect tube (3) between brake chamber and
slack adjuster from slack adjuster.
2) Remove tubes (4) and (5) between slack adjuster
* When lifting off the axle, there is danger that
the brake tube may be damaged, so always re-
move it.
WA600- 1
23-A’
*
4. Grease tubes
1) Disconnect grease tubes (6) and (7) from rear
axle support.
2) Disconnect grease tube (8) from front axle
support.
5. Rear axle, support assembly

1) Secure axle support (9) and rear axle (IO) with
chains.
2) Remove mounting bolt, then using hoist and

garage jack to maintain balance, lower rear axle
and support.
Rear axle, support: 3270 kg
3) Pull out rear axle and support (11) from under

the machine.
* Support both ends of the axle with jacks.
6. Front support
1) Remove front support (12) from rear axle.
* Be careful not to damage the O-ring.
Front support: 93 kg
WA600- 1 23-119
0
2) Remove retainer (13) from front support.
3) Remove O-ring (14) from retainer (13). (Serial

No. Id001 - 10387)
3A) Remove Packing (14A) from retainer (13). 426P721
(Serial No. 10388 and UP)
Serial No. Serial No.

10001-l 0387 10388 and up
Mounting surface
426F357 426FO1206
426P722
4) Remove O-ring (15) and bushing (16), (17) from

front support. (Serial No. 10001 - 10387)
4A) Remove Packing (15A) and bushing (16). (17)
from front support. (Serial No. 10388 and up)
426P723
I I
17 16 15
426FO1207
7. Rear support
1) Sling rear support, remove thrust cap (18).
* Using eyebolt (thread dia. = 10 mm, pitch =
1.5 mm), remove thrust cap (18). (Using eye
bolt applicable machine No. 10029 and up)
Thrust cap: 38 kg
23-20 WA600-1
2) Remove thrust washer (21), thrust plate (20) and
thrust washer (19) from rear axle.
426F359
3) Lift off rear support (22).
Rear support: 230 kg
426P726
4) Remove bushing (24) and O-ring (23) from rear

support. (Serial No. 10001 - 10387)
4A) Remove Packing (23A) and bushing (24) from
rear support (Serial No. 10388 and up)
426P727
Serial No. 10388 and UP
426FO1208
WA600- 1
23d
21
INSTALLATION OF REAR AXLE
1. Rear support
1) install bushing (24) and O-ring (23) to rear
support. (Serial No. 10001 - 10387)
* Assemble with the chamfered side of the
bushing on the thrust plate side.
* Fit the O-ring securely in the groove, and be
careful not to get it caught when assembling.
/is, Bushing, O-ring: Grease (G2-LI) Serial No. 10388 and up
IA) install bushing (24) and Packing (23A) to rear

support. (Serial No. 10388 and up)
* Assemble with the chamfered side of the 426P728
bushing on the thrust plate side.
* Be sure to assemble the packing facing in the
correct direction.
& Bushing, Packing: Grease (G2-LI)
23 24
426FO1209
2) Raise rear support (22). and set on rear axle

mount.
* Check that the O-ring side is on the axle hous-
ing side.
aL Rear axle mount: Grease (G2-LI)
3) install thrust washer (19), thrust plate (20) and

thrust washer (21).
& Thrust washer: Grease (G2-LI)
m Mounting bolt: 28.5 f 3.0 kgm 426P726
426F360
23-122
'e$
4) Install thrust cap (18).
& Mounting bolt: 28.5 + 3.0 kgm
* Using eyebolt applicable machine No. 10029

and up.
2. Front support
1) Install bushings (16) and (17), and O-ring (15) to
front support. (Serial No. 10001 - 10387)
* Assemble with the chamfered side of the
bushing on the same side as the inside of the
support.
* Fit the O-ring securely in the groove.
a Bushing, O-ring: Grease (G2-LI)
1A) Install bushings (16) (17) and Packing (15A)

to front support. (Serial No. 10388 and up)
* Assemble with the chamfered side of the 426P729
bushing on the same side as the insid'eof the
support.
* Be sure to assemble the packing facing in the
correct direction.
6 Bushing, Packing: Grease (G2-LI)
2) Assemble O-ring (14) in retainer (13). (Serial No.

10001 - 10387)
* Fit the O-ring securely in the groove.
& O-ring: Grease (G2-LI)
2A) Assemble Packing (14A) in retainer (13).

* Be sure to assemble the packing facing in the 426FO1207
correct direction.
& Packing: Grease (G2-LI)

14(14A)
SerialNo. 10001-10387 Serial No, 10388 and up
426P730
426F357 426FO1206
WA600- 1 23-123
cc
3) Install retainer (13) to front support.
426P723
4) Raise front support (12), and insert in rear axle

mount.
* Be careful not to damage the O-ring (Packing)
with the coupling.
az Rear axle mount: Grease (G2-LI)
3. Rear axle, support

1) Pull rear axle and support assembly (11) to
underside of the machine.
* Secure rear axle and axle support with chains.
2) Using hoist and garage jack to maintain balance,
set in mounting position, and tighten mounting
bolts of axle support.
* Tighten the mounting bolts of the front sup-
port on opposite sides in turn.
m Mounting bolt: 250 + 30 kgm

4. Grease tubes
I) Connect grease tube (8) to front axle support.
2) Connect grease tubes (6) and (7) to rear axle sup-
port.
23-A24
5. Brake piping
1) Install tubes (5) and (4) between slack adjuster
2) Connect hose (3) between brake chamber and
slack adjuster to slack adjuster.
6. Drive shaft
Connect rear drive shaft (2) at rear axle end.
* When connecting the drive shaft, wipe the con-
tact surface when installing.
7. Tire, wheel
1) Set left and right wheels (1) in mounting posi-
tion, then tighten mounting nuts.
w Mounting nut: 94.5 f 10.5 kgm

426P667
8. Lowering machine
1) Jack up machine, remove block @ from under
counterweight.
2) Remove block @ from rear axle housing.
9. Bleeding air from brakes

Bleed air from brakes, then check operation.
AND ADJUSTING.
WA600- 1 23-125
0
REMOVAL OF CENTER SUPPORT
A Stop
wheel
the machine
completely
on level ground,
to the left
turn the
and install the
safety bar on the frame. Lower the bucket to
the ground and stop the engine. Then apply
1. Drive shaft
1) Using lever block @ , disconnect center
drive shaft (1) from center support.
el kg Center drive shaft: 56 kg

426P731
-.
2) Using lever block @ , lift off front drive shaft
(2).
* Move the drive shaft towards the front differ-
ential, then move the center support end to
the side and remove the pilot portion at the
differential end.
m Front drive shaft: 56 kg
2. Center support
1) Disconnect grease tube (3) from center support,
and remove grease nipple.
* Check the angle of the grease nipple.
2) Sling center support (41, remove mounting bolts

and lift off.
* In case shims are inserted between center sup-
port and frame, check number of shims ac-
cording to standard used when assembling.
Center support: 47 kg
INSTALLATION OF CENTER SUPPORT
Special tool required
A 790-438-I 120 Centering tool 1
1. Center support
1) Set center support (4) in mounting position, and
tighten mounting bolts temporarily.
2) To make face of transmission coupling and face
of center support coupling parallel, install tool A
and dial gauge @ on center support. Rotate
center support coupling and adjust parallelism
and runout.
* Insert shims in the center support mount to
adjust.
* After adjusting with shims, tighten the mount-
ing bolts fully.
* Parallelism: Max. 0.1 mm
m Mounting bolt: 56.0 * 6.0 kgm

(Width across flats:’ 30 mm)
426F361
3) Install nipple, and connect grease tube (3) to

center support.
2. Drive shaft
1) Using lever block @ , set front drive shaft (2)
in mounting position, then tighten mounting
bolts.
* Install the differential end of the drive shaft
first.
m Mounting bolt: 18.0 i 2.0 kgm
2) Connect center drive shaft (1) to center support.

* Wipe the coupling mount surface clean with a
cloth.
w Mounting bolt: 18.0 ?r 2.0 kgm
WA600- 1 23-l 27
@
DISASSEMBLY OF CENTER SUPPORT
1. Coupling
Remove center bolt (I), then remove retainer (2), O-ring
(3). and coupling (4). 1 2
i
425P632
2. Retainer
Remove mounting bolts (5) of retainer.
* Remove all mounting bolts while rotating coupling.
425P633
3. Shaft
1) Sat shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
* Be careful because the shaft will fall out suddenly.
425F273
3) Remove spacer (81, bearing cone (9) and retainer (5)

from shaft.
425P634
23-l 28 WA600- 1
0
4. Oil seal
1) Remove oil seal (10) and O-ring (11) from retainer.
425F274
2) Remove oil seal (12) from case.
5. Case
Remove bearing cone (13) and bearing outer race (14)
and (15).
425F275
WA600- 1 23- 129

@
ASSEMBLY OF CENTER SUPPORT
1. Bearing outer race

Assemble bearing (14) and (15). in case (16).
425F276
2. Oil seal
Assemble oil seal (10) in retainer (5).
& Outer circumference of oil seal: Grease (G2-LI)
425F277
3. Bearing cone
Assemble retainer (5) shaft and press fit bearing cone
(9).
* After assembling bearing, check that there is no
clearance at tip of shaft.
* Assemble spacers.
& Lip of seal: Grease (G2-LI)
& Inner circumference of bearing: Grease (G2-LI)
4. Case
1) Assemble O-ring (11) in retainer.
* Insert O-ring completely in groove.
425P636
WA600- 1
23-iA3o
2) Stand shaft and insert case (16).
t Fill “a” and “b” of case and inner circumference
of oil seal completely with grease.
5. Retainer
Secure retainer (5) in case.
* Be careful that O-ring does not get caught when
installing.
425F278
6. Bearing cone, seal
1) Press fit bearing cone (14) to shaft.
2) Assemble oil seal (12) in case.
* Dimension of seal press fit and outer edge of case:
0.5 mm
& Seal: Grease (G2-LI)
7. Coupling
Assemble coupling (4), install O-ring (3) and retainer
(2), and secure center bolt (1).
m Center bolt: 95 + 10 kgm

(Width across flats: 36 mm) 425P633
8. Inspection of end play

Check that end play is within specified range.
t End play: Less than 0.22 mm
* If end play is “0”, with the seal and bearing coated
with grease, check that the free rotating torque is less
than 0.4 kgm.
425F279
425?637 425P632
WA600- 1 23-131
@
DISASSEMBLY OF DRIVE SHAFT
1. Shaft
1) Remove shaft (2).
* Make match marks a before removing to
ensure that the direction of the spider assem-
bly does not change.
* Cover (I) is caulked with a punch at four
places, so it must not be removed unless
necessary.
* When removing cover (1). be extremely
careful not to damage cover (I) and yoke
a
(IO).
* When removing the caulking, raise the caulk- 425P616-1
ing with a screwdriver.
Seal
426FO1203
2) Remove mounting bolts (3), then remove spider

assembly (4).
* Make match marks on yoke and spider.
3) Remove bearing cap (5) from spider assembly.

* Remove strap (6) of cap.
4) When replacing bearing (7), seal (8), and Derling

washer (9) from bearing cap, replace whole cap
assembly.
425P617
425F280 425P619 425P618
WAbOO-1
23-k32
\. ,J
2. Yoke
1) Remove mounting bolts (11) from yoke (lo),
then remove spider assembly (4).
* Stamp match marks on the yoke and spider.
4258620
2) Remove bearing cap (5) from spider assembly.

* Follow the same procedure as in Step 4) for
the shaft. 5
5
425P621
__.-
23-A33
WA600- 1
ASSEMBLY OF DRIVE SHAFT
1. Yoke
1) Install bearing (7), and seal (8) to bearing cap
(5).
a Bearing, seal: Grease (G2-LI)
/.---
425F281
2) Assemble Deirin washer (9), and bearing cap (5)

to bearing assembly (4).
* Be careful not to damage bearing with heat
when welding strap.
& Bearing cap: Grease (G2-LI)
425P623
3) Assemble spider assembly (4) to yoke (10).

* Carefully align match marks.
* Clean the mounting face of the bearing cap by
wiping with a clean cloth.
D Mounting bolt: 14.5 2 1 .O kgm
425P624
2. Shaft
1) Assemble bearing (7) and seal (8) in bearing cap
(5).
-A Bearing seal: Grease (G2-LI) 7

8
425F280 425P619
WA600-1
23-A34
._,
2) Assemble Delrin washer (9) and bearing cap (5)
to spider assembly (4).
* Be careful not to damage bearing with heat
when welding strap.
& Bearing cap: Grease (G2-LI)
425P625
3) Assemble spider assembly (4) to shaft (2).

* Carefully align match marks. 2
4
Ir Clean the mounting face of the bearing cap by
wiping with a clean cloth.
m Mounting bolt: 14.5 * 1 kgm
425P626
4) Align match marks, then install shaft (2) to yoke

(IO).
* Check that the direction of the spider as-
sembly is the same.
* If the spline is worn, replace the whole drive
shaft assembly.
6 Spline: Grease (G2-LI)
425P627-1
* If cover (1) has been removed, do as follows.

i) Insert’seal and retainer to cover (1) and Retainer 1 Cauling
shaft (2), assemble cover (I), then caulk 10
with a punch on diagonally opposite sides.
2
Seal
426FO1203
WA600-1 23-135
Cc
DISASSEMBLY OF FINAL DRIVE ASSEMBLY
Special tools
Part number I Part name Q’ty
A 1 793-520-1920 1 Fixture I 4
A Stop the machine

the safety
bar on the frame. Lower the work
moving.
1. Loosen wheel nuts, jack up machine with work

equipment, put stand @ under axle, then lower
machine.
2. Sling wheel assembly (I), remove wheel nuts, then

remove wheel assembly.
Wheel assembly: 990 kg
3. Remove drain plug (2). and drain oil from final

drive case.
.
& Final drive case: Approx. 110 Q
4. Remove mounting bolts (3), then remove final case

cover (4).
23-l 36
a
5. Screw bolts @ (thread dia. = 12 mm, pitch = 1.75
mm) into axle shaft, and pull out axle shaft (5).
6. Remove 3 mounting bolts (6), then using eyebolts

@ (thread dia. = 12 mm, pitch = 1.75 mm), lift off
planetary carrier assembly (7).
* The balance is poor, so use a bar to adjust the
center of gravity when lifting off.
Planetary carrier assembly: 115 kg
7. Using tool A, lock wheel hub (8) and brake housing

(9).
* Install the tools on opposite sides.
8. Remove mounting bolts (IO), then remove retainer

(11).
* There are shims on the inside of the retainer, so
check the number and thickness of the shims,
9. Remove ring gear assembly (12).
WA600- 1
10. Fine disassembly of planetary carrier assembly
I) Using press or copper bar, remove shaft (13),
then remove pinion gear (14).
* Ball (15) is installed in the shaft, so when re-
moving the shaft, be careful not to lose the
ball.
423F435A
2) Remove bearing (17) from pinion gear (16).
423P9388
3) Remove bearing cups (18) and (19) from pinion

gear, then remove spacer (20) and snap ring (21).
11. Fine disassembly of ring gear assembly

1) Remove lock plate (22). then remove ring gear
(23) from ring gear hub (24).
2) Remove bearing (25) from ring gear hub.
426F362
423P941A 426P745
23-138 WA600- 1
0
ASSEMBLY OF FINAL DRIVE ASSEMBLY
A 793-520-I 920 Fixture 4
1. Fine assembly of ring gear

1) Press fit bearing (25) in ring gear hub (24).
* After press fitting the bearing, check that
there is no clearance from the rib.
423P941 A
2) Assemble ring gear (23) in ring gear hub, then

install lock plate (22).
426P745
2. Fine assembly of planetary carrier

1) Assemble snap ring (21) and spacer (20) to pin-
ion gear (14), and press fit bearing cups (19) and 18
(18).
2) Install bearing to pinion gear (14).
426~362
3) Align holes of pinion gear (14) and carrier, then

press fit with lock ball facing outside circumfer-
ence. Stop before hole and align hole.
4) Assemble ball (15) in shaft (13). and press fit
shaft again.
* After press fitting the shaft, check that the
pinion gear rotates smoothly.
423F435A
WA600- 1 23-l 39
-a
“.
Pm~nd~~rn fnr ariillrtino wheel bearing
, .“““--. . . _. --,-_-..‘g
1) Install embly
ring gear ass1 (12) to axle housing,
and tighten retainer (11) temporarily with 3
t Tighten the retainer without assembling

shims (26).
* Rotate the hub 5 - 6 times and tighten the
bolts uniformly in turn to the specified tight-
ening torque.
4. Using a depth micrometer or calipers @ through

measuring hole of retainer, measure distance “a” to
end face of axle shaft.
* Measure in two places and take the average as
“a”.
5. Remove retainer, and measure thickness “b” of
retainer.
* Shim thickness: a - b + 0.3 mm
426F363
6. Assemble selected shim (26). and tighten retainer.

* Rotate the hub 5 - 6 times and tighten the bolts
uniformly in turn to the specified tightening
torque.
a Mounting bolt: Thread tightener (LT-2)
m Mounting bolt: 27.5 i 2.5 kgm
* After tightening the bolts, rotate the wheel hub

(8) and check that there is no abnormality in the
rotation of the bearing rollers.
7. After tightening retainer, remove tool A.
23- 140 WA600- 1

0
Fit O-ring, and using eyebolts @ (thread dia. = 12
mm, pitch = 1.75 mm), raise planetary carrier as-
sembly (7), set in mounting position and tighten 3
mounting bolts (6).
* The balance is poor, so use a bar to adjust the
position of the center of gravity when installing.
Screw bolts @ (thread dia. = 12 mm, pitch = 1.75

mm) into axle shaft, and install axle shaft (5).
* If the sun gear cannot be aligned, rotate the
wheel hub to align the teeth when installing.
10. Fit O-ring and install final drive case cover (4), then
& Mounting bolt: 7.0 i 1.0 kgm
11. Tighten drain plug (2), and add oil until it flows out
through the level plug.
12. Raise wheel assembly (I), and set in position on

wheel hub, then tighten wheel nuts temporarily.
13. Jack up machine with work equipment, remove

stand from under axle, then lower machine to
ground. Tighten wheel nuts to specified tightening
torque.
& Wheel nut: 90 ?r 15 kgm
WA600- 1 23-141
0
POWER TRAIN
24 MAINTENANCE STANDARD
Engine mount .................. . 24- 2

Transmission mount ............ 24- 3
Torque converter ............... . . 24- 4
Torque converter regulator valve . 24- 5
Transmission ................... . 24- 6
Transmission solenoid valve ..... . 24- 9
Transmission control valve ...... . . 24-10
. Upper valve ................. 24-10
- Lower valve ................. .. 24-12
Transfer ....................... 24-14
Drive shaft ..................... 24-16
Center support ................. 24-17
Axle mount .................... . 24-18
Differential ..................... 24-20
Final drive ...................... 24-24
WA600- 1 24-1
ENGIN’E MOUNT
I i ~..__ 3 >
Section B - 6
Section A-A SectionC-C
426F167A
Unit: mm
No. Check item Criteria Remedy
Clearance between engine damper Adjust

1 7.0
and trunnion support
2 Tightening torque of bolt 94.5 + 10.5 kgm
Retighten
3 Tightening torque of bolt 94.5 ? 10.5 kgm
24-2 WA600- 1
0
TRANSMISSION MOUNT
=4-b
.1 Section A-A
Section B-B
426F168
Unit: mm
Check item Criteria Remedy

NO.
, .5 mm (Outaf-parallel between coupling of center support Adjust

1 Thickness of shim for mounting and coupling of transmission: 0.1 mm)
Tightening torque of mounting 28.5 ? 3 kgm

2
bolt
Tightening torque of mounting 28.5 r 3 kgm

3
bolt
Retighten
Tightening torque of mounting 18%2 kgm
4
bolt
Tightening torque of mounting 28.5 2 3 kgm

5
bolt
WA600- 1 24-3
TORQUE CONVERTER
1 426F 170
Unit: mm
Inside diameter of seal ring

surface of retainer
8 Tightening torque of bolt 0.45 t 0.15 kgm
9 Tightening torque of bolt 5.0 t 0.5 kgm
24-4 WA600- 1
@
TORQUE CONVERTER REGULATOR VALVE
426F 171
Clearance
between poppetand
TRANSMISSION (l/2)
426F172
24-6 WA600- 1
Unit: mm
No Check item Criteria Remedy
I Standard size ( Repair limit I
Reverse clutch springs

1
(12 pieces)
2 Forward clutch springs (12 pieces) 68 61 8 kg 67 6.8 kg
3 4th clutch springs (12 pieces) 52 46 10.3 kg 51 8.8 kg
4 3rd clutch springs (12 pieces) 52 47 8.6 kg 51.3’ 7.3 kg

-
5 1st clutch springs (12 pieces) 52 45 12 kg 50.9 10.2 kg
Standard size Tolerance Repair limit
Thickness of assembled 4 discs

6
and 3 plates for reverse clutch 39 +. - 37.4

7 and 3 plates for forward clutch 39 I - 37.4
Thickness of assembled 3 discs -

8 and 2 plates for 4th clutch 27.8 26.6
I / I
9 45 43.0
-
and 4 plates for 2nd clutch I
10 and 2 plates for 3rd clutch 27.8 / - 26.6
-
11 and 2 plates for 1st clutch 27.8 26.6 Replace
-
Forward, Reverse,
5.4 - 5.0
Thickness 1st. 3rd. 4th
12
of 1 disc
2nd 5.0 - 4.6
Forward, Reverse,
Thickness 1st. 3rd. 4th 5.8 _ 5.2
13
of 1 plate
2nd 5.0 - 4.5
+0.018 +0.018
14 Outside diameter of input shaft 170
-0.007 -0.007
+0.016 +0.016
15 Outside diameter of input shaft 110
-0.006 -0.006
+0.016 +0.016
16 Outside diameter of output shaft 130
I -0.006 -0.006
+0.018 +0.018
17 Outside diameter of output shaft
-0.007 -0.007
Width 3.0 -0.01

Wear of seal ring -0.03 2.6
18
for input shaft
Thickness 3.7 50.12 3.55
Wear of seal ring

19
for output shaft
Wear of seal ring

20
for 2nd clutch
WA600- 1 24-7
‘2)
TRANSMISSION (Z/Z)
-1
-
I
426F173
Unit: mm
NO. Check item Criteria Remedy
Backlash between reverse sun gear and

1 0.13 - 0.32
planetary gear
Backlash between reverse planetary gear

2 0.15 - 0.38
and ring gear
Backlash between forward sun gear and

3 0.13 - 0.36
planetary gear I
Backlash between forward planetary gear
4 0.14 - 0.39
and ring gear
Backlash between 4th sun gear and

5 0.13 - 0.36
planetary gear I I
Replace
Backlash between 4th planetary gear
6 0.14-0.39
and ring gear
Backlash between 3rd sun gear and

7 planetary gear 0.13 - 0.36
Backlash between 3rd planetary gear

8 0.14 - 0.39
Backlash between 1st sun gear and

9 planetary gear 0.13 - 0.36
Backlash between 1st planetary gear

10 and ring gear 0.14 - 0.39
24-8 WA600- 1
TRANSMISSION SOLENOID VALVE
Section A - A
425F142
Tightening torque of solenoid valve

1 0.17 ? 0.01 kgm
mounting screw
Tightening torque df solenoid valve

2 0.17 ? 0.01 kgm
terminal screw

3 0.075 I 0.005 kgm
terminal screw
Retighten
4 0.07 ? 0.01 kgm
connector mounting screw
Tightening torque of temrinal

5 0.07 r 0.01 kgm
mounting screw

6 4.75 t 0.25 kgm
mounting bolt
WA600- 1 24-9
0
TRANSMISSION CONTROL VALVE
. UPPER VALVE
13
\_,_________-
4
10 w/f----// Y.zz
5
3
18 ni--lY--l
7
14
426F175
426F176
24-10 WA600- 1
Unit: mm
No Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between reducing valve Shaft Hole
1
and body
I
I 25 -0.045
-0.035 +0.012
0 0.0350.058
- 0.08
Clearance between torque converter -0.035 +0.013 0.035 -

2 relief valve spool and body 25 -0.045 0 0.058 0.08
Clearance between priority valve -0.035 +0.013 0.035 -

3 spool and body 25 -0.045 0 0.058 0.08
4 Clearance between quick return I 12 -0.035

-0.045
+0.013
0
/ o’“;T&8 1 0.681
valve spool and body
Clearance between modulating -0.035 +0.013 0.035 -

5 valve spool and body 25 -0.045 0 0.058 0.08
6 Clearance between main relief valve

spool and body
I 28
-0.035
-0.045
+0.013
0
0.035 -
0.058 0.08
Replace
Standard size I Repair limit
Free Installation Installation Free Installation

7 Priority valve spring length length load length load
62 37.7 22.1 kg 59.6 19.9 kg

I
8 Torque converter relief valve spring 62 48 12.8 kg 60.6 11.5 kg
9 Modulating valve spring (Inner) 118 110 5.55 kg 117 5.0 kg
10 1 Modulating valve spring (Outer) I 145.7 I 144 1 1.69 kg 1 145.5 1 1.52 kg 1
11 Main relief valve spring (Inner) 108 80.3 34.8 kg 105 31.3 kg
12 Main relief valve spring (Outer) 122 80.3 41 .O kg 118 36.9 kg
13 Thickness of shim for reducing valve 2.5 mm (pressure per 1 piece: 0.65 kg/cm2)
14 Thickness of shim for modulation valve 3 mm (pressure per 1 piece: 0.33 kg/cm2 )
I
15 Thickness of shim for priority valve 2 mm (pressure per 2 piece: 0.26 kg/cm’ ) Adjust
-
Thickness of shim for torque converter
16
relief valve
2 mm (pressure per 1 piece: 0.26 kg/cm* )
17 Thickness of shim main relief valve 1.5 mm (pressure per 1 piece: 0.39 kg/cm* )
18 Tightening torque of modulation lock nut 3.5 - 5.0 kgm Retighten
WA600- 1 24-11
0
. LOWER VALVE
Section B-B
F42601014-K
24-12 WA600- 1
0
Unit: mm
I I
NO Check item Criteria Remedy z
I
Tolerance
Clearance between FORWARD- Shaft Hole
REVERSE spool and body
-O.o35 +0.013 0.035 -
22 0.08
-0.045 0 0.058
-
Clearance between 1 st speed -0.035 +0.013 0.035 -
2 spool and body 22 -0.045 0 0.058 0.08
Clearance between 2nd speed -0.035 +0.013 0.035 -

3 spool and body 22 -0.045 0 0.058 0.08
Replace
Clearance between 3rd speed -0.035 +0.013 0.035 -

4 spool and body 22 -0.045 0 0.058 0.08
Clearance between 4th speed -0.035 +0.013 0.035 -

5 spool and body I 22 -0.045 0 0.058 0.08
-
Clearance between pilot reducing -0.035 +0.013 0.035 -
6 valve and body 25 -0.045 0 0.058 0.08
Clearance between lubrication -0.035 +0.013 0.035 -

7 valve plunger and body 22 -0.045 0 0.058 0.08

FORWARD-REVERSE, length length load length load
8 No. 1, No. 2, No. 3 and
No. 4 speed spring
78 47 10.9 kg 75 9.8 kg
9 Accumulator spring 162 125.6 40 kg 158.4 36 kg

Replace
I I / ---I
10 Pilot reducing valve spring I 62 I 43.7 / 16.7 kg 1 60.1 ) 15 kg (
11 Lubrication valve spring 39.4 / 37 / 6.2 kg / 39.2 / 5.6 kg )

1 I I 1 I I
Thickness of shim for pilot

12 3 mm (pressure per 1 piece: 0.26 kg/cm2) Ad; ust
redusing Mlve
WA600- 1 24-13
0
TRANSFER
426F174-1
24-14 WA600- 1
0
Unit: mm
NO. I Check item I Criteria Remedy
1 Outside diameter of idler shaft +0.045

f0.045
105
f0.023 +0.023
Outside diameter of input shaft

2 190 -:.046
bearing -E.O46
I I
Outside diameter of idler shaft 0
3 190 -:.046
bearing -0.046
Outside diameter of output shaft

4 bearing 190 -:.046 -:.046
1 Replace
Outside diameter of output shaft f0.045 +0.045
5 105 +0.023
bearing +0.023
Outside diameter of output shaft 150 -0.012 -0.012

6 bearina -0.052 -0.052
Outside diameter of output shaft +0.045 +0.045

7 85 +0.023
bearing +0.023
I
Oil seal sliding surface of output 104.82
8 105
shaft coupling I:.087
Oil seal sliding surface of output 1 i4.8

9 125
shaft coupling ~~.lOO
I I
1n
I”
I Clearance between
and case
input cover
Standard size
I
Repair limit
I
I
I
Preload 0.03 - 0.1 kgm
I
Adiust
Clearance between output cover 2 (shims)
11
and case
I
12 Clearance between idler cover and 2 (shims) Preload 0.03 - 0.1 kgm
case
13 Backlash between input gear and 0.22 - 0.60

idler gear
Replace
Backlash between output gear and 0.22 - 0.60
14
idler gear
I
Backlash between idler gear and 0.22 - 0.60
15
idler gear
I Retighten
Tightening torque of coupling 94.5 f. 10.5 kgm
16
mounting bolt
WA600- 1 24-15
0
DRIVE SHAFT
of front drive
21 .8 * 0.7
of center drive
181 2
21.8 + 0.7
14.7 A 1.2
24-16 WA600- 1
CENTER SUPPORT
‘7
426F177
Unit: mm
Standard . Tolerance
Standard Clearance
Shaft Hole
1 Clearance between case and bearing
-0.036 -0.018 -
140 -0.015
-:.Ol8 -0.061 -0.061
2 Clearance between case and bearing 130 -0.036 -0.018 - Replace

-0.061 -0.061 -0.015
3 Clearance between coupling shaft 80 +0.051 0 -0.032 -

and bearing +0.032 -0.015 -0.066 -0.029
4 Clearance between coupling shaft 75 to.051 0 -0.032 -

and bearing +0.032 -0.015 -0.029
-0.066
I I I I
5 Wear of oil seal surface

95 0 -0.18 Repair
-0.087 chrome
plating or
replace
6 Wear of oil seal surface 105 0
-0.087 -0.18
7 End play of coupling shaft (Preload max. 0.4 kgm)

Replace
max. 0.22
Tightening torque of coupling

8 95zlOkgm
mounting bolt
I
Retighten
9 Tightening torque of mounting bolt 6.7 ? 0.7 kgm
WA600- 1 24-17
0
AXLE MOUNT
13
,
Section A - A Section B - B
426F183
WA600- 1
24-18
0
Unit: mm
No
Clearance of shaft and hole

1
(Front support side)
5 Thickness of thrust plate
-
6 Thickness of wear plate 5 0
-0.1 1.3 Replace
+0.1
7 Thickness of rear bushing 4.9 -0.1 -
+,0.1
8 Thickness of front bushing 4.9 -0.1 -
-
Tightening torque of mounting
9 28.5 * 3 kgm
bolt
-
I
10 20.5 + 3 kgm
bolt

11 280 + 30 kgm Retighten
bolt
I
12 280 * 30 kgm
bolt

bolt 11.25 i 1.25 kgm
WA600- 1 24-19
0
DIFFERENTIAL (l/Z)
12 9 11
17
10
16
14.15
Section.A-A
2/ i
426F179-1
24-20 WA600- 1
q
Unit: mm
No. Check item Criteria
I
Tolerance
Standard Standard 1 Clearance
size clearance j limit
Clearance of bearing outer race Shaft 1 Hole
1
in differential gear assembly
225
2 Clearance of side bearing inner 150 +0.052 0 -0.027 -

race in differential gear assembly +0.027 -0.025 -0.077
-
3 shaft
Clearance
bearing
of outer raceof pinion 200 I 0
-IO.025 -0.016
+0.030 0.030
-0.041 ) -
Clearance of inner raceof pinion
4 1 88.9 ~ ;;:;$; 1 +;‘025 ) -Of;;64 ~ -
shaft bearina
5
Clearance of inner race of pinion
88.9
+0.030 +0.025 0.014 - ~
shaft bearing +0.011 0 -0.030 I -
Clearance of outer race of pilot
6 130
bearing
-
7 Clearance
bearing of inner race of pilot I 60 +0.051
+0.032 -0.015
0 -0.032
-0.066 -
8 Clearance between differential 245 0 +0.046 0 - 0.092 - Replace

carrier and cage -0.046 0
-
9 Clearance between spider and 40 -0.025 +0.110 0.025 0.35
differential pinion bushing -0.050 0 0.160
+0.025 +0.027 0.020 -

10 Clearance of bevel gear pin 18
+0.007 0 -0.025
11 Backlash of bevel gear 0.33 - 0.46
12 Backlash of differential gear 0.25 - 0.33
13 End play of pinion gear I 0.15
14 Free rotating torque of beve! gear 1.43 kgm
I
15 Preioad of bevel gear 2100 kg
I
16 Rear face runout of bevel gear 0.1

i
Standard rhickness of shims ior

17 Clearance “a” + (0.1 * 0.05)
stop shaft
WA600- 1 24-21
G?
DIFFERENTIAL (2/2)
l-
6-
5
12 /
426F180
24-22 WA600- 1
Unit: mm
Standard size
Thickness of side gear washer
Thickness of pinion gear washer
56 A 6 kgm

8 bolt 94.5 i 10.5 kgm
’ Retighten
9 bolt (for front) 28.5 i 3 kgm

10 bolt ifor front) 56 ? 6 kgm

11 bolt (for front) 28.5 i- 3 kgm
-
12 bolt 1751 20 kgm
Tightening torque of mounting 1st step: 0.4 c 0.1 kgm (when measuring clearance (no shim))
13 2nd step: 11.5 r 1.0 kgm (shim installed)
bolt
WA600- 1 24-23
c.$
FINAL DRIVE
Clearance between planetary shaft
Thickness of retainer at ring gear hub
Backlash between planet gear

0.21 -0.45
Backlash between planet gear

5 0.22 - 0.46
and ring gear
Thickness of standard shim for

6 2.3
wheel hub
First 6.4 + 0.5 +gm

Tightening torque of
7
mounting bolt Second 28.5 + 3.0 kgm
8 Tightening torque of mounting bolt 9.0 i 3.5 kgm
9 Tightening torque of mounting nut 84 f 9 kgm

Fietighten
10 Tightening torque of mounting bolt 3.2 L 0.3 kgm
11 Tightening torque of plug 15.5 + 2.5 kgm
24-24 WA600- 1
fp
.i
STEERING SYSTEM
General ......................................................... 41- 2

Steering column, gear box and linkage.. . ..41- 3
Hydraulic circuit for steering ...................... 41- 4
l Hydraulic circuit schematics.. ................. 41- 4
l Hydraulic circuit diagram ........................ 41- 5
Steering control system .............................. 41- 6
l Steering valve.. ......................................... 41- 6
l Steering relief valve ................................. 41- 8
l Safety valve (with suction valve) ........... .41- 9
l Operation of demand spool.. ................... 41-10
l Operation of steering valve .................... .41-13
Two-way restrictor valve ............................. 41-14
Steering cylinder ......................................... 41-15
Center hinge pin .......................................... 41-16
Emergency steering piping (If equipped) . .41-17
Emergency steering pump (If equipped) .. .41-18
Diverter valve (If equipped) ........................ 41-19
Steering demand valve
(Machine with joystick steering). ............... .41-23
Steering unit (Orbit-roll valve)
(Machine with joystick steering) ................. 41-34
WA600-1 41-1
0
GENERAL
OUTLINE
- When steering wheel is operated, the movement is * When steering valve (6) is actuated, oil from hydraulic
transmitted by steering column, universal joint, gear pump flows to steering cylinder (5) and the steering
box, drag link, and link, and actuates steering valve is actuated.
(6). . When steering wheel (2) is not being operated, all the
- The oil from hydraulic tank (1) is sent to steering oil which enters steering valve (6) flows to main con-
valve (6) by triple pumps (3) and (4). trol valve.
1. Hydraulic tank
* Illustration shows for Serial No. 10001 and up
(for D spec.) and Serial No. 10001-10880 (except for D spec.) 2. Steering wheel
3. Triple pump
4. Triple pump
5. Steering cylinder
6. Steering valve
7. Two-wav restrictor valve
41-2 WA600- 1
0
STEERING COLUMN, GEAR BOX AND LINKAGE
OUTLINE
. The steering gear is a recirculating ball type gear. - Balls (,8) move in the nut groove of the shaft to-
In this type of gear there is a round-bottomed gether with the rotating of the steering wheel. They
thread cut in the steering shaft. There are several pass from the end of the nut through the passage
balls (8) between the nuts which slide in this thread. on the outside, and return to the nut to be re-
Ball nut (7) moves up and down in accordance with circulated
the rotation of the steering shaft, and turns center
shaft.

Serial No. 10001-l 0880 (except D spec.)
Section A-A Section B-B
w
Section C-C Section D-D
1. Steering wheel
2. Center shaft
3. Steering column
4. Pitman arm
5. Gear box
6. Tilt lever
7. Ball nut Section E-E
8. Ball
9. Worn 426FO52
WA600- 1 41-3
0
Serial No. 10881. and up (except D spec.)
9’
1. Steering wheel
2. Center shaft
3. Steering column
4. Pitman arm
5. Gear box
6. Tilt lever
F42601015
7. Ball nut Section E-E
8. Ball
9. Worn 426FO52
41-3-l WA600-1
/ij:
HYDRAULIC CIRCUIT FOR STEERING
HYDRAULIC CIRCUIT SCHEMATICS
control valve
426FO55
In neutral, the steering wheel is not operated. There- mand spool (2) indicates that the engine is running at
fore, steering spool (3) does not move. low speed.) The merged oil further flows into port A
The oil from the steering pump flows port A and the and merges with the oil from the steering pump.
oil from the switch pump flows into port B. Some of - The merged oil flows to steering spool (3). However,
the oil from the hydraulic pump flows into the work since the steering valve is in neutral, the oil does not
equipment circuit and the rest of the oil pushes check flow into the cylinder, but into the drain through
valve (1) open to flow into port B and merges with port t.
the oil from the switch pump. (The motion of de-
41-4 WA600- 1
@
HYDRAULIC CIRCUIT DIAGRAM
14
I-
$
L I’*
I
ll -17
@I -1
’ 3’“~
I
To main controlvalve
FO42601001
1. Check valve 6. Switch pump (SAR(3)-100) 11. Safety valve (with suction)
2. Demand spool 7. Steering valve 12. Two-way restrictor valve
3. Steering spool 8. Hydraulic tank 13. Two-way restrictor valve
4. Steering Pump (SAR(4)-125) 9. Relief valve 14. Steering cylinder
6. Hydraulic pump (SAR(4)-260) 10. Safety valve (with suction)
WA600- 1 41-5
STEERING CONTROL SYSTEM
STEERING VALVE
425FO64
A. To steering cylinder E. From steering pump
6. To hydraulic circuit F. From switch pump
C. To steering cylinder G. To hydraulic tank
D. From hydraulic pump
41-6 WA600- 1
Section X - X
2’ \
1
Section Y - Y
Section Z - Z
425FO65
1. Demand spool 5. Lever
2. Check valve 6. Relief valve
3. Orifice 7. Valve body
4. steering spool 8. Safety valve (with suction)
WA600- 1 41-7
STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
56OBFO69
Function
. The steering relief valve is inside the steering valve.
When the steering cylinder reaches the end of its
stroke and abnormal pressure is generated, the oil
sent from the pump is relieved through this valve,
This prevents damage to the pump or circuit.
(The relief valve sets the maximum pressure of the
circuit.)
5606FO70
3
/
Operation
. Port A is connected to the pump circuit, and port ,, : ,, ‘:
C is connected to the drain circuit. The oil passes e’i‘f
..,..
,~ , N
through the orifice in main valve (1) and fills port t
B. Pilot poppet (3) is in contact with valve seat (2). f+F
56OBFO7 I
When the pressure inside port A and B reaches the

pressure set by the poppet spring (set pressure),
pilot poppet (3) opens and the hydraulic pressure at
port B escapes from port D to port C. This lowers
the pressure at port B.
When the pressure at port B drops, the orifice of
main valve (1) generates a difference in pressure
between port A and port B. Main valve (1) is
5606FO72
opened by the pressure at port A and the oil at port
A is relieved.
41-8 WA600- 1
SAFETY VALVE (with suction valve)
1. Suction valve
2. Main valve’
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
421FO45
Function
- The safety valve (with suction valve) is in the main valve.
If shock causes any abnormally high pressure in the cylin-
der when the main valve is at neutral the safety valve
(with suction valve) releases the abnormal pressure and
protects the cylinder from damage.
Operation
As a safety valve
* Port A is the cylinder circuit and port B is the drain cir-
cuit.
The pressure oil in port A flows to port D through a hole
in the pilot piston. It also flows to port C through an ori-
fice consisting of the main valve (2) and the pilot piston
(4).
The pilot piston is secured to the safety valve by a lock
nut. The diameter of the cross section (cross-sectional
area) gives a relationship of d2Xi>ds>d4.
* If abnormally high oil pressure occurs in port A, thesuc-
421 F046
tion valve (1) is not actuated because of the relationship
&Xl.
However, because of the relationship dsX4 in port A and
C, the hydraulic pressure on the main valve (2) is equiva-
lent to the area. difference between d3 and d4. If this
pressure goes up to the poppet spring force (set pressure),
the poppet is actuated, and the oil in port A flows into
port B.
As a suction valve
- If negative pressure is generated in port A, port D also has
negative pressure, because port D and A are connected
with each other. The tank pressure in port B is applied to 421 F047
port E.
Hydraulic pressure “a” equivalent to the area difference
between d2 and dI is applied to the safety valve because
of the tank pressure in port E.
Therefore, hydraulic pressure “e” acts to open the valve
and hydraulic pressure “a” acts to close the suction valve
(1).
- If the pressure in port A drops, (approaching negative
pressure) hydraulic pressure “a” becomes smaller than oil
pressure “e”.
When oil pressure “e” becomes larger than oil pressure
“a” + valve spring (5) force, the suction valve (1) opens,
E e 421 F048
causing the oil to flow from port B into port A. This pre-
vents negative pressure from building up in port A.
WA600- 1
OPERATION OF DEMAND SPOOL
Engine running at idling when turning to the left
From steering To steering

cylinder cylinder
E425F073
* The oil from the steering pump (4) flows into port As its flow increases, the oil pressure at port C rises
A and the oil from the switch pump (6) flows into because of orifice b in port A, and exceeds the force
port B. The oil from the hydraulic pump (5) pushes of spring (2A). Then, demand spool (2) moves in
check valve (1) open because the circuit is closed. the direction marked I). For this reason, some of
Then, the oil flows into port B and merges with the the oil from the hydraulic pump (5) flows into the
oil delivered from the switch pump (6) _ The work equipment circuit through port D.
merged oil then flows into port A and merges with Thus, all the oil delivered from the steering pump
the oil delivered from the steering pump (4). Then, (4) and the switch pump (6) plus some of the oil
the merged oil flows into port C through orifice a in delivered from the hydraulic pump (5) flow into
demand spool (2). the steering cylinder.
41-10 WA600- 1
fP
~:,
Engine running at medium speed when turning to the
left

cylinder cylinder
To main control
t
E425F074
. The oil from the steering pump (4) flows into port more than that when the engine is running at low
A and the oil from the switch pump (6) flows into speed, the oil pressure at port C rises because of
port B. The pressure of the oil from the hydraulic orifice b in port A, and exceeds the force of spring
pump (5) increases because the circuit is closed (2A). Then demand spool (2) moves in the direction
and pushes check valve (1) open, overcoming the marked I) . For this reason, all the oil from the
spring force in the valve. Thus, the oil flows into hydraulic pump (5) plus some of the oil from the
port B and merges with the oil delivered from the switch pump (6) flow into the work equipment
switch pump (6). Then, the merged oil further circuit through port D.
flows into port A and merges with the oil delivered . All the oil delivered from the steering pump (4) and
from the steering pump (4). some of the oil delivered from the switch pump (6)
. The merged oil flows through orifice a in demand flow into the steering cylinder.
spool (2) into port C. As the oil flow has increased
WA600- 1 41-11
Engine running at high speed when turning to the left

cylinder cylinder
~425FO 75
. The oil from the steering pump (4) flows into port more than that when the engine is running at
A and the oil from the switch pump (6) flows into medium speed, the oil pressure at port C further
port B. rises because of orifice b in port A, exceeding the
The oil from the hydraulic pump (5) increases force of spring (2A). Therefore, the demand spool is
its pressure because the circuit is closed and pushes further moved in the direction marked I) . For
check valve (l), overcoming the spring force in the this reason, the circuit is closed. Thus, all the oil
valve. Thus, the oil flows into port B and merges from the switch pump (6) and that from the hy-
with the oil from the switch pump (6). Further, draulic pump (5) flow through port D into the
the merged oil flows into port A and merges with work equipment circuit.
the oil from the steering pump (4). All the oil from the steering pump (4) flows into the
. The merged oil flows into port C through orifice steering cylinder.
a in demand spool (2). As the oil flow increases
41-12 WA600- 1
OPERATIONS OF STEERING VALVE
Turning right
.i
c
+‘.- H
t 426FO56
. When the steering wheel is turned to the right, spool (3). Then, the oil flows into the bottom of
steering spool (3) moves to the left through the the L.H. cylinder and the sides of the R.H. cylinder *
activated control linkage. rod through port D in the spool, making a R.H.
Some of the oil from the work equipment switch turn.
pump flows into port B and port A through the The oil from the L.H. and R.H. cylinders is drained
demand valve and merges with the oil from the from two-way restrictor valve (12) through Port E
steering pump. The merged oil flows to steering in the steering spool.
WA600- 1 41-13
TWO-WAY RESTRICTOR VALVE
1. Body
2. Spring
3. Poppet
425FO70
FUNCTION
. To reduce the shock caused by the inertia of the
machine when the steering is operated, an orifice
is installed in the oil line of the return circuiffrom
the cylinder. This applies pressure to the returning
oil, and regulates the movement of the cylinder
piston.
OPERATION ‘) II
L J
. When the oil is flowing to arrow + , it pushes
/ /
spring (2) and flows through the orifice, and be-
tween poppet (3) and the poppet seat.
425FO71
. When the oil is flowing to arrow * , the oil flows a
only from orifice a inside the poppet (3), so the

flow is controlled. /
Form
cylinder
*
425FO72
41-14 WA600- 1
STEERING CYLINDER
426FO58
1. Head
Specifications
Cylinder bore: 130 mm

2. Rod
Rod diameter: 70 mm
3. Cylinder
Stroke: 528.5 mm
4. Piston Cylinder max. length: 1494 mm
Cylinder min. length: 965.5 mm
5. Piston nut
Width across flats of piston nut: 80 mm
WA600- 1 41-15
CENTER HINGE PIN
OUTLINE
. The front frame (3) and rear frame (4) are con-
nected through a bearing by the center hinge pin
(51, (6). The steering cylinders are connected to
the leti and right front and rear frames, so when
the cylinders are operated, the frame bends at the
middle to give the desired angle, that is the desired
turning radius.
B-l
\ /
1 -__ 1’
426F123
1. Front frame
2. Rear frame
3. Upper hinge pin
4. Lower hinge pin

426F124
41-16 WA600- 1
EMERGENCY STEERING PIPING (If equipped)
426FO59
1. Hydraulic tank
2. Transmission
3. Steering pump
4. Steering valve
5. Emergency pump
6. Diverter valve
WA600- ‘B 41-17
EMERGENCY STEERING PUMP (If equipped)
Emerge& Transmission
steering pump
426FO65
5 Section A - A
426FO60
Specification
1. Drive gear (Teeth 12) * Model: SAM(3)-125
2. Front cover - Direction of revolution: Possible to rotate both directions.
* Theoretical delivery: 125.4 cc/rev
3. Gear case
* Max. delivery pressure: 210 kg/cm’
4. Rear cover * Max. speed: 2000 rpm
5. Driven gear (Teerh 12)
41-18 WA600- 1
DIVERTER VALVE (If equipped)
A. Sensor mounting port
6. To hydraulic oil tank
C. To steering valve
D. From emergency pump
E. From hydraulicoil tank
F. From steering Pump
‘C
1. Check valve
2. Check valve
3. Check valve
4. Check valve
5. Spool
6. Valve body
426FO61
Section X - X
FUNCTION
* If the engine stops, the pump seizes, when the ma-

chine is traveling, and it becomes impossible to steer,
the rotation of the transmission is used to turn the
emergency steering pump to make steering possible.
WA600- 1 41-19
0
OPERATION
- Pump, engine working normally
Sensor
To oil cooler
From steering cylinder
To steering cylinder
To main control valve
Hydraulic tank
Emergency steering
pump
Hydraulic pump
Steering pump
Switch pump
426F062A
Hydraulic oil circuit
When the steering pump and engine are working

normally, the hydraulic pump, steering pump, and
switch pump are rotated by the engine. Therefore,
oil is sent to the steering valve, and the machine can
be steered.
In addition, the emergency steering pump is rotated
by the transmission, so oil from port A of the diverter
valve pushes open check valve (2) and enters port B.
Pressure oil from the steering pump is flowing to port
C, so it pushes spool (3) in the direction of the arrow.
As a result, the oil from port B flows to port C and is
drained to the hydraulic tank.
426F063A
41-20 WA600- 1
5%
* Failure in pump or engine when machine is traveling.
Sensor
To oil cooler
From steering cylinder
Hydraulic tank
Emergency steering
pump
Hydraulic pump
Steering pump
Switch pump
If there is a failure in the pump or engine when the

machine is traveling, the rotation of the wheels is
transmitted through the transfer to rotate the emer-
gency steering pump.
The steering pump is not rotating, so no pressure oil
is formed at port D. As a result, spool (3) is pushed
in the direction of the arrow by spring (4).
The oil from the emergency steering pump passes
from port A through port B and flows to the steering
valve to make steering possible.
* The emergency steering pump is designed so that it

can rotate both directions.
WA600- 1
STEERING DEMAND VALVE
STRUCTURE AND FUNCTION
STEERING DEMAND VALVE

(MACHINE WITH JOYSTICK STEERING)
A
1. Overload relief valve
2. Main relief valve
3. Steering spool
4. Demand spool
5. Surge cut relief valve
A. To steering cylinder
B. To steering cylinder
PI. From steering pump

P2. From switch pump
PBS. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
5’ 4
A-A SEW01395
WA600- 1
41-23
0
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
l The overload relief valve is installed in the cylin-

der circuit of the steering demand valve. When
the demand valve is at neutral and any impact is
applied to the steering cylinder and abnormal
pressure is generated, this valve functions as a
safety valve to relieve the circuitto prevent break-
age of the cylinder or hydraulic piping.
It also functions to prevent any vacuum if any
negative pressure is generated at the cylinder
end.
OPERATION
1. Operation of relief valve I 2 3

l Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The
oil passes through the hole in poppet (I) and
acts on the area of diameters dl and d2.
Checkvalve poppet (3) and relief valve pop-
pet (2) are securely seated.
SDW01397
. When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens and the oil goes around pilot poppet
(4) and flows to port B.
A i3
SDW01398
41-24 WA600-1
0
. When pilot poppet (4) opens, the pressure at

the rear of poppet (I) drops, poppet (I) moves
to the right, and it is seated with pilot poppet
(4).
i3
SDW01399
. Compared with the pressure at port A, the

pressure on the inside is low, so relief valve
poppet (2) opens and the oil flows from port
A to port B to prevent any abnormal pres-
sure.
A 0
SDW01400
2. Operation of suction valve

Negative pressure is generated at port A, the
l
difference in the area of diameters d3 and d4

opens checkvalve poppet (31, and the oil flows
from port B to port A to prevent a vacuum
from forming in the circuit.
A
SDW01401
WA600- 1 41-25
0
MAIN RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
I
SD101402
FUNCTION
l The main relief valve of the steering demand

valve is inside the valve and sets the maximum
pressure in the steering circuit when it is oper-
ated. In other words, when the valve is being
operated and the steering circuit goes above
the set pressure of this valve, it relieves the oil
and actuates the flow control spool of the demand
valve to drain the oil to the steering circuit.
41-26 WA600- 1
0
OPERATION OF STEERING RELIEF VALVE
I-J To main control valve
I 2 3 II
From switch PUPP
%
From steering rump
SDW01631
When the pressure in the circuit rises and l When demand spool (4) moves, the oil from
reaches the pressure set by spring (2) and ad- the steering pump is drained and the oil from
justment screw (I 1, pilot poppet (3) opens and the switch pump is relieved to the main con-
drains the oil. trol valve, so the steering circuit pressure is
When this happens, the balance of the pres- prevented from going above the set value.
sure in pressure receiving chamber (I) and
pressure receiving chamber (II) is lost, and
demand spool (4) moves to the left.
WA600-1 41-27
0
OPERATION OF DEMAND VALVE
When steering spool is at neutral
From switch Pump
SDW01632
The oil from the steering pump enters port A l When the pressure in pressure receiving cham-
and the oil from the switch pump enters port ber (I) reaches a certain value (set by spring
B. (311, notch f opens and the oil from the steer-
When steering spool (2) is at the neutral posi- ing pump goes to the drain circuit. Notch g is
tion, pressure receiving pressure chamber (II) closed, so the oil from the switch pump all
is connected to the drain circuit through ori- flows to the main control valve.
fice b, and notch c is closed.
Notch c is closed, so the pressure of the oil at
port A and port B rises. This pressure passes
through orifice a, goes to pressure receiving
chamber (I) and moves demand spool (I) to
the left.
41-28 WA600- 1
0
WHEN STEERING SPOOL IS OPERATED

Engine running at low speed
_e
-
8 I
To main control val

II
itch pump
From steerins Pump

SDWOlG
When the steering is operated, oil flows from l The merged oil passes through notches c and
the Orbit-Roll to steering spool (2) and pushes d, pushes load check valve (5), and flows to
steering spool (2) to the right. The circuit be- the cylinder. The return oil from the cylinder
tween pressure receiving chamber (II) and the passes through notch e and flows to the drain
drain circuit is shut off, and at the same time, circuit.
notch c opens. . When this happens, the pressure before
As a result, the pressure in pressure receiving passing through notch c is sent to pressure
chamber (II) rises, and demand spool (I) receiving chamber (I) and the pressure after
moves to the right until notch h closes. passing through notch c is sent to pressure
The passage from port B to the main control receiving chamber (Ill. Demand spool (I) is
valve is shut off, so the oil from the switch actuated so that the difference in pressure
pump pushes up pump merge-divider check on both sides of notch c is kept constant.
valve (4) and merges with the oil from the Therefore, an oil flow corresponding to the
steering pump at port A. opening of notch c is supplied to the cylinder
port. These pressure differences (control pres-
sure) are set by spring (3).
WA600- 1 41-29
0
Engine running at high speed
From steerins Pump
SDW01634
. There is no need for supply of extra oil from l The oil from the steering pump passes through
the switch pump, so the steering pump pres- notches c and d, pushes load check valve (51,
sure rises until notch g closes and shuts off and flows to the cylinder. The return oil from
the merge passage from port B. the cylinder passes through notch e and flows
. The pressure difference on both sides of notch to the drain circuit.
c is controlled only by notch f, and the excess l Notch g is closed, so the oil from the switch
oil from the steering pump is drained from pump all flows from port B and is sent to the
notch f to the drain circuit. (At this point, notch main control valve.
g is completely closed.)
41-30 WA600 1
0
OPERATION OF STEERING VALVE

Neutral
Intro1 valve
SDWOl635
l The steering wheel is not being operated, so l When the pressure at ports A and B rises, de-
steering spool (2) does not move. mand spool (I) moves to the left, so the oil
l The oil from the steering pump enters port A. from the steering pump passes through port
The oil from the switch pump enters port B. C of the spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
WA600- 1 41-31
0
Turning right
From orbit-roll valve
From switch PIJ~P
From steering
9 PU~D
SDW01636
. When the steering wheel is turned to the right, ders passes through load check valve (5) of the
the Orbit-roll valve is operated and steering steering spool and is drained. The oil from the
spool (2) moves to the left. switch pump enters port B, goes through de-
The oil from the steering pump enters port A, mand spool (I 1, pushes open check valve (4),
then flows to steering spool (2) through de- and is merged with the oil from the steering
mand spool (I). The oil pushes open load pump.
check valve (6) of the spool, and flows to the
bottom end of the left cylinder and the rod end
of the right cylinder to turn the machine to
the right. The oil from the left and right cylin-
41-32 WA&O- 1
0
Turning left
From or ,bit-rol I valve
To maycontrol valve
9
am switch Pump
4
From steering Pump
SDWOl637
. When the steering wheel is turned to the left, ders passes through load checkvalve (6) of the
the Orbit-roll valve is operated and steering steering spool and is drained. The oil from
spool (2) moves to the right. the switch pump enters port B, goes through
The oil from the steering pump enters port A, demand spool (I), pushes open check valve
then flows to steering spool (2) through de- (4), and is merged with the oil from the steer-
mand spool (I). The oil pushes open load ing pump.
check valve (5) of the spool, and flows to the
rod end of the left cylinder and the bottom end
of the right cylinder to turn the machine to
the left. The oil from the left and right cylin-
WA600- 1 41-33
0
STRUCTURE AND FUNCTION STEERING UMIT
STEERING UMIT (ORBIT-ROLL VALVE)

a b
SEW01413
1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering cylinder (demand valve port Pb)
3. Check valve c. To steering cylinder (demand valve port Pa)
4. Spool d. From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin
41-34 WA600- 1
0
OUTLINE
. The steering unit is directly connected to the shaft

of the steering wheel. The oil from the PPC pump
passes through the steering demand valve, and
is switched to the left and right steering cylinders
to determine the direction of travel of the ma-
chine.
. The steering unit can be broadly divided into the
following: spool (4) and sleeve (5), which have a
rotor type direction selection function, and the
gear set (combination of gear (7) and gear rim
(6)), which acts as a hydraulic motor when the
steering is operated.
SEW01414
STRUCTURE
Connecter to
. Spool (4) is interconnected with the drive shaft of steering wheel shaft
the steering wheel and is connected to sleeve (5)
by neutral position spring (1) and center pin (10)
(when the steering wheel is at neutral, it does not
contact the spool).
l The top of drive shaft (9) is meshed with center
pin (10) and forms one unit with sleeve (5). The
bottom is meshed with the spline of gear (7) of
the gear set.
. Valve body (2) has four ports. These are connected
respectively to the pump circuit, tank circuit, and
SEW01636
pilot circuit of the steering demand valve.
In addition, the port at the pump end and the port
at the tank end are connected by check valve (3)
inside the housing. If there is any failure in the
PPC pump, oil is sucked in directly from the tank
end by the check valve.
SEW01416
WA600- 1 41-35
0
OPERATION
When turning
To steerins demand valve
To hudiaulic From PPC PUIUP

tank SEW01639
l When the steering wheel is turned, spool (4) l When the steering wheel is turned, the oil in-
overcomes neutral position spring (1) and side gear (7) flows, passes inside sleeve (5)
turns slightly in relation to sleeve (5). Because and spool (4), operates the spool of the steer-
of this rotation, the ports of sleeve (5) and ing demand valve, and actuates the steering
spool (4) overlap, so a passage is formed for cylinders.
the oil to flow, and the oil flows to gear (7).
At neutral
To steerino demand valve
To hydraulic From PPC PUIUP

tank SEW01640
l When the turning of the steering wheel is l When the non-reaction type steering valve is
stopped (the rotation of the spool is stopped), at the neutral position, the steering cylinder
the return force of neutral position spring (I) and spool (4) and sleeve (5) are blocked, so
returns spool (4) and sleeve (5) to the neutral the reaction from the machine is not transmit-
position, so the oil passage is shut off and the ted to the steering wheel.
oil stops flowing.
41-36 WA600- 1
0
STEERING SYSTEM
Standard value table ................................... 42- 2

Tool list for testing and adjusting .............. .42- 2
Measuring play of steering wheel ............. .42- 3
Measuring operating force of
steering wheel .......................................... 42- 4
Measuring operating time of
steering wheel .......................................... 42- 5
Testing and adjusting of steering linkage.. 42- 6
Adjusting steering linkage .......................... 42- 7
Measuring steering oil pressure.. ............. .42-8-4
Adjusting joystick steering.. ...................... .42-8-7
Troubleshooting. .......................................... 42- 9
* The following precautions are necessary when using the Standard Valve tables to make judgements
during troubleshooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they
should be used at target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values
based on the standard values for the machine when shipped from the plant, and on the results
of various tests.
Therefore, they should be used as reference in combination with repair and operating recods
when making judgements.
3. These standard valus tables must not be used for standard values when judging claims. In addi-
tion, do not use these values alone to make simple judgements.
WA600- 1 42-1
0
Testing and measuring item

I
Measurement condition 1 Unit 1 Standard value 1 Permissible va;
Steering wheel Engine speed: Engine stop

* Steering wheel play Road surface: Flat mm 20 - 70 20-100
* Steering wheel operating force horizontal, dry, paved surface kg 1 .o - 2.0 Max. 3.0
. Operating time of steering wheel * Hydraulic oil temperature: sec.
(Low idling) 45 - 55°C 3.8 - 4.3 Max. 6.5
(High idling) - Machine posture: 2.8 - 3.1 Max. 4.5
Facing straight
Tire inflation pressure:
wi Specified pressure
- Clearance between front and rear frame
Steering oil pressure Hydraulic oil temperature:

+10
* Main relief oil pressure 45 - 55°C kg/cm’ 210+; 210_ 8
Engine speed: High idling
I I
No. Testing and measuring item Tool Name Part No. Remarks
1 Steering wheel operating force Push-pullscale 79A-264-0020 O-25 kg

I I
2 Steering wheel operating play Convex scale Commercially available -
3 Steering wheel operating time Stop watch Commercially available 1 I1 0 second
Clearance between front frame -

4 Convex scale Commercially available
and rear frame
5 Steering oil pressure Hydraulic tester 799-l 01-5000 0 - 250 kg/c&
A When carrying out testing, adjusting or troubleshooting,

bar on the frame, lower the bucket to the ground, and stop the engine.
stop the machine on level ground, install the safety
A When installing or removing gauges, loosen the oil filler cap slowly to release the pressure inside the hydraulic
tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping.
A When taking measurements, do not allow unauthorized persons near the machine.
A The oil in the circuit is hot, so be careful not to get burnt.
42-2 WA600-1
0
MEASURING PLAY OF STEERING WHEEL
- Engine pseed: Stopped
- Machine posture: Facing straight forward
Measurement method
1. Turn the steering wheel two or three times lightly to

the left and right to confirm the center position of
the steering mechanism, then make mark (I) on the
outside frame of the machine monitor.
2. Turn the steering wheel to the right, align the posi-

tion where the operating force of the steering wheel
starts to become heavy (the point where the lever of
the steering valve starts to move) with mark (1). and
make mark (2) on the steering wheel.
3. Turn the steering wheel to the left, align the posi-

d-4 Prav
tion where the operating force of the steering wheel

starts to become heavy (the point where the lever of
the steering valve starts to move) with mark (1). and
make mark (3) on the steering wheel. Then measure
the distance in a straight line between mark (2) and
mark (3).
419F302A
Serial No. lOOOl--10880 Serial No. 10881 and UP

(except D spec.) (except D spec.)
* Inspect the steering linkage (4) and (5) for looseness

and play. If any, adjust the linkage.
1. Loosen locknuts (6) on the steering gear box.
2. Then, adjust by turning adjustment screw (7) in or

out.
* To decrease the play, turn the adjustment screw (7)

in, to increase the play, turn the screw out.
” _,,,
,,\:<a..-426P047b
423F311
WA600-1 42-3
8
MEASURING OPERATING FORCE OF STEERING WHEEL
- Road surface: Flat, horizontal, dry, paved surface.
* Coolant temperature: Inside operating range.
- Hydraulic oil temperature: 45 to 55’C
* Tire inflation pressure: Specified pressure.
- Engine speed: Low idling (bucket unload).
Unit: mm
I tern Standard value Permissible value
Force of steering wheel 1 .o - 2.0 Max. 3.0
Special tool

A 79A-262-0020 Push-pull scale 1
Measuring procedure
1. Hook push-pull scale A to the knob of the steering

wheel.
* Hook push-pull scale A to the center of knob.
2. Start the engine.

* After starting the engine, raise the bucket about
400 mm and remove the safety bar.
3. Set push-pull scale A at a tangent, and read thevalue

when the steering wheel is moving smoothly.
+ Do not read the value at the time the steering
wheel starts to move.
WA600- 1
MEASURING OPERATING TIME OF STEERING WHEEL
- Road surface: Flat, horizontal, dry, paved surface.
- Coolant temperature: Inside operating range.
- Hydraulic oil temperature: 45 to 55°C
- Tire inflation pressure: Specified pressure.
- Engine speed: Low idling and high idling.
Unit: sec.
^ _ ..,,
Low idling
Operating time
of steering wheel
Special tool
A 79A-262-0550 Stop watch 1
Measuring procedure
* After starting the engine, raise the bucket about
400 mm and remove the safety bar.
2. Turn the steering wheel so that the machine is

turned fully to the left or fully to the right.
3. Measure the time taken for the steering wheel to be

turned to the right (left) to the full lock position.
* Turn the steering wheel as fast as possible with-
out forcing it.
* Measure at low idling and high idling, and when
turning to the right and to the left.
WA600- 1 42-5
@
TESTING AND ADJUSTING OF STEERING LINKAGE
Measurement condition
Hydraulic oil temperature: 45 to 55*C
Road surface: Flat, horizontal, dry, paved surface
Tire inflation pressure: Specified pressure
Engine speed: 1200 rpm
Center lever: Right angle with the machine center
line.
Pitman arm: Perpendicular to the machine rear
frame.
426F258
Measuring procedure
1. Start the engine and operate the steering wheel to
set the front and rear frames in a straight line.
2. Check looseness of mounting bolt (1) and nut (2) of
linkage and play of ball joint (3), rod (4), and center
lever bearing (5).
3. Check that the center lever (6) is at right angles to
the center line of the machine.
* The steering spool should be at neutral.
4. Check that the pitman arm (7) is perpendicular.
5. Start the engine and turn the steering wheel to the
left and right to the full lock position. Measure
clearance “a” between the front frame and rear 426F259
frame stoppers.
* When measuring the clearance to the right, ad-
justment screw (8) should be in contact with
pitman arm.
When measuring the clearance to the left, adjust-
ment screw (9) should be in contact with pitman
arm.
* When measuring the clearance, adjustment screws
(10) and (1 1) do not in contact with center lever
(6) respectively.
(Clearance)
423F313
426F260
42-6 WA600-1
0
Adjustment procedure
1. Set the machine facing in a straight line.
A, Install the safety bar and stop the engine.
2. Disconnect steering linkage (1).

3. Adjust steering linkage (2), so that when steering
valve lever is at neutral, center lever is right angle
with chassis center line.
4. Set pitman arm (4) perpendicular to front frame,
adjust length of steering linkage (I), then connect
with center lever and pitman arm.
5. Remove the safety bar.
6. Start the engine, turn the steering wheel to the left
and right to the full lock position. Adjust so that
the pitman arm contacts stopper bolts (5) and (6)
when the clearance “a” between the front frame
and rear frame stopper is 23 to 27 mm, then tighten
the nut.
426PO56
(Clearance)
423F313
WA600-1 42-7
7. Stop engine.
8. Adjust so that stopper bolt (7) contact with center
lever (3) when turn steering wheel to left to full
lock position. Then return steering wheel to neutral
position.
9 Loosen stopper bolt (7) l/2 turns and lock nut (8).
* Adjust right turn as same procedure.
* After making above adjustment, check again that
value is within standard value.
426F261
42-8 WA600- 1
0
Testing conditions
Hydraulic oil temperature: 45 - 55’C
Engine’speed: 1200 rpm
Road surface: Flat, horizontal, dry, paved road sur-
face
Tire inflation pressure: Specified pressure
Set the center lever at right angles to the center line
of the chassis.
Set pitman arm (7) perpendicular to the rear frame.
Test method
1. Start the engine, operate the steering wheel, set the

4 ‘1 426FO1104
front and rear frames in a straight line, then stop the

engine.
2. Check linkage mounting bolt (1) and nut (2) for

looseness, and check ball joint (3), rod (4). and
center lever bearing (5) for play.
3. Check that face b of center lever (6j is at right angle

to the center line of the chassis.
* The steering spool is at neutral.
4. Check that pitman arm (7) is perpendicular.
5. Start the engine, and measure clearance a between

the front and rear frame stoppers when the steering
wheel is turned fully to the left and right.
* When measuring the clearance on the right, ad-
justment screw (8) contacts pitman arm (7).
When measuring the clearance on the left, ad-
justment screw (9) contacts pitman arm (7).
(Clearance)
423F313
WA600-1 42-8-l
8
* Check that adjustment screws (10) and (11) are
not contact with center lever (6).
426FO1106
Adjustment method
1 Set the machine facing straight forward.
A Fit. the safety bar and stop the engine.
2. Disconnect steering linkage (1).
3. Adjust steering linkage (2), and set so that face b of

center lever (3) isat right angles to the center of the
chassis when the steering valve lever is at neutral.
4. Set pitman arm (4) perpendicular to the front

frame, adjust the length of steering linkage (1). then
connect the center lever and pitman arm.
--\
5. Remove the safety bar.
0:o’,
0
6. Start the engine, adjust so that the pitman arm (4)
contacts stopper bolts (5) and (6). and so that the o-0
0 0/I
clearance between the front frame and rear frame ,’
stoppers is clearance a when the steering wheel is /I ,l
/ !I
turned fully to the left and right, then lock with
the nut.
Clearance a: 25 + 2 mm
;:
-_I_
a (Clearance)
423F313
42-8-2 WA600-1
@
7. Stop the engine.
8. Adjust so that stopper bolt (7) contacts lever (3)

when the steering wheel is turned fully to the left,
3
then .return the steering wheel to the neutral posi-
tion. For turning right
Face b
9. Turn back stopper bolt (7) l/2 turns, and lock with
nut (8).
* Carry out the same operation for turning to the
right.
* After carrying out the above adjustments, check
again to confirm that the measurements are
within the standard value. 426FO1107
WA600-1 42-8-3
@I
MEASURING STEERING OIL PRESSURE
- Hydraulic oil temperature: 45 to 55°C
* Engine speed: High idling
Measuring main relief pressure
Serial No. 10001-10867
A Loosen
pressure
the
inside
oil
the
filler cap
hydraulic
slowly
tank.
to
Then
release the
operate
the steering wheel several times to release the re-
maining pressure in the hydraulic piping.
426PO59
1. Fit safety bar (I) on the frame.
2. Remove plug (2) for measuring the right turn
steering circuit.
3. Install hydraulic tester A to the measuring port.
4. Start the engine and run at high idling. Turn the
steering wheel to the right and measure the pres-
sure when the relief valve is actuated.
* When removing the plug (3) for the left turn
steering circuit, turn the steering wheel to
the left and measure.
42-8-4 WA600- 1
@
Measuring main relief pressure
U
A.
4
Y Before loosening
(7) of the pressurizing
the oil filler
valve.
cap, close valve
* & Loosen the oil filler cap slowly to release the

A+ pressure inside the hydraulic tank.
u & Operate the steering wheel several times to re-

A+ lease the remaining pressure in the hydraulic
piping.
1. Fit safety bar (1) to the frame.
2. Remove plug (2) for measuring the right turn steer-

ing circuit.
3. Install hydraulic test kit @ to the measurement

port.
* Tighten the oil filler cap, and open valve (7) of
the pressurizing valve.
4. Start the engine, run at high idling, then turn the

steering wheel to the right, and measure the hydrau-
lic pressure when the relief valve is actuated.
* When plug (3) of the left turn steering circuit is
removed, turn the steering wheel to the left and
measure the hydraulic pressure.
* After completing the measurement, check that
valve (7) of the pressurizing valve is open.
426PO59
42-8-5
0
A Always stop
draulic pressure.
the engine before adjusting the hy-
1. Stop the engine.

2. Remove cap nut (4) of the relief valve.
3. Loosen lock nut (5). then turn adjustment screw
(6) to adjust.
* Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 24.8 kg/cm2
* Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
423F315
To DECREASE pressure, LOOSEN screw.
* If the relief pressure cannot be measured ac-
curately, do not try to adjust the pressure.
42-8-6 WA600-1
Go
TESTING AND ADJUSTING ADJUSTING JOYSTICK STEERING
ADJUSTING JOYSTICK STEERING
ADJUSTING STOPPER BOLT (FOR STOP VALVE)

Preparatory work
Operate the steering before adjusting the stop-
per bolt and check that there is contact of the
frame stopper at the steering end.
* If there is no contact because of chipping of
the frame stopper, carry out repairs so that
there is contact on both the left and right sides.
Adjusting
1. Set the stopper bolt to the minimum length.
Minimum
TDW01034
2. Run the engine at low idling and operate the steer-

ing slowly to contact the frame end.
Stop valve Bolt Lock nut
In this condition, loosen the bolt to pull it out un-
til the head of the stopper bolt contacts the tip of
the stop valve spool.
Ir Be careful not to loosen the bolt too far and
push the spool.
SPbOl
I TDW01035
3. From this condition, turn the chassis back to make

a clearance of approx. 20 mm between the tip of
the stop valve and the head of the stopper bolt, 4. 9-15.6mm
then stop the engine.
4. From the condition in Step 31, loosen the bolt 8.5

- 9 turns (14.9 - 15.8 mm), and secure it in posi-
tion with the lock nut.
5. Carry out Steps 1) to 4) on the opposite side.

Lock nut
TDW01036
WA600- 1
ADJUSTING JOYSTICK LEVER POTENTIOMETER

Preparatory work System cut-off switch
Loosen the potentiometer mounting screws, re- \ CN11
move potentiometer connector CN3, then connect
a T-adapter (X type 3-pin).
* Turn the starting switch OFF before doing this.
7 CNl
Neutral
detect ion
switch Potentiometer
1. Adjusting neutral position

1) Set the joystick selector switch to the OFF po-
sition wheel mark side) and set the joystick Turnins
..“I..“.
posit ion
to left
lever to the N position.
Turnins
tn riaht
2) Turn the starting switch ON.
* Turn only to the ON position. do not start
Joust ick- Kz
the engine. lever
X TEW01037
3) Check the voltage between pins @ and @ of

Joust ick
the T-adapter. selector switch
l Voltage between pins: DC 5V + 0.05V
Adjust the voltage by turning the potenti-
ometer slowly so that the voltage between
pins @ and @ of the T-adapter become
the standard value.
. Voltage between pins: DC 2.5V f O.lV (set
value)
After adjusting the voltage, tighten the poten-
tiometer mounting screws. Y
TEWO1038
Potentiometer
/ Potentiometer
Mountin; screws
TEW01040
42-8-8
0
2. Adjusting left and right turning position

1) Operate the potentiometer to adjust the volt-
Neutral
age at the left and right turn positions.
I Lever position
Voltage between
Dins (I) and (3) I
I Leftturn 1 DC0.83VkO.lV 1
1 Right turn ) DC 4.17V * O.lV J Turn lever
to r
2) After adjusting the voltage, lock the stopper

bolt in position.
TEW01041
ADJUSTING JOYSTICK LEVER NEUTRAL

DETECTION SWITCH Neutral
posit ion
Preparatory work
After adjusting the neutral position with the po-
tentiometer, set the lever to the neutral position
and loosen the nut of the cam plate.
Adjusting
1) Set so that the tip of the roller of the neutral de-
tection switch contacts the concave portion of the
cam plate, then tighten the switch mounting bolts.
Ir Never make the roller of the neutral detection
switch push into the concave portion of the
cam plate.
2) Tighten the nut so that the cam plate is not at an

angle. switch
TEW01042
WA600-1 42-8-9
0
TROUBLESHOOTING
Troubleshooting table . . .. . . .. . . .. . . . . . . . .. . .._...... 42-11

1. Steering wheel does not turn . .. . .. . . . . .. ...42-11
2. Steering wheel is sluggish . . .. . . .. .. .. . . . . . . . . 42-12
3. Steering wheel moves unsteadily or
is subjected to large shock .. . . .. . . . . . . . . .. .. . 42-13
4. Machine tends to turn naturally in one
particular direction when traveling . . .. . 42-13
5. Left and right turning radii
are different . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . 42-13
Troubleshooting of joystick steering
controller system (J mode) . . . . . . . .. . . . .. .. .. . 42-l 5
* Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOT-
ING” page 22-12, “METHOD OF READING TROUBLESHIITING TABLE” page 22-14 and “PREVENTING
RECURRENCE OF TROUBLE” page 22-16.
WA600- 1 42-9
0
1. Steering wheel does not turn.
Ask the operator the following questions.

* Did the steering wheel suddenly cease to turn?
+ Damage to equipment in steering circuit.
* Did steering wheel show signs of being slug-
gish for some time?+ Worn parts in steering
circuit or faulty seal.
Checks before troubleshooting.

- Is oil level in hydraulic tank and type of oil
satisfactory?
+ Is there any damage to the steering gear box or
the steering linkage?
- Has the safety bar been removed from the frame?
- Is the steering linkage properly adjusted?
I I I / / / / / t
I a b c d e f g
Remedy A A A A A A A
\ x x x x x x x
1 Steering wheel cannot turn left or right. 0 0 0 0 0
Fault of item 1 and also work equipment does not

2
operate normally.
0
3 Steering wheel can only turn to either left or right. 0 0
4 Steering wheel is sluggish and does not turn properly. 0 0 0 0
5 Oil pressure in steering circuit does not rise at ali 0 0
* Because the steering circuit and the work equip-

ment circuit are intimately related to each other,
check the operation of the work equipment if the
steering behaves abnormally.

WA600- 1 42-l 1
0
2. Steering wheel is sluggish.

- Did the steering wheel suddenly become slug-
guish?
Damage to equipment in steering circuit.
- Did the steering wheel show signs of being slug-
gish for some time? -+ Worn parts in steering
circuit or faulty seal.

- Is oil level in hydraulic tank and type of oil
satisfactory?
* Is there any abnormality in the steering gear box
mounting part, steering column or linkage?
- IS the adjustment of the steering valve control
lever correct?
* Is there any oil leakage from the oil pressure
hose, valves, cylinders, etc.?
* Is there any seizure between the pin, pin bearing
and bushing of the center hinge and the steering
cylinder pin and bushing?
- Check tire inflation pressure.
Fault check
- Measure the operating force of the steering
wheel and also the time required to turn the
machine when the steering is operated, then
check the results against the standard value
table to see whether or not there is any
abnormality.
ring wheel is sluggish in one of left and right directions.

42-12
0
3. Steering wheel moves unsteadily or is subjected to
large shock.

* Is oil level in hydraulic tank and also oil type
satisfactory?
- Is there any damage to the steering gear box
mounting part, steering column or linkage?
- Is there any play in the center pin hinge bear-
ring or steering cylinder pin bushing?
- Does tire inflation pressure fluctuate?
- Is play of steering wheel within standard value?
Fault check
Operate the wheel loader in a safe place and
check the conditions under which the steering
wheel becomes unsteady.
* If, in addition to the steering wheel being
unsteady, there are other faults such as
sluggishness, etc., refer to item 2 “Steering
wheel is sluggish”.
Machine body becomes unsteady when traveling at high speed.
Machine body becomes unsteady during engine starting.
4. Machine tends to turn naturally in one particular

direction when traveling.
Cause: Faulty steering valve

- Incorrect positioning of spool
* Faulty safety valve
* Oil leakage in steering cylinder.
- Does tire inflation pressure fluctuate? The following symbols are used to indicate the action
5. Left and right turning radii are different.
Cause: Incorrectly adjusted steering linkage.

Left and right steering balance, lock posi-
tion of stopper.
(Valve relief noise can be heard upon
completion of turning.)
WA600- 1 42-13
0
TROUBLESHOOTING OF JOYSTICK STEERING
CONTROLLER SYSTEM
(J MODE)
1. Function ........................................................................................................................................... 42-17
2. Troubleshooting .............................................................................................................................. 42-17
3. Table of failure codes ...................................................................................................................... 42-17
4. Table of failure modes and causes ............................................................................................... 42-18
J-l Failure code 1121

Abnormality in transmission F relay system ............................................................................... 42-19
J-2 Failure code 1131

Abnormality in transmission R relay system ............................................................................... 42-20
J-3 Failure code [I81

Abnormality in transmission N relay system .............................................................................. 42-21

Abnormality in caution lamp system ........................................................................................... 42-22

Abnormality in joystick steering F,N,R signal system ................................................................. 42-23
J-6 Failure code [301

Disconnection in steering R.H. steering solenoid ....................................................................... 42-24

Short circuit in steering R.H. steering solenoid ........................................................................... 42-25

Disconnection in steering L.H. steering solenoid ........................................................................ 42-26

Short circuit in steering L.H. steering solenoid ........................................................................... 42-27
J-IO Failure code 1341

Abnormality in steering solenoid cut relay system ..................................................................... 42-28
J-II Failure code [361

Abnormality in joystick steering neutral signal system .............................................................. 42-29

Abnormality in joystick steering lever potentiometer.. ............................................................... 42-30

Abnormality in model selection wiring harness ......................................................................... 42-31

Abnormality in power source voltage.. ........................................................................................ 42-32
J-15 Abnormality in joystick steering ON-OFF signal system ............................................................ 42-33
WA600- 1 42-15
0
J-16 Abnormality in transmission F solenoid system ......................................................................... 42-34
J-17 Abnormality in transmission R solenoid system ........................................................................ 42-35
J-18 Abnormality in transmission N solenoid system ........................................................................ 42-36
J-19 Disconnection in joystick steering F switch system .................................................................... 42-37
J-20 Disconnection in joystick steering R switch system.. .................................................................. 42-38
J-21 Disconnection in joystick steering N switch system .................................................................. 42-39
42-16 WA&O- 1
0
TROUBLESHOOTING JOYSTICK STEERING CONTROLLER SYSTEM
1. FUNCTION
The control mechanism of the joystick steering
controller consists of the controller, neutral de-
tection switch, potentiometer input, solenoid
valve output, and F,N,R display lamp output. This
control mechanism carries out control of the steer-
ing. The controller receives the data from the po-
tentiometer and neutral detection switch, carries
out processing according to the input signals from
each switch, and controls the solenoid valves.
2. TROUBLESHOOTING
The joystickcontroller has a troubleshooting func-
tion, and when failure codes J-l to J-14 are de-
tected, the failure mode is displayed on the digi-
tal display of the controller which is installed in-
side the right console box. There is no detection
function for failure codes J-15 to J-21. They are
used when there is a disconnection or other prob-
lem in the transmission F, N, or R solenoid relays
or switches.
3. TABLE OF FAILURE CODES
No. Code Nature of abnormality No. Code Nature of abnormality
Abnormality in transmission Abnormality in joystick steering

J-l 12 F relay system J-12 37 lever potentiometer
r J-2 ‘3 )
Abnormality in transmission
R relay system J-13 1 38
Abnormality in model selection
1 wiring harness I
F solenoid system
( J-9 ) 33
Short circuit in steering
L.H. steering solenoid J-20 1 - I
Disconnection in joystick steering
R switch system I
Abnormality in steering Disconnection in joystick steering
J-IO 34 solenoid cut relay system J-21 - N switch system
Abnormality in joystick steering

J-II 36 neutral signal system
WA600- 1 42-17
0
TROUBLESHOOTING JOYSTICK STEERING CONTROLLER SYSTEM
4. TABLE OF FAILURE MODES AND CAUSES
S/l turns fully to right 0 0 0
Veither S/l nor T/M work 0 0 0
* JST: Joystick steering

S/T : Steering
T/M: Transmission
42-18 WA600- 1
0
TROUBLESHOOTING J-l
J-l FAILURE CODE [12] ABNORMALITY IN TRANSMISSION F RELAY

SYSTEM
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Except when using the joystick steering lever, place it at the N position and turn the joystick steering
selector switch ON.
* Always connect any disconnected connectors before going on to the next step.
Ir Turn the starting switch to the OFF position before disconnecting any connector.
Cause Remedy
YES
Defective controller Replace
1
Is resistance I Defective contact or
Repair or
3 YES disconnection in wiring
I
between CNJSJ replace wiring
(female) (21) and Is resistance harness between CNJM (1)
harness
chassis normal? t and CNJS3 (21)
YES between CNJS4
1) Disconnect ;! (female) (2) and Defective contact or
chassis normal? Repair or
!
CNJS3. Is resistance disconnection in wiring
replace wiring
2) 250 - 33022 between CNJS4 _ 1) Disconnect NO harness between CNJS4 (2)
harness
and chassis
N IO (male) (1) and (2) CNJM.
normal? 2) Max. 1Q
1) Disconnect Defective CNJS4 F output
Replace
CNJS4. NO reverse relay
2) 250 - 33052
F selector
I:N.lSl!I relay
Controller
iNJS3
TDW01043
WA600- 1 42-19
0
TROUBLESHOOTING J-2
J-2 FAILURE CODE [13] ABNORMALITY IN TRANSMISSION R RELAY

SYSTEM
selector switch ON.
Ir Turn the starting switch to the OFF position before disconnecting any connector.
I Cause Remedy
YES
I
1 I
7
Is resistance contact or
Repair or
between CNJS3 YES disconnection wiring
replace wiring
(female) (20) and Is harness between (1)
harness
chassis normal? between and CNJS3
(female) (2)
contact or
in wiring
replace wiring
Disconnect NO between CNJSL
harness
(2) CNJSS. and
Replace
R selector
NJS13 relay
Controller
CNJS3
R output
CNJS!j reverse relay
CND7
TDW01044
42-20 WA600- 1
0
TROUBLESHOOTING J-3
J-3 FAILURE CODE [18] ABNORMALITY IN TRANSMISSION N RELAY

SYSTEM
selector switch ON.
Ir Always connect any disconnected connectors before going on to the next step.
j, Turn the starting switch to the OFF position before disconnecting any connector.
Replace
Is resistance
Repair or
between CNJS3
replace wiring
(female) (11) and Is resistance harness
chassis normal? YES between CNJSG and CNJS3 (11)
1) Disconnect 2 (female) (2) and Defective contact or

CNJSJ. Is resistance disconnection in wiring
replace wiring
2) 250 - 33O.Q between CNJSG _ 1) Disconnect harness between CNJSG (2)
harness
NO (male) (1) and (2) and chassis
CNJSG.
normal? 2) Max. 1Q
1) Disconnect N output
Replace
CNJSG. NO
2) 250 - 330R I
N selector
CNJS14 relay
1
2
6
Controller
45 6
iNJS3
N output
ChJ.56 reverse rela
TDW01045
WA600- 1 42-21
0
TROUBLESHOOTING J-4
J-4 FAILURE CODE [I91 ABNORMALITY IN CAUTION LAMP SYSTEM
selector switch ON.
* Turn the starting switch to the OFF position before disconnecting any connector.
Cause Remedy
Replace
1
Is resistance II Repair or
bewee” CNJSI
replace wiring
(female) (16) and
harness
chassis normal? YES
1) Disconnect 2 r
Repair or
CNJSl. Is resistance -1 I
H
replace wiring
2) 250 - 33OQ between CNJSll
harness
1) Disconnect
Replace
CNJSll.
2) 250 - 33022 I
Controller
CiJS3
taut ion
CbiJSl CNJSl 1 lamp relay
3
relay
3
CNDl
TDW01046
42-22 WA600- 1
0
TROUBLESHOOTING J-5
J-5 FAILURE CODE [25] ABNORMALITY IN JOYSTICK STEERING F,N,R

SIGNAL SYSTEM
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
selector switch ON.
* Turn the starting switch to the OFF position before disconnecting any connector, or before connect-
ing the T-adapter (or socket).
Remedy
Replace
Replace, repair
YES
2 r JST lever N
switch, or repair,
replace wiring
YES harness
IW
CNJSZ and I Replace ,
repair
JST lever R
switch, or repair,
replace wiring
harness
1) Disconnect Replace ,
repair
CNJSP and JST lever F
CNJS3. switch, or repair,
2) Min. 1MQ replace wiring
harness
Controller
C’NJSS
Joust ick
steering lever
CN2
CNJS2 CNl ocz
TOW01047
WA600- 1 42-23
TROUBLESHOOTING J-6
J-6 FAILURE CODE [30] DISCONNECTION IN STEERING R.H. STEERING

SOLENOID
selector switch ON.
* Insert the T-adapter to CNJS3 and turn the starting &itch-ON.
Cause Remedy
Defective controller or
YES defective CNJS7 cut relay Replace
(see Troubleshooting No.
10)
Defective contact or Repair or

r
Is resistance
1
II ifzzz7-
4 YEI disconnection in wiring
harness between CNJS7 (3)
replace wiring
harness
between CNJS3 YES and CNJSB (16)
(7) and CNJS3 (16) 3 Defective contact or Repair or
normal? Is resistance disconnection in wiring
YES between CNJS17 replace wiring
1) insert T-adapter.
- (male) (1) and 1) Disconnect NO harness between CNJS17 harness
2) Turn starting CNJS7 and (1) and CNJS7 (5)
CNJSl7 (male) (2)
switch ON. 2 normal? CNJS17.
3) Max. 3OQ 1) Disconnect 2) Max. IQ
Is resistance bet- Defective R.H. steering Replace
_ wean CNJS3 (7) _ CNJS17. NO solenoid valve
NO and CNJS17 (fe- 2) Max. 3OQ
male) (2) normal?
1) Turn starting disconnection in wiring replace wiring
switch OFF. NO harness between CNJS3 (7) harness
2) Disconnect and CNJS17 (2)
CNJS17.
3) Max. IQ
Controller
Steer ina
CNJS3 solenoid
CNJ S7 cut relay
I::q-
I I
I I I
Steer ine TDW01048
solenoid valve
42-24 WA600-1
0
TROUBLESHOOTING J-7
J-7 FAILURE CODE [31] SHORT CIRCUIT IN STEERING R.H. STEERING

SOLENOID
selector switch ON.
* Insert the T-adapter to CNJS3 and turn the starting switch ON.
Cause Remedy
3 YES
Isresistance
yES between CNJS3
- (female) (16) and -
2 CNJS7 (female) (3) Disconnection in wiring
lsresistance Repair or
normal? harness between CNJS7 (3)
replace wiring
YES between CNJS17 _ 1) Disconnect NO and CNJS17 (1). or short
harness
- (male) (1) and
1 CNJSl7 (male) (2) CNJS7 and circuit with ground
normal? I CNJS17.
between CNJS3 1) Disconnect 2) Max. 1Q Short circuit in R.H. steering
Replace
(female) (7) and CNJS17. NO solenoid
chassis normal? 2) lo-30R
1) Disconnect
CNJS3. Short circuit in power Repair or
2) Min. IOR source between CNJSJ (7) replace wiring
and CNJS17 (2) harness
Controller
Steer ine
CidJS3 solenoid
IS7 cut relay
R. H. S/T solenoid (+I
S/T solenoid cut relay
ChJS17
steer In0 TDW01048

solenoid valve
WA600- 1 42-25
0
TROUBLESHOOTING J-8
J-8 FAILURE CODE [32] DISCONNECTION IN STEERING L.H. STEERING

SOLENOID
selector switch ON.
Cause Remedy
Defective controller or
YES defective CNJS7 cut relay
Replace
(see Troubleshooting No.
10)
Defective contact or
1 I 4 YE: disconnection in wiring
Repair or
Is resistance Is resistance lr harness between CNJS7 (3)

replace wiring
I
harness
YES and CNJS3 (16)
r
between CNJS3
(6) and CNJS3 (16) l-l 3 Defective contact or
normal? Repair or
disconnection in wiring
replace wiring
1) Insert T-adapter. 1) Disconnect NO harness between CNJS16
harness
2) Turn starting CNJS7 and (1) and CNJS7 (5)
switch ON.
3) Max. 3OQ
Defective L.H. aeering
Replace
solenoid valve
male) (2) normal?

