WD600-3 Sebd022902 PDF

SEBM022902
MACHINE MODEL SERIAL NO.
WD600-3 50001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• WD600-3 mounts the SAA6D170E-3 engine.

For details of the engine, see the 6D170-3 Series Engine Shop Manual.
© 2003 1
All Rights Reserved 00-1
Printed in Japan 03-03(02) (2)
CONTENTS
01 GENERAL ............................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ........................................................... 10-1
20 TESTING AND ADJUSTING ................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
40 MAINTENANCE STANDARD ............................................................... 40-1
90 OTHERS ............................................................................................................... 90-1
00-2 WD600-3
(2)
The affected pages are indicated by the use of the
Revision Revision Mark
Revision Indication
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following
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numberIt is Mark
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tions be taken to these pages according to the table c Page to be newly added Add
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Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
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b 00-1 (2) 10-7 10-50 10-91 10-133

b 00-2 (2) 10-8 10-51 10-92 10-134
b 00-2-1 (2) 10-10 10-52 10-93 10-135
b 00-2-2 (2) 10-11 10-53 10-94 10-136
b 00-2-3 (2) 10-12 10-54 10-95 10-137
c 00-2-4 (2) 10-13 10-55 10-96 10-138
00-3 10-14 10-56 10-97 10-139
00-4 10-15 10-57 10-98 10-140
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10-35 10-76 10-118 10-159
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01-2 10-37 10-78 10-120 10-161
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20-7 (1) 20-142 (1) 20-310 (1) 20-391 (1) 20-506 (1)
20-8 (1) 20-143 (1) 20-311 (1) 20-392 (1) 20-507 (1)
20-9 (1) 20-144 (1) 20-312 (1) 20-393 (1) 20-508 (1)
20-10 (1) 20-145 (1) 20-313 (1) 20-394 (1) 20-509 (1)
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20-12 (1) 20-202 (1) 20-315 (1) 20-396 (1) 20-511 (1)
20-13 (1) 20-203 (1) 20-316 (1) 20-397 (1) 20-512 (1)
20-14 (1) 20-204 (1) 20-317 (1) 20-398 (1) 20-513 (1)
20-15 (1) 20-205 (1) 20-318 (1) 20-399 (1) 20-514 (1)
20-16 (1) 20-206 (1) 20-319 (1) 20-400 (1) 20-515 (1)
20-17 (1) 20-207 (1) 20-320 (1) 20-401 (1) 20-516 (1)
20-18 (1) 20-208 (1) 20-321 (1) 20-402 (1) 20-517 (1)
20-19 (1) 20-209 (1) 20-322 (1) 20-403 (1) 20-518 (1)
20-101 (1) 20-210 (1) 20-323 (1) 20-404 (1) 20-519 (1)
20-102 (1) 20-211 (1) 20-324 (1) 20-405 (1) 20-520 (1)
20-103 (1) 20-212 (1) 20-351 (1) 20-406 (1) 20-521 (1)
20-104 (1) 20-213 (1) 20-352 (1) 20-407 (1) 20-522 (1)
20-105 (1) 20-214 (1) 20-353 (1) 20-408 (1) 20-601 (1)
20-106 (1) 20-215 (1) 20-354 (1) 20-409 (1) 20-603 (1)
20-107 (1) 20-216 (1) 20-356 (1) 20-410 (1) 20-604 (1)
20-108 (1) 20-218 (1) 20-357 (1) 20-411 (1) 20-605 (1)
20-109 (1) 20-219 (1) 20-358 (1) 20-451 (1) 20-606 (1)
20-110 (1) 20-220 (1) 20-359 (1) 20-452 (1) 20-607 (1)
20-111 (1) 20-221 (1) 20-360 (1) 20-454 (1) 20-608 (1)
20-112 (1) 20-222 (1) 20-361 (1) 20-455 (1) 20-609 (1)
20-113 (1) 20-223 (1) 20-362 (1) 20-456 (1) 20-610 (1)
20-114 (1) 20-224 (1) 20-363 (1) 20-457 (1) 20-611 (1)
20-115 (1) 20-225 (1) 20-364 (1) 20-458 (1) 20-612 (1)
20-116 (1) 20-226 (1) 20-365 (1) 20-459 (1) 20-613 (1)
20-117 (1) 20-227 (1) 20-366 (1) 20-460 (1) 20-614 (1)
20-118 (1) 20-228 (1) 20-367 (1) 20-461 (1) 20-615 (1)
20-119 (1) 20-229 (1) 20-368 (1) 20-462 (1) 20-616 (1)
20-120 (1) 20-230 (1) 20-369 (1) 20-463 (1) 20-617 (1)
20-121 (1) 20-231 (1) 20-370 (1) 20-464 (1) 20-618 (1)
20-122 (1) 20-232 (1) 20-371 (1) 20-465 (1) 20-619 (1)
20-123 (1) 20-233 (1) 20-372 (1) 20-466 (1) 20-620 (1)
20-124 (1) 20-234 (1) 20-373 (1) 20-467 (1) 20-622 (1)
20-125 (1) 20-235 (1) 20-374 (1) 20-468 (1) 20-623 (1)
20-126 (1) 20-236 (1) 20-375 (1) 20-469 (1) 20-624 (1)
20-127 (1) 20-237 (1) 20-376 (1) 20-470 (1) 20-626 (1)
20-128 (1) 20-238 (1) 20-377 (1) 20-471 (1) 20-627 (1)
20-129 (1) 20-239 (1) 20-378 (1) 20-472 (1) 20-628 (1)
20-130 (1) 20-240 (1) 20-379 (1) 20-473 (1) 20-629 (1)
20-131 (1) 20-241 (1) 20-380 (1) 20-474 (1) 20-630 (1)
20-132 (1) 20-242 (1) 20-381 (1) 20-475 (1) 20-631 (1)
20-133 (1) 20-301 (1) 20-382 (1) 20-476 (1) 20-632 (1)
00-2-2 WD600-3
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20-634 (1) 20-811 (1) c 30-54 (2) c 30-108 (2)
20-636 (1) 20-812 (1) c 30-1 (2) c 30-55 (2) c 30-109 (2)
20-637 (1) 20-813 (1) c 30-2 (2) c 30-56 (2) c 30-110 (2)
20-638 (1) 20-814 (1) c 30-3 (2) c 30-57 (2) c 30-111 (2)
20-639 (1) 20-815 (1) c 30-4 (2) c 30-58 (2) c 30-112 (2)
20-640 (1) 20-816 (1) c 30-5 (2) c 30-59 (2) c 30-113 (2)
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20-642 (1) 20-818 (1) c 30-7 (2) c 30-61 (2) c 30-115 (2)
20-643 (1) 20-819 (1) c 30-8 (2) c 30-62 (2) c 30-116 (2)
20-644 (1) 20-820 (1) c 30-9 (2) c 30-63 (2) c 30-117 (2)
20-645 (1) 20-822 (1) c 30-10 (2) c 30-64 (2) c 30-118 (2)
20-646 (1) 20-823 (1) c 30-11 (2) c 30-65 (2) c 30-119 (2)
20-647 (1) 20-824 (1) c 30-12 (2) c 30-66 (2) c 30-120 (2)
20-648 (1) 20-825 (1) c 30-13 (2) c 30-67 (2) c 30-121 (2)
20-649 (1) 20-826 (1) c 30-14 (2) c 30-68 (2) c 30-122 (2)
20-650 (1) 20-827 (1) c 30-15 (2) c 30-69 (2) c 30-123 (2)
20-701 (1) 20-828 (1) c 30-16 (2) c 30-70 (2) c 30-124 (2)
20-702 (1) 20-829 (1) c 30-17 (2) c 30-71 (2) c 30-125 (2)
20-703 (1) 20-830 (1) c 30-18 (2) c 30-72 (2) c 30-126 (2)
20-704 (1) 20-831 (1) c 30-19 (2) c 30-73 (2) c 30-127 (2)
20-705 (1) 20-832 (1) c 30-20 (2) c 30-74 (2) c 30-128 (2)
20-706 (1) 20-833 (1) c 30-21 (2) c 30-75 (2) c 30-129 (2)
20-707 (1) 20-834 (1) c 30-22 (2) c 30-76 (2) c 30-130 (2)
20-708 (1) 20-901 (1) c 30-23 (2) c 30-77 (2) c 30-131 (2)
20-709 (1) 20-902 (1) c 30-24 (2) c 30-78 (2) c 30-132 (2)
20-710 (1) 20-904 (1) c 30-25 (2) c 30-79 (2) c 30-133 (2)
20-712 (1) 20-905 (1) c 30-26 (2) c 30-80 (2) c 30-134 (2)
20-713 (1) 20-906 (1) c 30-27 (2) c 30-81 (2) c 30-135 (2)
20-714 (1) 20-907 (1) c 30-28 (2) c 30-82 (2) c 30-136 (2)
20-715 (1) 20-908 (1) c 30-29 (2) c 30-83 (2) c 30-137 (2)
20-716 (1) 20-909 (1) c 30-30 (2) c 30-84 (2) c 30-138 (2)
20-718 (1) 20-910 (1) c 30-31 (2) c 30-85 (2) c 30-139 (2)
20-719 (1) 20-911 (1) c 30-32 (2) c 30-86 (2) c 30-140 (2)
20-720 (1) 20-912 (1) c 30-33 (2) c 30-87 (2) c 30-141 (2)
20-721 (1) 20-913 (1) c 30-34 (2) c 30-88 (2) c 30-142 (2)
20-722 (1) 20-914 (1) c 30-35 (2) c 30-89 (2) c 30-143 (2)
20-723 (1) 20-915 (1) c 30-36 (2) c 30-90 (2) c 30-144 (2)
20-724 (1) 20-916 (1) c 30-37 (2) c 30-91 (2) c 30-145 (2)
20-725 (1) 20-917 (1) c 30-38 (2) c 30-92 (2) c 30-146 (2)
20-726 (1) 20-918 (1) c 30-39 (2) c 30-93 (2) c 30-147 (2)
20-727 (1) 20-919 (1) c 30-40 (2) c 30-94 (2) c 30-148 (2)
20-728 (1) 20-920 (1) c 30-41 (2) c 30-95 (2) c 30-149 (2)
20-729 (1) 20-921 (1) c 30-42 (2) c 30-96 (2) c 30-150 (2)
20-730 (1) 20-951 (1) c 30-43 (2) c 30-97 (2) c 30-151 (2)
20-801 (1) 20-953 (1) c 30-44 (2) c 30-98 (2) c 30-152 (2)
20-802 (1) 20-954 (1) c 30-45 (2) c 30-99 (2) c 30-153 (2)
20-803 (1) 20-955 (1) c 30-46 (2) c 30-100 (2) c 30-154 (2)
20-804 (1) 20-956 (1) c 30-47 (2) c 30-101 (2) c 30-155 (2)
20-805 (1) 20-957 (1) c 30-48 (2) c 30-102 (2) c 30-156 (2)
20-806 (1) 20-958 (1) c 30-49 (2) c 30-103 (2) c 30-157 (2)
20-807 (1) 20-959 (1) c 30-50 (2) c 30-104 (2) c 30-158 (2)
20-808 (1) 20-960 (1) c 30-51 (2) c 30-105 (2) c 30-159 (2)
20-809 (1) 20-961 (1) c 30-52 (2) c 30-106 (2) c 30-160 (2)
WD600-3 00-2-3
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c 30-161 (2) 40-5 90-3

c 30-162 (2) 40-6 90-5
c 30-163 (2) 40-7 90-7
c 30-164 (2) 40-8 90-9
c 30-165 (2) 40-9 90-11
c 30-166 (2) 40-10 90-13
c 30-167 (2) 40-11 90-15
c 30-168 (2) 40-12 90-17
c 30-169 (2) 40-13 90-19
c 30-170 (2) 40-14 90-21
c 30-171 (2) 40-15 90-23
c 30-172 (2) 40-16
c 30-173 (2) 40-17
c 30-174 (2) 40-18
c 30-175 (2) 40-19
c 30-176 (2) 40-20
c 30-177 (2) 40-21
c 30-178 (2) 40-22
c 30-179 (2) 40-23
c 30-180 (2) 40-24
c 30-181 (2) 40-25
c 30-182 (2) 40-26
c 30-183 (2) 40-27
c 30-184 (2) 40-28
c 30-185 (2) 40-30
c 30-186 (2) 40-31
c 30-187 (2) 40-32
c 30-188 (2) 40-33
c 30-189 (2) 40-34
c 30-190 (2) 40-35
c 30-191 (2) 40-36
c 30-192 (2) 40-37
c 30-193 (2) 40-38
c 30-194 (2) 40-39
c 30-195 (2) 40-40
c 30-196 (2) 40-41
c 30-197 (2) 40-42
c 30-198 (2) 40-43
c 30-199 (2) 40-44
c 30-200 (2) 40-45
c 30-201 (2) 40-46
c 30-202 (2) 40-47
c 30-203 (2) 40-48
c 30-204 (2) 40-49
c 30-205 (2) 40-50
c 30-206 (2) 40-51
c 30-207 (2) 40-52
c 30-208 (2) 40-54
c 30-209 (2) 40-55
40-56
40-1 40-57
40-2
40-3 90-1
40-4 90-2
00-2-4 WD600-3
(2)
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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous 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 the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
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, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

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

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

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

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8 20 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3 10 0.31 0 0.10
1/8 8 20 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) (mm) (Reference)
inch, Thread series
9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 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
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
General assembly drawing ............................ 01-2

Specifications ................................................. 01-3
Weight table .................................................... 01-6
List of lubricant and water ............................. 01-7
WD600-3 01-1
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
Item Unit WD600-3
A Overall length mm 9,285
B Overall height mm 4,250
C Blade clearance mm 1,500
D Max. drop below ground mm 450
E Max. tilt adjustment mm 1,430
F Blade width mm 5,100
G Overall width mm 3,570
H Front overhung mm 2,210
I Wheel base mm 4,100
– Blade size (width x height) mm 5,100 x 1,470
01-2 WD600-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WD600-3
Serial Number 50001 and up
Operating weight kg 42,900

Weight
Front wheel load kg 20,400
Rear wheel load kg 22,500
Travel speed FORWARD 1st speed km/h 6.5
FORWARD 2nd speed km/h 11.4
FORWARD 3rd speed km/h 20.0
FORWARD 4th speed km/h 34.3
REVERSE 1st speed km/h 7.2

Performance
REVERSE 2nd speed km/h 12.6
REVERSE 3rd speed km/h 22.1
REVERSE 4th speed km/h 37.7
Max. rimpull kN {kg} 419.7{42,800}
Gradeability deg 25
Min. Center of outside wheel 6,980

turning mm
radius Outer end of blade 8,500
Overall length mm 9,285
Overall width (Outside of wheel) mm 3,570
(Blade) mm 5,100
Dimension
Overall height (Upper end of ROPS) mm 4,250
(Top of exhaust pipe) mm 4,125
Wheelbase mm 4,100
Tread mm 2,650
Min. ground clearance mm 495
WD600-3 01-3
Serial No. 50001 and up

Model SAA6D170E-3
4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger,
and after-cooler
No. of cylinders - bore x stroke mm 6 – 170 x 170
Piston displacement ¬ {cc} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 362/2,000 {485/2,000}

Engine
Performance
Maximum torque Nm/rpm {kgm/rpm} 2,390/1,400 {244/1,400}
Fuel consumption ratio g/kW•h {g/HP•h} 231 {172}
High idling speed rpm 2,175
Low idling speed rpm 700
Starting motor 24V, 7.5kW x 2
Alternator 24V, 50A
Battery (12V, 200Ah) x 2
Torque converter 3-element, 1-stage,

single-phase
Planetary gear, constant-mesh

Transmission multiple-disc, hydraulically actuated,
Power train
pressure rised lubrication, modulation type
Spiral bevel gear, splash lubrication

Reduction gear
Differential Straight bevel gear
Final drive Planetary gear single stage,

splash lubrication
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating

Axle, wheel
Rear axle Center pin support type, full-floating
Tire 35/65 x 33 – 24 PR (L4)
Wheel rim 28.00 x 33 WTB
Inflation pressure Front tire kPa {kg/cm2} 343 {3.5}

2
Rear tire kPa {kg/cm } 392 {4.0}
Main brake Front/rear wheel braking, separate front/rear wheel,

Brakes
wet disc, hydraulically actuated
Parking brake Drive shaft, dry caliper type disc brake,

Hydraulically released spring type
01-4 WD600-3
Serial Number 50001 and up

Steering
system
Type Articulated steering
Structure Hydraulic power steering
Work equipment pump 152 (Gear pump: SAL (3)-80)
Switch pump 204 (Gear pump: SAL (4)-100)
Delivery of Steering pump 246 (Gear pump: SAL (4)-125)

¬ /min
hydraulic PPC pump 63 (Gear pump: SAL (1)- 32)
pump
Transmission and PTO
Hydraulic system
lubrication pump 247 (Gear pump: SAL (3)-125)
For work equipment,

set pressure 2-spool type 20.6 {210}
Control
MPa {kg/cm2}
valve For steering system, Orbit roll + spool valve type 20.6 {210}
set pressure
Lift cylinder
No. - bore x stroke Double acting piston type 1 – 160 x 1,080
Cylinder Pitch and tilt cylinder mm Double acting piston type 2 – 180 x 236.5
No. - bore x stroke
Steering cylinder Double acting piston type 2 – 140 x 495
No. - bore x stroke
Blade width mm 5,100
Blade height mm 1,470

Dozer system
Max. lifting height mm 1,500
Max. tilting distance mm 1,430
Pitch angle deg 23
Max. digging depth mm 450
WD600-3 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
Unit: kg Unit: kg
Machine model WD600-3 Machine model WD600-3
Serial Number 50001 and up Serial Number 50001 and up
Engine assembly 2,900 Lift cylinder 205
Radiator assembly 630 Pitch and tilt cylinder 184
Torque converter assembly 340 Front frame 3,905
Transmission assembly 1,465 Rear frame 3,645
Upper drive shaft 27 Blade assembly 2,776
Center drive shaft 57 End bit (1 piece) 35
Front drive shaft 57 Edge (1 piece) 67
Rear drive shaft 49 H linkage 486
Center support 46 Y linkage 549
Front axle assembly 3,065 Rear bumper 410
Rear axle assembly 2,965 Fuel tank 405
Front differential assembly 499 Battery (1 piece) 59
Rear differential assembly 508 Cab 456
Planetary carrier assembly (1 piece) 115 ROPS 822
Wheel (1 piece) 453 Operator seat 35
Front axle support 126 Floor frame 184
Rear axle support 153 Counterweight (1 piece) 600
Tire (1 piece) 1,027 Bulk head 182
Steering valve 48 Engine hood 80
Steering cylinder (1 piece) 84 Side hood (1 piece) 38
Hydraulic tank assembly 362 Radiator guard 270
Steering + switch pumps 39 Side floor (beside cab) (1 piece) 71
Transmission + PPC pumps 24 Side floor (beside hood) (1 piece) 11
Work equipment pump 12.2 Step (beside hood) (1 piece) 38
Work equipment valve 71
★ This table describes mass of assemblies requiring teamwork or lifting tool for hauling.
01-6 WD600-3
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER
AMBIENT TEMPERATURE CAPACITY

RESER- KIND OF
VOIR FLUID –22 –4 14 32 50 68 86 104 122°F
Specified Refill
–30 –20 –10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil 62 ¶ 47 ¶
pan SAE 10W-30
SAE 15W-40
Engine
oil
Transmis- SAE 30
120 ¶ 110 ¶
sion case
SAE 10W
Hydraulic SAE 10W 330 ¶ 215 ¶

system
Axle
(Front and 124 ¶ 124 ¶
rear) See Note 1
(each)
Pins Grease NLGI No. 2 – –
Diesel ASTM D975 No. 2

Fuel tank 670 ¶ –
fuel
ª
Cooling
system Water Add antifreeze 160 ¶ –
ª ASTM D975 No. 1
Note 1:
For axle oil, use only recommended oil as follows.
Meker Description
SHELL DONAX TD 5W-30
MOBIL MOBILFLUID 424
WD600-3 01-7
GENERAL LIST OF LUBRICANT AND WATER
REMARK:
• When fuel sulphur content is less than 0.5 %,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5 %.
Change interval of
Fuel sulphur content oil in engine oil pan
0.5 to 1.0 % 1/2 of regular interval
Above 1.0 % 1/4 of regular interval
• When starting the engine in an atmospheric

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

oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill sys-
tem during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-8 WD600-3
10 STRUCTURE AND FUNCTION
Cooling system ............................................. 10- 2 Brake piping .................................................. 10-79

General .......................................................... 10- 4 Brake valve .................................................... 10-80
Power train system ...................................... 10- 6 Charge valve ................................................. 10-85
Torque converter and transmission piping .. 10- 8 Accumulator (for brake) ............................... 10-89
Torque converter .......................................... 10-10 Slack adjuster ............................................... 10-90
Torque converter regulator valve ................ 10-14 Brake .............................................................. 10-93
Lock-up valve ................................................ 10-16 Parking brake ................................................ 10-95
Lock-up solenoid valve ................................ 10-20 Spring cylinder ............................................. 10-97
Torque converter relief valve ....................... 10-21 Parking brake solenoid valve ...................... 10-98
Transmission ................................................ 10-23 Hydraulic piping ........................................... 10-99
Transmission control valve ......................... 10-28 Work equipment lever linkage .................. 10-100
Lubrication bypass valve ............................. 10-38 Hydraulic tank ............................................. 10-101
Transmission solenoid valve ....................... 10-39 Accumulator (for PPC valve) ..................... 10-104
Emergency manual spool ............................ 10-41 PPC valve .................................................... 10-105
Transfer ......................................................... 10-42 PPC relief valve ........................................... 10-110
Drive shaft ..................................................... 10-43 Work equipment valve ............................... 10-112
Center support .............................................. 10-44 DECO valve ................................................. 10-123
Axle ................................................................ 10-45 Air conditioner ............................................ 10-134
Differential .................................................... 10-47 Machine monitor system ........................... 10-137
Final drive ..................................................... 10-55 Main monitor .............................................. 10-138
Axle and center hinge pin ............................ 10-56 Maintenance monitor ................................. 10-142
Steering piping ............................................. 10-57 Engine starting circuit ................................ 10-144
Steering column ........................................... 10-58 Engine stop circuit ...................................... 10-145
Steering unit (orbit-roll valve) ..................... 10-59 Pre-heating circuit ...................................... 10-146
Steering valve ............................................... 10-62 Electric transmission control ..................... 10-147
Two-way restriction valve ............................ 10-73 Kick-down, hold switch .............................. 10-150
Stop valve ..................................................... 10-74 Transmission and joystick steering system ... 10-151
Emergency steering piping ......................... 10-75 Throttle control system .............................. 10-170
Diverter valve (for emergency steering) ..... 10-76
WD600-3 10-1
STRUCTURE AND FUNCTION COOLING SYSTEM
COOLING SYSTEM
1. After cooler SPECIFICATIONS

2. Water level sensor Radiator
3. Upper tank • Core model: PF2-7
4. Radiator core • Total heat dissipating area: 166.80 m2
5. Fuel cooler • Cross-sectional area of water flow:
6. Sub tank 233.43 cm2
7. Lower tank (hydraulic oil cooler 7A, 7B) Hydraulic oil cooler
Oil cooler 7A Oil cooler 7B
A: After cooler outlet port
B: After cooler inlet port Core type PTO-OL PTO-OL
C: Cooling water inlet port Heat dissipating area 1.829 m2
1.829 m2
D: Hydraulic oil cooler inlet port
E: Hydraulic oil cooler outlet port After cooler
F: Cooling water outlet port • Core type: CF40-1
• Total heat dissipating area: 6.45 m2
10-2 WD600-3
STRUCTURE AND FUNCTION COOLING SYSTEM
WD600-3 10-3
STRUCTURE AND FUNCTION GENERAL
GENERAL
• LOCATION OF COMPONENTS
OUTLINE
• The motive force from engine (1) is transmit- • The output shaft of transmission (4) transmits
ted from the flywheel through the ring gear the motive force through the gear of transfer
to torque converter (2).The torque converter (5) to the output shaft of the transfer.
uses oil as a medium to convert the transmit- At the front, the motive force is transmitted
ted torque to match the variation in the load. through center drive shaft (6), center support
It transmits this motive force to the input shaft (7), and front drive shaft (8) to front differen-
of transmission (4). tial (9).
• In addition, the motive power of the engine At the rear, the motive force is transmitted
passes through the pump drive gear and is from rear drive shaft (10) to rear differential
sent to the two double pumps, and drives each (11).
of the pumps. • The motive force transmitted to front differ-
• In transmission (4), solenoid valves are used ential (9) and rear differential (11) is transmit-
to operate the direction spool and speed spool ted to the sun gear shaft (axle shaft) of final
of the transmission valve. In this way, the six drives.
hydraulically operated clutches are actuated • The motive force of the sun gear is reduced
to select FORWARD and REVERSE speeds. by a planetary mechanism, and passes
The speed selection is carried out manually. through the planetary hub to front wheel and
rear wheel.
10-4 WD600-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
10-6 WD600-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
1. Engine OUTLINE
2. Torque converter
3. PTO • The motive force from engine (1) is transmit-
4. Steering + Switch pump ted from the flywheel through the ring gear
(SAL(4)125 + (4)100) to torque converter (2). The torque converter
5. Torque converter charging + PPC pump uses oil as a medium to convert the transmit-
(SAL(3)125 + (1)32) ted torque to match the variation in the load.
6. Work equipment pump It transmits this motive force to the input shaft
(SAL(3)80) of transmission (8).
7. Upper drive shaft
8. Transmission • In addition, the motive power of the engine
9. Transfer passes through the pump drive gear and is
10. Emergency steering pump (If equipped) sent to the pumps (4), (5) and (6), and drives
11. Center drive shaft each of the pumps.
12. Center support
13. Front drive shaft • In transmission (8), solenoid valves are used
14. Parking brake to operate the direction spools and speed
15. Front differential spools of the transmission valve. In this way,
16. Front axle the six hydraulically operated clutches are
17. Front brake actuated to select FORWARD and REVERSE
18. Front final drive speeds. The speed selection is carried out
19. Front wheel manually.
20. Rear drive shaft
21. Rear differential • The output shaft of transmission (8) transmits
22. Rear axle the motive force through the gear of transfer
23. Rear brake (9) to the output shaft of the transfer.
24. Rear final drive At the front, the motive force is transmitted
25. Rear wheel through center drive shaft (11), center support
(12), and front drive shaft (13) to front differ-
ential (15).
At the rear, the motive force is transmitted
from rear drive shaft (20) to rear differential
(21).
• The motive force transmitted to front differ-

ential (15) and rear differential (21) is trans-
mitted to the sun gear shaft (axle shaft) of fi-
nal drives (18) and (24).
• The motive force of the sun gear is reduced

by a planetary mechanism, and passes
through the planetary hub to front wheel (19)
and rear wheel (25).
WD600-3 10-7
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
1. Transmission
2. Transmission control valve
3. Torque converter
4. Oil cooler
5. Oil filter
6. Torque converter charging
and PPC pump
A. Oil inlet
B. Oil outlet
10-8 WD600-3
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
10-10 WD600-3
1. Regulator valve
2. Coupling
3. Housing
4. Torque converter inlet pressure
pick-up (PT 1/8)
5. Torque converter outlet oil temperature
pick-up
6. Torque converter outlet pressure
pick-up (PT 1/8)
7. Stator
8. Turbine
9. Drive case
10. Pump
11. Shaft
12. Lock-up valve
13. Lock-up clutch
14. One-way clutch
15. Mounting part of torque converter charge
pump and PPC pump
16. Mounting part of work equipment pumps
17. Mounting part of steering pump and
switching pump
18. Mounting part of drain piping
A. Inlet port Inlet

B. Outlet port
Specifications
Type: 3-element, single stage, single phase
WD600-3 10-11
Path of power transmission
Flow of power
Lock-up clutch disengaged Lock-up clutch engaged
• When the lock-up clutch is disengaged, the • When the lock-up clutch is engaged, drive
connection of drive case (3) and turbine (4) is case (3) and turbine (4) are connected and
disconnected, and the torque converter func- form one unit. Stator (11) is rotated by the
tions as normal. rotation of pump (6) and turbine (4).
The power generated by the engine is trans- The power generated by the engine is trans-
mitted from flywheel (1) to clutch housing (2), mitted from flywheel (1) to clutch housing (2),
and rotates drive case (3) and pump (6) as one and rotates drive case (3) and pump (6) as one
unit. unit. In addition, drive case (3) and turbine
The power from pump (6) uses oil as a me- (4) are connected by the clutch, so the power
dium to rotate turbine (4) and transmits the is transmitted directly from turbine (4) to
power from turbine (4) to transmission input transmission input shaft (14) without using oil
shaft (14). as a medium.
10-12 WD600-3
Flow of oil
• The oil passes through the main relief valve
and its pressure is adjusted by the torque con-
verter relief valve so that it is less than the set
pressure. It then enters inlet port A, passes
through the passage in stator shaft (8) and
case (9), and flows to pump (6). The oil is
given centrifugal force by pump (6). It then
enters turbine (4) and transmits the energy of
the oil to turbine (4).
• The oil from turbine (4) is sent to stator (11),
and enters pump (6) again. However, part of
the oil passes between turbine (4) and stator
shaft (8), and is sent through outlet port B to
the cooler.
WD600-3 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
1. Torque converter inlet pressure pick-up A. Torque converter inlet port

(PT 1/8) B. Torque converter outlet port
2. Torque converter outlet pressure pick-up
(PT 1/8)
3. Torque converter outlet oil temperature
pick-up
4. Regulator spool
5. Spring
6. Valve body
7. Poppet
10-14 WD600-3
STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE
FUNCTION
• The torque converter regulator valve is in-
stalled in the output circuit of torque converter
to regulate the hydraulic pressure inside the
torque converter to the specified pressure.
OPERATION
• The oil from the torque converter flows from
port A to port B. However, the hydraulic pres-
sure at port B is lower than the tension of
spring (5), so spool (4) does not move.
• When the hydraulic pressure at port B be-

comes higher than the tension of spring (5),it
pushes spool (4) in the direction of the arrow,
and the oil at port A flows to port C.
WD600-3 10-15
STRUCTURE AND FUNCTION LOCK-UP VALVE
LOCK-UP VALVE
1. Spring (Small) A: To lock-up clutch

2. Piston B: Rod piston oil pressure
3. Piston C: Pilot oil pressure
4. Piston T: Drain
5. Spring Dr: Drain
6. Body P: From pump
7. Spring (Large) P3: Lock-up clutch oil pressure
P4: Main oil pressure
10-16 WD600-3
FUNCTION
This valve sets the specified pressure for the
lockup clutch hydraulic pressure, and also
switches the lockup clutch.
It has a modulation valve, which engages the lock
up clutch smoothly, and reduces the shock when
shifting gear. Furthermore, it prevents the gen-
eration of peak torque in the power train. As a
result, the machine gives a good ride, and the
durability of the power train is greatly increased.
OPERATION
Driving in torque converter range
• When the machine is driving in the torque
converter range, solenoid valve (5) is switched
OFF by an electrical signal, and valve (5a) is
pushed to the right in the direction of the ar-
row by the tension of spring (5b), so port B
and port P of solenoid valve (5) are opened.
The oil from pump enters port A of lockup
valve (6), passes through port B and port P of
solenoid valve (5), and goes to port D.
Piston (8) is pushed to the left in the direction
of the arrow because of the hydraulic pres-
sure applied to port D. This force pushes
lockup valve (6), compresses spring (4), and
closes port A and port E.
The oil at port E and port H is drained, and
the lockup clutch is disengaged.
WD600-3 10-17
Driving in direct range

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

from the pump is sent to the lockup clutch. In
addition, the oil at port E flows to port F and
applies back pressure to load piston (2).
3) As the hydraulic pressure of the lockup clutch

rises, the pressure of the passing through ori-
fice a and entering port G also rises, and
pushes piston (7).
Because of the reaction force, lockup valve
(6) compresses spring (4) and pushes it to the
left in the direction of the arrow to throttle port
A and port E.
10-18 WD600-3
4) The oil from port E to port F applies pressure

to load piston (2), and pushes piston (2) to
the right in the direction of the arrow to com-
press spring (4).
Compressed spring (4) pushes lock up valve
(6) to the right in the direction of the arrow,
and opens port A and port E. When this hap-
pens, the increase in hydraulic pressure to
the lockup clutch starts again.
5) By repeating the actions in Steps 3) and 4),

the load on spring (4) is increased, and the
hydraulic pressure gradually rises.
Finally, when load piston (2) contacts stopper
(3), the rise in hydraulic pressure stops. The
pressure at this point is the set pressure of
the lockup valve.
• Set pressure: 1.86 MPa {19 kg/cm2}
WD600-3 10-19
STRUCTURE AND FUNCTION LOCK-UP SOLENOID VALVE
LOCK-UP SOLENOID VALVE
1. Cover A: From pump

2. Coil B: To piston
3. Spring C: To drain
4. Plunger
5. Valve seat holder
6. Valve seat
7. Spring
8. Valve seat
9. Cap
10. Cable
11. Connector
10-20 WD600-3
STRUCTURE AND FUNCTION TORQUE CONVERTER RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE

FUNCTION
• The torque converter relief valve acts to main-
tain the pressure of the oil entering the torque
converter at a constant pressure. It drains the
oil if it goes above the specified pressure.
OPERATION
• The oil from the pump passes through main
relief valve (1). It than enters port A and flows
to the torque converter.
• If the oil at port A goes above the specified

pressure, it passes through orifice "a" of
torque converter relief valve (2) and enters
port B. It then moves torque converter relief
valve (2) to the left.
As a result, the oil from A is drained, and oil
flowing to the torque converter is maintained
at the specified pressure.
WD600-3 10-21
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Coupling 6. Transmission control valve

2. Lubrication bypass valve 7. Oil filter
3. Transmission 8. Drain plug
4. Transfer 9. Strainer
5. Coupling 10. Breather
WD600-3 10-23
10-24 WD600-3
1. Input shaft
2. Sun gear (Teeth: 32)
3. Planetary gear (Teeth: 29)
4. Reverse clutch
5. Ring gear (Teeth: 112)
8. Forward clutch
13. 4th clutch
15. 2nd clutch
16. Hub
17. 3rd clutch
21. 1st clutch
25. Output shaft
26. Carrier
27. Carrier
28. Carrier
29. Carrier
WD600-3 10-25
OUTLINE
Speed range Clutch combination
• The transmission consists of a 4-FORWARD,
4-REVERSE speed planetary gear transmis- F1 No. 2, No. 6
sion, transfer, and transmission control valve.
• In the transmission, the motive force of the F2 No. 2, No. 4
input shaft is changed by the combination of
F3 No. 2, No. 5
Forward or Reverse clutch with 1st, 2nd, 3rd
or 4th clutch to give FORWARD 1 – 4 or RE- F4 No. 2, No. 3
VERSE 1 – 4 speed, and is transmitted to the
output shaft. R1 No. 1, No. 6
R2 No. 1, No. 4
R3 No. 1, No. 5
R4 No. 1, No. 3
OPERATION OF CLUTCH
• Engaged
The oil sent from the transmission control
valve passes through the oil passage inside
the transmission. When it reaches the back
of piston (2), it moves the piston (2).
When the piston (2) moves, disc (4) and plate
(5) are pressed together. Ring gear (6) is
meshed with disc (4), so its rotation is
stopped.
• Disengages
When the supply of oil from the transmission
control valve is shut off, the pressure of the
oil acting on the rear of piston (2) is reduced.
The piston is then pushed back to the right by
return spring (3), and disc (4) and plate (5) are
separated. Ring gear (6) then rotates freely,
and no motive force is transmitted.
10-26 WD600-3
FORWARD 1ST
• In 1st FORWARD, Forward clutch (17) and 1st • Ring gear (18) is held in position by Forward
clutch (30) are engaged. The motive force clutch so the rotation of planetary gear (19)
transmitted from the torque converter by in- rotates carries (36), which is on the inside of
put shaft (10) is transmitted to output shaft ring gear (18). This carrier (36) rotates carrier
(34). (37) through ring gear (23). Ring gear (31) is
• Forward clutch (17) is actuated by the hydrau- held by 1st clutch (30) so the rotation of sun
lic pressure applied to the clutch piston, and gear (33) is transmitted to carrier (38) through
it locks ring gear (18) in position. 1st clutch planetary gear (31) and rotate output shaft
(30) is actuated by the hydraulic pressure ap- (34).
plied to the clutch piston and holds gear (31)
in position.
• The motive force from the torque converter
is transmitted to the input shaft (10). The ro-
tation of the input shaft (10) is transmitted to
planetary gear (19) through sun gear (16).
WD600-3 10-27
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
1. Pilot reducing pick-up 8. Main relief pressure pick-up

2. Lower valve 9. Priority pressure pick-up
3. Upper valve 10. Reducing valve pressure pick-up
4. Main relief valve 11. Modulating pressure pick-up
5. Pilot oil filter 12. Transmission solenoid valve
6. Torque converter relief pressure pick-up 13. Emergency manual spool
7. Transmission lubricating pressure pick-up 14. Connector
10-28 WD600-3
UPPER VALVE
1. Piston
2. Torque converter relief valve
3. Main relief valve
4. Pilot reducing valve
5. Quick return valve
6. Modulating valve
7. Priority valve
8. Housing
OUTLINE
• The oil from the torque converter charging • The other oil line flows to the modulating
pump enters port A of main relief valve, and valve (6) and quick return valve (5). The ac-
passes through the priority valve (7) via by tion of the modulating valve (6) and quick re-
main relief valve (3). It is then divided into turn valve (5) raises the clutch pressure
three lines; there are; to the clutch pistons, to smoothly. This reduces the shock when actu-
the pilot reducing valve (4) and main relief ating the FORWARD, REVERSE and 1st, 2nd,
valve. The priority valve (7) acts to control 3rd, and 4th speed clutches to change gear.
the three lines so that the pilot reducing valve • The lubrication valve (15) controls the lubri-
(4) is the priority circuit. cation oil inside the transmission.
• The oil flowing to the pilot reducing valve (4)
controls the pilot pressure used to actuate the
directional and speed spools. The oil regu-
lated by the pilot reducing valve (4) presses
through the orifice in each spool and fills the
spool.
WD600-3 10-29
LOWER VALVE
9. 1st spool 14. Reducing valve

10. 2nd spool 15. Lubrication valve
11. Spacer 16. REVERSE spool
12. Pilot filter 17. 4th spool
13. FORWARD spool 18. 3rd spool
10-30 WD600-3
MAIN RELIEF VALVE

FUNCTION
• The main relief valve acts to supply the nec-
essary oil to the clutch when shifting gear.
When the gears are not being shifted, it sends
all of the oil directly to the torque converter.
OPERATION
• The oil from the pump passes through the oil
filter and enters port A of main relief valve
(1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
• When the pressure goes above the specified

level, oil passes through the orifice in relief
valve (1), pushes poppet (2), and moves re-
lief valve (1) to the left. The oil is relieved to
the torque converter, so the specified pres-
sure is maintained.
fl Specified pressure: 33.3 MPa {34 kg/cm2}
WD600-3 10-31
PRIORITY VALVE
FUNCTION
• The priority valve (1) controls the minimum
pressure of the pilot reducing valve (2). In
addition, the priority valve (1) gives the oil
flow to the pilot reducing valve (2) priority
over the other circuit.
OPERATION
• The oil from the pump flows to port A of pri-
ority valve (1) and port B of pilot reducing
valve (2).
• The oil entering port A flows from orifice "a"

of priority valve (1) to port D. The hydraulic
pressure and force of poppet spring (3) push
back spring (4) and move priority valve (1) to
the right.
When this happens, port A and port C are con-
nected, and the oil flows from port C to the
clutch spool.
10-32 WD600-3
MODULATING VALVE AND QUICK

RETURN VALVE
FUNCTION
• The modulating valve and quick return valve
act together to raise the transmission clutch
pressure slowly. In this way, they reduce the
shock when shifting gear, and prevent the
generation of peak torque in the power train.
As a result, operator fatigue is reduced, and
at the same time, operator comfort and the
durability of the power train are increased.
1) Immediately after shifting gear (Point A)
• The oil sent from the pump flows from prior- creates a difference in pressure between port
ity valve (1) through port A, passes through B and port C. The quick return valve moves to
modulating valve (2), and enters port B of the right and the oil flows to clutch (5). In ad-
quick return valve (3). The oil passes through dition, when quick return valve (3) moves to
orifice "a" of quick return valve (3) and flows the right, drain port D is opened, and the pres-
to the clutch piston, which has been actuated. surized oil at the rear of piston (4) flows to
However when it passes through orifice "a" it the drain circuit.
WD600-3 10-33
2) Clutch pressure rising (Point B)
• As the pressure at the clutch piston rises, the

pressure at port C also rises. Quick return
valve (3) is pushed back to the left and drain
port D is closed. The oil from the pump flows
from port C to the clutch piston and at the
same time it flows from orifice "b" through
quick return valve (3) and enters port E.
The oil at port E acts on the modulating pis-
ton (4). It pushes back spring (6) and moves
piston (4) to the right.
At the same time, pressurized oil also passes
through the orifice and enters poppet (7) of
modulating valve (2). It moves modulating
valve (2) to the left and some of the oil at port
A flows to port G.
10-34 WD600-3
3) Completion of rise in clutch pressure (Point C)
• The oil entering port E continues to push pis-

ton (4). When the piston reaches the end of
its stroke, the rise in pressure stops. When
this happens, the pressure reaches the set
pressure of the modulating valve. In addition,
port F and port G are closed by piston (4).
WD600-3 10-35
REDUCING VALVE
FUNCTION
• The reducing valve is in the circuit between
the quick return valve and the 2nd spool. It
reduces the pressure applied to the 2nd clutch.
The maximum pressure in the main circuit is
kept to the specified level by the main relief
pressure.
OPERATION
• The oil from the quick return valve enters port
A and then flows from port B to 2nd spool
(2).
• When the circuit to the 2nd clutch is filled with

oil and the hydraulic pressure rises, the oil
from port B which flows through orifice a to
port C pushes poppet (3). The reaction to this
compresses spring (4) and moves reducing
spool (1) to the left.
As a result, port A and port B are closed, and
the oil stops flowing.
The hydraulic pressure at this point is 1.96
MPa {20 kg/cm2}.
10-36 WD600-3
PILOT REDUCING VALVE

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

surized oil flows from orifice "a" of pilot re-
ducing valve (1) and goes to port D.
As a result, pilot reducing valve (1) moves to
the right, and port A and B are shut off, so the
pressurized oil at port C is maintained at the
same pressure.
WD600-3 10-37
STRUCTURE AND FUNCTION LUBRICATION BYPASS VALVE
LUBRICATION BYPASS
VALVE
FUNCTION
• When traveling in 4th gear, the transmission
gears are rotating at high speed. Because of
this, the churning resistance of the transmis-
sion lubrication oil increases. To reduce this
power loss, only enough oil to lubricate the
gears at 4th speed is kept. All the rest of the
oil is bypassed to the transmission case.
OPERATION
• 4th clutch not being operated
When the 4th clutch is not being operated,
there is no hydraulic pressure at port a of
spool (1). As a result, spool (1) is pushed to
the left by the spring. The oil from the torque
converter is stopped by spool (1), so all the
oil is used for lubricating the transmission.
• 4th clutch being operated

When oil flows to the 4th clutch, pressure oil
flows from 4th spool (2) to port a of spool (1).
When pressure oil enters port a, it pushed
back the spring and moves spool (1) to the
right. The oil from the torque converter flows
to the transmission lubrication system and
drain port b.
10-38 WD600-3
STRUCTURE AND FUNCTION TRANSMISSION SOLENOID VALVE
TRANSMISSION SOLENOID VALVE
1. 1st solenoid valve Actuation table for solenoid valve and clutch
2. 2nd solenoid valve
3. 3rd solenoid valve F R 1 2 3 4
4. 4th solenoid valve F1 fi fi
5. FORWARD solenoid valve
6. REVERSE solenoid valve F2 fi fi
7. Body F3 fi fi
8. Emergency manual spool F4 fi fi
9. Connector
N
STRUCTURE R1 fi fi
• The transmission solenoid valve is installed R2 fi fi
to the transmission together with the trans- R3 fi fi
mission valve. When the directional lever or
speed control lever are operated, the solenoid
R4 fi fi
valve is actuated and moves the spool inside
the transmission valve.
WD600-3 10-39
STRUCTURE AND FUNCTION TRANSMISSION SOLENOID VALVE
FUNCTION
• There is one solenoid valve installed for each
directional and speed spool in the transmis-
sion valve.
When the directional lever and speed control
levers in the operator's compartment are op-
erated, the solenoid valve is actuated, and oil
is drained to actuate the directional and speed
spools.
OPERATION
1) Solenoid valve OFF
The oil of spool (2) enters port A. However,
solenoid valve (1) shuts off the oil, so direc-
tional and speed spool (2) does not move.
2) Solenoid valve ON
When the directional and gear shift lever are
operated, the solenoid valve (1) is pulled up.
The oil from directional and speed spool (2)
enters port A and flows from port B to the
drain circuit. Therefore, port A becomes the
low pressure circuit, and directional and speed
spool (2) is actuated.
10-40 WD600-3
STRUCTURE AND FUNCTION EMERGENCY MANUAL SPOOL
EMERGENCY MANUAL SPOOL

FUNCTION
• If there is any failure in the electrical circuit of
the transmission control system, and the so-
lenoid 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 me-
chanically. (It is used to drive the machine to
a place where it can be repaired.)
fl Particular attention must be paid for when
using this spool.
OPERATION
1. When solenoid valve is normal:
(Emergency manual spool is at normal
position)
When the solenoid valve is working normally,
the spool is maintained in this position.
Oil from directional and speed spool (1) en-
ters port A, but it is shut off by solenoid valve
(2).
2. When solenoid valve is abnormal:

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

(Emergency manual spool is pulled to
the right)
When emergency manual spool (3) is
pulled to the right, the oil at port A is
drained to port B regardless of the opera-
tion of solenoid valve (2). As a result, the
clutch is actuated.
WD600-3 10-41
STRUCTURE AND FUNCTION TRANSFER
TRANSFER
OUTLINE 1. Transmission output shaft
• The transfer is installed to the output end of 2. Transfer input gear (teeth 46)
the transmission, and is secured to the trans- 3. Transfer idler gear (teeth 39)
mission case by bolts. 4. Idler gear (teeth 40)
5. Output shaft
TRANSMISSION PATH 6. Rear coupling
• Output shaft (1) of the transmission is coupled 7. Strainer
to transfer input gear (2) by a spline. The 8. Output gear (teeth 41)
motive force is transmitted to output gear (8) 9. Front coupling
through idler gear (3) and output shaft (5).
Part of the power transmitted to the output
shaft is transmitted to the front axle through
the center drive shaft and front drive shaft.
The rest of the power is transmitted to the rear
axle through the rear drive shaft.
10-42 WD600-3
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center drive shaft
OUTLINE
• The motive force from the engine passes • When the body is articulated, or when there
through the torque converter, upper drive is shock from the road surface during travel-
shaft (5), transmission and transfer. Part of this ing, or when there is shock during operations,
motive force passes through rear drive shaft the axle in front and behind the engine and
(4) and goes to the rear axle; the rest of the transmission change position.
motive force passes through center drive shaft To allow the motive force to be transmitted
(3), center support (2) and front drive shaft (1) without damage to parts of the machine when
and is sent to the front axle. In addition to there is shock or when the components move
transmitting the motive force, the drive shafts position, the drive shafts have a universal joint
have the following purposes. and a sliding joint. This allows them to handle
changes in angle and length.
WD600-3 10-43
STRUCTURE AND FUNCTION CENTER SUPPORT
CENTER SUPPORT
1. Front coupling FUNCTION

2. Case • The center support is installed to the front
3. Grease nipple frame between the center drive shaft and the
4. Rear coupling front drive shaft.
• With the articulating frame, this part is con-
stantly twisting from side to side, so there is
liable to be large stress on the drive shaft.
Therefore, the center support is used to trans-
mit the power smoothly, to reduce the stress
on the drive shafts, and in this way improve
the durability of the drive shafts.
10-44 WD600-3
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
1. Axle housing
2. Final drive
3. Brake
4. Differential
5. Parking brake
6. Spring cylinder
WD600-3 10-45
STRUCTURE AND FUNCTION AXLE
REAR AXLE
1. Axle housing
2. Final drive
3. Brake
4. Differential
A. Axle support retainer (Front)

B. Axle support retainer (Rear)
10-46 WD600-3
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Pinion (Teeth: 15)

2. Bevel pinion (Teeth: 8)
3. Shaft
4. Side gear (Teeth: 22)
5. Bevel gear (Teeth: 43)
WD600-3 10-47
REAR DIFFERENTIAL
1. Bevel gear (Teeth: 43)

2. Bevel pinion (Teeth: 8)
3. Shaft
4. Pinion (Teeth: 15)
5. Side gear (Teeth: 22)
10-48 WD600-3
OUTLINE
• The power from the engine passes through
the torque converter, transmission, and drive
shafts, and is transmitted to the front and rear
axles.
• The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted to
bevel gear (5). The bevel gear changes the
direction of the motive force by 90°, and at
the same time reduces the speed. It then
transmits the motive force through pinion
gear (4) to axle shaft (2).
• The power of the axle shaft is further reduced
by the planetary gear type final drive, and is
transmitted to the wheels.
When driving straight forward

• When the machine is driven straight forward,
the rotating speed of the left and right wheels
is the same, so pinion gear (4) inside carrier
(6) is sent through pinion gear (4) and side
gear (3) and is transmitted equally to the left
and right axle shafts (2).
When turning
• When turning, the rotating speed of the left
and right wheels is different, so pinion gear
(4) and side gear (3) inside the differential as-
sembly rotate in accordance with the differ-
ence between the rotating speed of the left
and right wheels. The motive force of carrier
(6) is then transmitted to axle shafts (2).
WD600-3 10-49
REAR DIFFERENTIAL
(NON-SPIN DIFFERENTIAL)
1. Bevel gear (Number of teeth: 43)

2. Non-spin differential assembly
3. Bevel pinion (Number of teeth: 8)
10-50 WD600-3
1. Spider
2. Center cam
3. Snap ring
4. Driven clutch
5. Holdout ring
6. Spring
7. Side gear
STRUCTURE
• The non-spin differential consists of the spi- ring (5) is fitted in the wide groove.
der (1), center cam (2), and snap ring (3). • The center cam (2) has cams as many as the
• On both sides of the spider (1), the clutch teeth clutch teeth and the cam surface is tilting. The
are arranged in the radius direction. On its center cam (2) and the spider (1) are sup-
outer periphery, four trunnions are mounted ported by the snap ring (3). Though the key
and on its inner periphery, a key is mounted of the spider (1) can slightly rotate in the
to limit rotation of the center cam (2) and hold- groove of the center cam (2), it is not thrown
out ring (5). out in the axial direction structurally.
• Grooves are provided on the outer periphery
of center support.
The key of the spider (1) is fitted in the nar-
row groove and the protrusion of the holdout
WD600-3 10-51
FUNCTION
• When the machine is traveling forward or
reverse, the clutch teeth of the spider (1) and
the right and left clutch teeth of the driven
clutch (4) are completely engaged each other.
In addition, they are engaged in the cam teeth
of the center cam (2) inserted in the spider. It
means that it is in the condition same as the
case without using the differential.
The contacting face of the clutch teeth differs
according to whether the engine is driving the
machine or the engine brake is applied.
When the machine is driven forward by the

engine to swing clockwise
• In case that the machine swings, the outer
wheels travel faster than the inner wheels,
namely, the machine turns. For this reason,
a differential is required.
• In case of an ordinary bevel gear type differ-
ential, the inner wheels rotate slower than the
ring gear and the outer wheels rotate faster
than it.
• When the machine with a non-spin differen-
tial is driven by the engine, the clutch teeth
are engaged, disabling both side wheels to
rotate slower than the ring gear.
• When the machine swings clockwise during
forward traveling, the right side (inner side)
driven clutch (4) is completely engaged to the
clutch teeth of the spider (1) to transmit a
torque. In this condition, the rpm same as
the ring gear's rpm is transmitted to the right
side (inner side) to make the machine travel
forward. On the left side (outer side), how-
ever, friction torque on the road surface
causes the driven clutch (4) to rise from the
spider on the inclined surface of the center
cam. This disengages the clutch teeth, allow-
ing the left side (outer side) to rotate faster
than the right side (inner side) to cause the
machine to swing.
• The left holdout ring (5) is disengaged from
the clutch teeth to contact the key of the spi-
der (1). At the same time, the protrusion rises
from the groove of the center cam (2) to be
positioned. During rotation of the driven
clutch (4) faster than the spider (1), therefore,
the driven clutch (4) is never engaged.
• When the differential is not required
after completing the swing, the differential
returns to the forward condition of the ma-
chine.
10-52 WD600-3
When the machine travels forward with the

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

during forward traveling
• The differential operates in the same manner
as when the machine swings clockwise while
the engine is driving the machine or serving
as a brake.
When the machine swings during reverse

traveling
• The differential operates in the same manner
as when the machine is traveling forward to
swing both clockwise and counterclockwise
while the engine is driving the machine or
serving as a brake.
WD600-3 10-53
When the machine travels on a rough terrain or

rugged road and requires continuous differen-
tial rotation
• If a wheel at one side floats from the road
surface when a machine with an ordinary dif-
ferential travels on a rough terrain or rugged
road, no load is applied to the wheel, and
therefore, it rotates (spins) faster than the
wheels contacting the road surface.
• If the spinning wheel contacts the road sur-
face, an impact torque is applied to the power
train, causing damage on the machine or a
fishtail skid. The non-spin differential enables
a quick changeover between full differential
lock and ordinary differential operation. It
means, even if a wheel at one side floats from
the road surface, that wheel rotates at the rpm
same as when it is contacting the road sur-
face. Accordingly, the wheel does not spin.
As a result, the machine makes safety travel
without a fishtail skid and also reduces dam-
age due to an impact torque.
When a wheel at one side is on the ice and the

wheels on the other side are on dry road
surface
• If a wheel at one side on the ice slips in case
of a machine with an ordinary differential, no
drive torque is transmitted to the wheels at
the other side on dry road surface. Accord-
ingly, the machine cannot travel. If a non-spin
differential is mounted on the machine, all
torques are transmitted to the wheels on the
dry road surface even if the above condition
occurs, allowing the machine to travel using
the friction on the road surface completely.
In this condition, the both wheels rotate at the
rpm of the ring gear regardless of the travel
and swing directions of the machine.
10-54 WD600-3
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Axle shaft OUTLINE

2. Planetary gear (Teeth: 25) • The final drive obtains a large driving force
3. Ring gear (Teeth: 71) by reducing the rpm with the planet gear
4. Planetary carrier mechanism to transmit it to the wheels.
6. Wheel
OPERATION
• The power transmitted from the differential
to the sun gear (5) through the axle shaft (1)
is transmitted to the planetary gear (2). The
planet gear rotates inside the secured ring
gear (3) to transmit the reduced rpm to the
wheel (6) mounted to the planetary carrier (4).
WD600-3 10-55
STRUCTURE AND FUNCTION AXLE AND CENTER HINGE PIN
AXLE AND CENTER HINGE PIN
1. Front frame 5. Rear axle support

2. Rear frame 6. Front axle
3. Rear axle support 7. Upper hinge pin
4. Rear axle 8. Lower hinge pin
OUTLINE
• Since the front axle (6) directly receives force • The front frame (1) and rear frame (2) are
of work, it is secured to the front frame (1) connected with the hinge pins (7) and (8)
with the axle mount bolt. through the bearing. The steering cylinder
• The rear axle (4) is mounted to the rear frame connects the right and left front frames and
(2) with the axle supports (3) and (5) so that rear frames to adjust the bending angle of the
each tire may contact the ground even dur- frame, i.e., turning radius, based on the cylin-
ing traveling on soft ground and the rear axle der movement.
can sway at the center of the rear axle.
10-56 WD600-3
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Steering cylinder (Right)

2. Stop valve (Right)
3. Steering and switching pump
4. Stop valve (Left)
5. Steering cylinder (Left)
6. Charging valve
7. Steering valve
8. Orbit-roll valve
9. Hydraulic tank
WD600-3 10-57
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Joint
4. Orbit-roll valve
10-58 WD600-3
STRUCTURE AND FUNCTION STEERING UNIT (ORBIT-ROLL VALVE)
STEERING UNIT (ORBIT-ROLL VALVE)
1. Neutral position spring a: To hydraulic tank

2. Valve body b: To steering valve port Pb
3. Check valve c: To steering valve port Pa
4. Spool d: From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin
WD600-3 10-59
OUTLINE
• The steering unit is directly connected to the
shaft of the steering wheel. The oil from the
PPC pump passes through the steering valve,
and is switched to the left and right steering
cylinders to determine the direction of travel
of the machine.
• The steering unit can be broadly divided into
the following: spool (4) and sleeve (5), which
have a rotor type direction selection function,
and the gear set (combination of gear (7) and
gear rim (6)), which acts as a hydraulic motor
when the steering is operated.
STRUCTURE
• Spool (4) is interconnected with the drive shaft
of the steering wheel and is connected to
sleeve (5) by neutral position spring (1) and
center pin (10) (when the steering wheel is at
neutral, it does not contact the spool).
• The top of drive shaft (9) is meshed with cen-
ter 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 con-
nected respectively to the pump circuit, tank
circuit, and pilot circuit of the steering demand
valve.
In addition, the port at the pump end and the
port at the tank end are connected by check
valve (3) inside the housing. If there is any
failure in the PPC pump, oil is sucked in di-
rectly from the tank end by the check valve.
10-60 WD600-3
OPERATION
When turning
• When the steering wheel is turned, spool (4) • 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
• When the turning of the steering wheel is • 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 (1) 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 trans-
position, so the oil passage is shut off and the mitted to the steering wheel.
oil stops flowing.
WD600-3 10-61
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
1. Overload relief valve A: To steering cylinder

2. Steering spool B: To steering cylinder
3. Demand spool P1: From steering pump
4. Main relief valve P2: From switch pump
PB: To main control valve
T: To hydraulic tank
Pa: From steering unit
Pb: From steering unit
10-62 WD600-3
OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
• The overload relief valve is installed in the
cylinder circuit of the steering demand valve.
When the demand valve is at neutral and any
impact is applied to the steering cylinder and
abnormal pressure is generated, this valve
functions as a safety valve to relieve the cir-
cuit to prevent breakage of the cylinder or
hydraulic piping.
It also functions to prevent any vacuum if any
negative pressure is generated at the cylin-
der end.
OPERATION
1. Operation of relief valve
• Port A is connected to the cylinder circuit
and port B is connected to the drain cir-
cuit. The oil passes through the hole in
poppet (1) and acts on the area of diam-
eters d1 and d2. Check valve poppet (3)
and relief valve poppet (2) are securely
seated.
• When the pressure at port A reaches the

set pressure of the relief valve, pilot pop-
pet (4) opens and the oil goes around pi-
lot poppet (4) and flows to port B.
WD600-3 10-63
• When pilot poppet (4) opens, the pressure

at the rear of poppet (1) drops, poppet (1)
moves to the right, and it is seated with
pilot poppet (4).
• Compared with the pressure at port A, the

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

• Negative pressure is generated at port A,
the difference in the area of diameters d3
and d4 opens check valve poppet (3), and
the oil flows from port B to port A to pre-
vent a vacuum from forming in the cir-
cuit.
10-64 WD600-3
MAIN RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
FUNCTION
• The main relief valve of the steering demand
valve is inside the valve and sets the maxi-
mum pressure in the steering circuit when it
is operated. In other words, when the valve is
being operated and the steering circuit goes
above the set pressure of this valve, it relieves
the oil and actuates the flow control spool of
the demand valve to drain the oil to the steer-
ing circuit.
WD600-3 10-65
OPERATION OF STEERING RELIEF VALVE
• When the pressure in the circuit rises and • When demand spool (4) moves, the oil from
reaches the pressure set by spring (2) and the steering pump is drained and the oil from
adjustment screw (1), pilot poppet (3) opens the switch pump is relieved to the main con-
and 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.
10-66 WD600-3
OPERATION OF DEMAND VALVE

WHEN STEERING SPOOL IS AT NEUTRAL
• The oil from the steering pump enters port A • When the pressure in pressure receiving
and the oil from the switch pump enters port chamber (I) reaches a certain value (set by
B. spring (3)), notch f opens and the oil from the
• When steering spool (2) is at the neutral posi- steering pump goes to the drain circuit. Notch
tion, pressure receiving pressure chamber (II) g is closed, so the oil from the switch pump
is connected to the drain circuit through ori- all 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 (1) to
the left.
WD600-3 10-67
WHEN STEERING SPOOL IS OPERATED

Engine running at low speed
• When the steering is operated, oil flows from • 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 pass-
• As a result, the pressure in pressure receiving through notch c is sent to pressure receiv-
ing chamber (II) rises, and demand spool (1) ing chamber (I) and the pressure after pass-
moves to the right until notch h closes. ing through notch c is sent to pressure receiv-
• The passage from port B to the main control ing chamber (II). Demand spool (1) is actu-
valve is shut off, so the oil from the switch ated so that the difference in pressure on both
pump pushes up pump merge-divider check sides of notch c is kept constant. Therefore,
valve (4) and merges with the oil from the an oil flow corresponding to the opening of
steering pump at port A. notch c is supplied to the cylinder port. These
pressure differences (control pressure) are set
by spring (3).
10-68 WD600-3
Engine running at high speed
• There is no need for supply of extra oil from • The oil from the steering pump passes
the switch pump, so the steering pump pres- through notches c and d, pushes load check
sure rises until notch g closes and shuts off valve (5), and flows to the cylinder. The re-
the merge passage from port B. turn oil from the cylinder passes through
• The pressure difference on both sides of notch notch e and flows to the drain circuit.
c is controlled only by notch f, and the excess • 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.)
WD600-3 10-69
OPERATION OF STEERING VALVE

Neutral
• The steering wheel is not being operated, so • When the pressure at ports A and B rises,
steering spool (2) does not move. demand spool (1) moves to the left, so the oil
• 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.
10-70 WD600-3
Turning right
• When the steering wheel is turned to the right, inders passes through load check valve (5) of
the Orbit-roll valve is operated and steering the steering spool and is drained. The oil from
spool (2) moves to the left. the switch pump enters port B, goes through
The oil from the steering pump enters port A, demand spool (1), pushes open check valve
then flows to steering spool (2) through de- (4), and is merged with the oil from the steer-
mand spool (1). The oil pushes open load ing 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 cyl-
WD600-3 10-71
Turning left
• When the steering wheel is turned to the left, the steering spool and is drained. The oil from
the Orbit-roll valve is operated and steering the switch pump enters port B, goes through
spool (2) moves to the left. demand spool (1), pushes open check valve
The oil from the steering pump enters port A, (4), and is merged with the oil from the steer-
then flows to steering spool (2) through de- ing pump.
mand spool (1). The oil pushes open load
check valve (5) of the spool, and flows to the
rod end of the left cylinder and the bottom
end of the right cylinder to turn the machine
to the left. The oil from the left and right cyl-
inders passes through load check valve (6) of
10-72 WD600-3
STRUCTURE AND FUNCTION WO-WAY RESTRICTION VALVE
TWO-WAY RESTRICTION VALVE
1. Poppet
2. Spring
3. Body
FUNCTION
• To reduce the shock caused by the inertia of
the machine when the steering is operated,
an orifice is installed in the oil line of the re-
turn circuit from the cylinder. This applies
pressure to the returning oil, and regulates
the movement of the cylinder piston.
OPERATION
• When the oil is flowing to arrow ➞, it pushes
spring (2) and flows through the orifice, and
between poppet (1) and the poppet seat.
• When the oil is flowing to arrow , the oil

➞
flows only from orifice a inside poppet (1), so
the flow is controlled.
WD600-3 10-73
STRUCTURE AND FUNCTION STOP VALVE
STOP VALVE
1. Boot A: From orbit-roll

2. Wiper B: To steering valve
3. Seal DR: To drain
4. Poppet
5. Spring
6. Spool
7. Spring
10-74 WD600-3
STRUCTURE AND FUNCTION EMERGENCY STEERING PIPING
EMERGENCY STEERING PIPING
1. Hydraulic tank
2. Transmission
3. Steering and switch pump
4. Diverter valve
5. Emergency steering pump
WD600-3 10-75
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE (for emergency steering)
1. Check valve A: To emergency pump FUNCTION

2. Check valve B: Sensor mounting port • The diverter valve is a selector valve which
3. Check valve C: To hydraulic oil tank senses the pilot pressure from the steering
4. Check valve D: To steering valve pump and if there is no abnormality in the
5. Spool E: From hydraulic tank steering circuit, it drains the oil from the emer-
6. Valve body F: From steering circuit gency pump to the tank. If no pilot pressure
from the steering pump reaches the diverter
valve, the oil from the emergency pump is
switched to the steering circuit and flows to
enable the machine to be steered.
10-76 WD600-3
OPERATION
• Pump and engine are working normally.
To steering cylinder
• When the steering pump and engine are work- Safety valve
(with suction)
ing normally, the hydraulic pump, steering
Diverter valve
pump, and switch pump are rotated by the
To main control valve
Emergency Steering
engine. Therefore, oil is sent to the steering pump spool
valve, and the machine can be steered. In ad- T/M
dition, the emergency steering pump is ro- Demand

Hydraulic spool
tated by the transmission, so oil from port A tank
of the diverter valve (1) pushes open check S/T S/W
valve (2) and enters port B.
Pressure oil from the steering pump is flow-
Oil cooler
ing to port D, so it pushes spool (3) in the di- SLW01242
rection of the arrow.

As a result, the oil from port B flows to port C
and is drained to the hydraulic tank.
WD600-3 10-77
Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when

the machine is traveling, the rotation of the wheels
is transmitted through the transfer to rotate the
emergency steering pump.
The steering pump is not rotating, so no pressure
oil is formed at port D. As a result, spool (3) is
pushed in the direction of the arrow by spring (4).
The oil from the emergency steering pump passes
from port A through port B and flows to the steer-
ing valve to make steering possible.
fl The emergency steering pump is designed so
that it can rotate both directions.
10-78 WD600-3
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1. Front brake (Right) 8. Accumulator

2. Slack adjuster (Front) 9. Brake valve (Left)
3. Brake valve (Right) 10. Parking brake
4. Rear brake (Right) 11. Front brake (Left)
5. Slack adjuster (Rear) 12. Strainer
6. Rear brake (Left) 13. Charging valve
7. Torque converter charging and PPC (used as 14. Parking brake valve
brake, too) pump
WD600-3 10-79
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
1. Brake pedal A. Pilot port (From brake valve (Left))

2. Rod B. Brake port (To rear brake)
3. Pilot piston C. Brake port (To front brake)
4. Spool D. Drain port
5. Upper cylinder E. P port (From accumulator)
6. Plunger
7. Spool
8. Lower cylinder
10-80 WD600-3
BRAKE VALVE (LEFT)
1. Brake pedal A. Drain port

2. Rod B. Brake port (To brake valve (Right))
3. Spool C. P port (From accumulator)
4. Cylinder
5. Plunger
OUTLINE
• There are two brake valves installed in paral- In addition, the left brake pedal operates the
lel under the front of the operator’s cab, and transmission cut-off switch to actuate the
these are actuated by depressing the pedal. transmission solenoid valve electrically and
• When the right pedal is depressed, oil is sent set the transmission to neutral.
to the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is de-
pressed.
WD600-3 10-81
OPERATION
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the oper- 1
ating force is transmitted to spool (3) through
rod (2) and spring (4). When spool (3) goes 2
down, drain port a is closed, and the oil from
the pump and accumulator flows from port A
to port C and actuates the rear brake cylin-
ders. 3
Drain
4
Lower portion a
Accumulator C
• When brake pedal (1) is depressed, the oper-
ating force is transmitted to spool (3) through A
rod (2) and spring (4). When spool (3) goes From pump To rear brake
Accumulator cylinder
down, spool (5) is also pushed down by b 6
plunger (6). When this happens, drain port b 5
is closed, and the oil from the pump and ac- From pump To front brake
cylinder
cumulator flows from port B to port D and B D SED00109
actuates the front brake cylinders.
Brake applied (left brake pedal)

• When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and drain 7
port c is closed. The oil from the pump and
the accumulator flows from port E to port F. Left brake valve
• Port F of the left brake valve and port PP of
the right brake valve are connected by a hose, 8
so the oil flowing to port F flows to pilot port
PP of the right brake valve. 9
• The oil entering pilot port PP enters port G C
10
from orifice d, and pushes pilot piston (11).
The spring pushes spool (3) down, so the op- F
eration is the same as when the right brake E
valve is depressed.
Right brake
valve
d
G PP
11 To rear brake
cylinder
From pump
3
From pump
To front brake
cylinder
SEW00110
10-82 WD600-3
Applying brake when upper valve fails (right

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

brake valve)
• Even if there is leakage of oil in the lower pip-
ing, the upper portion is actuated normally.
When actuation is balanced From pump To fear brake

cylinder
Upper portion
• When oil fills the rear brake cylinder and the
pressure between port A and port C becomes From pump To front brake
cylinder
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes 5 SEW00111
up spool (3) and shuts off the circuit between

port A and port C. When this happens, drain
port a stays closed, so the oil entering the
brake cylinder is held and the brake remains
applied.
Lower portion
• When spool (3) in the upper portion moves
up and the circuit between port A and port C
is shut off, oil also fills the front brake cylin-
der at the same time, so the pressure in the
circuit between port B and port D rises. The
oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount that
spool (3) moves, and shuts off port B and port
D. Drain port b is closed, so the oil entering 4
the brake cylinder is held, and the brake is 3
a
applied. e H
To rear brake
• The pressure in the space in the upper por- A
From pump C cylinder
tion is balanced with the operating force of 5
the pedal, and the pressure in the space in b To front brake
f
the lower portion is balanced with the pres- From pump Dcylinder
sure in the space in the upper portion. When
B
spools (3) and (5) move to the end of their J SEW00112
stroke, the circuits between ports A and C and
between ports B and D are fully opened, so
the pressure in the space in the upper and
lower portions and the pressure in the left and
right brake cylinders is the same as the pres-
sure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of
the brake can be adjusted by the amount that
the pedal is depressed.
WD600-3 10-83
Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operating 1
force is removed from the top of the spool,
the back pressure from the brake cylinder and
the force of the spool return spring move
spool (3) up. Drain port a is opened and the
oil from the brake cylinder flows to the hy-
draulic tank return circuit to release the rear
brake.
Lower portion 3
• When the pedal is released, spool (3) in the a
upper portion moves up. At the same time,
the back pressure from the brake cylinder and From pump From rear brake
the force of the spool return spring move cylinder
spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the hy- From pump b From front brake
draulic tank return circuit to release the front 5 cylinder
SEW00113
brake.
10-84 WD600-3
STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
A: To PPC valve FUNCTION

ACC:To brake valve • The charge valve is actuated to maintain the
PP: To brake valve oil pressure from the pump at the specified
P: From pump pressure and to store it in the accumulator.
T: Drain • When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.
WD600-3 10-85
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
6. Filter
10-86 WD600-3
OPERATION
1. When no oil is being supplied to accumula- T C T
tor (cut-out condition)
• The pressure at port B is higher than the set R3 R1
pressure of the relief valve (R1), so piston (8) 6
is forcibly pushed up by the oil pressure at
port B. Poppet (6) is opened, so port C and
8
port T are short circuited.
• The spring chamber at the right end of spool Front accumulator
pilot pressure
(15) is connected to port C of the relief valve
B
(R1), so the pressure becomes the tank pres-
sure. The oil from the pump enters port P,
16
pushes spool (15) to the right at a low pres- To front, rear
sure equivalent to the load on spring (14), and A accumulator 18
flows from port A to the PPC valve. To
At the same time, it also passes through ori- PPC R2
valve
fices (17), (18), and (16), and flows to the tank.
H1
14
P 17 15
SDW00116
2. When oil is supplied to accumulator T C T

1) Cut-in condition
• When the pressure at port B is lower than R3 R1 5
the set pressure of the relief valve (R1), 6
piston (8) is pushed back down by spring
(5). Valve seat (7) and poppet (6) are 7
brought into tight contact, and port C and 8
port T are shut off. Front accumulator
• The spring chamber at the right end of pilot pressure
spool (15) is also shut off from port T, so B
the pressure rises, and the pressure at port
P also rises in the same way. 16
To front, rear
• When the pressure at port P goes above A accumulator 18
the pressure at port B (accumulator pres- To
sure), the supply of oil to the accumula- PPC R2
valve
tor starts immediately. In this case, it is
decided by the size (area) of orifice (17)
and the pressure difference (equivalent to
H1
the load on spring (14)) generated on both
sides of the orifice. A fixed amount is sup-
plied regardless of the engine speed, and 14
the remaining oil flows to port A.
P 17 15
SDW00117
WD600-3 10-87
2) When cut-out pressure is reached T C T

• When the pressure at port B (accumula-
tor pressure) reaches the set pressure of R3 R1
the relief valve (R1), poppet (6) separates 6
from valve seat (7), so an oil flow is gen-
erated and the circuit is relieved. 7
• When the circuit is relieved, a pressure dif- 8
Front accumulator
ference is generated above and below pis- pilot pressure
ton (8), so piston (8) moves up, poppet B
(6) is forcibly opened, and port C and port
T are short circuited. 16
• The spring chamber at the right end of To front, rear
A accumulator 18
spool (15) is connected to port C of the
relief valve (R1), so the pressure becomes To
PPC R2
the tank pressure. valve
• The pressure at port P drops in the same
way to a pressure equivalent to the load
on spring (14), so the supply of oil to port H1
B is stopped.
14
P 17 15
SDW00118
3. Safety relief valve (R3) 3

• If the pressure at port P (pump pressure) goes R3 R1
above the set pressure of the relief valve (R3), 11
the oil from the pump pushes spring (3). Ball
(11) is pushed up and the oil flows to the tank
circuit, so this sets the maximum pressure in
Front accumulator
the brake circuit and protects the circuit. pilot pressure
To front, rear
accumulator
To
PPC R2
valve
H1
P
SDW00119
10-88 WD600-3
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
SEW00120
FUNCTION SPECIFICATIONS
• The accumulator is installed between the Gas used: Nitrogen gas
charge valve and the brake valve. It is charged Charge amount: 6,000 cc
with nitrogen gas between cylinder (3) and Charging pressure: 3.4 MPa
free piston (4), and uses the compressibility {35 kg/cm2} (at 50°C)
of the gas to absorb the pulse of the hydrau-
lic pump or to maintain the braking force and
to make it possible to operate the machine if
the engine should stop.
WD600-3 10-89
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1 2 3
5 4 B A SEW00121
1. Bleeder FUNCTION
2. Cylinder • The slack adjuster is installed in the brake oil
3. Check valve line from the brake valve to the brake piston.
4. Piston It acts to provide a fixed time lag when the
5. Spring brake is applied.
A: Inlet port
B: Outlet port
SPECIFICATIONS
Piston actuation pressure:
0.01 + 0.01
0 MPa {0.1 + 0.1 2
0 kg/cm }
Check valve cracking pressure:
0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2}
Check valve closing pressure:
0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2}
10-90 WD600-3
OPERATION
1. When brake pedal is depressed
• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full
stroke). When the brake pedal is depressed,
the oil discharged from the brake valve flows
from port P of the slack adjuster and is divided
to left and right cylinders (2), where it moves
piston (4) by stroke S to the left and right.
• When this is done, brake piston (7) moves by

a distance of stroke S. In this condition, the
closer the clearance between the brake pis-
ton (7) and disc is to 0, the greater the brak-
ing force becomes.
• If the brake pedal is depressed further, and

the oil pressure discharged from the brake
valve goes above the set pressure, check valve
(3) opens and the pressure is applied to port
C to act as the braking force.
Therefore, when the brake is applied, the time
lag is a fixed value.
WD600-3 10-91
2. When brake pedal is released

• When the brake is released, piston (4) is re-
turned by brake return spring (8) by an
amount equivalent to the oil for stroke S, and
the brake is released.
In other words, return stroke T of brake pis-
ton (7) is determined by the amount of oil for
stroke S of the slack adjuster. The time lag of
the brake is always kept constant regardless
of the wear of the brake disc.
10-92 WD600-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear (Teeth: 164)
6. Hub gear (Teeth: 112)
7. Plate
8. Disc
WD600-3 10-93
STRUCTURE AND FUNCTION BRAKE
FUNCTION
• Main brakes are wet-type multiple-disc brakes
and are installed to all four wheels.
OPERATION
• When the brake pedal is depressed, the pres-
sure oil from the brake valve moves brake pis-
ton (4) to the right in the direction of the ar-
row. This brings disc (8) and plate (7) into con-
tact, and friction is generated between the disc
and plate. The wheel is rotating together with
the disc, so the machine speed is reduced and
the machine is stopped by this friction.
• When the brake pedal is released, the pres-

sure at the back face of brake piston (4) is re-
leased, so the piston is moved to the left in
the direction of the arrow by the force of re-
turn spring (2), and the brake is released.
10-94 WD600-3
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Parking brake disc OUTLINE

2. Spring cylinder • The parking brake is a disc type and is installed
3. Caliper return spring on the front axle.
• The force of the spring inside the spring cyl-
inder (2) is used to apply the brake mechani-
cally; it is released by oil pressure.
• The parking brake caliper is fixed to the front
differential case.
The disc is installed to the differential yoke
and rotates together with the coupling.
WD600-3 10-95
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE CALIPER
1. Caliper
2. Pad
3. Piston
4. Piston shaft
5. Lever
6. Adjustment bolt
OUTLINE
• Caliper (1) is fitted with a piston guide. Piston • The caliper body follows the wear of pad (2)
(3) and piston shaft (4) are fitted inside, and and slides in the axial direction on the plate.
the rotation of the piston shaft moves the pis- Adjustment bolt (6) of lever (5) is used to ad-
ton in the axial direction to compress pad (2). just the clearance between the pad and the
• Lever (5) is connected by a spline to the spline disc. Hold the lever and turn the adjustment
side of the piston shaft. bolt to adjust the clearance as follows.
Pad (2) is fitted and held in position together To INCREASE, turn COUNTERCLOCKWISE.
with caliper (1) in the caliper mounting plate. To DECREASE, turn CLOCKWISE.
10-96 WD600-3
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
1. Outer spring OUTLINE

2. Inner spring • The oil pressure from the parking brake sole-
3. Piston noid valve pushes the spring and releases the
4. Cylinder parking brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by spring (1), so the machine is pre-
vented from moving.
WD600-3 10-97
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Solenoid valve assembly FUNCTION

2. Block • The parking brake solenoid valve is installed
to the inside left of the front frame. When the
B: Outlet port parking brake switch is turned ON/OFF, the
B1: Port for parking brake pilot lamp switch solenoid valve is energized or deenergized,
P: Inlet port so the brake oil pressure is taken to the brake
T: Drain port cylinder or removed from the brake cylinder
to set the parking brake at the PARKED posi-
tion or TRAVEL position.
• Parking brake solenoid valve
Energized: TRAVEL
Deenergized: PARKED
10-98 WD600-3
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
1. Lift cylinder 8. Hydraulic tank

2. Work equipment valve 9. Work equipment pump
3. Steering valve 10. Accumulator
4. Steering + switching pump
5. Torque converter charging + PPC pump A. To pitch cylinder (Right)
6. PPC valve B. To pitch and tilt cylinder (Left)
7. Accumulator charging valve
WD600-3 10-99
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. Work equipment control lever

2. PPC valve
3. Safety lever
10-100 WD600-3
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Filter bypass valve A. Brake return port

2. Oil filter B. Stop valve, charge valve, PPC, orbit-roll
3. Breather return port
4. Oil filler C. Hydraulic oil cooler return port
5. Oil level sight gauge D. Main return port
6. Hydraulic tank E. Main suction port
7. Drain valve F. Emergency steering suction port
G. Emergency steering return port
WD600-3 10-101
OPERATION OF OIL FILTER BYPASS

VALVE
When the filter is clogged.
Bypass valve (1) opens and the oil returns directly
to the tank without passing through the filter.
Bypass valve set pressure: 125 kPa {1.27 kg/cm2}
When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 25.5 kPa {0.26 kg/cm2}
10-102 WD600-3
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
FUNCTION
Preventing negative pressure inside the tank
The tank is a pressurized, sealed type, so nega-
tive pressure is formed inside the hydraulic tank
when the oil level drops during operations. When
this happens, the difference in pressure between
the tank and the outside atmospheric pressure
opens the poppet (3), and air from the outside is
let into the tank to prevent negative pressure.
Preventing rise in pressure inside the tank
When the hydraulic cylinder are being used, the
oil level in the hydraulic circuit changes and the
temperature rises. If the hydraulic pressure rises
above the set pressure, sleeve (4) is actuated to
release the hydraulic pressure inside the tank.
WD600-3 10-103
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Type of gas: Nitrogen gas
Gas amount: 500 cc
Max. actuation pressure: 3.4 MPa {35 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
FUNCTION
• The accumulator is installed between the ac-
cumulator charge valve and the PPC valve.
Even if the engine stops when the blade is
raised, it is possible to lower the blade under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumu-
lator to send the pilot oil pressure to the work
equipment valve to actuate it.
OPERATION
• After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa {30
kg/cm2}. When this happens, the bladder is
expanded by the pressure of the nitrogen gas
in chamber A, and the oil inside chamber B
is used as the pilot pressure to actuate the
work equipment valve.
10-104 WD600-3
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
P: From PPC pump

P1: To work equipment valve tilt spool
(Left tilt, rear pitch)
P2: To work equipment valve lift spool (Lower)
P3: To work equipment valve lift spool (Raise)
P4: To work equipment valve tilt spool
(Right tilt, forward pitch)
T: Drain
WD600-3 10-105
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Centering spring
7. Metering spring
8. Valve
9. Body
10-106 WD600-3
OPERATION OF PPC VALVE

[At neutral]
• The oil from the PPC pump enters port P of

the PPC valve, but the circuit is closed by spool
(8), so the oil is drained from relief valve (1).
At the same time, the oil at port P1B of the
main control valve is drained from port f of
spool (8).
In addition, the oil at port P1A is drained from
port g of spool (10).
WD600-3 10-107
FUNCTION OF PPC VALVE

The PPC valve supplies pressure oil from the
charging pump to the side face of the spool of
each control valve according to the amount of
travel of the control lever.
This pressure oil actuates the spool.
OPERATION
1. Control lever at “hold” (Fig. 1)
Ports P1B, P4, P1A and P1 are connected to
drain chamber D through fine control hole (f)
in valve (8).
2. Control lever operated slightly (fine control)

(Fig. 2):
When piston (2) starts to be pushed by plate
(10), retainer (5) is pushed. Valve (8) is also
pushed by spring (7) and moves down.
When this happens, fine control hole (f) is shut
off from drain chamber D. At almost the same
time it is connected to pump pressure cham-
ber PP, and the pilot pressure of the control
valve is sent through fine control hole (f) to
port P4. When the pressure at port P4 rises,
valve (8) is pushed back. Fine control hole (f)
is shut off from pump pressure chamber PP.
At almost the same time it is connected to
drain chamber D, so the pressure at port P4
escapes to drain chamber D.
Valve (8) moves up and down until the force
of spring (7) is balanced with the pressure of
port P4.
The position of valve (8) and body (9) (when
fine control hold (f) is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (8)
contacts the bottom of piston (2).
Therefore, spring (7) is compressed in propor-
tion to the travel of the control lever, so the
pressure at port P4 also rises in proportion to
the travel of the control lever. The spool of
the control valve moves to a position where
the pressure of port P1B (same as pressure at
port P4) and the force of the return spring of
the control valve are balanced.
10-108 WD600-3
3. Control lever moved back from slightly oper-

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

4):
Plate (10) pushes piston (2) down, and piston
(2) forcibly pushes in valve (8).
Fine control hole (f) is shut off from drain
chamber D, and is connected to pump pres-
sure chamber PP.
Therefore, pressure oil from the charging
pump passes through fine control hole (f), and
flows from port P4 to chamber P1B to push
the spool of the control valve.
The oil returning from chamber P1A flows
from port P1 through fine control hole (f’) to
drain chamber D.
WD600-3 10-109
STRUCTURE AND FUNCTION PPC RELIEV VALVE
PPC RELIEF VALVE
R2
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
1 2 3 4 5 6
SDW00149
FUNCTION A 1 C B 3 4
• The PPC relief valve is between the PPC, brake
pump and the PPC valve. When the PPC pump
is not being actuated, or when any abnormal
pressure is generated, the oil sent from the R2
pump is relieved from this valve to prevent To PPC
any damage to the pump or circuit. valve
OPERATION
D
• The relief valve is installed to the charge valve.
Port A is connected to the pump circuit and
port C is connected to the drain circuit.
The oil passes through the orifice in main
valve (1) and fills port B.
In addition, pilot poppet (4) is seated in valve SDW00150
seat (3).
• When the pressure at port A and port B
reaches the set pressure, pilot poppet (4) A C 1 B
opens and the oil pressure at port B escapes
from port D to port C to lower the pressure at
port B.
• When the pressure at port B goes down, a R2
difference in pressure is generated at ports A To PPC
and B by the orifice of main valve (1). Main valve
valve (1) is opened by the pressure at port A
and the oil at port A is drained to port C to
relieve the circuit.
SDW00151
10-110 WD600-3
STRUCTURE AND FUNCTION WORK EQUIPMENT VALVE
WORK EQUIPMENT VALVE
P1A. From PPC valve P1 A1. To pitch and tilt cylinder bottom side
P2A. From PPC valve P3 A2. To lift cylinder bottom side
P1B. From PPC valve P4 B1. To pitch and tilt cylinder head side
P2B. From PPC valve P2 B2. To lift cylinder head side
P1. From pump T. Drain port
P2. (Blind plug)
10-112 WD600-3
1. Tilt spool return spring

2. Lift spool return spring
3. Lift spool
4. Tilt spool
5. Body
6. Suction valve
7. Safety valve with suction
8. Main relief valve
WD600-3 10-113
MAIN RELIEF VALVE

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
• The main relief valve mounted at the inlet part
of the work equipment valve drains the oil to
the tank when it exceeds the specified pres-
sure. This specifies the maximum pressure
of the work equipment circuit to protect the
circuit.
OPERATION
• The port A connects to the pump circuit and
the port C connects to the drain circuit. The
oil goes through the orifice of the main valve
(1) to fill the port B. The pilot poppet (3) is
seated at the valve seat (2).
• When the hydraulic pressures at the ports A
and B reach the set pressure of the pilot pop-
pet spring (4), the pilot poppet (3) opens to
relieve the hydraulic pressure at the port B
through the port D to the port C, eventually
lowering the pressure at the port B.
• As the pressure at the port B lowers, the ori-
fice of the main valve (1) generates pressure
difference at the ports A and B, pushing the
main valve open. Then, the oil at the port A
goes through the port C to the drain circuit to
relieve abnormal pressure.
• The set pressure can be changed by chang-
ing tension of the pilot poppet spring (4). To
change the set pressure, remove the cap nut,
loosen the lock nut, and adjust the adjustment
screw (5); screw it in to raise the set pressure
and loosen it to lower it.
10-114 WD600-3
SAFETY VALVE (WITH SUCTION)
1 2 3 4 5 6 1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
SEW00166
FUNCTION
• The safety valve is mounted in the tilt
cylinder circuit in the work equipment valve.
If abnormal pressure is generated due to im-
pact to the cylinder with the work equipment
valve in the neutral position, the safety valve
relieves it to prevent damage on the cylinder.
OPERATION
Operation as a safety valve
• The port A connects to the cylinder circuit and A B C 2 4 D
the port B connects the drain circuit. The
hydraulic pressure at the port A is led to the
port D through the hole of the pilot piston (4)
and further to the port C through the orifice
consisting of the main valve (2) and the pilot
piston (4).
The pilot piston (4) is secured to the safety
valve and the relation of the cross-section
diameter (cross-sectional area) of its each part
is d2>d1>d3>d4. d1 d3 d4 d2 SEW00167
• If abnormal pressure is generated at the port
A, the suction valve (1) does not operate due
to the relation d2>d1. The main valve (2),
however, receives hydraulic pressure by dif-
ference in the areas of d3 and d4 due to the A B 1 2 3 D
relation d3>d4 of the port A and port C. When
the hydraulic pressure reaches the main valve
spring (3) force (set pressure), the main valve
(2) operates to flow the oil of the port A to the
port B.
SEW00168
WD600-3 10-115
OPERATION AS A SUCTION VALVE

• If negative pressure is generated at the port
A, the pressure at the port D also becomes
negative since the port D is led to the port A.
To the port E, the tank pressure at the port B
is applied. Due to this tank pressure at the
port E, the safety valve receives the hydraulic
pressure a generated by area differences in
d2 and d1.
Therefore, the hydraulic pressure e moves in
direction to open the valve and the hydraulic
pressure a moves in direction to close the
suction valve (1).
If the pressure at the port A lowers (ap-
proaches negative pressure) below the hy-
draulic pressure e and eventually reaches the
level, hydraulic pressure e > hydraulic pres-
sure a + valve spring (5) force, the suction
valve (1) opens to flow the oil from the port B
to port A to prevent negative pressure
generation at the port A.
SUCTION VALVE
1 2 3
1. Main poppet
2. Sleeve
3. Spring
FUNCTION
• The suction valve prevents negative
pressure generation in the circuit.
SEW00170
OPERATION
• If negative pressure is generated at the port
A (lift cylinder rod side) (if pressure lower than
the port B in the tank circuit is generated), the
area differences in d1 and d2 open the main
poppet (1) to flow the oil from the port B in
the tank side to the port A in the cylinder port
side.
10-116 WD600-3
LIFT AND TILT SPOOL HOLD POSITION
FUNCTION
• The oil flows from the pump to the port A and • The oil from the PPC pump goes through the
the relief valve (11) specifies its maximum check valve (13) to enter the port L of the PPC
pressure. valve. Since the work equipment control le-
• Since the bypass circuit is opened to protect ver is in the HOLD position, however, the oil
tilt spool (1), the oil in port A flows around returns from the PPC relief valve (12) to the
the spool into port B. hydraulic tank.
• Since the lift spool (2) is in the HOLD posi-
tion, the bypass circuit is open. The oil at the
port B goes around the spool to enter the port
C in the drain circuit and further goes through
the filter back to the tank.
WD600-3 10-117
LIFT SPOOL RAISE POSITION
OPERATION
• Placing the work equipment control lever (3) circuit of the lift spool (2). Since the bypass
at the RAISE position flows the oil from the circuit is closed by the spool, the oil pushes
port L of the PPC valve to the port N and port the check valve (10) open. The oil flows
T. The oil at the port S goes through the port through the port J and the port K to
M to the drain circuit. the cylinder rod side.
The pressure oil at the port T pushes the lift • The oil at the cylinder bottom side goes
spool (2) to the RAISE position. through the port I to the drain port C to re-
• The oil from the pump flows through the turn to the tank. Accordingly, the blade rises.
bypass circuit of the tilt spool to the bypass
10-118 WD600-3
LIFT SPOOL LOWER POSITION
OPERATION
• Placing the work equipment control lever (3) circuit is closed by the spool, the oil pushes
at the LOWER position flows the oil from the the check valve (10) open. The oil flows
port L of the PPC valve to the port M and port through the port H and the port I to
S. The oil at the port T flows to the drain cir- the cylinder bottom side.
cuit. The pressure oil at the port S pushes • The oil at the cylinder rod side goes through
the lift spool (2) to the LOWER position. the port K to the drain port C to return to the
• The oil from the pump flows through the tank. Accordingly, the blade lowers.
bypass circuit of the tilt spool to the bypass
circuit of the lift spool (2). Since the bypass
WD600-3 10-119
LIFT SPOOL FLOAT POSITION
OPERATION
• Placing the work equipment control lever (3) • The oil at the cylinder bottom side goes
at the FLOAT position moves the spool of the through the port H and the port C to the drain
PPC valve beyond the LOWER position to the circuit, and the oil at the cylinder rod side goes
FLOAT position. The pressure oil at the port through the port K and the port C to the drain
L flows to the port M and port S. The pressure circuit. Accordingly, the blade floats.
oil at the port T flows to the port N.
• The pressure oil at the port S pushes the lift
spool (2) to the FLOAT position.
10-120 WD600-3
TILT SPOOL AT RIGHT TILT POSITION
OPERATION
• If the work equipment control lever (3) is set • The oil on the cylinder rod side flows through
in the RIGHT TILT position, the hydraulic oil port D to drain port C and returns to the tank.
in port L of the PPC valve flows through port The circuit to the pitch cylinder (Right side) is
Q to port V and the oil in port R flows in the closed by the deco valve. Accordingly, the
drain circuit. The hydraulic oil in port V sets blade is tilted to the right.
tilt spool (1) in the RIGHT TILT position.
• Since the bypass circuit is closed by tilt spool
(1), the oil from port A pushes check valve (9)
open. The oil from check valve (9) flows
through ports F and G to the bottom side of
the pitch and tilt cylinder (Left side).
WD600-3 10-121
TILT SPOOL AT LEFT TILT POSITION
OPERATION
• If the work equipment control lever (3) is set • The oil on the cylinder bottom side flows
in the LEFT TILT position, the hydraulic oil in through port G to drain port C and returns to
port L of the PPC valve flows through port P the tank. The circuit to the pitch cylinder (Right
to port R and the oil in port V flows in the side) is closed by the deco valve. Accordingly,
drain circuit. The hydraulic oil in port R sets the blade is tilted to the left.
tilt spool (1) in the LEFT TILT position.
• Since the bypass circuit is closed by tilt spool
(1), the oil from port A pushes check valve (9)
open. The oil from check valve (9) flows
through ports D and E to the head side of the
pitch and tilt cylinder (Left side).
10-122 WD600-3
STRUCTURE AND FUNCTION DECO VALVE
DECO VALVE
1. Solenoid valve (sol. a) FUNCTION