_. - ‘I Defective contact or
Repair or
1) I urn stamng I disconnection in wiring
replace wiring
switch OFF. NO harness between CNJSJ (6)
harness
2) Disconnect and CNJS16 (2)
CNJS16.
3) Max. IQ
Controller
Steer ine
&JS3 solenoid
IS7 cut relay
p?ilEEj= -
0 A
I I
Left turn
J
Steer ina
solenoid valve
CtlJSl6
a- L
a
TDWO 1049
42-26 WA600- 1
0
TROUBLESHOOTING J-9
J-9 FAILURE CODE [33] SHORT CIRCUIT IN STEERING L.H. STEERING

SOLENOID
+ Except when using the joystick steering lever, place it at the N position and turn the joystick steering
selector switch ON.
I Cause Remedy
3 YES
Isresistance
YES between CNJSS

2
~ CNJS7 (female) (3) Disconnection in wiring
Is resistance Repair or
normal? harness between CNJS7 (3)
between CNJS16 replace wiring
YES
(male) (1) and
_ 1) Disconnect NO and CNJSlG(1). or short
harness
circuit with ground
1 CNJS7 and
H
CNJS16 (male) (2)
Is resistance normal? CNJS16.
between CNJSB 2) Max. 1R

1) Disconnect Short circuit in LH. steering
Replace
(6) and chassis CNJS16. NO solenoid
normal? 2) lo-30R
1) Disconnect I Short circuit in power Repair or

CNJSB. I
source between CNJS3 (6) replace wiring
2) Min. 1OQ NO and CNJS16 (2)
harness
Controller
Steer ina
Ct’4JS3 solenoid
ChJS7 cut relay
Steer ina
solenoid valve
CtqJSl6
@
a
TDWOlO49
WA600-1 42-27
0
TROUBLESHOOTING J-IO
J-IO FAILURE CODE [34] ABNORMALITY IN STEERING SOLENOID CUT

RELAY SYSTEM
selector switch ON.
f Turn the starting switch to the OFF position before disconnecting any connector, or before connect-
Cause Remedy
YES
1
H
Is resistance
between CNJSl
(female) (7) and
chassis normal?
1) Disconnect
Is resistance
YES
2
Is resistance
3 YES
II
harness between CNJS7 (2)
and chassis
Repair or
replace wiring
harness
CNJSl. Defective steering SOL cut

between CNJSl Replace
2)50-1lOR NO relay
- (female) (7) and - ‘) DisconneCt
NO CNJS7 (female) (1) CNJS7.
normal? 2)Max.50-110R
Repair or
1) Disconnect disconnection in wiring
replace wiring
CNJS7. NO harness between CNJSI (7)
harness
2) Max. 1R and CNJS7 (1)
Controller
CNJS3
Steer ina
L. H. S/T solenoid solenoid
(+I
CNJS7 cut relay
solenoid valve
I
TDW01050
42-28 WA600- 1
0
TROUBLESHOOTING J-l 1
J-l 1 FAILURE CODE [36] ABNORMALITY IN JOYSTICK STEERING

NEUTRAL SIGNAL SYSTEM
j, Except when using the joystick steering lever, place it at the N position and turn the joystick steering
selector switch 0%
Cause Remedy
YES Reolace
Defective controller
2
Is resistance disconnection in wiring
between CNJSZ Repair or
YES 4 YES harness between CNl (13) replace wiring
- (female) 115)and - and CNJSZ (15). or short
CNJSJ (female1(9) Is resistance harness
circuit with +24V
normal? YES between CNl
3 - (female) (12) and Defective contact or
1) Disconnect Repair or
Is resistance chassis normal? disconnection in wiring
CNJS2 and replace wiring
between CNl
CNJS3. 1
- (female) (12) and - ‘) Disconnect
~0 harness between CNl (12)
and chassis, or short circuit
harness
2) Operate JST NO CNl (female) (13) CNl.
with +24V
between CNJSZ lever fully to normal? 2) Max. 1R
(female) (15) and left or right.
1) Disconnect CNl. \ Defective JST lever neutral Replace
CNJSI (female) (9)
3) Max. la 2) Operate JST NO switch
1) Disconnect lever fully to left

CNJS2 and or right.
I
Repair or
replace wiring
1) Disconnect NO short circuiting with chassis harness
CNl. ground
2) Min. IMQ
Controller
I
Neutral detect ion
CNJS3
GND
CNJS2
@a
;a;
CND18 TDWOlO51
WA600-1 42-29
0
TROUBLESHOOTING J-12
J-12 FAlLl IRE CODE [37] ABNORMALITY IN JOYSTICK STEERING

LEVE 3 POTENTIOMETER
selector switch ON.
+ Connect the T-adapter and turn the starting switch ON.
Cause Remedy
Iefective controller Xeplace
kfective JST 7eplace. adjust

between CNJSS
3otentiometer. center point :enter point
(20) and CNJSP (9) 2 again
mt of alignment
normal?
Iefective contact or
1) 2.4 - 2.6V kconnection in wiring
between CNJSS larness between CNJS2
N( (20) and CNJSS (9) 10) and CNl (10). short
VFS :ircuit with +24V, short
Iepair or
:ircuit with ground or
1) Operate JST ,eplace wiring
jefective contact or
lever to left or Iarness
iisconnection in wirina
right. (0.8 - 4.2V) Jarness between CNJSP (9)
N( snd CNI (11). or short
:ircuit with +24V
Defective JST
lever to leh or NO >otentiometer
right. (0 - 2k.Q)
Controller
I I
CNJS2 CNl CN3 Potentiometer
Potentiometer GND 3 3
Potentiometer input I 3 3
Potentiometer signal qij 3
I I TDW01052
42-30 WA600- 1
0
J-13 FAILURE CODE [38] ABNORMALITY IN MODEL SELECTION WIRING

HARNESS
selector switch ON.
Cause Remedy
YES
3
Is voltage
between CNJSP Disconnection in wiring
Repair or
(18) and chassis 4 YES harness between CNJS28 replace wiring
normal? (1) and chassis, or short harness
_ Is continuity bet-
2 circuit with +24V ground
I) Max. 1V L ween CNJSP (18) _
Is voltage I NO and CNJS28 (fe- Disconnection in wiring Repair or
YE: i between CNJS2 male) (4) normal? harness between CNJS28 replace wiring
(17) and chassis I) Turn starting NO (4) and CNJSZ (18). or short harness
normal? I switch OFF. circuit with +24V ground
I) Max. IV 2) Max. IQ
Disconnection in wiring Repair or
5 YES harness between CNJS28 replace wiring
(1) and chassis, or short harness
circuit with +24V ground
between CNJSP Nf PIP
(16) and chassis harness between CNJS28 replace wiring
I) Turn starting NO 13) and CNJS2 (17). or short harness
switch OFF. circuit with +24V ground
I) Insert T-adapter.
2) Turn starting 2) Max. IQ
Disconnection in wiring
switch ON. 6 YES Repair or
harness between CNJS28 replace wiring
3) Max. IV Is continuity (1) and chassis, or short harness
between CNJSZ circuit with +24V ground
. (16) and CNJS28
Repair or
I) Turn starting NO (2) and CNJSS (16). or short harness
switch OFF. circuit with +24V ground
2) Max. 1R
Controller
I
Ct’jJS3
@
I CNJS28
CNJS2
@ Mode I
@ selection
TDWOIDSJ
WA600- 1 42-3 1
0
J-14 FAILURE CODE [39] ABNORMALITY IN POWER SOURCE VOLTAGE
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
selector switch ON.
* Connect the T-adapter and turn the starting switch ON.
Cause Remedy
2 YES Replace
Is continuitv I
YES between CNJS3
(8) and CNJSB (19)
1 normal? disconnection in wiring
Repair or
replace wiring
Is voltage 1) Turn starting NO harness between CNJS3 (8) harness
and CNJS3 (19)
between CNJS3 switch OFF.
(8) and chassis 2) Max. 1 R
1normal? 3 YES Blown chassis spare power Replace
1)20-30V Iscontinuity source fuse
between CNJS19
N0 and CNJSJ (8)
normal? disconnection in wiring
I replace wiring
1) Turn starting NO harness between CNJS3 (8) harness
switch OFF. and CNJS19
2) Disconnect
CNJS19.
3) Max. 1 ZL
Controller
I Spare
CNJS3 Dower
ChJ.519 source
DI I
10A
TDW01054
42-32 WA600- 1
0
J-15 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM
selector switch ON.
Cause Remedy
YES
1 Defective controller Replace
1 1
Repair or
Defective JST console limit
replace wiring
ON-OFF switch
harness
Defective contact of wiring

harness between CNJS2
(14) and CNl (female) (I), Replace switch
I) Turn starting NO or defective JST ON-OFF
switch OFF. switch
2) Disconnect
CNl.
3) Max. 1R
Joust ick
ON-OFF
switch
Spare
cl.412 TDW01055
WA600-1 42-33
0
J-16 ABNORMALITY IN TRANSMISSION F SOLENOID SYSTEM
selector switch ON.
Defective
. controller, or ab-
2 YES normahty in JST FNR signal Rep,ace
system (see Troubleshoot-
ing No. 5)
’ Defective contact or
NO harness between CNJS4 (5)
_ I) Disconnect
(male) (1) and and CNJS12 (5)
CNJSlZ (male) (2) CNJM and
normal? CNJS12.
2) Max. 1Q . Defective CNJSlP F output
1) Disconnect
CNJS12. NO selector relay
2) 250 - 33OQ
From joystick steering

ON-OFF switch F selector
CNJS12 relay
3
To GNDK 3
To transmission<
solenoid
Controller 3/
To transmission lever F
CNJS3
F output
CNJS4 reverse relay
f?$ +E’
CND8
TDW01056
42-34 WA600-1
0
J-17 ABNORMALITY IN TRANSMISSION R SOLENOID SYSTEM
selector switch ON.
Jr Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective controller, or ab-

2 YES normality in JST FNR signal
leplace
ing No. 5)
~~ lepair or
eplace wiring
harness between CNJSB (5)
larness
and CNJS13 (5)
I CNJSB and
CNJS13.
2) Max. 1R
I) Disconnect Defective CNJS13 R output
Leplace
CNJS13. NO selector relay
2) 250 - 33OQ

ON-OFF switch R selector
CNJSl3 relay
To transmission(
solenoid
Controller
I
To transmission lever R
CNJS3
R OUtDUt
CN JS5 reverse relay
8
CND7
TDW01057
WA600-1 42-35
0
J-18 ABNORMALITY IN TRANSMISSION N SOLENOID SYSTEM
selector switch ON.
I Remedy
1
Defective controller, or ab-
.
YES normahty m JST FNR signal ,+,,,ace
ing No. 5)
Repair or
replace wiring
NO $wn.wn;Jgtwy CNJSS (5) harness
1) Disconnect
CNJS.14.
I CNJSlA
2) Max. 1Q
,Deefzzye;;yJS14 N output Rep,ace
NO
2) 250 - 33OQ

ON-OFF sw i t.ch N selector
To transmission_=
solenoid
Controller
I
To transmission lever N
CNJS3
N output
CNJSb reverse relay
TOW01058
42-36 WA600- 1
0
J-19 DISCONNECTION IN JOYSTICK STEERING F SWITCH SYSTEM
selector switch ON.
Cause Remedy
YES
1 I
between CNJS2
(female) (13) and Disconnection in wiring Repair or
CNJSB (female) (8)
2
harness between CNl (6) replace wiring
and chassis power source harness
between CNJS?
(female1(13) and
CNJSZ and
harness between CNJSZ replace wiring
2) Press JST lever 1) Disconnect NO harness
(13) and CNl (5)
F switch. CNJS2 and
3) Max. IQ CNl.
2) Max. 1R
Controller
I I
CNJS3
Joust ick
steering lever
w2
-N
CNJS2 CNl .D ’
-N
3 1 3
-R
3 3~ ,
-F
3 3
3 3
TDWOI047
WA600-1 42-37
0
J-20 DISCONNECTION IN JOYSTICK STEERING R SWITCH SYSTEM
Ir Except when using the joystick steering lever, place it at the N position and turn the joystick steering
selector switch ON.
YES
1
Is resistance
between CNJSZ
(female) (12) and - Disconnection in wiring Repair or
CNJSJ Ifemale) (8) -
2 YES
harness between CNl (6) replace wiring
normal? Is resistance
and chassis power source harness
- between CNJS2
1) Disconnect
CNJS2 and NO CNl (female) (4)
CNJSB. Disconnection in wiring Repair or
normal?
2) Press JST lever 1) Disconnect NO (12) and CNl (4) harness
R switch. CNJS2 and
3) Max. 1R CNl.
2) Max. 1Q
Controller
TDW0104J
42-38 WA600- 1
0
J-21 DISCONNECTION IN JOYSTICK STEERING N SWITCH SYSTEM
selector switch ON.
Cause Remedy 1
YES
1
Is resistance
between CNJSZ
(female) (11) and - Disconnection in wiring Repair or
CNJSB (female) (8) _
2 -YES harness between CNl (6) replace wiring
normal? Is resistance and chassis power source harness
p between CNJSZ
1) Disconnect - (female)(ll)and -
CNJSP and NO CNl (female) (3) Disconnection in wiring Repair or
CNJSJ. normal? replace wiring
harness between CNJSP
2) Press JST lever 1) Disconnect NO (II) and CNl (3) harness
N switch. CNJS2 and
3) Max. 1Q CNl.
2) Max. 1R
Controller
TDWO1047
WA600-1 42-39
0
STEERING SYSTEM
STEERING GEAR STEERING CYLINDER

Serial No. 10001 - 10880 (Except D spec.) Removal ... . . . . _. . . . . . . . . . ... . . . 43-16
r,Serial No. 10001 and up (D spec.) I Installation . . . .... . . . . . . . . .... . . 43-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 43- 2 Disassembly . . . ..... . . . . . . . . .... . . . 43-19
Installation _ . . . . . . . . . . . . . . . . . . . . . . 43- 4 Assembly .. . . . ... . . . . . . . . .... . . . 43-21
STEERING GEAR CENTER HINGE PIN
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 43-5-l
Serial No. 10001 - 10880
[ Serial No. 10001 and up (D spec.)
Removal . . . . . . . . . . . _ . . .
(Except D spec.)
. . . . . . . . . 43-24
1
Installation . . . . . . . . . . . . . . . . . . . . . . 43-5-3
STEERING GEAR BOX Installation . . . . . . _ . _ . _ _ . . . . . . . . . . . 43-32
Disassembly. ..... . . . . . . . . . . . . . . 43- 6 CENTER HINGE PIN
Assembly . . . . . . . . . . . . . . . . . . . . . . 43- 7 [Serial No. 10881 and up (Except D spec.)l
STEERING VALVE Removal . . . . . . . . . . . . . . . . . . . . . . . . 43-42
Removal .... . . .. . . . . . . . . . . . . 43- 9 Installation . . . . . . . . . . . . . . . . . . . . . . . 43-51
Installation .. ....... . . . . . . . . . . . . . 43-l 1
Disassembly and assembly . . . . . . . . . . . . . 43-14
+ Air bleeding procedure
without going to the end of this stroke, (Stop approx. 100 mm before the end of the stroke.)
out from the plug.
w Plug: 1.15 +0.15 kgm
f Before loosening the oil filler cap, close the pressurizing valve; after adding oil, tighten the oil filler cap,
WA600- 1
REMOVAL OF STEERING GEAR
I Serial No. 10001

Serial No. 10001
- 10880 (Except
and up (D spec.)
D spec.)
1
A Stop the
the safety
machine on level ground and install
bar on the frame. Lower the work
moving.
* After stopping the engine, operate the steering wheel

2 or 3 times to the left and right and set the steering
valve in neutral.
1. Covers
Remove covers (1) and (2) under cab.
2. Steering linkage
Disconnect steering linkage (3) from pitman arm.
426P75 1
3. Column joint
Remove lock bolt (41, and pull out column joint (5)
from steering gear shaft.
* Make match marks on the joint and the steering
gear shaft.
* After pulling out the column joint, secure it with
wire to prevent the column joint from dropping
out.
4. Steering gear
1) Remove mounting bolts (6), then remove steer-
ing gear (7).
* The working space is restricted, so be careful
of your fingers.
43-2 WA600- 1
8
2) Remove mounting nut (9) of pitman arm (8).
426P754
3) Using press, remove’ pitman arm from steering

gear (7).
* Before removing, make match marks on the
pitman arm and the steering gear sector shaft.
WA600- 1
INSTALLATION OF STEERING GEAR
No. 10001 and up (D spec.) I
1. Steering gear
1) Align match mark, and install pitman arm (9)
to steering gear (7).
m Mounting nut: 19.0 * 3.0 kgm

426P756
2) Set Steering gear (7) in mounting position, and

m Mounting bolt: 11.5 + 1 .O kgm
2. Column joint
Align match marks of column joint (5) and steering
gear shaft, insert joint, then tighten lockbolt (4).
m Lockbolt (4): 5.7 ? 0.7 kgm
3. Steering linkage
Connect steering linkage (3) to pitman arm.
m Mounting nut: 12.5 + 1.0 kgm
426P75’
43-4 WA600- 1
9
4. Covers
Install covers (I) and (2) under cab.
5. Inspecting steering linkage

After completion of assembly, inspect linkage, and
adjust if necessary.
* For details of inspection and adjustment proce-
dure, see TESTING AND ADJUSTING.
WA600- 1 43-5
2
REMOVAL OF STEERING GEAR
A Stop the machine on level ground and install

the safety bar on the frame. Lower the work
moving.
* After stopping the engine, operate the steering wheel

2 or 3 times to the left and right and set the steering
valve in neutral.
1. Covers
Remove covers (I) and (2) under cab.
2. Steering linkage
Disconnect steering linkage (3) from pitman arm
(4).
3. Column joint
1) Remove 2 bracket mounting bolts (5) on oppo-
site sides, then install 2 bolts A.
* Prepare 2 bolts A (Ml 2 x P1.75, length below
head: 100 mm).
* Tighten bolts A securely.
2) Leaving bolts A in position, remove remaining
mounting bolts (5).
* Remove the mounting bolts carefully.
* Remove the clamps of the electrical wiring.
3) Remove lock bolts (6), then remove column joint
(7) from steering gear shaft.
* Make match
gear shaft.
marks on the joint and steering
426FO1212
u0
426FO1213
* After removing the column joint, secure the

column joint with wire to prevent it from
falling.
* If it falls out, it cannot be installed as it is, so
be extremely careful not to let it fall.
* The working space is confined, so carry out
the work carefully.
426FO1214
43F WA600- 1
4. Steering gear
1) Remove bolts A, then remove steering gear (8)
together with bracket (9).
Steering gear, bracket: 20 kg
2) Remove bracket (9). and mounting nut (10) of

pitman arm (4). then use a puller to remove
pitman arm from steering gear (8).
* Before removing, make match marks on the

pitman arm and steering gear sector shaft.
426FO1215
43:-2
WA600-1
INSTALLATION OF STEERING GEAR
[SerialNo.l0881and up(ExceptD spec.)]
1. Steering gear
1) Align match marks, fit pitman arm (4) to steering
gear (8), then tighten with mounting nut (IO),
and install bracket (9).
w Mounting nut (10): 19 f 3 kgm

w Bracket, steering gear mounting bolt:

11.5 f 1 .O kgm
2) Set steering gear (8) in mounting position, and

install with bolts A. 426FO1215
* Install 2 bolts A (Ml2 x P1.75, length below
head: 100 mm) on opposite sides.
* Tighten bolts A securely.
2. Column joint
1) Align match marks of column joint (7) and steer-
ing gear shaft, then insert joint, and tighten lock
bolt (6).
m Lock bolt (6): 5.7 + 0.7 kgm
2) Install bracket mounting bolts (5).

3) Remove bolts A, and install mounting bolts (5).
426FO1213 426FO1212
3. Steering linkage
Connect steering linkage (3) to pitman arm (4).
w Mounting nut: 12.5 + 1.0 kgm
4. Covers
Install covers (1) and (2) under cab.
5. Inspecting steering linkage

After completion of assembly, inspect linkage, and
adjust if necessary.
* For details of inspection and adjustment proce-
dure, see TEST AND ADJUSTING.
43-5-3 WA600-1
,a
DISASSEMBLY OF STEERING GEAR BOX
1. Side cover
I) Loosen lock nut (3) of adjustment screw (21, then
remove mounting bolts (4) of cover.
2. Sector shaft * ,’ j : c,“,:!:‘;

Turn steering gear shaft (5) so that sector shaft is in x
vertical position, and remove sector shaft (6).
* Be careful not to damage the thread and bushing of 7”
sector gear when removing.
3. Rear cover, shaft, ball nut assembly

Remove rear cover (7), then remove shaft and ball nut
assembly (8).
423P I502A
43-6 WA600- 1
0
ASSEMBLY OF STEERING GEAR BOX
Bearing outer race

1) Press fit bearing outer race (10) on gear box (9) and
rear cover (7).
2) Press fit oil seals (1 I), (12) on gear box and rear
cover.
* If bushing (13) of the gear box is badly worn,
replace the gear box.
Shaft, ball nut assembly, rear cover

Assemble shaft and ball nut assembly (8) in gear box,
then install rear cover (7).
& Shaft, ball nut assembly, bearing (14):

Grease (G2-LI)
* If there is any problem with shaft (15) or ball nut (8)

of the shaft and ball nut assembly, replace the whole
shaft and ball nut assembly.
Adjusting shim
Select shim thickness so that starting torque of shaft is
within standard range.
* First assemble a larger thickness than necessary, then
reduce the thickness to adjust.
* Measure the starting torque with torque wrench A.
* Standard range for starting torque: 3.5 - 6.5 kgcm 4i3P I so-5
w Mounting bolt (4) of rear cover: 4.5 f 1 kgcm
43-7
0
4. Sector shaft, side cover
Assemble so that sector gear is meshed at center of ball
nut.
* If bushing of the side cover (3) is badly worn, replace
the assembly.
@El Mounting bolt: 4.5 f 1 kgcm
5. Adjusting adjustment screw

1) Temporarily install pitman arm (17), move arm light-
ly and tighten adjustment screw (2) so that backlash
is “0”.
2) Turn adjustment screw so that starting torque of

shaft is within standard range, then tighten lock nut.
* Standard range for starting torque: 3.5 - 7 kgcm
m Lock nut: 2.5 f 0.5 kgm
6. Plug, dust cover

Pump in grease through plug mount, install plugs (18)
and (19), then install dust cover‘(20).
REMOVAL OF STEERING VALVE
Serial No. 10868 and UD ID Swc.)
A Stop the
the safety
machine
bar on the frame.
on level ground
Lower
and install
the bucket
the parking brake and put blocks unde,r the
*’ Loosen the oil filler cap slowly to release the

ate the steering wheel and steering lever several
times to the left and right to release the remain-
ing pressure in the hydraulic piping.
* Before loosening the oil filler cap, close
426FOl201
pressurizing valve (1 A).
Serial No. 10881 and up, (Except D soec.)
426FO1202
1. Covers
2. Hydraulic piping
Disconnect the following hoses.
- Remove hose (3) between steering valve and
main control valve at steering valve end.
- Disconnect tube (4) between switch pump and
steering valve at steering valve end.
* Disconnect tube (4) from hose (5), remove
clamp, then remove tube.
- Disconnect hose (6) between steering pump and
WA600-1
* Disconnect tubes (7) and (8) between steering
valve and steering cylinder at steering valve end.
- Disconnect tube (9) between steering valve and

cooler at steering valve end.
- Disconnect tube (10) between hydraulic pump
and steering valve at steering valve end.
* Remove the clamp and move it towards the
right side of the frame.
3. Linkage
Remove steering valve linkage (11) from steering
valve.
* Be careful not to lose the key.
4. Steering valve
1) Screw eyebolts into mounting bolt holes for
cover under cab, then using lever block 0,
sling steering valve.
* Be careful of the center of gravity when fit-
ting the hanging tool.
2) Remove mounting bolts, then lower steering

valve (12) carefully under machine body.
* After lowering the steering valve, pull it out
from the machine body.
Steering valve: 45 kg
INSTALLATION OF STEERING VALVE
1. Steering valve
1) Pull steering valve (12) under machine, screw in
eyebolts into mounting bolt hole of cover under
cab, then using lever block 0 , raise steering
valve.
* Be careful of the center of gravity when set-
ting the lifting tool in position.
2) Set steering valve (12) in mounting position, and

2. Linkage
Install steering valve linkage (11) to steering valve.
* Check that the steering valve is in neutral.
* Align the key groove correctly.
B Mounting bolt: 3.2 f 0.3 kgm
3. Hydraulic piping
Connect the following hydraulic hoses.
- Connect tube (9). between steering valve and
cooler at steering valve end.
* Connect tube (IO) between hydraulic pump and
* Install the tube clamp.
WA600- 1
* Connect tubes (7) and (8) between steering valve
and steering cylinder at steering valve end.
* Connect hose (6) between steering pump and

- Connect tube (4) between switch pump and
* Connect tube (4) to hose (5), and install the
clamp.
* Install hose (3) between steering valve and main
control valve at steering valve end.
4. Covers
Serial No. 10001-10880

(Except D spec.)
Serial No. 10001 and UD Serial No. 10881 and up
( D spec.) (Except D spec.)
Add hydrau,lic oil through oil filler to the specified
level.
Hydraulic oil : Approx. 20 !?
4y 2 WA600- 1
._i
Serial No. 10868-I 0880 (Except D spec.)
Serial No. 10868 and UD (D SDeC.)
* Tighten the oil filler cap, then open pressurizing
valve (IA). (Serial No. 10868 and up)
* Run engine to circulate oil through system.

426FO1201
Serial No. 10881 and qp (Except D spec.)
426Po1102 426FO1202
A,*
WA600-1
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE
C&-S
@F--7
-10
1
1
,e,,
@_\12
425F294
DISASSEMBLY OF STEERING VALVE
1. Remove tube (1). 5. Remove case (14), then remove spool assembly
(15).
2. Remove main relief valve assembly (2). rt Disassembly and assembly of spool assembly.
1) Remove bolt (16), then remove retainer (17),
3. Remove safety valve (with suction valve) assembly spring (18) and retainer (19) from spool (20).
+I Loosen bolt (16) with the spool assembled in
(3).
the body.
4. Remove case assembly (4).

* Disassembly and assembly of case assembly. 6. Remove plate (21), then remove orifices (22) and
1) Remove covers (5) and (6). (23).
2) Remove dust seal (7).
3) Loosen bolt (9) of lever (8), then remove shaft 7. Remove cover (24), then remove spring (25), washer
(10). (26) and spool (27).

4) Remove oil seal (11) and bearing (12) and (13).
8. Remove plate (28), then remove seat (29), spring
(30) and poppet (31).
,‘\
i-1
--_ Steering demand valve assembly: 55 kg
43-l 4 WA600- 1
‘3
ASSEMBLY OF STEERING VALVE
1. Assemble poppet (31) and spring (30) in valve body

(32).
2. Fit O-ring and backup ring to seat (29) in valve

body, then fit O-ring and install plate (28).
3. Assemble spool (27). washer (26) and spring (25) in

valve body, then fit O-ring and install cover (24).
4. Assemble orifice (23) and (22) in valve body, then

fit O-ring and install plate (21).
+ Disassembly and assembly of spool assembly.
1) Assemble retainer (191, spring (18) and retainer
(17) in spool (20) and tighten bolt (16).
* Tighten bolt (16) with the spool assembled in
the body.
5. Assemble spool assembly (15) in body, fit O-ring

and install case (14).
+ Disassembly and assembly of case assembly
1) Install bearing (13) and (12) and oil seal (11) in
case.
& Oil seal: Grease (G2-LI)
2) Assemble lever (8) in case, then fit ‘key, install

shaft (lo), and tighten bolt (9).
3) Install dust seal (7).
4) Fit O-ring and install covers (6) and (5).
6. Fit O-ring and install case assembly (4).
7. Fit O-ring and install safety valve assembly (3) with

suction valve.
w Safety’valve: 4.5 f 0.5 kgm
8. Fit O-ring and install main relief valve assembly (2).
m Main relief valve: 8.5 ?r 1.5 kgm
9. Fit O-ring and install tube (I).
WA600- 1
REMOVAL OF STEERING CYLINDER ASSEM’BLY
Serial No. 10868-10880 (Except D sped
A
*k Loosen the oil filler cap slowly to release the

426FO1201
pressurizing valve (1A).
Serial No. 10881 and up Except D spec.)
426FO1202
1. Hydraulic piping
1) Disconnect hose (1) at rod end from cylinder.
2) Disconnect hose (2) at bottom end from tube
(3).
426P765
2. Rod pin
1) Remove bolts, and pull out pin (4).
* Check the number and thickness of the shims
to act as a guide when assembling.
2) Blow in air through cylinder hydraulic pressure
port a to retract rod.
3. Bottom pin
1)
_
Fit a hanging tool from between the steps, then lift
off steering cylinder (7).
* Pass the bottom end through the frame, then pull
out.
* When removing only one of the cylinders, it is
easier if the steering is turned fully in the oppo-
site direction to the side where the cylinder is to
be removed.
* Be careful not to damage the cylinder rod.
elkg Steering cylinder: 77 kg
WA600-1
INSTALLATION OF STEERING CYLINDER ASSEMBLY
1. Steering cylinder
Fit a hanging tool from between the steps, then
raise steering cylinder (7) and set in mounting posi-
tion.
* First insert the cylinder inside the frame, check
that the rod portion is completely inside the
frame, then set in the mounting position.
2. Bottom pin
1) Assemble pin (6) at bottom, then install mount-
ing bolts.
A Use a bar to align the pin holes.

use your fingers.
Never
t Adjust with shims so that clearance b + c is

the specified value.
Clearance b + c = 1.5 mm
426F364A
2) Connect grease hose (5) to cylinder.
3. Rod pin
1) Blow compressed air into hose (2), and extend
rod.
* Adjust the height, and never blow the air in
hard.
2) Assemble pin (4) at rod end, then tighten mount-
ing bolts.
Use a bar to align the pin holes. Never

a
use your fingers.
* Adjust with shims so that clearance d + e is

the specified value.
Clearance d + e = 1.5 mm
426F365A
426P765
4. Hydraulic piping Serial No. 10868-10880 (Except 13 spec.)

Serial No. 10868 and up CD spec.)
1) Connect hose (2) at bottom end to tube (3).
2) Connect hose (I) at rod end to cylinder.
5. Greasing
Coat cylinder pin well with grease.
* Wipe off the grease which is squeezed out.
426FO1201
1A
; ,>‘, !
,,,,,,,,
x&\A__,
426PO1102 426FO1202
WA600-1
43-A8-’
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY
A 790-502-I 001 Cylinder repair stand 1
1. Set cylinder assembly (I) on tool A.
2. Remove piping.
3. Remove mounting bolts (2) of cylinder head.
207P490
4. Pull cylinder head and piston rod assembly (3) out

of cylinder (4) and lift off.
* Oil will come out when the piston rod assembly
is removed from the cylinder, so place a con-
tainer in position to catch the oil.
5. Remove cylinder (4) from tool A.
6. Set cylinder head and piston rod assembly on tool

A.
7. Remove nut (5) with power wrench @ and socket
0.
* Power wrench: 16 times
* Width across flats of socket: 80 mm
8. Remove piston assembly (6) and cylinder head as-

sembly (7).
9. Disassemble piston assembly as follows:

Remove wear ring (8) and piston ring (9) from 8 9
piston (10).
2OXP241
WA600- 1 43-19
0
10. Disassemble cylinder head assembly as follows:
1) Remove O-ring (11) and backup ring (12).
2) Remove snap ring, then remove dust seal (13).
207P494 207P495
3) Remove rod packing (14).

4) Remove bushing (15).
WA600- 1
ASSEMBLY OF STEERING CYLINDER ASSEMBLY
-*TGo-502-101I Cylinder
~ repair stand I 1
B 790-720-l 000 Expander 1
C 796-720-l 670 Ring 1
* Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil before
installing. Be careful not to damage U-packing, dust
seals or O-rings when installing. 207P498 2071’497
I. Assemble cylinder head assembly as follows.

1) Using push tool @ , press fit bushing (1.5) on
cyli,nder head (16).
* Be careful not to deform the bushing when
press fitting.
2) Assemble rod packing (14).
* Be careful to install the rod packing facing in
the right direction.
207P499 207P494
208F240A
3) Install backup ring (12) first, then O-ring (11).

* Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 to 6O’C)
before fitting it.
4) Using push tool @ , install dust seal (13) on
cylinder head, then secure with snap ring.
207P495
2, Assemble piston assembly as follows.

1) Using tool B, expand piston ring (9).
+ Set the piston ring on the tool C and turn the
handle 8 to 11 times to expand the ring.
2) Remove piston ring (9) from tool B and assemble
on piston (10).
3) Fit tool C on piston ring and compress piston
ring with clamp @ .
Clamp @ Part No.: 07281-01589
4) Assemble wear ring (8) on piston.
‘9
207P502
WA600- 1 43-2 1
3. Set piston rod (17) in tool A.
4. Assemble cylinder head assembly (7) and piston

assembly (6).
5. Using power wrench @ and socket @ , tighten

nut (5).
* Width across flats of socket: 80 mm
m Nut: 405 f 40.5 kgm
207P503
6. Set cylinder (4) in tool A, then raise cylinder head

and piston rod assembly (3) and install in cylinder
(4).
207P505
207P49 I -207P506
7. Tighten mounting bolt (2) of cylinder head.
w Cylinder head mounting bolt: 74.5 t 10.0 kgm
8. Fit O-ring and install piping.
9. Remove cylinder assembly (I) from tool A.
\
A
207P490
43-22 ‘dA600- 7
I_
P,
REMOVAL OF CENTER HINGE PIN
Serial No. 10001
Serial No. 10001
- 10880 (Except D spec.)
and up (D spec.)] 1 Serial No. 10868 and up
Special tools
1A
A 1 790-101 1002 1 Pump I 1

B 1 790-101-2102 1 Puller -1 1
* Remove the bucket before starting this operation.
A Stop the machine

Lower the bucket 426FO1201


a
pressurizing valve (1A). (Serial No. 10868
and up)
1. Covers
1) Remove (I), (2)
2) Remove
re-
move fuel cable from bracket.
42613777
Disconnect the following electric wiring from con-
nector.
- Wiring (6) for window washer.
* Remove the wiring clamp from the floor.
- Disconnect ground connection (7) from frame.
* Wiring (8), (9), (IO) and (1 I) for rear frame.
* Wiring (12) and (13) for main breaker.
* Wiring (14) and (15) for front frame.

* After removing the clamp, move it towards
the front frame.
4. POC piping
1) Disconnect hoses (16), (17), (18) and (19) be-
tween POC valve and main control valve at con-
nection with tube.
?) Disconnect hose (20) between main control valve
and hydraulic tank from connectionof bracket.
3) Disconnect hose (21) between POC valve and

hydraulic tank at POC valve end.
4) Disconnect hose (22) between POC valve and
accumulator at POC valve end.
* Remove the clamp from the floor.
426P784
-_
5. Brake, air piping

I) Disconnect hoses (23) and (24) between brake
valve and air tank from tube.
2) Disconnect hoses (25) and (26) between brake
valve and relay valve from tube.
WA600-1 43-25
3) Disconnect parking brake air hose (27) from
tube.
4) Disconnect hose (28) between brake chamber
and slack adjuster from tube at center hinge pin.
* Disconnect POC hose (29) from the connec-
tion of the bracket.
426P787
2) Sling cab and floor frame (31), remove mounting

* If there is any limit on the height of the hoist
crane, remove the ladder rail on either the left
or the right.
* Remove the mounting bolts of the rear frame.
11111111111111111111
kg Cab, floor frame: 660 kg
8. Hydraulic piping
1) Disconnect hoses (33) and (34) between steering
valve and steering cylinder from connection at
front frame end.
2) Disconnect hose (35) between steering valve and
hydraulic cooler from connection at front frame
end.
3) Disconnect the following hoses from connection

at front frame end.
* Hose (36) between steering pump and steering
valve
- Hose (37) between switch pump and steering
valve
ing valve
* Hose (39) between main control valve and
hydraulic tank
426P792
9. Drive shaft
Sling center drive shaft (40), remove mounting
* Pull the drive shaft in towards the front frame,
then pull out to the right side of the machine
body.
Center drive shaft: 56 kg
10. Frame support

1) Using hydraulic jack under rear frame, adjust
height and insert block @ .
* Insert hydraulic jacks and blocks on the left
and right sides of the frame.
2) Using a jack, insert block @ under front frame.
WA600- 1
3) Insert block @ under counterweight.
4) Using lever block @ , move hydraulic hoses to
right side of machine body.
11. Lower hinge pin

1) Remove mounting bolts, then remove retainer
(41).
* There are shims between the retainer and
frame, so check the number and thickness of
the shims, and keep in a safe place.
2) Using puller B and hydraulic pump A, remove

lower hinge pin (42).
* Adjust the height carefully to avoid raising
the machine body with puller B.
* Always pay careful attention to the pressure
in the hydraulic pump.
3) Remove spacer (43).
426P802
426F365
12. Upper hinge pin
(44).
2) Using puller 6 and hydraulic pump A, remove

upper hinge pin (45) and spacer (46).
13. Disconnecting frame

Remove safety bar, pull out front frame to front
and disconnect frame.
* Be careful not to let the spacer at the bottom of
the upper hinge bite into the rear frame.
* Be careful to maintain the balance when carrying
out the operation.
* Move the frame about 100 mm at a time.
14. Lower hinge

(47).
WA600- 1 43-29
0
2) Remove dust seal (48) from retainer.
426P805
3) Remove spacer (49) from front frame.
4) Remove plate (50) from front frame, then re-

move dust seal (51).
426P809
43&30 WA600- 1
15. Upper hinge
1) Remove retainer (53).
ttie shims, and keep in a safe place.
426P8 11
3) Remove plate (55) from front frame, then re-

426P814
WA600- 1
INSTALLATION OF CENTER HINGE PIN
Serial No. - (Except D spec.)
[Serial No. 10001 and up (D spec.) I
Special tools
1. Upper hinge
1) Assemble tools A, B, C, D, and D, at top of
front frame upper hinge, and set bearing (57) in
tool D. Set on press-fitting part from top and
press fit.
* When press fitting, use tool Dz as a guide.
* Be careful not to fit the bearing at an angle.
* Fill the inside of the bearing with grease.
* When assembling the bearing, do not forget to
426P816
assemble spacer (58).
* The clearance of the bearing and spacer (58)
is adjusted, so do not change the combination.
When replacing the bearing and spacer, replace
as a set.
D2-
426F366
426F367
2) Press fit dust seal (56) on retainer.

* When press fitting the dust seal, fit with the
lip on the outside.
R?_1, Seal lip: Grease (G2-LI)
426F368
426P817
WA600- 1
43G32
3) Tighten retainer (53) with mounting bolts, then
measure clearance “a” between retainer and
hinge at four places around the circumference.
Select shim of 0.08 - 0.18 mm less than meas-
ured value.
* Do not select a shim which is thicker than the
clearance at the four measured places.
* After selecting the shim, tighten the retainer
to the specified tightening torque.
m Mounting bolt (when adjusting shim):

3.5 + 0.3 kgm
m Mounting bolt: 28.5 t 3.0 kgm
426F369
4) Install dust seal (56) on hinge, then install plate

(55).
lip on the outside.
m Seal lip: Grease (G2-LI)
426P8 12
2. Lower hinge
1) Using tools A, 6, C, D, D,, Da and D+ press fit
bearing (52) and spacer (59) on front frame.
* When press fitting, use tool D2 as a guide.
426P820
WA600- 1
* The clearance of the bearing and spacer (59) is
adjusted, so do not change the combination.
as a set.
58
““-w------
59 426P82f
48
426F370
/
2) Press fit dust seal (48) on retainer (47).
lip on the outside.
& Seal lip: Grease (G2-LI)
48
426F371 426P822
3) Tighten retainer (47) with 6 mounting bolts,

then measure clearance “a” between retainer and
ured value.
/,,,/)
w Mounting bolt (when adjusting shim):
7.0 f 0.7 kgm ’
-42iP823
B Mounting bolt: 28.5 + 3.0 kgm
426F372
WA600- 1
43&y4
4) Assemble dust seal (51) on hinge, then install
plate (50).
lip on the outside.
a Seal lip: Grease (G2-LI)
5) Install spacer (49).

* Assemble with the larger’ chamfered side on
the bearing side.
& Inside diameter of spacer:

Grease (G2-LI)
3. Connecting frame
Move front frame towards rear frame and align pin
holes.
Qf Use a bar to align the pin holes.

use your fingers.
Never
* Align the pin holes correctly.
4. Upper hinge pin

1) Assemble spacer (46), insert upper hinge pin
(45), then tap lightly three times with a copper
hammer to settle in position.
* Always tap lightly with the copper hammer.
Never hit hard.
* Never coat the spacer with grease.
4 Outside circumference of hinge pin:

Grease (G2-LI)
WA600- 1
2) Install retainer (44).
* To tighten mounting bolts (60) and (61) to
the specified tightening torque, tap the head
of the upper hinge pin (45) with a copper
hammer, then tighten to the specified torque.
* If the mounting bolts do not reach the speci-
fied tightening torque, there may be grease on
spacer (46). so remove this and tighten again.
a Mounting bolt: Thread tightener

(Loctite 262)
m Mounting bolt (60): 28.5 f 3.0 kgm
m Mounting bolt (61): 56 f 6.0 kgm 426F373
5. Lower hinge pin

1) Insert lower hinge pin (42). then install spacer
(43).
& Outside circumference of hinge pin:

Grease (G2-LI)
426F374
2) Install retainer (41) to lower hinge pin without

using shims, then tighten mounting bolts until
they reach specified tightening torque.
* To tighten the mounting bolts to the specified
tightening torque, tap the head of the lower
hinge pin with a copper hammer, then tighten
to the specified torque.
m Mounting bolt (63): 56 f 6.0 kgm

3) Remove all mounting bolts (62), then measure

clearance C between retainer and frame at three
places around the circumference. Select shim of
0.08 - 0.18 mm less than measured value.
clearance at the three measured places.
426F375
WA600- 1
43z6
4) Install selected shim and retainer (41).
* Remove all grease and oil from the mounting
bolts and mounting bolt holes.
a Mounting bolts (62). (63) :

Thread tightener (Loctite 262)
w Mounting bolt (62): 28.5 k 3.0 kgm
m Mounting bolt (63): 56 + 6.0 kgm

5) Fit safety bar.
6. Frame support
1) Remove lever block @ .
2) Remove block @ from under counterweight.
3) Remove block @ from under front frame.

4) Jack up rear frame and remove block @
7. Drive shaft
Raise center drive shaft (40), set in mounting posi-
tion, then tighten mounting bolts.
* Insert the drive shaft from the right side of the
machine body, pull in towards the front frame,
and set in the mounting position.
* Install drive shaft guard bar.
m Mounting bolt: 18.0 i: 2.0 kgm
WA600- 1
37
hydraulic tank
ing valve
* Hose (37) between switch pump and steering
valve
we Hose (36) between steering pump and steering
valve
426P792
2) Connect hose (35) between steering valve and

hydraulic oil cooler to connection at front frame.
* If there is a plate at the connection, be very
careful not to get it caught in the O-ring at the
contact face.
3) Connect hoses (33) and (34) between steering
valve and steering cylinder to connection at front
frame.
9. Steering cylinder pins

Install left and right steering cylinder pins (32).

your fingers.
Never use
* Adjust with shims to make clearance “a, b” is the

specified value.
Clearance “a + b” = Max. 1.5 mm
426F376A
10. Cab, floor frame

1) Raise cab and floor frame (31). set in mounting
position and tighten mounting bolts.
m Mounting bolt: 28.5 * 3.0 kgm
Adjust shim so that clearance between floor

frame and upper face of frame is max. 0.5
426P788 ?c
mm, then tighten mounting bolts.
2) Connect steering linkage (30) to pitman arm.
* For details of adjusting the steering linkage,
see TESTING AND ADJUSTING.
w Mounting nut: 12.5 f 1 .O kgm
426P787

slack adjuster to tube at center hinge pin.
* Connect POC hose (29) to the connection of
the bracket.
2) Connect parking brake air hose (27) to tube.
3) Connect hoses (25) and (26) between brake valve

and relay valve to tube.
and air tank to tube.
12. POC hoses

1) Connect hose (22) between POC valve and accu-
mulator at POC valve end.
* Install the hose clamps.
2) Connect hose (21) between POC valve and hy-
draulic tank at POC valve end.
426P784
WA600- 1 43-39
22
3) Connect hose (20) between main control valve
and hydraulic tank to connection of bracket.
4) Connect hoses (16). (17). (18) and (19) between
POC valve and main control valve to tube.
13. Electrical wiring ,,

Connect the following electrical wiring to connec- ~ :,,
I.4
tor.
- Wiring (14) and (15) for front frame
* Install the wiring clamp to the floor.
* Wiring (8), (9). (10) and (11) for rear frame

* Wiring (12) and (13) for main breaker
+ Install the wiring clamp to the floor.
- Connect ground connection (7) to frame.

- Wiring (6) for window washer
* Install the wiring clamp to the floor.
43-40
0
14. Fuel cable
Connect fuel cable (4) to bottom of accelerator
pedal, install bracket (5), then tighten locknut.
* For details of adjusting the length of the cable,
‘see TESTING AND ADJUSTING.
426P777
15. Covers
1) Install center platform.
2) Install covers (I), (2) and (3) under cab.

Add hydraulic oil through oil filler (64) to the speci-
fied level.
2 Hydraulic oil : Approx. 40 Q

Q

valve (1A). (Serial No. 10868 and up)
* Run the engine to circulate the hydraulic oil
through the system, then check the level again,
Serial No, 10868 and up
17. Bleeding air

AND ADJUSTING.
426FO1201
WA600- 1
43i?
REMOVAL OF CENTER HINGE PIN
[Serial No. 10881 and up (Except D spec.)].
Special tools
1A
Part number Part name O’ty
A 790-101-1002 Pump 1
B 790-101-2102 Puller 1
* Remove the bucket before starting this operation.
A Stop
the safety
bar on the frame. Lower
and install
the bucket 426FO1202

*
A+ e Loosen the oil filler
pressure inside the hydraulic
cap slowly
tank.
to release the
Then oper-
* Before loosening the oil filler cap;close pres-
surizing valve (1 A).
1. Covers
1) Remove covers (I), (2) and (3) under cab.
2) Remove center platform (3A).
” -’ “-
: kg ] Center platform: 23 kg

Disconnect fuel control cable (4) from bracket and
lever together with plate (4A).
* Remove the side cover on the right side of the
machine.
* After disconnecting, remove the cable clamps
and move the cables towards the front of the
math ine.
3. Electric wiring
Disconnect the following connectors from the floor
wiring harnesses.
- Connector (5) for power source wiring harness.
- 4-pin connector (6) for window washer wiring
harness.
- 12-pin connector (7) for transmission wiring
harness.
- 12-pin connectors (8) and (9) for rear frame
wiring harness.
- 8-pin connectors (IO) and (11) for rear frame
wiring harness.
- 2-pin connector (12) for emergency steering
sensor wiring harness.
- l-pin connector (13) for air conditioner con-
denser wiring harness.
* Remove the wiring clamps from the floor
support.
12-pin connector (14) for front frame wiring
harness.
4-pin connector (I 5) for front frame wiring
harness.
* Remove the wiring clamps from the floor
support, then move towards the front frame.
+ After disconnecting the connectors, fit tags to
distinguish them.
4. PPC hoses
Disconnect the following hoses.
. Hoses (P2: Green (16), P3: Blue (17)) (for lift
spool) between PPC valve and main control valve.
- Hoses (PI: Yellow (18), P4: Red (19) (for dump
spool) between PPC valve and main control valve.
- Hose (20) between main control valve and
hydraulic tank.
. Hose (21) between PPC pump and PPC valve.

* Hose (22) between PPC valve and hydraulic tank.
* Remove the clamps from the floor.
* After disconnecting the hoses, fit tags to dis-
tinguish them.
WA600-1
1) Disconnect hose (23A) between air tank and
pressurizing valve.
* Remove the hose clamp from the floor, then
move the hose towards the hydraulic tank.
4) Disconnect parking brake air hose (27) from

tube.
5) Disconnect hydraulic hose (28) between brake
chamber and slack adjuster from tube at center
hinge pin.
6. Cab, floor frame

1) Disconnect steering linkage (30) from pitman
arm.
2) Sling cab and floor frame (31), remove mounting
* Remove the whole floor support.
* If there is any limit on the height of the hoist
crane, remove the ladder rail on either the left
or the right.
* Remove the mounting bolts of the rear frame.
t Check that there is no interference with the
hoses and electric wiring, then raise slowly.
Cab, floor frame: 690 kg

Remove left and rights steering cylinder pins (32).
* Check the number and thickness of the shims to
act as a guide when assembling.
8. Hydraulic piping
1) Disconnect hoses (33) and (34) between steering
valve and steering cylinder from connection at
front frame end.
2) Disconnect hose (35) between steering valve and
hydraulic cooler from connection at front frame
end.
3) Disconnect the following hoses from connection

at front frame end.
valve.
valve.
ing valve.
hydraulic tank.
WA600-1
9. Drive shaft
Sling center drive shaft (40), remove mounting
* Pull the drive shaft in towards the front frame,
then pull out to the right side of the machine
body.
Center drive shaft: 56kg
IO. Frame support

1) Using hydraulic jack under rear frame, adjust
height and insert block 0.
* insert hydraulic jacks and blocks on the left
and right sides of the frame.
2) Using a jack, insert block @under front frame.
3) Insert block @ under counterweight.

4) Using lever block @, move hydraulic hoses to
right side of machine body.
11. Lower hinge pin

(41).
43-46 WA600-1
(9
lower hinge pin (42).
* Adjust the height carefully to avoid raising
the machine body with puller B.
* Always pay careful attention to the pressure
in the hydraulic pump.
3) Remove spacer (43).
426F365
12. Upper hinge pin

(44).

upper hinge pin (45) and spacer (46).
WA600-1
13. Disconnecting frame
Remove safety bar, pull out front frame to front
and disconnect frame.
Be careful not to let the spacer at the bottom of
the upper hinge bite into the rear frame.
Be careful to maintain the balance when carrying
out the operation.
Move the frame about 100 mm at a time.
14. Lower hinge

(47).
426P805
3) Remove spacer (49) from front frame.
WA600-1
43$8
4) Remove plates (50) from front frame, then re-
426P809
15. Upper hinge

I) Remove retainer (53).
426P8: ”
43649
WA600-1
3) Remove plates (55) from front frame. th re-
426P8t4
WA600-1
INSTALLATION OF CENTER HINGE PIN
Special tools
A 790-101-1002 Pump 1
B 790-101-2102 Puller 1
C 790-101-2300 Push-puller 1
D 790-438-1010 Push tool 1
DI 790438-l 020 Guide (lower) 1
D2 790-438-I 030 Guide (upper) 1
D3 790-438-1050 Bar 2
D4 790-438-I 040 Screw 1
1. Upper hinge
1) Assemble tools A, B, C, D2 and D3 at top of
front frame upper hinge, and set bearing (57) in
tool D. Set on press-fitting part from top and
press fit.
When press fitting, use tool D, as a guide.
Be careful not to fit the bearing at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, do not forget to . 426P8t6
The clearance of the bearing and spacer (58)
is adjusted, so do not change the combination.
as a set.
D3-
D2-
426F367 426F366
2) Press fit dust seal (56) on retainer.

lip on the outside.
a Seal lip: Grease (G2-LI)
426F366
426P817
WA600- 1
3) Tighten retainer (53) with mounting bolts, then
measure clearance “a” between retainer and
ured value.
m Mounting bolt (when adjusting shim):

3.5 f 0.3 kgm
426F369
4) Install dust seal (56) on hinge, then install plate

(55).
lip on the outside.
w Seal lip: Grease (G2-LI)
426P8 12
2. Lower hinge
1) Using tools A, 6, C, D, D,, D, and D4, press fit
bearing (52) and spacer (59) on front frame.
* When press fitting, use tool D2 as a guide.
-\. 426P820
x.
* The clearance of the bearing and spacer (59) is
adjusted, so do not change the combination.
as a set.
426P821
426F370
2) Press fit dust seal (48) on retainer (47).

lip on the outside.
6 Seal lip: Grease (G2-LI)
426F371 426P822
3) Tighten retainer (47) with 6 mounting bolts,

then measure clearance “a” between retainer and
ured value.
+ After selecting the shim, tighten the retainer
w Mounting bolt (when adjusting shim):

7.0 * 0.7 kgm
-42’6P823
426F372
WA600-1
4) Assemble dust seal (51) on hinge, then install
plate (50).
lip on the outside.
& Seal lip: Grease (GZ-LI)
5) Install spacer (49).

* Assemble with the larger chamfered side on
the bearing side.
& Inside diameter of spacer:

Grease (G2-LI)
_._---. _;i/ .:Y

” 42613825
3. Connecting frame
Move front frame towards rear frame and align pin
holes.

use your fingers.
Never
* Align the pin holes correctly.
4. Upper hinge pin

1) Assemble spacer (46), insert upper hinge pin
(45), then tap lightly three times with a copper
hammer to settle in position.
* Always tap lightly with the copper hammer.
Never hit hard.
* Never coat the spacer with grease.
R-P% Outside circumference of hinge pin:

Grease (G2-LI)
43-54 WA600-1
0
2) Install retainer (44).
* To tighten mounting bolts (60) and (61) to
the specified tightening torque, tap the head /
of the upper hinge pin (45) with a copper
hammer, then tighten to the specified torque.
* If the mounting bolts do not reach the speci- --
fied tightening torque, there may be grease on
spacer (46), so remove this and tighten again.
& Mounting bolt: Thread tightener

(Loctite 262)
w Mounting bolt (60): 28.5 4 3.0 kgm
m Mounting bolt (61): 56 t 6.0 kgm 426F373
5. Lower hinge pin

1) Insert lower hinge pin (42), then install spacer
(43).
6 0 u t’d
SI e circumference of hinge pin:
Grease (G2-LI)
426F374
2) Install retainer (41) to lower hinge pin without

using shims, then tighten mounting bolts until
they reach specified tightening torque.
* To tighten the mounting bolts to the specified
tightening torque, tap the head of the lower
hinge pin with a copper hammer, then tighten
to the specified torque.
w Mounting bolt (63): 56 + 6.0 kgm

3) Remove all mounting bolts .(62), then measure

clearance C between retainer and frame at three
places around the circumference. Select shim of
0.08 - 0.18 mm less than measured value.
clearance at the three measured places.
WA600-1
4) Install selected shim and retainer (41).
* Remove all grease and oil from the mounting
bolts and mounting bolt holes.
& Mounting bolts (62), (63):

Thread tightener (Loctite 262)
w Mounting bolt (62): 28.5 ? 3.0 kgm
m Mounting bolt (63): 56 f 6.0 kgm

5) Fit safety bar.
6. Frame support
1) Remove lever block @ .
2) Remove block @ from under counterweight.
3) Remove block @ from under front frame.

4) Jack up rear frame and remove block @ .
7. Drive shaft
Raise center drive shaft (40), set in mounting posi-
tion, then tighten mounting bolts.
* Insert the drive shaft from the right side of the
machine body, pull in towards the front frame,
and set in the mounting position.
* Install drive shaft guard bar.
43G6 WA600-1
8. Hydraulic hoses
1) Connect the following hoses to connection at
front frame end. 7
hydraulic tank
ing valve
valve
valve
426P792
2) Connect hose (35) between steering valve and

hydraulic oil cooler to connection at front frame.
* If there is a plate at the connection, be very
careful not to get it caught in the O-ring at the
con tact face.
3) Connect hoses (33) and (34) between steering
valve and steering cylinder to connection at front
frame.
:.

Install left and right steering cylinder pin’s (32).

your fingers.
Never use
* Adjust with shims to make clearance “a, b” is the

specified value.
426F376A
IO. Cab, floor frame

1) Raise cab and floor frame (31). set in mounting
position and tighten mounting bolts.
w Mounting bolt: 28.5 F 3.0 kgm
* Adjust shim so that clearance between floor

frame and upper face of frame is max. 0.5
mm, then tighten mounting bolts.
WA600- 1
2) Connect steering linkage (30) to pitman arm.
* For details of adjusting the steering linkage,
see TESTING AND ADJUSTING.
m Mounting nut: 12.5 ? 1 .O kgm

slack adjuster to tube at center hinge pin.
2) Connect parking brake air hose (27) to tube.

and relay valve to tube.
and air tank to tube.
5) Connect hose (23A) between air tank and pres-

surizing valve.
* Install the clamps.
426PO1120
i .
43-$8 WA600-1
._J
12. PPC hoses
Connect the following hoses.
- Hose (21) between PPC pump and PPC valve
- Hose (22) between PPC valve and hydraulic tank
* Hoses (P2: Green (16), P3: Blue (17)) (for lift

spool) between PPC valve and main control valve
- Hoses (PI: Yellow (18), P4: Red (19) (for dump
spool) between PPC valve and main control valve
hydraulic tank
* Install the clamp to the floor.
13. Electric wiring

Connect the following connectors to the floor
wiring harnesses.
+ Connector (5) for power source wiring harness
- 4-pin connector (6) for window washer wiring
harness
- 12-pin connector (7) for transmission wiring
harness
- 12-pin connectors (8) and (9) for rear frame
wiring harness
- 8-pin connectors (IO) and (11) for rear frame
wiring harness
- 2-pin connector (12) for emergency steering
sensor wiring harness
- l-pin connector (13) for air conditioner con-
denser wiring harness
* 12-pin connector (14) for front frame wiring
harness
+ 4-pin connector (15) for front frame wiring
harness
* Install the wiring clamps to the floor support.
WA600-1
Connect fuel control cable (4) and plate (4A) to
lever and bracket.
* Adjust the length of the cable.
For details, see TESTING AND ADJUSTING.
* Install the clamp, then install the side cover on
the right side of the machine.
15. Covers
1) Install center platform (3A).
2) Install covers (l), (2) and (3) under cab.

Add hydraulic oil through oil filler to the specified
level.
Hydraulic oil: Approx. 4OQ

valve (1A).
* Run the engine to circulate the hydraulic oil
through the system, then check the level again.
17. Bleeding air

AND ADJUSTING.
426PollCG~ 426FO1202
w
STEERING SYSTEM
Steering column and gear box ........... 44- 2

Center hinge pin .................... 44- 4
Steering valve ...................... 44- 6
Steering cylinder mount ............... 44- 7
Steering cylinder .................... 44- 8
Diverter valve ...................... 44- 9
Emergency steering pump ............. 44-10
WA600- 1 44-l
@
STEERING COLUMN AND GEAR BOX
5/Section B-B
Section A-A _
15
11 13
18 14
13
17

426F185A
44-2 WA600- 1
@I
Unit: mm
-
NC Check item Criteria Remedy
and bushing
35 -0.009 +0.025 0.009 - -
-0.034 0 0.059 Replace
Clearance between sector shaft bushing
2 -0.007 +0.021 0.007 - -
and bushing 30
-0.028 0 0.049
Clearance between steering shaft +0.15 0.05 -

3 19 -:.08 0.4
and column bushing +0.05 0.23
Tolerance
Standard
Standard size
Interference of press-fitting clearance
a Shaft Hole
part of center lever bearing
+0.040 Replace
62 .O +0.010 0.010 - 0.053
-0”.013
Interference of press-fitting -0.021

5 62.0 0.008 - 0.051
part of center lever bearing -0.051
/ I
Clearance of articulation stopper
6 25 ? 2
(at engine speed 1,200 rpm)
7 Distance of link 784.6 Adjust
8 Distance of link 420.5

I I
-
9 Tightening torque of mounting nut 3 i 0.3 kgm

- I
10 5.7 t 0.7 kgm
bolt
11 Tightening torque of mounting nut 19 i 3.kgm
12 Tightening torque of lock nut 28.5 i- 3.0 kgm

-
13 Tightening torque of mounting nut 12.25 + 1.25 kgm

-
Retighten
14 Tightening torque of lock nut 7.75 t 1.25 kgm
15 Tightening torque of mounting nut 12.25 ? 1.25 kgm
16 Tightening torque of lock nut 7.75 ? 1.25 kgm
17 Tightening torque of lock bolt 3.15 i- 0.35 kgm

18 I 11.25 i 1.25 kgm
bolt
-
19 56 * 6 kgm
bolt I
i2.25tl.25 kgm
km
Section B-B
5.7f0.7 kgm
Section A-A
u\ I I I
F42601016
1 UJ
Section C-C Section D-D 426F 185A
44-3-1 WA600-1
@
Unit: mm
Tolerance
Clearance between sector shaft Shaft Hole
1
and bushing
-
35 -0.034
-0.009 +0.025
0 0.009 0.059 -
Replace
0.007 - bushing
2 bushina
Clearance between sector shaft and 30 -0.028
-0.007 +0.021
0 0.049 -
+0.150 0.050 -
3 and
Clearance
column between
bushing steering shaft 19 0
-0.08 f0.050 0.230 -
0 +0.040 0.007 -
4 center
Interference
lever bearing
of press-fitting part of 62.0 -0.013 f0.010 0.041 -
-0.021 -0.008 -
5 center
Interference
lever bearing
of press-fitting part of 62.0 -0.013
0 -0.05 1 0.051 -
Replace
0.010 -
6 and
Clearance
shaft between center bearing 30 -0.020
-0.033 -:.ot 0 0.033 -
Clearance between center lever -0.020 +0.053

7 bracket and shaft O-0.086 -
30 -0.033 -0.020
Clearance of articulation stopper

25 i 2
8 (at engine speed 1,200 rpm) I
9 1 Distance of link 798.4 1 Adjust
10 1 Distance of link 447.1

I I
I I I
WA600-1 44-3-2
0
CENTER HINGE PIN
426F197
12. 4 20 5 i4
Section A - A Section B - B
426F198
WA600- 1
Unit: mm
Tolerance
Clearance between lower hinge Shaft Hole
1
pin and rear frame
-0.101 0 0.051 -
108 -0.050 0.152 -
-0.152
-
2 Clearance between lower hinge 108 -0.101 -00.050 0.051 1 .o
pin and spacer (small) -0.152 0.152
-
3 Clearance between lower hinge 107.95 -0.051 +0.025 0.051 1.0
pin and bearing -0.102 0 0.127
-
4 I pin and spacer
Clearance (large)
between lower hinge 108 -0.107
-0.051 0
+0.025 0.127
0.051 1 .o I
-
5 spacer
Clearance
(large)
between rear frame and 140 -0.250
-0.300 -0.150
-0.200 0.050
0.1.50 -
-
6 and upper between
Clearance hinge bearing
front frame 160 -0.025
0 -0.127
-0.077 0.127
0.052 - I
between upper hinge -0.076 +0.025 0.056 -
pin and rear frame 100 -0.127 -0.020 0.152 Replace
-
-
8 I pin and bearing
Clearance between upper hinge 100 -0.127
-0.076 -:.020 0.127
0.056 1 .o I
-
9 and
Clearance
lower between
hinge bearing
front frame 212.725 +0.025
0 -0.102
-0.051 -0.051
-0.127 -
Clearance between rear frame +0.131 +0.166 -0.021 -

10
and bushing 132 -0.021 +0.110 0.181
Clearance at press-fitted part of +0.280 +0.025 -0.155 -

11 117.45
seal of upper hinge pin +0.180 -0.030 -0.310 -
Clearance at press-fitted part of +0.310 +0.025 -0.185 -

12 158.75
seal of lower hinge pin +0.210 -0.025 -0.335 -

Height of lower hinge spacer
13
(small)
45.2 kO.1 -
Height of lower hinge spacer

14 88.5 kO.1
(large)
Shim thickness for lower hinge

15 2.55
and retainer I
Shim thickness for lower hinge
16 1.65
and retainer
Shim thickness for upper hinge

17 1.50
and retainer
When adjusting with shim: 7 kgm

Tightening torque of lower hinge
18
retainer mounting bolt
Final value: 28.5 + 3 kam
Adjust
When adjusting with shim: 28.5 t 3 kgm
19
retainer mounting bolt
Final value: 28.5 ? 3 kgm

20 56 t 6 kgm
oin mountinq bolt
When adjusting with shim: 3.5 kgm

Tightening torque of upper hinge
21
pin mounting bolt
Final value: 28.5 ? 3 kgm

22 28.5 + 3 kgm
pin mounting bolt
Retighten
23 56 ? 6 kgm
pin mounting bolt
WA600- 1 44-5
0
STEERING VALVE
425F152 Unit: mm
-
NC Check item Criteria Remedy
I
Standard Tolerance Standard Clearance

Clearance between steering spool Shaft Hole
1
and valve body
Replace
-
I 26
-0.006
-0.012
+0.015
+o .OO?
0.013 -
0.027
assembly
Clearance between demand spool. -0.013 +0.015 0.020 -

2 26
and valve body -0.020 +0.007 0.035 -
-
Standard size Repair limit
Free Installation Installation _ Free Installation

3 Steering spool return spring length length load length load
93.6 49.5 34 kg - 32 kg Replace
4 Demand spool return spring 156.6 140 13.3 kg - 12.3 kg

I
5 Check valve return spring 42.4 33.5 0.345 kg 0.31 kg
-
Tightening torque of steering
6 relief valve 8.5 + 1.5 kgm
Tightening torque of safety

7 4.5 f 0.5 kgm Retighten
valve with suction I
8 Tightening torque of plug 3.8’s 0.2 kgm
44-6 WA600- 1
STEERING CYLINDER MOUNT
426F186
426F187
Section A - A
Unit: mm
Clearance between mounting pin

and bushing connection of steer-
ing cylinder rod and frame
Connection of steering cylinder

and front frame
STEERING CYLINDER
426F 188
Unit: mm
1 I
bushing
70 -0.03 +0.271 0.105 -
-0.104 i-o.075 0.375 0.675
2 Clearance between piston rod -0.030 +0.174 0.280 - Replace

mounting pin and bushing 75 -0.076 +0.100 0.426 1.0
bushing
3 mounting pin and bushing 75 -0.076 +0.100 0.426 1.0

Clearance between cylinder bottom -0.030 +0.174 0.280 - I
4 Cylinder bore
I 130
1
+0.350
0 I
-
-E&tening torque of cylinder

5 74.5 + 10 kgm
I
Retighten
6 Tightening torque of piston nut 405 i 40.5 kgm (Width across the flats 80 mm)
44-8 WA600- 1
a
DIVERTER VALVE
Section A - A
426F189
Unit: mm
Clearance between body and
4 Check valve spring 79.2 57.5 0.50 kg 77.9 0.47 kg

5 bolt 10 kgm
6 Lfztening torque of mounting 11.25 + 1.25 kgm

Retighten
7 bolt 6.75 ? 0.75 kgm

8 bolt 9.0 + 3.5 kgm
WA600- 1 44-9
0
EMERGENCY STEERING PUMP
l Model SAM3-125
/ - \
1 5
Section A - A
426F192
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 - 0.15 0.19
Repiace
Clearance between inside diameter

of plain bearing and outside dia- 0.020 - 0.043 0.075
mater of gear shaft
3 Insertion depth of pin Replace
14
-:.6
Rotating torque of spline

shaft 0.7 - 1.2 kgm
5 Tightening torque of bolt 25 - 31.5 kgm Retighten
Revolution Pressure Standard Repair limit

dischar e dischar e
Discharge (rpm) (kg/cm*) (Plmin 3 (Qlmin
I. 3
6 Oil: SAElOW
Temperature: 45 to 55°C 2500 210 276 244
44-10 WA600- 1
0
General .......................... .... . . . . 51- 2
l Brake and air circuit diagram ... . . . . . . . 51-2-2
Air governor ..................... ... . . . . 51- 5
Air tank ......................... ... . . . . 51- 6
Safety valve ..................... ... . . . . 51- 6
Brake valve ...................... .... . . . . 51- 7
l Brake actuated ................ .... . . . . 51- 8
l Operating in balance .......... ... . . . . 51- 9
l Brake.released ................ ... . . . . 51-10
Two-way valve ................... ... . . . . 51-11
Relay valve ...................... ... . . . . 51-12
Brake chamber ................... ... . . . . 51-13
Slack adjuster ................... .... .... 51-15
Brake.. .......................... .... ..., 51-18
Parking brake .................... ... .... 51-20
Brake caliper .................... ... .... 51-22
Spring cylinder ................... ... .... 51-23
Parking brake solenoid valve ...... ... .... 51-24
Hydraulic tank pressuring valve . __ . . .... 51-25
WA600- 1 51-l
0
GENERAL
OUTLINE
The air compressed by the air compressor enters When the brake valves are actuated, the air in
the wet tank and the moisture is removed. The the dry tanks flows to the brake chamber and
air then enters two dry tanks and also flows to applies pressure to the brake oil in the master
the parking brake valve. The air in the dry tanks cylinder. The pressurized oil passes through the
flows to the brake valves. slack adjusters and pushes the wheel piston to
l When the air compressed by the air compressor apply the brakes.
fills the circuit and the air pressure in the wet The parking brake is applied mechanically by the
tank reaches the maximum set pressure of the spring in the spring cylinder. It is designed to be
air governor, the air governor is actuated. It opens released by air pressure. Therefore, if the air
the unloader valve of the compressor, so the pressure is less than the force of the spring in
compressor is put in a noload condition and no the spring cylinder, the brake is kept applied. When
air is compressed. When the air is used and the the air pressure rises and the parking brake release
air pressure inside the tank drops below the is reached, a solenoid valve is actuated to supply
minimum set pressure of the air governor, the air air to the spring cylinder. This releases the parking
governor is actuated. It closes the unloader valve brake.
of the compressor and the compressor is actuated.
If the air governor does not work properly, and
the pressure inside the tank reaches the set
pressure, the safety valve opens and the air
pressure is released to the atmosphere. This
protects the air circuit.

426F066A
51-2 WA600- 1
8
1. Front slack adjuster
2. Horn
3. R.H. brake valve
4. L.H. brake valve
5. Rear brake
6. Rear slack adjuster
7. Air compressor
8. Relay valve
9. Front brake chamber
10. Rear brake chamber
11. Horn valve
12. Spring cylinder
13. Front brake
F42601017
WA600-1 51-2-1
63
BRAKE AND AIR CIRCUITDIAGRAM

Serial No.
10686 and up
0868 and up
-1
r-----Mm
9
h
Lx-l
7
Y 10
ym
8lo
F42601018-K
51-2-2 WA600- 1
a
1 Air compressor
2. Air governor
3. Tire inflation
4. Drain valve
5. Air tank (wet)
6 Atr tank (dry)
/ 9.5i0.4 kg/cm* 7. Air tank (dry)
8. Check valve
9. Check valve
10. Drain valve
11 Brake valve (R.H.)
12. Brake valve (L.H.)
13. Two-way valve
14. Two-way valve
_
Ir
9 6
rxl 16. Rear brake chamber
17. Front slack adjuster
18. Rear slack adjuster
19. Front brake
20. Rear brake
21. Parking brake solenoid valve
22. Parking brake sensor
23. Spring cylinder
24. Parking brake
25 Horn valve
26. Horn
27. Brake oil tank
28 Safety valve
29. Low air pressure switch sensor
30. Stop lamp switch
31. Transmission cut-off switch
32. Relay valve
33 Air pressure sensor
34 Hydraulic oil tank pressure valve
35 Stop valve
36 Hvdraulic tank
F42601019
WA600-1
Specification
AIR GOVERNOR
Open valve pressure: 8.4 kg/cm2
Close valve pressure: 7.3 kg/cm2
To unloader pump
(To air ccmpress~r)
1. Seat
2. Diaphragm
3. Body
4. Sleeve
5. Adjusting screw
From ta
6. Filter
7. Cover
8. Spring
426FO67
FUNCTION
* The tank port is connected to the air tank, and the

unloader port is connected to the unloader valve of
the air compressor. The air pressure inside the air
tank is always kept within the specified pressure
range. If the pressure starts to rise above the’speci-
fied pressure, the operation of the air compressor
stops so that the air pressure does not rise any fur-
ther. If the pressure drops below the specified pres-
sure, the operation of the air compressor starts again
to prevent any drop in the pressure.
I v---7 I
OPERATION
When pressure inside air tank is below specified level.

- The air pressure inside the tank is below the specified
pressure, so diaphragm (2) is pushed to the left by the
force of spring (8).
Compressor
- There is no pressure on the unloader valve, so the air
compressor continues to operate.
Check valve
I
10001-10232 10233 and up
426FO68.1
51-4 WA600- T
0
When pressure inside air tank is above specified level.
- When the pressure at port B of the air tank goes
above the specified pressure, diaphragm (2) is pushed
to the right. The compressed air from the air tank
pa’sses through passage a and actuates the unloader
valve of the air compressor.
To dry
“;”

10001-10232 10233 and up
426FO69.1
WA600- 1 51-5
0
AIR TANK Specification
Maximum
Name Capacity (P) pressure
* The air tank consists of one wet tank and two dry
tanks. The air from the compressor first enters the (Serial No.lOOOl-10056) 29.4
Wet tank 9.5 kg/cm*
(Serial No. 10057 and up) 39.4
wet tank and the moisture is removed. It is then
divided and sent to the left and right dry tanks. (Serial No.lOOOl-100561 29.4
Dry tank CL) 9.5 kg/cm’
* A safety valve and air pressure sensor are installed in (Serial No.10057 and UD) 39.4
the wet tank. (Serial No. 10001-l 0056) 29.4

Dry tank (R) 9.5 kg/cm*
(Serial No.10057 and up) 39.4
WET TANK DRY TANK
A. To air governor (PT1/2)
B. To air tank (dry)

(PT l/2)
C. From air compressor
(PT l/2)
D. Safety valve mount
-H (PT l/2)
C
_I!
E. To drain valve (PT l/8)
F. To relay valve (PT l/2)
-------
G. To relay valve (PT 112)
From air tank (wet) (PT l/2)

Safety valve mount (PT l/8)
F ‘.
E
-1
_-’ Drain valve (PT l/8)
426FO70 426FO71
Function 1. Adjustment nut

- The safety valve is installed in the wet tank, and acts
2. Spring cage
as a safety device for the air ‘bruit.
3. Spring
Operation 4. Ball
- If the air governor does not work properly and the 5. Lock nut
pressure inside the air tank rises above the set pres-
6. Relief valve
sure, ball (4) is pushed up and the air escapes to the
atmosphere. 7. Body
Specification
423FO96
Setting pressure: 9.5 kg/cm’
51-6 WA600- 1
c9
BRAKE VALVE
OUTLINE
- There are two brake valves installed in parallel at the
bottom of the operator’s compartment. These are
operated by depressing the pedal.
- When the right pedal is depressed, air is sent to the
brake chamber and the brake is actuated. When the
left pedal is depressed, the brake is actuated in the
same way as with the right pedal, but at the same
time, the transmission solenoid valve is actuated
electrically, and the transmission is put in neutral.
423FO97
1. Brake pedal A. From air tank
2. Plunger B. From air tank
3. Piston C. To front brake chamber
4. Inlet valve D. To rear brake chambdr
5. Piston
6. Inlet valve
7. Rubber spring
WA600- 1 51-7
BRAKE ACTUATED
Upper part
- When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (71, and
is transmitted to piston (3). When piston (3) moves
down, exhaust port (9) is closed, and at the time inlet
valve (4) is moved down and air from the air tank
(11) flows from port A to port C. This actuates the
relay valve (13).
Air from the air tank (11) flows to front brake
chamber (12).
Lower part
* When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (7). and
is transmitted to piston (3). When piston (3) moves
down, inlet valve (4) is moved down, and air from the _To f&j
air tank flows from port B, to port D. This actuates
the relay valve (14).
Air from the air tank (11) flows to rear brake cham-
ber (15).
426FO72
Operation of brake when lower valve fails

- Even if there is leakage of air in the lower piping, the
upper part will operate normally.
426FO73
51-8 WA600- 1
Operation of brake when upper valve fails
* Even if there is leakage of air in the upper piping, if
pedal (1‘) is depressed, piston (5) will be pushed down
mechanically and the upper part will operate normal-
lY.
OPERATING IN BALANCE
Upper part 426FO74

* When the pressure in the space below piston (3) and
the air pressure from the brake chamber become high,
the pressure pushes rubber spring (71, and piston (3)
moves up to close inlet valve (4). When this happens,
exhaust port (9) stays closed. The air pressure enter-
ing the brake chamber is retained and the brake is
kept applied.
Lower part
- Upper piston (3) moves up, and inlet valve (4) closes.
Piston (3) is pulled up by an amount equal to the
amount of movement and inlet valve (6) closes. The
exhaust valve is closed, so the air pressure is main-
tained and the brake is kept applied.
The air pressure in the space at the upper part bal-
ances the operating force of the pedal. The pressure
in the space at the lower part balances the pressure in
the space at the upper part.
When pistons (3) and (5) move to the end of their
stroke, inlet valves (4) and (6) are fully opened. The
spaces in the upper and lower parts, and the air pres-
sure in the left and right brake chambers become
equal to the air pressure in the tank. Therefore, the
braking effect can be adjusted by the amount the
brake pedal is depressed. When the pistons move
426FO75
down to the end of their stroke, the brake is applied
fully.
WA600- 1 51-9
BRAKE RELEASED
Upper part
- When the pedal (1) is released and the operating pres-
sure is removed from the top of the piston, the air at
the bottom of the piston, and the piston return spring
move the piston up. Exhaust port (9) is opened and
the air pressure in the brake chamber is released to
the atmosphere.
Lower part
- When the pedal is released and the air at the top of
piston (5) is let out, the air at the bottom of piston
(5) and spring (13) pull the piston up. Exhaust port
(10) opens at the air pressure in brake chamber is
released to the atmosphere:
adjuster
426FO76
51-10 WA600- 1
‘TWO-WAY VALVE
FUNCTION
- The two-way valve is installed between the two brake
valves. It acts to prevent the air pressure from escap-
ing from one brake valve when the other brake valve
is depressed.
OPERATION
* The air circuit of the left and right brake valves is
connected so that the brakes on all four wheels are
actuated when either of the pedals is depressed.
The air pressure entering from port A of the two-way
valve moves seat (2) and shuts off the circuit to port
5. Therefore, the air pressure flows only to port C
and actuates the brake chamber (5). i 4
423F 103
1. Body 4. Cap
2. Seat 5. Brake chamber
3. Plug
‘5
426FO77
WA600- 1 51-l 1
RELAY VALVE
1. Valve body
2. Relay piston
3. Spring
4. Inlet valve
A. To brake chamber
B. Exhaust port
C. From brake valve
Cl. From dry air tank
OPERATION
- When the brake valve is depressed and pressurized air From

brake valve
flows to the top of relay piston (2), the relay piston is
pushed down. Drain valve (5) closes and inlet valve
(4) opens. Pressurized air is then supplied to the
brake chamber from the tank. @ From tank
426FO79
* When the pressure on the brake valve is reduced, the

pressure of the pressurized air at the top of relay
piston (2) is reduced, so the pressure (spring force) at From
0 brake valve
the bottom of relay pistonJ2) pushes the relay piston
up. The drain valve (5) opens and the pressurized air
in the brake chamber is drained.
0 From tank
426F080
i
51-12 WA600- 1
BRAKE CHAMBER
Section A - A
425FO85
View Z
1. Air cylinder 6. Piston
2. Air piston 7. Master cylinder
3. Spring 8. Piston valve
4. Rod 9. Body
Specifications
5. Breather 10. Sensor 1. Air cylinder
Stroke: 133.5 mm
Cylinder capacity: 3,600 cc
2. Master cylinder
Stroke: 132.5 mm
Delivery: 472 cc
WA600- 1 51-13
OPERATION
Brake operated
When the brake pedal is depressed, compressed air is
supplied from the relay valve to the brake chamber. Air
piston (2) moves rod (4) and pushes piston (6) of master
cylinder (7) to the right. Brake oil is sent by piston (6)
to the brake piston to actuate the brake.
lack
ster
425FO86
Brake held in position

When the brake pedal is kept depressed at a constant
force, the hydraulic pressure is kept constant, so the
brake is kept applied.
To slack
From relay adjuster
valve @
*
425FO87
Brake released
When the operating force on the brake pedal is partly
released, the compressed air supplied to the back of pis-
ton (2) of the brake chamber is released from the relay
valve, and the hydraulic pressure inside master cylinder
(7) drops. If the brake pedal is released further, the
brake oil sent to the piston of the brake is sent back to
the inside of master cylinder (7) by the force of the
brake return spring.
From slack
To relay
adjuster
valve
0 .$&
425FO88
51-14 WA600- 1
SLACK ADJUSTER
427F105
1. Cylinder
2. Check valve
3. Bleeder
4. Piston
5. Spring
A. Inlet port
B. Outlet port
FUNCTION
- The slack adjuster is installed in the brake oil line
from the brake chamber to the brake piston. It acts
to keep the clearance between the brake piston and
discs constant even when the brake discs are worn. In
this way it acts to keep a constant time lag when the
brake is operated.
WA600- 1 51-15
0
OPERATION
1. Brake pedal depressed

The oil pumped out from the brake chamber (6)
flows in from port P of the slack adjuster. From
port E the oil is divided and sent to left and right
cylinders (2) and moves piston (4) a distance of S to
the right.
4 2
\ \
426FO81-1
Because of this, an amount of oil corresponding to

stroke S flows from port C to the brake cylinder
(7). When this happens, the clearance between the
brake piston and disc becomes 0, so no braking
force is generated.
426FO82-1
51-16 WA600- 1
0
If the oil pressure in the chamber (7) goes above a
certain specified pressure, check valve (3) opens and
the oil ‘flows through pilot circuit D and applies
pressure to port C. This gives the braking force.
3
\
426FO83-1
2. Brake pedal released

When the brake is released, pressure is applied to the
back of the brake piston because of the hydraulic
pressure of the brake chamber produced by return
spring. Piston (4) is moved back stroke S and the
disc clearance returns to normal.
From
relay valve +
426FO84.1
WA600- 1 51-17
0
BRAKE
FUNCTION
* The brakes are wet-type mutiple disc brakes,and are
fitted to all four wheels.
6 7
Detail P
426FO65
1. Guide pin 5. Inner gear (teeth 112)
2. Return spring 6. Plate
3. Brake piston 7. Disc
4. Outer gear (teeth 164)
51-18 WA600- 1
OPERATION
* When the brake pedal is depressed, pressure is applied
to the brake oil by the master bylinder of the brake
chamber. Brake piston (3) is moved to the right, and
disc (7) is kept in close contact with plate (6). Disc
(7) rotates together with wheel, so when it is held,
the rotation is stopped and the brakes are applied to
stoo the machine.
426F086
- When the brake pedal is released, the pressure on the

rear of brake piston (3) is released. The piston is then
moved to the left by the force of return spring (2)
and the brake is released.
To slack
adjuster
426FO87
WA600- 1
51-19
PARKING BRAKE
OUTLINE
* The parking brake is a disc type and is installed on - The parking brake caliper is fixed to the front dif-
the front axle. ferential case.
- The force of the spring inside the spring cylinder (2) The disc is installed to the differential yoke and ro-
is used to apply the brake mechanically; it is released tates together with the coupling.
by air pressure.
426FO88
1 Parking brake disc
2. Spring cylinder
51-20 WA600- 1
Brake operated
* When the parking brake switch lever is moved to ON, 2 OFF
solenoid valve is actuated and the air from the air
tank is shut off by valve. At the same time, the air
from the spring cylinder is released to the atmosphere
from between valve and body. Therefore, the piston
of spring cylinder (1) is pushed by the tension of the I’
spring, so when lever (2) is pushed, the parking brake 41
:__-
is applied.
* Lever (2) rotates piston shaft (3) and moves piston
(4) to the axial direction. Therefore, the pads are
pushed against the disc, and the parking brake is ap-
plied.
i i 426FO93
Brake released
- When the parking brake switch is turned to OFF, the
solenoid valve is actuated and valve closes the exhaust
port.
At the same time, the air in the air tank enters the solenoid valve
top part of the piston of spring cylinder (1). It over-
comes the force of the spring and pushes the piston.
This pulls rod (5), moves piston (4) and releases the
brake.
Therefore, air pressure is applied to the spring cylin-
der and the parking brake is kept released.
* However, if the air pressure inside the tank drops to a
level where it cannot maintain the normal operation
of the brake, the pressure sensor installed to the tank
sends an electric signal to the solenoid valve. This re-
leases the spring cylinder circuit, and the parking
brake is automatically applied.
Ii
426FO94
WA600- 1 51-21
BRAKE CALIPER
425FO95
Section A - A
1. Caliper
2. Pad
3. Piston
4. Piston shaft
5. Lever
6. Adjustment bolt
OUTLINE
- Caliper (I) is fitted with a piston guide. Piston (3) The caliper body follows the wear of pad (2) and
and piston shaft (4) are fitted inside, and the rotation slides in the axial direction on the plate.
of the piston shaft moves the piston in the axial direc- Adjustment bolt (6) of lever (5) is used to adjust the
tion to compress pad (2). clearance between the pad and the disc. Hold the
; Lever (5) is connected by a spline to the spline side of lever and turn the adjustment bolt to adjust the clear-
the piston shaft. ance as follows.
Pad (2) is fitted and held in position together with To INCREASE, turn COUNTERCLOCKWISE.
caliper (1) in the caliper mounting plate. To DECREASE, turn CLOCKWISE.
51-22 WAtiOO- 1
SPRING CYLINDER
Section A-A
426FO92
1. Spring OUTLINE
* The air pressure from the parking brake solenoid
2. Piston
valve pushes the spring (1) and compresses it to re-
3. Cylinder
lease the parking brake.
4. Boot Usually the parking brake is kept applied by spring
(1). so the machine is prevented from moving.
5. Rod
WA600- 1 51-23
0
PARKING BRAKE SOLENOID VALVE
l-l
I#+ 1. Coil A. Exhaust port
r 2. Body B. Outlet valve
c
3. Outlet port C. Inlet port
C 4. Filter
Function
- The parking brake solenoid valve is a valve to switch
air to the parking brake air chamber. It is controlled
and actuated by a switch in the operator’s compart-
ment.
426FO89
OPERATION
* Parking brake ON
When the parking brake switch in the operator’s com-
partment is turned ON, the solenoid valve is switched
OFF, and air from the spring cylinder enters port A.
It passes around valve (31, and is drained from port B.
In addition, air from the tank enters port C, but it is
shut off by valve (31, so the air does not flow.
Q
%&ake
426FO90
* Parking brake OFF

When the parking brake switch in the operator’s com-
partment is turned OFF, the solenoid valve is switch-
ed ON, and valve (3) moves up. The air from the
tank enters port C, but valve (3) has moved up, so the From
wet tank
air passes around valve (3) and enters port A. Air is
sent to the spring cylinder and the brake is released.
9
To brake
valve
426FO91
51-24 WA600- 1
HYDRAULIC TANK PRESSURIZING VALVE
Seiral No. 10868 and up
428FO1049
1. Body A. Inlet port FUNCTION

. The hydraulic tank pressurizing valve sends air
2. Spring B. Outlet port
to the hydraulic tank at the specified pressure
3. Valve to maintain the pressure inside the hydraulic tank
at a constant level.
WA600-1 51-25
a
BRAKE AND AIR SYSTEM
Standard value table . 52. 2

Tool list for testing and adjusting 52- 3
Measuring brake pedal 52s 4
Measuring air pressure .. 52. 5
Testing brake performance . . _. . . 52. 8
Checking brake piston leakage . 52. 9
Measuring wear of brake disc . . . 52-10
Air bleeding from brake line . . .. 52-11
Testing parking performance . . 52-12
Checking and adjusting parking brake 52-13
Troubleshooting . ... .. 52-15
1. The values in these tables are based on the values for new machines leaving the plant, so they should be used as
target values when repairing or when estimating wear after a period of use.
standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination with repair and operating records when making judgements.
3. These standard values tables must not be used for standard values when judging claims. In addition, do not use
WA6001 1 52-1
a
Standard Permissible
Testing and measuring item Measurement condition value value
Brake pedal
- Operating force - Engine speed: Low idling kg 39 -47 Max. 61
* Operating angle - Air pressure: 7 kg/cm’ degree 16.5 - 20.5 Max. 27
- Play * Brake pedal operating force: 43 kg 4 - 8” Max. IO”
Air system
. Air governor cut-in pressure * Coolant temperature: 6.7 - 7.3 6.7 - 7.3
- Air governor cut-off pressure kg/cm’ 8.0 - 8.6 8.0 - 8.6
* Safety valve actuating pressure 9.1 -9.9 9.1 -9.9
Warning buzzer
- Actuating starting pressure - Coolant temperature: 5.9 - 6.1 5.9 - 6.1
Inside operating range kg/cm’
- Actuating stopping pressure 6.0 - 6.h 6.0 - 6.4
. Road surface: Flat, horizontal, dry,

paved surface
* Speed when applying brakes:
20 km/h
- Time lag when pressing the pedal:
Brake performance 0.1 sec. m Max. 6.5 Max. 6.5
- Air pressure: 6 kg/cm1
* Brake pedal operating force:
38 kg
- Tire inflation pressure:
Specified pressure
- Coolant temperature:
Drop in brake oil pressure Inside operating range kg/cm’ Max. 5 Max. 5
- Test pressure: 53 kg/cm’/5 min.
. Coolant temperature:
Wear of brake disc Inside operating range mm 6.91 - 8.09 Max. 13.4
. Air pressure: Inside opirating range
* Tire inflation pressure:

Specified pressure
- Road surface: Machine
Parking brake performance stopped
Flat, dry, paved surface with
l/5 (11’20’) gradient
. Machine: In operating condition
* Thickness of pad * With back plate 31.7 12.7
* Clearance between disc and pad * Total of both side mm 0.88 - 1.24 Max. 2.1
52-2 WA600- 1
0
No. Testing and measuring item Tool name Part number Remarks
1 Brake pedal operating force Push gauge 799-101-1001 O-110kg
brake oil pressure Brake test kit 793-520-l 802 0 - 100 kg/cm’
2
Nipple 793-438-l 060
3 Wear of brake disc Vernier calipers Commercially available 150mm-2OOmm
4 Brake distance Tape measure Commercially available 30 m
5 Clearance of pad Feeler gauge Commercially available 0.1 - 3.0 mm

I
0 - 25 kg/cm’
0 - 50 kg/cm’
Measuring air -
6-3
I I Connector
20PE
(Commercially available)
-
A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
When taking measurements, do not allow unauthorized persons near the machine.
A
WA600- 1 52-3
MEASURING BRAKE PEDAL
. Coolant temperature: Inside operating range.
. Engine speed: Low idling
. Air pressure: 7 kg/cm2
Item
value value
I
Operating
39 - 47 kg Max. 61 kg
force
Operating
Brake pedal 16.5 - 20.5” Max. 27’
angle
Play 4 - 8’ Max. 10’
Special tool
A 799-101-1001 Push gauge 1
1. Measuring operating force of pedal

1) Fit push gauge A to the operator’s foot.
* Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then
depress the pedal and measure the operating
force.
2. Measuring travel of pedal

1) Fit push gauge A to the operator’s foot.
* Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then
depress the pedal with an operating force of
43 kg and measure the travel of the pedal with
an angle meter B.
3. Measuring play of pedal

1) Start the engine.
2) Push the brake pedal in lightly by hand, and use
an angle meter B to measure the travel of the
pedal to the point where it starts to become
heavy.
52-4 WA600- 1
0
MEASURING AIR PRESSURE
. Coolant temperature: inside operating range.
* When measuring, connect nipple @ , connector @
to gauge @ , then insert in the tire information
coupler on the machine.
Special tools
-1
I Part No. I Part Name / a’tv
1. Measuring set pressure of air governor

1) Open the drain valve and drain air from the
tank.
2) Start the engine and raise the pressure inside
the tank.
Measure the pressure at which the air governor
is actuated and the air compressor is cut-off
(no-load rotation).
3) With the engine at low idling, use the brake
pedal to lower the air pressure. Measure the
pressure at which the air compressor cuts in
(Start of operation).
* Carry out the above inspection, and if the value is

not within the standard range, replace the air r To unloader valve
governor assembly.
2. Measuring cut-off pressure of air pressure warning

buzzer
1) Start the engine and run at low idling. Use the From air tank-
brake pedal to lower the air pressure, and meas-

ure the pressure at which the buzzer starts to
sound.
2) Using brake pedal, lower air pressure further,
then start engine, and measure air pressure at
which buzzer stops to sound.
* If the pressure is not standard value, check
the switch. If necessary, replace the switch.
* After replacing the switch, measure the pres-
sure again.
WA600-1 52-5
0
3. Measuring safety valve
1) Loosen the adjustment screw of the air gover-
nor and set the actuating pressure of the air
governor above the actuating pressure of the
safety valve.
2) Start the engine and measure the pressure when
air comes out of the safety valve.
* After measuring, do not forget to return the air

governor to the specified pressure.
* If the safety valve is defective, replace the valve c
b a
assembly.
Do not try to adjust it. 423F318
* Hook the tool on part “a” when tightening or

removeing. Never use part “b” when tightening.
* Install so that the exhaust port (c) face down.
WA600- 1 52-7
0
TESTING BRAKE PERFORMANCE
. Time lag when pressing the pedal: 0.1 sec.
. Air pressure: 6.0 kg/cm’
. Road surface:
Flat, horizontal, straight, dry, paved surface.
. Machine speed:
Speed when applying brakes: 20 km/h
. Tire inflation pressure: Specified pressure.
Unit: m
item
I value I value
Brake
Max. 6.5 Max. 6.5
performance
Special tool
I Part No. I Part Name
I Commercially
available
Tape measure 1
Conditions for measurement

1) Start the engine and then start the machine.
2) Place the speed control lever in the highest speed
range and drive the machine.
3) When the machine is traveling at 20 km/h, depress
the left brake pedal with 38 kg.
* Decide the run-up road and point to apply the
brakes, then apply the brakes when the braking
point is reached.
4) Measure the distance from the braking point to the
point where the machine stops.
* Carry out the test three times and take the average
value.
Stopping point Braking point Brake pedal operating

I position
Braking distance Runup road
423F319
52-8 WA600- 1
CHECKING BRAKE PISTON LEAKAGE
Coolant temperature: Inside operating range
Test pressure: 43 to 53 kg/cm2
Air pressure: Upper limit of green range
Unit: kg/cm*
Drop in pressure Max. 5.0 Max. 5.0
Special tool
Part No. Part Name O’ty
A 793-520-l 801 Brake test kit 1
793-438-l060 1 Nipple
QT Block the tires securely.
Measuring procedure
1. Remove bleeder screw (I), then install tool A in
bleeder screw mount.
2. Start the engine and bleed the air.
* Two worker are need for this operation: one de-
press the brake pedal and the other bleeds the air
from bleeder screw (2).
+ Check that there is no leakage on air pipings and
brake pipings.
3. Rise air pressure to upper limit of green range.
4. Using block (length = 400 mm), depress brake pedal
fully, then stop engine.
5. When gauge reading is 43 to 53 kg/cm2, leave for 5
minutes and check how much pressure drops.
6. After measuring, loosen bleeder screw to release
pressure, then remove tool A.
t After completing operation, bleed air from brake
circuit again.
WA600- 1 52-9
0
MEASURING WEAR OF BRAKE DISC
- Air pressure: Inside operating range
Unit: mm
Piston stroke 1 6.91 - 8.09 1 Max. 13.4
Special tool
I Part No.
I Part Name Q’ty
c I Commercially
available
Vernier calipers
I ’
Stop the machine on level ground and block the

A! tires.
Method of testing
1. Remove plug (19.
2. Depress the brake pedal to the end of its travel.
3. Measure depth “a” from the end face of the housing
to the spring guide.
* Keep the brake pedal depressed when measuring.
4. Install a vinyl hose to bleeder (2), loosen the bleeder
and drain the brake oil.
+ After draining the brake oil, check that the brake
piston has returned to the end of its stroke.
5. Measure depth “b” from the end face of the housing
to the spring guide.
Calculating piston stroke
S=a-b
S = Max. 13.4 mm
426F263
52-10 WA600- 1
0
AIR BLEEDING FROM BRAKE LINE
A Block the tires securely.
Order of operation
1. Remove cap (1) of the bleeder screw, insert vinyl
hose .(2) into the screw and put the other end in a
container.
3. Depress the brake pedal, loosen the bleeder screw
and bleed the air. Then tighten the bleeder screw
and slowly release the brake pedal.
* Two workers are needed for this operation:
one depresses the pedal and the other bleeds
the air from bleeder screw.
* Depress the left brake pedal.
* Keep adding brake oil so that the oil circuit is
always full.
4. Repeat this operation until no more bubbles come
out from the hose. Then depress the pedal fully and
tighten the bleeder screw while oil is flowing out.
* Follow the same procedure to bleed the air
from each cylinder.
After bleeding all the cylinders, check the level
of the oil tank and add oil.
* To bleed the air completely, bleed the air first
from the cylinder furthest from the brake
chamber.
* When the air has been bled from all the cyl-
inders, remove cover (3), confirm that rod (5)
for the over-stroke sensor of brake chamber (4)
is in place. If it is out of place, push it in as far
as the sensor installation end face of chamber.
WA600- I
TESTING PARKING BRAKE PERFORMANCE
. Tire inflation pressure: Specified pressure
. Road surface: Flat, dry, paved surface with l/5
(11020’) gradient.
. Machine: In operating condition
Permissible
Item “‘zEd value
Keeps machine on l/5 (11’20’) 423F321

Parking brake performance
gradient
Measuring procedure
1. Start the engine and drive the machine straight up a
l/5 gradient with the bucket unloaded.
2. Depress the brake, place the F-R lever in neutral,
then stop the engine.
3. Turn the parking brake switch ON, then slowly
release the brake pedal and keep the machine must
be kept stopped.
. The measurement must be made with the
machine facing either up or down the slope.
423F322
52-12 WA600- 1
0
CHECKING AND ADJUSTING PARKING BRAKE
. Air pressure: Maximum set pressure
Unit: mm
Item
value value
Thickness of pad
31.7 12.7
(with back plate) / I
A Block the tire securely.
Measuring procedure
1. Turn the starting switch ON, and turn the parking
brake switch (1) OFF to release the brake.
* Operate the parking brake switch slowly. If
it is not operated slowly, it may be impossible
to release the brake.
2. Measure the thickness of pad (3) with vernier calli-
pers A.
-* When the starting switch is turned OFF, the
parking brake is applied, so be careful not to
turn it OFF.
* For details of removing the pad, see 53 DIS-
ASSEMBLY AND ASSEMBLY.
* Measure 2 pads.
* If the thickness is not within the standard
value, replace the 2 pads as one set.
Measuring clearance
Unit: mm
Item
value value
Clearance between disc and

0.88 - 1.24 Max. 2.1
oad
Measurement procedure
1. Turn the parking brake switch OFF to release brake.
2. Insert filler gauge B between disc (2) and pad (3),
then measure the clearances (a) and (b).
* The clearance value mentioned above indicates
the total value of both sides. (a + b)
425F208A
WA600- 1 52-13
0
Adjustment
* If the value is not within the standard range, adjust
as follows.
1. Turn the starting switch ON, then turn the parking

brake switch OFF to release the brake.
* If the starting switch is turned OFF, the park-
ing brake will be actuated,‘so be careful not to
switch it off.
2. Turn adjustment bolt (5) at the caliper lever clock-

wise until pad (3) is lightly in contact with disc (2).
* If the adjustment bolt is tightened too much
and pad (3) and disc (2) are brought strongly
into contact, it may cause the brake to squeak
or the discs to overheat.
3. Turn adjustment bolt 180” + 30” (three or four

notch) counterclockwise. This will adjust the total
clearance on the left and right between pad (3) and
disc (2) to 0.88 to 1.24 mm.
* When replacing the pad, always replace in sets
of two pads.
* After adjusting, measure the brake performance

again and check that it is within the standard value.
425F208B
52-14 WA600- 1
0
TROUBLESHOOTING
Troubleshooting table ,. . .. . . 52-16

1. Air pressure does not rises at all 52-l 6
2. Air pressure does not rise to the
specified range . 52-l 7
3. Brake is ineffective or not very
effective . . 52-18
4. Brake does not release, or drags 51-19
5. Parking brake does not release,
or drags . . 52-20
* Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”
page 22-12, “METHOD OF READING TROUBLESHOOTING TABLE” page 22-14 and “PREVENTING RECUR-
RENCE OF TROUBLE” page 22-16.
WA600- 1 52-15
0
1. Air pressure does not rise at all.

. Did the air pressure suddenly cease to rise? -+
Damage in air circuit or equipment.
. Was the air pressure difficult to raise for some
time? + Air leakage, performance drop in air
equipment.
Check before troubleshooting

. Damaged air hose or tube, external damage to
equipment associated with air system.
. Is the drain cock completely closed?
Fault check
. Check the air pressure by air gauge.
. If the pointer of the air gauge on the instru-
ment panel remains at “0” despite opening the
air drain valve and confirming that the air is
pressurized, the gauge is faulty.
Air is not discharged from discharge pipe of compressor

1
when engine is running. lololol I
2 Unusual noise can be heard from air compressor 0
Compressor starts to build up pressure when circuit

3 0
between air governor and unloader is cut.
Compressor does not start to build up pressure despite

4 cutting the circuit between the air governor and the
unloader.
Compressor starts to build up pressure when the intake

5 0
hose of the compressor is disconnected.
Air comes out of discharge pipe of compressor when

6 engine is running but pressure does not build up. 0

52-l 6 WA600- 1
0
2. Air pressure does not rise to the specified
range.

. Check for possible air leakage from air hose,
tube and air equipment.
. Is the drain cock completely closed?
. Check for deformation of compressor or air
intake hose.
Fault check
. Install a pressure gauge in the air circuit and
measure the air pressure, then compare the
measured value with the standard value table
to see whether or not it deviates from the
specified value.
I- Probl
Air discharge from compressor discharge pipe is weak

1 0 0
when engine is running.
Compressor starts to build up pressure when circuit

2 0
between air governor and unloader is disconnected.
Air comes out of discharge pipe of compressor when

3 0
engine is running but pressure does not build up.

X: Reblace A: Repair
A: Adjust C: Clean
WA600- 1 52-17
0
3. Brake is ineffective or not very effective.

. Did the brake suddenly ceases to be effective?
-+ Damge in air or brake equipment.
. Did brake gradually deteriorate? -+ Deteriora-
tion of seal or packing, wear of lining.

. Is kind of brake oil correct? (SAElOW-CD)
. Is air pressure and brake oil quantity satisfac-
tory?
. Is there any leakage of air or brake oil when the
brake is operated?
. Is there any external damage to air or brake
piping or equipment?
. Check residual thickness of brake lining.
. Check tire inflation pressure and tire tread.
. Measure the pressure in the air circuit. If there
is an abnormality, refer to item 1 “Air pressure
does not rise at all” and item 2 “Air pres-
sure does not rise to the specified value”. If
the measured value is normal, move on to the
following problems.
Fault check
. Check it against the value in the standard value
table to see whether or not braking perform-
ance is bad.
. Check braking of the left and right wheels or
both front and rear.
depressed. Braking action is effect when other brake pedal
2 When depress brake pedal, there is no resistance. 0 0’ 0

When depress the brake pedal, air leaks from the brake
3 0
chamber relay valve.
When brake is applied, abnormal noise is heard from axle

4
brake area. I / I / I / Iold I I
Sufficient air is not available from the pipe when the tube
-7
5 at the air inlet of the brake chamber is disconnected and
the brake pedal depressed.
Air leaks from the breather of the brake chamber when

6
the brake pedal is depressed.
7 I Excessive metal particles in axle oil

8 1 Leakage of brake oil inside axle more than specified.
I I I I lot I I I I
When the machine is raised using jack, the wheel
axles placed on a stand and the brake operated with the
9
engine in the forward 1st speed position, however a certain
wheel turns fast.

X: Replace A: Repair
A: Adjust C: Clean
52-18
0
4. Brake does not release, or drags.

. Does brake pedal return completely?
- Dbes parking brake completely disengage?
Fault check
. Abnormal hea? generation in brake.
. Inertial travel on flat ground.
Air comes out and brake disengaged if brake chamber air

1 0 0
input is disconnected when brake pedal is released.
Circuit pressure fails off and brake disengages if oil is bled

2 0 0 0
from air bleeder when brake pedal is released.
A certain wheel rotates sluggishly when the machine is

3 raised with jack, the wheel axles placed on a
0 0
stand, the engine run and place forward 1st position.

X: Replace A: Repair
A: Adjust C: Clean
WA600- 1 52-19
a
5. Parking brake does not release, or drags.

. Is’ the pressure in the air circuit within the
specified range? (if the air circuit pressure is
4.0 kg/cm’ or less, the parking brake solenoid
valve will automatically operate to engage the
parking brake.)
No. Problems .
1
When parking brake switch turned to OFF, air leaks from
spring cylinder, and cylinder rod does not return fully.
0
2
Parking brake not released even when parking brake switch
0
is turned OFF,
The spring cylinder operates normally and the rod and lever
3 0 0
return, however the brake drags.

52-20 WA600- 1
0
AIRSYSTEM
BRAKE VALUE SLACK ADJUSTER
1 .................
Serial No. 10001 - 10880 (Except D spec.) Removal . . 53-22
[ Serial No. 10001 and up (D spec.) Installation ............... . . 53-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 53- 2 Disassembly ............... . . 53-23
Installation . . . . . . . . . . . . . . . . . . . . . _ . 53- 4 Assembly ....... 1 ........ . . 53-24
BRAKE VALUE BRAKE
[Serial No. 10881 and up (Except D spec.)] Removal ................. . . 53-25
Removal . . . . . . . . . . . . . . . . . . . . . . . _ . 53-5-l Installation ............... . 53-28
Installation . . . . . . . . . . . . . . . . . . . . . . . 53-5-3 Disassembly ................ .. 53-31
l3 RAKE VALUE Assembly ................ .. 53-34
Disassembly. . . . . . . . . . . . . . . . . . . . . . . 53- 6 SPRING CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 53- 8 Removal ................. . 53-37
BRAKE CHAMBER Installation ............... . . 53-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 53-10 Disassembly ............... . . 53-39
Installation . . . . . . . . . . . . . . . . . . . . . . . 53-13 Assembly ................ . . 53-39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 53-16 PARKING BRAKE
Assembly . . . . . . _ . . . . . . _ . . _ . _ . . . . . 53-19 Removal ................. . . 53-40
Installation ............... . . 53-43
PARKING BRAKE PAD
Removal .......... : ...... . . 53-46
Installation ............... . 53-46
* Air bleeding procedure
out from the plug.
m Plug: 1 .I 5 * 0.15 kgm
WA600- 1
%’
REMOVAL OF BRAKE VALVE
Serial No. 10001 and up (D spec.) I
A Stop the
the safety
machine on level ground
bar on the frame. Lower
and install
the work
moving.
1. Draining air
Open drain valve (1) and drain air from air tank.
2. ‘Covers
3. Air piping
Disconnect the following air piping from brake
valve.
- Tube (4) between brake valve and dry tank
* Tube (5) between right brake valves
* Tube (6) between brake valve and relay valve
- Tubes (7), (8) and (9) between right brake

valves
* Tube (IO) between brake valve and dry tank
* Disconnect electric wiring (1 1) from connec-
tor, and remove clamp.
5%2 WA600- 1
4. Pedal
Pull out cotter pin of pin (II), then pull out pin,
and remove pedal (12).
* Remove the floor mat.
5. Brake valve
* Loosen bolts (14).
2) Remove bolts (14), and disconnect valve body
(15) and mount flange (16).
* Vaive body (15) will fall when bolts (14) are
removed, so be very careful when removing
the bolts.
* Pull out plunger (17) from mount flange.
426P839
WA600- 1 53-3
(II
INSTALLATION OF BRAKE VALVE
No. 10001 - 10880 (Except D spec.)
No. 10001 and up (D sped I
1. Brake valve
1) Assemble plunger (17) to mount flange.
KY!% PI unger: Brake oil
2) Set valve body (15) in mounting position, and

tighten mount flange (16) and bolts (14).
426P839
3) Tighten mounting bolts (13) to lock valve.
2. Pedal
Set pedal (12) in mounting position, insert pin (11 ),
then align hole of stopper on left side of pin and in-
stall right side cotter pin.
* Bend the cotter pin securely.
* Check that the spacer is assembled.
3. Air piping
Connect the following air piping to brake valve.
- Tube (10) between brake valve and dry tank
- Tubes (7), (8) and (9) between right brake
valves
* Connect electric wiring (11) with connector,
and tighten with clamp.
53-4
SC
- Tube (6) between brake valve and relay valve
- Tube (5) between right brake valves
* Tube (4) between brake valve and dry tank
426P834
4. Checking for air leakage

Tighten drain valve, start engine and check for
leakage of air. Check operation of brakes also.
5. Covers
WA600- 1 53-5
2
REMOVAL OF BRAKE VALVE
[Serial No. 10881 and up (Except D spec.)]’
A Stop
the safety
bar on the frame.
and install
Lower the work
moving.
1. Draining air
Open drain valve (1) and drain air from air tank.
2. Covers
3. Air piping
Disconnect the following air piping from the brake
valve. 13 Brake pedal (left)
- Tube (4) between front dry tank and brake valve
* Tube (5) between rear dry tank and brake valve
* Tubes (6), (7), (8), and (9) between left brake
, 0
valve and right brake valve
* Disconnect electric wiring (10) from the con- @Y
nector, then remove the clamp. 4
10
426FO1216
5%-1 WA600-1
4. Pedal
Pull out cotter pin of pin (11). then pull out pin,
and remove pedal (12).
* Remove the floor mat.
5. Brake valve
a,
* Loosen bolts (14).
is
2) Remove bolts (14), and disconnect valve body
(15) and mount flange (16).
* Valve body (15) will fall when bolts (14) are
removed, so be very careful when removing
the bolts.
* Pull out plunger (17) from mount flange.
426P839
16
426F0 1217
WA600-1
INSTALLATION OF BRAKE VALVE
1. Brake valve
1) Assemble plunger (17) to mount flange.
flu Plunger: Brake oil
2) Set valve body (15) in mounting position, and

tighten mount flange (16) and bolts (14).
426P839
3) Tighten mounting bolts (13) to lock valve.
2. Pedal
Set pedal (12) in mounting position, insert pin (1 I),
then align hole of stopper on left side of pin and in-
stall right side cotter pin.
* Bend the cotter pin securely.
* Check that the spacer is assembled.
3. Air piping
Connect the following air piping to the brake valve.
* Tube (4) between front dry tank and brake valve
* Tube (5) between rear dry tank and brake valve Brake pedal (left)
l Tubes (6), (7), (8), and (9) between left brake /
valve and right brake valve
* Connect electric wiring (IO) with the connector,

then install the clamp.
7 6
426FO1216
4. Checking for air leakage

Start engine and check for leakage of air.
Check operation of brakes also.
5. Covers
WA600-1
532-4
DISASSEMBLY OF BRAKE VALVE
1. Body assembly
1) Make match mark “a” on upper body and lower
body.
56OBP372
2) Loosen mounting bolts (1). remove upper body (2)

and lower body (3), then disconnect them.
5608P373
2. Upper valve assembly

/
1) Hold slot-head screwdriver @ in vice @ and fit in _
slot in stem inside exhaust passage of relay piston.
56OBP374
2) Loosen nut (4), then remove washer (5), plain washer

(6), spring seat (7), rubber spring (8), upper piston
(9), return spring (lo), relay piston spring (11 ), relay
piston (12), and stem assembly (13). 13
When loosening the nut, the piston may fly

out under the force of the return spring, so
hold the piston by hand when loosening the
nut.
56OBP375
53-6 WA600- 1
Q
3) Remove snap ring (14), then remove primary valve
(15) from upper body.
560BP376
4) Remove snap ring (16). then disassemble primary

valve into washer (17). O-ring retainer (18), O-rings
(19) and (20). upper valve spring (21), valve retainer
(22), and upper valve (23).
3. Lower valve assembly

1) Remove exhaust cover (24). then remove secondary
\_
valve assembly (25).
2) Remove O-ring (26) from lower body.
56OBP378
3) Remove snap ring (27), then disassemble secondary

valve assembly into washer (281, O-ring retainer (26),
O-rings (30) and (31), lower valve spring (32), valve
retainer (33), and lower valve (34).
3’1
56OBP37U
WA600- 1 53-7
.2
ASSEMBLY OF BRAKE VALVE
1. Lower valve assembly

1) Set lower valve (34) with valve seat at bottom, as-
sembly valve retainer (33). lower valve spring (32),
O-ring retainer (29) and washer (28), then secure with
snap ring (27).
* Assemble O-rings (30) and (31) on the O-ring
retainer first.
2) Assemble secondary valve assembly (25) in lower

body, then install exhaust cover (24).
2. Upper valve assembly

1) Set upper valve (23) with valve seat at bottom, as-
semble valve retainer (22). upper valve spring (21).
O-ring retainer (18) and washer (17), then secure
with snap ring (16).
+ Assemble O-rings (19) and (20) on the O-ring
retainer first.
2) Assemble primary valve assembly (15) in upper body,

then secure with snap ring (14).
56OBP376
5%8 WA600- 1
3) Hold slot-head screwdriver @ in vice @ , assemble
relay piston spring (ll), relay piston (12) and stem _
/
’ /
‘.
assembly (13) in bottom of upper body, then set with
screwdriver.
* Do not forget to fit an O-ring on the relay piston.
4) Assemble return spring (10). upper piston (9), rubber

spring (8), spring seat (71, and washers (5) and (6)
from top of upper body, then tighten with nut (4).
* Do not forget to fit an D-ring on the upper piston.
The piston may fly out under the force of

! the return spring, so hold the piston by hand
0
when assembling.
B Nut: 0.55 + 0.15 kgm
56OEP375
3. Body assembly
1) Install O-ring (35) on lower body (3)
56OBP380
2) Align match marks “a” on upper body (2) and lower a

body (3). assemble and tighten mounting bolts (1).
1
56OBP38 I
WA600- 1 53-9
(2’
REMOVAL OF BRAKE CHAMBER

Covers
Remove covers (I), (2) and (3).
Torque converter filters

Remove center bolt, then remove torque converter
filters (4).
* Remove all filters.
Rear brake chamber

1) Disconnect tube (5) between brake chamber and
slack adjuster at brake chamber end.
2) Disconnect tube (6) between brake valve and
brake chamber at brake chamber end.
3) Disconnect hose (7) between brake oil tank and

* Oil will flow out from inside the tank, so
catch it in a container.
53-10 WA600- 1
ty
4) Disconnect electrical wiring (8) and (9) from
connector.
* Always remove the clamp of electrical wiring
(9).
5) Remove bracket (lo), then remove rear brake

chamber (11).
* Remove only the lower bracket.

1) Disconnect tube (12) between brake chamber
and slack adjuster at brake chamber end.
2) Disconnect tube (13) between brake valve and
?I Disconnect hose (14) between brake oil tank and ’

-8
* Oil will flow out from inside the tank, so
catch it in a container.
WA600- 1
4) Disconnect electrical wiring (15) from connector.
* Always remove the clamp of electrical wiring.
5) Remove bracket (16), then remove front brake

chamber (17).
t Remove only the lower bracket.
WA600- 1
INSTALLATION OF BRAKE CHAMBER
I. Front brake chamber

1) Set front brake chamber (17) in mounting posi-
tion, and install bracket (16).
2) Connect electric wiring (15) to connector, and

install clamp.
4) Connect tube (13) between brake valve and

WA600- 1
2. Rear brake chamber
1) Set rear brake chamber (11) in mounting posi-
tion, and install bracket (10).
2) Connect electrical wiring (8) and (9) to connec-

tor.
* Install the wiring clamp.
3) Connect hose (7) between brake oil tank and

4) Connect tube (6) between brake valve and brake

chamber at brake chamber end.
53-14
2
3. Torque converter filters
Install torque converter filters (4).
m Center bolt: 8.0 _t 1 .O kgm
4. Covers
Install covers (I), (2) and (3).

Add oil to brake oil tank, and bleed air from brake
system.
* Keep the brake oil tank filled with oil.
* For details of the procedure for bleeding the air,
see 52 TESTING AND ADJUSTING.
* Push in the rod of the brake line failure sensor.
WA600- 1 53-l 5
i
DISASSEMBLY OF BRAKE CHAMBER
1. Accessories
Remove breather (1), bleeder (2) and sensor (3).
2. Cylinder
Loosen lock nut (4), then remove cylinder (5).
* There is O-ring fitted on the thread of the cylinder, so
remove it.
423P993
3. Piston assembly
1) Move retainer (6) to right, remove pin (7), then
remove piston assembly (8).
* Use a guide pin (Outer dia. = 2.5 mm, length = 50
mm) to remove the pin.
,,’ ,’ ,,,, ,,, ,~ ,_,_

,.
423P994,,.
_’
423F446
2) Remove rod (9), then remove O-ring.
423P995
4. Disassembly of piston assembly

1) Remove snap ring (lo), then remove seat (1 l), spring
(12) and valve (13).
+ Spring (12) is small, so be careful not to lose it.
2) Remove packing (15) from piston (14).
423 F447 423P996
53-16 WA600- 1
‘3
5. Body
Hold body (16) with hand, remove mounting bolt, then
remove body.
The tension of the spring on the body is 25

kg, so be careful when removing it.
* Remove the O-ring from the contact surfaces of the

body and air cylinder.
423P997
6. Disassembly of body ,,,,

1) Remove snap ring (17), then remove ring (181,
packing (19). seat (20) and packing (21).
423P998 423F448
423P999
7. Air piston
1) Remove spring (27) and piston assembly (26) from
air cylinder (25).
423P1000
WA600- 1
2) Remove nut, then remove piston (28) and rod (29).
3) Remove packing (30) and ring (31) from piston (28).
423PlOOl
4) Remove O-ring (32) and washer (33) from rod.
423P1002
WA600- 1
ASSEMBLY OF BRAKE CHAMBER
1. Assembly of piston assembly

1) install washer (33) and O-ring (32) on rod (29).
* When fitting the O-ring, wind tape around the
threads of the rod to prevent damage to the
O-ring.
/?, O-ring: Brake oil
423PlOO3
2) Assemble packing (30) and ring (31) on piston (28).
a Packing: Grease (G2-LI)
3) Insert rod (29) in mount of piston (28). then secure

with nut.
* After tightening the nut, check that there is no
clearance between the stepped part of the rod and
the piston.
a Piston mounting hole: Grease (G2-LI)
m Nut: 14 *2 kgm 423P I004
2. Assembly of body
1) install seal (24) and ring (23) in body (16). then
secure with snap ring (22).
* Install the seal with the lip facing the outside.
* Check that the snap ring is fitted securely in the
groove.
& Seal: Brake oil
423P1005
24 16
423F449
16 423P ,006
WA600- 1
2) Turn over body, assemble packing (21), seat (20) and
packing (19), insert ring (18), then secure with snap
ring (17).
t Install the seal with the lip facing the outside.
* Check that the snap ring is fitted securely in the
groove.
a Packing: Brakeoil
17
18
19
423F450
3. Piston assembly
Insert piston assembly (27) in air cylinder (25).
* Coat inside of air cylinder with grease.
t When inserting the piston assembly, tilt at’an angle
of about 30”, insert about l/3, then lay the air cyl-
inder on its side and insert the piston fully.
* Check that the piston assembly moves smoothly.
4. Body assembly
Insert spring (26) in mount of air cylinder, fit O-ring
(34) in body assembly (16), then install in air cylinder.
t Push in the body by hand, install 2 mouting bolts
in diametrically opposite positions, then tighten
together with bracket (35).
5. Assembly of piston
1) Insert valve (13). spring (12) and seat (11) in piston
(14), then secure with snap ring (10).
* Be careful to insert the spring facing in the correct
direction.
t Check that the snap ring fitted securely in the
groove.
53-20 WA600- 1
0
2) Assemble packing (15) on piston.
* Install the packing with the lip facing the outside.
& Packing: Grease (G2-LI)
423PiOl I
6. Piston assembly ,,,,,, ,,,,, ,,

,,,,,,, ,*,, ,,
,;,
:,,
.‘I” L,,, ,‘, ‘\ ,,
Blow air into air cylinder and blow out rod. Set piston
,,
‘\,,‘, !.
assembly (8) in mounting position, then connect with
pin (7).
* The pin hole is hidden by the retainer, so move the
retainer to the right and insert the pin.
* After inserting the pin, check that the retainer has
moved back to its original place and the pin is hidden.
423PIOtZ
7. Cylinder
Install nut (4) and O-ring (36) on cylinder (5), screw
into mount, then secure with nut.
* Screw the cylinder in fully, then turn back until the
breather and bleeder are in a straight line.
6 Inside surface of cylinder: Brake oil
m Nut: 14f3kgm
423P1013
8. Sensor
Fit O-rings on rod (9) and sensor (3), then install in
mounting position.
* Insert the rod until it is level with the body.
B Sensor: 5.6 ? 0.6 kgm
9. Accessories
Install breather (1) and bleeder (2).
m Bleeder: 0.95 + 0.25 kgm
423PlO14
WA600- 1 53-21
0
REMOVAL OF SLACK ADJUSTER

1. Brake piping
1) Disconnect tube (I) between slack adjuster and
brake chamber at slack adjuster end.
* Disconnect hose (2) at the rear.
2) Disconnect hoses (3) and (4) between slack ad-
juster and left and right brake pistons at slack
adjuster end.
* Disconnect tubes (5) and (6) at the rear.
2. Slack adjuster
Remove mounting bolts, then remove slack adjuster
(5).
* There is little space, so be careful when working.
INSTALLATION OF SLACK
ADJUSTER
1. Slack adjuster
Set slack adjuster (7) in mounting position, then
* Tighten the mounting bolts partially, then tight-
en fully after connecting the piping.
2. Brake piping
1) Connect hoses (3) and (4) between slack adjuster
and left and right brake pistons at slack adjuster
end.
* Connect tubes (5) and (6) at the rear.
2) Connect tube (2) between slack adjuster and
brake chamber at slack adjuster end.
* Connect hose (I) at the rear.
3. Bleeding air
Bleed air from brake system, and check that there is
no leakage of oil from connections.
AND ADJUSTING.
* Bleed the air from the brake end and slack ad-
juster end.
53-22 WA600- 1
??
DISASSEMBLY OF SLACK ADJUSTER
1. Bleeder
Remove bleeder (2) from body (I ).
423PI 019
2. Cylinder
Remove mounting bolts, then disconnect body (1) and
cylinder (4) together with bracket (3).
There is spring tension inside the cylinder, so

hold the contact surfaces and be careful when
removing.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring.
* Use a rod of 10 mm diameter and push out the
piston slowly.
+ Be careful not to damage the thread with the rod.
(L--7
423P : 02 I 423F451
4. Poppet
1) Remove cover (8) from cylinder (4), then remove
plug (9). spring (IO) andpoppet (11).
* When removing the poppet, blow in air from
the oil hole in the cylinder.
* Hold the oil port of the cylinder by hand, and
do not pump in air suddenly.
Be careful not to let the combination of poppet
(11) and cylinder (4) change. When replacing
them, change the poppet and cylinder as an as-
sembly.
2) Remove O-ring (12) from poppet. 423P I022
WA600- 1
53k23
ASSEMBLY OF SLACK ADJUSTER
1. Poppet
I) Fit O-ring (12) on poppet (11).
2) Install poppet (ll), spring (lo), plug (9) and cover
(8), then assemble cylinder (4).
2. Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder (4).
* Check that the piston moves smoothly.
,..
423PtO24 ,,x ,:\ ~, 423P1023
,‘,,,, _, _’
423P IO25 423P1026
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
* Installed road of spring: 4.4 kg
2) Install body (1) and cylinder (4) together with

bracket (3).
4. Bleeder 423P1027
Install bleeder (2).
423P I029 423P i 028

REMOVAL OF BRAKE ASSEMBLY
I Part number I Part name Q’ty
A 793-520-l 920 Fixture 4

QT the safety bar on the frame. Lower the work
moving.
1. Loosen wheel nuts, raise machine with work equip-

ment, insert stand @ under axle, then lower ma-
chine.
2. Sling wheel assembly (1). remove wheel nut, then

remove wheel assembly.
Wheel assembly: 990 kg
Remove drain plugs (2) and (3), and drain oil from
final drive case and brake case.
II :
- Final drive case, brake case: Approx. 1 IO Q
Remove mounting bolts (4), then remove final drive

case cover (5).
I; 425P640
WA600- 1
5. Screw bolt @ (thread dia. = 12 mm, pitch = 1.75
mm) into axle shaft, and pull out axle shaft (6).
6. Remove 3 mounting bolts (7). then using eyebolts

@ (thread dia. = 12 mm, pitch = 1.75 mm), lift off
planetary carrier assembly (8).
* The balance is poor, so adjust the position of the
center of gravity with a bar when removing.
&?Ikg Planetary carrier assembly: 115 kg
* For details of general disassembly of the plane-

tary carrier assembly,see REMOVAL OF FINAL
DRIVE ASSEMBLY.
7. Using tool A, lock wheel hub (9) and brake housing

(IO).
* Install tool A at opposite sides.
8. Remove mounting bolts (1 I), then remove retainer

(12).
* There are shims on the inside of the retainer, so
check the number and thickness of the shims,
9. Remove ring gear assembly (13).

* For details of general disassembly of the ring gear
assembly, see REMOVAL OF FINAL DRIVE
53-20 WA600- 1
‘2,
10. Remove cover, and disconnect brake tube (14).
11. Sling brake and wheel hub assembly, remove mount-

ing bolts, then remove wheel hub assembly (15).
m Brake, wheel hub assembly: 195 kg
12. Remove bearing and retainer from axle housing.
WA600- 1 53-27
@
INSTALLATION OF BRAKE ASSEMBLY
Specialtools required
A 793-520-l 920 Fixture 4
I_ install retainer and bearing to axle housing.
* After assembling the bearing, check that there is

no clearance at any point.
2. Fit O-ring, raise brake and wheel hub assembly (15),

align with axle housing mounting position, then
3. Connect brake tube (14) and install cover.
4. Install ring gear assembly (13).

* For details of fine assembly of the ring gear
assembly, see ASSEMBLY OF FINAL DRIVE
ASSEMBLY_
53-28 WAtXlO-1
9.
5. Fit retainer (12) and tighten mounting bolts (11).
* Select the shim thickness and adjust the wheel
bearing. For details, see ASSEMBLY OF FINAL
DRIVE ASSEMBLY.
6. After tightening retainer, remove tool A.
7. Fit O-ring, then using eyebolts @ (thread dia. = 12

mm, pitch = 1.75 mm), raise planetary carrier as-
sembly (8). align with mounting position and tight-
en 3 mounting bolts (7).
* The balance is poor, so adjust the position of the
center of gravity with a bar when installing.
* For details of the fine assembly of the carrier
assembly, see ASSEMBLY OF FINAL DRIVE
8. Screw bolt @ (thread dia. = 12 mm, pitch = 1.75

mm) into axle shaft, and install axle shaft (6).
* If the sun gear cannot be aligned, rotate the
wheel hub and align the teeth to install.
WA600- 1 53-29
@
9. Fit O-ring and install final drive case (5),
then tighten mounting bolts (4).
10. Tighten drain plugs (3) and (2), and add oil through
level plug (21) to the specified level.
11. Raise wheel assembly (l), and set on wheel hub,

then tighten wheel nut temporarily.
12. Jack up machine with work equipment, remove

stand under axle, and lower machine to ground.
Then tighten wheel nuts to specified tightening
torque.
m Wheel nut: 90 + 15 kgm
* Bleed the air from the brakes.

For details, see TESTING AND ADJUSTING,
Bleeding air from brake system.
WA600- 1
53-30
/2
DISASSEMBLY OF BRAKE ASSEMBLY (Front, rear)
Part number I Part name 1 Q’ty
A 1 793-520-1920 1 Fixture ~ 4
1. Cylinder
Using eyebolts 0 (thread dia. = 16 mm, pitch =
2.0 mm), lift out cylinder (1).
r-
/ 426P867
* Disassemble cylinder with following steps:

1) Screw in eyebolts @ (thread dia. = 16 mm,
pitch = 2.0 mm), push in spring with bar 0,
then pull out pin (2).
2) Remove spring (3) and shaft (4).
3) Remove piston (5)
WA600- 1
2. Plate, disc
2) Remove disc (7).

* Remove discs and plates alternately.
* When removing the discs, make match marks
on the inner gear and discs, and on the outer
gear and plates.
* The plates are made of a soft material, so be
careful not to damage them when removing.
3. Outer drum
* Remove tool A.
I) Using eyebolts @ (thread dia. = 16 mm, pitch =

2.0 mm), lift out outer drum (8).
WA600- 1
53&32
2.0 mm), remove hub (9).
3) Remove floating seal (10) and oil seal (11).
426P876

5) Remove floating seal (13)
13 426P878
6) Remove outer races (14) and (15).
WA600- 1 53-33
a
ASSEMBLY OF BRAKE ASSEMBLY (Front, rear)
1. Outer drum
1) Install outer races (15) and (14).
2) Using tools B and B,, install floating seal (13) to

retainer.
B Contact surface of seal: Engine oil

(EOSO-CD)
3) Using tools B and B1, install floating seal tb hub.
m Contact surface of seal: Engine oil

(E030-CD)
-
425F298
4) Install oil seal.
53-34 WA600- 1
2
Fit O-ring and install retainer (12).
2.0 mm), raise hub (9) and install.
426P880 426P881
e
Fit O-ring, and using eyebolts 0 (thread dia. =

16 mm, pitch = 2.0 mm), raise outer drum (8)
and install.
426P3882
8) Install tool A and tighten.
2. Disc, plate
1) Install disc (7).
* Align match marks of inner gear and disc and
install.
WA600- 1
* Align notched portion of outer teeth of plate
and assemble.
3. Cylinder
* Assemble cylinder with following steps:
1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3).

3) Screw in eyebolts @ (thread dia. = 16 mm,
pitch = 2.0 mm), push in spring with bar 0,
then install pin (2).
4) Fit O-ring, and using eyebolts 0 (thread dia.

= 16 mm, pitch = 2.0 mm), match with guide
bolt @ and lift and install cylinder assembly
(1).
a Mounting bolt: Thread tightener

(LT-2)
w Mounting bolt: 28.5 * 3.0 kgm
426P883
53-36 WA600- 1
0
REMOVAL OF SPRING CYLINDER ASSEMBLY

1. Linkage
1) Release parking brake and turn adjusting bolt (1)
in counterclockwise direction then check that
there is play in the linkage (2).
2) Remove pin (3) and disconnect linkage (2) from

adjuster (4).
2. Air piping
Release parking brake and disconnect air piping (5)
of spring cylinder.
* After removing, cover to prevent dust or dirt
from engine.
* Check that air isn’t in the spring in the spring

cylinder.
3. Spring cylinder
Remove mounting nut, then remove spring cylinder
(6).
WA600- 1
INSTALLATION OF SPRING CYLINDER ASSEMBLY
1 Spring cylinder
Set spring cylinder (6) in mounting position, and
install.
m Mounting nut: 28.5 + 3.0 kgm
2. Air piping
Connect air piping (5) to spring cylinder.
2) Turn adjusting bolt (1) in clockwise direction,

and at point adjusting bolt cannot be tightened
further, turn back 180’ or 3 or 4 notches.
* For details of adjusting the linkage, see TEST-
ING AND ADJUSTING.
* Check the operation of the parking brake.
53,-38
2
DISASSEMBLY OF SPRING CYLINDER
1. Remove screw, then remove holder (1) and filter

(2).
2. Remove retainer (3) and nut, then remove. boot (4).
3. Remove nuts (5) and (6), then remove shaft (7).
4. Remove nuts (8) and (9) from shaft (7).
5. Using a press, support piston (10) and support (1 l),

remove bolts (12), then slowly loosen press and re-
move support (11) and spring (13).
There is a pressure of 510 kg bearing on

A the piston and support, so operate the
press with care.
F56AO2219
F56A02218
6. Remove piston (lo), then remove rings (14) and

(15) from piston.
7. Remove rings (17) and (18) from case (16).
WA600- 1
ASSEMBLY OF SPRING CYLINDER

installing.
* Be careful not to damage the rings or seals when
assembling.
1. Install rings (18) and (17) to case (16).
cl-~-~ Ring (17): Engine oil (EO-30CD)
2. Install rings (15) and (14) on piston (lo), then in-

stall in case (16).
CL= Ring (15): Engine oil (EO-BOCD)
3. Set spring (13) and support (11) in position, then

using a press, gradually apply pressure until bolt
hole of support (11) is aligned with bolt hole of
case, then install bolt.
More than 510 kg of force is needed to

k?=30mm
n ! compress the spring, so operate the press
extremely carefully.
fl?IL Outer circumference of support:

Gasket sealant (LG-6)
w Mounting bolt: 1.4 t 0.4 kgm
4. Install nut (8) to shaft (7) so that distance Q is 30

mm, then lock with nut (9).
F56A02222
m Nut: 5 + 1 kgm
5. Set shaft (7) in position, install so that clearance S

between nut (6) and piston is 2 mm, then lock with
nut (5).
w Nut: 5 f. 1 kgm
6. Set boot (4) in position, and install nut and retainer

(3).
7. Set filter (2) in position, and install holder.
8. Finally, blow in air (approx. 7 kg/cm’) to check
operation of piston and to check for leakage of air.
““/ I \
7 6 5
F56A02223
53-39-I WA600-1
g
REMOVAL OF PARKING BRAKE

\~_$YW$~
b,+$y
wheels to prevent the machine from moving. i
1. Drive shaft
Using lever block @ , lift off front drive shaft (I),
then remove disc cover (2).
* Move the drive shaft towards the front differen-
tial, then move the center support end to the side
and remove the pilot portion.
Drive shaft: 57 kg
4. Spring cylinder
Remove nut, then remove spring cylinder (5).
5. Caliper
* Use a power wrench to remove the mounting
bolts.
* After removing the plate, remove pad (7).
* To prevent the caliper from falling out, insert
it securely into the groove of the lower plate.
53-40 WA600- 1
l2
2) Remove caliper (8).
* Use two men to remove caliper.
Caliper: 32 kg
6. Disc
Remove disc (9).
Disc: 31 kg
7. Disassembly of caliper
1) Remove snap ring (10) and pull out adjuster
(11).
426PB95
2) Remove washer (12) and (13) and seal (14).
426PB96
WA600- 1
3) Remove bolt, theri remove caliper (15) and
gasket (16).
426P897
4) Remove piston shaft (17) and thrust bearing

(18) from piston.
426P898
5) Remove piston (20) and piston seal (21) from

caliper (19).
2i Fi
426P899
WA600- 1
INSTALLATION OF PARKING BRAKE
1. Assembly of caliper
1) install piston seal (21) in caliper (19), then insert
position (20).
& Piston, piston seal: Grease (G2-LI)
426P899
2) Screw in piston shaft (17) into piston, then in-

stall thrust bearing (18).
* Be careful of direction of thrust bearing, then
install.
& Thrust bearing: Grease (G2-LI)
426P898
3) Fit gasket (16), then install cap (15).
w Mounting bolt: 18 f 2 kgm
426P897
4) Install seal (14) and washers (12) and (13).

* Insert seal in groove completely.
& Seal: Grease (G2-LI)
426P896
WA600- 1
5) Assemble adjuster (11) and secure with snap ring
(10).
426P895
2. Disc
Install disc (9).
3. Caliper
1) Set caliper (8) in mounting position.
* To prevent the caliper from falling out, insert
it securely into the groove of the lower plate.
* Before installing the plate, install pad (7), and
fit securely into the groove of the plate.

* Raise the caliper slightly, align the caliper and
groove of the pad with the plate, then install.

WA600- 1
53-44
6J
4. Spring cylinder
Set spring cylinder (5) in mounting position and
tighten nut.
* Install the spring cylinder so that the air hose
mount is at the top.
m Nut: 28.5 f 3.0 kgm
5. Linkage
Assemble pin (4) and connect linkage.
* For details, see TESTING AND ADJUSTING.
6. Air hose
Connect air hose (3) to spring cylinder.
7. Drive shaft
Using lever block @ , set front drive shaft (I) in
mounting position, tighten mounting bolts, then in-
stall cover (2).
* Install the drive shaft at the differential end
first.
* When connecting the drive shaft, wipe the con-
tact face of the spider and coupling clean before
installing.
WA600- 1. 53-45
0
REMOVAL OF PARKING BRAKE PAD

* Release the parking brake.
1. Turn the adjusting bolt (1) in a counterclockwise

direction, and increase the clearance between the
pad and the disc.
2. Remove plate (2).

* Always remove the top side of plate (2).
3. Raise the parking brake caliper slightly and remove

pad (3).
* When removing the front pad, first remove the
rear pad and move the caliper to the front, then
remove the front pad.
INSTALLATION OF PARKING
BRAKE PAD
1. Insert pad (3) between caliper and disc.

* Since the pad is new, turn the adjusting bolt
further in a counterclockwise direction to in-
crease the clearance.
* Lift the caliper up slightly and the pad will be
able to be smoothly inserted.
2. Install plate (2).

+ Align the caliper and groove of the pad correctly
with the left and right plates.
& Mounting bolt of plate: Thread tightener

(LT-2)
m Mounting bolt of plate: 94.5 f 10.5 kgm

3. Turn the adjusting bolt (1) clockwise and adjust pad

clearance.
* For details of adjusting, see TESTING AND AD-
JUSTING.
53-46 WA600- 1
2,
BRAKE AND AIR SYSTEM
Brake valve 54-2

Brake chamber . 54-4
Slack adjuster . 54-5
Brake . . 54-6
Parking brake 54-8
Spring cylinder 54-9
WA600- 1 54-1
BRAKE VALVE
425F156
54-2
WA600- 1
unit: mm
Clearance between pedal mounting

1
pin and mount plate
-
Crearance between roller and pin
2 10 -0.015
-0.050 +0.058
0 0.015
0.108 - I
Clearance between mount plate
3 26.5
and plunger
Clearance between primary piston +0.150 +0.401 0.175 - -

60
and upper body +0.050 +0.325 0.351
Clearance between relay piston +0.76 0.10 - -

66.5
and lower body -LO +O.lO 0.86

Outside diameter of roller
+0.1
26.2 26.0 Replace
-0.1
+0.2
7 Free height of rubber spring 14.4 12.0
I -0.2
Free Installation lnstallatioin Free Installation

8 Piston return spring
length length load length load
65.3 14.6 10.5 kg 54 -

-
9 Primary valve spring 41.3 14.3 4.5 kg 34 -
10 Inner stem spring 35.6 16.0 2.8 kg 30 -
11 Outer stem spring 41 .o 16.0 4.0 kg 34
12 Relay piston spring 39.5 12.1 4.7 kg 33
13 Secondary valve spring 16.5 10.2 3.0 kg 14 -
14 Tightening torque of nut 0.55 i 0.15 kgm Retighten
WA600- 1 54-3
BRAKE CHAMBER
Section A - A
425F157
Unit: mm
NO Check item Criteria Remedy
1
Clearance between cylinder and
1
piston
Replace
-
68 -0.030 +0.046 0.030 0.15
-0.076 0 0.122
-
2 Outside diameter of oil seal 69.6 +0.500 +0.046 0.346 1 .o
-0.300 0 0.500
3 Air piston stroke Min. 133.5 (Normal pressure: Max. 9.5 kg/cm’) -
4 Tightening torque of nut 14.0 + 3.0 kgm

Retighten
5 Tightening torque of nut 4.4 t 0.6 kgm
54-4 WA600- 1
SLACK ADJUSTER
427F214
Unit: mm

I I
Tolerance I I
Standard
size
Clearance between body and
piston
80 -0.030 +0.074 0.03 - 0.250

-0.076 0 0.15
Standard size Repair limit Reblace

Spring
230 88 12 kg
Spring 45.4 38 6.8 kg
Tightening torque of bolt 17.5 i 1.5 kgm

Retighten
Tightening torque of plug 5.7 i 0.7 kgm
WA600- 1 54-5
0
BRAKE
_-
‘,--
2 3 4
Dateil P 8
426F190
54-6 WA600- 1
unit: mm
Free Installation installation Free Installation

1 Return spring length length load length load
__-
107 91.3 75 kg 105.5 67.9 kg

2 Thickness of plate
2.4 2.15
3 Thickness of disc 5.1 4.6

-
4 Total thickness of plate and disc 99.9 89.9

5 Wear of contact surface of seal
430 -
-:.I55
- , Replace
Wear of surface in contact with +0.097 _
6 420
piston seal 0
Wear of surface in contact with +0.097 -

7 455
piston seal I I 0
Standard Repair limit

Deformation of friction surface
8
of plate and disc
Max. 0.4 0.7
Backlash between outer gear and

9 0.29 - 0.62
plate I
Backlash between inner gear and
10 0.17 - 0.52
disc
-
11 Tightening torque of bolt 11.5 c 1 .O kgm

Retighten
Tightening torque of bolt 28.5 t_ 3.0 kgm
Tightening torque of bolt 94.5 F 10.5 kgm
54-7
PARKING BRAKE
426F193
Unit: mm
Remaining thickness
22.7 3.7 Replace
of friction material
Wear
1
of pad
Including backing plate 31.7 - 12.7
2 Face runout of disc 0.4 0.8
3 Wear of rod connecting pin 12.7 -0.10 - Rebuild

-0.17
Thickness of plate
Wear of disc must be under 22 mm.
4 24 +0.5
(Thickness of disc plate)
Less than 22 mm Replace
Clearance between pad and disc

5 1.06 to.18 2.1
(Total of both sides)
Adjust
Clearance between brake body
6 1.25
and plate
7 Tightening torque of nut 7.25 f 1.75 kgm

I I
8 1Tighten. 1ng torque of bolt 94.5 f 10.5 kgm

Retighten
9 Tightening torque of bolt 56 I 6 kgm
10 Tightening torque of bolt 28.5 I 3.0 kgm
54-8 WA600- 1
SPRING CYLINDER
5 426F191A
Unit: mm

-
Tolerance
Clearance between cylinder and
1 Shaft Hole
piston
Hole: 159
0.35
Shaft:1 58.65
-
Clearance between piston insert Hole: 38.8

2 0.76 Replace
center boss Shaft r38.04
-
Standard size Repair limit I

Free installation Installation Free Installation
3 Piston spring
260 750 i 50 kg
4 Play of rod in axial direction 2.1

Adjust
5 installed dimension of rod 128 (stroke 63)
6 Tightening torque of rod, lock nut 7.25 ?; 1.75 kgm Retighten
WA600- 1 54-9
a
WORK EQUIPMENT SYSTEM
General ......................................................... 61- 2

Work equipment lever linkage.. ................ -61-3-I
Hydraulic circuit system.. ............................ 61- 4
l Hydraulic circuit schematics.. ................. 61- 4
l Hydraulic circuit diagram ........................ 61- 5
l Hydraulic circuit diagram
(Machine with joystick steering) ........... .61-5-3
Hydraulic tank .............................................. 61- 6
l Oil filter bypass valve.. ............................. 61- 7
l Breather .................................................... 61- 7
Hydraulic pump .......................................... 61-7-1
POC valve (Pilot Operated Contra1 valve). .61- 8
PPC valve (Proportional Pressure
Contra1 valve) ......................................... 61-13-1
POC relief valve ........................................ 61-13-5
PPC relief valve ......................................... 61-13-5
Main control valve.. ..................................... 61-14
l Relief valve ............................................... 61-16
l Safety valve (with suction valve) ............ 61-17
l Suction valve ............................................ 61-18
l Float selector valve and unloader valve. 61-19
Accumulator.. ............................................... 61-21
Operation of hydraulic circuit.. ................... 61-22
Hydraulic cylinder.. ...................................... 61-26
Bucket linkage .............................................. 61-28
Bucket positioner and boom kick-out ....... .61-29
WA&IO- 1 61-l
0
GENERAL
* The work equipment system consists of the hydraulic The maximum pressure of the hydraulic circuit is
circuit and steering circuit. The hydraulic circuit con- regulated by the relief valve inside the main control
trols the operation of the bucket and attachment. valve. There are two safety valves (with suction
* The oil in hydraulic tank (4) is sent by hydraulic valve) and an unloader valve in the dump cylinder cir-
pumps (6) and (7) to main control valve (2). When cuit to protect the circuit.
the dump and lift spools of the main control valve are Even when engine is at rest, the lift arm can be low-
at “HOLD”, the oil passes through the drain circuit ered to the ground because accumulator (8) is pro-
of the main control valve. It is then filtered by the vided in the circuit.
filter in the hydraulic tank, and returns the tank. Hydraulic tank (4) is a pressurized, sealed type and
* The dump or lift spool in POC(PPC) valve is activated has a breather with a relief valve. This acts to pres-
by operating the work equipment control lever, cau- surize the tank and at the same time prevents negative
sing each spool in the work equipment valve to be hy- pressure. This protects the pump from cavitation.
draulically actuated.
Thereby, the oil is allowed to
flow from the work equipment valve to lift cylinder
(12) or dump cylinder (I), thus operating the lift arm
or the bucket.
* Illustration shows for Serial No. 10001 and up
yf v 2.
(for D spec.) arld 10001-10880
Dump cylinder
Main control valve

(except for D spec.)
8.
9.
Accumulator
Oil cooler
3. Steering valve 10. POC (PPC) relief valve
4. Hydraulic tank 11. Steering cylinder
5. POC (PPC) valve 12. Lift cylinder
6. PTO (PPC) and transmission lubrication,

torque converter charging and switch
426FO97
pump
7. Hydraulic and POC (PPC) pump
61-2 WA600- 1
8
WORK EQUIPMENT LEVER LINKAGE

Section A - A
42 lFO65
1. Safety lever
2. Lift lever
3. Dump lever
4. Solenoid valve for bucket positioner
5. Solenoid valve for kick-out
6. POC valve
61-3-l WA600-1
8
421FO1024
1. Kick-down switch
2. Lock lever
3. Lift control lever
4. Dump control lever
5. Solenoid valve for bucket positioner
6. Solenoid valve for boom kick-out
7. PPC valve
WA600-1 61-3-2
@
HYDRAULIC CIRCUIT SYSTEM
Engine running, hydraulic control lever in “HOLD”
Serial No. 10001-l 0880 (except D spec.) _
426F121
61-4
Go
_ BA
@ Dump
0 Float
0 Lower
Raise
@
@ Tilt
426F 122
1. Hydraulic tank 12. Steering valve 23. POC lift spool

2. Hydraulic filter 13. Check valve 24. Relief valve
3. Breather 14. Demand spool 25. Dump spool
4. Switch pump (SAR(3)-100) 15. Relief valve 26. Safety valve (with suction)
5. Hydraulic pump (SAR(4)-250) 16. Steering spool 27. Lift spool
6. Steering pump (SAR(4)-125) 17. Safety valve (with suction) 28. Float selector valve
7. Pot pump (SAR (1 bo20) 18. Two-way restrictor valve 29. Unloader valve
8. Pilot oil filter 19. Steering cyli;der 30. Suction valve
9. Check valve 20. Oil cooler 31. Lift cylinder
10. Accumulator 21. POC valve 32. Dump cylinder
11. Relief valve 22. POC dump spool
WA600- 1 61-5
@
Engine running, hydraulic control lever in “HOLD”
32 1’
\
F42601020
61-5-l
0
32
@ Dump
19
Pli IF @ Float
@ Lower
@ Raise
@ Tilt
16,4N
Left r”r”
1 F42601021
1. Hydraulic tank 13. Check valve 24. Relief valve
2. Hydraulic filter 14. Demand spool 25. Dump spool
3. Breather 15. Relief valve 26. Safety valve (with suction)
4. Switch pump (SAR (3)-100) 16. Steering spool 27. Lift spool
5. Hydraulic pump (SAR (4)-250) 17. Safety valve (with suction) 28. Float selector valve
6. Steering pump (SAR (4)-l 25) 18. Two-way restrictor valve 29. Unloader valve
7. PPC pump (SAR (l)-020) 19. Steering cylinder 30. Suction valve
8. Pilot oil filter 20. Oil cooler 31. Lift cylinder
9. Check valve 21. PPC valve 32. Dump cylinder
10. Accumulator 22. PPC dump spool 33. Emergency steering pump
11. Relief valve 23. PPC lift spool 34. Diverter valve
12. Steering valve
WA600-1 6-I-5-2
0
1. Hydraulic tank
2. Hydraulic filter
(Set pressure : 0.12MPa{l.27kg/cm2})
3. Breather
4L
4. Switch pump (SAR (3)-100)
5. Hydraulic pump (SAR (4)-125)
6. Hydraulic pump (SAR (4)-125)
7. Steering pump (SAR (4)-125)
~______-____________------- --_______J 8. PPC pump (SAR (11-020)
------------ \____________________
_-_-_-_- 18 -----------L------___
A 0 9. Pilot oil filter
-_--_-_-_-_-_-.
__+q 25 10. Check valve
11. Accumulator
it-
A ’ I ‘_e_______
i- 12. PPC relief valve
j 4i L--I i
-_-_- (Set pressure : 3.7$zMPa138+~kg/cm2})
I_-___-_______------_
________------_______ 13. Steering demand valve
I
_________i_______ 13A. Demand spool

.t- .___
13B. Steering spool
@ :DumP
13C. Steering relief valve
@Float II{
@Lower I-_-__ I
/
I
! -jy-yl~l=y~i/y!!~ 14. Two-way restrictor valve
.----_--_-____________--~-~-,
I l3A I 15. Steering cylinder
I ‘-
16. Hydraulic oil cooler
17. PPC valve
j-Jf-+-p+__-_-- 17A. Dump spool

8 , I
17B. Lift spool
-----____+ 18. Main control valve
18A. Main relief valve
(Set pressure : 20.6MPa1210kg/cmzI)
-
18B. Dump spool
All _-_-_-_ I I i___________--__ 18C. Safety valve (with suction valve)

(Set pressure : 22.6MPa{230kg/cm2))
21. Emergency steering pump 18D. Unloader valve
22. Diverter valve 18E. Float selector valve
23. Emergency lamp switch (Set pressure : 1.9+0.1 MPa{lSfl kg/cm*})

24. Steering unit (orbit-roll valve) 18F. Lift spool
25. Stop valve 19. Dump cylinder
26. Solenoid valve 20. Lift cylinder
SDW01641
61-5-3 WA600- 1
0
HYDRAULIC TANK
OUTLINE
* The oil from the hydraulic tank is sent from the * The hydraulic filter (2) filters all the oil in the circuit.
pump through the control valve to the cylinders. In If the hydraulic filter (2) becomes clogged, a bypass
the return circuit, the oil from various parts merges. valve (1) acts to allow the oil to return directly to the
A part of oil is cooled in the oil cooler, passes tank (4). This prevents damage to the filter (2). The
through the hydraulic filter (2) and returns to the bypass valve (1) is also actuated when negative pres-
tank (4). sure is generated in the circuit.

Serial No. 10001-l 0880 (except D spec.
Section X - X Section Y - Y
426FO98
1. Filter bypass valve A. Main return port
2. Hydraulic filter 8. Steering oil cooler return port
3. Oil filler C. Main suction port
4. Hydraulic tank
5. Oil level sight gauge
6. Breather
61-6 WA600- 1
a9
F42601022
1. Filter bypass valve A. Main return port
2. Hydraulic filter B. Steering oil cooler return port

3. Oil filler C. Main suction port
4. Hydraulic tank D. Emergency steering suction port
5. Oil level sight gauge E. Emergency steering return port
6. Breather
WA600- 1 61-6-I
@
1
OIL FILTER BYPASS VALVE
When the filter is clogged.

Bypass valve (1) opens and the oil returns directly to the
tank without passing through the filter.
Bypass valve set pressure: 1.27 kg/cm*
When negative pressure is formed in the return circuit.

Valve (2) moves up and acts a check valve.
Check valve set pressure: 0.26 kg/cm* 426FO99
.
* The action of this device is explained using the hyd-
raulic system diagram for Serial Numbers 10001 - To main
c) control
10880 (except D spec.), but the basic action of the valve
oil filter bypass valve is also the same for Serial
Numbers 10881 and up (except D spec.).
BREATHER
Preventing negative pressure inside the tank

The tank is a pressurized, sealed type, so negative pres- 426FlOO
sure is formed inside the hydraulic tank when the oil
level drops during operations. When this happens, the
difference in pressure between the tank and the outside
atmospheric pressure opens the poppet (3), and air from
the outside is let into the tank to prevent negative pres- -2
sure.
Preventing rise in pressure inside the tank

When the hydraulic cylinder are being used, the oil level -3
in the hydraulic circuit changes and the temperature
rises. If the hydraulic pressure rises above the set pres-
sure, sleeve (4) is actuated to release the hydraulic pres-
sure inside the tank.
1. Body
2. Filter element
3. Poppet
4. Sleeve
423F133
W/4600- 1 61-7
03
HYDRAULIC PUMP
(Hydralilic pump + Steering pump + POC (PPC) pump)
1’1 1’0 i
Hydraulic pump Steering pump POC (PPC) w-w
I- i
426FO53
1. Front cover Specification
2. Drive gear (teeth 101 - Hydraulic pump

Model: SAR(4)-250
3. Gear case
Theoretical delivery: 250.1 cc/rev
4. Drive gear (teeth 10)
Max. delivery pressure: 210 kg/cm’
5. Gear case Max. pump speed: 2,000 rpm
6. Drive gear (teeth 12) - Steering pump

Model: SAR(4)-125
7. Gear case
8. Rear cover
Max. delivery pressure: 210 kg/cm2
9. Driven gear (teeth 12) Max. pump speed: 2,000 rpm
10. Driven gear (teeth 10) - POC (PPC) pump

Model: SAR(l)-20
11. Driven gear (teeth IO)
Max. delivery pressure: 210 kg/cm’
Max. pump speed: 2,000 rpm
61-7-l WA600-1
@
(Transmission lubrication -I- Torque converter charging -t- Switch pump)
\
10 9
k--
Transmission lubrication
”
pump 1
I
Torque converter charging pump Switch pump
426FO54
1. Front cover Specification
2. Drive gear (teeth 10) - Transmission lubrication pump

Model: SAR (4)-l 25
3. Gear case
4. Drive gear (teeth 10) 210 kg/cm*
Max. delivery pressure:
5. Gear case Max. pump speed: 2,200 rpm
6. Drive gear (teeth 12) * Torque converter charging pump

Model: SAR(3)-100
7 Gear case
Theoretical delivery: 100.5 cc
8. Rear cover
Max. delivery pressure: 2 IO kg/cm*
9. Driven gear (teeth 12) Max. pump speed: 2,200 rpm
10. Driven gear (teeth 10) - Switch pump

Model: SAR(3)-100
11. Driven gear (teeth 10)
Max. delivery pressure: 210 kg/cm*
Max. pump speed: 2,200 rpm
WA600-1 61-7-2
@
POC VALVE (Pilot Operated Control valve)
421FO69
FUNCTION
* The POC valve is installed at the bottom of the work
equipment control lever, and is connected to the
control lever by a linkage.
- The oil from the POC pump is supplied to the spool
end of the control valve according to the amount the
control lever is moved. This oil actuates the spool, SO
the operating force needed for the control lever is
small, and as a result, operator fatigue is reduced.
61-8 WA600- 1
0
8
Section A-A
Section B-B
421 FO70
1. Port A, (To lift cylinder bottom) (PA,) 8. Lever
2. Port 13, (To lift cylinder head) (PB,) 9. Spool (for operating lift arm)
3. Port P (From POC pump) 10. Spool (for operating bucket)
4. Port A, (To dump cylinder bottom) (PA, ) 11. Lever
5. Port B, (To dump cylinder head) (PB, 1 12. Return spring
6. Port T (Drain) 13. Return spring
7. Spool with variable throttle valve 14. Spool with variable throttle valve
(for operating lift arm) (for operating bucket)
WA600- 1 61-9
FUNCTION OF POC VALVE
LIFT AND DUMP LEVERS AT “HOLD” POSITION
‘i
@ To cylinder
@ To tank
@ To cylinder
@ From steering valve

426F106
Accumulator
0
@ Filter
@ Check valve
@ Hydraulic tank
@ To steering valve
0 POC valve
Operation fJ POCpump
* The oil from the pump enters port A, but the circuit is
closed by spool (l), so the oil is drained from relief
valve (3). The oil at pot-t AI of the main control
valve is connected to the drain circuit through port j
and k of spool (1); the oil at port A2 is connected to
the drain circuit through port i and k of spool (1).
61-10 WA600- 1
0
DUMP LEVER AT “DUMP”
LIFT LEVER AT “LOWER” (1) (Intermediate position)
@ From cylinder

426F107
Accumulator
0
@ Filter
@ Check valve
@ Hydraulic tank
0 To steering valve
0 POC valve
f?J POCpump
Operation
* When the control levers are moved to the left, POC control valve. The oil of chamber E passes from port
spool (1) for lift lever moves up and spool (2) for it j of spool (I) to port k, and flows to the drain circuit.
. Therefore, the pressure oil acting on port A2 of the
moves down, and spools (1) and (2) for dump lever
move conversely. main control valve is constant, so a difference in pres-
- The oil from the pump enters port a, passes through sure is generated at port Al. As a result, the spool of
chambers C and F, and flows to port Al of the main the main control valve only moves an amount in pro-
control valve. In addition, the pressure oil at cham- portion to the movement of the control lever.
ber F passes through port h of spool (2) and flows
from chamber E to the port AZ circuit of the main
WA600-1 61-11
0
DUMP LEVER AT “DUMP”
LIFT LEVER AT “LOWER” (2) (End of travel)
@ To cylinder
@ Totank
@ To cylinder

426F108
@ Accumulator
@ Filter
@ Check valve
@ Hydraulic tank
0 To steering valve
POC valve
0
@ POCpump
Operation
. When the control levers are moved further to the left,
port h closes a little at a time, and the pressure acting
on port A2 of the main control valve drops a little at
a time.
Therefore, the pressure difference between ports A,
and A2 increases more, and the spool of the main
control valve moves to its specified stroke.
WA600-1
.
PPC VALVE (Proportional Pressure Control Valve)
J I
P4
/
/ \
P3 Pl 421FO1027
P From PPC pump
P? To dump cylinder bottom
Pz To lift cylinder head
P3 To lift cylinder bottom.
Pa To dump cylinder head
T Drain
61-13-1 WA600-1
8
Section B -B Section A -A
Section D-D
Section C-C 421FO1028
1. Bolt 6. Center spring
2. Piston 7. Spring
3. Plate 8. Valve
4. Collar 9. Bodv
5. Retainer
WA600-1 61-13-2
a
FUNCTION OF PPC VALVE
l-l
The PPC valve supplies pressure oil from the charg-
ing pump to the side face of the spool of each control
valve according to the amount of travel of the control
lever.
This pressure oil actuates the spool.
Operation
1. Control lever at “neutral” (Fig. 1)
Ports PA,. P4, PB,, and P, are connected to drain
chamber D through fine control hole (f) in valve
(8).
2. Control lever operated slightly (fine contrtol)

(Fig. 2)
When piston (2) starts to be pushed by Plate
(IO), retainer (5) is pushed. Valve (8) is also
pushed by spring (7) and moves down.
When this happens, fine control hole (f) is shut
off from drain chamber D. At almost the same
time it is connected to pump pressure chamber
Pp, and the pilot pressure of the control valve is
sent through fine control hole (f) to port P,.
When the pressure at port P, rises, valve (8) is Control valve
pushed back. Fine control hole (f) is shut .off
from pump pressure chamber Pp. At almost the Fig 1 421 FO1032
same time it is connected to drain chamber D, so
the pressure at port P, escapes to drain chamber
D.
Valve (8) moves up and down until the force of

spring (7) is balanced with the pressure of port
P,.
The position of valve (8) and body (9) (when fine
control hold (f) is midway between drain cham-
ber D and pump pressure chamber Pp) does not
change until the head of valve (8) contacts the
bottom of piston (2).
Therefore, spring (7) is compressed in proportion
to the travel of the control lever, so the pressure
at port P, also rises in proportion to the travel of
the control lever. The spool of the control valve
moves to a positin where the pressure of port
PA, (same as pressure at port P,) and the force
of the return spring of the control valve are bal-
anced.
61-l 3-3 WA600-1
8
3 Control lever moved back from slightly oper- -
ated
When
position to neutral (Fine
plate (10) starts to be pushed
(21 is pushed up by a force
control) (Fig.
back, piston
corresponding to the
3)
R
i I
I4
-
f---+Lh
force of centering spring (6) and the pressure at
port P,.
At the same time, fine control hole (f) of valve (8) I0 ’
is connected to drain chamber D, so the oil at
port P, escapes.
If the pressure at port P, drops too far, valve (8)
is pushed down by spring (7). Fine control hole
(f) is shut off from drain chamber D, and at
almost the same time it is connected to pump
pressure chamber Pp. The pump pressure is sup-
plied until the pressure at port PA, returns to a
pressure equivalent to the position of the lever.
When the spool of the control valve returns,, the
oil in drain chamber D flows in from fine control
hole (f’) of the valve which has no moved. The
extra oil then flows through port P, to chamber
PB,.
Fig 3 421F0 1034
4. Control lever operated to end of travel (Fig. 4)

Plate (10) pushes piston (2) down, and piston (2)
forcibly pushes in valve (8).
Fine control hole (f) is shut off from drain cham-
ber D, and is connected to pump pressure cham-
ber Pp.
Therefore, pressure oil from the charging pump
passes through fine control hole (f), and flows
from port P, to chamber PA, to push the spool
of the control valve.
The oil returning from chamber PB, flows from
port P, through fine control hole (f’) to drain
chamber D.
Fig 4 421FO1035
WA600-1
POC RELIEF VALVE
Serial No. 10001-10880 (except D spec.) 3
PPC RELIEF VALVE
[Serial No. 10881 and up (except D spec.)]
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
421FO71
Function
* The POC(PPC) relief valve is between the POC(PPC)
pump and the POC(PPC) valve. When the POC(PPC)
valve is not being actuated, or when abnormal press -
ure is generated, the oil sent from the pump is relieved
through this valve to protect the pump and circuit
from damage.
(Sets maximum pressure in the circuit)
Operation
- Port A is connected to the pump circuit, and port C is Fig. 1
421 F072
connected to the drain circuit.
The oil passes through the orifice of main valve (1) D 3
and fills port B. Pilot poppet (3) is in close contact
with valve seat (2). (Fig. 1)
* If the pressure at ports A and B reach the pressure set
by the poppet spring, pilot poppet (3) opens and the
pressure oil at port B flows through port D to port C.
As a result, the pressure at port B drops. (Fig. 2)
* If the pressure at port B drops, a pressure difference
is generated between ports A and B due to the orifice
in main valve (1). Main valve (1) is pushed open by
the pressure at port A, and the oil at port A is re-
lieved. (Fig. 3)
421 F073
Fig. 2
1
61-l 3-5 WA600- 1

@
MAIN CONTROL VALVE
82
426FlOl
1. Main relief valve MA1 : From PA1 of POC valve

2. Dump spool return spring MA2: From PA2 of POC valve
3. Lift spool return spring MB1 : From PBl of POC valve

MB2: From PB2 of POC valve
4. Lift spool
Al : To dump cylinder bottom side
5. Dump spool
A2: To lift cylinder bottom side
6. Body Bl : To dump cylinder rod side
7. Suction valve 82: To lift cylinder rod side
8. Unloader valve P: Pump port
T: Drain port (to hydraulic tank)
9. Safety valve (with suction)
Dl : Drain port
10. Float selector valve
02: Drain port
61-14 WA600- 1
cj$
w
Section X - X
Section Y - V
Section W- W J
Section 2 - 2
425F105
The main control valve controls the actuation of the - There are two safety valves (with suction valves) (9)
attachments and the bucket in the hydraulic system. to protect the circuit if abnormal pressure is gener-
It has a tandem circuit which gives priority to the ated in the bucket circuit. If one of the two safety
bucket circuit. valves is acting as a relief valve, the other valve acts as
The oil from the pump enters port P. The maximum a suction valve to make up any lack of oil.
pressure is set by the main relief valve (1). The oil
passes through the bypass circuit of dump spool (5)
and lift spool (4). It then flo,ws from port T to the
drain circuit, passes through the filter and returns to
the tank. If the dump and lift spools are actuated,
the oil flows to the dump and lift cylinders.
However, the circuit gives priority to the bucket, so
when the dump spool is being operated, even if the
lift spool is operated, the lift arm will not move.
WA600- 1 61-15
PA1 PA2
Al l.b A2
‘B2
\
PB2
421FO1030
PA1 : From P4 of PPC valve Al: To dump cylinder bottom
PA2: From P2 of PPC valve A2: To lift cylinder bottom
PBl : From Pl of PPC valve Bl : To dump cylinder head
PB2. From P3 of PPC valve 82: To lift cylinder head
P: Pump port Dl: Drain port
Pl: From P2 of PPC valve D2: Drain port
P2: From P3 of PPC valve T: Drain port
61-15-1 WA600-1
0
Section A-A
Section B-B
Section E-E F42601023
Section C-C 1. Main relief valve
2. Dump spool return spring
3. Lift spool return spring
4. Lift spool
5. Dump spool
6. Body
7. Suction valve
8. Unloader valve
Section D-D 9. Float selector valve
10. Safety valve (with suction)
WA600-1 61-15-2
0
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
6. Adjustment screw
6. Lock nut
426F102
Function
* The relief valve is installed at the inlet of the main
control valve. When the oil goes above the set pres-
sure, the relief valve drains the oil to the tank. In this
way, it sets the maximum pressure in the hydraulic
circuit and protects the circuit.
Operation
* Port A is connected to the pump circuit and port C is
connected to the drain circuit. The oil passes through Fig. 1
426F103
the orifice of main valve (I) and flows to port B.
Pilot poppet (3) is in close contact with valve seat (2).
(Fig. 1)
* When the hydraulic pressure in the circuit inside port
A and port B reaches the set pressure of the pilot
poppet spring (4), pilot poppet (3) opens, and the
pressurized oil from port B flows from port D to port
C, so the pressure at port B drops. (Fig. 2)
* When the pressure at port B drops, the orifice effect
of main valve (1) generates a difference in pressure
between port A and port B. The main valve is pushed
open and the oil from port A passes through port C
Fig. 2
and flows to the drain circuit to release the abnormal
pressure. (Fig. 3)
- The set pressure can be varied by changing the ten-
sion of pilot poppet spring (4). To change the set
pressure, remove cap nut, loosen lock nut (6) and
turn adjustment screw (5) as follows.
Fig. 3
426FlO5
61-16 WA600- 1
SAFETY VALVE (with suction valve)
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
1 421 FO45
Function
. The safety valve (with suction valve) is in the dump
cylinder circuit in the main valve. If shock causes any
abnormally high pressure in the cylinder when the
main valve is at neutral, the safety valve (with suction
valve) releases the abnormal pressure and protests the
cylinder from damage.
Operation
As a safety valve
- Port A is the cylinder circuit and port B is the drain
circuit.
The pressure oil in port A flows to port D through a
hole in the pilot piston (4). It also flows to port C
through an orifice consisting of the main valve and
the pilot piston (4).
The pilot piston (4) is secured to the suction valve by
lock‘nut. The diameter of the cross section‘(cross-
sectional area) gives a relationship of d, > dl > d3 >
d4. (Fig. 1)
Fig. 1 42 1 F046
- If abnormally high oil pressure occurs in port A, the

suction valve (1) is not actuated because of the rela-
tionship d, > d,
However, because of the relationship d3 > d4 in port
A and C, the hydraulic pressure on the main valve (2)
is equivalent to the area difference between ds and
d4. If this pressure goes up to the main valve spring
force (set pressure), the main valve (2) is actuated,
and the oil in port A flows into port B. (Fig. 2)
WA600- 1 61-17
As a suction valve
If negative pressure is generated in port A, port D also
has negative pressure, because port D and A are con-
nected with each other. The tank pressure in port B
is applied to port E.
Hydraulic pressure “a” equivalent to the area differ-
ence between d, and dI is applied to the safety valve
because of the tank pressure in port E.
Therefore, hydraulic pressure “e” acts to open the
valve and hydraulic pressure “a” acts to close the suc-
tion valve (1).
. If the pressure in port A drops, (approaching negative
pressure) hydraulic pressure “a” becomes smaller
than oil pressure “e”.
When oil pressure “e” becomes larger than oil pres-
421 FO48
sure “a” + valve spring (5) force, the suction valve (1)
opens, causing the oil to flow from port B into port
A. This prevents negative pressure from building up
in port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
421 F088
Operation
* If negative pressure is generated in port A (lift cylin-
der rod end) (if the pressure is lower than in port B in
the tank circuit), the main poppet (I) opens because
oil then flows from port B at the tank end to port A
at the cylinder port end.
421 F089
61-18 WA600- 1
FLOAT SELECTOR VALVE AND UNLOADER VALVE
* The action,of this device is explained using the hyd-
FUNCTION raulic system diagram for Serial Numbers 10001 -
10880 (except D spec.), but the bacic action of the
- The float selector valve and the unloader valve are
selector valve and unloader valve is also the same for
inside the main control valve. When the lift control
Serial Numbers 10881 and up (except D sepc.).
lever is moved to the float position, the float selector
valve detects this. When it is actuated, it actuates the _@@
unloader valve and sets the lift arm in the FLOAT

position.
OPERATION
1. LOWER position
This shows the condition with the lift control

lever in the LOWER position.
Q
From steering valve
426F109
2. FLOAT position
When the lift control lever is pushed forward

from the LOWER position, it enters the FLOAT
position.
Lift spool (1) of the main control valve is in the
same condition as at the LOWER position.
The hydraulic pressure at port A is higher than at
the LOWER position, so float selector valve (2)
moves in the direction of the arrow. ‘The back
pressure of unloader valve (3) is drained, so un-
loader valve (3) opens to give the FLOAT con-
dition.
6
From steerlngvalve 426FllO
WA600- 1 61-19
8
3. FLOAT position (pushed up)
If the machine moves in reverse and the lift arm

is pushed up, the pressure at the cylinder rod end
becomes high. It passes through port B and is
drained through unloader valve (3).
A vacuum is formed at the cylinder bottom end,
so oil flows in from port C.
d @
Fromsreering valve
426F111
4. FLOAT position (lowering under own weight)
When the machine is moving in reverse and the

lift arm comes down under its own weight, the
pressure at the cylinder bottom end is high, and
it is drained from port C.
A vacuum is formed at the cylinder rod end, so
oil flows in from port B.
@
From steering valve
426F112
61-20 WA600- 1
ACCUMULATOR
FUNCTION
* The accumulator is installed between the hydraulic
pump and the POC (PPC) valve. Before operatioh
- When the engine is stopped with the lift arm raised
and the control lever is moved by the pressurized
nitrogen gas which has been compressed inside the
accumulator, the work equipment valve will actuate
so that the lift arm and bracket will lower under their
own weight.
.B
421 F076
After operation
421 F075
1. cap 4. Bladder
2. Nut 5. Oil port
3. Body 6. Nut 421FO77 -
OPERATION
* After the engine stops, when the valve is at NEU- When the POC (PPC) valve is operated, the pressure in
TRAL, chamber A (volume of nitrogen gas: 3000 cc) chamber B drops below 30 kg/cm* and the pressure
inside the bladder is compressed by chamber B. of the nitrogen gas in chamber A makes the bladder
expand. The actuating pressure is 12 to 30 kg/cm*.
WA600- 1 61-21
a
OPERATION OF HYDRAULIC CIRCUIT
LIFT AND DUMP SPOOLS AT “HOLD” * The action ofthis device is explained using the hyd-
raulic system diagram for Serial Numbers 10001 -
10880 (except D spec.), but the basic action of the
main control valve is also the same for Serial Numbers
10881 and up (except D spec.).
@ Dump
0 Float
@ ,Hold
Lower
0
@ Raise
@ Tilt
Hydraulic tank
0
Oil cooler
@
@ Steering valve
0
0 Filter
Check valve
0
Accumulator
0
Switch pump
8
Hydraulic pump
8
Steering pump
8
POC pump
0
426F113
Operation
* The oil from the pump enters port A and the maxi-
mum pressure is set by the relief valve (11).
* Dump spool (1) is at HOLD, so the bypass circuit is
open. The oil in chamber A passes around the spool
and flows to port 6. Lift spool (2) is also at HOLD,
so the bypass circuit is open. The oil in chamber B
passes around the spool and flows to chamber C in
the drain circuit. From here it passes through the
filter and returns to the tank.
61-22 WA600- 1
03
LIFT SPOOL AT “RAISE”
@ Dump
0 Float
0 Hold
0 Lower
@ Raise
0 Tilt
0 Hydraulic tank
@ Oil cooler
@ Steering valve
0 To steering cylinder
0 Filter
Check valve
_ @
0 Accumulator
@ Switch pump
Hydraulic pump
8
@ Steering pump
8 POC pump
426F114
Operation
* When the lift lever (3) is pulled, pressure oil from by the spool, so the oil pushes up check valve (10).
port L of the POC valve flows to ports N and S. The The oil then flows from port H to port I, and goes to
oil in port T passes through port M and flows to the the bottom end of the cylinder.
drain circuit. The pressure oil in port S pushes the * At the same time, the oil at the rod end of the cylin-
push piston against the force of the spring and moves der flows from port K to drain p&t C, and returns to
lift spool (2) to the RAISE position. the tank. Therefore, the lift arm rises.
* The oil flows from the pump through the bypass cir-
cuit of the dump spool, and then flows to the bypass
circuit of lift spool (2). The bypass circuit is closed
WA600- 1 61-23
LIFT SPOOL AT “FLOAT”
@ Dump
0 Float
0 Hold
0 Lower
03 Raise
0 Tilt
0 Hydraulic tank
@ Oil cooler
@ Steering valve
0 To steering cylinder
0 Filter
Check valve
@
0 Accumulator
0 Switch pump
8 Hydraulic pump
@ Steering pump
@ POCpump
426F116A
Operation
When the lift lever (3) is pushed to the FLOAT posi- right and opens ports C1 and C to connect them to
tion, the spool of the POC valve moves further from the drain circuit. When port Cl, is connected to the
the LOWER position to the FLOAT position. Pres- drain circuit, valve (8) moves up, and the oil from the
sure oil from port M of the POC valve flows to port M pump flows to the drain circuit.
and also to ports T and W. At the same time, pres- Therefore, the oil at the rod end of the cylinder flows
sure oil from port S of the POC valve flows to port N. from port K, and then flows from unload valves (8)
The pressure oil in chamber T pushes the push piston to the drain circuit. At the same time, the oil at the
against the force of the spring and moves lift spool bottom end of the cylinder flows from port I to port
(2) to the LOWER position. C, and then flows to the drain circuit. Therefore, the
If the pressure difference between port W and port X lift arm floats.
goes above the specified level, valve (7) moves to the
61-24 WA600- 1
0
DUMP SPOOL AT “TILT BACK”
Dump
@
0 Float
0 Hold
0 Lower
Raise
@
0 Tilt
0 Hydraulic tank
Oil cooler
@I
@ Steering valve
0
0 Filter
0 Check valve
0 Accumulator
8 Switch pump
8 Hydraulic pump
8 Steering pump
8 POC pump
426F117
Operation
- When the dump lever (4) is pulled, pressure oil from from port A then flows from port D to port E, and
port L of the POC valve flows to port R via port P. goes to the bottom end of the cylinder.
The oil in port V is connected to the drain circuit. At the same time, the oil at the rod end of the cylin-
The pressure oil in port R pushes the push piston der flows from port G to drain port C, and returns to
against the force of the spring and moves dump spool the tank. Therefore, the bucket is tilted.
(1)to the TILT position.
- The bypass circuit is closed by the spool (1). so the
oil from port A pushes up check valve (10). The oil
WA600- 1 61-25
HYDRAULIC CYLINDER
LIFT CYLINDER
426F119
1. Head Specifications
2. Rod
Cylinder bore 225 mm
3. Cylinder
Rod diameter 120 mm
4. Piston
5. Lock ring Cylinder max. length 3025.5 mm
Cylinder min. length 1896 mm
Stroke 1129.5 mm
61-26 WA600- 1
DUMP CYLINDER
426F
1. Head Specifications
2. Rod
Cylinder bore 280 mm
3. Cylinder
Rod diameter 140 mm
4. Piston
5. Lock ring Cylinder max. length I 2131 mm
Cylinder min. length I 1451 mm
Stroke I 680 mm
WA600- 1 61-27
BUCKET LINKAGE
1. Bucket
2. Tilt lever
3. Dump cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
7. Bucket hinge pin
8. Bucket link pin
9. Cord ring
4 FO42601002
Serial No. 10001-10758 Serial No. 10759 and up Serial No. 10001-10758 Serial No. 10759 and up
(Oil type) (Grease type) (Oil type) (Grease type)
Section A - A Section A - A Section B - B Section B - B
Section C - C Section E - E Section F - F

Section D - D
Section G - G Section H - H Section J - J
426F128.1
61-28 WA600- 1
6
BUCKET POSITIONER AND BOOM KICK-OUT
J
1’ 2
View Z
426F 130
1. Proximity switch
2. Proximity switch
3. Dump cylinder rod
4. Lever
5. Plate
WA600- 1 61-29
Bucket positioner
* The bucket positioner is electrically actuated and is
used to automatically obtain the optimum digging
angle for the bucket.
When the bucket is moved from the DUMP position
to the TILT position, and it reaches the desired angle,
the dump lever is automatically moved from the
TILT position to the neutral.
- Lever (4) is secured by bolts to dump cylinder rod
(3). A proximity switch (I) is fixed by bolts to the
cylinder.
* When the bucket is moved from the DUMP position
to the TILT position, the dump cylinder rod moves
to the left. At the same time, lever (4) also moves to
the left. When it reaches the desired position, lever
(4) separates from proximity switch, and the bucket
lever returns to neutral.
426F131
Boom kick-out
- The boom kick-out is electrically operated and acts
to stop the lift arm. When the lift arm reaches the
desired position before the maximum height, the lift
arm lever is returned to neutral.
- plate (5) is secured to the lift arm. A proximity
switch (2) is fixed to the frame. When the lift arm is
moved from the LOWER position to the RAISE posi-
tion, the lift arm rises. When it reaches the desired
position, the proximity switch and lever come into
contact and the lift arm lever is returned to neutral.
426F132
61-30 WA600- 1
WORK EQUIPMENT SYSTEM 0 1
62 TESTING AND ADJUSTING E
Standard value table . . . . 62- 2

Tool list for testing and adjusting . . . 62. 3
Measuring dump and lift control levers . ... 62. 4
Adjusting dump and lift control levers . 62. 5
Measuring and adjusting . 62- 6
POC relief valve pressure
Measuring and adjusting PPC relief valve pressure. _62- 6
Measuring and adjusting work equipment
relief valve pressure ... .
. . . 62-8-l .
Measuring work equipment. .. .
. . . 62. 9.
Measuring hydraulic drift of work equipment . . . 62-10
Adjusting bucket positioner . .. . ... . 62-11
Adjusting boom kick-out .. . . . . . . 62-12
Troubleshooting . . . .. . ... 62-13
The values in these tables are based on the values for new machines leaving the plant, so they should be used
The standard values in these tables for judgement when troubleshooting are estimated values based on the
These standard value tables must not be used for standard values when judging claims. In addition, do not use
WA600- 1 62-1
0
Serial No. 10001-10182
Testing and measuring item Standard Permissible

Measurement condition Unit
value value
Dump and lift control levers
* Lift control lever operating force

(Hold + Raise) 2.7 - 3.5 Max. 5.3
(Raise + Hold) 2.7 - 3.5 Max. 5.3
(Hold + Lower) 2.7 - 3.5 Max. 5.3
! Lower --f Hold) - -
(Lower -t Float1 4.0 - 5.5 Max. 8.3
(Float + Hold) kg 2.7 - 3.5 Max. 5.3
. Dump control lever operating force * Hydraulic oil temperature:

45 - 55°C
(Hold-t Dump) 3.0 - 3.5 Max. 5.3
* Engine speed: Low idling
(Hold --f Tilt) 3.0 - 3.5 Max. 5.3
(Tilt -t Hold) Inside operating range 3.0 - 3.5 Max. 5.3
* Lift control lever travel

(Hold + Raise) 32-62 17-77
(Hold -f Lower) 25 - 55 10-70
(Hold-f Float) 42 - 72 27 - 87
mm
* Dump control lever travel

(Hold + Dump) 34-64 19-79
(Hold -t Tilt) 34 - 64 19-79
Relief oil pressure * Hydraulic oil temperature:

. POC valve 45 - 55Oc
30+30 30+;
* Engine speed: High idling kg/cm2
. Main control valve * Coolant temperature: 210+05 21 O’iO
Operating speed Inside operating range
* Lifting time of lift arm - Hydraulic oil temperature: 7.7 - a.3 Max. 10.0
. Lowering time of lift arm 45-55Oc 5.2 - 6.2 Max. 7.5
. Dumping time of bucket - Engine speed: High idling sec. 2.1 - 2.7 Max. 3.3
* Tilt back time of bucket - Steering position: Neutral 2.8 - 3.4 Max. 4.1
(Full stroke) - Bucket: unloaded
* Tilt back time of bucket
1.9 - 2.5 Max. 3.0
(Horizontal position of bucket)
Hydraulic drift of lift arm and bucket Inside operating range
* Hydraulic oil temperature:
45 - 55OC
- Retraction of lift cylinder rod * Stop engine, leave for 5 minutes, Max. 30 Max. 30
then measure for next 15 mm
minutes.
* Retraction of dump cylinder rod - Lift arm horizontal Max. 20 Max. 20
- Bucket horizontal
Bucket positioner
3-5 -
* Clearance of switch
mm
Boom kick-out
- Clearance of switch 3-5
62-2 WA600- 1
@
Serial No. 101.83 and up (D spec.)
Testing and measuring item Measurement condition Unit
value value

- Lift control lever operating force
(Hold - Raise) 2.7 - 3.5 Max. 5.3
(Raise * Hold) 2.7 - 3.5 Max. 5.3
(Hold + Lower) 2.7 - 3.5 Max. 5.3
(Lower -+ Hold) - -
(Lower + Float) 4.0 - 5.5 Max. 8.3

(Float + Hold) kg 2.7 - 3.5 Max. 5.3
* Dump control lever operating force - Hydraulic oil temperature:

45 - 55Oc
(Hold -) Dump) 3.0 - 3.5 Max. 5.3
(Hold *Tilt) 3.0 - 3.5 Max. 5.3
(Tilt + Hold) Inside operating range 3.0 - 3.5 Max. 5.3

(Hold -+ Raise) 50 -80 35 - 95
(Hold - Lower) 33 - 63 18- 78
(Hold - Float) 50 - 80 35 - 95
mm
* Dump control lever travel

(Hold -t Dump) 42 - 72 22 - 87
(Hold + Tilt) 42 - 72 22 - 87
Relief oil pressure . Hydraulic oil temperature:

. POC valve 45 - 55°C
40+2
. Engine speed: High idling cg/cm2
. Main control valve . Coolant temperature: 21o+i
- Lifting time of lift arm . Hydraulic oil temperature: 7.7 - 8.3 Max. 10.0
. Lowering time of lift arm 45-555Oc 5.2 - 6.2 Max. 7.5
* Dumping time of bucket * Engine speed: High idling sec. 2.1 - 2.7 Max. 3.3
* Tilt back time of bucket - Steering position: Neutral

2.8 - 3.4 Max. 4.1
(Full stroke) * Bucket: unloaded
* Tilt back time of bucket 1.9 - 2.5 Max. 3.0
Hydraulic drift of lift arm and bucket Inside operating range
i Hydraulic oil temperature:
45-555°C
* Retraction of lift cylinder rod . Stop engine, leave for 5 minutes, Max. 30 Max. 30
minutes.
* Retraction of dump cylinder rod - Lift arm horizontal Max. 20 Max. 20
- Bucket horizontal
Bucket Positioner
3-5 -
mm
Boom kick-out
. Clearance of switch 3-5
WA600-1 62-2-I
0%
Testing and measuring item Measurement condition Unit
value value

* Lift control lever operating force
(Hold -> Raise) 1.5 - 2.5 Max. 3.8
(Raise + Hold) 1.5 - 2.5 Max. 3.8
(Hold + Lower) 1.5 - 2.5 Max. 3.8
(Lower -t Hold) 1.5 - 2.5 Max. 3.8
(Lower -t Float) 1.5 - 2.5 Max. 3.8
(Float + Hold) kg 1.5 - 2.5 Max. 3.8
. Dump control lever operating force * Hydraulic oil temperature:

45 -E&c
(Hold + Dump) 1.5 - 2.5 Max. 3.8
(Hold + Tilt) 1.5 - 2.5 Max. 3.8
(Tilt + Hold) inside operating range 1.5 - 2.5 Max. 3.8

(Hold -f Raise) 52 - 82 37 - 97
(Hold - Lower) 34 - 64 19-79
(Hold + Floitl 52 - 82 52-a2

mm
- Dump control lever travel
(Hold-t Dump) 52 - 82 30 - 90
(Hold -f Tilt) 45 - 75 30 - 90
Relief oil pressure . Hydraulic oil temperature:

. POC valve 45-555Oc
38+; 38;;
* Engine speed: High idling kg/cm’
- Main control valve * Coolant temperature: 210’; 210+10
-8
. Lifting time of lift arm - Hydraulic oil temperature: 7.7 - a.3 Max. 10.0
* Lowering time of lift arm 45-555Oc 5.2 - 6.2 Max. 7.5
. Dumping time of bucket - Engine speed: High idling sec. 2.1 - 2.7 Max. 3.3
. Tjlt back time of bucket - Steering position: Neutral 2.8 - 3.4 Max. 4.1
(Full stroke) * Bucket: un-loaded
* Tilt back time of bucket 1.9 - 2.5 Max. 3.0
Hydraulic drift of lift arm and bucket inside operating range
- Hydraulic oil temperature:
45-555OC
. Retraction of lift cylinder rod - Stop engine, leave for 5 minu Max. 30 Max. 30
minutes.
* Retraction of dump cylinder rod . Lift arm horizontal Max. 20 Max. 20
. Bucket horizontal
Bucket positioner
3-5 -
mm
Boom kick-out
* Clearance of switch 3-5
62-2-2 WA600-1
8
NO. Testing and measuring item Tool name Part number Remarks
1 Hydraulic pressure Hydraulic tester 799-101-5000 0 - 300 kg/cm*
2 Oil temperature Thermistor kit 799-iol-6000 0 - 1ooo”c
3 Engine speed Tachometer 799-203-8000 60 - 19999 rpm
Dump lever and lift lever 79A-262-0020 0 - 25 kg

4 Push-pull scale
I operating force I
5 Measuring travel Convex scale Commercially available -
Measuring operating time of Commercially available 1 I1 0 second

6 Stop watch
work equipment
A When carrying
bar on the frame,
out testing, adjusting
lower the bucket
or troubleshooting,
to the ground,
stop the machine
and stop the engine.
on level ground, install the safety
A Do not allow unauthorized persons near the machine.
When measuring the engine speed, one worker should measure the engine speed while the other sits in the
A
operator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.
A Be careful not to get caught in rotating parts.
WA600- 1 62-3
Cc
MEASURING DUMP AND LIFT CONTROL LEVERS
Measurement condition
Coolant temperature: Inside operating range
Hydraulic oil ternperature: 45 - 55’c
Engine speed: Low idling
A Install the safety bar on the frame.
Measuring procedure
1. Operating force of dump and lift control levers
. Fit push-pull scale A on dump and lift control
levers and measure operating force.
I
* Hook the push-pull scale A on the center of
the knob.
* Operate at the same speed as normal and
measure the minimum force needed to
operate the knob.
2. Travel of dump and lift control levers Float

. Measure the travel of the dump and lift control
levers at each position. 0 Dum
l Mark “a” the knob of the lever and use a
scale to measure.
423F324
62-4 WA600-1
8
ADJUSTING DUMP AND LIFT CONTROL LEVERS

1. Remove cover (1).
2. Place dump lever and lift lever in HOLD.

* Apply lever lock to hold in position.
3. Loosen nut, then adjust length of rod (2) so that

POC valve is in HOLD.
* If the plate (31, roller (4) and spring (5) are
damaged, replace them.
+ Operate the dump and lift levers, and check
that the lever is held in position at TILT,
DUMP, RAISE and FLOAT.
421F205
WA600-1
62-5
0
Remove cover (1).
Pull solenoid (6) and fix the solenoid so that the

clearance between cam (3) and roller (4) is dimen-
sion a.
Dimension a: 0 - 0.5 mm
* Set the bucket lever and lift lever at the HOLD

position.
* If cam (31, roller (4). and spring (5) are broken,
replace them before carrying out the operation.
ension a
426FO1109
Lift lever
Operate the lift lever and adjust the length of rod
(2) so that the distance of roller (4) is dimension b
at the notch at both ends of cam (3).
Dimension b: 0 - 1 mm
42lFOI I I5
62-5- 1
(ii>
4. Bucket lever
Operate the bucket lever and adjust the length of
rod (2) so that the distance of roller (4) is dimen-
sion c at the notch of cam (3).
Di’mension c: 0 - 1 mm
* Operate the bucket lever and lift lever and check

that the lever is held at the TI LT, DUMP, RAISE,
and FLOAT positions.
421FOI II6
WA600-1 62-5-2
0
MEASURING AND ADJUSTING POC RELIEF VALVE PRESSURE
Serial No. 10001 and up (D spec.) 1
Serial No. 10001-10880 (except D spec.)]
MEASURING AND ADJUSTING PPC RELIEF VALVE PRESSURE
[Serial No. 10881 and up (except D spec.)]
* Engine coolant temperature: Inside operating range
- Hydraulic oil temperature: 45 - 55°C
* Engine speed: High idling
Measuring
1) Raise the lift arm, set a support under the lift arm,
then remove front frame inspection cover (1).
S
A
+
& Before loosening
(7) of the pressurizing
the oil filler cap, close valve
valve. (Serial No. 10868
and up)
ti & Loosen the oil filler cap slowly to release the

*
A
+
Y Operate the control
pressure in the accumulator
levers slowly to release the
completely.
426FO1108
62-6 WA600- 1
0
2) Remove plug-(2) for measuring the hydraulic pres-
sure of the dump cylinder circuit of the main con-
trol valve.
426Po9:
3) Install hydraulic test kit @ to the measurement

port.
* Check that there is no oil leakage from any joint.
* Use a hydraulic hose that is long enough to reach
the operator’s compartment,
the pressurizing valve. (Serial No. 10868 and up)
4) Start the engine and raise the lift arm about 400
mm. Then operate the control lever to ‘tilt the
bucket back and actuate the relief valve. Measure
the pressure when the valve is relieved. ..
* Do not suddenly apply pressure to the hydraulic 426PO&
pressure gauge.
9 Lt When removing the hydraulic pressure gauge,
9 release the pressure in the same way as when

installing the gauge.
* After completing the measurement, check that

valve (7) of the pressurizing valve is open.
..
WAbOO-1 62-7
m
2. Adjusting
A Always
hydraulic
stop the
pressure.
engine before adjusting the
1) Stop engine and remove cover (1).
2) Remove cap nut (2) of relief valve.
3) Loosen locknut (3). then turn adjustment screw (4)

to adjust.
* One turn of the adjustment screw changes the
pressure by about 0.51 kg/cm2.
* Turn the adjustment screw to adjust as follows.
* If it is impossible to measure the relief pressure
accurately, do not try to adjust the pressure.
423F315A
62-8 WA600- 1
0
.--.m.-
MtASUKlNti ANU AUJUS I INti
mm._ a_ . .
WORK EQUIPMENT RELIEF

_I_ 1-..-.-.a
VALVE PRESSURE
* Engine coolant temperature: Within operating range
* Hydraulic oil temperature: 45 - 55°C
- Engine speed: High idling
Measuring
y & Before loosening the oil filler cap, close valve

A+ (7) of the pressurizing valve. (Serial No. 10868
and up)

* Serial No. 10868 and up

A+Lt Operate the control
pressure in the accumulator
levers slowly
completely.
to release the
1) Remove plug (1) for measuring the hydraulic pres- Forward

sure of the dump cylinder circuit.
2) Install hydraulic test kit @ in measuring port.

* Check that there is no leakage of oil from any
joint.
* Use a hydraulic hose long enough to reach the
operator’s compartment.
the pressurizing valve. (Serial No. 10868 and up) 426FO1108
3) Start the engine and raise the lift arm about 400
mm. Then operate the control lever to tilt the
bucket back and actuate the relief valve. Measure
the pressure when the valve is relieved.
* Do not suddenly apply pressure to the hydraulic
pressure gauge.
When removing the hydraulic pressure gauge,

release the pressure in the same way as when
installing the gauge,
* After completing the measurement, check that valve

(7) of the pressurizing valve is open.
42SPO97
WA600- 1 62-8-l
0
Adjusting
A Always
hydraulic
stop the
pressure.
engine before adjusting the
1) Raise lift arm, and put support under lift arm, then
remove inspection cover (1) of front frame.
2) Remove locknut (3) of relief valve (2).
3) Turn adjustment screw (4) to adjust.

* One turn of the adjustment screw changes the
pressure by about 52.9 kg/cm’.
* Turn the adjustment screw to adjust as follows.
* If it is impossible to measure the relief pressure
accurately, do not try to adjust the pressure.
426PO98
421 F206A
62-8-2 WA600-1
,(?$
MEASURING WORK EQUIPMENT
Measurement condition Lifting time of lift arm

. Steering position: Neutral
. Hydraulic oil temperature: 45- 55’C
. Enginespeed: High idling
Unit: sec.
Lifting time of lift arm 7.7 - a.3 Max. 10.0
Lowering time of lift arm 5.2 - 6.2 Max. 7.5
Dumping time of bucket 2.1 - 2.7 Max. 3.3

423F327
Tilt back time of bucket Lowering time of lift arm
2.8 - 3.4 Max. 4.1
(Full stroke)
Tilt back time of bucket
(From horizontal posi- 1.9 - 2.5 Max. 3.0
tion of bucket)
Special tool
Part No. Pert Name O’ty
A Commercially available Stop watch 1
Measuring procedure 423F328

Lifting time of lift arm Dumping time of bucket
Set the bucket near the maximum tilt back position
and at the lowest position on the ground. Raise the
bucket and measure the time taken for bucket to
reach the maximum height of the lift arm.
Lowering time of lift arm

Set the bucket horizontal with the lift arm at the
maximum height, lower the bucket and measure the
time taken for the bucket to reach the lowest posi-
tion on the ground.
Dumping time of bucket

Raise the lift arm to the maximum height and meas-
423F329
ure the time taken for the bucket to move from the
maximum tilt back position to the maximum dump
position.