2. Merge/divider valve • The deco valve is installed to the circuit be-
3. Solenoid valve (sol. b) tween the work equipment valve and pitch
and tilt cylinder and used to select the pitch-
A. From work equipment valve port A1 ing or tilting operation of the blade.
B. From work equipment valve port B1 • When the tilting operation is performed, the
C. To bottom side of pitch and tilt cylinder (Left 2 solenoid valves are turned off and the hy-
side) draulic oil from the work equipment valve
D. To rod side of pitch and tilt cylinder (Left side) flows to the left cylinder. The circuit to the
E. To bottom side of pitch cylinder (Right side) right cylinder is closed. As a result, the blade
F. To rod side of pitch cylinder (Right side) is tilted.
T. To hydraulic tank • When the pitching operation is performed, the
PL. Pilot port 2 solenoid valves are turned on and the hy-
draulic oil from the work equipment valve
flows to the both cylinders simultaneously. As
a result, the blade is pitched.
WD600-3 10-123
SOLENOID VALVE (SOL a)
a. Port X
b. Port A
c. Port B
d. Port Y
e. Port P
f. Port T
10-124 WD600-3
OPERATION OF SOLENOID VALVE (a)

When no electricity is flowing
• The pressure oil entering from port PL passes
through solenoid valve port A and enters
chamber AS. It than moves the spool to the
right and closes the passages between ports
P and A and ports B and T of the spool. Cham-
ber BS is also connected to port T the sole-
noid valve and is opened.
When electricity is flowing

through solenoid valve port B and enters
chamber BS. It then moves the spool to the
left and opens the passages between ports P
and A and ports B and T of the spool.
• The oil flows from port P to port A, and sends
oil to the cylinder head. The oil returning from
the cylinder bottom flows from port B to port
T. This actuates the cylinder.
WD600-3 10-125
SOLENOID VALVE (SOL b)
a. Port Ta
b. Port Tb
c. Port Y
d. Port B
e. Port P
f. Port A
g. Port X
10-126 WD600-3
OPERATION OF SOLENOID VALVE (b)

When no electricity is flowing
through solenoid valve port A and enters
chamber AS. It then moves the spool to the
left and opens the passages between ports A
and P and port T and B of the spool. Chamber
BS is also connected to port T of the solenoid
valve and is opened.
Oil flows is from ports T and A, merges with
the oil from ports B and P, and flows to the
cylinder.
When electricity is flowing

• When the solenoid valve is actuated, the pres-
sure oil entering from port PL passes through
solenoid valve port B and enters chamber BS.
It then moves the spool to the right and opens
the passages between ports P and B and ports
A and T of the spool. Chamber AS is also con-
nected to port T of the solenoid valve and is
opened.
When ports A and T and ports P and B are
connected, the oil stops flowing.
WD600-3 10-127
MERGE/DIVIDER VALVE
1. Spring FUNCTION
2. Cover Regardless of pressure difference fluctuation be-
3. Sub-spool tween A and B ports, oil in-flow is divided equally
4. Spool or merged.
5. Body
a. Port A
b. Port B
c. Port P
10-128 WD600-3
OPERATION MERGE/DIVIDER VALVE

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

port A and B moves the sub-spools to the in-
side.
The oil then passes from ports A and B
through the throttle in the sub-spools and
through the passages in the spools, and is
merged equally at port P.
When there is differential pressure generated
between ports A and B, the spools move in
the same way as when the flow is divided and
adjust the flow to merge the oil equally.
WD600-3 10-129
1. Operation of right tilt
10-130 WD600-3
• The pressure oil supplied from work 2. Operation of left tilt

equipment valve port A1 flows from port • The pressure oil supplied from work
A and enters the merge/divider valve. Part equipment valve port B1 passes through
of the pressure oil which is divided passes port B. Solenoid valve as is not actuated,
through port G and flows to port C. The so pilot spool (1) is also not actuated. As
other flows of pressure oil passes through a result, the pressure oil does not flow to
port H, and if solenoid valve (a) is not ac- port K, but flows to port D. It then flows to
tuated, pilot spool (1) is also not actuated, the rod end of left tilt/pitch cylinder (3).
so the pressure oil does not flow to port • At the same time, the oil at the bottom
J, but flows to port L and M. Solenoid end of left tilt/pitch cylinder (3) is divided
valve (b) is not actuated, so pilot spool (2) from port C. Some of the oil flows to port
is also not actuated. As a result, the pres- G, and the rest flows to port N and P.
sure oil passes through ports N and P, • Solenoid valve (b) is not actuated, so pi-
merges at port C, and flows to the bot- lot spool (2) is also not actuated. As a re-
tom end of left tilt/pitch cylinder (3). sult, the pressure oil passes through ports
• At the same time, the oil at the rod end of L and M, flows to port H, is merged at the
left tilt/pitch cylinder (3) flows from port merge/divider valve, passes through port
D to port B, and return to the tank. A and returns to the tank.
• The pressure oil at ports E and F does not • The pressure oil at port E and F does not
flow, so right pitch cylinder (4) does not flows, so right pitch cylinder (4) does not
move. move. Therefore, the work equipment tilts
Therefore, the work equipment tilts to the to the left.
right.
WD600-3 10-131
3. Operation of forward pitch
10-132 WD600-3
• The pressure oil supplied from work 4. Operation of rear pitch

equipment valve port A1 flows from port • The pressure oil supplied from work
A and enters the merge/divider valve. Part equipment valve port B1 flows from port
of the pressure oil which is divided passes B. Some of the pressure oil flows to port
through port G, flows to port C, and then D, and then flows to the rod end of left
flows to the bottom end of left tilt/pitch tilt/pitch cylinder (3). With the other flows
cylinder (3). of pressure oil, solenoid valve (a) is actu-
The other flows of pressure oil passes ated, so pilot spool (1) is also actuated,
through port H. Solenoid valve a is actu- and the oil flows to port L. It when flows
ated, so pilot spool (1) is also actuated, from port L, passes through ports K and F
and the pressure oil flows to port J. From and flows to the rod end of right pitch
port J, it passes through port M and E and cylinder (4).
flows to the bottom end of right pitch cyl- • At the same time, the oil at the bottom
inder (4). end of left tilt/pitch cylinder (3) flows from
When this happens, the solenoid valve is port C to port G, while the oil at the bot-
actuated so pilot spool (2) is actuated and tom end of right pitch cylinder (4) flows
the passages between ports N and P and from port E to port H. It is then merged at
ports Q and R are opened. the merge/divider valve, passes through
• At the same time, the oil at the rod end of port A and returns to the tank.
left tilt/pitch cylinder (3) flows from port When this happens, solenoid valve (b) is
D to port B, while the oil at the rod end of actuated so pilot spool (2) is actuated and
right pitch cylinder (4) flows from port F the passages between ports N and P and
through solenoid valve (a). It is then Q and R are opened. Therefore, the work
merged, passes through port B and re- equipment is pitched to the rear.
turns to the tank.
Therefore, the work equipment is pitched
forward.
WD600-3 10-133
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Vent 6. Comperssor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
10-134 WD600-3
CONDENSER
1. Refrigerant gas inlet port

2. Fan
3. Connector
4. Refrigerant gas outlet port
COMPRESSOR
1. Refrigerant outlet port

2. Refrigerant inlet port
3. Relief valve
4. Clutch
SPECIFICATIONS
Type: Piston pump type
Refrigerant used: R134a
WD600-3 10-135
DRY RECEIVER
1. Body
2. Dryer
10-136 WD600-3
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
OUTLINE
• The machine monitor system uses the sen- • There are also various switches built into the
sors and other devices installed to various monitor panel which function to operate the
parts of the machine to observe the condition machine.
of the machine. It processes this information
swiftly and displays it on the monitor panel ª The main monitor uses the network wiring to
to inform the operator of the condition of the send signals to the controller, and functions
machine. to display the following information.
• The machine monitor system consists of the 1) Shift indicator: 1st - 4th, N, F, R (F, R are
main monitor, maintenance monitor, sensors, optional) (When auto shift, joystick steer-
switches, relays, alarm buzzer, and power ing are installed)
source. 2) HOLD (When auto shift is installed)
• The displays can be broadly divided into the 3) Failure action code, failure code, time
following: Cautions displayed on the moni- elapsed since failure (failure data display
tors (abnormalities in the machine where an mode)
alarm is given) and normal conditions which
are always displayed on the instrument panel
(pilot lamps and readings for the gauges,
speedometer, and service meter).
WD600-3 10-137
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
1. Check lamp 4E. Speedometer 5. Switches

2. Caution lamp 4F. Shift hold 5A. Working lamp (front)
3. Caution items 4G. Parking brake switch
3A. Emergency steering actuated 4H. Emergency steering 5B. Working lamp (rear)
4. Pilot items normal switch
4A. Turn signal (left) 4I. Monitor pilot lamp 5C. Transmission cut-off
4B. Turn signal (right) (preheating, afterheating) switch
4C. High beam 4J. Failure action code 5D. Auto shift, manual
4D. Shift indicator selector switch
OUTLINE
• The main motor has a display function for the installed internally, and this processes the sig-
speedometer and other gauges and a switch- nals from the sensors and outputs the display.
ing function to control the electric compo- • A liquid crystal display and LEDs are used for
nents and controllers. the display. The switches are embossed sheet
• There is one CPU (Central Processing Unit) switches.
10-138 WD600-3
MAIN MONITOR DISPLAY FUNCTION

Display
category Symbol Display item Display range Display method
When there is Display flashes (for details, see

Check CHECK Check abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Emergency steering
actuated When actuated Display flashes
Parking brake actuated,

transmission not at Display flashes and buzzer
Caution sounds
neutral
CAUTION Caution Display flashes (buzzer may
When there is also sound) for details, see
abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Hi beam When operated Display lights up
Turn signal
(left, right) When operated Display lights up
Display lights up
Parking brake When operated Buzzer sounds when parking
brake is applied and shift lever
is not at N
Pilot Emergency steering When normal (oil is

normal flowing in hydraulic Display lights up
circuit)
Lights up
Lighting up time changes
Preheating When preheating according to engine water
temperature when starting
switch is turned ON
Shift hold
(Machine equipped When shift is held Display lights up
with auto shift)
Digital display (display switches

Speedo- Travel speed 0 – 99 km/h between tachometer and
meter speedometer)
Shift Shift indicator 1–4N Digital display

indicator
When controller detects

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action Failure action code CALL is displayed, (For details of the travel data
code or CALL AND E B B display mode, see TROUBLE
(action code) are DATA DISPLAY MODE)
displayed in turn
Shift F, R, display (when

indicator equipped with F. R Digital display
joystick steering)
WD600-3 10-139
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
Front working lamp lights up Lights up Front working lamp lights up

Working lamp or goes out each time switch is
(front) pressed when side lamps are
lighted up Goes out Front working lamp goes out
Rear working lamp lights up or Lights up Rear working lamp lights up

Working lamp goes out each time switch is
(rear) pressed when side lamps are
lighted up Goes out Rear working lamp goes out
Lights up Cut-off function actuated

Transmission Transmission cut-off function is
cut-off actuated or stopped each time
switch is pressed
Goes out Cut-off function stopped
Auto shift mode switches to Lights up Manual mode

Manual manual mode when switch
is pressed
Goes out Auto shift mode
10-140 WD600-3
TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (1) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
ON (000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
SDW00241 999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
ON
SPEED Failure code
x 100
RPM
km/h
MPH Time elapsed
since failure
SDW01254
SDW00242
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
ON
(flashing display) cannot be cleared.
SDW00243
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
WD600-3 10-141
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
1. Check items (Checks before 3. Gauge items 4. Service meter

starting) 3A. Fuel level 4A. Service meter numeric
1A. Engine water level 3B. Engine water tempera- display
1B. Engine oil level ture 4B. Service meter RUN
2. Caution items (warning 3C. Torque converter oil pilot lamp
items) temperature 5. Monitor module
2A. Engine oil pressure 6. Switch module
2B. Brake oil pressure
2C. Battery charge
2D. Air cleaner
OUTLINE
• The maintenance monitor has a display func- • The monitor module has a built-in CPU (Cen-
tion for the caution items and gauges, and tral Processing Unit). It processes the signal
switch functions to control the work equip- from the sensors, and carries out the display
ment controller. and output.
• The maintenance monitor consists of the • A liquid crystal display and LEDs are used for
monitor module, switch module, service the display portions.
meter, case, and other mechanisms.
10-142 WD600-3
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Check Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
CHECK lamp flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

pressure
––––––––––––––––––––-
Engine water temperature Above 102°C Buzzer sounds if above 105°C
––––––––––––––––––––-
Torque converter oil Above 120°C Buzzer sounds if above 130°C
Caution temperature
Fuel level Below low level Displays when engine is running

Display when normal: OFF
CAUTION lamp flashes
Battery charge When charge is Displays when engine is running

defective Display when normal: OFF
Air cleaner Above specified CHECK lamp flashes
negative pressure
Service meter 0 – 9999.9h Actuated when charge is normal

Advances 1 for every hour
Service
meter Service meter indicator Lights up when service meter is
running
Fuel level All lamps light up below applicable

EMPTY FULL level
1 2 3 4 5 6 7 Flashes when level is 1
E F
Red Green
Engine water temperature One place lights up to show

Gauges 67 80 90 97 102 105˚C
applicable level
Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
White Green Red
Torque converter oil One place lights up to show

temperature 50 70 90 110 120 130˚C
applicable level
Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
Green Red
WD600-3 10-143
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Function
• The neutral safety circuit is employed so that If the starting switch is turned to the START
the engine will be started safely, that is, the position, the current flows circuit [1] from
engine cannot start when the forward-reverse the positive (+) terminal of the battery
lever is not in the N (Neutral) position. through starting switch terminals B and C,
• If the starting switch is turned to the OFF po- neutral relay terminals 5 – 3, starting motor
sition, supply of the fuel is stopped to stop terminal C, and starting motor terminal E to
the engine. the ground.
• The ECM controller controls the fuel injec-
Operation tion rate and injection timing according to
• If the forward-reverse lever is set in the N various signals.
(Neutral) position, the neutral contacts of the • The circuit from the battery through battery
forward-reverse lever are “closed”. If the relay to starting motor terminal B is formed
starting switch is turned to the ON position, to start the engine.
the neutral relay operates to “close” termi- If the forward-reverse lever is not in the N
nals 3 - 5. Then the current flows from start- (Neutral) position, circuit [1] is not formed
ing switch terminal BR through the battery and the engine does not start.
relay coil to the ground to “close” the bat-
tery relay.
10-144 WD600-3
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
Operation
• If the starting switch is turned to the OFF po-
sition, starting switch terminals B and BR and
ACC are “opened”.
• The ECM controller outputs a signal to shut
off the fuel, then supply of the fuel is stopped
to stop the engine.
WD600-3 10-145
STRUCTURE AND FUNCTION PRE-HEATING CIRCUIT
PRE-HEATING CIRCUIT
AUTOMATIC PRE-HEATING SYSTEM
Outline Operation
• The automatic preheating system is installed • If the starting switch is turned to the ON posi-
so that the engine will start easily in a cold tion, the preheating relay operates to “close”
district. This system shortens the preheating the contacts according to the signal from the
time and sets the preheating time automati- ECM controller. Then, a current flows through
cally according to the engine coolant tempera- preheating relay terminal [5] to the heater re-
ture when then starting switch is operated. lay to “close” the contacts of the heater relay
• If the starting switch is turned to the ON posi- • The current flows from the battery through
tion, a current flows in the ribbon heater to the battery relay and heater relay to the rib-
preheat the sucked air. bon heater to preheat the sucked air.
The ECM controller determines the preheat- • When preheating is finished, the current from
ing time according to the coolant temperature the ECM controller to the preheating relay is
measured by the engine coolant temperature cut out and the heater relay contacts are
sensor. “opened”.
• During preheating, the preheating pilot lamp • During preheating, the current also flows from
of the main monitor keeps lighting up. When preheating relay terminal [5] to the main
preheating is finished, the preheating pilot monitor to turn on the preheating pilot lamp.
lamp goes off.
10-146 WD600-3
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
1. Transmission cut-off selector switch 8. Fuse boxes

2. Parking brake switch 9. Transmission controller
3. Directional lever (with auto shift transmission)
4. Speed lever 10. Transmission control valve
5. Work equipment control leveer 11. Speed sensor
5a. Kick-down switch 12. Transmission cut-off switch
5b. Hold switch 13. Brake valve (left)
6. Maintenance monitor 14. Brake valve (right)
7. Relays
Function
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch
3 Kick-down switch without using the speed lever. If directional lever is operated to R or N,
speed range automatically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated
5 Transmission cut-off selector function It is possible to select whether to actuate or not actuate the
transmission cut-off function.
To prevent seizure of the parking brake when traveling with the parking
6 Neutralizer brake applied, the transmission is shifted to neutral when the parking
brake is applied.
If the directional lever is not at the N position, the engine will not start
7 Neutral safety function when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)
8 Warning function When traveling in reverse, the backup lamp lights up and the backup
horn sounds to warn people in the area.
WD600-3 10-147
COMBINATION SWITCH
1 8 7
2 3 9 10 4 6 5
SDW00301
OUTLINE
• The directional lever has three positions and body by three screws. When each lever is
the speed lever switch has four positions. As operated to the desired position, the switch,
an individual part, the switch does not have a which is interconnected by a shaft, acts to al-
detent mechanism; the detent mechanism is low electric current to flow to that circuit only.
in the combination switch. Each switch is po-
sitioned by two pins, and is secured to the
General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd or 4th during
3 Speed lever stopper
operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position
5 Self cancel
after machines turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
Makes both left and right turn signal indicator lamps flash at the
8 Hazard switch
same time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10 Parking brake switch Applies or releases parking brake
10-148 WD600-3
OPERATION
• Directional lever (1) and shaft (2) of the speed F
lever of the combination switch form one unit
with magnet (3), and magnet (3) also moves
together with lever (1). N
• Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole
R
IC (4) is positioned on the board to match each 2
position. 1
• When directional lever (1) is operated to the F
position, magnet (3) is immediately above
hole IC (4) for the F position of the control
switch. The magnetism from magnet (3)
passes through the gap and case (6), and
magnetism is applied to hole IC (4).
• When this happens, hole IC (4) is inside a 3
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F 4
position signal to the electric current amplifi- 6
cation circuit. In the electric current amplifi-
cation circuit, a signal is output to actuate the 5
transmission. SEW00302
WD600-3 10-149
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
KICK-DOWN, HOLD SWITCH
1. Work equipment control lever

2. Hold switch
3. Kick-down switch
4. Tilt or pitch switch
5. Switch
KICK-DOWN SWITCH HOLD SWITCH

OPERATION With auto shift transmission
• The kick-down (shifting down from 2nd → 1st) • The hold switch is installed to the work equip-
is actuated only when traveling in F2. ment control lever, and when the hold switch
• When traveling in F2, if it is desired to shift is pressed, the speed range displayed on the
down to 1st without operating the speed le- main monitor transmission indicator is held.
ver, operate the kick-down switch on the boom • Press the hold switch again to cancel.
lever to ON to shift down to F1.
• After this, even if the kick-down switch is
pressed, the transmission is kept at F1.
CANCELLATION (or not actuated)

• When directional lever is at N
• When directional lever is at R
• When speed lever is not at 2nd
• When starting switch is OFF
10-150 WD600-3
STRUCTURE AND FUNCTION TRANSMISSION AND JOYSTICK STEERING SYSTEM
TRANSMISSION AND JOYSTICK STEERING SYSTEM

Outline of system
Automatic shift
Hold function
Kickdown function
Safety function
Manual shift
Kickdown function
Engine selecting function (Komatsu/Cummins)
Joystick steering control
Self-diagnosis function
Indication of condition (Output, failure code)
Troubleshooting (System trouble, wire breakage in system, detection of short circuit)
Communicating function
• The Automatic shift transmission system con- • The self-diagnosis function constantly moni-
sists of a transmission controller, directional/ tors the input and output conditions and indi-
gear shift lever, engine revolution sensor, cates the output condition on the two “7-seg-
travel speed sensor, and solenoid valve for ment LED” of the transmission controller. The
all gear speeds. fault detecting function detects a fault and in-
dicates it by an failure code. Then, the main
• The transmission controller shifts the trans- monitor indicates the “failure code” and
mission to a proper gear speed according to flashes the caution lamp according to the se-
the gear shift lever and travel speed signals. riousness of the fault to ensure safety.
• The safety function prevents the vehicle from • The transmission controller has a communi-
moving when the engine is started and the cating function. It sends the gear speed (N,
transmission protecting function protects the 1st – 4th) data to the main monitor, then the
clutch when the directional lever is operated, main monitor indicates the received gear
thus the durability of the vehicle is improved. speed. In the joystick mode, the main moni-
tor indicates the travel directions “F”, “N” and
“R”, too.
WD600-3 10-151
System configuration
D Lock-up switch
Model selection signal Lock-up solenoid valve D
D Directional switch F. solenoid valve D
D Range switch R. solenoid valve D
D Transmission cut-off switch 1st. solenoid valve D
D Kickdown switch (ª1) 2nd. solenoid valve D
P Engine speed 3rd. solenoid valve D
P Travel speed Transmission controller 4th. solenoid valve D
D Neutralizer relay signal Kickdown signal D

Indication
D Hold switch (ª2) Failure code S-Net
Indication
D Manual switch Shift indicator S-Net
Indication
D Engine selection Trouble indicating buzzer output S-Net
Indication
D Automatic shift transmission signal Main monitor F, N, R S-Net
Indication
Hold pilot lamp S-Net
D Joystick steering signal
Engine speed D
Indication
Manual indicator lamp (ª3)
D Joystick steering ON-OFF Backup lamp relay S-Net
D Joystick lever F.N.R switch Steering LEFT proportional solenoid valve A
A Steering lever angle potentiometer Steering RIGHT proportional solenoid valve A
D Steering neutral detection switch Steering solenoid valve cutting relay D
D Shift-up switch (ª2) Caution relay (Steering) D
D Shift-down switch (ª1) Engine speed P
Neutral safety output D
Steering N LED D
Steering F LED D
Steering R LED D
Indication
Lock-up pilot lamp S-Net
A : Analog signal
Engine speed control signal S-Net
D : Digital signal
P : Pulse signal
:Signal for joystick steering
ª1 :Kickdown switch : [Shift-down switch]

ª2 :Hold switch : [Shift-up switch]
ª3 :Output of the manual indicator lamp is judged by the main monitor.
10-152 WD600-3
Outline 4) Directional lever at “R” position

The gear is shifted automatically in a
1. Automatic shift function range from 2nd to 4th speed according to
Shift-up and shift-down operations of the the travel speed, just like to the operation
transmission are controlled with the signals at the “F” position.
from the directional lever, gear shift lever, and 5) Skip shift
travel speed sensor according to the “Auto- While the vehicle is coasting at speed be-
matic shift change points table” (Table 1) low 8km/h with the transmission at the 3rd
stored in the memory of the transmission con- or 4th speed, if the accelerator pedal is
troller when the engine speed is 1,450rpm or pressed, the gear is shifted to the 2nd
higher. speed position immediately so that the
1) Gear shift lever (1st – 4th) vehicle can be accelerated easily. If the
The gear shift lever limits the highest gear travel speed is 8km/h or higher, the gear
speed (gear shifting range) for Automatic speed is not changed. After the engine
shift operation. speed rises to 1,450rpm, the transmission
Examples: is set to a gear speed matched to the travel
Gear shift lever at 4th: 2nd – 4th speed speed.
Gear shift lever at 2nd: Fixed to 2nd speed 6) Gear-shift inhibition time
Gear shift lever at 1st: Fixed to 1st speed Once the transmission is set to a gear
2) Directional lever at “N” position speed, it is kept at that gear speed for a
If the directional lever is at the neutral po- certain time to prevent shift hunting. The
sition, only the gear speed clutch of the time during which the gear cannot be
transmission is operated. shifted depends on the gear shifting pat-
3) Directional lever at “F” position tern. See Table 1 “Automatic shift change
If the directional lever is shifted from N points table”.
position to F position, the F solenoid valve
and 2nd speed solenoid valve are turned 2. Hold function
“ON” (F2). Automatic start at 2nd speed. If the hold switch is pressed, the current gear
a) Shifting up When gear shift lever is speed is held as the optimum gear speed, and
at “4th”. it is not shifted down even if the travel speed
If the accelerator pedal is pressed and lowers. When the travel direction is changed,
the engine speed rises and the travel however, the gear is usually shifted down to
speed reaches about 9.3km/h, the 3rd the 2nd position according to the current
speed solenoid valve is turned “ON” travel speed, then shifted up again to the held
and the 2nd speed solenoid valve is position according to the gear shifting condi-
turned “OFF”. The gear is shifted to tion. This function prevents unnecessary
F3. shift-down operation while traveling on a fin-
If the travel speed reaches about ished ground or down a slope.
17.6km/h, the 4th speed solenoid
valve is turned “ON” and the 3rd 3. Kickdown function
speed solenoid valve is turned “OFF”. When the operator turns “ON” the kickdown
The gear is shifted to F4. switch, if the conditions (gear speed, travel
b) Shifting down When the gear shift le- speed) in Table 1 “Automatic shift change
ver is at “4th”. points table - 5. Kickdown” are satisfied, the
While the vehicle is traveling at the 4th gear is shifted to the 1st position forcedly, re-
speed, if the accelerator pedal is regardless of setting of the Automatic shift func-
leased and the travel speed drops to tion.
about 15.6km/h, the 3rd speed sole- This function is reset and the gear is shifted
noid valve is turned “ON” and the 4th to the 2nd position when the travel speed rises
speed solenoid valve is turned “OFF”. or the travel direction is changed. This func-
The gear is shifted to F3. tion is effective even if the gear speed is fixed
If the accelerator pedal is released and while the hold function is turned on or the
the travel speed lowers to about vehicle is in the engine revolution OFF mode.
9.8km/h, the 2nd speed solenoid valve
is turned “ON” and the 3rd speed so-
lenoid valve is turned “OFF”. The
gear is shifted to F2.
WD600-3 10-153
4. Travel modes 4) Transmission protect

While the vehicle is traveling in 3rd or 4th
1) Manual mode speed, if the directional lever is operated,
The Automatic shift mode or manual shift the gear speed is controlled and the alarm
mode can be selected. buzzer is turned on to protect the trans-
In the manual mode, the gear is shifted mission.
according to the operation of the gear shift a) Gear speed control
lever. While the vehicle is traveling in the When the engine speed and travel
F 2nd speed in this mode, the kickdown speed are in “Range I”, the gear is
function is available. shifted down to the 2nd position.
When the engine speed and travel
2) Joystick control function speed are in “Range II”, the gear is
a) If the joystick function is installed to not shifted immediately, but shifted
the vehicle, the operator can select the down to the 2nd position as the travel
steering wheel mode or joystick steer- speed lowers.
ing mode freely. See “Fig. 1 F-R change and gear-shift
b) When changing the steering wheel pattern” and “Table 1 Automatic shift
mode and joystick steering mode to change points table - 7. Changeover
each other, be sure to stop the vehicle of F and R to each other”.
and set the gear shift lever to the N b) Warning with alarm buzzer
(Neutral position). At this time, the When the engine speed and travel
neutral interlock is applied to the speed are in “Range III”, the alarm
transmission controller to prevent the buzzer sounds for warning (when the
vehicle from moving abruptly. engine speed is above 1,600rpm and
fl For details, see “List of travel modes travel speed is above 13km/h or when
and functions of transmission control- the travel speed is above 14km/h).
ler”.
5) Transmission protection in joystick
5. Safety function manual mode
1) Neutral safety Since change of the travel direction and
When the engine is started, if the direc- shift-down of the gear are facilitated, the
tional lever is not at the N position, the gear is shifted up from 1st or 2nd posi-
transmission controller holds the trans- tion to 3rd or 4th position in the joystick
mission to the neutral position and does manual mode, depending on the travel
not start the vehicle. This condition is re- speed and engine speed, to protect the
set when the first N signal is input after transmission. At this time, the alarm
the engine is started. buzzer sounds.
2) Neutral interlock 6) Manual shift

. When the steering wheel mode is If the travel speed cannot be detected be-
changed to the joystick steering mode, cause of a travel speed sensor, the vehicle
the transmission is always set to the is set to the manual shift mode.
neutral position.
. When the joystick steering mode is
changed to the steering wheel mode,
the vehicle cannot be started until the
first N signal is input.
3) Gear shift lever priority

The gear can be shifted down with the
gear shift lever at any time so that the
engine brake can be utilized while travel-
ing down a slope.
10-154 WD600-3
6. Torque converter lock-up control function

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

Travel mode F1 F2 F3 F4 R1 R2 R3 R4
Manual shift
Automatic shift ª ª ª ª
ª When the gearshift lever is in the 4th position and the actual gear speed is 2nd or 3rd in the
automatic shift mode, the torque converter is not locked up. When the gearshift lever is in
the 3rd position and the actual gear speed is 3rd, the torque converter is locked.
2) Lock-up gear speed

For the gear speed at which the lock-up is turned on and off, see “Automatic shift points list”.
Even if the manual gearshift is selected, the lock-up is turned ON and OFF at the same travel
speed as in the automatic shift mode.
The lock-up is reset automatically for safety if the travel speed exceeds 41.5 km/h. If the travel
speed lowers below 41.5 km/h again, the lock-up is turned ON again.
3) Lock-up protection function

The lock-up is turned ON only when the travel direction of the machine is the same as the lever
position.
Judgment of travel direction of machine
a. When the travel speed is equal to or higher than 6 km/h, the current travel direction of the
machine is determined by the lever position.
b. If the travel speed is kept equal to or higher than 6 km/h, the travel direction judged by “a”
above is applied.
c. If the travel speed is kept below 6 km/h for 1 second continuously, the travel direction judged
by “a” above is cancelled and it is assumed that there are no data.
d. If there are no data of F and R travel directions or when the travel direction is not the same as
the lever position, the lock-up function is not turned ON.
4) Lock-up indicator function

The lock-up indicator lights up when the lock-up solenoid output is turned ON. If the lock-up
solenoid is abnormal, the lock-up indicator flashes to notify the operator that the lock-up sole-
noid is abnormal.
WD600-3 10-155
7. Engine overrun prevention function

If the operator shifts down the gear while traveling downhill at high speed and pressing the accelera-
tor pedal, the engine may overrun because of the drive force of the tires.
To prevent the overrun in this case, the transmission controller limits the shift-down operation ac-
cording to the engine speed and transmission output shaft speed (= travel speed).
1) The protection application condition: If the gear is shifted down while the protection application
condition [A or (B and C)] is satisfied, the shift-down signal is not output but the alarm is turned
ON.
2) Protection reset condition: If the protection reset condition [D and (E or F)] is satisfied, the alarm
is turned OFF and the shift-down signal is output.
Application condition [A or (B and C)] Reset condition [D and (E or F)]
Condition A Condition B Condition C Condition D Condition E Condition F
Gear speed Transmission Transmission Transmission Transmission
shifted down output shaft output shaft Engine speed output shaft output shaft Engine speed
speed speed speed speed
To 3rd gear 2,100 rpm or 2,100 rpm or Below 1,900 Below 1,900
speed None higher higher None rpm rpm
To 2nd gear 2,100 rpm or 1,500 rpm or 2,100 rpm or Below 1,900 Below 1,300 Below 1,900
speed higher higher higher rpm rpm rpm
To 1st gear 1,500 rpm or 1,000 rpm or 2,100 rpm or Below 1,300 Below 800 Below 1,900
speed higher higher higher rpm rpm rpm
3) Protect alarm reset condition: The protect alarm output is turned OFF and the normal control is
started again in the following cases.
a. When the input command and output command become the same after operation of the
gearshift lever (gearshift switch)
b. When the gear speed of the output command or a higher one is selected by operation of the
gearshift lever (gearshift switch)
4) Control in shift-down protection control mode: The holding and kickdown operations are ineffec-
tive while the shift-down protection control is turned ON.
Transmission output shaft speed and travel speed (Reference)
Transmission output shaft speed (rpm) Converted travel speed (km/h)
2,100 34.6
1,900 31.3
1,500 24.7
1,300 – 21.4
1,000 16.5
800 13.2
8. Engine speed control function

Signals to control the engine speed are output to the throttle controller through the network to stabi-
lize the engine speed when the travel direction is changed, if necessary.
Table 1 Automatic shift change points table
Item Gear speed Travel speed (km/ h) Gear-shift inhibition

time (sec)
1. Basic shift change 1→2 5.6 (5.8) or higher 2
2→Lock-up at 2 8.0 or higher 0
2→3 9.3 (9.8) or higher 2

Forward : 14.2 or higher
3→Lock-up at 3 Reverse : 15.7 or higher 0
3→4 17.6 or higher 1

Forward : 24.9 or higher
4→Lock-up at 4 Reverse : 27.6 or higher 0
4→3 Below 15.6 1
3→2 Below 9.8 (9.3) 2
10-156 WD600-3
Item Gear speed Travel speed (km/ h) Gear-shift inhibition

time (sec)
Forward : Below 7.1
2. Engine speed Lock-up at 2→2 Reverse : Below 7.9 0
(Below 1,450rpm) Forward : Below 12.6
Lock-up at 3→3 Reverse : Below 14.0 0
Forward : Below 22.2
Lock-up at 4→4 Reverse : Below 24.5 0
4→2 Below 1.0 0
3→2 Below 1.0 0

3. Engine speed 4→2 Below 8.0 2
(Below 1,450rpm → 1,450rpm or
higher) 3→2 Below 8.0 2
4. Shift-up operation while hold 1→2 5.6 0
function is ON
2→3 9.3 0
3→4 17.6 0
5. Shift-down operation while 2→1 No limit 5
kickdown function is ON
3→1 Below 12.7 5
4→1 Below 12.7 5

6. Changeover of F and R to each other 4→2 Note 1)
(Range I in Fig. 1)
(F→)N→R 3→2 2
(R→)N→F
1→2
7. Changeover of F and R to each other Note 2)
(Range II in Fig. 1)
(F→)N→R →4 17.6 or higher 2
(R→)N→F →3 Below 9.3 – 17.6
8. Changeover of F and R to each other →4 17.6 or higher
F→N→F →3 Below 9.3 – 17.6 0
R→N→R
→2 Below 9.3
Note 1)The engine speed is below 1,800rpm and travel speed is below 16km/h, or travel speed is below 13km/h.
Note 2)When the engine speed is 1,800rpm or higher and travel speed is 13km/h or higher, or travel speed is
16km/h or higher, the gear is not shifted immediately, but shifted down to the 2nd position as the travel
speed drops.
WD600-3 10-157
9. List of travel modes and functions of transmission controller

Steering wheel Auto mode ←
Available functions: Automatic shift, kickdown switch, hold, transmission protect
Set the highest using gear speed according to the

position of the transmission shift lever.
Transmission protect function for changing over F
and R to each other is installed.
Position of Solenoid valve output Position of Solenoid valve output
transmission Gear speed before transmission
shift lever F R setting to N shift lever 1 2 3 4
F 1
N (*) 2
R 3
(*) Initial output value of gear speed solenoid valve 4
When transmission shift lever is at “1”: 1st gear Range where kickdown switch is available
When transmission shift lever is not at “1”: 2nd gear (Shift-down to 1st gear)
Conditions to reset kickdown function (Kickdown function is available in both F and R)

(1) Directional lever: F → N, R → N, or F ↔ R
(2) Rise of travel speed: As per Automatic shift change points table
(3) Power source: OFF
Conditions to reset hold function

(1) Hold switch: ON (GND) Press switch again.
(2) Manual switch: ON (GND) When set to manual mode.
Joystick steering Auto mode ←

Available functions: Automatic shift, kickdown switch, hold, transmission protect

Transmission protect function for changing over F
and R to each other is installed.
F 1
N (*) 2
R 3
When transmission shift lever is at “1”: 1st gear Range where kickdown switch is available
When transmission shift lever is not at “1”: 2nd gear (Shift-down to 1st gear)
Conditions to reset kickdown function (Kickdown function is available in both F and R)

(1) Joystick knob switch: F → N, R → N, or F ↔ R
(2) Rise of travel speed: As per Automatic shift change points table
Conditions to reset hold function

(1) Hold switch: ON (GND) Press switch again.
(2) Manual switch: ON (GND) When set to manual mode.
10-158 WD600-3
→ Manual mode
Available functions: Manual shift, kickdown switch

F 1
N (*) 2
R 3
Same gear speed as transmission shift lever Range where kickdown switch is available
(Only in F position)
Conditions to reset kickdown function (Kickdown function is available only in F2)

In the steering wheel
(1) Directional lever: F → N, F → R manual mode, change the
(2) Gear shift lever: * Shift to position other than 2nd gear. gear speed with the
(3) Power source: OFF transmission shift lever.
* When shifted to the first gear: 1st gear (Kickdown function is reset)
→ Manual mode
Available functions: Shift-up/down function, transmission protect


joystick knob Gear speed before transmission
switch F R setting to N shift lever 1 2 3 4
F 1
N (*) 2 –––––––
R 3 ––––––– –––––––
(*) Initial output value of gear speed solenoid valve 4 ––––––– ––––––– –––––––
When transmission shift lever is at “1”: 1st gear In the joystick manual mode, change the gear speed
When transmission shift lever is not at “1”: 2nd gear by one position with the shift-up/down switch.
(Note) When the gear shift lever is at “2” or higher position, if F and R are
changed over to each other at 1st speed, the gear is shifted to 2nd speed.
WD600-3 10-159
10. Change of travel mode of transmission controller
1) Specifications for change over “steering wheel and joystick” modes to each other and over “auto
and manual” modes to each other
a) Neutral interlock function
When the mode is changed, the neutral condition is held until the “N” signal is received
normally.
b) Gear speed
The output of the gear speed changes according to change of the mode.
Table 2 Output gear speed at change of mode

Condition after change of mode
Steering wheel Joystick
Auto Manual Auto Manual
Position of range 2nd speed (*1)

Auto lever (*2 (1)) (Changed at N)
Steering
Condition before
wheel
change of mode
2nd speed Gear speed is held.

Manual (*2(2)) (Changed at N)
2nd speed (*1) Previous gear

Auto (Changed at N) speed is held.
(*2 (2))
Joystick
Position of range 2nd speed
Manual lever (*2 (3))
(Changed at N)
(*1)Usually, the steering wheel mode and joystick mode are change over to each other while the
vehicle is stopped and the transmission is at the neutral, the gear is shifted to 2nd speed. If the
vehicle is traveling, the “restart data” of the Automatic shift function is used and the gear speed
matched to the current travel speed is set. If the gear shift lever is at “1”, 1st speed is set.
(*2)Auto and manual can be changed to each other in the same mode, even while the vehicle is
traveling.
(1) Steering wheel mode: When auto is changed to manual, the gear speed of the position of the
gear shift lever is set.
(2) Joystick mode: When auto is changed to manual, the gear speed is not changed.
(3) When manual is changed to auto, the gear speed matched to the current travel speed is set
according to the data of “Table 1 Automatic shift change points table - 8. Changeover of F and R
to each other”. If the gear shift lever is at “1”, however, 1st speed is set.
10-160 WD600-3
11. Self-diagnosis function

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

• Transmission control
1) Auto/Manual transmission control system
Main
System monitor
Code Item Remarks
Short Discon- Failure
circuit nection code
10 Lock-up solenoid valve No codes
11 None — — — —
12 F solenoid valve CALL
13 R solenoid valve CALL
14 1st speed solenoid valve CALL
15 2nd speed solenoid valve CALL
16 3rd speed solenoid valve CALL
17 4th speed solenoid valve CALL
18 None — — — —
19 Joystick directional switch E00
20 Directional switch signal CALL
21 Gear shift switch signal No codes
22 Travel speed sensor × E00
23 Engine revolution sensor × E00
2) Joystick control system

Main
monitor
Code Item Remarks
Short Discon- Failure
circuit nection code
56 Joystick caution relay output × No codes
57 Steering R (Right) solenoid valve (Detected when output) E00
58 Steering L (Left) solenoid valve (Detected when output) E00
59 Steering R (Right) solenoid valve shorted on HOT side × E00
60 Steering L (Left) solenoid valve shorted on HOT side × E00
61 Steering solenoid valve cut relay output E00
62 Joystick neutral switch trouble
E00
(For detecting range, see separate sheet.)
63 Joystick potentiometer trouble
E00
(Out of range from 0.5 to 4.5V)
fl E59 and E60 cannot be distinguished from each other, and they can be output simultaneously.
fl Since E56 is an output normally turned ON, disconnection cannot be detected.
WD600-3 10-161
12. Communicating function 5) Neutralizer relay signal

The transmission controller constantly com- This signal is a digital signal of +24V/
municates with the main monitor by using OPEN. If the parking brake is released,
communicating function based on the “S- +24V is input and the vehicle can travel.
net”. If any fault occurs, the transmission If the signal is OPEN, the transmission
controller indicates the failure code on the controller holds the neutral state.
main monitor to notify the operator accord- 24V: Parking brake is released.
ing to the seriousness of the fault to secure OPEN: Parking brake is applied.
the safety.
The failure codes stored in the main monitor 6) Transmission cut-off signal
can be checked in the fault condition mode. This signal is a digital signal of GND/
For the operating method of the main moni- OPEN, which is kept OPEN while the trans-
tor, see the section of the main monitor. mission cut-off switch is operated (while
the left brake is used). If the transmission
13. Power source for transmission controller cut-off switch is operated, the transmis-
While the starting key is at the “ON” position sion controller is set to the neutral state.
and the source voltage is 20V or higher and If the former is reset, the latter sets a gear
+20V or higher voltage is applied to the trans- speed matched to the current travel
mission controller solenoid valve, each sole- speed.
noid valve can be controlled.
If the source voltage lowers below 19V, all 7) Manual mode signal
output is turned “OFF” and each solenoid This signal is a digital signal of GND/
valve cannot be controlled (the vehicle can- OPEN. When the manual mode switch is
not travel). turned ON, GND is input.
14. Input signals 8) Lock-up switch signal

1) Directional lever (F, N, R) signal This signal is a digital signal of GND/
This signal is a digital signal of +24V/ OPEN. When the lock-up switch is turned
OPEN. Normally, one of F, N, and R sig- ON, GND is input.
nals (+24V) is input.
2) Gear shift lever (1st – 4th) signal

This signal is a digital signal of +24V/
OPEN. A +24V signal of the position of
the lever is input.
3) Kickdown switch/Shift-down switch

OPEN. If the kickdown switch installed to
the work equipment control lever is
pressed, +24V is input. Operation of the
switch is judged by the rise signal from
OPEN to +24V at this time. In the joystick
manual mode, the kickdown switch is
used as the shift-down switch.
4) Hold switch/Shift-up switch

OPEN. If the hold switch installed to the
work equipment control lever is pressed,
+24V is input. Operation of the switch is
judged by the rise signal from OPEN to
+24V at this time. In the joystick manual
mode, the hold switch is used as the shift-
up switch.
10-162 WD600-3
15. Function selecting signal

This signal is a digital signal of GND/OPEN. When the engine is started, each function is judged with
this signal.
1) Selection of model
Table 4. Model selecting signals table
Model CN3B-2 CN3B-10 CN3B-3
WD600-3 OPEN OPEN GND
2) Selection of engine used

Table 5. Engine selection table
Selected engine
Komatsu Cummins
Signal and data
Engine select (CN3A-10) OPEN GND
3) Selection of optional function

Table 6. Option (Function) selection table
Input signal name State of signal
Automatic shift transmission (CN3A-20) OPEN GND OPEN GND
Joystick steering (CN3B-1) OPEN OPEN GND GND
Objective model Function
Transmission
Transmission auto/manual
WD600-3 No setting (*1) auto/manual No setting (*1) and
joystick auto/
manual
(*1) If the state of no setting is detected, all outputs of the controller are turned OFF and the vehicle
cannot travel.
fl The LED indicates the part No. of the program, then indicates “0. 0.”.
16. Engine revolution sensor signal

This signal is a pulse signal. It is made by converting the number pulses from the electromagnetic
pickup sensor into the number of revolution for control.
The condition that the engine speed is 1,450rpm or higher is called the engine revolution ON mode,
and the condition that the engine speed is below 1,450rpm is called the engine revolution OFF mode.
17. Travel speed sensor signal

This signal is a pulse signal. It is made by converting the number pulses from the electromagnetic
pickup sensor into the number of revolution.
18. Communication signal (S-net)

The code of each detected fault is sent to the main monitor.
WD600-3 10-163
19. Output signals

1) Transmission solenoid valve signal
Table 7. Combination of gear speeds and
solenoid valves
: ON
Solenoid valve
F R 1st 2nd 3rd 4th
Gear speed
F1
F2
F3
F4
N
R1
R2
R3
R4
2) Backup lamp relay

This signal is an S-NET output. When the
forward-reverse lever is in the R position,
a signal is output to the throttle control-
ler.
3) Engine revolution signal (Open collector)

A signal having the same period as the
engine revolution sensor signal, which is
input to the transmission controller, is
output.
4) Communication signal (Data indicated on

main monitor)
For the indicating position and operation
of the main monitor, see the section of the
main monitor.
a) Indication of gear speed
1st speed output: “1”
2nd speed output: “2”
3rd speed output: “3”
4th speed output: “4”
Neutral: “N”
b) Indication of F and R
In the joystick steering mode, F and R
are indicated.
c) Indication of hold
When the hold function is turned ON,
is pilot lamp is indicated on the main
monitor.
5) Lock-up solenoid signal

When the lock-up is turned ON, a +24 V
ON/OFF signal is output.
10-164 WD600-3
20. Indication with LED

When the engine is started, the LED is set in 1. “Program part No. indication mode”, then in 2.
“Output gear speed indication mode”. If any trouble is detected, however, the LED is set in the
“Troubleshooting indication mode” immediately.
1) Program part No. indication mode

When the power is turned on, the following are changed at the interval of one second.
–°–° 7°8° 2°3° 1°6° A°1° 0°2° → To Indication mode 2

|→|→|→|→|→|→|
2) Output gear speed indication mode

Indication with LED: X° Y.. (Both dots are turned off.)
X: Condition of direction solenoid valve
Forward “F”: ‘F’, Reverse “R”: ‘A’, Neutral: ‘0’
Y: Condition of gear speed solenoid valve
1–4
→ If any error is detected, indi-
<Example> cation mode 3 is turned on.
– – 7 8
Indication Contents ° ° ° °
|→|→|
‘0° 2°’ Neutral, 2nd speed N Gear shifting
‘F° 1°’ Forward, 1st speed (F2 speed is indicated continuously.)
‘A° 2°’ Reverse, 2nd speed

‘F° F°’ Neutral safety state
3) Troubleshooting indication mode (Currently detected error)

“E (2 seconds)” and “Code (2 seconds)” are repeated as one routine.
a) When one error is detected

<Example>
E°–° 2 ° 3 ° → Repeated
|→|→|
b) When two errors are detected

<Example>
E°–° 2°3° E°–° 1 ° 8 ° → Repeated
|→|→|→|→|
WD600-3 10-165
21. Combination of joystick steering and transmission controller function

: Function is installed.
Steering wheel Joystick
Boom lever switch
Auto Manual Auto Manual
Kickdown function —
Hold function —
Up/Down function — — —
CN C5-5 input signal Kickdown Kickdown Kickdown Shift-down
CN C5-13 input signal Hold — Hold Shift-up
22. Controller input signals 4. Indicating position of main monitor

• Signal common to kickdown/shift-down
switches (CN C5-5 terminal)
• Signal common to hold/shift-up switches
(CN C5-13 terminal)
The above signals are judged by changing
with the joystick select signal and manual
signal.
23. Up/Down shift switch function

• Shift-up switch:
If signal is input, normal shift-up signal is
output.
• Shift-down switch:
If signal is input, normal shift-down sig-
nal is output.
• Input of the switch is judged by change
of ON/OFF of the signal. (The signal is 5. Indicating position of F, N, and R on console
turned ON when the switch is pressed.)
The latest signal is taken in constantly to
judge shift-up and shift-down.
• The highest using gear speed is with the
transmission lever.
Position of range lever Using gear speed

4 4–1
3 3–1
2 2, 1
1 1
10-166 WD600-3
CONTROLLER
10-168 WD600-3
Connector signals
CN1 CN3A CN4
Pin Input/ Pin Input/ Pin Input/
No. Signal name Output No. Signal name Output No. Signal name Output
1 Steering solenoid valve cut relay Output 1 NC — 1 NC —
2 Transmission F solenoid valve Output 2 NC — 2 Engine revolution sensor (+) Input
3 Transmission 1st gear speed solenoid valve Output 3 Steering lever potentiometer Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
5 Transmission 3rd speed solenoid valve Output 5 NC — 5 NC —
6 GND Input 6 Pressure sensor power source (+24V) Output 6 NC —
7 Power source (+24V) Input 7 Potentiometer power source (+5V) Output 7 NC —
8 Lock-up solenoid valve Output 8 NC — 8 Flush write switch Input
9 Transmission R solenoid valve Output 9 NC — 9 Engine revolution sensor (-) Output
10 Transmission 2nd speed solenoid valve Output 10 Engine selection Input 10 RS232C GND Input
11 Transmission 4th speed solenoid valve Output 11 NC — 11 NC —
12 GND Input 12 NC — 12 NC —
13 Power source (+24V) Input 13 NC —
14 NC — CN5
CN2 15 NC — Pin
Signal name
Input/
Pin Input/ No. Output
Signal name 16 Pressure sensor GND Output
No. Output 1 Pulse GND Output
17 Potentiometer GND Output
1 Solenoid valve power source (+24V) Input 2 Speed sensor (+) Input
18 NC —
2 Steering (Right) solenoid valve (+) Output 3 GND Output
19 Neutralizer relay Input
3 Steering (Left) solenoid valve (+) Output 4 GND Output
20 Automatic shift transmission Input
4 F LED (Steering) Output 5 Kickdown/Shift-down switch Input
5 R LED (Steering) Output 6 Transmission cut-off switch Input
CN3B
6 NC — 7 Joystick N (NC) Input
Pin Input/
7 N LED (Steering) Output No. Signal name Output 8 Joystick F (NC) Input
8 Neutral safety output (+) Output 1 Joystick steering Input 9 Joystick R (NC) Input
9 Caution relay (Steering) (+) Output 2 Model selection 1 Input 10 Pulse GND Output
10 Caution relay (Monitor) (+) Output 3 Model selection (EVEN relay) Input 11 Steering lever N switch Input
11 PGND Input 4 S-NET + Input 12 Lock-up switch Input
12 Solenoid valve power source (+24V) Input 5 Direction F Input 13 Hold/Shift-up switch Input
13 Steering (Right) solenoid valve (–) Output 6 Direction R Input 14 Neutral switch Input
14 Steering (Left) solenoid valve (–) Output 7 Gear shift switch 1 Input 15 Joystick N (NO) Input
15 NC — 8 Gear shift switch 3 Input 16 Joystick F (NO) Input
16 NC — 9 NC — 17 Joystick R (NO) Input
17 NC — 10 Model selection 2 Input
18 NC — 11 NC —
19 Caution relay (Steering) (–) Output 12 S-NET + Input Joystick selection
20 NC — 13 Direction N Input
OFF ON
21 PNGD Input 14 Joystick steering ON/OFF switch Input Pin
15 Gear shift switch 2 Input CN3B-1 OPEN GND
16 Gear shift switch 4 Input GND: Connected to CN2-9
Model selection
Model
WD600-3
Pin Automatic shift transmission selection Model selection
CN3B-2 OPEN Engine
OFF ON KOMATSU CUMMINS
CN3B-10 OPEN Pin Pin
CN3B-3 GND CN3A-20 OPEN GND CN3A-10 OPEN GND
GND: Connected to CN2-9 GND: Connected to CN2-9 GND: Connected to CN2-9
WD600-3 10-169
STRUCTURE AND FUNCTION THROTTLE CONTROL SYSTEM
THROTTLE CONTROL SYSTEM

OUTLINE OF SYSTEM
Throttle lock function

Engine speed setting function
Resuming function
Acceleration function
Deceleration function
Lock-up indicator output function
Backup buzzer relay output function
Engine speed control function
• The throttle control system consists of the

throttle controller, throttle lock switches (ON/
OFF switch, Set/Accelerate switch, and Re-
sume/Decelerate switch), brake pedal opera-
tion sensor switch, throttle lock indicator
lamp, accelerator pedal, etc.
• The throttle controller is installed between the

accelerator pedal (acceleration potentiometer
and low idling switch) and engine controller
and used to control the engine speed with the
throttle lock function, etc.
10-170 WD600-3
SYSTEM CONFIGURATION
D Throttle lock ON/OFF switch Accelerator pedal signal A
D Throttle lock Set/Accelerate

switch
Low idling switch relay D
D Throttle lock Resume/Decelerate
switch
Throttle lock indicator lamp D
Throttle controller
D Brake pedal operation sensor
switch
D Accelerator pedal low idling Lock-up indicator lamp D

switch
A Accelerator pedal signal

Backup buzzer relay D
S-Net Lock-up ON signal
S-Net Backup buzzer output signal
S-Net Engine speed control signal
A: Analog signal
D: Digital signal
WD600-3 10-171
OUTLINE
1. Throttle lock function
• If the throttle lock ON/OFF switch is set in the ON position and the accelerator pedal is pressed to
increase the engine speed to a desired level and the throttle lock Set/Accelerate switch is pressed,
the engine speed is set.
• If the accelerator pedal is pressed further after the engine speed reaches the set level, the engine
speed is increased according to the pressing distance of the accelerator pedal. (The signal of the
higher engine speed is taken first.)
• If the right or left brake pedal is pressed, the throttle lock function is reset temporarily and the
engine speed changes according to the pressing distance of the accelerator pedal.
• If the brake pedal is pressed to reset the throttle lock function temporarily and then the throttle
lock Resume/Decelerate switch is pressed, the engine speed returns to the set level.
• The set engine speed is cleared under either of the following conditions.
(1) Set the throttle lock ON/OFF switch in the OFF position.
(2) Set the starting switch in the OFF position.
• If the throttle lock Set/Accelerate switch or throttle lock Resume/Decelerate switch is pressed and
held, they start working as an accelerator switch and a decelerator switch. Then, the operator
can increase or decrease the set engine speed finely with these switches.
• While the throttle lock is controlled, the output of the low idling switch relay is kept turned ON.
Throttle lock ON/ Throttle lock Set/ Throttle lock Brake pedal Throttle lock
OFF switch Accelerate switch Resume/Decelerate operation sensor indicator lamp
switch switch
Switch configura- Alternate seesaw Momentary Momentary Lamp
tion switch seesaw switch proximity switch
Switch logic ON (GND) ON (GND) Brake operated ON (24-V output)
OFF (OPEN) OFF (OPEN) (GND)
Brake not operated
(OPEN)
When switch is ON, Engine speed Resuming function: If brake pedal is While throttle lock
throttle function is setting function: While throttle lock pressed, throttle ON/OFF switch is in
effective. Accelerator pedal function is reset by lock function is ON position, output
input voltage when operating right reset temporarily. is turned ON.
switch is ON is brake pedal, if this
saved and engine switch is pressed,
speed is controlled throttle lock
with fall of signal. function is
resumed. Throttle
Function lock function is
controlled with fall
of signal.
Acceleration Deceleration If any switch is
function: If this function: If this abnormal and
switch is kept switch is kept throttle lock ON/
pressed, set engine pressed, set engine OFF switch is in ON
speed is increased speed is decreased position, lamp
at rate. at rate. flashes.
Disconnection
Behavior of Cannot lock Cannot set throttle Cannot resume. Cannot reset Does not light up.
machine in throttle. lock. Cannot decelerate. throttle lock by
abnormal state operating brake
pedal.
Detection of Impossible Impossible Impossible Impossible Impossible
abnormality
Behavior of Cannot reset Increases engine Decreases engine Cannot lock Keeps lighting up.
machine in throttle lock. speed with speed with throttle.
abnormal state acceleration deceleration
function. function.
Short circuit
Detection of Impossible Continuous Continuous Impossible Impossible

abnormality operation (ON state) operation (ON state)
for 30 seconds or for 30 seconds or
more is judged more is judged
abnormal. (*) abnormal. (*)
Recovery from — Detection of OFF Detection of OFF — —
abnormality (OPEN) (OPEN)
(*) Remedy taken when abnormality is detected: Flashes throttle lock indicator lamp (ON for 0.8 seconds and OFF for 0.8 seconds).
Stops throttle control even when throttle lock is ON.
10-172 WD600-3
2. Lock-up indicator output function

Upon receiving the lock-up ON signal from
the transmission controller, the throttle con-
trol system lights up the lock-up indicator
lamp.
3. Backup buzzer relay output function

Upon receiving the backup buzzer ON signal
from the transmission controller, the throttle
control system outputs it to the backup buzzer
relay.
4. Engine speed control function

Upon receiving the engine speed control sig-
nal from the transmission controller, the
throttle control system changes the accelera-
tor pedal signal and output it to the engine
controller.
WD600-3 10-173
THROTTLE CONTROLLER
10-174 WD600-3
Connector signals
CN1 (CN C6) CN2 (CN C7) CN3 (CN C8)
Pin Input/ Pin Input/ Pin Input/
No. Signal name Output No. Signal name Output No. Signal name Output
1 NC — 1 NC — 1 Controller PWR Input
2 NC — 2 NC — 2 Solenoid PWR Input
3 NC — 3 NC — 3 Solenoid common GND Input
4 Signal GND — 4 232C_RXD Input 4 NC —
5 NC — 5 NC — 5 NC —
6 NC — 6 NC — 6 NC —
7 NC — 7 NC — 7 Backup buzzer relay Output
8 NC — 8 NC — 8 Throttle lock indicator lamp Output
9 Accelerator pedal signal Input 9 NC — 9 Low idling switch (Li) Input
10 Signal GND — 10 NC — 10 Throttle lock ON/OFF switch Input
11 NC — 11 Accelerator pedal signal Output 11 Controller PWR Input
12 NC — 12 NC — 12 Solenoid PWR Input
13 NC — 13 NC — 13 Solenoid common GND Input
14 NC — 14 NC — 14 Starting switch BR Input
15 NC — 15 NC — 15 NC —
16 NC — 16 NC — 16 NC —
17 NC — 17 NC — 17 Low idling switch relay Output
18 NC — 18 NC — 18 Lock-up indicator lamp Output
19 NC — 19 NC — 19 Throttle lock Set/Accelerate switch Input
20 NC — 20 NC — 20 Low idling switch (Acc) Input
21 Analog GND — Input/ 21 Controller GND Input
21 S-NET (+) Output
22 Potentiometer power source (+5 V) Output 22 Solenoid PWR Input
22 NC —
23 NC — 23 Solenoid common GND Input
23 NC —
24 NC — 24 Starting switch BR Input
24 NC —
25 NC —
25 NC —
26 NC —
26 NC —
27 NC —
27 NC —
28 NC —
28 NC —
29 NC —
29 Pulse GND —
30 Throttle lock Resume/Decelerate switch Input
30 NC —
31 Controller GND Input
31 S-NET (GND) —
32 NC —
33 NC —
34 NC —
34 NC —
35 NC —
35 NC —
36 NC —
36 NC —
37 NC —
37 NC —
38 NC —
38 NC —
39 NC —
39 NC —
40 Brake pedal operation sensor switch Input
40 NC —
WD600-3 10-175
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine .................................. 20- 2
Standard value table for chassis ................................. 20- 3
Standard value table for electrical parts ..................... 20- 9
Testing and adjusting ........................................................ 20-101
Troubleshooting ................................................................ 20-201
fl Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. It is used as a guideline for judging the progress of
wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt or other rotating parts.
WD600-3 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Engine SAA6D170E-3
Cat- Standard value Service limit
egory Item Measurement conditions Unit for new machine value
Low idling 700 ± 25 700 ± 25
Engine speed High idling rpm 2,190 2,190
Rated speed 2,000 —
Whole speed range

Exhaust temperature (ambient temperature: 20°C) ˚C 650 700
Air supply pressure

(boost pressure) At rated output kPa {mmHg} Min. 113 {850} 100 {750}
At sudden acceleration Max. 5.0 7.0

Exhaust gas color Bosch index
At rated output Max. 2.0 3.0
Valve clearance Intake valve 0.32 —

(normal temperature) mm
Exhaust valve 0.62 —
Compression pressure Oil temperature: 40 – 60°C 2

(SAE30 oil) (Engine speed: 210 – 250 rpm) MPa {kg/cm } Min. 2.9 {30} 2.1 {21}
Engine related
(Water temperature:
Blow-by pressure Green range) kPa {mmH2O}
(SAE30 oil) Max. 3.9 {400} 7.9 {800}
At high idling
(Water temperature:
Green range) MPa {kg/cm2} 0.39–0.54 {4.0–5.5} 0.21 {2.1}
At high idling (SAE30)
(Water temperature:
Green range) MPa {kg/cm2} 0.34–0.49 {3.5–4.0} 0.18 {1.8}
At high idling (SAE10W)
Oil pressure
At low idling (SAE30) MPa {kg/cm2} Min. 0.12 {1.2} Max. 0.07 {0.7}
At low idling (SAE10W) MPa {kg/cm2} Min. 0.1 {1.0} Max. 0.05 {0.5}
Whole speed range

Oil temperature (inside oil pan) °C 90 –␣ 110 120
Deflection of one belt when

Alternator belt tension pressed with finger force of
approx. mm 10 – 15 10 – 15
58.8 N {approx. 6 kg.}
Air conditioner compres- Deflection when pressed

sor belt tension with finger force of approx. mm 10 – 15 10 – 15
58.8 N {approx. 6 kg.}
20-2 WD600-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Operating N – FORWARD, • Engine stopped N {kg} 5.88 +4.9 +0.5

Directional
• Measure at center of lever – 2.94 {0.6 – 0.3 } 16.7 {1.7}

effort REVERSE
knob
lever
Travel N – FORWARD, mm 35 ±␣ 10 35 ±␣ 10
REVERSE
1st – 2nd • Engine stopped 5.88 +4.9 +0.5
– 2.94 {0.6 – 0.3 } 16.7 {1.7}
Speed control lever
Operating • Measure at center of lever

2nd – 3rd knob N {kg} 5.88 +4.9 +0.5
– 2.94 {0.6 – 0.3 } 16.7 {1.7}
effort
3rd – 4th 5.88 +4.9
– 2.94
{0.6 +0.5
– 0.3
} 16.7 {1.7}
1st – 2nd 35 ±␣ 10 35 ±␣ 20
Travel 2nd – 3rd mm 35 ±␣ 10 35 ±␣ 20
3rd – 4th 35 ±␣ 10 35 ±␣ 20
HOLD→RAISE • Engine speed: Low idling Max. 23.5 {2.4} 35.3 {3.6}
• Hydraulic oil temperature:
RAISE→HOLD 45 – 55°C Max.15.7 {1.6} 23.5 {2.4}
HOLD→LOWER Max. 24.5 {2.5} 37.3 {3.8}
Lift
Operating effort
LOWER→HOLD — —
LOWER→FLOAT Max. 34.3 {3.5} 52.0 {5.3}
Work equipment control lever
N {kg}
FLOAT→HOLD Max. 14.7 {1.5} 22.6 {2.3}
HOLD→
RIGHT TILT Max. 23.5 {2.4} 35.3 {3.6}
Pitch & (REAR PITCH)
tilt HOLD→
LEFT TILT Max. 23.5 {2.4} 35.3 {3.6}
(FORWARD PITCH)
HOLD→RAISE • Engine speed: Low idling 67 ±␣ 15 67 ±␣ 30
Lift HOLD→LOWER 45 – 55°C 53 ±␣ 15 53 ±␣ 30
HOLD→FLOAT 67 ±␣ 15 67 ±␣ 30
Travel
HOLD→ mm
RIGHT TILT 60 ±␣ 15 60 ±␣ 30
(REAR PITCH)
Pitch &
tilt HOLD→
LEFT TILT 60 ±␣ 15 60 ±␣ 30
(FORWARD PITCH)
• Engine stopped
Play • Machine facing straight to mm Max. 40 50 –␣ 100
front
• Flat, horizontal, straight, dry 10.0 ±␣ 3.0
Steering wheel
Operating effort paved road surface N {kg} {1.0 ±␣ 0.3} 19.6 {2.0}
• Engine speed: High idling

Turns • Left lock - right lock Turns 3.9 ±␣ 0.4 4.5
Low idling • Engine running Max. 5.8 6.5

Operating • Hydraulic oil temperature:
time 45 – 55°C sec.
High idling • Left lock - right lock Max. 4.1 5.0
WD600-3 20-3
(1)

Operating effort • Engine speed: Low idling
(Measure at 150 mm point • Hydraulic oil temperature: 58.8 ± 2.45
N {kg} {6.0 ± 0.25} 88.2 {9.0}
from pedal fulcrum) 45 – 55°C
Accelerator pedal
Operating angle
Neutral (α 1) 48 —
STD model
deg.
Max. (α 2) 35 —
Stopper height (L) mm 56 ± 5 —

• If high idling speed exceeds
specified value, adjust L longer.
Operating effort • Engine speed: Low idling

• Hydraulic oil temperature: 294 ± 29.4
(Measure at 150 mm point N {kg} {30 ± 3} 421.4 {43}
from pedal fulcrum) 45 – 55°C
Operating angle
Neutral (α 1) 45 —
Brake pedal
deg.
Max. (α 2) 15 +10 —
Play mm 5 ±␣ 0.5 —
• Tire inflation pressure:

A Specified pressure Max. 2.5 —
Fitting of wheel lock

ring
Tire
B Max. 4.0 —
mm
Clearance of wheel lock C 2 – 15 —

ring
• Engine water temperature:

Torque converter stall Green range 1,750 ± 100 1,750 ± 200
• Torque converter oil tempera-
ture: 60 – 80°C
Engine speed

45 – 55°C
Hydraulic stall • Gearshift lever: F4 or R4 2,140 ± 100 2,140 ± 200
rpm
Torque converter stall

+ 1,510 ± 100 1,510 ± 300
hydraulic stall
20-4 WD600-3
(1)

• Torque converter oil 0.96 – 1.16 0.96 – 1.16

Pilot reducing pressure {9.8 – 11.8} {9.8 – 11.8}
temperature:
60 – 80°C
• Coolant tem- At low idling 3.19 – 3.48 3.19 – 3.48
Medulating pressure perature: {32.5 – 35.5} {32.5 – 35.5}
(except F2, R2) Inside oprating
Transmission, torque converter
range At high idling 3.38 – 3.68 3.38 – 3.68

{34.5 – 37.5} {34.5 – 37.5}
At low idling 1.77 – 1.96 1.77 – 1.96

{18 – 20} {18 – 20}
Reducing valve oil pressure
(for F2, R2) 1.86 – 2.06 1.86 – 2.06
At high idling MPa {19 – 21} {19 – 21}
{kg/cm2}
Torque converter inlet 0.69 – 0.88 0.69 – 0.88
pressure {7 – 9} {7 – 9}
0.20 – 0.39 0.20 – 0.39

Lubrication pressure {2 – 4} {2 – 4}
Torque converter outlet 0.34 – 0.42 0.34 – 0.42

pressure {3.5 – 4.3} {3.5 – 4.3}
Lock-up pressure 1.77 – 1.96 1.77 – 1.96

{18.0 – 20.0} {18.0 – 20.0}
Steering relief pressure 45 – 55°C 20.6+0.98 +10
– 0.29 {210 – 3 } 20.6+0.98 +10
– 1.27 {210– 3 }
Steering

MPa
{kg/cm2}
Orbit-roll output pressure 3.72 +0.19
0 {38 +20 } 3.72 +0.39 +4
– 0.19 {38 – 2 }
• Point when brake

• Engine oil pressure
Accumulator
Charge cut-in pressure speed: warning lamp 5.88 +0.49

0 {60 +50 } 5.88 +0.98 +10
– 0.49 {60– 5 }
Low idling goes out
MPa
• Hydraulic {kg/cm2}
oil tem- • Point when oil
pressure is going
Charge cut-out pressure perature: up and then 9.8 +0.98
0 {100+10
0 } 9.8 +1.47 +15
– 0.49 {100– 5 }
45 – 55°C starts to go down
1st 6.5 ± 0.3 6.5 ± 0.3
2nd 11.4 ± 0.6 11.4 ± 0.6

FORWARD
3rd 20.0 ± 1.0 20.0 ± 1.0
Power train
4th 34.3 ± 1.6 34.3 ± 1.6

Travel speed km/h
1st 7.2 ± 0.4 7.2 ± 0.4
2nd 12.6 ± 0.7 12.6 ± 0.7

REVERSE
3rd 22.1 ± 1.1 22.1 ± 1.1
4th 37.7 ± 1.7 37.7 ± 1.7
WD600-3 20-5
(1)

• Hydraulic oil temperature: 4.9 ± 0.49 4.9 ± 0.69
Brake oil pressure 45 – 55°C {50 ± 5} {50 ± 7}
MPa
• Engine stopped {kg/cm2}
Drop in brake pressure • Keep brake pedal depressed at Max. 0.49 {5} 0.49 {5}
4.9 MPa {50 kg/cm2} and measure
drop in oil pressure after 5 min.
Wheel brake

Specified pressure
• Flat, horizontal, straight, dry
paved road surface
Performance • Speed when applying brake: m Max. 5 5
20 km/h, braking delay: 0.1 sec
• Brake pedal operating effort:
Specified operating effort
(294±29.4 N {30±3 kg})
• Measure stopping distance
• Measure piston stroke
Disc wear mm 7.5 ±␣ 0.6 13.4
• Torque converter oil 5.9 – 9.8 5.9 – 9.8

Parking Brake released temperature: 60 – 80°C {60 – 100} {60 – 100}
brake inlet • Engine at high idling MPa
port {kg/cm2}
pressure Max. 0.14 0.14
Brake operated {Max. 1.4} {1.4}

Specified pressure
• Flat dry paved road with
1/5 (11°20') grade
• Machine at operating condition
Parking brake
Performance — Stopped Stopped
Pad thickness Including pack metal 31.7 ±␣ 0.3 12.7

mm
Clearance Total of each end 1.06 ±␣ 0.18 2.1

PPC valve source pressure
(Orbit-roll source pressure)
45 – 55°C 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
PPC
MPa
45 – 55°C {kg/cm2}
PPC valve output pressure • Engine speed: High idling
• Work equipment control lever: 3.72 +0.2 +2
0 {38 0 } 3.72 +0.2 +2
– 0.2 {38 – 2 }
Operated fully
20-6 WD600-3
(1)

• Hydraulic oil temperature: MPa 20.6 +0.49 20.6 +0.49
Work equipment relief 45 – 55°C – 0.29 – 1.27
pressure {kg/cm2} {210+5
–3 } {210 +5
–13 }

45 – 55°C
• No load
Blade RAISE 2.0 ± 0.3 3.0
sec.
Blade LOWER 1.3 ±␣ 0.3 2.0

Work equipment
45 – 55°C
• No load
Blade FORWARD PITCH 2.1 ±␣ 0.3
Work equipment speed
3.0
sec.
Blade REAR PITCH 1.6 ±␣ 0.3 2.0

45 – 55°C
• No load
Blade RIGHT TILT 1.1 ± 0.3 3.0
sec.
Blade LEFT TILT 0.8 ± 0.3 2.0
WD600-3 20-7
(1)


45 – 55°C
• Leave for 5 minutes after
stopping engine then
measure for next 15 minutes
Work equipment
• Blade empty, blade raise

fully.
Hydraulic drift mm Max. 100 100
20-8 WD600-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

System Name of Connector Inspection Judgement table Measurement
component No. method conditions
If the condition is as shown in the table 1) Turn starting
Measure voltage
below, it is normal. switch OFF.
Between C1(7), (13) – chassis 2) Insert T-
adapter.
Power supply C1 3) Turn starting
Between C2(1), (12) – chassis
C2 switch ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
Measure voltage
2) Insert T-
Power supply Between (6) – (17) adapter.
C3A 20 – 30 V
(for signal) 3) Turn starting
Between (6) – chassis switch ON.
4) Turn parking
brake switch ON

Transmission & Joystick steering control
Measure
voltage
Turn parking brake 2) Insert T-

Parking L01 20 – 30 V adapter.
brake switch switch ON Between
(1) – (3) 3) Turn starting
Turn parking brake Max. 1 V switch ON.
switch OFF

resistance
Measure

Solenoid T01 2) Disconnect
(1st) (male) Between (H) – (B) 50 – 70 Ω connectors.
Between (H), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

(2nd) (male) Between (G) – (B) 50 – 70 Ω connectors.
Between (G), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

Between (F) – (B) 50 – 70 Ω connectors.
(3rd) (male)
Between (F), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.
resistance
Measure

Between (E) – (B) 50 – 70 Ω connectors.
(4th) (male)
Between (E), (B) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

Between (D) – (A) 50 – 70 Ω connectors.
(F) (male)
Between (D), (A) – chassis Min. 1 MΩ 3) Connect T-
adapter.
WD600-3 20-9
(1)

resistance
Measure
(R) (male) Between (C) – (A) 50 – 70 Ω connectors.
Between (C), (A) – chassis Min. 1 MΩ 3) Connect T-
adapter.
resistance
Measure
Engine speed E06 2) Disconnect
sensor (male) Between (1) – (2) 500 – 1000 Ω connectors.
Between (1), (2) – chassis Min. 1 MΩ 3) Connect T-
adapter.
Measure in AC range
Controller
1) Turn starting
Measure
voltage
Engine switch OFF.

C4 Between (2) – (9) Min. 0.5 V 2) Insert T-
speed
adapter.
3) Start engine.
Adjust
1) Screw in until the tip of sensor contacts

Engine speed — gear, then turn back 1 turn. —
2) It works normally by adjustment above.

resistance
Measure

T05 2) Disconnect
Speed
(male) Between (1) – (2) 500 – 1000 Ω connectors.
adapter.
1) Screw in until the tip of sensor contact

Adjust
Speed — gear, then turn back 3/4 –1 turn.

—
2) Sensor should work normally when
adjusted as above.
Measure
Speed
voltage
control Speed control lever 2) Insert T-

at 1st Between 20 – 30 V adapter.
lever (7) – 3) Turn starting
(1st) Speed control lever chassis switch ON.
Max. 1 V
not at 1st

Measure
Speed
voltage
control Speed control lever Between 2) Insert T-

at 2nd 20 – 30 V adapter.
(2nd) Speed control lever chassis switch ON.
Controller
Max. 1 V
not at 2nd

Measure
Speed
voltage

C3B Between 20 – 30 V adapter.
lever at 3rd
(8) – 3) Turn starting
(3rd) Speed control lever chassis switch ON.
Max. 1 V
not at 3rd

Measure
Speed
voltage

at 4th Between 20 – 30 V adapter.
(4th) Speed control lever chassis switch ON.
Max. 1 V
not at 4th
20-10 WD600-3
(1)

Measure
voltage
Directional Directional lever 2) Insert T-
lever at F Between 20 – 30 V adapter.
(F) (5) – 3) Turn starting
Directional lever chassis Max. 1 V switch ON.
not at F

Controller
Measure
voltage
Directional 2) Insert T-
lever C3B Directional lever Between 20 – 30 V
at R adapter.
(R) (6) – 3) Turn starting
not at R

Measure
Directional
voltage
lever Directional lever 2) Insert T-

at N Between 20 – 30 V adapter.
(N) (13) – 3) Turn starting
not at N

resistance
JS3 below, it is normal. switch OFF.

Measure
System cut-off (male) System cut-off 2) Disconnect

switch JS4 switch ON Between Max. 1 Ω connectors.
JS3(1) – 3) Connect T-
(female) System cut-off JS4(1) adapter.
Min. 1 MΩ
switch OFF

resistance
Measure

Joystick R.H. L27 2) Disconnect
solenoid (male) Between (1) – (2) 10 – 20 Ω connectors.
adapter.

resistance
Measure

Joystick L.H. L26 2) Disconnect
solenoid (male) Between (1) – (2) 10 – 20 Ω connectors.
adapter.

resistance
Between (1) – (3) of joystick N switch 2) Disconnect

Measure
Joystick connectors.
JS5 Not at N Max. 1 Ω
neutral (N) 3) Connect T-
(male)
switch At N adapter.
Min. 1 MΩ
Between (1) – chassis

resistance
Measure
2) Disconnect
Joystick JS2 Between (1) – (2) 0 – 2 kΩ ± 20% connectors.
potentiometer (male) Between (2) – (3) 2 kΩ ± 20% 3) Connect T-
adapter.
Between (3) – (1) 0 – 2 kΩ ± 20%
WD600-3 20-11
(1)

2) Set joystick
Between column to
Continue (7) – (3) 20 – 30 V
joystick
Measure
Joystick pushing
voltage
N switch Between position.
lever C5 Max. 1 V 3) Turn joystick
neutral (N) (15) – (3)
ON/OFF switch
switch Between ON.
(7) – (3) Max. 1 V
Not to push 4) Insert T-
N switch adapter.
Between 5) Turn starting
(15) – (3) 20 – 30 V
switch ON.

2) Set joystick
Between column to
Continue (8) – (3) 20 – 30 V
joystick
Measure
pushing
voltage
Joystick F switch Between position.

lever C5 (16) – (3) Max. 1 V 3) Turn joystick
F switch ON/OFF switch
Between ON.
Max. 1 V
Not to push (8) – (3) 4) Insert T-

F switch adapter.
20 – 30 V
Controller
(16) – (3) switch ON.

2) Set joystick
Between column to
Continue (9) – (3) 20 – 30 V
pushing joystick
Measure
voltage
Joystick R switch Between position.

lever C5 (17) – (3) Max. 1 V 3) Turn joystick
R switch ON/OFF switch
Between ON.
(9) – (3) Max. 1 V
Not to push 4) Insert T-
R switch adapter.
(17) – (3) 20 – 30 V
switch ON.

Measure
voltage
Neutralizer Parking brake is 2) Insert T-

relay C3A released 20 – 30 V adapter.
Between 3) Start engine.
Parking brake is (19) – (17)
applied Max. 1 V
System
network If the condition is as shown in the table 1) Turn starting
Measure

voltage
(S-NET)
(Between T/M 2) Insert T-
C3B adapter.
controller and Between (4), (12) – chassis 4–8V
main 3) Turn starting
monitor) switch ON.

resistance
Measure
Kick-down L15 2) Disconnect

Kick-down switch
switch & shift- (male) at ON Max. 1 Ω connectors.
down switch Between 3) Connect T-
Kick-down switch (1) – (2) adapter.
Min. 1 MΩ
at OFF
20-12 WD600-3
(1)

resistance
Measure
Shift-up switch 2) Disconnect
L15
Shift-up switch at ON Max. 1 Ω connectors.
(male) Between 3) Connect T-
Shift-up switch (3) – (4) adapter.
at OFF Min. 1 MΩ

resistance below, it is normal. switch OFF.
Measure
Transmission L12 2) Disconnect

cut-off switch (male) Normal condition Max. 1 Ω connectors.
Between 3) Connect T-
L.H. brake pedal (1) – (2) adapter.
Min. 1 MΩ
is depressed

Measure
voltage
Manual switch 2) Insert T-

Manual C5 Between Max. 1 V adapter.
switch at ON
Manual switch chassis switch ON.
at OFF 20 – 30 V

resistance
Controller
Measure
2) Disconnect
Solenoid T06 Between (1) – (2) 50 – 70 Ω connectors.
(Lock-up) (male) 3) Connect T-
Between (1), (2) – chassis Min. 1 MΩ
adapter.

resistance
Measure
Lock-up C10 Lock-up ON/OFF 2) Disconnect

ON/OFF switch ON Max. 1 Ω connectors.
(male) Between 3) Connect T-
switch Lock-up ON/OFF (3) – (4)
Min. 1 MΩ adapter.
switch OFF
WD600-3 20-13
(1)
Sys- Connector Inpsec- Measurement

Name of component tion Judgement table
tem No. method conditions
below, it is normal
Measure
switch OFF.
voltage
2) Insert T-
Power supply L05 Between (1), (2) –␣ chassis adapter.
20 – 30 V 3) Turn starting
Between (1), (2) – (3)
switch ON.

below, it is normal switch OFF.
Measure voltage Engine running
2) Insert T-
adapter.
(at above 1/2 throttle) Between 28 ±␣ 2 V
Battery charge L05
(alternator) Starting switch ON (5) – (3)
(Engine stopped) Max. 1 V
ª If the battery is old, or after starting in

cold areas, the voltage may not rise for
some time.

Measure
voltage
2) Insert T-
Directional switch (N) L05 Directional lever at N 20 –␣ 30 V adapter.3)
Between Turn starting
Directional lever (8) – (3) Max. 1 V switch ON.
not at N

Measure
voltage
2) Insert T-
Main monitor
Starting switch Srarting switch at START 20 –␣ 30 V adapter.

terminal C L05
Between
Srarting switch at (4) – (3) Max. 1 V
OFF or ON

Measure
voltage
2) Insert T-
Preheating ON signal L05 Preheating stopped Between Max. 1 V adapter.
3) Turn starting
Preheating operated (19) – (3) 20 –␣ 30 V switch ON.

Measure
voltage
2) Insert T-
Starting switch terminal Starting switch ON
BR L07 Between 20 –␣ 30 V adapter.
Starting switch OFF (10) – (12) Max. 1 V

Measure
voltage
2) Insert T-
Directional switch (F) Directional lever at F Between 20 –␣ 30V adapter.
Directional lever switch ON.
not at F chassis Max. 1 V
L08
Measure
voltage
2) Insert T-
Directional switch (R) Directional lever at R Between 20 –␣ 30V adapter.
Directional lever switch ON.
not at R chassis Max. 1 V
20-14 WD600-3
(1)

2) Insert T-
Measure
voltage
Between (1), (2) –␣ chassis adapter.
Power supply L18 20 – 30 V 3) Turn starting
Between (1), (2) – (3)
switch ON.

2) Insert T-
Measure voltage
Engine running adapter.
(at above 1/2 throttle) Between 28 ±␣ 2 V 3) Engine
(12) – started.
Battery charge Starting switch ON (3), (14) Max. 1 V
L18
(alternator)
ª If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.

2) Disconnect
Float connector.
Maintenance monitor
raised to
Measure resistance
3) Drain fuel.
stopper Approx. 4 Ω 4) Remove fuel
level sensor.
5) Connect
R07 T-adapter.
Fuel level sensor (male)
Float
lowered
to Approx. 85 Ω
stopper

2) Disconnect
resistance
Water level normal Between Max. 1 Ω

Measure
connector.
Radiator water level G01 (1) – (2) Min. 1 MΩ 3) Connect
switch (male) Water level low
T-adapter.

Measure voltage
2) Disconnect
Min. 0.05 MPa connector.
{0.5 kg/cm2} Between 20 – 30 V 3) Connect
Engine oil pressure sensor T-adapter.
switch R17 Max. 0.05 MPa 4) Engine
–
{0.05 kg/cm2} Chassis Max. 1V started.
(Starting switch
ON)
WD600-3 20-15
(1)

2) Disconnect
Measure resistance
Accumlator pressure: connector.
Min 5.39 ± 0.49 MPa Max. 1 Ω 3) Connect
Brake accumulator {5.39 ± 0.49 kg/cm2} T-adapter.
C03 (male) Between
low pressure switch C04 (male) Depress brake pedal (1) – (2)
and lower accumlator
pressure to below Min. 1 MΩ
4.41 ± 0.49 MPa
{45 ± 5 kg/cm }
2

Measure resistance
2) Disconnect
Normal temperature Approx. connector.
(25˚C) Between 40 kΩ 3) Connect
Engine water (1) – (2) Approx. T-adapter.
E04 (male) 100 ˚C
temperature sensor 3.7 kΩ
Maintenance monitor

Measure resistance

2) Disconnect
Normal temperature Approx. connector.
E07 (male) (25˚C) Between 40 kΩ 3) Connect
Torque converter oil
temperature sensor (1) – (2) T-adapter.
100 ˚C Approx.
3.7 kΩ

switch OFF.
Measure resistance
below, it is normal
2) Disconnect
Oil level normal Between Max. 1 Ω terminal.
Oil level abnormal (1) – (2) Min. 1 MΩ
Engine oil lever switch E10

Measure continuity
2) Disconnect
connector.
Air cleaner normal Between Continuity 3) Start engine.
E13 (1) 4) Measure
Dust indicator E13 (male) Air cleaner clogged – E14 (1) No continuity.
E14 (male) or engine stopped Continuity
20-16 WD600-3
(1)
Sys- Measurement
Name of component Judgement table
tem conditions
If the condition is as shown in Table 1, the monitor panel is 1) Turn starting
normal switch OFF.
2) Insert T-
Table 1 adapter.
Connec- Monitor item Measurement Sensor
tor No. (input connector) conditions Display signal
Engine water Engine stopped, Flashing 15 – 20 V
level starting switch ON
((8)–(3),(14)) OFF Max. 1 V
Engine oil Engine stopped, Flashing 15 – 20 V
level starting switch ON
CHECK items ((13)–(3),(14)) OFF Max. 1 V
CAUTION items Engine oil Flashing 15 – 20 V
pressure Engine running
L18 ((10)–(3),(14)) OFF Max. 1 V
(male) Brake oil Flashing 15 – 20 V
pressure Engine running
((11)–(3),(14)) OFF Max. 1 V
Battery charge Engine running Flashing Max. 10 V
((12)–(3),(14)) OFF Min. 12 V
Air cleaner Flashing 15 – 20 V
((15)–(3),(14))
Engine running
OFF Max. 1 V
Table 2 1) Turn starting

switch OFF,
Display level according then insert
Gauge display to sensor resistance dummy
resistance or
Maintenance monitor
(Starting switch ON) (Starting switch OFF) measure

resistance of
Min. Green 6 0 – 15.7 sensor.
Green 1
Green 2
Green 3
Green 4
Green 5
Green 6
Fuel level Green 5 12.6 – 24.0 2) Turn starting

Red
gauge Green 4 20.5 – 30.6 switch ON and

L18 (male)  check display.
Measure Green 3 26.7 – 39.6
resistance E F Green 2 35.2 – 51.6
between (6)
– (3), (14) Red Green 1 46.5 – 80.6
Green
Flash-  ON  Max. Red 73.8 –
ing ←→  ← (Ω)
67 102130°C
  
Engine Min. Red 2 0.24 – 3.47
Green 1
Green 2
Green 3
Green 4
water Red 1 3.13 – 3.75

White
Red 1
Red 2
Gauge tempera-
ture gauge Green 4 3.39 – 4.26
L18 (male)  Green 3 3.85 – 5.14
Measure
resistance E F Green 2 4.65 – 6.94
between (4) Green 1 6.27 –10.26
– (3), (14) White Green Red
→ ON  Flashing Max. White
←→ 9.29 –
 (1 place)  (1 place) (kΩ)
50 120130°C
   Min. Red 2 0.24 – 1.90
Torque
Green 1
Green 2
Green 3
Green 4
Green 5
converter Red 1 1.68 – 2.40

Red 1
Red 2
oil Green 5 2.15 – 3.05

tempera-  Green 4 2.74 – 5.14
ture gauge
L18 (male) Green 3 4.65 – 9.39
Measure E F
resistance Green 2 8.43 –18.18
Max. Geeen 1 15.88 –
between (5)  Green  Red
– (3), (14) → ON ←→
 Flashing
(kΩ)
(1 place) (1 place)
WD600-3 20-17
(1)

Measure voltage
Pre-heat system

2) Connect
Between (2) –␣ chassis 20 – 30 V T-adapter.
Pre-heat power HEAT 3) Turn starting
ª When water temperature is maintained switch ON.
at lower than 0ºC for more than 30 sec-
onds.
Measure voltage If the condition is as shown in the table 1) Turn starting

2) Insert T-
Between (1) – (31) adapter.
Power supply 3) Turn starting
C8 switch ON.
Between (2) – (31) 20 – 30 V
Between (14) – (31)

Measure

voltage
C7 2) Insert T-
S-NET adapter.
Between (21) –␣ (31) 4.8 V
3) Turn starting
switch ON.

resistance
Measure
2) Disconnect
Throttle lock ON/
Throttle lock ON/OFF C11 (male) OFF switch ON Max. 1 Ω connectors.
switch Between 3) Connect T-
Throttle control system
Throttle lock ON/ (3) – (4) Min. 1 MΩ adapter.

OFF switch OFF

Measure resistance
2) Disconnect
Set switch ON Between Max. 1 Ω connectors.
(1) – (2) Min. 1 MΩ 3) Connect T-
Set switch OFF adapter.
Throttle lock set/
resume switch C12 (male)
Resume switch
ON Max. 1 Ω
Between
Resume switch (2) – (3)
Min. 1 MΩ
OFF

2) Insert T-
Between (21) – (22) adapter.
Measure voltage
4.75 – 5.25 V 3) Turn starting

switch ON.
Between (9) – (21) 0.5 – 4.75 V
Accelerator pedal
signal C6
Between (9) – (21)
(at low idling) 0.5 – 1.6 V
Between (9) – (21) (Low-idling voltage
(at high idling) + 3V – 4.75V)
20-18 WD600-3
(1)

Above table shows standard voltage of ac-
celerator potentiometer at which throttle
controller can recognize accelerator po-
Adjust
Accelerator pedal tentiometer.
— When readjusting potentiometer, set its —
signal
voltage in range from 1.3 V to 1.6 V at low
idling to secure margin of error judgment
range.

Throttle control system

2) Insert T-
Measure voltage
Between (9) – chassis adapter.

(at low idling) Max, 1 V 3) Turn starting
Low-idling switch switch ON.
signal C8 (not at low idling)
17 – 30 V
(at low idling)
(not at low idling) Max. 1 V

Measure voltage

2) Insert T-
Right brake pedal Between (40) – chassis adapter.
signal C8 (Depress right brake pedal) Max, 1 V 3) Turn starting
Between (40) – chassis switch ON.
(Release right brake pedal) 17 – 30 V

2) Disconnect
Measure resistance
Accumlator pressure: connectors.