1) Raise the lift arm to the maximum height and
measure the time taken for the bucket to reach
the maximum tilt back position.
2) Set the bucket horizontal and measure the time
taken for the bucket to move from the hori-
zontal position to the maximum tilt back posi-
tion.
423F330
WA600- 1 62-9
0
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT ’
. Coolant temperature: Inside operating range
. Hydraulic oil temperature: 45 - 55°C
. Stop engine, leave for 5 minutes, then measure for
next 15 minutes.
. Lift arm horizontal
. Bucket horizontal
. Unloaded (operating load)
Unit: mm
Item value
value
Retraction of lift cylinder rod / Max. 30 / Max. 30
Retraction of dump cylinder rod 1 Max. 20 1 Max. 20
Special tool
I Part No.
I Part Name Q’ty
A Commercially available Convex scale 1
a Fit the safety locks on the,control levers.

423F331
Do not go under the work equipment.

B
Measuring procedure
1) Set the lift arm and bucket horizontal,‘then stop the
engine.
2) Stop the engine, wait for 5 minutes, then start
measuring.
3) Measure the amount the lift B and dump A cylinder
rods retract during 15 minutes.
A: Retraction of dump cylinder rod. 423F332
5: Retraction of lift cylinder rod.
62-18 WA600- 1
0
ADJUSTING BUCKET POSITIONER
1. Inspection procedure
1) With the engine stopped, check that the clear-
ance between switch (1) and angle (2) is within
the standard value.
2) Start the engine, run at high idling and check
the actuation position. (Measure three times
and take the average.)
2. Adjusting
1) Lower the bucket to the ground and operate
the bucket to the desired digging angle. Return
the lever to the hold position and stop the 426PO99
engine.
2) Fix support (3) to the bucket cylinder bracket
so that “a” part of angle (2) align the center of
the switch.
3) Remove cover (4) of switch.
4) Fix the switch so that the clearance “b” bet-
ween the sensing surface of the switch and the
angle is within the standard value.
D Switch mounting nut: 1.8 + 0.2 kgm

View X a X -’
Clearance b
425 F264A
5) Loosen 2 bolts (51, and adjust the position of
proximity switch mounting bracket (31, then
fix the bracket in position. Distance (A) be-
tween the center of the sensing surface of prox-
imity switch (1) and the rear end of angle (2)
varies according to the engine speed when the
bucket is tilted back, so use the values in the
tabie below for reference.
* After adjusting, operate the dump lever and
i
check that the bucket is actuated at the
F426C 1031-K
desired. position.
* Install cover (4) of switch.
Engine speed when

Distance (A)
bucket is tilted back
I
LOW idling range 10mm
Mid-range speed 27 mm
High idling range 41 mm

F426C1032-K
WA600-1 62-l 1
8
ADJUSTING BOOM KICK-OUT
1. Inspection procedure
1) With the engine stopped, check that the clea-
ante between switch (1) and plate (2) is within
the standard value.
2) Start the engine, run at high idling and check
the actuation position. (Measure three times
and take the average.)
2. Adjusting
1) Raise the lift arm to the desired position, then
mark the lifr arm at the position where the
Y
center of the switch align with the plate. 426P101
21 Lower the lift arm and stop the engine.
3) Align the marks “a” adjust the position of the
plate so that the center of switch (1) align with
the plate (2), then lock the plate in position.
4) Remove switch cover (3).
5) Adjust the switch so that the clearance between
the sensing surface of the switch and plate (2)
is within the standard value.
w Mounting nut of switch:

1.8 + 0.2 kgm
* After adjusting, operate the lift lever and

check that the lift arm stops at the desired
position.
423F335
426P103
62-12
0
TROUBLESHOOTING
Troubleshooting table . 62- 14

1. Lift arm does not rise . 62- 14
2. Lift arm moves slowly or does not have
sufficient lifting power.. 62- 15
3. Lift arm movement becomes slow after it
reaches a certain height ................ 62-l 6
4. Bucket cannot be held down with lift
cylinder .............................. 62-l 6
5. Lift arm has large hydraulic drift ........ 62-16
6. Lift arm movement is unsteady
during work .......................... 62-l 6
7. Lift arm lowers momentarily
when control lever is shifted
from “Hold” to “Raise” _............... 62-l 6
8. Bucket does not tilt back ............... 62-l 7
9. Bucket moves slowly or has insufficient
tilt back power ........................ 62-l 8
10. Bucket movement becomes slow during
tilt back .............................. 62-19
11. Bucket cannot be held down by the
bucket cylinder ....................... 62-l 9
12. Bucket has large hydraulic drift ......... 62-l 9
. 13. Bucket moves unsteadily when
machine travels under load
(Main control valve in “Hold”) .......... 62-l 9
14. Bucket dumps momentarily when
control lever is shifted from
“Hold” to “Tilt back” .................. 62-l 9
15. Control levers of lift arm and dump
move stiffly and sluggishly ............. 62-20
62G3
WA600- 1
1. Lift arm does not rise.
Ask the operator the following questions

* Did the boom suddenly fail to rise? --f Seizure
or damage to various units.
Was an unusual noise produced? (Where did it
emanate from?)
* Were there previous signs of the boom slowing
down. + Wear of parts of flattening of spring.

. Is oil ievel in hydraulic tank correct?
- Is travel of lift control lever and spool correct?
Tank - pump
No.
1 Bucket cannot operate and lift arm is unable to rise. 000000 0
The machine body can be lifted up by the lift arm however,

2 the lift arm is unable to rise. Or, the bucket 0 0 0
operates but the lift arm is unable to rise.
The lift arm can rise under no load but cannot rise
3
under load. 0 0 0
4 The hydraulic pump produces an unusual noise. 0 0 0
5 Lift cylinder has large amount of hydraulic drift. 0 0
When the engine is at high idling, steering action is light and

6
excessively fast. 0
When the engine is at high idling, steering action is heavy

7 and slow. 0 0
+ ppc valve is equipped for machines Serial No. 10881 and UP (except D spec.).

62-l 4 WA600- 1
8
2. Lift arm moves slowly or does not have
sufficient lifting power.

. Is. the travel of the lift control lever and also
the spool of the main control valve correct?
. Seizure of bucket linkage bushing.
(Does emits unusual noise)
Fault check
There is a strong relationship between faults in-
volving lifting force and lifting speed. Such faults
appear initially in the form of insufficient lifting
speed. Measure the lifting speed of the lift arm
when loaded and refer to the standard value table to
determine whether or not there is a fault.
Tank - $2 POC valve

pump 2 2 (PPC valve)
v)
a b c d e f
No.
Bucket tilt back force and speed are abnormal and lift arm
1 lifting speed is low. 0 0 0 0
Bucket tilt back force and speed are normal but lift arm
2
lifting speed is low. 0 0 0
Same as item 1 except that lift arm lifting speed becomes
3
particularly low when oil temperature rises. 0
4 Hydraulic pump emits unusual noise.

0 0
When the engine is at high idling, steering action is light and

5 0
excessively fast.
When the engine is at high idling, steering action is heavy

6 and slow. 0
7 Cylinder has a large amount of hydraulic drift.

0 0
8 The relief pressure of relief valve of main control valve,

0 0 0 0
* PPC valve is equipped for machines Serial No. 10881 and up (except D spec.).

WA600- 1 62-15
8
3. Lift arm movement becomes slow after it 6. Lift arm movement is unsteady during work.
reaches a certain height.
During excavation or ground leveling when the lift
Check before troubleshooting arm control lever is in the “Hold” position, the
* External deformation of lift cylinder. bucket and lift arm move up and down in accord-
ance with the terrain.
Cause
- Swollen or internally damaged lift cylinder Problem and cause
tube. Check the amount of hydraulic drift and whether or
* Regarding other faults occurring during lift arm not the machine body can be lifted up by the lift
rise, refer to item 2 “Lift arm moves slowly cylinder.
or does not have sufficient lifting power”. 1. If the amount of hydraulic drift is greater than
the standard value, refer to item 5 “Lift arm
has large hydraulic drift”.
4. Bucket cannot be held down with lift arm 2. If the machine body can not be lifted up by
cylinder. the lift cylinder, refer to item 4 “Bucket can
not be held down with lift cylinder”.
If the relief pressure in the circuit at the bottom of 3. If the amount of hydraulic drift is normal and
the lift cylinder is insufficient, refer to item 2 “Lift the machine body can be lifted up by the lift
arm moves slowly or does not have sufficient lifting cylinder after the lift arm is moved several
power”. times to cause the lift cylinder to move through
its entire stroke + the trouble is due to the
Checks before troubleshooting generation of a vacuum in the cylinder.
* Is level of oil in the hydraulic tank correct? * If a vacuum is generated frequently, + faulty
* Is travel of main control valve and lift arm suction valve on lift cylinder rod side.
spool correct?
Cause 7. Lift arm lowers momentarily when control

- Faulty main control valve or suction valve seat lever is shifted from “Hold” to “Raise”.
on lift arm cylinder rod side.
. Oil leakage from lift arm cylinder piston seal. The lift arm lowers momentarily under its own
weight when the lift arm control lever is gradually
shifted from the “Hold” position to the “Raise posi-
5. Lift arm has large hydraulic drift. tion while the engine is at low idling. When the
control lever is put completely into the “Raise”
Ask the operator the following questions position, the lift arm behaves normally.
* Did the hydrualic drift suddenly become large?
-+ Dirt lodged in valve or damaged parts. Cause
- Did the hydraulic drift gradually become large? . Faulty seating of main control valve or lift arm
--*Worn parts. check valve.

- Is the type and temperature of the oil in the
hydraulic tank correct?
. Is the lift arm spool in the neutral position? +
Seized link bushing, faulty spool detent.
Problem and cause

* When measuring hydraulic drift, internal of lift
cylinder produces oil leak noise + Damaged
piston packing.
52-16 WA600- 1
1
8. Bucket does not tilt back.
Ask the operator the following questions

. Did the bucket suddenly ceases to move? -+
Seized or damaged equipment.
Was any unusual noise emitted (where did it
emanate from )?
. Were there previous signs of the bucket slowing
down? + Worn parts of flattened spring.
Checks before troubl.eshooting

. Is amount of oil in hydraulic tank satisfactory?
. Is the travel of the dump control lever and
spool correct?
Tank -pump
1 Lift arm cannot operate and bucket is unable to tilt back. 0’0 0 0 0 0 0
The machine can be lifted up by the bucket but the bucket

2 cannot tilt back. Or, the lift arm operates but the 0 0 0
bucket cannot tilt back.
The bucket can tilt back under no load but cannot excavate
3 or scoop. 0 0
4 The hydraulic pump produces an unusual noise.

0 0 0
5 Bucket cylinder has large hydraulic drift.

010
Steering action is light and excessively fast when the engine

6 0
is at high idling.
Steering action is heavy and slow when the engine is at

7 0
high idling.
l PPC valve is equipped for machines Serial No. 10881 and UP (except C sPec.1.

WA600- 1 62-17
0
9. Bucket moves slowly or has insufficient tilt
back power.

* Is the oil quantity in the hydraulic tank and the
type of oil satisfactory?
. Is the travel of the dump control lever and the
main control valve spool correct?
. Seizure of bushing in bucket linkage.
(Does emits unusual noise)
Fault checks
* Check the amount of deficient titlt back force
by performing actual work.
* Measure the operating speed of the bucket and
check it against the standard value table to
determine whether or not it is normal.
Lift arm lifting force and lifting speed are abnormal and also
1
bucket tilt back force and tilt back speed are abnormal. lololo/o/
Lift arm lifting force and lifting speed are normal but bucket
2
tilt back force and tilt back speed are abnormal. I I 1 / loI /M&l
become particuiarly bad when the oil
7 The dump cylinder has a large amount of hydraulic drift.

000
The relief pressure of relief valve of main control valve is

8 0000
also low.
9 The discharge volume of the hydraulic pump is low.

Ioi I i I 1 i 1~ I
valve for machines Serial No. 10881 and
The following symbols are to indicate the

when a cause of failure
62-18 WA600- 1
0
10. Bucket movement becomes slow during tilt 13. Bucket moves unsteadily when machine
back. travels under load. (Main control valve in
“Hold”).
. External deformation of dump cylinder. Checks before troubleshooting
. Is oil lev.el in hydraulic tank and type of oil
Cause correct?
. Swollen or internally damaged dump cylinder . Excessive play in pin and bushing of work
tube. equipment linkage.
Regarding other faults which occur when the . Was an unusual noise produced?
bucket operates, refer to item 9 “Bucket moves
slowly or has insufficient tilt back power”. Cause
. Faulty piston seal of dump cylinder.
. Faulty safety valve with suction valve for the
11. Bucket cannot be held down by the bucket bottom side of dump cylinder.
cylinder. If the above symptoms occur together with
other symptoms, refer to the problems items
Refer to item 9 “Bucket moves slowly or has in- corresponding to each fault.
sufficient tilt back power”.
Check before troubleshooting 14. Bucket dumps momentarily when control

. Is oil level in the hydraulic tank satisfactory? lever is shifted from “Hold” to “Tilt back”.
. Is the travel of the main control valve dump
spool correct? The bucket dumps momentarily under its own
wieght when the dump control lever is gradually
Cause shifted from the “Hold” position to the “Tilt back”
. Faulty seat of safety with suction valve of con- position while the engine is at low idling.
trol valve for the bottom side of dump cylinder. When the control lever is put completely into the
. Oil leakage from seal of dump cylinder piston. “Tilt back” position, the bucket behaves normally.
Cause
12. Bucket has large hydraulic drift. . Faulty seating of main control valve dump
spool check valve.
. Did the hydraulic drift suddenly become large?
+ Dirt lodged in valve or damaged parts.
. Did the hydraulic drift gradually become large?
+ Worn parts.

. Is the type and temperature of the oil in the
hydraulic tank correct?
. Is the dump spool in the neutral position? +
Seized link bushing, faulty spool detent.
Fault check
. Use the standard value table to check whether
or not the hydraulic drift of the bucket is
actually large.
. If hydraulic drift is large.
Cause: Oil leakage in dump cylinder.
. If hydraulic drift returns to normal.
Cause: Faulty seating of overload relief valve
or suction valve on rod side.
Faulty oil sealing on spool of dump
control valve.
WA600- 1 62-19
0
15. Control levers of lift arm and dump move
stiffly and sluggishly.
Fault check
Using the standard value table, check whether
or not the operating force of the lever is large.
Main control valve
Movement of lift and dump levers becomes sluggish when

1
load is applied and oil pressure increases. 00 0 0
Movement of lift and dump levers becomes sluggish along
2 with change in oil temperature. 00 0 0
Movement of lift and dump levers becomes partially sluggish

3 irrespective of oil pressure and temperature. 0
Movement of lift and dump levers becomes generally sluggish
4
irrespective of oil pressure and temperature. 00 000 0
Movement of lift and dump levers does not become light even
5 when the link of the control lever is disconnected at the valve 0
connection part and the lever operated.
* PPC valve is equipped for machines Serial No. 10881 and up (except D spec.).

to be taken‘when a cause of failure is located.
62-20 WA600- 1
0
HYD.RAULlC SYSTEM l
63 DISASSEMBLY AND ASSEMBLY E
HYDRAULIC TANK CONTROL
1
Serial No. 10001 - 10880 (Except D spec.) Removal ......................... 63-13
[Serial No. 10001 and up (D spec.) Installation .......................
Removal ......................... 63- 2 MAIN VALVE
Installation ....................... 63- 4 Serial 10001 10880 D
HYDRAULIC TANK Serial 10001 up spec.)
[Serial No. 10881 and up (Except D spec.)] Disassembly ....................... 63-18
Removal ......................... 63-5-l Assembly ........................
Installation ....................... 63-5-3 MAIN VALVE
HYDRAULIC FILTER No. and (Except spec.)]
Serial No. 10001 - 10880 (Except D spec.) ......................
[ Serial No. 10001 and up (D spec.) I Assembly 63-19-3
Removal ......................... 63- 6 CYLINDER
Installation ....................... 7 ......................... 63-20
FILTER Installation .......................
No. and (Except spec.)] LIFT
......................... 63-7-l Removal 63-24
Installation ....................... ....................... 63-27
WORK STEERING, (PPC) LIFT CYLINDER AND DUMP CYLINDER
Removal 63- Disassembly ....................... 63-28
Installation 63-9:l Assembly 63-30
VALVE EQUIPMENT
Serial 10001 10880 D 63-32
Serial 10001 up spec.) ....................... 63-38
Removal ......................... 63-1’0 COUNTERWEIGHT
Installation 63-1 l-1 Removal ......................... 63-43
Disassembly. ....................... Installation .......................
Assembly ................ : ....... 63-12
PPC VALVE
[Serial No. 10881 and up (Except D spec.]
Removal ........................ 63-12-l
Installation ...................... 63-12-3
Disassembly. .....................
Assembly 63-12-5
WA600-
%’
- Air bleeding procedure
out from the plug.
m Plug: 1 .15 * 0.15 kgm
63-l-l WA600- 1
@
REMOVAL OF HYDRAULIC TANK
1
Serial No. 10868and LID
Serial No. 10001 and up (D spec.)]
A Stop
the safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket
1A

*‘,&Loosen the oil filler cap slowly to release the

ate the control levers several times to release
the remaining pressure in the hydraulic piping.
426FO1201
1. Draining oil
Remove plug (1). loosen valve (2). and drain
hydraulic oil.
A Hydraulic oil: Approx. 22612
426F379
2. Step
1) Sling ladder (3), and remove mounting bolts,
then lift off.
Ladder: 30 kg
2) Sling step (4). and remove mounting bolts, then

lift off.
* Be careful of the balance of the lifting tool.
* Remove the mounting bolts at the bottom of
the step cover.
* Do not forget to remove all four bolts con-
necting the step and floor.
e,
i- Step: 70 kg
f 426P905
63-2
0
3. Air piping (Serial No. 10868 and up)
1) Open pressurizing valve and drain air from air
tank.
2) Disconnect hose (10) between air tank and pres-
surizing valve at pressurizing valve end.
4. Hydraulic piping
1) Disconnect tube (5) between hydraulic tank and
hydraulic pump at hydraulic tank end.
2) Disconnect return tube (6) between main control
valve and hydraulic tank at hydraulic tank end.
3) Disconnect tube (7) between steering valve, hy-

draulic cooler and hydraulic tank at hydraulic
tank end.
* Disconnect from the manifold.
* Loosen the clamps of the steering and cooler
tubes.
5. Hydraulic tank
Sling hydraulic tank (8), remove mounting bolts,
then lift off.
* Be careful that the tube does not catch on the
tank.
* Raise the hydraulic tank slightly, move it to-
wards the outside, then lift it off.
Hydraulic tank: 365 kg
WA600-1
INSTALLATION OF HYDRAULIC TANK
1
[Serial No. 10001 and up (D spec.)
1. Hydraulic tank
Set hydraulic tank (8) in mounting position, and
* Be careful with the hydraulic piping when in-
stalling.

2. Hydraulic piping
1) Connect tube (7) between steering valve, hydrau-
lic cooler and hydraulic tank at hydraulic tank
end.
* Tighten the clamps of the steering and cooler
tubes.
* Check that the O-ring of the connection is
fitted in the groove.
2) Connect return tube (6) between main control

3) Connect tube (5) between hydraulic tank and
3. Air piping (Serial No. 10868 and up)

Connect hose (IO) between air tank and pres-
surizing valve.
4. Step
1) Raise step (4) and set in mounting position, then
2) Raise ladder (3) and set in mounting position,


Tighten drain plug and add engine oil through oil
filler to the specified level.
* Tighten the oil filler cap, then open pres-
* Run the engine to circulate the oil through the

system. Then check the oil level again.
a&b Hydraulic oil: Approx. 226Q
426FO1201
WA600-1
REMOVAL 0F HYDRAULIC TANK
A Stop the machine

Lower the bucket
*‘&Loosen the oil filler cap slowly to release the

1. Draining oil
Remove plug (11, loosen valve (2), and drain hy-
draulic oil.
:
- Hydraulic oil: Approx. 22611
426FO1218
2. Step
1) Sling ladder (3), and remove mounting bolts,
then lift off.
Ladder: 30 kg
2) Sling step (41, and remove mounting bolts, then

lift off.
* Be careful of the balance of the lifting tool.
* Remove the mounting bolts at the bottom of
the step cover.
* Do not forget to remove all four bolts con-
necting the step and floor.
Step: 70 kg
/
r 426P905
63-5-I
cc
3. Air piping
* Open the pressurizing valve and drain the air
from the air tank.
* Disconnect hose (6) between the pressurizing
valve and hydraulic tank at the pressurizing
valve end.
4. Hydraulic piping
1) Disconnect tube (7) between hydraulic tank and
2) Disconnect return tube (8) between main control
3) Disconnect tube (9) between steering valve, hy-

draulic cooler and hydraulic tank at hydraulic
tank end.
* Disconnect from the manifold.
* Loosen the clamps of the steering and cooler
tubes.
5. Hydraulic tank
Sling hydraulic tank (IO), remove mounting bolts
(1 I), then lift off.
* Be careful that the tube does not catch on the
tank.
* Raise the hydraulic tank slightly, move it to-
wards the outside, then lift it off.
Hydraulic tank: 425 kg
63
426FO1219
WA600-1
63-2-2
INSTALLATION OF HYDRAULIC TANK
1. Hydraulic tank
Set hydraulic tank (10) in mounting position, and
* Be careful with the hydraulic piping when in-
stalling.

426FO1219
2. Hydraulic piping
1) Connect tube (9) between steering valve, hydrau-
lic cooler and hydraulic tank at hydraulic tank
end.
* Tighten the clamps of the steering and cooler
tubes.
* Check that the O-ring of the connection is
fitted in the groove.
2) Connect return tube (8) between main control

3) Connect tube (7) between hydraulic tank and
3. Air piping
1) Connect hose (6) between pressurizing valve and
hydraulic tank.
63-5-3 WA600-1
‘&
4. Step
1) Raise step (4) and set in mounting position, then
2) Raise ladder (3) and set in mounting position,


valve (1A).

system. Then check the oil levei again.
a3 Hydraulic oil: Approx. 2268
426FO1202
63:-4
WA600- 1
I
REMOVAL OF HYDRAULIC FILTER
No. 10001
No. 10001
- 10880 (Except
and up (D spec.)
D spec.)
1 Serial No. 10868 and UP
*k Loosen the oil filler cap slowly to release the

1A
+ pressure inside the hydraulic tank.
* Before looseing the oil filler cap, close pres-
426FO1201
1. Draining oil
Remove plug (I), then loosen valve (2) and drain
hydraulic oil.
& Hydraulic oil: Approx. 16Q
426F379
2. Cover
Loosen plug (3A) and remove cover (3).
The cover is under tension from a spring,

so be careful when removing it.
t Be careful not to damage O-ring (4) at the con-

tact face of the cover and tank.
3. Filter
1) Remove spring (5) and bypass valve (6).
2) Remove hydraulic filter (7).

INSTALLATION OF HYDRAULIC FILTER
1. Filter
1) Install hydraulic filter (7).
* Insert securely into the pilot inside the filter.
2) Install bypass valve (6) to filter, then install

spring (5).
2. Cover
Assemble O-ring (4) in groove of cover, then install
cover (3) to tank, and tighten plug (3A).
* Push the cover into contact with the cover spring
seat, then lift up slightly to install the cover.
* Replace th,e O-ring with a new part.
* Fit the O-ring securely in the groove, and be care-
ful not to get it caught.


system. Then check the oil level again. Serial No. 10868 end up
& Hydraulic oil: Approx. 16P
426FOl201
WA600-1
REMOVAL OF HYDRAULIC FILTER

pressure inside the hydraulic tank.
426FO1202
1. Cover
2) Loosen plug (2) and remove mounting bolts,

then remove cover (3).
Sa II The cover is under tension from a spring,
4 so be careful when removing it.
* Be careful not to damage O-ring (4) at the con-

tact face of the cover and tank.
2. Filter
1) Remove spring (5) and bypass valve (6).
2) Remove hydraulic filter (7).
426FO1220
INSTALLATION OF HYDRAULIC FILTER
1. Filter
1) Install hydraulic filter (7).
* Insert securely into the pilot inside the filter.
2) install bypass valve (6) to filter, then install

spring (5).
426FO1220
2. Cover
1) Assemble O-ring (4) in groove of cover (3), then
install cover (3) to tank, and tighten plug (2).
* Replace the O-ring with a new part.
* Fit the O-ring securely in the groove, and be
careful not to get it caught.
w Plug: 1.2 f 0.1 kgm
* Tighten the oil filler cap, then open pres-

426FO1202
WA600-1
63;-2
REMOVAL OF WORK EQUIPME T, STEERING,
POC (PPC) PUMP Serial No. 10868-10880 (Except D spec.)

! Serial No. 10001 and up (D spec.) I

A Stop
the safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket
426FO1201

pressure inside the hydraulic tank. Then oper-
1. Cover
Open bulkhead inspection cover (1).
* Secure firmly with the lock.
2. Hydraulic piping
Disconnect the following hydraulic piping from
pump.
- Hose (2) between hydraulic tank and hydraulic
pump
- Hose (3) between hydraulic tank and steering
pump
* Loosen the clamps of hoses (2) and (3), then
push the hoses down.
* Hose (4) between hydraulic pump and steering
valve
- Branch hose (5)
- Hose (6) between steering pump and steering
valve
- Tube (7) between POC (PPC) pump and POC
(PPC) strainer
WA600-1
3. Hydraulic + Steering + POC (PPC) pump
Sling hydraulic + steering + POC (PPC) pump (8),
remove mounting bolts, then lift off.
* Be careful of the O-ring at the mounting face
when lifting off.
* After removing the pump from the mount, tilt
the pump to the right and remove.
A
_
kg Hydraulic + steering + POC (PPC) pump:
51 kg
WA600-1 63-9
@
INSTALLATION OF WORK EQUIPMENT, STEERING,
PO@ (PPC) PUMP
Serial No. 10001 - 10880
[ Serial No. 10001 and up (D spec.)
(Except D spec.)
1
Hydraulic + Steering + POC (PPC) pump

Raise hydraulic + Steering + POC (PPC) pump (8),
and set in mounting position, then tighten mounting
bolts.
* Fit the O-ring at the mounting surface securely
into the groove.
Hydraulic piping
Connect the following hydraulic piping to pump.
* Tube (7) between POC (PPC) pump and POC
(PPC) strainer
* Always connect tube (7) first.
- Hose (6) between sterring pump and steering
valve
- Branch hose (5)
- Hose (4) between hydraulic pump and steering
valve
- Hose (3) between hydraulic tank and steering
pump
- Hose (2) between hydraulic tank and hydraulic
pump
* When connecting hoses (2) and (3), tighten
the lower clamp first before tightening the
mounting bolts.
3. Cover
Close bulkhead inspection cover (1).
(Except D spec.)
Serial No, 10881 and up
(Except D spec.)
Add oil through oil filler to the specified level.
Hydraulic oil: Approx. 5Q
63F
Serial No, 10868-10880 (Except D spec.)
* Ruti the engine to circulate the oil through the

426FO1201
426FO1202
%\\
WA600-1
63z-2
REMOVAL OF POC VALVE ASSEMBLY
Serial No. 10001 - 10880 (Except D spec.) Serial No. 10868 and LID
Serial No. 10001 and up (D spec.)] I
a Stop the machine on level ground and install

*’ Loosen the oil filler cap slowly to release the

426FO1201
1. Cover
Remove cover (1) under cab and cover (2) of con-
sole box on right side of operator’s seat.
2. Hydraulic piping
- Disconnect hoses (3) and (4) of lift spool at POC
valve end.
- Disconnect hose (5) between POC valve and
hydraulic tank at POC valve end.
- Disconnect hose (6) between POC pump and
POC valve at POC valve end.
- Disconnect hoses (7) and (8) of dump spool at
POC valve end.
* After disconnecting the hoses, mark with a tag to
distinguish when installing.
426P923 426P924
3. Linkage
Remove cotter pin and loosen locknut (9), then
disconnect linkage (IO).
426P925
WA600- 1
4. POC valve
Remove plate (1 l), then remove POC valve (12).
* The working space is restricted, so be careful
when working.
* There is a washer between the plate and valve
and the console box, so be careful not to lose it.
* Lift out POC valve.
42613926
WA600- 1
INSTALLATION OF POC VALVE
No. 10001
No. 10001
- 10880 (Except
and up (D spec.)
D spec.)
1
1. POC valve
Set POC valve (12) in mounting position, then set
plate (ll), and tighten mounting bolts.
* Be careful not to assemble the valve facing in the
wrong direction.
* Set a cushion between the plate and valve and
the console box, then insert the washer securely
and tighten the mounting bolts.
2. Linkage
Set linkage (10) in mounting position, tighten lock-
nut (9). then secure with cotter pin.
* For details of adjusting linkage, see TESTING
AND ADJUSTING.
3. Hydraulic piping
* Connect hoses (7) and (8) of dump spool at POC
valve end.
- Connect hose (6) between POC pump and POC
valve at POC valve end.
- Connect hose (5) between POC valve and hydrau-
lic tank at POC valve end.
* Connect hoses (3) and (4) of lift spool at POC
valve end.
426P924 426P923
4. Cover
Install cover (1) under cab and cover (2) of console
box on right side of operator’s seat.
63-k’
-’
Add hydraulic oil through oil filler to the specified
level.

system. Then check the oil level again. 1A
\
426FO1201
63-A’
WA600- 1
-2
DISASSEMBLY OF POC VALVE ASSEMBLY
No. 10001 - 10880 (Except D spec.)
1. Loosen nipple (1). then remove bottom cover (2).

* It is only necessary to loosen the nipple if it catched
on the lower cover.
2. Remove bracket (3).
3. Remove plug (4), then remove shim (5), spacer (6),

springs (7), (8). (9) and (IO). and spacer (II ).
* Make match marks to prevent mistakes in the com-
bination of spool and spring.
207P432 207P433
4. Remove case assembly (12).
5. Remove set screw (13), and pull out levers (14) and
(15). then remove spools (16) and (17).
ASSEMBLY OF POC VALVE

ASSEMBLY
No. 10001 - 10880 (Except D spec.)
207P434
1. Make spools (17) and (16) into a set, then install levers
(15) and (14), and tighten set screw (I 3).
* Lock securely with wire.
2. Fit O-ring and install case assembly (12).
3. Assemble spacer (I I), springs (IO), (9), (8) and V),

spacer (6) and shim (5). then install plug (4).
t Be careful not to mistake the combination of spool
and spring.
4. Install bracket (3).
5. Fit O-ring and install bottom cover (2), then tighten

loosened nipple (I ). 207P435
207P436 207P437 207P438
2
,\
y WA600-1
REMOVAL OF PPC VALVE ASSEMBLY
a Stop the machine on level ground and install

1A
the safety bar on the frame. Lower the bucket Front of
* &Loosen the oil filler cap slowly to release the

a
426PO^ 702 426FO1202
surizing valve (IA).
1. Cover
Remove cover (1) under cab and cover (2) of con-
sole box on right side of operator’s seat.
2. Hydraulic piping
Disconnect the following hydraulic piping from the
PPC valve.
- Hose (3) between PPC pump and PPC valve
- Hoses P2 (5) and P3 (6) for lift spool
* Hoses P4 (7) and Pl (8) for dump spool
‘.
* After disconnecting the hoses, fit- .tags: to
distinguish them.
r- -x Front of
_._ ,>
math ine
426FO1221
WA600-1 63-12-l
cc
3. Linkage
I) Loosen locknut (9)
2) Disconnect linkage (10) from PPC valve.
PPC valve
Remove mounting bolts, then remove PPC valve
(11) from under floor.
* The working space is confined, so carry out the

work carefully.
WA600-1
63-12-2
13
INSTALLATION OF PPC VALVE ASSEMBLY
1. PPC valve
Set PPC valve (11) in mounting position, and
2. Linkage
1) Install linkage (10) to PPC valve.
2) Tighten locknut (9).
* Adjust the linkage.

3. Hydraulic piping
Connect the following hydraulic piping to the PPC
valve.
+ Hose (3) between PPC pump and PPC valve
- Hoses P2 (5) and P3 (6) for lift spool
- Hoses P4 (7) and PI (8) for dump spool
(Red)
426FO1221
WA600- 1 63-12-3
4. Cover
Install cover (1) under cab and console box cover
(2) at right side of operator’s compartment.

valve (1.A).

426FO1202
63-12-4 WA600- 1
!i:,
DISASSEMBLY OF PPC VALVE ASSEMBLY
[Serial No. 10881 and up (Except D spec.) ]
1. Remove bolt (1).

2. Remove plate (2).
3. Remove seal (3), then remove collar (4).
4. Remove valve assembly and center spring (7) from
valve body (IO).
5. Remove collar (ll), then remove retainer (6), shim
(12). and spring (8) from valve.
ASSEMBLY OF PPC VALVE

ASSEMBLY
8
1. Push shim (12), spring (8). and retainer (6) into

valve (9), and install collar (11).
2. Install center spring (7) and valve assembly to valve
F42101154
body (10).
3. Install spool (5).
4. Fit O-ring and install collar (4).
5. Install seal (3).
6. Fit plate (2) and install bolt (1).
m Bolt: 4.5 * 0.5 kgm
F42101155
WA600- 1
63-12-5
&
REMOVAL OF MAIN CONTROL VALVE
Serial No. 10868-10880 (Except D spec.1

the safety bar on the frame. Lower the bucket 1A
\
‘Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then oper-
t Before loosening the oil filler cap, close
pressurizing valve (IA).
426FO1201
“426~01102. 426FO1202
%x
1. Cover
Remove inspection cover (1) of front frame.
2. Hydraulic piping
Disconnect the following hydraulic piping from
main control valve.
* Tubes (2) and (3) between main control valve
and dump cylinder
+ Remove the clamp for the connection of the
hose on top of the front frame from the
bracket.
* After removing the tubes, move them to both
sides of the main control valve.
- Hoses (4) and (5) between main control valve
and lift cylinder
-
I
Pw&l
rG
-
y 426?92%, 15i; 426P9i9
L
WA600-1
63i3
Hose (6) between steering valve and main control
valve
Tube (7) between main control valve and hydrau-
iic tank
* Remove the clamp at the connection with the
hose and tie tube (7) to the top with wire.
* When moving the tube be careful not to
damage the O-ring.
3. POC (PPC) piping

POC Valve: Serial No. 10001 - 10880
r (Except 0 spec.)
PPC Valve: Serial No. 10881 and up
(Except D spec.)
i 1
Disconnect the following POC (PPC) piping from

main control valve.
- Tubes (8) and (9) between POC (PPC) valveand
dump spool piston
* Tubes (IO) and (11) between POC (PPC) valve

and wrist spool piston
- Hose (12) between main control valve and hy-
draulic tank
4. Main control valve

1) Screw eyebolts in main control valve, then using
lever block 0, raise main control valve.
* Secure the lever block firmly to the dump
cylinder.
63-14 WA600- 1
0
2) Rotate main control valve 90”, set wooden block
@ in position, then lower main control valve
on to it.
3) Raise main control valve (13) and remove to out-

side of frame.
Main control valve: 90 kg
WA600-1
INSTALLATION OF MAIN CONTROL VALVE
1. Main control valve

1) Using eyebolts, insert main control valve (IS)
inside frame and set on wooden block 0.
2) Using lever block 0, rotate main control valve

90”. set in mounting position, then tighten
mounting bolts.
2. 3C (PPC) piping
POC valve: Serial No. 10001 - 10880
(Except D spec.)
PPC valve: Serial No. 10881 and up
(Except D spec.)
Connect the following POC (PPC) piping to main

control v&e.
. Hose (12) between main control valve and hy-
draulic tank
. Tubes (10) and (11) between POC (PPC) valve
and wrist spool piston
. Tubes (8) and (9) between POC (PPC) valve and
dump spool piston
3. Hydraulic piping
Connect the following hydraulic piping to main
control valve.
* Tube (7) between main control valve and hydrau-
lic tank
* Install the clamp at the connection between
the hose and tube (7).
- Hose (6) between steering valve and main control
valve
- Hoses (4) and (5) between main control valve

and lift cylinder
* Tubes (2) and (3) between main control valve
and dump cylinder
* Install the clamp at the connection of the
hose on top of the front frame.
4. Cover
Install inspection cover (1) of front frame.
Serial No. 10001-10880

(Except D spec.)
(D spec.) (Except D spec.)
Add oil through oil filler to the specified level.
Hydraulic oil: Approx. 40 P
.*426POl!O5s
2’ ,i I’~_ /r
WA600-1
Serial No. 10868--10880 (Except D spec.)
* Tighten the oil filler cap, then open presstirizing
1A
\
426FO1201
Serial No. 10881 and UD (Except D spec.)
426FO1202
WA600-1
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE
!Serial No, 10001 and up (D spec.) 1
425F300 425F301
WA600- 1
DISASSEMBLY ASSEMBLY
1. Spool assembly 1. Assemble valve (29), seal (28) and spring (27) in
1) Remove sleeve (1) and case (2). body (30), fit O-ring and install flange (26).
2) Remove piston (3). spring (4) and retainer (5).
3) Remove springs (6). (7) and (8). and retainer (9). 2. Check valve assembly
4) Remove spools (IO) and (11). Assemble valve (25) and spring (24) in body (30),
fit O-ring and install plate (23).
2. Main relief valve assembly
1) Remove main relief valve assembly (12). 3. Selector valve assembly
* Disassemble main relief valve assembly. Fit O-ring and install selector valve assembly (22).
2) Loosen nut (13), then remove holder (14) and
Qa Selector valve: 7 ? 1 kgm
seat (15).
3) Remove snap ring (16). then remove valve (17)
4. Suction valve assembly
and spring (18) from sleeve (19).
Fit O-ring and install suction valve assembly (21).
* If there is any defect in spool or valve, replace
the whole assembly. These parts are not avail- w Suction valve: 19 + 1 kgm
able individually.
5. Safety valve assembly with suction valve

3. Safety valve assembly with suction valve Fit O-ring and install safety valve assembly (20).
Remove safety valve assembly (20).
w Safety valve: 19 + 1 kgm
Remove suction valve assembly (21). 6. Main relief valve assembly
1) Assemble valve (17) and spring (18) in sleeve
5. Selector valve assembly (19), and install snap ring (16).
Remove selector valve assembly (22). 2) Fit O-ring and backup ring and assemble seat
(15) in sleeve (19).
6. Check valve assembly 3) Screw nut (13) into holder (14), fit O-ring and
Remove plate (23), then remove spring (24) and assemble in sleeve (19), then tighten nut (13).
valve (25). 4) Fit O-ring and backup ring, then install main
relief valve assembly (12).
7. Remove flange (26), then remove spring (27), seal
m Main relief valve: 33 * 4.5 kgm
(28) and unload valve (29).
* Do not disassemble the safety valve further as the
7. Spool assembly
pressure cannot be adjusted after the valve is
1) Assemble spools (11) and (IO) in body.
installed on the machine.
2) Install retainer (9) and springs (8), (7) and (6).
3) Assemble retainer (5). spring (4) and Piston (3),
fit O-ring and install case (2) and sleeve (1).
WA600- 1
DISASSEMBLY OF MAIN CONTROL VALVE
39 43
426FOl222
1. Removal of selector valve assembly 6. Check valve assembly (39)
1) Remove hose (I), tee (2), and valve (3). Remove plate (40), then remove spring (41) and
2) Remove hose (4), tee (5), and joint (6). valve (42).
2. Spool assembly (7) 7. Unload valve assembly (43)

1) Remove sleeve (8j, then remove spacer (9), Remove flange (44), then remove spring (45), seal
spring (10). piston (ll), spring (12), and case (46), and valve (47).
(13).
2) Remove sleeve (14). then remove spacer (9),
spring (10). piston (ll), spring (15), retainer
(16), spring (17), and case (18). 8. Remove plugs (48) and (49).
3) Remove retainer (19), then remove spool (20).
3. Main relief valve assembly (21)

1) Remove main relief valve assembly (21).
2) Loosen nut (22) and remove holder (23).
3) Remove nut (24) from holder (23), then remove
screw (25). retainer (26). spring (27), spacer
(28), and poppet (29).
4) Remove seat (30) and backup ring (31) from
sleeve (32).
5) Remove snap- ring (33), then remove retainer
(34), valve (35), and spring (36).
* If there is any abnormality in sleeve (32) or valve
(35), they cannot be replaced as individual parts,
so replace the whole assembly,
-4. Safety valve assembly with suction

Remove safety valve assemblys (37) with suction,
w* The safety valve cannot be adjusted on the
machine, so do not disassemble it.

Remove suction valve assembly (38).
WA600-1
63-k9-2
,
ASSEMBLY OF MAIN CONTROL VALVE
[Serial No. 10881 and up (Except D spec.)]’
” ____I_,
44
/ I
426FO1222
6349-3 WA600-1
‘.9,
1. install plugs (49) and (48) to body (50). 8. Assemble spool assembly (7)
I) Assemble spool (20) in body (50), and install re-
w Plug (47): 7.0 + 1.0 kgm
tainer (19).
m Plug (46): 15.5 f 2.5 kgm 2) Assemble spacer (9). spring (lo), and piston (1 1)
in sleeve (14), and fit O-ring to sleeve.
3) Assemble. spring (17), retainer (16), and spring
2. Assembly of unload valve assembly (43) (15) in case (18). then fit O-ring to case, and
Assemble valve (47), seal (46), and spring (45) in install at same time as sleeve (14).
body, then fit O-ring to flange (44) and install. 4) Assemble spacer (9), spring (lo), and piston (11)
in sleeve (8). and fit O-ring to sleeve.
5) Assemble spring (12) in case (13), then fit O-ring
3. Assembly of check valve assembly (39) and install at same time as sleeve (8).
Assemble valve (42) and spring (41) in body, then
fit O-ring to plate (40) and install.
9. Installation of selector valve assembly
1) Fit joint (6)‘ tee (5), and hose (4) to body, and
4. Suction valve assembly (38) connect to elbow.
Install suction valve (38) to body. 2) Fit valve (3), tee (2), and hose (1) to body, and
connect to elbow.
m Suction valve: 19.0 f 1 kgm
m Valve : 7 ? 1 .O kgm
D Tee : 3.5 rt 0.5 kgm

5. Safety valve assembly (37) with suction
Install safety valves (37). w Hose : 5.0 + 2.0 kgm
* The safety valve cannot be adjusted on the ma-
w Joint : 3.5 ? 0.5 kgm
chine, so do not disassemble it.
w Safety valve: 19.0 ?I 1.0 kgm
6. Assembly of main relief valve assembly (21)

Assemble spring (36). valve (35), and retainer
(34) in sleeve (32). then install snap ring (33).
Install O-ring and backup spring (51) to sleeve
(32).
Install O-ring and backup ring (31) to seat (JO).
then assemble in sleeve (32).
Assemble poppet (29), spacer (28), spring (27),
retainer (26). and screw (25) in holder (23). then
fit O-ring to holder, tighten nut (22), fit O-ring
and install nut (24).
7. install main relief valve assembly (21).
w Main relief valve: 33.0 + 4.5 kgm
WA600-1 63-19-4
@
REMOVAL OF DUMP CYLINDER
Serial No. 10868-10880 (Except D 5Pec.j
Serial No. 10868 and up (D 5Pec.j
Special tools
Part number Part name O’ty
A 790-101-1102 Pump 1
B 790-101-2102 Puller 1
C / 791-735-1001 / Remover I 1
426FO1201
c4 791-112-1180 Nut 1

mN Loosen the oil filler cap slowly to release the

surizing valve (IA). (Serial No. 10868 and up) 426FO1202
1. Bucket positioner wiring

Disconnect wiring (1) from connector, and remove
clamp (2).
2. Grease tube
1) Disconnect tube (3) from bottom pin, and re-
move nipple.
* Check the angle of the grease nipple.
2) Disconnect hose (4) from rod pin.
* Remove the grease nipple.
. I
426P940
67;?0 WA600-1
ji
3. Hydraulic piping
2) Disconnect hose (6) at bottom end from tube at
body end.
4. Dump cylinder
1) Using lever block 0, lock bellcrank and front
axle:
2) Sling cylinder, and remove lockbolt. Set tools A,

B and C on rod mounting pin (7) and bottom
mounting pin (81, and pull out slowly.until they
come out of cylinder.
* full the pin out slowly, and leave it in the
frame and bellcrank.
* If there are shims at the bottom end, check
the number and thickness of the shims, and
keep in a safe place.
* When slinging, lift at two points and be care-
ful about the center of gravity.
ToA
426F380
WA600-1
63621
3) Lift off dump cylinder (9).
* Be careful not to damage the cylinder rod.
,-i
m Dump cylinder: 520 kg
5. Cylinder pin
1) Lift off bottom pin (8).
Bottom pin: 42 kg
2) Lift off rod pin (7).
Rod pin: 45 kg
63-%’
-’‘_,
WA600-1
INSTALLATION OF DUMP CYLINDER
1. Cylinder pin
1) Raise rod pin (7) and insert in bellcrank.
2) Raise bottom pin (8) and insert in front frame.
* insert each pin to the face of the bellcrank
and frame and make sure that the pins do not
protrude from the cylinder mounts.
426P945
2. Dump cylinder
1) Raise dump cylinder (9) and set in mounting
position.
2) Insert rod mounting pin (7) and bottom mount-

ing pin (8), and tighten lockbolts.
A Usea bar to align the pin holes. Never

use your fingers.
* Align the bottom pin hole and assemble shims

so that the total clearance “a, b” between the
cylinder and frame is within the standard
value.
426F381 A
3) Remove lever block @ holding bellcrank and

front axle.
42
63-22
‘5j.l
3. Hydraulic piping
1) Connect hose (6) at bottom end to tube at body
end.
2) Connect hose (5) at rod end to cylinder.
* F’it the O-ring securely in the groove.
* Install the hose without twisting or inter-
ference.
4. Grease tube
1) Connect hose (4) to rod pin.
* Install the grease nipple.
2) Install nipple, and connect tube (3) to bottom
pin.
/
,A”
\
\
4 !-..
426P940
5. Bucket positioner wiring

Connect wiring (1) to connector, and install clamp
(2).
6. Tighten the oil filler cap, then open pressurizing

valve (1A). (Serial No. 10868 and up)

Serial No. 10868 and up (D spec.) Serial No. 10881 and up (Except D spec.)
1A
Front of ,:
426FO1201 426PO17 02 426FO1202

-
WA600-1 63-23
g$
REMOVAL OF LIFT CYLINDER
Special tools
A 790-I 01-l 102 Pump 1
B 790-101-2102 Puller 1
C 791-735-l 001 Remover 1
Cl 790-438-l 070 Sleeve 1
c2 791-739-1110 Adapter 1
c3 790-438-I 110 Screw 1
c4 790-l 12-1180 Nut 1

A Stop the machine
Lower the bucket
1. Fender
Lift off fender (1).
ke
rcllil Fender: 47 kg
2. Grease hose
Disconnect grease hose (2) of rod pin.
To A
3. FIC ,d pin
1 Sling lift cylinder (3), and remove lockbolt. Set
tools A, B and C on rod mounting pin (4) and
pull out slowly until it comes out of cylinder.
* Lift off mounting pin (4).
Mounting pin: 27 kg
2) Start engine, and operate control lever to retract

cylinder rod on side where pin was removed.
* Set a wooden block between the frame and
cylinder, and lower the cylinder.
426F382
63GF4 WA600- 1
i/
* k Loosen the oil filler cap slowly to release the
a
+ pressure inside the hydraulic tank. Then oper-
426FO1201
426FO1202
4. Hydraulic piping
* Loosen the bracket of the tube.
2) Disconnect hose (6) at bottom end from cylin-
der.
5. Bottom pin
Set tools A, B and C on bottom mounting pin (7),
and pull out slowly until it comes out of cylinder.
* Adjust the height and set a wooden block under
the cylinder.
* Lift off mounting pin.
&B ottom pin: 54 kg
WA600-1
6. Lift cylinder
1) Using lever block 0, raise lift cylinder (3).
‘L-e&
/-1 Lift cylinder: 412 kg
2j Using lever block, raise bottom end until it is

horizontal, then lift off cylinder (3) from front
end.
63-26 WA600-1
9
INSTALLATION OF LIFT CYLINDER
1. Lift cylinder
1) Using lever block @ to adjust height, raise lift
cylinder (3) and set in mounting position.
2) Select shim to bring total clearance “a, b” be-

tween cylinder and frame within specified range.
426F383
3) Assemble shim, and using lever block 0, align

with hole of pin.

use your fingers.
Never
2. Bottom pin
Assemble bottom mounting pin (7). and lock with
bolt.
WA600-1
3. Hydraulic piping,
1) Connect hose (6) at bottom end to cylinder.
2) Connect hose (5) at rod end to tube.
* Tighten the bracket of the tube.
* Be careful not to get the O-ring caught.
4. Rod pin
1) Sling cylinder (3), and run the engine, then oper-
ate control lever to extend rod and align pin
hole.
Serial No. 10868-I 0880 (Except D spec.)

ing valve (IA). (Serial No. 10868 and up) IA
A Use a bar to align the pin holes. Never \ Ooen

use your fingers.
2) Assemble mounting pin (4), and lock with bolt.
426FO1201
Serial No. 10881 and up (Except D WC.)
426FO1202
63-$7-1
WA600-1
5. Grease hose
Connect grease hose (2) to rod pin.
6. Fender
Install fender (1).
WA600- 1 63-27-2
0
DISASSEMBLY OF LIFT CYLINDER AND DUMP CYLINDER
ASSEMBLY
Special tool
Part number Part name 1 Q’ty 3

/ I
A 790-502-I 001 Unit repair stand 1
1. Cylinder assembly
1) Set cylinder assembly (1) on repair stand A.
2) Remove head cover mounting bolts (4).
* Set a container under the cylinder to catch
the oil.
3) Lift off piston rod (5).

* Remove the cylinder from the repair stand.
,
1: i$ -1 Dump cylinder piston rod assembly:
220 kg
‘/kg
F? Lift cylinder piston rod assembly:
200 kg
* Remove cylinder from the repair stand.
f97Pk263
2. Cylinder rod
1) Set piston rod (5) on repair stand A.
2) Remove spacer mounting bolts, then remove
spacer (6).
3) Pull out piston (7).
4) Remove backup rings (8) and (9) and O-ring (10)

from rod.
5) Raise head cover (11) and pull out from rod.
.!
kg ’ Dump cylinder head cover: 66 kg
A
: kg . Lift cylinder head cover: 36 kg
63-28 WA600- 1
:!
3. Piston
1) Remove wear ring (12).
2) Remove piston ring (13).
4. Head cover
1) Remove O-ring (14) and backup ring (15).
2) Remove snap ring (16). then remove seal (17)
and bushing (18) and packing (19) from head
cover (11).
18
197P1270
I97F379
WA600- 1 63-29
@
ASSEMBLY OF LIFT CYLINDER AND DUMP CYLINDER
ASSEMBLY
A 790-502-I 001 Unit repair stand 1

installing.
I97F379
1. Head cover
1) Press fit packing (19), bushing (18) andseal (17)
in head cover (1 I), then install snap ring (16).
2) Install backup ring (15) and O-ring (14) to head
cover (11).
* Warm, the backup ring in warm water (50 -
6O’C) before fitting it.
2. Piston
1) Set piston ring (13) in tool B, and expand.
* Set the piston ring on the expander and turn
the handle 8 - 10 times to expand the ring.
2) Remove piston ring (13) from tool B, then install
to piston (7).
3) Set ring C in position, then using clamp @ ,
compress piston ring (13).
* Ring part No.
796-720-l 710 (Lift cylinder)
796-720-l 720 (Dump cylinder)
* Clamp part No.
197Pi272
07281-02429 (Lift cylinder)
07281-02909 (Dump cylinder)
I97F377
63&yo WA600- 1
4) Install wear ring (12) to piston (7).
3. Cylinder rod
1) Set piston rod on repair stand.
2) Raise head cover (II), and install to rod.
3) Install O-ring (IO), backup rings (9) and (8) to
rod.
* Coat the O-ring and backup rings with grease.
4) Install piston (7).

5) Set spacer (6) in position, then tighten spacer
mounting bolts.
* After tightening spacer mounting bolt, leave it

for min. 30 minutes.
* Remove the piston rod from the repair stand.
4. Cylinder assembly
1) Set cylinder on repair stand.
2) Assemble piston rod (5) in cylinder.
3) Tighten head cover mounting bolts (4).
* Coat the O-ring and backup ring on the cover
side with grease.
* The mounting bolts are long, so be careful
about selecting the place to install them.
m Dump cylinder mounting bolt:

200 * 20 kgm
w Lift cylinder mounting bolt:

94.5 t 10.5 kgm
(Width across flats : 36mm)
4) Remove cylinder assembly (1) from repair stand

A.
WA600- 1 63-31
/.
id
2
REMOVAL OF WORK EQUIPMENT
Part’number Part name Q’ty
790-101-1002 Pump 1
A ~
B ~ 790-101-2102 Puller 1
c I 791-735-1001 Remover
I ’
Cl / 790-438-I 070 Sleeve
I 1
c2 I
790-438-I 090 / Sleeve I ’
C3 1 791-739-11 IO 1 Adapter I ’
C4 1 790-438-1110 / Screw I ’
Cs 1 791-112-1180 / Nut I 1
C6 790-438-l 080 Adapter 1
c7 101016-31670 Bolt 3

moving.
1. Bucket link
1) Remove retainer (I).
* If there are shims between the retainer and
bucket, check the number and thickness of
the shims to act as a guide when assembling.
2) Remove mounting bolts of flange (2).
* Remove the left and right flange bolts.
3) Remove pin stopper bolt (3) and cam (4).
4) Sling bucket link (5), set tools A, B and C on

mounting pin (6). and pull out slowly until it
comes out of bucket link. ,
* Use tool C, for the sleeve.
&] Mounting pin: 45 kg
6
426F384
63&32 ‘< /
WA600- 1
2. Bucket
* If there are shims between the retainer and
bucket, check the number and thickness of
the shims to act as a guide when assembling.
426P962
2) Remove mounting bolts of flange (8).

* Remove the left and right flange bolts.
3) Remove pin stopper bolt (9) and cam (10).
4) Set tools A, B and C on mounting pin, and pull

out slowly until it comes out of lift arm.
* Use tool C, for the sleeve.
* Remove the left and right mounting pins.
&zlkg Mounting pin: 37 kg
5) Move machine to rear, and disconnect bucket.
3. Flange
1) Remove flange (12) from bucket link and lift
arm.
WA600- 1 63-33
@
2) Remove dust seal (13), oil seal (14) and O-ring
(15) from flange (12).
t Serial No. 10759 and up: Dust seal (13) only
Serial No. 10001-10758 Serial No. 10759 and up
15 426P967
13 14
426F385 425F401 A
4. Dump cylinder
1) Using lever block @ , secure bellcrank to front
axle.
* This is to prevent the bellcrank from falling
towards the machine when the dump cylinder
pin is removed.
2) Sling dump cylinder (16), set tools A, B and Con

mounting pin (17). and pull out mounting pin
slowly to disconnect cylinder rod and bellcrank.
* Use C, for the sleeve.
* Remove the grease hose from the pin, then re-
move the nipple.
* Do not pull the pin out completely. Pull it
until it comes out of the cylinder rod, then in-
sert it into the mount and secure with the
lock bolt to use it again when removing the
bellcrank.
426P969
& Dump cylinder: 520 kg
3) Insert block @ between front frame and bot-

tom of dump cylinder to hold in position.
* For safety reasons, secure the dump cylinder
and frame with a chain also.
426P970
5. Lift cylinder pin
1) Disconnect grease hose (18) from mounting pin.
2) Sling lift cylinder (19), set tools A, B and C on
mounting pin (20), and pull out mounting pin
slowly to disconnect lift cylinder and lift arm.
* Remove the pins on both the left and right
sides, set wooden blocks on the front frame,
then lower the lift cylinder on to the frame.
* Remove the mounting pin.
[e Lift cylinder: 412 kg
F- a Mounting pin: 27 kg
6. Bellcrank
1) Sling bucket link (21), set tools A, B and C on
mounting pin (22). and pull out mounting pin
slowly to disconnect from bellcrank.
* There is a cord ring installed in the connec-
tion, so remove it.
* Do not remove the mounting pin completely.
Lift it off after removing the bucket link.
kg Bucket link: 147 kg

6
Mounting pin: 45 kg
&zIkg
2) Set tools A, B and C on mounting pin (23), and

pull out mounting pin slowly to disconnect bell-
crank (24) from lift arm.
* Use tool Cz for the sleeve.
t Do not remove mounting pin (23) completely.
Lift it off after removing the bellcrank.
* Remove the lever block holding the bell-
crank and front axle.
Bellcrank: 842 kg
( Mounting pin: 98 kg
426P975
WA&O- 1
7. Lift arm
1) Remove boom kick-out switch (25).
* Remove the switch after removing the cover.
3) Sling lift arm (30). set tools A, 6 and C on

mounting pin (31). pull out mounting pin slowly,
then lift off lift arm.
* There are shims at the connection of the front
frame and lift arm, so check the number and
thickness of the shims, and keep in a safe
place.
* Remove the mounting pin after removing the
lift arm.
r!IT?l
kg Lift arm: 2940 kg
Mounting pin: 54 kg
8. Dust seal, bushing

1) Pull out bushing (31) from lift arm (30).
* Remove the dust seals from the connection of
the lift cylinder and the lift arm and frame.
426P980
I 426F386
63-36 WA600- 1
(12;
2) Pull out dust seal (32) and bushing (33) from
bellcrank (24).
3) Pull out dust seal (34) and bushing (35) from 426F387
bucket link (21).

Remove only the dust seal at the connection
of the bellcrank.
After using for a long time, if wear of the pin

makes it difficult to remove the pin, make a
jig such as the one shown below, and use it to
remove the pin.
428F388
426F384A
3-16~2Depth30
Perforation depth 40
(circumference of equal parts)
\
\ /
Dimension of pin hole
(For adapter mounting bolt) <
427F2053
WA600-1
INSTALLATION OF WORK EQUIPMENT
c
! Use a bar to
your fingers.
align the pin holes. Never use
Part number _ Part name I Q’ty
A / 790-101-5401 1 Pusher tool I 1
426P980
Hydraulic cylinder
1. Dust seal, bushing Lift arm
Using a press, press fit bushings (31) and dust seals

to bucket link, bellcrank, and lift arm.
us
* Assemble the dust seals so that the seal lip faces
the outside.
& Bushing: Grease (G2-LI)
426F389
2. Lift arm
1) Raise lift arm (30), set in mounting position,
then assemble mounting pin, and lock with
bolts.
* Align the holes of the front frame and lift arm
mounts, then insert shims so that clearance
“a” is equal on the left and right.
* Clearance “a”: Max. 1.5 mm
* After installing the pin, set a support under
the tip of the lift arm.
--4--a --H--a
426F390
2) Install grease nipples (28) and (29), andconnect

hoses (26) and (27).
63-38 WA600-1
g
3) Install boom kick-out switch (25).
* For details of adjustment procedure, see
TESTING AND ADJUSTMENT.
3. Bellcrank
1) Raise bellcrank (24). set in mounting position,
then assemble mounting pin (23), and lock with
bolts.
* Raise the mounting pin and set it in position
on the frame, then push it in until it is level
with the surface of the frame.
426P975
2) Raise bucket link (21) and set in mounting posi-

tion, then install mounting pin (22).
* Raise the mounting pin and set it in position
on the bellcrank, then push it in until it is
level with the surface of the bellcrank.
3) Insert cord ring (36) in groove.

* Pull the cord ring slightly when inserting it in
the groove.
4) Insert bolts (37) in cord ring to secure it.
* Tighten the bolts, but stop when the cord ring
starts to deform.
WA600- 1
5) Using lever block @ , secure bellcrank to front
axle.
4. Lift cylinder pin

1) Raise lift cylinder (19), align lift arm holes, then
install mounting pin (20) and lock with bolt.
2) Connect grease hose (18) to mounting pin.
5. Dump cylinder
Raise dump cylinder (16). and set in mounting posi-
tion. Operate lever block and hoist crane to align
pin holes, then install mounting pin (17) and lock
with bolt.
+ Raise the mounting pin and set it in position on
the bellcrank, then push it in until it is level with
the surface of the bellcrank.
* Install the grease nipple, and connect the hose to
the pin.
* Remove the lever block.
426P969
63-40 WA600-1
r\,
_A
6
6. Flange Serial No. 10001-10758
I) Using tools AI, AZ, A3 and B, press-fitting oil
The+ must ba
seal (14). dust seal (13) to flange (12) then install no clearance
O-ring (15).
Serial No. 10759 and up: Dust seal (13) only
Press-fitting tools
* Bucket link. . . Al (Clip), As (Bolt)

B (Plate)
* Lift arm . . . . . . AI (Clip), AZ (Bolt)
As (Plate)
Be careful to fit the dust seal and O-ring with

the lip facing in the correct direction, and
426F391 426F394
press fit uniformly around the circumference.
Check that there is no clearance between the
dust seal and oil seal.
Check that the dust seal does not protrude Press-fitting
from the end face of the flange. dimension:
0.25-0.8 mm
Dust seal press-fitting dimension -
(Serial No. 10001-10758): O-O.5 mm

(Serial No. 10759 and up) : 0.25-0.8 mm
Oil seal press-fitting dimension
(Serial No. 10001-10758): 8 mm
& Lip of oil seal, O-ring: Grease (G2-Li)
425F402A
2) Assemble flange (8) to pin (II), and insert in lift

arm and bucket link.
* Insert the pin slowly until the flange seal con-
tacts the bushing.
& Bushing circumference: Grease (G2-LI)
3) Using pin as a guide, rotate flange to left and

right by hand and insert into lift arm and bucket
link.
After inserting, rotate the flange 2 or 3 times
by hand to settle the contact of the seal.
Pull the flange out about 5 mm from the lift
arm and check that there is no abnormality in
the dust seal.
Insert the flange until the inside surface con-
tacts the end face of the bushing, then tilt the
mounting bolt hole part of the flange about
25’ towards the rear of the lift arm.
Never hit the flange with a hammer.
Repeat the same procedure for the other
flanges.
426P985
WA600- 1 63-41
@
7. Bucket
1) Bring bucket and lift arm together, operate con-
trol lever to align bucket mounting pin holes,
then insert pin.
* When doing this, be careful not to let the
bucket hit the flange.
* When installing the pin, check that the air
bleed hole on the pin is at the top.
* Align the flange bolt holes and the mounting
bolt holes of the bucket flange.
2) Select shim
Serial No. 10001-10758
(Serial No. 10001-10758)
Push flange (8) evenly towards boss of lift arm
and measure clearance “c”. Assemble shims so
that clearance is within standard value.
* Clearance “c”: 0.2 mm
* When selecting the shim, measure clearance
“c” for both the top and bottom split shims,
assemble the most suitable shim for each, and
be careful that the flange is not at an angle.
w Flange mounting bolt: 28.5 + 3.0 kgm
426F392
(Serial No. 10759 and up) Serial No . 10759 and up

After selecting the number of shims to make the %
clearance at the lift arm boss (* mark) less than
0.5 mm, remove two 0.5 mm shims and install
flange (8) so that ,the clearance (* mark) is
1.5 mm.
* When selecting the shim, measure clearance
for both the top and bottom split shims, as-
semble the most suitable shim for each, and
be careful that the flange is not at an angle.
Shim -.--l-A 425F404
3) Tighten bolt (9) temporarily so that can (10)

contacts mounting pin.
* Tighten fully after installing retainer (7).
w Mounting bolt: 94.5 i 10.5 kgm

4) Install retainer (7), and measure clearance “d”.
Assemble shims so that clearance is within stand-
ard value.
* Clearance “d”: Max. 0.2 mm
Clearance db
II,. ‘i I I
426F393
8. Bucket link
Raise bucket link (51, align hole of mounting pin
(6), then insert pin.
* Be careful not to let the bucket hit the flange.
* The remaining procedure is the same as for the
bucket pin.
9. Refilling with oil (Serial No. 10001-10758)

1) Remove bolt (38) in middle between bucket pin
and bucket link, and add oil to the specified
level.
* Before adding oil, remove air bleed bolt (39).
* After adding oil, check that there are O-rings
fitted to bolts (38) and (39). then install the
bolts.
a Pin oil: Gear oil (G0140)
%k Pin oil: Approx. 100 cc
2) Grease each pin.
IO. Greasing (Serial No. 10759 and up)

1) Grease bucket pin from grease fitting in center of
pin, and bucket link from grease fitting in link.
Add grease until grease comes out from dust seal.
&?YY Bucket pivot portion: Grease (G2-LI)
& Bucket link portion : Grease (G2-LI)
2) Grease each pin.
WA600-1
REMOVAL OF COUNTERWEIGHT

1
moving.
1. Radiator grille
Remove radiator grille (l), and open engine inspec-
tion panel (2).
* Open both left and right covers.
426P994
2. Radiator guard
1) Sling engine hood (3), and remove mounting
bolts holding it to radiator guard.
* Remove the door catch of the engine inspec-
tion panel.
* Be careful not to raise the engine hood too
far.
4258995
2) Disconnect electric wiring (4) and (5) from con-

nector.
* After disconnecting the radiator water level
sensor wiring, move the connector towards
the radiator.
3) Remove mounting bolts of radiator guard (6),

then move it towards rear of machine. (Approx.
50 mm)
4268998
WA600-1 63-43
@
426P999
3. Counterweight
Sling counterweight (7), remove mounting bolts,
then lift off.
* Be careful of the lamps when removing the
counterweight.
m Counterweight: 2170 kg (Serial No.

10001-10068)
2314 kg (Serial No.
10069 and up)
426PFOOO
63-44 WA600- 1
0
INSTALLATION OF COUNTERWEIGHT
1. Counterweight
Raise counterweight (7), set in mounting position,
and tighten mounting bolts.
Mounting bolt: 175 t 20 kgm

(Serial No.10001 - 10581,
10587 - 10590)
Mounting bolt: 280 * 30 kgm I

(Serial No. 10582 - 10586,10591 and up)
426PlOOO
2. Radiator guard
1) Raise radiator guard (6), and set about 50 mm to
rear of mounting position.
2) Sling engine hood (3), move radiator guard (6)

to mounting position, then tighten mounting
bolts temporarily.
* Tighten fully after installing the engine hood.
* Be careful not to raise the engine hood too
far.
WA600- 1
4) Tighten mounting bolts of engine hood (3) and
radiator guard.
* Install the door catch of the engine inspection
panel.
* Tighten the radiator guard mounting bolts
fully.
426P995
3. Radiator grille
Close engine inspection panel (21, and install radia-
tor grille (1).
426P994
63-46 WA600- 1
,-2
_/
WORK EQUIPMENT SYSTEM
Bucket linkage .. . :. . .. 64-

64-
64-
. 64-
Main control valve ... _. . 64-
POCvalve .._.................. 64-12
PPC valve . . _. . . . . _. . . . . . . . . . . . . . . 64-12
Dump cylinder . . . . . . . . . . . . . . . . _. . 64-16
Lift cylinder . _. . _. . _. _. . 64-17
WA600- 1 64 1
0
BUCKET LINKAGE
FO42601003
Serial No. 10001-10758 Serial No. 10759 and up Serial No. 10001-10758 Serial No. 10759 and UP
(Oil type) (Grease type) (Oil type) (Grease type)
11 12 12
?
/ /
2,
a’ a ‘b a’ b a’ b
Section A - A Section A - A Section B - B Section B - B
13 15 16
/
a b a b a b a b
Section C - C Section D - D Section E - E Section F - F
10 17
7.
a’ b a b
‘b
Section G - G Section H - H Section J - J
426F200-1
64-2 WA600- 1
@
Unit: mm
NO Check item Criteria Remedy
Tolerance
Clearance between pin and bushing Shaft Hole
1
at boss ends of bucket link
-0.043 +0.395 0.338 -
140 1 .o
-0.106 +0.295 0.501
Clearance between pin and bushing -0.043 +0.395 0.338 -

2 125 1.0
at joint of lift arm and bucket -0.106 +0.295 0.501
Clearance between pin and bushing -0.043 / +0.395 0.338 -

3 140 1 .o
at joint of lift arm and frame -0.106 +0.295 0.501 Replace also if
other parts are
Clearance between pin and bushing biting into pin
-0.043 +0.395 0.338 -
4 at joint of dump cylinder bottom 140 1 .o
-0.106 +0.295 0.501
and frame

5 at joint of dump cylinder rod and 140 1 .o
-0.106 +0.295 0.501
tilt lever

6 160 1 .o
at joint of tilt lever and lift arm -0.106 +0.295 0.501
Clearance between pin and bushing

7 -0.043 +0.395 0.338 -
at joint of lift cylinder bottom and 140 1 .o
-0.106 +0.295 0.501
frame
Clearance between pin and bushing

a at joint of lift cylinder rod and lift 125
-0.043 +0.395 0.338 -
1 .o
-0.106 +0.295 0.501
arm
Joint of dump cylinder and frame
Insert shims on
both sides to
make clearance
BUCKET
Section B--B
Section A-A ‘3 FO42601004
Unit: mm
1
r1 Wear of bucket tooth
I Standard size I Repair limit I
Replace
68 40
I I I
Thickness of shims for tooth
2 Max. 0.5 Adjust
(Clearance between tooth and bucket)
I
Tightening torque of mounting bolt for
3 290 + 30 kgm
bucket tooth
Retighten
4 290 t 30 kgm
corner tooth
64-4 WA600- 1
9’
,../
BUCKET POSITIONER AND BOOM KICK-OUT
View V
2’
View Z
426F202
Unit: mm
1 Clearance of bucket positioner switch 3-5

Adjust
2 Clearance of boom kick-out switch 3-5
Tightening torque of mounting bolt for 9.0 c 3.5 kgm

3
adjuster
Retighten
4 1.8 ? 0.2 kgm
switch
WA600- 1 64-5
@
HYDRAULIC PUMP
SAR250 (Hydraulic) + SAR125 (Steering) -I- SAR20 (POC (FTC) pump)
1’ .m16-2Okgm w 10 - 12.5 kg;
426F204A
unit: mm
No
Side clearance
Clearance between inside dia-

meter of plain bearing and out-
side diameter of gear shaft
Discharge
Oil: EOlO-CD
Temperature: 45 - 55’~
Model Standard size Tolerance Repair limit
0
SAR250 21
-0.5
SAR125 0 -
21
-0.5
0 -
SAR20 10
-0.5
-
5 Rotating torque of spline shaft 2.2 - 3.5 kgm
WA600-1
SAR125 (Transmission lubrication) + SARlOO (Torque converter charging) -I SAN00 (Switch pump)
2 1 -16-2Okgm /if/m’ 1 \
2 1 25-31.5kgm 2 -25-31.5kgm
426F205B
Unit: mm
-
NO
-
1 Side clearance
-
2
-
Discharge
3 Oil: EOlO-CD
Temperature 45 - 55’C
SAR125 21 -
-:.5
0 -
SARlOO 14
-0.5
5 Rotating torque of spline shaft 2.4 - 3.9 kgm _
WA600- 1 64-7
a
MAIN CONTROL VALVE

Section A-A Section C-C
Section D - D
Section B-B
Section E - E
425F163
WA600- 1
Unit: mm
Free Installation Installation Free lnstailatron

1 Spool return spring
length 1 length load length load
83.8 82.0 7.7 kg 83.4 6.2 kg
2 Spool return spring 84.1 ’ 82.0 9.9 kg 83.7 7.9 kg
3 Spool return spring 63.0 60.5 23.5 kg 62.5 18.8 kg
4 Spool return spring 25.1 / 17.5 23.5 kg 23.6 18.8 kg
I
5 Main valve spring 52.3 j 38.0 2.6 kg - - Replace
/
I
6 Check valwspring 78.2 52.0 1.92 kg - -
7 Suction valve spring of safety valve 27.9 18.1 0.69 kg - -
8 Suction valve spring 27.9 19.0 0.65 kg - -
9 Float selector valve spring 44.4 35.6 9.85 kg - -
10 Unloader valve spring 82.7 47.0 5.0 kg - _
11 Relief valve poppet spring , 49.3 43.3 21.4 kg _ -
12 Tightening torque of check valve-bolt 9.0 2 1 .O kgm
13 Tightening torque of suction valve 19.0 i 1.0 kgm
14 Tightening torque of main relief valve 32.75 ? 4.75 kgm
15 Tightening torque of float selector valve 7.0 ? 1 .O kgm
Retighten
16 Tightening torque of safety valve 19.0 * 1.0 kgm
17 .. Tightening torque of nipple 2.25 t 0.25 kgm
18 Tightening torque of plug 15.5 t 2.5 kgm
19 Tightening torque of sleeve 2.5 t 0.5 kgm
WA600-1 64-9
w
15.5i25 kgm ~
w
19il kgm
13
/
i 12 %gm zO.025 kgm
w
19il kgm
‘P ,
‘\
\
F42601024
WA600-1
Unit: mm
Standard sue Repair limit

1 Spool return spring length length load length load
64.4 63.1 11.5 kg - 9.2 kg
2 Spool return spring 18.6 14.9 11.5kg - 9.2 kg
3 Spool return spring 64.4 63.1 11.5kg - 9.2 kg
4 Spool return spring 18.6 14.9 11.5 kg - 9.2 kg
5 Spool return spring 89.2 82.0 62.8 kg - 60.8 kg
6 Spool return spring 83.3 82.0 10.35 kg - 8.3 kg Replace
7 Spool return spring 42.0 42.0 0 -
8 Main valve spring 52.3 38.0 8.8 kg - 7.0 kg
9 Check valve spring 78.2 52.0 1.92 kg - 1.5 kg
10 Suction valve spring of safety valve 27.9 18.0 0.70 kg 0.6 kg
11 Suction valve spring 27.9 18.0 0.70 kg - 0.6 kg
12 Float selector valve spring 53.0 40.1 16.5 kg - 13.2 kg
13 Unloader valve spring 82.7 47.0 5.0 kg - 4.0 kg

I I
14 Relief valve poppet spring 49.3 43.3 21.4 kg - 17.1 kg
WA600-1 64-l 1
0
POC VALVE

1 5 6 3 421F155
Unit: mm

1 Spool return spring length load
length length load
57.3 33 8.0 kg 6.4 kg Replace if

damaged or
deformed.
2 Spool return spring 57.3 33 8.0 kg 6.4 kg
3 Spool return spring 33.8 31 1.5 kg - 1.2 kg
4 Spool return spring 33.8 31 1.5 kg - 1.2 kg
5 Tightening tqrque of plug ‘0.75 * 0.15 kgm

I
6 Tightening torque of plug 0.75 i 0.15 kgm
7 Tightening torque of set screw 2.25 * 0.25 kgm Retighten
8 Tightening torque of lock nut 2.25 ? 0.25 kgm
9 Tightening torque of plug 0.75 * 0.15 kgm
Free Installation Installation Free Installation Replace

10 Main valve Spring length length load length load if damaged
or deformed.
47 26 2.1 kg -
11 Poppet spring 33.6 30.5 5.97 kg 33 4.8 kg Replace
12 Set presssure 30 kg/cm’ Adjust
64-l 2 WA600- 1
cs,
PPC VALVE
4.5+0.5kgm
1.8 2 0.4 kgm
I I I
421FO1075
WA600- 1
Unit: mm
Centering spring Free Installation Installation Free Installation

1
(for bucket dump and lift lower) length length load length load
52.8 36.0 3.0 kg - 2.4 kg

-
Centering spring -
2
[for bucket tilt and lift raise) 52.8 36.0 4.0 kg 3.2 kg Replace if
damaged of
Spring 31.4 29.4 1.7 kg - 1.4 kg deformed
3
4 Main valve spring 47 26.0 2.1 kg - -

-
5 Poppet spring 33.6 29.7 7.5 kg 33 4.8 kg
6 Set pressure 38 kg/cm> Adjust
WA600- 1
DUMP CYLINDER
426F195
Unit: mm
. Clearance between rod and

’ bushing I
-
140 -0.034 io.277 0.095 0.720
-0.143 +0.061 0.42
Replace
2 Clearance between piston rod 140 -0.043 +0.395 0.338 - 1 .o bushing
mounting pin and bushing -0.106 +0.295 0.501
-
3 Clearance between cylinder 140 -0.043 +0.395 0.338 1 .o
bottom mounting pin and bushing -0.106 +0.295 0.501
4 Cylinder bore +0.35 - -

280 Replace
0
Tightening torque of cylinder

5 200 i 20 kgm
head mounting bolt
Retighten
Tightening torque of piston
6 18t2kgm
mounting bolt
64-l 6 WA600-1
/-
&
_
LIFT CYLINDER
426F196
Unit: mm
Tolerance
Standard Standard Cleararice
Clearance between rod and size clearance limit
1 Shaft Hole
bushing
1 , I I
I 1 I
I I 120 -0.123
-0.036 + 0.062
+0.277 0.0980.40- 0.700
I Replace
bushing
Clearance between piston rod -
2 mounting pin and inside diameter 125 -0.043 +0.30 0.338 -
of hole -0.106 10.20 0.501
3 Clearance between cylinder bottom 140 -0.043 + 0.395 0.338 -

mounting pin and bushing -0.106 + 0.295 0.501 1 .o
,
_ +0.30 - -
4 Cylinder bore 225 Replace
0
Tightening torque of cylinder head

5 94.5 I 10.5 kgm
mounting bolt
. Retighten
Tightening torque of piston
6 18i2kgm
mounting bolt
WA600-1 64-17
g;:
ELECTRIC AND ELECTRONIC SYSTEM
8x STRUCTURE AND FUNCTION
Electrical wiring diagram circuit.. .............. .81- 3

Electrical wiring diagram circuit
(Machine with joystick steering). .............. .81-6-7
Engine starting circuit ................................. 81- 7
Engine stop circuit.. ................................... .81-8-l
Electrical transmission control ................... 81- 9
l Combination switch ................................. 81-11
l Transmission cut-off switch.. .................. .81-12
l Transmission cut-off selector witch ....... .81-13
. Neutralizer relay ................................... .81-13-2
l Kick-down switch ................................. .81-13-4
l Kick-down electric circuit.. ................... .81-13-5
Electrical parking brake control ................. .81-14
Contact switch ............................................. 81-23
Auto priming system (APS) ....................... .81-28
Electronic vehicle monitoring system
(EVMS) ...................................................... 81-33
. Monitor panel ........................................... 81-33
. Indication on monitor panel ................... .81-37
. Wiring harness ......................................... 81-39
. Controller .................................................. 81-41
l Sensors ..................................................... 81-42
WA600- 1 81-1
0
Serial No. 10343-10494
426FOlC01
-t L
-
‘
426FO1002
WA600- 1
*2-’
------------ ____p_-----
..._..
426F81003
I
81-6-3
I
I 0
WA600-1
.---.- ---- ...-__

YO”l,O. Pcd
81-6-4
@
F42601025
__--_-
“,~1,,O,~“.,d n.,n.u
_ -..______--
_~.I______
F42601026
81-6-5
WA600-1
(7)
ENGINE STARTING CIRCUIT
Serial No. 10001 - 10342
FUNCTION OPERATION
To ensure safety when starting the engine, a neutral * When the directional lever is placed in neutral, the
safety circuit is installed. With this circuit, it is im- neutral contacts of the directional lever switch are
possible to start the engine if the directional lever is closed.
not at N (neutral). In this condition, when the starting switch is turned
to START, electric current flows in circuit (I):
Battery (+) - starting switch terminal B + starting
switch terminal C + starting motor terminal C +
starting motor terminal E + directional lever switch
terminal N -+ ground.
In addition, electric current flows from starting
switch terminal BR + battery relay coil -+ ground, so
the battery relay switch is closed.
The following circuit (2) is formed: Battery (+) +
battery relay + starting motor terminal B, and the
engine starts.
If the directional lever is at any position other than N
(neutral), circuit (I) is not formed, and the engine
does not start.
Fuel cut Alternator

solenoid
Directional !ever :@
Starting
motor
Fuel cut-off
switch
l-l 0
0
0
0 0
Battery relay
Starting switch
Battery
lf?r w
Battery
0
relay
l%
426F149.1
WA600- 1 81-7
g
FUNCTION
l A neutral safety circuit is employed to ensure 2) Electric current flows from battery (-I) +
safety when starting the engine. With this circuit, starting switch terminal B + starting switch
it is impossible to start the engine if the directional terminal ACC + engine stop motor relay coil
lever is in any position other than N (Neutral). - ground connection. When this happens, the
Operation circuit between engine stop motor relay
l When the directional lever is placed at N (neutral), contacts (3) and (5) becomes continuous.
the neutral contacts of the directional lever switch In this condition, electric current flows from
close. In this condition, if the starting switch is battery (-I-) - engine stop motor terminal B -
turned to the START position, electric current flows engine stop motor terminal P2 -+ engine stop
in the following circuit. motor relay -+ engine stop motor terminal A
1) Battery (+) + starting switch terminal B -+ - ground connection. As a result, the engine
starting switch terminal C + starting motor stop motor is actuated to cancel the fuel cut,
terminal C + starting motor terminal E + so a circuit is formed battery (+) + battery relay
directional lever switch terminal N + ground --+ starting motor terminal B, and the engine
connection. starts.
In addition, current also flows from starting l If the directional lever is in any position other than
’ switch terminal BR + battery relay coil -+ N (Neutral), the circuit in Item 1) is not formed,
ground connection, so the switch of the battery so the engine does not start.
relay coil is closed.
Engme stop
Engine stop motor motor r&v ===ggg
Alternator
Dlrectlonal lever
F42601027
WA600-1
ENGINE STOP CIRCUIT
FUNCTION
. The engine can be stopped and started by turning the

starting switch ON-OFF. An electrically operated
fuel-cut svstem (fuel-cut solenoid) is used to improve
ease of ooeration.
Serial No. 10001-10342
OPERATION
* Starting switch ON . Starting switch OFF

Electric current flows through circuit (1): Battery Circuit (I) is cut, but the engine is rotating, so there
(+) + starting switch terminal B --f starting switch is still voltage at terminal R of the alternator.
terminal ACC + fuel cut solenoid + ground. As a result, the following circuit (2) is formed: Alter-
When electric current flows to the fuel-cut solenoid, nator terminal R + battery relay + ground.
the fuel control linkage moves to place the fuel
governor in the FREE position. Fuel flows to the
fuel injection pump, and the engine starts.
Starting switch ON Starting switch OFF
Fuel cut solenoid

Fuel cut solenoid
-Km 9
‘I
Fuel cut-off
Fuel cut-off
switch
Starting switch
11.1
Battery relay ’ Battery relay
Battery
426F150.1 426F151.1
WA600- 1
Operation
l When the starting switch is turned OFF, current
stops flowing to the coil of the engine stop motor
relay. No electric current flows, so the continuity
between relay contact (3) and (5) is shut off, and
the circuit between contacts (3) and (6) becomes
continuous.
When this happens, current flows from battery (+)
+ engine stop motor terminal I3 + engine stop
motor terminal Pi -+ engine stop motor relay
(contact 3 and 6) -+ engine stop motor terminal
A -+ ground connection. When current flows in
the above circuit, the fuel supply is cut, and the
engine stops.
II Stamng motor
F42601028
81-8-2 WA600-1
‘7,
ELECTRICAL TRANSMISSION CONTROL

Transmission cut-off _
selector switch
Relays (inside right console)
\.
\
Combination switch
Directional iev
Speed control lev
control valve
Circuit breaker
iSSiOn cut-off switch
Transmission wiring harness
423F189
FUNCTION
Selection of FORWARD, REVERSE

Directional lever
and NEUTRAL
Selection of travel speed range Speed control lever
Transmission returned to neutral when left brake pedal is

Transmission cut-off function
operated.
Selects if transmission cut-off function is used or not used.

With this function, the left brake pedal can be used to get even
Transmission cut-off selection function
better performance than conventional loaders in digging opera-
tions or ease of steerino when loadino on to trailers.
To prevent the operator from driving off when the parking brake
Neutralizer function is still applied and causing seizure of the parking brake, the trans-
mission is returned to neutral when the parking brake is applied.
The engine can only be started if the FORWARD-REVERSE

lever is in neutral. In any other position the engine wilt not
6 Neutral safety function
start. This prevents the machine from starting suddenly.
(For details, see STARTING CIRCUIT)
When the machine is driven in reverse, a back-up lamp lights up

7 Warning functFon and a back-up horn sounds to warn people standing near the
machine.
WA600- 1 81-9
8
Kick-down switch
(Lift control lever)
Combination switch
Floor wiring harness

FORWARD-REVERSE leve
Speed control lever
ission control val
Transmission &-off switch
421FO1049
Function
1 Selection of FORWARD, REVERSE FORWARD-REVERSE lever

and NEUTRAL
2 Selection of travel speed range Speed control lever
3 Kick-down switch When traveling in F2 it is possible to use this switch to shift

down to Fl regardless of the position of the speed control
lever.
If the directional lever is placed in R or N, the transmission
automatically returns to 2nd.
4 Transmission cut-off function Transmission returned to neutral when left brake pedal is
operated.
5 Transmission cut-off selection Selects if transmission cut-off function is used or not used.
function
With this function, the left brake pedal can be used to get even
better performance than conventional loaders in digging
operations or ease of steering when loading on to trailers.
6 Neutralizer function To prevent the operator from driving off when the parking
brake is still applied and causing seizure of the parking
brake, the transmission is returned to neutral when the
parking brake is applied.
Neutral safety function The engine can only be started if the FORWARD-REVERSE
lever is in neutral. In any other position the engine
will not start.
This prevents the machine from starting suddenly. (For details,
see STARTING CIRCUIT.)
Warning function When the machine is driven in reverse, a back-up lamp lights up
and a back-up horn sounds to warn people standing near the
machine.
81-10 WA600- 1
0
COMBINATION SWITCH
423F I 88A
OUTLINE
* The FORWARD-REVERSE lever has three contacts; switch is secured to the base by three screws.
the speed control lever switch has four contacts. The When the lever is moved to the desired position, the
switch alone has no detent mechanism. The detent switch, which is connected by a shaft, moves and
mechanism is in the combination switch itself. Each electric current flows in only that circuit to move the
switch is held at two places by pins. In addiiton, each machine.
FUNCTION
1 FORWARD-REVERSE lever switch Selecting FORWARD, REVERSE or NEUTRAL
2 Speed control lever switch Selecting machine speed range
Prevents speed control lever from going into 3rd or 4th speed
3 Speed control lever stopper
during operations
4 Direction indicator lamp Indicates direction when turning left or right
Returns direction indicator lamp lever to neutral automatically

5 Self cancel
after turning left or right
6 Lamp switch Selects clearance lamps, headlamps, parking lamps
7 Dimmer switch Selects travel beam, low beam
8 Emergency flasher switch Makes left and right winkers flash at the same time
9 Emergency flasher pilot lamp Lights up when emergency flasher lamp is ON.
WA600- 1 81-11
0
TRANSMISSION CUT-OFF SWITCH
. When the left pedal is operated, the switch detects

the air pressure in a brake circuit. It shuts off the
power supply of the solenoid valve circuit for the
FORWARD-REVERSE clutch, and returns the trans-
mission to neutral.
Brake valve (R.H)
From brake oil tank
Relay valve
From
air tank
Two-way valve
Transmission
cut-off switch
From brake oil tank
Relay valve
To rear
Stop lamp switch 4261 ,158
Diaphragm
\ To fransmission
0 00
To transmission
directional circuit
Restored Actuated
Low voltage - High voltage

421F123
WA600-1
81-12
0
TRANSMISSION CUT-OFF SELECTOR SWITCH
Outline
* The - When is
turned to OFF (switch points in contact), (+)24V is
applied through this switch to the circuit of the sole-
noid valve for the directional clutch. The left brake
pedal then operates as a normal brake in the same
way as the right brake pedal.
* When the transmission cut-off switch is turned to ON
(switch points not in contact), if the left brake pedal
is depressed, it will act as a normal brake, and at the
same time the transmission will be placed in neutral.
-- +---- Neutralizer relay * Neutralizer relay

(battery power source) (battery power source)
_^.
machine To machine
monitor monitor
1
Transmission
cut-off selector
switch (manual)
* si$;;t7ission cut-off -
ON
(actuated by air pressure) by air pressure)
Starting motor Starting motor

(terminal E) (terminal El
To Buck-up Machine monitor To Buck-up Machine monitor

lamp relay system neutral lamp relay system neutral
terminal terminal
421F124
WA600-1 81-13
@
421FO1051
Outline
l This is a waterproof toggle switch for two circuits
installed in parallel with the transmission cut-off
switch at the power source end of the transmission
directional circuit.
Operation
1. Transmission cut-off selector switch at OFF Transmission cut-off selector switch at ON
l The points of the cut-off selector switch are l The points of the cut-off selector switch are
in contact, and current always flows to the separated, and current flows to the directional
directional clutch solenoidvalvesfrom the cut- clutch solenoid valves only from the cut-off
off selector switch and cut-off switch. switch.
l When the left brake pedal is depressed, the l When the left brake pedal is depressed, the
points of the cut-off switch are separated by points of the cut-off switch are separated by
air pressure, and the electric current is shut air pressure, and the electric current to the
off. However, electric current still flows to the directional solenoid valve is shut off.
directional solenoid valve from the cut-off As a result, the brake acts as a normal brake,
selector switch, so the brake acts normally in and, at the same time, places the transmission
the same way as the right brake. is neutral.
81-13-1 WA600- 1
1/8.,
NEUTRALIZER RELAY
* When the parking brake is being used, no electric WARD-REVERSE circuit of the transmission which
current flows to the relay coil. The input terminal is connected to output terminal “5”. When the park-
“3” is connected to output terminal “6”. ing brake is being used, the transmission is kept in
For this reason, no electric current flows to the FOR- neutral. Machine will not start.
Parking brake Parking brake &ing brake

switch-(man* safetv +lav Neutralizer relay
Battery relay - ---- r--- ----
C-l
Battery
Starting switch
natural terminal
426F159
WA600-1 81-13-2
8
Back-up lamp.& stop lamp
I_
Parkma brake switch (manual1
C
To machme
monitor 1 I I II I t
TraIlSmiSSIOn
cut-off Selector
switch (manual)
h
OFF
rd
Back-up tar” Back-up lamp
F42601029
Operation
1. When the parking brake is applied (ON), electric 3. When the parking brake switch is turned OFF
current flows from battery relay+ parking brake (brake released), and the engine is started, the
switch terminal (3) - terminal (2) * parking circuit in Section 1 is not formed, so the parking
brake safety relay terminal (2) + ground. As a brake switch must be turned ON before the
result, the coil of the safety relay is actuated, engine will start,
and terminal (3) and terminal (5) of the safety
relay are joined to form this circuit.
2. When the parking brake is applied, no electric

current flows to the coil of the neutralizer relay,
so terminal (3) and terminal (5) of the neutralizer
relay are separated. As a result, no electric
current flows to the transmission directional
circuit, so the transmission is kept in neutral
while the parking brake is applied.
81-13-3 WA600- 1
@
KICK-DOWN SWITCH
1. Switch
2. Washer
3. Screw
4. Cover
5. Body
6. Cable
Circuit structure
421FO1053
Operation The kick-down is canceled (or will not Operate)

The kick-down (shift down from 2nd to 1st) under the following conditions.
operates only when the transmission is in FOR- When the directional lever is at N
WARD 2. When the directional lever is at R
When traveling in FORWARD 2, if it is desired to When the speed control lever is at any position
shift down to 1st without operating the speed other than 2
control lever, it is possible to shift down to 1 st When the parking brake is applied
by pushing the kick-down switch at the top of When the starting switch is at OFF
the lift lever.
After this, even if the kick-down switch is
pressed, the transmission remains in FORWA-
RAD 1.
WA600- 1 81-l 3-4

60
KICK-DOWN ELECTRIC CIRCUIT
Normally ON
F42601035
When directional lever is in FORWARD When speed control lever is placed in 2nd
l If the directional lever is placed at F, current flows When the speed control lever is placed in 2nd,
from battery (+) -+ neutralizer relay terminal (3) current flows from battery (-I) + 2nd solenoid
- terminal (5) -+ FORWARD solenoid relay relay terminal (2) - terminal (1) + speed control
terminal (6) - terminal (5) + directional switch lever switch 2nd terminal + ground, and the 2nd
terminal F+ ground. solenoid relay is actuated.
As a result, the FORWARD solenoid relay is When the 2nd solenoid relay is actuated, the circuit
actuated, and the circuits between terminals (1) between terminals (3) - (5) is closed, and current
and (2), and terminals (3) and (4) are closed. flows from battery (-I-) ---* 2nd solenoid + 2nd
l Next, current flows from battery (i-) + neutralizer solenoid relay terminal (5) -terminal (3) + 2nd-
relay terminal (3) - terminal (5) --+ transmission 1st selector relay terminal (6) - terminal (3) +
cut-off switch -+ FORWARD solenoid -+ FOR- ground, and the 2nd solenoid is actuated to shift
WARD solenoid relay terminal (2) - terminal (1) the transmission to 2nd.
+ ground. The FORWARD solenoid is actuated, When the kick-down switch is actuated, the circuit
and the FORWARD clutches are joined. between terminals (3) and (6) of the 2nd-1st
selector relay contacts is opened, and the circuit
between contact terminals (3) and (5) is closed,
so current passes through the 1st solenoid, and
the transmission is shift to 1 st.
81-13-5 WA600- 1
0
When kick-down switch is operated
(When operating or traveling with speed control lever at F2)
F42601033
When kickSdown swith is pushed ON

l When the kick-down switch is pressed, current relay terminals (2) - (1) + ground. The coil of
flows from battery (+) -+ neutralizer relay. the Znd-1st selector relay is actuated, the circuit
terminals (3) - (5) ---, kick-down switch -+ between terminals (3) and (6) is opened, and the
FORWARD solenoid relay terminals (4) - (3) -+ circuit between terminals (3) and (5) is closed.
kick-down relay terminals (6) - (5) -+ speed l When the circuit between 2nd-1st selector relay
control lever switch 2nd terminal -+ ground. As terminals (3) and (6) is opened, electric current
a result, the kick-down relay coil is actuated, and stops flowing to the 2nd solenoid.
the circuits between terminals (1) and (2). and l When the circuit between the Znd-1st selector
terminal (3) and (4) of the kick-down relay are relay terminals (3) and (5) is closed, the electric
closed. current is switched to a circuit from battery (i)
l A circuit is then formed form kick-down relay -+ 1 st solenoid-+ 2nd-1 st selector relayterminals
terminals (2) - (1) -+ FORWARD solenoid relay (5) - (3) -+ ground, and flows from the 2nd
terminals (4) - (3) --+ kick-down relay terminals solenoid to the 1st solenoid, so the transmission
(6) - (5)+ speed control lever siwtch 2nd terminal is shifted down from 2nd to 1 st.
+ ground. Following this, even if the kick-down After the transmission is shifted down, even if the
switch is canceled, the kick-down relay continues kick-down switch is pressed again, the circuit
to be actuated. (Self-hold circuit of kick-down relay) between kick-down relay terminals (1) and (2)
l When the kick-down relay is actuated, in the Znd- (connected in parallel to both ends of the switch)
1 st selector relay coil, current flows from battery is closed, so there is no effect on the operation
(+)-+ neutralizer relay terminals (3) - (5) + kick- of the kick-down switch when it is being operated. _
down relay terminals (4) - (3) -+ 2nd-1st selector
WA600-1 81-13-6
0
Cancellation of kick-down switch I
(When directional lever is placed at N or R)
*act-up horn Back-up lamp

F42601034
. If the directional lever is placed at any position l The electric current stops flowing in the circuit
except F, the F terminal contacts are OFF, so from battery (-I) * 1st solenoid - 2nd-1st
electric current stops flowing in the circuit from selector relay terminals (5) - (3) - ground, so
battery (+) --* neutralizer relay terminals (3) - the kick-down to 1 st is canceled.
(5) - FORWARD solenoid relay terminals (6) - l Next, the circuit between terminals (3) and (6) of
(5) + directional switch terminal F - ground, the 2nd-1st selector relay is closed, so electric
and the FORWARD solenoid is reset. current flows to the 2nd solenoid, and the
. When this happens, the circuit between FOR- transmission is shifted back to 2nd, the position
WARD solenoid relay terminals (3) and (4) is of the speed control lever.
opened, so electric current stops flowing to the l In this way, the operation of the kick-down switch
circuit between kick-down relay coil terminals (6) is canceled, and the machine travels at the position
and (5). The kick-down relay is then reset, and indicated by the speed control lever.
the self-hold circuit is canceled. If the directional lever is shifted to R, the machine
. When the kick-down relay is reset, the circuit will travel in REVERSE 2.
between terminals (3) and (4) of the kick-down
relay is opened, so the current stops flowing in
the circuit from neutrailizer relay terminal (5) +
kick-down relay terminals (4) - (3) + 2nd-1st
selector relay terminals (2) - (1) - ground. The
2nd-1st selector relay is reset, so the circuit
between terminals (3) and (5) is opened, and the
circuit between terminals (3) and (6) is closed.
81-l 3-7 WA600-1
0
Cancellation of kick-down switch II
(When speed control lever is at position other than 2nd)
F42601030
If the speed control lever is placed at any position At the same time, the circuit between terminals
except 2, the circuit between the speed control (3) and (4) of the kick-down relay is opened, so
lever 2nd terminal and ground is opened, so the electric current does not flow in the circuit
electric current stops flowing in the circuit from from neutralizer relay terminal (5) -+ kick-down
battery (-I) - neutralizer relay terminals (3) - relay terminals (4) - (3) + 2nd-1st selector relay
(5) + kick-down relay terminals (2) - (1) -+ terminals (2) - (1) + ground.
FORWARD solenoid relay terminals (4) - (3) kick- As a result, the 2nd-1st selector relay is reset,
down relay terminals (6) - (5) + speed control so the circuit between terminals (3) and (5) is
lever switch 2nd terminal -+ ground, and the kick- opened. The current then stops flowing to the 1 st
down relay is reset. solenoid, so the kick-down to 1 st is canceled, and
When this happens, the circuit between kick-down the transmission is shifted back to the position
relay terminals (1) and (2) is opened, and the self- of the speed control lever.
hold circuit is canceled. Therefore, even if the The circuit between speed control lever 2nd
speed control lever is again placed in 2nd, the terminals and ground is opened, so the 2nd
system will not be returned to the condition where solenoid is reset. As a result, even if the circuit
the kick-down switch is actuated: between terminals (3) and (6) of the 2nd-1st
selector relay is closed, the circuit between 2nd
solenoid terminals (3) and (5) is open, so the 2nd
solenoid circuit is also canceled.
In this way, the operation of the kick-down switch
is canceled, and the machine travels at the position
indicated by the speed control lever.
WA600-1 81-13-8
0
Cancellation of kick-down switch III
(When parking brake is applied)
F42601031
. If the parking brake switch is turned ON (brake l When the 2nd-1 st selector relay is reset, the circuit
applied), electric current stops flowing to the between terminals (3) and (5) of the 2nd-1st
parking brake valve and the parking brake is selector relay is opened, electric current stops
applied. When this happens, the neutralizer relay flowing to the 1 st solenoid, and the circuit between
is also reset at the same time, so the circuit terminals (3) and (6) is closed, so a circuit is formed
between neutralizer relay terminals (3) and (5) is from battery (+) --, 2nd solenoid + 2nd solenoid
opened, and electric current stops flowing to the relay terminals (5) - (3) ---* 2nd-1st selector relay
directional circuit of the transmission. The terminals, (6) - (3) -+ ground. Current flows to
transmission is set in neutral, the kick-down relay the 2nd solenoid, and the transmission is shifted
and 2nd-1st selector relay are reset, and the to 2nd, the position of the speed controllever.
actuation of the kick-down is canceled. . In this way, the kick-down operation is canceled
when the parking brake is applied. In addition, the
directional lever switch is set at neutral, the
transmission gear is set to 2nd, and the machine
stops.
81-13-9 WA600- 1
r\
8
_i
Cancellation of kick-down switch IV
(When starting switch is turned OFF)
F42501032
. When the starting switch isturned OFF, the battery

relay is opened, so electric current stops flowing
to the directional circuit and speed circuit of the
transmission, so the kick-down action is canceled.
When the starting switch is at OFF, the kick-down
switch cannot be actuated even if the kick-down
switch is turned ON (actuated).
WA600-1 81-13-10
0
ELECTRICAL PARKING BRAKE CONTROL
OUTLINE
+ When electric current flows to the parking brake valve - When the electric current is stopped, the air pressure
isolenoid valve), air pressure from the air tank (wet from the air tank is cut off. The air pressure inside
yank) is applied to the spring cylinder and the parking the spring cylinder passes through the parking brake
brake is released. valve and is released. The parking brake is then actu-
ated by the force of the spring.
j--------
2--
4
L---I
(except D spec.)
‘h
/I’
i
1 ;,,
‘_ .
,’
1. Parking brake switch
2. Parking safety relay
3. Parking brake relay

[only for Serial No. 10001-10880 (except D spec.)l
4. Neutralizer relay
5. Air tank (wet)
6. Emergency brake switch
7. Parking brake valve
8. Parking brake indicator switch
9. Spring cylinder
WA600- 1
FUNCTION
1 Actuation and release of parking brake Parking brake switch used.