Min. 3.92 ± 0.49 MPa Between Max. 1 Ω 3) Connect
{40 ± 5 kg/cm2} C01 (1) – T-adapter.
Emergency brake C01 (male) C01 (2)
switch C02 (male) Depress brake pedal &
and lower accumlator C02 (1) –
Others
pressure to below C02 (2) Min. 1 MΩ

3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

Measure resistance

2) Disconnect
Between (1) – (2) 19 – 23 Ω connector.
Parking brake solenoid
(Emergency brake F14 (male) Between (1), (2) –␣ chassis Min. 1 MΩ 3) Connect
solenoid) T-adapter.
WD600-3 20-19
(1)
Table of tools for testing, adjusting, and troubleshooting ................................................................... 20-102

Measuring engine speed ........................................................................................................................ 20-104
Measuring exhaust gas color ................................................................................................................. 20-106
Adjusting valve clearance ....................................................................................................................... 20-107
Testing and adjusting injector lift ........................................................................................................... 20-108
Measuring compression pressure ......................................................................................................... 20-110
Measuring blow-by pressure ................................................................................................................. 20-112
Measuring engine oil pressure .............................................................................................................. 20-113
Replacing fan belt adjusting auto-tensioner ......................................................................................... 20-114
Testing and adjusting alternator belt tension ....................................................................................... 20-115
Testing and adjusting belt tension for air conditioner compressor .................................................... 20-116
Handling equipment in fuel circuit ........................................................................................................ 20-117
Measuring fuel pump outlet port pressure ........................................................................................... 20-117
Bleeding air from fuel circuit .................................................................................................................. 20-118
Measuring exhaust temperature (Overall engine) ............................................................................... 20-120
Measuring exhaust gas temperature (Each cylinder) .......................................................................... 20-121
Measuring air supply pressure (Boost pressure) ................................................................................. 20-122
Adjusting speed sensor .......................................................................................................................... 20-123
Measuring oil pressure of torque converter and transmission ........................................................... 20-124
Method for operation of emergency manual spool ............................................................................. 20-127
Testing and adjusting steering oil pressure .......................................................................................... 20-129
Testing and adjusting steering stop valve ............................................................................................. 20-131
Testing brake oil pressure ....................................................................................................................... 20-132
Measuring wear of brake disc ................................................................................................................ 20-133
Measuring brake performance ............................................................................................................... 20-134
Testing and adjusting parking brake ...................................................................................................... 20-135
Testing and adjusting accumulator charge cut-in and cut-out pressure ............................................ 20-137
Testing and adjusting PPC oil pressure ................................................................................................. 20-138
Testing and adjusting work equipment hydraulic pressure ................................................................ 20-140
Adjusting work equipment lever linkage .............................................................................................. 20-141
Adjusting main monitor (Speedometer module) ................................................................................. 20-143
Bleeding air .............................................................................................................................................. 20-144
Releasing remaining pressure in hydraulic circuit ............................................................................... 20-145
WD600-3 20-101
(1)
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Test, measurement item Symbol Part No. Part Name Remarks
L : 60 – 2,000 rpm
Digital display
799-203-8001 Multi-tachometer H : 60 – 19,999 prm
Engine speed A Kit part No. : 799-203-9000
• 799-203-8240 Nut 7/8 –␣ 18 NS
1 799-101-1502 Digital temperature

gauge –99.9 to + 1,299°C
Water, oil, exhaust
temperatures B
2 — Heat gun
(surface temperature gauge)
2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog hydraulic tester Pressure gauge:
{25, 60, 400, 600 kg/cm2}
1
790-261-1203 Digital hydraulic tester Pressure gauge: 68.6 MPa {700 kg/cm2}
Oil pressure C 2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}

Both male and female 14 × 1.5
790-261-1311 (female PT 1/8)
3 Adapter
Both male and female 18 × 1.5
790-261-1321 (female PT 1/8)
1 795-502-1590 Compression gauge
Compression pressure D 0 – 6.9 MPa {0 – 70 kg/cm2}
Kit part No. : 795-502-1205
2 795-502-1350 Adapter
799-201-1504 Blow-by checker

Blow-by pressure E
799-201-1590 Gauge 0 – 98 kPa {0 – 1,000 mmH2O}
1 6162-23-4500 Barring device

Valve clearance F
2 Commercially Feeler gauge
available
1 799-201-9000 Handy smoke checker Discoloration 0 – 70 %
Exhaust color G (with standard color)
Commercially (Discoloration x 1/10 =
•
• Bosch
2 Smoke meter index)
available
Air supply pressure (boost –101.3 to + 199.9 kPa
H 799-201-2202 Pressure gauge {–760 to + 1,500 mmHg}
pressure)
1 793-520-1805 Brake test kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No. : 799-101-5002
1 79A-264-0020 0 – 294.2N {0 – 30 kg}

Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3N {0 – 50 kg}
Commercially Scale
Stroke, hydraulic drift K available
Commercially Stopwatch —
Work equipment speed L available
Measuring brake disc Commercially Caliper gauge
wear M —
available
Measuring voltage, 79A-264-0211 Tester
resistance value N —
20-102 WD600-3
(1)
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
Test, measurement item Symbol Part No. Part Name Remarks
1 799-601-7400 T-adapter assembly —
2 799-601-3460 MS 10P
3 799-601-7360 Adapter Relay 5P
4 799-601-7370 Relay 6P
Troubleshooting of 5 795-799-5460
wiring harness, Q
sensors 6 795-799-5470 Cable
7 795-799-5480
For engine
8 795-799-5520
9 795-799-5530 Addapter
10 795-799-5540
WD600-3 20-103
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

¤ Put blocks securely under the tires.
¤ When removing or installing the measuring
equipment, be careful not to touch any high tem-
perature parts.
¤ Before starting measurement, check that there
is no one in the surrounding area.
fl Measure the engine speed under the following
conditions.
• Coolant temperature: Within green range
• Hydraulic temperature: 45°C – 55°C
• Power train oil temperature: 70°C – 90°C
1. Measuring engine speed (low idling and high

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

chometer.
2) Start the engine.
3) Turn the transmission cut-off selector switch
(2) OFF and depress the left brake securely.
(Check that the transmission cut-off selector
pilot lamp is OFF.)
4) Place the gearshift lever at F4 or R4.
• For machines equipped with automatic
transmission, turn the main monitor
manual switch ON and place the speed
lever at F4 or R4.
5) Release the parking brake.
6) Depress the accelerator pedal gradually to
raise the engine speed to high idling, then
measure the engine speed when the torque
conver ter stalls.
fl Avoid stalling more than 20 seconds and prevent
the torque converter oil temperature from going
above 120˚C.
20-104 WD600-3
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
3. Measuring hydraulic stall speed

chometer.
2) Start the engine and run at high idling.
3) Retract the lift cylinder or tilt and pitch cylin-
der and measure the engine speed when the
circuit is relieved.
4. Measuring torque converter stall + hydraulic

stall (full stall) speed
chometer.
2) Start the engine.
3) Turn the transmission cut-off selector switch
OFF and depress the left brake securely.
(Check that the transmission cut-off selector
pilot lamp is OFF.)
4) Place the gearshift lever at F4 or R4.
• For machines equipped with automatic
transmission, turn the main monitor
manual switch ON and place the speed
lever at F4 or R4.
5) Release the parking brake.
6) Run the engine at high idling and stall the
torque converter, and at the same time, re-
tract the lift cylinder or tilt and pitch cylinder
and measure the engine speed when the cir-
cuit is relieved.
WD600-3 20-105
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

• When measuring in the field when there is no air
or power supply, use smoker checker G1; when
recording official data, use smoke meter G2.
fl Raise the coolant temperature to the green range
before measuring.
¤ When removing or installing the measuring
equipment, be careful not to touch any high tem-
perature part.
1. Measuring with handy smoke checker G1

1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the ex-
haust pipe, accelerate the engine suddenly,
and at the same time operate the handle of
tool G1 to catch the exhaust gas on the filter
paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2

1) Insert probe of tool G2 into the outlet port of
exhaust pipe, then tighten the clip to secure it
to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
fl The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC outlet.
fl When connecting the port, check first that
the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump, then
fit the filter paper.
fl Fit the filter paper securely so that the ex-
haust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.
20-106 WD600-3
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Remove the cover of the flywheel housing, then 5. Tighten locknut (4) to hold adjustment screw
install barring device F1. (3) in position.
3 Locknut :
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
After tightening the locknut, check the clear-
ance again.
2. Remove the cylinder head cover.
3. Using barring device F1, rotate the crankshaft

in the normal direction to set No. 1 cylinder at
compression top dead center, and align pointer 6. Turn the crankshaft 120º each time in the nor-
b with the [1.6TOP] line a on the crankshaft mal direction and repeat the procedure in
pulley. Steps 3 to 5 to adjust the valves of each cylin-
fl At compression top dead center, the valve der according to the firing order.
rocker arm can be moved by hand by the fl Firing order : 1 – 5 – 3 – 6 – 2 – 4
amount of the valve clearance. If the rocker
arm does not move, the crankshaft is not 7. After completing the measurement, set to the
at compression dead center, so rotate it one original condition.
more turn. 3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
5. To adjust the valve clearance, insert feeler

gauge F2 into clearance c between rocker arm
(1) and crosshead (2), and adjust the valve clear-
ance with adjustment screw (3).
fl Insert the feeler gauge and turn the adjust-
ment screw until the clearance is a sliding
fit.
fl Valve clearance
Intake valve: 0.32 mm
Exhaust valve: 0.62 mm
WD600-3 20-107
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING INJECTOR LIFT

INJECTOR LIFT fl Max. lift c: 20.00 mm
Inspection
1. Remove the cover of the flywheel housing, then
install barring device F1.
3. Using barring device F1, rotate the crankshaft

in the normal direction to set No. 1 cylinder at
compression top dead center, and align pointer
b with the [1.6TOP] line a on the crankshaft pul-
ley.
fl Watch the movement of the rocker arm and
check that the No. 1 cylinder is at the com-
pression stroke. (If the rocker arms for both
the intake and exhaust sides move only the Adjusting
amount of the valve clearance, the cylin- fl If the lift is not correct, adjust as follows.
der is at the compression stroke.) 1. Use the inspection procedure to set the cylin-
fl The cylinder where at compression top is der at the compression top position so that
different from the cylinder where the injec- the injector can be adjusted.
tor is being checked, so check the table fl The cylinder where at compression top is
below when carrying out the operation. different from the cylinder where the in-
fl Cylinder at compression top and cylinder jector is being checked, so check the table
for inspection of injector: below when carrying out the operation.
Compression top 1 5 3 6 2 4 fl Cylinder at compression top and cylinder
Injector to inspect 2 4 1 5 3 6
for inspection of injector:
Compression top 1 5 3 6 2 4
Injector to inspect 2 4 1 5 3 6
4. Set dial gauge [1] to the head of the plunger of
the injector to be inspected. 2. Fully loosen adjustment screw (1) of the in-
fl Use a dial gauge with a stroke of at least jector to be adjusted, then tighten it by hand.
30 mm. fl Check that the socket at the tip of the
rocker arm and the ball of the push rod
5. Crank the crankshaft and measure the lift of are both fitted securely into the injector
the plunger at the point where the deviation of and push rod, respectively.
the dial gauge is the maximum.
20-108 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING INJECTOR LIFT
3. Tighten adjustment screw (1), repeat the loos-

ening operation, then tighten finally.
3 Adjustment screw:
1st time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2nd time : Loosen fully
3rd time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4th time : Loosen fully
5th time : 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4. Hold adjustment screw (1) in position, then

tighten locknut (2).
3 Locknut: 205.8 – 245 Nm {21 – 25 kgm}
fl After completing the adjustment, carry out
the inspection procedure to check the lift
again.
5. After completing the inspection and adjust-

ment, set to the original position.
3 Cylinder head mounting bolt :
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
WD600-3 20-109
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
¤ When measuring the compression pressure,
be careful not to touch the exhaust manifold
or muffler, or to get caught in rotating parts.
fl Measure the compression pressure with the en-
gine warmed up.
(Oil temperature: 40°C – 60ºC)
2. Remove rocker arm assembly (1).
5. Install rocker arm assembly (1), then adjust

the valve clearance.
2 Mounting bolt thread, seat:
Engine oil (E030CD)
3 Mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
fl For details, see ADJUSTING VALVE
CLEARANCE.
6. Disconnect 2 large-sized intermediate connec-

tors (4) of the engine.
fl This sets so that no fuel is supplied from
3. Remove injector push rod (2) and injector (3). the fuel pump to the injector.
4. Fit adapter [1] of compression gauge D1, then 7. Measure the compression pressure when the
connect to the compression gauge. engine is cranked with the starting motor.
fl Hold the adapter in position with an injec- fl Measure the compression pressure when
tor holder. the gauge indicator is stable.
3 Mounting bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
20-110 WD600-3
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
8. After completing the measurement, remove the

measurement equipment and set to the original
condition.
fl Check the length under the head of the mount-
ing bolt of the injector holder. If it is more
than 80 mm, replace the bolt with a new part.
2 Injector mounting bolt thread, seat:
Engine oil (E030CD)
3 Injector mounting bolt:
1st time : 24.5 – 34.3 Nm (2.5 – 3.5 kgm)
2nd time : Tighten 90º – 120º
2 Rocker arm mounting bolt thread, seat:
Engine oil (E030CD)
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
fl Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
fl Adjust the injector. For details, see TESTING
AND ADJUSTING INJECTOR LIFT.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
WD600-3 20-111
(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
fl Raise the coolant temperature to the operating
range before measuring.
1. Install blow-by checker E1 to the end of engine

breather hose, then connect gauge E2.
2. Run the engine at near rated output, and mea-

sure the blow-by pressure.
¤ When measuring, be careful not to touch any
hot parts or rotating parts.
Note:
fl Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective
exhaust gas color, and prematurely dirty or
deteriorated oil.
20-112 WD600-3
(1)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
fl Measure the engine oil pressure under the fol-
lowing conditions.
• Coolant temperature: Within operating range
1. Remove oil pressure measurement plug (1).
2. Fit the nipple of pressure test kit C, then connect

to the pressure test kit.
3. Start the engine and measure the oil pressure

when the engine is running at low idling and high
idling.

measuring equipment and set to the original con-
dition.
WD600-3 20-113
(1)
TESTING AND ADJUSTING REPLACING FAN BELT ADJUSTING AUTO-TENSIONER
REPLACING FAN BELT

ADJUSTING AUTO-TENSIONER
Replacing
1. Loosen locknut (1), then screw adjustment bolt
(2) back as far as bracket (3).
2. Insert bar [1] (length: approx. 50 cm) into the ob-

long hole in tension pulley lever (4), then pull
strongly and hold in position.
3. The spring will extend and the tension pulley will

move to the inside. Remove the oil belts and re-
place it with new bolts.
Adjusting
1. Tighten adjustment bolt (2) to bring the tip of ad-
justment bolt (2) into contact with tension pulley
lever (4), then tighten a further twoturns and se-
cure in position with locknut (1).
3 Locknut: 245 – 309 Nm {25 – 31.5 kgm}
fl If a clearance is formed between the tip of ad-
justment bolt (2) and tension pulley lever (4)
during operations, use the same procedure
as above to adjust.
fl If the fan belt screeches, adjust in the same
way.
20-114 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
1. Testing
• Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
alternator pulley and the drive pulley.
fl Deflection a of V-belt (standard value):
10 – 15 mm
2. Adjusting
1) Loosen the alternator mount bolt (1).
2) Loosen locknut (2), then turn adjustment nut
(3) to adjust the tension of belt.
3) After adjusting the belt tension to the stan-
dard value, tighten locknut (2), then tighten
alternator mount bolt (1).
WD600-3 20-115
(1)
TESTING AND ADJUSTING BELT TENSION FOR AIR
TESTING AND ADJUSTING CONDITIONER COMPRESSOR

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
1. Testing
• Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
fl Deflection b of V-belt (standard value):
10 –␣ 15 mm
2. Adjusting
1) Loosen air compressor mounting bolts (1) and
(2), nut (3) and adjusting bolt lock nut (4) and
adjusting bolt (5).
2) Adjust the tension of fan belt (7) by shifting
the position of compressor (6).
3) After adjusting the fan belt tension to the
specified value, tighten adjusting bolt lock nut
(4), mounting bolts (1) and (2), and nut (3).
3 Nut (3) tightening torque:
98 – 123 Nm {10.0 – 12.5 kgm}
20-116 WD600-3
(1)
HANDLING EQUIPMENT IN FUEL CIRCUIT
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
HANDLING EQUIPMENT IN MEASURING FUEL PUMP

FUEL CIRCUIT OUTLET PORT PRESSURE
fl Precautions when carrying out inspection and fl Measure the outlet port pressure of the fuel
maintenance of fuel system. pump with the signal voltage of the fuel pump
With the HPI type fuel injection system, more pressure sensor.
precise equipment is used than on the con-
ventional fuel injection pump and nozzle. 1. Insert a T-adapter into the connector of fuel
Problems may occur if dirt or dust get in, so pump pressure sensor (1), then connect to T-
always be careful of the following points. adapter box Q.
When carrying out inspection or maintenance
of the fuel line, pay more attention than usual
to prevent dirt or dust from getting in. If there
is any dirt stuck to any part, use clean fuel to
wash it off completely.
fl Precautions when replacing fuel filter cartridge
Always use a genuine Komatsu part for the
fuel filter cartridge.
With the HPI type fuel injection system, more
precise equipment is used than on the con-
ventional fuel injection pump and nozzle.
Problems may occur if dirt or dust get in, so a
special filter with highly efficient filtering per-
formance is used.
For this reason, do not use imitation filters. If 2. Start the engine and measure the power
they are used, there is danger of problems source voltage of the fuel pump pressure sen-
occurring in the fuel line. sor.
fl Check that the power source voltage is
within the following range.
fl Sensor power source voltage (between (A)
and (B)): 4.75 – 5.25 V
3. Run the engine at each speed and measure
the signal voltage of the fuel pump pressure
sensor.
fl Check that the power source voltage is
within the following range.
fl Sensor power source voltage (between (C)
and (B)):
Engine Signal Fuel pump outlet port
speed voltage pressure (reference)
(rpm) (V) (MPa{kg/cm2})
0.83±0.14
600 1.78±0.21
{8.45±1.41}
0.93±0.1
700 1.94±0.21
{9.50±1.41}
1.03±0.14
800 2.10±0.21
{10.53±1.41}
1.14±0.14
900 2.26±0.21
{11.60±1.41}
1.25±0.14
1,000 2.42±0.21
{12.70±1.41}
1.34±0.14
1,100 2.59±0.21
{13.70±1.41}
1.46±0.14
1,200 2.76±0.21
{14.90±1.41}
4. After completing the measurement, remove

the measuring equipment and set to the origi-
nal condition.
WD600-3 20-117
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
fl Bleed the air from the fuel circuit as follows if the fl Fill with fuel through the 8 inlet port
engine does not start or is difficult to start after portions a of the filter. Portion b is the
the following operations. outlet port (clean side) after filtering, so
• When starting the engine for the first time fuel must not be added from here.
• When the fuel filter has been replaced
• When the fuel tank has been cleaned
• When fuel has been added after the engine
stopped
1. Open the valves at the supply side and return side

of the fuel tank.
fl At the same time, check that there is ample
fuel in the tank.
2. Fill the fuel filter with fuel.

fl Do this only after the fuel filter has been re-
placed.
fl If the fuel filter has not been replaced, there
is danger of dirt or dust getting in, so do not
remove the fuel filter.
20-118 WD600-3
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
fl There is no problem with starting if a small

amount of air gets in, so if fuel flows out, the
operation is completed.
3. Crank the engine with the starting motor, push

air bleed valve (2) at the discharge side, and
bleed the air from the discharge circuit.
fl There is no problem with starting if a small
amount of air gets in, so if fuel flows out,
the operation is completed.
4. Start the engine and run at low idling.

fl The injector forms an open circuit, so
when the engine is operated, the air re-
maining in the circuit escapes from the
injector to the inside of the cylinder or the
fuel tank.
fl After starting the engine, there is a small
amount of variation in the engine speed
until the air is completely removed, so
continue to run the engine at low idling
until the speed becomes stable.
WD600-3 20-119
(1)
MEASURING EXHAUST TEMPERATURE
TESTING AND ADJUSTING (OVERALL ENGINE)
MEASURING EXHAUST
TEMPERATURE
(OVERALL ENGINE)
¤ Wait for the exhaust manifold temperature to go
down before removing or installing the measur-
ing equipment.
1. Remove exhaust temperature measurement plug
(1).
2. Fit the sensor of digital temperature gauge B, then

connect to the digital temperature gauge.
3. Start the engine and measure the exhaust tem-

perature when the engine is running at rated
horsepower.
fl When measuring with the engine mounted on
the machine, measure according to the con-
ditions given in the shop manual for the ma-
chine.

measurement equipment and set to the original
condition.
20-120 WD600-3
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS TEMPERATURE (EACH CYLINDER)
MEASURING EXHAUST GAS

TEMPERATURE fl Method of judgement
(EACH CYLINDER) After compensating, add up the values for
the exhaust gas temperature and calculate
fl If the engine output has dropped or any other the average value. Any cylinder that is
problem has occurred, and there is a possibility more than 20ºC lower than the average
that it is caused by defective combustion due to value can be considered abnormal.
defective injection by the injector, use the follow- fl Measurement and judgement example 1
ing procedure to measure the exhaust gas tem- Unit:ºC
perature of each cylinder and determine the cyl- Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
inder with the defective injection (defective com-
Measured
bustion). value 85 62 79 112 89 82
Compen-
1. Stop the engine and wait for it to cool down. sated 105 67 79 112 94 102
fl A guideline for judging if the engine has value
cooled down is that the temperature of the Average
value 93
exhaust manifold is less than 20ºC above the
ambient temperature.
No. 2 cylinder is more than 20ºC lower than
2. Start the engine and run at low idling for at least the average value, so judge it as abnormal.
10 minutes.
fl Run for at least 10 minutes to stabilize the ex- fl Measurement and judgement example 2
haust gas temperature. Unit:ºC
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
3. Using heat gun R, measure the temperature at Measured
86 96 73 91 94 103
the exhaust manifold outlet port of each cylinder. value
fl Measure the exhaust gas temperature of each Compen-
cylinder at the same place at the top of the sated 106 101 79 91 99 123
value
outlet port of the manifold.
Average
value 99
No. 3 cylinder is more than 20ºC lower than

the average value, so judge it as abnormal.
fl Measurement and judgement example 3

Unit:ºC
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured
value 70 88 88 93 86 7ºC
Compen-
sated 90 93 88 93 91 92
value
4. Compensate the measured value for each cylin- Average

value 91
der and judge if there is any cylinder with a prob-
lem.
No cylinder is more than 20ºC lower than the
fl Compensation value Unit:ºC average value, so judge all cylinders as nor-
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 mal,
Compen-
sation +20 +5 0 0 +5 +20
value
WD600-3 20-121
(1)
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE (BOOST PRESSURE)
¤ Be careful not to touch any hot or rotating parts
when measuring or when removing or install-
ing the measuring tools.
1. Open the engine side cover (top right), remove

air supply pressure measurement plug (1) (PT 1/
8), and install the coupler (contained in oil pres-
sure kit C1).
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge H (–101.3 to +
199.9 kPa {–760 to + 1,500 mmHg}).
Note: Operate the engine at midrange speed or

above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
• Insert the gauge about half way, repeat
the action to open the self-seal portion,
and bleed the oil.
fl If there is oil inside the hose, the gauge

will not work, so always bleed the oil.
3. Carry out the torque converter stall operation at

high idling and read the gauge indicator.
fl The air supply pressure (boost pressure) should

be measured with the engine running at rated
ouput. However, when measuring in the field, a
similar value can be obtained by operating at
torque converter stall.
20-122 WD600-3
(1)
TESTING AND ADJUSTING ADJUSTING SPEED SENSOR
ADJUSTING SPEED SENSOR

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

fl If the engine speed sensor or flywheel has been
removed or replaced, adjust as follows.
1) Screw in sensor (1) until the tip contacts the
tip of the tooth of flywheel ring gear (2).
2 Thread: Loctite gasket
(Hydraulic sealant No. 21028)
2) After the sensor contacts the tip of the tooth,
turn it back 1/2 – 3/4 turns.
fl This makes a clearance of 1.25 mm be-
tween the tip of the sensor and the tip of
the gear tooth.
3) Hold sensor (1) in position, then tighten lock-
nut (3).
3 Locknut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}
WD600-3 20-123
(1)
MEASURING OIL PRESSURE OF TORQUE
TESTING AND ADJUSTING CONVERTER AND TRANSMISSION
MEASURING OIL PRESSURE OF

TORQUE CONVERTER AND
TRANSMISSION
fl Measurement conditions
• Torque converter oil temperature: 60 – 80˚C
Preparatory work
fl The preparatory work given below is preparatory
work needed for all measurements of the oil pres-
sure.
• Open cover (1) at the rear of the cab (trans-
mission oil pressure) and cover (3) (torque con-
verter oil pressure).
• Turn transmission cut-off selector switch (2)
OFF and use the left brake.
(Check that the pilot lamp is OFF.)
• Remove the plug from the measuring port of
the transmission valve.
• Install hydraulic tester A to the measuring port,
pull the gauge to the operator's compartment,
then start the engine and measure the pres-
sure.
fl When assembling the oil pressure measurement
plug again, coat the plug with sealant.
2 Plug: Sealant (LG-5)
fl Check that there is no leakage of oil from any joints.
Unit: MPa {kg/cm2}

Item Standarad value Permissible value
Pilot reducing pressure 9.8 – 11.8 9.8 – 11.8
At low idling: At low diling:
Modulating pressure 3.19 – 3.48 3.19 – 3.48
(except F2, R2) {32.5 – 35.5} {32.5 – 35.5}
At high idling At high idling
3.38 – 3.68 3.38 – 3.68
{34.5 – 37.5} {34.5 – 37.5}
Torque converter 0.69 – 0.88 0.69 – 0.88
relief pressure {7.0 – 9.0} {7.0 – 9.0}
Lubrication oil pressure 0.20 – 0.39 0.20 – 0.39
{2.0 – 4.0} {2.0 – 4.0}
At low idling: At low idling:
Reducing valve oil 1.77 – 1.96 1.77 – 1.96
pressure (for F2, R2) {18.0 – 20.0} {18.0 – 20.0}
At high idling At high idling
1.86 –2.06 1.86 –2.06
{19.0 – 21.0} {19.0 – 21.0}
Torque converter 0.34 – 0.42 0.34 – 0.42
outlet pressure {3.5 – 4.3} {3.5 – 4.3}
Lock-up 1.77 – 1.96 1.77 – 1.96
pressure {18.0 – 20.0} {18.0 – 20.0}
20-124 WD600-3
(1)
1. Measuring pilot reducing pressure

1) Measuring port (P5).
2) Put the direcetional lever in neutral, and
measure the pressure when the speed con-
trol lever is operated.
2. Measuring modulating pressure
2) Put the directional lever in neutral, and
measure the pressure when the speed con-
trol lever is operated.
fl Measure pressure except F2 and R2.
3. Torque converter relief pressure
2) Start the engine and measure the pressure
at high idling.
4. Measuring lubrication valve pressure
at high idling.
5. Measuring reducing valve pressure
at high idling.
6. Torque converter outlet pressure
at high idling and low idling.
WD600-3 20-125
(1)
7. Lock-up valve (L/C) oil pressure

2) Run the engine at full throttle and mea-
sure the lock-up oil pressure.
Note) Measure the oil pressure while the ma-

chine is traveling.
20-126 WD600-3
(1)
TESTING AND ADJUSTING METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
METHOD FOR OPERATION OF

EMERGENCY MANUAL SPOOL
fl If the machine cannot be moved because of a fail-
ure in any part of the transmission valve system
(electrical system, solenoid valves, spools, etc.),
it is possible to move the machine by operating
the emergency manual spool.
¤ The emergency manual spool is only for emer-
gency use when there has been a failure and it
is necessary to move the machine from a dan-
gerous working area to a safe place for repairs.
Do not operate the spool except in emergencies.
¤ When carrying out this operation, keep strictly
to the procedure and pay careful attention to
safety when moving the machine .
¤ To prevent the machine from moving, lower the
work equipment completely to the ground, ap-
ply the parking brake, and put blocks securely
under the tires.
¤ Carry out the operation with the engine stopped.
1. Remove inspection cover (1) at the rear of the cab.
2. Remove lock plate (2) of the emergency manual

spool of the transmission valve.
fl Simply loosen the mounting bolts to remove
the lock plate.
3. Decide the direction to move the machine (for-

ward or in reverse) then move the emergency
manual spool to the operating position.
FORWARD: Rotate FORWARD clutch spool and
1st spool counterclockwise, and pull
out approx. 10 mm to the operating
position.
REVERSE: Rotate REVERSE clutch spool and 1st
spool counterclockwise, and pull out
approx. 10 mm to the operating po-
sition.
WD600-3 20-127
(1)
TESTING AND ADJUSTING METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
4. Check that the area around the machine is safe,

remove the blocks from under the wheels.
5. Sit in the operator's seet, amd depress the left

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

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

ply the parking brake, and blocks the wheels.
8. Return the emergency manual spool to the neu-

tral position, and install the lock plate.
20-128 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE

STEERING OIL PRESSURE
fl Hydraulic oil temperature: 45°C – 55°C
MEASURING
1. Measuring steering relief pressure
¤ Loose the oil filler cap slowly to release the pres-
sure inside the hydraulic tank. Then operate the
steering wheel and control levers several times
to release the remaining pressure in the hydrau-
lic piping.
¤ Install the safety bar to the frame.
1) Remove oil pressure measurement plug (PT1/
8) (1) from the elbow at the right steering cyl-
inder head end, then install oil pressure gauge
C1 (39 MPa {400 kg/cm2}).
2) Start the engine, run the engine at high idling,
then turn the steering wheel to the right and
measure the pressure when the relief valve is
actuated.
fl When removing the oil pressure measure-
ment plug on the left steering cylinder,
turn the steering wheel to the left.
2. Measuring steering pilot pressure

¤ Install the safety bar to the frame.
1) Disconnect pilot hose (2) or (3) from steering
valve (1).
2) Install adapter C3 (M18 x 1.5) to the elbow at
the valve end, then assemble the hose again.
3) Install oil pressure gauge C1 (5.9 MPa {60 kg/
cm2}) to adapter C3.
4) Start the engine and measure the oil pressure
when the steering wheel is turned with the
engine running at high idling.
fl Hose (2): Turn steering to right
Hose (3): Turn steering to left
WD600-3 20-129
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting
¤ Always stop the engine before adjusting the
pressure.
1. Adjusting steering relief valve
Loosen locknut (2) of steering relief valve (1), then
turn adjustment nut (3) to adjust.
fl Turn the adjustment screw to adjust the set
pressure as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl Pressure adjustment for one turn of adjust-
ment screw: Approx. 14.2 MPa {145 kg/cm2}
3 Lock nut: 29.4 ± 2.0 Nm {3 ± 0.2 kgm}
20-130 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOP VALVE

STEERING STOP VALVE
TESTING
1. Set the front frame and rear frame facing straight.
2. Check that locknut (2) of stopper bolt (1) is not
loose.
3. Start the engine, and check that there is a clear-
ance between the front frame stopper and rear
frame stopper when the steering is turned to the
right or left.
¤ Measure the clearance with the engine
stopped.
fl Measure the clearance between the front
frame and rear frame when steering stop
valve contact surface (3) and stopper bolt (1)
coming into contact and the turning stops.
• Standard clearance a: 30– 02 mm
Adjusting
fl If the clearance between the front frame and rear
frame is not within the standard value, adjust as
follows.
¤ When turning, be extremely careful not to
get your arm or any other part of your body
caught between the front frame and rear
frame.
1. Loosen locknut (2), tighten stopper bolt (1), and
make sure that there is no contact with the steer-
ing stop valve.
2. Start the engine, run at low idling, then turn the
steering wheel slowly to bring the front frame and
rear frame into contact.
3. From the condition in Item 2, turn the steering
wheel back and align the clearance between the
front frame and rear frame to the stand ard value.
4. Stop the engine, loosen stopper bolt (1), put in
contact with contact surface (3) of the steering
stop valve, then loosen st opper bolt (1) a further
1.5 turns and tighten locknut (2).
fl Carry out the procedure in Steps 1 – 4 to ad-
just both the left and right sides.
5. Start the engine, turn the machine, and check that
clearance a between the front frame and rear
frame is within the standard value for both the
left and right and that the steering stopper valve
and stopper bolt come into contact and the steer-
ing is stopped.
WD600-3 20-131
(1)
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL PRESSURE

1. Inspecting brake oil pressure

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

1) Remove bleeder screw (1), then install oil
pressure gauge tool I (19.6 MPa {200 kg/cm2}),
the elbow, joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and
bleed the air from the brake circuit. For de-
tails, see BLEEDING AIR.
3) Stop the engine, depress the left brake pedal,
leave for 5 minutes with the oil pressure at
4.9 MPa {50 kg/cm2}, and measure the drop in
pressure.
fl Be careful not to move the brake pedal for 5
minutes.
fl After completing the operation, bleed the air
from the brake circuit again.
20-132 WD600-3
(1)
TESTING AND ADJUSTING MEASURING WEAR OF BRAKE DISC
MEASURING WEAR OF BRAKE

DISC
fl Brake oil pressure: 4.9 ± 0.49 MPa {50 ± 5 kg/cm2}
¤ Park the machine on horizontal ground and put

blocks securely under the tires.
Measurement method
1. Remove plug (1).
2. Depress the brake pedal fully.
3. Use caliper gauge M to measure depth a from

the end face of the housing to the spring guide.
fl When measuring, keep the brake pedal de-
pressed.
4. Install a vinyl hose (3) to bleeder (2), then loosen

the bleeder and drain the brake oil.
fl After draining the brake oil, check that the
brake piston has returned to the end of its
stroke.
5. Measure depth b from the end face of the hous-

ing to the spring guide.
Calculating piston stroke

• S=a–b
S : Max. 13.4 (mm)
WD600-3 20-133
(1)
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE PERFORMANCE

fl Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec.
• Tire inflation pressure: Specified pressure
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position

and drive the machine.
3. When the travel speed reaches 20 km/h, depress

the left brake pedal with the specified operating
force.
fl Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then apply the brakes when the ma-
chine reaches that point.
fl Switch the transmission cut-off switch ON
when carrying out this operation.
4. Measure the distance from the point where the

brakes were applied to the point where the ma-
chine stopped.
fl Repeat this measurement three times and take
the average.
20-134 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE

PARKING BRAKE
Measuring pad
1. Turn the starting switch ON, then turn the park-

ing brake switch OFF to release the brake.
2. Remove pad (1) from caliper (2) and measure the

thickness of the pad.
fl If the starting switch is turned OFF , the park-
ing brake is actuated, so be extremely careful
not to turn the starting switch OFF .
fl For details of removing and replacing the pad,
see DISASSEMBLY AND ASSEMBLY.
fl Measure the two pads.
fl If the measurement is not within the standard
value, replace the two pads as one set.
Measuring clearance
1. Turn the parking brake switch OFF to release the

brake.
2. Insert feeler gauge F between pad (1) and disc

(3), and measure the clearance.
fl The clearance is the total value (a + b) of the
measurements at both sides.
WD600-3 20-135
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PARKING BRAKE
Adjusting
fl If the measurement is not within the standard

value, adjust as follows.
1. Turn the starting switch ON, then turn the park-

ing brake switch OFF to release the brake.
fl If the starting switch is turned OFF, the park-
ing brake is actuated, so be extremely careful
not to turn the starting switch OFF.
2. Turn adjustment bolt (4) at the caliper lever coun-

terclockwise until pad (1) and disc (3) are brought
into tight contact and resistance is felt when turn-
ing the bolt.
3 From the above position, turn adjustment bolt (4)

180˚ ± 30˚ (3 notches) back in the clockwise direc-
tion.
This adjusts the total clearance on the left a and
right b between pad (1) and disc (3) to the stan-
dard value of 1.06 ± 0.18 mm.
fl After completing the above adjustment, measure

the performance of the parking brake to check that
it is the standard value.
20-136 WD600-3
(1)
TESTING AND ADJUSTING ACCUMULATOR
TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE

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

¤ Depress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulat or circuit.
1. Remove the cover and disconnect accumulator

inlet hose (1).
2. Install the adapter (M18 x 1.5) to elbow (2) at the
charge valve end, then assemble hose (1) again.
3. Install oil pressure gauge C1 (39 MPa {400 kg/cm2})
to adapter C3.
4. Measure the accumulator charge cut-in pressure.
Start the engine, run the engine at low idling, and
measure the oil pressure when the accumulator
pressure warning” pilot lampon the maintenance
meter goes out.
5. Measure the accumulator charge cut-out pres-
sure.
After the accumulator charge cut-in is actuated,
measure the oil pressure when the indicator of
the oil pressure gauge has risen and suddenly
starts to drop.
Adjusting
fl When the accumulator charge cut-out pressure
is adjusted, the cut-in pressure also changes in
proportion to the ratio of the valve area. For this
reason, there is no adjustment nut for the cut-in
pressure.
1. Loosen locknut (4) of accumulator charge cut-out
valve (3), then turn adjustment screw (5) to ad-
just.
fl Turn the adjustment screw to adjust the pres-
sure as follows.
• To RAISE pressure, turn CLOCKWISE
• To LOWER pressure, turn COUNTER-
CLOCKWISE
fl Pressure adjustment for 1 turn of adjustment
screw: 5.59 MPa {57 kg/cm2}
3 Locknut : 9.8 – 11.8 Nm {1 – 1.2 kgm}
fl After completion of adjustment, repeat the
measurement procedure given above to check
the accumulator cut-in pressure and cut-out
pressure again.
WD600-3 20-137
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC OIL PRESSURE
TESTING AND ADJUSTING PPC

OIL PRESSURE
fl Hydraulic oil temperature: 45 – 55°C
¤ Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
¤ Operate the control levers several times to re-
lease the pressure in the PPC accumulator cir-
cuit.
Measuring
1. Measuring PPC valve source pressure
(orbit-roll source pressure)
8) (1), then install oil pressure gauge C1 (5.9
MPa {60 kg/cm2}).
then operate the work equipment control le-
ver and measure the oil pressure.
2. Measuring PPC valve output pressure

1) Remove the main control valve cover.
2) Remove oil pressure detection plug (PT1/8)
(1) of the circuit to be measured, then install
oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).
fl Plug A: Blade LOWER, FLOAT
Plug B: Blade RAISE
Plug C: RIGHT TILT
Plug D: LEFT TILT
then operate the work equipment control le-
ver and measure the oil pressure.
20-138 WD600-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC OIL PRESSURE
Adjusting
1. Adjusting PPC relief valve
Loosen locknut (3) of PPC relief valve (2), then turn
adjustment screw (4) to adjust.
fl Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE the pressure, turn CLOCK-
WISE.
• To DECREASE the pressure, turn COUN-
TERCLOCKWISE.
fl Amount of adjustment for one turn of adjust-
ment screw: 1.79 MPa {18.3 kg/cm2}
3 Locknut : 78.5 –␣ 88.3 Nm {8 – 9 kgm}
fl After completion of the adjustment, re-check
the accumulator charge cut-in pressure and
cut-out pressure again referring to the section
“Testing and Adjusting Accumulator charge
pressure”.
WD600-3 20-139
(1)
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING HYDRAULIC PRESSURE

WORK EQUIPMENT HYDRAULIC
PRESSURE
fl Hydraulic oil temperature: 45 – 55°C
1. Measuring blade relief pressure

1) Lower the blade to the ground and stop the
engine.
fl After stopping the engine, operate the
blade lever several times to release the
remaining pressure in the hydraulic pip-
ing.
fl If there is no pressure in the accumulator,
run the engine for approx. 10 sec. to
charge the accumulator.
8) (1) or (2), then install oil pressure gauge C1
(39 MPa {400 kg/cm2}).
• (1) : For blade RAISE circuit
• (2) : For blade LOWER circuit
3) Start the engine, run it at high idling, then op-
erate the blade to the end of the RAISE or
LOWER stroke, and measure the pressure
when the relief is actuated.
¤ After completing measurement, release
the pressure remaining in the circuit in
the same way as when installing the
hydraulic gauge, then remove the gauge.
2. Adjusting blade relief valve

Loosen locknut (4) of blade relief valve (3), then
turn adjustment screw (5) to adjust.
fl Turn the adjustment screw to adjust the pres-
sure as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
fl Pressure adjustment for one turn of adjust-
ment screw: Approx. 5.18 MPa {Approx. 52.9
kg/cm2}
3 Locknut : 34.3 - 44.1 Nm {3.5 - 4.5kgm}
fl After completion of the adjustment, use the
procedure given above to measure the blade
relief pressure again.
20-140 WD600-3
(1)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
fl If the operating effort or travel of the work equip-

ment lever is not within the standard value, or
the work equipment lever or PPC valve have been
removed, adjust as follows.
fl Carry out the adjustment with the engine stopped.
fl Check that the operating effort of the work equip-
ment lever is within the standard value.
fl Remove the side cover at the bottom of the work
equipment lever.
WD600-3 20-141
(1)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE
1. Adjusting PPC valve linkage

1) Install 2 sets of joint (1) to the PPC valve spool.
2) Install trunnion (2) to the center bolt of the
PPC valve, then use 2 nuts (3) to adjust di-
mension a from the center of trunnion (2) to
the top surface of the floor.
• Dimension a (target value): 54 mm
3) Install levers (4), (5) to trunnion (2) and se-
cure with nut (6).
3 Bushing portion: Grease (G2-LI)
2. Adjusting rod
1) Connect rod (7).
2) Operate work equipment lever (8) to the
LOWER position and adjust the length of rod
(7) so that cam follower (9) enters the detent
of cam (10) without any play at the detent.
• Clearance b: 0 - 1 mm
3. Adjusting lock lever

1) Set work equipment lever (8) to the HOLD
position.
2) Adjust the position of bracket (12) so that work
equipment lever (8) is locked when lock lever
(11) is operated to the LOCK position.
4. Adjusting release effort for work equipment

lever
1) Temporarily assemble spring (13) to the 2nd
hole from the top, then operate work equip-
ment lever (8) to the FLOAT position.
2) Measure the effort needed to release work
equipment lever (8) from the FLOAT position,
and adjust the mounting hole of spring (13)
so that it is the standard value.
fl Measure the release effort with push-pull
scale J1.
• Standard release effort: 19.6 N {2 kg}
fl Standard spring mounting hole: 2nd hole
from top
20-142 WD600-3
(1)
ADJUSTING MAIN MONITOR
TESTING AND ADJUSTING (SPEEDOMETER MODULE)
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal
for the travel speed differs according to the ma-
chine, so it is necessary to adjust the monitor for
use with the particular model.
• In addition, the tire diameter also differs accord-
ing to the type of tire fitted, so it is necessary to
adjust to give the correct travel speed.
Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model
1) Remove the rubber caps from dipswitches (1),
(2) and (3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-headed
screwdriver, turn this switch to adjust it to the
settings in the table below.
DIP SW 1 DIP SW 2 DIP SW 3

(model (speed- (tachom-
Tire size ometer cor- eter input
selection)
rection) selection)
35-65-33-24PR
6 7 0
(STD)
29.5-29-28PR
(OPT) 6 A 0
3) When the cap is removed from dipswitch (4)

at the back of the speedometer, an ON/OFF
switch can be seen.
Function of switch
Switch Adjustment position
(reference)
1 ON
2 ON Prohibition of
DIPSW4 monitor switch
3 ON
function
4 OFF
4) After completing the adjustment, fit the rub-

Reference
ber caps securely and install the main moni-
Amount of correction for switch (2)
tor.
Switch position 0 1 2 3 4 5 6 7
Amount of
correction (%) +14 +12 +10 +8 +6 +4 +2 +0
Switch position 8 9 A B C D E F
Amount of
correction (%) 0 –2 –4 –6 –8 –10 –12 –14
WD600-3 20-143
(1)
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. Bleeding air from brake system
1) After charging the accumulator, stop the en-
gine, insert vinyl hose (2) into bleeder screw
(1), and put the other end in a container.
2) Depress the brake pedal, then loosen bleeder

screw (2) and bleed the air. Tighten bleeder
screw (1), then slowly release the brake pedal.
fl When depressing the brake pedal, use the
left pedal.
3) Repeat the above operation, and when no
more bubbles come out with the fluid from
vinyl hose (2), depress the pedal fully and
tighten bleede rscrew (1) while the oil is still
flowing.
4) Repeat the procedure to bleed the air from
each brake cylinder.
fl To bleed the air completely, start with the
brake cylinder that is farthest from the
brake pedal.
fl If the accumulator pressure goes down,
start the engine and charge the accumu-
lator again.
fl Repeat the operation to bleed the air from
the other cylinders, and after completing
the operation, check the level in the oil
tank and add more oil if necessary.
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 – 5 times in succession.
fl Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat Step
2). After that, run the engine at low idling,
and operate the piston rod to the end of its
stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the pitch & tilt and steering cylinder.
fl When the cylinder has been replaced,
bleed the air before connecting the pis-
ton rod.
20-144 WD600-3
(1)
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE

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

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

tor circuit
fl If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
• Operate the control levers 2 – 3 times to re-
lease the remaining pressure in the circuit.
WD600-3 20-145
(1)
TROUBLESHOOTING
Points to remember when troubleshooting .......................................................................................... 20-202

Sequence of events in troubleshooting ................................................................................................ 20-203
Points to remember when carrying out maintenance ......................................................................... 20-204
Checks before troubleshooting .............................................................................................................. 20-212
Connector types and mounting locations ............................................................................................. 20-213
Connector arrangement diagram .......................................................................................................... 20-218
Connection table for connector pin numbers ....................................................................................... 20-222
Method of using troubleshooting charts ............................................................................................... 20-239
Method of using matrix troubleshooting tables ................................................................................... 20-241
Troubleshooting of engine system (S mode)........................................................................................ 20-301
Troubleshooting of engine controller system (EA mode) .................................................................... 20-351
Troubleshooting of mainmonitor system (M mode) ............................................................................ 20-451
Troubleshooting of maintenance monitor system (K mode)............................................................... 20-501
Troubleshooting of electrical system (E mode) .................................................................................... 20-601
Troubleshooting of hydraulic and mechanical system (H mode) ....................................................... 20-701
Troubleshooting of transmission control system
(T mode) (Only for machine with joystick and automatic shift control) ......................................... 20-801
Troubleshooting of joystick steering system
(J mode) (Only for machine with joystick and automatic shift control) ......................................... 20-901
Troubleshooting of throttle control system (TH mode) ....................................................................... 20-951
WD600-3 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
¤ Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
¤ When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
¤ If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
¤ Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
¤ When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
¤ When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 3) Other inspection items.

to disassemble the components. 4) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
• Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
• It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. fl When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 – 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from fl The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-202 WD600-3
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes.
Step 3
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
• Was there anything strange about the ma-

chine before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
failure?
WD600-3 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1 Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2 Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204 WD600-3
(1)
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4 High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
5 Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
fl When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
fl If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
WD600-3 20-205
(1)
2) Removing, installing, and drying connectors and

wiring harnesses
‡ Disconnecting connectors
1 Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
fl Never pull with one hand.
2 When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
fl If the connector is twisted up and down
or to the left or right, the housing may
break.
3 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
fl If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 WD600-3
(1)
‡ Connecting connectors
1 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
fl If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
fl If there is any damage or breakage, re-
place the connector.
2 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3 Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
fl If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
4 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
WD600-3 20-207
(1)
‡ Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
1 Disconnect the connector and wipe off the
water with a dry cloth.
fl If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
2 Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
fl Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
3 Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
fl After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 WD600-3
(1)
3) Handling control box

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

box.
4 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
5 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6 Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7 Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
fl If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
fl If there is any change, there is probably defective contact in that circuit.
WD600-3 20-209
(1)
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 WD600-3
(1)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
WD600-3 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item standard Remedy
1. Check fuel level, type of fuel — Add fuel

Lubricating oil, cooling water
2. Check for impurities in fuel — Clean, drain

3. Check hydraulic oil level — Add oil
4. Check hydraulic filter
. (Torque converte, Transmission hydraulic oil) — Clean, drain
5. Check brake oil level — Add oil

6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

equipments
Electrical
10. Check for looseness, corrosion of alternater terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal,
wiring — Tighten or replace
12. Check operation of instruments — Repair or replace

Hydtaulic, mechani-
cal equipments
13. Check for abnormal noise,smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
16. Check effect of parking brake, wheel brake — Repair or replace
17. Check battery voltage (engine stopped) 24 – 26 V Replace

18. Check battery electrolyte level — Add or replace
Electrics, eiectrical equipment
19. Check for discolored, burnt, exposed wiring — Replace

20. Check for missing wiring clamps, hanging wiring — Repair
21. Check for water leaking on wiring (be particularly careful Disconnect
attention to water leaking on connectors or terminals) — connector and dry
22. Check for blown, corroded fuses — Replace
23. Check alternator voltage

(engine runing at 1/2 throttle or above)
(If the battery charge is low, the voltage may be approx. 28.5 – 29.5 V Replace
25V immediately after starting.)
24. Sound of actuation of battery relay

(when starting switch is turned ON, OFF) — —
20-212 WD600-3
(1)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

fl The Address column in the table below shows the address in the connector arrangement drawing
(3-dimensional drawing).
Con- No. Con- No.

nector Type of Place of use Add- nector Type of Place of use Add-
No. pins ress No. pins ress
1939 HD 9 Connector for connecting J1939 W7 C01 X 2 Low pressure switch (emergency) H1
equipment
A02 Connector 1 Battery relay (BR) L3 C01 M 6 Front wiper motor B7
A03 Terminal 1 Battery relay (E) L3 C02 X 2 Low pressure switch (emergency) H1
A04 Connector 1 Battery relay (BR) L4 C02 PA 9 Cassette stereo B7
A4 X 2 Air conditioner air servo motor P6 C03 X 2 Low pressure switch (brake) G1
A05 Terminal 1 Battery relay (E) L4 C03 M 2 Front working lamp (R.H.) D8
A5 M 2 Air conditioner thermistor R5 C04 X 2 Low pressure switch (brake) G1
A6 SWP 6 Air conditioner air mixing motor R5 C04 M 2 Front working lamp (L.H.) D8
KYOURITSU
A7 M 6 Air conditioner blower motor, resistor R4 C05 ES 4 Beacon lamp switch (OP) D8
A8A S 10 Intermediate connector (air conditioner) R4 C06 KES 1 2 Room lamp E9
A8B S 8 Intermediate connector (air conditioner) R4 C07 M 4 Rear wiper motor H9
A9 Yazaki 4 Air conditioner blower relay (M) R2 C08 Connector 1 Cigar lighter B7
A10 Yazaki 4 Air conditioner blower relay (Hi) Q1 C09 Terminal 1 Cigar lighter C7
Intermediate connector (Transmis-
A11 Yazaki 4 Air conditioner blower relay (M2) R2 C1 MIC 13 sion & joystick steering controller) P8
A12 Yazaki 4 Air conditioner condenser relay Q1 C1A MIC 13 Transmission & joystick steering P8
controller
A13 Yazaki 4 Air conditioner blower relay (M1) R2 C2 MIC 21 Transmission & joystick steering P9
controller
A14 X 2 Air conditioner switch R5 C3A AMP040 20 Transmission & joystick steering P8
controller
A14 Yazaki 4 Air conditioner condenser relay Q2 C3B AMP040 16 Transmission & joystick steering P8
controller
A15 Yazaki 2 Air conditioner switch R5 C4 AMP040 12 Transmission & joystick steering P8
controller
Intermediate connector (Transmis-
A15 Yazaki 4 Air conditioner condenser relay Q2 C5 MIC 17 sion & joystick steering controller) P9
A16 Yazaki 4 Air conditioner compressor relay Q2 C5A MIC 17 Transmission & joystick steering P8
controller
A16 AMP 12 Air conditioner controller P1 C6 DRC 24 Throttle controller Q8
A17 AMP 16 Air conditioner controller O1 C7 DRC 40 Throttle controller Q8
A18 SWP 8 Air conditioner air servo motor (L.H.) P1 C8 DRC 40 Throttle controller Q8
A19 SWP 8 Air conditioner air servo motor (R.H.) M4 C9 — 5 Low idling limit switch relay M9
AAPR Connector 3 Air pressure sensor V5 C10 DT-T 6 Lock-up ON/OFF switch M5
ASS X 2 Air suspension R5 C11 Terminal 1 Door switch (R.H.) E11
B01 X 1 Air conditioner condenser I2 C11 DT-T 6 Throttle lock acceleration/ M5

deceleration switch
B02 X 2 Air conditioner condenser J2 C12 Terminal 1 Door switch (L.H.) G9
B03 X 1 Air conditioner condenser L6 C12 DT-T 6 Throttle lock acceleration/ M4

deceleration switch
B04 X 2 Air conditioner condenser L5 C13 KES 0 2 Speaker switch (L.H.) G9
Intermediate connector
B05 KES 1 2 Diode (window washer) I9 C13 SWP 6 (Brake pedal proximity switch) M2
B06 KES 1 2 Diode (window washer) I9 C13A SWP 6 Left brake pedal proximity switch N1
B07 KES 1 2 Window washer (front) H9 C14 KES 0 2 Speaker switch (R.H.) F9
B08 KES 1 2 Window washer (rear) H9 C14 SWP 6 Right brake pedal proximity switch N1
BR1 SWP 6 Intermediate connector (bulk head) J2 C15 Connector 1 Beacon lamp (OP) D8
WD600-3 20-213
(1)
Con- No. Con- No.

C16 M 2 Side working lamp (L.H.) G9 E31 Terminal 1 Slow blow fuse W2
C17 M 2 Side working lamp (R.H.) E8 E32 Terminal 1 Slow blow fuse V1
CAN Terminal 3 CAN connector W6 E33 Terminal 1 Heater relay W9
CH1 L 2 Intermediate connector D8 ECMA DRC26 40 Engine controller T5

(Deco valve)
CH2 M 2 (Deco valve solenoid relay) Q6 ECMB DRC26 40 Engine controller V9
CL1 S (blue) 12 Intermediate connector (cab harness) M7 ECB2 DT 2 — S6
CL2 S 10 Intermediate connector (air conditioner) M7 ER1 SWP 14 Intermediate connector (engine harness) V1
CL3 M 6 Intermediate connector (air conditioner) M7 ER2 SWP 14 Intermediate connector (engine harness) V1
CL4 M 6 Intermediate connector (power window) M7 ER3 X 3 Intermediate connector V1
CL18 Connector 1 Power window regulator (L.H.) E1 F01 M 3 Intermediate connector (head lamp R.H.) A4
CL19 Connector 1 Power window regulator (L.H.) E1 F02 M 3 Intermediate connector A4

(combination lamp R.H.)
CL20 Connector 1 Power window regulator (R.H.) C7 F03 M 3 Intermediate connector A2
(combination lamp L.H.)
CL21 Connector 1 Power window regulator (R.H.) C7 F04 M 3 Intermediate connector A2
(head lamp L.H.)
CLTP Connector 2 Engine cooling water temperature T8 F07 Connector 1 Horn (L.H.) A3
sensor
CR1 X 4 Low pressure switch (brake) I1 F08 Connector 1 Horn (R.H.) A5
E01 Terminal 1 Slow blow fuse (80A) W2 F09 Connector 1 Horn (R.H.) A4
E04 X 2 Water temperature sensor X4 F10 Connector 1 Horn (L.H.) A2
E06 X 2 Engine speed sensor T2 F13 Terminal 1 GND (front frame) A6

Torque converter tempera-
E07 X 2 ture sensor (monitor) T2 F14 X 2 Parking brake solenoid D1
E08 X 2 Starting motor U1 F15 X 2 Parking caution (monitor) C1
E09 X 2 Starting motor T1 FD1 Connector 2 Deco valve A3
E10 X 1 Engine oil level switch T5 FD2 Terminal 1 GND (front frame) B6
1-Pin
E12 X 1 Air conditioner compressor switch U9 FH3 Connector 1 Intermediate connector (Pitch) O3
E13 Connector 1 Dust indicator T3 FLTP Connector 2 Fuel temperature sensor U9
E14 Connector 1 Dust indicator T3 FR1 S 10 Intermediate connector (front lamp) F9
E15 Terminal 1 Alternator (B) S7 FR2 SWP 6 F1
E16 Terminal 1 Alternator (R) S6 FSO- Terminal 1 Fuel shutoff valve (-) S7
E17 Terminal 1 Alternator (E) S7 FSO+ Terminal 1 Fuel shutoff valve (+) S8
E18 Terminal 1 GND L3 FS1 L 2 Fuse I Q6
E19 KES 1 2 Diode (starting motor) X3 FS2 S (blue) 12 Fuse I Q6
E20 KES 1 2 Diode (starting motor) X3 FS3 M 6 Fuse I Q6
E21 KES 1 2 Diode (starting motor) T1 FS4 L 2 Fuse II Q6
E22 KES 1 2 Diode (starting motor) T1 FS5 M 6 Fuse II P6
E23 Connector 2 Diode (air conditioner compressor) U9 FS6 M 4 Fuse II P6
E24 Terminal 1 Heater relay V9 G01 X 2 Radiator water level switch K9
E25 Terminal 1 Heater relay W9 G02 M 2 Working lamp (R.H.) J9
E26 Terminal 1 Heater relay U9 G03 M 2 Working lamp (L.H.) L8
E27 Terminal 1 Heater relay W9 G04 M 6 Rear combination lamp L8
20-214 WD600-3
(1)
Con- No. Con- No.

G05 M 6 Rear combination lamp L6 L14A DT-T 3 Accelerator limit switch N2

Intermediate connector Intermediate connector
GR1 SWP 6 (radiator harness) L7 L15 M 4 (Kick-down & hold switch) N6
GRE SWP 6 Auto-grease (OP) R3 L18 AMP040 16 Maintenance monitor (sub motor) N5
GND Terminal 1 GND (OP) M7 L19 AMP040 8 Maintenance monitor (sub motor) M5
GND Terminal 1 Engine block GND M6 L21 KES 1 2 Maintenance monitor (sub motor) N6
GND Terminal 1 GND S6 L22 KES 1 2 Maintenance monitor (sub motor) O6
GND Terminal 1 GND S7 L28 Connector 1 LED O8

HEAT DT 2 (electronically governor) W9 L29 Connector 1 LED R8
IL11 — 5 Joystick indicator relay N9 L30 Connector 1 LED R8
IMPR Connector 3 Suction air pressure sensor T8 L31 Connector 1 LED R8
IMTP Connector 2 Suction air temperature sensor T9 L32 Connector 1 LED R8
JC01 DT 6 Joint connector W6 L33 Connector 1 LED Q8
JC02 DT 8 Joint connector V6 L34 Terminal 1 Selector switch R9
JC03 DT 8 Joint connector V5 L35 Terminal 1 Selector switch R9
JC04 DT 8 Joint connector U5 L36 Terminal 1 Selector switch R8
JC11 DT 6 Joint connector U5 L37 Terminal 1 Diagnosis switch Q9
JC12 DT 6 Joint connector U5 L38 Terminal 1 Diagnosis switch Q9
JC13 DT 8 Joint connector V5 L40 Yazaki 7 Power window switch (R.H.) M5
JC14 DT 8 Joint connector V6 L41 Yazaki 7 Power window switch (L.H.) M5
JC15 DT 6 Joint connector W6 L42 Connector 1 Caution buzzer O6

JL1 S 8 (Joystick steering) P1 L43 Connector 1 Caution buzzer O6
JL2 S 8 (Joystick steering) R5 L44 KES 0 6 Wiper relay O6
JL2A S 8 (Joystick steering) R4 L46 KES 1 4 Flasher unit O8
Work equipment control lever
JS14 S 8 (Tilt pitch, kick-down & hold switch) N5 L51 — 6 Side working lamp relay O9
L01 SWP 6 Parking brake switch M3 L52 — 5 Hazzard relay M8
L02 SWP 6 Light & dimmer switch M2 L53 — 5 Stop lamp relay M8
L03 SWP 6 Turn signal switch M3 L55 — 5 Horn relay O8
L04 SWP 14 Transmission switch M2 L57 — 5 Neutral relay M8
L05 AMP040 20 Main monitor M4 L58 — 5 Neutralizer relay M9
L06 AMP040 16 Main monitor M4 L59 — 5 Parking brake safety relay M9
L07 AMP040 12 Main monitor M4 L60 — 6 Front working lamp relay N9
L08 AMP040 8 Main monitor M4 L61 — 6 Rear working lamp relay O9
L09 M 6 Starting switch M3 L62 — 5 Pre-heating relay M9
L10 S 10 Wiper switch M2 L63 Connector 8 Horn switch O1
L12 X 2 Transmission cut off switch P1 L64 — 5 Engine oil pressure switch relay M8
L13 DT-T 3 Intermediate connector N1 L65 — 5 Joy stick caution relay O8

(Accelerator potentiometer)
L13A DT-T 3 Accelerator potentiometer N1 L66 — 5 Joy stick switch relay O8
L14 DT-T 3 (Accelerator limit switch) N1 L67 — 6 Joy stick solenoid relay O8
WD600-3 20-215
(1)
Con- No. Con- No.

L76 — 5 Backup lamp relay N8 R12 Terminal 1 Battery relay (B) L5

L80 — 5 Dust indicator relay M9 R13 Terminal 1 Back buzzer L6
L81 X 2 Stop lamp switch O1 R14 Terminal 1 Back buzzer L6
L91 — 5 Power window relay (left rise) O9 Intermediate connector
R16 HD-24 31 (electronically governor) W8
L92 — 5 Power window relay (left lower) O8 Intermediate connector
R17 HD-24 21 (electronically governor) W8
L93 — 5 Power window relay (right rise) N9 RA1 X 2 Intermediate connector (battery relay) L5
L94 — 5 Power window relay (right lower) O9 RAIL Connector 3 Fuel rail actuator S5
L95 — 5 Steering neutral interlock relay O9 RPR Connector 3 Fuel rail pressure sensor W5
LINK DT 6 Data link crossover W7 Intermediate connector
SIG HD-24 31 (engine wiring harness) X8
LR1 S (blue) 12 Intermediate connector (lamp, horn) R4 SP1 Connector 2 Engine revolution sensor (master) X9
LR2 SWP 14 (air conditioner, washer) R3 SP2 Connector 2 Engine revolution sensor (backup) X9
LR3 SWP 12 Intermediate connector (engine) R3 SWL Connector 1 Connector for connection N6
LR4 SWP 14 Intermediate connector (engine) R3 T01 MS 10 Transmission control valve E8
LR5 X 4 Intermediate connector (GND) R3 T02 KES 1 2 Diode (transmission control valve) F9
LR6 L 2 Intermediate connector (power supply) R3 T03 KES 1 2 Diode (transmission control valve) F1
LR7 SWP 6 Intermediate connector R4 T04 KES 1 2 Diode (transmission control valve) F9
LR9 DT-T 2 (Lock-up solenoid) F1 T05 X 2 Speed sensor C7
OLPR Connector 3 Engine oil pressure sensor S6 T06 DT-T 2 Lock-up solenoid T2
Connector for connecting wind- Intermediate connector
OP1 Connector 1 shield heater (OP) R7 T08 DT-T 2 (lock-up solenoid) V1
OP1 Connector 1 Intermediate connector N6 TAC — 1 Tachograph (OP) N7
OP2 Connector 1 Intermediate connector R7 TIMG Connector 3 Timing rail actuator V9
OP3 Connector 1 Intermediate connector R7 TL1 SWP 2 Intermediate connector R2
OP4 Connector 1 Intermediate connector R7 TPR Connector 3 Timing rail pressure sensor W6
OP5 Connector 1 Connector for connection R7
OP5 Connector 1 Intermediate connector N6
PMPR Connector 3 IMO pump pressure sensor T5

POW HD-24 21 (engine wiring harness) X8
PUMP Connector 3 Pump actuator S5
R01 X 2 Emergency steering switch H1
R03 KES 1 2 Diode (battery relay) K2
R04 KES 1 2 Diode (battery relay) K3
R05 KES 1 2 Fuel level sensor J2
R06 Terminal 1 Slow blow fuse (30A) X2
R07 Terminal 1 Slow blow fuse (30A) W2
R10 Terminal 1 GND K3
R11 Terminal 1 Battery relay (M) L4
20-216 WD600-3
(1)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
20-218 WD600-3
(1)
WD600-3 20-219
(1)
20-220 WD600-3
(1)
WD600-3 20-221
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
1
1
2
2
TEW00221 TEW00222
1 3 1
3
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-222 WD600-3
(1)
No. SWP type connector

of
1 4 4 1
3 6
TEW00235
6 3 BLP00033
1 5 5 1
4 8 8 4
TEW00237 TEW00238
4 1
1 4
12
8 5
5 8
12 9 9 12
BLP00034 BLP00035
1 4 8 11 11 8 4 1
14
3 7 10 14 14 10 7 3
TEW00239 TEW00240
4 1 4
1
8 5
5 8
16
12 9 9 12
16 13
BLP00036 13 16 BLP00037
WD600-3 20-223
(1)
No. M type connector

of
2 2
1 BLP00038 1 BLP00039
2 3 3 2
1 1
TEW00243 TEW00244
1 3
3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3 TEW00248
TEW00247
4 1 4
1
8 5
BLP00040
5 8 BLP00041
20-224 WD600-3
(1)
No. S type connector

of
1 5 5 1
4 8 TEW00249 8 4 TEW00250
6 1
1 6
10
5 10 10
TEW00251 5 BLP00042
1 6 6 1
12
5 12
BLP00043 12 5 TEW00254
1 8 8 1
16
7 16 BLP00044 16 7 TEW00256
WD600-3 20-225
(1)
No. AMP040 type connector

of
4 8
8 4
1 5
BLP00053
5 1 BLP00054
6 12 12 6
12
1 7
BLP00055 7 1 BLP00056
8 16
16 8
16
9 1
1 9
BLP00057 TEW00232
10 20
20 10
20
11 1
1 11 TEW00234
BLP00058
20-226 WD600-3
(1)
No. Automobile connector

of
2 2
1 1
BLP00063 BLP00064
1 1 3
3
4 6
6 4 BLP00069 BLP00070
WD600-3 20-227
(1)
No. MIC type connector

of
3 1
1 3
4 5 4
5
5
BLP00045 BLP00046
1 5 5 1
9 9 6
6
9
BLP00047 BLP00048
7 7 1
1
13 13 8
8
13
BLP00049 BLP00050
1 9 9 1
10 17
17 10
17
BLP00051 BLP00052
1 11
11 1
12 21
21 12
21
TEW00259 TEW00260
20-228 WD600-3
(1)
No. L type connector

of
1 1
2 2
TEW00257 TEW00258
No. PA type connector

of
No. Bendix type connector

of
10
WD600-3 20-229
(1)
No. Relay connector (socket)

of
pins Female Relay (male pins)
2 5 2 1
1 3 6 5 6 3
BLP00073 BLP00074
6 4 3 6 5
4 3 1 2
5 2 1
BLP00075
BLP00076
20-230 WD600-3
(1)
(Pin No. is printed on connector (wire insertion side), too.)

Type HD30 series connector
(Shell
size Part No. of
code) Body (Plug) Body (Receptacle)
T-adapter
Pin (male terminal) Pin (female terminal)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 01891-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
WD600-3 20-231
(1)

(Shell
size Part No. of
T-adapter
799-601-9230
Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

18-20
799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102
799-601-9240
Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

18-21
799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-232 WD600-3
(1)

(Shell
size Part No. of
T-adapter
799-601-9250
Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

24-9
799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102
799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
WD600-3 20-233
(1)

(Shell
size Part No. of
T-adapter
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.:08191-81201,08191-81202,08191-81203, Part No.: 08191-84101,08191-84102,08191-84103,

24-22 08191-81204,08191-81205,08191-80206 08191-84104,08191-84105,08191-84106
799-601-9280
Part No.:08191-82201,08191-82202,08191-82203, Part No.:08191-83101,08191-83102,08191-83103,

08191-82204,08191-82205,08191-82206 08191-83104,08191-83105,08191-83106
20-234 WD600-3
(1)

(Shell
size Part No. of
code) Body (Plug) Body (Receptacle) T-adapter
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
WD600-3 20-235
(1)

Type
(Shell DT series connector
size
code) Body (Plug) Body (Receptacle) Part No. of T-adapter
2 799-601-9020
Part No.: 08192-12200 (Normal type) Part No.: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-236 WD600-3
(1)

Type
(Shell DT series connector
size
8GR :799-601-9060
8B :799-601-9070
8
8G :799-601-9080
8BR :799-601-9090
12GR :799-601-9110
12B :799-601-9120
10 12G :799-601-9130
12BR :799-601-9140
WD600-3 20-237
(1)

Type
(Shell DTM series connector
size
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
Type
(Shell DTHD series connector
size
2 —
Part No.: 08192-31200 (Contact size #12) Part No.: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-238 WD600-3
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No Component
S-cc Troubleshooting of engine system
EA-cc Troubleshooting of engine controller system
M-cc Troubleshooting of main monitor system
K-cc Troubleshooting of maintenance monitor system
E-cc Troubleshooting of electrical systems
H-cc Troubleshooting of hydraulic, mechanical system
T-cc Troubleshooting of transmission control system
J-cc Troubleshooting of joystick steering system
TH-cc Troubleshooting of throttle control system
2. Method of using troubleshooting table

1) Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the problem
with the machine.
2) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a), b)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item.
3) General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top of
the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when carrying
out the check inside the .
4) Method of following troubleshooting chart
YES
• Check or measure the item inside NO

, and according to the answer follow either the
YES line or the NO line to go to the next . (Note: The number written at the top right
corner of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy col-
umn on the right.
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin num-
ber connection. When carrying out troubleshooting, see this chart for details of the connector
pin number and location for inspection and measurement of the wiring connector number ap-
pearing in the troubleshooting flow chart.
WD600-3 20-239
(1)
<Example>
1 M-15 Abnormality in buzzer
2 a) Buzzer does not sound for 3 second during self-check when starting switch is turned ON
b) Buzzer always sounds
Cause Remedy
Defective contact or discon-

YES nection in wiring harness Repair or
1 between L06 (female) (8) replace
and L43 (male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
• Turn starting switch L42 (female) and
ON. NO chassis ground Defective contact or discon-
• Contact L43 (female) normal? nection in wiring harness Repair or
to chassis ground. • 20 – 30 V between L42 (female) (1) replace
NO
• Turn starting switch and FS2 (female) (9)
ON.
M-15 Related electric circuit diagram
20-240 WD600-3
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTHING TABLES
METHOD OF USING MATRIX TROUBLESHOOTHING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to
locate the causes of failures in the machine. The troubleshooting tables are divided broadly into catego-
ries for the main components, such as the steering system and work equipment hydraulic system. Fol-
low the procedure given below and carry out troubleshooting to lecate the problems accutately and
swiftly.
Step 1. Questioning the operator 1. Steering does not work ← Symprom [Example]
The questions to ask the opetator are given
below the failure symptom. If the answers to Ask the operator about the following points.
• Did the steering suddenly stop working? →
the questions match the information given, Breakage in steering equipment
follow the arrow to reach the probable cause • Had the steering gradually been becoming
of the failure. heavy? → Internal wear of steering equipment,
defective seal
Consider the contents of the questions and
consult the table while proceeding to Steps 2
and 3 to grasp the true cause.
Step 2. Checks before troubleshooting Checks before staring [Example]

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check • Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
the Checks before Starting items, and check • Is there any leakage of oil from the steering
for oil leakage and loose bolts. These checks valve or Orbit-roll?
may avoid time wasted on unnecessary • Has the safety bar been removed from the
frame?
troubleshooting.
The items given under Checks before Srarting
are items which must be considerd particu-
larly for that symptom before starting trouble-
shooting.
[Example 1]
Step 3. Using cross-reference table
1) Operate the machine to carry out the No. Remedy
Problems
checks in the troubleshooting item col-
1 Steeing does not work to the left or right.
umn.
Mark the items where the results match Same as Item 1, but abnormality in actuation
2 of work equipment.
the symptom.
3 Steering can only be operated to one side.
fl It is not necessary to follow the
troubleshooting checks in order; fol- 4 Steering wheel is heavy and cannot be turned.
low an order which is easiest to carry
out troubleshooting.
2) Find the appropriate cause from the cause [Example 2]

column. If the symptom appears, the c
marks on that line indicate the possible
ses
causes. (For item No. 2 in the table on

Cau
the right, the possible causes are c or e.)

If there is only one c: a b c d e
Carry out the other troubleshooting items Remedy
× C A ×
(where the same cause is marked with c), Problems ×
check if the symptom appears, then re- 1
pair.
2
If there are two c:
Go on to Step 3) to narrow down the pos- 3
sible causes. 4
5
WD600-3 20-241
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTHING TABLES
3) Operate the machine and check the trouble-

shooting items other than those in 1).
ses
Operate the machine and check the items
Cau
in the same way as in 1), and if the symp-
tom appears, mark that item. (In the chart a b c d e
on the right, the symptom appears again Remedy
× C A ×
for item 5). Problems ×
1
4) Find the appropriate cause from the cause
column. In the same way as in Step 2), if 2
the symptom appears, the c marks on 3
that line indicate the possible causes. (For 4
item No. 5 in the table on the right, the 5
possible causes are b or e.)
Applicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
5) Narrow down the possible causes.
There is one common cause among the
causes located in Steps 2) and 4). (One
cause marked c appears on the line for Ignore these causes
ses
both items.) This cause is common to
Cau
both the symptoms in troubleshooting
Common causes
Steps 1) and 3). a b c d e
fl The causes which are not common to Remedy
both troubleshooting items (items × C A ×
Problems ×
which are not marked c for both
symptoms) are unlikely causes, so ig- 1
nore them. 2
(In the example given on the right, the 3
causes for Troubleshooting Item 2 are 4
c or e, and the cause for Troubleshoot-
5
ing Item 5 are b or e, so cause e is
common to both.)
6) Repeat the operations in Steps 3), 4) and

5) until one cause (one common cause)
ses
remains.
Cau
fl If the causes cannot be narrowed

down to one cause, narrow the causes a b c d e
down as far as possible.
Remedy Action to take
× C A ×
7) Remedy Problems ×
If the causes are narrowed down to one 1
common cause, take the action given in 2
the remedy column. 3
The symbols given in the remedy column
4
indicate the follwing:
×: Replace, t: repair, A: Adjust, C: Clean 5
20-242 WD600-3
(1)
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts ............................................................................................... 20-302

S- 1 Starting performance is poor (starting always takes time) ....................................................... 20-306
S- 2 Engine does not start
(1) Engine does not turn ............................................................................................................. 20-308
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ..................... 20-309
(3) Exhaust gas smoke comes out but engine does not start (fuel is being injected) ........... 20-310
S- 3 Engine does not pick-up smoothly (follow-up is poor) ............................................................. 20-311
S- 4 Engine stops during operations .................................................................................................. 20-312
S- 5 Engine does not rotate smoothly (hunting) ............................................................................... 20-313
S- 6 Engine lacks output ...................................................................................................................... 20-314
S- 7 Exhaust smoke is black (incomplete combustion) .................................................................... 20-315
S- 8 Oil comsumption is excessive (or exhaust smoke is blue) ....................................................... 20-316
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-317
S-10 Fuel consumption is excessive .................................................................................................... 20-318
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-319
S-12 Oil pressure lamp lights up (drop in oil pressure) ..................................................................... 20-320
S-13 Oil level rises ................................................................................................................................. 20-321
S-14 Water temperature becomes too high (overheating) ................................................................ 20-322
S-15 Abnormal noise is made .............................................................................................................. 20-323
S-16 Vibration is excessive ................................................................................................................... 20-324
WD600-3 20-301
(1)
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without us-
ing troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the Causes
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and (1) (2) (3)
[Check items].
(a) w
Questions
A (b) w
(c) w
(d) c
(e) c
Check items
B
C
i b
shooting
Trouble-
ii b
iii b
20-302 WD600-3
(1)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with c, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items] in
turn, and marked the c or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
ª1. For [Confirm recent repair history] in the Causes
[Questions] Section, ask the user, and mark
the Cause column with t to use as refer-
n)
ence for locating the cause of the failure.
ctio
However, do not use this when making cal-
inje
culations to narrow down the causes.
sive
ª2. Use the t in the Cause column as reference
e
renc
xces
zzle
for [Degree of use (Operated for long pe-
n no
erfe
p (e
e
ing
inde
riod)] in the [Questions] section as reference.
lem
, int
ctio
pum
n tim
As a rule, do not use it when calculating the
er e
, cyl
rger
inje
ion
points for locating the cause, but it can be
lean
ctio
ring
cha
zed
ject
included if necessary to determine the order
e
air c
urbo
, sei
ston
r inj
e in
for troubleshooting.
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
ª1 Confirm recent repair history
ª2 Degree of use Operatred for long period
WD600-3 20-303
(1)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Air cleaner clogging caution lamp is flashing].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black Causes
• Insufficient intake of air
• Improper condition of fuel injection
d )
ead
n)
eize
• Excessive injection of fuel
ctio
nd h
er s
inje
er a
lung
at
sive
e se
harg
ck, p
elem rence
xces
n tim nozzle
valv
boc
p (ra
ent
terfe
p (e
r
lve,
r
n tu
ing
fler
ce
nde
tion
pum
pum
r, in
aran
f va
muf
e
, cyli
e
rope ized inje
etw
n pis cleaner
arge
ion
ct o
le
rope jection
d
ctio
ring
c
e
ject
air b
a
lve
logg
Clog urboch
t
Legend
inje
con
e in
ton
r va
, se
in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
e
e
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
on reduced cylinders
When check is made using delivery method, injection timing

is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-304 WD600-3
(1)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WD600-3 20-305
(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(starting always takes time)
Causes
General causes why exhaust gas comes out but engine does
not start.
• Defective electrical system
uck)
• Insufficient dupply of fuel
er st
• Improper selection of fuel (At ambient temperature of –
seat
lung
10°C or below, use ASTEM D975 No. 1)
nozz attery
fl Battery charging rate
alve
ck, p
ent
Charging rate
ve, v
devi trainer
Ambient
p (ra
100 % 90 % 80 % 75 % 70 %
ctive d pump iner
b
temperature
er
le
lem
injec iorated
ng
cont , cylind
20°C 1.28 1.26 1.24 1.23 1.22
f val
stra
pum
timi
s
er e
ce
0°C 1.29 1.27 1.25 1.24 1.23
ctive ernator
r
act o
tion
–10°C 1.30 1.28 1.26 1.25 1.24
lato
r
eter
lean
tion
tion
filte
ng
• The specific gravity should exceed the value for the charging rate of 70%
Defe ve regu
Defe iston ri
APS
or d
injec
injec
air c
in the above table.
fuel
alt
fee
• In cold weather the specific gravity must be for the charging rate of at
ctive
ctive
ctive
least75% in the above table.
ged
ged
ged
tive
tive
np
cti
Clog
Clog
Clog
Defe
Defe
Defe
Defe
Defe
Defe
Wor
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Replacement of filters has not been carried out according to operation manual
Type of oil is not used according to operation manual
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
APS combustion portion does not become warm

Voltage is 26–30V between alternator terminal B and terminal E Yes
with engine at low idling No
Either specific gravity of electrolyte or voltage of battery is low
Some cylinders does not change engine speed when operating on reduced cylinders
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it is found to be heavy or does not return
(when blind plug at rear of pump is removed, it can be seen that plunger
control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff, or always stays open
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
: Possible cause (jugding from Questions and Check items)

Clean
Clean
Clean
: Most probable causes (judging from Questions and Check items) Remedy
: Items confirm the cause
20-306 WD600-3
(1)
Repair Leak
age,
Clean Clog clog
ged ging
Replace Defe fuel , air
in fu
tive tank
Replace i a el sy
WD600-3
Eng njec ir br stem
tin p eath
ine o
il vis ump er
cosi over hole
ty is flow
too v
high alve
Causes
TROUBLESHOOTING
(1)
S-1
20-307
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not turn
General causes why engine does not turn

Causes
• Internal parts of engine seized
wire
fl If internal parts of the engine are seized, carry out
otor
troubleshooting for "Engine stops during opera-
tions".
op m
itch
n
ctio
• Failure in power train
ty sw
it
op m gine st
ttery
nne
circu
• Defective electrical system
al co
safe
otor
d ba
rting
f en
ch
or
rmin
Defe ve batte elay or
rate
nt o
f sta
lay
mot
swit
o
ctive ttery te
ry re
e
ctive gine st
ctive r deteri
ng o
stm
ting
ting
ty r
r
gea
adju
Defe ive safe
wiri
star
star
ba
en
ing
o
ctive
ctive
ctive
ctive
en r
cti
ct
Defe
Defe
Defe
Brok
Defe
Defe
Defe
Defe
Questions

Condition of horn when start- Horn does not sound
ing switch is turned ON Horn sound level is low
Rotating speed is slow
When starting switch is Makes grating noise
turned to START, pinion
moves out, but Soon disengages again
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not move out
Check items
wiring of starting circuit
When starting switch is turned to ON, there is no clicking

shooting for defective
sound
Carry out trouble-
Battery terminal is loose
When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) – 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are
defective wiring of starting circuit
Carry out troubleshooting for
connected, engine starts

Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V voltage between terminal B and terminal
E of battery relay
When ring gear is inspected directly, tooth surface is found to
be chipped
Does not move even when engine stop mtoro linkage is
disconnected
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
: Possible cause (jugding from Questions and Remedy —

Check items)
: Most probable causes (judging from Questions and
Check items)
20-308 WD600-3
(1)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out

(fuel is not being injected)
General causes why engine turns but no exhaust smoke Causes

comes out
zed)
• Supply of fuel impossible
r sei
• Supply of fuel is extremely small
ck, p ey
nge
,k
• Improper selection of fuel (particularly in winter)
otor ole
u
pum ve shaft
l
Lack d feed p , straine ston
rh
★ Standards for use of fuel
athe
p pi
p (ra
iner
ping
r
dri
r bre
pm
stra
el pi
u
AMBIENT TEMPRATURE
mp
ed p
KIND
e sto
i
ump
n pu
14 32 50 68 86°F
g fu
ctive l tank a
d
OF FLUID
ed, b jection
ilter
l use
–10 0 10 20 30°C
n fe
ngin
Clog d, leakin
Defe injectio
f
roke
r fue
fuel
fue
ASTM D975 No. 2
in
el
e
Diesel fuel
of fu
ctive
rope
ged
ged
en
ge
ge
ASTM D975 No. 1
Defe
Brok
Clog
Clog
Clog
Seiz
Imp
Exhaust gas suddenly (when starting again) stopped coming out
Questions
Replacement of filters has not been carried out according to

operation manual
Fuel tank is found to be empty
There is leakage from fuel piping, crushed piping
When starting switch is turned ON, linkage does not move
When fuel filter is drained, fuel does not come out
Check items
1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pipe sleeve nut is
loosened
Rust and water are found when fuel is drained
Inspect injection pump directly

Inspect feed pump directly
Troubleshooting
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Does not move even when engine stop motor linkage is dis-
connected
Legend
Replace
Replace
Replace
Replace
Replace
Repair
Repair
: Possible cause (jugding from Questions and

Clean
Clean
Remedy
Add
Check items)
Check items)
WD600-3 20-309
(1)
TROUBLESHOOTING S-2
Causes
.)
(3) Exhaust gas comes out but engine does not start
r, etc
k)
(fuel is being injected)
stuc
leve
ray
ger
cker
e sp
General causes why exhaust gas comes out but engine
defe tem
n
e, ro
u
ole
ge
dose not start
ctiv
ck, p
s
ery
nka
(valv
el sy
er h
er
batt
r lin
er li
a
t
er
eath
men
r
tem
in fu
• Lack of rotating force due to defective electrical
pum ainer
(
rain
inde
p
zle,
ated
l lev
e sys
pum
r
system
d
e
air b
p st
, air
l
e fu oil use
z
r
vice
er e
, cyl
r, st
ntro
rior
• Insufficient supply of fuel
n
valv
ion
ging
ion
tank
lean
S de
dete
filte
ring
el co
ject
ken
,
ject
Defe er fuel
Clog e, clog
eed
air c
e AP
fuel
fuel
• Improper selection of fuel and oil
ston
, bro
e or
e in
n
f
i
ged
ged
ged
ged
ged
ctiv
ctiv
ctive
ctiv
ctiv
n pi
rop
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Imp
Defe
Wor
Lea
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around
cylinder head
Questions

operation manual
Type of oil is not used according to operation manual
Rust is found when fuel is drained
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
1) Little fuel comes out even when injection pump sleeve nut
is loosened
Check items
2) Little fuel comes out even when fuel filter air bleed plug is loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Even when fuel control lever is moved, fuel injection pump
lever does not move
Remove head cover and inspect directly

Troubleshooting

APS combustion portion does not become warm even when
starting switch is turned to HEAT
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response or pump is heavy
Speed of some cylinders does not change when operating on
reduced cylinders
Play, stiffness in fuel control lever linkage
Legend
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

Clean
Clean
Clean
Clean
Clean
Remedy
Check items)
Check items)
20-310 WD600-3
(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick-up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly Causes
r
leve
stop
r
sa t o
y
spra
mp
pe n
• Use of improper fuel
se a t
hole
n pu
tive
r pu ost com
e
• Defective fuel injection pump
renc
lve
efec
ectio
her
, va
mp
ent
terfe
ng
er
r
ed p ozzle, d
reat
der
aine
j
p bo
alve
pipi
e
of in
lem
ranc
stra
r, in
cylin
air b
, str
of v
er e
pum
fuel
n ai
p
ent
clea
ump
arge
m
n
r
ank
lean
,
ion
stm
u
roke
filte
a ct
ring
king
hrag ction
lve
h
ed p
t
Clog d fuel t
adju
c
c
n
air c
m, b
fuel
urbo
inje
, lea
r va
ston
e co
e fe
diap en inje
fe
r
rope
ged
ged
rope
ged
ged
ged
ctiv
ctiv
ed t
n pi
ge
Clog
Clog
Clog
Defe
Defe
Clog
Clog
k
Seiz
Wor
Imp
Imp
Bro
operation manual
Questions

Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items
There is leakage from fuel piping

High idling speed under no load is normal, but speed suddenly
drops when load is applied

Some cylinders does not change engine speed when operating
Troubleshooting
Inspect feed pump

When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
When starting switch is turned ON, there is a clearance
between stop lever and stopper bolt
When boost compensator diaphragm is inspected it is found
to be broken, or pipe is crushed
Legend
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust
Clean
Clean
Clean
Clean
: Possible cause (jugding from Questions and Remedy

Check items)
Check items)
WD600-3 20-311
(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations Causes
• Internal parts of engine seized
)
c.)
tuck
r, et
er s
• Overheating
leve
rod
lung
fl If there is overheating and the engine stops, carry
ker
t
g
ting
key
n
pum er hole
ston
out troubleshooting for overheating.
ck, p
n
e
, roc
eari
ipm
nec
aft,
in
• Failure in power train
p pi
iner
p (ra
ing
r tra
aft b
alve
equ
ump iner
e sh
con
eath
fl If the engine stops because of a failure in the
p
n
pum
stra
owe
i
v
h
el p
r tr a
iary
a
v
ir br
on,
power train, carry out troubleshooting for the
(
s
r
i
t
k
stem
p dr
s
cran
feed
g fu
sis p
uxil
pist
gea
chassis.
ion
lter,
nk a
pum
y
ed p
n
a
ject
zed
zed
has
s
zed
i
zed
a
i
f
p
k
t
e
fuel
, lea
pum
fuel
valv
e in
l
fuel
, sei
, sei
, sei
in c
e
, sei
f
of fu
ged
ged
ged
ctiv
ged
ken
ken
ken
ken
ken
ken
ken
ure
Clog
Lack
Clog
Defe
Clog
Clog
Bro
Bro
Fail
Bro
Bro
Bro
Bro
Bro
Abnormal noise was heard and engine
stopped suddenly
Condition when Engine overheated and stopped
engine stopped
Questions
Engine stopped slowly

There was hunting and engine stopped
Fuel gauge lamp lights up
operation manual
When feed pump is operated, there is no response or it is heavy
Engine turns, but stops when transmission control lever is operated
Does not turn at all
Carry out troubleshooting
Check items
Try to turn by hand using Turns in opposite direction

in chassis volume
barring tool
Moves amount of backlash
Shaft does not turn

Metal particles are found when oil is drained
Remove oil pan and inspect directly

Carry out troubleshooting in

When gear train is inspected, it does not turn
Troubleshooting
Turns when pump auxiliary equipment is removed

When fuel filter, strainer are inspected directly, they are
chassis volume
found to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
Inspect feed pump directly
not return
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Clean
Clean
Clean
Remedy —
Add
Check items)
Check items)
20-312 WD600-3
(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly Causes
p
e
pum
ozzl
• Air in fuel system
nd n
feed
• Defective governor mechanism
a
and
pum
tank
hole
rack
feed
rnor
r
erno
fuel
her
trol
ove
een
er
een
reat
gov
iner
rain
con
of g
betw
ump
betw
air b
stra
o of
p st
o f
t
w
n
ed p
t
rcui
o lo
ion
tme
cuit
pum
ratin
lter,
n k
erat
in ci
el fe
r
is to
el ta
djus
i
i
c
f
ope
eed
air in
fuel
e op
e fu
, air
el
u
a
f
f
of fu
e
tive
ged
ged
spe
ged
ctiv
ctiv
ged,
ged
ctiv
c
Clog
Clog
Defe
Defe
Clog
Defe
Lack
Defe
Clog
Low
Clog
Occurs at fixed speed range
Condition of hunting Occurs at low idling
Questions
Occurs even when speed is raised

Occurs on slopes
operation manual
Rust is found when fuel is drained
When feed pump is operated,
1) No response, light, return is quick
Check items
2) No response, light, return is normal

Engine speed sometimes changes greatly
Sometimes difficult to stop engine
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting
When control rack is pushed, it is found to be heavy or

does not return
When fuel cap is inpsected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
to be clogged
Check fuel feed pump
Legend
Replace
Repair
Repair
Adjust
Adjust
Adjust
Adjust

Clean
Clean
Clean
Remedy
Add
Check items)
Check items)
WD600-3 20-313
(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output

Carry out troubleshooting to decide if the cause is in the Causes
enginer or in the machine. (Measure engine stall speed).
ragm
e nt
iaph
General causes why engine lacks output
st m
se a t
y
or d
spra
adju
nsat
lve
le
tive
nce
d va
o
mpe
tive
h
efec
r
ge r
fere
leve
e
efec
e an
st co
ent
er
ing
h
plun
pum ainer
le, d
reat
r
r
rain
• Use of Improper fuel
inde
lem
e
nce
t op
l pip
e, d
valv
boo
, int
air b
z
p st
ump
(If non-specified fuel is used, output drops)
tr
l too ion of s
er e
a
noz
, cy l
ka g
rger
mp
s
f
clea
u
o
,
• Lack of output due to overheating
f
lean
on p
r lin
t a nk
tion
u
filte
t a ct
g
high
ing
cha
on p
n
lve
fl If there is overheating and lack of output,
osit
r
leve
air c
con
c
k
feed
i
fuel
urbo
uel
ton
inje
, lea
jecti
r va
njec
carry out troubleshooting for overheating
p
f
e
s
l
ged
t
ged
en in
ged
t fue
rope
ged
ged
ged
n pi
ctiv
ed t
rrec
ed i
eve
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Wor
Seiz
Inco
Brok
Seiz
Oil l
Ben
Imp
Suddenly
Power was lost
Gradually
Questions

operation manual
Black
High idling speed under no load is normal, but speed suddenly
drops when load is applied
Check items

High idling speed of engine is low
When injection pipe is held between fingers, there is no pulse,
or there are cylinders with a weak pulse

Go to S-3 Engine does not pick up smoothly

Troubleshooting
to be clogged
When lever is placed at FULL position, it does not contact stopper
When feed pump is operated, operation is too light or too heavy
Legend
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust

Clean
Clean
Clean
Clean
Remedy
Check items)
Check items)
20-314 WD600-3
(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust gas is black Causes
ead
d)
der h
)
tion
eize
cylin
njec
er s
ung
ve i
r and
seat
k, pl
e
e ssi
renc
arge
alve
zzle
(exc
(rac
boch
n no
ent
e, v
erfe
e
inde
ump
lem
ump
valv
imin
ranc
, int
n tur
ctio
r
er e
zzle
uffle
, cy l
on p
rger
on p
inje
clea
on t
t of
wee
S no
lean
ed m
ring
ntac
cha
jecti
r bet
ecti
zed
i
ject
lve
air c
e AP
urbo
, sei
r inj
r va
e co
ston
of ai
clog
n
e in
i
ctive
rope
rope
ged
ged
ctiv
ctiv
ctiv
ed t
n pi
hed,
age
Defe
Clog
Defe
Clog
Defe
Defe
Leak
Seiz
Crus
Wor
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
Check items

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

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

When check is made using delivery method, injection timing is
found to be incorrect
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not
return
Legend
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust

Clean
Clean
Clean
Clean
Remedy
Check items)
Check items)
WD600-3 20-315
(1)
TROUBLESHOOTING S-8
S-8 Oil comsumption is excessive (or exhaust smoke is blue)

fl To prevent the oil from leaking up or down, do
not run the engine at idling for more than 20
minutes continuously. (Both low and high idling) Causes
m
General causes why oil consumption is excessive
hrag
r
arge
diap
• Abnormal combustion of oil
t c.
och
ator
d, e
al
• External leakage of oil
n se
ce
Turb
pens
em
he a
e
a
• Wear of lubrication system
hos
f
ler
oke
r
syst
er
al su
c om
de r
coo
r lin
he r
), br
plug
ylin
take
l, se
oos t
reat
, oil
inde
nd
uide
nd
ping
n, c
n
rain
cked ear sea
b
e
er e
ilter
or b
i
, cyl
ump
bine
m, g
from
il pa
il pi
oil d
g
low
oil f
high
ther
n rin
r
ring
on p
oole
t tur
(ste
mo
mo
nr
n
at b
m
m
i
brea
isto
roke
jecti
ton
l too
al a
oil c
e fro
e fro
e fro
e fro
v e
a l
l
s
en p
en in
n va
n se
n se
ged
n, b
n pi
eve
t su
kag
kag
ken
kag
kag
Brok
Clog
Wor
Wor
Wor
Wor
Wor
Brok
Oil l
Dus
Lea
Lea
Bro
Lea
Confirm recent repair history Lea
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Abnormally excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
Check items
Inside of turbocharger intake pipe is dirty with oil