-
2 Automatic parking brake Parking brake is automatically applied when engine is stopped
(starting switch is turned to OFF). This prevents the machine
from running away when the operator leaves his seat.
3 Emergency brake The parking brake is automatically applied when it is impossible

to maintain braking power because of a drop in the air pressure
inside the tank caused by damage to the air circuit. In this way,
the parking brake acts as an emergency brake.
Parking brake safety After the automatic parkingbrake is actuated, it is dangerous if
the parking brake can be released simply by turning the starting
switch to ON.
Therefore, after the starting switch has been turned ON, the park-
ing brake switch must be operated to release the brake. This
ensures safety.
Neutralizer If the machine is driven with the parking brake still applied, the
parking brake will seize up.
Therefore, the caution lamp lights up, and the caution buzzer
sounds to warn the operator of this mistake in operation. At the
same time, when the parking brake is applied, the transmission is
moved to neutral, so it is impossible for the machine to move.
However, when the parking brake is used as an emergency brake,
if the transmission is returned to neutral, the braking distance will
increase and the machine may stop in a dangerous place (for
example, on a railroad crossing). For this reason, the circuit is
designed so that the transmission is not returned to neutral when
the emergency brake is applied.
Parking brake switch

Large size multi-pin connector
(3 pole blue) with lock
Connection table
“\,Terminad /
_,_ No, 1 j 2 ! 3
Position ‘\ I i
polyvinyl chloride
& 2
Waier proof O-ring
View 2
for oanel face
423F195
WA600- 1 81-15
PARKING BRAKE VALVE
Valve actuation table
ml
o parking brake chamber
Exhaust
Port No.1
Port No.4
423F196
PARKING BRAKE RELAY

[Serial No. 10001 and up (D sped, Serial No, 10001-10880 (except D spec.)l
PARKING SAFETY RELAY
NEUTRALIZER RELAY
Relay connection chart

Relay actuation table
Terminal No.1
Terminal No.2 Terminal No.5

ON
No.3
Black Terminal No.6
423F197
EMERGENCY BRAKE SWITCH
423F198
81-16 WA600- 1
0
1. STARTING SWITCH OFF
l When the starting switch is turned OFF, the
battery relay is opened, so no electricity flows
to the parking brake circuit. For this reason,
if the starting switch is OFF, no electricity
flows to the parking brake valve regardless of
whether the parking brake switch is ON
(actuated) or OFF (released). As a result, the
parking brake is actuated. (Automatic parking
brake)

Parklna brake Parkuw brake Parking brake

switch~(manual1 relay - safety r&y Neutralizer relay
Starting swtch
FORWARD-REVERSE
circuit
To transmission Emergency brake
speed circuit switch
(with wet tank)
F42601037-K

Parking brake
Parking brake
switch Imanual)
safety r&y Neutralizer relav
F- _.. -4 --- -
OFF
I_~ _ -__--___----_A_
“J ,
TO transmission
FORWARD-REVERSE
circuit
To transmlswan Emergency brake
speed wcuit switch
F42601038-K
iwith wet tank)
WA600-1 81-17
@
2. STARTING SWITCH ON
2-1. When parking brake switch is turned ON
before starting switch is turned ON
Electric current flows as follows. The circuit of the parking safety relay remains
;1, Battery
relay coil
(+) -+
-+
starting
ground
switch
connection,
-+ battery
so the
closed
switch
because
is turned
of circuit
OFF.
“3” until the starting
battery relay is CLOSED. . In this condition, no electric current flows to the

Electric current also flows as follows. parking brake valve, so the parking brake is
(2) Batery (+) + battery relay -+ parking brake actuated.
switch terminal “3”+ parking brake switch l Also, in this condition, the circuit between terminal
terminal “2” + parking safety relay “3” and “5” of the neutralizer relay is open, so
terminal “1” + parking safety relay no electric current flows to the FORWARD-
terminal “2” + ground connection. REVERSE circuit of the transmission, and the
When this happens, the parking safety relay transmission is kept in neutral.
is actuated and circuit is closed. Therefore,
the following circuit is formed.
(3) Battery (-I-) + battery relay -+ parking
safety relay terminal “3” -+ parking safety
relay terminal “5” -+ parking safety realy
terminal “1” -+ parking safety relay
terminal “2” -+ ground connection.
Parking brake Parktng brake Parking brake

swtch (manual1 relay safety relay Neutralizer relay
i--t- ---
1 ---- ----
Batteryrelay OFF I
:
Battery
Starting switch
To traj+,i;b
(with wet tank)
F42601039-K
81-18 WA600- 1
0
2-1A. When parking brake switch is turned ON

Electric current is flowing in circuit 0 battery (+) In this condition, electric current does not flow
-+ starting switch -+ battery relay coil - ground, to the parking brake valve, so the parking brake
so the battery relay is closed. For this reason, the is applied.
current flows in circuit 0 battery (+) + battery Furthermore, in this condition, the circuit between
relay --+ parking brake switch teminals (3) - (2) terminals (3) and (5) of the neutralizer relay is
-+ parking safety relay terminals (2) - (1) + opened, so electric current does not flow to the
ground. Because of this, the parking safety relay directional circuit of the transmission, and the
is actuatd, and the circuit between terminals (5) transmission is placed in neutral.
and (3) of the safety relay is closed.
When this happens, the following circuit @ is
formed: battery (-I-) + battery relay -+ parking
safety relay terminals (3) - (5) + parking safety
relayterminals(2)-(l)-+ground,andtheparking
safety relay remains as circuit @ until the starting
switch is turned OFF.
Parking brake Parking brake

switch (manual) safety relay Neutralizer relay
--
Battery relw OFF n ON

(with wet tank)
F42601040-K
WA600-1 81-19
8
2-2. Parking brake switch turned OFF (released)
l Electric current flows as follows. to the parking brake valve. Therefore, after the
(1) Battery (-I-) -+ starting switch + battery relay automatic parking brake is actuated, even if the
coil -+ ground connection, so the battery relay starting switch is turned to ON, the parking brake
is CLOSED. is not automatically released.
However, in this case, the parking brake switch l In addition, no electric current flows to the
is OFF (released), so the parking safety relay is FORWARD-REVERSE circuit of the transmission,
not actuated. For this reason, no electricity flows so the machine does not move.

Parking brake Parking brake Parking brake
switch imanual) relay Safety relay Neutralizer relay
Batteryrleay c - ---- ---- ----
lpq
I III
1’
Startlng switch
11-1 I I
I
Alternator
terminal R ‘III
(with wet tank)

F42601041 -K

switch (manual) safety relay Neutralizer !lay
Battery relay - -t ---- ----
Battery
FORWARD-REVERSE
Emergency brake
F42601042-K
(with wet tank)
81-20 WA600-1
0
3. PARKING BRAKE SWITCH TURNED OFF
(Released) AFTER STARTING SWITCH IS
TURNED ON.
. If’the parking brake switch is turned OFF (4) Battery (i-) -+ battery relay ---* parking brake
(released), circuits 1 and 2 of the parking relay’ terminal 3 -+ parking brake relay
brake switch are connected. When this terminal 5 -+ parking brake valve + ground
happens, electric current flows as follows. connection.
(1) Battery (-I-) + battery relay -+ parking safety The parking brake is released, and at the
relay ---* parking brake switch -+ (2) and (3). same the following circuit is formed.
(2) Emergency brake switch -+ parking brake (5) Battery (+) + battery relay + neutralizer
relay coil - ground connection. relay terminal 3 + neutralizer relay terminal
(3) Neutralizer relay coil + ground connection. 5 --+ transmission FORWARD-REVERSE
The parking brake relay and neutrlizer relay circuit. When the transmission switch is put
are actuated, and the circuit between to FORWARD or reverse, the machine will
terminals 3 and 5 of each relay is closed. move.
As a result, the following circuit if formed.

switch (manual) relay safety relay Neutralizer relay
Batten/ WlaV bN
OFF-
Starting switch
Alternator
terminal R
I I
I
To transmission Parking
I
To transmission
FORWARD-REVERSE
circuit
Emergency brake
brake
valve I

(with wet tank)
F42601043-K
WA600-1 81-21
Go
3A. PARKING BRAKE SWITCH TURNED OFF
(Released) AFTER STARTING SWITCH IS
TURNED ON.

l If the parking brake switch is moved from ON Circuit 0 is formed from emergency brake switch
(applied ) to OFF (released), a circuit is formed - parking brake valve - ground, and the parking
between terminals (1) and (2) of the parking brake brake is released.
switch. In addition, the parking brake safety relay Circuit @ is formed from battery (+) --+ battery
is actuated, so electric current flows from circuit relay -+ neutralizer relay terminals (3) - (5) -+
0 battery (+) - battery relay -+ parking brake Transmission directional circuit, so the machine
safety relay + parking brake switch to the moves according to the operation of the directional
following circuits @ and 0. lever.

- --- 1 --- 1
Battery relay ,‘,’ ON
Alternator
terminal R
I
To transmission
FORWARD-REVERSE
circuit
To transmwlon Emergency brake
(with wet tank)
F42601044-K
81-22 WA600- 1
@
4. PARKING BRAKE SWITCH ON (operated)
l After operating with the parking brake switch l At the same time, the neutralizer relay is also
at OFF (released), if the parking brake switch restored, so the circuit between terminals “3” and
is turned to ON (operated), the circuit becomes “5” is OPEN. No electric current flows to the
as shown below. FORWARD-REVERSE circuit of the transmission,
l No eJectric current flows to the parking brake so the transmission is placed in neutral. In this
valve, so the air pressure from the air tank way, when the parking brake is operated, the
acting on the spring cylinder is shut off. At neutralizer relay shuts off the electric current to
the same time, the air pressure inside the the transmission solenoid valve and puts the
spring cylinder passes through the parking transmission in neutral. As a result, there will be
brake valve and is released, so the parking no seizing of the parking brake caused by the
brake is actuated by the force of the spring. machine being drive with the parking brake still
applied.

Parking brake ParkIng brake Parking brake
switch (manual) relay safety r&y Neutralzer relay
Starting switch
_ _ _ ._
FORWARD-REVERSE
circuit
(with wet tank) F42601045-K

switch (manual) safety relay Neutraltzer relay
~~!!,,E~\ERSE & gyp

To transm,sso” Emergency brake
(with wet tank) F42601046-K
WA600-1 81-22-1
a0
5. WHEN AIR PRESSURE DROPS.
(Emergency brake actuated)

Operation
l if the air pressure drops, the emergency brake switch l For this reason, electric current flows to the FOR-
installed to the wet tank is opened. WARD-REVERSE circuit of the transmission, and
For this reason, no electric current flows to the coii it is possible to connect the transmission clutch.
of the parking brake relay. The parking brake relay is Threfore, when the emergency brake is actuated,
restored, and the circuit between terminals “3” and the engine also acts as a brake. This makes the brak-
“5” becomes OPEN. No electric current flows to the ing sistance shorter, and at the same time, if the emer-
parking brake valve, so the air pressure inside the gency brake is actuated, and it is nececessary move to
spring cylinder is released and the parking brake is the machinetfor example, if the emergency brake was
actuated. However, this case is different from when actuated on a railroad crossing), the machine can be
the parking brake switch is turned ON (operated). driven by operating the transmission lever.
In this case, there is electric current flowing tothe coil
of the neutralizer relay.

switch (manual) relay safety relay Neutralizer relay
-- ---- -__
-T--l
R
i
Starting switch
A--
To transmission
;:fz:P;~
circuit
\ Emergency brake
I
sDeed circuit switch

(with wet tank)
F42601047 -K
81-22-2 WA600-1
0
5A. WHEN AIR PRESSURE DROPS.
(Emergency brake actuated)
Operation
l If the air pressure drops, the emergency brake l For this reason, electric current flows to the
switch installed to the dry tank is opened. FORWARD-REVERSE circuit of the transmission,
Fo: this reason, the electric current stops flowing and it is possible to connect the transmission
to the parking valve, so ?he air pressure inside clutch. Therefore, when the emergency brake is
the spring cylinder is released, and the parking actuated, the engine also acts as a brake. This
brake is applied. makes the braking distance shorter, and at the
However, this case is different from when the same time, if the emergency brake is actuated,
parking brake switch is turned ON (brake applied), and it is necessary to move the machine (for
because electric current is flowing to the neutral- example, if the emergency brake was actuated on
izer relay coil. a railroad crossing), the machine can be driven by
operating the transmission lever.

-- ---
^I-- .I
Battery relay OFF \?I ON
Emergency brake
To transmission.
switch
speed circuit
(with wet tank)
F42601046-K
WA600-1 81-22-3
Go
PROXIMITY SWITCH
. DIAGRAM
To battery relay
Positioner rela
Solenoid for positioner
Proximity switch 1 Kick-out relay
rqjjij
for boom kick-out
Solenoid for kick-out
421F117
Function
- Proximity switches are installed by a support to the switch, the electric current flows to a magnet and the
lift and dump cylinders. The lift arm RAISE position lift or dump lever is returned to the hold position.
and the TILT BACK position can be selected to When this happens, the main control valve is also
match the operating conditions. When these posi- returned to hold and the movement of the lift arm
tions are reached, a pulse is generated from the or bucket stops.
WA600- 1 81-23
0
OPERATION
LIFT ARM “RAISE”

Proximity switch for
boom kick-out
HOLD
When the lift arm is lower than the set position for
the boom kick-out, the detection unit (steel plate) is
not on the sensing surface of the proximity switch. 787
The relay switch is at OFF and the electric current of
the solenoid is shut off. Kick out relay
Lift lever
Lift arm Lift lever
Detection unit
LwJ~ POC(PPC) valve
426F133-7 A
RAISE Proximity switch for

When the lift control lever is moved to the RAISE boom kick-out
position, the lever cam and the cam plate detent keep . Battery relay
the lift spool in the RAISE position, so the lift arm

goes up.
Kick out relay
Lift lever
/’
; i;/ i
Liff arm Cam
Proximity switch 1
/Roller
Detection unif
i _rd~ POC(PPC) valve 426F134-1 A
81-24 WA600- 1
0
When the lift arm goes up and reaches the set position
for the kick-out (that is, the detection unit (steel
plate) is in contact to the sensing surface of the prox-
imity switch), the proximity switch and relay circuit
act to send electric current to the solenoid. This
actuates the magnet, the roller is pulled out of the
cam plate detent, and the lift spool is returned to the
hold position by the return spring.

boom kick-out
Battery relay
Kick-out relay
q
m;
7%
Lift levet
Cam
---A.
POC(PPC)vaIve
426F135.1 A
Movement of proximity switch
Sensing surface of proximity switch Sensing surface of proximity switch

Position
is in contact with detection unit. separated from detection unit.
Proximity switch display ON OFF
Kick-out relay Current flows Current shut off

I
Solenoid Current flows Current shut off
WA600- 1 81-25
(3
BUCKET “TILT”
HOLD
When the bucket is lower than the set position for the Proximity switch for
boom kl
bucket leveler, the detection unit (steel plate) is on
Battery relay
the sensing surface of the proximity switch. Elec-
tricity flows through the proximity switch. The relay
switch is at OFF and the electric current from the
battery is shut off.
Positioner relay
Solenoid for bucket
Bucket lever
Cam
n
n /
3
I
I’;
__-_ /
, -5
?* Proximity
Detection unit
1%
,.+J---POC(PPC) valve
426F136-1A
TILT
When the bucket control lever is moved to the TILT bucket positioner
position, the lever keeps the dump spool in the TILT Battery relay
position by cam plate detent, so the bucket tilts.
Positioner relay
Bucket lever
/c
fv/
,~
-s
“_--_
Detection unit
k.
-A
I __-__
_,; _L
,“i
Proximity
-lA
81-26 WA600- 1
'i,,
POSITIONED
When the bucket tilts and reaches the set position for
the bucket leveler (that is, the detection unit (steel
plate) is separated from the sensing surface of the
proximity switch), the proximity switch and relay
circuit act to send electric current to the solenoid.
This actuates the magnet, the roller is pulled out of
the cam plate detent, and the dump spool is returned
to the hold position by the return spring.

bucket positioner
Battery relay
I Positioner relay
Solenoid for bucket
Bucket lever
Solenoid
Detection unit broximity switch
\
4w-1 POC (PPC) valve

426Fl38-1A
Movement of proximity switch
Sensing surface of proximity switch Sensing surface of proximity switch

Position
is in contact with detection unit. separated from detection unit.
_
Proximity switch display ON OFF
Proximity switch (relay switch) Current flows Current shut off

I I
Solenoid circuit Current shut off Current flows
I I
WA600- 1 81-27
0
AUTO PRIMING SYSTEM (APS)
1. Vehicle monitor
2. Afterheating monitor
3. Preheating monitor
4. Heater switch
5. Starting switch
11
6. Fuel cut-off switch
7. APS controller
8. APS water temperature

SW!SOr
9. Bimetal timer
10. APS resistor
11. APS hold relay
12. Battery
13. APS relay
14. Fuel tank
15. Fuel injection pump
16. Fuel cut-off solenoid

valve
16A Engine stop motor
17. Fuel filter
18. Fuel valve
19. Bracket
20. APS fuel injection

nozzle
21. Glow plug

10001-10342 10343and UP
426F152-1
FUNCTION OUTLINE
- The APS system is used in cold areas to make it easier - The fuel flows from the tank through the feed pump
to start the engine. It works by burning fuel inside of fuel injection pump (15) and is sent to fuel filter
the intake manifold to heat the intake air. (17). At the outlet port of the fuel filter, it is con-
nected to the APS fuel circuit,
* The APS fuel circuit consists of fuel valve (18),
bracket (19) which divides the fuel, and APS fuel in-
jection nozzle (20) which uses APS controller (7) to
automatically adjust the amount of the fuel spray.
81-28 WA600- 1
:x;
APS starts APS stops completely
Passage of time I ___.

_______.._____.
____
_.._.__
Glow plug preheat Starting Engine starts,

motor is intake air heated
cranked.
Starting switch ON START ON

I
Preheater switch OFF ; ON AUTO OFF

I I
APS water temperature
sensor
I
ON (Below 20°C)
I
I
OFF
Hold relay OFF ON OFF
APS relay OFF ON OFF
Glow plug OFF ON OFF
Bimetal timer ON OFF
Preheat monitor display out On out
Fuel injection nozzle No injection Intermittent injection No injection
Afterheating
display
monitor
out Flashes
I out
Starting using APS
1. Open the cock of the APS fuel valve at the center of After preheating for about 80 seconds, (the period
the left side of the engine. during which the bimetal timer operates), the pre-
* When the temperature drops, and the season heat monitor lamp goes out. Turn the starting
comes where the APS system is to be used, leave switch to START to start the engine.
the fuel valve open. * If the starting switch is turned to START when
2. Turn the starting switch to ON. the preheat monitor lamp is lighted up, the glow
plug will become wet and will be unable to heat
3. With the fuel cut-off switch at OFF, turn the start-
up.
ing switch to START and crank the starting motor
for about 10 seconds. When the engine starts, return the starting switch
* This operation is necessary to circulate the oil key to ON.
through the whole engine. After starting the engine, wait for the engine to ro-
* When the fuel cut-off switch is turned OFF, the tate smoothly and for the exhaust gas colour to
fuel cut solenoid valve is turned OFF and the return to normal, then turn off the PREHEAT
fuel injection pump is set to the NO INJECTION switch.
position. * After starting the engine, when the engine water
4. Turn the fuel cut-off switch ON. temperature reaches approximately 2O”C, the
* The switch returns automatically when released. afterheating will automatically be stopped and
the afterheating monitor lamp will go out.
5. When the PREHEAT switch is turned ON, the pre-
heat monitor lamp lights up and the glow plug pre-
heats.
* When the preheat monitor lamp lights up, turn
the preheat switch to AUTO.
6. Depress the accelerator pedal half way.
WA600- 1 81-29
OPERATION OF APS
1. Preheat monitor lamp on vehicle monitor ON
1 A.P.S. controller
n4 I “I .
Alternator
AT Starting
b
motor
m7 k!
B
Battery relay
:
Battery relay
Preheat switch Main switch connecting

table
-7777
Heverse lever
426F153-2
When starting switch (1) is at ON, and PREHEAT When this happens, the rated voltage of glow plug
switch (2) is turned to ON, APS hold relay (3) and (7) is 18 V, so APS resistor (6) is used to lower it.
APS relay (4) are actuated. When glow plug (7) is being heated, electric current .
When this happens, if the temperature of the engine flows from terminal (2) to terminal (3) of bimetal
cooling water is under 13”C, APS water temperature timer (8).
sensor (5) is closed (ON). However, the voltage is about 6V. At the same
Because of this, even if PREHEAT switch (2) ,is time, electric current flows from terminal (2) +
returned to ON or AUTO, terminal (3) and terminal terminal (1) + resistor (9) + ground, and 24 V is
(5) of APS hold relay (3) are connected. When APS applied to both ends of resistor (9). This is detected
water temperature sensor is above 20°C. terminal and the display of preheat monitor (10) on the
(3) and terminal (5) of APS hold relay (3) separate vehicle monitor lights up. After a fixed time
and move to the OFF position. (approx. 80 seconds) has passed, the contacts of
Electric current flows from terminal A of APS relay bimetal timer (8) open and preheat monitor lamp
(4) to terminals R4 and R3 of APS resistor (6) -+ (10) goes out. This shows that glow plug (7) is
terminal (3) and terminal (4) of preheat switch (2) heated up sufficiently to actuate the APS system.
+ glow plug (7) + ground, and glow plug (7) be-
comes red hot.
81-30 WA600- 1
r
!J
2. Afterheating monitor on vehicle monitor ON
A.P.S. controller
4
77h Starting
motor
7m
Battery relay
J LJ
Fuel cut-off p’, t $ 3 j m_+_r
Starting
switch
Battery relay
I]
Preheat switch lyaakeswitch connecting

__
connectina table
,I//
neverse lever
426F154-2
After preheat monitor lamp (IO) goes out, if start- play for afterheating monitor (13) flashes.
int switch (1) is turned to the START position, the After starting, when the engine warms up and the
starting motor will turn and at the same time APS engine cooling water temperature goes above 2O”C,
controller (12) is actuated. APS fuel injection noz- APS water temperature sensor (5) opens (OFF) and
zle (11) in the intake manifold is switched ON and APS hold relay (3) goes OFF, so the APS relay also
OFF to inject fuel intermittently (10 times/set) on goes OFF.
glow plug (7). (When the power source voltage is When this happens, the power source circuit to glow
applied to APS controller (12), and the starting plug (7) and APS controller (12) is cut off, so the
signal or charging signal is input, the ON-OFF inter- operation of the APS stops. At the same time the
mittent injection signal is output to APS fuel injec- preheating monitor display goes out.
tion nozzle (11) .)
The fuel injected on glow plug (7) burns inside the * To start operations when the APS system is operating
intake manifold and heats the intake air. and the engine is running, but the engine water tem-
In addition, to avoid the effect caused by the drop perature is below 20°C, turn the PREHEAT switch
in voltage when starting, the battery voltage is OFF and this will cut off the power source circuit to
applied through terminal R2 of starting switch (1) the glow plug and APS controller. The operation of
directly to APS controller (12) and glow plug (7). the APS system will stop, and at the same the pre-
After the engine starts, the charge signal from the heating monitor display will go out.
alternator actuates the fuel injection nozzle and (If operations are started with the preheating system
carries out afterheating. still working, there will be insufficient oxygen in the
When this happens, the voltage between the preheat intake air, so black exhaust smoke will be produced
switch and the glow plug is detected, and the dis- and the engine will lack power.)
WA600- 1 81-31
@
APS CONTROLLER
-.-
/--
______
Connecting diagram
I. Connector
2. Fuse (5 A)
3. APS controller
426F155
RESISTOR
1. Case
2. Coil
426F156
BIMETAL TIMER
H
rl
Ii
p Inner connecting
diagram
i:;
1. Timer
2. Connector
426F157
81-32 WA600- 1
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
Serial No. 10001-l 0494
OUTLINE MONITOR ‘PANEL

The electronic vehicle monitoring system is a system
to inform the operator of the condition of the ma- - The monitor consists of the following components.
chine. It consists of sensors installed in various parts CHECK module (11, CAUTION module (2). CAU-
of the machine, which observe the condition of the TION module (3), gauge module (51, speedometer
machine and process the information speedily, and module (including service meter), the case, and vari-
display the situation on the monitor panel. ous other components.
The electronic vehicle monitoring system consists of - Each module (excluding the service meter) has its
the monitor panel, sensors, controller, warning buzz- own microcomputer which processes the signals from
er, warning lamp and power source. the sensor and gives a display.
The displays can be broadly divided into CHECK The panel uses a liquid crystal display.
items (I) and CAUTION items (2) and (31, which dis- * CHECK (I), and CAUTION (2) and (3) modules all
play warnings if any abnormality arises in the ma- use common parts.
chine; and gauges (51, speedometer (7). and service The microcomputer judges which module it is from
meter (9), which always display the condition of the the wiring harness to which it is connected.
machine.
Warning lamp Warning buzzer
Battery
24V
F===Y
m
-
Buzzer signal
426~145
WA600- 1
{A 126 /2C/3A,3B,JC
4A’,’ f @O\ Q
I \
View Z
426F146
35. Engine oil pressure 5. Gauge

1. Check
3C. Coolant level 5A. Air pressure
1 A. Brake oil level
3D. Air pressure 5B. Coolant temperature

1:. Engine oil level
3E. Coolant temperature 5C. Torque converter oil temperature

1 C. Coolant level
3F. Torque converter oil 5D. Fuel level

2. Caution (Warning)
temperature
6. Winkers
2A. After-heating
4. Pilot indicator
7. Speedometer
28. Battery charge
4A. Transmission cut-off
8. Head lamp (High beam)
2C. Fuel level
48. Parking brake
9. Service meter
2D. Transmission oil filter
4C. Work lamp
IO. Service meter indicator
2E. Steering failure
4D. Preheat monitor
11. Cap (Spare bulb)
3. Caution (Emergency warning)
3A. Main steering failure
WA600- 1
81-34
Outline
- The electronic vehicle monitoring system is a system

to inform the operator of the condition of the
machine. It consists of sensors installed in various
parts of the machine, which observe the condition of
the machine and process the information speedily,
and display the situation on the monitor panel.
- The electronic vehicle monitoring system consists of
the monitor panel, sensors, warning buzzer, warning
lamp and power source.
* The displays can be broadly divided into CHECK
items (I) and CAUTION items (2) and (31, which
display warnings if any abnormality arises in the
machine; and gauges (5). speedometer (7). and service
meter (9). which always display the condition of the
machine.
Warning lamp Warning buzzer
Battery
Sensor
426FO1007
WA600- 1
8’635
7 8 6 2B 2A 2C 3A 38 3C
5A
1A 30
1B 3E
5B 3F
1C
4A’ 5c 5i 1’0 2k 2’D 4’0 iC ‘4B
View Z
426FO1008
1. Check 36. Engine oil pressure 5. Gauge
1 A. Brake oil level 3C. Coolant level 5A. Air pressure
1 B. Engine oil level 3D. Air pressure 5B. Coolant temperature
1 C. Coolant level 3E. Coolant temperature 5C. Torque converter oil temperature
2. Caution (Warning1 3F. Torque converter oil 5D. Fuel level

temperature
2A. After-heating 6. Winkers
4. Pilot indicator
28. Battery charge 7. Speedometer
4A. Transmission cut-off
2C. Fuel level 8. Head lamp (High beam)
4B. Parking brake
2D. Transmission oil filter 9. Service meter
4C. Work lamp
2E. Steering failure 10. Service meter indicator
4D. Preheat monitor
3. Caution (Emergency warning)
3A. Main steering failure
81-36 WA600- 1
:$i_.,
INDICATION ON MONITOR PANEL
1
Symbol Indication item Indication range Description
Brake oil level I3elow low mark
Displayed when starting switch is turned

4 Engine oil level I3elow low mark to ON with engine stopped.
Q
Display goes out when normal.
Display flashes when abnormal.
Coolant level 3elow low mark
\iNhen after-
ml
Displays when engine is running.
After-heating
Iieating
Display flashes during after-heating.
1
When charging is
defective.
,
4 Fuel level
Transmission oil filter

Below
I low mark
Differential pres-
Displays
Display
Display
when engine is running.
goes out whennormal.
flashes when abrnormal and lamps
sure above specified
clogged flash at same time.
level
7-r
u I
Emergency steering When operated
When stroke is
Brake line failure
over.
Below specified
Engine oil pressure
pressure
Below low mark Displays when engine is running.

Display goes out when normal.
Below specified Display flashes when abnormal; buzzer
pressure and lamp actuated.
Above 102’C
Torque converter oil

Above 102’C
temperature
0 1 Parking brake When operated
Displays when starting switch is turned ON.

Work lamp When operated
Lights up when operated.
01 Transmission cut-off When operated
When normal
Displays when starting switch is turned ON;
u / Emergency steering circuit
lights up when normal.
4
PREHEAT When preheating
lights up during preheating.
WA600- 1
8’i37
Gate.
Symbol Indication item Indication range Description
wrv
Travel speed O-lOOkm/h Digital display
High beam When operated

lights up when operated.
Winkers (right, left) When operated
Hazard When operated Lights up when operated.
0 - 99999/h Actuated when engine oil pressure is normal.

Service meter
displayed Advances 1 for every hour of operation.
Service meter indicator Flashes when service meter is operating.
Red 11.0
8.7
7.5
Green
Air pressure I 6.7 One lamp lights up to indicate level.
6.0
Red 2.7
Red 108’C
102*
3’C
97*c
Coolant temperature Green
One lamp lights up to indicate level.
9o*c
8O’C
‘67°C
White
I
C
H
Red 130-C
120 c
Torque converter oil 1lOC

One lamp lights up to indicate level
temperature Green 11 90 c
70 c
5O’C
F
FULL
Fuel level All lamps light up below indicated level.
Red EMPT’ I
E
-
81-38 WA600- 1
'3.'
WIRING HARNESS
Serial No. 10001-10494
To
423F182
-Operation of monitor panel

If the monitor panel is working normally, the lamps on c) The CHECK item lamps will go out when the
the monitor panel will work as follows. engine is started. (Judge whether the engine is
1) When the starting switch is turned to ON. running by the rise in the engine oil pressure, or
a) All monitor lamps will light up for 3 seconds. see if there is a voltage of over 1OV from the
b) The night lights will light up for several seconds. alternator.)
2) CHECK MONITOR GROUP 3) CAUTION MONITOR GROUPS
All monitor lamps will light up for 3 seconds, then a) All monitors are working from the time the engine
if there is any abnormality in any check item, that starts to the time the engine stops and the starting
item will flash. (About 0.8 seconds ON, then 0.8 switch is turned to OFF.
seconds OFF repeated.) If there is any abnormality in the machine, the
If the outside air temperature is low (below about lamp for that item will start to flash (0.8 seconds
-1O’C). the flashing interval will change slightly, ON, 0.8 seconds OFF).
but this is not an abnormality.
WA600- 1 81-39
'I$‘
CNPI
(16Pi
CNP4
(IZPi
CNP3
(16P)
I0
U41901066A
Operation of monitor panel

If the monitor panel is working normally, the lamps on c) The CHECK item lamps will go out when the
the monitor panel will work as follows. engine is started. (Judge whether the engine is
1) When the starting switch is turned to ON. running by the rise in the engine oil pressure, or
a) All monitor lamps will light up for 3 seconds. see if there is a voltage of over 10 V from the
b) The warning buzzer will sound for 2 seconds. alternator.)
2) CHECK MONITOR GROUP 3) CAUTION MONITOR GROUPS
a) All monitor lamps will light up for 3 seconds, then a) All monitors are working from the time the engine
if there is any abnormality in any check item, that starts to the time the engine stops and the starting
item will flash. (About 0.8 seconds ON, then 0.8 switch is turned to OFF.
seconds OFF repeated.) If there is any abnormality in the machine, the
b) If the outside air temperature is low (below about lamp for that item will start to flash (0.8 seconds
- lO’C), the flashing interval will change slightly, ON, 0.8 seconds OFF).
but this is not an abnormality.
8 l/-e0 WA600- 1
5,
CONTROLLER
Serial No, 10001-10494

Function
* The auxiliary controller acts as the power source box
and provides electric power to the panel.
The power source (battery, alternator) for the ma-
chine has a large difference in voltage, so the auxiliary
controller converts this to a stable voltage and sup-
plies it to the panel.
Even if excessive voltage is generated by failure in the
alternator or regulator, it is cut by the auxiliary con-
troller. 423F171
Lamp
Buzzer
Battery
___-_- _I
Batterv relay 423F172-1
terminal E
WA600- 1
SENSORS
FUNCTION
* There are three types of sensor: contact type, resistor If the contact of the sensor that sends the signal
type, and solenoid type. directly to the monitor is closed, the monitor judges
* With contact type sensors, one end of the wiring is the signal to be normal.
grounded at the chassis end, and the other end sends If the contact of the sensor that sends the signal to
the signal from the sensor directly to the monitor or the monitor through a relay is opened, the monitor
sends it through a relay. jueges the signal tob normal. (The signal is reversed
by the relay.)
Sensor actuation table
1) ENGINE OIL LEVEL SENSOR

Serial No. IOOOI- l
1. Connector
1 2 3 4 2. Wire
3. Plug
4. Float
5. Switch
ON - OFF Circuit structure

(UP) (DOWN)
423F174A
Serial No. . - 10880

I. Connector
/’ 2 3 4 5 2. Wire
I 3. Plug
4. Float
5. Switch
&IIIz!I
U41901061A
Circuit structure
81-42 WA600- 1
7,.
1. connector
2. Wire
3. Case
4. Bracket
Circuit structure
5. Wire
6. Float
421F01041A
FUNCTION
l The engine oil level sensor is installed on the
engine oil pan. When the engine oil goes below
the specified level, the float goes down and the
switch is turned OFF. The machine motitor lamp
then lights up to indicate the abnormality.
2) BRAKE OIL LEVEL SENSOR

Serial No. 10001-10182
1. Connector
2. Wire
3. Plug
4. Float
5. Switch
Cl 0:#
ON - OFF
(UP) (DOWN)
Circuit structure
423F173
.”
.-
Serial No. 10183 and up .

.,. 1. Connector
2 3 4 5 2. Wire
3. Plug
4. Float
5. Switch
Circuit structure
421F01042A
FUNCTION
l The brake oil level sensor is installed on top of
the brake oil tank. When the brake oil goes below
the specified level, the float goes down and the
switch is turned OFF. The machine monitor lamp
then flashes to indicate the abnormality.
WA600-1 81-43
0
3) COOLANT LEVEL SENSOR
Serial No. 10001-10182
1. Connector
2. Wire
3. Plug
4. Float
5. Switch
ON -
(UP)
OFF
(DOWN)
e
Circuit structure
423F175A
1. Connector
2. Wire
3. Plug
e Circuit structure
4.
5.
Float
Switch
421F01042A
FUNCTION
- The coolant level sensor is installed on top of the
radiator. When the coolant level goes down, the
float goes down and the electric current is shut off.
The machine monitor lamp then flashes to indicate
the abnormality.
4) FUEL GAUGE SENSOR
FUNCTION
* The fuel gauge is installed on top of the fuel tank.
The float moves up and down according to the fuel
level. The movement of the float is sent through a
arm to actuate a variable resistor. This sends a signal
to the machine monitor to display the fuel level.
When the display on the machine monitor drops to a
certain level, a signal is generated between the mod-
ules inside the machine monitor, and the warning
lamp lights up.
1. Connector
2. Variable resistor
3. Arm
4. Float
Circuit structure
426F147A
WA600- 1
8’&44 J
5) ENGINE OIL PRESSURE SENSOR
Serial No. lOOOl- .
1. Connector
2. Wire
3. Switch
4. Diaphragm
5. Plug
/@-f$
.-
Circuit structure
423F177A
Serial No. . -
1. Contact ring
2. Contact
3. Diaphragm
4. Spring
‘Circuit structure
FUNCTION 427FO1023
. The engine oil pressure sensor is installed on the

engine block. The diaphragm detects the oil and air
pressure, and when the pressure goes below the spe-
cified pressure, the machine monitor lamp lights up
to indicate the abnormality.
6) PARKING BRAKE SENSOR
1. Connector
2. Wire
3. Switch
4. Diaphragm
5. Plug
c Air
I$$=@
..
Circuit structure
423F177~
FUNCTION
* The parking brake sensor is parking brake solenoid
valve. The diaphragm detects the oil and air pressure,
and when the pressure goes below the specified pres-
sure, the machine monitor lamp lights up to indicate
the abnormality.
WA600- 1 81-45
0
7) AIR PRESSURE SENSOR
FUNCTION
- The air pressure sensor is installed to the wet air tank.
It acts through a diaphragm to actuate a sliding re-
sistor according to changes in the air pressure. This
sends signals to the machine monitor to indicate the
air pressure. If the air pressure drops below the spe-
cified level, it generates a signal to the module inside
the machine monitor, and the warning lamp flashes.
I. Connector
2. Ventilation tube
3. Wire
4. Resistor
5. Resistor selector contact
m 2
Circuit structure
423F181
8) COOLANT TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE SENSOR

Serial No. 10001-10188
1. Connector
2. Wire
3. Tube
4. Plug
5. Thermistor (Beat type)
0
0
Circuit structure
Serial No. 10189 and up 423F176A
1. Connector
2. Wire
3. Tube
(Yellow: Coolant temperature)
(Black: Torque converter oil
temperature)
4. Plug
5. Thermistor
B
Circuit structure 421F01043A
FUNCTION
* These sensors are installed on the engine thermostat goes above the specified temperature, the machine
housing and transmission case. They use a thermistor monitor lamp flashes to indicate the abnormality.
to detect the temperature, and when the temperature
81-46 WA600- 1
/_-;‘
3,
9) ROTATIONAL SPEED SENSOR
FUNCTION
- The rotational speed sensor is installed on the trans-
1. Connector
mission output gear. A pulse voltage is generated by
the rotation of the gear teeth, a signal is then sent to 2. Magnet
the machine monitor, and this displays the travel 3. Case
speed.
Serial No. 10001-10342 Serial No. 10343 and up
Section A-A
Section A-A
==DCircuit structure
Circuit structure
423F 178 421FO1045
10) BRAKE LINE FAILURE SENSOR
1. Ball
1 2 3 4 5 2. Shaft
3. Switch
4. Wire
Circuit structure
423F180
FUNCTION
- The brake line failure sensor is installed to the brake
chamber. When the stroke of the air piston in the
brake chamber goes above the specified stroke (over-
stroke), the rod installed to the brake chamber pushes
the ball and shuts off the electric current. This turns
the switch OFF and the machine monitor lamp
flashes indicate the abnormality.
WA600- 1
8’647
11) TRANSMISSION OIL FILTER CLOGGING SENSOR
fQ3
Circuit structure
425F178
FUNCTION 1. Connector
* These sensors are installed on the oil filter outlet
2. Wire
port. A switch sensors when the filter becomes clog-
ged and pressure rises above the specified range, and 3. Boot
the machine monitor lamp lights up to warn of an 4. Body

abnormality.
12) EMERGENCY STEERING OPERATION SENSOR
1. Shaft
FUNCTION
* This sensor is installed on the diverter valve body. 2. Body
When the hydraulic pressure drops because of ab-
3. Terminal
normality in the main steering circuit, the diverter
valve spool moves and oil flows to the emergency cir- 4. Wiring
cuit. At the same the switch is turned OFF,,and the 5. Connector

vehicle monitor lamp flashes to indicate that the
emergency steering is operating.
*v*
/ WA600- 1
ELECTRIC AND ELECTRONIC
SYSTEM
Standard value table for

electrical system . . . . . . . . . . . . . . . . . . . 82- 2
Adjusting speedometer module
of machine monitor . . . . . . . . . . . . . . . . . 82-2-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . 82- 3
1. The values in these tables are based on the values for new machines leaving the plant, so they should be used
3. These standard value tables must not be used for standard values when judging claims. In addition, do not use
WA600- 1 82-1
@
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Serial No. 10495 - 10880 (except D spec.)
Xonnectol Measurement
Syster Name of component Judgement table
No. conditions
If the condition is as shown in the table below, Starting

the sensor is defective switch ON
mi
Radiatorwater level
CN136
sensor
the sensor is normal switch OFF
Oil level, water level normal Continuity
Oil level, water level abnormal No continuity

Engine oil level sensor CN120

Engine oil level normal Continuity
Engine oil level abnormal No continuity

Air pressure 1 kg/cm* Approx. 1 k.Q

Air pressure sensor CNllO
Air pressure 5 kg/cm’ Approx. 600 a

I

temperature sensor, CN121
engine water temperature CN123
sensor

Fuel level sensor CN127
When engine is running (l/2 throttle or above): Start engine

27.5 - 29.5V
- * If the battery is old, or after starting

Alternator
in cold areas, the voltage may rise
for some time.
82-2 WA600-1
‘10,
nspec-
:onnector ileasurement
Systelr Name of component tion Judgement table
No. conditions
lethod

Short connector connected Monitor OFF
CN60 disconnected Monitor ON

I
Transmission filter
ZN60
iensor If the condition is as shown in the table below, Starting
Filter normal Continuity

I
~ Filter clogged No continuity


I
Emergency steering
CN108
actuation
If the cocdition is as shown in the table below, Starting
Emergency steering stopped Continuity

I
Emergency steering actuated No continuity

1~;;;;;ryt;;xt;~cted 1 ;~vI:;; 1: 1
Brake stroke limit CN61

switch CN62 If the condition is as shown in the table below, Starting

Terminal wiring harness grounded

Engine oil pressure CN249
sensor (Terminal
If the condition is as shown in the table below, Engine
the sensor is normal started
WA600- 1 82-2-l
@.!a
I nspec-
Connector Measurement
System Name of component tion Judgement table
No. conditions
method

switch ON
111
Parking brake switch CN34

Y
:
5
>
.=: Parking brake OFF Continuity
.-z
;
Parking brake ON No continuity
8

switch ON
11,
Brake oil level

CN59
sensor
Y
0 I
If the condition is as shown in the table below,
the sensor is normal
Starting
switch OFF
82-2-2 WA600-1
@a
Syster n Name of component

C0nnect01 lnspec
tion Judgement table
Measurement
No. conditions
netho


Radiator water level
sensor
Oil level, water level abnormal

Engine oil level sensor CNIZO


Air pressure sensor CNllO Air pressure 1 kg/cm* Approx. 1 kC2
Air pressure 5 kg/cm* Approx. 600 n

temperature sensor, CN121 Approx.
Normal temperature (25”)
engine water temperature CN123 37 - 50 ka i
sensor
Approx.
100°C
3.5 - 4.0 kn

Approx.
Fuel level sensor CN127 1 Full tank
12 R or less /
I Approx.
1 Empty 85-110~
When engine is running (112 throttle or above): Start engine

27.5 - 29.5 V
Alternator - % If the battery is old, or after starting

in cold areas, the voltage may rise
for some time.
WAbOO-1 82-2-3
@
Zonnector Aeasurement
Systen Name of component tion Judgement table
No. conditions
nethoc

:he sensor is defective switch ON
Transmission filter
CN105
sensor If the condition is as shown in the table below, Starting
:he sensor is normal switch OFF
Filter normal Continuity
Filter clogged No continuity


I
Emergency steering
CNlOB
actuation
Emergency steering stopped Continuity
Emergency steering actuated No continuity

CN106, 107 disconnected Monitor ON I

Brake stroke limit CN106
switch CN107
Brake normal Continuity
Brake abnormal No continuity

I..::.:::’
Terminal wiring harness grounded

Engine oil pressure CN249
sensor (Terminal
If the condition is as shown in the table below, Engine
the sensor is normal started
82-2-4 WA600-1
@3
Connector
Iripec- Measurement
System Name of component tion Judgement table
conditions
No.
method

Parking brake switch CN34

For is normal switch OFF
If the condition is as shown in the table below,

the sensor is defective
Brake oil level

CN104
sensor Starting
If the condition is as shown in the table below.
I Brake oil level normal Continuity

/
Brake oil level abnormal No continuity
WA600-1 82-2-5
@I
ADJUSTING SPEEDOMETER MODULE OF MACHINE
MONITOR
Serial No. 10001-10494
The same the speedometer is used for all models. How-

ever, the input signals for travel speed are different for
each machine, so the speedometer must be adjusted to
match the model of machine being used.
In addition, if a different size of tire is used, it is also
necessary to adjust the speedometer.
Adjustment procedure
Remove the machine monitor and adjust the adjustment
at the back of the speedometer.
1. Adjustment according to machine model

1) Remove rubber cap II at the back of the
speedometer.
2) Under the rubber cap there is a rotary siwtch.
Rotate the switch with a screwdriver to adjust
as shown in the diagram.
* The adjustment position differs according
to the machine, so adjust to match the
machine.
3) After adjusting, fit the rubber cap on securely
and install the machine monitor.
Machine 1 Switch position 1 Switch setting ~

Driver C-1 423F336
I I
Rotary
1 Switch
WA600 E , RoTn*
P
423F337
2. Adjustment according to tire sizes

‘Reference: Correction factor (%) of switch III
1) Remove rubber cap III on the rear side of the
speedometer. Switch position Correction factor (%)
2) When the rubber cap is removed, a rotary
0 -14
switch similar to switch II will be seen. Then,
1 -12
adjust the switch to a position corresponding to
the tire size by turning the siwtch with a screw- 2 -10
driver. 3 -8
3) After completing the adjustment, restore the 4 -6
rubber cap to tis original position and install
5 -4
the vehicle monitor.
6 -2
Tire size Switch III position 7 0
8 0
35/65-33-24R 7 9 +2
A +4
29.529-28PR 5 8 +6
C +8
* Switch I has no relation to the speedometer
D +1n
adjustment.
Do not touch this switch. The normal position E +12
of this switch is F. F +14
82-2-6 WA600- 1
a
The
according to the model, so it is

necessary
plicable to the model on which it is being used.
In addition, diameter of the tires differs accord-
ing to the type of tires fitted, so it is necessary
Procedure for adjustment
l Turn starting switch OFF. Remove the machine

monitor, and adjust at the adjustment portion at 428FO1416
the rear of the speedometer.

Rotary switch
1) Remove rubber caps 1 and 2 at the rear of
the speedometer.
2) Inside the rubber caps there are rotary

switches. Using a flat-headed screwdriver,
turn the switch to adjust as shown in the
table.
* Switch 3 has no connection with adjustment

of the speedometer, so do not touch it.
1 2 3
F41E01113
3) After completing adjustment, fit the rubber

caps securely, and install the machine
monitor.
Reference Compensation values for switch 2
Switch position 0 1 2 3 4 5 6 7
Suitable setting
/+14/+12~+10/ f8 1+6 I f4 1+2 1 0
(%) / / ! I I I
Switch position 8 9 A 8 C D E F
Suitable setting
i%) 0 -2 ‘-4 -6 -8 -10 -12 -14
u41901770
WA600- 1 82-2-7
@
TROUBLESHOOTING
Check before troubleshooting . . . . . . . . . . . 82- 4

Method of using YES-Nb Troubleshooting
flow chart . . . . . . . . . . . . . . . . . . . . . . . . 82- 5
Connector terminal numbers . . . . . . . . . . . 82- 7
Precaution when handling connector . . . . . . 82-l 1
Electrical wiring diagram and
location of connectors . . . . . . . . . . . . . . . 82-13
Electrical circuit system . . . . . . . . . . . . . . . 82-l 5
Troubleshooting chart for electric system . . . 82-l 9
Troubleshooting chart for electronic vehicle
monitoring system
[Serial No. 10001 - 104941 . . . . . . . . . . . 82-44
monitoring system
[Serial No. 10495 and up (D spec.)]
[Serial No. 10495 - 10880
(Except D spec.)] . . . . . . . . . . . . . . . . . . 82-109
monitoring system
[Serial No. 10881 and up
(Except D spec.)] . . . . . . . . . . . . . . . . . . 82-167
WA600- 1 82-3
,$$,
CHECK BEFORE TROUBLESHOOTING
Item Standard value Remedy
1. Check fuel level Add fuel

2. Check for dirt or water in fuel Clean, drain
3. Check hydraulic oil level Add oil
4. Check hydraulic oil strainer Clean, drain
5. Check brake oil level Add oil
6. Check engine oil level (Level of oil in oil pan) Add oil
7. Check cooling water level Add water
8. Check condition of dust indicator - Clean or replace
9. Check air pressure - Refer to troubleshooting
10. Check for loose or corroded battery terminals - Tighten or replace

11, Check for loose or corroded alternator terminals - Tighten or replace
12. Check for loose or corroded starting motor terminals Tighten or replace
13. Check for abnormal noise or smell - Repair

14. Check for oil leakage - Repair
15. Bleed air from system - Bleed air
16. Check battery voltage (engine stopped) 23 - 26V Replace

17. Check level of battery electrolyte Add or replace
18. Check for discolored, burnt, or bare wiring Replace
19. Check for missing wiring clamps, hanging wires - Repair
20. Checks for water leaking onto wiring (check carefully water - Disconnect connector
leakage at connectors and terminals) and dry connection
21. Check for broken or corroded breaker Replace
22. Check alternator voltage
27.5 - 29.5V Replace
(engine running at overhalf throttle)
23. Noise when battery relay is operated - Replace
(switch starting switch from on to off)
82-4 WA600- 1
a
METHOD OF USING YES-NO TROUBLESHOOTING FLOW
CHART
The electric system can be broadly divided into the following two parts.
1. Starting system, transmission electrical control system, brake system.

2. ELECTRONIC VEHICLE MONITORING SYSTEM.
The charts for these systems are marked as E-xx, and M-xx respectively.
E-XX Troubleshooting of starting system, transmissionelectrical control system, brake system.
M-XX T Troubleshooting of electronic vehicle monitoring system.
1. Method for troubleshooting YES

. Check or measure the items inside the rectangle I--/I
NO
According to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle. (Note:
The number given at the top right of the rectangle is a reference number. It does not indicate the order for
troubleshooting.)
. If the result of the check or measurement leads directly to the CAUSE column, note the cause and take the
action given in the REMEDY column.
. The value for the check and the measurement method is given inside the rectangle. If the value is correct, or
the answer is yes, follow the YES arrow; if the value is not correct, or the answer is no, follow the NO arrow.
. Below the rectangle, there is a list giving preparatory work, methods of operating and handling, and judgement
values needed for checking and measuring. If the preparatory work is ignored, or the wrong method of operat-
ing or handling is used, or the judgement is wrong, this could result in damage to the equipment. Therefore,
always read the procedure carefully before starting the check or measurement, and carry out the operations
In the order given.
2. Precautions when carrying out troubleshooting

The precautions to be followed when carrying out troubleshooting for each failure is marked *under the descrip-
tion of the failure. Always follow these precautions when making measurements.
3. Tools needed for troubleshooting

The tools needed for troubleshooting foreach problem are listed as follows.
Troubleshooting
tools
Prepare these tools before starting troubleshooting.
4. Place to install connectors, connector pin numbers

When troubleshooting some problems, measurements have to be made of continuity, voltage and resistance at each
step during the troubleshooting procedure. The location for measurement at each step (location of connector,
connector pin number) is shown in a photograph or diagram. For this reason, use these photographs together with
the YES - NO type troubleshooting flow charts to carry out troubleshooting quickly and accurately.
WA600- 1 82-5
0
Example
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnect-
ing the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (ro socket adapter), connect to the connector specified. (CNxx( ))
* When disconnecting connectors or connecting T-adapters, return them to the orifiganl condition immediately after
checking, then go to the next check.
a) m (BRAKE OIL LEVEL) FLASHES.
Defective brake oil level

sensor
Defective CHECKES BEFORE

STARTING module
1) Connect short
socket adapter 3
to CN59
(female) (brake
oil level sensor1
2)Turn starting
switch ON
Is there continuity
YES
2 rl Is there continuity
between CNP4
(female) (41 and
IS)?
between CN59 1IConnect

short
socket adapter
to CN59
(female). ti0
c Disconnection in wiring After inspection,
1) connect 2)Connect harness, or defective contact repair (clean1 or
T-adapter (or T-adapter (or between CN59 (female) 11) rep&e
socket adapter) socket adapter) - CN64 (2) - CN65 (31
to CNP4 (female). - CNP4 (female) 14)
to CN59
(female). 3)Turn starting
2)Turn starting switch OFF.
switch OFF.
NO
Disconnection in wiring After inspection.
harness between CN59 repair (clean) or
(female) (2) - CN64 13) - WElICe
Tester Short socket adapter
Troubleshooting CN65 (4) - chassis ground.
tools
T-adapter or socket adapter
T-adapter (for DLII
POSITION OF CONNECTOR
CN59 (female)
CNP4 (female)
82-6 WA600- 1
‘3
CONNECTOR TERMINAL NUMBERS
ECONOSEAL CONNECTOR
Connector
Female terminal (Socket) Male terminal (Pin)
CN17, CN21
a
CN34, CN35
CN59, CN60
CN61, CN62
CN88, CN98,
CN108, CNl06
CNllO, CN12(
CN121, CN12:
CN123, CNI 2;
CN136 142F401 A 142F400A
CN40
CN41
CNl16
CN125
CN126
i
142F403A 142F402A
a
CN42
4 3
2 1
142F405A 142F404A
CN14
CN85
CN86
CN115
CN136
142F407A 142F406A
7 11 12 10
CN15
CN16
CN31
CN77
CN78
CN79
CN89
CN114
6 2 1 3
142F409A 142F408A
WA600- 1 82-7
0
DLI CONNECTOR (For monitor panel)
Connector
CNPl
CNP3
CNP5
CNP7
142F418 142F419
CNP2
142F420 142F421
CNP4
CNP6
CNP8
CNPlO
142F422 142F423
82-8 WA600- 1
ii:
N-SLC CONNECTOR
CN12
CNI?
CN22
CN23
CN93
CN94
CNlOO
423F349 4’3F35C
CNll
2 3 3’ ‘2
423F351 423F352
CN18 1 2
CN20
CN119
B
3
423F353 423F354
4 6
423F355 423F355
423F357 423F358
WA&OO- 1 82-9
i.7
BENDIX CONNECTOR
No. of Pins
14
423F346 423F347
10
421FO1132 421FO1133
No. of Pins RELAY CONNECTOR
423F348
WA600- 1
PRECAUTION WHEN HANDLING CONNECTOR
1. If the connector has a lock, always release the lock

before disconnecting the connector.
When connecting, align

this arrow and push in.
Be sure to fit rubber When removing, press
When conn’ecting, align
cover tightly. this part and pull
the auide inside the
n the connector out.
conriector and push in.
n removing, press in
on both sides and oull
the connector out: F142A093
F142A092
2. Never pull the cord to disconnect the connector.
F142A094 F142A095
3. If the connector is difficult to disconnect, do not

try to pull it out.
(If it is difficult to reach by hand, remove the clamp
and move the wiring harness.)
This must be removed. ,
F142A096
WA600- 1
4.
F142AO97
(Do not use any connector which has

deposits left on it after drying.)
Coat with contact restorer.
(When drying, be particularly careful to dry the gaps
in the rubber.)
6. When assembling the connector, be sure to fit it

correctly. F142A098
(For connectors with locks, it should be possible to

heat the locks click as they fit completely into
position.)
F142AlOO
F142A099
Correct any protrusion of the boots
82-12 WA600- 1
0
ELECTRICAL WIRING DIAGRAM AND LOCATION OF
CONNECTORS
Serial No. 10001 and up (D spec.) 1. Preheat switch
Serial No. 10001-10880 (except D spec.) CN134 2. Working lamp switch
3. Parking lamp switch
CN70 CN71 cCN77 CN136 4. Starting switch
\ I / CN78 CN13T 5. Transmission cut-off selector
CN72 \ i / / CN79
CN120 switch
CN40
19 6. Fuel cut-off switch
7. Circuit breaker
8. APS switch
CN123 \J i
9. Bimetal timer
CN127 \ 17 'B /
10. Resistor
View W 11. APS relay
CN5? 12. APS controller
13. Controller
(Serial No. 10001-10494)
14. Warning buzzer
15. Engine oil pressure sensor
~1 View z C 16. Engine water temp. sensor
17. APS water temp. sensor
18. Fuel cut-off solenoid
(Serial No. 10001-10342)
Engine stop motor
19. Radiator water temp. sensor
20. Alternator
21. Engine oil level sensor
22. Main breaker
23. Battery relay
24. Fuel level sensor
25. Starting motor
26. Torque converter oil temp. sensor
27. Emergency brake switch
28. Air pressure sensor
29. Brake oil level sensor
30. Brake line traveling sensor
View X
31 Transmission oil filter clogging
sensor
Serial No. 10495 and up Speedometer sensor
32
CNP2 CNPl CNP4 CNP5 426FOlOll
34. Lift proximity switch
35. Parking brake solenoid valve
36. Parking brake display switch
37. Bucket proximity switch
38. Engine stop motor relay
View X
CN84
CN3i ‘CN88
\
CN65
View V
WA600-1
82-13
cs
1. Preheating switch
2. Working lamp switch
3. Parking brake switch
4. Starting switch
6. Engine stop switch
(CN58)
CN6
7. Fuse box
75
8. APS switch
CN1f 4
CN123 9. APS controller
10. APS relay
_CN135 11. Bimetal timer
12. Resistor
CN122
13. Back-up lamp relay
14. Foward travel solenoid relay
15. Kick-down switch relay
16. 2nd-1st selector relay
CN164
17. 2nd solenoid relay
18. Reverse solenoid relay
19. Warning buzzer
CNll? 20. Stop lamp switch
22. Engine oil pressure sensor
f View Y .CN112
B 23. Engine water temperature
sensor
24. APS water temperature sensor
CN32 25. Engine stop motor
26. Engine water temperature
CN85 sensor
27. Alternator
28. Engine oil level sensor
‘CN115 29. Main breaker
CN31
CN114 30. Battery relay
31. Fuel level sensor
CN108
32. Starting motor
33. Torque converter oil tempera-
ture sensor
View V 34. Emergency brake switch
35. Air pressure sensor
CNP2 CNPl CNP4 CNP5
36. Brake oil level sensor
\ \ / \‘\ K -%
37. Brake chamber limit switch
38. Transmission oil filter clogging
426FO1112
sensor
\ 39. Speed meter sensor
39 40. Lift proximity switch
CN98 41. Parking brake solenoid valve
42. Bucket proximity switch
View X
82-14 WA600- 1
8
ELECTRICAL CIRCUIT SYSTEM
ENGINE STARTING CIRCUIT SYSTEM
Starting switch To APS controller
Main
Serial No. 10881 and up (except D spec.) 426F267
Transmission control switch

----
3ttery relay
CN,C$ I
To meter panel
//I
Main switch
To fuse box
Ii Main breaker
L===C
Starting motor 1
428FO1418
WA600-1 82-l 5
8
ENGINE STOP CIRCUIT SYSTEM
Serial No. 10001-l 0342
II II II To starting motor I
CN 77
Main
426F268

Serial No. 10343-I 0880 (except D spec.)
Main switch
CNI4
To starting mater
terminal B
1
To Circuit breaker
426F01113
82-16 WA600- 1
8
Enaine stoD relay Batterv relay
Main switch
To starting motor
B terminal
Main
FULL STOP
r- 1%
Alternator
428FO1419
WA600-1 82-17
0
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM

I
ParkIng
/
/ I
1
Meter pane,
J
/ Parklng brake relay

/
Meter panel To heater Watch
Transmlss~on
Cut-off S&Cl
5 To alternater
CN89
426F269-2
82-18 WA600-1
@
Parking
brake valve
Parkmg brake
safety relay
Emergency brake
SWl,Ch
Transmission
cut-off swttch
Matn breaker
OFF
ParkIng brake
switch
ON
- ..---..
r Transm,ss~o”
control
- __._-____ --- To startmg mote
Speed selector relay

(2nd-1st)
Soleno,d relay
(Forward)
Klckdown swfch relay
Klckdown watch
1; I -Tostoplamp&backupfuse
To backup lamp
CN196
426FO1114-1
WA600-1 82-18-1
03
PARKING BRAKE SYSTEM
Serial No. 10001-10880 (except D spec.) Parking Parkmg brake Neutralizer
safety relay relay reiay
To transmission
control
Serial No.
10495 and up Emergency brake
switch
1 Meterpanel j Meter panel 1 Parking brake

display switch
426F270-2
Parking Neutralizer
safety relay relay
- 1 Tocontrol 1 I
Parking
brake switch
Meter panel Parking brake

display switch
426FO1115-1
82-18-2 WA600-1
0
APS relav
Eimeial
I
ilr r
To c,rc”lf
Main breaker
breaker
Meter panel
APS relay
Meter panel
II
i
APS relay
Fuse box II Fuse box II-1 APS
Bimetal I ZLW‘” m
c- To fuse box -
A To engine stop motor
I
Main switch
I Alternater
Meter panel
Heat
426F272.2
82-18-6 WA600- 1
‘8,
z
0
82-18-8
8
VEHICLE MONITOR SYSTEM
Serial No. 10001-l 0494
Emerg+y S/T
Speedometer
426F273
WA600-1 82-18-9
Go
IHead & Turn signal lamp switch 1

Caution iamp
Transmission
cut-off switch
Caution IamP
426FO1122
82-18-10 WA600-1
8
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM
(E-l. to E-l 7.1
CONNECTOR TYPES AND LOCATION OF COMPONENTS . . . . . . . . . . . 82-19-I
ENGINE STARTING AND STOP CIRCUIT

E-l .. Engine does not start. ...................................... . 82-20
E-2. Engine does not stop ....................................... 82-22
E-3. Engine stop when traveling .................................... 82-23-l
PARKING BRAKE CIRCUIT

E-4. a) Parking brake does not work (Parking brake switch ON) .................. 82-24
b) Parking brake does not work (Air pressure less than 2.0 kg/cm21 ............. 82-24
E-5. Parking brake is not released ....................................... . 82-26
E-6. Parking brake is released when starting switch is turned to ON ................ 82-27-3
E-7. Transmission is not returned to neutral when parking brake is applied ........... 82-29
I
TRANSMISSION CONTROL CIRCUIT Serial No. 10001 and up (D spec.)
i Serial No. 10001-10880 (except D spec.)
E-8. Machine ...............................
does not travel forward 82-30
E-9. Machine does not travel reverse ................................ 82-32
E-IO. Transmission does not shift gear (F-R direction normal) ................ 8234
E-l 1. Machine does not travel when transmission cut-off selector switch is ON _. 82-36
E-12. Transmission cannot ................................
be cut-off 82-37
E-l 3. Transmission does not return to neutral .......................... 82-38
TRANSMISSION CONTROL CIRCUIT [Serial No. 10881 and up (except D spec.)]

E-8. Transmission does not work normally ............................ 82-39-2
E-9. Kick-down switch does not work ............................... 82-39-23
E-10. Kick-down only works when kick-down switch is ON ................. 82-39-26
E-l 1. Kick-down operation ............................
is not canceled 82-39-27
E-12. Kick-down works mistake when traveling in F2 ..................... 82-39-29
E-13. Machine does not traveling when kick-down switch is pressed ............ 82-39-29
PREHEATING CIRCUIT
E-l 4. Preheating is not carried out .................................. 82-39-32
E-15. Preheating display does not go out ............................... . 82-42
E-l 5A. Preheating stays ON ....................................... 82-43
E-16. Afterheating does not display ................................. : 82-43-3
E-l 7. Afterheating display does not go out ............................ 82-43-3
WA600-1 82-l 9
8
CONNECTOR TYPES AND LOCATION OF COMPONENTS
Battery relay (a) (x 2) Starting switch
426P104
CN116 (battery relay input)
Econoseal 3-pin
CN11 (parking brake switch)

N-SLC connector 3-pin
1 1
E3 2 3 3 2
ing brake switch
CN18 (transmission cut-off selector switch) Working lamp

CN~IJ (preheating switch) switch
N-SLC connector
Preheating switch
1 2 2 1
B
cw20 ci12
3 4 4 3 428F01427A-K
CN13 (fuel cut-off switch)

1
FB
Central warnin; lamp C‘N17CNjj8F0,429A_K
82-19-l WA600- 1
0
CN14 (starting switch input)
Econoseal 8-pin
CN16 (directional lever, speed lever input)

428FO l42E
Econoseal 12-pin
62 13 31 26
CN21
m
1 1
‘d: Parking brake solenoid

e: Parking brake display switch
!
WA600-1 82-19-2
8
CN65 (intermediate connector)
Econoseal 12-pin
CN70 (parking brake safety relay)

CN72 (neutralizer relay)
Relay connector
CNM CN69 CN70 CN72 CN76 CN73
6’ ‘3
CN77 (fuse box 11-2)

CN78 (fuse box 11-I)
E conoseal 12-pin
I
- To left console
box
CN78
CN88 (bimetal timer) CN77

KES connector 3-pin
CN52
surface of floor
421F01137A-K
CN67 A f-----A
CN82 (APS unit)
KES connector B-pin
3 6
- Bimetal timer
Resisto;
426FO1136
82- 19-3 WA600-1

i’$
Econoseal 8-pin

Econoseal 12-pin
10 12 11 7 7 11 12 10
------
m Im
k----x
62 13 31 26
CN99 (transmission control valve)

MS connector 1 O-pin
CN102 (APS water temperature sensor relay)

Relay connector
CN88
APS switch
Bmetal timer
/ ‘\
6 3
Resistor
426FOl i3E
CNI 33 (emergency brake switch)
Econoseal 2-pin
WA600-1 82-19-4
@
Econoseal 12-pin
CNI 19 (glow plug)

a: Glow plug
b: Glow plug
CN125, CN126 (starting motor (b) inlet port)

Econoseal 3-pin
2 3
[II
1
1
CNI 17 (engine stop motor)

Econoseal 8-oin
31 25
82-19-5 WA600-1
@I
CN73 (engine stop motor relay) cNfj8 CN69 CN70 CN72 EN76 cy73
CN59 (2nd speed solenoid relay)
CN60 (2nd-1st speed selector relay)
CN63 (backup lamp relay)
Relay connector
Alarm buzzer
CN58 (reverse solenoid relay)

CN61 (kick-down switch relay)
CN62 (forward solenoid relay)
Relay connector 6-pin
-APS switch
Bimetal timer
CN67 (kick-down switch) 426FO1136
WAbOO-1 82-19-6
8
TROUBLESHOOTING CHART No. E-l m
Failure mode: ENGINE DOES NOT START.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( ))
* When disconnecting connectors or connecting T-adapter, return them to
the original condition immediately after checking, then go to the next Cause Remedy
check.
* If the head lamps and other electrical parts are not working normally,
check battery - battery relay - starting switch first.
YES
(a) Checking startil “9 c:ircuit 2- Defective starting motor Replace
assembly.
IS there continuity
YEis r between CN125
and CN126 (fe- _
male) (3) and YES
chassis ground? 4fterchecking.
.epair or replace
harness between CN125
1)Disconnect CN 125 Is there continuity and CN126 (female) (31 -
and CN126 between CN 16 CNl 14 (7) - CN85 (8)
ing mOtOr inlet). - CN 16 (female) (9) or
2) Place F-R lever at defective contact or dlscon-
N. nection in wiring harness
3)Tum starting 1 Iconnect between F-R switch and
switch OFF. T-adapter (or chassis ground
CN125andCN126
(female) (1) and
socket adapter)
toCN16.
NO Defective F-R switch. 4fter checking,
2) Place F-R lever at .epair or replace
N.
3lTurn starting
1) Disconnect CN125 switch OFF.
and CN126 (start-
ing motor ass’y). YES
Defective contact or r\fter checking,
2) Measure with
disconnection in wiring .epair or replace
starting switch
H
at START. harness between CN125
Is there continuity and CN126 (female) (1) -
between CN 14 CN114 14) - CN85 (51 -
NO (female1 (3) and I1 I? CN14 (3).
L
11 Connect I Defective starting switch Replace
T-adapter (or ND
socket adapter)
toCN14.
PIMeasure with
starting switch
at START.

Tester
Troubleshooting I (for Econoseal)
tools 1
CN125, CN126 (female)

CN14 (female)
. Battery relay - Starting switch
425F216 425F217
WA600- 1
Remedy
(b) Checking battery - battery relay - starting switch

YES
2 I c rfter checking.
jisconnection in wiring epair or replace
Isvoltage between harness between battery
YES both thick relay and starting motor
- terminals of battery - assembly.
relay and chassis
ground 20 - 3OV’
1 11Turn starting c
If NO for both terminals rfterchecking.
switch ON NO defective contact or epair or replace
2lMeasure voltage disconnection in wiring
Is there sound of between two harness between battery and
battery relay _ terminals battery relay.
working7 connected by If NO for one terminal leolace
thick insulated defective battery realy
cable
1 ITurn starting
swtch ON -
YES
OFF. I y Defective battery relay 7eplace
Defective contact or dis- \fter checking,

connection in wiring har- epair or replace
ness between battery relay
chassis ground 20 (+) terminal - CNl 16 (21
NO 4 - Diode - CN85 (2) -
terminal Band CN14 (2) - starting switch
El
1 )Turn starting Is voltage between terminal BR.
switch ON. starting switch
terminal Band
chassis ground 20 1 )Turn starting Defective starting switch
- 3ow switch ON.
1 i connect
T-adapter (Or
socket adapter) Defective contact or Prfter checking.
m
toCN14 NO disconnection in wiring ,epair or replace
(female). harness between batter,
Z)Turn starting relay-CN116(1)-
switch OFF. CN85 (71 - CN77 (1) -
Breaker - CN77 (2) -
T-adapter or socket adapter CN14 11) - starting witch
Tester (for Econoseal) terminal 6.
Troubleshooting
tools
CN85
CN116 (female)
i i 1 3
CNI 14
CN14 (female)
CN77
10 12 11 1 ~~52 CN?,, CN78 $N79 FN80
WA600- 1 82-21
8
c) inspection of starting switch - engine stop motor

YE between CN227
1
1) Disconnect I
CN227 NO
El
1
Does engine stop
motor cable work’
I Turn starting
switch ON -
OFF and check
YE
El
Is continuity
between CN227
(female) (3) - (7).
(5) - (7) as show”
in Table 17
3
6’
YES
visuals. 1) Disconnect
Is there continuity
CN227 YES
_ between CN236(2) _
and chassis?
5_
1) Disconnect
Is voltage between CN236 NO
. CN236 (1) and
h chassis 20 - 3OV?
1) Disconnect
CN236
2) Turn starting
1, ulsconnect switch ON. NO
CN227
Table 1
WA600- 1
82-21-l
0
Cause Remedy
I
Defectwe adjustment of lankage Adlust ISee Shop

between
engine
stopmotor and Manual Engme
g0”W”“r volume1
Defective engme stop motor ReplaCe
Defective contact. or disconnec

rio” in wring harness between After ,nspect,on,
’ CN227 (femaie) (8) and chaws repau or replace
ground
Defective engine stop relay. Or

defective contact, or disconnec-
tion I” wring harness between After rnspecto”,
’ CN227 (female) (5) - CN236 repa,r or replace
(5). or between CN227 (female)
(7) - CN236 (3)
Defectwe contact, or dlsconnec

After ,nspect,o”,
tton in wiring harness between
repalrorreplace
CN236 (2) and chassts ground
Defectlve kill switch, or defec-

tive contact. or dtsconnectio” !r
AfterInspection.
repaur or replace
--starting swtch terminal ACC
Defective contact. or dlsconnec-

tion in wiring harness between After-mspectlo”.
CN227 (female) (4) - CN115 (1) repa,r
Drreplace
- CN65 (9) - CN77 (2). (1) -
CN85 (7) - CNl16
CN236 CN227
52 13
CN236
‘_
.. / /
b 426FO1137
WA600-1 82-21-2
8
c) Inspection of starting switch - engine stop motor
YES
4
Is there continuity
‘ES between CN117
(female) (8) and
chassis?
------I
1) Disconnect
CN117.
NO
1
I Does engtne stop

motor cable work?
Is continuity bet-
Ii
1 Turnstamng
YfIS
l-
wee” CN117
IfemaleJ 13) - (7).
swtch ON - 151- (7) as shown YES
OFF and check inTable 1)
visually. II Disconnect
CN117. ‘YE
pjyG$[_
n CN73.
Is voltage
between NO
I
CN73 (1 and chassis
Isvoltage between
CN117 (female) (4)
and chassis 20 -
NO 11 Disconnect
i 3ov7 t CN73.
2) Turn starting
1) Disconnect switch ON.
CN117.
NO
Table 1
Dperatlon Continuity
(3) - 171: (5) - 171.

Stanlng switch ON No continwty Contlnulty I
I Starting swttch OFF (5) - 171. (31 - I71
No contmuitv Continultv
82-2 1-3 WA600-1

1%
.’
Cause Remedy
Defectwe adjustment of lhnkage Adlust (See Shop

. between engine stop motor and Manual Engine
governor YoIumeI
. Defective engine stop motor
Defecrive contact. or dw
connection in wiring harness After mspect!on.
- between CN117 (female) (8) repaIr or replace
and chassis ground
Defective engine stop relay,

or defective contact, or dis-
connection in wiring harness
between CN117 (female) (5) After mspect~~n.
- CN73 15). or between repair or replace
CN117 (female] (7) - CN73
(31
Defective contact. or dis-

connection in wiring harness After mspectnn,
1 between CN73 (2) and chassis repair or replace
ground
Defective kill swtch. or defec-

tive contact, or disconnection
in wiring harness between After Inspectnn.
- CN73 It) - CN13 121. (1) - repaIr or replace
CN14 (5) - starting’ &itch
terminal ACC
Defective contact. or dlsconnec-

tion in wiring harness between
After mspectio”.
CN117(female)(41-CN115ll
repaIr or replace
- CN65 (9) - CN77 121. 11) -
CN85(7)-CN116ili
WA600-1 82-2 l-4

8
TROUBLESHOOTING CHART No. E-2.
Failure
When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnect-
ting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (
*
Serial No. 10001-10342 Cause
YES
d Iefectlve adjustment of See 12 TESTING
4ND
1 I inkage between fuel cut
r-----w
Does spool of fuel _
solenoid and governor 4DJUSTING
:NGINE
OF
cut solenoid work’ NO 2 YES

Defective fuel cut solenoid Replace
, Is voltage between
CNl 15 (female) (1)
Turn stamng switch _
and chassis ground -
ON - OFF and check _(,,
““I
vlsuaily
I
1) Connect T-adapter
to CNl 15 (female1 Wrong wirinq or contact After Inspection.
2)Turn starting between +?4V wiring har- repar or replace
switch OFF ness and CN14 (male) (51
fuel cut off switch -
cN86 (81 - CNl 15 (1)
Defectwe starting switch

Turn starting switch NO
OFF.
Tester T-adapter or socket adapter

Troubleshooting
tools
Fuel cut-off solenoid (a)
CNl 15 (female)
82-22 WA600- I
@
Cause Remedy
YES Defective adjustment of linkage Ad,ust (See Shop

between eng,ne str,p motor and Manual Engine
governor VOlUflWl
1 Defective engine stop motor or

relay. or defectwe contact, or 3eplSX
3 disconnection is wiring harness
engine between CN236 (3) (female) -
Is voltage between ifter Inspectlo”.
CN227 (7). (8) - chassis grounc epalr or replace
CN236 (6) (female)
c ;;w&hassis 20 -
1 I Turn startmg Defectwe contact. or disconnec-
2 tion in wlrlng harness between
switch ON -
1) connect NO CN236 (6) (female) - CN227 After mspect~o”.
OFF and check
T-adapter (31. (4) - CN77 (2) rep?.,r or replace
visually. Is voltage between
L CN236 (1) (female) - (socket adapter) to
NO and chassts OV? CN236 (female).
Contact between + 24V and
4 YES wirmg harness between CN14
L 4 After Inspectlo”.
1) connect (6) (male) - kill switch CN236
‘epalr or replace
T-adapter (1). or misconnected wiring
(socket adapter) to
CN236 (female). F
2) Turn starting
switch OFF. Defectwe starltng swtch ReplaCe
1I Turn starting
switch OFF
3efectwe adjustment of lmkage AdJust (See Shop

YES
between engme stop motor and Wanual Engme
governor rrolumei
Defective engine stop motor

or relay. or defective contact ?epiXZ
3 YES or disconnection in wiring
harness between CN73 (31
Does engtne
stop (female) - CN117 17). (8) ifter InspectIon.
motorcable work, YE chassis ground epa,r or replace
Defective contact. or dls-

1) Turn starting connection in wirina harness
switch ON - between CN73 161 (iemalei After ,“spectm”.
OFF and check CN117 (3). (4) - CN77 (21 ‘epalr or rep!ace
T-adapter
visually
(socket adapter)
to CN73 (female).
Contact between i24V and
4 YES wiring harness betwen CN14
xfter Inspectra”
(5) (male) - kill switch CN73
‘epalr or replace
(I), or misconnected wiring
Defective starting swtch

1) Turn starting NO
switch OFF

TrO”ble- (for Econoseal)
shooting
tools
WA600-1 82-23
@
Failure mode: ENGINE STOPS WHEN TRAVELING.
* When disconnecting connectors or connecting T-adapters, return them to
the original condition immediately after checking, then go to the nex t
check.
F
Cause Remedy
Serial No. 10001-I 0342
YES
Table
1 Defective adjustment in
llnkage between fuel Cut
solenoid and governor
See 12 TESTING
AND
ADJUSTING OF
ENGINE.
YES
1 Fuel extended Approx. 0.812 1 Defective contact, or After w.pection.
disconnectlo” in wiring repair or replace
Fully retracted (Pushed I” Approx. harness between starting
with pressure of approx. 4 kg) 50 - 6511 switch terminal BR -
Does spool of fuel
cut solenoid work? CN86 (4) - CN115 (1)
YE
Turn starting switch
ON - OFF and check 3 terminal Act and
chassis ground
visually
ES
k
between CN115l3)
(female) and 1) Turn starting
chassis ground’ switch ON.
between CN115
L (male1 11) and 1 I Connect T-adapter Defective startmg switch
nIO (3) as shown in (socket adapter) to NC
CNl 15 (female)
2lTurn starting
1 )Connect T-adapter switch OFF.
(socket adapter) to
CNl15 (male)
2)Turn starting Defective chaws ground, or After inspection,
switch OFF. defective contact, or repair or replace
disconnecbon in wiring rep,ece.
harness between CN 115
(3) (female) and chassis
ground
Defective fuel cut solenoid Replace

NC

Troubleshooting (for Econoseal)
tools
Fuel cut-off solenoid (a)
CN115
CN86 Starting switch (a).
5 2 1 3
425F217
82-23-7 WA600-1
8
Cause
3efect,ve ad,ustment of llnkage 4djust (See Shop

between eng,ne stop motor ant Manual Engtne
gCl”W”0r volume1
5 YE:
Defective engine stop relay
Doeseng,nestop
motoicalbe work - Defective contact, or disconnec
normally? tmn I” wring harness betweer differ inspection.
~ ;TNo2u3R) Ifemale) - chassis .epa,r or replace
Yf
1 i Turn startmg
watch ON -
Defective engine stop motor. or SSpLKe
OFF and check
2 L I
contact between t 24V and WII
VIsUallY 1) connect ,ng harness between CN236 (3 4fter LnspectIo”.
T-adaprer
k voltagebetween (socket adapter) to No
(female) - CN227 (71. (81 - .epa,r or replace
_ CN236 (1) (female) chassis
CN236 (female).
NO and chassis ZO- 2) Turn starting
3OV’ switch ON. Defective contact, or disconnec
4 YFS t,on I” w,r,ng harness betweer After,nspect,on,
11 Connect
T-adaoter
j
CN236 (1 (female) -- kil swtct repaw or replace
-CN14(5)(maie)
(sock& adapter) to
CN236 (femalei.
21 Turn stait~ng
switch ON. Defectwe starting switch ReplXe
NO
v _ efectlve ad,ustme”t of Ilnkagc Adjust (See Shop

between eng,ne stop motor ant Manual Engine
1
governor volume1
YES1
Defectw eng,ne stop relay RepkXX
is there continuity
YES between CN73 121 _
3 - (female) and
- chassis, Defective contact, or dls
connect,on ,n wylrjng harness After ,nspec!Ion
YES is voltage between 1) Turn starting NO between CN73 (21 (female1 .epa~r or repiace
1) Turn starting - CN73 (31 (female) - switch OFF. chaws ground
switch ON - and chassis 0’0
OFF and check Defectwe eng,ne stop motor. or 3epkKe
2 contact between 4 24V and WI’
VlsUally t 1) connect
_ ing harness between CN73 I31 \fter inspectlo”
T-adapter
Is voltage between (female) - CN117 17). (8) - epa,r or replace
(socket adapter) No
_ CN73 (1) (female) _ chassis
to CN73 ifemale).
JO and chassis 20 -
2) Turn starting
3ow
switch ON. Defective contact. or dw
4 YES connectIon in wiring harness 4fier Inspection.
1) Connect
between CN73 (11 (female) - xpair or replace
T-adapter Is voltage between kill switch - CN14 15) [male)
(socket adapter)
to CN73 (female). L- ‘tart’“’ switCh
Nr) terminal ACC and
2) Turn starting
chassis 20 - 3OV7
switch ON.
1 I I
NO

(for Econoseali
WA600- 1 82-23-2
@
Failure mode: a) PARKING BRAKE DOES NOT WORK. (PARKING BRAKE SWITCH ON)
* When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
* Parking brake lamp does not light up. Table
* Even when air pressure drops, parking brake does not work.

a) Parking brake does not work (Parking brake with ON)

YES
YES
CN35 (1) (male)
1) Connect
T-adapter (or NO 2 4
socket adapter)
to CN35(malel Is there continuity
2)Turn parking Yf between CNl1
brake switch ON (male) (1) and (2)
(parking). 1 asshownintable? 1
3) Start epgine
charge air 1) Interchange 11Disconnect
pressure. CN73 (back-up CNll.
lamp r&Y) and Z)Turn starting
CN7 1 (parking switch OFF.
brake relay).
2)Turn parking IO
brake switch ON
(parking). Is problem
3)Start engine , removed when
charge air 1 disconnect CN7 1 ?
pressure.
1) Disconnect
CN71. cm
2) Start engine
charge air
pressure.
b) Parking brake does not work. (Air pressure less than 2.0 kg/cm2 )
YES
I
Is work parking
brake when
disconnect
CNlOS?
_ NO
1)Starting switch
ON.
2) Parking brake
switch OFF.

Short socket adapter
tools
Tester
82-24 WA600- 1
0
CN35 (male)
Cause Remedy
)efectwe parking brake eplace

;olenoid
CN71, CN73 Serial No. 10001-10494
2 I
Defective parking brake relay Xeplace
YES
4bnormal contact or ifter inspection.
nistaken winng between epair or replace
CN 1 1 (female) (1) -
CN66 3
I_
(6) - CN109 (11.12) -
CN65 (7) - CN71 (2).
1 Defective
switch
parking brake %soiace
Serial No. 10495-10880
CN238
Abnormal contact or After inspection.

mistaken wiring between repair or replace CN74 CN+3 CN72 CN70 CN71
CN71 (male) (51 - CN31 426FOll38
(1 1) - CN35 (1).
CNI 09 (male)
Defectwe emergency brake R.+SCX

switch
Defective parking brake. Repair
CNI 1 (male)
3 2
WA600- 1
82-25
0
Cause Remedy
a) If parking brake does not work when parking brake switch is
ON (applied).
YES
Defective parking brake swltcl R.+XX
YES :o”tact of wiring harness at After inspecton.

VI I
L ZNl 1 (female) (1) and (21 repair or replace
1 I Disconnect Is there continuity

CNll
N
s between CNl 1
21 start engrne (female) (1) and 121) 3 YES
Defective parking brake solenc
iChargea,r
pressure) - Is voltage between
3) Turn parktng 1)Disconnect L CN35 jfemalei 11 j
brake switch ON CNll. and chassis approx
2)Turn starting NO
ov,
switch OFF. Contact of wiring harness at After Inspection,
31 Disconnect :Nl 1 (female) (1) and (3) repair or replace
1) Connect NO
CNX.
T-adapter
4) Disconnect
(socket adapter)
CN70
to CN35
21 Starte”gl”e
(Chargear
Pressure)
3) Turn parkIng
brake switch ON
b) If parking brake does not work then air pressure has dropped.
(does not work as emergency brake)
1 YES Defective emergency brake

I I
H
I iwtch
is problem removed
when CN133 IS dls-
connected?
57zzz+’ switch ON
NO lefective parklng brake solena
21 Turn park,ng
brake swtfch ON
-OFF
T-adapterorsocket adapter
Trouble- (for Econoseali
shooting
tools
82-25-l WA600-1
Failure mode: PARKING BRAKE IS NOT RELEASED.
* Parking brake lamp does not light up.
* Even when air pressure drops, parking brake does not work.

3 YES
I II
Is there continuity
YES between CN35
(male) (2) and -
chassis ground?
NO
1 I connect
T-adapter lor
socket adapter)
to CN35 (male)
2iTurn starting
CN35 lmalei 1: 1 switch ON.
and chassts ground
BITurn parking
20 - 3OV?
brake swtch
ON-OFF.
1) connect
T-adapter (or
socket adapter)
to CN35
2) start engwle
NO 4 6
(charge air
voltage
I I
Is between
pW$SUrei
CN71 (female) (2)
3)Turn parking ~od~h;~as,ground
brake swtch
ON-OFF. YES
1 IInterchange 1) Disconnect
NO 7I
CN73 (back-up CN71 Is Droblem I
lamp relay) anb 2)Start engine r&wed when
CN71 (parking (charge air shott socket
brake r&v). oressure). adapter is
21 start eng,ne
(charge air
B)?urn parking
brake swtch ON
connected’ I NO a
pW%SUd -OFF. 1 )Connect short
socket adapter
Is air pressure in 3)Tum parking
b2;;Fswitch ON
NO 5 toCN109
removed when
reservoir normal !7
(female).
CN71 (female) 13) 2istart engine
and chassts ground (charge air
pressure) 1 I Interchange
20 - 3ov7
1: start eng,ne CN73 (back-w
3lTurn parking
(charge 88r
“_raFF;,witch ON
iamprelay) anb
p:essure) 1)Disconnect CN70 [parking
CN71 brake safety relay).
2ITurn starting 2)Start engine
switch ON. (charge air
pressurei.
3)Turn parklng
bra;e;,wltch ON
NO
IO
W Troubleshooting for air circut
Tabie 1
t
?-adapter or socket adapter
/ ~~;~~mmng ‘forEconoseal)
i
82-26 WA600- 1
t‘s;,
CN35
Cause Remedy
c Defectwe parklng brake eplace

solenoid
CN70, CN71 and CN73

Serial No. 10001-10494
3lsconnectlon I” w,r,ng after inspection.
lames% or defectwe contact *place
xtween CN35 (male1 (21
and chassis ground
c Defective parking brake relay leplace
W Disconnection in wnng \fter InspectIon.

harness, ordefectlve contact eplace
between CN71 (female) (5)
- CN31 (11) - CN35 (1).
Serial No. 10495-10880
CN238
c 3efective
switch
emergency brake
Defective parklng safety relay Gplace
NO 9 NO Defectwe parking brake Gplace

IS there continuity - swtch
between CN 1 1
- (male1 (1) - 121, - CN,i CN;3 CN!‘2 C1;70 2N71 bN69
(2) - (3) as shown
in table 1 Disconnection in wiring 4fter Inspectnon, 426FOl! 38
YES harness, or defective contact .eplace
1 )Disconnect
CNll
between CNl 1 (female) CN78
(1) - CN65 (6) - CN109
2)Tum starting
(l).(2) -CN65 (7) -
switch OFF.
CN7 1 (2). or braker -
CN78 (10) - CNl 1 (3) or
CN70 (5) - CN70 (21 -
CNl 1 (2)
DisconnectIon in wwng After nspection.

harness. or defective contact eplace
between braker - CN78
I;;’ - CN70 (3) - CN71
CN109 (male)
CN11
WA600-1 82-27
0
ISthere continuity
between CN35 (2)
bnale) and chassis’
1) Disconnect
CN35.
2) Turn starting
switch OFF.
YES
YES
Is voltage between 15problem removed

CN35 (1) Imale) and when relay is
chassis 20 - 3OV?
I I
1) Connect 1) Interchange
T-adapter parking brake
(socket adapter) safety relay
to CN35 (malel. (CN701 with
2) Start engine. Lack”& lamp 5
(TraVelI relay (CN63).
(Charge air 2) Start engine. Is problem removed
pressure) (Change air when short
pressure) 1 connector is
connected?
t-t
1) Connect short
YES
connector tcl
CN133 (femaleI
2) Start engine
7
Is continuity of CNl1 (Charge air
preSStIre)
Is voltage between
YES CNl 1 (2) (female) _
1 I and chassis 20 -
1) Disconnect 6 3OV?
CNll.
2) Turn starting
1 1) Disconnect
switch OFF. 15voltage between CNl 1
3) Turn parking _ CN70 (3) (female) _ 2) Turn starting
brake switch ON r. 1 and chassis 20 - switch ON NO
-OFF. 3ow 3) Turn parking
c , y;k?:witch ON
1 I Disconnect
CN70.
21 Turnitaning 1
I I I
Short connector
I I
82-27-l WAtSOO-I
@
Table 1
OFF Cause Remedy

Contlnutly NO continuity
ITRAVEL)
)efectwe parkmg brake s&no11 IepLXe
lefective contact. or
lts.~~nne~t~~n I” wnng harness ifter inspectIOn.
etween CN35 (2) (male) and epa,r or replace
‘hassls
Defective parkIng brake safety

&V
defective emergency brake

7eDlace
witch
3efective contact. or dis-

10 YES :onnection in wiring harness 4fter inspectton.
I 1 I Mwx?n CN133 (21 @male) ,epair or replace
Isvoltage between - CN35 (1) (male)
YES CN133 (1) (female)
- and chassis 20 -
3ov7 defective contact. or dis-
9 :onnection in wiring harness 4fter inspectIon,
- 11 Disconnect NO xtween CN133 (1) (female) ,epair or replace
CN133. - CN31 (11) Ifemale]
YE Is there cont,nu!ty 2) Turn starting
. between CN70 I1 1 - sw,tc,,
ON.
Ifemale) and chaws) 3) Turn parking
9 L b_ra;zFyitch ON
11 Disconnect
CN70
21 Turn starong 3efectwe contact. or
CN70 12) (female1 jisconnectnn I” wmng harness After inspection.
and chass,s 20 - swatch OFF
wtween CN70 (1) (female] - repaw or replace
NO
:hassis
1) Disconnect
CN70 3efective contact. or
2) Turn starting jisconnectlon in wirina harness After inspection.
switch ON NO &wee” CN70 I21 (f&ale) - repair or replace
31 Turn parklng CNl 1 (2) (female)
brake swtch ON
Iefective contact, or
disconnection I” wiring harness After inspectIon.
setween CNI 1 (21 (female1 - vpar or replace
CN70 (5) (female1
3efective contact, or
jlsconnectlon I” w,r,ng harness 4fter Inspectlo”.
xtween CN70 (31 (female) - epar or replace
ZN7B (10) - fuse
Defective parklng brake swtch ReplaCe
WA600-1 82-27-2
8
Failure mode: ;$RU&NG BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED
* When disconnecting or connecting the Tradapter (or socket adapter) or short socket adapter, or when disconnect-
* When disconnecting connectors or connecting T-adapters, return them to
the original condition immediately after checking, then go to the next
check.
Serial No. 10001 and up (D spec.) Cause Remedy
Serial No. 10001-10880 (except D spec.)~

Defective parking brake Replace
safety relay
Defective parking brake relay Reolace
moved when relay
Is problem re-
I
1 Interchange
moved when relay Defective parking brake Replace
parking brake
is interchanged? switch
safety relay
(CN70) and
back-up lamp 1) Interchange removed when
relay KN73). parking brake
2) Start engine relay lCN7 1 and I disconnected?
(charge air back-up lamp
pressure). relay (CN73). 1) Disconnect Abnormal contact or mis- After inspection,
31 Turn starting 2) Start engine CNll. take wiring between CN35 replace
switch ON. (charge air 21 Start engine I;;.- CN31 (11) - CN71
pressure). (charge air
3)Turn starting pressurel.
switch ON. BITurn starting
switch OFF -
ON.
CN35
CN70, CN71
Serial No. 10001-10494
CN73
Seriai No. 10495-10880
CNll
CN238
Warning buzzer
CN74 CN73 CN72 CN70 CN71 CN69
426FO1138
82-27-3 WA600-1
0
Serial No. 10881 and up (except D spec.) Cause Remedy
YES Iefectwe parklng brake sat%’

eiay
1
/
/ Is problem removed
)efect,ve park,ng brake switch
1, Interchange Is problem removed

parking brake
safety relay
- when CNl 1 ,s ),sconnect~on I” wmng harries’
No disconnected, wtween CN70 131 and (51. 1’2)
<CN70) with
I female1
backup lamp I
reiay iCN631. 1) Disconnect
2) starterqne. CNll
&
(Charge air 2) start eng,ne
pressuret (Charge au
),sconnectcm \n wnng
harnes
ztween CNl 1 (1) and 131
31 Turn starting Pressurei 1) Disconnect NO female)
swtch ON. 3) Turn starting CN70
swttch ON 21 Turn statilng
watch OFF
82-28 WA600-1
e
Failure mode: TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING
BRAKE IS APPLIED.
* When disconnecting or (or socket adapter) or socket or when disconnect-

ing the for checking, turn starting switch to prevent
When connecting (or socket connect to the specified. ( ))
* When
Cause Remedy
Defective neutralizer relay Replace
1) In&change neu- Abnormal contact or mistake Replace or repair

tralizer relay wiring between CN72 (5) -
(CN72) and back- CN21 (11,12)-CN89W.[CN56
up lamp relay (8)1- CN99 (A)
(CN73).
Note) [CNOO] is for serial No. 10881 and up (except D spec.).
CN72 and CN73 Serial No. 10001-10494
CNR5
CN~:,CN~ c,~32 cN84 CU84
i CN86 ,
I I _. uw:
Serial No. 10495-10880 CN99

CN238
Warning buzzer
CN7d CN;3 CN72 Crj70 C’N71
426FO1138
WA600-1 82-29
0
Failure mode: MACHINE DOES NOT TRAVEL FORWARD.

* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( 1)
YES
YE/j-&j&H_
I 1
NO between CN16
- Refer to E-5 1 )~lace F-R lever in NO
(femalei (2) and c FORWARD.
1 1 chassisground? 1 2)Connect T-adapter
(or socket adapter)
to CN16 (m&l.
3)Turn starting
I so&i
toCN16
(fern&l.
adapter)
NO
switch OFF.
1 3 Z)Turn starting
I I swtch OFF.
Is there continuity
YE between CN99 (fe-
male) (D) and
chassis ground’
- YES
1)Place
F-R lever in
FORWARD.
2)Disconnect CN99.
3)Turn stariing
switch OFF.
Is voltagebetween
YES
CN99 (female) (A)
and chassis ground 6 r
Is problem re- YES

1)Disconnect CN99. s moved when relay - 7’
2) Turn starting h is interchanged?
switch ON. (Do Is problem
not start engine.) removed when
3) Switch parking 1 )Interchange - short socket
brake switch neutralizer relay NO adapter is
ON-DFF(released1. (CN72) and connected?
back-up lamp
relay (CN731. 1) Connect short
2) Start engine. socket adapter
to CN21
(female).
2lStart engine.

Short sock& adapter
Troubleshooting (for Econoseal) (for MS connect)
toois
Tester I 1
CN99 (female)
82-30 WA600-1
$2
POSITION ,gF CONNECTOR
Cause Remedy CNI 6 (female)
lwxnnection I” wiring After Inspectlo”.

harness, or defectw? contact epw or replace
between CN16 (female) (21
- CN99 (Dl -
:N99 lmalei (A).
Iefectlve F-R switch CN72, CN73

Serial No. 10001-10494
4fter inspection. 5
)wonnectio” in wiring
wness. or defective contact ‘epar or replace
,etwee” CN16 knalei (1)
Ind chassis ground
Defective forward solenoid

Serial No. 10495-10880
CN238
c )efectlve neutralizer relay Replace
I jefective transmission tbplW2

u-off switch
CN741 CN;3 . .._ P&7

_..._ C1;170 C’N71
426FO1138
Disconnection in wiring After inspection,
between main breaker repair or replace CN21 (female)
CN72 (5) - CN18 ll)or
CN18 12) - CN89 (8) -
CN99 (A).
CN 89 (female)
10 12 11 1
6 2 1 3
WA600-1 82-31
Go
Failure mode: MACHINE DOES NOT TRAVEL REVERSE.
Serial No. 10001 and up spec.)

h NO
Refer to E-5
1) Connect toCN16.
T-adapter (or 3)Turn starting
socket adapter) switch OFF.
toCNl6
(female). NO
PITurn starting
switch OFF.
between CNQQ
~female) CC) and
chassis ground?
1 )Place F-R lever in

REVERSE.
ZlDisconnect CN99.
3)Tum starting
switch OFF.
YES 2
YES
6 I
back-up lamp
I J
NO
relay KN731 1) Connect short
2) Start engine. socket Bdapter
to CN21
lfemalel.
21start engine.

Tester
Troubleshoottng I (for Econoseall
tools
CN99 (female) CN18

CNI 6 (female)
Cause Remedy
Disconnection IIT wring After ~nspect~o”.

harness, or defectwe contact repar or replace
CN99 (0 - CN99 Imale)
(A)
CN72, CN73
Serial No. 10001-10494
Defective F-R swtch Replace

harness. or defective contact repa,r or replace
between CN16 (male) (1)
and chassis ground.
Defective reverse solenoid
Serial No. 10001-10880

CN238
Defective neufral~zer relay
Warning buzzer
Defective transmission
cut-off swtch
m~-yy++N225
CN74 CN73 CN72 CN70 CN71 CN69
)isconnection in wring har”eS After inspection, 426FOll38

,etween main breaker repair or replace
CN21 (female)
:N72 (51 - CNl8 (1) or
:N18 (2) - CN89 18) -
:N99 iAl.
CN89 (female)
IO 12 11 7
6 2 1 3
WA600- 1 82-33
@I
TROUBLESHOOTING CHART No. E-l 0.
Failure mode: TRANSMISSION DOES NOT SHIFT GEAR (F-R DIRECTION NORMAL).
* When disconnecting or connecting T-adapter (or socket adapter) short socket adapter, when disconnect-
ing connector for checking, turn switch to accidents.
When connecting T-adapter (or socket to connector specified. (CNxx ))
* connectors or connecting T-adapters, return them to the original condition immediately after
Cause Remedy
YES
Defective 1 st solenoid
I 1
harness, or defective contact
2)Place speed between CN99 (female) (HI
lever in 1 st and CN 16 (4). or defective
3)Turn starting speed switch
switch OFF.
YES
2nd *
h
A
Is there continuity
between CNgg
(female) (G) and
chassis ground?
/ES between CN16 NO

1 )Disco”nect - Disconnection in wiring
(female) (8) and CN99. harness, or defective contact
chassis ground? 2)Place speed between CN99 (female1 (G)
lever in 2nd. and CN16 (5). or defective
11Connect 3)Turn starting speed switch
T-adapter tbr switch OFF.
socket adapter)
to CN16
(female). ‘ES
1 2)Turn starting
3rd !i c Defective 3rd solenoid
switch OFF.
Is voltagebetween Is there continuity
CN99 Ifemale) 16) between CN99
and chassis ground (female) (F) and
chassis ground?
1) Disconnect CN99. 1) Disconnect NO

2) Turn starting CN99.
harness. or defective contact
switch ON. 2)Place speed
3) Switch parking between CN99 (female1 IFI
lever in 3rd.
and CN16 (6). or defective
brake switch BITurn starting
speed switch
ON-OFF(releasad I. switch OFF.
“y
4th Defective 4th solenoid
H
Is there continuity
between CN99
(female) (E) and
chassis ground?
NO
- Disconnection in wiring
1) Disconnect harness, or defective contact
CN99. between CN99 (female) (El
PIPlace speed and CN16 (71, or defective
lever in 4th. speed switch
3)Turn starting
switch OFF.
harness, or defective CO”tSCt
between CN16 (8) (female)
and chassis ground
NC harness. or defective contact
between Mann breaker -
T-adapter or socket adapter CN78 (8) - CN89 (7) -
Tester
Troubleshooting (for Econoseal) CNg9 (female) (8).
tools
82-34 WA600- 1
0
CN99 (female)
G FM E
CN16 (female)
s 1 i j
CN78
CN89
WA600-1 82-35
@
TROUBLESHOOTING CHART No. E-l I.
Failure mode: DOES NOT WHEN TRANSMISSION
SELECTOR SWITCH ON. (MACHINE WHEN TRANSMISSION
SELECTOR SWITCH OFF.)
Serial No. 10001-10880 (except D spec.1
ing the connector for checking turn the starting switch OFF to prevent accidents.
Cause Remedy
YES
harness, or defective contact replace
betweenCN21 (1) - CN18
1 (l),orCN21 (2) - CN18 (21.
Isthere continuity
between CN2 1
(male1 (1) and 1217
i
1 /Connect
T-adapter (or
socket adapter) NO
to CN21 (male). * Defective transmission Replace
* Do not press the cut-off switch
left brake pedal.

tools
CN21 (male)
WA600-1
Failure mode: TRANSMISSION CANNOT BE CUT-OFF.
(WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON AND
DEPRESS LEFT BRAKE PEDAL.)
Serial No. 10001-l 0880 (except E spec.) Cause Remedy
YES
1 , * Defective transmission
cut-off switch
removed when
NO 2,
disconnected?
, YES
Defective transmssion
Is problem removed
and does transmis- cut-off selector switch
sion cut-off monitor
CN21. lamp light up when
21 Start engine. CN18 is discon-
YES
(Charge air Abnormal contact. or After nspectlon.
preSSUreI
1 I Dwonnect
CN18.
NO 3- mistaken wiring between
+ 24V terminal and wiring
harness of maln breaker -
repair or replace
21 Start engine
between CN106. CN72 (3). (5) - CN21 (1)
(Charge air (2) - CN99 (A).
pressure) CN107 (male)(l)
and (2) as shown in
1) Disconnect
NO
CN106, CN107. L Defective diode (CN 106 or Replace
2) Turn starting CN107)
switch OFF.
Black rod of tester to CN106 or CN107 (1) NO

Red rod of tester to CN106 or CN107 (2)
* CN106 (Diode) is not equipped on machines
Red rod or tester to CN106 or 0~107 (11
YES
serial No. 10343 and up.
Black rod of tester to CN 106 or CN107(2)

to015 I 1
CN21 CN93 and CN94
CN18 CN72 Serial No. 10001-10494
Serial No. 10495-10880

CN99 CN238
Warning buzzer
CN225
CN74 CN73 CN72 CN70 CN71 CN69 426FO1136
82-37
8
Failure mode: TRANSMISSION DOES NOT RETURN TO NEUTRAL.

Serial No. 10001-10880 (except E spec.)
YES
3 YES
I
”
Isthere continuity
between CN16 NO 1
(male) 19) and (2). Is there continurty
(91 and (3)7 between CN99
-7
(female) 0) and
1 IConnect chassis ground,
T-adapter Ior CN99 (female) (Cl
socket adapter) and chassis
to CNl 6 (male). around?
2)Tum starting
switch OFF. 1) Disconnect
3lPlace F-R CN99.
lever at 2)Tur” starting
NEUTRAL. switch OFF.
ES 1) Connect
l- NEUTRAL when
T-adapter (or
socket adapter) to
CN106. CN107
1 )Start engine. (male).
2)Tur” parking 2) Turn starting
swithc OFF.
brqke switch ON. I
NO
Is transmission
L-l
returned to
NEUTRAL when
left brake 1s
applied’
IO
1 )Starte”gine.
2)Tum transmis-
SlO” cut-off
selector switch
ON.
3)Turn parking
E;;;,witch ON
NIO
+ CN106 (Diode) is not equipped on machines

serial No. 10343 and up.
Table
Red rod of tester to CN106 or CNlO? (2)
Red rod or wster to CN106 or CN107 (1)

YES
Black rod of tester to CN 106 or CN 107(Z)

tools
82-38 WA600- 1
‘El
Cause Remedy
CN16 (male)
- D efective F-R swtch ,bCe
A,bnormal contact. Or “XS-

ti *ken Waring between chassis er inspection.
I
g round and CN99 (female)(D) a,r or replace
- CN16 (2) or CN99 Ifemale)
i :) - CN16 (3).
CN99 (female)
)J KAB
14bnormal contact. or miS-

t aken wiring between chassis
4
Eiround and CN16 (male) (2) - ter inspection, G FM E
(:N99 (female)(D) or CN16 xiror reDlaCe
male) (3) - CN99 (female)
I
CN106 and CN107
lefective diode (CNI 06 or ?place

:N107)
l c ;ee E-7 “Transmission is no’

?turned to NEUTRAL when
taking brake is applied”.
c j,e E-l 2 “Transmission

:annot be cut-off”
WA600-1 82-39
@
E-8: TRANSMISSION DOES NOT WORK NORMALLY.

Sr When carrying out troubleshooting of the brake system, stop the machine on level ground.
* When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
necting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA ( 1)
+ When disconnecting connectors or connecting T-adapters, return them to the original condition immedi-
ately after checking, then go to the next check.
Carry out a check of the transmission solenoid con- Table 1 Transmission Normal Actuatnn Table
trol circuit with the tester as follows. \ I

CN56
\ Pin No. I
a Stop the machine on level ground and put blocks
under the tires.
1. Install a T-adapter (for Econoseal) to CN56, and

check the voltage between the pin in Table 1
and the chassis ground.
2. Turn the starting switch ON.
a Do not start the engine.
3. Turn the parking brake siwtch ON-OFF (release)

0. 0 - 0.5v Icontlnuousl
0’ 20 - 30V Lbattery voltage1

4. When depressing the foot brake, depress the
R.H. brake.
* If the L.H. brake is depressed, the transmis-
sion is cut-off, SO it is impossible to check.
Table 2 Result of in.$pectnn when operating F-R lever
5. Check the voltage and continuity using Table 1. Result Of Trouble-

Cause
inspection shooting
According to Results Tables 2 and 3, go to the
troubleshooting table in the right column accord- 0 No [battery Problem in transmission cut-off switch, Go to
voltagel at all parklng brake, neutral relay c,rcu,t E-8-a)
ing to the results of the check.
0 No Go to
Problem I” F c,rcu,t
Icontinuous iF) E-8-b)
0 No Go to
Problem ,n R cxwt
lContinuous1
(R) E-8-c) -
0 [continuous1 Go to
Problem I” R c,rc”,t
at two places E-8-d)
Table 3 Result of inspection when operating speed lever
Result of Trouble-
Cause
lnspectlon shootng
0 \continuousl
Go to
at two places Contact in speed circuit
E-8-f)
or more
WA600- 1 82-39-2
@
a) Problem in parking brake, transmission cut-off switch, neutral relay circuit
L
r
connector to
1 CN81 (female).
2) Turn transmi-
ssion cut-off ‘ES
when transmission selector switch
cut-off switch is ON.
3) Start engine.
1) Start engine.
YES
L
r.JO'
7 YES
1) Interchange
neufralizer relay YE
:$jjGLH
ICN72) with back-
up lamp relay
(CN63). L
Is problem removed I) Disconnect
2) Start engine. NO
6 CN72.
21 Turn .starbng
Is voltage between switch OFF.
YE
1, Interchange CN72 (2) (female).
parking brake and chassis 20 -
safety relay 3OV?
r r
(CN70) with YES
backup lamp 1 I Disconnect
relay (CN63). CN72.
2) Start engine. 5 2) Turn starting
switch ON. Is voltage between
CN70 (female) (2).
IScontinuity of CNl 1
rJO $, ,p;;7chassis
F (male1 (1). 12). 13) as
shown in Table 17
El 1) Disconnect
1) Disconnect CN70.
CNll. 21 Turn starting
2) Turn starting switch ON.
switch OFF. 3) Turn parking NO
3) Turn parking brake switch ON
brake switch ON @pliedI.
- OFF.

Troubk- (forEco”oseal)
shooting
tlw1s
Short co”nectW
82-39-3 WA600-1
0
Table 1
Between terminals Between terminals

Operation
(1) and 121 !31 and 12)
ON
NO contmwty COlltlWlty
(PARKING)
Cause Remedy
OFF
COMWiY NO cont,nulty
(TRAVEL)
Defective transmfssnn cut-off

Replace
switch
Defective contact, or dis-

connection in wiring harness AtIer inspection.
between CN81 (female) 111. repa,: or replace
12) -- CN18 (female1 (1). 12)
Defective neutralizer relay ReplaCe
Defectw parkng brake Safety

Replace
relay

connection in wring harness After npect,on.
beween CN72 (51 (female) -
repaIr or replace
CN81 (1) (femalei. CN81 (21
(female) - CN99 (Ai (female1
Defective contact. or
dlsconnectnn on wnng harnes Afrer ,nspect,on.
between CN72 (1) (female1 an repar or replace
chasss
Defectwe contact. or
9 YES disconnection I” wmng harnes After inspecton.
I between CNl 1 (1) ffemale) - repau or replace
CN72 121 (female1
Is there co”t,nwty
- between CN70 Ill -
item&i and chass!s) Defective contact. or
I I I disconnect!on !n wrmg harnes After ,nspect~on.
1) Dusconnect NO between CN70 11) (female) - repa,r or replace
CN70 chassis
2) Turn starhng
switch OFF If lnc.Orrect voltage for 131
Defective contact, or
disconnection I” wiring
(female) - CN78 - fuse
If Incorrect vo1taae for 121. After inspection
(51. Defective contact. or repaIr or replace
disconnection I” wring
harness between CN70 12
(5) (female) - CNl 1 12).
CNl 1 (3) (female) - CN7
- fuse
Defective parklng brake swltcl
WA600-1 82-39-4
8
b) Defective continuity in FORWARD solenoid circuit
‘ES
Y
CN99
(female) and
I
1 I Disconnect YES
CN99.
2) Turn starting
swttch OFF.
3) Place F-R lever in
H
FORWARD. there
nuiv CN62
(female)
chassis)
11 Interchange
FORWARD
5- 11 Disconnect CN62
2) Turn starung
solenoid relay 1
Is voltage between switch OFF.
(CN62) with YES_ CN62 (6) (female) _ 3) Place F-R lever ND
REVERSE
and chassis 20 - in FORWARD.
solenoid relay
3ov7
(CN581.
2) Start engine. 4-
31 Turn parking - 1) Disconnect CN62.
1) Disconnect
“_‘“;;yvitch ON 21 Turn starting
CN99. Is there continuity switch ON.
2) Turn startfng - between CN16 - 31 Turn parking
switch ON. (male) (11 and (21) brake witch ON ~0
FORWARD.
Turn parking - OFF.
1) Disconnect
CN16.
21 Turn starting
switch OFF.
3) Place F-R lever rn No
FORWARD.

Trouble- ifor Econoseal)
82-39-5 WA600-1
@
Cause Remedy
Defective FORWARD solenoid ‘leplaCe
Defectwe FORWARD solenad

Replace
r&v

? YES connection in wiring harness After inspecbon,
between CN62 121 (female) - repax or replace
Is there continuity CN99 (Di
between CN62 (1)
- (female) and
chassis’ Defective contact, or dis-
connection in wiring harness 4fter Inspection.
between CN62 (1) (female) _ .epa,r or replace
1) Disconnect CN62. NO
chassis
2) Turn starting
switch OFF.
Defective contact, or dlscon-

nection II? wring harness After ,nspectlon.
between CN16 (2) (female) - repa,r or replace
CN62 (5)

connection in wiring harness After ,nspect,on.
between CN16 (1) (female) - repar or replace
CN16. chassis
21 Turn start,ng
switch OFF Defective contact, or dis-
connection I” wirina harness After ~nspect,on.
between CN62 (6) (iemale) - repa,r or replace
CN72 (5)
Defective F-F lever switch R@KX?

connection in wiring harness
After inspection,
between CN99 (Al lfemalei -
repaar or replace
transmission cut-off switch -
CN72 (5)
WA600- 1 82-39-6
@
c) Defective continuity in REVERSE solenoid circuit
Is there continuity
between CN99 ICI
ifemale) and ChaSSIS’
1) Disconnect
YES
21 Turn starting
sw,tch OFF. 6
3) Place F-R lever I” r
I
REVERSE Is problem removed Is there ConflnuitY
YES between CN58 (51 _
(female) and
chassis’
1) Interchange 5 1) Disconnect
REVERSE
CN58.
solenoid relay
is voltage between 21 Turn starting
lCN58) with YES rU0
CN58 (6) Ifemale) _ swtch OFF.
FORWARD
and chassis 20 .- 31 Place F-R lever in
solenoid relay
3OV’ REVERSE
(CN62).
2) Start engine. 3F
31 Turn startinq
I - 1) Disconnect
1) Disconnect CN58.
brake switch ON
CN99 Is there contl”“lty 2) Turn starring
- OFF.
21 Turn start!“g between CN16 - switch ON.
switch ON
4) Place F-R lever I” 10
i\
(male) (11 and (317 3) Turn parklng
REVERSE. NO
31 Turn parklng b_ragkFeFswltchON
?l&wtch ON
1) Disconnect
CN16
2) Turn starting
switch OFF I
3) Place F-R lever I” No
REVERSE

Trouble- (for Econoseall
shooting
, tools
82-39-7 WA600-1
3
Cause Remedy
_Defective REVERSE s&nOld ReplaCe
. ~&c,,ve REVERSE solenod FlepiWX
relay
!Defective contact, or dls-

? YES xonnecfion in wiring harness After inspection.
between CN58 (21 (female1 - repa,r or replace
Is there continuity CN99 (Cl
between CN58 11~
- (female) and
chassis) Defective contact, or dls-
connection in wiring harness After mspeCtl0”.
between CN58 (1) (female) -- repa,r or replace
1) Disconnect CN58 NO
. 2) Turn start,“g chassis
switch OFF.
Defecrive contact. or dis-

8 YES connection in wiring harness After InsPWtlO”.
between CN58 (5) (female) - repa,r or replace
Is there contlnuty CN16 (31 ,
- betweenCN16 (11 -
ifemale) and chaws?
connection in wiring harness After inspectlo”.
1 I Dwxnnect NO between CN16 ill (female) - repa,r or replace
CN16 chassis
21 Turn starting
swtch OFF
Defective contact. or dls-
connection in wiring harness After InspeCtlO”.
. between CN58 61 !femaleJ -- repa,r or replace
CN78 (fuse1
Defectwe F-R lever swtch Replace
Defective contact. Or
d,sco”“ectlo” I” w,r,ng harness After i”SWCtKW
between CN99 iA) (female) - repav or replace
transm,ss,on cut-off watch -
CN72 I51
WA600-1 82-39-8
0
d) Contact in F-R circuit (l/2)
1 Is there contlnuitv II
Is there conbnuity YES

Continucus locations
when there is between chassis and
problem in FORWARI (Cl. (El. (F). IG). and
3
1) Disconnect 1
CN99. Is there continuity
21 Turn starting
switch OFF.
, between CN99 (01 _
h (female) and YES
connector body?
4
1) Disconnect CN99.
2) Disconnect CN56.
3) Turn starting Is there continuity
switch OFF. L betweenCN56(51 _ YES
NO (male) and (1). (21.
(3). (4). (6)?
5
1) Disconnect CN99.
Is there continuity
2) Disconnect CN56.
_ between CN56 (5) _ YES
3) Turn starting
~0 (female) and
switch OFF.
chassis? 6
Check for lever 1) Disconnect CN56. y Is there continuity

positions other than 2) Disconnect CN16.
_ between CN16 12) _
specified where there 3) Disconnect
NO (male) and (l), (31,
FORWARD
is continuity, and gd (4). (5). (6). (7). 18)’
solenoid relay
(CN62). 1) Disconnect
1) connect 4) Turn starting
CN16.
T-adapter to switch OFF.
2) F-R leverat Nor NO
CN99.
R posibon
21 Turn starting
3) Turn starting
switch ON.
switch OFF.
3) Turn parking
brake switch ON
-OFF.
YES
9
IS there continuity
Continuous locations between CN99 (Cl
when there is (male) and chassis7
oroblem in REVERSE. Is therecontinuity _
between chassis and
CD). (El. (F). iG1, and
10,
(H) 7
_ Is there continuity
1I Disconnect _ between CN99 (Cl _
CN99. NO ifemalel and
2) Turn starting connector body?
switch OFF. To A (2/2)
2) Disconnect CN56.
3) Turn starting
switch OFF.
82-39-9 WA600-1
0
Cause Remedy
’ Defectwe insulation betwee

CN92 (Dl (male) and
connector body. orabnorm;
contact between chassis 4fter inspectwn.
ground and wiring harness ( ‘epair or replace
CN99 (0) inside control vah
* Defective wiring between
pins of CN99
Defective insulation between

4fter Inspection.
CN99 01 (female) and
epair or replace
cO”MXtOr body
Abnormal contact with wiring

harness between CN56 (5)
(female) - CN99 (D) (female)
and wiring harness between 4fter inspection.
CN69 (1). (21. (3). (4). (6) epair or replace
(female) - CN99 (C). (E). IF),
(G).(H)
(femaW
Abnormal contact with winng
harness between CN56 (5) 4fter Inspection.
(male) - CN62 (2) (female) .epair or replace
and chassis or ground con-
nection wmng
Defective transmission control

?eplace
switch
YES Defective transmission control

%place
7 switch
IS there confinulty
- between CN 16 (2) - Abnormal contact with wiring
(male) and chass.Is) 8 YES harness between CN16 (2) After Inspection.
ifemale) - CN62 (5) (female) repair or replace
1) Disconnect CN16 IS there contmuity
and chassis or ground
connection wiring
21 Turn starting N; between CN16 (21 -
switch OFF (female) and chassis)
Short circuit between
terminals (1) and (2) of
11 Disconnect CN16. NO FORWARD solenoid relay
2) Disconnect CN62. CN62 (male)
31 Turn starting
switch OFF.
Defective msulation
betweeen CN99 (Cl (male1
and Connector body, or
abnormal contact between
chassis ground and wiring 4fter Inspectlo”,
harness of CN99 (D) inside rpau or replace
control valve
Defective wirmg between
pins of CN99
Defective insulation between ifter inspection,

:N99 (Cl (female) and epair or replace
onnector body
I
Trouble- I T-adapter or socket adapter
Ifor Econoseal) I I
WA600-1 82-39-l 0
@
d) Contact in F-R circuit (2/2)
11 I
Is there confinulty
between CN56(6) _ YES
A --t
[female) and (1). (2).
(From l/21
(3). (4). (51?
12
1I Disconnect CN99.
2) Disconnect CN56. Is there continuity bet- YES
OFF. ‘” l(female) andchassis? 17 I
I
1) Disconnect CN56. IS therecontmuity
2) Disconnect CN16. between CN16 (31 _ YES
3) Disconnect NO (male) and (11, (21.
REVERSE (4). (5). (61. (7). (81, 14
solenoid relay
(CN58). 1) Disconnect CN16.
4) Turn starting 21 F-R IeveratN or _ 1s there con’t~nuitv
switch OFF. R position between CN16 13) - 1s YES
No (male) and chassis?
31 Turn starttng
switch OFF.
1) Disconnect Is there conbnuty
CN16 - between CN16 (3) -
21 Turn starting No ifemale) and chas%s)
switch OFF
11 Disconnect CN16. NO
21 Disconnect CN58
31 Turn starting
switch OFF.
82-39-11 WA600-1
8
Cause Remedy

(female) - CN99 K) (female)
After mspect,on.
and wring harness between
repair or repiace
CN56 (1). w, (3). (4). (51-
(female) - CN99 (D). (E), (F), (G.
(H) (female]
Abnormal contact with wring After mspect~o”.

harness between CN56 (6) repau or replace
(male) - CN58 (2) (female) and
chassis or ground connectlo”
wiring

switch
Defectwe tra”smlS*lO” Control

ReDlace
switch

After inspectlO”.
(female) - CN56 (5) (female)
repair or replace
and chassis ground connection
wiring
Short circuit between terminals

- (1) and (2) of REVERSE solenoic
relay CN58 (male)
WA600- 1 82-39-12
8
e) Problem in speed solenoid circuit (l/2)
YES
B 1
3) Turn stanlng 1) Disconnect CN16. NO

. switch OFF. 21 Place speed lever
in 1 St.
3) Turn stantng
YES swttch OFF.
Is there continuity
between CN99 (G) - YES
ip to problem speed
(female) and chassis, 6
lnge
I) Disconnect Is problem removed

CN99 - when relay IS
2) z2c;dyed lever NO replace,,, 7 YES
31 Turn starting -L
switch OFF. 1) Interchange 2nd Is problem removed
solenoid relay N; when relay IS
(CN59) with replaced’
backup lamp relav 1
I .lL
(CN63j.
2) Start engine.
1) Interchange NO
2nd.1st selecror
Is there continuity 3) Turn parking brake relay (CNGOJ with
between CN16 (8) switch ON - OFF. backup lamp relay
ifemale) and chassis7 (CN63).
I 1 2) Start egnine.
11 Connect 3) Turn parking
T-adapter yok;Fswitch ON
(socket adapter)
to CN16 Ifemale).
2) Turn starting
swtch OFF.
3rl
4t
1) Disconnect
CN99.
2) Turn starting
switch ON.
3) Turn parking
E;;;witch ON
Nl

Trouble- ifor Econoseal)
shooting
toois
82-39-13 WA600- 1
is,
I Cause I Remedy
Defective 1 st solenoid Replace
Defective contact, or disconnec-

tion in wiring harness between After inspection.
’ ~~99(H) (female) - CN56 - reap? or replace
CN16 14)
Oefective speed lever switch Replace
Defectwe 2nd solenoid Replace
Defective 2nd solenoid relay Replace
Defective 2nd-1 st $.electOr relay Replace
___t To A (To 212)
- To 8 (To 212)
_-b To C (To 2/2l

disconnection in wmng harness After vspection,
between CN16 (8) (female) - reapu or replace
chassis
Defective contact. or disconnec-

tion in wiring harness between After uxpection,
CNgg (6) (female) - CN56 17) - reap,r or replace
CN76 (8) - fuse - CN78 (7) -
main breaker
WA600-1 82-39-I 4
8
e) Problem in speed solenoid circuit LX?)
Cause Remedy
10 Yl Defective contact, or disconne

After Inspectmn.
tion in wiring harness be&veer
CN59 (5) (female) - CN99 (GJ repair or replace
YES Is voltage between
- CN59 (2) (female) and -
chassis 20 - 3OV?
Defective contact, or disconnei
i tion in &wring harness between
After Inspection.
1) Disconnect CN59. h CN59 (2) (female) - power
9 repar or replace
21 Turn staning source
switch ON.
YES Is there continuity bet- 31 Turn parking brake
-wee” CN53 (3) - switch ON - OFF.
ifemale) and chassis?
1) Disconnect CN59.
21 Turn starting 11 YL After wpectao”.
8
switch OFF.
CN59 (3) (female) - CN60 16)
repairor replace
Is there continuin, bet-
& ween CN60 (3)
A Is there continuity bet-
NO (female) and chassis?
IFrom 1 ‘21 - wee” CN59 (1)
Ifemale) and chassis? r\fter inspecton.
1) Disconnect CN60. N .epa,r or replace
CN60 (3) (female) - chassis
21 Turn starting
1) Disconnect CN59.
switch OFF.
21 Place speed lever
I” 2nd.
12 YES Defective contact, or disconnec
3) Turn starting 4fter inspecton.
switch OFF. I III CN59 (1) (female) - CN16 (5) ,epair or replace
I 1
Defective speed lever switch 7ep1ace
1I Disconnect
CN16
2) Place speed lever
,n 2nd
31 Turn starting
swtch OFF.
YES
3efectlve 3rd solenoid ?eplace
3efective contact, or
jlsconnectlon in wiring harness After !nspectIo”.
xtween CN99 (F) (female) - epar or replace
ZN16 16)
Ifemale) (6) - (8)’
Defective speed lever switch 7ephX

NO
switch OFF.
YES
Defective 4th solenoid
13 I
C Is there cantinulty bet-

[From l/2) --t wee” CNSS IF)
14 YES Defective contact, or disconnec
(female) - chassis? rfter Inspection.
ion in wiring harness between
:NSS (El (female] - CN16 (61 spair or replace
1) Disconnect CNSS. Is there continuio, bet-
2) Place speed lever -wee” CN16 (female) -
in 4th. NO (7) - w?
3) Turn starting
switch OFF. Defective speed lever switch leDlace
NO
82-39-15 WA600- 1
8
f) Contact in speed circuit (l/3)
1st 7
Is there conitnuity
between CN99 (H)
(male) and chassis?
Is there continuity
between (C) - (G)
1) Disconnect CNSS.
2) Turn starting
LJ
switch OFF. Is there continuity
between CN99 (H)
N (female) and
connector body?
1) Disconnect CN99.
2) Disconnect CN56.
3) Turn starting
switch OFF.
between CN56 (1)
10 (female) and (2) - (6)?
\
11 Disconnect CN99.
2) Disconnect CN56. 5
3) Turn starting
switch OFF. Is there continuity
1 between CN56 (1)
N YES
r
(male) and chassis?
Check for lever
positions other than
specified where there 1) Disconnect CN56. 6
H
is continuity, and go 2) Disconnect CN16.
3) Turn starting Is there continuity
switch OFF. between CN56 (1)
1) Connect T-adapter
to CNSS.
I\ Imale) and (2). 13).
(4). (51. (6)?
2) Turn starting
switch ON.
1) Disconnect CN56.
3) Turn parking brake
2) Disconnect CN16.
witch ON - OFF.
4) Turn starting
switch OFF.
2nd
P* To A (To 2/3)
3rd To 6 (To 313)

Trouble- (for Econoseal)
shooting
tools
82-39-17 WA600- 1
0
Cause Remedy
Defective insulation betwee

CN99 (HI and cOnnectOr
body, or abnormal Contact
After Inspectvx.
between chassis ground a”
repair or replace
wiring harness of CN99 (Hl
Inside control valve
Defective wiring between
pins of CN99
Defectwe msulatio” between

After ~“spectlo”.
CN99 (HI (female) and repair or replace
zonnector body

(female) - CN99 (H) (female) After !“spectlo”.
and wiring harness between repair or replace
CN56 (2) - (6) (female) - CNS
(C) -(G) (female)

After ~“swctlo”.
(male) - CN16 (4) (female) -
rapafr or replace
CNlOl (5) (female] and chassi!
wiring harness

(male) - CN16 (4) (female) - After inspection,
CN60 (5) (female) and wiring rapalr or replace
harness of line between CNBE
(21- (61
4bnormal contact wth wiring

harness of CN16 (4) (female) After inspectlo”.
and wiring harness of CN16 repair or replace
(5) (fern&.
YES Defective transmisslo” control

switch
1) Disconnect CN99. Is there continuity

2) Disconnect CN56. between CN16 (41
31 Disconnect CN16. b YES Defective transmlssmn contra
(male) and (11, (21, FlC!PlXZ
41 Turn starting 91 switch
swtich OFF.
11 Dtsconnect
CN16
21 Place speed lever h s
in 2nd. Defectwe 2nd-1 st selector reli ReDlace
31 Turn starting
switch OFF.
4bnormal contact with wiring

After inspection,
_.; larness of CN60 (5) (female)
repair or replace
11 Disconnect 2nd.1st N(3 (snd wiring harness of CN60 (3)
Selector r&y (female)
(CN60).
WA600-1 82-39-18
0
f) Contact in speed circuit (2/3)
A
(From l/3)
YES
!“d 11
Isthere continuity
between CN99 (Gl
(malel and chassis?
Is there continuity YES
-
between (0. (D). (EL
(FL (GI (HI and
chassis?
12
- Is there continuity
I) Disconnect
_ betweenCN99 (G) _ ES
CN99.
NO (female) and
I) Turn starting
connector body?
switch OFF.
1) Disconnect CNSS.
2) Disconnect CN56.
I
1) Disconnect CN99.
3) Turn starting pu between CN56 (2)
switch OFF. (male) and chassis?
r-l
L
1) Disconnect CNSS. Is there continuity

2) Disconnect CN16. between CN56 (2)
3) Turn starting male and (1). (3).
switch OFF.
. I
1) Disconnect CN56.
2) Disconnect CN16. between (3) - (5) of
3) Disconnect CN59. h 2nd solenoid relay
4) Turn startina
switch OFF.-
I
I) Disconnect CN59.
‘I
82-39-19 WA600-1
Go
I Cause Remedy
I
l Defective insulation betwee
CN99 (G) and connector
body, or abnormal contact
-I between chassus ground an<d

wring harness of CN99 (G)
\fQ?r Inspectlo”,
epau or replace
I
I
’
mslde control valve
Defective wiring between
pins of CN99 male)
\fter Inspect,o”.
epalr or replace
\fter I”spect!o”.
3palr or replace
Abnormal contact wfh wiring

harness between CN56 (2) rfter Inspection.
(male) - CN59 (5) (female)
epair or replace
and chassis or ground con-
nection wiring

harness of line for CN56 (2)
IeplaCG!
(male) and wiring harness of
hne for CN56 (1). (3). (4). (5).
(6) (male)
Defective 2nd solenoid relay :eplaCe

YES harness of CN59 (3) (male) and tfter Inspectlo”,
wiring harness of CN59 (5) zpalr or replace
17 (male)
I
YES Defective transmission control

:ep1ace
18 switch
1) Disconnect CN59. Is there continwty

3) Turn starting NC (male) and (1). (2). - 19 YES Defective transmission control
switch OFF. (3). (4). 16). (7). l8)7 :eplace
switch
1) Disconnect Is there continuity

CN16. - betweenCN16 (5) -
2) Place speed lever No (male) and chassis,
in 1 st or 2nd. ifter mspection.
(male) - CN61 (5) (male) -
3) Turn starting 1) Disconnect NO ?par or replace
CN16 (5) (male) and chassis or
switch OFF. CN16. ground connection wiring
2) Turn starting
swtch OFF.
WA600-1 82-39-20
0
f) Contact in speed circuit (3/3)
B (From 113)
Is there continuity
between CN99 (F)
(male) and chassis?
3rd Is there continuity
‘ES
between chassis and
;;;;‘“I, (E). (G). and
1) Disconnect
CN99. YES
2) Turn starting NO
22,I.
switch OFF
I I I
YES
3) Turn starting
switch OFF.
N . (female) and (1). (2). -.
(4). (5). (6) 23
A
21 Disconnect CN56. _ between CN16 (6)
3) Turn starting NO (male) and (1). (21. (3). - 24 YES
switch OFF. (41. (5), (7). (617

2) Turn starting i between CN16 (6) -
switch OFF. NO (male) and chassis,
IL
1) Dwonnect CN16. NO
2) Turn starbng
swatch OFF
Is there continuity
between CN99 (E)
(male) and chassis?
4tt Is there continuity
between chassis and
YES
I
(C), ID). (F). (G). and
(HI?
4
H
2) Turn starting between CN99 (E) YES
switch OFF. (female) and
connector body?
27 I
21 Disconnect CN56. between CN56 (4)
3) Turn starting YES
NO (female) and (1). (2).
switch OFF.
(3). (5). (6)? 28
i d
2) Disconnect CN56. _ between CN16 (7)
3) Turn starting. NO (male) and 11). (2). 131.- 29 YES
switch OFF. (4). (5). (6). (a)?
1) -
Disconnect CN16. Is there continuity
2) Turn starting L betweenCNlB(7) -
switch OFF. NO (male) and chassis?
-IL
2) Turn starting
switch OFF.
82-39-21 WA600- 1
3)
Cause Remedy
l Defective insulation between

CN99 (F) (male) and
connector body. or abnormal
contact between chassis After nspect,on.
’ ground and wiring harness repair or replace
of CN99 (F) inside control
valve
l Defective wiring between
pins of CN99 (male1
Defective insulation between After mspect,on.

CN99 (F) Ifemale] and connector repa,r or rep,ace
body

(male) - CN99 (F) (female) and ~~~:rl~:~~;t’O,“,
wiring harness between CN56
(1). (2). (4). (5). (6) (female) -
CN99(CL ,(D). (EL (GL (HI
(female)

ReplaCe
switch

?/switch /liPLace /
. Defective insulation between
~~~~. After,“spect,on,
CN99 (F) (female) and connector repa,r Dr replace

(male) - CN99 (El (female) and After inspection.
wiring harness between CN56 repa,r or replace
(1). (2). (3). 15). (6) (female) -
CN99 (CL (DL (0 (G). C-U
(female]
))II/
R?.piWX

switch Replace

(female) - CN56 (4) (male) and ~~‘eb’,“:,l~:~~~~“~~
chassis or ground connection
wiring
WA600-1 82-39-22
0
E-9: KICK-DOWN SWITCH DOES NOT WORK (l/2)
(NORMAL Fl - F4 SWITCHES CORRECTLY)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNO A ( ))
* When disconnecting connectors or connecting T-adapters, return them to the original condition immedi-
Y
I Is problemremoved
when relay is
replaced?
I YES
1) Interchange
kick-down relay
(CN61) with
REVERSE solenoid Is problem removed
relay (CN58).
21 Start engine. I
1) lnterchafige
FORWARD
solenoid relay
(CN62) with
REVERSE
1 solenoid relay
(CN58).
2) Start engine.
Is there continuity
between CN67 (1) YES
1) Interchange
2nd.1st selector
relay (CNGOI with
6
1) Disconnect CN67.
backup lamp relay
2) Press kick-down
(CN63) YES Is there continuity
switch.
21 Start engine - between CN60 (51 -
3) Turn starting
(female) and chassis)
switch OFF.
5
1) Disconnect CN60.
Is there continuity 2) Place speed
between CN60 I1 1 - lever in 1 st.
NO
(female) and chassis, 3) Turn starting
switch OFF.
NO
82-39-23 WA600- 1
0
Cause Remedy
1 Defective kick-down relay ReplaCe
Defective FORWARD solenoid

RepiXX
relay
’ Defective 2nd-1st selector relay

I
Replace
I
.I L.l_.l I_.,.. .“,.,

fro” I” wlrlng narness betwee,, .,.I. 11..7r-“.11.1.
between CN60 (2) ‘I :;;$..727 L’yo’ INO CN61 (2). (4) [fern&l - CN72 repair or replace
(female) and CN61 (3) 21 Turn starting (5) (female)
switch OFF.
._
1) Disconnect CN60 Defective contact. or disconnri-
and CN61 tion in wiring harness between After nnspection,
2) Turn starting NO CN60 12) (female) -- CN61 (3) repar or replace
swtch OFF. [female)
Defectwe contact, or disconnec-

ei C$O/5; (female, - CN16 (4) :;:,In,:::$“,ne
Defective contact, or disconnec- After ,nspect,on,

ml CN60 (71 (female) - chassis repa’r Or rep’ace
Defective kick-down switch Replace
WA600- 1 82-39-24
6%
E-9: KICK-DOWN SWITCH DOES NOT WORK(2/2)
(NORMAL Fl - F4 SWITCHES CORRECTLY)
Cause Remedy

12 YES don in wiring harness between After inspect&
. CN67 12) (female) - CN72 (5) repair or replace
Is there continuity (female)
YES between CN62 (1)
11 - (female) - CN67 (1) -
1 (female)? Defective contact. or disconnec-
tion in wiring harness between Aftermspection.
Is there continuity repa,r or replace
P No CN61 (1) (female1 - CN67 (1)
YES between CN62 (4) 11 Disconnect CN61
(female)
- (female) - CN61 (1) - and CN62.
10 Ifemale)? 2) Turn starting
switch OFF.
Is there continuity 1) Disconnect CN61 tion in wiring harness between After inspection,
and CN62.
A (From 112)
between CN61 161 _
2) Turn starting NO ’ CN62 (4) (female1 - CN61 (1) repair or replace
(female) - CN62 (3) (female)
(female)? switch OFF.
1) Disconnect CN61 Defective contact, or disconnec-

and CN62. tion in wiring harness between Afterinspectlon.
2) Turn starting CN61 (6) (female) - CN62 (3) repair or replace
NO
switch OFF. (female)
82-39-25 WA600- 1
@
E-10: KICK-DOWN ONLY WORKS WHEN KICK-DOWN
SWITCH IS ON. (KICK-DOWN SWITCH RELAY
DOES NOT CARRY OUT SELF-HOLD OPERATION).
Serial No.. 10881 and up (except D spec.)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA ( )I
* W-en disconnecting connectors or connecting T-adapters, return them to the original condition immedi-
Cause Remedy
YES
Defective kick-down relay Replace
Is problem removed
when relay IS
replaced’ 2 YES
. fion in wiring harness between Aneri”sfXctio”.
CN61 (2) (female) - CN72 (5) repair or replace
IS there continuity
1) Interchange L between CN61 (2)
;$;;dpcwN:g;;;;~ NO (female) and
CN72 (5)? Defective contact. or disconnec-
REVERSE solenoid tion in wiring harness between After inspectvan.
relay (CN58) CN61 (1) (female) - CN67 (1) repanr or replace
2) Start engine. 1) Disconnect CN61 NO
and CN72. (female)
2) Turn starting
switch OFF.
WA600- 1 82-39-26
0
E-11: KICK-DOWN OPERATION IS NOT CANCELED.

* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A ( ))
ES
Is problem removed
(1) Kick-down is not
canceled eve”
3 YES
when F-R lever is
1) Interchange moved from F to
2nd-1st selector N0rR. Is problem removed
relay (CN69) with when relay is
backup lamp relay replaced?
(CN63)
ISthere continuity
2) Start engine.
between CN60 -+
1) Interchange
(female) 131 and (5)? FORWARD
solenoid relay
L I (CN62) with
1) Disconnect CN60. REVERSE solenoid 5 YES
2) Turn starting relay (CN58).
switch OFF. 21 Start engine.
YES Is problem removed
- when relay is
replaced?
?) Kick-down is not
4
canceled even
io to problem when parking 1) Interchange NO
xation brake is applied. neutralizer relay
Does parking brake
- (CN72) with
) work?
backup lamp relay
(CN63).
4 2) Start enaine.
11 Parking brake
switch ON.
I
NO
I) Kick-down is not YES

canceled even
when speed lever
6
is moved from
2nd to other
speed range. Is problem removed
when relay is YES
replaced?
7-
I
1) interchange Is there continuity
kick-down relay _ bewee” CN61
(CN61) with NO (female) (3) and (4)?
REVERSE solenoid
relay ICN58).
2) Start engine. 1) Disconnect CN61.
2) Place F-R lever in co
NEUTRAL.
3) Turn starting
switch OFF.
I _. .1I
Trouble-
T-adapterorsocket
(for Econoseal)
adapter
I I
I-“- I
tools
I I
82-39-27 WA600-1
0
Cause Remedy
Defective 2nd-1 *t selector relay Replace
Contact with wiring harness

between CN60 (female) (31 and After inspection
I (5). or contact with wiring
repair or replace
[female) and chassis
Defective FORWARD solenoid RepkW2

relay

After Inspection.
between CN62 (femalel 13) and repair or rep,ace
(4)
Defective neutralizer relay RepbX
Contact with wiring harness After inspection.

. between CN72 (female1 (3) and repair or replace
(5)
For details. see TroubleshOOtl”g

_ chart E-4 “Parking brake
does not work”
Defective kick-down switch

Replace
relay

After inspection,
1 between CN61 (female) (3) and
repair or replace
(4)

8 YES After inspection,
. between CN61 (female) (1) and
repair or replace
12)
Is there continuity
- between CN61
(female1 (11 and @I?
Contact with wiring harenss
After inspection.
between CN62 (female) (1) and
repair or replace
1) Disconnect CN~I. NO (4)
2) Turn starting
switch OFF.
WA600-1 82-39-28
0
E-12: KICK-DOWN WORKS MISTAKE WHEN TRAVELING
IN F2.
Serial No. 10881 and up (except D SPec.)

YES
1
Is there continuity
between (1) and 12) of YES
kick-down relay CN61 -
Knalel, and between
(3) and 1417 2
1 I Disconnect
kick-down relay Is problem removed
CN61. - when relay is
2) Turn starting No replaced?
switch OFF. 3
J
1) Interchange
2nd.1st selector Is there continuity
relay (CM91 with Nc ~;~;;;2~~67 (male) - YES
backup lamp relay 4 I
(CN63) J
2) Start engine.
1) Disconnect CN67.
2) Turn starting
switch OFF. N
3) Do not press
kick-down witch.
1 I
1) Disconnect CN6l
2) Turn starting
switch OFF
NEUTRAL.
E-13: MACHINE DOES NOT TRAVEL WHEN KICK-DOWN

SWITCH IS PRESSED.

I YES
Is problem removed
when relay is
replaced?
I/ lnterchanoe NO
2nd.1st s&ctor
relay (CN60) wth
backup lamp relay
(CN63).
2) Start engine.
3) Place speed lever
in 2nd.
4) Place F-A lever I”
FORWARD.
Trouble-
shootmg
tOOIS
82-39-29 WA600- 1
g(?
Cause Remedy
Defectwe kick-down relay @We
Defectwe Znd- 1 st selector rela eplace
Defectwe kick-down swtch e$Me

xfter ,nspect,on.
?pair or replace
(2)

fter Inspectlo”,
between CN61 (femalei (11 and
!P?.K or replace
(2)

fterinspectlon.
,pa,r or replace
14)
Defective 2nd.1st selector relay epbXe
Defective contact, or disconnec

fter uxpection.
don in wiring harness between
!pair or replace
CN99 [HI - CN66 (5) Ifemale)
WA600-1 82-39-30
0
TROUBLE SHOOTING CHART Nix E-14
Failure mode: PREHEATING IS NOT CARRIED OUT.
ately’after checking, then go to the next check.
. Preliminary troubleshooting
Cause Remedy
ordetails, see
;;;;tive preheating display roubleshootmg (
rachine monitor
l-4-5)
Is intake manifold _
warIll?
arry O”t
1) Turn starting NO oubleshootmg
switch ON.
2) Turn heater
switch ON.
1 YES :arry cJ”f

Is there continuity roubleshooting
between heater
switch CN20 (male) _
(1) - 121. and
between (2) - (3)?
Iefectwe heater switch IeplaCe
I) Disconnect CN20. NO
2) Turn heater switch
to ON
WA600-1 82-39-32
@
a) Preheating is not carried out manually or automatically.
Serial No. 10001-l 0494
YES
Is voltage
between
CNl 00 Ifemale) ES
(2) and chassis
1)Disconnect
CNl 00. 1
2)Tum starting 1,I 1
switch ON. k voltage between
3)Tum preheating CN81 (fern&) (2)
switch ON.
t
1)Disconnect
CN81.
2) Turn starting
switch ON.
BITurn preheating APS relay terminal
switch ON. h A and chassis
ground 20- 3OV?
1 )Turn starting
switch ON.
,,,,,,,,,,I
NO
PITurn preheating 2)Turn starting
Y
switch ON. Is there continuity switch ON.
between APS relay
ND terminal (n) and YES
(8))
I
c
is there continuity
,I
6
between APS relay YES

ND terminals 18) and - 7-
(SW)?
p Is there ContinuitY
L betweenCN20 _
ND (male) (1) and (217
L
NO
82-40 WA600- 1
0
Remedy
CNIOO CN81
-m Defectwe monitor panel Replace 1

_--_A
-m Defective bi-metal timer Replace i

LJ
”
‘2
After inspection. CN82 3 fi

Disconnection in wring har-
repair or replace.
ness or defective contact
between APS r&w terminal
_) (Aj - resister terminal (R4] -
CN82 (female) (2) - bimetal
timer - CN81 (female) (1) -
CN82 (1) - CNlOO (2).
&connection in wiring har- After inspection,

wss or defective contact be- repair or replace.
ween CN62 (female) (5) -
4PS relay terminal (S). CN79
After inspection. CN;;, C:78 yNi9 f”80

Xsconnection in wiring har-
wss or defective contact be- repair or replace.
tween CN82 (male) (5) -
CN79 (male) (21 and (41.
Lefective APS relay.
3isconnection in wring har- After inspection,

mess or defective contact be- repair or replace.
CN20
tween CN82 (6) - CN20
(1). or CN20 12) - CN213
xdefective APS relay.
Defective preheating switch. Replace
CN73
CN102
CN150
APS water
temperature
sensor (b)
WA600-1 82-41
@
YES
1) Disconnect CN88.
2) Starting switch 2 4 YES
ON.
3) Preheating switch Is voltage between ’
ON. APS unit terminal (A) YI CN82 (male) (5) -
n - chassis ground 20 chassis ground 20 -
3OV?
1) Starting switch Disconnect CN82.

ON. ;;,rting switch
NO
2) Heater witch ,,
CN81 (Bimetal timer)

KES Connector 3 Pin
1 1
CN82 (APS Unit)

KES Connector 6 Pin
; !I i i
T-adapter or socket (for Econoseal)

Trouble-
shooting
to&
82-41-7 WA600-1
Go
CalSe Remedy
Defective bimetal timer
Defective contact, or d!sconnec

APS unit terminal (A) - res~sto Uter inspection.
terminal (R4) - CN82 (female) epair or replace
(2) - bi-metal timer - CN88
(female) 11) - CN82 (1)
Defective contact, or disconnec
tion in wiring harness between Wer inspection,
CN82 (female) [5) - APS unit epair or replace
terminal (6).
Defective contact, or disccanner.

tion in wiring harness between 4fter inspection,
CN82 Imale) (5) - CN7S (male) ‘epair or replace
2). (4). or fuse broken.
Defective contact, or disconne( Replace

tion in wiring harness between After inspection,
CN82 (6) - CN20 (1). and CNZC repair or replace
12) - CN218.
Defective heater switch
Defective APS unit
CN102 (APS water temperature relay) Serial No. 10495-10880 (except D spec.)
For connector relay
CN82
CN81
APS switch
Bimetal timer
Resistor
426FO1133
WA600- 1 82-41-2
b) Preheating is not carried out automatically.

Cause Remedy
YES
Defective APS water tem- Replace
perature sensor relay.
I YES
I
Disconnection in wiring har- After inspection.
repair or replace.
I
ness or defective contact be-
4 Is problem is re-
tween CN82 (male1 (6) -
CN102 (2) - CN102 (3). or
CN102 (5) - CN150.
moved when relay -
2
is interchanged?
Is there continuity
p between APS
1 )Intercha”ge L watertemperature _
back-up lamp NO sensor CN150 and
relay KN73) and chassis ground?
APS water tem-
perature sensor
relay CN102).
Z)Turn starting
switch ON.
3)Turn preheating
Defective APS water tem-
switch AUTO.
perature sensor.
CN73 Serial No. 10001-10494 CN150

APS water
temperature
sensor (b)
CN238
Warning buzzer
CN225
CN74 CNj3 CNj2 CPj70 dN71 bN69
426FO1138
82-41-3 WA600-1
C-R
CWJSe Remedy
Serial NO. 10881 and up (except D spec.)
YES Defective APS water

Rt?plaCe
temperature sensor relay.
Disconnection in wiring harness

1 or defective contact between 4fter inspection.
CN82 (male) (6) - CN102 (2) - .epair or replace
CN102 (31, and CN102 (5) -
Is problem removed CN159
when relay is
replaced?
- NO 2
Is there continuity
1) Interchange APS YES
Normal
’ 31
relay (CN631. I) Disconnct CN159.

^, ^. . -.
L, ararrrng SWllC”
ON. 2O’C or more?
3) Heater switch
AUTO. Defective APS water
3ePlaCe
temperature se”sclr.
T-adapter or socket lfor Econoseall
WA600- 1 82-41-4
8
Failure mode: PREHEATING DISPLAY DOES NOT GO OUT.
(PREHEATING DISPLAY DOES NOT GO OUT AFTER TURNED PREHEAT-
ING SWITCH ON ABOUT 80 SECONDS PASSED.)
Serial No. 10001-10494
1 Cause Remedy
r
YIES
* -[ Xafective bi-metal timer. ?eplace
YES Is there continwty
1 - betwee”CN81
hale)(1) and (2)?
Is voltage between P
CNlOO (female1 _
(2) and chassis
c Abnormal contact or mistake After inspection.
ground 20 -3OV? 2)Turn staning N” wiring between CN81 (11 - repair or replace.
switch OFF. CN82 (1) -CNl 00 (2) and
+ 24V.
Defective monitor panel. Refer to

“Monitor panel
troubleshooting”
CNIOO CN81 CN82
82-42 WA600-1
@
E-15A: PREHEATING STAY ON

* When disconnecting or connecting the T-adapter (or socket adapter),or short connector, or when discon-
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A ( )).
l Preliminaly troubleshooting
Cause Remedy
1 YES Carry wt
troubleshooting
Is intake manifold _
warm?
For details, see
Defective preheating display troubleshooting of
circuit machine monitor
1) Starting switch NO
M-4-f)
ON.
2) Heater switch
ON.
a) Autamatic preheating is not canceled.
1 YES
Defective bimetal timer ReplaCe
Is there continuity
between CN88 (male)
Trouble-
WA600-1 82-43
@
b) Preheating continues even when heater switch is turned OFF
1
15there continuity YES
between heater
switch CN20 Imalel 13)
- (dl?
4 YES
1) Disconnect CN20
2
2) Heater switch OFF Is there continuity
3) Starting switch IS there continuity between APS relay
OFF between APS water YES terminal (A) - chassis
_ temperature *ensor &- 3 - groundZO-30V -
NO CN159 - chassis even when APS relay
ground? terminal (SW) is
Is there continuity
disconnected?
between APS relay 1
N& terminal (A) - chassis - 1) Startengine
ground 20 - 3OV? 2) Heater switch NO
L AUTO
1) Starting engine
2) Heater switch
AUTO
NO
CN81 (Bimetal timer) Serial No. 10495-10880 (except D Wet.)

KES Connector 3 Pin
CN82
CN81
APS switch
wtal timer
426FO1133
Trouble-
shootmg
tools
82-43-l WA600-1
CR
Dkfective heater switch ReplaCe
Defective APS water ReplaCe

temperature sensor
-xl Defective APS relay -
CN82 (APS unit)

KES Connector 6 Pin
CN 102 .(APS water temperature relay)

For connector relay
WA600-1 82-43-2
@I
Failure mode: AFTERHEATING DOES NOT DISPLAY.
* Refer to M-4 b).

Failure mode: AFTERHEATING DISPLAY DOES NOT GO OUT.
(AFTERHEATING DISPLAY DOES NOT GO OUT AFTER COOLANT TEM-
PERATURE BECAME ABOVE 20°C.)
Serial No. 10001-l 0494
* Inspect with coolant temperature above 2O’C.
r Cause Remedy
ES
Defective APS water Replace
temperature sensor.
3 YES
Defective APS relay
I=!--
YES
water temperature
sensor CN150 and
1)Start engine.
kc----- -f Contact with chassis ground
and APS relay terminal ISW)
- CN82 (6) - CN102 (2)
After inspection,
repair or replace.
2)Turn preheating
- CN102 (31, I51 - CN150.
switch AUTO.
2
Is voltagebetween
APS relay terminal
IA) and chassis
ground ZO-3OV?
1 IStart engine.
PITurn preheating
switch AUTO.
i Contact with +24i and After inspection.
NO APS relay terminal (n) - repair or replace.
resister terminal (R4). (R5) -
CN82 (3) - CN20 (3). (41 -
CN86 (6) - CNl15 (5) -
CNl 19 (1) - glow plug, Or
CN 119 14) - glow plug.
CN86 CN115
5 2 1 3
CN119 Resister (c)
I 2
82-43-3 WA600-1
@
TROUBLESHOOTING CHART FOR ELECTRONIC
VEHICLE MONITORING SYSTEM
(M-l. to M-l 1.)
Serial No. 10001 - 10494

M- 1. When starting switch is turned ON (do not start engine), and there is no abnormality in machine,
check before starting itme flashes.
a) Brake oil level ................................................. 82- 48
b) Engine oil level. ................................................ 82- 49
c) Coolant level .................................................. 82- 50
M- 2. When starting switch is turned ON (at engine running), and there is no abnormality in
machine, caution item flashes.
a) Battery charge................................................. 82- 51
b) Fuel level .................................................... 82- 52
c) Afterheating lights up ............................................ 82- 53
d) Afterheating does not light up. ...................................... 82- 54
e) Clogging in transmission oil filter ..................................... 82- 55
M- 3. When starting switch is turned ON (engine started), and there is no abnormality in machine,
emergency items flashes.
a) Failure in brake line ............................................. 82- 56
b) Engine oil pressure .............................................. 82- 57
c) Coolant level .................................................. 82- 58
d) Drop in air pressure. .............................................. 82- 59
e) Coolant temperature ............................................. 82- 60
f) Torque converter oil temperature .................................... 82- 61
M- 4. When starting switch is turned ON (do not start engine), and there is no abnormality in
machine, pilot item lights up abnormally, or does not light up.
a) Parking brake display does not go out. ................................. 82- 62
b) Parking brake display does not light up................................. 82- 63
c) Working lamp display does not go out ................................. 82- 64
d) Working lamp display does not light up. ................................ 82- 65
e) Preheating lights up. ............................................. 82- 66
f) Preheating does not light up ........................................ 82- 67
g) Failure in main steering display light up (If equipped) ....................... 82- 68
h) Failure in main steering display does not light up (If equipped) ................. 82- 69
i) Transmission cut-off display lights up .................................. 82- 70
j) Transmission cut-off display does not light up ............................. 82- 71
M- 5. Turn signal lamps, high beam light up abnormally, or do not light up.
a) Pilot display of turn signal lamp (right) ..........................
lights up. 82- 72
b) Pilot display of turn signal lamp (left) ...........................
lights up 82- 72
c) Pilot display of turn signal lamp (right) does not light up ..................... 82- 73
d) Pilot display of turn signal lamp (left) does not light up ...................... 82- 74
e) HIGH BEAM pilot lamp does not light up ............................... 82- 75
f) HIGH BEAM pilot lamp does not work normally .......................... 82- 76
M- 6. Speedometer display does not work normally .............................. 82- 77
M- 7. Servicemeter does not work normally .................................... 82- 78
M- 8. Abnormality in monitor panel.
a) None of monitor panel works . . ... ............. . .... . 82- 80
b) Part of monitor panel does not work . . . . . . . . _. . . . . . . . . . . . ... : ... 82- 82
cl Even when engine is stopped, engine oil pressure flashes, caution buzzer sounds and
warning lamp also lights up. .... . . . .... ..... .. .. . ... . 82- 83
4 Even when engine is stopped, battery charge flashes and warning lamp lights up .. . 82- 84
e) No lamps on monitor lights up
(immediately after turning starting switch to “ON”, engine stopped) . . . .. . . 82- 84
f) Monitor displays no abnormality, but central warning lamp lights up intermittently 82- 85
9) Central warning lamp lights up continuously .. .. . . 82- 86
h) Monitor displays no abnoramlity, but central warning buzzer sounds intermittently 82. 87
i) Central warning buzzer sounds continously .. . . .. .. .... 82- 88
82-44 WA600- 1
lo,
M- 9. Abnormality in panel lamps on monitor.
a) No panel lamps light up even when only small lamp in combination lamp is used . 82- 90
b) No panel lamps light up even working lamp is switched on .... . .......... 82- 92
c) Panel lamps of gauge module do not light up . .... . . ........ ... 82- 93
d) Panel lamps of CHECKS, CAUTION 1 and 2, speedometer module do not light up _ . 82- 94
e) Panel lamps of service meter do not light up .... . _ . . . . . ._. . . _ . . . . . . . . . . . 82- 95
M-70. Abnormality in alarm buzzer or warning lamp.
a) Emergency item is flashing, but alarm buzzer does not sound ..... . ... . . . . 82- 96
b) Emergency item or non-emergency item is flashing, but warning lamps does not flash . . 82- 98
M-l 1. Abnormality in gauge.
a) Fuelgauge.................................................... 82-100
b) Air pressure gauge .. . ... . . . . . . . . . .-. . . . . . . . . . . . . . . 82-102
c) Coolant temperature gauge . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . 82-104
d) Torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-106
WA600- 1 82-45
e
TROUBLESHOOTING TABLE (ELECTRONIC VEHICLE
Module group
-------
Even when engine is stopped, and there is no abnormality in machine,
1
level) flashes.
2
level) flashes.
3
level) flashes.
4 m(B attery charge) flashes at engine running.
5 q (Fuel level) flashes at engine running.

LT
6 El
m (Afterheating) flashesat engine running. 0 0
7 ‘6-1 (Clogging transmission oil filter) flashes at engine running. 0 0
8 There is no abnormality
running.
in machine,
@j
(Failure
,’
in brake line) flashes at engine
0 0
There is no abnormality in machine, m (Engine oil pressure) flashes at engine
9 rllnnin” 0 0
10 There is no abnormality in machine,

Ij
8 (Coolant level) flashes at engine running. 0
0
There is no abnormality in machine, (Drop in air pressure) flashes at engine
11
running. •z
0 0 0
There is no abnormality in machine, (Coolant temperature) flashes at engine
12
running. •I
0 0 0
There is no abnormality in machine, 71 (Torque converter oil temperature) flashes
13
at engine running. L%L! 0 0 0
Speedometer display does not work normally.
21 Service meter does not work normally. 0 0

22 All or part of monitor panel does not work normally. 0 0 0 0
0
Even when engine is stopped, (Engine oil pressure) flashes, or (Battery 0

23 0 0
charge) flashes. L!zG
No lamps on monitor light up (Immediately after turning starting switch to “ON”
24 0 0 0 0
enaine stoooed)
WA600- 1
82if6
MONITORING SYSTEM)
Electrical parts group Sensor group
TORQUE
Work- Trans. Electri-
Con_ Engine Brake Cool- ETj,“e conver-
Alter- ing mission Cal air Diode Lamp Parking s~$r$g~~~{~_ tL_ B,?$ Fuel t %%
oil oil ant ransmi Speed teroil
nator lamp cut-off intake buzzer troller pres- brake
level level level SUE failure ‘eve’ ssion -WllPW-
switch switch ‘heater sure eQe”d’iP- ature
oil filter ature
0
0
0
0
0
0
0
0
0
--
0
0
I I I I / 0
-
0
0
0
0
I 0
I I I I I
0
/ / I I / I
0 0
0 0
0 0
0 0
/
0 0
0 0
I
I 0
0
0
0
WA600- 1 82-47
0
TROUBLESHOOTING CHART No. M-l.
(Fluid level of CHECKS BEFORE STARTING items are correct)
Failuremode: WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),
AND THERE IS NO ABNORMALITY IN MACHINE, CHECK BEFORE
STARTING ITEM FLASHES.
* When disconnectiong or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnect-
Cause Remedy
a) 1 ($1 1(BRAKE OIL LEVEL) FLASHES.

YES
* Defective brake oil level +place
sensor
Defective CHECKS BEFORE Replace

STARTING module
Is there continuity
between CNP4
1 )Connect short After inspectin.

Iisconnection in wiring
socket adapter ,arness, or defective contact repair (clean) or
to CN59 setwee” CN.59 (female) (1) replace
(female).
Z)Connect
- CN64 (2) - CN65 (3)
- CNP4 (female1 (4).
T-adapter (or
I I , I socket adapted
to CNP4 (female)
3)Tum starting
switch OFF.
1 )Connect
T-adapter (or
socket adapter) NO
to CN.59 c Disconnection in wiring After inspectin.
(female). harness between CN59 repair Mean) or
ZITurn starting (female1 (2) - CN64 (3) - replace
switch OFF. CN65 (4) - chassis ground

Troubleshooting
toots T-adapter or socket adapter
T-adapter (for DLI) lfor Econoseal)
CN59 (female) 6~65
CNP4 (female)
82-48
,-. WA600- 1
,I.
b)
q g (ENGINEOIL LEVEL) FLASHES.
Cause Remedy
Defective engine oil level

W”SW
YES
Defective CHECKS BEFORE Replace
STARTING module
YIES
4-y
1)Connect short Iisconnection in wiring After inspection.

socket adapter socket adapter NO repair (clean) or
?arness. or defective contact
to CN120 toCN120 between CN120 (female1 PSphX
(female1 (engine (female). (1) - CN115 (8) - CN86
oil level sensorl. 2)Connect (2) - CNP3 (female) (31.
2)Turn starting T-adapter to
switch ON. CNP3 (female)
Is therecontinuity
3)Turn starting
between CN 120
switch OFF.
1 I Connect
T-adapter (or
socket adapter) ~
toCN120 3isconnection in wiring After inspection,
IfemaleJ. NO ?arness. or defective contact repair (clean) or
2lTurn starting between CN120 (female) PSpLXe
switch OFF. l22,,TNll5 (3) - chassis

Troubleshooting
tools T-adapter or socket adapter
T-adapter (for DLII
(for Eco”oseal)
CN120 (female) CN115
CNP3 (female) CN86
5 8
WA600- 1
(COOLANT LEVEL) FLASHES.
F
Cause Remedy
3efective radiator water level k@SX

sensor
Defective CHECKS BEFORE ?&Xe

STARTING module
Yl
I I
1 I Connect short 3isconnection in wiring 4fter inspection,
socket adapter socket adapter “amess, or defective contact .epair (clean) Or
to CN136 toCN136 between CN136 (female) (1) .epL%e
(female) (radiator (femalei. - CN128 (2) - CN84 (2)
water level 2)Connect - CNP3 (female) (5).
sensor1 2 T-adapter to
2lTurn starting CNP3 (female)
switch ON. Is there continuity 3)Tur” starting
1
between
. ._.
CN136
(ternale) UI and
I switch OFF.
c
chassis ground?
I
1)Connect
T-adapter (or
socket adapter)
to CN136
(female).
- Disconnection in wiring After inspection.
2)Turn starting
10 harness, or defective contact repair (clean) Or
switch OFF.
between CN136 (female) (2) replace
- chassis ground

Troubleshooting ,
tools T-adapterorsocket adapter
T-adapter (for DLI)
(for Econoseal)
CN136 (female) CN84

Radiator water
level sensor (a) 10 12 11 1
6 2 I 3
CNP3 (female)
1 4
82-50 WA600- 1
IT)
TROUBLESHOOTING CHART No. M-2.
(Fluid level of CHECKS BEFORE STARTING items are correct.)
Failure mode: WHEN STARTING SWITCH IS TURNED ON (AT ENGINE RUNNING),
AND THERE IS NO ABNORMALITY IN MACHINE, CAUTION ITEM
FLASHES.
* When’connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( 1)
* When disconnecting connectors or connecting T-adapters, return them td the original condition immediately after
a) Cause
I I
flashes when engine is stopped, refer to M8-d).
Defective CAUTION module
1
alternator terminal
Disconnection in Wiring After inspection.
harness, or defective Contact repair (clean) Or
2)Turn starting
between alternatOr terminal replace
switch ON.
(Start engine1 R ---c;.(l( (1) - CN86 (11
switch ON. Start -
2) Measure voltage
between
Defective alternator

Troublleshooting
T-adapter (for DLI)
(for Econoseal)
CNP5 (female) CN86
CNI 14
82-51
0
b) R‘ (FUEL LEVEL) FLASHES.
n
Cause
YES
I) See M-l 1 -a) “Abnormality Replace
in, fuel gauge”.
r Does fuel gauge

display show
EMPTY?
1 )Turn starting
switch ON.
1
NO
Defective
1
CAUTION
Defective gauge module

module
In a rare case, contact

wiring harness between
CNP2 (female) (3) - CNP5
(female) (6) and other
wiring harness.
Replace
After inspection,
repair (clean1 or
replace

harness, or defective contact repair (clean) or
CNP5‘lfemale). replace
between CNP2 (female) (31
2) Turn starting and CNP5 (female) (6).
switch ON.

Troubleshooting
T-adapter (for DLI)
(for Econoseall
Module 1 (e)
CNP2 CNP5 (female)
7
I2 5
I 6 I
82-52 WA600- 1
cl;
C) m (AFTERHEATING) LIGHTS UP.
LII
Remedy
Contact with + 24V and After inspection.

CNP6 Ifemale) (11) CN86- repar (clean) or
(6) - CN115 (5) - CNllS replace
~11-CN117~3)orCN119
(4) - CNl18 (3)
1) Disconnect
CNZO.
2)Turn starting Defective preheating switch.
NO
switch OFF.
1)Connect T-
adapter to CNP6
(female).
P)Turn starting
switch ON. Disconnection in wiring har- After inspection,
ness or defective contact be- repair (clean) or
Is resistance between CNP6 (female) (11) - replace.
tween CNP6 CN86 (6) - CN115 (5) -
(female) (1 1) and CNllS(l)-CN117l310r
h chassis ground CNl 19 (4) - CNl 18 (3).
more than 20Kfi?
1) Connect T- Defective CAUTION module

adapter to CNP6 NO 1.
(female).
Z)iurn st&ting
switch OFF.
Table
CN20 CNP6
CN86 CN115
5 2 1 3
WA600- 1 82-53
i-
L1‘
d) l-lw (AFTERHEATING) DOES NOT LIGHT UP.
Cause Remedy
Defective CAUTION module Gplace.

1.
Is voltagebetween
CNPG (female) (1 1) YES
and chassis ground - 2’ * Contact with chassis ground After inspection,
more than 4V? and wiring harness between repair Mean) or
Is there continuity
CNP6 (female) I1 1) -
CN86 replace.
(6)-CN11515)-CN119
1 I Connect T- L between CN20 (1) - CN117 (3) or CN119
adapter to CNPG NO ~~~~~~~ F$$ (4) - CNl 18 (3).
(female).
2)Tum starting
switch ON. 1) Disconnect IJefective preheating switch. Replace
CN20. NO
2)Turn starting
switch OFF.
Table
OFF I NO

Troubleshooting I
tools T-adaoter or socket adapter
T-adapter (for DLII
(for Econoseal)
CN20
CN119 Resister (c)
82-54
0
e) (CLOGGING IN TRANSMISSION OIL FILTER) FLASHES.
Cause Remedy
Defective transmission oil Replace

filter clogging sansor
YES
1.
Socket aoapter
to CN 60
(female) Is there continuity
(transmission oil YES between CNP5 (7) I-
filter clogging 2 - (female) and
SEXlSOd. chassis ground.
2)Turn starting Is there continuity
switch ON. _ batwaa” CN 60 _ 1 I Connect short
3)Start engine. NO (2) (female) and socket adapter
chassis ground? to CN 60
(female). Disconnection in wiring After inspection,
1)Connect 2)Connect harness. or defective Contact repair (clean) or
T-adapter (or T-adapter to 1
between CN60 I1 (female) replace.
socket adapter) CNP5 (female). - CN64 (11 - CN65 (2)
to CN 60 3)Turn starting - CNP5 (female) (7).
Ifemale). switch OFF.
2)+&n starting I Disconnection in wiring After inspection.
c
switch OFF. NO harness. or defective Contact repair (clean) Or
- CN64 (3) - CN65 (4)
- chassis ground.

Troubleshooting
tools
T-adapter (for DLi)
(for Econoseal)
CN60 (female) (Transmission oil filter clogging sensor “b”)
CNP5 (female)
WA600- 1 82-55
a
TROUBLESHOOTING CHART NO. ~-3.
Failure mode: WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), AND
THERE IS NO ABNORMALITY IN MACHINE, EMERGENCY ITEMS
FLASH ES.
Cause Remedy
(FAILURE IN BRAKE LINE) FLASHES.

YES
Defective CAUTION module Replace
4‘
7
ISthere continuity
YES between CNP8
2 r (female) I1 11
and -
r chassis ground?
Is there continuity
between CN62
. (female) (2)and - l)Co”“ect
T-adapter to
chassis ground? CNP8 (female).
Is there continuity 4 2)Turn starting c Disconnection in wiring After inspection,
between CN62 1)Connect short switch OFF. NO , harness, or defective contact repair (clean) or
(male) (1) and (2)? socket adapter between CN62 (female) (1 I replace
to CN61 - CN64 (7) - CN65 (9)
I
- CNP8 (female) (1 1).
1
Is there continuity
I_
between CN 6 1
(male) (1) and (2)?
I
I
1)Connect
T-adapter (or
socket adapter)
2~~~zjg~~;er) )
to CN62 (malel. to CN62 NO harness, or defective contact repair (clean) or
1 Iconnect 2)Turn starting Ifemale). between CN62 (female) (2) replace
T-adapter (or switch OFF. 3)Turn starting - CN61 Ifemale) (1) or
socket adapter) switch OFF. CN61 (female) (2) - CN64
to CN61 (male). I41 - CN65 (41 - chassis
2)Tur” starting ground.
switch OFF.
Defective brake line failure 1 Replace
NO %?“SOr
Defective brake line failure 2 Replace

sensor

Troubleshooting
T-adapter (for DLI)
(for Econoseal~
CN61 CNP8 (female)

(female)
CN62 CN65
(male)
82-56 WA600- 1
:j;:
b) I +& ~ (ENGINE OIL PRESSURE) FLASHES.
Cause Remedy
r
Yl
Defective engine oil pressure ?eplace
X”SW
3efective CAUTION module Wlace

3 2
Isthere continuity
ES between CNP7
l-
(female) (2) and
chassis ground?
---I
1 I Connect short 1 )Connect short Disconnection in wiring 4fter inspectlon.
socket adapter socket adapter harness, or defective contact .epair I&an1 Or
to CN122 toCN122 between CN122 (female) .eolace
(female) (engine (engine oil (1) - CN115 (4) - CN86
oil pressure pressure sensor). (7) - CNP7 (female) (2).
Sl?llSd 2)Connect
PITurn starting T-adapter to
switch ON. Is there continuity
CNP7 (female).
3)Start engine. between CN122 3)Turn starting
(female) (2) and switch OFF.
1 )Connect
T-adapter (or
socket adapter)
to CN122
(femaleI.
SITurn starting
switch OFF.
(Engine stopped.) Disconnection in wiring After inspection,
NC between CN122 (female1 replace
(2) - CNl 15 (3) - chassis
ground.
Note: If w flashes
when the engw 1s
c see M-8-c) “Even when After inspectton,
mgine is stopped, engine oil repair (clean) or
xessure lamp or battery replace
:harge lamp flashes”.

Troubleshooting
T-adapter (for DLI) ifor Econoseall
POISTION OF CONNECTOR
CNI 22 (female) CN86
CNP7 (female) CN115
WA600- 1 82-57
0
(COOLANT LEVEL) FLASHES.
Cause Remedy
YES
3efective coolant level sensor Replace
3 YES
Defective CAUTION 2 Replace
module
Yl
‘EH--
I I
* Defective contact. or After inspection,
1)Connect short NO disconnection in wiring repair (clean) or
7
socket adapter harness between CN136 replace
toCN136 (female) (1) - CN128 (2) -
Is there continuity
(female). CN84 (2) - CNP7 (female)
1 I Connect short between CN136 2)Connect (61.
socket adapter NO (female) (2) and T-adapter to
to radiator water chassis ground? CNP7 (female).
I
level sensor I 3)Turn starting
CN 136 (female). 1) Connect T-adapter switch OFF.
2) Turn starting (or socketadapter)
switch ON. to CN136 (female).
3) Start engine. 2)Turn starting
switch OFF.
Iefective contact, or After inspection.

lisconnection in wiring repair lcleanl or
lames5 between CN136 reolace
:female) (2)
- chassis ground.

Troublsshootlng
T-adapter (for DLI) /‘^. E..nr*ra&
CN 136 (male) (Radiator water level sensor “a”) CN84
CNP7 (female)
82-58 WA600- 1
/iJ
_,
d’ I@\(DROP
I 1
IN AIR PRESSURE) FLASHES. (AT ENGINE RUNNING)
Cause Remedy
See M-l 1 -b) “Abnormality in Replace

air pressure gauge.”
Defective CAUTION module Replace

2
1 ITurn starting NC Defective gauge module Replace

switch ON.
swtch ON. 1) Connect I c Disconnection in wiring After inspection,

T-adapter to NO harness, or defective contact repair (clean) or
CNP7 (female). between CNP2 (female) (7) replace
2)Turn starting and CNP7 (female) (31
switch ON.

Troubleshooting
toots T-adapter or socket adapter
T-adapter (for DLIJ
(for Econoseal)
Module 2(e)
CNP2 CNP7 (female)
WA600- 1 82-59
0
e) (COOLANT TEMPERATURE) FLASHES.
Cause
YES
-- See M-l 1 -c) “Abnomality in
coolant temperature”.
YES
Defective CAUTION module Repkace
2
1
Does coolant
temperature gauge - //?
‘
move to red level?
1 ITurn starting NC Does go out? -

switch ON. •II
3 YES
c Defective gauge module Replace
1) Interchange IS voltage between
CAUTION CNP7 (female) (71
modules 1 and 2. NO
L and chassis ground
2)Turn starting more than 3.5V?
switch ON.
Z Disconnection in wiring After inspection.
1) Connect NO harness. or defective contact repair (clean) or
T-adapter to between CNPZ (female) (2) replaCe
CNP7 (female). and CNP7 (female) (7)
2)Turn starting
switch ON.

Troubleshooting
T-adapter (for DLI)
(for Econoseall
Module 2(e)
CNP2 CNP7 (female)
WA600- 1
(TORQUE CONVERTER OIL TEMPERATURE) FLASHES.
Cause
*
YES
r See M- 1 1 -d) “Abnormality
:orque converter oil
in
zmperature gauge”.
1
2
Does torque
converter oil
temperature gauge 2
move to red level?
1 ITurn starting
switch ON.
3 YES
1-
Defective gauge module Replace
1) Interchange
CAUTION CNP7 (female) (5)
L-
modules 1 and 2. p and chassis ground
2)Turn starting more than 3.5V?
switch ON.
Disconnection in wiring After inspecbon,
1) Connect harness, or defective contact repair (clean1 or
T-adapter to between CNP2 (female) (8) replace
CNP7 (female). and CNP7 (female) (5)
2)Turn starting
switch ON.

Troubleshooting
T-adapter (for DLII
(for Econoseall
Module 2(e)
CNP2 CNP7 (female)
WA600- 1 82-61
c:
Failuremode: WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),
AND THERE IS NO ABNORMALITY IN MACHINE, PILOT ITEM LIGHTS UP
ABNORMALLY, OR DOES NOT LIGHT UP.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( 1)
Cause Remedy
Defective parking brake

sensor.
Y
Does
I(@) goout!
1 I Connect short 4 YE!
socket adapter Defective CAUTION module Replace
to CN34
(female) (parking
II-Is therecontinuity
I)
L
YES between CNP8

brake sensor).
ZlTurn starting 3 r (female) (2) and -
switch ON. 1 chassis ground?
Is there continuity After inspection,
b Disconnection in wiring
between CN34 repair (clean) or
i (female) (2) and - l)Co”“ectshort
cO”“ector to NC
chassis ground? CN34 (female) - CN32 (1 I- CNP8
(parking brake (female) (2)
1 ITurn starting 1) Connect sensor).
switch ON. T-adapter (or 2) Connect
socket adapter) T-adapter to
to CN34 CNP8 (female).
(female) (parking 3)Tum starting
brake sensor). switch OFF.
2)Turn startina
switch OFF.-

between CN34 (female) (21 replace
and chassis ground
See troubleshooting for

machine

Troubleshooting
T-adapter (for DLI) (for Econoseall
CN34 (female)
CNP8 (female)
82-62 WA600- 1
@
b) ~(8) I
DOES NOT LIGHT UP.
Cause Remedy
Defective parking brake teplace

sansor
YES
c Short circuit between Ifter inspection,
Does parking brake _

3 chassis ground and wiring
(female) I1 1- CN32 (11 -
epair (clean) or
eplace
actuate when park- _ , ,Dlsconnect

CNP8 (female1 (2)
ing brake switch
connector CN34. NO
turned ON - OFF?
2)Tum starting
switch ON.
1) Turn starting Defective CAUTION module k!place
switch ON. 2
CNP8 (female).
2) ysy4ynect
3)Turn starting
switch OFF.
See troubleshooting for

NO machine

Troublleshooting
T-adapter (for DLI)
(for Econoseal)
CN34 (female)
CNP8 (female)
WA600- 1
Note: If all working lamp bulbs are broken, or there is defective contact or
a disconnection in the wiring harness of the working lamp,
>,gz (working lamp) will stay on.
Cause Remedy
Defective working lamp Replace

switch
1) Disconnect
CN12.
2)Turn starting
switch ON.
YES
c Defective CAUTION module
2
I. Is there continuity
between CNPE
ifemalel (10) and
1
I CN12 (fern&l (217

I
1)connect c Disconnection in wiring After inspection.
T-adapter to NO harness, or defective contact repair (clean1 or
CNP8 (femaleI. between CNP8 (female) (101 replace
2)Turn starting and CN12 (female) (2).
switch OFF.

Troubleshooting
to015 T-adapter or socket adapter
T-adapter (for DLI)
(for Econoseal)
CN 12 (female)
CNP8 (female)
WA600- 1
821164
..,
d) ,,g DOES NOT LIGHT UP.
i--i
T
Remedy
Defective CAUTION module ?eplace

2
Iisconnectlon in wiring 4fter inspection,

larness, or defectwe contact epalr (clean) or
Mween CN12 (female) (2) epkx
CNP8 (femaleI. - CNP (8) (female) (10).
Z)Turn starting
switch ON.
3)Turn working
lamp switch ON.
ISvoltage between
CN79 (male) (9)
1I Connect
T-adapter (or
socket adapted
to CN79 (male).
Z)Turn starting
switch ON.
3efective working lamp

witch

NO harness. or defective contact repair (clean) or
batwaen main breaker and replace
CN79 (male) (91.
* Table
Tester Shon socket adapter

Troubleshooting .
mi tools T-adapter or socket adapter
T-adapter (for DLI) lfor Fronoseall
CN 79 (female) CNP8
IO 12 11 1
6 2 1 3
CN12 (male)
WA600- 1 82-65
0
e) w (PREHEATING) LIGHTS UP.
I
Cause Remedy
Contact with +24V and After inspection,

CNP8 (female) (3) - CN24 epair (clean) Or
(diode) (2.1. (1) - CNl 00 eplace.
(female) (1) or CN82 (1 b-
CN81 (11 - CN81 (21 -
CN82 (2).
IL 11Connect
show” in table?
Defective preheating switch. replace

T-adapter to
CN20 (male1.
2)Turn starting
switch OFF.
1
Is voltage between Disconnection in wiring har- 4fter inspection.

CNP8 (female) (3) ness or defective contact be- epair (clean) Or
and chassis ground tween CNPS (female) (3) - .eplace
more than 4V? CN24 Idiode) (2). (1) -
Is resistance be- CNl 00 (female) (1) or
CN82
- tween CNP8 11) - CN81 (1) - CN81 (21
11Connect T-
- (female) (3) and - CN82 (2).
adaptertoCNP8 NO chassis grou”d
(female).
more than ZOKfi?
2)Turn starting
switch ON.
1 )Connect T-
adapter to CNP8 Defective CAUTION module Replace
(female). 2.
2)Tum starting
switch OFF.

Troubleshooting
T-adapter (for DLI) (for Econoseal)
Table
OFF NO
CNP8 (female) CNlOO
CN20
WA600- 1
82/;:66
d
f) r-lw (PREHEATING) DOES NOT LIGHT UP.
Cause Remedy
vi iS fqeplace
w Defective CAUTION module
2
YI 3
1
CNP8 (female) (3)
1 and chassis ground
more than 4V?
Does intake mani- ,

fold become warm? T-adapter to
CNP8 (female). L Disconnection in wiring har- i 4fter inspection,
ness or defective contact be- I-epair (clean) or
2)Turn starting
switch ON. tween CNlOO (female) (1) - Isplace.
1 )Turn starting CN82 (11 - CN81 (female)
switch ON. (1).
2)Turn preheating
switch ON.
1
Defective electrical intake air Replace
NV heater circuit

Troubleshooting
_. _*.
10015 T-adapter or socket adapter
T-adapter (for DLII (for Econoseal)
I
CNP8 (female)
CNlOO CN82 CN81
WA600- 1 82-67
0
9) IV/ (FAILURE IN MAIN STEERING) LIGHTS UP. (IF EQUIPPED)
-
Cause Remedy
Defective main steering Mace

failure sensor
YES
Defective CAUTION module ieplace
1
Yf
a---;
1)Connect short \fter inspection,

socket adapter NO .epair or replace
toCN108 CNP6 (female). between CN 108 (female) (2)
(female) (main
steering sensor).
2)Connect short - CN88 (1) - CN44
2) Turn starting
socket adapter
toCN108
(female) (1) - CN44
Ifemale) (2) - CNP6
switch ON. (female). (female) (2) or defective
3)Tum starting diode CN44 (male).
switch OFF.
IS ground?
1) Connect
T-adapter (or
socket adapter)
toCNlO8
(femaleI.
2)Turn starting
switch OFF.
L Disconnection in wiring 4fter inspection,

between CNlO8 (female) (1)
- CN88 (2) - chassis
ground.
Troubleshooting
tools T-adaoter or socket adapter
T-adapter (for DLII
(for Econoseall i
CN108 (female) CN88
CNP6 (female)
I .I
CNP:!
i
CNP10? * NP6 CNPS
426P123
1
82-68 WA600- 1
I’!.
h) [uj (FAILURE IN MAIN STEERING) DOES NOT LIGHT UP. (IF EQUIPPED)
Cause Remedy
Defective main steering Replace

failure sensor
YES
Does -lJ- light UP’ - c Short circuit between After inspection,
cl 2 repair Iclean) or
chassis ground and CN108
(female) (21 - CN88 (1 I- replace
_ Is there continuity CN41 (1). (2) - CNP6
1) Dwonnect i between CNPG (female) (21.
CN108 (female) NO (female) (21 and -
(main steering chassis ground?
sensor).
2)Turn starting 1) connect & L Defective CAUTION module
switch ON. T-adapter to NO 1
CNP6 (femaleI.
2)Turn starting
switch OFF.

Troubleshooting
T-adapter (for DLII
(for Econoseall
CN108 (female)
i)
m-i (TRANSMISSION CUT-OFF) LIGHTS UP.
Cause Remedy
YES
Defective transmission Replace
Cut-off switch
YES
3p Defective CHECKS BEFORE Replace
STARTING module
ISthere continuity
YES between CNP4
- (female) (10Jand -
chassis ground?
1 IShort-circuit 1) Transmission After inspection.

- Disconnection in wiring
CN18 (female) cut-off Selector NO repair (clean) Or
(3) and (4). switch ON. replace
PITurn starting 2)Connect
and CNP4 (female) (10)
switch ON. T-adapter to
? _.._.

harness, or defective contact .epair (clean) or
and chassis ground
Tester
Troublleshooting
T-adapter (for DLI)
(for Econoseal)
CNI 8 (female) CNP4 (female)
CN18 (male)
8220 WA600- 1
i)
01 (TRANSMISSION CUT-OFF) DOES NOT LIGHT UP.
Cause
YES
lefective transmission leplace
M-off switch
Contact between chassis Wer inspection.

ground and CN18 (female) epair Wean1 Or
(4) - CNP4 (female) (10) eplace
1)connect I * Defective CHECKS BEFORE Replace

T-adapter to NO STARTING module
CNP4 (femaleI.
2)Turn starting
switch ON.
Tester
Troubleshooting
took. T-adapterorsocket adapter
T-adapter (for DLI)
(for Econoseal)
CNP4 (female)
WA600- 1 82-71
:x
Failuremode: TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP ABNORMALLY,
OR DO NOT LIGHT U-P.
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( 1)
When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS up.
Iefective speedometer 1eplace

llodUle.
between CNPlO
(female) (3) and
chassis ground
1 ~Connect
T-adapter to w See troubleshooting for
CNPl 0 (female). NO machine.
ZlTurn starting
switch ON.
3)Tum turn signal
switch ON.
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS up.
YES
c Defective speedometer ?eplace
module.
1 I
Does voltage
between CNPlO
(female) (7) and
chassis ground
change alternately
OV and 20 - 3OV?
1)connect
T-adaoter to I * See troubleshooting for -
CNPl b (female). NO machine.
21 Turn starting
switch ON.
3)Turn turn signal
switch ON.
Tester
Troubleshooting
to&. T-adapter or socket adapter
T-adapter (for DLI)
(for Econoseali
CNPIO (female)
82-72 WA600- 1
‘$
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP.
Cause Remedy
Defective speedometer
module
Do front and rear c Defective contact, or Zfter inspection.

turn signal lamps _ disconnection in wirina
1)connect epair Iclean) or
work normally? harness between CNP”l0
T-adapter to eplace
CNPlO (female). ifenele) (3) and CN15 (male)
2)Starting switch
1) Operate right
turn ON.
turn signal lamp.
3)Turn turn sianal
2)Starting switch
switch ON.”
turn ON.
Defective turn signal

NO
Tester
Troubleshooting _
T-adapter (for DLI)
(for Econoseal)
CNPlO CN15
WA600- 1
d) PILOT DISPLAY 0~ TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT up.
Cause Remedy
YES
* Defective speedometer 7eplace
module
I
between CNPlO
lY (female) (7) and
change alternately
Do front and rear
turn signal lamps 1) Connect
T-adapter to I Defective contact, or 4fter inspection.
CNPlO (female). NO disconnection in Wiring .epair (clean) or
2)Starting switch harness between CNPl 0 ,eDlace
turn ON. (female) I1 1) and CNl5
3)Turn signal (male) (61
switch turn ON.
Defective turn signal Replace
Tester
Troubleshooting
tools T-adgoter or socket adapter
T-adapter (for DLII (for Econoseall
CNPI 0 (female)
* CN15
7 11 12 10
3 I 2 6
82-74 WA600- 1
(3
Al.,
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP.
Cause Remedy
YES
) Defective speedometer Replace
module
I
CNPlO (female) (41
and chassis ground
20 - 3OV?
I 1 I
Do both left and c Defective contact, or After inspection.
right head lamps 1) Connect NO disconnection in wiring repair (clean) or
light up? T-adapter to harness between CNPlO replace
CNPlO (female). (female) (4) and CN31
2)Turn starting (female) (1).
1 )Turn starting switch ON.
switch ON. 3)Turn
2)Turn combination
combination switch to head
switch to head lamp position.
lamp position. 4)Turn dimmer
3)Turn dimmer switch to HIGH
switch to LOW BEAM.
BEAM.
c Bulbs broken in both head
NO lamps (low beam lamps) (If
the low beam bulb is broken,
the oilot lame will not liaht UD
even if the switch is &Led io
HIGH BEAM.)
Tester
Troubleshooting
T-adapter (for DLII
(for Econoseal)
CNPlO (female) CN31
CN31 CNBE
WA600- 1 82-75
0
f) HIGH BEAM PILOT LAMP DOES NOT GO OUT.
Cause Remedy
YES
Defective speedometer Replace
module
YES
c Defective contact, or After inspection.
disconnection in wiring repair (clean) or
harness between CN15 reolace.
(femalel (9) and combi-
I
1 Turn starting nation switch
switch ON.
2) Turn
combination
switch to head
lamp position.
BITurn dimmer
switch to LOW
YES
Does head lamp Defective contact, or After inspection.
BEAM. disconnection in wiring repair (clean) or
light up at HIGH
r BEAM? harness between CN15 replace.
(female) (12) and combi-
nation switch
Defective contact, or After inspection,

switch to HIGH disconnection in wiring repair (clean) or
BEAM. harness between CN15 replace.
(male) (121 and chassis
ground
Tester
Troubleshooting _
tools T-adipter or socket adapter
T-adapter (for DLI)
(for Econoseal)
CNI 5 (male)
WA600- 1
Failure mode: SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
* When disconnecting connectors or connecting T-adapters, return them to the original condition immediate!y after
Cause Remedy
4 YE: j
c Defective speedometer RepI.%2
module
YES Is gap of speed
3 - sensorsetat 0.5 - _
1.5 mm?
Is resistance
ES ) Defective speed sensor Adjust
between CNPlO
(female, (10) end - * Loosen the lock nut NC1 mount
(2) 3OOn. - lkfi? of the speed sensor.
and turn thesensor
Isresistance clockwise. If it
YES between CN89 1) connect contacts the gear
1 - (female) (31 and (4) ’ T-adapter to within one turn. the
3OOn - lkn? CNPlO (female). gap is within 1.5 mm.
Is resistance 2)Turn starting
between CN 98 switch OFF.
(male1 (1) and (2) - 1)Connect
T-adapter (or
3OOn - lkR? _,
- --Socket adapter)
/
to CN89 (female)
1) Connect 2)Turn starting
T-adapter (or Disconnection in wiring After Inspection.
switch OFF.
socket adapter) harness, or defective contact repair (clean1 or
to CN98 (male). between CNPlO (female) replace
2)Turn starting (10). (2) - CN89 (1 1). (12).
switch OFF.
Xsconnection in wiring After inspection,

,arness, or defective contact .epairor
xtween CN89 (female) replace.
(12). (1 1) - CN98 (1). (2).
Defective speed sensor Replace
Tester
Troubleshooting
tools
T-adapter (for DLI) T-adapter or socket adapter
(for Econoseal)
CN98 (male) CNPIO (female)
CN89
82-77
cc
METER NOT WORK NORMALLY.
ing the connector for checking, turn the starting switch OFF to prevent accidents_
* When connecting the T-adapter (or socket adapter). connect to the connector specified. (CNxx ))
* disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
Cause
YI ES
.
1NAmectshort
socketadapter
toCN122
wemak~ (ensine
1I
Iuo
yEs
to CNl22 Ifemale).
.
-
F
kthwcontinuity
CNps&smak~0
andehmsk
gmund7
1Icanectshort
=c-tadapter
toCN122
lfemakl.
2Nzomect
T-adapterm
CNP9 0.
YEs
3
_
-
r-----4
p
kvobgebetween
CNWIfematill)
and (3) 20 - 3ov7
llconnect
T-adapterCNW
bnak~.
2)Tumstming
switch ON.
-
rI
-
-il-lw*ins
b-,WCkfS?CtiW~
between CN42 bmak) (1)
and CNP9 (female) (11. (3).
2ITm stding 3)Tum statirg

switchOFF. SwitchoFF.
&CNl22(femaU(l)
- CNl15 (4) - CN86 (7)
- CNPS Ifem& w.
mtwem CN122 bemale)

t2~-CN115(3)-chassis
WAtSOQ-1
CN42 (male)
CNP9 (female)
CNI 22 (female)
CN115
82-79
0;
Failure mode: ABNORMALITY IN MONITOR PANEL.
ing the connector for checking turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter), connect to the
connector specified. (CNxx ( 1)
* When disconnecting connectors or connecting T-adapters, return them
Cause Remedy
to the original condition immediately after checking, then go to the next
check.
.a) NONE OF MONITOR PANEL IT_adipter ;,, -1

c Defective contact or 4fter inspection,
WORKS. I disconnection in wiring spair (clean) or
harness between CN42 ‘eplaCe
(male) (1) - all
modules
(f24). and CN42 (male) (4)
- all modules (ground
connection).
‘ES
Is voltage between
CN42 (1) and (4)
20 - 3OV?
One of modules defective. Jfter inspection,
Is voltage between Is voltage between (Contact connectors in turn. epair (clean) or
CN42 (female) (1) 1 IConnect CN42 (1) and (4) If there is no voltage for any epklce
and (4) 20 - 3OV? T-adapter to module, check it.)
CN42.
2)Turn starting
1) Connect switch ON. 1) Disconnect
T-adapter (or cO”“ectOrs
socket adapter) (CNPl, P4, P6,
Short circuit between CN42 After inspection,
to CN42 P8,PSandPlO). N<
(1) and (41 (Power shut off opair (clean) or
1 Iconnect (female). 2)Turn starting I to protect controllerl. Bplace
T-adapter (or PITurn starting switch ON. I
socket adapter) switch ON.
to CN40
(female).
2)Turn starting
switch ON.
- Controller defective IeplaCe
NO
Disconnection in wiring 4fter inspection,

harness, or defective contact epair (clean) or
between CN40 (female) (11 ‘eplace
CN79 (6) - fuse -
C~60 (5) - cNi49 -
main breaker.
1) Connect I c Disconnection in wiring After inspection,

T-adapter (or NO harness. or defective contact repair (clean) or
socket adapter) between CN40 (female) (2) replace
to CN40 - CN64 (5) - chassis
(fern&l. ground
2)Turn starting
switch OFF.
Contact with wiring harness Replace

Fit adapter 1_‘“!
between CN42 (male) (1)
and (41.
One of modules defective After inspection,

(connect connectors one at a repair (clean) or
I
El-l
time to check) replace
Is there continuity
NO 4
between CN42
I
(male) (1 and (417
Is there continuity ’
between CN42
(male) (41 and
(11 and all con-
1) Disconnect
nectors in table
I CO”neCtorS
(CNP 1, P4, P6,
P8, P9 and Pl0).
below?
N’(
After inspection.
IrepairWean) or
I 1 Konnect to
2)Connect socket
CN42 (male) and 1 harness between CN42 Ireplace
corresponding CNP (male) (1) -all modules

CN42 (male). (+?4). and CN42 (male) (4)
connectors with
socket adapter. - all modules (ground
-- connection)
Table
CNPl CNP4 CNP6 CNP8 CNP9 CNPlO ~

CN42 connector
- (81 - (8) - (8) - (8) - (3) -_(16)
(male) (4)
4
CN42 connector
i
(female) 1)
- (4) - (16) -_(16) -(16) -_(I) - 181
82-80 WA600- 1
@
CN40 (female) CN42 (male) CN42 (female)
CN79
CNPl (female) CNP4, CNPG, CNP8 and CNP9 (female)

CNPI 0 (female)
12 9
1
6 I
WA600- 1
82-81
a
b) PART OF MONITOR PANEL DOES NOT WORK. Cause Remedy
YI
-- Defective module Replace
Is voltage
at power
module 20 - 3OV7
1) connect
T-adapter to
connector Of
module which L
NO
A disconnection In wiring After inspection,
does not light up. wrness, or defective contact repair (clean) or
KNP connector) 3t power source pin replace
2)Turn starting
switch ON.
Table
CNPl CNP4 CNP6 CNPS CNP9 CNPlO
Power source pin (+) (4) (16) (16) (16) (1) (8)
Power source pin I-) (81 (8) (8) (8) (3) (16)
Tester
Troubleshooting
T-adapter (for DLI)
(for Econoseal)
CNPl (female) CNP4, CNP6, CNP8 and CNP9 (female)

CNPlO (female)
5 4
1 8
WA600- 1
c) EVEN WHEN ENGINE IS STOPPED, (ENGINE 0iL PRES-
SURE) FLASHES, CAUTION BUZZER SOUNDS AND WARNING
LAMP ALSO LIGHTS UP.
Cause Remedy
Replace
Defective module Replace
1 I Remove wiring
PITurn starting 11CHECKS,

switch ON. (Do CAUTION 1 and hntact between +24V After inspection,
not start engine.) CAUTION 2 terminal and alternator repair (clean) or
modules are krminal R - CNl14 (1) - replace
interchangeable, EN 86 11) - CNPB, P5, P7
so interchange 11).
them.
2)Turn starting
switch ON.
(Leave terminal R
POISITON OF CONNECTOR
Module 1 (d) and Module 2(e) CN86
CN31 CM8 CM4 CN85 0489
CNI 14
S-S
WA600- 1 82-83
0
d) EVEN WHEN ENGINE STOPPED, (BATTERY CHARGE)
FLASHES AND WARNING LAMP LIGHTS UP.
Cause Remedy
kfective engine oil pressure Replace

Sensor
1
3efective module Replace
Contact
between chassis After inspection.
ground and CN122 (female) repair (clean) Or
(1) - CNl 15 (4) - CN86 (7) replace
CAUTION 2 CNP3 12). CNP5 (21.
modules are :NP7 (2).
interchangeable.
so interchange
them.
3)Tum starting
switch ON.
CN122 Module 1 (d) and Module 2(e)
e) NO LAMPS 0~ MONITOR LIGHTS uP (IMMEDIATELY AFTER TURNING STARGING SWITCH TO

“ON”, ENGINE STOPPED.)
(1) No lamps on any module light up when starting switch is turned ON.
All lamps go out when engine is started.
F
See M-S-al, b). c). d)
(2) Lamps on some modules do not light up.
I
Defective module
WA600- 1
82-84
f) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL
WARNING LAMP LIGHTS UP INTERMITTENTLY.
YES
c Defective CAUTION 2 \eplace
module
Does central
warning lamp go -
out?
warning lamp go I
1 Disconnect
CNP7.
2) Start engine.
- Defective CAUTION 1 ?eplace
1 k&ryct module
2)Start engine.
Tester
Troubleshooting
tools
T-adapter (for Econoseal)
CN42
CNP7
82-85
@
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY.
Cause Remedy
YES
L Defective CAUTION 2 ReDlace
2 module
Does central
warning lamp go
Defective CAUTION 1 Replace

CNP7. NO mcdule
2ISta1-t engine.
1
Contact between chassis After inspection.
Does central
warning lamp go ground and wiring harness repair (clean) or
between CN41 (male) (3) replace
out?
and CN17 (female) 12)
I
Is there continuity
I
1 Disconnect between CN41
CN42. I
2lStart engine. chassis ground?
1) Connect
T-adapter (or
socket adapter) NO
to CN41 (male).
2)Tum starting
switch OFF.
Tester
Troubleshooting I
tools
T-adapter (for Econoseall
CN42 CN41 (male)
CNP7 CN17
82-86 WA600- 1
Q
h) MONITOR DISPLAYS NO ABNORMALITY, BUT CENTRAL
WARNING BUZZER SOUNDS INTERMITTENTLY.
Cause Remedy
I
YES
I w lefective CAUTION 2 R @ace
lodule
1
,
Does Central
warning buzzer -
stop?
I) Di~i”;l”“C’
- lefective controller Fteplace
2) Start engine. NO
Tester
Troubleshooting
(for Econoseal)
CN42
WA600-1 82-87
@
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY.
Cause Remedy
YES
C Defective CAUTION module FkplaCe
2
1
,
Does Central
YES
warning buzzer _ b Contact between chassis After inspection,
stop? 2 . ground and wiring harness repair Mean) or
between CN41 (male) (2) replace
1 Is there continuity
and CN 148 (male).
1 )Disconnect between CN41
CN42. - (male) (2) and
2)Star-t engine. No chassis ground?
\
1)Connect
T-adapter (or
socket adapter)
to CN41 (male]. L C Defective controller Replace
2)Turn starting NO
switch OFF.
I
Troubleshooting
tools
Tester
T-adaoter or socket adaoter

I
1 I
* Module 1 (d)
CN42 CN41 (male) Module 2 (e)
82-88 WA600- 1
!T;
Failure mode: ABNORMALITY IN PANEL LAMPS ON MONITOR.
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( ))
rI-
Cause Remedy
NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SIDE LAMP
IN COMBINATION LAMP IS USED.
YES f
a Defective contact or wtter
disconnection in wiring nspection.
harness between CN23 epair (clean1
(female) (1) - )r replace
CNPl (female) (3).
CNP4 (female’ (I 5).
CNP8 (female’ (151,
1 CNPS (female) (2).
CNPlO (female’ (151,
Is voltage between in a rare case, all panel
Yl CN23 (female) (1) lamps may be broken)
and chassis ground
20 - 3OV?
_-- l’ij$Jz;;to
[ )
r
T-adapter 3isconnection in wiring ifter
2’Check voltage NO larness, or defective xpection.
YES between CN23 :ontact between CN15 epair (cleant
(female) wiring (male) (8’ - CN77 (1 1). >r replace
Is voltage between harness end (1) (12) - CN23 (female)
CN15 (male) (8’ and chassis (2). or defective diode
‘i and chassis ground - ground with assembly
1 20- 3OV? diode assembly
.I still connected.
1) Connect 3lTurn starting
YE
T-adapterto switch ON. Disconnection in wiring After
CN15 (male). harness, or defective nspection.
2)Turn starting 0 4 :ontact between CN15 epair (clean’
switch ON. (female) (4) - combination )r replace
1 ’ 31 Turn Is there continuity
lamp switch - CN15
combination between CN15
ifemale) (8). or defective
Is voltage between lamp switch to (female’ (4’ and
switch.
CN15 (male) (4) side lamps. (8) as shown in
and chassis ground ---Itable?
20 - 3OV?
1 I Disconnect
II CN15 (female).
I
L--_-
1 I Connect 2)Tum starting +aplace
4 lefective contact of
T-adapter (or switch OFF. NO combination lamp switch
socket adapter’
to CN15 (maleI.
2)Tum starbna
switch ON. ” I * Disconnection in wiring 4frer
NO I I 1 wrness, or defective nspection.
zontact between ,epair Mean)
I Combitiona
switch
lamp
I
Continuity
I
battery relay output -
CN7& (1’. (2’ - CN15
(male) (4)
x replace
Table
YES
step 3
Defective combination Replace

lamp switch
Tester
Troubleshooting
:001s T-adapter or socket adapter
T-adapter or socket adapter (for DLI) ifnr Ecnnncnall
POSITION OF
WA600- 1
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS
SWITCHED ON.
Cause Remedy
YES
Defective contact or Uter inspection,
disconnection in wiring epair (clean) or
harness between CN22 eplace
Ifemale) (1) - CNPl
Ifemale) (3). CNP4
Ifemale) (151. CNP6
(female) (15); CNPB
(female) (151, CNP9
(female) (21, CNPlO
Is voltage between (female) (15)
CN22 (female) (1) (In a rare case, all panel lamps
and chassis ground may be broken)
20 - 3OV?
YI Is voltage between I J
CN12 (female) (2) 1 ITurn working
1 and chassis ground lamp switch ON.
20 - 3ow 21Check voltage
Is voltage
between between CN22 _,
L c Disconnection in wiring 4fter inspection.
CN12 (female) (11 1 ITurn starting Ifemale) wiring NO harness. or defective contact ,epair (clean) or
and chassis ground switch ON. harness end (1) between CN12 (female) (2) .eplzx
20 - 3OV? 2)Turn working and chassis - CN22 (female) (2). or
lamp switch ON. ground with defective diode assembly.
1)Turn starting 3ICN12still diode assembly
switch ON. connected. still connected.
2)CNl 2 still
Disconnection in wiring \fter inspection,

harness. or defective contact ,epair (clean) or
between CN12 (male) (1) - .eplace
working lamp switch -
CN12 Imale) (2). or defective
working lamp switch
Disconnection in wiring 4fter inspection.

harness. or defective contact .epair (clean) or
between battery relay output wlace
CN79 (9). (10). (1 1) and
n2) - CN12 (female) (1)
Tester
Troubleshooting .
(for Econoseal)
CN12 (female) CN22 (female)
82-92 WA600- 1
0
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP.
Remedy
YES
z . [:lefective lamp \eplace
1) Remove lamp IDefective gauge module

and chassis ground socket of module s
and check
resistance of
1 I connect small bulb.
T-adapter to If it is over
CNPl (female). lOOn,bulbis
2)Turn starting broken.
switch ON.
3lTum light switch
ON.
- CN22 (female1 (1) -
CNPl (female) (3) - CNP4
(female) (15) - CNP6
(female) (15) - CNPB
(female) (2) - CNPlO
(female) (15)
Tester
Troubleshooting
T-adapter (for DLII
(for Econoseal)
CNPl (female) CN23
WAr!iOO- 1 82-93
0
d) PANEL
MODULE
LAMPS
DO
OF
NOT
CHECKS,
LIGHT
CAUTION
UP.
1 AND 2, SPEEDOMETER
r Cause Remedy
YES
L >efective lamp Replace
YES
chassis ground and

CO”“eCtor Of
module which does 1 I Remove lamp D Defective module
not light up 20 - socket of module NO
and check
resistance of
small bulb. If it is
1 IConnect over 100 II, bulb
T-adapter to if broke”.
connector of
module which
does not light up.
PITurn starting m Disconnection in wiring After inspection.
NO harness. or defective contact repair (clean) or
switch ON.
3)Turn light switch between CN23 (female) (1) replace
ON. - CN22 Hemale) (11 -
CNPl (female) (3) - CNP4
Module Connector (female) (15) - CNP8
[female) (2) - CNPlO
[female) (15)
CHECKS CNP4 (15)
CAUTION 1 CNP6 (15)
I CAUTION2 I CNP8 I1 5) I
Tester
Troubleshooting
tools
T-adapter (for DLI)
,
CNP4 (female)
CNP6
CNP8
CNPIO
9 IS
82-94 WA600- 1
‘j
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP.
Cause Remedy
YES
Ijefective lamp Replace
YES,i -
Is voltage
between
CNP9 (female) (2) 1) Remove lamp
yOdch;r&&ground
I , ,~~~,,d”~e (
Defective service meter Replace
1 I Connect small bulb. NO module
T-adapterto If it is war
CNP9 (female). lOOn. bulbis
2)Turn starting broken.
switch ON.
3)Tum light switch
ON.
between CN23 (female) (1) reDlace
- CN22 (female) (1 I-
CNPl (female) 13) - CNP4
(female) I1 5) - CNP6
(female) (2) - CNPlO
(female) (15)
Tester
Troubleshooting
T-adapter (for DLI)
lfor Fronnsaall
Monitor panel lamp
CNP9 (female) CNPI (with spare bulb)
WA600- 1
TROUBLESHOOTING CHART No. M-l 0.
Failure mode: ABNORMALITY IN ALARM BUZZER OR WARNING LAMP.
* When disconnecting connectors or donnecting T-adapters, return them to the original condition immediately after
a) EMERGENCY ITEMS IS FLASHING, BUT ALARM BUZZER DOES

NOT SOUND.
Cause Remedy
YES
+ Defective buzzer qeplace
YES CNJ 47 (female) and

CN148 (male)
change alternately
OV and 20 - 3OV?
%l!!z; 1 )
Xsconnection in wiring After inspection.
NO xwness. or defective contact repair (clean1 or
I CN136 (coolant
level).
Mween CN41 (male) (11 - replace
Does voltage CN147 (female), or CN41
3) Turn starting (male) (2) - CN148 (male).
between CN41
switch ON.
(female) (1) and (2)
(Start engine.)
change alternately
OV and 20 - 3OV?
1 )Connect
T-adapter (or
socket adapter)
to CN41
(female).
2)Disconnect
CN136 (coolant
level).
3)Turn starting YES
switch ON. Defective module Replace
4)Start engine.
Does caution
buzzer sound when
3 7
1 )Interchange
CN42 (female) (1) Disconnection in wiring After inspection,
emergency
NO and (2) are harness, or defective contact repair (clean) or
display item
short-circuited? between CNP7 (female) (8) replace
CAUTION
and CN42 (male) (2)
1) Stop engine. module and
2)Connect T- CHECK module.
adapter (or socket 2)Turn startino
adapted to CN42 switch ON. -
(female).
S)Short-circuit
when CN42
@male) (11 and
(2). i Defective controller or con-
4)Turn starting NO tact between CN41
switch ON. (female) (1) and (21
(CN41 (female) (1) and (21 _ (repair or replace1
are in contact, so protection
device in controller is
actuated.)

Troubleshooting
T-adapter (for DLI) lfnr F,-““#x0lll
82-96 WA600- 1
g;
WA600- 1
82-97
0
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING,
BUT WARNING LAMPS DOES NOT FLASH.
Cause Remedy
3efective lamp Reolace
H
2
Does voltage
YES between CN17
(female) (1) and I21
change alternately
OV and 20 - 3OV?
1 )Turn starting
switch ON.
21 Disconnect Xsconnection in wiring Sfter inspection,
CN136 (coolant ND larness, or defective contact ‘epalr l&a”1 or
level). xtween CN41 (male) (1) - eplace
3) Start engine. :Nl 7 (female1 (1). or CN41
Does voltage male) (3) - CNl 7 (female)
between CN41 2)
change alternately
I,I
OV and 20 - 3OV7 YES
0 Defective module
1)Connect
h
T-adapter (or
socket adapter) YI3 IS problem
removed when
to CN41
modules are
(female).
interchanged?
2)Disconnect
CN136 (coolant 3 1 )lnterchange
level). 1
w :ontact with chassis ground,
3)Turn starting module which NO rdisconnection in Gina
switch ON. does not light up
Does warning lamp arness between CNP7 ”
4)Start engine. with other
:emale) (4) - CNP5
INO light up?
module.
$male) (4) - CN42 (male)
2)Turn starting
switch ON.
1 )Stop engine
2) Connect
T-adapter (or
socket adapter)
to CN42
jefective controller or con- qfter inspection,
(female). NC act between CN41 ,epair (clean) or
JIShort-circuit
female) (1) and (31. eplace
CN42 (female)
(1) and (3). (CN41 (female) (1) and (3)
4)Turn starting are in contact, so protection
switch ON. device in controller is
actuated.)
* The voltage can be checked when the power is ON (starting switch

at ON).
Tester
Troubleshooting
tools
(for Econoseall
82-98 WA600- 1
0
4 3
2 1
CNI 7 (female) CNP7
CN136 (Radiator water level sensor “a”)
WA600- 1
82-99
0
TROUBLESHOOTING CHART No. M-l 1.
Failure mode: ABNORMALITY IN GAUGE.
ing the connector for checking, turn the,starting switch OFF to prevent accidents.
When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ( ))
(FUEL GAUGE)
LX!3
Nothing shown in display area. Cause Remedy
Y ES
* Iefective fuel level sensor
I Does fuel gauge

show FULL?
1)Connect short
socket adapter
to CN127
Memale) (fuel
level sensor).
2)Turn starting
switch ON.
$El
1
NO
Is there continuity
between CNP2
(female) (6) and
(12)?
1 )Connect
T-adapter to
CNPP (female).
2) Connect short
connectore 10
2
YES
NO
Iefective gauge module
wness, or defective contact
After inspection,
repair (clean) or
CN 127 (female). )etween CN 127 (female) (2) repkVX
3)Turn starting CN65 (1) - CNP2

switch OFF. Fernale) (6). or CN 127
[female) (1) - CN66 (3) -
CNP2 (female) (12)

Troublleshooting
too15
T-adapter (for DLI)
CNI 27 (female) CNP2 (female)
82-100 WA600- 1
',I.,
ii) Stays at FULL and does not move.
Cause Remedy
3efective fuel level sensor eplace
1 YES
* lontact between chassis \fter inspection.
around and wiring harness epair Wean) or
Does all of display xtween CNP2 (female) (61 eplace
area for fuel gauge - CN85 (1) - CN127
go out? NO 2 lfemalel (21, CNP2 (female)
112) - CN86 (3) - CN127
Is there continuity (female) (1)
1) Disconnect _ between CNP2
CN127 (fuel ;y2;l,e) (6) and -
level sensor).
ZlTurn starting L
switch ON. 1) Connect
T-adapterto
Defective gauge module
3)Tum starting
switch OFF.

Troubleshooting
tools
T-adapter (for DLII
CN127 (female)
CNP2 (female)
WA600- 1 82-101
@
b) (AIR PRESSURE GAUGE)
i) Nothing shown in display area.
Cause Remedy
Defective air pressure sensor Replace
r-l
Does air pressure
gauge display top
position?
1)Connect short
connector to
NO
1
YES
*, I
CNl 10 (air
pressure sensor)
2)Turn starting Disconnection in wiring After inspection,
switch ON. T-adapterto NO harness, or defective contact repair (clean) or
CNP2 lfemalel. between CNl 10 (female) replace
2) Connect short (1) - CN65 (1 j- CNPP
socket adapter !female) (9). or CNI 10
toCNll0 (female) (21 - CN65 (4) -
(female). CNP2 (female) (6).
3)Turn starting
switch OFF.
rTroubleshooting
to015
.
Tester
T-adapter (for DLI)

CNI IO (female) CNP2 (female)
CN65
82-102 WA600- 1
0
ii) Stays at top level and does not move.
Cause Remedy
YES
Iefective air pressure sensor 3eplace
/
YES
c Contact with chassis 4fter inspection,
ground and wiring harness repair l&an) or
xtween CNP2 (female) (9) rl?pl.Xe
Does all of display
area for air -CN65(11-CNllO
pressure gauge gel [female) (1 I, or contact
.with chassis ground and
Niring harness between
Is there continuity 3NP2 (female) (6) - CN65
between CNP2
I4) - CNl 10 (female) (2).
pressure sensor)
2)Turn starting
switch ON. -1 1) Connect
go. j * 3efective gauge module

switch OFF. NO

Troubleshooting I
tools
T-adapter (for DLI)
WA600- 1 82-103
0
cl j $ 1 (COOLANT TEMPERATURE GAUGE)
i) Nothing shown in display area
Cause
YES
I Defective coolant Replace
temperature sensor
I
1
I
~~~1 I
Contact with wiring harness 4fter inspection,
between CN123 (female) repair (clean) or
(1) - CN114 (3) - CN94 replace
(9) - CNP2 (female) (10)
and CN123 (female) (2) -
CNl14 (2l- CN94 (10)
- CNP2 (female) (4).
switch ON. 1) Connect