Oil level in clutch or TORQFLOW transmission damper case rises
When oil level is checked with dipstick, it is found to be above
H mark
Clamps for intake system are loose
If engine is run at low idling, oil leaks from joint of turbocharger
and exhaust manifold
Inside of joint bolt of injection pump and boost compensator

pipe is wet with oil
Troubleshooting
When breather element is inspected, it is found to be clogged

with dirty oil
There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with oil
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Adjust

Clean
Remedy
Check items)
Check items)
20-316 WD600-3
(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Intake of exhaust gas due to internal wear Causes

• Clogging of lubrication passage
• Improper combustion
• Use of improper oil
end
• Operation under excessive load
bine
• Interval between oil change too long
r tur
pipe
e
r tub
arge
ain
athe
r
inde
h
r dr
ide
boc
e
, bre
e gu
arge
, cyl
valv
k
t tur
blac
r
ther
oole
high
ring
valv
och
ilter
ety
al a
s is
brea
oil c
turb
f
oil f
ston
e sa
e se
lve,
l too
t ga
n va
ged
ged
ged
ctiv
ctiv
ged
n pi
eve
aus
Defe
Defe
Clog
Clog
Clog
Clog
Wor
Wor
Oil l
Exh
Questions

Black
Carry out troubleshooting also

Abnormally excessive
Amount of blow-by gas
None
for "Exhaust gas is black".
Oil filter caution lamp stays on even when oil pressure rises
Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be
dirty with oil
Engine oil temperature rises quickly
When oil level is checked with dipstic, it is found to be above
H mark
Carry out troubleshooting also

for "Exhaust gas is black".
When breather element is inspected directly, it is found to be

Troubleshooting
clogged with dirty oil, or hose is broken

When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is inspected directly, spring is found to be
catching or broken
Legend
Replace
Replace
Replace
Replace
Replace
Adjust

Clean
Clean
Clean
Remedy —
Check items)
Check items)
WD600-3 20-317
(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel Causes

)
n)
ca p
ctio
r
)
filte
ing
e
o
ka g
inje
t
(pis
tain
f ue l
r lin
s ive
e re
ng,
pum
r
eve
nge
xc es
ray
loos
pipi
ng
l
u
feed
e sp
f ue l
p (e
timi
l
zle (
p
f ue l
ump
ozzl
t of
pum
ide
ion
noz
from
men
l ins
on n
p
ject
ion
ion
ion
age
l sea
n
just
ecti
ject
ject
ject
l i
r fue
leak
e ad
j
e in
e in
e in
e oi
e in
rope
ctiv
rnal
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Imp
Questions
More than for other machines of same model

Condition of fuel Gradually increased
consumption
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
Check items

Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump test shows that injectin amount is too high

Troubleshooting

not return
When check is made using delivery method, injection timing is
found to be incorrect
Remove nozzle holder and inspect directly
Remove feed pump and inspect direclty
When engine speed is measured, low idling speed is found to be high
Legend
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust
Adjust

Check items)
Check items)
20-318 WD600-3
(1)
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
Causes
• Internal leakage in lubrication system
ed)
• Internal leakage in cooling system
ittin
ogg
by p
t
le cl
aske
used
r ho
ne r
ad g
s ca
er li
athe
r he
in
lock
hole
d
r tra
(bre
cylin
inde
-ring
er b
ng,
owe
ump
l
re, O
y
n of
O-ri
lind
d, c
ter p
usio
r for
r co
hea
y
line
c
n wa
ks in
rotr
oole
oole
der
der
eal o
p
cylin
crac
ylin
oil c
oil c
ent
en c
en s
ffici
rnal
ken
ken
ken
Brok
Brok
Insu
Inte
Bro
Bro
Bro
Questions

Suddenly increased
Increase in oil level
Gradually increased
Hard water is being used as cooling water (corrosion resistor
valve is closed)
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, water spurts back

Hydraulic oil, torque converter, transmission oil is cloudy white
When hydraulic oil, torque converter, transmission oil is
drained, water comes out

Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage

Remove cylinder head and inspect directly
Inspect water pump
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Check items)
Check items)
WD600-3 20-319
(1)
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp
lights up.
• Leakage, clogging, wear of lubricating

system
Causes
• Defective oil pressure control
• Used of improper oil (improper viscosity)
• Deterioration of oil due to overheating
n
★ Standards for engine oil selection
il pa
n
ortio
ng
de o
KIND AMBIENT TEMPRATURE
pipi
an
OF FLUID -20 –10 0 10 20 30 40 50°C
an
sor
insi
oil p
ing
oil p
ulic
sen
sor
e
braz
SAE 30CD
pipe
valv
ydra
side
l in
l sen
nal
e
lve
ssur
pipe
l
SAE 10WCD
eve
er in
ator
n oi
ed h
mp
jour
r
f va
oole
eve
ilter
Engine oil
il
l pre
l pu
oil l
roke
in o
ion
Defe e regul
n
Defe , crush
elie
ring
oil l
SAE 10W-30CD
oil c
oil f
stra
suct
e oi
e oi
ent
r
b
uel
a
e
,
n be
ged
ged
ctiv
ged
ged
ctiv
ctiv
ffici
SAE 15W-40CD
ctiv
ctiv
king
er, f
ken
Clog
Clog
Defe
Clog
Clog
Defe
Defe
Wor
Insu
Wat
Lea
Bro
Questions

operation manual
Caution lamp lights up
Lights up at low idling
Condition when oil pres- Lights up at low, high idling
sure lamp lights up
Lights up on slopes
Sometimes lights up
Crushed piping, leakage from hydraulic piping (external)
Check items
Oil level sensor lamp lights up

When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected directly, it is found to be

clogged
Carry out troubleshooting

Troubleshooting
Oil pump rotation is heavy, there is play

for "Oil level rises".
There is catching of relief valve, regulator valve, or spring,

valve guide is broken
When oil level sensor is replaced, oil pressure sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Check oil cooler
Legend
Replace
Replace
Replace
Replace
Repair
Repair
Adjust
Adjust

Clean
Clean
Clean
Clean
Remedy —
Add
Check items)
Check items)
20-320 WD600-3
(1)
S-13 Oil level rises

fl If there is oil in the cooling water, carry out
troubleshooting for "Oil is in cooling water".
Causes
General causes why oil level rises
g
seal
ca p
ittin
e nt
ding
ctive
by p
• Water in oil (cloudy white)
ning
ipm
nclu
• Fuel in oil (diluted, and smells of diesel fuel)
defe
ade
i
e qu
a
r ret
• Entry of oil from other component
et (i
les m
ole,
iary
olde
a ce
ber) gask
g, ho
uxil
e
surf
ther
-ring
zle h
leev
k
d
or a
O-rin
c
a
brea
r blo
eat
se a l
n pu
e
er s
noz
re, O
core
on c ead, h
mp
tat s
liner
ham
hold
e
ctio
rear
ump
from
r co
d
f pu
oler
cylin
mos
h
inje
der
er p
ged
zzle
oole
der
al o
r-co
fuel
r
cylin
side
e
side
usti
cylin
e no
ama
wat
e se
e th
oil c
afte
e of
ks in
omb
aged
ct in
ged
ctiv
ctiv
ctiv
n, d
ken
kag
ken
ken
Defe
Defe
Clog
Defe
Defe
Crac
prec
Dam
Wor
Bro
Lea
Bro
Bro

Questions

There is oil in radiator cooling water
Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
Check items
When water pump breather hole is cleaned, water comes out

Oil level does down in TORQFLOW transmission, or damper case
Oil level does down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

Remove water pump and inspect directly
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to be
broken
Remove nozzle holder and inspect directly
Remove injection pump and inspect directly
There is improper contact of thermostat seat valve
Pressure-tightness test of after-cooler core shows there is leakage
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

Check items)
Check items)
WD600-3 20-321
(1)
S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high
Causes
• Lack of cooling air (deformation, damage of fan)
g
• Drop in heat dissipation efficiency
ittin
• Defective cooling circulation system
by p
• Rise in oil temperature of power train
ure
ade
fl Carry out troubleshooting for chassis
e n)
)
erat
5A-1
les m
e
t
a ug
t op
a ske
y
emp
ulle
(D47
g, ho
e
g
s no
ad g
ka g
in
an p
ure
oil t
t or f
O-rin
otor
doe
, lea
oole
erat
, he
e
e
f
t
rter
valv
adia
a
n
pum k
pm
tat (
ng w
wor
core
ead
p
oil c
liner
bloc
tem
e
ump
ed r
v
sure
mos
er h
con
ing,
ooli
ator
ken
der
der
ater
Clog water p
Clog d, crush
Bro ve pres
lind
ther
lipp
rque
cylin
nt c
, bro
fan
ylin
radi
ew
y
s
e
c
e
ctive
c
in to
aged
ged
ffici
ged
ctiv
ctiv
belt
k in
ken
ken
cti
ge
Defe
Clog
Defe
Insu
Defe
Defe
Crac
Dam
Rise
Fan
Bro

Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Carry out troubleshooting for chassis

Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Check items
Engine oil level has risen, oil is cloudy white

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine
water temperature
Temperature difference between top and bottom radiator tanks

is excessive
Temperature difference between top and bottom radiator tanks

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

When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
: Possible cause (jugding from Questions and Remedy — —

Add
Check items)
Check items)
20-322 WD600-3
(1)
S-15 Abnormal noise is made

fl Judge if the noise is an internal noise or an external
noise.
Causes
on)
ad
General causes why abnormal noise is made
r he
d)
ositi
tc.)
n)
eize
linde
ctio
er, e
of p
• Abnormality due to defective parts
er s
inje
d cy
r lev
ranc
esso ard out

lt
• Abnormal combustion noise
lung
ing
ive
r an
b
ocke
clea
• Air sucked in from intake system
nce
f fan
cess
r pip
ck, p
e
pum ozzle
o
er
g
ir co viding b
r
fere
r
alve
a
r lin
ash
x
h
p (ra
ve,
p (e
rboc
e
n
ng
nter
renc
inde
of v
ackl
(val
ion
hing
eari
mpr
pum
n tu
di
er, i
erfe
in b
, cyl
ent
c
stem
ler (
ft, b
inje
twee
bus
ion
ion
harg
m
t
f
ring
n, in
ar tr
muf
sha
e sy
t
zed
ject
r be
ject
ma
zed
djus
rboc
rank
d fa
ston
r ge
, sei
side
valv
of ai
, sei
n
e in
e fro
a
i
u
r
rme
rope
ed c
rope
ged
ct in
n pi
ctiv
ctiv
ed t
sing
age
ken
kag
Defo
Defe
Defe
Clog
Wor
Seiz
Seiz
Defe
Leak
Imp
Bro
Imp
Mis
Lea
Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred
Black
Metal particles are found in oil filter
Check items
Abnormal noise is loud when accelerating engine

Leakage of air between turbocharger and cylinder head
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly (flywheel housing top cover)
Troubleshooting

Fan is deformed, or belt is loose
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Check for leakage from air compressor piping
Remove oil pan and inspect
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Adjust
Adjust

Check items)
Check items)
WD600-3 20-323
(1)
S-16 Vibration is excessive

fl If there is abnormal noise together with the vibra-
tion, carry out troubleshooting for "Abnormal noise
is made" Causes
d)
seize
in
General causes why vibration is excessive
ion
r tra
k
nger
ring
st uc
ush
owe
per)
• Defective parts (abnormal wear, breakage)
, plu
be a
en c
tc.)
nd p
da m
• Improper alignment
ction
er, e
ain
utpu ts, brok

• Abnormal combustion
a
aft (
n da ssive inje
d, m
v
e
er le
ngin
lash
t sh
l
g ro
r
g bo
mpe
rock
en e
(exce
k
zzle
ba c
ctin
ntin
twe
ve,
n no
de o
p
nne
m
ng
t
mou
i
pilo
atio
r tra
(val
n pu
t be
i
d co
ctio
ush
insi
vibr
Defe injectio
t
a
n
tem
e
r
r ge
inje
ppo
mb
ngin
nme
eize
part
e
s
rope
e sy
ctiv
n su
n ca
ged
n, s
se e
alig
ctive
ken
Valv
Wor
Clog
Wor
Wor
Mis
Imp
Defe
Loo
Bro
Questions
Condition of vibration Suddenly increased

Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust gas is black

Remove side cover and inspect directly
Troubleshooting
Check directly for worn support pilot, play

Inspect directly for loose engine mounting bolts, broken
cushion
Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are found
to be outside standard
Remove front cover, and inspect directly
Legend
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Adjust

Check items)
Check items)
20-324 WD600-3
(1)
TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(EA MODE)
Method of error code display ...................................................................................................................... 20-353

Action taken by controller and condition of machine when error code is displayed .................................... 20-356
Schematic diagram for engine control system ............................................................................................ 20-364
EA- 1 Error code [111] (Abnormality in controller memory)....................................................................... 20-366
EA- 2 Error code [112] (Abnormality in timing rail actuator ....................................................................... 20-366
EA- 3 Error code [113] (Abnormality with electric current in timing rail actuator system) ......................... 20-367
EA- 4 Error code [115] (Abnormality in engine speed sensor 2 system) .................................................. 20-368
EA- 5 Error code [116] (Abnormality in timing rail pressure sensor system high level) ............................ 20-370
EA- 6 Error code [117] (abnormality in timing rail pressure sensor system low level) .............................. 20-371
EA- 7 Error code [118] (Abnormality in fuel pump pressure sensor system high level) ............................ 20-372
EA- 8 Error code [119] (Abnormality in fuel pump pressure sensor system low level) ............................. 20-373
EA- 9 Error code [121] (Abnormality in engine speed sensor 1 system) .................................................. 20-374
EA-10 Error code [122] (Abnormality in boost pressure sensor system high level)................................... 20-375
EA-11 Error code [123] (Abnormality in boost pressure sensor system low level) .................................... 20-376
EA-12 Error code [131] (Abnormality in accelerator sensor system high level)......................................... 20-377
EA-13 Error code [132] (Abnormality in accelerator sensor system low level) .......................................... 20-378
EA-14 Error code [135] (Abnormality in oil pressure sensor system high level) ........................................ 20-379
EA-15 Error code [141] (Abnormality in oil pressure sensor system low level) ......................................... 20-380
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1)) .............................................................. 20-381
EA-17 Error code [144] (Abnormality in water temperature sensor system high level) ............................. 20-382
EA-18 Error code [145] (Abnormality in water temperature sensor system low level)............................... 20-383
EA-19 Error code [151] (Abnormal rise in water temperature) .................................................................. 20-383
EA-20 Error code [153] (Abnormality in intake air temperature sensor system high level)........................ 20-384
EA-21 Error code [154] (Abnormality in intake air temperature sensor system low level) ......................... 20-384
EA-22 Error code [221] (Abnormality in atmospheric pressure sensor system high level) ........................ 20-385
EA-23 Error code [222] (Abnormality in atmospheric pressure sensor system low )................................. 20-386
EA-24 Error code [234] (Overspeed) ......................................................................................................... 20-388
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage).............................................. 20-389
EA-26 Error code [259] (Abnormality in fuel shut-off valve)....................................................................... 20-390
EA-27 Error code [261] (Abnormal rise in fuel temperature) ..................................................................... 20-390
EA-28 Error code [263] (Abnormality in fuel temperature sensor system high level) ................................ 20-391
EA-29 Error code [265] (Abnormality in fuel temperature sensor system low level).................................. 20-391
EA-30 Error code [316] (Abnormality in fuel pump actuator system current) ............................................ 20-392
EA-31 Error code [318] (Abnormality in fuel pump actuator) ..................................................................... 20-393
EA-32 Error code [343] (Abnormality in controller internal communication) .............................................. 20-393
EA-33 Error code [346] (Abnormality in controller power down)................................................................ 20-394
EA-34 Error code [384] (Abnormality in preheating heater control system) .............................................. 20-395
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) .............................................................. 20-396
EA-36 Error code [423] (Abnormality in timing rail pressure sensor system in range) .............................. 20-397
WD600-3 20-351
(1)
EA-37 Error code [431] (Abnormality 1 in idling validation switch system) ................................................ 20-399
EA-38 Error code [432] (Idling validation process error) ............................................................................ 20-401
EA-39 Error code [441] (Abnormality in battery voltage low level)............................................................. 20-404
EA-40 Error code [442] (Abnormality in battery voltage high level) ........................................................... 20-404
EA-41 Error code [451] (Abnormality in fuel rail pressure sensor system high level) ................................ 20-405
EA-42 Error code [452] (Abnormality in fuel rail pressure sensor system low level) ................................. 20-406
EA-43 Error code [455] (Abnormality in fuel rail actuator system current) ................................................. 20-407
EA-44 Error code [467] (Abnormality in timing rail actuator control).......................................................... 20-408
EA-45 Error code [468] (Abnormality in fuel rail actuator control).............................................................. 40-408
EA-46 Error code [514] (Abnormality in fuel rail actuator) ......................................................................... 20-408
EA-47 Error code [527] (Abnormality in dual output solenoid A system) ................................................... 20-409
EA-48 Error code [551] (Abnormality 2 in idling validation switch system) ................................................ 20-409
EA-49 Error code [554] (Abnormality in fuel rail pressure sensor in range)............................................... 20-410
20-352 WD600-3
(1)
TROUBLESHOOTING METHOD OF ERROR CODE DISPLAY
METHOD OF ERROR CODE

DISPLAY
· ERROR CODE DISPLAY
1. An error code display device with tricolor lamps
is installed at the foot of the operator's seat.
2. The error code display device is composed of
three lamps of different colors, e.g. orange (1),
yellow (2) and red (3), selector switch (4) and
diagnosis switch (5).
3. Checking blown lamps
1) When turning the engine starting switch ON:
When starting the engine starting switch ON,
the three lamps light up for about two sec- Example of display: When displaying error code [253]
onds to show if there is any blown lamp and
then go off, if there is none. At that time,
keep diagnosis switch (5) at the OFF posi-
tion.
2) Manual check:
It can be checked whether a lamp is blown or
not by turning diagnosis switch (5) ON, after
the engine starting switch has been turned
ON and if there is no engine trouble
occurred. If each of the three lamps lights up,
it is normal. A lamp which does not light up
may well be replaced, as it is all likely blown.
If there is any engine trouble occurred at that
time, an error code is displayed.
4. Always keep diagnosis switch (5) at the OFF
position (normal position), except when seeing
an error code.
· An engine controller displays the engine con-

ditions in the following two modes.
1. Display of engine trouble
If any of the three color lamps lights up while the
engine is running, or when the engine starting
switch is in the ON position, it indicates that an
engine trouble has occurred and also the nature
and extent of such a trouble.
2. Display of error code
By calling an error code in the display after the
engine starting switch is turned ON but when the
engine is not run, a three-digit error code may be
confirmed through times that the lamp flashes.
· Display of nature and extent of engine trou-

ble
1. When the orange lamp lights up:
This indicates that the engine controller has
recorded some abnormality in the engine. The
device automatically regulates the engine output
depending upon nature of such abnormality.
2. When the yellow lamp lights up:
This indicates that some abnormality has
occurred in the engine, but that such abnormality
is still light enough to tolerate the engine to keep
running.
WD600-3 20-353
(1)
TROUBLESHOOTING METHOD OF ERROR CODE DISPLAY
3. When the red lamp lights up:

This indicates that some serious abnormality has
occurred in the engine, and that the engine must
be stopped immediately.
· Display of error code (Method for confirming

three-digit error code)
1. Turn the engine starting switch ON and turn
diagnosis switch (5) ON.
2. In this condition, the lamps light up and then go
off, if there is no blown lamp. (A function of
checking a blown lamp) If there is an engine
trouble occurred, meanwhile, an error code for
the trouble is displayed by the time that the red
lamp flashes. At that time, the orange (white)
lamp remains lit, while the error code is dis-
played.
3. Counting error code (Example: Case of Error
Code 253)
At first the yellow lamp flashes once. (Start-
ing display of error code)
All the lamps go off for about one second.
The red lamp repeats flashing so many times
as the third digit number of the error code.
(Example: 2 times)
as the second digit number of the error code.
(Example: 5 times)
as the first digit number of the error code.
(Example: 3 times)
The yellow lamp flashes once. (The end of
that error code number)
The processes of 2) through 9) are repeated.
4. When plural troubles have occurred:
If it is suspected that more than two engine trou-
bles have occurred at a time, push up selector
switch (4) for about two seconds, then the dis-
play advances to the next error code number. In
case only one trouble has occurred, on the other
hand, the display shows the same error code
number. Continue to advance the display until
the same error code number is shown to read
out all the error codes. Push down selector
switch (4) to return to the immediately preceding
error code.
5. Turning off diagnosis switch
Turn diagnosis switch (5) OFF. (Return to normal
condition)
6. An error code is deleted, once the engine trouble
is removed and the engine starting switch is
turned OFF.
20-354 WD600-3
(1)
ACTION TAKEN BY CONTROLLER AND CONDITION OF
TROUBLESHOOTING MACHINE WHEN ERROR CODE IS DISPLAYED

MACHINE WHEN ERROR CODE IS DISPLAYED
User System with abnormality Nature of abnormality Condition when normal
code
Failure of memory hardware inside control-

Abnormality in controller
111 ler or communications failure in internal —
memory processor
• Abnormality in timing rail Excessive differ-

ence between timing rail command fuel
value and actual timing fuel
Abnormality in timing rail
112 Judgment value (reference): —
actuator
Difference more than 400 mm3/st or less
than –750 mm3/st (when coolant tem-
perature is 0°C or above)
• Abnormality has occurred in timing rail • Resistance of timing rail actuator

Abnormality with electric actuator circuit Between TIMG (A) and (C): 7 – 9 z
Between ECMA (1) and (20) (reference
113 current in timing rail
actuator system value):
Detected outside range of 0.40±0.35A
(engine stopped)
• No signal is input from engine speed sen- • Resistance of engine speed sensor
Abnormality in engine sor circuit system 2 Between SP2 (A) and (B) (signal 1):1 – 2 kz
115
speed sensor 2 system ECMA (27), (28): Signal 1 Between SP1 (A) and (B) (signal 2):1 – 2 kz
ECMA (37), (38): Signal 2
• Abnormality has occurred in timing rail • Voltage of timing rail pressure sensor
Abnormality in timing rail pressure sensor circuit Between ECMA (5) and (18) (power source):
116 pressure sensor system ECMA (33): 4.78 V or more detected 4.75 – 5.25 V
Between ECMA (33) and (18) (signal):
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in timing rail • Voltage of timing rail pressure sensor
pressure sensor circuit Between ECMA (5) and (18) (power source):
Abnormality in timing rail ECMA (33): 0.30 V or less detected 4.75 – 5.25 V
117 pressure sensor system
low level Between ECMA (33) and (18) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel pump • Voltage of fuel pump pressure sensor
Abnormality in fuel pump pressure sensor circuit Between ECMA (5) and (18) (power source):
ECMA (32): 4.78 V or more detected 4.75 – 5.25 V
high level Between ECMA (32) and (18) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel pump • Voltage of fuel pump pressure sensor
Abnormality in fuel pump
ECMA (32): 0.30 V or less detected 4.75 – 5.25 V
119 pressure sensor system Between ECMA (32) and (18) (signal):
low level 0.42 – 0.58 V
(engine stopped)
• 15. No signal is input from engine speed • Resistance of engine speed sensor
Abnormality in engine sensor circuit system 2 to one of following Between SP2 (A) and (B) (signal 1): 1 – 2 kz
121 speed sensor 1 system ECMA (27), (28): Signal 1 Between SP1 (A) and (B) (signal 2): 1 – 2 kz
ECMA (37), (38): Signal 2
• Abnormality has occurred in boost pres- • Voltage of boost pressure sensor

sure sensor circuit Between ECMA (6) and (17) (power source):
Abnormality in boost
122 pressure sensor system ECMA (35): 4.72 V or more detected 4.75 – 5.25 V
high level Between ECMA (35) and (17) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in boost pres- • Voltage of boost pressure sensor

Abnormality in boost ECMA (35): 0.30 V or less detected 4.75 – 5.25 V
low level 0.42 – 0.58 V
(engine stopped)
20-356 WD600-3
(1)
Action by controller Problem that appears on machine Probable cause
• Red lamp lights up • Engine cannot be started • Defective engine controller
• Red lamp lights up • Engine speed goes down • Excessive negative pressure at inlet port
• Limits engine speed to 1500 rpm of fuel pump
• Defective timing rail actuator or clogged
screen
• Broken injector O-ring
• Defective engine controller
• Yellow lamp lights up • Engine output goes down • Defective timing rail actuator
• Engine emits white smoke • Defective wiring harness and connector
of timing rail actuator circuit
• Red lamp lights up • Engine stops • Defective engine speed sensor

• Outputs speed signal 0 rpm • Defective wiring harness and connector
of engine speed sensor circuit
• Red lamp lights up • Engine makes abnormal explosion • Defective timing rail pressure sensor
• Carries out open control of timing rail sound or emits white smoke, then • Defective wiring harness and connector
• Limits engine speed to 1500 rpm engine speed becomes 1500 rpm of timing rail pressure sensor circuit
• Red lamp lights up • Engine makes abnormal explosion • Defective timing rail pressure sensor
• Carries out open control of timing rail sound or emits white smoke, then • Defective wiring harness and connector
• Limits engine speed to 1500 rpm engine speed becomes 1500 rpm1 of timing rail pressure sensor circuit
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector
— of fuel pump pressure sensor circuit
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector
of fuel pump pressure sensor circuit
— • Defective engine controller
• Yellow lamp lights up • Defective engine speed sensor

• Defective wiring harness and connector
—
of engine speed sensor circuit
• No lamps light up • Exhaust gas color is poor when • Defective boost pressure sensor
accelerating • Defective wiring harness and connector
• Engine output increases of boost pressure sensor circuit
• No lamps light up • Engine output goes down • Defective boost pressure sensor
of boost pressure sensor circuit
WD600-3 20-357
(1)

code
• Abnormality has occurred in throttle sen-

131 Abnormality in throttle sor circuit
sensor system high level ECMB (29): 4.80 V or more detected —
• Abnormality has occurred in throttle sen-

Abnormality in throttle sor circuit
132 ECMB (29): 0.30 V or less detected —
sensor system low level
• Abnormality has occurred in oil pressure • Voltage of oil pressure sensor

Abnormality in oil sensor circuit Between ECMA (6) and (17) (power source):
ECMB (24): 4.88 V or more detected 4.75 – 5.25 V
high level 0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in oil pressure • 14. Voltage of oil pressure sensor
Abnormality in oil sensor circuit Between ECMA (6) and (17) (power source):
141 pressure sensor system ECMA (24): 0.31 V or less detected 4.75 – 5.25 V
low level
0.42 – 0.58 V
(engine stopped)
• Oil pressure sensor detected pressure

lower than set oil pressure (level 1)
Level 1 judgment value (reference)
143
Abnormal drop in oil At 600 rpm Max. 0.05 MPa { 0.5 kg/cm2} —
pressure (level 1) At 1000 rpm Max. 0.09 MPa { 0.9 kg/cm2}
At 1500 rpm Max. 0.15 MPa { 1.5 kg/cm2}
At 1800 rpm Max. 0.18 MPa {1.85 kg/cm2}
At 2000 rpm Max. 0.21 MPa { 21 kg/cm2}
• Abnormality has occurred in water tem- • Resistance of water temperature sensor

Abnormality in water perature sensor circuit Between CLTP (A) and (B): 600 – 36k z
144 temperature sensor
ECMA (22): 4.95 V or more detected
system high level
• Abnormality has occurred in water tem- • Resistance of water temperature sensor

Abnormality in water perature sensor circuit Between CLTP (A) and (B): 600 – 36k z
ECMA (22): 0.21 V or less detected
system low level
• Water temperature sensor has detected

151 Abnormal rise in water
temperature temperature higher than set temperature
Judgment value (reference): Min. 105°C
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
temperature sensor temperature sensor circuit Between IMTP (A) and (B): 36 – 600 z
153
system high level ECMA (23): 4.88 V or more detected
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
temperature sensor temperature sensor circuit Between IMTS (A) and (B): 36 – 600 z
154 system low level ECMA (23): 0.08 V or less detected
• Abnormality has occurred in atmospheric • Voltage of atmospheric temperature sensor

Abnormality in
221 atmospheric pressure ECMA (34): 4.78 V or more detected 4.75 – 5.25 V
sensor system high level Between ECMA (34) and (17) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in atmospheric • Voltage of atmospheric pressure sensor

Abnormality in atmo- ECMA (34): 0.20 V or less detected 4.75 – 5.25 V
222 spheric pressure sensor Between ECMA (34) and (17) (signal):
system low level 0.42 – 0.58 V
(engine stopped)
• Engine speed sensor has detected speed

higher than set speed
Judgment value (reference):
234 Overspeed D375A :2,400 rpm or more —
WA600 :2,500 rpm or more
PC1100 :2,400 rpm or more
Morita :2,550 rpm or more
20-358 WD600-3
(1)
• Red lamp lights up • Engine output and speed suddenly • Abnormality in throttle controller system
• Holds engine at constant speed go down • Defective wiring harness and connector
of throttle sensor circuit
• Red lamp lights up • Engine output and speed suddenly • Abnormality in throttle controller system
• Holds engine at constant speed go up • Defective wiring harness and connector
of throttle sensor circuit
• Yellow lamp lights up • Defective oil pressure sensor

of oil pressure sensor circuit
• Yellow lamp lights up • Defective oil pressure sensor

— of oil pressure sensor circuit
• Orange lamp lights up • Defective engine

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective water temperature sensor

— • Defective wiring harness and connector
of water temperature sensor circuit
• Yellow lamp lights up • Defective water temperature sensor

—
of water temperature sensor circuit

• After 10 seconds limits injection amount to — • Defective water temperature sensor
50%
• Yellow lamp lights up • Defective intake air temperature sensor

—
of intake air temperature sensor circuit
• Yellow lamp lights up • Defective intake air temperature sensor

— of intake air temperature sensor circuit
• Yellow lamp lights up • Defective atmospheric pressure sensor

— of atmospheric pressure sensor circuit
• Yellow lamp lights up • Defective atmospheric pressure sensor

of atmospheric pressure sensor circuit
—
• Red lamp lights up • Defective engine

• Shut off common rail actuator (fuel cut-off). • Defective engine speed sensor
• Defect on machine
—
WD600-3 20-359
(1)

code
• Abnormality has occurred in fuel shut-off • Resistance of fuel shut-off valve

Abnormality in fuel shut- valve circuit Between FSO (+) and (-): 23 – 40 z
254 Between ECMA (30) and (8):
off valve system voltage
Voltage of 6.0 V or less or resistance of
20 z or less detected
• Fuel shut-off valve remains open and

259 Abnormality in fuel shut- does not close (even when electric power —
off valve
is turned off, engine does not stop)
Abnormal rise in fuel • Fuel temperature sensor has detected

261 temperature higher than set temperature —
temperature Judgment value (reference): 76°C or more
• Abnormality has occurred in fuel tempera- • Resistance of fuel temperature sensor

Abnormality in fuel
263 temperature sensor ture sensor circuit Between FLTP (A) and (B): 600 – 36k z
system high level ECMA (26): 4.95 V or more detected
• Abnormality has occurred in fuel tempera- • Resistance of fuel temperature sensor

Abnormality in fuel
265 temperature sensor ture sensor circuit Between FLTP (A) and (B): 600 – 36k z
system low level ECMA (26): 0.21 V or less detected
• Abnormality has occurred in fuel pump • Resistance of fuel pump actuator

actuator circuit Between PUMP (A) and (C): 7 – 9 z
Abnormality in fuel pump Between ECMA (11) and (40) (reference
316 actuator system current value):
Detected value outside range of
0.40±0.35A (engine stopped)
• Excessive difference between fuel pump

command pressure value and actual pres-
sure
318 Abnormality in fuel pump Judgment value (reference): —
actuator Difference more than ±2.11 MPa {2.1 kg/
cm2}
(when coolant temperature is 38°C or
above)
Abnormality in controller • Microprocessor error inside controller

343 —
internal communication
• Error in data recorded in power-down

Abnormality in controller internal memory of controller
346 —
power down
• Abnormality has occurred in preheating • Resistance of heater relay

heater control circuit Between relay coils: 200 c 400 z
Abnormality in preheating
384 ECMB (2):
heater control system
Circuit open or short circuit in circuit
detected
• Oil pressure sensor detected pressure

lower than set oil pressure (level 2)
Level 1 judgment value (reference)
Abnormal drop in oil At 600 rpm Max. 0.04 MPa {0.4 kg/cm2}
415 At 1,000 rpm Max. 0.08 MPa {0.8 kg/cm2}
—
pressure (level 2)
At 1,500 rpm Max. 0.13 MPa {1.3 kg/cm2}
• Timing rail pressure sensor detected

Abnormality in timing rail abnormal pressure
423 pressure sensor system Judgment value (reference) —
in range when starting switch is ON:
2.42 MPa {24.65 kg/cm2} or more
• Simultaneous detection of voltage from • Voltage of accelerator limit switch relay

both ON signal and OFF signal of idling Between C9(3) – (6):
validation switch Min. 5 V (pedal depressed)
Abnormality 1 in idling
431 ECMB (12): Idling OFF signal Max. 1 V (pedal released)
validation switch system
ECMB (13): Idling ON signal Between C9(3) – (5):
Max. 1 V (pedal depressed)
Min. 5 V (pedal released)
20-360 WD600-3
(1)
• No lamps light up • Engine stops • Defective fuel shut-off valve

• Shuts off power supply to fuel shut-off valve • Defective wiring harness and connector
of fuel shut-off valve circuit
• Red lamp lights up • Engine cannot stop • Defective fuel shut-off valve
• Shuts off power supply to fuel shut-off valve • Defective injector

• After 30 seconds limits engine speed to 800 — • Defective fuel temperature sensor
rpm • Defect on machine
• Yellow lamp lights up • Defective fuel temperature sensor

—
of fuel temperature sensor circuit
• Yellow lamp lights up • Defective fuel temperature sensor

of fuel temperature sensor circuit
• Yellow lamp lights up • Defective fuel pump actuator

— of fuel pump actuator circuit
• Yellow lamp lights up • Engine speed becomes unstable • Defective fuel pump actuator
• Excessive negative pressure at inlet port
of fuel pump
• Defective fuel temperature sensor
• Defective injector
• Yellow lamp lights up • Defective controller

—
• Yellow lamp lights up • Loss of power-down data • Defective battery

(maintenance data, present controller • Blown fuse
data, engine operating time, etc.) • Defective wiring harness and connector
of controller power source circuit
• Yellow lamp lights up • Defective heater relay

— of heater relay circuit

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective timing rail pressure sensor

• Limits high idling speed to 1,500 rpm • Defective wiring harness and connector
— of timing rail pressure sensor circuit
• Excessive suction resistance of fuel filter
• Red lamp lights up • Defective wiring harness and connector

of idling validation switch
• Defective accelerator limit switch relay
WD600-3 20-361
(1)

code
• Resistance of idling switch

• Throttle sensor signal and idling validation Between L14A(1) – (2):
Idling validation process ON signal, OFF signal do not match Max. 1 z (pedal released)
432 error ECMB (12): Idling OFF signal Between L14A(1) – (3):
ECMB (13): Idling ON signal Max. 1 z (pedal depressed)
• Abnormality has occurred in controller • Voltage of controller power source

power source circuit Between ECMB (3)(4)(5) and ECMA (7)(8):
Abnormality in battery
441 ECMB (3)(4)(5): 12 V or less detected 17.3 – 34.7 V
voltage low level
(When starting switch is OFF)
• Abnormality has occurred in controller • Voltage of controller power source

power source circuit Between ECMB (3)(4)(5) and ECMA (7)(8):
Abnormality in battery
442 voltage high level ECMB (3)(4)(5): 38 V or less detected 17.3 – 34.7 V
(When starting switch is OFF)
• Abnormality has occurred in fuel rail pres- • Voltage of fuel rail pressure sensor
Abnormality in fuel rail ECMA (31): 4.78 V or more detected 4.75 – 5.25 V
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail pres- • Voltage of fuel rail pressure sensor
Abnormality in fuel rail sure sensor circuit Between ECMA (5) and (18) (power source):
452 pressure sensor system ECMA (31): 0.15 V or less detected 4.75 – 5.25 V
low level Between ECMA (31) and (18) (signal):
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail actu- • Resistance of fuel rail actuator
Abnormality in fuel rail ator circuit Between RAIL (A) and (C): 7 – 9 z
455 actuator system current Between ECMA (1) and (20) (reference
value): 0.40 ± 0.35 A (engine stopped)
• Excessive difference between timing rail

command fuel value and actual timing
467 Abnormality in timing rail fuel, does not reach target value —
actuator control
• Excessive difference between fuel rail

command injection amount value and
Abnormality in fuel rail actual injection amount, does not reach
468 actuator control target value —
• Excessive difference between fuel rail

command injection amount value and
actual injection amount
Abnormality in fuel rail
514 actuator Fuel rail judgment value (reference): —
Difference ±600 mm3/st or more for
±50 msec or difference ±250 mm3/st
or more for ± 200 msec
• Abnormality has occurred in dual output • Resistance of dual output solenoid A

527 Abnormality in dual output solenoid A circuit Between R17(female)(A) – chassis: 28 – 32
solenoid A system ECMB (1): z
Circuit open or short circuit detected
• Abnormality has occurred in dual output • Resistance of dual output solenoid B

Abnormality in dual output solenoid B circuit Between solenoid pins: 28 – 32 z
529
solenoid B system ECMB (9):
Circuit open or short circuit detected
• Simultaneous detection of no voltage from • Resistance of idling switch

Abnormality 2 in idling both ON signal and OFF signal of idling Between IVS (A) and (B):
551 validation switch system validation switch Max. 125 z (pedal released)
ECMB (12): Idling OFF signal Between IVS (A) and (C):
ECMB (13): Idling ON signal Max. 125 z (pedal depressed)
• Fuel rail pressure sensor detected abnor-

Abnormality in fuel rail mal pressure
554 pressure sensor in range Judgment value (reference): —
When starting switch is ON:
0.17 MPa {1.76 kg/cm2} or more
20-362 WD600-3
(1)
• Red lamp lights up • Defective idling validation switch

• Recognizes throttle signal as 0% • Defective wiring harness and connector
— of idling validation switch
• Defective throttle controller
• Defective accelerator limit switch relay
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector
• Red lamp lights up • Defective fuel rail pressure sensor

• Carries out open control of fuel rail • Defective wiring harness and connector
— of fuel rail pressure sensor circuit
• Red lamp lights up • Defective fuel rail pressure sensor

• Carries out open control of fuel rail • Defective wiring harness and connector
— of fuel rail pressure sensor circuit
• Red lamp lights up • Defective fuel rail actuator

• Sets current to fuel rail actuator to 0 A • Defective wiring harness and connector
— of fuel rail actuator circuit
• Yellow lamp lights up • Excessive negative pressure at inlet port

• Limits engine speed to 1500 rpm of fuel pump
• Defective timing rail actuator or clogged
— screen

• Limits maximum injection amount to 217 of fuel pump
mm3/st • Defective fuel rail actuator or clogged
— screen

• Limits maximum injection amount to 217 of fuel pump
mm3/st • Defective fuel rail actuator or clogged
— screen
• Yellow lamp lights up • Defective dual output solenoid A

of dual output solenoid A circuit
• Yellow lamp lights up • Defective dual output solenoid B

of dual output solenoid B circuit
• Red lamp lights up • Defective idling validation switch

• Recognizes throttle signal as 0% • Defective wiring harness and connector
— of idling validation switch circuit
• Yellow lamp lights up • Defective fuel rail pressure sensor

• Limits maximum injection amount to 270 • Defective wiring harness and connector
mm3/st — of fuel rail pressure sensor circuit
• Excessive suction resistance of fuel filter
WD600-3 20-363
(1)
TROUBLESHOOTING SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM
SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM
20-364 WD600-3
(1)
TROUBLESHOOTING SCHEMATIC DIAGRAM FOR ENGINE CONTROL SYSTEM
WD600-3 20-365
(1)
TROUBLESHOOTING EA-1, EA-2
EA-1 Error code [111] (Abnormality in controller memory)

! "###$ % &

,- *
' "###$

( ! *((
( + *
) &

*

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

& #'
%
) (

!
! "

*%(
!
! !

#$! $ % %
%!
! ! #$!
$ % % %!
"
%

#
%
*%( %'
(

+$ , '
20-366 WD600-3
(1)
TROUBLESHOOTING EA-3
EA-3 Error code [113] (Abnormality with electric current in timing rail
actuator system)
+

- # #% & (..! #
'( / % # $# ,
- /$
! 0 1 2 Ω3
)*
- # #% & (..! #

'(
%#$ $# / % # $# ,
- /$
!
& " 4Ω3
)*
!
#
/ $ $$ $#
- # #% & (..! "
,# $#
- /$

'( &$# # #% &#
#,
" ##$% #%
"

!
&# &$ "3
)*
"
#
/ $ $$ $#
- # #% & (..!
'( &$# # #% &# ,# $#
- /$

! ##$% #% #,
&# &$ 3
)*
/ % $#$# ,
"

"

! " Ω

! " Ω

"

! "
Ω
##$% #% &#
! "
Ω ##$% #% &#
EA-3 Related electrical circuit diagram
WD600-3 20-367
(1)
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between SP1 (male)
NO Defective engine speed sensor Replace
• Disconnect SP1 and SP2. (A) and (B), and between SP2
(male) (A) and (B) 1k – 2kΩ?
YES
2
Is resistance between SP1 (male)
• Turn starting switch OFF. (A) and ground, and between NO
Defective engine speed sensor Replace
• Disconnect SP1 and SP2. SP2 (male) (A) and ground more
than 10 MΩ?
YES
3
Is resistance between SP1 (male)
• Turn starting switch OFF. (A) and SP2 (male) (A), and NO Replace
between SP1 (male) (B) and SP2 Defective engine speed sensor
• isconnect SP1 and SP2.
(male) (B) less than 10 Ω?
YES
4
• Remove engine speed Is engine speed sensor NO Defective engine speed sensor Replace
sensor. damaged?
YES
5
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (37) and SP2 (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and SP1. (A), and between ECMA (female)
(37) and surrounding wiring ECMA (female) (37) and SP2 (female) replace
harnesses as shown in Table 1? (A)
YES
6
• Disconnect ECMA and SP1. (B), and between ECMA (female) ECMA (female) (38) and SP2 (female) replace
(38) and surrounding wiring
harnesses as shown in Table 2? (B)
YES
7
(A), and between ECMA (female)
• Disconnect ECMA and SP2. (27) and surrounding wiring ECMA (female) (27) and SP1 (female) replace
YES
8
(female) (28) and SP1 (female)
• Turn starting switch OFF. (B), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and SP2. (28) and surrounding wiring ECMA (female) (28) and SP1 (female) replace
harnesses as shown in Table 4? (B)
YES
Defective engine controller Replace
20-368 WD600-3
(1)
Table 1 Table 2
ECMA (female), SP2 (female) Resistance value ECMA (female), SP2 (female) Resistance value
Between ECMA (37) and SP2 (A) Max. 10 Ω Between ECMA (38) and SP2 (B) Max. 10 Ω
Between ECMA (37) and Between ECMA (38) and
surrounding wiring harnesses Min. 1 MΩ surrounding wiring harnesses Min. 1 MΩ
Table 3 Table 3
ECMA (female), SP1 (female) Resistance value ECMA (female), SP1 (female) Resistance value
Between ECMA (27) and SP1 (A) Max. 10 Ω Between ECMA (28) and SP1 (B) Max. 10 Ω
WD600-3 20-369
(1)
EA-5 Error code [116] (Abnormality in timing rail pressure sensor system
high level)

3 4 ( % .* ( (

3 ' ') "*
% ''(' ( /01 )( (2

4 ) ' 7' ' (' 7
5 ' " 4 ( (( ('

3 ' ') "* 66% #
3 4 ( % "
*(' ' "') *' " 7' ('
# ''() "') # '7
*' *(" 2

!
5 ' " 4 ( (( ('
3 ' ') "* 66% ,
*(' ' "') *' " 7' ('
3 4 ( % ! "
, ''() "') , '7
*' *(" +2 !

"
5 ' " 4 ( (( ('
3 ' ') "* 66% --
*(' ' "') *' " 7' ('
" -- '7
3 4 ( % -- ''() "')
*' *(" -2

4 ) ('(' 7
+

!" # $% & Ω !" , ! $% & Ω
!" # % Ω !" , % Ω
''() "') *' ''() "') *'
-

!" -- $% & Ω
!" -- % Ω
''() "') *'
20-370 WD600-3
(1)
EA-6 Error code [117] (abnormality in timing rail pressure sensor system
low level)
($
"1

2$ '

4 2$* 56 *
# $ -. 7!& %' %"% *% 6*$$(* $$*
6&
4 (* $ * % $% &+ .- $+ % 3
/0
2$ *$%$ & 7!& %' & & # %$&& %# *

4 (* $ * % $% &+ .88 !"
!" # -. $+* &%*&(% % %*% +*$$
6%* *
!"
4 7%$&&
$(**(% %*% +*$$$ !"
!" *6&
$ $+ % 3
/0
!
2$ *$%$ & 7!& %' & & # %$&& %# *
4 (* $ * % $% &+ .88 !"
!"
# !" -. $+* &%*&(% % %*% +*$$
6%* *
4 7%$&&
$(**(% %*% !"
!" *6&
+*$$$ $ $+ % ,3
/0
"
2$ *$%$ & 7!& %' & & # %$&& %# *
4 (* $ * % $% &+ .88 !" ,,
!" -. $+* &%*&(% % %*% +*$$
6%* *
# !" !" ,,
!" *6&
4 7%$&&
,, $(**(% %*%
+*$$$ $ $+ % 3
/0
7!& %' % & **
6&

!"#
!"
$%$ & '(

) Ω

$(**(% %*% +*$$$ % Ω
,
!"#
!"
$%$ & '( !"#
!"
$%$ & '(

) Ω ,,
) Ω
,,
$(**(% %*% +*$$$ % Ω $(**(% %*% +*$$$ % Ω
WD600-3 20-371
(1)
EA-7 Error code [118] (Abnormality in fuel pump pressure sensor system
high level)

2 3( % .* (
2 ' ') "* % ( ''(' ( /,0 )( ( 1

3 6 6 6' ' (' 6
4 ' "

2 ' ') "* 55% # 3 ( (( ('
23( " *(' ' "') *' " 6' ('
% # ''( ) "') # '6
*' *(" 1

!
4 ' "
2 ' ') "* 55% , 3 ( (( (' 6' ('
2 3( ! " *(' ' "') *' " '6
% , ''( ) "') ,
*' *(" +1 !

"
4 ' " 3 ( (( ('
2 ' ') "* 55% -+
23( " *(' ' "') *' " 6' ('
% -+ ''( ) "') -+ '6
*' *(" -1

3 ) ('(' 6
+

!" # $% & Ω !" , ! $% & Ω
!" # % Ω !" , % Ω
''( ) "') *' ''( ) "') *'
-

!" -+ $% & Ω
!" -+ % Ω
''( ) "') *'
20-372 WD600-3
(1)
EA-8 Error code [119] (Abnormality in fuel pump pressure sensor system
low level)
($ "1

4 2$* 56*
2$ '
-.
4 (* $*% $%&+ .- # $ 7!&%' !( 6("6 6*$$(* $$ * 6&
$+ % 3
/ 0
2$ *$%$&
7!&%' & &# %$& &% # *
4(* $*% $%&+ .88 !"
!" -.
47%$& &
#
!" $+ * &%*&(% % %*% +*$$ 6%* *

$(** (% %*%
!"
!" *6&
+*$$$ $ $+ % 3
/ 0
!
2$ *$%$&
7!&%' & &# %$& &% # *
4(* $*% $%&+ .88 !"
!" -. $+ * &%*&(% % %*% +*$$ 6%* *
47%$& &
#
!"
$(** (% %*%
!"
*6&

!"
+*$$$ $ $+ % ,3
/ 0
"
2$ *$%$&
7!&%' & &# %$& &% # *
4(* $*% $%&+ .88 !" ,
!" -. $+ * &%*&(% % %*% +*$$ 6%* *
47%$& &
#
!"
, $(** (% %*%
!" ,
*6&

!"
+*$$$ $ $+ % 3
/ 0
7!&%' % & * * 6&

!"#
!" $%$& '(

) Ω

$(** (%
%*% +*$$$
%
Ω
,

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

) Ω
,

) Ω

,
$(** (% %*% +*$$$
%
Ω $(** (% %*% +*$$$
%
Ω
WD600-3 20-373
(1)
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)

★ Carry out troubleshooting for error code [115].
20-374 WD600-3
(1)
EA-10 Error code [122] (Abnormality in boost pressure sensor system

high level)

4 5 ) & 0+ )
4 ( (* # + & ) (()( ) 1,,2 *) ) 3

5 ! )) 8( ( )( 8
( # 5 ! ) ) ) )(

4 ( (* # + 66& -
45 ) " # +)( ( #(* +( # 8( )(
& - (() * #(* $ (8
+( +)# ,3

!
( # 5 ! ) ) ) )(
4 ( (* # + 66& 7
4 5 ) " # +)( ( #(* +( # 8( )(
& 7 (() * #(* - (8
+( +)# ,3 "

"
( #
4 ( (* # + 66& ./ 5 ! ) ) ) )(
4 5 ) # +)( ( #(* +( # 8( )(
& ./ (() * #(* ./ (8
+( +)# .3

5 ! * )()( 8
,
! !
"# $ %& ' Ω "# - " %& ' Ω
"# $ & Ω "# - & Ω
(() * #(* +( (() * #(* +(
.
!
"# ./ %& ' Ω
"# ./ & Ω
(() * #(* +(
WD600-3 20-375
(1)
EA-11 Error code [123] (Abnormality in boost pressure sensor system low
level)
)% #3

5 %, 67,
% (
/0
$ % 9"'&( % 7,%%), %%, 7'
5 ), %,& %&'- 0/
%- & 4
1!2
% ,%&%' !
9"'&( ''$ &%''&$ ,
5
), %,& %&'- 088 "# *
"#
5
9&%'' !
$ !
"# /0 %-, '&,')& & &,& -,%% 7&, ,

* %),,)& &,& !
"# *
"# ,7'
-,%%% % %- & 4
1!2
!
% ,%&%' !
9"'&( ''$ &%''&$ ,
5), %,& %&'- 088 "#
"# /0 %-, '&,')& & &,& -,%% 7&, ,
59&%'' !
$ !
"#
%),,)& &,& !
"#
,7'

-,%%% % %- & .4 "#
1!2
"
% ,%&%' !
9"'&( ''$ &%''&$ ,
5), %,& %&'- 088 "# .
"# /0 %-, '&,')& & &,& -,%% 7&, ,
59&%'' !
$ !
"# ,7'
. %),,)& &,& !
"# .

"#
-,%%% % %- & 4
1!2
9"'&( & ',, 7'

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

+ Ω
!
*
%),,)& &,& -,%%%
&
Ω
.
!
"#$
"# %&%' () !
"#$
"# %&%' ()
!

+ Ω !
.

+ Ω
!
!
.
%),,)& &,& -,%%%
&
Ω %),,)& &,& -,%%%
&
Ω
20-376 WD600-3
(1)
EA-12 Error code [131] (Abnormality in accelerator sensor system high

level)
Cause Remedy
Display troubleshooting of
throttle controller system (HT 1
mode) "TH-1 Abnormality in
accelerator pedal sensor Are results of TH-1 and TH-4 free NO
system is displayed" and carry Defective throttle controller system Repair
from abnormality?
out "TH-4 Abnormality in
electronic governor voltage YES
command system".
2
Is resistance between ECMB Defective contact, disconnection, or
(female) (11) and L13 (female) (2), NO
• Turn starting switch OFF. and between ECMB (female) (11) short circuit in wiring harness between Repair or
• Disconnect ECMB and L13. and surrounding wiring harnesses ECMB (female) (11) and L13(female) replace
as shown in Table 1? (2)
YES
3
(female) (29) and L13 (female) (1),
• Turn starting switch OFF. and between ECMB (female) (29) NO short circuit in wiring harness between Repair or
• Disconnect ECMB and L13. and surrounding wiring harnesses ECMB (female) (29) and L13 (female) replace
YES
4
• Turn starting switch OFF. (female) (26) and L13 (female) (3), NO short circuit in wiring harness between Repair or
and between ECMB (female) (26)
• Disconnect ECMB and L13. and surrounding wiring harnesses ECMB (female) (26) and L13 (female) replace
YES
Table 1 Table 2
ECMB (female), L13 (female) Resistance value ECMB (female), L13 (female) Resistance value
Between ECMA (11) and L13(2) Max. 10 z Between ECMB (29) and L13(1) Max. 10 z
Between ECMB (11) and Between ECMB (29) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
ECMB (female), L13 (female) Resistance value

Between ECMB (26) and L13(3) Max. 10 z
Between ECMB (26) and
surrounding wiring harnesses Min. 1 Mz
WD600-3 20-377
(1)
EA-13 Error code [132] (Abnormality in accelerator sensor system low

level)
a Carry out troubleshooting for error code [131].
20-378 WD600-3
(1)
EA-14 Error code [135] (Abnormality in oil pressure sensor system high
level)
Cause Remedy
1
• Disconnect CLPR. When CLPR is disconnected, NO
• Turn starting switch ON. does error code [135] go out?
YES
Defective oil pressure sensor Replace
2
Is resistance between ECMA
• Turn starting switch OFF. (female) (6) and CLPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness between Repair or
CLPR. (6) and surrounding wiring ECMA (female) (6) and CLPR (female) replace
YES
3
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness between Repair or
CLPR. (17) and surrounding wiring ECMA (female) (17) and CLPR replace
harnesses as shown in Table 2? (female) (B)
YES
4
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness between Repair or
(24) and surrounding wiring ECMA (female) (24) and CLPR replace
CLPR. harnesses as shown in Table 3? (female) (C)
YES
Table 1 Table 2
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (6) and CLPR (A) Max. 10 Ω Between ECMA (17) and CLPR (B) Max. 10 Ω
Table 3
ECMA (female), CLPR (female) Resistance value

Between ECMA (24) and CLPR (C) Max. 10 Ω
Between ECMA (24) and
surrounding wiring harnesses Min. 1 MΩ
WD600-3 20-379
(1)
EA-15 Error code [141] (Abnormality in oil pressure sensor system low
level)
Cause Remedy
1
Is voltage between CLPR (A) and
• Insert T-adapter to CLPR. NO Defective oil pressure sensor Replace
(B), and between (C) and (B) as
• Turn starting switch ON.
shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (6) and CLPR (female) NO
(A), and between ECMA (female) short circuit in wiring harness between Repair or
• Disconnect ECMA and ECMA (female) (6) and CLPR (female)
(6) and surrounding wiring replace
CLPR. (A)
harnesses as shown in Table 2?
YES
3
• Turn starting switch OFF. (female) (17) and CLPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and replace
(17) and surrounding wiring ECMA (female) (17) and CLPR
CLPR.
YES
4
• Turn starting switch OFF. (female) (24) and CLPR (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(24) and surrounding wiring ECMA (female) (24) and CLPR replace
CLPR.
harnesses as shown in Table 4? (female) (C)
YES
Table 1 Table 2
CLPR Voltage ECMA (female), CLPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and CLPR (A) Max. 10 Ω
Between (C) and (B) 0.42 – 0.58 V Between ECMA (6) and
Table 3 Table 4
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (17) and CLPR (B) Max. 10 Ω Between ECMA (24) and CLPR (C) Max. 10 Ω
20-380 WD600-3
(1)
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))

- ".
, #

! " #
$%&'( $%)%( +#
*
"

+#
#
+#
WD600-3 20-381
(1)
EA-17 Error code [144] (Abnormality in water temperature sensor system

high level)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between CLTP NO Defective water temperature sensor Replace
• Disconnect CLTP. (male) (A) and (B) 600 – 36kΩ?
YES
2
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (22) and CLTP (female)
(A), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and
(22) and surrounding wiring har- ECMA (female) (22) and CLTP (fe- replace
CLTP.
nesses as shown in Table 1? male) (A)
YES
3
• Turn starting switch OFF. male) (17) and CLTP (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and (B), and between ECMA (female) ECMA (female) (17) and CLTP (fe- replace
CLTP. (17) and surrounding wiring har-
nesses as shown in Table 2? male) (B)
YES
Table 1 Table 2
ECMA (female), CLTP (female) Resistance value ECMA (female), CLTP (female) Resistance value
Between ECMA (22) and CLTP (A) Max. 10 Ω Between ECMA (17) and CLTP (B) Max. 10 Ω
Between ECMA (22) and Between ECMA (17) and surround-
surrounding wiring harnesses Min. 1 MΩ ing wiring harnesses Min. 1 MΩ
20-382 WD600-3
(1)
EA-18 Error code [145] (Abnormality in water temperature sensor system

low level)
EA-19 Error code [151] (Abnormal rise in water temperature)

- '

(
+ ,

*
'

-*
!"##$ !"#%$ ) * ,
&
' '

(
) *
', '
'
WD600-3 20-383
(1)
EA-20 Error code [153] (Abnormality in intake air temperature sensor sys-
tem high level)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between IMTP NO Defective intake air temperature sen- Replace
• Disconnect IMTP (male) (A) and (B) 600 – 36kΩ? sor
YES
2
male) (23) and IMTP (female) (A),
• Turn starting switch OFF. and between ECMA (female) (23) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and IMTP. and surrounding wiring harnesses ECMA (female) (23) and IMTP (fe- replace
as shown in Table 1? male) (A)
YES
3
s resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (17) and IMTP (female) (B), NO short circuit in wiring harness between Repair or
and between ECMA (female) (17) ECMA (female) (17) and IMTP replace
• Disconnect ECMA and IMTP. and surrounding wiring harnesses
as shown in Table 2? (female) (B)
YES
Table 1 Table 2
ECMA (female), IMTP (female) Resistance value ECMA (female), IMTP (female) Resistance value
Between ECMA (23) and IMTP (A) Max. 10 Ω Between ECMA (17) and IMTP (B) Max. 10 Ω
EA-21 Error code [154] (Abnormality in intake air temperature sensor

system low level)
20-384 WD600-3
(1)
EA-22 Error code [221] (Abnormality in atmospheric pressure sensor sys-

tem high level)
Cause Remedy
1
• Disconnect AAPR. When AAPR is disconnected, NO
• Turn starting switch ON. does error code [221] go out?
YES Defective atmospheric pressure

Replace
sensor
2
• Turn starting switch OFF. (female) (6) and AAPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness between Repair or
AAPR. (6) and surrounding wiring ECMA (female) (6) and AAPR (female) replace
YES
3
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness between Repair or
AAPR. (17) and surrounding wiring ECMA (female) (17) and AAPR replace
YES
4
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness between Repair or
(34) and surrounding wiring ECMA (female) (34) and AAPR replace
AAPR. harnesses as shown in Table 3? (female) (C)
YES
Table 1 Table 2
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (6) and AAPR (A) Max. 10 Ω Between ECMA (17) and AAPR (B) Max. 10 Ω
Table 3
ECMA (female), AAPR (female) Resistance value

Between ECMA (34) and AAPR (C) Max. 10 Ω
WD600-3 20-385
(1)
EA-23 Error code [222] (Abnormality in atmospheric pressure sensor

system low )
Cause Remedy
1
Is voltage between AAPR (A) and Defective atmospheric pressure
• Insert T-adapter to AAPR. NO Replace
(B), and between (C) and (B) as sensor
shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (6) and AAPR (female)
NO short circuit in wiring harness between Repair or
(6) and surrounding wiring ECMA (female) (6) and AAPR (female) replace
AAPR.
YES
3
• Turn starting switch OFF. (female) (17) and AAPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness between Repair or
AAPR.
YES
4
• Turn starting switch OFF. (female) (34) and AAPR (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and (C), and between ECMA (female)
AAPR.
harnesses as shown in Table 4? (female) (C)
YES
Table 1 Table 2
AAPR Voltage ECMA (female), AAPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and AAPR (A) Max. 10 Ω
Between (C) and (B) 0.42 – 0.58 V Between ECMA (6) and
Table 3 Table 4
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (17) and AAPR (B) Max. 10 Ω Between ECMA (34) and AAPR (C) Max. 10 Ω
20-386 WD600-3
(1)
WD600-3 20-387
(1)
EA-24 Error code [234] (Overspeed)

$%& #
"
!

$%&
!

!

!

$%&

!

20-388 WD600-3
(1)
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)
".

3 & &( ) $ / & " , 4 )*' 6
3 4' " *$ * " 0 1! Ω2
-
3
& &( ) $ / & " ,
3
4' " *$ * " '& ) %!! 4 )*' 6
5Ω2
-
!
/ &

%+ " * " 4 ' "'' '&
3 & &( ) $
%+ " , )'& & &( )& 6& '&
3 4'
" *$ &&'"( &( )&
%+ " * &6
)' %2
-
"
/ &

3& &( ) $ ! " " 4 ' "'' '&
34'
"
! "
, )'& & &( )& 6& '&
&&'"( &( )&
! " &6
$
)' 2
-
4 ( '&'& 6
%

*

%+ " *
#$ %! Ω
! "
#$ %! Ω

%+ "
! "
&&'"( &( )&
$ %
Ω &&'"( &( )&
$ %
Ω
WD600-3 20-389
(1)
EA-26 Error code [259] (Abnormality in fuel shut-off valve)

'

( ! #

! ! "!! ##

)!# ! "!! ##
!
$ $
%$ % ! !
!$

$ $ %$
% ! ! !$
"
)!#
! &

)!# &
EA-27 Error code [261] (Abnormal rise in fuel temperature)

- ".
, #

! " #
$%&'( $%&)( +#
*
"

+#
# #

20-390 WD600-3
(1)
EA-28 Error code [263] (Abnormality in fuel temperature sensor system

high level)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between FLTP NO Defective fuel temperature sensor Replace
• Disconnect FLTP. (male) (A) and (B) 600 – 36k Ω?
YES
2
(female) (26) and FLTP (female)
• Turn starting switch OFF. (A), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and FLTP. (26) and surrounding wiring ECMA (female) (26) and FLTP replace
harnesses as shown in Table 1? (female) (A)
YES
3
• Turn starting switch OFF. (female) (17) and FLTP (female) NO short circuit in wiring harness between Repair or
(B), and between ECMA (female) ECMA (female) (17) and FLTP replace
• Disconnect ECMA and FLTP. (17) and surrounding wiring
YES
Table 1 Table 2
ECMA (female), FLTP (female) Resistance value ECMA (female), FLTP (female) Resistance value
Between ECMA (26) and FLTP (A) Max. 10 Ω Between ECMA (17) and FLTP (B) Max. 10 Ω
EA-29 Error code [265] (Abnormality in fuel temperature sensor system

low level)
WD600-3 20-391
(1)
EA-30 Error code [316] (Abnormality in fuel pump actuator system

current)
,

2 $ $& ' )33" - $
() 4 66 %$ 6
2 4%
" . / 0 Ω1
*+
2
$ $& ' )33" - $
()
&$% %$ 4 66 %$ 6
2
4%
"
' # 5Ω1
*+
!
- $
4 % %% %$
2 $ $& ' )33" ##
() '%$ $ $& '$ 6$ %$
2 4%

## $$% & $&
##
$6

" '$ '% #1
*+
"
- $
4 % %% %$
2 $ $& ' )33"
() '%$ $ $& '$ 6$ %$
2 4%

$6

" $$% & $&
'$ '% 1
*+
4 & %$%$ 6
#

##

!" # Ω

!" # Ω

##

$$% & $& '$
" #
Ω $$% & $& '$
" #
Ω
20-392 WD600-3
(1)
EA-31 Error code [318] (Abnormality in fuel pump actuator)

2 #3
%
1 &

!

!
"

4%& %
!
! !

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

)*$+,)-./0
" & % %
%
#
# %

56678 56698
! #

4%& % %

$
#
4%&
% :

4%& :
EA-32 Error code [343] (Abnormality in controller internal communication)

% &'(') * +

01 // ./

!"
!# % &'(') * +
, -
" $
!" !#

01 // ./
WD600-3 20-393
(1)
EA-33 Error code [346] (Abnormality in controller power down)
1
Is battery terminal connected NO Defective connection of battery Repair
normally? terminal
YES
2
• Turn starting switch OFF.
Is voltage of battery 17.3 – 34.7 V ?
NO Drop in battery voltage Charge or
• Disconnect battery terminal. replace
YES
Is slow blow fuse blown? NO
YES
Blown slow blow fuse Replace
4
• Turn starting switch OFF. Is resistance between slow blow
• Disconnect slow blow fuse fuse inlet and battery (+), and Defective contact, disconnection, or
NO Repair or
inlet terminal and battery between slow blow fuse inlet and short circuit in wiring harness between
surrounding wiring harnesses as slow blow fuse inlet and battery (+) replace
(+) terminal.
shown in Table 1?
YES
5
• Turn starting switch OFF. (female) (3)(4)(5) and slow blow fuse NO
• Disconnect ECMB and slow short circuit in wiring harness between Repair or
outlet, and between ECMB (female)
blow fuse outlet terminal. (3)(4)(5) and surrounding wiring ECMB (female) (3)(4)(5) and slow replace
harnesses as shown in Table 2? blow fuse outlet
YES
Table 1 Table 2
Slow blow fuse inlet, battery (+) Resistance value ECMB (female), C slow blow fuse outlet Resistance value
Between slow blow fuse inlet and Between ECMB (3)(4)(5) and slow
Max. 10 z Max. 10 z
battry (+) blow fuse outlet
Between slow blow fuse inlet and Between ECMB (3)(4)(5) and
surrounding wiring harness Min. 1 Mz surrounding wiring harness Min. 1 Mz
20-394 WD600-3
(1)
EA-34 Error code [384] (Abnormality in preheating heater control system)
Cause Remedy
1
Is resistance between L62 (male) NO Defective heater relay Replace
• Disconnect preheating relay
(1) and (2) 200 – 400 z?
L62.
YES
2
Is the wiring harness resistance Defective contact, disconnection short
• Turn starting switch OFF. value between ECMA(female) (2) NO Repair or
circuit wiring harness between ECMA replace
• Disconnect L62. and C62(female) (1) as indicated
in Table 1? (female) (2) – L62 (female) (1)
YES
3
Is the resistance value between There is ground fault or short-circuiting
• Turn starting switch OFF. the chassis and ECMA(female)(2) NO Repair or
in the wiring harness between
• Disconnect ECMA, L62. or L62(female)(1) as indicated in replace
ECMA(female)(2)and L62(female)(1).
Table 1?
YES
4
Is the resistance value in the There is a disconnection or connection
wiring harness between NO fault in the wiring harness between Repair or
L62(female)(2) and the chassis replace
as indicated in Table 1? L62(female)(2) and the chassis.
YES
Table 1
ECMA (female), preheating relay (L62) Resistance value

Between ECMA (2) and L62(female)(2) Max. 10 z
Between ECMA (2) and L62(female)(2) – chassis Min. 1M z
WD600-3 20-395
(1)
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))
20-396 WD600-3
(1)
EA-36 Error code [423] (Abnormality in timing rail pressure sensor system
in range)
Cause Remedy
• Remove timing rail pressure 1

sensor and fuel rail pressure Is voltage between TPR (C) and
sensor. NO Replace
(B) same as voltage between Defective timing rail pressure sensor
• Insert T-adapter into TPR
and RPR. RPR (C) and (B)?
• Turn starting switch ON. YES
2
• Turn starting switch OFF. (female) (5) and TPR (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and TPR. (5) and surrounding wiring ECMA (female) (5) and TPR (female) replace
YES
3
(female) (18) and TPR (female) NO short circuit in wiring harness between Repair or
• Turn starting switch OFF. (B), and between ECMA (female) ECMA (female) (18) and TPR (female) replace
• Disconnect ECMA and TPR. (18) and surrounding wiring (B)
YES
4
(female) (33) and TPR (female)
• Turn starting switch OFF. (C), and between ECMA (female) NO short circuit in wiring harness between Repair or
• Disconnect ECMA and TPR. (33) and surrounding wiring ECMA (female) (33) and TPR (female) replace
harnesses as shown in Table 3? (C)
YES
5
Is negative pressure at suction
NO
• Start engine. side (tank side) of fuel filter more Defective engine controller Replace
than 27kPa{203mmHg}?
YES
Excessive suction resistance of fuel Repair or
filter replace
Table 1 Table 2
ECMA (female), TPR (female) Resistance value ECMA (female), TPR (female) Resistance value
Between ECMA (5) and TPR (A) Max. 10 Ω Between ECMA (18) and TPR (B) Max. 10 Ω
Table 3
Between ECMA (33) and TPR (C) Resistance value

Between ECMA (33) and TPR (C) Max. 10 Ω
WD600-3 20-397
(1)
20-398 WD600-3
(1)
EA-37 Error code [431] (Abnormality 1 in idling validation switch system)
Cause Remedy
1
• Turn starting switch OFF. (female) (21) and C9 (female) (3), NO short circuit in wiring harness between Repair or
. Disconnect ECMB and C9. and between ECMB (female) (21)
and surrounding wiring ECMB (female) (21) and C9 (female) replace
harnesses as shown in Table 1? (3)
YES
2
• Turn starting switch OFF. (female) (13) and C9 (female) (6), NO short circuit in wiring harness between Repair or
and between ECMB (female) (13) ECMB (female) (13) and C9 (female) replace
• Disconnect ECMB and C9. and surrounding wiring
harnesses as shown in Table 2? (6)
YES
3
Is resistance between ECMB (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (12) and C9 (female) (5), NO
and between ECMB (female) (12) short circuit in wiring harness between Repair or
• Disconnect ECMB and C9. and surrounding wiring harness- ECMB (female) (12) and C9 (female) replace
es as shown in Table 3? (5)
YES
4
• Insert T-adapter in C9. Is voltage between C9(3) and (6) NO
and between (3) and (5) as Defective accelerator limit switch relay Replace
• Turn starting switch ON. shown in Table 4?
YES
Table 1 Table 2
ECMB (female), C9 (female) Resistance value ECMB (female), C9 (female) Resistance value
Between ECMA (21) and C9 (3) Max. 10 z Between ECMB (13) and C9 (6) Max. 10 z
surrounding wiring harnesses Min. 1 Mz Min. 1 Mz
surrounding wiring harnesses
Table 3 Table 4
ECMB (female), C9 (female) Resistance value Voltage
C9
Between ECMB (12) and C9 (5) Max. 10 z Pedal depressed Pedal released
Between ECMB (12) and Between (3) and (6) Min. 5 V Max. 1 V
Between (3) and (5) Max. 1 V Min. 5 V
WD600-3 20-399
(1)
20-400 WD600-3
(1)
EA-38 Error code [432] (Idling validation process error)
Cause Remedy
1
Is resistance between L14A
• Turn starting switch OFF. NO Replace
(female) (1) and (2), and between Defective idling validation switch
• Disconnect L14A. (1) and (3) as shown in Table 1?
YES
2
Is resistance between C8 Defective contact, disconnection, or
• Turn starting switch OFF. (female) (31) and L14A (male) (1), NO
and between C8 (female) (31) short circuit in wiring harness between Repair or
• Disconnect C8 and L14A. and surrounding wiring harnesses C8 (female) (31) and L14A (male) (1) replace
as shown in Table 2?
YES
3
• Turn starting switch OFF. (female) (9) and L14A (male) (2), NO short circuit in wiring harness between Repair or
and between C8 (female) (9) and C8 (female) (9) and L14A (male) (2) replace
• Disconnect C8 and L14A. surrounding wiring harnesses as
shown in Table 3?
YES
4
(female) (20) and L14A (male) short circuit in wiring harness between Repair or
• Turn starting switch OFF. (3), and between C8 (female) NO
• Disconnect C8 and L14A. (20) and surrounding wiring C8 (female) (20) and L14A (male) (3) replace
5
Is resistance between C8
(female) (17) and C9 (female) (1), NO Defective contact, disconnection, or
• Turn starting switch OFF. short circuit in wiring harness between Repair or
and between C8 (female) (17)
• Disconnect ECMB and L14. and surrounding wiring harnesses C8 (female) (17) and (9) replace
YES
6
Defective contact, disconnection, or
Is resistance between C9
(female) (2) and C8 (female) (31), NO short circuit in wiring harness between
• Turn starting switch OFF. Repair or
and between C9 (female) (2) and C9 (female) (2) and chassis ground or
• Disconnect ECMB and L14. surrounding wiring harnesses as replace
between C8 (female) (31) and chassis
shown in Table 6? ground
YES
7
• Insert T-adapte to C9. Is voltege between C9 (1) and (2) NO Defective throttle controller Replace
• Turn starting switch ON. as shown in Table 7?
YES
8
Is resistance between ECMB
(female) (21) and C9 (female) (3) Defective contact, disconnection, or
and between ECMB (female) (21) NO short circuit in wiring harness between Repair or
• Disconnect ECMB and C9. and surrounding wiring harnesses replace
ECMB (female) (21) and C9 (female)
(3)
YES
9
• Turn starting switch OFF. (female) (13) and C9 (female) (6) NO Repair or
and between ECMB (female) (13) short circuit in wiring harness between
• Disconnect ECMB and C9. ECMB (female) (13) and C9 (female) replace
and surrounding wiring harnesses
YES
Go to next page 10.
WD600-3 20-401
(1)
From previous page 9.

Cause Remedy
10
Is resistance between ECMB Defective contact, disconnection or
• Turn starting switch OFF. (female) (12) and C9 (female) (5) NO Repair or
and between ECMB (female) (12) short circuit in wiring harness between
• Disconnect ECMB and C9. ECMB (female) (12) and C9 (female) replace
and surrounding wiring harnesses
YES
11
• Insert T-adapter in C9. Is voltage between C9 (female)
(3) and (6) and between (3) and NO Defective accelerator limit switch relay Replace
• Turn starting switch ON. (5) as shown in Table 11?
YES
Table 1 Table 2
L14A (female) Pedal Resistance C8 (female), L14A (male) Resistance

Between (1) and (2) Released (idling ON) Max. 1 z Between C8 (31) and L14A (1) Max. 1 z
Between (1) and (3) Depressed (idling OFF) Max. 1 z Between C8 (31) and surrounding
Min. 1 Mz
wiring harnesses
Table 3 Table 4
C8 (female), L14A (male) Resistance C8 (female), L14A (male) Resistance

Between C8 (9) and L14A (2) Max. 1 z Between C8 (20) and L14A (3) Max. 1 z
Between C8 (9) and surrounding Between C8 (20) and surrounding
wiring harnesses Min. 1 Mz wiring harnesses Min. 1 Mz
Table 5 Table 6
C8 (female), C9 (male) Resistance C9 (female), C8 (male) Resistance

Between C8 (17) and C9 (1) Max. 1 z Between C9 (2) and C8 (31) Max. 1 z
Between C8 (17) and surrounding Between C9 (2) and surrounding
wiring harnesses Min. 1 Mz Min. 1 Mz
wiring harnesses
Table 7 Table 8
Between C9 (1) and (2) Voltage ECMB (female), C9(male) Resistance

Pedal depressed 20 -- 30 V Between ECMB (21) and C9 (3) Max. 10 z
Pedal released Max. 1 V Between ECMB (21) and
Table 9 Table 10
ECMB (female), C9 (male) Resistance ECMB (female), C9 (male) Resistance

Between ECMB (13) and C9 (6) Max. 10 z ECMB (12) and C9 (5) Max. 10 z
Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
surrounding wiring harnesses
Table 11
Voltage
C9
Pedal depressed Pedal released
Between (3) and (6) Min. 5 V Max. 1 V
Between (3) and (5) Max. 1 V Min. 5 V
20-402 WD600-3
(1)
WD600-3 20-403
(1)
EA-39 Error code [441] (Abnormality in battery voltage low level)

EA-40 Error code [442] (Abnormality in battery voltage high level)

20-404 WD600-3
(1)
EA-41 Error code [451] (Abnormality in fuel rail pressure sensor system
high level)

5 /( % 0* ( (
5 ' ') "* % ''(' ( 12#3 )( ( 4

/ ' .' ' (' .
6 ' " / ( (( ('

5 ' ') "* 77% #
5 /( % " *(' ' "') *' " .' ('
# ''( ) "') # '.
*' *(" 4

!
6 ' "
5 ' ') "* 77% , / ( (( ('
5 /( % ! " *(' ' "') *' " .' ('
, ''( ) "') , '.
*' *(" +4 !

"
6 ' "
- / ( (( ('
5 ' ') "* 77% " *(' ' "') *' " .' ('
5 /( % - ''( ) "') - '.
*' *(" -4

/ ) ('(' .
+

!" # $% & Ω !" , ! $% & Ω
!" # % Ω !" , % Ω
''( ) "') *' ''( ) "') *'
-

!" - $% & Ω
!" - % Ω
''( ) "') *'
WD600-3 20-405
(1)
EA-42 Error code [452] (Abnormality in fuel rail pressure sensor system
low level)
($ "1

4 5$* 62 *
5$ '
-.
# $ 3!& %' !( *% 2*$$(* $$* 2&
4 (* $ * % $% &+ .-
$+ % 8
/0
5$ *$%$ & 3!& %' & & # %$&& %# *

!"
!"
4 (* $ * % $% &+ .77 # !" -. $+* &%*&(% % %*% +*$$ 2%* *
4 3%$&&
$(**(% %*% !"
!" *2&
+*$$$ $ $+ % 8
/0
!
5$ *$%$ & 3!& %' & & # %$&& %# *
4 (* $ * % $% &+ .77 !"
!" -. $+* &%*&(% % %*% +*$$ 2%* *
# !"
4 3%$&&
$(**(% %*% !"
!" *2&
+*$$$ $ $+ % ,8
/0
"
5$ *$%$ & 3!& %' & & # %$&& %# *
4 (* $ * % $% &+ .77 !" ,
!" -. $+* &%*&(% % %*% +*$$ 2%* *
4 3%$&&
# !" !" ,
!" *2&
, $(**(% %*%
+*$$$ $ $+ % 8
/0
3!& %' % & ** 2&

!"#
!" $%$ & '(

) Ω

$(**(% %*% +*$$$ % Ω
,
!"#
!" $%$ & '( !"#
!" $%$ & '(

) Ω ,
) Ω
,
$(**(% %*% +*$$$ % Ω $(**(% %*% +*$$$ % Ω
20-406 WD600-3
(1)
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)
,

. # #% & )//" # () 0 # $# -
. 0$ " 1 2 3 Ω4
*+
#
. # #% & )//" %#$ $# () 0 # $# -
. 0$ " & 5Ω4
*+
!
#
0 $ $$ $#
'
. # #% & )//"
() &$# # #% &# -# $#
. 0$
" ' ##$ % #%
' #-
&# &$ 4
*+
"
#
0 $ $$ $#
. # #% & )//" () &$# # #% &# -# $#
. 0$

#-
" ##$ % #%
&# &$ 4
*+
0 % $#$# -

'
!" Ω

!" Ω

'

##$ % #% &#
"
Ω ##$ % #% &#
"
Ω
WD600-3 20-407
(1)
TROUBLESHOOTING EA-44, EA-45, EA-46
EA-44 Error code [467] (Abnormality in timing rail actuator control)

EA-45 Error code [468] (Abnormality in fuel rail actuator control)
Cause Remedy

Is another error code displayed at NO
Turn starting switch ON.
same time?
Go to
YES
troubleshooting

for service
code displayed
When engine is run at rated speed,

NO
Start engine does output go up or down, or
does exhaust temperature go up?
YES
Defective fuel rail actuator Replace
!
Is there clogging, looseness,
NO
breakage, or leakage from fuel
filter, piping?
YES
Clogging, looseness, breakage, or Repair or
leakage from fuel filter, piping replace
"
Is fuel rail actuator screen NO
clogged with dirt?
YES
Clean or
Clogged fuel rail actuator screen
replace
#
NO Defective fuel rail actuator or defective Replace
Is engine oil diluted with fuel?
engine controller
YES
Broken injector O-ring Replace
EA-46 Error code [514] (Abnormality in fuel rail actuator)

20-408 WD600-3
(1)
TROUBLESHOOTING EA-47, EA48
EA-47 Error code [527] (Abnormality in dual output solenoid A system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance of relay L64 (male) NO Defective engine oil pressure relay Replace
• Disconnect L64. (1) and (2) 200 – 400 Ω?
YES
2
Is resistance between ECMB Defective contact or disconnection in
• Turn starting switch OFF. NO wiring harness between ECMB Repair or
• Disconnect ECMB and L64. (female) (1) and L64 (female) (1) replace
less than 1 Ω? (female) (1) and L64 (female) (1)
YES
3
Is the resistance value between There is a disconnection or connection
• Turn starting switch OFF. NO fault in the wiring harness between L64 Repair or
L64(frmale) (2) and the chassis
• Disconnect L64. replace
less than 1 Ω? (female) (2) and the chassis.
YES
4
Is resistance between ECMB
Short circuit in wiring harness between
(female) (1) and surrounding NO Repair or
• Turn starting switch OFF. ECMB (female) (1) and L64 (female)
wiring harnesses more than 100 replace
• Disconnect ECMB and L64. (1)
kΩ?
YES
EA-48 Error code [551] (Abnormality 2 in idling validation switch system)

WD600-3 20-409
(1)
EA-49 Error code [554] (Abnormality in fuel rail pressure sensor in range)

* $ % # +# #
$# # , $% /.
+# # $#! $% 1 # +# # $# +
* , #
-+# $
3

!
*
# #% & ./! :2
, # 1 $ $$ $#

*
# #% & .00!
* 1 $ ! /. &$# # #% &# +# $#
#+
##$% #%
&# &$
3
:2
!
, # 1 $ $$ $#
*
# #% & .00! ( /. &$# # #% &# +# $#
( #+
* 1 $ ! ( ##$% #%
&# &$
'3
:2
"
4! , # 1 $ $$ $#
*
# #% & .00! ) /. &$# # #% &# +# $#
) #+
* 1 $ ! ) ##$% #%
&# &$
)3
:2
#
, % +# # $ /.
* 2# %! 5 $ # $# 1 % $#$# +
& '657'")8%93
:2 $ # $ +# $#
# #+

'

! " Ω ( ! " Ω
! Ω ( ! Ω
##$% #% &# ##$% #% &#
)

) ! " Ω
)) ! Ω
##$% #% &#
20-410 WD600-3
(1)
WD600-3 20-411
(1)
TROUBLESHOOTING OF MAIN MONITOR
SYSTEM
(M MODE)
Electrical circuit diagram for main monitor .......................................................................................... 20-454

Electrical circuit diagram for lamp and horn ........................................................................................ 20-456
M- 1 Main monitor does not work ....................................................................................................... 20-457
M- 2 When starting switch is turned ON and engine is started immediately, all lamps stay
lighted up ...................................................................................................................................... 20-458
M- 3 Speedometer display does not work properly ........................................................................... 20-459
M- 4 Abnormality in shift indicator ...................................................................................................... 20-460
a) Displays N even when directional lever is at F .................................................................... 20-460
b) Displays N even when directional lever is at R ................................................................... 20-460
c) Does not display N even when directional lever is at N ..................................................... 20-460
d) Does not display 1st even when speed control lever is at 1st ........................................... 20-461
e) Does not display 2nd even when speed control lever is at 2nd ........................................ 20-461
f) Does not display 3rd even when speed control lever is at 3rd .......................................... 20-461
g) Does not display 4th even when speed control lever is at 4th .......................................... 20-461
M- 5 High beam display does not light up .......................................................................................... 20-463
M- 6 Turn signal display does not light up ......................................................................................... 20-464
a) L.H. turn signal display does not light up ............................................................................ 20-464
b) R.H. turn signal display does not light up ............................................................................ 20-464
M- 7 Abnormality in parking lamp display ......................................................................................... 20-465
a) Parking lamp display does not light up ............................................................................... 20-465
b) Parking lamp display stays lighted up ................................................................................. 20-465
M- 8 Abnormality in preheating display ............................................................................................. 20-466
a) Preheating display does not light up ................................................................................... 20-466
b) Preheating display stays lighted up ..................................................................................... 20-466
M- 9 Night lighting of monitor does not light up ............................................................................... 20-467
M-10 Abnormality in front working lamp ............................................................................................ 20-468
a) Neither monitor display nor front working lamp light up .................................................. 20-468
b) Working lamp lights up but monitor display does not light up ......................................... 20-468
c) Monitor display lights up but working lamp does not light up .......................................... 20-468
M-11 Abnormality in rear working lamp .............................................................................................. 20-470
a) Neither monitor display nor rear working lamp light up ................................................... 20-470
b) Working lamp lights up but monitor display does not light up ......................................... 20-470
c) Monitor display lights up but working lamp does not light up .......................................... 20-470
M-12 Abnormality in transmission cut-off ........................................................................................... 20-472
a) When transmission cut-off switch is pressed, cut-off function is not switched
and display does not change ................................................................................................ 20-472
b) Transmission cut-off does not work or stays working ........................................................ 20-472
WD600-3 20-451
(1)
M-13 Abnormality in parking brake dragging warning ...................................................................... 20-473
a) When parking brake is applied, buzzer sounds intermittently and caution lamp
flashes even when directional lever is at N ......................................................................... 20-473
b) When parking brake is applied, buzzer does not sound and caution lamp does not
light up even when directional lever is at position other than N ....................................... 20-473
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated ....................................................................................... 20-474
a) Actuated continuously ........................................................................................................... 20-474
b) Not actuated ........................................................................................................................... 20-474
M-15 Abnormality in buzzer .................................................................................................................. 20-475
a) Buzzer does not sound for 3 seconds during self-check when starting switch is
turned ON ............................................................................................................................... 20-475
b) Buzzer always sounds ........................................................................................................... 20-475
M-16 Condition of monitor switches is not stored in memory .......................................................... 20-476
M-17 Abnormality in failure display mode .......................................................................................... 20-477
a) Failure display mode does not work .................................................................................... 20-477
b) Count for time elapsed since failure in failure display mode does not advance ............. 20-477
M-18 Abnormality in emergency steering display .............................................................................. 20-478
a) Emergency steering display does not flash ......................................................................... 20-478
b) Emergency steering display stays flashed .......................................................................... 20-478
M-19 Failure code is not sent to main monitor (abnormality in network) ........................................ 20-479
20-452 WD600-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR
20-454 WD600-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR
WD600-3 20-455
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
20-456 WD600-3
(1)
TROUBLESHOOTING M-1
M-1 Main monitor does not work

fl Before disconnecting or connecting connectors, always turn starting switch OFF.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage
between L05 (1), Defective contact or discon-
(2) – (3) normal? 2 YES nection in wiring harness Repair or
Is resistance bet- between L05 (female) (1), replace
• 20 – 30 V ween L05 (female) (2) and FS2 (female) (9)
• Turn starting NO (3) and chassis Defective contact or discon-
switch ON. ground normal? Repair or
nection in wiring harness
• Turn starting NO between L05 (female) (3) replace
switch OFF. and LR5 (male) (3)
• Disconnect L05.
• Max. 1 Ω
M-1 Related electrical circuit diagram
WD600-3 20-457
(1)
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON and engine is started immedi-

ately, all lamps stay lighted up
Cause Remedy
1 YES
Is voltage between
L05 (4) and chassis
ground normal? Defective contact or discon-
nection in wiring harness Repair or
• 20 – 30 V NO between L05 (female) (4) replace
• Turn starting switch and L57 (female) (3)
to START.
20-458 WD600-3
(1)
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

fl Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 YES
Is resistance
YES between L07
1 (female) (1) and (2) Defective contact or discon-
normal? nection in wiring harness
Is resistance Repair or
between L07 (female) (1),
between CN3 • 500 Ω – 1 kΩ NO replace
(2) – TM2 (9), (10) CN3
(male) (1) and (2) • Turn starting switch (female) (1), (2)
normal? OFF.
• 500 Ω – 1 kΩ • Disconnect L07.
• Turn starting switch NO Defective speed sensor Replace
OFF.
• Disconnect CN3.
WD600-3 20-459
(1)
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

fl Check that the transmission gear is shifted normally.
a) Displays N even when directional lever is at F

Cause Remedy
1 YES
Is voltage between
L08 (7) and chassis
ON.
• Directional lever: F
b) Displays N even when directional lever is at R

Cause Remedy
1 YES
Is voltage between
L08 (8) and chassis
ON.
• Directional lever: R
c) Does not display N even when directional lever is at N
Cause Remedy
1 YES
Is voltage between
L05 (8) and chassis
ground normal? Short circuit with power
source in harness Repair or
• 20 – 30V NO between L05 (female) (8) replace
• Turn starting switch and neutral relay
ON.
• Directional lever: N
20-460 WD600-3
(1)
TROUBLESHOOTING M-4
d) Does not display 1st even when speed control lever is at 1st
Cause Remedy
1 YES
Is voltage between
L05 (12) and
chassis ground Defective contact or
normal? disconnection in wiring
harness between L05 Repair or
• Turn starting NO (female) (12) and C1A replace
switch ON. (female) (3)
• Speed control lever : 1st
e) Does not display 2nd even when speed control lever is at 2nd
1 YES
Is voltage between
L05 (13) and
• Speed control lever : 2nd
f) Does not display 3rd even when speed control lever is at 3rd
1 YES
Is voltage between
L05 (14) and
• Speed control lever : 3rd
g) Does not display 4th even when speed control lever is at 4th
1 YES
Is voltage between
L05 (15) and
• 20 – 30 V NO (female) (15) and C1A replace
• Turn starting (female) (11)
switch ON.
• Speed control lever : 4th
WD600-3 20-461
(1)
TROUBLESHOOTING M-4
20-462 WD600-3
(1)
TROUBLESHOOTING M-5
M-5 High beam display does not light up

fl Check the bulb for breakage.
Cause Remedy
2 YES
Is resistance bet-
YES ween L06 (female)
1 (13) and chassis
Is voltage between ground normal? Repair or
L06 (12) and • Max. 1 Ω NO between L06 (female) (13) replace
chassis ground • Turn starting switch OFF. and L02 (female) (3)
normal? • Disconnect L06.
• 20 – 30 V • Dimmer switch: Hi beam nection in wiring harness Repair or
• Turn starting NO between L06 (female) (12) replace
switch ON. and FS2 (female) (2)
WD600-3 20-463
(1)
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

fl Check the bulb for breakage.
Cause Remedy
a) L.H. turn signal display does not light up
1 YES
Is voltage between
L06 (14) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (14) replace
20 – 30V. and L03 (female) (4)
• Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up

Cause Remedy
1 YES
Is voltage between
L06 (15) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (15) replace
20 – 30V. and L03 (female) (3)
• Turn R.H. turn signal ON.
20-464 WD600-3
(1)
TROUBLESHOOTING M-7
M-7 Abnormality in parking lamp display

a) Parking lamp display does not light up

fl Before carrying out troubleshooting, check the bulb for breakage.
Cause Remedy
1 YES
Is voltage between
L06 (11) and
chassis ground Short circuit with chassis
normal? ground in harness between
L06 (female) (11) and LR2
Repair or
• 20 – 30V NO (14), FR2 (6) and F15 replace
• Turn starting switch ON. (female) (1)
• Turn parking switch ON.
b) Parking lamp display stays lighted up
YES Defective main monitor Replace

1
Is voltage between
L06 (11) and
chassis ground 2 YES Defective parking brake Replace
normal? indicator switch
Is resistance bet-
• 20 – 30 V ween L06 (female)
• Turn starting NO (11) and F15 Defective contact or
switch ON. (female) (1) normal? disconnection in wiring Repair or
harness between L06
• Max. Ω NO (female) (11) and F15
replace
• Turn starting switch OFF. (female) (1)
• Disconnect L06 and F15.
WD600-3 20-465
(1)
TROUBLESHOOTING M-8
M-8 Abnormality in preheating display

a) Preheating display does not light up

Cause Remedy
1 YES Defective main monitor

(monitor module) Replace
Is resistance
between E27 and
L05 (female)(19) Defective contact or
normal ? disconnection in wiring Repair or
• Max. 1Ω NO harness between E27 and replace
L05 (female) (19)
• Turn starting
switch OFF.
• Disconnect L05 and E27
b) Preheating display stays lighted up
Cause Remedy
1 YES Defective main monitor Replace

Is voltage (monitor module)
between L05
(female) (19) and
chassis ground Short circuit with power
normal? source in wiring harness Repair or
NO between E27 and L05 replace
• Max. 1V
(female) (19)
• Disconnect L05 and E27
20-466 WD600-3
(1)
TROUBLESHOOTING M-9
M-9 Night lighting of monitor does not light up

fl Before starting troubleshooting, check that the lamp bulbs of night lighting are not blown.
Cause Remedy
1 YES
Is voltage between
L05 (16) and
chassis ground
Defective contact or
normal? Repair or
disconnection in wiring
• 20 - 30 V NO harness between L05 replace
• Turn starting switch (female) (16) and FS2 (5)
ON.
• Turn small lamp switch
ON.
WD600-3 20-467
(1)
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

fl Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor front working lamp light up
Cause Remedy
YES Repair or
harness between L60
(female) (1), L05 (female) replace
(17) and CL1 (female) (7)
1
Is voltage 3 YES Defective front working Replace
between L60 (1) Is voltage lamp relay
and chassis YES between L60 (1)
ground normal? and chassis Defective main monitor or
2
ground normal? defective contact or discon
•0–3V Is voltage between Repair or
-nection in wiring harness
• Turn starting L60 (2), (5) and •0–3V NO between L60 (female) (6) replace
switch ON. NO chassis ground • Turn starting switch ON. and L06 (female) (1)
normal? • Turn working lamp switch ON.
Defective contact or discon
• 20 – 30 V -nection in wiring harness Repair or
• Turn starting NO between L60 (female) (2), replace
switch ON. (5) and FS5 (female) (1)
b) Working lamp lights up but monitor display does not light up
Cause Remedy
1 YES
Is voltage between
L05 (17) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up
Cause Remedy

between L60 (1) – CL1 (7) – Repair or
C03 (female) (1), C04 replace
(female) (1), or blown
working lamp bulb
20-468 WD600-3
(1)
WD600-3 20-469
(1)
M-11 Abnormality in rear working lamp

fl Before starting troubleshooting, check that night lighting of monitor is lighted up.
a) Neither monitor display nor rear working lamp light up

Cause Remedy

YES Repair or
between L61 (female) (1)
and L05 (female) (18), CR1 replace
(female) (12)
1
Is voltage 3 YES Defective front working Replace
between L61 (1) Is voltage lamp relay
and chassis YES between L06 (2)
ground normal? and chassis Defective main monitor or
2
ground normal? defective contact or discon
•0–3V Is voltage between -nection in wiring harness Repair or
• Turn starting L61 (2), (5) and •0–3V NO between L61 (female) (6) replace
switch ON. NO chassis ground • Turn starting switch ON. and L06 (female) (2)
normal? • Turn working lamp switch ON. Defective contact or discon
• 20 – 30 V -nection in wiring harness Repair or
• Turn starting NO between L61 (female) (2), replace
switch ON. (5) and FS5 (female) (2)
b) Working lamp lights up but monitor display does not light up
Cause Remedy
1 YES
Is voltage between
L05 (18) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up
Cause Remedy

between L61 (1) – LR1 (12) Repair or
– G02 (female) (1), G03 replace
(female) (1), or blown
working lamp bulb
20-470 WD600-3
(1)
WD600-3 20-471
(1)
M-12 Abnormality in transmission cut-off

a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not
change
Cause Remedy
b) Transmission cut-off does not work or stays working

fl Carry out T-15 of TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM.
20-472 WD600-3
(1)
M-13 Abnormality in parking brake dragging warning

fl Check that the transmission gear is shifted normally (F, N, R).
a) When parking brake is applied, buzzer sounds intermittently and caution lamp flashes even when
directional lever is at N
Cause Remedy
1 YES
Is voltage between
L05 (8) and chassis
• 20 – 30 V NO between L05 (female) (8) – replace
L57 (female) (1)
• Turn starting switch
ON.
• Directional lever: N
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even
when directional lever is at position other than N
fl Check that the synchronous flash signal is normal. Cause Remedy
YES
1
Is voltage
between L05 (8) Short circuit with power
and chassis 2 YES source in wiring harness Repair or
ground normal? replace
Is resistance between L05 (female) (8)
•0–5V between L05 and L57 (female)(1)
• Turn starting NO (female) (8) and
switch ON. (3) normal?
• 3 kΩ – 4 kΩ NO
OFF.
• Disconnect L05.
WD600-3 20-473
(1)
M-14 When parking brake dragging warning is given, buzzer and cau-
tion lamp are actuated continuously, or they are not actuated
fl Before disconnecting or connecting connectors, surely turn starting switch OFF.
a) Actuated continuously
Cause Remedy
2 YES Defective maintenance Replace

monitor
YES Does buzzer stop
1 and lamp go out? Defective contact or discon-
Does buzzer stop • Turn starting switch NO between L07 (female) (6) replace
and lamp go out? ON. and L19 (female) (5)
• Connect L19 (female) (5)
• Turn starting switch to chassis ground.
ON. Defective main monitor Replace
NO
• Connect L07 (6) to
chassis ground.
b) Not actuated
Cause Remedy
2 YES Defective maintenance Replace

monitor
YES Do buzzer and
1 lamp work? Short circuit with power
source in harness between Repair or
Do buzzer and • Turn starting switch NO L07 (female) (6) and L19 replace
lamp work? ON. (female) (5)
• Disconnect L19.
ON. Defective main monitor Replace
NO
• Disconnect L07.
20-474 WD600-3
(1)
M-15 Abnormality in buzzer

a) Buzzer does not sound for 3 seconds during self-check when starting switch is turned ON
Cause Remedy

YES nection in wiring harness Repair or
1 between L06 (female) (8) replace
and L43 (male) (1)
Does buzzer
sound? 2 YES
Is voltage between
• Turn starting switch L42 (female) and
ON. NO chassis ground Defective contact or discon-
• Contact L43 (female) normal? nection in wiring harness Repair or
to chassis ground. • 20 – 30 V between L42 (female) (1) replace
NO
• Turn starting switch and FS2 (female) (9)
ON.
b) Buzzer always sounds

Cause Remedy
YES
1
Does buzzer stop
when L06 is YES Go to Troubleshooting
disconnected? —
2 for maintenance monitor
• Disconnect L06. Does buzzer stop

• Turn starting when L19 is Short circuit with power
NO disconnected? 3 YES source in harness between Repair or
switch ON.
L06 (female) (8) and L43 replace
Does buzzer stop (male) (1)
• Disconnect L19. when L43 is
• Turn starting NO disconnected?
switch ON.
• Disconnect L43. NO
ON.
WD600-3 20-475
(1)
M-16 Condition of monitor switches is not stored in memory

Cause Remedy
1 YES
Is voltage between
L07 (10) and
chassis ground
normal? Repair or
ON.
20-476 WD600-3
(1)
M-17 Abnormality in failure display mode

a) Failure display mode does not work Cause Remedy
1 YES
Is voltage between
L05 (5) and chassis Short circuit with power
ground normal? source in wiring harness
between L05 (female) (5) – Repair or
•0–5V NO LR4 (6) – ER1 (9) – replace
• Turn starting switch alternator terminal R, or
defective alternator
ON.
b) Count for time elapsed since failure in failure display mode does
not advance
Cause Remedy
1 YES
Is voltage between
L05 (5) and chassis Defective contact or discon-
ground normal? nection in wiring harness
between L05 (female) (5) – Repair or
• 20 – 30 V NO LR4 (6) – ER1 (9) – replace
• Start engine. alternator terminal R, or
defective alternato
WD600-3 20-477
(1)
M-18 Abnormality in emergency steering display

a) Emergency steering display does not flash Cause Remedy
YES
2
Is voltage between
YES L05 (11) and Defective contact or discon
chassis ground 3 YES -nection in wiring harness Repair or
normal? Is resistance bet- between R01 (female) (2) replace
1 ween L05 (female) and chassis ground
•0–2V
Is resistance (11) and R01
• Turn starting NO (female) (1) Defective contact or discon
between R01
switch ON. normal? -nection in wiring harness Repair or
(male) (1) and (2)
normal? • Max. 1 Ω NO between L05 (female) (11) replace
• Turn starting switch OFF. and R01 (female) (1)
• Max. 1 Ω • Disconnect L05 and R01.
• Turn starting
switch OFF. Defective emergency Replace
• Disconnect R01. NO steering lamp switch
b) Emergency steering display stays flashed

Cause Remedy
2 YES
Is voltage between
YES L05 (11) and
1 chassis ground
Short circuit with chassis
Is resistance normal? Repair or
ground in harness between
between R01 • 20 – 30 V NO L05 (female) (11) and R01 replace
(male) (1) and (2) • Start engine. (female) (1)
normal?
• Min. 1 Ω Defective emergency
Replace
• Start engine. NO steering lamp switch
• Disconnect R01.
20-478 WD600-3
(1)
M-19 Failure code is not sent to main monitor (abnormality in network)

fl Set dipswitch 3 at the rear of the main monitor to “F”.
fl MDC : Multiple Display and Condition.
Cause Remedy
2 YES Applicable controller is

defective Replace
Is voltage between
YES LM1 (male) (5) and Defective contact or discon-
1 (6) normal? nection in wiring harness
between L08 (female) (1) Repair or
Is voltage between (3) – LM1 (male) (5), L08
L08 (male) (1) and • Repeats 0V and NO (female) (2) (4) – LM1
replace
(2) normal? 12V (male) (6)
• Repeats 0V and • Disconnect LM1.
12V NO
ON.
• Disconnect L08.
WD600-3 20-479
(1)
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
Electrical circuit diagram for maintenance monitor ............................................................................. 20-502

K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds
Maintenance monitor does not work .......................................................................................... 20-504
a) No lamps on maintenance monitor light up ....................................................................... 20-504
b) Some lamps do not light up ................................................................................................. 20-504
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out even after 3 seconds ............................................................................................ 20-505
K- 3 When engine is started immediately after starting switch is turned ON
within 3 seconds, no lamps on maintenance monitor go out .................................................. 20-506
K- 4 When engine is stopped and starting switch is turned ON, CHECK item display flashes ..... 20-507
a) Engine oil level display flashes ............................................................................................. 20-507
b) Engine water level display flashes ....................................................................................... 20-508
K- 5 When engine is stopped and starting switch is turned ON, CAUTION item display
flashes ........................................................................................................................................... 20-509
a) Engine oil pressure display flashes ...................................................................................... 20-509
b) Battery charge display flashes .............................................................................................. 20-510
c) Brake oil pressure display flashes ........................................................................................ 20-511
d) Air cleaner clogged display flashes ...................................................................................... 20-512
K- 6 CAUTION item display is flashing, but caution buzzer does not sound .................................. 20-513
K- 7 No monitor display lights up, but caution buzzer sounds ........................................................ 20-514
K- 8 CAUTION item display is flashing, but central CHECK lamp or central CAUTION lamp
does not flash ............................................................................................................................... 20-515
a) CHECK lamp ........................................................................................................................... 20-515
b) CAUTION lamp ....................................................................................................................... 20-515
K- 9 No maintenance monitor display lights up, but central CHECK lamp or central
CAUTION lamp lights up ............................................................................................................. 20-516
a) CHECK lamp ........................................................................................................................... 20-516
b) CAUTION lamp ....................................................................................................................... 20-516
K-10 Only night lighting of monitor does not light up when lamp switch is turned ON ................ 20-517
K-11 Night lighting of monitor lights up even when lamp switch is OFF ........................................ 20-518
K-12 Service meter does not work ....................................................................................................... 20-519
K-13 Service meter is running even when engine is stopped ........................................................... 20-519
K-14 Abnormality in gauges ................................................................................................................. 20-520
a) Abnormality in fuel gauge .................................................................................................... 20-520
b) Abnormality in engine water temperature gauge ............................................................... 20-521
c) Abnormality in torque converter oil temperature gauge ................................................... 20-522
WD600-3 20-501
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR
ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR
20-502 WD600-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR
WD600-3 20-503
(1)
TROUBLESHOOTING K-1
K-1 When starting switch is turned ON, all display on maintenance moni-
tor do not light up for 3 seconds
Maintenance monitor does not work
a) No lamps on maintenance monitor light up
Cause Remedy
YES Defective monitor module

Replace
of maintenance monitor

1 nection in wiring harness Repair or
YES between L18 (female) (1), replace, or
Is voltage between
3 (2) – FS2 (9) – fuse I-10 –
replace fuse
L18 (1), (2) – (3)
FS1 (male) (2), or blown
normal? Is voltage between fuse I-10
YES FS1 (female) (2)
• 20 – 30 V and chassis
• Turn starting switch 2 ground normal? Defective contact or discon-
ON. nection in wiring harness
Is resistance • 20 – 30 V between FS1 (female) (2) – Repair or
between L18 • Disconnect FS1. LR6 (1) – slow blow fuse - replace, or
(female) (3),(14), L19 NO
NO • Turn starting switch battery relay, or blown replace fuse
(8) and chassis
ground normal?
ON. slow blow fuse (80A)
• Max. 1 Ω Defective contact or discon-

• Turn starting switch nection in wiring harness
Repair or
between L18 (3),(14), L19
ON. NO replace
(female) (8) – LR4 (12) –
• Disconnect L18. chassis ground
b) Some lamps do not light up

Cause Remedy
Defective monitor module

Replace
20-504 WD600-3
(1)
TROUBLESHOOTING K-2
K-2 When starting switch is turned ON, all lamps on maintenance

monitor light up but do not go out even after 3 seconds
Cause Remedy
Defective monitor module

Replace
K-1,2 Related electrical circuit diagram
WD600-3 20-505
(1)
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned

ON within 3 seconds, no lamps on maintenance monitor go out
Cause Remedy
1 YES
Defective monitor module Replace
When starting engine,
is voltage between
L19 (female) (1) and
chassis ground Defective contact or discon-
normal? nection in wiring harness Repair or
• Disconnect L19. and neutral relay
• Start engine.
• Measure when starting
motor is turning
(starting switch at START).
K-3 Related electrical circuit diagram
20-506 WD600-3
(1)
TROUBLESHOOTING K-4
K-4 When engine is stopped and starting switch is turned ON, CHECK
item display flashes
a) Engine oil level display flashes

fl Before starting troubleshooting, check the engine oil level again.
(Check that the engine oil level is correct.)
Cause Remedy
2 YES Defective monitor module

of maintenance monitor Replace
Is resistance bet-
1 (13) and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance bet- Repair or
harness between L18
ween E10 (male) • Max. 1 Ω NO replace
(female) (13) – LR4 (4) –
(1) and chassis • Turn starting switch ER1 (3) – E10 (female) (1)
ground normal? OFF.
• Max. 1 Ω • Disconnect L18. Defective engine oil level Replace
• Turn starting switch NO sensor
OFF.
• Disconnect E10.
K-4 a) Related electrical circuit diagram
WD600-3 20-507
(1)
TROUBLESHOOTING K-4
b) Engine water level display flashes

fl Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)
Cause Remedy

Replace
Is resistance bet- of maintenance monitor
2 (8) and chassis Defective contact or discon-
ground normal? nection in wiring harness
Is resistance bet- Repair or
YES ween G01 (female) between L18 (female) (8) –
• Max. 1 Ω NO LR3 (2) – GR1 (3) – G01 replace
(1) and chassis • Turn starting switch (female) (1)
1 ground normal? OFF. Defective contact or discon-
Is resistance • Disconnect L18.
• Max. 1 Ω nection in wiring harness Repair or
between G01
(male) (2) and (1) • Turn starting switch NO between G01 (female) (2) – replace
OFF. GR1 (2) – chassis ground
normal?
• Disconnect G01.
• Max. 1 Ω
• Turn starting switch Defective radiator water
Replace
OFF. NO level sensor
• Disconnect G01.
K-4 b) Related electrical circuit diagram
20-508 WD600-3
(1)
TROUBLESHOOTING K-5
K-5 When engine is stopped and starting switch is turned ON, CAUTION
item display flashes
fl Check that Error Code [527] is not displayed in the engine controller.
a) Engine oil pressure display flashes

(Check that the engine oil pressure is correct.)
Cause Remedy
YES Defective engine oil

Replace
1 pressure relay
Is indication set
normal when
engine oil pressure 2 YES Defective maintenance
relay L64 is Replace
replaced? Is resistance bet- monitor module
• Replace engine oil ween L18 (female)
pressure relay with (10) and chassis
discon-nection in wiring
dust indicator relay ground normal? harness between L18 Repair or
(L80). NO (female) (10) and L64 (3), replace
NO • Max. 1 Ω (6), CL1 (12) and chassis
• Disconnect L18. ground
• Turn starting
switch OFF.
WD600-3 20-509
(1)
TROUBLESHOOTING K-5
b) Battery charge level display flashes
Cause Remedy

Replace
Is voltage between of maintenance monitor
YES L18 (female) (12)
1 and chassis Defective contact or discon-
Is voltage between ground normal? nection in wiring harness
Repair or
between L18 (female) (12) –
alternator terminal • 20 – 30 V NO replace
LR4 (6) – ER1 (9) –
R and chassis • Start engine. alternator terminal R
ground normal?
• 20 – 30 V
Defective alternator Replace
• Start engine. NO
20-510 WD600-3
(1)
TROUBLESHOOTING K-5
c) Brake oil pressure display flashes

(Check that the brake oil pressure is correct.)
Cause Remedy

Replace
Is voltage between of maintenance monitor
YES L18 (11) and
3 chassis ground
Is resistance bet- normal? between L18 (female) (11) – Repair or
YES ween B08 (female) • Start engine. NO LR2 (8) – BR1 (6) – B08 replace
(2) and chassis (female) (1)
• Max. 3 V
2 ground normal? Defective contact or discon-
Is resistance nection in wiring harness
YES between B13 • Max. 1 Ω between B08 (female) (2) – Repair or
(male) (1) and (2) • Turn starting switch NO B13 (female) (1), or between replace
normal? OFF. B13 (female) (2) – BR1 (4) –
1 chassis ground
• Disconnect B08.
Is resistance • Max. 1 Ω Defective brake
between B08 • Start engine. accumulator charge oil Replace
(male) (1) and (2) • Disconnect B13. NO pressure switch (B13 end)
normal?
• Max. 1 Ω Defective brake
• Start engine. accumulator charge oil Replace
• Disconnect B08. NO pressure switch (B08 end)
K-5 c) Related electrical circuit diagram
WD600-3 20-511
(1)
TROUBLESHOOTING K-5
d) Air cleaner clogged display flashes

Cause Remedy
(Check that there is no clogging of the air cleaner.)
YES Defective dust indicator

Replace
sensor
1
Does display go Defective dust indicator
YES
out when E19 is Replace
relay
disconnected?
2
• Start engine. Does display go
• Disconnect E19. out when dust 4 YES
To A
NO indicator relay L80 Is resistance bet-
is interchanged? YES ween L80 (female)
3 (6) and chassis Defective contact or discon-
ground normal? nection in wiring harness Repair or
Is voltage between between L80 (female) (6) –
E19 (female) (1) • Max. 1 Ω NO replace
LR5 (2) – chassis ground
NO and chassis • Turn starting switch
ground normal? OFF. Short circuit with chassis
• Disconnect L80. ground in wiring harness
• Turn starting switch between E19 (female) (1) – Repair or
ON. NO ER1 (5) – LR4 (5) – L80 replace
• Disconnect E19. (female) (2) (short circuit or
• 20 – 30 V contact with chassis ground)
Replace
From A ween L18 (female)
(15) and chassis
ground normal? nection in wiring harness Repair or
• Max. 1 Ω NO between L18 (female) (15) replace
and L80 (female) (3)
OFF.
• Disconnect L18.
K-5 d) Related electrical circuit diagram
20-512 WD600-3
(1)
TROUBLESHOOTING K-6
K-6 CAUTION item display is flashing, but caution buzzer does not sound
fl The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
fl Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in the
wiring harness between fuse I-10 – FS2 (9) – L42.
Cause Remedy

Replace
2 of maintenance monitor
Does buzzer sound
YES when L19 (female) Defective contact or discon-
(4) is connected to 3 YES nection in wiring harness Replace
chassis ground? between L19 (female) (4)
1 Does buzzer sound
• Turn starting when L43 (female) and L43 (male) (1)
Is voltage between
L42 (female) (1)
switch ON. NO (1) is connected to
chassis ground?
and chassis Defective buzzer Replace
ground normal? • Turn starting NO
switch ON.
• 20 – 30 V
• Disconnect L42. Defective contact or discon-
• Turn starting switch nection in wiring harness Repair or
ON. NO between fuse I-10 – FS2 (9) replace
– L42 (female) (1)
WD600-3 20-513
(1)
TROUBLESHOOTING K-7
K-7 No monitor display lights up, but caution buzzer sounds

fl Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy

Replace
1 (4) and chassis Short circuit with chassis
ground normal? ground in wiring harness
Is resistance bet- between L19 (female) (4) – Repair or
ween L43 (female) • Min. 1 MΩ NO L43 (male) (1) – L06 replace
(1) and chassis • Turn starting switch OFF. (female) (8) (contact with
ground normal? • Disconnect L06, L19, chassis ground)
• Min. 1 MΩ and L43.
• Turn starting NO
switch OFF.
• Disconnect L42 and L43.
20-514 WD600-3
(1)
TROUBLESHOOTING K-8
K-8 CAUTION item display is flashing, but central CHECK lamp or central
CAUTION lamp does not flash
fl Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a) CHECK lamp Cause Remedy

1
Does CHECK lamp
light up when L19
(female) (2) is Defective contact or discon-
connected to chassis 2 YES nection in wiring harness Repair or
ground? Does CHECK lamp between L19 (female) (2) replace
• Disconnect L19. light up when L06 and L06 (female) (10)
(male) (10) is
• Turn starting NO connected to chassis
switch ON. ground?
ON.
b) CAUTION lamp
Cause Remedy

1
Does CAUTION
lamp light up when
L19 (female) (3) is Defective contact or discon-
connected to chassis 2 YES nection in wiring harness Repair or
ground? Does CAUTION between L19 (female) (3) replace
• Disconnect L19. lamp light up when and L06 (female) (10)
L06 (male) (9) is
• Turn starting NO connected to chassis
switch ON. ground?
ON.
K-8 a), b) Related electrical circuit diagram
WD600-3 20-515
(1)
TROUBLESHOOTING K-9
K-9 No maintenance monitor display lights up, but central CHECK lamp
or central CAUTION lamp lights up
fl Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a) CHECK lamp
Cause Remedy
1 YES
ween L19 (female)
(2) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
• Min. 1 MΩ NO and L06 (female) (10) (contact
replace
• Turn starting switch with chassis ground)
OFF.
b) CAUTION lamp
Cause Remedy
1 YES
ween L19 (female)
ground normal? ground in wiring harness Repair or
• Min. 1 MΩ NO and L06 (female) (9) (contact
replace
• Turn starting switch with chassis ground)
OFF.
20-516 WD600-3
(1)
TROUBLESHOOTING K-10
K-10 Only night lighting of monitor does not light up when lamp switch
is turned ON
fl Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
1 YES Disconnection in wiring

Replace
harness of lamp holder
Is voltage between
L21 (female) (1)
and (2) normal? Defective contact or discon-
• Disconnect L21. and FS2 (5)
ON.
• Turn lamp switch ON.
WD600-3 20-517
(1)
K-11 Night lighting of monitor lights up even when lamp switch is OFF
Cause Remedy
Contact of +24V with wiring

2 YES harness between FS2 Repair or
(male) (4) – fuse box – FS2 replace
Is voltage between
(5) – L21 (female) (1)
YES FS2 (female) (4)
1 and chassis Contact of +24V with wiring
ground normal? harness between L02 Repair or
Is lamp switch • Max. 1 V NO (female) (5) and FS2 replace
normal? • Disconnect FS2. (female) (4)
• Turn lamp switch OFF.
• Turn starting switch • Turn starting switch ON.
OFF. Defective lamp switch Replace
NO
• Disconnect L02.
• Check that continuity between
L02 (male) (1) and (5) is as
shown in table below when
lamp switch is turned ON-OFF.
Switch Continuity
ON YES
OFF NO
20-518 WD600-3
(1)
TROUBLESHOOTING K-12, 13
K-12 Service meter does not work

fl Before disconnecting or connecting connectors, always turn
starting switch OFF.
fl Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
fl Always connect any disconnected connectors before going on Cause Remedy
to the next step.
YES
Defective service meter Replace
1 disconnection in wiring
Is voltage 3 YES harness between L22 Repair or
between L22 Is resistance bet- (female) (2), LR4 (6), ER1 (9) replace
(female) (2) and (1) YES ween L22 (female) and terminal R of alternator
normal? 2 (1) and chassis Defective contact or
ground normal? disconnection in wiring Repair or
• 20 – 30 V Is voltage between
terminal R of harness between L22
• Start engine. • Max. 1 Ω NO replace
(female) (1), CL1 (12) and
• Disconnect L22. NO alternator and • Turn starting switch OFF. chassis ground
chassis ground
• 20 – 30 V Defective alternator Replace
• Start engine. NO
K-13 Service meter is running even when engine is stopped

fl Before disconnecting or connecting connectors, always turn
starting switch OFF.
Cause Remedy
fl Always connect any disconnected connectors before going on
to the next step.
YES
Defective service meter Replace
1
Is voltage bet-
ween L22 (female) Contact of +24V with wiring
(2) and (1) normal? 2 YES harness between L22 Repair or
Is voltage between (female) (2) – LR4 (6) – ER1 replace
• Max. 3 V alternator terminal (9) – alternator terminal R
• Turn starting NO R and chassis
switch ON. ground normal?
• Disconnect L22. Defective alternator Replace
• Max. 3 V NO
ON.
K-12,13 Related electrical circuit diagram
WD600-3 20-519
(1)
K-14 Abnormality in gauges

a) Abnormality in fuel gauge

fl Before carrying out troubleshooting, check the fuel level Cause Remedy
again. (Check that the fuel level is correct.)
(1) Little or nothing is displayed
YES
Defective fuel sensor Replace
1
Does fuel gauge 3 YES Defective maintenance
indicates FULL when Replace
Is resistance bet- monitor module
short connector is ween L18 (female)
connected to R05 YES
(6) and chassis gro-
(female)? und normal when Defective contact or disco-
2
• Disconnect R05. short connector is nnection in wiring harness
Is resistance bet- connected to R05? between R05 (female) (1), Repair or
• Connect short
ween R05 (female) • Max. 1 Ω NO LR4 (10) and L18 (female) replace
connector to R05
NO (2) and chassis • Turn starting switch OFF. (6)
(female). ground normal?
• Turn starting • Connect short connector to R05 (female).
Defective contact or disco-
switch ON. • Max. 1 Ω • Disconnect L18. Repair or
nnection in wiring harness
• Turn starting NO between R05 (female) (2) replace
switch OFF. and chassis ground
• Disconnect R05.
(2) Display always shows FULL

Cause Remedy
YES
Defective fuel sensor Replace
1
Do all display areas
on fuel gauge go
out when R07 is 2 YES Defective monitor module
disconnected? Replace
• Disconnect R07. ween R07 (female)
• Turn starting NO (1) and chassis Short circuit with chassis
switch ON. ground normal? ground in wiring harness Repair or
• Min. 1 MΩ NO between R07 (female) (1) – replace
• Turn starting switch LR4 (10) – L18 (female) (6)
OFF.
• Disconnect L18 and R07.
20-520 WD600-3
(1)
b) Abnormality in engine water temperature gauge

(1) Nothing is displayed
Cause Remedy
YES Defective engine water

Replace
Does engine water
temperature gauge
show minimum level
when E04 is 2 YES Defective monitor module
Replace
disconnected? Is resistance bet- of maintenance monitor
• Disconnect E04. ween E04 (female)
• Turn starting NO (1) and chassis ground in wiring harness
switch ON. ground normal? between E04 (female) (1) – Repair or
• Min. 1 MΩ NO ER1 (6) – LR4 (1) – L18 replace
• Turn starting switch (female) (4) (contact with
OFF. chassis ground)
• Disconnect L18 and E06.
(2) Display shows lowest level Cause Remedy
YES Defective engine water

Replace
temperature sensor
1
When short connec-
tor is connected to
E04 (female), does
Replace
engine water temper- Is resistance between of maintenance monitor
ature gauge display L18 (female) (4) and
area rise one stage at YES chassis ground nor-
a time, and finally do mal when short con-
2 Defective contact or discon-
all lamps go out? nector is connected
to E04 (female)? nection in wiring harness Repair or
Is resistance bet- between E04 (female) (1) –
• Disconnect E04. replace
ween E04 (female) • Max. 1 Ω NO ER1 (6) – LR4 (1) – L18
• Connect short
(2) and chassis • Turn starting switch OFF.
connector to E04 NO ground normal? (female) (4)
• Connect short connector to E04 (female).
(female). Defective contact or discon-
• Turn starting • Disconnect L18. nection in wiring harness Repair or
• Turn starting
switch ON. switch OFF. NO between E04 (female) (2) – replace
• Disconnect E04. ER1 (7) – chassis ground
• Max. 1 Ω
WD600-3 20-521
(1)
c) Abnormality in torque converter oil temperature gauge

(1) Nothing is displayed
Cause Remedy
YES Defective torque conver-

Replace
1 ter oil temperature sensor
Does torque conver-
ter oil temperature
gauge show mini-
mum level when 2 YES Defective monitor module
Replace
CN18 is disconnected? Is resistance of maintenance monitor
• Disconnect CN18. between CN18
(female) (1) and Short circuit with chassis
• Turn starting NO chassis ground ground in wiring harness
switch ON. normal? between CN18 (female) (1) Repair or
• Turn starting NO – TM2 (8) – L18 (female) (5) replace
switch OFF. (contact with chassis
• Disconnect L18 and CN18. ground)
• Min. 1 MΩ
(2) Display shows lowest level and does not move

Cause Remedy
YES Defective torque conver-

Replace
ter oil temperature sensor
1
When short connec-
tor is connected to
CN18, does torque
Replace
converter oil temper- Is resistance between of maintenance monitor
ature gauge display L18 (female) (5) and
area rise one stage at YES chassis ground nor-
a time, and finally do mal when short con-
2 nector is connected Defective contact or discon-
all lamps go out?
Is resistance to CN18 (female)? nection in wiring harness Repair or
• Disconnect CN18. between CN18 between CN18 (female) (1) – replace
• Max. 1 Ω NO
• Connect short (female) (2) and TM2 (8) – L18 (female) (5)
NO chassis ground • Turn starting switch OFF.
connector to
normal? • Connect short connector to CN18 (female). Defective contact or discon-
CN18 (female).
• Max. 1 Ω • Disconnect L18. nection in wiring harness Repair or
• Turn starting between CN18 (female) (2) replace
switch ON. • Turn starting NO – TM2 (15) – LR4 (12) –
switch OFF. chassis ground
• Disconnect CN18.
K-14 c) Related electrical circuit diagram
20-522 WD600-3
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram for power supply, engine starting, engine stopping system .................... 20-603
Electrical circuit diagram for transmission control system ................................................................. 20-604
Electrical circuit diagram for parking brake .......................................................................................... 20-606
Electrical circuit diagram for lamp and horn ........................................................................................ 20-607
E-1 Engine does not start ................................................................................................................... 20-608
E-2 Preheating fault ............................................................................................................................ 20-614
E-3 Parking brake does not have effect ............................................................................................. 20-615
a) Parking brake has no effect when parking brake switch is turned ON .............................. 20-615
b) Parking brake has no effect and does not work as emergency brake
when parking brake pressure drops ..................................................................................... 20-615
E-4 Parking brake is applied when machine is traveling ................................................................. 20-616
E-5 Parking brake is released when starting switch is turned ON .................................................. 20-618
E-6 Transmission does not change to neutral when parking
brake is applied, but parking brake works normally ................................................................. 20-618
E-7 Transmission does not work properly ........................................................................................ 20-620
a) Abnormality in parking brake circuit, transmission cut-off
switch circuit or neutralizer relay circuit .............................................................................. 20-622
b) No continuity in travel FORWARD solenoid circuit ............................................................. 20-626
c) No continuity in travel REVERSE solenoid circuit ............................................................... 20-628
d) Short circuit to chassis ground in directional solenoid circuit ........................................... 20-630
e) Abnormality in shift solenoid circuit .................................................................................... 20-636
f) Short circuit to chassis ground in shift solenoid circuit ..................................................... 20-641
E- 8 When hold switch is pressed, gear speed is not fixed or reset ................................................ 20-646
E- 9 Kick-down system does not work ............................................................................................... 20-646
E-10 Power window does not work ..................................................................................................... 20-647
a) Power window does not rise
(This troubleshooting shows about L.H. power window) .................................................. 20-647
b) Power window does not lower
(This troubleshooting shows about L.H. power window) .................................................. 20-648
E-11 Abnormality in front working lamp ............................................................................................ 20-650
E-12 Abnormality in rear working lamp .............................................................................................. 20-650
E-13 Abnormality in transmission cut-off ........................................................................................... 20-650
E-14 Abnormality in parking brake dragging warning ...................................................................... 20-650
E-15 Abnormality in buzzer .................................................................................................................. 20-650
WD600-3 20-601
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE

STARTING, ENGINE STOPPING SYSTEM
WD600-3 20-603
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROL SYSTEM
20-604 WD600-3
(1)
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM
WD600-3 20-605
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE
20-606 WD600-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN
WD600-3 20-607
(1)
TROUBLESHOOTING E-1
E-1 Engine does not start

fl When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
checks, always turn the starting switch OFF before starting.
fl When connecting the T-adapter (or socket adapter), connect to the connector specified as CNct( ).
fl After checking, connect the disconnected connectors and disconnect the T-adapter immediately to
return to the original condition before going on to the next check.
Starting motor does not turn
YES
3
5 YES
Is voltage between
YES starting motor Is voltage between
terminal (B) and YES both battery relay
chassis normal? terminals and
chassis normal?
• 20 – 30 V
• Turn starting 4 • 20 – 30 V NO
switch OFF. • Turn starting switch
Does battery ON.
relay make sound • Check voltage
NO of actuation? YES
between chassis
and both terminals
• Starting switch connected by thick
2 6
ON ↔ OFF. cable.
Is there continuity Is voltage between
both connection
YES between starting terminals of R12 and
motor terminal (E) NO R13 of battery relay
and chassis? normal?
• Turn starting • 20 – 30 V
1
switch OFF. • Turn starting
Is voltage between switch OFF.
E13 (female) (1) NO
and chassis
normal?
• 20 – 30 V
• Disconnect E13.
• Directional lever:
Neutral
• Turn starting
NO
switch to START.
NO
20-608 WD600-3
(1)
TROUBLESHOOTING E-1
Cause Remedy
Defective starting motor

assembly Replace

-nection in cable between Repair or
battery relay and starting replace
motor
• If answer is NO for both ter-
minals: Defective contact or
disconnection in wiring har Repair or
-ness between battery and replace
battery relay
• If answer is NO for one ter-
minal: Defective battery relay
Defective battery relay Replace

8 YES between starting switch
terminal BR – L09 (2) – LR4 Replace
Is resistance (9) – R03 (diode) (2), (1) –
YES between R13 R12 (female)
7 (female) and
chassis normal? Defective contact or discon
Is voltage between -nection in wiring harness Repair or
starting switch • Max. 1 Ω NO between R13 and chassis replace
terminal BR and • Turn starting switch ground
chassis normal? OFF.
• 20 – 30 V • Disconnect R13.
Defective starting switch Replace
switch ON.
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WD600-3 20-609
(1)
TROUBLESHOOTING E-1
YES
YES
11
Is voltage between 13 YES
YES L57 (female) (5)
and chassis Is voltage between
9 normal? YES starting switch
12 terminal C and
Does starting • 20 – 30 V chassis normal?
From A motor rotate when Is voltage between
• Disconnect L57.
neutral relay is • Turn starting starting switch • 20 – 30 V NO
replaced? switch to START.
NO terminal B and • Turn starting switch
chassis normal? to START.
• Replace neutral
relay (L57) with stop • 20 – 30 V
lamp relay (L53). • Turn starting NO
• FR lever: Neutral switch OFF.
to START.
YES
10
Is voltage
between L57
NO (female) (1) and
(2) normal? 15 YES
• 20 – 30V Is voltage between 17
• Disconnect L57. YES L05 (female) (8)
Is voltage
• Directional lever: and chassis
YES between L04 (3)
Neutral normal?
and chassis
• Turn starting switch • 20 – 30 V normal?
to START.
• Disconnect L05. • 20 – 30 V
• Turn starting • Connect T-adapter NO
switch ON. 16 to L04.
Is voltage between • Directional lever: N.
L04 (female) (1) • Turn starting switch
NO and chassis ON.
normal? YES
14
Is resistance • 20 – 30 V
between L57 • Disconnect L04. 19
(female) (2) and • Turn starting
NO chassis normal? switch ON. Does battery
relay make sound
• Max. 1 Ω NO of actuation?
• Turn starting
switch OFF.
• Disconnect L57. • Starting switch
ON ↔ OFF.
NO
NO
20-610 WD600-3
(1)
TROUBLESHOOTING E-1
Cause Remedy
Defective neutral relay Replace

between L57 (female) (3) –
LR4 (8) – ER1(10) – E19 (2) – Repair or
(1) and E08 (female) (1) or replace
E22 (2) – (1) and E09
(female) (1)
Defective contact or discon- Repair or
between starting switch replace
terminal C – L09 (3) – L57
(female) (5)

nection in wiring harness bet-
ween starting switch terminal
Repair or
B - L09 (1) – FS3 (4) – fuse I-12,
FS3 (6) – LR5 (1)– slow blow replace
fuse 30A – battery relay
harness between L57
(female) (1) - L05 (female) (8)
18 YES Carryout troubleshooting of

M-4, T-8.
Is voltage between
C3B (female) (13)
and chassis Defective contact or discon-
normal? nection in wiring harness Replace
• 20 – 30 V NO
and C3B (female) (13)
• Disconnect C3B.
Defective directional lever
Replace
switch

20 YES between battery relay - Repair or
slow blow fuse 80A – LR6 replace
Are both voltages (1) – FS1 (2) fuse I-9 – FS2
between battery (8) – L04 (female) (1)
relay terminal M
and chassis Defective battery relay or
normal? defective contact or Repair or
• 20 – 30 V NO disconnection in wiring replace
• Turn starting switch harness between battery -
battery relay
ON.
21
Defective battery relay Replace
Are both voltages
between battery
relay A02, A03 and
A04, A05 connection
terminals normal?
Go to B on next page
• 20 – 30 V NO
• Turn starting
switch ON.
(female) (2) – LR5 (2) and replace
chassis ground
WD600-3 20-611
(1)
TROUBLESHOOTING E-1
Cause Remedy

23 YES between starting switch Repair or
terminal BR – L09 (2) – LR4
Is resistance replace
(9) – R03 (diode) (2), (1) –
YES between A03, A05 RA1 (1) – A02, A04 (female)
22 and chassis
normal? Defective contact or discon-
Is voltage between nection in wiring harness Repair or
From B starting switch • Max. 1 Ω NO between A03, A05 – RA1 (2) replace
terminal BR and • Turn starting and chassis ground
chassis normal? switch OFF.
• Turn starting • Disconnect A03, A05.
switch ON. NO
• 20 – 30 V
20-612 WD600-3
(1)
TROUBLESHOOTING E-1
E-1 Related electrical circuit diagram
WD600-3 20-613
(1)
TROUBLESHOOTING E-2
E-2 Preheating fault

fl Check that Error Code [384] is not displayed in the engine controller.
Cause Remedy
2 YES Heater relay fault Replace

Has the resistance
YES value returned to
normalcy after
1 replacing the
Is the resistance heater relay?
Heater fault Replace
value between • Replace the NO
E31 and E24 or heater relay.
between E32 and
E25 normal? Disconnection or
connection fault in wiring Repair or
• Max. 1Ω harness between E31 and
NO replace
• Turn starting E24 or between
switch OFF.
• Disconnect E31, E24, E32 and E25
E-2 Electrical circuit diagram for APS system
20-614 WD600-3
(1)
TROUBLESHOOTING E-3
E-3 Parking brake does not have effect

fl When carrying out troubleshooting of the brake system, stop the machine on flat ground.
a) Parking brake has no effect when parking brake switch is

turned ON
Cause Remedy
YES Defective parking brake

Replace
switch
1
Does condition
become normal Contact of wiring harness Repair or
YES
when L01 is at L01 (female) (2) end
2 replace
disconnected? and (3) end
Is resistance
• Start engine.
between L01
(Charge brake oil
pressure) NO (female) (2) and (3) 3 YES Defective parking brake
Replace
normal? solenoid
Is voltage between
• Disconnect L01. CN10 (female) (1)
• Turn starting NO and chassis Contact of wiring harness
switch OFF. normal? Repair or
at L01 (female) (2) end
• Disconnect L58. • Max. 1 V NO replace
and
• Disconnect L59. • Start engine.
(Charge brake oil
pressure)
• Turn parking brake
switch ON.
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure
drops
Cause Remedy
1 YES Defective emergency

Replace
Is parking brake brake switch (C01, C02)
normal when C01
and C02 are
disconnected? Defective parking brake Replace
• Turn starting NO solenoid
switch ON.
switch ON, then OFF.
WD600-3 20-615
(1)
TROUBLESHOOTING E-4
E-4 Parking brake is applied when machine is traveling

fl When carrying out troubleshooting of the brake system, stop the machine on flat ground.
2 YES
Is resistance
YES between CN10
(female) (2) and
chassis normal?
• Max. 1 Ω NO
• Turn starting
switch OFF.
• Disconnect L59.
YES
1
Is voltage between
4
CN10 (female) (1)
Does condition YES
and chassis
normal? YES become normal
when parking brake
• 20 – 30 V safety relay is
• Start engine. replaced?
(Charge brake oil • Replace parking
pressure) brake safety relay
(L59) with stop
lamp relay (L53).
• Start engine.
(Charge brake oil
3 pressure)
5
Is continuity of Does condition
L01 (male) become normal
NO (1)(2)(3) as shown when B09 and B10
in Table 1? NO are connected to
short connector?
• Turn starting
switch OFF. • Connect short
• Operate parking connector to B09 YES
brake switch (female) and B10
ON/OFF. (female). 7
• Disconnect L01. • Start engine.
(Charge brake oil Is resistance
pressure) YES between L59
(female) (1) and (3)
6 normal?
Is voltage between • Max. 1 Ω

L59 (female) (5) • Turn starting
NO and chassis switch OFF. NO
• 20 – 30 V
• Turn starting
switch ON. NO
• Disconnect L59.
NO
Table 1
Operation Between (2) – (3) Between (1) – (3)
ON (Parking) Min. 1 MΩ Max. 1 Ω
OFF (Travel) Max. 1 Ω Min. 1 MΩ
20-616 WD600-3
(1)
TROUBLESHOOTING E-4
Cause Remedy
Defective parking brake

solenoid Replace

between CN10 (female) (2) replace
and chassis

Replace
safety relay
Defective emergency
Replace
brake switch

11 YES nection in wiring harness Repair or
between B10 (female) (2) –
Is voltage between BR1 (8) – LR4 (14) – TH2 replace
YES B10 (female) (1) (11) – CN10 (female)
10 and chassis
Is voltage between normal? nection in wiring harness Repair or
YES B09 (female) (1) • 20 – 30 V NO between B09 (female) (2) replace
and chassis • Turn starting switch ON. and B10 (female) (1)
9 normal? • Turn parking brake Defective contact or discon-
Is resistance switch ON → OFF. nection in wiring harness
YES between L59 • 20 – 30 V • Disconnect B10. Repair or
• Turn starting between B09 (female) (1) –
(female) (2) and NO BR1 (7) – LR4 (13) – L01 replace
switch ON.
8 chassis normal? (female) (2)
Is voltage between • Max. 1 Ω switch ON → OFF. Defective contact or disco-
L59 (female) (1) • Turn starting • Disconnect B09. nnection in wiring harness Repair or
and chassis switch OFF. NO between L59 (female) (2) replace
normal? • Disconnect L59. and chassis
• 20 – 30 V Defective contact or discon-

nection in wiring harness bet- Repair or
• Turn starting
ween L59 (female) (1) and L01
switch ON. NO (female) (3), or between FS2 replace
• Turn parking brake (female) (7) and L01 (female) (1)
switch ON.
• Disconnect L59. Defective contact or discon-
between L59 (female) (1) replace

between L59 (female) (5) – replace
FS2 (7) – fuse I-9

Replace
switch
WD600-3 20-617
(1)
TROUBLESHOOTING E-5, E-6
E-5 Parking brake is released when starting switch is turned ON

Cause Remedy
YES Defective parking safety

Replace
relay
1
Is problem removed
when parking
YES Defective parking brake
safety relay (L59) is Replace
replaced?
2 switch
• Replace parking Does it become

safety relay (L59) normal when L01 Contact of wiring harness
with stop lamp NO is disconnected? 3 YES Repair or
between L59 (5) and
relay (L53). Is there continuity replace
(female)(3)(1)
• Turn starting • Disconnect L01. between L59
switch ON.
• Turn starting NO (female) (3) and
• Start engine. (5)? Contact of wiring harness
switch ON. Repair or
(Stop engine after • Start engine. between L01 (female) (1)
• Disconnect L59. NO replace
charging brake oil (Stop engine after and (2)
pressure) • Turn starting
charging brake oil switch OFF.
pressure) • Turn parking brake
switch OFF.
E-6 Transmission does not change to neutral when parking brake is

applied, but parking brake works normally
20-618 WD600-3
(1)
E-3, 4, 5 Related electrical circuit diagram
WD600-3 20-619
(1)
TROUBLESHOOTING E-7
E-7 Transmission does not work properly

Perform tester check of the transmission solenoid Table 1 Normal operation table of transmission
control circuit according to the following proce- Pin No. T01
dure. Ope- (1) (2) (3) (4) (F) (R) (GND) (GND) Remedy
ration
of lever H G F E D C B A
¤ Stop the machine on flat ground and put Forward
FR lever
(F) b c c
blocks under the tires. Go to
Reverse Table 2.
(R) c b c
1. Install a T-adopter (or socket adopter) to trans- 1st b c c c c
Gear shift lever

mission connector T01, then check the volt-
age between the pins in Table 1 and chassis 2nd c b c c c Go to
ground. Table 2.
3rd c c b c c
2. Turn starting switch ON. 4th c c c b c
¤ Do not start the engine. c : 0 – 0.5V (Continuity)

b : 20 – 30V (Battery voltage)
3. Turn the parking brake switch ON, then OFF

(release) again. Table 2 Result of check during operation of
directional lever
4. If required, press the right-hand foot brake Check result Cause Trouble-
pedal. shooting
Defective transmission cut-
fl If the left-hand brake pedal is pressed, the b [Battery volt- off switch, parking brake or Go to E-9-a).
transmission is cut off and cannot be age] is zero. neutralizer relay circuit
checked. c There is not Defective circuit on forward
[continuity] side. Go to E-9-b).
(Forward side).
5. Check the voltage and continuity according
to Table 1. Then, go to the troubleshooting c There is not Defective circuit on reverse
[continuity] side. Go to E-9-c).
shown in the right columns of Table 2 and (Reverse side).
Table 3 according to the inspection result c [Continuity] Contact of circuits on
shown in those tables. is higher than forward and reverse sides Go to E-9-d).
specification. with each other
Table 3 Result of check during operation of gear

shift lever
Check result Cause Trouble-
shooting
b [Battery volt- Defective power supply

age] is zero. circuit
Go to E-9-e).
c There is not Defective circuit on gear
[continuity] shifting side
c [Continuity]
is higher than Contact of circuits on gear
shifting side Go to E-9-f).
specification.
20-620 WD600-3
(1)
TROUBLESHOOTING E-7
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit
3 YES
Is resistance
YES between L12
(male) (1) and (2)
normal?
• Max. 1Ω NO
2 • Turn starting
Does condition
switch OFF.
YES become normal
when transmission • Disconnect L12.
YES
cut-off selector
switch to turn OFF?
• Start engine.
4
Does condition YES
become normal
when replacing
NO neutralizer relay is
replaced?
• Replace neutralizer YES
relay (L58) with stop 5
lamp relay (L53). Does condition 7
• Start engine. become normal
1 when parking brake Is voltage between
NO safety relay is YES L58 (fremale) (1)
Is resistance bet-
replaced? and chassis
ween L04 (female)
• Replace parking ground normal?
(10) and chassis
ground normal? brake relay (L59) • 20 – 30 V
with stop lamp 6 • Turn starting
• Max. 1Ω
relay (L53). Is resistance of L01 switch ON.
• Turn starting
• Start engine. (male) (1), (2) and • Disconnect L58.
switch OFF. NO
• Disconnect L04. NO (3) conformed to • Turn on parking
Table 1? brake switch, then
• Turn starting release it.
switch OFF.
• Disconnect L01.
NO
NO
Table 1
Operation Terminals (1) – (3) Terminals (3) – (2)
ON (Parking) Max. 1 Ω Min. 1 Ω
OFF (Travel) Min. 1 Ω Max. 1 Ω
20-622 WD600-3
(1)
TROUBLESHOOTING E-7
Cause Remedy

between L12 (female) (1) Repair or
and L06 (female) (3) or replace
and CL1 (female) (12).
Defective transmission Replace

cut-off switch
Defective neutralizer relay Replace

Replace
safety relay
Defective contact or disconn-
ection in wiring harness
between L58 (female) (3) and
C3A (female) (19) or between Repair or
L58 (female) (2), CL1 (female) replace
(12) and chassis ground
2 YES between L59 (female) (2),
Is voltage between CL1 (12) and chassis
YES L59 (female) (5) ground
1 and chassis ground Defective contact or disco-
normal? nnection in wiring harness
Is resistance between L59 (female) (5) Repair or
between L01 replace
(female) (3) and • 20 – 30 V NO and FS2 (female) (7)
L59 (female) (1) • Turn starting Defective contact or disco-
and (3) normal? switch ON. nnection in wiring harness
• Max. 1 Ω • Disconnect L59. between L01 (female) (3) Repair or
• Turn starting and L59 (female) (1) and (3) replace
NO
switch OFF.
• Disconnect L01 Defective parking brake
and L59. switch
Replace

Repair or
LR5 (3) and chassis ground
replace
WD600-3 20-623
(1)
TROUBLESHOOTING E-7
E-7 a) Related electrical circuit diagram
20-624 WD600-3
(1)
TROUBLESHOOTING E-7
b) No continuity in travel FORWARD solenoid circuit
2 YES
Is resistance
YES between T01
(female) (A) and
chassis ground
normal?
1 • Max. 1 Ω NO
Is voltage between • Turn starting
T01 (female) (D) switch OFF.
and chassis • Disconnect T01. YES
ground normal?
• 20 – 30 V 3
• Disconnect T01. Is voltage between
• Turn starting TL1 (male) (5) and YES
switch ON.
• Release parking NO chassis ground 4
brake normal?
(Turn switch OFF). Is voltage between
• 20 - 30 V
• Shift FR lever to • Disconnect TL1. C1A (female) (2)
YES
Forward. and chassis
ground normal? 5
switch ON.
• Release parking • 20 - 30 V Is voltage between
brake • Connect T-adapter C3B (female) (5) YES
(Turn switch OFF). to C1A. NO and chassis
• Shift FR lever to • Turn starting ground normal? 6
Forward. switch ON. Is voltage between
• Release parking • 20 - 30 V
• Connect T-adapter L04 (female) (2)
brake
in C3B. and chassis 7 YES
(Turn switch OFF). NO ground normal?
• Shift FR lever to • Turn starting Is voltage between
switch ON. L04 (female) (1)
Forward.
brake • Connect T-adapter NO and chassis
in L04. ground normal?
(Turn switch OFF).
• Shift FR lever to • Turn starting • 20 – 30 V
switch ON. NO
Forward. • Disconnect L04.
• Release parking
brake • Turn starting switch ON.
(Turn switch OFF).
• Shift FR lever to Forward.
E-7 b) Related electrical circuit diagram
20-626 WD600-3
(1)
TROUBLESHOOTING E-7
Cause Remedy
Defective forward
Replace
solenoid

between T01 (female) (A), Repair or
TL1 (7), CL1 (12) and replace
chassis ground
disconnection in wiring Repair or
harness between TL1
(female) (5), T03 (1), and replace
T01 (D) (female)
harness between C1A replace
(female) (2), C1 (2), and
TL1 (male) (5)
Defective transmission &
joystick steering Replace
controller
harness between L04 replace
(female) (2) and C3B
(female) (5)
Defective forward-reverse
and gear shift switch Replace
(female) (1), FS2 (8), and
fuse I (9)
WD600-3 20-627
(1)
TROUBLESHOOTING E-7
c) No continuity in travel REVERSE solenoid circuit
2 YES
Is resistance bet-
YES ween T01 (female)
(A) and chassis
ground normal?
1 • Max. 1 Ω NO
Is voltage between • Turn starting
T01 (female) (C) switch OFF.
and chassis • Disconnect T01. YES
ground normal?
• 20 – 30 V 3
• Turn starting Is voltage between
switch ON. TL1 (male) (6) and YES
• Disconnect T01. NO chassis ground
• Release parking normal?
4
brake (Turn switch Is voltage between
ON, then OFF). • 20 - 30 V C1A (female) (9)
• Disconnect TL1. YES
• Set directional NO
and chassis
lever to REVERSE. • Turn starting ground normal? 5
switch ON.
• Release parking • 20 - 30 V Is voltage between
brake.
• Insert T-adapter C3B (female) (6) YES
in C1A. NO and chassis
• Set directional lever • Turn starting ground normal? 6
to REVERSE. switch ON. Is voltage between
• Insert T-adapter L04 (female) (4)
brake.
in C3B. and chassis 7 YES
• Shift FR lever to • Turn starting
NO ground normal?
Is voltage between
Reverse.
switch ON. L04 (female) (1)
• Release parking • 20 - 30 V and chassis
brake. • Insert T-adapter NO
in L04. ground normal?
• Shift FR lever to • Turn starting
Reverse.
switch ON.
• 20 - 30 V NO
• Release parking • Disconnect L04.
brake.
• Turn starting
switch ON.
• Shift FR lever to
Reverse.
E-7 c) Related electrical circuit diagram
20-628 WD600-3
(1)
TROUBLESHOOTING E-7
Cause Remedy
Defective forward
Replace
solenoid

between T01 (female) (A), Repair or
TL1 (7), CL1 (12) and replace
chassis ground
harness between TL1
(female) (6), T04, and T01 replace
(female) (c)
harness between C1A replace
(female) (9), C1 (9), and
TL1 (male) (6)
controller
(female) (4) and C3B
(female) (6)
Defective forward-reverse
and gear shift switch Replace
(female) (1), FS2, (8), and
fuse I (9)
WD600-3 20-629
(1)
TROUBLESHOOTING E-7
d) Short circuit to chassis ground in directional solenoid circuit

1) Short circuit to chassis ground in travel FORWARD circuit
YES
6
Is resistance bet-
YES ween L04 (male)
(4) and chassis
5 ground normal?
Is resistance bet- • Min. 1 MΩ
YES ween L04 (male) • Turn starting NO
(4) and (2), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
YES ween TL1 (male) • Turn starting
(6) and chassis switch OFF. NO
ground normal? • Disconnect L04.
3 • Set directional lever
to N or F.
YES ween TL1 (female) • Turn starting
(6) and (1), (2), (3), switch OFF. NO
(4), (5), (7) normal? • Disconnect TL1,
2
• Min. 1 MΩ L04 and L67.
Is resistance bet-
YES ween T01 (female) • Turn starting
1 (C) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (c) and TL1.
and chassis ground • Min. 1 MΩ
normal? • Turn starting
Is resistance NO
between (A), (B), (C), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 MΩ
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-630 WD600-3
(1)
TROUBLESHOOTING E-7
Cause Remedy

7 YES
joystick steering control- Replace
Is resistance bet- ler
ween L04 (male)
ground normal? or ground wire in harness Repair or
• Min. 1 MΩ NO between L04 (female) (2) replace
• Turn starting and C3B (female) (5)
switch OFF.
• Disconnect L04 and C3B. Defective transmission Replace
control switch

control switch
Short circuit with chassis or

ground wire in harness Repair or
between TL1 (male) (5) and
replace
C1A (male) (2)
Short circuit of harness
between TL1 (female) (5) and
T01 (female) (D) and harness
between TL1 (female) (1), (2),
(3), (4), (6), (7) and T01
(female) (A), (C), (E), (F), (G)
and (H) with each other
Defective insulation Repair or
between T01 (female) (D) replace
and connector body
Defective insulation between
T01 (male) (D) and connector
Repair or
body, or short circuit of
harness and chassis ground replace
with T01 (D) in control valve
and defective insulation
among pins of T01
WD600-3 20-631
(1)
TROUBLESHOOTING E-7
2) Short circuit to chassis ground in travel REVERSE circuit
YES
6
Is resistance bet-
YES ween L04 (male)
(4) and chassis
5 ground normal?
YES ween L04 (male) • Turn starting NO
(4) and (2), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
YES ween TL1 (male) • Turn starting
(6) and chassis switch OFF. NO
ground normal? • Disconnect L04.
3 • Set directional lever
to N or F.
YES ween TL1 (female) • Turn starting
(6) and (1), (2), (3), switch OFF. NO
(4), (5), (7) normal? • Disconnect TL1,
2 L04 and C1A.
1 (C) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (c) and TL1.
and chassis ground • Min. 1 MΩ
normal? • Turn starting
Is resistance NO
between (A), (B), (D), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 MΩ
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-632 WD600-3
(1)
TROUBLESHOOTING E-7
Cause Remedy

7 YES
joystick steering control- Replace
Is resistance bet- ler
ween L04 (male)
ground normal? or ground wire in harness Repair or
• Min. 1 MΩ NO between L04 (female) (4) replace
• Turn starting and C3B (female) (6)
switch OFF.
• Disconnect L04 and C3B. Defective transmission Replace
control switch

control switch
Short circuit with chassis or

ground wire in harness Repair or
between TL1 (male) (6) and
replace
C1A (male) (9)
Short circuit of harness
between TL1 (female) áE and
T01 (female) (C) and harness
between TL1 (female) (1), (2),
(3), (4), (5), (7) and T01
(female) (A), (D), (E), (F), (G)
and (H) with each other
Defective insulation Repair or
between T01 (female) (C) replace
and connector body
Defective insulation between
T01 (male) (C) and connector
body, or short circuit of Repair or
harness and chassis ground replace
with T01 (C) in control valve
and defective insulation
among pins of T01
WD600-3 20-633
(1)
TROUBLESHOOTING E-7
E-7 d) Related electrical circuit diagram
20-634 WD600-3
(1)
TROUBLESHOOTING E-7
e) Abnormality in shift solenoid circuit

1) 1st gear
Cause Remedy
4 YES
To A
Is voltage between
YES L04 (5) and chassis
ground normal?
3 Defective gear shift lever
Replace
Is resistance bet- • 20 – 30 V NO switch
(B) and chassis switch ON.
2 ground normal? • Connect T-branch to
L04. Defective contact or dis-
Is voltage between • Max. 1 Ω • Set gear shift lever to connection in wiring har-
YES L04 (female) (1) • Turn starting 1st. ness between T01 (fe- Repair or
1 and chassis switch OFF. NO male) (B), TL1 (7), CL1 replace
Is resistance be-
ground normal? • Disconnect T01. (12), and chassis ground
tween L04 (female) • 20 – 30 V Defective contact or dis-
(10) and chassis • Turn starting connection in wiring har- Repair or
ground normal? ness between L04 (fe- replace
switch ON. NO male) (1), FS2 (8), and
• Max. 1 Ω • Disconnect L04. fuse I (9)
• Turn starting Defective contact or dis-
switch OFF. connection in wiring har- Repair or
• Disconnect L04. NO ness between L04 (fe- replace
male) (10), LR5 (3), and
chassis ground
8 YES Defective solenoid for 1st

gear speed Replace
Is voltage between
YES T01 (female) (H)
and chassis Defective contact or dis-
7 ground normal? connection in wiring har- Repair or
Is voltage between • 20 – 30 V NO ness between TL1 (female) replace
YES TL1 (male) (1) and • Disconnect T01. (1) and T01 (female) (H)
chassis ground • Turn starting
6 normal? switch ON.
• Set gear shift lever
Is voltage between • 20 – 30 V to 1st. Defective contact or dis-
YES C1A (3) and • Disconnect TL1. connection in wiring har- Repair or
5 chassis ground • Turn starting ness between C1A (fe-
replace
switch ON. NO male) (3) and TL1 (male)
normal? (1)
From A
Is voltage between • 20 – 30 V to 1st.
C3B (7) and chassis • Insert T-adapter in Defective transmission &
ground normal? C1A. joystick steering control- Replace
• Turn starting NO ler
• 20 – 30 V switch ON.
• Turn starting • Set gear shift lever Defective contact or dis-
switch ON. to 1st. connection in wiring har- Repair or
• Insert T-adapter in NO ness between L04 (fe-
male) (5) and C3B (fe- replace
C3B.
male) (7)
to 1st.
20-636 WD600-3
(1)
TROUBLESHOOTING E-7
2) 2nd gear
Cause Remedy
4 YES
To A
Is voltage between
ground normal?
Replace
(B) and chassis switch OFF.
2 ground normal? • Disconnect L04.
• Set gear shift lever to Defective contact or dis-
Is voltage between • Max. 1 Ω 2nd. connection in wiring har-
YES L04 (female) (1) • Turn starting ness between T01 (fe- Repair or
Is resistance be-
male) (10), LR5 (3), and
chassis ground
8 YES Defective solenoid for 2nd

gear speed Replace
Is voltage between
YES T01 (female) (G)
and chassis
Defective contact or dis-
YES TL1 (male) (2) and • Disconnect T01. (2) and T01 (female) (G)
Is voltage between • 20 – 30 V to 2nd. Defective contact or dis-
YES C1A (10) and • Disconnect TL1 connection in wiring har- Repair or
replace
normal? (2)
Is voltage between • Set gear shift lever
From A C3B (15) and • 20 – 30 V to 2nd.
chassis ground • Insert T-adapter in Defective transmission &
C1A. joystick steering control- Replace
normal? NO ler
• Turn starting
switch ON. to 2nd connection in wiring har- Repair or
C3B.
male) (15)
to 2nd.
WD600-3 20-637
(1)
TROUBLESHOOTING E-7
3) 3rd gear
Cause Remedy
4 YES
To A
Is voltage between
ground normal?
Replace
YES L04 (female) (1) • Turn starting 3rd. ness between T01 (fe- Repair or
Is resistance be-
male) (10), LR5 (3), and
chassis ground
8 YES Defective solenoid for 3rd

gear speed Replace
Is voltage between
YES T01 (female) (F)
and chassis
YES TL1 (male) (3) and • Disconnect T01. (3) and T01 (female) (F)
Is voltage between • 20 – 30 V to 3rd. Defective contact or dis-
replace
normal? (3)
Is voltage between • 20 – 30 V to 3rd.
From A C3B (8) and chassis
• Insert T-adapter in Defective transmission &
ground normal? C1A. joystick steering control- Replace
• Turn starting NO ler
switch ON. to 3rd connection in wiring har- Repair or
C3B.
male) (8)
to 3rd.
20-638 WD600-3
(1)
TROUBLESHOOTING E-7
4) 4th gear
Cause Remedy
4 YES
To A
Is voltage between
ground normal?
Replace
YES L04 (female) (1) • Turn starting 2nd. ness between T01 (fe- Repair or
Is resistance be-
male) (10), LR5 (3), and
chassis ground
8 YES Defective solenoid for 4th

gear speed Replace
Is voltage between
YES T01 (female) (E)
and chassis
YES TL1 (male) (4) and • Disconnect T01. (4) and T01 (female) (E)
Is voltage between • 20 – 30 V to 4th. Defective contact or dis-
replace
normal? (4)
Is voltage between • Set gear shift lever
From A C3B (16) and • 20 – 30 V to 4th.
chassis ground • Insert T-adapter in Defective transmission &
C1A. joystick steering control- Replace
normal? NO ler
• Turn starting
switch ON. to 4th connection in wiring har- Repair or
C3B.
male) (16)
to 4th.
WD600-3 20-639
(1)
TROUBLESHOOTING E-7
E-7 e) Related electrical circuit diagram
20-640 WD600-3
(1)
TROUBLESHOOTING E-7
f) Short circuit to chassis ground in shift solenoid circuit

1) Short circuit to chassis ground in 1st solenoid circuit
Cause Remedy
YES
To A
4
Short circuit with wiring
Is resistance bet- harness between following
YES ween TL1 (male) couples in wiring harness
(1) and (2), (3), (4), between TL1 (male) (1) and
(5), (6), (7) normal? C1A (female) (3); TL1 (male)
(2) and C1A (female) (10), TL1
3 • Min. 1 MΩ (male) (3) and C1A (female) Repair or
(5), TL1 (male) (4) and C1A
Is voltage between • Turn starting NO (female) (11), TL1 (male) (5) replace
YES TL1 (male) (1) and switch OFF. and C1A (female) (2), TL1
(male) (6) and C1A (female)
chassis ground • Disconnect TL1, L04 (9), and TL1 (male) (7) and
normal? and C1A. chassis ground
2 • 0 – 0.5V Short circuit with power
Is resistance • Disconnect TL1, source in wiring harness Repair or
between T01 L04 and C1A.
YES NO between TL1 (male) (1) and replace
(female) (H) and (A), • Turn starting C1A (female) (3)
(B), (C), (D), (E), (F),
(G) normal?
switch ON.
1
• Min. 1 MΩ Short circuit with wiring
Is resistance harness between following
between T01 (male) • Turn starting groups in wiring harness
(H) and chassis switch OFF. between T01 (female) (H)
ground normal? Repair or
Is resistance • Disconnect T01 NO
and TL1 (female) (1); T01 replace
and TL1. (female) (A), (B), (C), (D),
between (A), (B), (C), (E), (F), (G) and TL1 (fe-
(D), (E), (F), (G) and male) (2), (3), (4), (5), (6), (7)
chassis ground
normal?
Defective insulation
• Min. 1 MΩ between T01 (male) (H) and
• Turn starting connector body, or short Repair or
switch OFF. circuit of harness and replace
• Disconnect T01. NO chassis ground with T01
(H) in control valve and
defective insulation among
pins of T01
5 YES Defective transmission Replace

Is resistance control switch
From A between L04
(female) (5) and Short circuit with wiring
harness between following
(2), (4), (6) normal? groups in wiring harness Repair or
• Min. 1 MΩ NO between C1A (female) (3) replace
and TL1 (male) (1); C1A
• Turn starting (female) (2), (5), (9), (10),
switch OFF. (11) and TL1 (male) (2), (3),
• Disconnect L04, (4), (5), (6)
TL1 and C1A.
WD600-3 20-641
(1)
TROUBLESHOOTING E-7
2) Short circuit to chassis ground in 2nd solenoid circuit
Cause Remedy
YES
To A
4
(5), TL1 (male) (4) and C1A
Is resistance • Disconnect TL1, L04 source in wiring harness Repair or
between T01 and C1A.
(female) (G) and (A), • Turn starting C1A (female) (5)
(B), (C), (D), (E), (F),
(H) normal?
switch ON.
1
Is resistance • Min. 1 MΩ Short circuit with wiring
between T01 (male) • Turn starting harness between following
(G) and chassis switch OFF. groups in wiring harness
ground normal? between T01 (female) (G) Repair or
Is resistance • Disconnect T01 NO and TL1 (female) (2); T01 replace
between (A), (B), (C), and TL1. (female) (A), (B), (C), (D),
(D), (E), (F), (H) and (E), (F), (H) and TL1 (fe-
chassis ground male) (1), (3), (4), (5), (6), (7)
normal?
Defective insulation
• Min. 1 MΩ between T01 (male) (G) and
• Turn starting connector body, or short Repair or
switch OFF. circuit of harness and replace
• Disconnect T01. NO chassis ground with T01
(G) in control valve and
pins of T01
5 YES Defective transmission

Replace
Is resistance control switch
From A between L04
(female) (6) and harness between following
(2), (4), (5) normal? groups in wiring harness Repair or
between C1A (female) (10)
• Min. 1 MΩ NO and TL1 (male) (2); C1A replace
• Turn starting (female) (2), (3), (5), (9), (11)
and TL1 (male) (1), (3), (4),
switch OFF. (5), (6)
• Disconnect L04,
TL1 and C1A.
20-642 WD600-3
(1)
TROUBLESHOOTING E-7
3) Short circuit to chassis ground in 3rd solenoid circuit
Cause Remedy
YES
To A
4
(10), TL1 (male) (4) and C1A
Is resistance • Disconnect TL1, source in wiring harness Repair or
between T01 L04 and C1A.
(female) (F) and (A), • Turn starting C1A (female) (5)
(B), (C), (D), (E), (G),
(H) normal?
switch ON.
1 Short circuit with wiring
Is resistance • Min. 1 MΩ harness between following
(F) and chassis between T01 (female) (F)
switch OFF. and TL1 (female) (3); T01 Repair or
ground normal?
Is resistance • Disconnect T01 NO (female) (A), (B), (C), (D), replace
between (A), (B), (C), and TL1. (E), (G), (H) and TL1
(D), (E), (G), (H) and (female) (1), (2), (4), (5), (6),
chassis ground (7)
normal?
• Min. 1 MΩ Defective insulation
• Turn starting between T01 (male) (F) and
connector body, or short Repair or
switch OFF. replace
NO circuit of harness and
• Disconnect T01. chassis ground with T01 (F)
in control valve and
pins of T01
5 YES Defective transmission

Replace
Is resistance bet- control switch
From A ween L04 (female)
(7) and (2), (4), (5), harness between following
(6) normal? groups in wiring harness Repair or
between C1A (female) (5)
• Min. 1 MΩ NO and TL1 (male) (3); C1A replace
• Turn starting (female) (2), (3), (9), (10),
(11) and TL1 (male) (1), (2),
switch OFF. (4), (5), (6)
• Disconnect L04,
TL1 and C1A.
WD600-3 20-643
(1)
TROUBLESHOOTING E-7
4) Short circuit to chassis ground in 4th solenoid circuit
Cause Remedy
YES
To A
4
(10), TL1 (male) (3) and C1A
2 • 0 – 0.5V
• Disconnect TL1, Short circuit with power
between T01
source in wiring harness
YES L04 and C1A. replace
NO between TL1 (male) (4) and
(female) (E) and (A), • Turn starting C1A (female) (11)
(B), (C), (D), (F), (G),
(H) normal?
switch ON.
1 Short circuit with wiring
Is resistance • Min. 1 MΩ harness between following
(E) and chassis switch OFF. between T01 (female) (E)
ground normal? and TL1 (female) (4); T01 Repair or
Is resistance • Disconnect T01 NO (female) (A), (B), (C), (D), replace
between (A), (B), (C), and TL1. (E), (F), (G) and TL1
(D), (F), (G), (H) and (female) (1), (2), (3), (5), (6),
chassis ground (7)
normal?
• Min. 1 MΩ Defective insulation
• Turn starting between T01 (male) (E) and
Repair or
switch OFF. connector body, or short
NO circuit of harness and replace
• Disconnect T01. chassis ground with T01 (E)
in control valve and
pins of T01
5 YES Replace
Is resistance bet- Defective transmission
From A ween L04 (female) control switch
(8) and (2), (4), Short circuit with wiring
(5),(6) normal? harness between following Repair or
groups in wiring harness replace
• Min. 1 MΩ NO between C1A (female) (11)
• Turn starting and TL1 (male) (4); C1A
switch OFF. (female) (2), (3), (5), (9), (10)
and TL1 (male) (1), (2), (3),
• Disconnect L04, (5), (6)
TL1 and C1A.
20-644 WD600-3
(1)
TROUBLESHOOTING E-7
E-7 f) Related electrical circuit diagram
WD600-3 20-645
(1)
E-8 When hold switch is pressed, gear speed is not fixed or reset
Gear speed is not shifted up
E-9 Kick-down system does not work

Gear speed is not shifted down
20-646 WD600-3
(1)
TROUBLESHOOTING E-10
E-10 Power window does not work

fl Check that fuse (12) is not blown.
a) Power window does not rise

(This troubleshooting shows about L.H. power window)
Cause Remedy
4 YES Replace
Defective relay (L92)
Is resistance bet-
3 (6) and chassis Defective contact or disco-
ground normal? nnection in wiring harness
YES between CL19 • Max. 1 Ω NO CL1 (12) and chassis replace
(female) and L92 • Turn starting ground
(female) (3) normal? switch OFF.
• Max. 1 Ω • Disconnect L19 and L92. nnection in wiring harness Repair or
• Turn starting NO between CL19 (female), replace
2 switch OFF. CL2 (2) and L92 (female)
• Disconnect CL19 (13)
Is voltage between and L92.
YES 6 YES
CL18 and chassis Defective relay (L91) Replace
ground normal? Does condition
YES become normal
• 20 – 30V when relay is
• Turn starting replaced?
To A
switch ON. 5 • Turn starting NO
• Set left-hand switch ON.
1 Is resistance
power window • Replace L91
Is there continuity between CL18
switch to UP (Left-hand UP relay)
between CL18 position. NO (male) and L91 with L93 (Right-hand
(female) and CL19 (female) (3) normal? UP relay).
(male)? • Set left-hand power
window switch to UP
• Turn starting position. Defective contact or disco-
switch OFF. nnection in wiring harness Repair or
• Disconnect CL18 NO between CL18 (male), CL2 replace
and CL19. (1) and L91 (female) (3)
Defective power window

Replace
NO motor

YES between L91 (female) (2), Repair or
CL1 (12) and chassis replace
ground

7 10 YES nnection in wiring harness Repair or
Is voltage between between L41 (female) (5) replace
Is voltage between and L91 (female) (1)
From A L91 (female) (1) YES L91 (female) (5)
and chassis 9 and chassis
ground normal? Is voltage between ground normal? Repair or
YES L41 (female) (1) and • 20 – 30V NO between OP2 (male) and replace
• 20 – 30V
chassis ground • Turn starting L91 (female) (5)
• Turn starting 8 normal? switch ON.
switch ON. Is resistance bet- Defective contact or disco-
• Disconnect L91. • 20 – 30V • Disconnect L91. Repair or
ween L41 (male) nnection in wiring harness
• Set left-hand • Turn starting NO between L41 (female) (1) replace
NO (1) and (5)
power window normal? switch ON. and OP2 (male)
switch to UP • Disconnect L41.
position. • Max. 1 Ω
• Turn starting Repair or
Defective switch (L41)
switch OFF. NO replace
• Disconnect L41.
• Set left-hand power
window switch to
UP position.
WD600-3 20-647
(1)

fl Check that fuse (12) is not blown.
b) Power window does not lower

(This troubleshooting shows about L.H. power window)
Cause Remedy
4 YES Replace
Defective relay (L91)
Is resistance bet-
3 (6) and chassis Defective contact or disco-
ground normal? nnection in wiring harness
YES between CL18 • Max. 1 Ω NO CL1 (12) and chassis replace
(male) and L91 • Turn starting ground
(female) (3) normal? switch OFF.
• Disconnect L92 and L91. Defective contact or disco-
• Max. 1 Ω nnection in wiring harness Repair or
• Turn starting NO between CL18 (male), CL2 replace
2 switch OFF. (1) and L91 (female) (3)
• Disconnect CL18
Is voltage between and L92.
YES 6 YES
CL19 and chassis Defective relay (L92) Replace
ground normal? Does condition
YES become normal
• 20 – 30V when relay is
• Turn starting replaced?
switch ON. To A
5 • Turn starting NO
• Set left-hand switch ON.
1 Is resistance
power window • Replace L92
Is there continuity between CL19
switch to DOWN (Left-hand UP relay)
between CL18 NO (female) and L92 with L94 (Right-hand
position. (female) (3) normal?
(female) and CL19 DOWN relay).
(male)? • Set left-hand power
window switch to
• Turn starting DOWN position. Defective contact or disco-
switch OFF. nnection in wiring harness Repair or
• Disconnect CL18 NO between CL19 (female), replace
and CL19. CL2 (2) and L92 (female) (3)
Defective power window

Replace
NO motor

YES between L92 (female) (2), Repair or
CL1 (12) and chassis replace
ground

7 10 YES nnection in wiring harness Repair or
Is voltage between between L41 (female) (6) replace
Is voltage between and L92 (female) (1)
From A L92 (female) (1) YES L92 (female) (5)
and chassis 9 and chassis
ground normal? Is voltage between ground normal? Repair or
YES L41 (female) (1) and • 20 – 30V NO between OP2 (male) and replace
• 20 – 30V
chassis ground • Turn starting L92 (female) (5)
• Turn starting 8 normal? switch ON.
switch ON. Is resistance bet- Defective contact or disco-
• Disconnect L91. • 20 – 30V • Disconnect L91. Repair or
ween L41 (male) nnection in wiring harness
• Set left-hand • Turn starting NO between L41 (female) (1) replace
NO (1) and (6)
power window normal? switch ON. and OP2 (male)
switch to DOWN • Disconnect L41.
position. • Max. 1 Ω
• Turn starting Defective switch (L41) Replace
switch OFF. NO
• Disconnect L41.
• Set left-hand power
window switch to
DOWN position.
20-648 WD600-3
(1)
E-10 Related electrical circuit diagram
WD600-3 20-649
(1)
TROUBLESHOOTING E-11, E-12, E-13, E-14, E-15
E-11 Abnormality in front working lamp

fl Go to Troubleshooting M-10.
E-12 Abnormality in rear working lamp

E-13 Abnormality in transmission cut-off

fl Go to Troubleshooting T-15.
E-14 Abnormality in parking brake dragging warning

fl Go to Troubleshooting M-13, M-14.
E-15 Abnormality in buzzer

20-650 WD600-3
(1)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
POWER TRAIN
H- 1 Machine does not move .............................................................................................................. 20-702
H- 2 Machine does not travel smoothly (machine jerks) .................................................................. 20-703
H- 3 Lock-up clutch cannot be disengaged (engine stalls) ............................................................... 20-703
H- 4 Machine lacks power or speed when traveling ......................................................................... 20-704
H- 5 Excessive time lag when starting machine or shifting gear ..................................................... 20-706
H- 6 Torque converter oil temperature too high ................................................................................ 20-707
STEERING SYSTEM
H- 7 Steering wheel does not turn ...................................................................................................... 20-708
H- 8 Steering does not turn [machine with joystick] ......................................................................... 20-709
H- 9 Turning, response of steering is poor ......................................................................................... 20-710
H-10 Turning, response of steering is poor [machine with joystick] ................................................. 20-712
H-11 Steering is heavy .......................................................................................................................... 20-714
H-12 Joystick is heavy [machine with joystick] .................................................................................. 20-714
H-13 Steering wheel shakes or jerks .................................................................................................... 20-715
H-14 Steering shakes or there is excessive shock [machine with joystick] ...................................... 20-716
H-15 Turning radius is different between left and right at maximum steering ................................ 20-716
BRAKE SYSTEM
H-16 Wheel brakes do not work or braking effect is poor ................................................................. 20-718
H-17 Wheel brakes are not released or brakes drag .......................................................................... 20-720
H-18 Parking brake does not work or braking effect is poor ............................................................. 20-721
H-19 Parking brake is not released or brake drags (including emergency release system) ........... 20-722
WORK EQUIPMENT
H-20 Blade does not rise ....................................................................................................................... 20-723
H-21 Blade moves slowly or does not have sufficient lifting power ................................................. 20-724
H-22 Blade becomes slow at certain height when raising ................................................................. 20-725
H-23 Lift cylinder cannot hold down blade ......................................................................................... 20-725
H-24 Blade has large amount of hydraulic drift .................................................................................. 20-725
H-25 Blade fluctuates while working ................................................................................................... 20-726
H-26 Blade drops momentarily when lever is operated from HOLD to RAISE ................................ 20-726
H-27 Blade does not tilt ......................................................................................................................... 20-727
H-28 Blade moves slowly or has insufficient tilt power ..................................................................... 20-728
H-29 Blade does not pitch ..................................................................................................................... 20-729
H-30 Blade pitch movement is slow or lacks power .......................................................................... 20-729
H-31 Work equipment lever does not move smoothly ...................................................................... 20-730
WD600-3 20-701
(1)
TROUBLESHOOTING H-1
TROUBLESHOOTING TABLE
H-1 Machine does not move
Ask the operator the following points.
• Did the machine suddenly stop moving?
ive
Yes = Component seized or damaged.
fect
)
side
• Was there any abnormal noise when this machine
l de
ht in
stopped moving?
poo
caug
Yes = Component broken.
of s
dirt
ion
e
Checks before troubleshooting
ive
g or
erat
ecti
e)
tive
tive
fect
• Is oil level in transmission case correct?
(bitin
i
f
p
t
e
efec
c
efec
o
ch d
it de
ses
• Is monitor display normal?
defe
ed,
on
ive
ump
ol d
g va valve d
• Is drive shaft broken?
Cau
clut
i
ircu
e
orat
fect
g
ctiv
s
n
spo
smi
p
eali
ch c
sion
i
l de
r
defe
f
e
de o
tran
t
lve
f
oil s
e
relie
clut
mis
d
spoo
alve
n si
d
ring
rt of
(
eize
ans
g
ive
g
tatin
ctio
alve
id v
latin
latin
e sp
a
of tr
t
s
p
c
defe
h
t su
rol v
leno
in ro
rnal
ratin f modu
odu
lutc
l v
e
g va
up a
roov
cont
ive
f so
e
m
utch
on c
ing
t
to in
ucin
fect
g of
o
o
g of
g
ing
r
i
l
The following symbols are used to indicate the
s
c
g
n
l
,
a
s
p de
g
ratin
ratio
ting
t red
age
suck
smi
action to be taken when a cause of failure is
ft se
ratin
l rin
located.
Dam
Rota
Pum
Tran
Ope
Ope
Ope
Pilo
Sha
Ope
Sea
Air
X: Replace : Repair
A: Adjust C : Clean
a b c d e f g h i j k l
Remedy
No. × × × × × × ×
Problems × ×
1 Abnormal noise between pump and filter
2 Machine does not move in any speed range (Item 1 normal)
3 Machine moves normally in certain speed ranges
4 Machine will not move when T/C oil temperature rises
5 Transmission Low at every speed range
6 modulating pressure Low at certain speed ranges
7 too low Indicator fluctuates violently
8 Pilot pressure defective
Note 1: If the solenoid valve and hydraulic pressure are normal, the “l” in the Causes column indicates
that the valve spool does not work.
Note 2: If the transmission clutch pressure is low, but the cause cannot be found in the above table, a
possible cause is cracks in the valve or transmission.
20-702 WD600-3
(1)
TROUBLESHOOTING H-2, H-3
H-2 Machine does not travel smoothly (machine jerks)

• There is hunting.
• Lock-up lamp flashes
Causes Remedy
• Drop in main relief pressure 

 See H-4
• Worn clutch seal ring 
H-3 Lock-up clutch cannot be disengaged (engine stalls)

• Is the oil level in the transmission case correct?
alve
noid v
Causes
e
p valv
p sole
lock-u
lock-u
o n of
o n of
h
p clutc
ctuati
ctuati
lock-u
tive a
tive a

Seized
Defec
Defec
located.
X: Replace : Repair
A: Adjust C : Clean
a b c
Remedy C
No.
Problems
1 Lock-up pressure does not become "0"
Lock-up clutch is not disengaged even when lock-up

2
pressure is "0"
3 Operation of lock-up valve is normal
4 Operation of lock-up solenoid valve is normal
WD600-3 20-703
(1)
TROUBLESHOOTING H-4
H-4 Machine lacks power or speed when traveling

a. Abnormality at all speed ranges
g
g)
d sprin
ose plu
valve)
d
• Are the transmission oil filter and strainer
riorate
mage
ring, lo
verter
clogged?
ort da
n)
• Is the oil level in the transmission case cor-
e, dete
l
e con
e
e
k
rect?
o
e
r
utlet p
efectiv
rivet b
lv
(torqu
• Is there any external oil leakage from the pip-
v a
ing or valve joints?
e
e
erter (d
erter o
engag
ter reli
rbine
valve
• Is there any dragging of the wheel brake and
pump
el
parking brake?
Causes
ter (tu
e conv
v
onver
s not
h
relief
e con
w
• How are the tire inflation pressure and shape
e
e
ide of
ter fre
f engin
e torqu
p d oe
of tire tread?
onver
rque c
main
q u
• Is working method correct?
r
tion s
ond to
onver
lock-u
rque c
n of to
e insid
ure of
nce o
a t s uc
Checking for abnormalities
g b ey
rq ue c
leakag
ide to
forma
verter
p ress
ainer
ti
ump
• Engine high idling speed
r a
cked in
v e o pe
r, pipin
• Torque converter stall speed
tive to
ge ins
ed str
e con
in per
ive oil
tive p
in set
• Machine travel speed
Defecti
Excess
Torqu
Air su
Clogg
Dama
Coole
Defec
Defec
• Transmission clutch pressure

Drop
Drop
• Torque converter lock-up pressure

• Main relief pressure a b c d e f g h i j k
Remedy A A
No. C
Problems See "Torque converter lock-up does not engage".
1 Abnormal noise comes from between pump and

filter
2 Torque converter stall speed is high
3 Torque converter stall speed is low
4 Low at every speed

range (Item 2 abnormal)
Set pressure of Indicator is unstable and
5 transmission is low fluctuates excessively
Low after entering See "Torque converter lock-up
6 torque converter lock-up does not engage".
Hydraulic pressure at torque converter inlet port is
7 low (Items 4 - 6 normal)
Hydraulic pressure at torque converter outlet port is
8 low (Item 7 normal)
Pieces of iron and aluminium stuck to strainer and
9
drain plug of transmission case
10 Hydraulic pressure at pump outlet port is low
11 When oil temperature rises, oil pressure drops

located.
X: Replace : Repair
A: Adjust C : Clean
20-704 WD600-3
(1)
TROUBLESHOOTING H-4
b. Torque converter lock-up does not engage

Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnor-
mal noise?
Yes = Broken part
ool
lve sp
• Is the oil level in the transmission case cor-
oid va
spool
valve
rect?
Causes
g
solen
e
• Is there any external oil leakage?
eal rin
p valv
relief
• Is electricity flowing to the lock-up solenoid?
ck-up
(Use a checker.)
lock-u
main
case
iston
oid
h disc
n of lo
solen
ure o f
lutch
o n of
h p
• Main relief pressure
p clutc
p clutc
o
k-up c
ck-up
p re ss
perati
perati
• Lock-up oil pressure
lock-u
lock-u
• Machine travel speed tive lo
ed loc
tive o
tive o
in set
Defec
Defec
Defec
Worn
Worn
Crack
Drop
a b c d e f g
Remedy
No.
Problems
1 Main relief pressure is low
2 With Item 1 normal, lock-up pressure is low or "0"
3 Solenoid is normal in Item 2 (proper continuity, no

short circuit)
Solenoid is defective in Item 2 (no continuity, there is
4
short circuit)
5 With Items 1 - 4 normal, lock-up pressure is low
6 Oil pressure is normal in Item 5
Lock-up pressure is low and main pressure is also

7
low
8 Lock-up takes time to engage

located.
X: Replace : Repair
A: Adjust C : Clean
WD600-3 20-705
(1)
TROUBLESHOOTING H-5
H-5 Excessive time lag when starting machine or shifting gear

• Is there any leakage of oil from joints of piping or
valves?
ive
fect
l de
poo
of s
tive
ctiv
clog eration
e )
efec
de f e
ctiv
ged
ses
defe
uit d
e
d, o
h
ctiv
p
c
Cau
t
pum
circ
rate
ing
defe
c l
lve
sion
seal
terio
f
utch
de o
e
n va
valv
mis
(oil
g cl
e
n si
d
etur
rans
turn
ive
g
tatin
ctio
n
ick r
spri
fect
k re
t
t su
e of
n ro
h de
f qu
alve
quic
up a
roov
ng i
ive
lutc
ng v
fect
n of
fole
al ri
g, g
ing
c
i
p de
ratio
ulat
ting
ft se
suck
ttle
l rin
Mod
Pum
Thro
Rota
Ope
Sha
Sea
Air
a b c d e f g h
Remedy
No. × × × ×
Problems × ×
1 Abnormal noise between pump and filter
2 Excessive time lag in every speed range
3 Machine moves normally in certain speed ranges
4 Transmission modulating pressure too low in every speed range
5 As in item 4; indicator fluctuates violently
6 Torque converter oil temperature is above operating range

located.
X: Replace : Repair
A: Adjust C : Clean
20-706 WD600-3
(1)
TROUBLESHOOTING H-6
H-6 Torque converter oil temperature too high

• Does not torque converter oil temperature go up
during torque converter stall, and down when the
e,
lo o s
torque converter is not stalled?
Yes = Normal (Incorrect selection of gear speed)
lu g
e, p
ctiv
d e fe
e
ctiv
• Is filter clogged?
ring
d e fe
eal
lv e
e r (s
f va
mp
fl If the oil temperature is normal but the oil tem-
ses
vert
f pu
elie
perature gauge is outside the operating range,
Cau
n
ter r
the oil temperature gauge is defective.
de o
crac rque co
r
n si
)
onv
ked
ctio
o
turb side t
ue c
t su
torq
ine
il in
up a
ive
n of
fect
pum ge of o
ing
p de
ratio
p or
suck
ka
Pum
Ope
Lea
Air
Tank to Torque
Pump converter
a b c d
Remedy
No. ×
Problems × × ×
1 Pump makes abnormal noise when oil temperature is low
2 High idling and low idling speeds are too low
3 Hydraulic pressure at inlet port of torque converter too low
4 Transmission modulating pressure too low

located.
X: Replace : Repair
A: Adjust C : Clean
WD600-3 20-707
(1)
TROUBLESHOOTING H-7
H-7 Steering wheel does not turn

Ask the operator the following questions.
• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this hap-
pened? Where did the noise come from?