T-adapter to
CNP2 (female).
2) Disconnect
CNl23.
3)Turn starting
NO
switch OFF.
Tester Short !ocket adapter

Troublkshooting
tools
T-adapter (for DLI)
CN 123 (female) CNP2 (female)
CN114 CN84
ii) Stays at bottom position and does not move.
Cause
YES
1 c Defectwe coolant ?eplace
temperature sensor
Does all of display
YES
area for coolant
m Defective gauge module Replace
temperature gauge 2
goout)
Isthere continuity
11Connect short between CNPP _
socket adapter L (male) (4) and
toCN123 NO HO)?
(female).
21 Turn starting 1)Connect
switch ON. Disconnection in wiring \fter inspection,
T-adapter to NO harness, or defective contact epair (clean) or
CNP2 (female).
between CNP2 (female) (10)
2)Connect short
- CN84 (91 - CN114 (3)
connector to
- CN123 (female) 11I, or
CN123 (female).
CNP2 (female) (4) - CN84
3)Turn starting
(10) - CNl 14 (2) -
switch OFF.
CN123 (female) 121.

Troubleshooting
toois
T-adapter (for DLli
CNI 14
WA&OO- 1 82-105
0
d) (TORQUE CONVERTER OIL TEMPERATURE GAUGE)
i) Nothing shown in display area.
Cause Remedy
YES
-- Defective torque converter t%Dl.3W
oil temperature sensor
YES
ti Contact with wiring harness After inspection,
between CN121 (female) repair (clean) or
(l)-CNl14(5)-CNPP replace
(female) (1 1) and CN 12 1
(female) (21 - CNl 14 18)
~ - CN85 (6) - CNP2
(female) (5).
2)Turn starting 1)connect

watch ON. T-adapter to
CNP2 (female).
2) ;isxy,yection
3) Turn starting
L Defective gauge module Replace
switch OFF. NU

Troubleshooting
tools
T-adapter (for DLI)
CN121 (female) CNP2 (female)
CN114 CN85
82-106 WA600- 1
,'?
1;
ii) Stays at bottom position and does not move.
Cause Remedy
Iefective torque c0nverter Ieplace

3il temperature SeWOr
Defective gauge module Iepkxe
2)Turn starting
switch ON.
Disconnection in wiring r\fter inspection.
harness, or defective contact ‘epair (clean! or
between CNPP (female1 (1 1) -+3X
socket adapter
toCN121
- CN85 (4) - CNl 14 (5)
CN121 (female) (l).or
(female).
cNP2 (female) (5) - CN85
3)Turn starting
switch OFF. (6) - CN114 (81 -
CNl 21 (female) (2).
7
Tester Shoti socket adapter
Troubleshooting
tools
T-adapter (for DLI)
WA600- 1 82-107
@
Connector types and location of components . . . .. . . . . . . . . _. . 82-111
M- 1. (BRAKE 01 L LEVEL) flashes when engine is stopped .......................... 82-118
M- 2. (ENGINE OIL LEVEL) flashes when engine is stopped ......................... 82-118
M- 3. (RADIATOR WATER LEVEL) Flashes when engine is stopped .................... 82-120
M- 4. (BATTERY CHARGE) flashes when engine is running .......................... 82-120
M- 5. (TRANSMISSION OIL FILTER CLOGGING) flashes when engine is running .......... 82-122
M- 6. (FUEL LEVEL) flashes when engine is running .............................. 82-124
M- 7. (BRAKE LINE FAILURE) flashes when engine is running ....................... 82-124
M- 8. (ENGINE OIL PRESSURE) flashes when engine is running ...................... 82-126
M- 9. (RADIATOR WATER LEVEL) flashes when engine is running .................... 82-126
M-10. (DROP IN AIR PRESSURE) flashes when engine is running ...................... 82-128
M-11. (ENGINE WATER TEMPERATURE) flashes when engine is running ................ 82-128
M-12. (TORQUE CONVERTER OIL TEMPERATURE) flashes when engine is running ........ 82-128
M-13. (PARKING BRAKE) lights up abnormally, or does not light up ................... 82-130
a) If stays lighted up ................................................. 82-130
b) If does not light up ................................................ 82-130
M-14. (WORKING LAMP) lights up abnormally, or does not light up .................... 82-132
a) If stays lighted up ................................................ 82-132
b) If does not light up ............................................... 82-132
M-15. (PREHEATING) lights up, or does not light up .............................. 82-134
a) (Preheating) lights up ............................................. 82-134
b) (Preheating) does not light up ........................................ 82-134
M-16. (TRANSMISSION CUT-OFF) li.ghts up, or does not light up. ..................... 82-136
a) Lightsup ..................................................... 82-136
b) Does not light up ................................................ 82-136
M-17. Turn signal Hi beam light up, or do not light up .............................. 82-138
a) Turn signal‘ (right) pilot display lights up ................................. 82-138
b) Turn signal (left) pilot display lights up .................................. 82-139
c) Turn signal (right) pilot display does not light up ........................... 82-140
d) Turn signal ileft) pilot display does not light up ............................ 82-140
e) Hi beam pilot does not light up ........................................ 82-141
f) Hi beam pilot stays lighted up ........................................ 82-141
M-18. Turn signal does not flash even when hazard switch is turned ON ................... 82-143
M-19. Speedometer display does not work normally ............................... 82-144
M-20. Hourmeter does not work normally ...................................... 82-145
M-21. When starting switch is turned ON, monitor panel does not work, or only part works. ..... 82-146
a) None of monitor panel lights up ...................................... 82-146
b) Except for speedometer module, none of monitor panel lights up ............... 82-146
c) None of CAUTION items light up ..................................... 82-147
d) Some. other parts do not light up ...................................... 82-147
M-22. When starting switch is turned ON, all monitor panel lights up, but does not go out ...... 82-147
M-23. (ENGINE OIL PRESSURE) flashes or (BATTERY CHARGE) flashes
when engine is stopped .............................................. 82-148
a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated ........ 82-148
b) (Battery charge) flashes, and warning lamp lights up ......................... 82-148
M-24. None of machine monitor panel lighting lights up, or part does not light up ............ 82-150
a) Even when combination lamp is placed at SMALL, none of panel lighting lights up ..... 82-150
b) Even when working lamps is switched ON, none of monitor panel lights up .......... 82-151
c) Even when starting switch is turned ON, none of monitor panel lights up ........... 82-152
d) Part of Panel does not light up ............. .' ......................... 82-152
M-25. When starting swtich is turned to on position (ENGINE STOPPED), buzzer does not sound
for 1 sec. CAUTION ...................
item is flashing but buzzer does not sound 82-154
M-26. No abnormality is shown on monitor display, but alarm buzzer sounds ............... 82-154
WA600-1
82-Ao9
M-27. When starting switch is turned to ON position (ENGINE STOPPED), warning lamp does not
light up for 2 sec. CAUTION item is flashing but warning lamp does not flash .......... 82-156
M-28. No abnormality is shown on monitor display, but warning lamp lights up ............. 82-157
M-29. Abnormality in(FUEL GAUGE) system................................... 82-158
a) If nothing is displayed in display ....................................
area 82-158
b) If indicator remains at FULL ........................................ 82-158
M-30. Abnormality in (AIR PRESSURE GAUGE) system. ........................... 82-160
a) If nothing is displayed in display area ................................... 82-160
b) If indicator remains at maximum level .................................. 82-160
M-31. Abnormality in (ENGINE WATER TEMPERATURE GAUGE) system ............... 82-162
b) If indicator remains at minimum level ................................... 82-162
M-32. Abnormality in (TORQUE CONVERTER OIL TEMPERATURE GAUGE) system ....... 82-164
82-110 WA600-1
m./
COMBINATION SWITCH
DIMMER SWITCH
428FO144C
CNPl
DLI l&pin CNPZ CNPl CNP4
\
CNP3
428F0141E
CNP2
DLI 8-pin
CNP3 (CHECK module)

DLI 16-pin
WA600-1 82-111
@
CNP4 (CHECK module)
DLI 12-pin CNP2 CN?l CYP4
I 6
1 6
P3
428FO1416
CNP5
DLI 8-pin
CNP6
MIC 5-pin
m
3 I
0
4
5
CN12 (Warking lamp switch)

Parking brake switch
Working lamp
switch
Preheating
switch
CN'20 428F01427A-K
82-112 WA600-1
$,i$
CN15 (Lamp switch)
Econoseal 12-pin
CN15
CN16
4Z.SFO I428
CN17 (Warning lamp)

N-SLC connector 2-pin Transmission cut-off
switch
warnin; lamp CiCl7 CM13

428F01429A.K
CNI 8 (Transmission cut-off selector switch)

CN22, 23 (Diode)
N-SLC connector 2.pin
WA600-1
d Parklng brake soienold
\e Parklng brake display switch
CN59 (Brake oil level sensor)

CN60 (Transmission oil filter clogged sensor)
::b
Econoseal 2-pin
Brake oil level sensor

Transmlsslon 011filter clogged sensor
CN61 (Brake chamber stroke sensor (a))

Econoseal 2-pin
CN62 (Brake chamber stroke sensor (b))

Econoseal 2-pin
82-114
'il$
CN79 (Circuit breaker)
Econoseal 12-pin

Econoseal 12-pin
CN98 (Speedometer sensor (a))

Econoseal 2-pin
CNI 10 (Air pressure sensor)

Econoseal 2-pin
f: Air pressure sensor
i g: Emergency brake switch
WA600-1
82-115
63
CN120 (Engine oil level sensor)
Econoseal 1 -pin
CNIPO’ CNII;
CN121 (Torque converter oil temperature sensor (a))

Econoseal 2-pin
CN123 (Engien coolant temperature sensor)

Econoseal 2-pin
a Engine coolant temperature sensor

b APS coolant temperature sensor
CN127 (Fuel level sensor)

Econoseal 2-pin
_-_ ..-.._
I
CN127
82-116
jJj
CN136 (Radiator water level sensor (a))
Econoseal 2-pin
426Pf 24
CN 147 (Caution buzzer)

CN148 (Caution buzzer)
Camon buzzer
14i 426F503
NC249 (Engine oil pressure sensor)

Terminal
426F505
426F504
WA600-1 82-117
@
M-‘: (g
El (BRAKE OIL LEVEL) FLASHES WHEN ENGINE
IS STOPPED.
* vvnen alsconnectlng or connecting the I -adapter lor socket adapter) or short connector, or wnen
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter),
connect to the connector specified. (CNOA ( 1)
* When disconnecting connectors or connecting T-adapters,
return them to the original condition immediately after Cause Remedy
3
Defective monitor panel
I I
Is there continuity
YES between CNP3
2 - (female) (1) and - Defectwe contact, or
chassisground? dwonnection in wiring After inspection,
harness between CNP3 epair (clean1 or
between CN59
(female1 12) and
(female) (1) -
CN65 eolace
adapter to CNP3 (3) - CN64 (2) - CN59
(female). (female) (1).
9
Defective contact. or after inspection.
disconnection in wirlna epair (clean) or
harness between CN55 e&X
(female) (2) - CN64 (3) -

CN65 (4) - chassis ground.
%fective brake oil level sensa
(male) (brake oil

level sensor).
2) Turn starting
swtch OFF.
M-2: (ENGINE OIL LEVEL) FLASHES WHEN ENGINE

IS STOPPED.
Cause Remedy
YES
Defective engme oil level sensor replace
1 I
a y” ““1’ 2 YES
DefecvJe monitor pane, Replace
I Isthere continuity
1) Connect short between CNP3
connector to - (female) (2) and -
NO Defective contact, or
CN120 (female) chassis ground’
disconnection in wiring After inspectlon,
2) Turn startmg
switch ON. 1) Connect CN 120 NO (female)(l)-CN115(8)- replaCe
(engine oil level CN86 (2) - CNP3 (female)
(2) or CN120 (female) (2) -
2) Connect T- CN115 (3) - chassis
adapter to CNP3 ground.
(female).
3) Turn start,“9
swtch OFF

Trouble- T-adapter (for DLI)
(for Econoseall
shootmg
tools
Short connector
82-118 WA600-1
@I
M-l Related electrical circuit drawing
CNP3 CN65 CN64 CN59

Brake oil
level sensor
Monmx
panel I
777
426F506
M-2 Related electrical circuit drawing
CNP3
CNl20 Engine 011
level sensor
Monitor
panel
426F507
WA600- 1 82-119
,fjj
M-3: @ (RADIATOR WATER LEVEL) FLASHES WHEN
/ - ENGINE IS STOPPED.
necting the connector for Checking, turn the starting switch OFF to prevent accidents.
* When connecting the T-adapter (or socket adapter). connect to the connector specified. (CN 0 A ( 1)
return them to the original condition immediately after
Cause Remedy
YES
>efectlve radiator water level
X”SW
3 YES
-II Sefectwe monitor panel
4 Is there continuity
between CNP3
1 (female) (31 and Jefective contact. or
1) Connect short chassis ground? jisconnection in wiring After inspection,
connector to
CN136 (female)
1j Connect
short
xrness between CN136
female) (1) - CNllS (2) -
repair (clean) or
replace
COnnectOr to
(radiator water between CN136 31‘184 (2) - CNP3 (female)
CN136 (female).
level sensor). (female) (2) and 3).
21 Connect T-
2) Turn starting chassis ground?
adapter to CNP3
swtch ON.
(female).
1) Connect T- 31 Turn starting
adapter (socket )efectwe contact, or After inspection,
switch OFF.
adaoterl to lisconnection In wiring rePaIr Iclean) or
3 larness between CN136
CNi36 ifamale).
2) Turn starting female) (2) and chassis
switch OFF. wound.
(BATTERY CHARGE) FLASHES WHEN ENGINE

7 RUNNING.
M-4:
1-1 IS
(If a flashes when the engine is stopped, go to M-8. Engine oil pressure abnormal.)
2 YES
I 1
H
Rl?plZlCe
I
Is voltage between
CNP4 (female) (5)
w.sis ground
Defective contract, or
I)
disconnection in wiring After inspection,
harness between alternator repair (clean) or
NO
terminal R - CNl 14 (1) - rf2PlaCe
alternator termmal R CNP4 (female) CN86 (1) -

CNP4 (5).
starting
_....zh ON. (Start
I engine.1
1I Turn startmg 3) Is reading 20 -
switch ON 3ov7
21 Measure voltaoe Defective alternator 9eplace
tetween NO
alternator
terminal R and
chassis ground
3) Is readvlg 20 -
3ov7

T-adapter (for DLII
shooting
toois
Short connector
82-120 WA600-1
CNP 3 CNB4 CNll9 CNl36

Radiator water
level sensor
Monitor
panel
426F508
CNP4 CN86 CNll4
Alternator
Monitor
0 terminal R
panel
426F509
WA600- 1 82-121
Ifa
(TRANSMISSION OIL FILTER CLOGGING)
WHEN ENGINE IS RUNNING.
It When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
t When connecting the T-adapter (or socket adapter),
connect to the connector specified. (CNOA ( ))
Cause Remedy
YES Defective transmission 011

filter clogging sensor
3 YES
Defective monitor panel IeplClCe
i I III
Is there continuity
Does ii:: goout’ - between CNP3
YES
Defectwe contact, or
chassis ground?
disconnection in wirmg rfter Inspection,
1) Connect short 2-Y harness between CN60 epa,r (clean) or
connector ,O p 1) Connect short NO (female)(l)- CN64 (1) - @Xe
CN60 (female) Is there ccmt,“wty cOnnectOr to CN65 (21- CNP3 (female1
(transm~won oil between CN60 CN60 (female).
(101
filter clogging NO (female) (2) and - 2) Connect T-
sensor) chaws ground? adapter to CNP3
2) Turn startmg (female).
swtch ON. 3) Turn starting Defective contact. or
1) Connect T-
switch OFF disconnectlon in wlrlng rfter tnspection.
adapter (socket
harness between CN60 epair (clean) or
adapter) to CN60 NO
(female) (2) - CN64 (3) - E+lWX
(female).
CN65 (4) - chassis ground
2) Turn starting
switch OFF.
M5 Related electrical circuit drawing
CNP3 CN65 CN64 CN 60 Transmission filter

clogging sensor
Monitor
panel 1
426F510

T-adapter (for DLII
Trouble- lfor Econoseall
shootmg
tools
Short connector
82-122 WAbOO-1
?o;
M-6: (FUEL LEVEL) FLASHES WHEN ENGINE
* When disconnecting or connecting the T-adapter (or socket adapter) or short connecter, or when discon-
*, When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN OA ( 1)
* When
Cause Remedy
1 YES
See M-29 (Abnormality in fuel
level gauge)
I II
I H
Does fuel gauge
display EMPTY,
I 1 I Defective rnonltor panel

1 J Turn start,“9 NO
swtch ON
(BRAKE LINE FAILURE) FLASHES WHEN ENGINE

IS RUNNING.
* Check that there is no abnormality with the chassis.
3 YES
)efective momtor panel
YE
2 EH--
disconnection in wiring Xfter inspectaon,
harness between CN62 epair (clean) or
(female) (1) - CN64 (7) ‘eplXX
between CN62 1) Connect NO
CN86 (8) - CNP3 (female)
(female) (2) and T-adapter to
(4).
CNP3 (female)
2) Turn start,“9 Defective contact. or
1) Connect T- switch OFF disconnectmn in wiring \fter inspectm”,
Is there continuity of
each sensor7 - adapter (socket NO harness between CN62 epair (clean) or
(total: 2) adapter) to CN62 (female) (2) - CN61 eDlaCe
(female). (female) (1) or CN61
‘ 21 Turn starting (female) (2) - CN64 (4)
1 J Connect T- switch OFF CN65 (4) - chassis ground.
adapter (socket Non-continuous sensor is
adapter) to each NO defective
sensor (male)
21 Turn startIn‘s
swtch OFF.
3) Ca”“ector
numbers are
CN61 and 62
82-124 WA600- 1
f,Q
CNP4 CN 86 CNl27
Monitor
palld Fuel level sensor
CN85
426F511
CN62
CNP3 CN 64
Monitor
DL3lWl Brake stroke
426F512
0 --
WA600-1 82-125
@
M-8: [--&-- (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE
iv] IS RUNNING.
or When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
* Whenconnecting the T-adapter (or socket adapter), connect
to the connector specified. (CNO A ( 1)
YES Oefectlve engme oil pressure RePlXe

S?“SW
1 I
_I
3 YES
Defective monKx panel ReplaCe
Does I&, go out’ -
- Is there contlnulty
YES between CNP3 _ Defective contact. or
2 - (female) (9) and disconnection in wlnng
1) olsconnect _ chassis ground’ harness between chassis After Inspection.
CN249 ground - CN75 (3). (6) - repaw (clean) or
Is voltage between _ pNO CNP3 (female) (9). or
2) Turn starting 1) connect replace
switch ON. - CN249 andchassIs - T-adapter to defective engine 011
NO normal?
3) Start engine. CNP3 (female) pressure sewor relay
1 2) Turnstarting
Contact between chassis After Inspection.
1 I Turn starting swtch OFF
ground and winng harness repair (clean) or
switch ON. (Start NC between CN249 - CN115 replaCe
engme.) (4) - CN86 (7) - CN75 (2)
2) Is reading 20 -
3ov7
Go to M-23 (Engine oil
__ -- I pressure or Datrery cnarge
Note) If i&/flashes when engine is stopped. i m /ISdefectiw. flashes when engine is
L1 stopped.)
-7
M-9: (RADIATOR WATER LEVEL) FLASHES WHEN

ENGINE IS RUNNING.
YES Defective radiator water level Replace

sensor
I
--
1
II Is there continuity
3 YES
’ 0 lgoout? - YES between CNP3 _

Ows Lz
- (female) (31 and
chassis ground? After inspection,
4 disconnection in wiring
1 repair (clean) or
1) Connect short harness between CN136
2 1) Connect short NO replaCe
Connector to (female) (1) - CNI 26 (21-
connector to
radiator water CN84 (2) - CNP3 (female) (3).
Is there contmuity CN136 (female)
level sensor 2) Connect T-
between CN136
CN136 (female). L
(female) (2) and - adapter to CNP3
2) Turn starting NO (female).
chaws ground?
switch ON. . 3) Turn startmg
3) Start engine. switch OFF.
1) Connect T-
adapter (socket
Defective contact. or After inspection,
disconnection in wiring repair (clean) or
2) Turn starting harness between CN136
swtch OFF. NO replace
(lemale) (2) and chaws
ground.

T-adapter (for OLI)
shooting
took. Short connector
82-l 26 WA600- 1
Q
Engine 011pressure relay
Monitor
panel
Service Engine 011

meter pressure sensor
426F513
CNP3 CN84 CNl28 CN 136 Radiator water

level sensor
Monitor
panel I
426F514
WA600-1 82-127
$3
M-l 0: (DROP IN AIR PRESSURE) FLASHES WHEN
ENGINE IS RUNNING.
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
When connecting the T-adapter (or socket adapter),
When disconnecting connectors or connecting T-adapters,
Cause Remedy
1 <ES See M-30 (Abnormalitv in air

pressure gauge1
IS ar pressure gauge
WithIn red level’
Defective monitor panel FIeplaCe

1 I Turn starting NO
t
switch ON.
q
M-II: (ENGINE WATER TEMPERATURE) FLASHES
1 YES See M-31 (Abnormality in

engine water temperature
gauge)
Is engjne water
temperature gauge -
wlthin red level?
Iefectlve monitor panel FIeplace

1) Turn starting NO
switch ON.
M-l 2:
q , (TORQUE
FLASHES
CONVERTER
WHEN ENGINE
OIL TEMPERATURE)
IS RUNNING.
See M-32 (Abnormality in

torque converter oil
temperature gauge)
Defective monitor panel RepbC.2

1) Turn starting NO
switch ON.
T-adapter (for DLII

Trouble-
shooting
tools
82-128 WA600- 1
@3
M-l 0 Related electrical circuit drawing
CNP4 CN65 CN 110
Monitor
panel Air pressure
sensor
426F5 15
CNP4 CN84 CN114 CN123

Engine water
temperature sensor
Monitor panel
425F521A
CNP4 CNI 14 CN 121 Torque converter

oil temperature Sensor
Monitor
panel
426F516
WA600-1 82-129
@
M-13: - (PARKING BRAKE) LIGHTS UP ABNORMALLY,
1 @I j OR DOES NOT LIGHT UP.
* When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
connect to the connector specified. (CN 0 A ( 1)
t When disconnecting connectors or connecting T-adapters,
a) If !a stays lighted up
YES
Iefectlve parking brake sense
11 YE
H
Iefecttve monitor paw
Is there continuity
between CNP3
(female) (5) and )efectwe contact. or
chasss ground’ lisconnectlon in wiring 4ff.a Inspectlo”.
,arness between CN34 .epan (cleani or
1) Connect short
connector to
I ) Connect short N( female) (1) -CN32 (4) - replace
connector to :NP3 (female) (5).
CN34 (female)
Is there cont,nu,ty CN34(female)
(parkmg brake
between CN34 (parking brake
WWX).
SlXlSOr).
2) Turn startmg
Does parkIngbrake chassis ground? 2) Connect T-
switch ON.
work when swtch IS adapter to CNP3
(female).
turned ON-OFF, 1) Connect T-
3) Turn starting
adapter (socket
switch OFF.
adapter) to CN34 )efectwe contact. or
I Turn startmg 4fter !“spect,on.
(female) (parking lisconnectton in wiring
swtch ON
brake sensor). ‘epalr (clean) or
urness between CN34
21 Turn starting Thxe
female) (2) and chassis
switch OFF. Iround.
;ee Troubleshootmg for

hassn
b) If m does not light UP
YES
1 r I&fectlve parking brake sense Redace
‘
YES
Contact between chassis
3 YES around and wirmg harness After Inspecton.
xtween CN34 (female) (1) repa,r (clean1 or
- Is there contimnty - CN32 (4) - CNP3 WPlXe
1) Disconnect between CNP3 female) (5).
connector CN34 N; (female) (5) and
2) Turn starting chassis ground?
Does parking brake switch ON.
3efective monitor panel Gdace
work when switch is 1) Connect T- NO
turned ON-OFF? adapter to CNP3
(female).
2) Disconnect CN34
switch ON 3) Turn startwg
switch OFF.
See Troubleshootmg fo!

:hassls

T-adapter (for DLI)
(for Econoseall I
Short connector
82-130 WA600-1
\@
M 13 Related electrical circuit drawing
CNP3 CIu32 CN34
Monitor
panel
Parking brake
sensor
425F523A
82-131
@a
M-14: (WORKING LAMP) LIGHTS UP
,I9 ABNORMALLY, OR DOES NOT LIGHT UP.
0
* When disconnecting or connecting the T-adapter (or socket
adapter) or short connector, or when disconnecting the
connector for checking, turn the starting switch OFF to
prevent accidents. Note) Even is all the working lamp bulbs
t When connecting the T-adapter (or socket adapter), are broken, or there is defective
connect to the connector specified. (CNO A ( 1) contact or a disconnection in the
* When disconnecting connectors or connecting T-adapters, wiring harness for the working
return them to the original condition immediately after lamp, m will stay lighted up.
Cause Remedy
a) If 1,,G
stays lighted up
YES
Defectwe working lamp switch ReDlace
1 I
Does (go out? -

2 YES
Defectwe monitor panel ReplaCe
- IS voltage between
1) Remove CN12.
_ CNP3 lfemale) 1141 _
2) Turn starting
NO and chassis ground
switch ON.
normal? Contact between +24V and After mspect,on.
L I L wiring harness between repair (clean1 or
1) Connect T- NO CN12 (female) (2) and CNP3 WPlEUX
adapter to CNP3 (female) (14).
(female).
2) Turn starting
switch ON:
3) Remove CN12.
4) Is reading O-
lV?
b) If M does not light up

3 YES
Defective monitor panel Replace
YE PI- Defective contact, or

harness between CN12 After inspection.
(female) (2) - CNP3 repair (clean1 or
1 1) connect NO (female) (14) or CN12 repk+X
T-adapter to (female) (1) - CN79 (male)
CNP3 (female1 (lO)W(12).
YE between CN 12 2) Turn starting
(male) (1) and (2) as switch ON.
3) Turn working
lamp switch ON.
4) Is reading 20 -
1) Disconnect CN12
3ov7
(male).
Is voltaqe between
2) Turn starting
CN79 (r&le) (9).
switch OFF.
(11) and Chassis
3) Turn working Defective workmg lamp switch %place
ground normal? 0
lamp switch ON
- OFF.
1) Connect T-
adapter (socket
adapter) to CN79 Defective contact. or
After inspection,
(male). disconnection in wiring
repaIr (clean) or
2) Turn starting harness between main
switch ON. breaker - CN79 (male1 (11)
3) Is reading 20 -
3ov7
I
Table
T-adapter (for DLI) Tester

Trouble-
shooting I
82-132 WA600-1
qij
Circuit breaker 4
G-J
I I t24v
CN23 (
t
CNPI
Monitor
panel
CNP7
Lamp
Circuit breaker 2
Lamp
CN7
CNP 9
f24V
Lamp
CN 12
Service
CN
47-L 1
I
meter
426F517
WA600- 1
82-133
@I
M-l 5: w (PREHEATING) LIGHTS UP,
cl OR DOES NOT LIGHT UP,.
* disconnecting when discon-

necting the connector for checking, turn the starting switch OFF to prevent accidents
+ When connecting the T-adapter (or socket adapter), connect
to the connector specified. KN 0 A ( 1)
+ When disconnecting connectors or connecting T-adapters,
Cause Remedy
a) TIT ’ (Preheating) lights up

LJ
1 YES
:arry cut troubleshooting
Is voltage between >f APS
CNP3 (female) (151 _
;ak;,.y ground
Iefective monitor panel Replace

1) Connect NO
T-adapter to
CNP3 (female)
2) Turn starting
swtchON
3) Is reading 20 -
3ov7
-
b) m (Preheating) does not light up
kfectw monitor pane1 ReplaCe

Isvoltage between
CNP3 (female) I1 51 _
and chassis ground kfect1ve contact. or
normal? lisconnection in wiring 4fter inspection
wrness between CN81 repair (clean) or
1) connect NO male)(l)-CN82(1)- repk.e
T-adapter to :NP3 (female) (15). of
CNP3 (femaleI. lefective APS system.
2) Turn starbng Carry out troubleshooting
switch ON. ,f APS)
3) Is reading 20 -
3ov7
T-adapter ifor DLII

Trouble-
shooting
tools
82-134 WA600- 1
@J
To APS unit
II Starting switch
Bimetal timer CN81 CN82 CN 14
426F518
WA600- 1 82-135
@
(TRANSMISSION CUT-OFF) LIGHTS UP,
DOES NOT LIGHT UP.
Sr When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
* When connecting the T-adapter (or socket adapter), connect
to the connector specified. (CN 0 A ( )I
Cause Remedy
a) @ lights up
/
lefectlve transmissKr cut-ofl

IePlWe
wtch
3 YES
kplace
kfective mpnltpr panel
‘efectlveco”tact. or
1) Short circut ,sconnect,on 1” wnng harnes \fW !“spectvx.
between CN18 etween CN18 lfemalel (31 an epar klean) or
(female) (3) and ,~~ ‘NP3 (female) (1 1 I ep&X
(4).
2) Turn starting N
swtich ON. chasss ground? swtch ON
2) Connect l-adapter to
CNP3 lfemalei
l/ Turn stainno lefective contact. or
tartng switch OFF 4fWr inspectlon,
switch OFF.” 6connect10” I” wwng harnes
L31 epar (clean) or
NO between CN18 (female) (41 ar
eplace
hassis ground
b) 181 does not light up
Ck?fect1ve tra”smIssI0” Cut-Of

5.witch
Does @ light up)

C:ontact between cha?s6
Sfter Inspectlo”.
i 2 YES 9Iround and wiring harness epair (clean) or
-t W.veen CNl 8 (female) (31
eDlaCe
Is there continuity aInd CNP3 (female) (1 1 I
1I Remove CN18 . betweenCNP3 _
2) Turnstaaing N (female) (1 11 and
switch ON. chassis ground’.
-_[ kfective monltpr panel ?eplace
1) Connect NO
T-adapter to
CNP3 (female).
2) Turn starling
‘switch OFF
T-adapter (for DLII Tester

Trouble-
shooting
tools
82-136 WA600-1
@J
CNP3 CNl8
Monltor panel
Transmission
cut-off switch
425F526-K
WA600-1 82-137
a!a
M-l 7: TURN SIGNAL HI BEAM LIGHT UP,
OR DO NOT LIGHT UP.
to the connector specified. KN 0 A ( ))
a) Turn signal (right) pilot display lights up

Cause Remedy
Contact between +24V and

w,r,ng harness between CN15
YES (female1 (31 - right turn s,gnal After Inspecton.
switch, or between CNl 5 repav or replace
ifemale (51 and turn slgnal
swtch
Contact between +24V line

and wiring harness After ,nspectlo”.
between CN15 (male) 15) repa,r or replace
and CN74 (female) (4).
Does voltage switch repeatedly between 0 - 20 - 30V’
Defectwe mon,tor panel Replace

winng harness between CNPl After,nspectlo”.
(female) (71 and CNl 5 (male) repa,r or replace
1) Connect NO
T-adaoter to 131
CNPl ‘(female).
21 Turn starting
switch ON
3) Turn right turn
signal switch ON
41 Does voltage
swtch
repeatedly
between 0 - 20
- 3ow
I
Trouble- I T-adapter (for DLII

iforEconoseal~
82-138 WA600-1
@
b) Turn signal (left) pilot display lights up Cause Remedy

.vwl”g harness between CN15
2 YES Ifemale) I61 - left turn sIgnal After mspection,
, swtch, or between CN15 repaar or repiace
Ifemale) 15) and turn signal
jwltch
Contact between t24V line,

and wmng harness After ~nspectvx.
between CN15 (male) (5) repair or replace
and CN74 (female) (41.
CNl 5 (male)
2) Turn startmg swtch ON
Does voltage switch repeatedly between 0 - 20 - 3OW
Defectwe mowor panel RepLW
lontact between +24V and

1 I I Nwing harness between CNPl After !nspect~~“,
1) Connect NO Ifemale) (6) and CNl 5 (male) repair or replace
T-adapter to 61
CNPl (female).
2) Turn starting
switch ON
31 Turn left turn
signal swtch ON
4) Does voltage
switch
repeatedly
between 0 - 20
- 3ov7
I
Trouble- I T-adapter or socket adapter
(for Econoseall I 1
T-adapter [for DLII

I 1
WA600-1 82-139
@
c) Turn signal (right) pilot display does not light up
Is voltage between
YES CNPl (female1 (7)
“,ifa;,,sis ground
After inspectIon.
disconnection !n wiring harness
6 repair lcleanl or
1) Connect between CNPl (female1 (7) and
NO
1 T-adapter to CN15 (male) (3)
CNPl ‘Ifemale).
2) Turn startmg
Do front and rear turn
switch ON.
signal lamps work -
3) Turn turn signal
normally?
switch ON.
4) Does voltage
1i Operate right switch
turn SQwl. repeatedly
21 Turn start,ng between 0 - 20
- 3OV’ Carry out troubleshooting of
Swtch ON.
NO
turn signal
d) Turn signal (left) pilot display does not light UP
2 YES
Do front and rear turn 2) Turn starting

signal lamps work - switch ON.
normally~ 3) Turn turn signal
switch ON.
’ 4) Doesvoltage
1) operate
left turn switch
signal. repeatedly
2) Turn starting between 0 - 20
switch ON. - 3ov7 Carry out troubleshooting of
NO turn signal

shooting
T-adapter (for DLI)
WA600- 1
e) Hi beam pilot does not light up Cause Remedy
If the head lamp does not switch to Hi beam, check the head
lamp system.
Defective mo”,tor panel

Is voltage between
YE CNPl ifemale) 151 _
and chasss ground
“OUllal? {fter Inspection.
disconnection in wlrlng
epa,r iclean) or
harness between CNPl
1) Connect NO epk3
(female) (5) and CN31
T-adapterto
(female) (1).
CNPl (female1
2) Turn starting
watch ON
31 Place
combmatlon
swtch at HEAD.
4) Place dimmer
1) Turn starting switch at Hi
swttch ON beam
21 Place 5) Is reading 20 -
comblnatio” 3ov7
Both head lamp bulbs (Lo beam
swtch at HEAD lamps) broke”?
31 Place d!mmer (If the Lo beam bulb IS broken,
switch at Lo the HI beam pilot will not light kpkxe
beam. IY”
up eve” if the lamp is swltched
toHI beam)
f) Hi beam pilot stays lighted up
Defective mo”!tor panel kDl+X
Do both left and r,gh, Defectwe contact. or after

front lamps l,ght up, YES dtsconnection I” wiring harness epair iclean)
2 I between CN15 (female) (91 ant I ep1ace
xambination switch
-I
1) Turn starting
switch ON Does head lamp light Defective contact. or ifter
2) Place ~0 up at HI beam, 3 YES disconnection in wiring harness epar (clean)
combmatlon between CN15 (female) (12) eplace
switch at HEAD. Is there contmuity and combination switch
3) Place dunmer 1) Turn starting between CN15
swtch at Lo swttch ON. NO (male) (12) and
beam 2) Place chassis ground? I%fectwe contact, or \fter
combmation jlsconnectlon I” wring harness epair (clean)
switch at HEAD. 1) connect NO xetwee” CN15 (male) (12) and
eplace
3) Place dimmer T-adapter :hassis ground
switch at HI (socket adapter)
beam to CN15 (male).
21 Turn staning
switch OFF.
T-adapter ifor DLII

Trouble-
shooting -
(for Econoseall
WA600-1 82-141
03
M-l 7 a), b), c), d) related electrical circuit drawing
+24
CNl5
CNPI t
Hazard switch
Hazard
7
I
Monitor
panel
Turn slgnal switch
I_.!&- El
3
I
J
Turn signal unit

t24v 2
t
1 ~Ni78 1ml 79 1 CN46 lCN47
425F527A-K
M-l e), f) related circuit drawing
Circuit breaker 4
+24V I I
CN15
Head lamp switch 1 CN77
CN31
82-142 WA600-1
'Q@
M-l 8: TURN SIGNAL DOES NOT FLASH EVEN WHEN
HAZARD SWITCH IS TURNED ON.
f When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
connect to the connector specified. (CN 0 A ( ))
return ‘them to the original condition immediately after
Cause Remedy
2 YES
Defective monitor panel FleDlaCe
Is voltage between
YE . CNPl (female) (61.
(71 and chassis
ground normal
NO See M-l 7 c). d)
1) Connect T-adapter ?o CNPl (female1 Troubleshooting of turn s!g”al
2) Turn start,“g switch ON
3) Does voltage switch repeatedly between 0 - 20 - 3OV7
CNPl (female1 13) ~efect1ve contact. or
and chassis ground After ,nspect,o”.
j~sconnection in wiring harries!
repa,r l&an1 or
xtween CNPl (fern&l 13) -
reDlace
ZN15 lmalei (21
1) Connect 3
T-adapter to
CNPl (female1 Is voltagebetween
2) Turn hazard Iefect1ve contact, or
, CNl5 (female1 (2)
swtch ON. jlsconnection in wvlng harries!
N and chassis ground
3) Is reading 2’3 - normals YES xtween CN15 (female) I1 1 After inspectton.
3ov7 and hazard swtch. or between repar wean1 or
4’ reDlaCe
3Nl 5 Ifemale) 12) and hazard
1 t Connect swtch. of defective hazard
T-adapter to Is voltage between
;wltch
CNl 5 (female) _ CN15 (male1 il)and _
21 Turn hazard NO chassis ground
switch ON norm.317
31 Is reading 20 - )efect1ve contact. or
After inspection.
3ov7 11 Connecr jlsconnectton in wlrlng harries:
repaIr (clean1 or
T-adapter to NO ,et~een CN15 (male) (1) and
replace
CN15 (male) f24V line
21 Turn hazard
switch ON,
3j IS reading 20 -
3ov7

shooting
to015
T-adapter (for DLll

t24
CN15
1 I
CNPl I
_
Hazard
7
425F527A.K
WA600-1 82-143
@
M-l 9: SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
t When connecting the T-adapter (or socket adapter),
Cause Remedy
4 YE
Defectwe mon,tor panel
YES ls proximity setting of

- speed sensor 0 5 - -
1.5 mm,
1efectwe speed sensor mount ReDlace

3 E Loosen speed N(
sensor locknut
Is resistance and turn speed
YE between CNPl sensor clock-
- (female) (9) and (10) - wise.‘f It
300 Q - 1 kQ? Contacts the gear
within one turn.
2 the distance is
1) Connect
within 1.5 mm.
T-adapter to
I--l
Is resistance
YE CNPl (female).
between CN89 )efective contact. or
2) Turn starting After ,nspect!o”.
(female) (12) and jisconnection in wiring
switch OFF. repair Iclean) or
(11)3OOR-1 kfl? NO wrnees between CNPl (91.
I 10) (female) - CN89 (12).
replace
11).
r-l
1) Connect T-
Is resistance adapter (socket
between CN98 adapter) to CN89 3efective contact, or After inspection,
(male) (1) and (2) (female).
JO disconnection in wiring repair or replace
3OOfI-lkn? 2) Turn starting
switch OFF.
[female) (12). (11) - CN98
1) Connect T- I1 ), (2).
adapter (socket
adapter) to CN98 Jefectlve speed sensor Replace
(speed sensor) 40
(male).
2) Turn starting
switch OFF.

T-adapter (for DLI)

I I
M-19 Related electritil circuit drawing
CNPl CN89 CN98

Speed sehsor
425F530A-K
82-144 WA600-1
8
M-20: HOURMETER DOES NOT WORK NORMALLY.
t When disconnecting or connecting the T-adapter (or socket

connector for checking, turn the starting switch OFF to pre-
vent accidents.
t When connecting the T-adapter (or socket adapter), connect
to the connector specified. (CN 0 A ( 1)
Cause Remedy
‘ES Defective engine 011pressure

ReplaCe
%?“SW
YES
Defective mowor panel
3-
Does hourmeter
work. or does display
Is there continuity
lamp light up? YES between CNP6
c (female) (4) and
chassrs ground? Defective contact, or
1) Remove CN249
2 dlsconnectlan in wiring
2) Turn starting harness between chassis After mspect,on.
switch ON. - Ii Connect repaIr Iclean) or
T-adapter to ground - CN75 (3). (6) -
Is voltagebetween NO reolace
CNP3 (female). CNP3 (female) (91. or
. CN249and chassis -
21 Turn starting defective engine oil
ground normal? pressure sensor relay
swtch OFF.
1I Turn starting
ground and wiring harness After inspecrmn.
between CN249 - CN115 repaw (clean) or
2) Is reading 20 - NO
(41- CN86 (7) - CN75 (2). replace
3OV?

Short connector

T-adapter (for DLli
(for MICI I
Engine oil pressure relay
CNP 3
Monitor
panel
Service Engine oil

426F513
82-145
aI
M-21: WHEN STARTING SWITCH IS TURNED ON,
MONITOR PANEL DOES NOT WORK,
OR ONLY PART WORKS.
to the connector specified. (CNO n ( 1)
Cause Remedy
a) None of monitor panel lights up
2 YES
Defectwe monmr paw
I I I
disconnection in wring
Clean (defecttve
- CNPl (l), or between
contact)
orrepiac
CNPl (2) -chassis ground.
‘1$igECN7Q ADnormality in wiring

harness between battery
After mspecbon.
terminal (+)-battery relay
2) Tmurn
starting NO _ ma,” breaker - CN149 repair or replace
switch ON. - CN79 (male) (5).
b) Except for speedometer module, none of monitqr panel

lights up
1
- YES
Isvoltage between y 3efect1ve monitor panel ?eplXe
CNP5 (female) (11
.-
and 17) 10 - 2OV?
IS voltage between 3efect1ve contact or
121 and (7) approx jisconnecbon m wlrng harness
5V? xtween CNP2 (1) - CNP5 :lean (defective
- ._
NO l), CNP2 121 - CNPS 121. :ontact) or replacf
1) connect :NP2 (7) -CNP5 (7). or
T-adapter to jefecuve momtor panel
CNP5 (female)
2) Turn startmg
swtch ON.

Tester
shoobng
toois
I I T-adapter lfor DLII I I
82-146 WA600- 1
@
Cause Remedy
c) None of CAUTION items light up
efect1ve contact. or
1 YES ,sconnectlon ,n winng harness :iean ldefectlve
etween CNPZ (female) and ontact) or reDlace
Is there disconnection
I” w,r,ng harness NP5 (female1
between CNPZ
(female) and CNP5
(femalei’
1) Connect NO
T-adapter to
CNPZ and CNP5
,ifemalei
21 Turn starbng
swtch OFF.
d) Some other parts do not light up
lefectlve mon,tor panel kpi.Xe