• Is the oil level in the hydraulic tank correct?
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
ses
ool
ol
p
frame?
pum
Cau
o
d sp
s p
ring
lve
itch
man
n va
stee
w
f de
nd s
o
valv
f
i
on o
o
t
seal
p
alve
-suc
ng a
m
ion
-roll
C pu
arge
ston
op v
tuat
fety
tuat
eeri
t
Defe ve Orbi
e PP
e ch
a
e ac
e ac
e st
e pi
e st
e s
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Charge Orbit- Stop Steering Cylin-
pump valve roll valve valve der
a b c d e f g h i
Remedy
No. × × ×
Problems × × × × × ×
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Steering wheel is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
Oil pressure is low or there is no pressure
8 When steering in both directions (left and right)
relief pressure
is measured Oil pressure is low or there is no pressure
9
in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is

10
found to be low or there is no oil pressure
11 When PPC valve (Orbit-roll) Oil pressure is low
12 basic pressure is measured There is no oil pressure
fl There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-708 WD600-3
(1)
TROUBLESHOOTING H-8
H-8 Steering does not turn [machine with joystick]


• Is the steering shaft broken?
e
valv
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
oid
ses
l
ol
o
frame?
olen
pum
spo
spo
Cau
alve
• Is the operation of the steering and the steer-
ck s
alve
and
ing
d of
e
ing mode switch correct?
op v
valv
ysti
teer
tor v
dem
n en
t
of jo
tion
of s
of s
alve
stric
ctio
o f
seal
ump
-suc
ion
tion
tion
tion
oll
t su
y re
arge
bit-r
ston
tuat
PC p
fety
ctua
ctua
Defe e actua
a
Defe e 2-wa
suck TO
r
d in
filte
e Or
e ch
e ac
e sa
e pi
P
eP
a
a
e
e
e
e
ctiv
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic Charge Orbit- Stop Steering Cylin-

pump Joystick valve Valve
valve roll valve der
a b c d e f g h i j k l m
Remedy C
No. × × × ×
Problems × × × × × × × ×
1 When steering Steering does not move (steering wheel mode only)
2 mode switch Steering does not move (joystick mode only)
3 is switched Steering does not move in either mode
4 Steering wheel does not turn in both directions (left and right)
5 Steering wheel turns only in one direction (left or right)
7 Steering wheel is heavy in one direction (left or right)
Oil pressure is low, or there is no pressure
relief pressure
is measured Oil pressure is low, or there is no pressure
13
in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure

14
is found to be low or there is no oil pressure
When joystick solenoid valve output pressure is measured,
15
oil pressure is found to be low or there is no oil pressure
16 When PPC valve (Orbit-roll) Oil pressure is low
17 basic pressure is measured There is no oil pressure
WD600-3 20-709
(1)
TROUBLESHOOTING H-9
H-9 Turning, response of steering is poor

• Did the problem gradually appear?
Yes = Wear of related parts, defective seal

ses
ool
poo
pum
Cau
g sp
e
nd s
valv
d of
alve
erin
ema
stop
n en
alve
on v
e
p
t
of d
s
m
mp
e
v
o
n of
f
valv
al
u
ucti
o
i
p
f
suct
ng p
relie
n se
h pu
pum
ion
tion
ll
atio
it-ro
ty-s
arge
tuat
n at
isto
eeri
ctua
witc
ain
suck TO
u
PPC
safe
Orb
t
e ch
e ac
e ac
m
ve p
ed i
e st
eP
a
s
e
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ecti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
IDef
Air
Charge Orbit- Stop Cylin-

Hydraulic pump valve roll valve Steering valve der
a b c d e f g h i j k l m
Remedy
No. × × × ×
Problems × × × × × × × ×
1 Turning, response of steering is poor in both directions (left and right)
2 Turning, response of steering is poor in one direction (left or right)
3 Steering wheel is heavy in both directions
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or there is no pressure
relief pressure
is measured Oil pressure is low or there is no pressure
11 in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure

12
is found to be low
13 When PPC valve (Orbit-roll) basic pressure is measured,

oil pressure is found to be low
20-710 WD600-3
(1)
TROUBLESHOOTING H-10
H-10 Turning, response of steering is poor [machine with joystick]

• Was there previously any symptom, such as
difficulty in steering?
Yes = Wear of related equipment, defective
seal
e
valv
oid
ses
ump
ool
olen
Cau
p
lve
of p
s
ck s
and
p va
end
ysti
dem
lve
f sto
p
of jo
f va
ion
m
mp
e
f
valv
u
o
o
mp
suct
relie
p
h pu
ion
ion
tion
-roll
ing
C pu
arge
tuat
tuat
n at
ctua
witc
ain
teer
Clog e Orbit
suck TO
er
e PP
e ch
e ac
e ac
em
ed i
t
eP
s
s
a
f i
e
e
e
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Charge Orbit- Stop Steering

Hydraulic pump valve roll
Joystick valve
valve
a b c d e f g h i j k l
Remedy C
No. × × × ×
Problems × × × × × × ×
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Turning, response of steering is poor in both directions (left and right)
5 Turning, response of steering is poor in one direction (left or right)
11 Abnormal noise comes from around steering pump or hydraulic tank
12 Abnormal noise comes from around switch pump or hydraulic tank
13 When steering Oil pressure is low in both directions (left and right)
relief pressure
14 is measured Oil pressure is low in one direction (left or right)
15 When Orbit-roll output pressure is measured, oil pressure is found to be low
When joystick solenoid valve output pressure is measured,
16 oil pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured,
17 oil pressure is found to be low
20-712 WD600-3
(1)
×
×
valve
Defe
m n
ctiv
Steering
e ac
WD600-3
Defe tuat
ctiv ion
× ×
Valve
Defe e sa of s
fety teer
o p
ctiv - ing
der
e suct spo
Cylin-
Defe 2-w ion ol
ay r valv
ctiv
e pi estr
icto e
ston r va
seal lve
TROUBLESHOOTING
(1)
H-10
20-713
H-11 Steering is heavy

• Is the steering difficult to turn?
Yes = Go to H-7 or H-8
• Measure the operating effort and turning
speed, and check the STANDARD VALUE
TABLE to see if they are abnormal.

aft
g sh
• Was there previously any symptom, such as
erin
heavy steering?
ses
whe spool
r ste
Yes = Wear of related equipment, defective
Cau
lve
seal
el o
ring
p va
stee
f sto
ring
n of
o
ion
stee
oll
atio
bit-r
tuat
e of
actu
• Is the tire inflation pressure correct?
e Or
e ac
enc
e
ctiv
ctiv
ctiv
rfer
Defe
Defe
Defe
Inte
Orbit- Stop
roll valve
S/V Others
a b c d
Remedy
No.
Problems × × × ×
1 Steering is heavy when turned in both directions (left and right)
2 Steering is heavy when turned in one direction (left or right)
Steering is heavy even when joint between steering shaft and
3
Orbit-roll is disconnected
4 When steering Oil pressure is low in both directions (left and right)
relief pressure
5 is measured Oil pressure is low in one direction (left or right)
6 When Orbit-roll output pressure is measured, oil pressure is found to be low
H-12 Joystick is heavy [machine with joystick]

Causes and Remedy
• Abnormality of joystick (×)
(The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in
the joystick.)
20-714 WD600-3
(1)
H-13 Steering wheel shakes or jerks

Yes = Go to H-9
• Is there any abnormal noise from around the
steering equipment?

• Is the steering wheel play correct?
• Is there any abnormality in the connection be-
tween the steering shaft and the Orbit-roll?
ses
ool
ol
spo
Cau
d sp
e
valv
ing
lve
man
teer
top
n va
lve
e
of s
of d
a
of s
e Or e valve
ctio
v
seal
e f
ion
ion
ion
oll
y-su
e li
bit-r
r
tuat
ston
tuat
tuat
arg
Defe e safet
a i
e ch
e ac
e ac
e ac
em
e pi
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Charge Orbit- Stop Cylin-
valve roll valve Steering valve der
a b c d e f g h
Remedy
No. ×
Problems × × × × × × ×
1 Steering wheel shakes or jerks in both directions (left and right)
2 Steering wheel shakes or jerks in one direction (left or right)
During operations or when traveling (when steering), steering
3
wheel shakes or jerks in both directions (left and right)

4
wheel shakes or jerks in one direction (left or right)
Steering wheel jerks or there is excessive shock when steering

5
is operated to end of its stroke
6 Work equipment also jerks
Oil pressure is unstable in both directions
7 When steering (left and right)
relief pressure
is measured Oil pressure is unstable in in one direction
8 (left or right)
Oil pressure is unstable in both directions

9 When Orbit-roll (left and right)
output pressure
is measured Oil pressure is unstable in in one direction
10 (left or right)
When PPC value (Orbit-roll) basic pressure is measured,

11
oil pressure is found to be unstable
WD600-3 20-715
(1)
H-14 Steering shakes or there is excessive shock [machine with joystick]

Yes = Go to H-10
• Is there any abnormal noise from around the
steering equipment?

• Is any failure code for the electrical system
displayed on the main monitor?
• Is the steering wheel play correct?
e
valv
• Is there any abnormality in the connection be-
noid
tween the steering shaft and the Orbit-roll?
ses
l
o
on v g spoo
sole
o
Cau
p
e
s
valv
e
and
valv
tick
alve
r i n
dem
joys
top
e
stee
ctor
a l v
of s
e Or e valve
v
n of
i
n of
ucti
o
r
seal
f
rest
relie
ion
tion
oll
atio
s
atio
-
bit-r
ston
tuat
fety
way
arg
ctua
ain
actu
actu
e ch
e sa
e ac
e 2-
e pi
a
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Charge Orbit- Joy- Stop Cylin-
valve roll stick valve
Steering valve Valve
der
a b c d e f g h i j
Remedy
No. × ×
Problems × × × × × × × ×
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Steering wheel shakes or jerks in both directions (left and right)
5 Steering wheel shakes or jerks in one direction (left or right)
6
wheel shakes or jerks in both directions (left and right)

7
wheel shakes or jerks in one direction (left or right)
Steering wheel jerks or there is excessive shock when steering

8
is operated to end of its stroke
9 Confirm recent repair
10 When steering Oil pressure is unstable in both directions (left and right)
relief pressure
11 is measured Oil pressure is unstable in in one direction (left or right)
12 When Orbit-roll Oil pressure is unstable in both directions (left and right)
output pressure
14 When joystick solenoid Oil pressure is unstable in both directions (left and right)
valve output pressure
When PPC valve (Orbit-roll) basic pressure is measured,
16
oil pressure is found to be unstable
H-15 Turning radius is different between left and right at maximum

steering
Causes and Remedy
• Defective adjustment of stop valve (t)
20-716 WD600-3
(1)
H-16 Wheel brakes do not work or braking effect is poor

• Measure the actual brake performance, and
check if there is actually an abnormality or
ator
whether it is just the feeling of the operator.
mul
For details, see TESTING AND ADJUSTING,
accu
Measuring brake performance.
rom
as f
of g
ing
leed
ses
ump
e
ve b
Cau
ton
valv
of p
brak ake pis

i
fect
arge
end
al
r de
e
r ch
v
lve
e
br
l
s
r
ion
e va
e
al o
ston
e
e va
t
f
lato
o
mp
suct
adju
brak
tion
n se
i
u
C pu
p
a
ccum
side
ft br
n at
rake
Brea e actua
k
isto
• Is the brake pedal play correct?
ight
suck TO
c
e sla
e PP
e in
ed i
e le
eP
b
a
• Is there any leakage of oil from the brake tube?
r
e
e
e
e
ctiv
ctiv
ctiv
kag
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Is there any deformation of the tube?
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
• Is the tire inflation pressure and tread pattern
Air
correct? PPC pump Charge Accu- Brake Slack

Wheel brake
valve mulator valve adjuster
a b c d e f g h i j k
Remedy
No. ×
Problems × × × × × × × × ×
1 Brake has no effect only when left brake pedal is depressed
2 Left brake pedal is light when it is depressed
3 Right brake pedal is light when it is depressed
4 Left brake pedal is heavy when it is depressed
5 Right brake pedal is heavy when it is depressed
6 Abnormally large operating force is needed to obtain specified braking force
7 Abnormal noise is heard from brake when brake is applied
8 Work equipment, steering also do not work
9 Movement of work equipment, steering is slow
12 Many metal particles are found in oil drained from axle case
13 When accumulator charge pressure is measured, oil pressure is found to be low
14 Brake stops having effect immediately when engine is stopped
15 There is a time lag before brake takes effect
16 When brake oil pressure is measured, it is found to be low
17 When drop in brake piston pressure is measured, it is found to be excessive
18 When wear of brake disc is measured, it is found to be excessive
19 When air is bled from brake line, air comes out
fl The PPC pump is used for the wheel brake actuation pressure in the same way as for the work
equipment circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the
condition of actuation of the work equipment and steering also (the circuit set pressure is different).
20-718 WD600-3
(1)
×
brake
Wheel
Defe
ctiv
×
Defe e br
ake
WD600-3
l m n
ctiv
Others
Brea e actu
pist
on s
kag atio eal
e in n of
side brak
brak e pi
e ston
TROUBLESHOOTING
(1)
H-16
20-719
H-17 Wheel brakes are not released or brakes drag


• Does the brake pedal come back fully?
• Is the parking brake still applied?
ses
er
ton
Cau
just
, pla ake pis
k ad
e
c
valv
a
ve
br
l
of s
te
e rig ake val
rake ion of
rake
ion
disc
ht b
tuat
t
ft br
a
Seiz ve actu
e ac
e le
ed b
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Brake Slack Wheel

valve adjuster brake
a b c d e
Remedy ×
No.
1 Machine cannot travel at all
2 Machine can travel a small amount
When remaining pressure is released from brake accumulator
3
circuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator

4
circuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows
5
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out
When brake disc wear is measured and brake pedal is
7
released, piston returns
When brake disc wear is measured and brake pedal is

8
released, piston does not return
20-720 WD600-3
(1)
H-18 Parking brake does not work or braking effect is poor

alve
• Is parking brake emergency release switch
se v
on
open? (Normally it is open)
elea
pist
eme d valve
• Is parking brake mechanical release operation
ses
cy r
rake
being carried out?
Cau
rgen
ng b
i
l eno
arki
so
ake
ake
of p
ng
g br
g br
spri
ion
rkin
rkin
disc
tuat
ake
e pa
e pa
e br
e ac
ake
ctiv
ctiv
ctiv
n br
ctiv
Defe
Defe
Defe
Defe
Wor
Parking
SOL Value
brake
a b c d e
Remedy ×
No. × ×
Problems × ×
1 Parking brake does not work when engine is stopped
When parking brake disc wear is measured, disc thickness is
2
found to be less than specified value
There is no oil pressure when parking
When parking brake brake switch is ON (normal)
3 inlet port pressure
is measured There is oil pressure when parking
brake switch is ON
When parking brake There is no oil pressure when parking

solenoid valve brake switch is ON (normal)
4
output pressure There is oil pressure when parking
is measured brake switch is ON
WD600-3 20-721
(1)
H-19 Parking brake is not released or brake drags

(including emergency release system)
• Is there any abnormality in the power train
system?
Yes = Carry out Troubleshooting H-1 – H-3
ed
(Power train hydraulic system)
tuat
ac
een
alve
as b
se v
ke h
elea
eme d valve
ses
l bra
cy r
Cau
hee
rgen
i
leno
or w
late
eal
o
c, p
ch f
s
on s
ake
ake
cy b ake dis
swit
g br
g br
pist
rake
rkin
rkin
br
ake
Eme wheel
e pa
e pa
e br
rgen
ctiv
ctiv
ctiv
ed
Defe
Defe
Defe
Seiz
Parking
SOL Value
brake
Wheel
a b c d e
Remedy × ×
No.
Problems × ×
When emergency release switch is turned ON, parking brake
1
is released (not released with parking brake switch)
When manual method for release of parking brake is carried

2 out, parking brake is released (not released with parking brake
switch or emergency release switch)
3 When parking brake inlet port Oil pressure is normal

pressure is measured (when
4 parking brake switch is operated) Oil pressure is low
5 When parking brake output pressure Oil pressure is normal
is measured (when emergency
6 release switch is operated) Oil pressure is low
When parking brake solenoid valve output pressure is
7
measured, oil pressure is found to be low
When oil pressure in wheel brake piping is measured, oil

8 pressure is found to be less than emergency brake actuation
pressure (3.6 ±0.49 MPa {37 ± 5 kg/cm2})
fl The power train main relief pressure is used for the parking brake release pressure, so if any abnor-
mality is felt in the parking brake release system, check the condition of actuation of the power train
(the emergency release circuit uses the wheel brake circuit pressure).
20-722 WD600-3
(1)
H-20 Blade does not rise

il
• Did the problem suddenly fail to rise?
in o
Yes = Seizure or damage to various units
ined
• Was unusual noise produced?
onta
(Where did it emanate from?)
air c
• Were there previous signs of blade slowing
down ?
t of
oun
Yes = Wear of parts of flattening of spring
e am
ssiv
• Is oil level in hydraulic tank correct?
exce
• Is travel of work equipment lever correct?
e
ses
ool)
valv
l
p or
poo
Cau
ft sp
p
lief
al
pum
nd s
m
valv
n se
en
i
u
in re
l
dy (
of p
l
ema
driv
itch
poo
lief
isto
f ma
e bo
port
of re
w
of d
of s
er p
ing
nd s
on o
valv
e
p PT suction
lind
ion
ion
n
b
lic a
o
ump
not
uati
i
age
tuat
tuat
tuat
t cy
drau
O is
t
PC p
dam
e ac
d lif
e ac
e ac
e ac
e in
age
lty h
ctiv
ctiv
ctiv
kag
lty P
ctiv
rnal
Dam
Pum
Defe
Defe
Defe
Bloc
Defe
Fau
Fau
Inte
Steering PPC Work Cylin-
Tank-pump valve valve
equipment
der
control valve
a b c d e f g h i j
Remedy C
No. × × ×
1 The blade is unable to pitch, tilt, or rise
The machine body can be lifted up by the blade however the
2 blade is unable to rise. Or the blade can tilt however the blade
is unable to rise.
3 The blade can rise under no load but cannot rise under load
4 The hydraulic pump produces an abnormal noise
5 Lift cylinder has large amount of hydraulic drift
When the engine is at full, steering action is light and excessively
6
fast
7 When the engine is at full, steering action is heavy and slow
WD600-3 20-723
(1)
H-21 Blade moves slowly or does not have sufficient lifting power
il
in o
ned
• Seizure of bushing in work equipment link-
ted
ntai
djus
age?
ir co
(Does emits abnormal noise?)
rly a
of a
rope
Fault check
unt
imp
There is strong relationship between faults involv-
amo
ulty
ing lifting force and lifting speed. Such faults
sive
d fa
appear initially in the form of insufficient lifting
xces
speed. Measure the lifting speed of the blade
e an
when loaded and refer to the standard value table
ses
or e
valv
l
dy
poo
to determine whether or not there is a fault.
Cau
mp
e bo
mp
lief
al
nd s
n se
u
l
f pu
f va
n re
ch p
valv
ol
ema
isto
relie
o
o
mai
swit
orn
port
of d
er p
f
f
f
or w
o
o
o
and
ion
lind
tion
tion
ion
ion
suct
ulic
age
tuat
tuat
t cy
ctua
ctua
ydra
dam
d lif
e ac
e ac
e of
a
a
e
e
age
lty h
ctiv
ctiv
ctiv
kag
ctiv
rnal
Dam
Defe
Defe
Defe
Bloc
Defe
Fau
Inte
Tank- Steering PPC Work Cylin-
equipment
pump valve valve control valve der
a b c d e f g h
Remedy C
No. ×
Blade Pitch and tilt force and speed are abnormal and blade
1
lifting speed is low
Blade Pitch and tilt force and speed are normal but blade
2
lifting speed is slow
Same as item 1 except that work equipment linkage lifting

3
speed becomes particularly low when oil temperature rises
4 Hydraulic pump emits abnormal noise
5 When the engine is at full, steering action is light and excessively

fast
6 When the engine is at full, steering action is heavy and slow
7 Cylinder has a large amount of hydraulic drift
8 The relief pressure of relief valve of work equipment control

valve
20-724 WD600-3
(1)
TROUBLESHOOTING H-22, H23, H-24
H-22 Blade becomes slow at certain height when raising

• External deformation of lift cylinder
Cause
• Swollen or internally damaged lift cylinder tube
fl Regarding other faults occurring during blade rise, refer to item "H-21 Blade moves slowly or does
not have sufficient lifting power"
H-23 Lift cylinder cannot hold down blade

Refer to item "H-21 Blade moves slowly or does not have sufficient lifting power".

Cause
• Defective lift cylinder rod side suction valve seat of work equipment control valve
• Oil leakage from lift cylinder piston seal
H-24 Blade has large amount of hydraulic drift

• Did the hydraulic drift suddenly become large?
Yes = Dit lodged in valve or spool in the position
• Did the hydraulic drift gradually become large?
Yes = worn parts
Troubleshooting and cause

• When measuring hydraulic drift, internal leakage of lift cylinder makes oil leakage noise.
= Damaged cylinder packing
• When measuring hydraulic drift, lift cylinder does not make oil leakage noise.
= Defective oil sealing of blade lift spool
= Defective check valve between pipings
WD600-3 20-725
(1)
H-25 Blade fluctuates while working

During excavation or ground leveling when the work equipment lever is in the "HOLD" position, the
blade moves up and down in accordance with the terrain.
Troubleshooting and cause

Check the amount of hydraulic drift and whether or not can be lifted up bjy the lift cylinder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item "H-24 Blade has large
amount of hydraulic drift".
2. If the machine body can not be lifted up by the lift cylinder, refer to item "H-23 Lift cylinder cannot
hold down blade".
3. If amount of hydraulic drift is normal and the machine body can be lifted up by the lift cylinder after
the blade is moved several times to cause the lift cylinder to move through its entire stroke.
= The trouble is due to the generation of a vacuum in the cylinder,
fl If a vacuum is generated frequently = defective suction valve on lift cylinder rod side
H-26 Blade drops momentarily when lever is operated from HOLD to

RAISE
The blade drops momentarily under the own weight when the work equipment lever is gradually shifted
from the "HOLD" position to the "RAISE" position while the engine is at low idling. When the work
equipment lever is put completely into the "RAISE" position, the blade moves normally.
Cause
• Defective seating of work equipment control valve or blade spool check valve
20-726 WD600-3
(1)
H-27 Blade does not tilt

il
in o
• Did the blade suddenly cease to move?
ned
Yes = Seized or damaged equipment
• Was any abnormal noise emitted?
ntai
(Where did it emanate from?)
ir co
• Were there previous signs of the blade slow-
of a
ing down?
unt
Yes = Wear parts or flattening of spring
amo
sive
Check before troubleshooting
• Is travel of the work equipment lever correct?
xces
ol)
ump
lve
ses
or e
o
l
poo
f va
lt sp
Cau
ng p
mp
al
relie
nd s
valv
y (ti
n se
en
f pu
eeri
bod
driv
ain
lief
isto
m
o
d st
f de
of m
port
of re
er p
lve
eing
n
lic a
d va
mp
p PT suction
lind
ion
n
ion
ot b
o
drau
C pu
i
age
tuat
tuat
tuat
t cy
ool
n
O is
e hy
dam
e PP
e sp
d til
e ac
e ac
e ac
e in
age
ctiv
ctiv
ctiv
ctiv
ctiv
kag
ctiv
rnal
Defe
Dam
Pum
Defe
Defe
Defe
Defe
Bloc
Defe
Inte
Steering PPC Work Cylin-
Tank-pump valve valve
equipment
der
control valve
a b c d e f g h i j
Remedy C
No. × A
× ×
1 Blade cannot be operated and unable to tilt
The machine body can be lifted up by the blade however the
2 blade is unable to tilt. Or the blade can rise but the blade
is unable to tilt.
3 The hydraulic pump produces an abnormal noise
4 Tilt cylinder has large hydraulic drift
Steering action is light and excessively fast when the engine is at
5
full
6 Steering action is heavy and slow when the engine is at full
WD600-3 20-727
(1)
H-28 Blade moves slowly or has insufficient tilt power

il
in o
• Is the travel of work equipment lever correct?
er
ned
• Seizure of bushing in work equipment link-
lind
age?
ntai
t cy
(Does emits abnormal noise?)
ed
ir co
e til
just
of t h
of a
e bo h suctio ectly ad
Fault check
unt
lve)
• Check deficient tilt force by performing actual
amo
n va
corr
work.
ool)
sive
• Measure the operating speed of the blade and
d in
lt sp
check it against the standard value table to
xces
e an
y (ti
determine whether or not it is normal.
(wit
ses
or e
valv
d
l
poo
Cau
ama y valve
mp
mp
lief
al
nd s
n se
valv
u
l
f va
f pu
n re
ch p
ol
ema
afet
isto
relie
e
o
spo
mai
swit
g
port
of d
of s
er p
f
f
f
o
o
o
and
ion
or d
lind
tion
ion
tion
tion
ion
suct
ulic
tuat
tuat
t cy
ctua
ctua
ctua
orn
ydra
d til
e ac
e ac
e in
ly w
a
a
a
e
e
e
age
lty h
ctiv
ctiv
ctiv
ctiv
kag
ctiv
rnal
Dam
Defe
Defe
Defe
Defe
Bloc
Defe
Fau
Inte
Tank- Steering PPC Main control Cylin-
pump valve valve valve der
a b c d e f g h i
Remedy C A
No. × ×
Blade lifting force and lifting speed are abnormal and also blade
1
tilt force and tilt speed are abnormal
Blade lifting force and lifting speed are normal but blade tilt
2
force and tilt speed are abnormal
Phenomena of item 1 become particularly bad when the oil

3
temperature increases
4 The hydraulic pump emits an abnormal noise
5 Steering action is light and excessively fast when the engine is

at full
6 Steering action is heavy and slow when the engine is at full
7 The tilt cylinder has a large amount of hydraulic drift
8 The relief pressure of relief valve of work equipment control

valve is also low
9 The discharge volume of the hydraulic pump is low
20-728 WD600-3
(1)
H-29 Blade does not pitch

If the blade cannot be pitched or tilted when the work equipment lever is operated (while pressing the
switch at the top of the lever), go to "H-27 Blade does not tilt".
If the blade can be tilted, but does not pitch, the possible causes are as follows.
• Defective operation of tilt or pitch switch at top of lever.
• Defective operation of solenoid valve of deco valve.
H-30 Blade pitch movement is slow or lacks power

If bothe the blade tilt and blade pitch movement is slow or lacks power, go to "H-28 Blade moves slowly
or has insufficient tilt power".
If there is no abnormality in the tilt operation, and only the pitch operation is abnormal, the possible
causes are as follows.
• Defective operation of solenoid valve of dico valve.
• Defective operation of selector valve of deco valve.
• Solenoid valve of deco valve clogged.
WD600-3 20-729
(1)
H-31 Work equipment lever does not move smoothly

Fault check
s
bolt
ool
Using the standard value table, check whether or
d sp
ting
not the operating effort of the lever is large.
y an
oun
e sp ool
lve m
bod
sp
ool
d
lve
f va
y an
ool
l va
ool
ng o
valv
e sp
bod
o
d sp
r
teni
t
v
trol
n
alve
l
o
a
y an
link
c
rol v
tigh
con
t
l
ol v
poo
n
bod
e
s of
form
ent
ipm
n
men ol
r
nd s
t
o
n
s po
part
alve
ipm
ses
o
equ
-uni
c
dy a
e
t
alve
equ
PC v
Cau
n
ting
valv
non
k
e
r
e bo
uipm
quip
o
ol v
rota
ork
P
o
C
n
n
n PP
valv
rk e
nw
due
wee
ontr
k eq
e
f
e
o
etw
o
ed i
ad i
ver
PPC
y
t
nt c
wor
w
e
d
ol
ce b
ce b
o
t of
ol le
odg
odg
spo
t wo f valve b
e
f
f
m
o
o
aran
eten
aran
quip
ter l
ter l
ontr
s
lve
nes
nes
of d
t cle
C va
t cle
mat
mat
of c
rk e
no
und
und
rrec
ortio
rrec
king
t PP
ign
ign
ure
r ro
r ro
Fore
Inco
Fore
Seiz
Inco
Ben
Poo
Stic
Dist
Ben
Poo
Lever Work equipment
PPC valve control valve
a b c d e f g h i j k
Remedy C C
No. × × × × ×
1 Movement of work equipment lever becomes sluggish when
load is applied and oil pressure increase
Movement of work equipment lever becomes sluggish along
2
with change in oil temperature
Movement of work equipment lever becomes partially sluggish
3
irrespective of oil pressure and temperature
Movement of work equipment lever becomes generally sluggish

4
irrespective of oil pressure and temperature
Movement of work equipment lever does not become light even

5 when the link of the control lever is disconnected at the valve
connection part and the lever operated
20-730 WD600-3
(1)
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM (T MODE)
(ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT
CONTROL)
Method of displaying action code and failure code ...........................................................................20-802

Judgement table for transmission control system .............................................................................20-803
Action taken by controller when abnormality occurs, and problems on machine .........................20-804
Electrical circuit diagram for transmission control system ...............................................................20-808
T- 1 Failure code [10] (Short circuit, disconnection, or short circuit with power supply in
lock-up solenoid) is displayed ..................................................................................................20-810
T- 2 Failure code [12] (Short circuit, disconnection, or short circuit with power supply in F
solenoid) is displayed ................................................................................................................20-811
T- 3 Failure code [13] (Short circuit, disconnection, or short circuit with power supply in R
T- 4 Failure code [14] (Short circuit, disconnection, or short circuit with power supply in 1st
T- 5 Failure code [15] (Short circuit, disconnection, or short circuit with power supply in 2nd
T- 6 Failure code [16] (Short circuit, disconnection, or short circuit with power supply in 3rd
T- 7 Failure code [17] (Short circuit, disconnection, or short circuit with power supply in 4th
T- 8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is
displayed ..................................................................................................................................20-817
T- 9 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed ..................................................................................................................................20-818
T-10 Failure code [21] (Short circuit, disconnection in shift switch system) is displayed ......... 20-822
T-11 Failure code [22] (Disconnection in travel speed sensor system) is displayed ..................20-825
T-12 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed ..................................................................................................................................20-826
T-13 When hold switch is pressed, gear speed is not fixed or reset
Shift up does not work .............................................................................................................20-827
T-14 Kick-down does not work
Shift down does not work ........................................................................................................20-827
T-15 Transmission cutoff does not work or stays working ...........................................................20-828
T-16 Neutralizer does not work or stays working ..........................................................................20-829
T-17 Buzzer does not work ................................................................................................................20-830
T-18 Abnormality in network system ...............................................................................................20-831
T-19 Abnormality in transmission controller power supply ..........................................................20-832
T-20 Short circuit in travel speed sensor system ...........................................................................20-833
T-21 Abnormality in machine selection wiring harness ................................................................20-834
WD600-3 20-801
(1)
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING ACTION

CODE AND FAILURE CODE
1. Outline
The speedkometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit.
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are two types of action code: E00 + CALL
and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer dis-
play.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which
controller has failed, so carry out troubleshoot-
ing for the applicable controller.
4. Saving failure code

The transmission controller writes the failure
codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as fol-
lows: (1) Failure code
(2) Time elapsed since failure
(up to 1000 hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not saved.
4) If there are already 9 items in memory, and
a 10th failure occurs, the oldest item is de-
leted and the new item is saved.
fl It is possible to display the failure code and
time elapsed since failure for items saved in
memory by operating the main monitor set
switch.
20-802 WD600-3
(1)
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM
Self-diagnostic display (abnormality display)
Short circuit, disconnection in joystick directional switch system
Short circuit, disconnection in engine speed sensor system

Short circuit, disconnection in directional switch system
Abnormality in network signal system or main monitor

Abnormality in transmission cut-off signal system
Short circuit, disconnection in shift switch system
Short circuit, disconnection in lock-up solenoid
Abnormality in kickdown switch signal system

Disconnection in travel speed sensor system
Short circuit, disconnection in 2nd solenoid
Short circuit, disconnection in 3rd solenoid
Short circuit, disconnection in 4th solenoid
Abnormality in alarm buzzer signal system

Short circuit, disconnection in 1st solenoid
Short circuit, disconnection in R solenoid
Short circuit, disconnection in F solenoid
Abnormality in neutralizer signal system

Location of failure
Trouble-
Abnormality in network signal system

shooting
code when
no abnor-
mality
display is
given
Failure
code
Failure mode
10 12 13 14 15 16 17 19 20 21 22 23 — — — — — —
1 Travel is impossible c c c c c c t t t E-1, H-1
2 Directional lever and direction of travel are c

different
3 Machine travels forward when directional c c

lever is not at F
4 Machine travels in reverse when directional c c

lever is not at R.
5 There is excessive gearshifting shock c c H-2, H-3
6 There is shift hunting when traveling c
7 There is shift hunting when shifting gear c
8 Speed range cannot be controlled with speed
control lever c
9 Kickdown does not work c T-14, E-7

10 Transmission is not cut off with left brake c T-15
11 It is possible to travel even when parking
brake is applied c T-16, E-3
12 If F-R lever is operated when traveling at high

speed, alarm buzzer does not sound c T-17
13 Alarm buzzer continues to sound c T-17, J-1

14 Main monitor does not display transmission control-
ler information (alarm buzzer, failure code, etc.) c T-18
Troubleshooting code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T-6 T-7 T-8 T-9 T-10 T-11 T-12 — — — — — —
WD600-3 20-803
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS, AND PROBLEMS ON MACHINE

OCCURS, AND PROBLEMS ON MACHINE
(1) TRANSMISSION CONTROLLER SYSTEM
Failure code Abnormal system Nature of abnormality
1) Defective lock-up solenoid

2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Abnormality in transmission & joystick controller C1A (female) (8) – C1 (female) (8)
10
lock-up solenoid – T06 (1)
3) Defective contact or disconnection in wiring harness between lock-
up solenoid T06 (female) (2) and chassis ground
4) Defective transmission & joystick controller
1) Defective F solenoid
Abnormality in F transmission & joystick controller C1A (female) (8) – C1 (female) (2)
12
solenoid system – TL1 (5) – T01 (D)
3) Short circuit with chassis ground, defective contact, disconnection
in wiring harness between chassis – TL1 (7) – T01 (A)
1) Defective R solenoid
13 Abnormality in R transmission & joystick controller C1A (female) (9) – C1 (female) (9)
solenoid system – TL1 (6) – T01 (C)
in wiring harness between chassis – TL1 (7) – T01 (A)
1) Defective 1st solenoid
Abnormality in 1st transmission & joystick controller C1A (female) (3) – C1 (female) (3)
14
solenoid system – TL1 (1) – T01 (H)
in wiring harness between chassis – TL1 (7) – T01 (B)
1) Defective 2nd solenoid
Abnormality in 2nd transmission & joystick controller C1A (frmale) (10) – C1 (female)
15
solenoid system (10) – TL1 (2) – T01 (G)
in wiring harness between chassis–TL1 (7)–T01 (B)
1) Defective 3rd solenoid
16 Abnormality in 3rd transmission & joystick controller C1A (female) (5) – C1 (female) (5)
solenoid system – TL1 (3) – T01 (F)
4) Defective transmission controller
1) Defective 4th solenoid
17 Abnormality in 4th transmission & joystick controller C1A (female) (11) – C1 (female)
solenoid system (11) – TL1 (4) – T01 (E)
4) Defective transmission controller
20-804 WD600-3
(1)
Condition when normal Action by controller Problem that appears Trouble-

when abnormality is on machine when shooting
(voltage, current, resistance) detected there is abnormality code
1) Resistance between transmission & joystick None in particular Lock-up system does
controller C1A (8) and chassis ground: 5 – 15 Ω not work or it keeps
2) Voltage between transmission & joystick operating
controller C1A (8) and chassis ground when T-1
lock-up system is turned OFF: Max. 1 V
1) Resistance between transmission & joystick Neutral It is impossible to

controller C1A (female) (2) and chassis ground: (F, R, 1st, 2nd, 3rd, 4th travel
5 – 15 Ω solenoid output: off)
2) Voltage between transmission & joystick
controller C1A (2) and chassis ground at T-2
neutral: Less than 1 V

controller C1A (9) and chassis ground at
T-3


controller C1A (female) (10) and chassis (F, R, 1st, 2nd, 3rd, 4th travel
ground: 5 – 15 Ω solenoid output: off)
2) Voltage between transmission & joystick T-5


controller C1A (female) (11) and chassis (F, R, 1st, 2nd, 3rd, 4th travel
ground: 5 – 15 Ω solenoid output: off)
T-7
WD600-3 20-805
(1)
Failure code Abnormal system Nature of abnormality
1) Defective joystick directional lever F, N, R switch

2) Disconnection between joystick directional lever connector JS1 (8)
and chassis ground
When the wiring harness is in any of the following conditions with
the switch not pressed
3) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5A (female) (8) – C5 (female) (8)
– JS1 (2) – joystick lever connector (4)
or short circuit with chassis ground in wiring harness between
C5A (female) (16) –C5 (female) (16) – JS1 (3) – joystick lever connector
Abnormality in (3)
19 4) Defective contact or disconnection in wiring harness between
joystick directional transmission & joystick controller C5A (female) (7) –C5 (female) (7)
switch – JS1 (4) – joystick lever connector (4)
or short circuit with chassis ground in wiring harness between
C5A (female) (15) –C5 (female) (15) – JS1 (5) – joystick lever connector
(5)
transmission & joystick controller C5A (female) (9) –C5 (female) (9)
– JS1 (6) – joystick lever connector (6)
or short circuit with chassis ground in wiring harness between C5A
(female) (17) –C5 (female) (17) – JS1 (7) – joystick lever connector
(7)
1) Defective directional lever

2) Defective combination switch power source
Abnormality in Short circuit with power source, short circuit with chassis ground,
20 directional switch defective contact, disconnection in the following wiring harness
signal system 3) Wiring harness between transmission & joystick controller C3B
(female) (5) and L04 (2)
4) Wiring harness between transmission & joystick controller C3B
1) Defective directional lever

2) Defective combination switch power source
Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in the following wiring harness
Abnormality in shift 3) Wiring harness between transmission & joystick controller C3B
21 switch signal (female) (7) and L04 (5)
system (female) (15) and L04 (6)
1) Defective speed sensor

2) Defective adjustment of speed sensor mount
Disconnection in transmission & joystick controller C5A (female) (2) – C5 (female) (2)
22 – TL1 (11) – T05 (1)
speed sensor 4) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5A (female) (10) – C5 (female)
(10) – TL1 (12) – T05 (2)
1) Defective engine speed sensor

2) Defective adjustment of engine speed sensor mount
Abnormality in transmission & joystick controller C4 (female) (2) – E06 (1)
23 4) Defective contact or disconnection in wiring harness between
engine speed transmission & joystick controller C4 (female) (9) – E06 (2)
sensor system 5) Defective transmission & joystick controller
20-806 WD600-3
(1)

1) Resistance between joystick directional lever Neutral Cannot travel in
connector (8) and chassis ground: Less than 1 Ω (F, R, 1st, 2nd, 3rd joystick mode (possible
The following conditions are when the switch is solenoid output: off) in steering wheel
not pressed mode)
2) Resistance between transmission & joystick
controller C5A (female) (8) and chassis ground:
Less than 1 Ω
Less than 1 Ω
and resistance between C5A (female) (15) and
chassis ground: Min. 1 MΩ T-8
Less than 1 Ω
and resistance between C5A (female) (17) and
chassis ground: Min. 1 MΩ
1) Voltage between combination switch L04 (1) • Shifts to neutral It is impossible to

and chassis ground: 20 – 30 V immediately when travel
2) Voltage for only 1 system in accordance with short circuit with
position of directional lever: 20 – 30 V (Others: power supply is T-9
Less than 1 V) detected
F: Between transmission & joystick controller • When there is no
C3B (5) – chassis ground signal
N: Between transmission & joystick controller (disconnection),
C3B (13) – chassis ground holds previous signal
R: Between transmission & joystick controller condition for 2
C3B (6) – chassis ground seconds
1) Voltage between combination switch L04 (1) • If 2 signals are input, 1) Auto-shift limit is
and chassis ground: 20 – 30 V it judges speed range different from
2) Voltage for only 1 system in accordance with position in order of range position
position of range lever: 20 – 30 V (Others: Less priority 4←3←2←1 selected by
than 1 V) • When there is no operator (OP)
1st: Between transmission & joystick controller signal 2) Impossible to shift T-10
C3B (7) – chassis ground (disconnection), gear in manual
2nd: Between transmission & joystick controller holds previous signal mode
C3B (15) – chassis ground condition (speed
3rd: Between transmission & joystick controller range position)
C3B (8) – chassis ground
4th: Between transmission & joystick controller
C3B (16) – chassis ground
1) Resistance between travel speed sensor T05 1) Switches to manual 1) Does not carry out
(1) and (2): 500 – 1,000 Ω mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick 2) Shifts gear 2) Switches to
controller C5A (female) (2) and (10): Min. 0.5 V according to manual shift
operation of range T-11
lever
1) Resistance between engine speed sensor E06 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 Ω mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick 2) Shifts gear 2) Switches to
controller C4 (female) (2) and (9) according to manual shift
operation of range T-12
lever
WD600-3 20-807
(1)
TROUBLESHOOTING CONTROL SYSTEM

CONTROL SYSTEM
20-808 WD600-3
(1)
TROUBLESHOOTING CONTROL SYSTEM
WD600-3 20-809
(1)
TROUBLESHOOTING T-1
T-1 Failure code [10] (Short circuit, disconnection, or short circuit with
power supply in lock-up solenoid) is displayed
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the failure code is no longer displayed on the monitor display, the
problem has been removed.
fl Check that the lock-up indicator is flashing.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T06
(female) (2) and Defective contact or
3 chassis ground disconnection in wiring
Is resistance normal? harness between T06 Repair or
(female) (2) and chassis replace
YES between C1A • Max. 1 Ω NO ground
(female) (8) and
2 normal? switch OFF. Short circuit with chassis
Is resistance • Disconnect T06. ground or another part in
YES between C1A
• Min. 1 MΩ harness between C1A Repair or
(female) (8) and T01
• Turn starting NO (female) (8) and T06 replace
1 (female) (1) normal? switch OFF. (female) (1)
• Disconnect C1A
Is resistance between
T06 (male) (1) and (2)
• Max. 1 Ω and T06. Defective contact or
Repair or
• Turn starting disconnection in wiring
and between (1), (2) harness between C1A replace
and chassis ground switch OFF. NO
normal? • Disconnect C1A (female) (1)
• Between (1) and and T06.
(2): 5 – 15 Ω Defective lock-up
Replace
• Between (1), (2) NO solenoid
and chassis ground: Min. 1 MΩ
• Disconnect T06. Defective transmission &
5 YES
Is voltage between controller
C1A (female) (8)
From A and chassis ground
Short circuit with power
normal?
supply in wiring harness Repair or
• Turn starting NO between C1A (female) (8) replace
switch ON. and T06 (female) (1)
• Disconnect C1A
and T06.
• Max. 1 V
T-1 Related electrical circuit diagram
20-810 WD600-3
(1)
TROUBLESHOOTING T-2
power supply in F solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (1) and disconnection in wiring
3 chassis ground
harness between T01 Repair or
Is resistance normal?
(female) (A) and chassis replace
YES between C1A • Max. 1 Ω NO
(female) (2) and ground
Is resistance
• Min. 1 MΩ • Disconnect T01. ground or another part in
Repair or
YES between C1A harness between C1A
(female) (2) and T01 • Turn starting NO (female) (2) and T01
replace
(female) (D) switch OFF.
1 normal? (female) (D)
• Disconnect C1A
T01 (male) (D) and
Repair or
(A) and between (D), • Turn starting disconnection in wiring
replace
(A) and chassis switch OFF. NO harness between C1A
ground normal? • Disconnect C1A (female) (2) and T01
• Between (D) and and T01. (female) (D)
(A): 5 – 15 Ω Defective F solenoid Replace
• Between (D), (A) NO
• Disconnect T01. Defective transmission &
5 YES
C1A (female) (2)
normal?
switch ON. and T01 (female) (D)
• Disconnect C1A
and T01.
• Max. 1 V
WD600-3 20-811
(1)
TROUBLESHOOTING T-3
power supply in R solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
(female) (A) and
3 chassis ground
YES between C1A • Max. 1 Ω (female) (A) and chassis replace
(female) (9) and
NO
• Turn starting ground
2 chassis ground
normal? switch OFF. Short circuit with chassis
Is resistance • Min. 1 MΩ • Disconnect T01. ground or another part in
Repair or
YES between C1A harness between C1A
• Turn starting NO replace
1 (female) (C) normal? switch OFF.
(female) (C)
• Disconnect C1A
T01 (male) (A) and (C)
Repair or
and between (A), (C) • Turn starting disconnection in wiring
replace
and chassis ground switch OFF. NO harness between C1A
normal? • Disconnect C1A (female) (9) and T01
• Between (A) and and T01. (female) (C)
(C): 5 – 15 Ω Defective R solenoid Replace
• Between (A), (C) NO
and chassis ground: Min. 1
MΩ
• Turn starting switch OFF. 5 YES Defective transmission &
• Disconnect T01. joystick steering Replace
C1A (female) (9)
From A and chassis ground Short circuit with power
• Max. 1 V NO between C1A (female) (9) replace
• Turn starting and T01 (female) (C)
switch ON.
• Disconnect C1A
and T01.
20-812 WD600-3
(1)
TROUBLESHOOTING T-4
power supply in 1st solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
(female) (B) and disconnection in wiring
3 chassis ground harness between T01
(female) (B) and chassis
YES between C1A • Max. 1 Ω NO ground replace
(female) (3) and
YES between C1A • Min. 1 MΩ harness between C1A Repair or
(female) (3) and T01 • Turn starting NO (female) (3) and T01 replace
(female) (H) switch OFF. (female) (H)
1 normal? • Disconnect C1A,
T01 (male) (B) and (H)
• Max. 1 Ω T01 and L05. Defective contact or
Repair or
and between (B), (H) • Turn starting disconnection in wiring
replace
(female) (H)
• Between (B) and and T01.
(H): 5 – 15 Ω Defective 1st solenoid Replace
• Between (B), (H) NO
• Disconnect T01. 5 YES Defective transmission &
C1A (female) (3)
From A and chassis
ground normal?
source in wiring harness Repair or
• Turn starting and T01 (female) (H)
switch ON.
• Disconnect C1A,
T01 and L05.
WD600-3 20-813
(1)
TROUBLESHOOTING T-5
power supply in 2nd solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
(female) (B) and disconnection in wiring
3 chassis ground
normal?
harness between T01
Is resistance
(female) (B) and chassis Repair or
YES between C1A
(female) (10) and
• Max. 1 Ω NO ground
replace
2 switch OFF. Short circuit with chassis
normal?
YES between C1A • Min. 1 MΩ harness between C1A Repair or
(female) (10) and • Turn starting NO (female) (10) and T01
replace
T01 (female) (G) switch OFF.
1 normal? (female) (G)
• Disconnect C1A,
T01 (male) (B) and (G)
• Max. 1 Ω T01 and L05. Defective contact or
Repair or
and between (B), (G) • Turn starting disconnection in wiring replace
• Between (B) and and T01. (female) (G)
(G): 5 – 15 Ω Defective 2nd solenoid Replace
• Between (B), (G) NO
C1A (female) (10)
From A and chassis ground Short circuit with power
normal? supply in wiring harness Repair or
• Max. 1 V NO between C1A (female) replace
• Turn starting (10) and T01 (female) (G)
switch ON.
• Disconnect C1A,
T01 and L05.
20-814 WD600-3
(1)
TROUBLESHOOTING T-6
power supply in 3rd solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
(female) (B) and
YES between C1A • Max. 1 Ω (female) (B) and chassis replace
(female) (5) and
NO
2 chassis ground
Is resistance
• Min. 1 MΩ • Disconnect T01. ground in harness Repair or
YES between C1A
switch OFF. and T01 (female) (F)
1 (female) (F) normal?
• Disconnect C1A, Defective contact or
Is resistance between • Max. 1 Ω T01 and L05. Repair or
T01 (male) (B) and (F)
and between (B), (F) harness between C1A replace
(female) (F)
(F): 5 – 15 Ω Defective 3rd solenoid Replace
• Between (B), (F) NO
C1A (female) (5)
normal?
• Turn starting and T01 (female) (F)
switch ON.
• Disconnect C1A,
T01 and L05.
WD600-3 20-815
(1)
TROUBLESHOOTING T-7
power supply in 4th solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
(female) (B) and
YES between C1A • Max. 1 Ω (female) (B) and chassis replace
(female) (11) and
NO
2 chassis ground
Is resistance
• Min. 1 MΩ • Disconnect T01. ground in harness Repair or
YES between C1A
(female) (11) and • Turn starting NO between C1A (female) replace
T01 (female) (E) switch OFF. (11) and T01 (female) (E)
1 normal? • Disconnect C1A, Defective contact or
Is resistance between • Max. 1 Ω T01 and L05. Repair or
T01 (male) (B) and (E)
and between (B), (E) harness between C1A replace
(female) (E)
(E): 5 – 15 Ω Defective 3rd solenoid Replace
• Between (B), (E) NO
C1A (female) (11)
normal?
• Max. 1 V NO between C1A (female) replace
• Turn starting (11) and T01 (female) (E)
switch ON.
• Disconnect C1A,
T01 and L05.
20-816 WD600-3
(1)
TROUBLESHOOTING T-8
T-8 Failure code [19] (Short circuit, or disconnection in joystick

directional switch system) is displayed
Cause Remedy

4 YES joystick steering
controller Replace
Is voltage between
YES C5A (female) (7), Short circuit, short circuit
(8), (9), (15), (16), with chassis ground,
3 (17) and chassis as defective contact, or
Is resistance shown in table 1? disconnection in wiring
harness between JS1
Repair or
YES between JS1 • Turn starting NO (female) (2), (3), (4), (5), (7) replace
(female) (8) – switch ON and C5A (female) (7), (8), (9),
2 chassis normal? (15), (16), (17)
Is voltage Defective contact or
YES between JS1 (1) • Max. 1 Ω Repair or
• Turn starting NO harness between JS1
replace
and chassis
switch OFF. (female) (8) and chassis
1 normal?
• Disconnect JS1. Short circuit, short circuit
Is voltage between • 20 – 30 V with chassis ground, Repair or
JS1 (8) and (2), (3), • Turn starting defective contact, or replace
(4), (5), (6), (7) as switch ON. NO
shown in Table 1? harness between C3A
(male) (6) and chassis
• Turn starting
switch ON. Defective joystick lever Replace
NO
Table 1 Voltage on each position of joystick lever

Position
F N R
Terminal
JS1 (male) (8) – (2) Between C5A (8) and chassis 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (8) – (3) Between C5A (16) and chassis Max. 1 V 20 – 30 V 20 – 30 V
JS1 (male) (8) – (4) Between C5A (7) and chassis Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (8) – (5) Between C5A (15) and chassis 20 – 30 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (6) Between C5A (9) and chassis Max. 1 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (7) Between C5A (17) and chassis 20 – 30 V 20 – 30 V Max. 1 V
WD600-3 20-817
(1)
TROUBLESHOOTING T-9
T-9 Failure code [20] (Short circuit, or disconnection in directional

switch system) is displayed
YES
6
YES C3B (female) (6) and
chassis ground and
between C3B (female)
5 (6) and (13) normal
Is voltage • Min. 1 MΩ
YES between C3B (5) • Disconnect L04,
and chassis C3B and L08. NO
4 ground normal? • Turn starting
Is resistance between • 20 – 30 V switch OFF.
YES C3B (female) (5) and • Turn starting
chassis ground and
between C3B (female) switch ON. NO
3 (5) and (6), (13) normal? • Set directional
Is resistance • Min. 1 MΩ lever to F.
YES between L04 • Disconnect L04,
(female) (10) and
chassis ground C3B and L08. NO
2 normal? • Turn starting
Is voltage between • Max. 1 Ω switch OFF.
YES L04 (female) (1) • Turn starting
and chassis switch OFF. NO
between L04 • Turn starting
(female) (1) and
switch ON.
chassis ground NO
normal?
• Min. 1 MΩ
• Disconnect FS2
and L04. NO
• Turn starting
switch OFF.
20-818 WD600-3
(1)
TROUBLESHOOTING T-9
Cause Remedy

10 YES joystick steering
Replace
YES L04 (2), (3), (4) and
9 chassis ground as
Is voltage shown in Table 1? Defective directional Repair or
YES between C3B (13) switch replace
and chassis switch ON. Defective contact or
8 ground normal? disconnection in wiring
Is resistance
YES between C3B • 20 – 30 V
(female) (3) and C3B (female)
(female) (13) and • Turn starting NO replace
(13), or defective lever
chassis ground switch ON.
7 normal? Short circuit with chassis
• Set directional
Is voltage ground in harness between
• Min. 1 MΩ lever to N. L04 (female) (3) and C3B
between C3B (6) Repair or
• Disconnect L04, (female) (13)
and chassis NO replace
C3B and L08. Defective contact or
ground normal? • Turn starting disconnection in wiring
• 20 – 30 V switch OFF. harness between L04
(female) (4) and C3B (female) Repair or
• Turn starting (6), or defective lever
switch ON. NO replace
Short circuit with chassis ground
• Set directional in harness between L04 (female)
lever to R. (4) and C3B (female) (6), or short
circuit of harness between L04 Repair or
(female) (4) and C3B (female) (6)
and harness between L04 replace
(13) with each other
Defective contact or Repair or
disconnection in wiring replace
harness between L04
Short circuit with chassis ground in
harness between L04 (female) (2) Repair or
and C3B (female) (5), or short circuit
of harness between L04 (female) (2) replace
and C3B (female) (5) and harness
between L04 (female) (3) and C3B
(female) (13) with each other
harness between fuse I (9)
(female) (10) and chassis
ground
ground in harness Repair or
between FS2 (female) (8) replace
Table 1
Directional lever position
F N R
Terminal
Between L04 (2) – chassis 20 – 30 V Max. 1 V Max. 1 V
Between L04 (3) – chassis Max. 1 V 20 – 30 V Max. 1 V
Between L04 (4) – chassis Max. 1 V Max. 1 V 20 – 30 V
WD600-3 20-819
(1)
TROUBLESHOOTING T-9
20-820 WD600-3
(1)
TROUBLESHOOTING T-10
T-10Failure code [21] (Short circuit, or disconnection in shift switch

system) is displayed
Table 1
Directional lever position
1st 2nd 3rd 4th
Terminal
Between L04 (5) – chassis 20 – 30 V Max. 1 V Max. 1 V Max. 1 V
Between L04 (6) – chassis Max. 1 V 20 – 30 V Max. 1 V Max. 1 V
Between L04 (7) – chassis Max. 1 V Max. 1 V 20 – 30 V Max. 1 V
Between L04 (8) – chassis Max. 1 V Max. 1 V Max. 1 V 20 – 30 V YES
6
YES C3B (female) (8) –
chassis and between
C3B (female) (8) –
5 (15), (16) normal?
Is voltage • Min. 1 MΩ
YES between C3B (7) • Disconnect L04,
and chassis C3B. NO
Is resistance between • 20 – 30 V switch OFF.
YES C3B (female) (7) – • Turn starting
chassis and between
C3B (female) (7) – (8), switch ON. NO
3 (15), (16) normal? • Set speed control
Is resistance
• Min. 1 MΩ lever to 1st.
YES between L04
• Disconnect L04,
(female) (10) and
chassis ground C3B. NO
Is voltage • Max. 1 Ω switch OFF.
YES between L04 (1) • Turn starting
and chassis switch OFF. NO
between L04 • Turn starting
(female) (1) and
switch ON.
chassis ground NO
normal?
• Min. 1 MΩ
• Disconnect FS2,
L04. NO
• Turn starting
switch OFF.
20-822 WD600-3
(1)
Cause Remedy
12 YES Defective transmission &

YES L04 (5), (6), (7) and
11 chassis ground as
Is voltage shown in Table 1? Repair or
Defective lever
between C3B (16) • Turn starting NO replace
From A
and chassis switch ON.
normal? Defective contact or
• 20 – 30 V harness between L04
Repair or
• Turn starting NO (female) (8) and C3B (female) replace
switch ON. (16), or defective lever
• Set directional
lever to 2nd. 10 YES
Go to A Replace
Is resistance
YES between C3B
9 (female) (16) and Short circuit to chassis
chassis normal? ground between L04 Repair or
Is voltage (female) (8) and C3B (female)
YES between C3B (15) • Min. 1 MΩ NO (16) replace
and chassis • Disconnect L04, C3B. Defective contact or
8
normal? • Turn starting disconnection in wiring
Is resistance harness between L04
between C3B • 20 – 30 V switch OFF. (female) (6) and C3B (female) Repair or
YES (15), or defective lever
(female) (15) and • Turn starting NO replace
(16) chassis switch ON.
7 normal?
Short circuit to chassis
• Set directional ground between L04 (female)
Is voltage • Min. 1 MΩ lever to 2nd. (6) and C3B (female) (15), or
between C3B (8) short circuit inwiring harnass Repair or
• Disconnect L04, between L04 (female) (8) and
and chassis NO C3B (female) (16)
replace
C3B.
normal? • Turn starting Defective contact or
• 20 – 30 V switch OFF. disconnection between L04
(female) (7) and C3B (female) Repair or
• Turn starting (8), or defective lever
switch ON. NO replace
Short circuit with chassis ground
• Set directional in harness between L04 (female)
lever to 3rd. (7) and C3B (female) (8), or short
circuit in wiring harness between Repair or
L04 (female) (7) and C3B (female)
(8) – L04 (female) (6) and C3B replace
(female) (15), or between L04
disconnection between L04
(female) (5) and C3B (female) replace
Short circuit with chassis ground in
wiring harness between L04
(female) (5) and C3B (female) (7), or
short circuit between L04 (female) Repair or
(5) and C3B (female) (7), or between replace
L04 (female) (6) and C3B (female)
(15), or between L04 (female) (7) and
C3B (female) (8), or between L04
harness between fuse I (9)

replace
harness between L04
ground in wiring harness Repair or
between FS2 (female) (8) and replace
L04 (female) (1)
WD600-3 20-823
(1)
20-824 WD600-3
(1)
T-11 Failure code [22] (Disconnection in travel speed sensor) is

displayed
Cause Remedy

Is resistance
between C5A
controller
YES
2 T05 (female) (2) disconnection in wiring
harness between C5A Repair or
between C5A
YES (female) (2) and T05 • Max. 1 Ω NO (female) (10) and T05 replace
(female) (1) normal? • Disconnect C5A, T05 and (female) (2)
1 L07.
Is resistance between Defective contact or
• Max. 1 W • Turn starting switch OFF. disconnection in wiring Repair or
T05 (male) (1) and (2)
and between (1), (2) • Disconnect T05, NO harness between C5A replace
and chassis ground C5A and L07. (female) (2) and T05
normal? • Turn starting (female) (1)
• Between (1) and switch OFF.
Defective speed sensor Replace
(2): 500 – 1000 Ω NO
• Disconnect T05.
• Turn starting
switch OFF.
WD600-3 20-825
(1)
T-12 Failure code [23] (Short circuit, or disconnection in engine speed

sensor system) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between C4 Defective contact or
3 (female) (9) and E06 disconnection in wiring
(female) (2) normal?
Is resistance harness between C4 Repair or
YES between C4 (female) • Max. 1 Ω NO (female) (9) and E06 replace
2
(2) and chassis • Disconnect C4 and E06. (female) (2)
ground normal? • Turn starting switch
Is resistance
• Min. 1 MΩ OFF. ground in harness Repair or
YES between C4
(female) (2) and E06 • Disconnect C4, NO between C4 (female) (2) replace
1 (female) (1) normal E06 and L07. and E06 (female) (1)
• Turn starting Defective contact or
Is resistance • Max. 1 Ω switch OFF. disconnection in wiring Repair or
between E06 • Disconnect C4,
NO harness between C4 replace
(male) (1) and (2) E06 and L07. (female) (2) and E06
normal? • Turn starting (female) (1)
• 100 – 500 Ω switch OFF.
• Disconnect E06. Defective engine speed Replace
• Turn starting NO sensor
switch OFF.
6 YES joystick steering Replace
Is resistance controller
YES between C4 Short circuit of harness
From A 5 (female) (2) and between C4 (female) (2)
(9) normal? and E03 (female) (1) and Repair or
Is resistance harness between C4
between C4 (female) • Min. 1 MΩ NO replace
(female) (9) and E06
(9) and chassis • Disconnect C4, (female) (2) with each
ground normal? E06 and L07. other
• Turn starting switch OFF. Short circuit with chassis Repair or
• Min. 1 MΩ
• Disconnect C4 NO ground in harness replace
and E06. between C4 (female) (9)
• Turn starting and E06 (female) (2)
switch OFF.
20-826 WD600-3
(1)
TROUBLESHOOTING T-13, T-14
T-13 When hold switch is pressed, gear speed is not fixed or reset
Shift-up does not work
fl Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Cause Remedy

YES
1 controller
Is resistance
between C5A Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
Is resistance in wiring harness replace
• Disconnect C5A. between L15 between C5A (female)
• Hold switch (male) (3) and (4) (13) and L15 (female) (3)
NO normal?
ON: Max. 1 Ω
OFF: Min. 1 MΩ Defective hold switch Replace
• Hold switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
T-14 Kick-down does not work Cause Remedy

Shift-down does not work
YES joystick steering Replace
1 controller
Is resistance Short circuit with chassis
between C5A ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
Is resistance in wiring harness replace
• Disconnect C5A. between L15 between C5A (female) (5)
• Kick-down (male) (1) and (2)
NO normal?
switch Defective kick-down
ON: Max. 1 Ω • Disconnect L15. switch
Replace
NO
OFF: Min. 1 MΩ • Kick-down switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
T-13, T-14 Related electrical circuit diagram
WD600-3 20-827
(1)
T-15 Transmission cutoff does not work or stays working

Cause Remedy

1 controller
• Short circuit with chassis
Is resistance ground, defective contact, or
between C5A disconnection in wiring
(female) (6) and 2 YES harness between C5A (female) Repair or
chassis normal? (6) and L12 (female) (1)
Is resistance • Short circuit with chassis replace
ground in wiring harness
• Disconnect C5A. between L12 between C5A (female) (6) and
• Transmission NO (male) (1) and (2) L06 (female) (3)
cut-off switch normal?
ON: Max. 1 Ω Defective transmission Replace
• Disconnect L12. NO cut-off switch
OFF: Min. 1 MΩ • Transmission
cut-off switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
20-828 WD600-3
(1)
T-16 Neutralizer does not work or stays working

fl Check that the parking brake works normally.
Cause Remedy

YES
controller
1 4 YES Defective neutralizer

Is resistance relay Replace
Is voltage
between C3A (19) YES between C3A Defective contact or
(female) (6) and
and chassis 3 disconnection in wiring
C3A (female) (19)
normal? Is voltage harness between C3A
normal?
(female) (6) – L58 (female) Repair or
YES between L58 • Disconnect C3A and NO (5), L58 (female) (3) – C3A replace
• Turn starting
(female) (1) and L58.
2 chassis normal? • Short circuit L58
• Parking brake (female) (3) and (5) Short circuit with chassis
switch: Is resistance • Disconnect L58. • Max. 1 Ω ground, defective contact, Repair or
ON → OFF between L58 • Turn starting or disconnection in wiring replace
NO harness between L58
• 20 – 30 V NO (female) (2) and switch ON.
(female) (1) and L01
chassis normal? • Parking brake switch: ON → OFF (female) (2)
• Disconnect L58. • 20 – 30 V
• Max. 1 Ω NO disconnection in wiring replace
harness between L58
WD600-3 20-829
(1)
T-17 Buzzer does not work

fl Check that the main monitor alone and alarm buzzer alone work normally.
Cause Remedy

Is resistance
between C2 controller
YES
1 L08 (female) (6)
harness between C2
between C2 • Disconnect C1 NO replace
(female) (10) and and L08. (female) (6)
chassis normal? • Max. 1 Ω
• Disconnect C1 Short circuit with chassis
Repair or
and L08. ground in wiring harness
NO replace
• Min. 1 MΩ betwen C2 (female) (10)
20-830 WD600-3
(1)
T-18 Abnormality in network system

Cause Remedy

controller
YES C3B (female) (4), (12)
and L08 (female) (1), Defective contact or
1 (3) or LM1 (female) disconnection in wiring
Is resistance (5) normal? harness between C3B Repair or
between C3B (female) (4), (12) and L08
• Max. 1 Ω NO replace
(female) (4), (12) (female) (1), (3), or LM1
and chassis • Turn starting switch OFF.
(male) (5)
normal? • Disconnect C3B, L08 and
LM1. Short circuit with chassis
• Min. 1 MΩ Repair or
ground in wiring harness
• Turn starting NO replace
betwen C3B (female) (4),
switch OFF.
(12) and L08 (female) (1),
• Disconnect C3B, (3), or LM1 (male) (5)
L08 and LM1.
WD600-3 20-831
(1)
T-19 Abnormality in transmission controller power supply

fl Check that fuse II (6) is normal.
Cause Remedy

1 controller
Is voltage between Short circuit with chassis
C1A (7), (13), C2 (1), ground, defective contact or
(12) and C1A (6), disconnection in wiring
(12), C2 (11), (21) 2 YES harness between C1A Repair or
normal? (female) (7), (13) and FS5
Is resistance between (female) (6), and between C2 replace
• 20 – 30 V C1A (female) (6), (12) (female) (1), (12) and OP5
and chassis, and C2 (female) (1)
• Turn starting NO (female) (11), (21)
switch ON. and chassis normal? Defective contact or
• Max. 1 Ω NO harness between C1A replace
• Turn starting (female) (6), (12) and chassis,
and between C2 (female) (1),
switch OFF.
(12) and chassis
• Disconnect C1A
and C2.
20-832 WD600-3
(1)
T-20 Short circuit in travel speed sensor system

Cause Remedy

2 YES Replace
joystick steering
YES between C5A Short circuit in wiring
1 (female) (2) and harness betwen C5A (female)
(10) normal? (2) – L07 (female) (1) – T05
Is resistance (male) (1) or short circuit in Repair or
between C5A • Min. 1 MΩ NO wiring harness between C5A replace
(female) (2) and • Turn starting switch OFF. (female) (10) – L07 (female)
(2) – T05 (female) (2)
chassis normal? • Disconnect C5A, T05 and
L07. Short circuit in wiring
• Min. 1 MΩ harness betwen C5A (female) Repair or
• Turn starting NO (2) – TM2 (9) – CN3 (female) replace
switch OFF. (2), or short circuit in
between C5A (female) (2) and
• Disconnect C5A, L07 (female) (1)
BC01 and L07.
WD600-3 20-833
(1)
T-21 Abnormality in machine selection wiring harness

fl Check that machine selection connector is properly selected.
Cause Remedy

between C3B
(female) (2), (3), (10) Defective machine
and C1A (female) selection connector, or
(6), (12) normal? Repair or
defective contact or
• Turn starting NO disconnection in wiring replace
switch OFF. harness
• Disconnect C3B
and C1A.
Table 1
Machine model
WA600-3
Connector
Between C3B (female) (2) and C1A (female) (6), (12) Min. 1 MΩ
Between C3B (female) (3) and C1A (female) (6), (12) Max. 1 Ω
Between C3B (female) (10) and C1A (female) (6), (12) Min. 1 MΩ
20-834 WD600-3
(1)
TROUBLESHOOTING OF JOYSTICK STEERING
SYSTEM (J MODE)
(ONLY FOR MACHINE WITH JOYSTICK AND AUTOMATIC SHIFT
CONTROL)
Judgement table for joystick control system ......................................................................................20-902

Action taken by controller when abnormality occurs and problems on machine ..........................20-904
Electrical circuit diagram for joystick steering system .......................................................................20-908
J- 1 Failure code [56] (Short circuit, or disconnection in caution relay output) is displayed ....20-910
J- 2 Failure code [57] (Short circuit in steering right solenoid (detected when signal
is output)) is displayed ................................................................................................................20-911
J- 3 Failure code [58] (Short circuit in steering left solenoid (detected when signal
is output)) is displayed ................................................................................................................20-912
J- 4 Failure code [59] (Short circuit in steering right solenoid (power supply side))
is displayed ...................................................................................................................................20-913
J- 5 Failure code [60] (Short circuit in steering left solenoid (power supply side))
is displayed ...................................................................................................................................20-914
J- 6 Failure code [61] (Short circuit, or disconnection in steering solenoid cut relay
output) is displayed .....................................................................................................................20-915
J- 7 Failure code [62] (Short circuit, or disconnection in joystick steering neutral
circuit) is displayed ......................................................................................................................20-916
J- 8 Failure code [63] (Short circuit, or disconnection in joystick steering
potentiometer) is displayed ........................................................................................................20-917
J- 9 Abnormality in power supply, or power supply voltage ........................................................20-918
J-10 Abnormality in joystick steering ON-OFF circuit ......................................................................20-919
J-11 Disconnection in steering right solenoid ..................................................................................20-920
J-12 Disconnection in steering left solenoid .....................................................................................20-921
WD600-3 20-901
(1)
TROUBLESHOOTING JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM
JUDGEMENT TABLE FOR JOYSTICK CONTROL SYSTEM
Self-diagnostic display (abnormality display)
Location of failure
Short circuit in steering right solenoid (detected when signal is output)

Short circuit in steering left solenoid (detected when signal is output)
Short circuit, or disconnection in steering solenoid cut relay output

Short circuit, or disconnection in joystick steering neutral switch
Short circuit, or disconnection in joystick caution relay output
Short circuit in steering right solenoid (power supply side)

Short circuit in steering left solenoid (power supply side)
Short circuit, or disconnection in joystick potentiometer

Abnormality in power supply, or power supply voltage
Troubleshooting code
when no abnormality
display is given
Abnormality in joystick ON-OFF circuit
Failure
code
Failure mode
56 57 58 59 60 61 62 63 — —
1 Buzzer does not stop fi T-17
2 Steering does not turn to left fi fi fi fi H-7, H-8, H-9, H-10, J-9, J-12
3 Steering does not turn to right fi fi fi fi H-7, H-8, H-9, H-10, J-9, J-11
4 Steering is always turned to left fi fi fi
5 Steering is always turned to right fi fi fi
6 Both steering and transmission do not work at all fi fi J-9, J-10
Troubleshooting code when failure code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 — —
20-902 WD600-3
(1)

OCCURS AND PROBLEMS ON MACHINE
JOYSTICK CONTROL SYSTEM
Failure code Abnormal system Portion of abnormality
1) Defective caution relay

2) Short circuit with ground, defective contact, or
disconnection in wiring harness between C2 (female) (9) –
L65 (1)
56 Joystick caution relay
disconnection in wiring harness between C2 (female) (19)
– L65 (2) – chassis ground
4) Defective transmission & joystick steering controller
1) Defective steering right solenoid

2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between C2 (female) (2) –
(13)
Short circuit with ground, defective contact, or disconnection
in the following wiring harness
57 Steering right solenoid 4) Wiring harness between C2 (female) (2) – L27 (2)
5) Wiring harness between C2 (female) (13) – L67 (3)
6) Wiring harness between L67 (female) (5) – L27 (1)
1) Defective steering left solenoid

3) Short circuit in wiring harness between C2 (female) (3) –
(14)
Short circuit with ground, defective contact, or disconnection
in the following wiring harness
58 Steering left solenoid 4) Wiring harness between C2 (female) (3) – L26 (2)
5) Wiring harness between C2 (female) (14) – L67 (3)
6) Wiring harness between L67 (female) (5) – L26 (1)
1) Defective steering right solenoid

Short circuit with power supply 2) Short circuit with power source in wiring harness between
59 in steering right solenoid C2 (female) (2) – L27 (2)
circuit 3) Defective transmission & joystick steering controller
1) Defective steering left solenoid

2) Short circuit with power source in wiring harness between
Short circuit with power supply C2 (female) (3) – L26 (2)
60 in steering left solenoid circuit 3) Defective transmission & joystick steering controller
20-904 WD600-3
(1)

1) Joystick caution relay: ON (voltage between C2 Caution output: OFF Joystick caution
(9) – (19): 20 – 30 V) actuated
2) Resistance of relay coil between C2 (female) (9)
– (19): 200 – 400 Ω
3) Resistance of wiring harness between C2
J-1
(female) (9) – L65 (female) (1): Less than 1 Ω
4) Resistance of wiring harness between L65
(female) (2) – C2 (19): Less than 1 Ω
1) Steering solenoid cut relay: ON (voltage Steering right, left Impossible to use
between C2 (2) and chassis ground: 20 – 30 V) solenoid output: OFF joystick
2) Resistance of steering right solenoid: 10 – 20 Ω and steering solenoid and joystick caution
3) Resistance between C2 (female) (2), (13) – cut relay output: OFF actuated
chassis ground: Min. 1 MΩ and caution relay
Resistance of the following wiring harness: Less output: OFF
than 1 Ω J-2
4) Wiring harness between C2 (female) (2) – L27
(female) (2)
(female) (3)
6) Wiring harness between L67 (female) (5) – L27
(female) (1)
between C2 (3) – chassis ground: 20 – 30 V) solenoid output: OFF joystick
2) Resistance of steering left solenoid: 10 – 20 Ω and steering solenoid and joystick caution
3) Resistance between C2 (female) (3), (14) – cut relay output: OFF actuated
chassis ground: Min. 1 MΩ and caution relay
Resistance of the following wiring harness: Less output: OFF
than 1 Ω J-3
(female) (2)
(female) (3)
6) Wiring harness between L67 (female) (5) – L27
(female) (1)
When joystick lever is at neutral Steering right, left Impossible to use

Voltage between C2 (female) (2) – chassis ground: solenoid output: OFF joystick
Less than 1 V and steering solenoid and joystick caution
cut relay output: OFF actuated
J-4
and caution relay
output: OFF
When joystick lever is at neutral Steering right, left Impossible to use

Voltage between C2 (female) (3) – chassis ground: solenoid output: OFF joystick
Less than 1 V and steering solenoid and joystick caution J-5
and caution relay
output: OFF
WD600-3 20-905
(1)
Failure code Abnormal system Portion of abnormality

disconnection in wiring harness between C1A (female) (1)
– C1 (female) (1) – L67 (female) (1)
61 Steering solenoid cut relay disconnection in wiring harness between JS5 (3) – chassis
ground
1) Defective joystick neutral switch

disconnection in wiring harness between C5A (female)
(11) – C5 (female) (11) – JS5 (female) (1)
3) Defective contact or disconnection in wiring harness
62 Joystick neutral switch between JS5 (3) – chassis ground
1) Defective boom angle potentiometer

2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness
between C3A (female) (3) – JS2 (1)
3) Short circuit with power source, defective contact, or
63 Joystick potentiometer disconnection in wiring harness between C3A (female) (7)
– JS2 (2)
4) Short circuit with power supply, short circuit with ground,
defective contact, or disconnection in wiring harness
between C3A (female) (17) – JS2 (female) (3)
20-906 WD600-3
(1)

Resistance between C5A (female) (11) – chassis Steering right, left Impossible to use
ground: Min. 1 MΩ (joystick at neutral), Less than solenoid output: OFF joystick
1 Ω (joystick angled ± 5 – 15° from neutral) and steering solenoid and joystick caution
and caution relay
output: OFF J-6
Voltage between C3A (female) (3) – (17): 0.5 – 4.5 V Steering right, left Impossible to use
(voltage when joystick is at neutral: Approx. 2.5 V) solenoid output: OFF joystick
and steering solenoid and joystick caution
and caution relay
output: OFF J-7
between C1A (1) – chassis ground: 20 – 30 V) solenoid output: OFF joystick
2) Resistance of relay coil between C1A (female) and steering solenoid and joystick caution
(1) – chassis ground: 200 – 400 Ω cut relay output: OFF actuated
3) Resistance of wiring harness between C1A and caution relay
(female) (1) – L67 (female) (1): Less than 1 Ω output: OFF
4) Resistance of wiring harness between steering J-8
solenoid cut relay L67 (female) (2) – chassis
ground: Less than 1 Ω
WD600-3 20-907
(1)
TROUBLESHOOTING JOYSTICK STEERING SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING

SYSTEM
20-908 WD600-3
(1)
TROUBLESHOOTING JOYSTICK STEERING SYSTEM
WD600-3 20-909
(1)
TROUBLESHOOTING J-1
J-1 Failure code [56] (Short circuit, or disconnection in caution relay

output) is displayed
fl When the joystick steering lever is not being used, leave it at the neutral position and turn the
joystick steering selector switch ON.
fl Always turn the starting switch OFF before disconnecting any connector.
Cause Remedy

4 YES
Is resistance
between C1
controller
YES
(female) (19) and
3 chassis ground Short circuit with chassis
Is resistance normal? ground in harness between Repair or
YES between C2 replace
(female) (9) and
• Min. 1 MΩ NO C2 (female) (19) and L65
• Turn starting (female) (2)
chassis ground
2
• Min. 1 MΩ • Disconnect C2. ground in harness between Repair or
Is resistance
between C2 • Turn starting C2 (female) (1) and L65 replace
YES NO
(female) (9) and C2 switch OFF. (female) (1)
(female) (19) • Disconnect C2. Defective contact or
5 YES Repair or
1 • 200 – 400 Ω harness between C2
Is resistance replace
Is failure code • Turn starting (female) (19) and L65
displayed when L65 switch OFF. between C2 (female) (2)
is replaced with • Disconnect C2. NO (female) (9) and L65
(female) (1) normal?
other relay of same Repair or
type?
• Max. 1 Ω replace
NO harness between C2
• Turn starting • Turn starting (female) (9) and L65
switch OFF. switch OFF. (female) (1)
• Replace L65 with • Disconnect C2 and L65.
another relay of Defective caution (J/S) Replace
same type. NO relay
• Turn starting
switch ON.
J-1 Related electrical circuit diagram
20-910 WD600-3
(1)
TROUBLESHOOTING J-2
J-2 Failure code [57] (Short circuit in steering right solenoid (detected
when signal is output)) is displayed
Cause Remedy

joystick controller Replace
Is resistance
YES between C2 Short circuit of wiring
3 (female) (2) and harness between C2 (female)
Is resistance (13) normal? (2) and L27 (female) (2) and Repair or
wiring harness between C2
YES between C2 • Min. 1 MΩ NO replace
(female) (13) and (female) (13) and L67
chassis ground • Turn starting (female) (3) with each other
2
Is resistance normal? switch OFF. Short circuit with chassis
between C2 • Min. 1 MΩ • Disconnect C2. ground in harness between Repair or
YES
(female) (2) and • Turn starting NO C2 (female) (13) and L67 replace
chassis ground switch OFF. (female) (3)
1 normal? • Disconnect C2
Is failure code • Min. 1 MΩ Short circuit with chassis
displayed when L67 and L67.
• Turn starting ground in harness between Repair or
is replaced with C2 (female) (2) and L27 replace
switch OFF. NO
other relay of same (female) (2)
type? • Disconnect C2
• Turn starting and L27.
switch OFF. Defective steering
solenoid cut relay Replace
• Replace L67 with NO
other relay of
same type.
• Turn starting
switch ON.
WD600-3 20-911
(1)
TROUBLESHOOTING J-3
J-3 Failure code [58] (Short circuit in steering left solenoid (detected
when signal is output)) is displayed
Cause Remedy

Is resistance
YES between C2 Short circuit of wiring
3 (female) (3) and harness between C2 (female)
Is resistance (14) normal? (3) and L26 (female) (2) and Repair or
YES between C2 wiring harness between C2 replace
(female) (14) and
• Min. 1 MΩ NO
2 (female) (3) with each other
Is resistance normal? switch OFF.
between C2 • Min. 1 MΩ • Disconnect L26. Repair or
YES ground in harness between
(female) (3) and • Turn starting NO C2 (female) (14) and L67 replace
chassis ground switch OFF.
1 (female) (3)
normal? • Disconnect C2
Is failure code • Min. 1 MΩ Short circuit with chassis
displayed when L67 and L67.
• Turn starting ground in harness between Repair or
is replaced with C2 (female) (3) and L26 replace
switch OFF. NO
other relay of same (female) (2)
type? • Disconnect C2
Replace
• Replace L67 with NO solenoid cut relay
other relay of
same type.
• Turn starting
switch ON.
20-912 WD600-3
(1)
TROUBLESHOOTING J-4
J-4 Failure code [59] (Short circuit in steering right solenoid (power
supply side)) is displayed
Cause Remedy
1 YES
1 Defective transmission &
C2 (female) (2) and
• Max. 1 V NO between C2 (female) (2) replace
• Turn starting and L27 (female) (2)
switch ON.
WD600-3 20-913
(1)
TROUBLESHOOTING J-5
J-5 Failure code [60] (Short circuit in steering left solenoid (power
supply side)) is displayed
fl Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter
(or socket adapter).
Cause Remedy

1 YES
1
C2 (female) (3) and
• Max. 1 V NO between C2 (female) (3) replace
• Turn starting and L26 (female) (2)
switch ON.
20-914 WD600-3
(1)
TROUBLESHOOTING J-6
J-6 Failure code [61] (Short circuit, or disconnection in steering

solenoid cut relay output) is displayed
to its original position, if the failure code is no longer displayed
on the monitor display, the problem has been removed. Cause Remedy
fl Always connect any disconnected connectors
before going on to the next step. 4 YES
Go to A
Is resistance
fl When the joystick steering lever is not being between L67
YES Defective contact or
used, leave it at the neutral position and 3 (female) (2) and
chassis ground disconnection in wiring
turn the joystick steering Is resistance harness between L67 Repair or
normal?
selector switch ON. YES between C1A • Max. 1 Ω NO (female) (2) and chassis replace
(female) (1) and
2 chassis ground • Turn starting ground
Is resistance
• Min. 1 MΩ • Disconnect L67. ground in harness Repair or
YES between C1A
switch OFF. and L67 (female) (1)
1 (female) (1) normal?
Is failure code • Disconnect C1A Defective contact or
displayed when L67
• Max. 1 Ω and L67. disconnection in wiring Repair or
is replaced with • Turn starting harness between C1A replace
other relay of same switch OFF. NO
type? • Disconnect C1A (female) (1)
Replace
• Replace L67 with NO solenoid cut relay
other relay of
same type.
• Turn starting Defective transmission &
5 YES
switch ON. joystick steering Replace
Is resistance
between C5A controller
From A (female) (11) and Defective contact or
JS5 (female) (1)
normal? Repair or
harness between C5A
• Max. 1 Ω NO (female) (11) and JS5
replace
• Turn starting switch OFF. (female) (1)
• Disconnect C5A and JS5.
WD600-3 20-915
(1)
TROUBLESHOOTING J-7
J-7 Failure code [62] (Short circuit, or disconnection in joystick

steering neutral circuit) is displayed
Cause Remedy

YES joystick controller or
defective installation of
Replace
joystick potentiometer
2
Is resistance Defective contact or
YES between C5A 4 YES disconnection in wiring Repair or
(female) (11) and Is resistance harness between JS5 replace
chassis ground between JS5 (female) (1) and C5A
YES
normal? (female) (3) and (female) (11)
• Disconnect C5A. 3 chassis ground
• Pull JST lever to Is resistance normal? Repair or
1 right or left end. between JS5 • Disconnect JS5. NO harness between JS5
replace
Is resistance • Max. 1 Ω NO (male) (1) and (3) • Max. 1 Ω (female) (3) and chassis
between C5A
normal? ground
(female) (11) and
chassis ground • Disconnect JS5. Defective neutral switch Replace
normal? • Pull JST lever to NO
• Disconnect C5A. right or left end.
• Min. 1 MΩ • Max. 1 Ω Short circuit with chassis
5 YES ground in harness Repair or
Is resistance between JS5 (female) (1) replace
between JS5 and C5A (female) (11)
NO (male) (1) and (3)
normal?
Defective neutral switch Replace
• Disconnect JS5. NO
• Min. 1 MΩ
20-916 WD600-3
(1)
TROUBLESHOOTING J-8
J-8 Failure code [63] (Short circuit, or disconnection in joystick

steering lever potentiometer) is displayed
fl After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
Defective joystick Repair, adjust

YES potentiometer, neutral neutral
2 position misaligned position again
Does voltage
YES between C3A Short circuit with power
supply short circuit with
(female) (3) – (17) 3 YES ground, defective contact, or Repair or
change? Does resistance 3 disconnection in wiring replace
1 between JS2 harness between C3A
• Turn joystick
(female) (3) – JS2 (female) (1)
Does voltage lever to left or to NO (male) (1) and (3)
between C3A (7) right. change? Defective joystick
• 0.5 – 4.5 V Replace
– (17) change? • Turn joystick NO potentiometer
lever to left or to
• 4.9 – 5.1 V right.
• 0.2 – 5 kΩ Defective transmission &
NO controller
WD600-3 20-917
(1)
TROUBLESHOOTING J-9
J-9 Abnormality in power supply, or power supply voltage

fl Check that fuse I (10) is normal.
Cause Remedy

C1A (female) (7),
(13) – chassis Defective contact or
normal? disconnection in wiring Repair or
harness between C1A
• 20 – 30 V NO
(female) (7), (13) – Fuse
replace
• Turn starting (II) (15)
switch ON.
20-918 WD600-3
(1)
TROUBLESHOOTING J-10
J-10 Abnormality in joystick steering ON-OFF circuit

fl Check that fuse I (11) is normal.
Cause Remedy

YES Replace
joystick steering
controller
1
Is voltage 3 YES Defective system cutoff
Replace
between C3A (19) Is voltage switch
– chassis normal? YES between JS3 Defective contact or
2 (female) – and disconnection in wiring
• 20 – 30 V Is resistance between chassis normal? Repair or
harness between fuse I (11) –
• Turn starting L27 (female) (14) and FS2 (10) – L32 (1) – JS3 replace
switch ON. chassis normal when
• 20 – 30 V NO
• Turn starting (female)
• Turn joystick NO S4 (male) is grounded
ON- OFF switch: to chassis? switch ON. Defective contact or
Replace switch,
ON. • Turn starting or repair or
harness between L27
switch OFF. NO replace
(female) (14) – JS5 (1), (2) –
• Disconnect S4 S4 (male), or defective
and L27. joystick ON–OFF switch
• Max. 1 Ω
WD600-3 20-919
(1)
J-11 Disconnection in steering right solenoid

Cause Remedy

Is resistance
YES between L27 Defective contact or
3 (female) (1) and L67 disconnection in wiring
Is resistance (female) (5) normal? harness between L27 Repair or
YES between C2 • Max. 1 Ω NO (female) (1) and L67 replace
(female) (13) and (female) (5)
L67 (female) (3) • Turn starting
2 Defective contact or
normal? switch OFF.
Is resistance • Disconnect L27 and L67. disconnection in wiring
YES between C2
• Max. 1 Ω Repair or
harness between C2
(female) (2) and L27 • Turn starting NO (female) (13) and L67 replace
(female) (2) normal? switch OFF. (female) (3)
1
• Disconnect C2
Is resistance • Max. 1 Ω Defective contact or
and L67.
between L27 • Turn starting disconnection in wiring Repair or
(male) (1) and (2) switch OFF. NO harness between C2 replace
(female) (2)
• 10 – 20 Ω and L27.
Defective joystick
• Turn starting Replace
steering right solenoid
switch OFF. NO
valve
• Disconnect L27.
20-920 WD600-3
(1)
J-12 Disconnection in steering left solenoid

Cause Remedy

Is resistance
YES between L26 Defective contact or
3 (female) (1) and L67 disconnection in wiring
Is resistance (female) (5) normal? harness between L26 Repair or
YES between C2 • Max. 1 Ω NO (female) (1) and L67 replace
(female) (14) and (female) (5)
• Turn starting
2 L67 (female) (3)
normal? switch OFF.
Is resistance • Disconnect L26 and L67. disconnection in wiring
YES between C2
• Max. 1 Ω Repair or
harness between C2
(female) (3) and L26 • Turn starting NO (female) (14) and L67 replace
(female) (2) normal? switch OFF. (female) (3)
1
• Disconnect C2
Is resistance • Max. 1 Ω Defective contact or
and L67.
between L26 • Turn starting disconnection in wiring Repair or
(male) (1) and (2) switch OFF. NO harness between C2 replace
(female) (2)
• 10 – 20 Ω and L26.
Defective joystick
• Turn starting Replace
steering left solenoid
switch OFF. NO
valve
• Disconnect L26.
WD600-3 20-921
(1)
TROUBLESHOOTING OF THROTTLE
CONTROL SYSTEM
(TH MODE)
Judgement table for throttle controller system related parts ............................................................. 20-953
Electric circuit diagram of throttle controller system ........................................................................... 20-954
TH-1 Abnormality in accelerator pedal sensor system is displayed ................................................. 20-955
TH-2 Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system is displayed .......... 20-956
TH-3 Disconnetion in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system ............................. 20-957
TH-4 Abnormality in electronic governor voltage command system ............................................... 20-958
TH-5 Abnormality in brake pedal switch system ................................................................................ 20-959
a) Abnormality in left brake pedal switch .................................................................................. 20-959
b) Abnormality in right brake pedal switch ............................................................................... 20-960
TH-6 Abnormality in RPM-SET ON/OFF switch system ..................................................................... 20-961
TH-7 Short circuit, disconnection, or short circuit with power supply in backup lamp relay ......... 20-962
WD600-3 20-951
(1)
JUDGEMENT TABLE FOR THROTTLE CON-
TROUBLESHOOTING TROLLER SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR THROTTLE CONTROLLER SYSTEM

RELATED PARTS
Disconnection in RPM-SET IDLE-UP/RESUME IDLE0DOWN switch system

Location of failure
Abnormality in power supply system of throttle controller system

Abnormality in electronic governor voltage command system
Diagonosis code when failure code is not displayed

Short circuit or disconnection in backup lamp relay
Abnormality in RPM-SET ON/OFF switch system
Abnormality in accelerator pedal sensor system
Failure mode Abnormality in brake pedal switch system
1 Engine speed does not rise even if accelerator pedal is pressed fi fi fi TH-1
2 Engine speed does not change even if RPM SET ON/OFF switch operated fi fi TH-6
3 Engine speed can be set while RPM SET ON/OFF switch is OFF fi TH-6
4 RPM-SET IDLE-UP/RESUME IDLE-DOWN switch does not work fi fi TH-2, 3
5 Backup lamp and backup buzzer do not work fi TH-7
WD600-3 20-953
(1)
ELECTRIC CIRCUIT DIAGRAM OF
TROUBLESHOOTING THROTTLE CONTROLLER SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF THROTTLE CONTROLLER

SYSTEM
20-954 WD600-3
(1)
TROUBLESHOOTING TH-1
TH-1 Abnormality in accelerator pedal sensor system is displayed

Cause Remedy
3 YES
Go to A —
Is resistance
YES between C6
(female) (22) and Disconnection or
2 L13A (male) (3) defective contact in
between C6 wiring harness between
YES
(female) (9) and
• Max. 1 Ω NO C6 (female) (22) – L13A replace
• Turn starting (male) (3)
1 chassis ground switch OFF.
Is resistance
normal? • Disconnect C6 Short circuit with chassis
between C6 (female)
• Min. 1 MΩ and L13. ground in wiring harness Repair or
(9) and L13A (male) • Turn starting NO between C6 (female) (9) – replace
(1) normal? switch OFF. L13A (male) (1)
• Disconnect C6 Disconnection or
• Max. 1 Ω and L13A. defective contact in Repair or
• Turn starting wiring harness between replace
switch OFF. NO
C6 (female) (9) – L13A
• Disconnect C6 (male) (1)
and L13A.
6 YES Defective throttle
Replace
controller
YES Is voltage between
L13A (1) and (2)
5 normal?
Is resistance Defective accelerator
Replace
YES between C6 • At low idling: NO pedal potentiometer
(female) (9), (22) 0.5 – 1.6 V
From A 4 and chassis ground At high idling: Short circuit of wiring
normal? (Low idling voltage + 2.1 V) – 4.75 V harness between C6
Is resistance
between C6 (female)
• Min. 1 MΩ • Turn starting switch ON. (female) (22) – L13A Repair or
(22) and L13A (male) • Turn starting NO (male) (3) with wiring replace
switch OFF. harness between C6 (9) –
(3) normal? L13A (male) (1)
• Disconnect C6
• Max. 1M Ω and L13A. Short circuit with chassis
Repair or
• Turn starting ground in wiring harness
NO between C6 (female) (22) replace
switch OFF.
– L13A (male) (3)
• Disconnect C6
and L13A.
TH-1 Related electrical circuit diagram
WD600-3 20-955
(1)
TH-2 Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch

system is displayed
fl When a connector is disconnected and a T-adapter is inserted for troubleshooting while abnormality
is detected or when the T-adapter is removed and the connector is connected again, if the throttle
lock ON/OFF switch indicator stops flashing, the condition has returned to normal.
Cause Remedy

Is resistance
Replace
controller
YES between C8
(female) (30) and
2 chassis ground Short circuit with chassis
Is resistance normal? ground in wiring harness Repair or
between C8
YES
(female) (19) and
• Max. 1M Ω NO between C8 (female) (30) replace
• Turn starting – C12 (male) (3)
Is resistance • Min. 1 MΩ and C12. ground in wiring harness Repair or
between C12 (male)
(1), (2) and (3) as
• Turn starting NO between C8 (female) (19) replace
shown in Table 1? switch OFF. – C12 (male) (1)
• Disconnect C8
• Disconnect C12 and C12. Defective SET IDLE-UP
• Turn starting /RESUME IDLE-DOWN Replace
switch OFF. NO switch
Table 1
Switch RPM-SET IDLE- RESUME•IDLE-
OFF
Terminal UP switch ON DOWN switch ON
Between C12 (male) (2) – (3) Min. 1 MΩ Max. 1 Ω Min. 1 MΩ
Between C12 (male) (1) – (2) Max. 1 Ω Min. 1 MΩ Min. 1 MΩ
20-956 WD600-3
(1)
TH-3 Disconnetion in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch

system
Cause Remedy

Replace
YES between C12
(female) (2) and
3 chassis ground Disconnection in wiring
Is resistance normal? harness between C12 Repair or
between C8
YES
(female) (30) and
• Max. 1 Ω NO (male) (2) – chassis replace
2 C12 (male) (3) • Turn starting ground
normal? switch OFF.
Disconnection in wiring
Is resistance
• Min. 1 Ω • Disconnect C12. harness between C8 Repair or
YES between C8 (female)
(19) and C12 (male) • Turn starting NO (female) (30) – C12 (male) replace
1 (1) normal? switch OFF. (3)
• Disconnect C8 Disconnection in wiring
Is resistance • Max. 1 Ω and C12. harness between C8 Repair or
between C12 (male) • Turn starting (female) (19) – C12 (male) replace
(1), (2) and (3) as switch OFF. NO
shown in Table 1? (1)
• Disconnect C8
• Disconnect C12 and C12.
Defective RPM-SET IDLE-
• Turn starting UP/RESUME IDLE-DOWN Replace
switch OFF. NO switch
Table 1
Switch RPM-SET IDLE- RESUME•IDLE-
OFF
Terminal UP switch ON DOWN switch ON
Between C12 (male) (2) – (3) Min. 1 MΩ Max. 1 Ω Min. 1 MΩ
Between C12 (male) (1) – (2) Max. 1 Ω Min. 1 MΩ Min. 1 MΩ
WD600-3 20-957
(1)
TH-4 Abnormality in electronic governor voltage command system

Cause Remedy

3 YES source in wiring harness Repair or
Is voltage between between C7 (female) (11) replace
YES C7 (female) (11) and – BCMB (female) (29)
2 chassis ground
Defective throttle
YES between C7 Replace
(female) (11) and
• At low idling: NO controller
chassis ground Max. 0.5 V
1
Is resistance normal? • At high idling: 3.8 – 5 V Short circuit with chassis
between C7 • Min. 1 MΩ • Turn starting switch ON. ground in wiring harness Repair or
(female) (11) and • Turn starting NO between C7 (female) (11) replace
BCMB (female) (29) switch OFF. – BCMB (female) (29)
normal? • Disconnect C7 Disconnection or
• Min. 1 Ω and BCMB. defective contact in
• Turn starting wiring harness between Repair or
switch OFF. NO C7 (female) (11) – BCMB replace
• Disconnect C7 (female) (29)
and BCMB.
20-958 WD600-3
(1)
TH-5 Abnormality in brake pedal switch system

fl Check that fuse (10) is normal.
a) Abnormality in left brake pedal switch
Cause Remedy

Replace
Is voltage between
controller
YES C8 (female) (40) and
3 chassis ground
Defective left brake pedal
Replace
YES between C13A • Press left brake NO switch
(female) (1) and pedal: Max. 1 V
2 FS2 (female) (9) Release left brake
normal? pedal: 17 – 30 V
Disconnection or
Is resistance • defective contact in
• Min. 1 Ω Turn starting switch ON.
wiring harness between Repair or
(40) and chassis • Turn starting NO C13A (female) (1) – FS2 replace
1 ground normal? switch OFF. (female) (9)
• Disconnect C13A,
Is resistance • Max. 1M Ω Short circuit with chassis
C14 and FS2. Repair or
between C8 (female) • Turn starting ground in wiring harness
(40) and C13A NO between C8 (female) (40) replace
switch OFF. – C13A (female) (2)
(female) (2) normal? • Disconnect C8,
Disconnection or
• Max. 1 Ω C13A and C4.
defective contact in
• Turn starting wiring harness between
Repair or
switch OFF. NO C8 (female) (40) – C13A replace
• Disconnect C8, (female) (2)
C13A and C4.
WD600-3 20-959
(1)
b) Abnormality in right brake pedal switch
Cause Remedy

Replace
Is voltage between
controller
YES C8 (female) (40) and
3 chassis ground
Defective right brake
Replace
YES between C14 • Press right brake NO pedal switch
(female) (1) and pedal: Max. 1 V
2 FS2 (female) (9) Release right brake
normal? pedal: 17 – 30 V
Disconnection or
Is resistance • defective contact in
• Min. 1 Ω Turn starting switch ON.
wiring harness between Repair or
(40) and chassis • Turn starting NO C14 (female) (1) – FS2 replace
1 ground normal? switch OFF. (female) (9)
• Disconnect C13A,
Is resistance • Max. 1M Ω Short circuit with chassis
C14 and FS2. Repair or
between C8 (female) • Turn starting ground in wiring harness
(40) and C14 NO between C8 (female) (40) replace
switch OFF. – C14 (female) (2)
(female) (2) normal? • Disconnect C8,
Disconnection or
• Max. 1 Ω C13A and C14.
defective contact in
• Turn starting wiring harness between
Repair or
switch OFF. NO C8 (female) (40) – C14 replace
• Disconnect C8, (female) (2)
C13A and C14.
20-960 WD600-3
(1)
TH-6 Abnormality in RPM-SET ON/OFF switch system

Cause Remedy

controller Replace
Is voltage between
YES C8 (female) (10) and Short circuit with chassis
2 chassis ground ground, disconnection,
normal? defective contact, or
Is resistance short circuit with power Repair or
YES between C11 • RPM-SET ON/OFF NO source in wiring harness replace
(female) (3) and between C8 (female) (10)
chassis ground switch OFF: Max. 1 V
1 – C11 (female) (4)
normal? ON: 17 – 30 V
• Turn starting switch OFF. Disconnection or
Is resistance • Min. 1 Ω defective contact in Repair or
between C11 (male) • Turn starting NO wiring harness between replace
(3) and (4) normal? switch OFF. C11 (female) (3) – chassis
• Disconnect C11. ground
• RPM-SET ON/OFF Defective RPM-SET
switch Replace
NO ON/OFF switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
• Turn starting
switch OFF.
• Disconnect C11.
WD600-3 20-961
(1)
TH-7 Short circuit, disconnection, or short circuit with power supply in

backup lamp relay
to its original position, if the failure code is no longer displayed on the monitor display, the problem
has been removed.
Cause Remedy
4 YES
Go to A
Is resistance
YES between L76
between C8 harness between L76
YES
(female) (7) and
• Max. 1 Ω NO (female) (2) and chassis replace
Is resistance
YES between C8
• Min. 1 MΩ and L76. ground in harness Repair or
(female) (7) and L76 • Turn starting NO between C8 (female) (7) replace
1 (female) (1) normal? switch OFF. and L76 (female) (1)
• Disconnect C8 Defective contact or
Backup relay is
• Max. 1 Ω and L76. disconnection in wiring Repair or
replaced with other • Turn starting harness between C8 replace
relay of same type? switch OFF. NO
• Disconnect C8 (female) (1)
switch OFF. Defective backup lamp
Repair
• Replace backup NO relay
relay with other relay of same type.
• Set directional lever to R. 5 YES Defective throttle
Repair
C8 (female) (7) and
From A
• Turn starting NO between C8 (female) (7) replace
switch ON. and L76 (female) (1)
• Disconnect C8
and L76.
• Max. 1 V
20-962 WD600-3
(1)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................... 30- 3 FRONT DIFFERENTIAL

PRECAUTIONS WHEN CARRYING OUT Removal .................................................... 30-107
OPERATION ................................................ 30- 4 Installation ................................................ 30-108
SPECIAL TOOL LIST ..................................... 30- 6 REAR AXLE
SKETCHES OF SPECIAL TOOLS .................. 30-10 Removal .................................................... 30-109
STARTING MOTOR Installation ................................................ 30-112
Removal and Installation ........................... 30-14 REAR DIFFERENTIAL
ALTERNATOR Removal .................................................... 30-113
Removal and Installation ........................... 30-15 Installation ................................................ 30-114
RADIATOR DIFFERENTIAL GEAR
Removal ...................................................... 30-16 Disassembly ............................................. 30-115
Installation .................................................. 30-18 Assembly .................................................. 30-119
ENGINE AND TORQUE CONVERTER FINAL DRIVE
ASSEMBLY Disassembly ............................................. 30-127
Removal ...................................................... 30-19 Assembly .................................................. 30-129
Installation .................................................. 30-22 ORBIT-ROLL
TORQUE CONVERTER Removal and Installation ......................... 30-132
Removal ...................................................... 30-23 STEERING CYLINDER
Installation .................................................. 30-24 Removal .................................................... 30-133
Disassembly ............................................... 30-25 Installation ................................................ 30-134
Assembly .................................................... 30-31 STEERING VALVE
TRANSMISSION Removal .................................................... 30-135
Removal ...................................................... 30-38 Installation ................................................ 30-136
Installation .................................................. 30-40 BRAKE VALVE
Disassembly ............................................... 30-41 Removal and Installation ......................... 30-137
Assembly .................................................... 30-56 BRAKE VALVE (R.H.)
TRANSMISSION VALVE Disassembly ............................................. 30-138
Removal and Installation ........................... 30-72 Assembly .................................................. 30-140
TRANSFER BRAKE VALVE (L.H.)
Disassembly ............................................... 30-73 Disassembly ............................................. 30-142
Assembly .................................................... 30-82 Assembly .................................................. 30-144
CENTER SUPPORT SLACK ADJUSTER
Removal and Installation ........................... 30-92 Removal and Installation ......................... 30-146
Disassembly ............................................... 30-94 Disassembly ............................................. 30-147
Assembly .................................................... 30-96 Assembly .................................................. 30-148
DRIVE SHAFT BRAKE
Disassembly ............................................... 30-99 Removal and Installation ......................... 30-149
Assembly .................................................. 30-102 Disassembly ............................................. 30-150
FRONT AXLE Assembly .................................................. 30-153
Removal .................................................... 30-105
Installation ................................................ 30-106
WD600-3 30-1
(2)
HYDRAULIC PUMP PARKING BRAKE
Removal .................................................... 30-157 Removal and Installation ......................... 30-199
Installation ................................................ 30-158 PARKING BRAKE CALIPERS
HYDRAULIC TANK Disassembly ............................................. 30-200
Removal .................................................... 30-159 Assembly .................................................. 30-201
Installation ................................................ 30-160 PARKING BRAKE PAD
HYDRAULIC FILTER Removal and Installation ......................... 30-202
Removal and Installation ......................... 30-161 REAR TIRES
PPC VALVE Removal and Installation ......................... 30-203
Removal and Installation ......................... 30-162 AIR CONDITIONER COMPRESSOR
Disassembly and Assembly .................... 30-163 Removal and Installation ......................... 30-204
DECO VALVE AIR CONDITIONER CONDENSER
Removal and Installation ......................... 30-164 Removal and Installation ......................... 30-205
WORK EQUIPMENT VALVE RECEIVER TANK
Installation ................................................ 30-166 AIR CONDITIONER UNIT
PITCH & TILT CYLINDER Removal .................................................... 30-207
Removal and Installation ......................... 30-167 Installation ................................................ 30-208
LIFT CYLINDER MONITOR
Installation ................................................ 30-169
CENTER HINGE PIN
Removal .................................................... 30-170
Installation ................................................ 30-175
WORK EQUIPMENT
Removal .................................................... 30-178
Installation ................................................ 30-181
BULKHEAD
Removal .................................................... 30-182
Installation ................................................ 30-183
FLOOR FRAME
Removal .................................................... 30-184
Installation ................................................ 30-186
COUNTERWEIGHT
Removal and Installation ......................... 30-187
FUEL TANK
Removal .................................................... 30-188
Installation ................................................ 30-189
CAB
Removal .................................................... 30-190
Installation ................................................ 30-192
STOP VALVE
ACCUMULATOR
Removal and Installation ........................ 30-194
ACCUMULATOR CHARGE VALVE
PARKING BRAKE SOLENOID VALVE
DIVERTER VALVE
EMERGENCY STEERING PUMP
30-2 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
2) Any special techniques applying only to the installation procedure are marked 1, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF cccc ASSEMBLY ............... Title of operation
¤ ...................................................................... Precautions related to safety when carrying out
the operation
1. X X X X (1) ..................................................... Step in operation
fl .................................................................. Technique or important point to remember
when removing XXXX (1).
2. t t t t (2): ............................................... 1 Indicates that a technique is listed for use
during installation
3. assembly (3)
6 .................................................................... Quantity of oil or water drained
INSTALLATION OF cccc ASSEMBLY .... . Title of operation

• Carry out installation in the reverse order to removal.
1 ............................................................. Technique used during installation
fl .................................................................. Technique or important point to remember when
installing t t t t (2).
• Adding water, oil ................................. Step in operation
fl ............................................................ Point to remember when adding water or oil
-.........................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools

1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
WD600-3 30-3
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12 Taper 1/8
øD
ød
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25 L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30 DEW00401
27 07049-02734 27 22.5 34
30-4 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the steering, bucket, and boom cylinders to the end of their stroke 3 - 4 times, stop
the engine, loosen air bleed plug (1), bleed the air from the hydraulic tank, then tighten plug (1)
again.
4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this operation until no more air
comes out from the plug.
5. After doing this, run the engine at normal speed.
fl When using the machine for the first time after repair or
long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
WD600-3 30-5
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79cT-ccc-cccc can not be supplied (they are items to be locally manu-
factured).
fl Necessity: : .......... Cannot be substituted, should always be installed (used)
b : .......... Extremely useful if available, can be substituted with commercially avail-
able part.
New/remodel: N : .......... Tools with new part numbers, newly developed for this model.
R : .......... Tools with upgraded part numbers, remodeled from items already available
for other models.
Blank: .... Tools already available for other models, used without any modification
fl Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Nece- New/ Ske-

Component Symbol Part No. Part Name ssity Q’ty model
re-
tch Nature of work, remarks
1 792-400-1110 Bracket 1 Engine slinging jig
2 795-902-1430 Push tool 1

795-902-1410 Sleeve 1
Installation of front seal
3 01050-32240 Bolt 3
01050-32235 Bolt 3
4 795-902-1420 Sleeve 1
795-902-1440 Push tool 1
01582-02016 Nut 2 Installation of rear seal
5
795-902-1450 Bolt 2
01050-32050 Bolt 4
Disassembly, assembly 6 790-331-1110 Wrench 1 Tightening of cylinder head

of engine A Removal, installation of
7 790-471-1001 Lifting tool 1 cylinder head
8 795-601-1110 Push tool 1 Removal of water pipe
795-799-5410 Adapter 1 N Disassembly, assembly of

9 engine
795-799-5420 Remover 1 N
798-621-1140 Push tool 1 N
10 795-902-1460 Bolt 3 Assembly of engine
01582-02218 Nut 3
795-621-1130 Push tool 1 N
11 Assembly of engine
01050-32280 Bolt 5
12 Commercially Feeler gauge 1 Assembly of engine
available
Disassembly, assembly 1 793-613-1110 Wrench 1 Removal, installation of

A
of torque converter pump
2 792-201-0200 Wrench 1
Disassembly, assembly Check of operation of clutch
A 799-301-1500 Leak tester 1 piston
of transmission
Disassembly, assembly Check of operation of clutch

A 799-301-1500 Leak tester 1 piston
of transfer
30-6 WD600-3
(2)
Nece- New/ Ske-

re-
Disassembly, assembly Centering of transmission -
of transfer D 33 790-438-1120 Centering tool 1 center support
790-201-2850 Spacer 1 Press fitting of center
support main bearing
790-201-2750 Spacer 1
Press fitting of center
790-101-5401 Push tool kit 1 support sub bearing
1 • 790-101-5451 • Plate 1 Press fitting of center
support bearing outer race
• 790-101-5461 • Plate 1
Sub bearing
• 790-101-5421 • Grip 1
Main bearing
• 01010-51240 • Bolt 1
793T-620-1150 Plate 1 N
• 790-101-5431 • Plate 1 Press fitting of oil seal of
2 center support housing
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-501-5200 Unit repair stand 1 For overseas countries
3 790-901-4110 Bracket 1
793-310-2190 Plate 1
Removal, installation of axle
4 793-560-1201 Rod 1 shaft
793T-623-1140 Push tool 1 N
Disassembly, assembly H Press fitting of differential
of differential 73T-623-1150 Spacer 1 N cage oil seal
5 Press fitting of differential
790-101-5221 Grip 1 case dust seal
01010-51240 Bolt 1
6 Pinion shaft main bearing
793T-623-1160 Push tool 1 N inner race
7 Pinion shaft sub bearing
793T-623-1170 Push tool 1 N inner race
790-101-5401 Push tool kit (C) 1
• 790-101-5621 • Plate 1 Press fitting of main
8 bearing outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit (C) 1
• 790-101-5551 • Plate 1 Press fitting of sub bearing
9 outer race
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
Press fitting of differential
10 793T-622-1180 Push tool 1 N case bearing
792-525-1000 Micrometer 1
Adjusting preload of
11 792-525-1220 Adapter 1 bearing
792-533-1400 Wrench 1
WD600-3 30-7
(2)
Nece- New/ Ske-

re-
1 Removal, installation of
793T-622-1190 Fixture 3 N wheel hub
793T-622-1210 Plate 1 N
Disassembly, assembly 2 • 790-101-5421 • Grip 1 Press fitting of oil seal

of rear brake J
• 01010-51240 • Bolt 1
792-520-2110 Installer 1
3 Fitting of floating seal
792-530-1600 Push tool 1
790-101-2300 Push puller 1
• 790-101-2310 • Block 1
• 790-101-2320 • Screw 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2350 • Leg 2
• 790-101-2360 • Plate 4 Installation of upper center
1 hinge bearing
• 790-101-2410 • Joint 2
• 02215-11622 • Nut 2
793-520-2640 Push tool 1
790-438-1030 Guide 1
790-438-1050 Bar 2
790-101-2102 Puller (30ton) 1
790-101-1102 Pump 1
Installation of center
hinge bearing K 790-101-2300 Push puller 1
• 790-101-2310 • Block 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2350 • Leg 2
• 790-101-2360 • Plate 4
• 790-101-2410 • Joint 2
Installation of lower center
2 • 02215-11622 • Nut 2 hinge bearing
790-438-1050 Bar 2
01580-12016 Nut 2
790-438-1010 Push tool 1
790-438-1020 Guide 1
790-438-1040 Screw 1
790-101-2102 Puller 1
790-101-1102 Pump 1
30-8 WD600-3
(2)
Nece- New/ Ske-

re-
799-703-1200 Service tool kit 1
Vacuum pump
Charging air conditioner X 799-703-1110 (220V) 1 Charging air conditioner
1
with gas Vacuum pump with gas
790-703-1120 (240V) 1
799-703-1400 Gas leak detector 1
WD600-3 30-9
(2)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

H2 Plate
H5 Push tool
30-10 WD600-3
(2)
H5 Spacer
H6 Push tool
WD600-3 30-11
(2)
H7 Push tool
H10 Push tool
30-12 WD600-3
(2)
J1 Fixture
J2 Plate
WD600-3 30-13
(2)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR
¤ Stop the machine on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma-
chine from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open engine left side cover (1).
2. Disconnect connectors (2) (E08) and (3) (E09).
3. Disconnect cable (4).
4. Disconnect cable (5) between upper and lower

starting motors.
5. Remove the mounting bolts, then remove start-

ing motor (6).
0 Starting motor: 18kg × 2pcs
fl The mounting bolts of the upper and lower start-

ing motors are also used to install the ground
cable.
INSTALLATION OF STARTING
MOTOR
• Carry out installation in the reverse order to re-
moval.
30-14 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
chine from moving.
1. Open engine right side cover.
2. Disconnect alternator terminals (1) (E15) and (2)

(E16) and (3)(E17).
3. Loosen locknuts (4).
4. Loosen adjustment rod (7) and mounting bolt (5).
5. Remove lock bolt (6) and move adjustment rod

(7) outside.
6. Loosen alternator mounting bolt (8), then remove

belt (9). 1
7. Remove mounting bolt (8), then remove alterna-

tor (10).
0 Alternator: 12kg
INSTALLATION OF
ALTERNATOR
moval.
1
fl Adjust the deflection of the belt to the speci-
fied value. For details, see TESTING AND AD-
JUSTING ALTERNATOR BELT TENSION.
WD600-3 30-15
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
chine from moving.
1. Open right and left side covers (1), then remove

engine hood (2).
0 Engine hood: 73kg
2. Loosen drain valve (3) and drain the engine cool-

ing water.
= Engine cooling water: Approx. 160 ¬
3. Lift off radiator grille (4).

0 Radiator grille: 29kg
4. Disconnect radiator water level sensor connector

(5) (G01).
5. Remove baffle plate (6).
6. Remove radiator guard mounting bolts (7).
30-16 WD600-3
(2)
7. Disconnect tail lamp connector (8) (GR1).
8. Remove baffle plates (9) and (10).
9. Remove radiator guard mounting bolts (11).
10. Remove right and left side pillar mounting bolts

(12).
11. Remove the mounting bolts, then remove the ra-

diator guard (13).
0 Radiator guard: 270kg
fl When slinging the radiator guard, take care
that radiator guard fitting portion will not in-
terfere with the radiator fitting portion.
12. Disconnect engine cooling water drain hose (14).
13. Disconnect 2 hoses (15) of the hydraulic oil cooler.

fl Prepare plugs to stop the oil from flowing out.
14. Disconnect hose (16) between the radiator and

water pump.
WD600-3 30-17
(2)
15. Disconnect 2 hoses (17) of the fuel cooler.
16. Disconnect aeration hose (18).
17. Disconnect engine cooling water return hose (19).
18. Disconnect sub-tank hose (20).
19. Disconnect two hoses (21) to after-cooler.
20. Remove upper and lower fan guards (22).
21. Remove fan (23) and place it on the radiator side.
22. Disconnect right and left radiator supports (24)

from the radiator, then let it fall down on the en-
gine side.
23. Apply corrugated cardboard [1] to the radiator

side, and lower fan (23) slowly and tense rope [2]
so that the fan will not fall down outward.
0 Fan: 46kg
24. Remove mounting bolts (25), then sling and re-

move radiator (26).
0 Radiator: 630kg
INSTALLATION OF RADIATOR
moval.
• Refilling with water

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
30-18 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND TORQUE CONVERTER ASSEMBLY
REMOVAL OF ENGINE AND

TORQUE CONVERTER
ASSEMBLY
chine from moving.
1. Remove the radiator . For details, see REMOVAL

OF RADIATOR.
2. Disconnect engine oil drain valve (1) from the fit-

ting portion.
3. Disconnect connectors (2) (ER1, ER2, ER3).
4. Disconnect body grounding terminals (3) (E18,

R10).
5. Disconnect wire (4) (E01) between the alternator

and slow blow fuse on the slow blow fuse side.
6. Disconnect torque converter lockup wiring har-

ness connector (5) (T08).
7. Disconnect heater hot water supply hose (6).
8. Disconnect heater hot water return hose (7).
9. Disconnect tube (8) between engine oil cooler and

torque converter oil cooler.
10. Disconnect hose (9) between water pump and

torque converter oil cooler.
WD600-3 30-19
(2)
11. Disconnect cable (10) connecting with battery re-

lay from engine starting motor.
12. Disconnect grounding cable (11) from main frame.
13. Disconnect two air compressor hoses (12).

fl Plug the hoses to prevent foreign objects from
entering.
fl Collect new fleon gas using tool X1.
14. Disconnect hose (13) between fuel tank and fuel

filter.
15. Remove the bulkhead. For details, see REMOVAL

OF BULKHEAD.
16. Disconnect steering pump suction tube (14).

fl Plug the tube to prevent foreign objects from
entering.
17. Disconnect discharge tube (15) between the steer-

ing valve and steering pump.
18. Disconnect switch pump suction tube (16).

ing valve and switch pump.
20. Remove mounting bolts (18) and lift off steering

and switch pump assembly (19).
0 Steering and switch pump assembly:
39kg
30-20 WD600-3
(2)
21. Disconnect transmission pump suction tube (20).
22. Disconnect discharge tube (21) between the trans-

mission and transmission pump.
23. Disconnect discharge hose (22) between the ac-

cumulator charge valve and PPC pump.
24. Disconnect PPC pump suction tube (23).
25. Remove mounting bolts (24) and transmission

and PPC pump assembly (25).
26. Disconnect work equipment pump suction tube

(26).
27. Disconnect discharge tube (27) between the work

equipment valve and work equipment pump.
28. Remove mounting bolts (28) and work equipment

pump assembly (29).
29. Disconnect torque converter oil temperature sen-

sor connector (30) (E07).
30. Disconnect tube (31) between the torque con-

verter and torque converter oil cooler.
31. Disconnect hose (32) between the torque con-

verter and transmission.
32. Disconnect air hose (33) between the torque con-

33. Disconnect drive shaft (34). 1
WD600-3 30-21
(2)
34. Remove engine front mount (35) and rear mount

(36). 2
35. Sling and remove engine and torque converter

assembly (37) slowly.
0 Engine and torque converter assembly:
3,240kg
fl When lifting off the engine and torque con-
verter assembly, check that the all wires,
hoses and connectors are disconnected.
INSTALLATION OF ENGINE
AND TORQUE CONVERTER
ASSEMBLY
moval.
1
9 Drive shaft mounting bolt:
98 – 123Nm {10.0 – 12.5kgm}
2
9 Mounting bolt:
824 – 1030Nm {84 – 105kgm}
• Refilling with water

Add water to the specified level. Run the engine
to circulate the water through the system. Then,
check the water level again.
30-22 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
REMOVAL OF TORQUE
CONVERTER
chine from moving.
OF BULKHEAD.
2. Disconnect steering pump suction tube (1).

fl Plug the tube to prevent foreign objects from
entering.

ing valve and steering pump.
4. Disconnect switch pump suction tube (3).

ing valve and switch pump.
6. Remove mounting bolts (5) and steering and

switch pump assembly (6).
39kg
7. Disconnect transmission pump suction tube (7).
8. Disconnect discharge tube (8) between the trans-

mission and transmission pump.
9. Disconnect discharge hose (9) between the accu-

mulator charge valve and PPC pump.
WD600-3 30-23
(2)
10. Disconnect PPC pump suction tube (10).
11. Remove mounting bolts (11) and transmission

12. Disconnect work equipment pump suction tube

(13).
13. Disconnect discharge tube (14) between work

equipment valve and work equipment pump.
14. Remove mounting bolts (15) and work equipment

pump (16).
15. Disconnect torque converter oil temperature sen-

sor connector (17) (E07).
16. Disconnect hose (18) connected to the oil cooler.
17. Disconnect hose (19) connected to the transmis-

sion.
18. Disconnect connecting hose (20) between torque

converter and transmission.
20. Disconnect torque converter lockup wiring har-

ness connector (22) (T06).
21. Remove 16 mounting bolts (23), then sling and

remove torque converter assembly (24). 2
0 Torque converter assembly: 340kg
INSTALLATION OF TORQUE
CONVERTER
•Carry out installation in the reverse order to re-
moval.
1
9 Drive shaft mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
2
9 Torque converter mounting bolt:
98 – 123Nm {10 – 12.5kgm}
30-24 WD600-3
(2)
DISASSEMBLY OF TORQUE
CONVERTER
Special tools
New/Remodel
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
1 793-613-1110 Wrench b 1
A
2 792-201-0200 Wrench b 1
1. Coupling
1) Set torque converter assembly (1) horizon-
tally.
2) Remove coupling (2).
2. Lockup valve assembly

Remove lockup valve assembly (3).
3. Relief valve assembly

Remove relief valve assembly (4).
4. Lubrication tubes
Remove lubrication tubes (5) and (6).
5. Pilot
1) Set torque converter assembly (1) with the pi-
lot side up.
2) Remove the mounting bolts and pilot (7), us-
ing forcing screw [1].
6. Lock bolt of output shaft

fl Note that the bolt has left-hand threads.
1) Remove seal ring (8).
2) Remove bolt (9) by “turning it to the right”.
3) Remove washer (10).
WD600-3 30-25
(2)
7. Housing
1) Remove 30 mounting bolts (12) of housing
(11).
2) Using puller [2], pull housing (11) out of the

boss of the turbine.
fl Hold the boss of the turbine.
fl A half of the inner race of the bearing
comes out.
3) Using hanging bolt [3], remove housing (11).
4) Remove bearing (13) and lockup piston (14)

from housing (11).
8. Lockup clutch disc

Remove disc (15).
30-26 WD600-3
(2)
9. Lockup clutch case

1) Sling torque converter assembly and remove
cover (16).
2) Remove drain plug (17) to drain the oil from
the torque converter.
3) Remove 36 mounting bolts (19) from pump
(18) and lower the torque converter assem-
bly onto the block.
4) Using hanging bolt [4], remove case (20).
10. Turbine assembly

Remove turbine assembly (21).
11. Stator assembly

1) Remove rings (59).
2) Pull up and remove stator assembly (22), turn-
ing it “clockwise”.
WD600-3 30-27
(2)
12. Output shaft

1) Turn over torque converter assembly (1).
2) Remove mounting bolts (23).
3) Using forcing screw [5], remove output shaft
assembly (24).
4) Check the thickness and quantity of shims

(25), then keep them.
5) Secure stator shaft (27) with several bolts (26).
fl This step is for loosening the pump hold-
ing nuts from the pump side.
6) Remove cage (36) from the output shaft.

7) Remove snap ring (37), spacer (38), and bear-
ing (39).
13. Pump assembly

1) Using tool A1, remove nut (28).
30-28 WD600-3
(2)
2) Remove spacer (29).

3) Remove pump assembly (30).
4) Remove bolt (31) and plate (32), and then re-

move gear (34) and outer race (44) from pump
(33).
14. Stator shaft

1) Remove the bolts tightened temporarily.
2) Using hanging bolt [6], remove stator shaft
assembly (35).
15. Pump drive gear assembly

fl Since all of the 3 assemblies have the same
structure, the procedure for disassembling
only 1 assembly is described below.
1) Using tool A2, remove nut (58).
fl When loosening the nut, prevent the
pump drive gear from turning with a bar.
WD600-3 30-29
(2)
2) Using push tool [9], pull out pump drive gear

(50) and remove bearing (51).
fl Apply the push tool to the base of the gear
shaft to secure the gear shaft, and then
remove the pump drive gear by hitting it,
taking care not to damage the threads.
3) Remove ring (52), and then remove bearing

(53) from pump drive gear (50).
4) Remove bearing outer races (54) and (55), and
then remove ring (56) from housing (57).
fl Since bearings (51) and (53), bearing outer
races (54) and (55), and rings (52) and (56)
are an assembly, keep them together,
checking their part Nos. and match marks.
30-30 WD600-3
(2)
ASSEMBLY OF TORQUE
CONVERTER
Special tools
New/Remodel
Symbol
Necessity
Part No. Part Name
Sketch
Q'ty
1 793-613-1110 Wrench b 1
A
2 792-201-0200 Wrench b 1
• Precautions for assembly

fl Clean the all parts and check them for dirt or
damage before installing.
fl Coat the sliding surfaces of the parts with en-
gine oil before installing.
fl Install the piston seal ring with the pressure
receiving side directed to the housing.
1. Pump drive gear assembly

fl Since all of the 3 assemblies have the same
structure, the procedure for disassembling
only 1 assembly is described below.
fl The bearing of the pump drive gear is an as-
sembly. When assembling its inner race,
outer race, and seat, check their part Nos. and
match marks.
1) Install ring (56) to housing (57).
2) Using push tool [11], press fit bearing outer
races (54) and (55).
3) Using push tool [10], press fit bearing (53) to
pump drive gear (50).
4) Install ring (52).
5) Set the pump drive gear. Then, using push

tool [12], press fit bearing (51).
fl Place the pump drive gear on the block
and fix its end, and then press fit the bear-
ing.
fl When press fitting the bearing, do not
damage the threads of the gear shaft.
WD600-3 30-31
(2)
6) Using tool A2, tighten nut (58).

fl When tightening the nut, prevent the
pump drive gear from turning with a bar.
3 Nut: 416.8 ± 24.5 Nm {42.5 ± 2.5 kgm}
7) Similarly to 1) - 6) above, assemble the other
pump drive gear assemblies.
2. Stator shaft
1) Fit spacer (41) to stator shaft (40) and install
bearing (42).
2) Install seal ring (43).
8 Seal ring: Grease (G2-LI)
3) Using hanging bolt [6], install stator shaft as-

sembly (35) to the torque converter case.
3. Pump assembly
1) Set outer race (44) and gear (34) to pump (33).
2) Fit spacer (32) and tighten bolt (31).
8 Bolt (31): Adhesive (LT-2)
3 Bolt (31):
58.8 – 73.5 Nm {6 – 7.5 kgm}
30-32 WD600-3
(2)
3) Install pump assembly (30) to the stator shaft.

fl Since the nut will be tightened, secure the
pump assembly temporarily with several
bolts.
4) Fit spacer (29).
5) Using tool A1, tighten nut (28).

8 Nut: Adhesive (LT-2)
3 Nut: 441.3 – 490.3 Nm {45 – 50 kgm}
3. Output shaft
fl Use an inner race and an outer race having
the same serial No. and match mark to as-
semble each bearing.
1) Install bearing (39) to the shaft.
2) Fit spacer (38) and install snap ring (37).
3) Install outer race (45) (a half) to cage (36).
4) Fit oil seal (46).

8 Press fitting part of oil seal:
Gasket sealant (LG-5)
8 Lip of oil seal: Grease (G2-LI)
5) Install the output shaft to cage (36), and then
install the other half outer race (45).
WD600-3 30-33
(2)
6) Using hanging bolt [7], install output shaft as-

sembly (24).
7) Adjust the shims according to the following

procedure.
i) Install 4 bolts (26) equally spacing them
without setting the shims.
3 Bolt: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
ii) Measure clearance “a” between stator
shaft (40) and cage (36) at 4 points equally
spaced on the circumference and obtain
the average clearance.
fl Dispersion of measured clearances:
Max. 0.05 mm
iii) Prepare shims so that “the measured
clearance” – “the thickness of the shims”
will be 0 – 0.05 mm.
fl A maximum clearance of 0.05 mm will
be made.
iv) Set the prepared shims and tighten
mounting bolts (26).
8 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
4. Stator
1) Install stator (47) to outer race (46), and then
install snap ring (48).
30-34 WD600-3
(2)
2) Install stator assembly (22), turning it “clock-

wise”.
3) Install rings (59).
5. Turbine assembly
1) Install inner race (49) (a half) to the boss of
the turbine assembly.
2) Install turbine assembly (21).
6. Lockup clutch case

1) Install guide bolt [8] to the bolt hole by the
cut for the drain plug on case (20).
2) Using hanging bolt and matching the guide
bolt to mounting hole “b” of pump (18), in-
stall case (20).
WD600-3 30-35
(2)
3) Tighten 36 mounting bolts (19) and 2 drain

plugs (17) from pump (18) side.
3 Mounting bolt:
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
3 Drain plug:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
4) Install cover (16).
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.51 kgm}
7. Lockup clutch disc

Install disc (15).
8. Housing
1) Fit the seal rings and install piston (14) to
housing (11).
fl Fit 2 sets of the seal rings back to back.
2) Install bearing (13) to the housing.
3) Using hanging bolt [3], install housing (11)

and tighten mounting bolts (12) temporarily.
4) Install the bearing inner race (49) (the other
half).
5) Tighten 30 mounting bolts (12).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
30-36 WD600-3
(2)
9. Lock bolt of output shaft

fl Note that the bolt has “left-hand threads”.
1) Install washer (10).
2) Tighten bolt (9) by turning it to the left.
8 Lock bolt: Adhesive (LT-2)
3 Lock bolt:
176.4 – 215.6 Nm {10 – 22 kgm}
3) Install seal ring (8).
8 Seal ring: Grease (G2-LI)
10. Pilot
Install pilot (7).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
11. Lubrication tube

1) Set torque converter assembly (1) on its side.
2) Install lubrication tubes (6) and (5).
3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
12. Relief valve assembly

Install relief valve assembly (4).
13. Lockup valve assembly

Install lockup valve assembly (3).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
14. Coupling
Install coupling (2).
WD600-3 30-37
(2)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
REMOVAL OF TRANSMISSION
chine from moving.
1. Drain the hydraulic oil and transmission oil.
= Hydraulic oil: 215 ¬
= Transmission oil: 110 ¬
2. Remove the floor frame. For details, see RE-

MOVAL OF FLOOR FRAME.
3. Disconnect hoses (1) from the diverter valve.
4. Remove brackets (2) and (3).
5. Disconnect tubes (4).
6. Disconnect drain hose (5).
7. Remove mounting bolts (6), then remove emer-

gency steering pump (7).
8. Remove filler tube (8).
9. Remove guard (9), then disconnect drive shaft

(10).
0 Center drive shaft: 56kg 1
10. Disconnect speed sensor connector (11) (T05).
11. Disconnect hoses (12) and (13) of the diverter

valve.
12. Disconnect tubes (14) and (15) between the

diverter valve and hydraulic tank.
13. Disconnect transmission connector (16) (T01).
14. Remove bracket (17), then disconnect hose (18)

between the switch pump and steering valve.
15. Disconnect hose (19) between the PPC pump and

accumulator charge valve.
16. Disconnect hose (20) and remove clamp (21), then

remove tube (22).
17. Disconnect tube (23) between the oil cooler and

transmission.
30-38 WD600-3
(2)
18. Disconnect trunnion greasing hose (24).
19. Disconnect hose (25).
20. Loosen bands (26).
21. Remove clamp (27) from bracket (30).
22. Remove clamp (28), then disconnect tube (29)

from the transmission valve.
23. Disconnect hose (31) between the torque con-

24. Disconnect upper drive shaft (32). 2

0 Upper drive shaft: 27kg
25. Disconnect rear drive shaft (33). 3

0 Rear drive shaft: 57kg
26. Remove suction tube (34) connected to the trans-

mission pump.
fl Disconnect this tube from the intermediate
clamp.
27. Disconnect drain tube (35).

fl Remove bracket (30).
28. Remove transmission mounting bolts (36), then

remove cap (37).
29. Remove mounting bolt (38), then remove bracket

(39). 4
fl Sling the transmission temporarily.
WD600-3 30-39
(2)
30. Remove trunnion mounting bolts (40), then re-

move transmission (41). 5
0 Transmission: 1,465kg
fl Adjusting the level of the transmission with
lever blocks [1], sling slowly.
INSTALLATION OF
TRANSMISSION
moval.
1
9 Center drive shaft:
157 – 196Nm {16 – 20kgm}
2
9 Upper drive shaft:
98 – 123Nm {10 – 12kgm}
3
9 Rear drive shaft:
157 – 196Nm {16 – 20kgm}
4
9 Cap and bracket mounting bolt:
245 – 309Nm {25.0 – 31.5kgm}
5
9 Trunnion mounting bolt:
157 – 196Nm {16 – 20kgm}
fl Using tool D33, center the center support and
transmission.
• Refilling with oil

- Hydraulic oil: 215 ¬
- Transmission oil: 110 ¬

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then, check
the oil level again.
30-40 WD600-3
(2)
DISASSEMBLY OF
TRANSMISSION
Special tool
Part No. Part Name Q'ty
A 799-301-1500 Leak tester 1
1. Control valve assembly

1) Remove tubes (1), (2) and (3).
2) Remove 11 mounting bolts.

fl Different length of bolts are used. Check
bolt length then remove.
fl Do not remove bolts which do not indi-
cate in diagram.
3) Using eyebolts [1] (thread dia. = 10mm, pitch
= 1.5mm), lift off control valve assembly (4).
0 Control valve assembly: 70kg
2. Sleeve
Using eyebolt [2] (16mm, P = 2.0), remove sleeves
(6).
3. Oil supply pipe

Remove 4 mounting bolts, then remove oil sup-
ply pipe (7).
WD600-3 30-41
(2)
4. Coupling cage
1) Using eyebolts, sling the transmission and
transfer case, then put on blocks [3].
0 Transmission and transfer case:
1,350kg
fl Take care not to crush the lubrication tube
on the underside of the case.
2) Remove mounting bolts (8), then remove

plate (9).
3) Remove 8 mounting bolts, then pull coupling
cage (10) out of the transmission case by us-
ing forcing screws.
0 Coupling cage: 30kg
4) Further disassemble the coupling cage ac-

cording to the following procedure.
i) Set the coupling cage to the press, then
remove coupling (11) by using push tool
[4] (Outside diameter: 90mm).
ii) Remove snap ring (12).
iii) Set the coupling cage to the press, then

remove bearing (13) by using push tool
30-42 WD600-3
(2)
iv) Remove oil seal (14).
5. Collar
Remove collar (15) from the shaft.
6. Transmission case
fl Plate (16) mounting bolt is 5mm longer
than the others. Keep it separately.
2) Using eyebolts [6] (12mm, P = 1.75), sling

transmission case (17) temporarily.
0 Transmission case: 115kg
3) Using a forcing screw, sling and remove trans-
mission case (17).
WD600-3 30-43
(2)
7. Tie bolts
fl Using tool A, check the operation of the pis-
ton before removing the tie bolts.
fl Referring to disassembly of transfer, leave two

tie bolts to remove transmission from the
transfer case.
Remove 17 tie bolts (18).
fl Make marks on the two shorter tie bolts
among 17 tie bolts.
8. Housing and carrier assembly

1) Using eyebolts [7] (14mm, P = 2.0), sling and
remove housing and carrier assembly (19).
0 Housing and carrier assembly: 55kg
fl Take care not to screw the eyebolts untill
they contact with housing.
2) Further disassemble the housing and carrier

assembly, according to the following proce-
dure.
i) Remove snap ring (20).
ii) Set the housing and carrier to the press,
then remove carrier (22) from housing (21)
by using push tool [8] (Outside diameter:
135mm).
30-44 WD600-3
(2)
iii) Remove snap ring (23).

iv) Set the housing and carrier assembly to
the press, then remove bearing (24) by
using push tool [9] (Outside diameter:
155mm).
v) Remove collar (25).

vi) Pull out the roll pin and remove pin (26),
then remove thrust washers (27), plan-
etary gear (28) and needle bearing (29).
9. Guide pin
Remove guide pin (30).
10. Spring
Remove spring (31).
WD600-3 30-45
(2)
11. Plate, disc and spring

Remove plate (32), disc (33) and spring (34).
12. Ring gear

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

remove piston and housing (36).
0 Piston and housing: 30kg
2) Remove piston (38) from housing (37).
14. Spring
Remove springs (39).
15. Disc, plate and spring

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

1) Remove snap ring (43).
remove the No. 2 piston and housing together
with No. 3 piston (44), ring gear and plate.
0 No. 2 piston, housing, No. 3 piston,
ring gear and plate: 65kg
30-46 WD600-3
(2)
3) Disassemble the piston and housing accord-

ing to the following procedure.
i) Remove plate (46), ring gears (47) and
(48).
ii) Remove No. 2 piston (50) and No. 3 pis-
ton (51) from housing (49).
iii) Remove snap ring (52) of ring gear (47).
17. Spring
Remove spring (53).

Remove disc (54), plate (55) and spring (56).
19. Collar
Remove collar (57).
20. Housing
Using eyebolts [7] (14mm, P = 2.0), sling and re-
move housing (58).
0 Housing: 25kg
WD600-3 30-47
(2)
21. Shaft and carrier assembly

1) Using bolt (8) and collar (9), sling and remove
shaft and carrier assembly (59).
0 Shaft and carrier assembly: 50kg
2) Disassemble the shaft and carrier assembly

according to the following procedure.
i) Set the assembly to the press, then re-
move shaft (61) from carrier (60).
ii) Remove sun gear (62) from the carrier.

iii) Set the assembly to the press, then re-
move bearing (63) by using push tool [10]
(Outside diameter: 80mm).
iv) Remove sun gear (64) from the carrier .
30-48 WD600-3
(2)
v) Set the assembly to the press, then re-

move sun gear (65) by using push tool [11]
vi) Set the assembly to the press, then re-

vii) Pull the roll pin out of carrier (67) and
remove pin (68), then remove thrust
washers (69), planetary gear (70) and
needle bearings (71).
22. Collar
Remove collar (72).
WD600-3 30-49
(2)
23. Rotary clutch

1) Remove snap ring (73).
remove rotary clutch (74).
0 Rotary clutch: 75kg
3) Further disassemble the rotary clutch accord-

i) Remove 22 mounting bolts (75).
ii) Using forcing screws, remove case (76).
iii) Remove hub (77).
iv) Using puller [13] and push tool [14] (Out-

side diameter: 115mm), remove bearing
(78).
v) Remove disc (79), spring (80) and plate

(81).
30-50 WD600-3
(2)
¤ Be extremely careful since the tension

of 217kg is applied to the snap ring.
vi) Set the rotary clutch to the press and hold
the belleville spring with push tool [15]
(Inside diameter: 180mm), then remove
the snap ring.
vii) Loosen the press gradually, then remove
snap ring (82) and belleville spring (83).
viii)Remove piston (84).

ix) Set it to the press, then remove bearing
(85) by using push tool [14] (Outside di-
ameter: 105mm).

remove housing and carrier assembly (86).
0 Hosing and carrier assembly: 55kg
2) Further disassemble the housing carrier as-

sembly according to the following procedure.
i) Remove snap ring (87).
ii) Set the assembly to the press, then re-
move carrier assembly by using push tool
[17] (Outside diameter: 120mm)
WD600-3 30-51
(2)
iii) Pull out the roll pin and remove pin (89),
then remove thrust washer (90), planetary
gear (91) and needle bearing (92).
iv) Remove 3 mounting bolts, then remove

collar (93) with forcing screws.
v) Remove snap ring (94).

25. Guide pin

Remove guide pin (96).
26. Spring
Remove spring (97).

30-52 WD600-3
(2)
28. Sun gear

Remove snap ring (101), then remove sun gear
(102).
29. Shaft and carrier

1) Inserting a pin (95mm or longer) in the hole
(Diameter: 8mm) of the shaft, remove shaft
and carrier assembly (103).
0 Shaft and carrier assembly: 50kg
2) Further disassemble the shaft and carrier as-

sembly according to the following procedure.
i) Remove 3 mounting bolts, then remove
plate (104).
ii) Remove snap ring (105), then remove ring
gear (106).
iii) Remove snap ring (107).

iv) Set the assembly to the press, then re-
move carrier (108) by using push tool [18]
(Inside diameter: 210mm).
WD600-3 30-53
(2)
v) Remove snap ring (109).

move sun gear (110) by using push tool
[12] (Inside diameter: 106mm).
vii) Remove snap ring (111), then remove

bearing (112) by using the push tool (Out-
side diameter: 130mm).
viii)Set the assembly to the press, then re-

move collar (113) by using the push tool
ix) Pull out the roll pin and remove pin (114),
then remove thrust washer (115), plan-
etary gear (116) and needle bearing (117).
30-54 WD600-3
(2)

1) Using eyebolt [7] (14mm, P = 2.0), sling and
remove No. 5 piston and housing assembly
(118).
0 No. 5 piston and housing assembly:
40kg
31. Spring
Remove spring (121).

33. Ring gear

Remove ring gear (125).

remove No. 6 piston and housing (126).
0 No. 6 piston and housing: 40kg
WD600-3 30-55
(2)
ASSEMBLY OF TRANSMISSION
fl Precautions for assembly
• Before installing the parts, apply engine oil
(EO10-CD) to their rotary portions and sliding
portions.
• Apply grease (G2-LI) to each seal ring, and fit
it evenly.
• When installing each bearing, apply adhesive
(ThreeBond 1373B) to its inside and outside
surfaces to be fixed.
• When install a disc, match its notch to the
mating part.
• Check that each snap ring is fitted.
Preparation work
Clean each part and remove all burrs.

1) Fit the seal ring, then install piston (128) to
housing (127).
fl Set the seal ring groove on the housing
side as shown in the figure.
2) Fit the O-ring to the transfer case, then sling
No. 6 piston and housing (126) using eyebolts
[7] (14mm, P = 2.0). Then, install the assem-
bly with matching the dowel pin.
2. Guide pin
Install guide pin (96).
fl Length of guide pin: 150mm
3. Ring gear
Install ring gear (125).
30-56 WD600-3
(2)

1) Install disc (122), plate (123) and spring (124).
fl Note that spring (124) is different from the
other springs.
Free length: 8mm
5. Spring
Install spring (121).
6. No. 5 piston and housing assembly

1) Install the seal ring, then install piston (120)
to housing (119).
fl For installation of the seal ring, see 1-1).
install No. 5 piston and housing assembly
(118) with matching the dowel pin.
fl When installing the assembly, check that
spring (121) will not fall through the clear-
ance between the housing and transfer
case.
3) Using bolt [19] (14mm, P = 2.0, ¬ = 200mm)
and nut, insert the dowel pin of the housing.

1) Assemble the shaft and carrier assembly ac-
i) Install the seal ring and set needle bear-
ing (117), planetary gear (116) and thrust
washer (115), then insert pin (114) and
install the roll pin.
WD600-3 30-57
(2)
ii) Install collar (113) by expansion fit.
iii) Set the assembly to the press, then press

fit bearing (112) to the No. 6 sun gear by
using push tool [8] (Outside diameter:
135mm).
iv) Install snap ring (111).
v) Install snap ring (109) to the shaft.

vi) Set the assembly to the press, then press
fit sun gear (110) by using push tool [12]
vii) Install carrier (108) to the shaft with push

tool [8].
viii)Install snap ring (107).
30-58 WD600-3
(2)
ix) Install ring gear (106), then install snap

ring (105).
x) Install sun gear (102), then install snap
ring (101).
xi) Install plate (104).
2) Inserting a pin in the hole of the shaft, sling

and install shaft and carrier assembly (103).
fl Fit the tooth surfaces of the planetary gear
and ring gear to each other.

Install disc (98), plate (99) and spring (100), then
remove bolt [19].
WD600-3 30-59
(2)
9. Spring

1) Assemble the housing and carrier assembly
i) Install the assembly to the press, then
press fit bearing (95) by using push tool
ii) Install snap ring (94).
iii) Install collar (93), the tighten the three

mounting bolts.
8 Mounting bolt:
13.7 ± 1.0Nm {1.4 ± 0.1kgm}
3 V-groove on periphery of collar:

Gasket sealant (LG-I)
iv) Set needle bearing (92), planetary gear
(91) and thrust washer (90) and install pin
(89), then install the roll pin.
30-60 WD600-3
(2)
v) Set the assembly to the press, then install

carrier assembly (88) with push tool [8]
vi) Install snap ring (87).

install housing carrier assembly (86).
11. Rotary clutch

1) Assemble the rotary clutch according to the
following procedure.
i) Install the seal ring and set the rotary
clutch to the press, then press fit bearing
(85) by using push tool [14] (Outside di-
ameter: 125mm).
ii) Install the seal ring, then install piston (84).
iii) Set belleville spring (83), snap ring (82)

and spacer retainer.
iv) Set it to the press and hold the belleville
spring by using push tool [15] (Inside di-
ameter: 180mm), then press fit snap ring
(82).
WD600-3 30-61
(2)
v) Set it to the press, then press fit bearing

(78) to hub (77) by using push tool [14]
vi) Set hub (77) to the rotary drum.
vii) Disc, plate and spring

Install disc (79), plate (81) and spring (80).
viii)Install case (76), then tighten mounting

bolt (75).
9 Mounting bolt:
112.8 ± 9.8Nm {11.5 ± 1.0kgm}

install rotary clutch (74).
fl Push in the rotary clutch until the snap
ring groove of the shaft appears.
3) Install snap ring (73).
30-62 WD600-3
(2)
12. Collar
Install the seal ring, then install collar (72).
13. Housing
Using eyebolt [7] (14mm, P = 2.0), sling and in-
stall housing (58).
14. Collar
Install collar (57).
15. Guide pin

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

17. Spring
WD600-3 30-63
(2)
18. No. 2 piston, housing and No. 3 piston

1) Install the seal ring, then install No. 2 piston
(50) and No. 3 piston (51) to housing (49).
install the No. 2 piston, housing and No. 3 pis-
ton (44).
fl Take care not to drop the No. 3 piston.

1) Assemble shaft and carrier assembly (67) ac-
i) Set needle bearing (71), planetary gear
(70) and thrust washer (69), and install pin
ii) Set the assembly to the press, then press

fit bearing (66) by using push tool [20] (In-
iii) Set the assembly to the press, then press
sun gear (65) by using push tool [16] (Out-
iv) Install sun gear (64).
30-64 WD600-3
(2)
v) Set the assembly to the press, then press

fit bearing (63) by using push tool [13]
vi) Install sun gear (62).
vii) Install the seal ring to shaft (61).

viii)Set the assembly to the press, then press
fit shaft (61) to carrier assembly (60) by
using push tool [21] (Inside diameter:
75mm).
2) Using bolt (8) and collar (9), sling and install

shaft and carrier assembly (59).
3) Hit the shaft to press fit the bearing part.
20. Ring gear

WD600-3 30-65
(2)
21. Ring gear

Install snap ring (52), then install ring gear (47).
22. Plate
Matching the roll pin, install plate (46), then in-
stall snap ring (43).
fl Check that the snap ring installed to the ring
gear is securely set between the plate and
carrier.

24. Spring

1) Install the seal ring, then install piston (38) to
housing (37).
install the No. 1 piston and housing (36).
30-66 WD600-3
(2)
26. Ring gear


28. Spring

1) Assemble shaft and carrier assembly accord-
i) Set needle bearing (29), planetary gear
(28) and thrust washer (27), and install pin
ii) Install the seal ring, then install collar (25),

matching the dowel pin.
WD600-3 30-67
(2)
iii) Install the seal ring to the housing and set

them to the press, then install bearing (24)
by using push tool [22] (Outside diameter:
185mm).
iv) Install snap ring (23).
v) Set the assembly to the press, then install

carrier assembly to housing (21) by using
push tool [22] (Inside diameter: 145mm).
vi) Install snap ring (20).

install housing carrier assembly (19), match-
ing the dowel pin.
30. Tie bolts

Install 17 tie bolts (18).
9 Tie bolt: 166.7 ± 9.8Nm {17 ± 1kgm}
fl When the transfer has been removed, install
it to the transfer case, referring to the instal-
lation procedure of the transfer.
30-68 WD600-3
(2)
31. Check of operating condition of piston

Using tool A, check the operation and stroke of
the piston.
fl Air pressure: 0.3 – 0.5MPa {3 – 5kg/cm2}
fl Piston stroke
mm
Piston Stroke
No.1 4.0
No.2 4.0
No.3 3.2
No.5 3.2

1) Install the O-ring to the transfer case, then
sling transmission case (17) temporarily, us-
ing eyebolts [6] (12mm, P = 1.75).
2) Matching the dowel pin, install transmission
case (17).
fl When installing, confirm that the bolt for
plate (16) is 5mm longer than the other
bolts.
fl Install the bolt 60mm long to the portion
marked with ª.
33. Collar
34. Coupling and cage assembly

1) Assemble the coupling and cage assembly
i) Using push tool [23] (Outside diameter:
145mm), install oil seal (14).
8 Oil seal lip surface: Grease (G2-LI)
WD600-3 30-69
(2)
ii) Set the assembly to the press, then install

bearing (13) by using push tool [24] (Out-
side diameter 165mm).
iii) Install snap ring (12).
vi) Set the assembly to the press, then in-

stall coupling (11) with push tool [25] (Out-
side diameter 90mm).
2) Using eyebolts (12mm, P = 1.75), sling and

install coupling and cage assembly (10).
3) Install the O-ring, and install collar (9), then
tighten mounting bolt (8).
9 Mounting bolt:
279.5 ± 29.4Nm {28.5 ± 3.0kgm}
35. Oil supply pipe

1) Using the eyebolts, sling the TORQFLOW
transmission and transfer, then place it on
blocks [3].
30-70 WD600-3
(2)
2) Install oil supply pipe (7).
36. Sleeve
Install the O-ring, then install sleeve (6).

1) Fit O-ring using eyebolts [1] (thread dia. =
10mm, pitch = 1.5mm), install control valve
assembly (4).
2) Install 11 mounting bolts.
9 Mounting bolt:
49.0 ± 4.9Nm {5.0 ± 0.5kgm}
fl Check bolt length, then install.
3) Install tubes (3), (2) and (1).
WD600-3 30-71
(2)
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE
REMOVAL OF TRANSMISSION
VALVE
chine from moving.
1. Remove the mounting bolts, then remove step

(1) and cover as an assembly.
2. Disconnect transmission solenoid valve connec-

tor (2) (T01).
3. Remove lubrication tubes (3) and (4). 1

fl Before removing tube (3), remove the sleeve
nut of tube (4).
4. Remove tube (5).
5. Remove the mounting bolts, then remove trans-

mission valve (6). 2
0 Transmission valve: 65kg
INSTALLATION OF
TRANSMISSION VALVE
moval.
1
9 Mounting bolt:
19.6 – 24.5Nm {2.0 – 2.5kgm}
2
9 Transmission valve mounting bolt:
44.1 – 53.9Nm {4.5 – 5.5kgm}
30-72 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY TRANSFER
DISASSEMBLY OF TRANSFER
ASSEMBLY
Special tool
Part No. Part Name Q'ty
A 799-301-1500 Leak tester 1

1) Remove tubes (1), (2) and (3).

fl Different length of bolts are used. Check
bolt length then remove.
fl Do not remove bolts which do not indi-
cate in diagram.
3) Using eyebolts [1] (thread dia. = 10mm, pitch
= 1.5mm), lift off control valve assembly (4).
0 Control valve assembly: 70kg
2. Sleeve
Using eyebolt [2] (16mm, P = 2.0), remove sleeves
(6).
3. Lubrication tube
Remove the joint bolts, then remove lubrication
tube (7).
4. Oil supply pipe

Remove oil supply pipe (8).
5. Shaft mounting bolt

Loosen shaft mounting bolt (9).
WD600-3 30-73
(2)
6. Strainer
1) Using the eyebolts, sling and set transmission
and transfer case on block [3] with the trans-
fer case down.
0 Transmission and transfer: 1,350kg
2) Remove cover (11).

fl Since the cover may jump out because of
the spring, hold it when removing the
bolts.
3) Remove spring (12) and strainer (13), then re-
move flange (14).

1) Remove mounting bolts (15), then remove
plate (16).
2) Remove 8 mounting bolts, then sling and re-
move coupling and cage assembly (17), us-
ing forcing screws.
8. Collar
Remove collar (18) from the shaft.
30-74 WD600-3
(2)
fl The bolts for plate (19) are 5mm longer
than the other ones. Store them sepa-
rately.
2) Using eyebolts [4] (12mm, P = 1.75), sling

transmission case (20) temporarily.
3) Using a forcing screws, sling and remove
transmission case (20).
10. Tie bolt

fl Using tool A, check the operation of the pis-
ton before disassembly.
Remove 15 tie bolts (21) other than the bolts

marked with ª.
WD600-3 30-75
(2)
11. Transmission
Using eyebolts [5] (14mm, P = 2.0), sling and re-
move transmission (22).
12. Cage
1) Remove 4 mounting bolts, then remove cage
(23), using a forcing screws.
2) Remove outer race (24) from cage (25).
13. No. 1 gear

1) Remove gear (26).
2) Using a puller, remove 2 bearings (27) from
gear (28).
14. Cage
1) Remove the mounting bolts, then remove the
fitted part of the cage, using forcing screws.
remove cage (29).
fl Since the cage is thick, lift it straight up.
30-76 WD600-3
(2)
15. No. 3 gear

1) Remove No. 3 gear (32).
2) Using a puller, remove bearing (33) from the
gear.
16. Coupling
Remove coupling (34).
17. Cage
1) Remove cage (35).
2) Remove oil seal (36) from cage (37).
WD600-3 30-77
(2)
18. Shaft
1) Remove mounting bolt (9) and plate (38), then
remove shaft (39).
2) Remove snap ring (40), then remove inner

race (41) from shaft (42).
19. Bearing
Remove bearing (43) from the transfer case.
20. Cage
1) Remove the mounting bolts, then remove
cage (44) and shim (45), using forcing screws.
fl Check the thickness and number of the
shims, then store them.
30-78 WD600-3
(2)
21. Cage
cage (48), using forcing screws.
shims (49), then store them.
22. Cage
cage (52) and shims (53), using forcing screws.
23. No. 2 gear

1) Remove No. 2 gear (56).
2) Using a puller, remove bearing (57) from gear
(58).
24. Outer race

Remove outer race (59) from the transfer case.
WD600-3 30-79
(2)

coupling and cage assembly (60), using forc-
ing screws [6] (12mm, P = 1.75).
2) Further disassemble the coupling and cage

assembly according to the following proce-
dure.
i) Remove mounting bolts (61), then remove
coupling and bearing (62) and shims (63)
from cage (64), by using push tool [7]
ii) Remove collar (65) and outer race (66)

from cage (67).
iii) Using push tool [8] (Outside diameter:

105mm), remove coupling (68).
iv) Remove bearing (69) and (70), then re-
move outer race (71). Remove oil seal (72)
from cage (73).
30-80 WD600-3
(2)
26. No. 4 gear and collar

1) Take No. 4 gear (74) and collar (75) out of the
transfer case.
WD600-3 30-81
(2)
ASSEMBLY OF TRANSFER
Preparation work
• Clean each part carefully and check that it is free
from dirt, stain, etc.
1. Cage
1) Using push tool [9] (Outside diameter:
190mm), press fit outer race (46) to cage (47).
2) Install the O-ring, then install cage (44) and

shim (45).
fl Standard thickness of shim: 2mm
2. Cage
2) Install the O-ring, then install cage (48) and

shim (49).
30-82 WD600-3
(2)
3. No. 1 gear
105mm), press fit 2 bearings (27) to gear (28).
2) Install gear (26).
i) Turn over the transfer case.
4. Cage
2) Install the O-ring, then install cage (23).
5. Adjusting preload of No. 1 gear bearing

Set tool [12] and measure the preload with a
torque wrench.
fl Standard preload: 0.1 – 1.0Nm {0.01 – 0.1kgm}
fl If the preload is out of the standard range,
adjust it with shim (45).
WD600-3 30-83
(2)

Set No. 4 gear (74) and collar (75) in the transfer
case.
7. No. 3 gear
105mm), install bearing (33) to the gear.
2) Install No. 3 gear (32).
8. Cage
2) Install the O-ring, then sling and install cage

(29), using eyebolt [1] (10mm, P = 1.5).
30-84 WD600-3
(2)

1) Turn over the transfer case, then remove in-
spection cover (76).
2) Set tool [14] and measure the preload with a
torque wrench.
fl Standard preload: 0.1 – 1.0Nm {0.01 –
0.10kgm}
fl Move the No. 4 gear so that its teeth will
not interfere with the bearing.
10. Outer race

Using push tool [11] (Outside diameter: 190mm),
press fit outer race (59) to the transfer case.
11. No. 2 gear

105mm), install 2 bearings (57) to gear (58).
2) Install No. 2 gear (56).
12. Cage
WD600-3 30-85
(2)
2) Install the O-ring, then install shim (53) and

cage (52).

1) Set tool [18] to the No. 3 gear and measure
the preload with a torque wrench.
fl Standard preload: 0.3 – 2.9Nm {0.03 –
0.310kgm}
2) Install inspection cover (76).
fl Check that each gear does not have play.

1) Assemble the coupling and cage assembly ac-
i) Using push tool [15] (Outside diameter:
155mm), install oil seal (72) to cage (73).
8 Oil seal fitting surface:
Gasket sealant (ThreeBond 110B)

fl Thinly apply the gasket sealant to the oil
seal fitting surface on the cage side. Wipe
off projected sealant.
ii) Using push tool [11] (Outside diameter:
185mm), press fit outer race (66) to cage
(67).
iii) Install bearing (69), collar (65) and bear-
ing (70), then press fit outer race (71) to
cage (67), using push tool [11] (Outside
diameter: 185mm).
30-86 WD600-3
(2)
iv) Install the O-ring, then install cage (76) to

cage (77) and measure clearance S by
using a filler gauge.
v) Install shim (63).
Adjustment shim value = Clearance S +
(0.05 to 0.10)
vi) Using push tool [19] (Outside diameter:

125mm), press fit coupling (68) to cage
(78).
2) Install the O-ring, then install cage and cou-
pling assembly (60) to the transfer case.

Reverse the transfer case, then position No. 4 gear
and collar (75).
16. Bearing
Using push tool [16] (Outside diameter: 145mm),
press fit bearing (43) to the transfer case.
WD600-3 30-87
(2)
17. Shaft
1) Using push tool [17] (Inside diameter: 90mm),
press fit inner race (41) to shaft (42), then in-
2) Matching the spline, install shaft (39), then

install plate (38) and tighten mounting bolt (9).
9 Mounting bolt:
931.7 ± 98.1Nm {95 ± 10kgm}
18. Cage
135mm), install oil seal (36) to cage (37).
8 Oil seal fitting surface:
Gasket sealant (ThreeBond 110B)

fl Thinly apply the gasket sealant to the oil
seal fitting surface on the cage side. Wipe
off projected sealant.
2) Install cage to the transfer case.
19. Coupling
Install coupling (34) with matching the spline of
the shaft.
fl Install the coupling to the same position as
the coupling on the front output side.
30-88 WD600-3
(2)
20. Transmission
1) Install the O-ring to cage (25).
2) Install the seal ring, then sling and install
transmission (22), using eyebolt [5] (14mm,
P = 2.0) and matching the dowel pin.
fl Install the seal ring evenly.
21. Tie bolts

Install 15 tie bolts (21).
9 Tie bolt: 166.7 ± 9.8Nm {17 ± 1kgm}
22. Check of operating condition of piston

Using tool A, check the operation and stroke of
the piston.
fl Air pressure: 0.3 – 0.5MPa {3 – 5kg/cm2}
fl Piston stroke
mm
Piston Stroke
No.1 4.0
No.2 4.0
No.3 3.2
No.4 3.2

1) Install the O-ring to the transfer case, then
sling transmission case (20) temporarily,
using eyebolts [4] (12mm, P = 1.75).
2) Matching the dowel pin, install transmission
case (20).
fl When installing, confirm that the bolt for
plate (19) is 5mm longer than the other
bolts.
fl Install the bolt 60mm long to the portion
marked with ª.
WD600-3 30-89
(2)
24. Collar

1) Using the eyebolts (12mm, P = 1.75), sling and
install coupling and cage assembly (17).
2) Install the O-ring, then install plate (16) and
tighten the mounting bolts (15).
9 Mounting bolt:
279.5 ± 29.4Nm {28.5 ± 3.0kgm}
26. Strainer
1) Install flange (14), then install strainer (13) and
spring (12).
2) Install cover (11).
27. Shaft mounting bolt

1) Using hooks, sling transmission and transfer
assembly (10), and place it on block [3].
30-90 WD600-3
(2)
2) Loosen shaft mounting bolts (9).

9 Mounting bolt:
931.7 ± 98.1Nm {95 ± 10kgm}
28. Oil supply pipe

Install oil supply pipe (8).
29. Lubrication tube

Install the gasket, then install lubrication tube (7)
and tighten the joint bolts.
30. Sleeve
Install the O-ring, then install sleeve (6).

1) Fit O-ring and using eyebolts [1] (thread dia.
= 10mm, pitch = 1.5mm), raise control valve
assembly (4) and install.
2) Tighten 11 mounting bolts.
9 Mounting bolt:
49.0 ± 4.9Nm {5.0 ± 0.5kgm}
fl Check the length of the bolt before install-
ing.
3) Install tubes (1), (2) and (3).
WD600-3 30-91
(2)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
REMOVAL OF CENTER
SUPPORT
¤ Stop the machine on level ground and fully steer
to the left and lower the work equipment com-
pletely to the ground, then put blocks under the
wheels to prevent the machine from moving.
1. Disconnect center drive shaft (1). 1

0 Center drive shaft: 56kg
fl When disconnecting the drive shaft, sling it
with a rope, etc. to prevent it from falling.
2. Disconnect front drive shaft (2). 2

3. Disconnect grease tube (3).
4. Sling the center support temporarily, then remove

mounting bolts (4). 3
5. Sling and remove center support (5).

0 Center support: 47kg
fl If there are shims between the center support
and frame, check its quantity to refer when
assembling.
INSTALLATION OF CENTER
SUPPORT
moval.
1
9 Mounting bolt: 157 – 196Nm {16 – 20kgm}
2
30-92 WD600-3
(2)
3
fl Install tool D33 and dial gauge [1] to the cen-
ter support, then turn the coupling on the cen-
ter support side to set the transmission cou-
pling face and center support face in parallel
with each other and center them.
fl Adjust the shims on the center support mount-
ing face.
fl After adjusting the shims, tighten the mount-
ing bolts.
9 Mounting bolt:
490.0 – 608.0Nm {50.0 – 62kgm}
fl Parallelism: 0.1 max.
WD600-3 30-93
(2)
DISASSEMBLY OF CENTER
SUPPORT
1. Coupling
Remove center bolt (1), then remove retainer (2),
O-ring (3), and coupling (4).
2. Retainer
Remove mounting bolts (5).
fl Remove all mounting bolts by rotating cou-
pling.
3. Shaft
1) Set shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
fl Be careful because the shaft will fall out
suddenly.
3) Remove spacer (8), bearing cone (9) and re-

tainer (5) from shaft.
30-94 WD600-3
(2)
4. Oil seal
1) Remove oil seal (10) and O-ring (11) from re-
tainer.
2) Remove oil seal (12) from case.
5. Case
Remove bearing cone (13) and bearing outer race
(14) and (15).
WD600-3 30-95
(2)
ASSEMBLY OF CENTER
SUPPORT
1. Bearing outer race
Assemble bearing outer race (14) and (15) to
case (16).
2. Oil seal
Assemble oil seal (10) to retainer (5).
2 Outer circumference of oil seal :
Grease (G2-LI)
3. Bearing cone
Assemble retainer (5) shaft and press fit bearing
cone (9).
fl After assembling bearing, check that there is
no clearance at tip of shaft.
fl Assemble spacers.
2 Lip of seal : Grease (G2-LI)
2 Inner circumference of bearing :
Grease (G2-LI)
4. Case
1) Assemble O-ring (11) in retainer.
fl Insert O-ring completely in groove.
30-96 WD600-3
(2)
2) Stand shaft and insert case (16).

fl Fill “a” and “b” of case completely with
grease.
5. Retainer
Secure retainer (5) to case.
fl Be careful that O-ring does not get caught
when installing.
9 Mounting bolt :
65.7 ± 6.9 Nm {6.7 ± 0.7 kgm}
6. Bearing seal
1) Press fit bearing (13) to shaft.
2) Assemble oil seal (12) to case.
fl Concave or protrusion of oil seal: even to
end surface of case: ± 0.5mm
2 Seal : Grease (G2-LI)
7. Coupling
Assemble coupling (4), install O-ring (3) and re-
tainer (2), and secure center bolt (1).
3 Center bolt : 931 ± 98 Nm {95 ± 10 kgm}
WD600-3 30-97
(2)
8. Inspection of end play

Check that end play is within specified range.
fl End play : Less than 0.22 mm
fl If end play is “O”, with the seal and bearing
coated with grease check that the free rotat-
ing torque is less than 3.9 Nm {0.4kgm}.
30-98 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT
1. Shaft
1) Remove shaft (2)
fl Make match makes a before removing to
ensure that the position does not change.
fl Cover (1) and (1A) is caulked with punch

at four places, so it must not be removed
unless necessary.
fl When removing cover (1) and (1A) be ex-
tremely careful not to damage cover (1),
(1A) and yoke (3).
fl When removing the caulking, raise the
caulking with a screwdriver.
2) Remove mounting bolts (4), then remove spi-

der assembly (5).
fl Make match marks on yoke and spider.
WD600-3 30-99
(2)
3) Remove bearing caps (6) from spider assem-

bly.
fl Remove strap (7) of cap
4) When replacing bearing (8), seal (9), and plas-

tic washer (10) from bearing cap (6), replace
whole cap assembly.
2. Yoke
1) Remove mounting bolts (11) from yoke (3),
then remove spider assembly (12).
fl Stamp match marks on the yoke and spi-
der.
2) Remove bearing caps (13) from spider assem-

bly.
30-100 WD600-3
(2)
3) When replacing bearing (14), seal (15), and

plastic washer (16) from bearing cap (13), re-
place whole cap assembly.
WD600-3 30-101
(2)
ASSEMBLY OF DRIVE SHAFT

1. Yoke
1) Install bearing (14), and seal (15) to bearing
cap (13).
2 Bearing, seal : Grease (G2-LI)
2) Assemble plastic washer (16), and bearing cap

(13) to spider assembly (12)
fl Be careful not to damage bearing with
heat when welding strap.
2 Bearing cap : Grease (G2-LI)
3) Assemble spider assembly (12) to yoke (3).

fl Carefully align match marks.
fl Clean the mounting face of the bearing
cap by wiping with a clean cloth.
2 Mounting bolts :
142.2 ± 9.8 Nm {14.5 ± 1.0 kgm}
2. Shaft
1) Assemble bearing (8) and seal (9) in bearing
cap (6).
2 Bearing seal : Grease (G2-LI)
30-102 WD600-3
(2)
2) Assemble plastic washer (10) and bearing cap

(6) to spider assembly (5).
fl Be careful not to damage bearing with
heat when welding strap.
2 Bearing cap : Grease (G2-LI)
3) Assemble spider assembly (5) to shaft (2).

fl Carefully align match marks.
fl Clean the mounting face of the bearing
cap by wiping with a clean cloth.
9 Mounting bolt :
142.2 ± 9.8 Nm {14.5 ± 1kgm}
4) Align match marks “a”, then install shaft (2)

to yoke (3).
fl Check that the direction of the spider as-
sembly is the same.
fl If the spline is worn, replace the whole
drive shaft assembly.
2 Spline : Grease (G2-LI)
WD600-3 30-103
(2)
5) If cover (1) and (1A) has been removed, do as

follows.
• Front and rear drive shaft.
Insert seal and retainer to cover (1) and
shaft (2), assemble cover (1), then caulk
with a punch on diagonally opposite
sides.
• Center drive shaft.
Insert shaft (2) to cover (1A), assemble
cover (1A), then caulk with a punch on di-
agonally opposite sides.
30-104 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE

¤ Stop the machine on level ground and install the
safety bar on the frame.
1. Set block [1] to the front frame.

fl Since the machine body moves forward, keep
the parking brake turned off.
fl Remove the work equipment. For details, see
REMOVAL OF WORK EQUIPMENT.
2. Sling and remove tires (1). 1

0 Tires: 1,450kg
3. Put blocks [2] under the rear wheels.
4. Disconnect hose (2) for the parking brake.
5. Disconnect hose (3) for both front brakes.
6. Disconnect front drive shaft (4). 2

0 Front drive shaft: 56kg
WD600-3 30-105
(2)
DISASSEMBLY AND ASSEMBLY FRONT AXLE
7. Sling the front axle temporarily, then remove

mounting bolt (5). 3
8. Slowly sling and remove front axle (6).

fl Remove the front axle by operating the crane
so that it will not interfere with the boom end.
0 Front axle: 3,065kg
INSTALLATION OF FRONT AXLE

moval.
1
9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm}
2
9 Mounting bolt:
157.0 – 196.0Nm {16.0 – 20.0kgm}
3
9 Mounting bolt:
2450.0 – 3038.0Nm {250.0 – 310.0kgm}
• Bleeding air from brake

Bleed air from front brake. For details, see BLEED-
ING AIR.
30-106 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL
1. Remove the front axle. For details see REMOVAL
OF FRONT AXLE.
2. Remove drain plug (1) from right and left final

drives, and drain oil.
= Axle oil: 124 ¬ each
3. Remove mounting bolts (2), then remove cover

(3).
fl Remove the cover with the top mark up.

1
4. Install bolt [1] to the end of drive shaft (4), then

pull out the shaft.
5. Sling and remove drive shaft (4).

0 Drive shaft: 50kg
6. Remove the mounting bolt, then remove shaft (5).

2
fl Check the number of the shims.
7. Remove parking brake disc cover (6).
8. Remove plate (7), then remove pad (8). 3
9. Remove calipers and spring cylinder (9).
10. Remove plate (10). 4
11. Remove mounting bolts, then remove disc plate

(11). 5
WD600-3 30-107
(2)
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
12. Remove mounting bolts (12). 6
13. Sling front differential (13) temporarily, then dis-

connect it from the axle, using forcing screws [2].
14. Sling and remove front differential (13).

0 Front differential: 510kg
INSTALLATION OF FRONT
DIFFERENTIAL
moval.
1
9 Cover mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
2
fl Adjustment procedure of shims of shaft
1) Tighten the shaft evenly to the specified
torque without inserting any shim, and mea-
sure clearance A.
• Specified torque: 3.9 ± 1.0Nm {0.4 ±
0.1kgm}
2) Combine shims so that clearance between the
shaft end and differential cap will become B.
• Clearance B: 0.1 ± 0.05mm
3) Insert the shims and tighten the mounting
bolt.
9 Mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
34
8 Plate mounting bolt: Adhesive (LT-2)
9 Plate mounting bolt:

824.0 – 1030.0Nm {84.0 – 105.0kgm}
5
8 Disc mounting bolt: Adhesive (LT-2)
9 Disc mounting bolt:

490.0 – 608.0Nm {50.0 – 62.0kgm}
6
9 Differential mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}
30-108 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE

safety bar on the frame and put blocks under
the wheels.
1. Set blocks [1] on right and left sides of the rear

axle.
fl Set these block to prevent the tires from jump-
ing up when removed.
2. Raise the machine body with jacks (5ton) [2], then

set support stand [3] under the counter weight.
3. Adjusting jack [2], set blocks [4].
4. Sling tire (1) temporarily, then remove the hub

nuts.
5. Sling and remove tires (1). 1

0 Tires: 1,450kg
6. Disconnect rear drive shaft (2). 2

0 Drive shaft: 57kg
7. Disconnect hose (3) from the brake valve.
8. Disconnect tubes (4) and (5) connected to right

and left brakes from the slack adjuster. 3
WD600-3 30-109
(2)
9. Disconnect rear support grease tubes (6) and (7).
10. Disconnect front support grease tube (8).

fl Disconnect the clamp on the frame side.
11. Secure the axle support and rear axle by tighten-

ing them with lever block [5] with a chain, etc.
12. Sling either one side temporarily and support the

other side on a garage jack, then remove the sup-
port mounting bolts. 4
13. Balancing rear axle (9), lower it slowly.

0 Rear axle: 2,965kg
fl Operate the crane and garage jack to pull out
the rear axle from under the frame.
14. Sling and remove front support (10) from the rear
axle.
0 Front support: 126kg
30-110 WD600-3
(2)
15. Remove the mounting bolt from front support

(10), then remove retainer (11). 5
16. Remove packings (12) and (13) from the front sup-
port.
17. Remove 2 bushings (14) from the front support.

fl Remove all dirt and oil from the bushings and
front support bushing fitting face. 6
18. Remove thrust cover (16) and outer thrust washer

(17) from rear support (15). 7
0 Thrust cover: 38kg
19. Remove thrust plate (18) from rear support (15),

then remove inner thrust washer (17). 8
WD600-3 30-111
(2)
20. Remove rear support (15) from the rear axle.

0 Rear support: 153kg
21. Remove packing (19) from rear support (15).
22. Remove bushing (20) from the rear support.

fl Remove all dirt and oil from the bushings and
rear support bushing fitting face.
INSTALLATION OF REAR AXLE

moval.
1
9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm}
2
9 Mounting bolt:
157.0 – 196.0Nm {16.0 – 20.0kgm}
3
fl Bleed air from the slack adjuster. For details,
see BLEEDING AIR FROM EACH PORTION.
4
9 Support mounting bolt:
2450.0 – 3038.0Nm {250.0 – 310.0kgm}
5
9 Mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
69
fl Apply Loctite Prism 411 to the sticking face
on the support side, then stick the bushing
quickly.
fl The set time is 30 – 60 seconds.
78
9 Mounting bolt:
245.0 – 309.0Nm {25.0 – 31.5kgm}
30-112 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REMOVAL OF REAR
DIFFERENTIAL
1. Remove the rear axle . For details see REMOVAL
OF REAR AXLE.
2. Remove drain plugs (1) from right and left final

drives, and drain oil.
= Axle oil: 124 ¬ each
3. Remove mounting bolt (2), then remove cover (3).

fl Remove the cover with the top mark up.
1
4. Install bolt [1] to the end of drive shaft (4), then

pull out the shaft.
5. Sling and remove drive shaft (4).

0 Drive shaft: 50kg
6. Remove the mounting bolt, then remove shaft (5).

2
fl Check the number of the shims.
7. Remove front support (6) from the rear axle.

0 Front support: 126kg
8. Remove the mounting bolts, then remove differ-

ential (7). 3
0 Rear differential : 508kg
WD600-3 30-113
(2)
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
INSTALLATION OF REAR
DIFFERENTIAL
moval.
1
9 Cover mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
2
fl Adjustment procedure of shims of shaft
1) Tighten the shaft evenly to the specified
torque without inserting any shim, and mea-
sure clearance A.
• Specified torque:
3.9 ± 1.0Nm {0.4 ± 0.1kgm}
2) Combine shims so that clearance between the
shaft end and differential cap will become B.
• Clearance B: 0.1 ± 0.05mm
3) Insert the shims and tighten the mounting
bolt.
9 Mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
3
9 Differential mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}
30-114 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR
DISASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
1. Set differential assembly (1) on special tools H3.
4 Differential assembly : 230kg
fl Install bracket and plate in H3 to unit repair
stand in H3, and set defferential assembly (1)
to H3 assembly.
2. Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) and dust seal (3A) from

case.
3) Screw in forcing screws [1] (Thread dia. = 18

mm, Pitch = 1.75 mm), and fit out pinion as-
sembly (4).
fl Check number of shims (5).
WD600-3 30-115
(2)
3. Differential gear case assembly

1) Remove left and right locks (6), and with a bar,
turn nut (7) until it becomes loose.
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential gear case

assembly(10).
30-116 WD600-3
(2)
FINE DISASSEMBLY OF PINION

ASSEMBLY
4. Bearing, collar, cage

1) Support cage (11), push shaft with press and
push out pinion.
2) Remove bearing (12) and collar from cage.
3) Remove outer races (13) and (14) from cage

(11).
5. Pinion, bearing
1) Remove snap ring (15), then remove bearing
(16).
2) Remove bearing (17).
WD600-3 30-117
(2)
FINE DISASSEMBLY OF DIFFERENTIAL

GEAR CASE ASSEMBLY
6. Bevel gear (large)

Remove mounting bolts, using eye-bolts [2]
(Thread dia. = 16 mm, Pitch = 2.0 mm), lift off
bevel gear (18).
7. Bevel gear (small)

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

Remove pinion gears (21), cross shaft (22), and
washers (23) as assembly.

Remove bevel gear (24) and thrust plate.
10. Bearing
Remove bearing (26) from case (25).
30-118 WD600-3
(2)
ASSEMBLY OF DIFFERENTIAL
GEAR
FINE ASSEMBLY OF DIFFERENTIAL GEAR
CASE
1. Bearing
Using press fit kit H10 (Inner diameter: 120 mm ),
press fit bearing (26) to case (25).

Install thrust and small bevel gear (24) to case.
fl Align thrust with dowel pin and install.
3. Pinion gear, cross shaft

Assemble pinion gears (21) and washers (23) with
cross shaft (22).
fl Align washer groove with dowel pin of case
and install.

Install bevel gear (20) and thrust plate (19).
WD600-3 30-119
(2)
5. Bevel gear (large)

Using eye-bolts [2] (thread dia. = 16 mm, Pitch =
2.0 mm), lift and install bevel gear (18).
fl Align pin hole of thrust and dowel pin on case
side and install.
FINE ASSEMBLY OF PINION ASSEMBLY
6. Bearing
1) Using press fit kit H6 (Inner diameter: 26 mm),
install pinion bearing (17).
2) Using press fit kit H9 (Inner diameter: 55 mm),

install bearing (16).
2 Rotating surface of bearing :
Engine oil (EO30-CD)
3) Install snap ring (15).
7. Cage
1) Install outer race (14) by using H8 and install
outer race (13) by using H9.
2) Install cage (11) to pinion assembly.
30-120 WD600-3
(2)
8. Collar
9. Bearing
Using press fit kit H6 (Inner diameter: 76 mm),
install bearing (12).
ASSEMBLY OF DIFFERENTIAL ASSEMBLY
fl Set differential case on special tool H3.
10. Pinion assembly

1) Assemble shims (5) removed when disas-
sembled.
fl Standard shims thickness : 2.1 mm.
2) Using eye-bolts [5] (Thread dia. = 12 mm, Pitch
= 1.75 mm), install pinion assembly (4).
3) Install oil seal (3) and dust seal (3A) to case.

2 Lip of oil seal : Grease (G2-LI)
2 Lip of dust seal : Grease (G2-LI)
4) Fit O-ring to case, and install case (2).

3 Mounting bolt :
279.3 ± 29.4 Nm {28.5 ± 3.0 kgm}
2 Mounting bolt : Tread tightener (LT-2)
WD600-3 30-121
(2)
5) Insert coupling (28), fit O-ring and tighten

holder.
2 Mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt :
824 – 1030 Nm {84 – 105 kgm}
fl Fit the balancer [6] to bolt hole of coupling,

and measure the rotating torque.
fl Rotating torque : Max. 50 N {5.1 kg}
11. Differential gear assembly

Sling differential gear assembly (10) and install
case.
12. Nut, cap

1) Align nut (7) with differential case groove and
install.
2) Install cap (8) and tighten (9).

2 Mounting bolt :
Thread tigntener (LT-2)
3 Mounting bolt :
1,520 – 1,910 Nm {155 – 195 kgm}
fl Check match marks on bearing cup
before installing.
fl Rotate bevel gear 20 – 30 times to
settle in, then tighten bolts.
30-122 WD600-3
(2)
fl Bearing pre-load adjustment steps are as fol-

lows.
1) Install tool H11 to cap on both sides.
2) Measure dimension “a” by using H11.
3) Add 0.47 ± 0.09 mm to dimension “a” and

set scale on tool H11.
fl The added dimension becomes the
amount of bending of the case, given
before pre-load and given after pre-
load.
4) Tighten adjusting nut with bar until in-

creased amount becomes 0.47 ± 0.09 mm.
fl Caution for pre-load adjustment

When adjusting nut is overtightened, in case
the amount of increased bending surpasses
the standard measurement, return adjusting
nut to position before adjusting. Then while
rotating bevel gear, lightly tap bearing cap and
bevel gear with plastic hammer, and check
that there is no clearance in position b.
WD600-3 30-123
(2)
13. Adjusting tooth contact, backlash

Adjust the backlash, and at the same time adjust
tooth contact.
1) Adjust backlash as follows:
i) Movement of bevel gear is done with ad-
justing nuts (7). At this time, so as not to
change pre-load pressurization of bearing,
turn nuts on both sides, the same amount
each, in same direction.
ii) Put dial gauge [3] in vertical contact with
forward and reverse sides of outer edge
of bevel gear tooth face, and while turn-
ing adjusting nut, adjust until gauge meter
fluctuation becomes 0.33 – 0.46 mm.
fl Measure at 3 or 4 places, and keep the
pinion gear fixed when measuring.
2) Adjust tooth contact as follows:

i) Adjust bevel pinion by adjusting shims be-
tween differential case and bearing cage.
ii) Adjusting tooth contact
For details, see ADJUSTING TOOTH CON-
TACT.
30-124 WD600-3
(2)
3) Adjusting tooth contact

Coat face 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by
hand to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left
on the teeth.
Tooth contact Cause Procedure for adjustment

The tooth contact pattern Adjust the pinion gear by adjusting the shims at the
should start from about 5 cage. Adjust the bevel gear in the same way as when
mm from the toe of the adjusting back lash.
bevel gear and
cover about 50% of the
length of the tooth.
It should be in the center of
the tooth height.
Pinion gear is too far from 1. Reduce shims at pinion gear

bevel gear. to bring closer to bevel gear.
2. Move bevel gear further

away from pinion gear and
adjust backlash correctly.
Pinion gear is too close to 1. Increase shims at pinion gear

bevel gear. to move away from bevel
gear.
2. Move bevel gear closer to

pinion gear and adjust back-
lash correctly.
Bevel gear is too close to 1. Reduce shims at pinion gear

pinion gear. to bring closer to bevel gear.
2. Move bevel gear further

away from pinion gear and
adjust backlash correctly.
Bevel gear is too far from 1. Increase shims at pinion gear

pinion gear. to move away from bevel
gear
2. Move bevel gear closer to

pinion gear and adjust back-
lash correctly.
fl When adjusting the driven gear, do not change the pre-load of the bearing. Tnrn the left and right
adjusting nut, the same amount each (check by the number of notches), in the same direction.
WD600-3 30-125
(2)
14. Lock
After adjusting tooth contact and backlash, install
lock (6).
3 Mounting bolt:
98 ± 123 Nm {10.0 ± 12.5 kgm}
2 Mounting bolt : Thread tightener (LT-2)
30-126 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE

safety bar on the frame.
1. Set block [1] to the front frame.

fl Remove the work equipment. For details, see
REMOVAL OF WORK EQUIPMENT.
2. Sling and remove tires (1).

0 Tires: 1,450kg
3. Using tools J1, secure the brake housing and

wheel hub.
fl Install tools J1 to 3 places equally spaced.
fl Do not remove tools J1 before adjusting the
preload of the wheel bearing.
4. Remove drain plug (2), and drain oil.
= Axle oil: 124 ¬

fl Turn the tire on the opposite side to set the
drain plug to the bottom.
5. Remove bolts (3), and remove cover (4).
6. Install bolt [1] to drive shaft (5) so that the shaft

will be pulled out easily.
7. Pull out drive shaft (5), then sling and remove it.
0 Drive shaft: 50kg
8. Remove 3 bolts, then sling and remove planetary

carrier (7).
fl Use eyebolt [2].
fl When removing the planetary carrier, keep it
horizontal with a bar, etc.
0 Planetary carrier: 115kg
WD600-3 30-127
(2)
9. Remove mounting bolts (8), then remove retainer

(9).
fl Check the number of the shims inside the re-
tainer.
10. Sling and remove ring gear (10).

0 Ring gear: 80kg
11. Disassembly of planetary gear

1) Using a press, pull out shaft (11), then remove
pinion gear (12).
fl If the shaft is projected by about 25mm,
the lock ball falls. Take care not to lose
them.
fl Write a No. on the case so that the re-
moved parts will not be mixed with the
other parts.
2) Remove 2 bearings (13) from pinion gear (12).

fl Keep the fitted parts such as bearings as
a set so that they will not be combined
with the other parts.
12. Disassembly of ring gear

1) Remove lock plates (15) from ring gear hub
(14), then remove ring gear (16).
2) Remove bearing (17) from ring gear hub (14).
30-128 WD600-3
(2)
ASSEMBLY OF FINAL DRIVE

1. Assembly of ring gear
1) Press fit bearing (17) to ring gear hub (14).
fl After press fitting the bearing, check that
there is not any gap between bearing and
hub.
2) Fit ring gear hub (14) to ring gear (16), then
install lock plate (15).
fl Install the lock plate with the wider side
in.
fl Degrease the screw holes sufficiently.
9 Mounting bolt:
27.0 – 34.0Nm {2.8 – 3.5kgm}
2. Assembly of planetary carrier

1) Install bearings (13) to pinion gear (12), then
set them to the carrier case.
2) Matching the hole of the pinion to that of the
carrier case, press fit shaft (11).
fl Press fit the shaft with the lock ball hole
outward. Stop before the hole, then ad-
just the holes to each other.
3. Adjustment procedure of wheel bearing

1) Insert ring gear (10) in the axle housing, then
secure retainer (9) with mounting bolts (8)
without inserting any shim.
9 Mounting bolt:
57.9 – 67.7Nm {5.9 – 6.9kgm}
fl Turn the hub by 5 – 6 turns and tighten
the bolts alternately and evenly.
WD600-3 30-129
(2)
2) Measure thickness b of retainer (9) in advance.
3) Measure distance a between the retainer and

end of the axle housing with depth gauge [3]
or slide calipers through the measuring hole
of the retainer.
fl Measure the distance at 2 places, then
obtain the average.
fl Thickness of shim: a – b + 0.3mm
fl Select the shims so that its quantity will
be the minimum.
fl Install the selected shims and retainer (9),
then tighten mounting bolts (8) alternately
and evenly to the specified torque.
9 Mounting bolt:
245.0 – 309.0Nm {25.0 – 31.5kgm}
4. Remove tools J1.
5. Install the O-ring to the planetary carrier (7), then

sling bolt [2] and install the planetary carrier in
the ring gear.
fl Keep the planetary carrier and ring gear in par-
allel with each other with a bar, etc., and in-
sert the carrier, matching it to the stud bolt.
6. Tighten 3 mounting hexagon socket head bolt (6).

9 Mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
30-130 WD600-3
(2)
7. Install drive shaft (5).

fl If it is difficult to insert the drive shaft,
1) Remove the snap ring and pull out the sun
gear halfway, then insert a pipe having the
diameter of the drive shaft in the empty hole.
2) Pushing down and revolving the inserted pipe
in either direction, press in the drive shaft.
fl If the sun gear is not engaged with the
pinion gear, engage it by turning the tire
on the opposite side.
8. Install the O-ring, then install final drive case cover

(4) and tighten bolt (3).
9 Mounting bolt:
98.0 – 123.0Nm {10.0 – 12.5kgm}
9. Tighten drain plug (2).

9 Drain plug: 59.0 – 78Nm {6.0 – 8.0kgm}
10. Sling tire (1), and install it to the wheel hub.

fl Turning the tire on the opposite side, match
the stud bolts to the mounting holes of the
wheel.
9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm}
11. Refilling with oil

1) Remove level plug (18) and oil filler plug (19).
Add oil until it flows out of the level check
hole, then tighten the plugs.
9 Plug:
127.0 – 176.0Nm {13.0 – 18.0kgm}
WD600-3 30-131
(2)
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL
REMOVAL OF ORBIT-ROLL
chine from moving.
1. Remove boot (1). 1
2. Remove joint lock bolt (2).
4. Disconnect hose (4) of the left-hand stop valve.
5. Disconnect hose (5) of the charge valve.
6. Disconnect hose (6) of the right-hand stop valve.
7. Remove mounting bolt (7), then remove orbit-roll

(8).
8. Remove 4 lock bolts(9), then remove joint (10).