ALL MONITOR PANEL LIGHTS UP,
BUT DOES NOT GO OUT.
lefective mO”ltOr panel
I
Tester
Trouble- ifor Econoseall
shooting
tools
T-adapter (for OLI)
M-21.22 Related electrical circuit drawing
Circuit breaker 2
Main breaker
I I
I I Battery relay
I I 0 0
CN 176 CNl77
CNP I
CN 149
1 Battery
I L
Otermlnal H-i
CN213
426F519
WA600- 1 82-147
@
(ENGINE OIL PRESSURE) FLASHES
(BATTERY CHARGE)
FLASHES WHEN ENGINE IS STOPPED.
Cause Remedy
a) (Engine oil pressure) flashes, and alarm buzzer and
warning lamp are actuated.
YES
Defective alternata
1 I
~~~,~ Contact between +24V and

wirina harness between 4fter Inspectlo”.
alter&or terminal R - ‘epair (clean) or
1) Connect NO CN114(1)-CN86(1)- replace
(Do not start T-adapter to
engine.1 CNP4 (female) (5).
CNP4 (female).
2) Turn starting
switch ON.
(With wiring at R
terminal
removed)
3) Is reading 0 -
1V)
b) a (Battery charge) flashes, and warnivg lamp lights up

!-J
YES Defective engjne 011pressure
sensor
1
, 3, YES
Defective monrtor panel .?elhce
t
Yl
n
ground and wiring harness After mspectnn,
1) Connect CN249 between CN75 (3). (6) - rewr (clean) or
to chassis 11 Connect T-adap- NO CNP3 (female) (9). or replaCe
ground. Is voltage
between ter to CNP3 defective engine oil
2) Turn starting I CN249 and chassis (female). pressure sensclr r&y.
switch bN. NO normals 2) Turn starting switch ON.
3) Connect CN249 to chassis
ground.
I) Turn starting 4) IS reading 20 - 3OV? Defective contact. or
watch ON. (Start 4fter Inspectlo”,
engine.) .epair (clean) or
0 harness between CN249 -
2) Remove CN249. CNl15 (4) - CN66 (7) -
3) Is reading 20 - CN75 (2). (1) - +24V lone
3OV?

shoobng
tools
T-adapter (for DLll
82-148 WA600-1
@
M23 a) Related electrical circuit drawing
CNP4 CN86 CNll4
Monitor Alternator
panel O terminal R
426F509
M23 b) Related electrical circuit drawing
n
CNP 3
ph17C m
Engine 011
pressure sensor
426F513
WA600-1 82-149
a3
M-24: NONE OF MACHINE MONITOR PANEL LIGHTING
LIGHTS UP, OR PART DOES NOT LIGHT UP.
Cause Remedy
a) Even when combination lamp is
placed at SMALL, none of panel
lighting lights up. 4bnormality I” monitor panel, 01
111lamp bulbs broke”, or
jefectlve contact. or Qfter !“spectIo”.
YES jisconnectlon in wiring harness repa,, iclean) or
5 - Detween CNPl (female) (16) - replace
amp cclnnector, or between
ISvoltage between
,atip connector, CNPG (female)
YES CNPl (female) (15)
- and CNPG Ifemale) - 31 - chassts ground
(2) - Chassas ground
nromal? Defective contact, or
3 _ disconnectmn in wiring 4fter Inspection.
1 - 1I Connect T-adapter
harness between CN23 .epaur (clean1 or
t0 CNPl (fe”7ak-Z) NC
YE:s_
Is voltage between
and CNP6 (female).
(female) (1I- CNPl .ep1ace
CN23 11) and (female) 115). CNP6 (female)
chaws ground - 21 Turn starting switch
ON. (2).
normal?
3) Place combmatton
1) Place w,,tch at SMALL.
4) Is reading 20 - 3OV’ Defective contact, or
combmaton After uwpectlon.
disconnection in wmng
swtch at SMALL repax lcleali or
2 harness between CN15
2) Measure voltage NO replace
(male) (8) - CN77 (111, (12)
between CN23
- CN23 (female) (2). or
(female)(l) and
YE.S Is voltage between defective diode a&y.
chaws ground
CN15 (8) and chassis
with CN15 still
connected.
I
3) Turn starting.
watch ON.
T-adapter to 4) Is reading 20 - Defectwe contact. or
1 CN15 3ow 3sconnect!on I” wiring harness ?fte: Inspectlo”.
r 1 2) Turn stan,“g
1 YES
between CN15 (female) (4) - epeir iclean) or
voltage
L-t
Is between switch ON. head lamp and parklng lamp eDlaCe
CNl 5 (male) (41 and 3) Place ‘Is continuity between
switch - CNl 5 (female1 181
chassis ground combination CNl 5 (female) (4)
normal? swtch at SMALL. R +6i ;s show” in
4) Is readmg 20 - Defective contact of head IamP
1) Connect 3ov7
1) Disconnect
and parklng lamp switch
T-adapter
CN15.
(socket adapter1
to CN15 Imale) 2) Turns starting
swatch OFF
21 Turn startong Defective contact, or 4fter !nspectlon.
swtch ON disconnection I” wiring .epa,r (cleani or
31 IS reading 20 - NO harness between battery 2plXZ
3ov7 relay output - CN15 (male)
(4).
Table 1
OFF NO
I
Trouble-
I T-adapter or socket adapter
(for Econoseal)
I 1
shooting
to015
82-150' WA600-1
@
b) Even when working lamp is switched ON, none of monitor
panel lights up
Cause Remedy
Abnormality in monator
panel. or all lamp bulbs
broken. or defective contact.
or dlsconnect!on in wiring
harness between CNPl iiter Inspec.t,on,
YE
:female) (16) - lamp epalr (clean) or
:on”ector il I, or between epkXe
Is voltage between lamp connector (2). CNPG
CNPl (female) (15) female) (3) -chassis
and CNPG (female) around.
n IDefective contact. or
,9isconnection I” wiring ifter InspectIon.
harness between CN22 epatr [clean) or
CNPl (female) and N
YE CNP6 (female).
O I
:female) (1) - CNPl eplace
2) Turn starting switch ON

I
:female) (15). CNPG (female)
:2).
3) Place combination switc h ’
at SMALL.
0 4) Is reading 20 - 3OV?
1) Turn working Defecwe contact. or
lamp switch ON. llsconnectlon in wirtng ifter inspection.
2) Measure voltage harness between CN12 epair (clean) or
between CN22 NO :female) (2) - CN22 eplace
chass!s ground 1
(female) I1 and Ifemale) (2) or defective
r
chassis.&&nd diode ass’y.
with CN22 still
1 1) Keep CN12 connected.
connected. 3) Is reading 20 - Defective contact, or
3OV?
Is voltagebetween 2) Turn starting disconnection on wmng sfter inspectlon,
CN12 (female) (1) switch ON. harness between CN12 apaIr wean) or
and chassis g,ound 3) Turn working 3 (male)(l)- working lamp splace
normal? lamp swtch ON switch - CN12 (male) (2).
4) Is reading 20 - or defectwe workmg lamlp
3OV? switch.
1) KeeoCN12
con&cted.
Defective contact, or %fter InspectIon.
2) Turn starting I disconnection in wring epair (clean) or
switch ON. I harness between battery eDlace
3) Is reading 20 - NO
3OV? relay output - CN12
[female) (1)
WA600-1 82-151
03
Cause Remedy
c) Even when starting switch is turned ON, none of monitor
panel lights up
411lamps broken, or defective

:o”tact. or dasconnectlon in I 4fter inspection.
1 YES wring hame& between CNPl Iepair (clean) or
female) I1 6) - lampconnect~ x r‘eplXe
Is voltage between 1). lamp cO”“ectOr (21 -
CNPl (female) (1 6) _ :hassis ground
and chassis ground
normal?
Iefective monitor panel I?epbX
11 Connect NO
T-adapter to
CNPl (female).
2) Turn starting
switch ON.
31 Is reading 20 -
3OV?
d) Part of panel does not light up
1 YES
IIsconnection in lamp wiring I
Is lamp bulb broke”? -

Iefective contact. 01
disconnection I” wwng harnes s I4fter inspecton.
xtween CNPl (female1 I1 6) - ,epw (clean) or
1) Remove lamp NO amp COnnectOr (1). (2) - I@ace
and check :hassts ground
visually.
T-adapter (for OLI)
shooting
tools
82-152 WA600-1
co
..
Circuit breaker 4
CN23
CNPI
Head lamp
switch
Monitor
panel
3
,
.,:
Lamp
Circuit breaker 2
CNP8
CNP 9221
Lamp
Lamp
CNP6 C:N 22
Service
2 1 lamp
3
meter El=
7: I -
;,:-,;,c,
,
/. ‘!I y.L,‘,
.,,-_,:‘ ‘i
,, , ,i. !,
‘,,. s
426F517
,,. .”
C,l,,_
WA600-1 8% l-53
0-J
M-25: WHEN STARTING SWITCH IS TURNED TO ON
POSITION (ENGINE STOPPED),
BUZZER DOES NOT SOUND FOR 1 SEC.
CAUTION ITEM IS FLASHING BUT BUZZER
DOES NOT SOUND.
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
When connecting the T-adapter (or socket adapter), connect
checking, then go to the next check. Cause Remedy
The buzzer does not sound for charge level and fuel level of
CAUTION items.
YES
)efective monitor panel 3epbX
1efect1ve contact. or
YES jisconnection in wiring :lean (defectwe
urness between CN148 ontact) or replac e
male) - CNP4 (female) (8)
1) Connect
T-adapter to
CNP4 (female1 N
21 Connect CNP4 1efectwe alarm buzzer
(81 to chassis
ground. ~
31 Turn starting
swtch ON lefective contact, or
4fter inspection,
II lisconnection in wring
harness between CN 147
‘epair (clean) or
1) Turn starting NO -eDlace
switch ON. female) - +24V line.
2) Is reading ?O -
3OV’
M-26: NO ABNORMALITY IS SHOWN ON MONITOR

DISPLAY, BUT ALARM BUZZER SOUNDS.
t The alarm buzzer sounds when the parking brake is applied
and the transmission is in any position except NEUTRAL.
2 YES
r I1
ReDlace
J-l H
YES Disconnect CN148.
Does alarm buzzer
1 sound? bntact between chassis
After mspect,on.
1 II ground and wiring harness
xtween CNP4 (female) (8) repax (clean) or
Disconnect CNP4 NO
1) Disconnect WplXe
(female) Does alarm - CN148.
CN148.
buzzer sound’
2) Turn starting
switch ON.
1) Disconnect CNP4
Ifemale) Defective monitor panel Replace
UO
21 Turn stanfng
swttch ON
T-adapter or socket adapter Wiring harness with

Trouble- (for Eco”oseal) croccdlle clip
shooting
tools
T-adapter (for DLI)
82-154 WA600-1
c!zt
M25, 26 Related electrical circuit drawing
426F520
WA600- 1 82-155
c!iI
WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.
CAUTION ITEM IS FLASHING BUT WARNING LAMP
DOES NOT FLASH.
necting the connector for checking, turn the starting switch dFF to prevent accidents.
Sr When connecting the T-adapter (or socket adapter), connect
to the connector specified. (CN 0 A ( ))
Cause Remedy
Defectwe momtorpanel Fi&?G?
1 I Warning lamp bulb broken. Or

defective contact. or After mspectlo”.
3 YES dwxmnecttion in wiring harness repar (clean) or
Does warmng lamp _ between CN17 (male) (11 - replaCe
kght up? IS there continuity lamp, or CN17 {male) (2) -
YES between CN 17 lamp
2 - (female) (21 and -
11 connect p chassts ground’ Defective contact. or After anspectra”.
T-adapter to Is voltage between disconnect,on m wiring harness repax (clean) or
CNP4 Ifemale). CN17 (female) (1) 1) Connect NO between CNl 7 (female) 12) - replace
2) ConnectCNP4 L and chassis ground - T-adapter to chassa ground
(female) (7) to No “ormal? CN17 (female)
chassis ground. 21 Turn starting Defective contact, or
3) Turn starting switch OFF. After mspectm”.
1) connect disconnection in wiring
switch ON. repanr (clean1 or
T-adapter to harness between CNP4
NO replace
CN17 (female). (female) (7) - CN76
2) Connect CNP4 (female) (2), (1)- +24V
(female) (7) to line. or between CN17
chassn ground. (female) (1) - CN76
3) Turn starting (female) (3), (5) - +24V
switch ON line. or defective lamp relay.
I
Trouble- I T-adapter or socket
(for Econoseal)
adapter
I
T-adapter (for DLI)
CN76 +24V
CNP4 CN17
Warnmg lamp
Monitor panel
425F534A-K
82-l 56 WA600-1
0.3
M-,28: NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,
BUT WARNING LAMP LIGHTS UP.
or When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
connect to the connector specified. KN 0 A ( 1)
Cause -r~ Remedy
YES
Defective monitor panel Replace
1*
Doeswarninglamp
go out? After inspection.
2 YES ground and winng harness
repair (cleanI or
- Is there continuity replace
- CN76 (female) (2).
1) Disconnect CNP4 ,_ between CNP4
(female). ND (female) 171 and -
2) Turn starting chassis ground, Contact between f24V lme
and wiring harness After inspecton.
switch ON.
repajr (clean) or
1) Connect NO w&ace
T-adapterto
- CN76 (female) (3). or
defective lamp relay.
CNP4 ifemale)
2) Turn starting
switch OFF.
ITrouble- j T-adapter (for DLI)
Short connector
CN76
panel
425F534A-K
WA600-1 82-157
_ 63
M-29: ABNORMALITY IN 1 @I (FUEL GAUGE) SYSTEM
L-J
t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA ( 1)
Cause Remedy
a) If nothing is displayed in display area
YES
Defectwe fuel sensor Repke
1
Does fuel gauge

show FULL’
2 YES
Iefective monotor panel Replace
i
- Is there cont,n”,ty
1) Connect short L between CNP4
connector to ~0 (female) (4) and - Defectwe contact. or
CN127 (female) chassis ground? disconnectron in wiring
(fuel sensor). harness between CN127 After Inspectaon.
2) Turn starting Ifemale) (2) - CN85 (1) - repaar (clean) or
1) Connect T- NO
switch ON. :hassis ground. or between replaCe
adapter’fo CNP4
(female).
CN127 (female) (1) - CN88
‘3) - CNP4 (female) (4).
2) Connect short
ccBnnector to
CN127 (female).
3) Turn starting
swatch OFF.
b) If indicator remains at FULL
YES
kfectwe fuel sensa
1
Does whole display

xe;p, Of fuel gauge go - Contact between chassis
2 YES Iround and wiring harness xfter Inspect,o”.
between CNP4 (female) (4) epair (clean) or
A Is there continuity - CN86 (3) - CNl27 epi.Xe
1) Disconnect between CNP4 female) (1 I.
CN12J(fuel ~0 (female) (41 and -
sensor). chassis ground?
2) Turn starting
Cjefect1ve mO”ltOr pane1 3ethX
I
switch ON. 1) Connect T-
adapter to CNP4
(female).
2) Remove CN127
3) Turn starting
switch OFF.
T-adapter (for DLI)

Trouble-
shooting
tools
Short connector
82-158 WA600-1
03
CNP4 CN 86 CNl27
Monitor
pEHX?l
CN85
426F511
WA600-1
82-159
@a
M-30: ABNORMALITY IN ;e (AIR PRESSURE GAUGE) SYSTEM
L-J
l* When disconnecting connectors or connecting T-adapters.
Cause Remedy
Defective au pressure sensor ReplEG
Does air pressure

gauge show
maximum level? 2 YES
Defective momtor panel
i IS there contmuity
11Connect
short between CNP4
CNl 10 (air I
(female) (1 and -
h
pressure sensor). disconnection I” wiring
chassis ground’
2) Turn starting harness between CNl 10 After inspection,
switch ON.
11 Connect T- NO
(female) (1) -CN65 (1) - repair (clean) or
CNP4 (female) (1), or repl.WX
adapter to CNP4
between CNllO (female) (21
(female).
2) Connect short
- CN85 (1) -chassis
ground.
connector to
CNllO (female).
3) Turn starting
switch OFF.
b) If indicator remains at maximum level
Iefective air pressure sensor
hntact between chassis 4fter inspection.

2 YES ground and wiring harness .epair (clean) or
wtween CNP4 (female) (1) .eLelce
Is there contmuity -CN65(1)-CNllO
1) Disconnect _ betweenCNP4 _ female) (1).
CNllO(air N , (female) (1) and
pressure sensor). chassis ground?
2) Turn starting
Iefective monitor panel Gplace
switch ON NO
1) Connect T-
adapter to CNP4
(female).
2) Disconnect
CNllO.
3) Turn starting
Switch OFF.
T-adapter (for DLI)

Trouble-
shooting
tools
Short connector
82-160 WA600-1
@
CNP4 CN65 CN 110
CN 85
426F515
WA600-1 82-l 61
03
M-31: ABNORMALITY IN ” (ENGINE WATER
C
ial
TEMPERATURE GAUGE) SYSTEM
to the connector specified. KNOA ( 1)
Cause Remedy
YES IIefective engme watel IeplXe

1 I 1:emperature sensqr
-1
Does engme water
(hntact between chassis
temperature gauge - ifter Inspectran.
2 YES cground and wiring harness
show mmimum level? epar Mean) or
-t eween CN123 (female) (1)
-CN114(3)-CN84(9)- epiG3
- Is there contmuity
1) Dlsconnecr between CNP4
i :NP4 (female) (2).
CN123 (engine & (female) (2) and -
water chassis ground’
temperature).
I kplXe
2) Turn startmg 1) Connect T- NO
switch ON. adapter to CNPL
Ifemale).
2) blsconnect
CN123.
3) Turn starting
sw,tch OFF.
b) If indicator remains at minimum level
Iefective engme water

b+Xe
emperature sen*cr
area of engine water

temperature gauge 2 YES
IeplaCe
Is there continuity
1) Connect short between CNP4 _ kfective contact, or
connector tcl h ’ (female) (2) and iisconnection in wiring
CN123 (male) chassis ground? 7ar”es.s between CNP4 Sfter Inspectlo”.
2) Turn startmg female) (2) - CN84 (9) -
epav i&an) or
swtch ON. :N114(3)-CN123
1) Connect T-adapter to ND ‘eplace
CNP4 (female). female) (1). or between
2) Connect short connector 3N123 ~fe~ale) (2) -
fo CN123 (female). :N114(2)-CN84(10)-
3) Turn starting switch OFF :hassts ground.
T-adapter (for DLI)

Trouble-
shooting
tools
Short connector
82-162 WA600-1
@
CNP4 CN84 CN114 CN123 _ Engine water

temperature sensor
Monitor panel
425F521 A
WA600- 1 82-163
@
M-32: ABNORMALITY IN2 ’ (TORQUE CONVERTER OIL
w
* When disconnecting or connecting the i-adapter (or socket adapter) or short connector, or when discon-
Remedy
a) If nothing is displayed in display area I
YES Defective torque converter oil

1 temperature sensor
Does torque
converter WI
temperature gauge - Contact between chassis After mswction.
show minimum 2 YES ground and wiring harness
repaw Wean) or
level? between CN121 (female) (1) replace
- Is there continuity -CN114(5)-CN85(4)-
1) Disconnect between CNP4 CNP4 (female) (31.
CN121 (torque & (female)(3) and -
converter oil chassis ground?
temperature). Defective monitor panel R~plKZe
2) Turn starting 1) Connect T- NO
switch ON. adaoter to CNP4
(female).
2) Remove CN121
3) Turn starting
switch OFF.
YES Defective torque converter oil

R&3X
1 temperature sensor
Does whole display

area Of torque
converter oil
temperaturegauge ~ 2 ~YES Defective monitor panel ReplaCe
goout?
1) Connect short _ betweenCNP4 _
connector to Defective contact, or
NO (female) (3) and
CN121 (female). disconnection in wiring
chassis ground? After inspectton.
2) Turn starting harness between CNP4
(female) (3) - CN85 (4)- repair (clean1 or
switch ON. 1) Connect T- NO replace
CN114(5)-CN121
adapter to CNP4 (female) (1). or between
(female). CN121 (female) (2) -
2) Connect short CNl14 (8) - CN85 (6) -
connector to chassis ground.
CNl21 (female).
3) Turn starting
swtch OFF.
T-adapter (for DLII

Trouble-
shooting L
to015
Short cc~nnector
82-164 WA600-1
43
Torque converter
CNP4 CN85 CNll4 CN121 oil temperature sensor
Monitor
panel
WA600- 1 82-165

Connector types and location of components. .................................... 82-169
M- 1. ‘(BRAKE 01 L LEVEL) flashes when engine is stopped .......................... 82-176
M- 2. (ENGINE OIL LEVEL) flashes when engine is stopped I ................
........ 82-176
M- 3. (RADIATOR WATER LEVEL) Flashes when engine is stopped ................... 82-178
M- 4. (BATTERY CHARGE) flashes when engine is running. ......................... 82-178
M- 5. (TRANSMISSION OIL FILTER CLOGGING) flashes when engine is running .......... 82-180
M- 6. (FUEL LEVEL) flashes when engine is running .............................. 82-182
M- 7. (BRAKE LINE FAILURE) flashes when engine is running ....................... 82-182
M- 8. (ENGINE OIL PRESSURE) flashes when engine is running ...................... 82-184
M- 9. (RADIATOR WATER LEVEL) flashes when engine is running .................... 82-184
M-10. (DROP IN AIR PRESSURE) flashes when engine is running ...................... 82-186
M-l 1. (ENGINE WATER TEMPERATURE) flashes when engine is running ................ 82-186
M-12. (TORQUE CONVERTER OIL TEMPERATURE) flashes when engine is running ........ 82-186
M-13. (PARKING BRAKE) lights up abnormally, or does not light up ................... 82-188
M-14. (WORKING LAMP) lights up abnormally, or does not light up .................... 82-190
M-15. (PREHEATING) lights up, or does not light up .............................. 82-192
a) (Preheating) lights up ............................................. 82-192
b) (Preheating) does not light up ........................................ 82-192
M-16. (TRANSMISSION CUT-OFF) lights up, or does not light up. ..................... 82-194
a) Lights up ..................................................... 82-194
b) Does not light up ................................................ 82-194
M-17. Turn signal Hi beam light up, or do not light up .............................. 82-196
a) Turn signal (right) pilot display lights up ................................. 82-196
b) Turn signal (left) pilot display lights up .................................. 82-197
c) Turn signal (right) pilot display does not light up ........................... 82-198
d) Turn signal (left) pilot display does not light up ............................ 82-198
e) Hi beam pilot does not light up ........................................ 82-199
f) Hi beam pilot stays lighted up ........................................ 82-199
M-18. Turn signal does not flash even when hazard switch is turned ON ................... 82-201
M-19. Speedometer display does not work normally ............................... 82-202
M-20. Hourmeter does not work normally ...................................... 82-203
M-21. When starting switch is turned ON, monitor panel does not work, or only part works . 82-204
a) None of monitor panel lights up ...................................... 82-204
b) Except for speedometer module, none of monitor panel lights up ................ 82-204
c) None of CAUTION items light up ..................................... 82-205
d) Some other parts do not light up ...................................... 82-205
M-22. When starting switch is turned ON, all monitor panel lights up, but does not go out ...... 82-205
M-23. (ENGINE OIL PRESSURE) flashes or (BATTERY CHARGE) flashes
when engine is stopped .............................................. 82-206
a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated . 82.206
b) (Battery charge) flashes, and warning lamp lights up ......................... 82-206
M-24. None of machine monitor panel lighting lights up, or part does not light up ............ 82-208
a) Even when combination lamp is placed at SMALL, none of panel lighting lights up 82-208
b) Even when working lamps is switched ON, none of monitor panel lights up .......... 82.209
c) Even when starting switch is turned ON, none of monitor panel lights up ........... 82-210
d) Part of panel does not light up ....................................... 82-210
WA600-1
82-A67 1
M-25. When starting swtich is turned to on position (ENGINE STOPPED), buzzer does not sound
for 1 sec. CAUTION ...................
item is flashing but buzzer does not sound 82-212
M-26. No abnormality is shown on monitor display, but alarm buzzer sounds ............... 82-212
M-27. When starting switch is turned to ON position (ENGINE STOPPED), warning lamp does not
light up for 2 sec. CAUTION item is flashing but warning lamp does not flash .......... 82-214
M-28. No abnormality is shown on monitor display, but warning lamp lights up ............. 82-215
M-29. Abnormality in(FUEL GAUGE) system ................................... 82-216
b) If indicator remains at FULL ......................................... 82-216
M-30. Abnormality in (AIR PRESSURE GAUGE) system ............................ 82-218
b) If indicator remains at maximum level .................................. 82-218
M-31. Abnormality in (ENGINE WATER TEMPERATURE GAUGE) system ............... 82-220
....................................
a) If nothing is displayed in display area 82-220
M-32. Abnormality in (TORQUE CONVERTER OILTEMPERATURE GAUGE) system ....... 82-222
...................................
a) If nothing is displayed in display area 82-,222
82-A68
WA600-1
1
COMBINATION SWITCH
DIMMER SWITCH
428FO144C
CNPI CN,Pl CNP4 CNPS

DLI 16-pin
\
CNP3
w8F0141E
CNP2
DLI 8-pin
CNP3 (CHECK module)

DLI 16.pin
WA600-1 82-169
@
CNP4 (CHECK module)
DLI 12-pin CN
P3
428FO1416
CNP5
DLI 8-pin
CNP6
MIC 5-pin
m
3 1 I 3
D
5 4
4 5
c7
CN12 (Working lamp switch)

Working lamp
428F01427A.K
82-178 WA600-1
@
CN15 (Lamp switch)
Econoseal 12-pin
CN15
1 lj 1,2 y
CN16
i i i 6
I 428F0 I428
CN17 (Warning lamp)

N-SLC connector 2-pin Transmission cut-off
switch
2
Fuel cut. -off switch 3 / nl
R
1
Warning lamp Ml7 CN13

428F01429A.K
CNI 8 (Transmission cut-off selector switch)

82-121
@
CNl 00 (Torque converter oil temperature sensor (a))
Econoseal 2-pin
@
1 2
CN106 (Brake chamber stroke sensor (a))

Econoseal 2-pin
WA600-1 82-173
@
CN107 (Brake chamber stroke sensor (b))
Econoseal Z-pin
CNI 20 (Engine oil level sensor)

Econoseal 2-pin
@
1 2
CNlBti CNlli 426F502
CN123 (Engine coolant temperature sensor)

Econoseal 2-pin
a’ Engine coolant temperature sensor

i b. APS coolant temperature sensor
CN 127 (Fuel level sensor)

Econoseal 2-pin
h27
82-174
@s
CNI 36 (Radiator water level sensor (a))
Econoseal Z-pin
426P 124
CN148 (Caution buzzer)

CN148
CNl50 (Caution buzzer)
aution
428FO1457
1
CN249 (Engine
Terminal
oil pressure sensor)
1
426F505
WA600-1 82-175
@I
(BRAKE OIL LEVEL) FLASHES WHEN ENGINE
IS STOPPED.
3 YES
>efective monitor panel leprace
Is there continuity
YES between CNP3
2 r (female) (1) end - Defective contact, or
chassrs ground? disconnection In wirina \fter inspection.
Is there continuity harness between CNPS epair (clean) or
between CN104 Ifemale) (1) -CN65 (3) - +3W
CN66(2)-CN104(1).
disconnectin in wiring \fter inspection.
1) Connect T-
Is there continuity
adapter (socket
I harness between CN104 epair (clean1 or
between CN104 eplaCe
(male) (1) and (2)? adapter) to CN104 No [female) (2) - CN66 (3) -
(female). CN65 (4) - chassis grand
2) Turn starting
switch OFF.
adapter (socket I Defective brake oil level senson
adapter) to NO
CN104 lmalel
(brake dil Ievil
sensor 1).
2) Turn starting
switch OFF.
M-i!: (ENGINE OIL LEVEL) FLASHES WHEN ENGINE

Q
c IS STOPPED.
I Cause Remedy
Defective engine oil level sense ReplSX

1
2 YES
I II
1) Connect T-
adapter to CN 120
(female), then After inspection.
repair (clean) or
chaws ground replace
2) Turn starting
swtch ON.
(female).
3) turn starting
switch OFF.

Trouble- T-adapter (for DLII
(for Econoseal)
shooting
tools
Short connector
82-176 WA600-1
0.3
M-l Related electrical circuit drawing
CNP3 CN65 CN66 CNl04

Brake oil
level sensor
Monitor
panel 1
426F521
M-Z Related electrical circuit drawing
CNP3 CN86 CN115 CNl20

Engine oil
level sensor
Monitor
panel
425F512A
WA600-1 82-177
@D
M-3: (RADIATOR WATER LEVEL) FLASHES WHEN
ENGINE IS STOPPED.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A ( )I’
Cause Remedy
YES defective radiator water level

X”SW
3 YES
Defective monltcx panel
I iHH 3efective contact, or

1) Connect short disconnection in wiring After inspection,
cOnnectOr
to harness between CN136 repaIr Wean) or
CN136 (female) Is there continuity 1) Connect short NO :female)(l)-CN119(2)- replaCe
(radiator water between CN136 connector to CN136 CN84 (2) - CNP3 (female)
level sensor). (female). :31.
21 turn starting chassis ground? 2) Connect T-adapter to
switch ON, CNP3 (female).
3) Turn starting switch
1) Connect T-
OFF Iefective contact, or After inspection,
adamer (socket
jisconnection in wiring repair (clean1 or
ada;ter)‘to
0 7ar”es.s between CN136 replace
CN136 (female)
female) (2) and chassts
2) turn starting
3round.
switch OFF.
(BATTERY CHARGE) FLASHES WHEN ENGINE

D
M-4:
I- IS RUNNING.
(If a flashes when the engine is stopped, go to M-8. Engine oil pressure abnormal.)
2 YES
Replace
Is voltage between
YE , CNP4 Ifemale) (5) _
and chassis ground Xfective contact, or
1 nCK”lal? iisconnection in wirlna After inspection.
wrness between alter;ator repair (clean) or
1) Connect NO terminal R - CNl14 (1) - replace
T-adapter to CN86 (1) -CNP4 (5).
alternator terminal R CNP4 Ifemalel.
2) Turn starting
Switch ON. (Start
engine.)
1) Turn starting 3) Is reading 20 -
switch ON. 3OV?
2) Measure voltage Defective alternator Replace
IO
between
alternator
terminal R and
chassis ground.
3) Is reading 20 -
3OV?

T-adapter (for DLI)
shooting
tools Short connector
82-178 WA600-1
@a
CNP 3 CN84 CNll9 CN136 Radiator water

level sensor
Monitor
panel 1
426F508
CNP4 CN86 CNll4
Monitor Alternator
panel O terminal R
426F509
WA600-a 82-I 79
63
M-5: , (TRANSMISSION OIL FILTER CLOGGING)
0 FLASHES WHEN ENGINE IS RUNNING.
/8
connect to the connector specified. (CNOA ( ))
Cause Remedy
‘FS
Defective transmission oil
Replace
filter clogging sensor
1
3
.,,)
YES
Defective momtor panel R-+%X
n (fema!e) (10) and

.-
Cnassls grounac
1) Connect short ‘) II Defective contact. or
dtsconnection in wiring
After inspection,
connector to repar (clean) or
NO harness between CN 105
CN105 (female) reDlace
(female) (1) - CN66 (1) -
(transmission oil
CN65 (2) - CNP3 (female)
filter clogging h (10).
SellSOr). ~,~
2) Turn starting
switch ON.
Defective contact, or After inspection,
NO harness between CN105
‘epair (clean) or
CN105 (female). v?p1ace
(female) (2) - CN66 (3) -
2) Turn starting
CN65 (4) -chassis ground.
svwtch OFF.
CNP3 CN65 CNl05

Transmission filter
clogging sensor
Monitor
panel
426F522

T-adapter (for DLII
shooting
to&
Short connector
82-A80 1
WA600-1
M-6: (FUEL LEVEL) FLASHES WHEN ENGINE
*, When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNOA ( 1).
Cause Remedy
1 YES See M-29 (Abnormality in fuel

level gauge)
I I
H
Does fuel gauge
display EMPTY?
L I I Defective monitor panel

1) Turn startq NO
switch ON
(BRAKE LINE FAILURE) FLASHES WHEN ENGINE

IS RUNNING.
* Check that there is no abnormality with the chassis.
3 YES
Is there continuity
YES_ betweenCNP3 _ Defective contact, 01
Ifemale) (41 and disconnection in wiring
2 After inspection.
chassis ground’ harness between CN107
repair (clean1 or
Is there continuity L ~
(female) (1) - CN66 14) -
rep(ace
YES 1) connect NO CN64 (8) - CNP3 (female)
between CN 107
r (female) (2) and - T-adapter to (4).
1 chasss ground? CNP3 (female).
-) 2) Turnstaelng
swtch OFF After inspection,
Is there continuity of 1) Connect T- harness between CN107
repair (clean) or
each sensor? - adapter (socket NO \female) (2) - CN106
reDlace
(total: 2) adapter) to (female) (1). or CN106
CN107 (female). (female) (2) - CN66 (3) -
A 2) Turn starting CN65 (4) - chassis ground.
1) Connect T- switch OFF.
adapter (socket Non-continuous sensor IS
adapter) to each NO defect;ve
sensor (male).
2) Turn startmg
switch OFF.
3) connector
numbers are
CN107and 106
82-182 WA600-1
63
CNP4 CN 86 CNl27
Monitor
panel
Fuel level se”SOr
7ib CN85
426F511
CNl07
CNP3 CN64 CN66
Brake stroke
CN65 CNl06
426~523
WA600-1 82-183
@a
M-8: (ENGINE OIL PRESSURE) FLASHES WHEN ENGINE
IS RUNNING.
* Whenconnecting the T-adapter (or socket adapter), connect
Defective engine 011pressure RepiXZS

Se”SOr
3 YES
Defective monitor panel wlace
Is there continuity
YES between CNP3 _ Defective contact, or
2 - (female) (91 and disconnection in wiring
_ chassis ground7 harness between chassis After inspection,
ground - CN75 (3). (6) - repair (clean) or
Is voltage between p p
1) connect NO CNP3 (female) (9). or
- CN249andchassis - replace
T-adapter to defective engine oil
normal?
CNP3 (female). pressure sensor relay.
2) Turn starting
11 Turn starting switch OFF.
ground and wiring harness
After inspection.
switch ON. IStart NO repair (clean) or
,etween CN249 - CN115
1 .
enaine)
4) - CN66 (7) - CN75 (2).
R?PlZO2
2) Is reading 20 -
3ov7
Go to M-23 (Engine oil
wessure or battery charge
Note) If & flashes when engine is stopped, ais defective.
i ilashes when engine is
stopped.)
M-9: (RADIATOR WATER LEVEL) FLdSHES WHEN

ENGINE IS RUNNING.
YES
Defective radiator water level I?eplace
Se”SOl
I
3 YES
3efective monitor panel 7epkZ
IS there continuity
YES between CNP3
ifemale) (3) and
chassis ground, Iefective contact. or
iisconnection in wiring I\fter inspection,
1 I Connect short narness between CN136 .‘epair (clean) or
crJnnector to 2 1) Connect short NO
(female) (1) - CN119 (2) - replace
connector to
radiator water CN64 (2) - CNPB (female)
level Sensor Is there continuity CNl36 (female).
2) Connect T- (3).
CN136 (female). between CN136
- adapter to CNPJ
2) turn starting NO - (female) (2) and
chassis ground? (female).
switch ON.
3) start engine. i 3) Turn starting
1) Connect T- switch OFF.
After inspection,
disconneciton in wiring
repair (clean) or
NO harness between CN136
switch OFF. replace
(female) (2) and chassis
ground.

T-adapter (for DLI)
shcotmg .
82-184 WA600-1
63
CNP 3
Monitor
panel
+24V
Service Engine oil

I I
4
426F513
M-S Related electrical circuit drawing
CNP3 CN84 CNI IQ

Radiator water
level sensor
Monitor
panel
426F524
WA600-1 82-185
@
M-10:
q4P
(DROP IN AIR PRESSURE)
ENGINE IS RUNNING.
FLASHES WHEN
connect to the connector specified. (CN 0 A ( 1)_
+ When disconnecting connectors or connecting T-adapters.
Cause Remedy
1 YES See M-30 (Abnormality in air

pressure gauge)
Is a,r pressure gauge _

tiithln red level7
Defective monitor panel FkPlVX

1) Turn startmg NO
swtch ON.
M-11: (ENGINE WATER TEMPERATURE) FLASHES

1 YES See M-31 (Abnormality in

engine water temperature
gauge1
Is engine water
temperat”re gauge -
within red level7
IDefective monitor panel f?ep1ace

1 I Turn starting NO
switch ON.
M-l 2: (TORQUE CONVERTER OIL TEMPERATURE)

FLASHES WHEN ENGINE IS RUNNING.
1 See M-32 (Abnormality in

rorque converter oil
temperature gauge)
IS torque
converter 011
temperature gauge -
withm red level?
Replace
1) Turn starting NO
watch ON.
T-adapter (for DLII

Trouble-
shootmg
tools
82-186 WA600-1
@
CNP4 CN 110
Monitor
panel Air pressure
sensor
426F515
CNP4 CN84 CN114 CN123 Engine water

temperature sensor
Monitor panel
425F521 A
CNP4 CN85 CNl14 CN 121 Torque converter

oil temperature sensor
Monitor
panel
426F516
WA600-1 82-187
@
(PARKING BRAKE) LIGHTS UP ABNORMALLY,
cl
M-13:
@ OR DOES NOT LIGHT UP.
* When connecting. the T-adapter (or socket adapter),
connect to the connector specified. (CNO A ( 1)
Cause Remedy
a) If @ stays lighted up
L-l
YES
Defective parking brake stns( bxdace
I
Defective monitor panel ?eplace
disconnection in wiring 4fter tnspection,
1) Connect short harness between CN34 gpair (clean) or
connector to
N( (female) (1) - CN32 (4) - .c?piace
CN34 (female) COnneCtOr to CNP3 (female) (5).
(parking brake CN34 (female)
SWWX).
(parking brake
SMlSOr).
Does parking brake 2) Connect T-
work when swatch is adapter to CNP3
turned ON-OFF? (female).
3) Turn starting
switch OFF.
II Turn starting
(fe&lej (parking 4fter inspectton.
switch ON. disconnection in wiring
brake sensor). repair Wean) or
2) Turn starting replace
(female) (2) and chassis
switch OFF.
ground.
l- See Troubleshooting for

NO chassis
b) If w does not light up
YES
Defectwe parking brake sense
dd
-I Does
cl@ lightup? Contact between chassis
ground and wiring harness
4fter Inspection,
epair I&an) or
‘eplXe
ISthere continuaty - CN32 (4) - CNP3
1) Disconnect between CNP3 (female) (5).
connector CN34. (female) (51 and
2) Turn starting
Does parking brake switch ON.
work when switch is Defective monitor panel kplaCe
1) Connect T-
turned ON-OFF?
adapter to CNP3
(female).
2) Disconnect
switch ON. CN34.
3) Turn starting
switch OFF.
see Troubleshooting for
NO :hassis
Trouble-
shootmg
I l-adapter (for DLI)
II
(for Econoseall I
1
to&
Short connector
I I
82-188 WA600-1
@
CNP3 CN32 CN34
425F523A
WA600-1 82-189
03
M-14: (WORKING LAMP) LIGHTS UP
ABNORMALLY, OR DOES NOT LIGHT UP.
When disconnecting or connecting the T-adapter (or socket

connector for checking, turn the starting switch OFF to
prevent accidents. Note) Even is all the working lamp bulbs
When connecting the T-adapter (or socket adapter), are broken, or there is defective
connect to the connector specified. (CN 0 A ( 1) contact or a disconnection in the
When disconnecting connectors or connecting T-adapters, wiring harness for the working
return them to the original condition immediately after lamp, //,5?/ will stay lighted up.
Cause Remedy
If m stays lighted up
YES
Iefecttve working lamp switct Replace
1 I
2 YES
Iefective monitor panel ReDlace
IS voltage between
1) Remove CN12.
CNP3 (female) (14)
2) Turn starting
NO and chassis ground
switch ON.
normal? :ontact between +24V and After mspect,on.
Miring harness between repair (clean1 or
1) Connect T- NO :N12 (female] (2) - CNP3 replace
adapter to CNP3 female) (14).
(female).
2) Turn starting
switch ON.
3) Remove CN12.
4) Is reading O-
lV? c
b) If w does not light up

3 YES
)efectlve monitor panel
YI
lefective contact, or
harness between CN 12 After Inspectto”,
‘emale) (2) - CNP3 wair (clean) or
1) connect NO wace
:emale) (14) or CN12
T-adapter to
‘emale) (1) - CN79 (male)
CNP3 (female)
IO)and(l2).
YES between CN12 2) Turn startnng
(male) (1) and (2) as switch ON.
shown in Table? 31 Turn working
lamp switch ON.
4) Is reading 20 -
Afl 1) Disconnect CN12
3ov7
(male).
Is voltage between
CN79 (male) (11) 2) Turn starnng
switch OFF.
and (9) - chassts
_.
ground normal? 3) Turn working Defective working lamp swltct
lamp switch ON
- i-la
I
1) Connect T-
adapter (socket
adapter) to CN79 lefective contact, or After inspecton.
(male). , lisconnection in wiring repar (clean) or
2) Turn startina NO wness between main replace
switch ON. - ;
weaker - CN79 (male) (9)
3) Is reading 20 - md(l1).
3OV?
Table
T-adapter (for DLI) Tester

Trouble-
shoatlng
tools
82-190 WA600-1
(0%
Fuse box
1r I I
t24V
L(
I CN 15
CN23 CN 77
CNPI
Head lamp switch
Monitor
panel
Lamp
Fuse box
Lamp
Lamp
CNP6
Service
meter
Monitor
panel
H CNP 3
2
I
I - Working lamp
426F525
WA600- 1 82-191
@
M-l 5: w (PREHEATING) LIGHTS UP,
[? OR DOES NOT LIGHT UP.
* When connecting the T-adapter (or socket adapter). connect
Cause Remedy
a) $7’ (Preheating) lights up

I
1
I Carry out troubleshooting of
APS
Is between
CNPJ (female) (1 5) II

1) Connect
T-adapter to
CNP3 (female).
21 Turn starting
switch ON
3) Is reading 20 -
3OV?
-
b) m (Preheating) does not light up
1 YES
kfective mawor panel
Is voltage between
CNP3 Ifemale (151 _
and chassis ground Jefective contact, or
normal? disconnection in wiring
11 connect NO
(male) (1) - CN82 (1) -
T-adapter to CNPJ (female) (15).
CNPB (female) ;y;;ry;ut troubleshooting
2) Turn starting
switch ON.
3) Is reading 20 -
3ov7
T-adapter (for DLll

Trouble-
shooting
tools
82-192 WA600-1
03
M-l 5 Related electricla circuit drawing
To APS unit
AA
Starting switch
Bimetel timer CN88 CN82 CN14
CNP3
426F526
WA600-1 82-193
@I
M-l 6: (TRANSMISSION CUT-OFF) LIGHTS UP,
•&l DOES NOT LIGHT UP.
to the connector specified. (CN 0 A ( )I
Cause Remedy
a) @ lights up
El
Iefective transmission cut-off

RepiXe
iwitch
3 YES
Iefective monitor panel
Does’~go O”t?
I
YfES
ml-
kfective contact. or
1I Short circut 2 kconnecfion in wiring harness
between CN18 between CN18 Ifemale) 13) ant
1) Turn NO
;feWe, I31 and
tran.smlSSlO” ZNP3 ifemalel 11 11
between CN 18
(female) (4) and cut-off Selector
21 Turnstarting N
chassis ground’ switch ON.
swtlch ON.
2) Connect T-adapter fo
CNP3 (fern&l.
1I Turn starting kfective contact. or
watch OFF.
3) Turn starting watch OFF
IlScOnnection in wiring harness
ifter InspectlOn.
epair (clean) or
NC Mween CN18 (female) 14) ant
epk%X
hassis ground
b))d oes not light up
Defective transmission cut-off

Rt?plaCe
switch

After Inspect,on,
2 YES around and wir,ng harness
repair (clean) or
I I It between CN18 (female) (3)
WhX
Is there continuity snd CNP3 (female) (1 1)
1) RemoveCN18. between CNP3
I
21 Turnstan!ng NO (female) (1 1) and
switch ON. chassis ground?
ReDlace
1) Connect NO
T-adapter to
CNP3 (female)
21 Turn starttng
&itch OFF.
T-adapter (for DLII Tester

Trouble-
shooting
tools
82-194 WA600- 1
@
CNP3 CNl8
Monitor panel
Transmission
cut-off switch
425F526-K
WA600-1 82-195
03
M-l 7: TURN SIGNAL HI BEAM LIGHT UP,
OR DO NOT LIGHT UP.
Sr When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when discon-
necting the connector for checking, turn the starting switch OFF to prevent accidents,
Sr When connecting the T-adapter (or socket adapter), connect
a) Turn signal (right) pilot display lights up

Cause Remedy

wiring harness between CN15
2 YES (female) (3) - right turn signal After inspection.
I I I switch, or between CN15 repair or replace
Is voltage
between (female) (5) and turn signal
YfiS CN15 (male) (51 and _ switch
chassis ground
I
normal? Contact between +24V line
After wxpectlo”.
and wiring harness
repair or replace
1) Connect NO between CN15 (male) (5)
T-adapter to and CN74 (female) (4).
CNl 5 (male).
Does turn signal go 2) Turn starting switch ON.
3) Does voltage swttch repeatedly between 0 - 20 - 30V’
3 YES
1) RemoveCNlS. Defective monitor panel
2) Turn starting
Is voltage between
switch ON.
CNPl (female) (7) _
40 and chassis ground
normal?
wiring harness between CNPl After Inspection.
(female) (7) and CN15 (male) repair or replace
1) Connect NO
T-adapter to (3)
CNPl (female).
2) Turn startina
switch ON. _
3) Turn right turn
sig~l switch ON
4) Does voltage
switch
repeatedly
between 0 - 20
_- 3ov7
T-adapter (for DLI)

Trouble-
teds
I T-adapter or socket adapter

(for Eccnoseal)
I
82-196 WA600-1
03
b) Turn signal (left) pilot display lights up Cause Remedy

wirmg harness between CN15
(female) 16) - left turn signal After inspection.
switch. or between CN15 repav or replace
(female) 15) and turn signal
YE
switch
Contact between +24V line.

I I I and wiring harness After inspectlon.
1) Connect NO between CN15 (male1 (51 repair or replace
T-adapter to and CN74 Ifemale) (4).
CNl 5 imale)
Does turn signal go 2) Turn starting switch ON
out) I 3) Does voltage switch repeatedly bet&en 0 - 20 - 3OW
I I 3 YES
1I Remove CN 15. Defective monitor panel Replace
21 Turn startmg
Is voltage between
switch ON
, CNPl (female) (61 _
N and chassis ground
normal?
wiring harness between CNPl After inspection,
NO lfemalel 16) and CN15 (male) repair or replace
11 Connect
T-adapter to (6)
CNPl (female)
21 Turn starting
swfch ON.
31 Turn left turn
signal switch ON
4) Does voltage
switch
repeatedlv
b&ween 0 - 20
- 3ow
T-adapier or socket adapter

shooting
tools
T-adapter (for DLI)
WA600-1 82-197
@
Cause Remedy
c) Turn signal (right) pilot display does not light up
2 YES
Iefectlve monitor panel FkpkXe
YES
)efect1ve contact. or
4fter ,nspa%on.
lisconnectlon in wring harness
1
hGr---l’ NO wtween CNPl (fem.&l (71 and
:Nl 5 Imale) 13)
wpar (cieani or
T-adapter to
CNPl (femaleI.
2) Turn stafling
Do front and rear turn
switch ON.
sIgnal lamps work
3) Turn turn slgnal
normally?
swtch ON.
i I 4) Does voltage
1I operate right switch
turn SIgnal. repeatedly
2) Turn stamng between 0 - 20
- 3ov7 :arry out troubleshooting of
watch ON
tlml SIgnal
3
d) Turn signal (left) pilot display does not light up
2 YES
Iefectwe monitor panel ReplaCe
Is voltage between
YES CNPl (female) (6)
and chassis ground
normal7 )efectwe contact, or
After !“spectno”.
lrxonnectton I” wiring harness
repax wean1 or
1) connect NO eween CNPl (female) (6) and
WplWe
1 T-adapter to :Nl 5 (male1 161
CNPl (femaleI.
Do front and rearturn 21 Turn starting
signal lamps work - swtch ON
fl0rmally’ 3) Turn turn signal
watch ON
4) Does voltage
1) operate left turn switch
sgna1. repeatedly
2) Turn stamng between 0 - 20
switch ON. - 3ov7 :arry out troubleshooting of
NO urn signal
T-adapter or socket
adapter
shooting
tools T-adapter (for DLII
WA600-1
82-A98
i.
e) Hi beam pilot does not light up Remedy
If the head lamp does not switch to Hi beam, check the head
lamp system.
Defectwe monitor panel

Isvoltage between
CNPl (female) 6)
and chassis ground
normal? Defectwe contact. or
H \tter Inspectw!.
dlsconnectlon in wrung
epar icieani or
1) Connect NO eplaCe
[female) (5) and CN31
T-adaoter to
[female) (1).
CNPl ‘lfemalei
21 Turn starnna
L-t
switch ON -
Do both left and right 31 Place
front lamps light up? combmatton
swttch at HEAC
4) Place dimmer
1) Turn stanfng switch at HI
switch ON beam
2) Place 51 IS reading 20 -
combination 3ov7
Both head lamp bulbs (Lo beam
swtch at HEAD lamps1 broken’
31 Placedimmer ilf the Lo beam bulb IS broken.
swtch at Lo the Hi beam pllot will not light k!plWe
beam up even If the lamp IS watched
to HI team 1
f) Hi beam pilot stays lighted up I
Defective mon,tor panel kplXe
Do both left and i,ght Defective contact. or

front lamps l,ght up? YES dtsconnecton I” w,nng harness
2 between CN15 Ifemale) I91 ant
combination watch
switch ON Does head lamp light Defectwe contact. or titer Inspectlo”.

21 Place NO up at HI beam? 3 YES drsconnect,on I” w,r,ng harness sp.%r Iclean) or
combnation between CN15 (female1 (121 eDlace
switch at HEAD 1 Is there continuity and combmatlon swtch
3) Place drnmer 1) Turn starting between CN15
switch at Lo switch ON NO_ lmalel (1 2) and
beam 2) Place chassts ground? Defectwe contact. or
combination dlsconnectnn m wiring harness
swtch at HEAD 1) Connect NO between CNl 5 (male) (12) and
31 Place dimmer T-adapter chassis ground
switchatH1 (socket adapter)
beam to CNl 5 (male)
2) Turn starting
switch OFF
-
T-adapter (for DLI)
Trouble-
I i
--_a
(for Econoseal)
I I
WA600- 1 82-199
@
M-l 7 a), b), c), d) related electrical circuit drawing
+24
A CN15
CNPl
Hazard
‘ I
I
CN74
\ I I Turn signal switch
425F527A-K
M-l 7 e), f) related electrical circuit drawing
CN29
CNPl
CN27
Right head lamp-lo Left head lamp-lo
425F01366A
82izoo1
WA600- 1
M-l 8: TURN SIGNAL DOES NOT FLASH EVEN WHEN
HAZARD SWITCH IS TURNED ON.
4 When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
return’ them to the original condition immediately after
Cause Remedy
2 YES Defective monitor panel

Is voltage between
YE CNPl (female) (6).
(71 and chasss
ground normal?
NO See M-l 7 cl. d)
1 1) Connect T-adapter to CNPl (female) Troubleshootmg of turn signal
2) Turn startmg switch ON.
L-l
Isvoltage between 3) Does voltage switch repeatedly between 0 - 20 - 3OV,
CNPl Ifemalel 131 Defective Contact. Or
and chassis ground After Inspection.
disconnection in wirmg harness
normal? repair (clean) or
between CNPl Ifemale) 131 -
repI%?
CN15 (male) (2)
11 Connect
4
T-adapter to
CNPl (female) isvoltage between
21 Turn hazard CN 15 (female) 121
switch ON. disconnecton in wnng harness
hIO and chassis ground
31 Is reading 20 - between CN15 (female) (1) After inspection.
normal?
3ov7 and hazard swtch. or between repaw (clean) or
CNl 5 (female) I21 and hazard replaCe
1) connect
swtch. of defective hazard
T-adapter to ISvoltage
between
switch
CN15 (female). L CN15 (male) (l)and _
21 Turn hazard NO Chassis ground
switch ON. ll0rrlla17
3) Is reading 20 - Defective contact. or After inspection.
3ov7 l! Connect disconnection in wirmg harness repair (clean1 or
T-adapter to NO between CN15 hale1 (1) and
CN 15 (male) +24V line
2) Turn hazard
switch ON
3) Is reading 20 -
3ov7

T-adapter (for DLI) I I

+24
CN15
+ I
425F527A-K
WA600-1 82-201
@
M-l 9: SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.
Cause Remedy
4 YE
mr Defective monitor panel ReplaCe
H
Is proximity setting of
YES
speed sensor0.5 -
15mm?
I Defectwe speed sensor mount RePlace

i Loosenspeed
between CNPl
I sensor locknut
and turn speed
sensorclock-
vase. If it
3CXJQ-1 k0, Contacts the gear
within one turn.
the distance is
within 1 .5 mm
T-adapter to
Is.resistance
1
YE .S between CN85
2)
CNPl (female)
Turn starting
Iefective contact. or
After Inspection.
(female) (12) and I lisconnenion in wiring
switch OFF repaw Iclean) or
(11)300Q-lkn?
H NO urness between CNPl (9).
WPkX
10) (female) - CN85 (12).
’j
‘Jg;i:iL5
2) Turn starting NO
11).
Iefective contact. or
7arnes.s between CN85
After Inspection.
repaw or replace
female) (12). (11) - CN98
1 I swtch OFF.
1). (2).
1)Connect
T-
adapter (socket
adapter) to CN98 Defective speed sensor Rep!ace
(speed sensor) NC
1
imalel
2) iurn &tin9
Switch OFF.

Trouble- (for Econose.4
shooting
toois
T-adapter (for DLI)
M-l 9 Related electric& cirw it drawing
CNPl . CN85 CN98

Speed sensor
@5F530A-K
82-202
0-Q
M-20: HOURMETER DOES NOT WORK NORMALLY.
+ When disconnecting or connecting the T-adapter (or socket

connector for checking, turn the starting switch OFF to pre-
vent accidents.
to the connector specified. (CNOA ( 1)
Cause Remedy
YES Defectwe engme 011pressure

ReplaCE!
St?“SCX
YES
Replace
Does hourmeter
work. or does display
“I
between CNP6
(female) (4) and
Chassis ground? Defectwe contact, or
1) Remove CN249.
disconnection in wring
2) Turn starting
harness between chassis After inspection.
switch ON. L
ground - CN75 (3). (6) - rewr (clean1 or
I -adapterto NO
ISvoltage between CNP3 (female) CNP3 (female) (9). or replace
CN249 and chassis defective engme oil
2) Turn startmg
ground normal? pressure sensor relay
switch OFF
El
1) Turn starbng
switch ON (Start Contact between chassis
ground and wiring harness After mspectron.
engme.)
between CN249 - CN115 repair (clean) or
21 Is readmg 20 - 0
(4) - CN66 (7) - CN75 (2). replace
3ov7

Short connector
Trouble- (f?r Econoseall
shootnng
T-adapter (for DLII
(for MICI
CNP 3
Monitor
panel
Engine oil
Service
pressure SenSol
meter
426F513
MONITOR PANEL DOES NOT WORK,
OR ONLY PART WORKS.
When disconnecting connectors or connecting T-adapters.
Cause Remedy
a) None of monitor panel lights up
2 YES
Defectwe monitor panel RE&+Ze

CNPl (female) (1) -
and 12) 20 - 3OVp Defective contact. or
1 ~lsconnecfion in wiring
Clean (defectwe
harness between CN79 (6) contact) or repkx
Is voltage between 11 Connect NO - CNPl (1 ), or between
CN79 (male) (5) and T-adapter to CNPl (2) - CN85 (6) -
chassis ground 20 CNPl chassis ground.
- 3OV? 2) Turn starting
watch ON.
1 i Connect T- I Abnormality in wiring

adapter to CN79 harness between battery
(male). terminal (+) - battery relay After inspection,
2) Turn startmg NO _ main breaker - CN149 repa,r or replace
switch ON. - CN79 (male) (5).
b) Except for speedometer module, none of mOnitOr Panel

lights up
1
- YES
Isvoltage between 2 Defectwe monitor panel Replace
CNP5 (female) (1)
and (71 10 - 2OV’
is voltage between Defective contact or
(2) and (7) approx. disconnection in wirng harness
5v7 between CNP2 (1) - CNP5 Clean (defective
p NO (1). CNP2 (2) - CNP5 (2). :ontact) or repkac
II Connect CNP2 (7) - CNPS (7). or
T-adapter to defective monitor panel
CNP5 (female).
2) Turn starting
switch ON.

Tester
‘rouble- (for Econoseal)
.hooting
tools
T-adapter (for DLI)
82-204 WA600-1
al
Cause Remedy
c) None of CAUT!ON items light up
efectivecontact. Or
1 YES sconnectnn in wiring harness lean (defectwe
atween CNP2 (female) and 3ntactl or replace
Is there dlsconnectlon
in winng harness NP5 (female)
between CNP2
(female) and CNPS
~femalel?
efectwe mO”ltOr panel
1) Connect NO
T-adapter to-
CNPZ and CNP5
.(female).
2) Turn starting
switch OFF
d) Some other parts do not light up
I lefectlve mO”ltcJrpanel

ALL MONITOR PANEL LIGHTS UP,
BUT DOES NOT GO OUT.
I ,efectwz mO”ltOr panel

Tester
Troubk- (for Econoseal)
shooting
tools T-adapter (for DLIl
M-21.22 Related electrical circuit drawing
Fuse box
Main breaker
Battery relay
CNPl
\ CN149
Battery terminal (+I
Monitor
425F531 A-K
WA600-1 82-205
a3
(ENGINE OIL PRESSURE) FLASHES
OR rml (BATTERY CHARGE)
FLAS&&VHEN ENGINE IS STOPPED.
i Cause Remedy
a) w (Engine oil pressure) flashes, and alarm buzzer and
warning lamp are actuated.
-C lefective alternator
-C lefectlve monitor panel Gx%3ce
~~~,~ C:ontact between +24V and

r viring harness between 4fter Inspectlo”,
(Do not stal

1) Connect
T-adapter to
NO z lternator terminal
:N114[1)-CN86(1)-
C:NP4 (female) (5).
R- epair (clean) or
ZPlaCe
engme I CNP4 IfemaleO.

2) Turn startina
switch ON. -
(With wrmg at R
terminal
removedl
31 is readmg 0 -
lV?
b) E (Battery charge) flashes, and warniyg lamp lights up
Defective engme al pressure

sensor
Defective mon,tor panel
YE
ground and wiring harness Ifter inspecton.
1) Connect CN249 between CN75 (3). (6) - spalr (clean1 or
to chasss CNP3 (female) (9). or
1 j Connect T-adapter to ND ‘ePlXe
ground Is voltage between defective engine oil
CNP3 (female).
2) Turn startmg CN249 and chassis pressure sensor relay.
2) Turn startmg swtch ON.
swatch ON.
3) Connect CN249 to
chassis around.
1) Turn starting
switch ON. (Start Sfter inspectmn,
engine.) epair (clean) or
‘WXZ
2) Remove CN249.
3) Is reading 20 -
3OV?

shootmg
toois
T-adapter (for DLI)
82-206 WA600- 1
@
M-23 a) Related electrical circuit drawing
CNP4 CN66 CN114
Monitor Alternator
panel 0 terminal R
426F509
M-23 b) Related electrical circuit drawing
Monitor
panel
CNP6 i24V
Eng1ne 011
Service
pressure sensor
meter
426F513
WA600- 1
82207
M-24: NONE OF MACHINE MONITOR PANEL LIGHTING
LIGHTS UP, OR PART DOES NOT LIGHT UP.
return them to the original condition immediateiy after
Cause Remedy
Even when combination lamp is
placed at SMALL, none of panel
lighting lights up. Abnormality ,n monitor panel. t
all lamp bulbs broken. or
defective contact. or After inspection,
YES disconnecton m wiring ham% repair (clean) or
5’ between CNPl (female) 11 6) - replace
1s voltage between lamp connector. or between
YES CNPl (female) (15) lainp connector, CNP6 (female
- andCNP6 Ifemale) - (3) - chassis ground
(2) - chassis ground
nromal? Defective contact, or
3- disconnection in wiring After inspection.
_ 1) Connect T-adapter
Is voltage between to CNPl (female) N;
(female) (1) - CNPl replace
Yl . CN23(l)and and CNP6 (female).
(female) (15). CNP6 (female)
chassis ground - 2) Turn starting switch
ON. (2).
normal?
3) Place combination
switch at SMALL.
1) Place Defective contact. or
combination 4) Is reading 20 - 3OV7
disconnection in wiring After mspection.
switch at SMALL. harness between CN 15
2 repa1r (clean) or
2) Measure Voltage NO (male) (8)- CN77(11), (12) reDlaCe
between CN23 - CN23 (female) (2). or
(female) (1) and defective diode ass’y.
chassis &und
with CN15 still
connected.
3) Turn starting
switch ON.
T-adapter to 4) Is reading 20 1 3efective contact. or
CN15. 3OV? 4 .YES disconnection in wiring harnes: \fter inspection.
Turn starbng
wtween CN15 (female) (41 - epair (clean) or
Isvoltage
between switch ON.
9eead lamp and parking lamp epke
CN15 (male) (4) and Place
witch - CN15 (female) (6)
combination
switch at SMALL. h
Is reading 20 -
I X?fective contact of head lamp
1) Connect 3ov7 I I
1I Disconnect NO and parking lamp switch

T-adapter
(socket adapter) CNl5
to CN15 Imale). 2) Turns starting
21 Turn starting switch OFF.
_. 3efective contact, or After inspection.
SwltCh UN. I jisconnection in wiring
epair (clean) or
3) Isreading 20 - NO wrness between battery @X.?
3ov7 .elay output - CN15 (male)
4).
Table 1
Combination
Contlnuity
switch I
I SMALL I Yes I
I OFF I NO I

shooting
WA600-
82-;08 1
1
b) Even when working lamp is switched ON, none of monitor
panel lights up
Cause Remedy
Abnormality I” monitor
panel, or all lamp bulbs
broken, or defectwe contact.
or disconnectlot? in w$r~ng
YES (female) (16) - lamp
4r connector (1). or between
lamp connector (2). CNP6
CNPl Ifemale) I1 51 (female) (3) - chaws
and CNPG Ifemale) ground.
(2) - chassis ground
disconnection in wiring After
harness between CN22 Inspectlo”.
(female) (1) - CNPl repair (clean) or
Yl (female) (15). CNP6 (female) replace
(21.
2 1) Turn working Defective contact. or

I 1 lamp switch ON. disconnection in wlrlng After
21 Measure voltaoe harness between CN12 inspectlo”,
YE between CN22- (female) (2) - CN22 repa,r (clean) or
(female) (1) and (female) (2) or defective
chassis ground diode ass’v.
with CN22 still
connected.
CO”“&Xed 3) Is reading 20 - Defectwe contact. or
2) Turn starting 3ov7 disconnection in wiring After
swtch ON. harness between CNl2 inspection,
.., -
.¶I I urn working (male) (1) - workrng lamp repair (clean) or
lamp watch ON switch - CN12 (male) (21. reDlace
1 i 4) Is readmg 20 - or defective working lamp
1) Keep CN12 3OV? switch.
connected.
2) Turn startmg Defectwe contact, or
disconnecton m wwng After
swlfch ON.
harness between battery Inspection,
31 Isread~ng 20 - NO
relay output - CN12 repair (clean) or
3OV’
(female)(l) EplaCe
WA600- 1 82-209
@
Cause Remedy
c) Even when starting switch is turned ON, none of monitor
panel lights up
(II lamps broken. or defectwe

ontact. or d\sconnect!on in After Inspect,o”.
1 vwng harness between CNPl repajr Iclean) or
female1 1161 - lamp connects
II
replaCe
Isvoltage between 1 I, lamp connector (2) -
CNPl (female) (161 hass,$ ground
and chassx ground
normal?
)efect,ve mon,tcJr panel
11 Connect
T-adapter to
CNPl (female).
21 Turn starting
swtch ON.
3) Is reading 20 -
3OV?
d) Part of panel does not light up
1 YES
Is lamp bulb broken? -

)efectwe contact. or
lisconnectlon in wiring harness 4fter inspection,
etween CNPl (female) (161 - .epa,r Iclean) or
1) Remove
lamp NO unpconnector (11. (2) - TplaCe
and check .hassIs ground
visually.
T-adapter (for OLI\

Trouble-
shooting -
tool.5
82-210 WA600-1
0
M-24 Related.electrical circuit drawing
Fuse box
CNP I
CN23
L (
Head lamp switch
Monitor
panel
CNP7
1
Lamp
2 -
I%
Fuse box
CNPB
Lamp
-
D
CNP 9
\
Lamp
-J
CNP6 :N22
2
Service
meter g lamp
3
Ek I z Working lamp
CNP 3
\ 1
Monitor
panel
426F525
WA600- I 82-211
@a
POSlTlON (ENGINE STOPPED),
BUZZER DOES NOT SOUND FOR 1 SEC.
CAUTION ITEM IS FLASHING BUT BUZZER
DOES NOT SOUND.
to the connector specified. (CN 0 n ( 1)
checking, then go to the next check. Remedy
The buzzer does not sound for charge level and fuel level of
CAUTION items.
Connect CNP4
ifemalei (8) and Defectwe contact. or
chassis ground Does YES disconnectvx7 in wiring &a” (defectwe
2 r harness between CN 148 :ontact) or replace
(male) - CNP4 (female) (8)
T-adapter to
CNP4 (female1 N
2) Connect CNP4 Defective alarm buzz% ReplaCe
(8) to chassis
around
31 iurn stamng
swtfch ON Defective contact, or
After inspection.
L disconnection in wiring
repair (clean) or
1) Turn stan,ng NO harness between CN150
replace
switch ON. (female) - f24V line.
2) Is reading 20.-
3ov7
M-26: NO ABNORMALITY IS SHOWN ON MONITOR

DISPLAY, BUT ALARM BUZZER SOUNDS.
* The alarm buzzer sounds when the parking brake is applied
and the transmission is in any position except NEUTRAL.
2 YES
Defective alarm buzzer Rt?Pli3Ce

ground and wiring harness After inspectvan.
between CNP4 (female) (8) repair (clean) or
- CN148. WhX
1) Disconnect CNP4
Defective monitor panel ReplXe
(female).
2) Turn starting
switch ON.
T-adapter or socket adapter Wiring harness with

Trouble- (for Econoseal) crocodile clip
shooting
tools
T-adapter (for DLI)
82-212 WA600-1
@
M-25, 26 Related electrical circuit drawing
+24V
I CNI 50
CNP4
Alarm buzzer
I CN148
425FO1367A
WA600-1 82-213
@t
WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.
CAUTION ITEM IS FLASHING BUT WARNING LAMP
DOES NOT FLASH.
to the connector specified. (CNOA ( 1)
sr When disconnecting connectors or connecting T-adapters,
Cause Remedy
YES
Defectw monitor panel ReplWe
Warning lamp bulb broken. or

defectwecontact. or After Inspect,on.
3 YES dlsconnecbon in wlrmg harnes repw &an) or
Does warning lamp
II between CN17 (male) (1) - reDlaCe
light up’ lamp. or CNl 7 (male) (2) -
1) Connect 3efectlve contact. or After wqe.ctvn

T-adapter to disconnection I” wiring harnes repaIr (clean) or
CNP4 (female). Detween CN 17 (female) 121 -
2) Connect CNP4 :hassis ground
lfemalel (71 to h
chassrs ground.
3) Turn starting After ,nspect,on.
harness between CNP4
switch ON , repair lcleani or
T-ad&r to (female) (7) - CN76
NO replace
CN17 (female). Ifemale) 12). (1)- +24v
2) Connect CNP4 iine. or between CN17
^.._^
(female) (7) to (female)(l)-w/o
chaws ground ffemalelf3l. 15) - +24v
3) Turn starting itne, or b&tive lamp relay
switch ON.

shooting .
tools T-adapter (for DLli
CN76 +24V
CNP4 CN17
1 I t Warning lamp
Monitor panel
425F534A-K
82-214 WA600-1
03
M- 28: NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,
BUT WARNING LAMP LIGHTS UP.
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents
+ When connecting the T-adapter (or socket adapter),
return ‘them to the original condition immediately after
Cause Remedy
YES
I
Does warnmg lamp

Contact
between chassis
2 YES ground and winng harness
Is there cO”tmuty - CN76 (female) (2)
11 Dsconnect CNP4 L between CNP4
lfemalel. NO Ifemale) (71 and
21 Turn starbng Chassts ground, Contact between 124’J line
and wring harness After ~“spect,on.
switch ON
between CN17 (female) (1) repaIr (clean) or
11 connect NO
T-adapter to
- CN76 (female) (3). or repl.Xe
defective lamp relay.

CNP4 (female).
21 Turn startlng
switch OFF
I
1 -adapter (for DLII
Trouble-
Short ConneCtOr
Monitor panel
425F534A.K
WA600-1 82-215
aI
M-29: ABNORMALITY IN :@ (FUEL GAUGE) SYSTEM
I
t When disconnecting or connecting the T-adapter (or socket adapter) or short connector,,or when discon-
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A ( 1)
Cause Remedy
YES
Defectwe fuel sensor RWIIXZ
1
Does fuel gauge

show FULL?
2 YES
>efective mOnltOr panel RdaCe
1) Connect short L between CNPL
connector to Iefective contact, or
NO (female) (4) and -
CN127 (female) iisconnection in wiring
chassis ground?
(fuel sensor). urness between CN127 After inspecton.
2) Turn starting 1) Connect T- NO
female) (2) - CN85 (1) - repair (clean) or
:hassis ground, or between W&%X
switch ON. adapter to CNP4
:N127 (female) (1) - CN86
(female).
3) - CNP4 (female) (4).
2) Connect short
connector to
CN127 (female).
31 Turn starting
switch OFF.
b) If indicator remains at FULL
YES
kfective fuel *ens01 RePlaCe
1 I
Does whole display

ku%xt between chassis
ground and wiring harness lfter inspection,
2 YES
xtween CNP4 (female) (4) xpair (clean) or
Is there continuity - CN86 (3) - CN127 replace
1) Disconnect between CNP4 female)(l).
CN127 (fuel r ; (female) (4) and -
SellSOr). chassis ground?
2) Turn starting
kfective monitor panel Replace
switch ON. 1) Connect T- NO
adapter to CNP4
(female).
2) Remove CN127.
3) Turn starting
switch OFF.
T-adapter (for DLI)

Troubk-
shooting
to015
Short connector
82-216 WA600-1
Q
\;.,I
CNP4 CN 66 CN127
Monitor
panel
Fuel level SenSOr
77L CN85
426F511
WA600-1 82-217
63
M-30: ABNORMALITY IN ;@’ (AIR PRESSURE GAUGE) SYSTEM
i
** When disconnecting connectors or connecting T-adapters.
Cause Remedy
YES
1efectw au pressure sensor
dd
3efect1ve monitor Panel Rf?plaCe
Jefective contact. or
disconnection !n wiring
harness between CNllD
prassure sensor). 1 I I
2) Turn starting [female)(l)-CN65(1)-
1) Connect T- NO replaCe
switch ON.
.I
CNP4 (female) (11, or
adaoter to CNP4 between CNl 10 (female) (2)
(female). - CN85 (1) -chaws
2) Connect short ground.
connector to
CNllO(female).
3) Turn starting
switch OFF.
b) If indicator remains at maximum level
YES
kfecttve ax pressure sensor
1 I
r----i1
Does whole display
area of au pressure - :ontan between chassis After inspection.
gauge go out’ 2 YES Jround and wiring harness repair (clean) or
between CNP4 (female) (1) Wpl?.Ce
- IS there continuity -CN65(1)-CNllO
1) Disconnect CNllO _ between CNP4 female) (1).
(air pressure NO (female) (1) and
sensor). chassis ground?
2) Turn starting
Iefective monitor panel
switch ON. 1) Connect T- NO
adapter to CNP4
(female).
2) Disconnect
CNllO.
3) Turn starting
switch OFF.
ITrouble- T-adapter (for DLI)
shooting
toois
i I Short connector
I
82-218 WA600-1
(18
CNP4 CN65 CN 110
Monitor
panel
CN 85
426F515
WA600-1 82-219
0
M-31: ABNORMALITY IN
n (ENGINE WATER
/$I
TEMPERATURE GAUG;) SYSTEM
to the connector specified. KN 0 A ( 1)
Cause Remedy
Defectwe engine water kDlZG

temperature sensor
Contact between chasss

ground and wiring harness After Inspection.
between CN123 (female) (1) repair (clean) or
-CN114(3)-CN84(9)- replace
CNP4 (female) (2).
temperature).
2)Turn starting
1
1) Connect T-
I INO Defective monitor panel
swtch ON. adapter to CNP4

(female).
2) Disconnect
CN123.
3) turn starting
switch OFF.
YES Defective engine water

Replace
temperature sensor
1
area of engine water

temperature gauge
1) Connect short Defective contact. or

connector to disconnection in wirina
CN123 (male). ’ harness between CNP;I
After inspection,
2) Turn starting lfemalel(21- CN84 I91 -
1 repair (clean) or
switch ON. NO CN114(3)-CN123.
1) Connect T-
(female) (1). or between
adaoter to CNW
CN123 (female) (2) -
(fen&l.
CN114(2)-CN84(10),-
2) Connect short
chassis ground.
Connector to
CN123 (female)
3) Turn starting
switch OFF
T-adapter (for DLI)

Trouble-
shooting
tools
Short cbnnector
82-220 WA600-1
@
CNP4 CN84 CN114 CN123

Engine water
temperature sensor
Monitor panel
425F521 A
WA600- 1 82-221
@
M-32: ABNORMALITY IN
” ’ (TORQUE CONVERTER OIL
C
Fzil
Remedy
“ES Defectwe torque converter oil ReDlace

1 temperature sen*or
Does torque
conveneroll
temperature gauge - Contact between chassis After ux.pect,on.
show nxnimum 2 YES ground and wiring harness repar Mean) or
level? between CN121 (female) (1) reDlace
- Is there contmwty - CN114 (5) - CN85 (4) -
1) Disconnect between CNP4 CNP4 (female) (3).
CN121 (torque N; (female1 (3) and -
converter oil chassis ground’
temperature)
Defectwe monitor panel Replace
2) Turn starting NO
1) Connect T-
switch ON
adaoter to CNP4
(female).
2) Remove CN121.
3) Turn starting
swttch OFF.
YES Defective torque converter 011

Repl.PX
1 I temperature sensor
Does whole dtsplay

area Of torque
converter 011
temperature gauge 2 YES
Defectwe monitor panel
go out)
1 Is there conbnuity
1) Connect short _ betweenCNP4 _
connector to Defectwe contact, or
NO (male) (31 and
CN121 (female). disconneclion in wirmg
chassis ground? After ,nspect,on.
2) Turn starting harness between CNP4
repav (clean) or
watch ON (female) (3) - CN85 (4) -
1, Connect T- NO
CN114(5)-CN121
adapter to CNP4
(female) (1). or between
(female). CN121 (female) (2) -
2) Connect short
CN114 18) - CN85 (6) -
connector to
chassis ground.
CN121 (female)
3) Turn start!ng
switch OFF.
T-adapter (for DLI)

;Trouble-
shootmg
82-222 WA600-1
@
Torque converter
CNP4 CN85 CNI 14 CN 121
I oil temperature sensor
Monitor
panel
426F516
WA600-1 82-223
@
ELECTRIC AND ELECTRONIC
SYSTEM
MACHINE MONITOR
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-2
Installation . . . .. . 83-2
WA600- 1 83-l
@
REMOVAL OF MACHINE MONITOR
Stop the machine on level ground and install the

A! safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
. Disconnect the cable from the negative (-) terminal of

the battery.
1. Covers
Remove covers (1) and (2) of machine monitor.
2. Wiring
Disconnect the following wirings from connector.
Connectors (3) and (4) for CAUTION 2 module
Connectors (5) and (6) for CAUTION 1 module
Connector (7) for speedometer module
Connector (8) for service meter
Connectors (9) and (10) for gauge module
Connectors (11) and (12) for check module
After disconnecting the connectors, mark with a tag
to distinguish when installing.
3. Machine monitor
Remove mounting bolts, then remove machine monitor
(13).
* When removing the machine monitor, be careful not
to give it any sudden shock.
INSTALLATION OF MACHINE
MONITOR
1. Machine monitor
Set machine monitor (13) in mounting position and
install.
* Be careful not to tighten the screw too much.
2. Electric wiring
Connect the following electric wirings to machine
monitor.
* Connectors (11) and (12) for check module
- Connectors (9) and (10) for gauge module
- Connector (8) for service meter
* Connector (7) for speedometer module
- Connectors (5) and (6) for CAUTION 1 module
* Connectors (3) and (4) for CAUTION 2 module
* After inserting the connectors, apply the connector
lock securely. Assemble so that there is no strain on
the wiring.
3. Covers
Install covers (1) and (2) of machine monitor.
WA600- 1
*$I2 X.2’
91 OTHERS
Cab ............................. 91- 2

Air conditioner ..................... 91- 3
l Air conditioner wiring diagram ....... 91- 4
l Air conditioner electric circuit ........ 91- 5
l Air conditioner unit ............... 91- 6
l Compressor ..................... 91- 8
l Condenser ...................... 91- 9
l Dry reservoir .................... 91-10
WA600- 1 91-1
0
CAB

426F139
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
View 2
91-2 WA600- 1
0
F42601047
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
View 2
WA600-1 91-2-1
@
AIR CONDITIONER
For DAIKIN air conditioner
I_
For DENS0 air conditioner
F42601048.K
1. Air vent A. Water inlet port
2. Air conditioner unit 6. Water outlet port
3. Dry reservoir C. Cooler inlet port
4. compressor D. Cooler outlet port
5. Tube
6. Tube
7. Condenser
WA600- 1
91-3
0
AIR CONDITIONER WIRING DIAGRAM
3abin unit
Side condenser unit

1 1
7/8-14CiNF
--I I
/’
Screw 718-l 4UN F
-
423F165
91-4 WA600- 1
0
AIR CONDITIONER ELECTRIC CIRCUIT
Blower box
Cab unit
- -
Condensor fan motor
Compressor
426F143A
(Condenser end1
I~=WY =IIUI (Reznd)
Air-cclnditioner relay
Blower unit
Blower switch
L---__-_--_A/C switch
_~_
(Switch end) (Switch end) (Air conditioner

unit end)
WA600- 1
AIR CONDITIONER UNIT
Function Cooling
* The air conditioner acts to reduce operator fatigue by * The refrigerant gas is compressed and pressurized in
providing the operator with a comfortable operating air conditioner compressor. It then enters the air
environment. conditioner condenser where it is cooled, and goes to
air conditioner unit.
Heating The fan blows out cold air, the temperature of the
* The heating system uses the engine cocling water. refrigerant gas rises and it returns to the compressor.
Hot water enters the air conditioner unit from hot
water outlet port (2). A fan blows hot air out. The
temperature of the cooling water goes down, it re-
turns to inlet port (1) and then flows back to the
engine cooling circuit.
426F142
1. Hot water inlet port 4. Refrigerant gas outlet port

2. Hot water outlet port 5. Condensation drain port
3. Refrigerant gas inlet port
91-6 WA600- 1
ri
./
15
423F630
1. Temperature requlator lever 6. Connector 11. Refrigerant gas inlet port

2. Mode selector lever 7. Air conditioner relay 12. Refrigerant gas outlet port
3. Air conditioner switch 8. Condenser relay 13. Drain pipe
4. Blower switch 9. Hot water pick-up port 14. Heater coil ass’y
5. RECIRC/FRESH selector cable 10. Hot water return port 15. Evaporator ass’y
WA600- 1 91-7
0
COMPRESSOR
I 1. Charge valve
2. Clutch
3. Front head .
4. Case
A. Air outlet port
B. Air inlet port
423F163
1. Discharge service valve
2. Suction service valve
3. Clutch
4. Oil plug
423F632
WA600- 1
91-8
0
CONDENSOR
Condenser motor
3
1, 2
/
2. Fan
3. Refrigerant gas inlet

port
4. Refrigerant gas outlet

Pofl
423F162
1. Refrigerant gas inlet

port
3. Fan
4. Refrigerant gas outlet

port
423F631
WA600- 1 91-9
0
DRY RESERVOIR
1. Body
2. Sight glass
3. Drier
4. Filter
423F164
1 z 2
1. Body
View 2 2. Sight glass
3. Drier
4. Drier
423F633
WA600- 1
OTHERS
CAB
Removal ......................... 93- 2
Installation....................... 93- 3
(For DAI KIN air Conditioner)
Removal ............ . ............ 93- 4
Installation ....................... 93- 6
(For DENS0 air conditioner)
Removal ......................... 93- 8
Installation ....................... 93-10
AIR CONDITIONER CONDENSER
Removal ......................... 93-12
Installation ....................... 93-12
DRY RESERVOIR
Removal ......................... 93-13
Installation ....................... 93-13
COMPRESSOR FOR AIR CONDITIONER
(For DAI KI N air conditioner)
Removal ......................... 93-14
Installation ....................... 93-14
COMPRESSOR FOR AIR CONDITIONER
Removal ......................... 93-15
Installation ....................... 93-16
WA600-1
REMOVAL OF CAB

1. Electric wiring
1) Remove mounting bolt, then remove arm rest
(1).
2) Remove mounting screw, then remove cover (2).
3) Disconnect electric wiring from connector (3).
2. Cab
1) Remove cap, then remove mounting bolts (4),
(5) and (6).
* There are 2 mounting bolts on both sides of
the rear of the cab, so do not forget to remove
them.
2) Lift off cab (7).

* Lift off the cab evenly.
&I Cab: 310 kg
9&,2 WA600- 1
INSTALLATION OF CAB
1. Cab
1) Sling cab (7) and set in mounting position.
* Coat the seal evenly with adhesive compound
& Seal : Adhesive compound

(cemedine 366E)
2) Tighten mounting bolts (6). (5) and (4), and

assemble cap.
2. Electric wiring . ‘. L-1

__ ;_
_.__
n
L
1) Connect electric wiring at connector (3). \
2) Tighten mounting screw and install cover (2).
3) Install arm rest (1).
WA600- 1
9;.-3
12‘
REMOVAL OF AIR CONDITIONER UNIT
(For DAIKIN air conditioner)
little, and drain.
1. Air conditioner, heater hoses

1) Disconnect air conditioner hoses (1) and (2) from
bottom of air conditioner unit.
* After disconnecting the air conditioner hoses,
cover the openings to prevent dirt and water from
entering.
2) Loosen clamps of heater hoses (3) and (4), then dis-
connect hoses.
2. Operator’s seat
Remove operator’s seat.
Operator’s seat: 40 kg
3. Arm rest, covers and seat support

1) Remove arm rests (5) and (6), then remove covers
(7) and (8).
2) Remove cover (9) and seat support (10).
4. Electric wiring
Disconnect the following electric wiring from connector.
* Wiring (11) for cab
* Wirings (12), (13), (14) and (15) for front and rear.
* Remove the plate inside the tool box and push to
the front, then disconnect wiring.
WA600- 1
6. A.P.S. electric wiring
Disconnect A.P.S. electric wiring (29), (30), (31) and
(32) from connector.
7. Filter, blower box

1) Disconnect ventilation-selector cable (17) from lever.
2) Disconnect electric wirings from connectors (18),

(19), (20) and (21).
* Remove the clamp of cab wiring (22), then move
it towards the air conditioner unit.
3) Remove mounting bolts, then remove filter and

blower box (23).
* Be careful not to damage the seal at the contact
surface with the air conditioner unit.
8. Air conditioner unit

I) Disconnect connectors (24), (25) and (26) for cab
wiring and wiring (27) for radio antenna.
2) Remove mounting bolts, then remove air conditioner

unit (28).
* Move the air conditioner unit outside the cab, then
lift off.
* Be careful not to damage the connector of the air
conditioner hose.
Air conditioner unit: 115 kg
WA600- 1
INSTALLATION OF AIR CONDITIONER UNIT
1) Set air conditioner unit (28) in mounting position,
2) Connect connectors (241, (25) and (26) for cab

wiring and wiring (27) for radio antenna.
2. Filter, blower box

1) Set filter and blower box (23) in mounting position,
* Be careful not to damage the seal at the contact
surface with the air conditioner unit when instal-
ling.
2) Connect connectors (18). (191, (20) and (21) of

electric wiring.
* Install clamp of wiring (22) for cab.
3) Connect ventilation-selector cable (17) to lever.
3. A.P.S. electric wiring

Connect A.P.S. electric wiring (32), (31). (30) and (29)
to connector.
93-6
9.
4. Circuit breaker
install circuit breaker (16).
5. Electric wiring
Connect the following electric wirings to connector.
- Wirings (12). (13), (14) and (15) for front and rear
* Wiring (11) for cab
t install the plate inside the tool box.
6. Arm rests, covers, seat support

I) Set seat support (10) in mounting position, and
install cover (9).
2) Fit covers (7) and (8). then install arm rests (5) and
(6).
Install operator’s seat.

1 ) Connect heater hoses (3) and (4). then tighten clamp.
2) Connect air conditioner hoses (1) and (2) to bottom
of air conditioner unit.
* To prevent water or dirt and dust from entering,
do not remove the covers from the hoses until just
before installing them.
* Hold the hoses securely with a wrench to prevent
them from twisting when they are tightened.
/; Hose connector, flared part: Compressor oil
D Hose (1) nut: 3.7 ir 0.4 kgm
w Hose (2) nut: 5.6 ? 0.6 kgm
9. Filling with gas

Fill with air conditioner gas.
- Connect cable to negative (-1 terminal of battery.
WA600- 1
REMOVAL OF AIR CONDITIONER UNIT
A Stop the machine .on level ground and install the
the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels to
prevent the machine from moving.
. Disconnect the cable from the negative (-) terminal

of the battery.
- Remove the cover under the cab.
. Loosen air conditioner hoses (1) and (2), and drain
the gas from the air conditioner.
* Do not disconnect the hose completely. Loosen
a little, and drain.

1) Disconnect air conditioner hoses (1) and (2)
from bottom of air conditioner unit.
* After disconnecting the air conditioner hoses,
cover the openings to prevent dirt and water
from entering.
2) Loosen clamps of heater hoses (3) and (4). then
disconnect hoses.
Remove operator’s seat (5).
* Pull the operator’s seat out to the ladder, then
lift it off.
+ Be careful not to hit the glass in the cab door
when lifting off.
Operator’s seat: 40 kg
426FO1223
3. Armrest, covers
Remove armrest (6). then remove covers (7) and
(8).
426FO1228
4. Electric wiring
Disconnect the following electric wiring from the
connector.
Wiring (9) and (IO) for wiper
Wiring (11) for air conditioner relay
Wiring (12), (13), and (14) for radio
Wiring (15) for air conditioner unit
Wiring (16) for radio antenna
Wiring (17) for air blower
Wiring (19) for intermittent wiper relay (for
machines with intermittent wiper)
Wiring (20) for condenser relay
Remove the clamps after disconnecting the con- 426FO1224
nectors.
5. Blower
1) Disconnect cable (18), and remove damper
(21A).
2) Remove mounting bolts, then remove blower
(21).
* Be careful not to damage the seal on the
mating face with the air conditioner unit.

Remove mounting bolts (22). then remove air con-
ditioner unit (23).
* Move the air conditioner unit outside the cab,
then lift it off.
* Be careful not to crush the air conditioner hose
joints.
Air conditioner unit: 23 kg
22
426FO1225
WA600-1
9%9
INSTALLATION OF AIR CONDITIONER UNIT

Set air conditioner unit (23) in mounting position,
and tighten mounting bolts (22).
22
426FO1225
2.
1) Set blower (21) in mounting po sition, and
* Be careful not to damage the seal at the con-
tact surface with the air conditioner unit
when installing.
2) Install damper (21A), and connect cable (18).
3. Electric wiring
Connect the following electric wiring to the con-
nector.
- Wiring (20) for condenser relay
* Wiring (19) for intermittent wiper relay (for ma-
chines with intermittent wiper)
- Wiring (16) for radio antenna
- Wiring (17) for air blower
* Wiring (12). (13). and (14) for radio
* Wiring (15) for air conditioner unit
- Wiring (11) for air conditioner relay
- Wiring (9) and (10) for wiper
* Install the clamps after connecting the con- 426FO1224
nectors.
4. Armrest, covers
Fit covers (7) and (8), and install armrest (6).
426FO1228
WA600-1
Install operator’s seat (5).
426FO1223

1) Connect heater hoses (3) and (4), then tighten
clamp.
2) Connect air conditioner hoses (I) and (2) to
bottom of air conditioner unit.
* To prevent water or dirt and dust from enter-
ing, do not remove the covers from the hoses
until just before installing them.
* Hold the hoses securely with a wrench to
prevent them from twisting when they are
tightened.
& Hose connector, flared part:

Compressor oil
m Hose (I) nut: 1.35kO.15 kgm
w Hose (2) nut: 3.25 f 0.25 kgm
7. Filling with gas

Fill with air conditioner gas.
* For details, see the separate AIR CONDI-
TIONER volume.
. Connect cable to negative (-) terminal of battery.

. Install the cover under the cab.
WA600-1
REMOVAL OF AIR CONDITIONER CONDENSER
A Stop the
safety
machine
bar on the frame.
on level ground and install the
Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
1. Open cover (1).
2. Disconnect electric wiring (2) from connector.
3. Loosen air conditioner hoses (3) and (4). and drain air
conditioner gas.
‘* Do not disconnect the hose completely. Loosen it
slightly to drain the gas.
* After draining the air conditioner gas, disconnect
hoses (3) and (4).
* After disconnecting the hoses, fit covers to the con-
nectors and hoses to prevent water or dirt and dust
from entering.
4. Remove mounting bolts, then remove air conditioner

condenser (7).
INSTALLATION OF AIR
CONDITIONER CONDENSER
1. Set air conditioner condenser (7) in mounting position,
2. Connect air conditioner hoses (3) and (4).

+ To prevent water or dirt and dust from entering, do
not remove the covers from the hoses until just
6 Hose connector, flared part: Compressor oil
w Hose (3) nut: 5.6 * 0.6 kgm

w Hose (3) nut: 2.25 f 0.25 kgm

w Hose (4) nut: 3.7 + 0.4 kgm

D Hose (4) nut: 1.35 t 0.15 kgm

3. Connect electric wiring (2) to connector.
4. Close cover (1)
5. Fill air conditioner with gas.

* For details, see the separate AIR CONDITION-
ER volume.
i
93F WA600- 1
REMOVAL OF DRY RESERVOIR
A Stop the
safety
machine
bar on the frame.
on level ground and install the
Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
1. Open cover (1).
3. Loosen air conditioner hoses (4) and (5), and drain air
conditioner gas.
Do not disconnect the hose completely. Loosen it
slightly to drain the gas.
After draining the air conditioner gas, disconnect
hoses (4) and (5).
After disconnecting the hoses, fit covers to the
connectors and hoses to prevent water or dirt and
dust from entering.
4. Remove clamp, then remove dry reservoir (6)
INSTALLATION OF DRY
RESERVOIR
1. Set dry reservoir (6) in mounting position, and tighten

clamp.
2. Connect hoses (4) and (5).

* To prevent water or dirt and dust from entering, do
not remove the covers from the hoses until just
a Hose connector, flared part: Compressor oil
w Hose (4), (5) nut: 3.7 + 0.4 kgm

(For DAI KIN air conditioner)
w Hose (4), (5) nut: 1.35 ? 0.15 kgm
3. Connect electric wiring (3) to connector.
4. Close cover (1).
5. Fill with air conditioner gas.

* For details, see the separate AIR CONDI.
TIONER volume.
WA600- 1
REMOVAL OF COMPRESSOR FOR AIR CONDITIONER
(For DAI KIN air conditioner)
A Stop
safety
the machine
bar on the frame.
on level ground
Lower
and install
the bucket to the
the
ground and sto the engine. Then apply the parking

brake and put blocks under the wheels to prevent
the machine from moving.
2. Loosen hoses (2) and (3), and drain gas from air condi-
tioner.
* When draining the gas, do not completely disconnect
the hoses. Loosen them slightly.
* After draining the gas, disconnect hoses (2) and (3).
* After disconnecting the hoses, cover the operatings
to prevent dirt and water from entering.
3. Remove bolts (41, (5) and (61, remove V-belt, then

remove compressor (7) of air conditioner.
* There is little space, so be careful when working.
INSTALLATION OF
COMPRESSOR FOR AIR
CONDITIONER
1. Set compressor (7) of air conditioner in mounting posi-
tion, fit V-belt (81, then secure with bolts (41, (5) and
(6).
+ Clearance “a” between bracket ancd compressor for
air conditioner: “a” = Within 0.6 mm.
l For details of adjusting V-belt, see TESTING AND
ADJUSTING.
w Mounting bolt of bracket: 5.5 ? 0.5 kgm
2. Connect hoses (2) and (3).

* To prevent dirt and water from entering the hoses,
do not remove the covers until just before installing.
* To prevent the hoses from twisting, hold them secure-
ly with a wrench when tightening.
K‘ Hose connector thread, flare: Compressor oil
m Hose (2) nut: 5.6 i 0.6 kgm
m Hose (3) nut: 7.0 + 0.7 kgm
3. Connect electric wiring (1) at connector.
4. Fi!i air conditioner with gas.
421 F3060
93-l 4 WA600- 1
p
REMOVAL OF COMPRESSOR FOR AIR CONDITIONER
A Stop the machine on level ground and install the

the ground and stop the engine. Then apply the
parking brake and put blocks under the wheels to
prevent the machine from moving.
1. Electric wiring
Disconnect electric wiring (I) from connector.
2. Air conditioner hose

Loosen hoses (2) and (3). and drain gas from air
Serial No. 10001-l 0880
conditioner.
* When draining the gas, do not completely dis-
connect the hoses. Loosen them slightly.
* After draining the gas, disconnect hoses (2) and
(3).
* After disconnecting the hoses, cover the operat-
ings to prevent dirt and water from entering.
3. Air compressor (Serial No. 10001 - 10880)

1) Loosen bolt (5), and remove V-belt.
* Remove clamp (9).
2) Remove mounting bolts (7), then remove air
compressor (8).
3A. Air compressor (Serial No. 10881 and up)

1) Loosen bolt (6). and remove V-belt.
* Remove clamp (9).
2) Remove bolt (6), then remove air compressor
(8).
* The working space is confined, so carry out the
work carefully.
Serial No. 10001-l 0880 Serial No. 10881 and up
426FO1226 426FO1227
WA600-1
INSTALLATION OF COMPRESSOR FOR AIR CONDITIONER
Serial No. 10001-10880
1. Air compressor (Serial No. 10001 - 10880)

1) Set air compressor (8) in mounting position, and
secure with mounting bolts (7).
2) install V-belt, and secure with bolt (5).
* install clamp (9).
* Adjust the V-belt.
IA. Air compressor (Serial No. 10881 and up)

1) Set air compressor (8) in mounting position, and
secure with bolts (6).
426FOl226
* Tighten bolts (6) temporarily. Serial No. 10881 and up
2) Install V-belt, and secure with bolts (6).
* Adjust the V-belt.
2. Air conditioner hose

Connect hoses (2) and (3).
* To prevent dirt and water from entering the
hoses, do not remove the covers until just before
installing.
* To prevent the hoses from twisting, hold them
securely with a wrench when tightening.
f-_ Hose connector thread, flare: 426FO1227
Compressor oil Serial No. 10001-10880
w Hose (2) nut: 2.25 f 0.25 kgm
m Hose (3) nut: 3.25 ? 0.25 kgm
3. Electric wiring
Connect electric wiring (I) at connector.
4. Fill air conditioner with gas.

* For details, see the separate AIR CONDI-
TIONER volume.
93-l 6
‘F,
GEAR PUMP
97 GENERAL
General . . . . . . . . . . . . . . . . . . . 97-002
Principle of operation ................. 97-003
Pressure loaded type gear pump .......... 97-006
Fixed side plate type gear pump .......... 97-008
GEAR PUMP 97-00 7

GEAR PUMP GENERAL
GENERAL
The hydraulic pump is a device which receives mechani- Gear pumps installed on KOMATSU machines are called
cal energy from a prime mover such as an engine, converts KOMATSU standard pumps. They are designated as
the energy into fluid energy, and functions as the source follows.
of energy in a hydraulic system.
The fluid energy can be divided into the energy of
velocity, pressure, and potential. Almost all of the fluid
energy used for hydraulic pressure is pressure energy.
The hydraulic pump receives and transmits the energy S: For high pressure: 210 kg/cm’,
through the static pressure of a fluid, and easily produces pressure loaded type
a high pressure since its delivery is determined by the ? K: For high pressure: 175 kg/cm’,
transfer of volumetric displacement enclosed by the (210 kg/cm2 for some pumps)
fixed walls. Therefore,
significantly
It follows
the pump delivery is not changed
with variations in the load.
that the pump itself is a device whicfi makes
the oil flow, rather than a device to produce pressure.
c pressure loaded type
P: For medium pressure:
(155 kg/cm*
140 kg/cm2
for some pumps)
pressure loaded type
The pump pressure is generated by the resistance (the G: For medium pressure: 125 kg/cm2,
load) against the oil flow. Therefore, when there is no fixed side plate type
resistance, no pressure is produced. F: For low pressure (30kg/cm2),
Structurally, hydrau!ic pumps can be broadly classified fixed side plate type
into rotary pumps and reciprocating pumps. Functionally,
- f- A: Flange type mount section
they can be classified into fixed displacement pumps
and variable displacement pumps. B: Foot type mount section
The hydraulic pumps used in construction machinery
are external gear pumps and are classified as fixed
displacement rotary pumps.
External gear pumps employ involute spur gears, and
- f- L: Counter-clockwise rotation
can be structurally classified into the following types.
l Type of side plate adjustment R: Clockwise rotation
Fixed side plate type (FAL, FAR)
(GAL, GAR)
Pressure loaded type (PAL, PAR)
(KAL, KAR) Theoretical pump delivery at
-
(SAL, SAR) 1,000 rpm (liters/min)
I Pressure plate type
0 Type of bearing
Ball or roller bearing type
t Plain bearing type
97-002 GEAR PUMP

GEAR PUMP PRINCIPLE OF OPERATION
PRINCIPLE OF OPERATION
0 MECHANI’SM FOR DELIVERING OIL

The drawing at right shows the operational principle
of an external gear pump in which two gears are
rotating in mesh.
The oil entering through the suction port is trapped
Suction Discharge
in the space between two gear teeth, and is delivered
to the discharge port as the gear rotates.
Except for the oil at the bottom of the gear teeth,
the oil trapped between the gear teeth is prevented
from returning to the suction side with the gears 23QFl37
in mesh.
Since the gears are constantly delivering oil, the oil
delivered to the discharge port is forced out of
the port.
The amount of discharge increases with the speed
of rotation of the gear.
If,there is no resistance in the oil passage into which
the discharged oil flows, the oil merely flows
through the passage, producing no increase in
pressure.
If, however, the oil passage is blocked with some- 23OF138
thing like a hydraulic cylinder, there will be no
other place for the oil to flow, so the oil pressure
will rise. But the pressure which rises in this way
will never go higher, once the hydraulic cylinder
piston starts moving because of the oil pressure.
As described earlier, the pump produces the oil
flow, but not the oil pressure. We can therefore
conclude that pressure is a consequence of load.
In other words, the pressure depends on a counter-
part.
23OF139
23OF140
GEAR PUMP 97-003

l INTERNAL OIL LEAKAGE

Oil leaks from a place under higher pressure to a
place under lower pressure, provided that a gap or
a clearance exists in between.
In the gear pump, small clearances are provided
between the gear and the case and between the gear
and the side plate to allow the oil to leak out and
to serve as a lubricant so that the pump will be
protected from seizure and binding.
The drawing at right shows how the leaked oil
flows in the pump. As such, there is always oil
leakage in the pump from the discharge side (under
higher pressure) to the suction side. The delivery
of the pump is reduced by an amount equal to the
pump discharge.
In addition, the delivery of the pump will also
decrease as the amount of oil leakage increases
because of expanded radial clearance resulting from
the wear of pump parts, the lower oil viscosity
resulting from increases in the oil temperature, and
23OF141
the initial use of low viscosity oil.
0 FORCES ACTING ON THE GEAR

The gear, whose outer surface is subjected to oil
pressure, receives forces poining towards its center.
Due to the action of the delivery pressure, the oil
pressure is higher on the delivery side of the pump,
and, due to suction pressure, is lower on the suction
side. In the intermediate section, the pressure will
gradually lower as the position moves from the
delivery side to the suction side. This phenomenon
is shown in the drawing at right.
In addition, the gears in mesh will receive interact-
ing forces.
These forces pushing the gears toward the suction
side are received by the bearings. Since the gears are scharge side
pressed toward the suction side by these forces, the

radial clearance becomes smaller on the suction side
in the case. In some pumps (PAL, PAR, KAL, KAR),
the clearance may become zero, thus allowing the
gear teeth and the case to come into light contact.
For this reason, an excessive increase in the delivery
pressure must be avoided, since it will produce a
large force which will act on the gears, placing an
overload on the bearings, and resulting in a shortened re distribution
service life of the bearing or interference of the gear
with the case.
23OF142
97-004 GEAR PUMP

0 “TRAPPING” PHENOMENON OF THE OIL

When a gear pump is rotating with the gears in mesh
as shown in the drawing at right, in some instances
two sets of gear teeth are in mesh while in other
instances only one set of the gear teeth is in mesh.
Suction side
When two sets of the teeth are in mesh simultaneous-
ly, the oil in the space between the meshed gear
teeth will be trapped inside - the front and rear
exits will be completely shut.
This is called the “trapping” phenomenon of oil.
The space in which the oil is trapped moves from Trapping starts
the suction side to the delivery side as the gears
rotate. The volume of the space gradually decreases
from the start of trapping until the space reaches the
center section, and then gradually increases after
leaving the center section until the end of trapping. The space reaches
the minimum
Since the oil itself is non-shrinkable, a reduction of
the volume of space will greatly increase the oil
pressure, unless some prosion is made to relieve oil
Trapping ends
pressure. The high pressure oil will cause the pump
to make noise and vibrate.
To prevent this, relief notches are provided on the
side plates to release the oil to the delivery side.
As shown in the drawing below, the relief notches
are provided in such a way that the oil can be
relieved from the trapping space to the delivery side
when the volume of the space is reduced.
Relief notches are also provided on the suction side 23OF143
to prevent the formation of a vaccum in the space
by allowing the oil to enter the space from the
suction side when the space is expanded.
Fixed side plate type Pressure loaded type
Side plate 4
Bushing
23OF144 23OF145
GEAR PUMP 97-005

GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
PRESSURE LOADED TYPE GEAR PUMP
‘9
23OF146
GENERAL DESCRIPTION
Hydraulic pumps used for the work equipment 1. Drive gear
hydraulic units on construction machinery are 2. Bracket
pressure loaded type gear pumps. Some gear pumps 3. Bushing
of this type have a maximum delivery pressure of 4. Gear case
210 kg/cm2 or higher. 5. Cover
The pressure loaded type gear pump is designed so 6. Seal plate
that the clearance between the gear and the side 7. Collar
plate can be automatically adjusted according to 8. Back-up ring
the delivery pressure. Therefore, the oil leakage 9. Driven gear
from the side plate is less than that in the case of
the fixed side plate type under a high discharge
pressure. Consequently, no significant reduction of
the pump delivery occurs, even when the pump is
operated under high pressure.
97-006 GEAR PUMP

GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
STRUCTURE AND OPERATION

In a pressure loaded type pump, two bushings acting
as side plates are inserted into the pump case, and
are pressed toward the sides of the gears. The oil
leakage from the gear sides is thus minimized.
Since the bushings are constantly pressed toward
the gears by the oil pressure, there is no fear of an
increase in oil leakage, even when the bushings
are worn out and the clearances are expanded many
hours of operation.
The bushings are pushed towards the gears from the
cover side by the oil pressure, and they are pushed
from the gear side by the pressure of oil trapped
between the gear teeth and that which has leaked
out from the clearance between the gear and the
bushing.
Since the oil pressure in the gears is higher on the
pump delivery side and is lower on the suction side,
provisions are made so that the pressing force acting
on the bushings from the cover side is regulated
in such a way that the delivery side is pressed harder
and the suction side weaker to match the counter
pressure.
More specifically, .the area of the bushing on the
discharge side is made larger than that on the
suction side by partitioning the area of the bushing
subjected to pressure on the cover side, with a back-
up ring installed to the seal plate as shown in
the drawing at right.
When the pump is operated at high speed, the
pressure on the suction side is lowered and the distri-
bution of pressure around the periphery of the
gear will change into the state shown in the drawing
at right below.
\
Pressure balance grooves are therefore provided on
Discharge
the bushings to keep the balance of the force on without balance groove
the cover side against the pressure acting on the \ (high speed)
bushing from the gear side that varies with the

pump rotation and the pressure distribution. Thus
the delivery pressure is led as shown in the drawing 05F140
and the pressure distribution is stabilized at any
rotational speed.
GEAR PUMP 97-007

GEAR PUMP FIXED SIDE PLATE TYPE GEAR PUMP
FIXED SIDE PLATE TYPE GEAR PUMP
GENERAL DESCRIPTION
Hydraulic pumps used for the main clutch, trans- I. Drive gear
mission, and steering system on bulldozers are 2. Bracket
fixed side plate type gear pumps which can be 3. Gear case
classified as follows: pumps generally called FAL or 4. Cover
FAR pumps having a maximum delivery pressure of 5. Driven gear
30 kg/cm* and pumps generally called GAL or GAR
pumps having a maximum delivery pressure of
125 kg/cm*.
Since the bracket and the case cover serve as the side
plates and the gear teeth bottom land is closer to
the outer race of the bearing in the case of the
fixed side plate type gear pump, oil leakage is liable
to occur at the clearance between the gear and the
side plate. However, this is only a small problem,
as the pump is used for steering control which is
operated at a low service pressure.
97-008 GEAR PUMP

GEAR PUMP
97 SA SERIES
Structure ......................... 97-102

Testing and adjusting ................. 97-105
Disassembly ....................... 97-108
Assembly ......................... 97-112
Maintenance standard ................. 97-117
GEAR PUMP 97-101

SASERIES STRUCTURE
STRUCTURE
Side plate
FEATURES
The gear pump is a high quality, reliable product that is

specially designed for use in construction equipment 3
which works under severe conditions.
l The side plate, given surface treatment to improve
its matching characteristics with the special copper
alloy, ensures minimum torque loss and excellent
wear resistance.
0 With the improved hydraulic balance mechanism,
the pump offers stable performance and high
durability.
2OOF132
STRUCTURE
9,lO 8 1. Drive gear

2. Driven gear
t_\ i 3. Snap ring
4. Oil seal
5. Plate
6. Bracket
7. O-ring
8. Side plate
9. Back-up ring
10. Seal ring
11. Gear case
12. Side plate
13. Back-up ring
14. Seal ring
15. Cover
16. O-ring
17. Bolt
18. Dowel pin
21FO23
97-102 GEAR PUMP

SASERIES STRUCTURE
SA-1 Series single pump
26.2
----_I 06.4 --I -1
*m_: _--_--___B----_I
Depth: F Delivery port
(The drawing above shows a pump of the counter-clockwise rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
SA-2 series single pump
0 Side port type
Delivery Port
0 Rear port type
,_--_-----,,4--_~_
,_-p-~- -,46--,
GEAR PUMP 97-103

SA SERIES STRUCTURE
0 Side port type
Delivery port
Depth -: F
:----75 -~-.- -55--i
0 Rear port type
_~~~_~ _~*,3~. -- -,
-___A’_ _
(The drawing above shows a pump of the counter-clockwise rotation type: In a clockwise
35.8
Delivery port
F
(Note) Dimensions A through H in the drawings vary with the pump capacity.
97- 104 GEAR PUMP

SA SERIES TESTING AND ADJUSTING
TESTING AND ADJUSTING

Measure
the pump delivery with a test bench or flow meter kit (790-303-1001).
% See Note on page 97-107. The capacity codes marked * are for triple pumps.
No. Check item

Series apacity
Delivery
pressure
Rotation
Standard
Delivery
r Repair limit
Rotation Delivery
No. code
lkg/cm*) literslmin)
(rpm) ( literslmin) (rpm)
'erformance 008 25 23
Hydraulicoil: ’ 010 32 29
f
EOlO-CD 012 38 34
Oil temperature: 014 210 3500 47 43
50°c 016 52 48
020 66 61
025 83 76
l 016 44 40
*020 55 50
l 025 67 62
028 77 71
2 032 210 3000 88 3000 82
036 100 92
040 Ill 103
045 121 111
050 138 128
l 020 45 42
I *025 55 51
*040 90 82
so50 112 102
056 210 129 2500 119
063 145 134
071 158 146
080 184 170
100 231 214
112 212 192

140 2000
125 236 213
112 233 215
125 253 234

2200
140 287 266
160 328 303

210
180 336 310
200 373 345
224 411 385
250 460 425
For SA pumps operating at a service pressure of 50 kg/cm’ or less, see the standard and the repair limit in Table,
No. 2. (Examples: Pumps for power traines and servo-hydraulic pumps for excavators)
GEAR PUMP 97- 105

NO Check item
Series Zapacitl
Delivery
pressure
T Standard Repair limit
NO. code Rotation Delivery Rotation Delivery

(kg/cm* 1 (litars/min) (rpm) (litersimin)
(rpmi
Performance 008 27 25
Hydraulic oil: 010 33 30
EOlO-CD 012 40 37
Oil temperature: 014 30 3500 48 3500 44
5o”c 016 54 50
020 68 63
025 86 79
* 008 23 21
* 016 47 43
* 020 59 53
* 025 72 66
028 80 74
30 3000 3000
032 92 84
036 104 95
040 115 106
045 126 115

2
050 144 132
* 020 49 44
* 025 60 55
l 040 96 88
l 050 119 109
056 30 2500 134 2500 123
063 151 138
071 164 150
080 192 176
100 241 221
112 217 198

30 2000 2000
125 240
112 242 222
125 264 242

2200
140 300 275
160 342 314

4 30
180 350 321
200 389 357

2000
224 434 398
250 480 440
97- 106 GEAR PUMP

Note 1.) If it is impossible to raise the pump speed to

the value shown in the table because of limita-
tions of the test bench, calculate the allowance
for the delivery from the following formula:
Q = Q. _ (No - N) Qth
1000
however, N => 1000 rpm

where, N: RPM of test bench
Q: Repair limit for delivery at N rpm
(Iiters/min)
No: RPM in the table
Qo: Repair limit for delivery in the table
(liters/min)
Qth: Capacity code
Note 2.) If the test bench allows the pump to raise its
delivery pressure above 140 kg/cm2 but not
above 210 kg/cm’, use the repair limit for
delivery given in Table, No. 1.
Note 3.) For pumps whose service pressure exceeds

50 kg/cm’ in operation, use Table, No. 1.
(Do not use Table, No. 2)
Note 4). The volumetric efficiency of a pump decreases

after the pump is reassembled. After reassembly,
therefore, perform the following tests with a
test bench or flow-meter kit (790-303-1001).
(1) Shock test

20 times
t 252 kg/cm’ max.
I t t _
Time
(2) Performance test (measure the delivery)
GEAR PUMP 97-107

DISASSEMBLY
c Match mark
(I) Single pump
* Cautions before disassembly
To avoid confusion in the reassembly, stamp
match marks on connecting sections of bracket
(6) to gear case (11) and gear case (11) to cover
(15). 15
6 IOOPO50
1) Put the pump assembly on a work bench with

the bracket side facing down, and loosen
mounting bolts (17) for cover (15).
t Use the bracket mounting bolt holes to secure

the pump assembly.
: j. I OOPO5 I
2) Remove cover assembly (15).

* Place the internal parts in line in the order of
removal, taking care not to damage the contact-
15
ing surfaces or sliding surfaces of the parts.
* Pull out cover assembly (15). taking care not
to damage the hole for the dowel pin. Do not
pry the cover.
I OOP052
3) Remove O-ring (16) from the cover.
I OOPO53
97- 108 GEAR PUMP

SA SERIES DISASSEMBLY
4) Pull out side plate (12) on the cover side. J”
I OOPO54
5) Remove backup ring (13) and seal ring (14).
23OF221
6) Remove drive gear (1) and driven gear (2).

* Pull out the gears by hand. Do not use a
hammer.
* If the oil seal is not replaced, tape the drive gear
and the spline section to protect the oil seal
from damage.
I OOPO55
7) Remove bracket (6) from gear case (11).

* When removing bracket (6) from gear case (111,
take care not to let side plate (8) on the bracket
side fall down and leave the side plate-installed
as is to the gear case.
* Do not hit the side plate surface.
I OOP056
GEAR PUMP 97-109

8) Pull out side plate (8) from gear case (11).
I OOPO59
97-110 GEAR PUMP

(2) Tandem pump

1) Stamp match marks.
2) Put the pump on a work bench with the front

pump bracket surface facing down, and remove
the four bolts that connect the front pump to
the rear pump.
Match
3) Disconnectthefront pump from the rear pump.
4) For the disassembly of single pumps, see the

section on single pumps.
P7050 1003‘
(3) Triple pump

Follow the same procedure for tandem pumps.
GEAR PUMP 97-111

ASSEMBLY
(1) -. pump
Single
When a used gear case is assembled, remove the
burrs from the case and make sure that the side
plate can be slided smoothly.
Make sure that the dowel pin on the case
has specified length (Q).
c Q = Lengthof dowel
2
pin
3
! OOPO60
Put cover (15) on a work bench.
2) Install side plate (12) into gear case (11) with

the seal groove facing outside.
* Do not install the backup ring and the seal to
side plate (12) at this stage.
* Do not confuse the suction side of the side
plate with the delivery side.
* Do not damage the periphery of the side plate,
especially around the seal section.
Measurement of side clearance

Temporarily assemble bracket (6) and gear case (11)
as shown in the drawing at right. Place the assembly on
a work bench and measure the difference between the
stack height including drive gear (11, side plates (8)
and (12) and the height of gear case (11).
Measure with a depth dial gauge or depth micrometer.
Judgement criteria
Confirm that the measurements conform to the standard
clearance given in the Maintenance Standard Table.
97-112
3) Install gear case (11) to cover (15) with the
match marks aligned.
4) Install drive gear (I) and driven gear (2).
IOOP064
5) Install side plate (8) with the backup and seal

ring grooves facing upward.
8
IOOP065
10 Dischargeport
6) Install backup ring (9) and seal ring (10). 9

* Install them with care to prevent gaps between
the ring and the gear case as shown in Fig. P.
* If it is impossible to eliminate the gap, replace
the seal ring and the backup ring.
Gap
Gap
23OF223
GEAR PUMP 97-113

SA SERIES ASSEMBLY
7) Apply some hydraulic oil to the shafts of gears

(1) and (2) and also to the sliding section of
the side plate.
* Take care to keep the gear case free from oil.
,,,,’I OOPo66
8) Install O-ring (7) to bracket (6).
I OOP097
9) Install bracket (6).

* Align the match marks when installing the
bracket.
* Before installing the bracket, make sure that
the seal and backup rings are properly installed
according to the precautions in item 6.
* Make sure O-ring (7) is fit properly.
* Confirm that the contact surface is free from
dirt and dust.
IO) Carefully turn the gear pump assembly upside

,,
down so that the bracket side will face down-
ward, and put the gear pump assembly on a
work bench.
,* When turning the pump upside down, take care
,”
not to let the contact surfaces open out and not
to let the O-ring and seal come off.
,,,, I OOPo99
97-114 GEAR PUMP

SASERIES ASSEMBLY
3) install the coupling to the front pump. Coupling

/
4) Fit the‘O-ring to the rear pump bracket.

5) Put the rear pump on top of the front pump. O-ring
* Take care not to let the O-ring come off. /
* Align the match marks.
~7050 IO06
6) Tighten four mounting bolts.
* Tighten the bolts with a torque wrench to
the specified torque in the order shown in the
drawing below.
Tightening order
* After the pump is assembled, carry out the Match mark

performance test (measure the pump delivery)
with a test bench or flow-meter kit (790-
303-1001). Confirm that the performance
is within the repair limits.
3) Triple pump
Follow the same assembly procedure as for the
tandem pump.
97-116 GEAR PUMP

f
SA SERIES MAINTENANCE STANDARD
MAINTENANCE STANDARD
Unit: mm
I I I
Criteria
NO Check item Series No. Remedy
Clearance
Standard clearance
limit
-
0.10 - 0.15
Clearance between the SA;020-060 0.10 - 0.15 0.19

Replace the side plate
1 gear case and the gear 3
plus the side plate SA: or the pump assembly
100 - 125 0.13 - 0.18 0.22
SAk 112 - 180 0.11 - 0.16 0.19

4
SA:, 200 - 250 0.14 - 0.19 0.22
-
1 l-1
Clearance between the
I.D. of the plain bearing
2 snd the 0.0. of the gear 2 0.06 - 0.125 0.20 Replace
shaft
3 0.06 - 0.149
I
I 4 0.06 - 0.140
I
Tightening torque for

the case mounting
301ts.
GEAR PUMP 97-117

Komatsu America international Company
440 North Fairwav Drive 1
Vernon Hills, IL U.S.A.
Attn: Technical
E
R
MACHINE MODEL:
S/N IF APPLICABLE:
PROBLEM:
Attach photo or
If more space is use sheet.
1 FOR INTERNAL
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Wa600 1 PDF

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SEBM04260111

. WA600-1 mount the S6D170-1 engine.

10 ENGINE No. of page

50 BRAKE AND AIR SYSTEM

60 WORK EQUIPMENT SYSTEM

80 ELECTRIC AND ELECTRONIC SYSTEM

LIST OF REVISED PAGES

Revisior Revisior Revision Revision Revision

0 00-I 0 12-16 @ 13-39 8 21-34 23-2-l @

23-39 0 23-94 0 24-4 0 41-33 43-3

43-54 8 52-8 43-38 @ 61-21 63-9-l @

63-46 @ 81-20 @ 82-15 @ 82-39-4 @ 82-59 0

82-113 @ 82-166 @$ 82-219 @ 97-107

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

Example 2 (Engine volume): 63 kg Weight lecting hoisting wire, or when

rightenins 1 Places that require special at-

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

10.0 as 4000 kg if they sling a 2000 kg load at a

* The allowable load value is estimated to

2) Sling wire ropes from the middle portion

LT-1A 7go-129-9030 1 150g Tube

Plastic l Used as sealant for machined holes

Lithium grease G2-LI SYG-400LI-A Various Various

. Used for normal temperature, light load bearing

Molybdenum * Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

27 41 135215 132Ok 140

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Thread diameter Width

IO 14 6.720.7 65.7 + 6.8

TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

Thread diameter rNidth across flats

14 19 2.5kO.5 24.5 It 4.9

ELECTRIC WIRE CODE

2 26 0.32 2.09 3.1

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

CLASSIFICATION BY COLOR AND CODE

White & Green

Red & Green Yellow

& Blue Green & Black

Blue & Black

METHOD OF USING THE CONVERSION TABLE

2. Convert 550 mm into inches.

Millimeters to inches 1 mm = 0.03937 in