(12) from orbit-roll (8). 2
INSTALLATION OF ORBIT-ROLL
moval.
1
9 Joint lock bolt:
55.9 ± 7.8Nm {5.7 ± 0.8kgm}
2
9 Bracket mounting bolt:
51.9 ± 7.8Nm {5.3 ± 0.8kgm}
• After installing the orbit-roll, check the operation
of the steering system.
30-132 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER
chine from moving.
1. Set safety bar (1).
2. Disconnect grease tube (2).
3. Disconnect bottom hose (3).
4. Remove mounting bolt (4), then pull out pin (5).
5. Disconnect head hose (6).
6. Remove mounting bolt (7), then pull out pin (8).
7. Sling and remove steering cylinder (9).

0 Steering cylinder: 84kg 1
fl Check the number of shims installed on both
head and bottom sides.
WD600-3 30-133
(2)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER
moval.
¤ When aligning the position of the pin hole, use

a bar. Never put your fingers in the pin hole.
1
fl Adjust the shims so that the clearance on the
bottom side will be the specified value.
Specified values: a + b = 0.5mm max.
fl Adjust the shims so that the clearance on the

head side will be the specified value.
Specified value: c + d = 0.5mm max.
• Bleeding air
Bleed air from the steering cylinder. For details,
see BLEEDING AIR.
30-134 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VALVE

chine from moving.
1. Remove the mounting bolt, then remove cover

(1).
2. Remove inspection cover (2).
3. Disconnect tubes (3) and (4) going to the steering

cylinder.
fl Take care not to drip check valve and orifice
(5) and (6).
4. Disconnect hose (7) coming from the right stop

valve and hose (8) coming from the left stop valve.
5. Remove U-bolt (9) and disconnect tube (10) com-
ing from the steering pump.
6. Remove U-bolt (11) and disconnect tube (12) com-
ing from the switching pump.
7. Disconnect tube (13) coming from the loader
pump.
9. Remove mounting bolts (15) and lift off steering
valve assembly (16).
0 Steering valve assembly: 35kg
WD600-3 30-135
(2)
DISASSEMBLY AND ASSEMBLY STEERING VALVE
INSTALLATION OF STEERING
VALVE
moval.
• When installing the check valve and orifice, con-

firm that their front and rear directions are aligned
properly.
• After installing the all parts, secure the tubes with
the bolts.
• When installing the tubes and valves, check that
the O-rings are no damage and deterioration, then
fit the tubes and the valves securely.

30-136 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

chine from moving.
1. Disconnect transmission cut-off switch connec-

tor (1) (L12). (Left brake valve only)
2. Disconnect hose (2) from the accumulator.
4. Disconnect pilot tube (4).
5. Pull out pin (5).

fl Be careful not to lose L-pin.
6. Remove pedal (6).
7. Disconnect brake pedal cancel switch connector

(7). 1
Connector (7): Left brake valve (C13A)
: Right brake valve (C14)
8. Remove plunger (8), then remove boot (9).
9. Remove 4 mounting bolts (10), then remove brake

valve (11).
INSTALLATION OF BRAKE
VALVE
1
Adjust the sensor so that it will operate when the
pedal end moves 16 mm.

moval.
• After installing the brake valve, check the opera-

tion of the brake.
WD600-3 30-137
(2)
DISASSEMBLY OF BRAKE
VALVE (R.H.)
(TANDEM BRAKE VALVE)
1. Remove snap pin (1) and L-pin (2), then pull out
pedal plate fitting pin (3).
fl Take care not to lose the L-pin.
2. Remove pedal plate (4).
3. Remove seat (5), boot (6) and pedal stopper (7).

(9).
5. Remove mounting bolt (10), then disconnect

flange (11) and cylinder (12).
6. Remove holder (13) and springs (14), (15) and (16)

from cylinder (12).
7. Pull rod (17) out of flange (11).
8. Pull pilot piston (18) out of rod (17).
9. Remove the snap ring from pilot piston (18), then

remove retainers (20) and (21).
10. Remove dust seal (22) and O-ring (23) from flange
(11).
30-138 WD600-3
(2)
11. Disconnect cylinders (22) and (23).
12. Remove return spring (24) and O-ring (25).
13. Pull spool (26) out of cylinder (22).
14. Remove piston (27) and spring (28) from spool

(26).
15. Remove snap ring (29) from spool (26), then re-
move retainer (30).
16. Remove nut end (31) from cylinder (23), then re-
move spring (32).
17. Remove O-ring (33) from nut end (31).
19. Pull piston (35) out of spool (34).
move retainer (37).
WD600-3 30-139
(2)
ASSEMBLY OF BRAKE VALVE

(R.H.)
(TANDEM BRAKE VALVE)
1. Install retainer (37) to spool (34), then secure it
with snap ring (36).
2. Insert piston (35) in spool (34).

fl Apply engine oil.
3. Insert spool (34) in cylinder (23).
4. Install O-ring (33) to nut end (31).
5. Install spring (32) to nut end (31), then install them

to cylinder (23).
9 Nut end: 152.0 ± 24.5Nm {15.5 ± 2.5kgm}
6. Install retainer (30) to spool (26), then install snap

ring (29).
7. Install spring (28) and piston (27) to spool (26).
9. Install O-ring (25) to cylinder (22).
10. Set spring (24) to cylinder (23).
30-140 WD600-3
(2)
11. Press fit dust seal (22) to flange (11), then install
O-ring (23).
12. Install retainers (21) and (20) to pilot piston (18),

then install snap ring (19).
13. Insert pilot piston (18) in rod (17).
14. Set holder (13) to cylinder (12), then install springs

(14), (15) and (16).
15. Assemble cylinder (12) and flange (11), and se-

cure them with mounting bolt (10).
9 Mounting bolt:
66.2 ± 7.3Nm {6.75 ± 0.75kgm}
16. Set bracket (9) on the flange (11), then secure it

with mounting bolt (8).
9 Mounting bolt:
66.2 ± 7.3Nm {6.75 ± 0.75kgm}
17. Install pedal stopper (7) and boot (6) to bracket,

then set seat (5).
18. Set pedal plate (4) to bracket (9), then insert pin
(3).
19. Install snap pin (1) and L-pin (2) to pin (3).
WD600-3 30-141
(2)
VALVE (L.H.)
(SINGLE BRAKE VALVE)
1. Remove snap pin (1) and L-pin (2), then pull out
pedal plate fitting pin (3).
fl Take care not to lose the L-pin.
2. Remove pedal plate (4).
3. Remove seat (5), boot (6) and pedal stopper (7).

(9).
5. Remove mounting bolt (10), then disconnect

flange (11) and cylinder (12).
6. Remove holder (13) and springs (14), (15) and (16)

from cylinder (12).
7. Pull rod (17) out of flange (11).
8. Remove snap ring (18) from rod (17), then remove

retainers (19) and (20).
9. Remove dust seal (21) and O-ring (22) from flange

(11).
30-142 WD600-3
(2)
10. Remove nut end (23) from cylinder (12), then re-
move spring (24).
11. Remove O-ring (25) from nut end (23).
13. Pull piston (27) out of spool (26).
move retainer (29).
WD600-3 30-143
(2)
ASSEMBLY OF BRAKE VALVE

(L.H.)
(SINGLE BRAKE VALVE)
1. Install retainer (29) to spool (26), then secure it
with snap ring (28).
2. Insert piston (27) in spool (26).
fl Apply engine oil.
4. Install O-ring (25) to nut end (23).
5. Install spring (24) to nut end (23), then install them

to cylinder (12).
9 Nut end: 152.0 ± 24.5Nm {15.5 ± 2.5kgm}
6. Install dust seal (21) and O-ring (22) to flange (11).
7. Install retainers (20) and (19) to rod (17), then in-

8. Insert rod (17) in flange (11).
9. Install holder (13) to cylinder (12), then set springs

(16), (15) and (14).
10. Install cylinder (12) to flange (11), then secure

them with mounting bolt (10).
9 Mounting bolt:
66.2 ± 7.3Nm {6.75 ± 0.75kgm}
30-144 WD600-3
(2)
11. Set bracket (9) to flange (11), then secure them

with mounting bolt (8).
9 Mounting bolt:
66.2 ± 7.3Nm {6.75 ± 0.75kgm}
12. Install pedal stopper (7), boot (6) and seat (5).
13. Set pedal plate (4) and insert pin (3), then install
L-pin (2) and snap pin (1).
WD600-3 30-145
(2)
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER
chine from moving.
1. Disconnect hose (1) of the brake valve.
2. Disconnect tubes (2) and (3) of right and left

brakes. 1
3. Remove mounting bolt (4), then remove slack ad-

juster (5).
INSTALLATION OF SLACK
ADJUSTER
moval.
1
9 Tube sleeve nut: 68.6 ± 9.8 {7.0 ± 1.0kgm}
• Bleeding air
Bleed air. For details, see BLEEDING AIR.
30-146 WD600-3
(2)
DISASSEMBLY OF SLACK
ADJUSTER
1. Bleeder
Remove bleeder (2) from body (1).
2. Cylinder
Remove mounting bolts, then disconnect body
(1) and cylinder (4) together with bracket (3).
¤ There is spring tension inside the cylinder,
so hold the contact surfaces and be careful
when removing.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring
fl Use a rod of 10mm diameter and push out
the piston slowly.
fl Be careful not to damage the thread with
the rod.
4. Poppet
fl Do not disassemble the poppet unless neces-
sary. If it is disassembled, replace the whole
cylinder assembly.
1) Remove cover (8) from cylinder (4), then re-
move plug (9), spring (10) and poppet (11).
fl When removing the poppet, blow in air
from the oil hole in the cylinder.
fl Hold the oil port of the cylinder by hand,
and do not pump in air suddenly.
fl Be careful not to change the combination
of poppet (11) and cylinder (4).
When replacing, replace the poppet and
cylinder as an assembly.
2) Remove O-ring (12) from poppet.
WD600-3 30-147
(2)
ASSEMBLY OF SLACK
ADJUSTER
1. Poppet
1) Fit O-ring (12) on poppet (11).
2) Install poppet (11), spring (10), plug (9) and
cover (8), then assemble cylinder (4).
2. Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder (4).
fl Check that the piston moves smoothly.
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
fl Installed road of spring 43.1 Nm {4.4 kg}
2) Install body (1) and cylinder (4) together with
bracket (3).
4. Bleeder
Install bleeder (2).
30-148 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY BRAKE
REMOVAL OF BRAKE
put the safety bar on the frame and set blocks
under the wheels to prevent the machine from
moving.
1. Remove the final drive. For details, see REMOVAL

OF FINAL DRIVE
2. Disconnect brake tube (1). 1
3. Sets tools J1.
4. Sling the brake and wheel hub temporarily, then

remove mounting bolts (2). 2
5. Sling and remove brake and wheel hub (3).

0 Brake and wheel hub: 195kg
6. Remove bearing (5) and retainer (6) from axle (4).
INSTALLATION OF BRAKE
moval.
1
fl Bleed air from the brake. For details, see
BLEDING AIR FROM EACH PORTION, of TEST-
ING AND ADJUSTING,.
2
9 Brake and wheel hub mounting bolt:
824.0 – 1030.0Nm {84.0 – 105.0kgm}
3
fl Adjust the preload of the bearing. For details,
see ASSEMBLY OF FINAL DRIVE.
WD600-3 30-149
(2)
(FRONT, REAR)
1. Cylinder
Using eye-bolt [1] (Tread dia. = 16 mm, Pitch = 2.0
mm), lift out cylinder (1).
fl Disassemble cylinder with following steps:

1) Screw in eye-bolts [1] (Tread dia. = 16 mm,
Pitch 2.0 mm), push in spring by using bar
[2], then pull out pin (2).
2) Remove spring (3) and shaft (4).
3) Remove piston (5).
2. Plate, disc
1) Remove plate (6).
30-150 WD600-3
(2)
2) Remove disc (7).

fl When removing the disc and plates, put
counter marks on the inner gear and disc,
and outer gear and plate before remov-
ing.
fl The discs are made of soft material, so be
careful not to damage then when remov-
ing.
fl Remove discs and plates alternately.
3. Gear assembly
1) Remove 3 tools J1.
2) Using eyebolt [3] (Thread dia.=12mm, Pitch

=1.75mm), lift off gear (8).
3) Remove plate (9) from gear (8).
4) Remove floating seal (10) and oil seal (11)

from gear (8).
WD600-3 30-151
(2)
4. Floating seal, outer race

1) Remove floating seal (12) from hub (13).
2) Remove outer races (14) and (15) from hub
(13).
30-152 WD600-3
(2)
ASSEMBLY OF BRAKE
(FRONT, REAR)
1. Outer race, floating seal
1) Using push tool [4], press fit outer race (15)
to hub (13).
2) Using push tool [5], press fit outer race (14)
to hub (13).
3) Using tool H9, install floating seal (12) to hub

(13).
2 Seal contact surface :
fl Assemble O-ring (12) to floating seal.
fl Use alcohol to completely remove all the
white blooming from the surface of the
O-ring.
fl Remove all oil and grease from the float-
ing seal and hub O-ring contact surface.
fl Tighten tool J3 uniformly to prevent twist-
ing of the floating seal O-ring. After press
fitting, measure height t at 4 places around
the circumference and check that the dif-
ference in dimension t at all four places is
within 1 mm.
2. Gear assembly
1) Using tool J2, install oil seal (11) to gear (8).
2 Mating surface of oil seal hub :
Thread tightener (Loctite #648)
WD600-3 30-153
(2)
2) Using tool J3, install floating seal (10) to gear

(8).
2 Seal contact surface :
fl Assemble O-ring (10) to floating seal.
fl Use alcohol to completely remove all the
white blooming from the surface of the
O-ring.
fl Remove all oil and grease from the float-
ing seal and retainer O-ring contact sur-
face.
fl Tighten tool J3 uniformly to prevent twist-
ing of the floating seal O-ring. After press
fitting, measure height t at 4 places
around the circumference and check that
the difference in dimension t at all four
places is within 1 mm.
3. Assemble plate (9), then using eyebolt [3] (Thread

dia.=12mm, Pitch=1.75mm), raise gear (8) and
install.
4. Install 3 tools J1.
30-154 WD600-3
(2)
5. Disc, plate
1) Install disc (7).
2) Install plate (6).

fl Align notched portion of outer teeth of
plate and assemble.
fl Align the counter marks on the disc and
inner gear, and plate and outer gear, then
assemble the plates and discs in turn.
6. Cylinder
fl Assemble cylinder with following steps:
1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3).

3) Screw in eye-bolts [1] (Thread dia. = 6 mm,
Pitch = 2.0 mm), push in spring with bar
[2], then install pin (2).
WD600-3 30-155
(2)
4) Fit O-ring and using eye-bolts [1] (Thread

dia. = 16 mm, Pitch = 2.0 mm), match with
guide bolt [4] and lift and install cylinder
assembly (1).
2 Mounting bolt :
Thread tightener (LT-2)
3 Mounting bolt :
245 – 309 Nm {25.0 – 31.5kgn}
30-156 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP
chine from moving.

OF BULKHEAD.
2. Steering and switch pump

1) Disconnect steering pump suction tube (1).
fl Plug the tube to prevent foreign objects
from entering.
2) Disconnect discharge tube (2) between the
steering valve and steering pump.
3) Disconnect switch pump suction tube (3).
steering valve and switch pump.
5) Remove mounting bolts (5) and lift off steer-
ing and switch pump assembly (6).
39 kg
3. Transmission and PPC pump

1) Disconnect transmission pump suction tube
(7).
transmission and transmission pump.
3) Disconnect discharge tube (9) between the ac-

cumulator charge valve and PPC pump.
WD600-3 30-157
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
4) Disconnect PPC pump suction tube (10).

5) Remove mounting bolts (11) and transmission
4. Work equipment pump

1) Disconnect work equipment pump suction
tube (13).
work equipment valve and work equipment
pump.
3) Remove mounting bolts (15) and work equip-
ment pump (16).
INSTALLATION OF HYDRAULIC
PUMP
moval.

30-158 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
TANK
chine from moving.
¤ Loosen the filler cap to release the pressure from
the hydraulic tank.
1. Sling and remove ladder floor (1).

0 Ladder floor: 120kg
2. Loosen hydraulic tank drain valve (2), and drain

oil.
3. Remove mounting bolts (3) from the bottom of

the hydraulic tank. 1
4. Disconnect return tube (4) coming from the charge

valve.
5. Disconnect return tube (5) coming from work

equipment valve.
6. Disconnect tube (6) going to the hydraulic oil

cooler.
7. Disconnect hydraulic pump tube (7).
8. Disconnect emergency steering suction tube (8).
9. Disconnect emergency steering return tube (9).
WD600-3 30-159
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
10. Disconnect return tube block (10) and tube (11)

together and move them toward the chassis.
11. Disconnect return hose (12) coming from the

brake valve.
12. Disconnect hydraulic tank breather hose (13).
13. Sling the hydraulic tank temporarily and remove

mounting bolts (14). 2
14. Lift off hydraulic tank assembly (15).

0 Hydraulic tank assembly: 362kg
TANK
moval.
1
9 Mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}
2
9 Mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}

30-160 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
FILTER
chine from moving.
1. Remove cover (1).
2. Loosen plugs (2) to release the residual pressure.
3. Remove covers (3). 1
4. Remove spring (4) and valve (5), then remove

hydraulic filter (6).
FILTER
moval.
1
9 Plug: 9.8 – 12.7Nm {1.0 – 1.3kgm}
WD600-3 30-161
(2)
DISASSEMBLY AND ASSEMBLY PPC VALVE
REMOVAL OF PPC VALVE

chine from moving.
1. Remove cover (1), then loosen plugs (2) on the

hydraulic tank to release the residual pressure in
the hydraulic circuit. 1
2. Remove console box cover (3).
3. Disconnect control rods (4).
4. Disconnection of hoses from PPC valve

1) Disconnect blade left tilt hose (5).
2) Disconnect blade right tilt hose (6).
3) Disconnect blade raise hose (7).
4) Disconnect blade lower hose (8).
5) Disconnect hose (9) of the accumulator charge
valve.
6) Disconnect drain hose (10).
5. Remove 6 mounting bolts (11), then remove PPC

valve (12) and bracket together.
INSTALLATION OF PPC VALVE

moval.
1
9 Plug: 9.8 – 12.7Nm {1.0 – 1.3kgm}
30-162 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY PPC VALVE
DISASSEMBLY OF PPC VALVE

1. Remove bolt (1).
2. Remove plate (2).
3. Remove seal (3), then remove collar (4).
4. Remove valve assembly and center spring (7)

from valve body (10).
5. Remove collars (11), then remove retainer (6),

shims (12), and spring (8) from valve (9).
ASSEMBLY OF PPC VALVE

1. Push shims (12), spring (8), and retainer (6) into
valve (9), and install collars (11).
2. Install center spring (7) and valve assembly to

valve body (10).
3. Install spool (5).
4. Fit O-ring and install collar (4).
5. Install seal (3).
6. Fit plate (2) and install bolt (1).

3 Bolt : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
WD600-3 30-163
(2)
DISASSEMBLY AND ASSEMBLY DECO VALVE
REMOVAL OF DECO VALVE

¤ Stop the machine on level ground and put blocks
under the wheels and set the boom on the sup-
port stand, then confirm that the boom will not
lower by itself.
1. Remove inspection cover (1).
2. Disconnect lockup solenoid connector (FD1) (2).
3. Disconnect tubes (3), (4), (5), (6), (7), and (8).
4. Disconnect hoses (9) and (10).
5. Remove the mounting bolts and lift off deco valve

(11).
0 Deco valve: 90kg
INSTALLATION OF DECO VALVE

moval.

30-164 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT VALVE
REMOVAL OF WORK
EQUIPMENT VALVE
¤ Stop the machine on level ground and put blocks
under the wheels and set the work equipment
on the support stand, then confirm that the boom
will not lower by itself.
1. Remove cover (1) under the lift cylinder.
2. Disconnect lift cylinder head hose (2) from tube

(4).
3. Disconnect lift cylinder bottom hose (3) from tube

(5).
fl Before disconnecting, confirm that no pres-
sure is remaining.
4. Remove clamp U-bolts (6) and (7) of tubes (4) and

(5).
5. Remove the mounting bolt, then remove tube (8)

of the loader pump.
WD600-3 30-165
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT VALVE
6. Disconnect tubes (10) and (11) going to the deco

valve.
7. Disconnect brade lowering PPC tube (12).
8. Remove clamp (13), then disconnect brade rais-

ing PPC tube (14).
9. Disconnect brade right tilting PPC tube (15).
10. Disconnect brade left tilting PPC tube (16).

fl Disconnect the clamp.
12. Sling and remove the work equipment valve (18).

0 Work equipment valve: 75kg
INSTALLATION OF WORK
EQUIPMENT VALVE
moval.

30-166 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY PITCH & TILT CYLINDER
REMOVAL OF PITCH & TILT

CYLINDER
chine from moving.
1. Disconnect hose (1) on the pitch and tilt cylinder

head side and tube (2) on the bottom side.
fl Checking the residual pressure, disconnect
the hoses.
2. Pull out bottom pin (3).

fl Pull out the pin until the cylinder can be re-
moved.
fl Sling the cylinder temporarily.
3. Pull out head pin (4).

fl Pull out the pin until the piston can be re-
moved.
4. Lift off pitch and tilt cylinder assembly (5).

0 Pitch and tilt cylinder assembly: 184kg
INSTALLATION OF PITCH & TILT

CYLINDER
moval.
¤ When aligning the position of the pin hole, use

a bar. Never put your fingers in the pin hole.
WD600-3 30-167
(2)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
REMOVAL OF LIFT CYLINDER

ASSEMBLY
put blocks under the wheels.
¤ Loosen the filler cap to release the pressure
gradually from the hydraulic tank, then operate
the work equipment level three to four times to
decrease the pressure within the piping up to
the ambient pressure level.
1. Disconnect head-side hose (1) and bottom-side

hose (2) for the lift cylinder.
fl Disconnect the hoses with confirmation to ex-
istence of the remained compressed air.
2. Pull out head-side pin (3).

fl Pull it up to the position where the piston can
be removed.
3. Disconnect grease tube (4) for the bottom-side pin.
4. Pull out bottom-side pin (5).

fl Pull it up to the position where the piston can
be removed.
5. Sling and remove lift cylinder assembly (6).

0 lift cylinder assembly: 205kg
30-168 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
INSTALLATION OF LIFT
CYLINDER ASSEMBLY
moval.
¤ Use stick, bar or similar tool to align the holes

for the pin and never put a finger into the hole.
WD600-3 30-169
(2)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
¤ Stop the machine on level ground and place a
support stand under the bucket, then put blocks
moving.
¤ Loosen the filler cap and release the pressure
from the hydraulic tank gradually, then operate
the work equipment control lever 3 – 4 times to
release the pressure from the piping.
1. Remove the floor frame. For details, see RE-

MOVAL OF FLOOR FRAME.
2. Disconnect hoses (1) and (2) between the stop

valve and steering valve.
3. Remove bracket (3).
4. Remove the mounting bolt , then remove clamp

(4).
fl Bind the hoses and harnesses, and shift them
toward the front frame.
5. Disconnect drain hose (5) of the work equipment

valve.
6. Disconnect PPC hoses (Orange) (6), (Yellow) (7),

(Blue) (8) and (Red) (9).
7. Disconnect drain hose (10) of the work equipment

valve.
8. Disconnect hose (11) of the hydraulic oil cooler.
9. Disconnect hose (12) of the work equipment valve.
10. Disconnect hose (13) between the switch pump

and steering valve.
11. Disconnect hose (14) between the steering pump

and steering valve.
12. Disconnect hoses (15) and (16) of the parking

brake solenoid valve.
13. Disconnect hose (17) of the front brake slack ad-

juster.
14. Remove drive shaft guard (18).
30-170 WD600-3
(2)
15. Remove the lock bolt of steering cylinder head

pin (19) on right and left sides, then pull out the
pin. 1
fl If shims are installed, check its quantity.
fl Cut the hose and shorten the piston.

0 Drive shaft: 56kg
17. Place jacks (50ton) under the front frame and rear
frame, then adjust the height of the frames and
set support stand [1].
18. Using jacks (50ton × 2 units) under the counter

weight, set the support stand.
19. Remove the mounting bolt, then remove retainer

(21).
fl Check the number of shims installed between
the retainer and frame. 3
WD600-3 30-171
(2)
20. Adjust height carefully and set so that lower hinge

pin (22) can be removed easily by hand.
21. Remove spacer (23).
22. Remove 6 mounting bolts (24) and 4 mounting

bolts (25), then remove retainer (26). 4
23. Using puller, remove upper hinge pin (27) and

spacer (28). 5
30-172 WD600-3
(2)
24. Remove safety bar, then pull out front frame to-
wards front and disconnect frame.
fl Be careful not to let the spacer at the top of
the lower hinge get caught in the rear frame.
fl Carry out the operation carefully and pay at-
tention to maintaining the balance.
fl Move approx. 100 mm at a time.
25. Remove mounting bolts, then remove retainer

(29).
fl If there are shims between the retainer and
frame, check the number and thickness.
26. Remove dust seal (30) from retainer (29).
27. Remove spacer (31) and dust seal (32) from front
frame.
WD600-3 30-173
(2)
28. Remove bearing (33).
29. Remove retainer (34). 6

fl If there are shims between the retainer and
frame, check the number and thickness.
30. Remove dust seal (35) from retainer.

fl Remove dust seal (36) at the frame end.
31. Remove bearing (37).
30-174 WD600-3
(2)
INSTALLATION OF CENTER
HINGE PIN
moval.
1
fl Adjust the shims so that the clearance is in
the specified range.
Clearance a + b = Less than 1.0 mm
2
3 Drive shaft mounting bolt :
157 – 196 Nm {16 – 20 kgm}
3
2 Outer circumference of hinge pin :
Grease (G2-LI)
fl Measure clearance c between the retainer and
frame at 4 places on the inside circumference,
and select a shim thickness to make the value
0.08 – 0.18 mm less than the measured value.
fl When adjusting the shim, temporarily tighten
the retainer mounting bolts to act as a stop-
per.
fl When tightening the mounting bolts, tighten
the retainer mounting bolts first to the speci-
fied torque, then tighten the pin mounting
bolts.
fl After selecting the shim, assemble the retainer
to the specified torque.
fl Remove all oil and grease from the mounting
bolts and mount holes.
2 Mounting bolt :
Thread tightener (Loctite 262)
3 Mounting bolt (33) when adjusting shims :
245 – 309 Nm {25.0 – 31.5 kgm}
3 Mounting bolt (34) :
409 – 608 Nm {50 – 62 kgm}
WD600-3 30-175
(2)
4
fl Assemble spacer (30), insert upper hinge (29),
then tap three times with a copper hammer
to settle the parts.
fl Never coat spacer (30) with grease.
2 Outer circumference of hinge pin :
Grease (G2-LI)
Thread tightener (Loctite 262)
245 – 309 Nm {250.0 – 31.5 kgm}
409 – 608 Nm {50 – 62 kgm}
fl If the mounting bolts cannot be tightened to
the specified tightening torque, there may be
grease on spacer (28), so remove it and
tighten again.
5
fl When using tool K2 to press fit the bearing
and spacer to the frame, be careful that the
bearing is not at an angle.
fl Fill the inside of the bearing with grease.
fl When assembling the bearing, be careful not
to forget to assemble the spacer.
fl The clearance of the bearing is adjusted, so
do not change the combination of bearing and
spacer.
When replacing, replace as a set.
fl Press fit so that the lip of the dust seal is fac-
ing the outside.
2
Lip of oil seal : Grease (G2-LI)
fl Measure clearance a between retainer (31)
and hinge at 4 places on the inside circumfer-
ence, and select a shim thickness to make the
value 0.08 – 0.18 mm less than the measured
value.
3 Mounting bolt (when adjusting shims) :
98.0 ± 9.8 Nm {10.0 ± 1.0 kgm}
3 Mounting bolt :
176.4 ± 19.6 Nm {18 ± 2.0 kgm}
30-176 WD600-3
(2)
6
fl Using tool K1, press fit the bearing and spacer
to the frame.
fl When press fitting the bearing, be careful that
the bearing is not at an angle.
fl Fill the inside of the bearing with grease.
fl When assembling the bearing, be careful not
to forget to assemble the spacer.
fl The clearance of the bearing is adjusted, so
do not change the combination of bearing and
spacer.
When replacing, replace as a set.
fl Press fit so that the lip of the dust seal is fac-
ing the outside.
fl Measure clearance a between retainer (36)
and the hinge at 4 places on the inside cir-
cumference, and select a shim thickness to
make the value 0.08 – 0.18 mm less than the
measured value.
3 Mounting bolt (when adjusting shims) :
34.3 Nm {35 kgm}
3 Mounting bolt :
245 – 309 Nm {25.0 – 31.5 kgm}
fl After completion of mounting the hinge pin,
fill with oil and bleed the air.
1) Tighten the plug on the top of the hydraulic

tank filter, then add hydraulic oil through oil
filler to the specified level.
3 Plug on top of filter :
11.8 ± 1.0 Nm {1.2 ± 0.1 kgm}
5 Hydraulic oil : Approx. 215 ¬
Run the engine to circulate the oil
through the system. Then check the
oil level again.
2) Bleed the air from the brake system. For de-

tails, see TESTING AND ADJUSTING.
WD600-3 30-177
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT
put the safety bar on the frame and set blocks
moving.
1. Set blocks [1] and [2] under the left and right
straight frame.
2. Sling lift cylinder (1), remove lock bolt (2), and

pull out head pin (3). 1
fl After pulling out the pin, start the engine and
retract the lift cylinder. At this time, secure
the cylinder with wires, etc. so that it will not
fall.
3. Sling Y-link (4), remove the lock bolt, and pull out
blade pin (5). 2
fl If shims are inserted, record its quantity.
4. Remove lock bolt (6) and pull out cord ring (7)
and frame pin (8). 3
5. Lift off the Y-link.

0 Y-link: 549kg
30-178 WD600-3
(2)
6. Sling H-link (9), remove lock bolt (10), and pull

out the cord ring and pin (11). 4
7. Lift off the H-link.

0 H-link: 486kg
8. Remove cover (12) and (15).
9. Disconect hoses (13) and (14) from connector.
WD600-3 30-179
(2)
10. Remove left and right trunnion caps (16).

fl Make match marks on the left and right trun-
nion caps. 5
11. Strat engine, and move machine slowly in reverse

to disconnect work equipment assembly from
machine.
12. Sling bar (17), remove lock bolt (18), and pull out
pin (19).
13. Lift off the bar.

0 Bar: 62kg
14. Sling trunnion (20) and remove mounting bolts

(21).
15. Lift off the trunnion.

fl Take care not to damage the spherical surface.
0 Trunnion: 58kg
16. Sling trunnion support (22), remove lock bolt (23),

and pull out pin (24). 6
17. Lift off the trunnion support.

0 Trunnion support: 1,266kg
30-180 WD600-3
(2)
INSTALLATION OF WORK
EQUIPMENT
moval.

¤ When aligning the pin holes, use a bar. Never

insert your fingers in the pin holes.
1
8 Mounting pin: Lubricant (LM-G)
2
For shim thickness a, b press fit bushings (25),
(27) then tighten to the specified tightening torque
and measure the clearance at four places equally
spaced around the circumference of flanges (26),
(28) with no shims inserted. Take the average
clearance for three places and subtract 0 – 0.1 mm
to give the value for shim thickness a, b.
34
fl Clearance c + d = Max. 1.5mm
fl Take care that the cord ring will not be caught.
fl When installing Y-link (4) and H-link (9), match

the stamps on them to each other.
5
3 Trunnion cap mounting bolt:
632 – 828Nm {64.5 – 84.5kgm}
6
fl Clearance e + f = Max. 1.5mm
WD600-3 30-181
(2)
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
chine from moving.
¤ Collect the air conditioner refrigerant.
1. Remove engine hood (1).

0 Engine hood: 80kg
2. Remove side hoods (2) on both sides.

0 Side hood: 38kg
3. Remove inspection covers (3), (4) and (5).

0 Inspection cover (3): 30kg
4. Open transmission inspection cover (6) and re-

move the mounting bolt, then remove the cover
together with step (7).
5. Disconnect hose (8) between the receiver tank and

air conditioner unit.
6. Disconnect washer hose (9).

fl If any cleaning water is in the tank, bend the
hose and tie it with a tape, etc.
7. Disconnect hydraulic tank breather hose (10).
8. Disconnect hose (11) of the air compressor, then

remove clamp (12).
9. Disconnect air conditioner condenser connector

(13) (BR1).
10. Remove 2 rear mounting bolts (14).
30-182 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY BULKHEAD
11. Remove clamps (15) and disconnect dust indica-

tor hose (16).
12. Disconnect heater hose clamp (17) and air condi-

tioner hose clamp (18).
13. Remove 4 front mounting bolts (19).

fl Sling the bulkhead temporarily.
14. Sling and remove bulkhead (20).

0 Bulkhead: 190kg
fl Sling carefully, checking that each clamp, etc.
is disconnected securely.
INSTALLATION OF BULKHEAD
moval.
• Refilling air conditioner with refrigerant

Using tool X1, refill the air conditioner with re-
frigerant (R134a).
WD600-3 30-183
(2)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

chine from moving.
1. Remove ROPS (1), cab (2), right and left ladders

(3) and side cover (4). For details, see REMOVAL
OF CAB.
2. Disconnect 2 heater hoses (5).

fl Plug the holes to prevent the engine cooling
water from flowing out.
3. Disconnect 2 air conditioner hoses (6).

fl Using tool X1, collect air conditioner refriger-
ant (R134a).
fl Be sure to use 2 spanners to disconnect the
hoses.
4. Disconnect connector (7).

Connector: (LR1.2.3.4.7.9), (TL1), (FR1.2), (CH1)
5. Remove clip (8), then disconnect 2 washer hoses

(9).
fl If any cleaning water is in the washer tank,
bend the hoses and tie them with tape.
6. Disconnect hose (10) between the right-hand

brake valve and rear brake, and hose (11) between
the right-hand brake valve and front brake.
7. Disconnect hose (12) of the left-hand brake valve

accumulator.
8. Disconnect hose (13) between the orbit-roll and

accumulator, drain hose (14), hose (15) of right-
hand stopper valve and hose (16) of the left-hand
stop valve.
30-184 WD600-3
(2)
9. Disconnect hose (17) between the accumulator

charge valve and PPC valve.
10. Disconnect PPC valve drain hose (18).
11. Disconnect hoses (19) (Right tilt blade), (20) (Left

tilt blade), (21) (Raise blade) and (22) (Lower blade)
between the PPC valve and work equipment valve.
fl Each hose is connected by means of quick
coupler. It is disconnected easily by pushing
it up a little and turning it.
12. Disconnect hoses (23) and (24) between the right-

hand brake valve and accumulator.
fl These hoses must be disconnected since there
is a hanging clamp on the floor frame.
13. Disconnect right-hand brake valve drain hose (25).
14. Disconnect left-hand brake valve drain hose (26).
15. Disconnect ground cable (27).
16. Remove 4 nuts of floor frame mount (28). 1
WD600-3 30-185
(2)
17. Sling and remove floor frame (29).

fl Sling carefully, checking that each clamp,
wire, etc. is disconnected securely.
0 Floor frame: 290kg
INSTALLATION OF FLOOR
FRAME
moval.
1
9 Mounting bolt:
277.3 ± 32.3Nm {28.3 ± 3.3kgm}

frigerant (R134a).
30-186 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
chine from moving.
1. Sling front fender (1) and remove mounting bolts

(2). 1
2. Lift off the front fender.

0 Front fender: 40kg
3. Sling counterweight (3) temporarily.
4. Remove mounting bolts (4).
5. Lift off the counterweight (3).

0 Counterweight: 600kg
INSTALLATION OF
COUNTERWEIGHT
moval.
1
9 Mounting bolt: 59 – 74Nm {6.0 – 7.5kgm}
WD600-3 30-187
(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

chine from moving.
1. Drain fuel through drain valve (1).

fl Before draining the fuel, check the remaining
quantity.
= Fuel (When full): 670 ¬
2. Remove handrail (2), then remove step (3).
3. Disconnect engine oil drain valve (4).
4. Disconnect radiator drain valve (5).

fl Disconnect the clamp on the top of the fuel
tank.
5. Remove handrail (6), then remove step (7).
6. Remove step (8).
7. Disconnect engine oil cooler drain hose (9) and

muffler drain hose (10).
8. Disconnect fuel level sensor connector (11) (R05).
9. Disconnect torque converter oil cooler coolant

drain valve (12) from the fuel tank.
10. Disconnect fuel return hose (13).
11. Disconnect hose (14) of the fuel strainer.
30-188 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY FUEL TANK
12. Sling fuel tank (15) temporarily, then remove

mounting bolt (16). 1
fl Place a pallet under the fuel tank, then lower
the tank slowly, balancing it.
0 Fuel tank: 420kg
INSTALLATION OF FUEL TANK

moval.
1
3 Mounting bolt:
824.0 – 1030.0Nm {84.0 – 105.0kgm}
WD600-3 30-189
(2)
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB
chine from moving.
1. Remove right and left covers (1).
2. Remove ROPS mounting bolts (2). 1

fl Sling the ROPS temporarily.
3. Sling and remove ROPS (3).

0 ROPS: 810kg
4. Remove screws (4), then remove plate (5).
6. Disconnect bracket (7).

fl Move the harness and switch toward column.
30-190 WD600-3
(2)
8. Disconnect bracket (9).

fl Move the harness and switch toward column.
10. Remove connecting bolts (11) of column and cab.
11. Disconnect window washer vinyl tubes (12).
12. Disconnect connectors (13) (CL2), (14) (CL3), (15)

(CL4) and (16) (CL1).
13. Remove cab mounting bolts (17) and (18).

fl Sling the cab temporarily.
WD600-3 30-191
(2)
14. Sling and remove cab (19).

fl Sling carefully, checking that each harness is
disconnected securely.
0 Cab: 440kg
INSTALLATION OF CAB
moval.
1
9 Mounting bolt:
1520.0 – 1910.0Nm {155.0 – 195.0kgm}
30-192 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY STOP VALVE
REMOVAL OF STOP VALVE

chine from moving.
1. Disconnect hose (1) connected to steering valve.
2. Disconnect hose (2) connected to orbit-roll.
3. Disconnect return hose (3).
4. Remove the mounting bolt, then remove stop

valve (4).
INSTALLATION OF STOP VALVE

moval.
WD600-3 30-193
(2)
DISASSEMBLY AND ASSEMBLY ACCUMULATOR
REMOVAL OF ACCUMULATOR
chine from moving.
¤ Release the pressure from the accumulator by
operating the work equipment control lever and
brake pedal.
1. Remove covers (1) and (2).
2. Disconnect connectors (3) (C01), (4) (C02), (5) (C03)

and (6) (C04).
3. Disconnect hose (7) between the rear brake accu-

mulator and accumulator charge valve.
4. Disconnect hose (8) between the front brake ac-

cumulator and accumulator charge valve.
5. Disconnect hose (9) connected to parking brake

solenoid valve.
6. Disconnect tube (10) connected to left-hand brake

valve.
7. Disconnect tube (11) connected to right-hand

brake valve.
fl Loosen 2 clamps of tubes (10)
and (11).
8. Remove bands (12).
9. Remove mounting bolts, then remove rear brake

accumulator (13) and front accumulator (14).
fl Each accumulator is secured with 2 mount-

ing bolts at its bottom.
INSTALLATION OF
ACCUMULATOR
moval.

30-194 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE
REMOVAL OF ACCUMULATOR
CHARGE VALVE
chine from moving.
¤ Release the pressure from the accumulator by
operating the work equipment control lever and
brake pedal.
2. Disconnect hose (2) connected to PPC pump.

charge valve and rear accumulator block for the
front brake.

charge valve and block.
5. Disconnect hose (5) from hydraulic tank.
6. Disconnect tube (6) between the accumulator

charge valve and PPC accumulator.
7. Disconnect tube (7) connected to PPC valve.
8. Remove accumulator charge valve (8).
INSTALLATION OF
ACCUMULATOR CHARGE
VALVE
moval.

WD600-3 30-195
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE SOLENOID VALVE
REMOVAL OF PARKING BRAKE

SOLENOID VALVE
chine from moving.
1. Disconnect upper connector (1) (F14).
2. Disconnect suction tubes (2).
4. Remove 4 mounting bolts (4), then remove park-

ing brake solenoid valve (5).
INSTALLATION OF PARKING
BRAKE SOLENOID VALVE
moval.
30-196 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY DIVERTER VALVE
REMOVAL OF DIVERTER VALVE

chine from moving.

oil.
= Hydraulic oil : 215 ¬
2. Disconnect connector (2) (R01).
3. Disconnect 2 hoses (3) between the diverter valve

and emergency steering pump.
4. Disconnect suction tube (4).
5. Disconnect tube (4) between the diverter valve

and the intermediate block.
7. Disconnect tube (6) between the diverter valve

and the intermediate block.
8. Remove mounting bolts of brackets (7) and (8),

then remove diverter valve (9) together with the
bracket.
0 Diverter valve: 50kg
INSTALLATION OF DIVERTER
VALVE
moval.

- Hydraulic oil: 215 ¬
WD600-3 30-197
(2)
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING PUMP
REMOVAL OF EMERGENCY
STEERING PUMP
chine from moving.

oil.
2. Disconnect hoses (2) between the emergency

steering pump and diverter valve.
3. Remove brackets (3) and (4).
4. Disconnect 2 tubes (5) connected to diverter valve.
5. Remove mounting bolts (7), then remove emer-

gency steering pump (8).
0 Emergency steering pump: 30kg
INSTALLATION OF
moval.

Hydraulic oil: 215 ¬
30-198 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE

chine from moving.
1. Remove disc plate cover (1).
0 Drive shaft: 20kg
3. Turn adjustment bolt (3) clockwise to increase the
clearance between the pad and disc. 2
4. Pull out connecting pin (4).
5. Disconnect hose (5).
6. Remove spring cylinder (6).
7. Disconnect plate (7). 3
fl Secure the calipers.
fl Since 2 dowel pins are installed, raise the cali-
pers a little, then remove the plate.
8. Remove pad (8).
9. Remove calipers (9).
0 Calipers: 32kg
10. Remove mounting bolts (10), then remove disc
(11).
0 Disc: 31kg 4
BRAKE
moval.
1
2
fl Adjust the parking brake. For details, see
TESTING AND ADJUSTING PARKING BRAKE
of TESTING AND ADJUSTING,.
3
9 Mounting bolt:
824.0 – 1030.0Nm {84.0 – 105.0kgm}
4
9 Mounting bolt:
490.0 – 608.0Nm {50.0 – 62.0kgm}
WD600-3 30-199
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
DISASSEMBLY OF PARKING
BRAKE CALIPERS
Remove the parking brake calipers. For details, see
REMOVAL OF PARKING BRAKE.
1. Remove snap ring (1), then pull out slack adjuster

(2).
2. Remove washers (3) and (4), and seal (5).
3. Remove bolts, then remove cap (6) and gasket

(7).
4. Remove piston shaft (8) and thrust bearing (9).
5. Remove piston (11) and piston seal (12) from cali-

pers (10).
30-200 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
ASSEMBLY OF PARKING BRAKE

CALIPERS
1. Install piston seal (12) to calipers (10), then insert
piston (11).
2. Screw piston shaft (8) in the piston, then install

thrust bearing (9).
3. Install gasket (7), then install cap (6).
4. Install seal (5) and washers (3) and (4).

fl Fit the seal in the seal groove securely.
3 Seal: Grease (G2-LI)
5. Install slack adjuster (2), then secure it with snap

ring (1).
WD600-3 30-201
(2)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD

PAD
chine from moving.
1. Remove disc plate cover (1).
2. Turn adjustment bolt (2) counterclockwise to in-

crease the clearance between the pad and disc.
1
3. Secure calipers (3) with wires.
4. Remove plate (4). 2

fl Since 2 dowel pins are installed, raise the cali-
pers a little, then remove the plate.
5. Remove pad (5).
BRAKE PAD
moval.
1
fl Adjust the parking brake pad. For details, see
TESTING AND ADJUSTING PARKING BRAKE
of TESTING AND ADJUSTING,.
2
9 Mounting bolt:
824.0 – 1030.0Nm {84.0 – 105.0kgm}
30-202 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY REAR TIRES
REMOVAL OF REAR TIRES

¤ Stop the machine on level ground and set the
safety bar on the frame, then put blocks under
the front wheels.
1. Set blocks [1] to right and left rear axles.

fl Set these blocks to prevent the tires from
jumping when they are removed.
2. Lift the machine body with 2 jacks (50ton) [2], then

set support stand [3] under the counterweight.
3. Sling the tire temporarily, then remove hub nuts

(1). 1
4. Sling and remove tire (2).

fl Tighten the sling at the center of the tire.
0 Tires: 1,450kg
INSTALLATION OF REAR TIRES

moval.
1
9 Hub nut: 736.0 – 912.0Nm {75.0 – 93.0kgm}
fl Match the stud bolts to the holes by turning
the tire on the opposite side.
WD600-3 30-203
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
chine from moving.
1. Using tool X1, collect air conditioner refrigerant

(R-134a)
2. Disconnect connector (1) (E12).
3. Remove adapter bolts (2) and (3).
4. Remove bracket (4) and hoses (5) and (6) together.

fl Remove these parts without removing the
clamp.
5. Loosen mounting bolt (7) and adjustment bolt (8).
6. Turn down the air conditioner compressor toward

the engine, then remove belt (9).
7. Remove mounting bolts (10), then remove air con-

ditioner compressor (11).
INSTALLATION OF AIR
moval.

frigerant (R134a).
30-204 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
chine from moving.
1. Open bulkhead cover (1).
2. Disconnect condenser connectors (2) (B03), (3)

(B04), (4) (B02) and (5) (B01).
3. Disconnect hose (6) of the receiver tank. 1

fl Collect the refrigerant (R134a). For details,
see REMOVAL OF AIR CONDITIONER COM-
PRESSOR.
fl Be sure to apply spanners to the hose side
and condenser side.
4. Disconnect hose (7) of the air conditioner com-

pressor.
and condenser side.
5. Disconnect hose (8) between the upper and lower

condensers.
and condenser side.
6. Remove mounting bolt (9), then remove air con-

ditioner condensers (10) and (11).
INSTALLATION OF AIR
CONDITIONER CONDENSER
moval.
1
fl Install each hose without twisting it.
fl When connecting each hose, take care that
dirt, dust, water, etc. will not enter it.
fl Using tool X1, refill the air conditioner with
new refrigerant (R134a).
WD600-3 30-205
(2)
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
REMOVAL OF RECEIVER TANK

chine from moving.
1. Open bulkhead cover (1).
2. Disconnect hose (2) of the air conditioner unit.

PRESSOR.
3. Disconnect hose (3). 1
4. Remove clamps (4), then remove receiver tank (5).
INSTALLATION OF RECEIVER
TANK
moval.
1
fl Install each hose without twisting it.
fl When connecting each hose, take care that
dirt, dust, water, etc. will not enter it.
fl Using tool X1, refill the air conditioner with
new refrigerant (R134a).
30-206 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
chine from moving.
1. Remove the cab . For details, see REMOVAL OF

CAB.
2. Disconnect operator’s seat suspension switch

connector (1) (ASS).
fl This connector is installed at the rear of the
seat.
3. Remove operator’s seat (2).

0 Operator’s seat: 50kg
4. Remove covers (3) and (4).
5. Remove console box (5).
6. Disconnect connectors (6) (A5), (7) (A7) and (8)

(A6).
7. Disconnect connectors (9) (A8B) and (10) (A8A).
8. Disconnect expansion valve switch connector (11)

(A15).
9. Disconnect tube (12) of the receiver tank.
10. Disconnect tube (13) of the air conditioner com-

pressor.
PRESSOR.
fl Take a measure to prevent dirt, water, etc.
from entering the tube.
11. Disconnect heater hot water inlet hose (14).
12. Disconnect heater hot water outlet hose valve.

fl Close the valve on the engine side.
fl Plug each disconnected hose.
WD600-3 30-207
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
13. Remove screw (16).
14. Remove mounting bolt (17), then remove air con-

ditioner unit (18).
fl Pull out the air conditioner unit to remove it.
INSTALLATION OF AIR
CONDITIONER UNIT
moval.

Using tool X1, refill the air conditioner with new
refrigerant (R134a).
fl If the air conditioner is used without charg-
ing it with the refrigerant, its compressor may
be broken. Be extremely careful.
30-208 WD600-3
(2)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL OF MONITOR
chine from moving.
2. Remove screw (2).
3. Remove covers (3) and (4) on both sides.
4. Remove bracket (5).
5. Disconnect connectors (6) (L08), (7) (L06), (8) (L07)

and (9) (L05).
6. Remove 12 screws (10), then remove monitor (11).
INSTALLATION OF MONITOR
moval.
WD600-3 30-209
(2)
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

Transmission mount .................................... 40- 3
Torque converter .......................................... 40- 4
Lock-up valve ................................................ 40- 6
Torque converter regulator valve ................ 40- 7
Transmission ................................................. 40- 8
Transmission solenoid valve ....................... 40-11
Transmission control valve .......................... 40-12
Transfer ......................................................... 40-16
Drive shaft ..................................................... 40-18
Center support .............................................. 40-19
Differential .................................................... 40-20
Non-spin Differential .................................... 40-24
Final drive ..................................................... 40-26
Axle mount ................................................... 40-28
Center hinge pin ........................................... 40-30
Steering column ........................................... 40-32
Steering valve ............................................... 40-33
Emergency steering pump .......................... 40-34
Diverter valve ................................................ 40-35
Steering cylinder mount .............................. 40-36
Brake valve .................................................... 40-37
Slack adjuster ............................................... 40-40
Brake .............................................................. 40-41
Parking brake ................................................ 40-42
Hydraulic pump ............................................ 40-43
PPC valve ...................................................... 40-46
Work equipment valve ................................. 40-48
Hydraulic cylinder ........................................ 40-50
Work equipment linkage .............................. 40-54
Rops canopy ................................................. 40-57
WD600-3 40-1
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
40-2 WD600-3
MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
Unit: mm
No. Check item Criteria Remedy
1.5mm (out-of-parallel between coupling of center support

1 Thickness of shim for mounting and coupling of transmission: 0.1mm) Adjust
WD600-3 40-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
40-4 WD600-3
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm

Standard size Tolerance Repair limit
Coupling oil seal sliding por-
1 tion outside diameter 0
ø 115 ø 114.8
– 0.087
Correction by
2 Input shaft seal ring sliding ø 40 + 0.025 ø 40.1 chrome plat-
portion inside diameter 0 ing or replace-
Pump housing seal ring slid- + 0.040 ment
3 ø 140 ø 140.5
ing portion inside diameter 0
4 Input shaft seal ring sliding ø 65 + 0.030 ø 65.1

portion inside diameter 0
4.45 0 4.0
Width – 0.1
5 Stator shaft
seal ring wear
Thickness 5.2 ± 0.1 4.7
Outer race one-way clutch

6 transmission face inside ø 102.555 ± 0.008 ø 102.585
diameter
Inner race one-way clutch + 0.004
7 transmission face outside ø 83.6 – 0.009 ø 83.57
diameter
Bushing sliding portion in- + 0.015
8 ø 83.71 0 ø 83.79
side diameter Replace
9 Bushing sliding portion 6 ± 0.05 5.5
thickness
10 Clutch disc thickness 5.4 ± 0.1 4.8
Tolerance Standard Clearance

Standard size clearance limit
Clearance between clutch Shaft Hole
11 housing and piston (out-
side) ø 420 – 0.5 + 0.097 0.5 – 0.797 0.88
– 0.7 0
12 Clearance between clutch ø 295 – 0.110 + 0.081 0.11 – 0.272 0.30

housing and piston (inside) – 0.191 0
WD600-3 40-5
MAINTENANCE STANDARD LOCK-UP VALVE
LOCK-UP VALVE
Unit: mm
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
1 Clearance between lock-up
clutch spool and body
– 0.035 +0.016 0.035 –
32 – 0.045 0 0.061 0.081
Standard size Repair limit

Free Installation Installation Free Installation
Lock-up valve spring length length load length load Replace
2 (Large)
104.9 N 99.8 N
123.5 88.4 {10.7 kg} 119.8 {10.1 kg}
Lock-up valve spring 179.5 N 170.5 N

3 (Small) 78.1 67.1 75.8
{18.3 kg} {17.4 kg}
4 Poppet spring of lock-up 20.6 N 19.5 N

30 16 {2.1 kg} 29.6 {1.99 kg}
valve
40-6 WD600-3
MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
Unit: mm

Clearance between popet size Shaft Hole clearance limit
1 and spool
– 0.020 +0.021 0.020 –
22 – 0.030 0 0.051 0.071
Clearance between spool – 0.035 +0.016 0.035 –

2 and body 32 0.081
– 0.045 0 0.061
Replace
3 Poppet spring length length load length load
43.9 21 22.4 N 42.6 21.6 N

{2.28 kg} {2.2 kg}
4 Spool spring 87.6 80.0 96.1 N 85.0 91.2 N

{9.8 kg} {9.3 kg}
WD600-3 40-7
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION (1/2)
40-8 WD600-3
Unit: mm

Reverse clutch springs
1 (12 pieces) length length load length load
146 N 125 N
68 55 {14.9 kg} 64 {12.6 kg}
Forward clutch springs 78.5 N 66.7 N
2 (12 pieces) 68 61 64
{8 kg} {6.8 kg}
4th clutch springs 101 N 86.3 N
3 (12 pieces) 52 46 49
{10.3 kg} {8.8 kg}
3rd clutch springs 84.3 N 71.6 N
4 (12 pieces) 52 47 {8.6 kg} 49 {7.3 kg}
1st clutch springs 155 N 131 N
5 52 42.8 {15.8 kg} 49 {13.4 kg}
(12 pieces)
Thickness of assembled 4 Standard size Tolerance Repair limit

6 discs and 3 plates for re-
verse clutch 39 ± 0.35 36.9
Thickness of assembled 4 discs

7 and 3 plates for forward clutch 39 ± 0.35 36.9
Thickness of assembled 3 discs 27.8 ± 0.30 26.2

8 and 2 plates for 4th clutch
9
and 4 plates for 2nd clutch 45 ± 0.30 42.3

10
and 2 plates for 3rd clutch 27.8 ± 0.30 26.2

11 and 2 plates for 1st clutch 27.8 ± 0.30 26.2
Forward, Reverse, Replace
Thick- 1st, 3rd, 4th 5.4 ± 0.15 4.9
12 ness of
1 disc 2nd 5.0 ± 0.10 4.5
Forward, Reverse,
Thick- 1st, 3rd, 4th 5.8 ± 0.10 5.2
13 ness of
1 plate 2nd 5.0 ± 0.10 4.5
Outside diameter of input +0.018 +0.018
14 shaft 170 – 0.007 – 0.007
Outside diameter of input +0.016 +0.016
15 shaft 110 – 0.006 – 0.006
Outside diameter of output +0.018 +0.018
16 shaft 130 – 0.007 – 0.007
Outside diameter of output +0.018 +0.018
17 shaft 140 – 0.007 – 0.007
– 0.01
Wear of seal Width 3.0 2.7
18 ring for input – 0.03
shaft Thickness 3.7 ±0.12 3.55
– 0.01
19 ring for out- – 0.03
put shaft Thickness 5.4 ±0.12 5.25
– 0.01
20 ring for 2nd – 0.03
clutch Thickness 6.0 ±0.15 5.85
– 0.01
21 ring for out- – 0.03
put shaft Thickness 5.2 ±0.12 5.05
WD600-3 40-9
TRANSMISSION (2/2)
Unit: mm
Backlash between reverse

1 sun gear and planetary 0.13 – 0.32
gear
Backlash between reverse
2 planetary gear and ring 0.15 – 0.38
gear
Backlash between forward
3 sun gear and planetary 0.13 – 0.36
gear
Backlash between forward
gear
5 Backlash between 4th sun

gear and planetary gear 0.13 – 0.36
Replace
Backlash between 4th
gear
Backlash between 3rd sun
7 gear and planetary gear 0.13 – 0.36
Backlash between 3rd

gear
Backlash between 1st sun
9 gear and planetary gear 0.13 – 0.36
Backlash between 1st plan-

10 etary gear and ring gear 0.14 – 0.39
40-10 WD600-3
MAINTENANCE STANDARD TRANSMISSION SOLENOID VALVE
TRANSMISSION SOLENOID VALVE
Unit: mm

Tightening torque of solenoid
1 valve mounting screw 147 – 177 Nm {15 – 18 kgm}

2 valve terminal screw 147 – 177 Nm {15 – 18 kgm}
3 valve terminal screw 68.6 – 78.5 Nm {7 – 8 kgm}
Retighten
4 valve connector mounting screw 58.8 – 78.5 Nm {6 – 8 kgm}
Tightening torque of terminal
5 mounting screw 58.8 – 78.5 Nm {6 – 8 kgm}
6 valve mounting bolt 44.1 – 49.0 Nm {4.5 – 5.0 kgm}
WD600-3 40-11
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

• UPPER VALVE
40-12 WD600-3
Unit: mm

1 Clearance between reduc-
ing valve and body +0.013 0.035 –
– 0.035
25 – 0.045 0 0.058 0.08
Clearance between torque
2 converter relief valve spool – 0.035 +0.013 0.035 –
25 – 0.045 0 0.058 0.08
and body
Clearance between priority – 0.035 +0.013 0.035 –
3 valve spool and body 25 0.08
– 0.045 0 0.058
Clearance between quick
4 return valve spool and – 0.035 +0.011 0.035 –
12 – 0.045 0 0.056 0.08
body
Clearance between modu-
5 lating valve spool and – 0.035 +0.013 0.035 –
25 – 0.045 0 0.058 0.08
body
6 Clearance between main – 0.035 +0.013 0.035 –

relief valve spool and body 28 – 0.045 0 0.058 0.08

Replace
7 Priority valve spring length length load length load
62 37.7 217 N 60.1 206 N

{22.1 kg} {21 kg}
8 Torque converter relief 62 48 126 N 60.1 120 N

valve spring {12.8 kg} {12.2 kg}
9 Modulating valve spring 118 110 91.6 N 114.5 87.3 N

(Inner) {9.34 kg} {8.9 kg}
10 Modulating valve spring 145.7 144 16.6 N 141.3 15.8 N

(Outer) {1.69 kg} {1.61 kg}
11 70 57 293 N 67.9 279 N

Reducing valve spring {29.9 kg} {28.4 kg}
12 Main relief valve spring 108 80.6 337 N 104.8 320 N

(Inner) {34.4 kg} {32.7 kg}
13 Main relief valve spring 128 80.6 457 N 124.1 434 N

(Outer) {46.6 kg} {44.3 kg}
Thickness of shim for re-
14 ducing valve 3.5 mm (pressure per 1 piece: 63.7 kPa {0.65 kg/cm2})
Thickness of shim for

15 modulation valve 3.0 mm (pressure per 1 piece: 32.4 kPa {0.33 kg/cm2})
Thickness of shim for pri-

16 ority valve 2.0 mm (pressure per 1 pieces: 25.5 kPa {0.26 kg/cm2})
Adjust
Thickness of shim for
17 torque converter relief 2.0 mm (pressure per 1 piece: 25.5 kPa {0.26 kg/cm }) 2
valve
18 Thickness of shim main re- 0.5 mm (pressure per 1 piece: 38.2 kPa {0.39 kg/cm2})
lief valve
19 Tightening torque of modu- 34.3 – 49.0 Nm {3.5 – 5.0 kg/cm}

lation lock nut
Clearamce between torque
converter cold relief valve size Shaft Hole clearance limit
20 spool and body
(Only cold area) 28 –0.035 +0.021 0.035 – 0.08
–0.045 0 0.066
Standard size Repair limit Replace
Torque converter cold relief Free Installation Installation Free Installation
21 valve spring length length load length load
(Only cold area)
92.8 64 201 N 90 191 N
{20.5 kg} {19.5 kg}
WD600-3 40-13
• LOWER VALVE
40-14 WD600-3
Unit: mm

Clearance between FOR- size Shaft Hole clearance limit
1 WARD-REVERSE spool and
body – 0.035 +0.013 0.035 –
22 – 0.045 0 0.058 0.08
Clearance between 1st – 0.035 +0.013 0.035 –

2 speed spool and body 22 0.08
– 0.045 0 0.058
3 Clearance between 2nd – 0.035 +0.013 0.035 –

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

5 Clearance between 4th – 0.035 +0.013 0.035 –

Replace
6 Clearance between pilot re- – 0.035 +0.013 0.035 –
ducing valve and body 25 – 0.045 0 0.058 0.08
Clearance between lubrica- – 0.035 +0.013 0.035 –

7 tion valve plunger and 22 – 0.045 0 0.058 0.08
body
FORWARD-REVERSE, No. Free Installation Installation Free Installation
8 1, No. 2, No. 3 and No. 4 length length load length load
speed spring
107 N 102 N
78 47 {10.9 kg} 75 {10.4 kg}
164 N 156N
9 Pilot reducing valve spring 62 43.7 {16.7 kg} 60.1 {15.9 kg}
60.8 N 57.9 N
10 Lubrication valve spring 39.4 37 {6.2 kg} 38.2 {5.9 kg}
11 Thickness of shim for pilot 3.0 mm (pressure per 1 piece: 25.5 kPa {0.26 kg/cm2}) Adjust
reducing valve
WD600-3 40-15
MAINTENANCE STANDARD TRANSFER
TRANSFER
40-16 WD600-3
MAINTENANCE STANDARD TRANSFER
Unit: mm

1 Outside diameter of idler
shaft 105 +0.045 +0.045
+0.023 +0.023
Outside diameter of input 190 0 0

2 shaft bearing – 0.046 – 0.046
Outside diameter of idler 190 0 0

3 shaft bearing – 0.046 – 0.046
Outside diameter of output 190 0 0

4 shaft bearing – 0.046 – 0.046
Outside diameter of output +0.045 +0.045 Replace

5 105
shaft bearing +0.023 +0.023
Outside diameter of output 150 – 0.012 —

6 shaft bearing – 0.052
Outside diameter of output 85 +0.045 +0.045

7 shaft bearing +0.023 +0.023
Oil seal sliding surface of 105 0 104.8

8 output shaft coupling – 0.087
Oil seal sliding surface of 125 0 124.8

9 output shaft coupling – 0.100
Standard size Adjust valve of bearing preload

10 Clearance between input
cover 0.29–0.98 Nm {0.03–0.10 kgm}
2 (shims)
(Preload, gear as individual part)
Clearance between output Measurement clearance Adjust

11 1 (shims)
cover and case + (0.05 – 0.10 mm)
12 Clearance between idler 0.29–0.98 Nm {0.03–0.10 kgm}

cover and case 2 (shims)
(Preload, gear as individual part)
Backlash between transfer

13 input gear and transfer 0.22 – 0.60
idler gear
14 Backlash between transfer Replace

idler gear and idler gear 0.22 – 0.60
15 Backlash between output

gear and idler gear 0.22 – 0.60
16 Tightening torque of cou- 824 – 1,030 Nm {84 – 105 kgm} Retighten

pling mounting bolt
WD600-3 40-17
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
40-18 WD600-3
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
Unit: mm

1 Clearance between case
and bearing 0 – 0.036 –0.018 –
140 – 0.018 – 0.061 –0.061 – 0.015
Clearance between case 0 – 0.036 –0.018 – Replace

2 and bearing 130 – 0.018 – 0.061 –0.061 – 0.015
Clearance between cou- +0.051 0 – 0.032 –

3 pling shaft and bearing 80 +0.032 – 0.015 –0.066 – 0.029
Clearance between cou- +0.051 0 – 0.032 –

4 pling shaft and bearing 75 +0.032 – 0.015 –0.066 – 0.029

5 Wear of oil seal surface 0 Repair
95 – 0.087 –0.18 chrome
plating or
0 replace
6 Wear of oil seal surface 105 –0.18
– 0.087
7 End play of coupling shaft Max. 0.22 (Preload max. 3.9 Nm {0.4 kgm}) Replace
WD600-3 40-19
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (1/2)
40-20 WD600-3
Unit: mm

Clearance of side bearing size Shaft Hole clearance limit
1 outer race in differential
gear assembly 0 +0.030 0.060 –
225 –
– 0.030 – 0.016 –0.016
Clearance of side bearing
2 inner race in differential 150 +0.052 0 –0.027 – –
gear assembly +0.027 – 0.025 –0.077
Clearance of outer race of 190 0 +0.030 0.060 – –

3 pinion shaft bearing – 0.030 – 0.016 –0.016
Clearance of inner race of 111.125 +0.025 +0.069 0.069 – –

4 pinion shaft bearing 0 +0.047 0.022
Clearance of inner race of 90 0 +0.025 0.045 – –

5 pinion shaft bearing – 0.020 0 0
6 Clearance of outer race of 130 0 +0.039 0.014 – –

pilot bearing – 0.018 +0.014 0.057
7 Clearance of inner race of 60 0 +0.056 0.071 – –

pilot bearing – 0.015 +0.037 0.037
Replace
8 Clearance between differ- 255 +0.046 – 0.030 –0.040 – –
ential carrier and cage +0.010 – 0.070 –0.116
Clearance between spider
9 and differential pinion 46 – 0.13 – 0.13 0.03 – –
bushing – 0.16 – 0.18 –0.05
10 Backlash of bevel gear 0.33 – 0.46
Backlash of differential
11 gear 0.25 – 0.33
12 End play of pinion gear 0 – 0.196
Free rotating torque of

13 bevel gear 13.3 Nm {1.36 kgm}
14 Preload of bevel gear 9.81 – 19.61 KN {1,000 – 2,000 kg}
15 Rear face runout of bevel 0.1

gear
16 Standard thickness of Clearance "a" + (0.1±0.05)

shims for stop shaft
WD600-3 40-21
DIFFERENTIAL (2/2)
40-22 WD600-3
Unit: mm

1 Thickness of side gear
washer 4.0 – 3.5
2 0
Wear of oil seal surface 110 – 0.087 – Replace
Thickness of pinion gear

3 washer 1.5 – 1.3
1st step: 3.9±1.0 Nm {0.4±0.1 kgm}

Tightening torque of (when measuring clearance (no shim))
4 mounting bolt 2nd step: 113±10 Nm {11.5±1.0 kgm} (shim installed)
WD600-3 40-23
MAINTENANCE STANDARD NON-SPIN DIFFERENTIAL
NON-SPIN DIFFERENTIAL
40-24 WD600-3
MAINTENANCE STANDARD NON-SPIN DIFFERENTIAL
Unit: mm

Clearance of side bearing size Shaft Hole clearance limit
1 outer race in differential
gear assembly 0 +0.030 0.060 –
225 –
– 0.030 – 0.016 –0.016
Clearance of side bearing
2 inner race in differential 150 +0.052 0 –0.027 – –
gear assembly +0.027 – 0.025 –0.077
Clearance of outer race of 190 0 +0.030 0.060 – –

3 pinion shaft bearing – 0.030 – 0.016 –0.016
Clearance of inner race of 111.125 +0.025 +0.069 0.069 – –

4 pinion shaft bearing 0 +0.047 0.022
Clearance of inner race of 90 0 +0.025 0.045 – –

5 pinion shaft bearing – 0.020 0 0
6 Clearance of outer race of 130 0 +0.039 0.014 – –

pilot bearing – 0.018 +0.014 0.057
7 Clearance of inner race of 60 0 +0.056 0.071 – –

pilot bearing – 0.015 +0.037 0.037
8 Clearance between differ- 255 +0.046 – 0.030 –0.040 – –

ential carrier and cage +0.010 – 0.070 –0.116
Replace
9 Backlash of bevel gear 0.33 – 0.46
10 End play of pinion gear 0 – 0.196
Free rotating torque of

11 bevel gear Max. 13.3 Nm {1.36 kgm}
12 Preload of bevel gear 9.81 – 19.61 KN {1,000 – 2,000 kg}
Rear face runout of bevel Max. 0.1

13 gear
Standard thickness of Clearance "a" + (0.1±0.05)

14 shims for stop shaft
15 Wear of oil seal surface 0

110 –
– 0.087
1st step: 3.9±1.0 Nm {0.4±0.1 kgm}
16 Tightening torque of (when measuring clearance (no shim))
mounting bolt 2nd step: 113±10 Nm {11.5±1.0 kgm} (shim installed)
17 Backlash of center cum

and driven clutch Max. 0.3
Installation load
Installation length
standard size Repair limit Replace both
18 Spring
side at once
36.3 978.7 N {99.8 kgm} 774.7 N {74.0 kgm}
WD600-3 40-25
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-26 WD600-3
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Tolerance
Standard Standard Clearance
1 Clearance between plan-
etary shaft and bearing
55 +0.015 0 –0.002 – –
+0.002 – 0.015 –0.030
Clearance between ring +0.052 +0.025 0.005 –

2 gear hub and bearing 257.175 –
+0.020 0 –0.052
Thickness of retainer at Replace
3
ring gear mount 22 ±0.1 21.6
Backlash between planet 0.21 – 0.45

4 gear and sun gear
Backlash between planet 0.22 – 0.46

5 gear and ring gear
6 Thickness of standard shim 2.1 ± 1.4

for wheel hub
Tightening torque of 245 – 309 Nm {25 – 31.5 kgm} Retighten

7 mounting bolt [Preload 2,942–27,459 N {300–2,800 kg}]
WD600-3 40-27
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
Unit: mm

1 Clearance of shaft and hole
(Front support side) 0.128 –
350 – 0.062 +0.381 1.0
– 0.151 +0.066 0.532
Clearance of shaft and hole +2.5 +0.089 –0.911 – Replace

2 (Front support side) 360 –2.5 –
+1.0 0
Clearance of shaft and hole – 0.056 +0.381 0.117 –

3 (Rear support side) 310 0.518 1.0
– 0.137 +0.061
Clearance of shaft and hole +2.5 +0.089 –0.911 –

4 (Rear support side) 320 –2.5 –
+1.0 0
5 Thickness of thrust plate – 0.25
26 – 0.39 –
Thickness of wear plate 0

6 5 – 0.1 1.3 Replace
7 Thickness of rear bushing 4.9 ±0.1 –
8 Thickness of front bushing 4.9 ±0.1 –
40-28 WD600-3
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
40-30 WD600-3
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
Tolerance
Standard Standard Clearance
1 Clearance between lower
hinge pin and rear frame
– 0.101 0 0.051 –
108 – 0.152 – 0.050 0.152 –
Clearance between lower

hinge pin and spacer – 0.101 0 0.051 –
2 108 0.152 1.0
(small) – 0.152 – 0.050
Clearance between lower – 0.051 +0.025 0.051 –

3 hinge pin and bearing 107.95 0.127 1.0
– 0.102 0
Clearance between lower
hinge pin and spacer – 0.101 0 0.051 –
4 108 0.152 1.0
(large) – 0.152 – 0.05
Clearance between rear – 0.250 – 0.150 0.050 –

5 frame and spacer (large) 140 –
– 0.300 – 0.200 0.150
Clearance between front
6 frame and upper hinge 0 – 0.077 –0.127 – Replace
160 – 0.025 – 0.127 –0.052 –
bearing
Clearance between upper – 0.076 +0.025 0.056 –
7 hinge pin and rear frame 100 –
– 0.127 – 0.020 0.152
Clearance between upper – 0.076 0 0.056 –

8 hinge pin and bearing 100 1.0
– 0.127 – 0.020 0.127
Clearance between front
9 frame and lower hinge +0.025 – 0.051 –0.127 –
212.725 0 – 0.102 –0.051 –
bearing
Clearance between rear +0.131 +0.166 –0.021 –
10 frame and bushing 132 –
– 0.021 +0.110 0.181
Clearance at press-fitted
11 part of seal of upper hinge +0.280 +0.025 –0.310 –
117.45 +0.180 – 0.030 –0.155 –
pin
Clearance at press-fitted
12 part of seal of lower hinge +0.310 +0.025 –0.335 –
158.75 +0.210 – 0.025 –0.185 –
pin
Height of lower hinge
13 spacer (small)
45.2 ±0.1 –
Height of lower hinge

14
spacer (large) 88.5 ±0.1 –
15 Shim thickness for lower

hinge and retainer 2.55
16 Shim thickness for lower

17 Shim thickness for upper

Adjust
Tightening torque of lower When adjusting with shim: 68.6 Nm (7 kgm)
18 hinge retainer mounting
bolt Final value: 279.0±29.4 Nm {28.5±3 kgm}
Tightening torque of lower When adjusting with shim: 279.0±29.4 Nm {28.5±3 kgm}
19 hinge retainer mounting
bolt Final valuue: 279.0±29.4 Nm {28.5±3 kgm}
Tightening torque of upper When adjusting with shim: 34.3 Nm {3.5 kgm}
20
hinge pin mounting bolt Final value: 279.0±29.4 Nm {28.5±3 kgm}
WD600-3 40-31
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
Unit: mm

Clearance between steer- size Shaft Hole clearance limit
1 ing shaft and column bush- Replace
ing 19 0 +0.15 0.05 – 0.4
– 0.08 – 0.05 0.23
40-32 WD600-3
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit: mm

Steering spool return Free length Installed length Installed load Free length Load limit
1 spring
74.5 N 58.8 N
41.8 38 {7.6 kg} – {6 kg}
Load check valve spring 8.8 N 7.0 N

2 20.9 13.2 – {0.71 kg}
{0.9 kg} Replace
3 Demand spool return 409.9 N 327.5 N

spring 90.8 83 {41.8 kg} – {33.4 kg}
182.4 N 145.1 N
4 Relief valve spring 24.0 22.19 – {14.8 kg}
{18.6 kg}
8.8 N 7.0 N
5 Check valve return spring 20.9 13.2 – {0.71 kg}
{0.9 kg}
WD600-3 40-33
MAINTENANCE STANDARD EMERGENCY STEERING PUMP

(SAM3-125)
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside di-

2 ameter of plain bearing and 0.020 – 0.043 0.075 Replace
outside diameter of gear shaft
3 Insertion depth of pin 0
14 –0.5
Rotating torque of spline 6.86 – 11.8 Nm {0.7 – 1.2 kgm}

4 shaft
Revolution Pressure Standard Repair limit

discharge discharge –
Discharge (rpm) (MPa {kg/cm2})
– (¶/min.) (¶/min.)
Oil: SAE10W
Temperature: 45 to 55°C 20.6
2,500 {210} 276 244
40-34 WD600-3
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
Unit: mm
Standard Tolerance
Standard Clearance
Clearance between body
1 and spool – 0.013 +0.015 0.020 –
40 – 0.015 –
+0.007 0.030
2 Spool return spring length length load length load Replace
216.7 N 205.9 N
122.6 84 {22.1 kg} 120.7 {21.0 kg}
3 Check valve spring 5.6 N 5.3 N

79.2 54.5 {0.57 kg} 77.9 {0.54 kg}
4 Check valve spring 4.9 N 4.6 N

79.2 57.5 {0.50 kg} 77.9 {0.47 kg}
WD600-3 40-35
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Unit: mm

Clearance between mount- size clearance limit
ing pin and bushing con- Shaft Hole
1 nection of steering cylinder
rod and frame – 0.030 +0.350 0.280 –
75 – 0.076 +0.250 0.426 1.0
Clearance between mounting pin

and bushing at connection of steer- – 0.030 +0.350 0.280 –
2 75 – 0.076 +0.250 0.426 1.0
ing cylinder bottom and frame Replace
Width of boss Width of hinge Standard clearance
(Clearance a + b)
Connection of steering cyl-
3 inder and front frame
85 – 00.5 Max. 0.5 after ad-
90.5±1.2 justing shim
Connection of steering cyl- Max. 0.5 after ad-

4
inder and rear frame 85 – 00.5 90.5±1.2 justing shim
40-36 WD600-3
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
(LEFT)
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1 mount hole and bracket
hole – 0.025 +0.1 0.175 –
10 – 0.075 0 0.025 0.25
Clearance between roller – 0.025 +0.1 0.175 –

2 10 – 0.075 0 0.025 0.25
and pin
3 Outside diameter of roller 0
30 – 0.5 29.2

Replace
Free length Test height Test load Free length Test load
4 Control spring
114 N
20 18 {11.6 kg} 19 –
103 N
5 Control spring 32.6 28 {10.5 kg} 31.6 –
37.2 N
6 Control spring 47.2 46 {3.8 kg} 46.2 –
60.8 N
7 Return spring 86.2 58 {6.2 kg} 78 –
16.7 N
8 Return spring 31.5 19.5 {1.7 kg} 28 –
WD600-3 40-37
(RIGHT)
40-38 WD600-3
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1 mount hole and bracket
hole – 0.025 +0.1 0.175 –
10 – 0.075 0 0.025 0.25
Clearance between roller – 0.025 +0.1 0.175 –

2 and pin 10 – 0.075 0 0.025 0.25

3 Outside diameter of roller 0
30 29.2
– 0.5
Free length Test height Test load Free length Test load Replace
4 Control spring
114 N
20 18 {11.6 kg} 19
103 N
5 Control spring 32.6 28 {10.5 kg} 31.6
37.2 N
6 Control spring 47.2 46 {3.8 kg} 46.2
60.8 N
7 Return spring 86.2 58 {6.2 kg} 78
Spring 17.7 N
8 17 16.5 {1.8 kg} 16.2
9 Return spring 31.5 19.5 16.7 N 28

{1.7 kg}
WD600-3 40-39
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
Unit: mm

Clearance between body
1 and piston
– 0.030 +0.074 0.030 –
55 – 0.076 0 0.150 0.25
Replace
Free length Test height Test load Free length Test load
2 Slack adjuster spring
118 N
230 88 {12 kg} – –
40-40 WD600-3
MAINTENANCE STANDARD BRAKE
BRAKE
Unit: mm

Installation Installation Installation
Free length length Free length load
1 Return spring load
677 N 642 N
104.8 92.4 {69 kg} 102.7 {65.5 kg}
2 Thickness of plate
2.4 2.15
3 Thickness of disc 5.1 4.6

Total thickness of plate and
4 disc 99.9 89.9
Standard size Tolerance Repair limit Replace

Wear of contact surface of
5 seal 0
430 – 0.155 –
6 Wear of surface in contact +0.097

with piston seal 420 –
0
Wear of surface in contact +0.097
7 with piston seal 455 –
0
Deformation of friction sur-
8 face of plate and disc Max. 0.4 0.7
Backlash between outer 0.29 – 0.62

9 gear and plate
Backlash between inner
10 gear and disc 0.17 – 0.52
WD600-3 40-41
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit: mm

Remaining thick-
ness of friction ma- 22.2 – 3.7
Wear terial Replace
1 of pad
Including backing
plate 31.7 – 12.7
Wear of rod connecting pin 12.7 – 0.10 –

2 – 0.17
Rebuild
Thickness of plate
must be under
Wear of disc 22 mm.
3 24 ±0.5 –
(Thickness of disc plate)
Less than 22 mm Replace
Clearance between pad

4 and disc 1.06 ±0.18 2.1
(Total of both sides) Adjust
Clearance between brake 0.36 – 1.0
5 body and plate
40-42 WD600-3
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAL(4)-125 (Steering) + SAL(4)-100 (Switch) pump
Unit: mm
Model Standard clearance Clearance limit

1 Side clearance SAL(4)-125 0.11 – 0.16 0.19
SAL(4)-100 0.11 – 0.16 0.19
Clearance between inside diam- SAL(4)-125 0.06 – 0.14 0.20
2 eter of plain bearing and out-
side diameter of gear shaft SAL(4)-100 0.06 – 0.14 0.20
Model Standard size Tolerance Repair limit Replace
3 Insertion depth of pin SAL(4)-125 21 0 –

– 0.5
SAL(4)-100 21 0 –
– 0.5
Rotating torque of spline SAL(4)-125

4 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
shaft
SAL(4)-100
Discharge Standard Repair limit
Model Revolution pressure discharge discharge
(rpm) MPa{kg/cm2} (¶/min.) (¶/min.)
Discharge
– Oil: EO10-CD –
Temperature: 45 – 55°C SAL(4)-125 2,200 210 253 234
SAL(4)-100 2,200 210 205 190
WD600-3 40-43
SAL(3)-080 (Work equipment) pump
Unit: mm
Standard size Clearance limit

Clearance between gear
1 case and side plate, gear 0.10 – 0.15 0.19
Clearance between inside di- Replace

2 ameter of plain bearing and 0.06 – 0.149 0.20
outside diameter of gear shaft
3 Insertion depth of pin 0

14 – 0.5
4 Rotating torque of spline 6.9 – 11.8 Nm {0.7 – 1.2 kgm}

shaft
Discharge Standard Repair limit
Revolution pressure discharge discharge —
Discharge (rpm) MPa {kg/cm2} (¶/min.) (¶/min.)
– EO10-CD
45 – 55°C 20.6
2,500 184 170
{210}
40-44 WD600-3
SAL(3)-125 (Torque converter charging) + SAL(1)-32(PPC) pump
Unit: mm
Model Standard clearance Clearance limit

Clearance between gear
1 case and side plate SAL(3)-125 0.13 – 0.18 0.22
SAL(1)-32 0.10 – 0.15 0.19
Clearance between inside diam- SAL(3)-125 0.06 – 0.149 0.20
2 eter of plain bearing and out-
side diameter of gear shaft SAL(1)-32 0.06 – 0.119 0.20
Model Standard size Tolerance Repair limit Replace
3 Insertion depth of pin SAL(3)-125 14 0 –

– 0.5
SAL(1)-32 10 0 –
– 0.5
4 Rotating torque of spline 8.8 – 16.7 Nm {0.9 – 1.7 kgm}

shaft
Revolution Discharge Standard Repair limit

Model (rpm)
pressure discharge discharge
Discharge MPa{kg/cm2} (¶/min.) (¶/min.)
– Oil: EO10-CD –
Temperature: 45 – 55°C SAL(3)-125 2,000 30 240 220
SAL(1)-32 2,000 30 61 52
WD600-3 40-45
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
Unit: mm

Free length Installed Installed Installed
Centering spring × O.D. length Free length load
1 load
(RIGHT TILT, LOWER)
29.4 N 23.5 N Replace
52.8 × 12.3 36.0 {3.0 kg} – {2.4 kg} spring if
damaged or
Centering spring 39.2 N 31.4 N deformed
2 (LEFT TILT, RAISE) 52.8 × 12.3 36.0 {4.0 kg} – {3.2 kg}
16.7 N 13.7 N
3 Metering spring 31.4 × 7.4 29.4 {1.7 kg} – {1.4 kg}
40-46 WD600-3
MAINTENANCE STANDARD WORK EQUIPMENT VALVE
WORK EQUIPMENT VALVE
40-48 WD600-3
MAINTENANCE STANDARD WORK EQUIPMENT VALVE
Unit: mm
Spool return spring Free length ✕ O.D. Installed length Installed load Free length Load limit
1 (For tilt)
125 N
54.8 ✕ 34 53.5 {12.7 kg} – –
2 Spool return spring 235.5 N

(For tilt, lift) 54.8 ✕ 33.7 52.2 {24 kg} – –
Spool return spring 235.5 N

3 (For tilt, lift) 30.7 ✕ 32.5 26.8 {24 kg} – –
Spool return spring 233 N

4 (For lift) 55.3 ✕ 16.9 40 {23.8 kg} – –
Replace
Spool return spring 208 N
5 (For lift) 86.8 ✕ 34.7 83.5 {21.2 kg} – –
Main valve spring of main 33 N

6 relief valve 39.5 ✕ 11.2 23.2 {3.4 kg} – –
44 N
7 Check valve spring 32.6 ✕ 10.9 24.5 {4.5 kg} – –
7N
8 Suction valve spring 27.9 ✕ 13 19 {0.7 kg} – –
Poppet spring of relief 259 N 208 N

9 49.3 ✕ 12.8 41.9 {26.4 kg} 47.8 {21.2 kg}
valve
WD600-3 40-49
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
STEERING CYLINDER
Unit: mm

1 Clearance between rod and
bushing
– 0.030 +0.279 0.095 –
75 – 0.076 +0.065 0.355 –
Clearance between piston 0.077 –

rod mounting pin and – 0.030 +0.227
2 75 +0.047 0.303 –
bushing – 0.076 Replace
Clearance between cylin- 0.077 –
der bottom mounting pin – 0.030 +0.227
3 75 – 0.076 +0.047 0.303 –
and bushing
4 Cylinder bore +0.15
140 0 –
40-50 WD600-3
LIFT CYLINDER
Unit: mm

Clearance between rod
and bushing (For cold area)
1 –0.100 +0.0271 0.161 –
80 –0.174 +0.061 0.445 0.745
Clearance between rod –0.120 +0.027 0.181 – Replace

and bushing 90 –0.207 +0.061 0.477 0.777 bushing
Clearance between piston +0.046 0.03 –
2 rod mounting pin and –0.030
70 –0.076 0 0.12 1.0
inside diameter of hole
Clearance between cylin-
der bottom mounting –0.030 +0.046 0.03 –
3 70 –0.076 0 0.12 1.0
pin and bushing
+0.25 Replace
4 Cylinder bore 160 – 0 – –
5 Tightening torque of cylin-

der head mounting bolt 250 ± 24.5 Nm{25.5 ± 2.5 kgm}
Retighten
Tightening torque of piston
6 mounting bolt 110 ± 12.3 Nm{11.25 ± 1.25 kgm }(with LT-2)
WD600-3 40-51
TILT, PITCH CYLINDER
Unit: mm

1 Clearance between rod
and bushing
–0.036 +0.257 0.084 – Replace
90 –0.090 +0.048 0.347 – bushing
Clearance between piston
2 rod mounting pin and –0.30 +0.20 0.30 –
75 –0.40 0 0.60 –
bushing
Clearance between cylin-
3 der bottom mounting –0.30 +0.174 0.40 –
70 –0.50 0.100 0.674 –
pin and bushing
4 Cylinder bore +0.30 Replace

180 – 0 – –
5 Tightening torque of cylin- 343 ± 34.3 Nm{35 ± 3.5 kgm}

der head mounting bolt
Retighten
6 Tightening torque of piston 98 – 123 Nm{10 – 12.5 kgm }(with LT-2)
mounting bolt
40-52 WD600-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
40-54 WD600-3
Unit: mm

Clearance between bearing size Shaft Hole clearance limit
1 and pin at joint of lift cylin-
der rod and blade –0.030 +0.046
70 –0.076 0 0.03 – 0.12 1
Clearance between bearing

2 and pin at joint of support –0.025 +0.039
50 –0.069 0 0.025 – 0.108 1
and blade
Clearance between bush-
3 ing and pin at joint of –0.5 +0.3
70 –0.6 0 0.5 – 0.9 2
frame and blade
4 and pin at joint of tilt, pitch –0.3 +0.2
75 –0.4 0 0.3 – 0.6 2
cylinder and blade
5 ing and pin at joint of sup- –0.030 +0.285
75 –0.076 +0.184 0.214 – 0.361 1
port and front frame
6 ing and pin at joint tilt, –0.3 +0.174
70 –0.5 +0.100 0.13 – 0.674 2
pitch cylinder and frame
Spherical clearance be-
7 tween trunnion cap and –0.5 +0.5
195 –1.0 0 0.5 – 1.5 –
trunnion
8 ing and pin at joint of lift –0.030 +0.046
70 –0.076 0 0.030 –0.122 1
cylinder bottom and frame
9 and bushing at joint of lift +0.070 +0.24
135 –0.010 +0.19 0.12 – 0.25 –
cylinder and blade
10 and bushing at joint of sup- +0.070 +0.24 Replace
135 –0.010 +0.19 0.12 – 0.25 –
port and blade
+0.45
11 and bushing at joint of 140 ±0.05 +0.35 0.30 – 0.50 1
frame and blade
12 ing and pin at joint of sup- –0.025 +0.039
50 –0.069 0 0.025 – 0.108 1
port and blade
Clearance between pin and
13 boss at joint of cylinder rod –0.030 +0.1
70 –0.076 0 0.03 – 0.176 1
and blade
14 boss at joint of support and –0.025 +0.1
50 –0.069 0 0.025 – 0.169 1
blade
15 boss at joint frame and –0.5 +0.3
70 –0.6 0 0.5 – 0.9 2
blade
16 boss at joint of tilt, pitch –0.3 +0.1
75 –0.4 0 0.3 – 0.5 2
cylinder and blade
17 boss at joint of support and –0.030 +0.1
75 –0.076 0 0.03 – 0.176 1
front frame
18 boss at joint of tilt, pitch –0.3 +0.1
70 –0.5 0 0.3 – 0.6 2
cylinder and frame
19 boss at joint of lift cylinder –0.030 +0.30
70 –0.076 +0.20 0.230 – 0.376 1
bottom and frame
20 ing and boss at joint of –0.036 +0.054
82 –0.090 0 0.036 – 0.144 1
support and blade
WD600-3 40-55
Unit: mm
Width between Standard clearance

Width of hinge (Clearance a + b)
bosses
21 Joint of lift cylinder rod
and blade +0.5 0
110 +0.2 110 – 0.2 0.2 – 0.7
22 Joint of frame and blade 140 +0.8 140 –0.2 0.5 – 1.5
0.3 –0.7
23 Joint tilt, pitch cylinder and 106 ± 2 100 –0.1 4.1 – 8.3 —
blade –0.3
25 Joint of tilt, pitch cylinder 74 ± 1.5 70 0 2.5 – 6

and frame – 0.5
26 Joint of lift cylinder bottom 110 +2.0 110 0 0.5 – 2.2

and frame +0.5 – 0.2
Adjust with
shims so that
clearance is
27 Joint of H-link and boss 89 ± 1 86 ± 0.8 1.2 – 4.8 less than 1.5
mm on both
left and right
40-56 WD600-3
MAINTENANCE STANDARD ROPS CANOPY
ROPS CANOPY
WD600-3 40-57
90 OTHERS
BRAKE CIRCUIT DIAGRAM ................................ 90- 2

HYDRAULIC CIRCUIT DIAGRAM
FOR POWER TRAIN ............................................ 90- 5
HYDRAULIC CIRCUIT DIAGRAM ....................... 90- 7
ELECTRIC CIRCUIT DIAGRAM
FOR MACHINE WITH JOYSTICK STEERING
AND AUTOMATIC SHIFT CONTROL
Electric circuit diagram (1/8) ......................... 90- 9
Electric circuit diagram (2/8) ......................... 90-11
WD600-3 90-1
OTHERS BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
90-2 WD600-3
OTHERS BRAKE CIRCUIT DIAGRAM
1. Hydraulic pump (tandem)

1A. Torque converter charging pump
1B. PPC pump
2. Strainer
3. Accumulator charge valve
3A. Safety relief valve
3B. PPC relief valve
4. Check valve
5. Low pressure switch
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
9. Brake valve (left)
10. Transmission cut-off switch
11. Brake valve (right)
12. Stop lamp switch
13. Rear slack adjuster
14. Front slack adjuster
15. Parking brake solenoid valve
15A. Parking brake emergency release
solenoid
16. Parking brake emergency release switch
17. Parking brake
18. Parking brake pilot lamp switch
19. Strainer
WD600-3 90-3
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
2. PTO case
3. Strainer
4. Torque converter charging pump
(SAL(3)-125)
5. PTO pump (SAL(1)-32)
6. PTO lubrication
7. Oil filter (3 pcs)
8. Transmission main relief valve
9. Pilot oil filter
10. Pilot reducing valve
11. Priority valve
12. Modulating valve
13. Quick return valve
14. Torque converter
15. Torque converter relief valve
16. Torque converter regulator valve
17. Oil cooler
18. Lubrication valve
19. Transmission lubrication
20. Lubrication bypass valve
21. Reducing valve
22. Reverse spool
23. Forward spool
24. 4th spool
25. 3rd spool
26. 2nd spool
27. 1st spool
28. Emergency manual spool
29. Solenoid valve
30. Reverse clutch
31. Forward clutch
32. 4th clutch
33. 3rd clutch
34. 2nd clutch
35. 1st clutch
36. Last chance filter
37. Lock-up valve
38. Lock-up clutch
39. Solenoid valve
WD600-3 90-5
HYDRAULIC CIRCUIT DIAGRAM
WD600-3 90-7
ELECTRIC CIRCUIT DIAGRAM (1/8)
FOR MACHINE WITH JOYSTICK STEERING AND AUTOMATIC SHIFT CONTROL
WD600-3 90-9
WD600-3 90-11
WD600-3 90-13
WD600-3 90-15
WD600-3 90-17
WD600-3 90-19
WD600-3 90-21
WD600-3 90-23

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SEBM022902

MACHINE MODEL SERIAL NO.

WD600-3 50001 and up

• WD600-3 mounts the SAA6D170E-3 engine.

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

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

20 TESTING AND ADJUSTING ................................................................ 20-1

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

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

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

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

b 00-1 (2) 10-7 10-50 10-91 10-133

10-175 20-134 (1) 20-302 (1) 20-383 (1) 20-477 (1)

c 30-161 (2) 40-5 90-3

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS