SEBM036909

MACHINE MODEL SERIAL NUMBER

WD900-3 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.

• WD900-3 mount the SA12V140-1 engine.

For details of the engine, see the 12V140 Series Engine Shop Manual.

© 2024
All Rights Reserved
Printed in Japan 02-24 (01)
00-1
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GENERAL

CONTENTS

No. of page
00 SAFETY .................................................................................................................................. 00-3

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 WD900-3
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SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE
Important safety notice
Proper service and repair are 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 k is used to mark safety precautions in this manual. The cau-
tions accompanying these symbols should always be followed carefully. If any dangerous situation
arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situa-
tion.

1. General precautions 7) Keep all tools in good condition, learn the

k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition, read
this manual and understand its contents
before starting the work.
1) Before carrying out any greasing or repairs,
read all the safety labels stuck to the
machine. For the locations of the safety
labels and detailed explanation of precau-
tions, see the Operation and Maintenance
Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
q Always wear safety glasses when hit-
ting parts with a hammer.
q Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operat-
ing procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning signs
in the operator's compartment.
5) Only the approved personnel can do the
work in a closed environment or in a pro-
hibited area.
6) Only qualified workers must carry out work
and operation which require license or
qualification.
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
8) If welding repairs are needed, always have
a trained and experienced welder carry out
the work. When carrying out welding work,
always wear welding gloves, apron, shield-
ing goggles, cap and other clothes suited
for welding work.
9) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
10) Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in speci-
fied safe places.
11) When you work in high places, use a plat-
form.
12) Before you start the work, use the personal
fall-arrest equipment to prevent falling. There
is a danger of personal accident that you fall
by slipping.
13) Always do the work correctly. If you find the
unsafe behavior of co-worker, give him/her
a notice and stop it.
14) Because there is a danger that you are
caught, be very careful when the work is
done in dangerous areas such as: when
you go in the range where the lifted load
possibly falls, or when you stand directly in
front of tire, or when you are near the slid-
ing parts.
15) When you handle chemical materials (such
as nitrogen gas), see the MSDS (safety
data sheet) and local guidelines, and get
the important information (such as a safe
handling method). Also, put on applicable
protective equipment (such as protective
goggles, gloves, and masks).

WD900-3 00-3
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SAFETY
16) If necessary, cut out all the power sources
(electricity, oil pressure, compressed air,
etc.) before you start the work. If the
machine has a lock mechanism, set it to
the LOCK position and install the warning
tag in a position where it is easy to see. Do
not release the lock until the work is com-
pleted.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
Prohibition of operation and handling by
5
unlicensed workers
6 Safety check before starting work
Wearing protective goggles
7
(for cleaning or grinding work)
Wearing shielding goggles and protectors
8
(for welding work)
9 Good physical condition and preparation
Precautions against work which you are
10
not used to or you are used to too much
2. Preparations for work
1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work equip-
ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the
lock pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders
o r s t e p s w h e n g e t t i n g o n o r o ff t h e
machine. Never jump on or off the
machine. If it is impossible to use the hand-
rails, ladders or steps, use a stand to pro-
vide safe footing.
00-4
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SAFETY NOTICE
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and cool-
ant to cool before carrying out any work on
the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating part,
in particular, stop the engine. When check-
ing the machine without stopping the
engine (measuring oil pressure, revolving
speed, temperature, etc.), take extreme
care not to get rolled or caught in rotating
parts or moving parts.
4) For the machine equipped with a battery
disconnct switch, turn the battery dis-
connect switch to the OFF (O) position
and pull the switch key out, before start-
ing the work. For machines without a bat-
tery disconnct switch, remove the cable
from the battery, before starting the work.
Always remove the cable from the negative
(-) terminal first.
5) When raising a heavy component (heavier
than 20 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
WD900-3
SAFETY
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and
then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
8) 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 and can
even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical
parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be dam-
aged by contact with other parts when the
machine is operated.
11) When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely
careful when installing tubes for high pres-
sure circuits. In addition, check that con-
necting parts are correctly installed.
12) When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate vio-
lently or rotate at high speed, be particu-
larly careful to check that they are installed
correctly.
13) When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14) When measuring hydraulic pressure, check
that the measuring tools are correctly
assembled.
15) Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
16) If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate
well.
WD900-3
SAFETY NOTICE
4. Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
k Do not do the work while the lifted
load is in the range where it possi-
bly falls. It is not allowed to go in
the range where the lifted load pos-
sibly falls.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swing-
ing or falling down by holding it
simply with the hands.
k The sling workers and assistant
workers other than the guide must
move to a place where they are not
caught between the load and mate-
rials or equipment on the ground or
hit by the load even if the crane
starts abruptly.
q When you lift or fix the machine, see
“Operation and Maintenance Manual”
or “Field Assembly Instruction”.
k Do not lift or fix the machine by the
positions where the name plate is
not attached.
q When you lift the machine for the dis-
assembly and assembly, follow the
instructions on the Disassembly and
Assembly.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire ropes
symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding
position on the load, which can
result in a dangerous accident.
00-5
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SAFETY
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more ropes,
the force subjected to each rope will
increase with the hanging angle. The table
below shows the variation of allowable load
in kN {kg} when hoisting is made with 2
ropes, each of which is allowed to sling up
to 9.8 kN {1,000 kg} vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 19.6 kN {2,000 kg} of
total weight can be suspended. This
weight is reduced to 9.8 kN {1,000 kg}
when the 2 ropes make a hanging angle of
120°. If the 2 ropes sling a 19.6 kN {2,000
kg} load at a lifting angle of 150°, each of
them is subjected to a force as large as
39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular
load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material
to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q Slinging near the tip of the hook may
cause the rope to slip off the hook during
hoisting. The hook has the maximum
strength at the middle portion.
00-6
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SAFETY NOTICE
11) Do not use twisted or kinked wire ropes.
12) When lifting up a load, observe the follow-
ing.
q Wind in the crane slowly until wire
ropes are stretched. When settling the
wire ropes with the hand, do not grasp
them but press them from above. If
you grasp them, your fingers may be
caught.
q After the wire ropes are stretched, stop
the crane and check the condition of
the slung load, wire ropes, and pads.
q If the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.
q Do not lift up the load slantingly.
13) When lifting down a load, observe the fol-
lowing.
q When lifting down a load, stop it tem-
porarily at 30 cm above the floor, and
then lower it slowly.
q Check that the load is stable, and then
remove the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
5. Precautions for using mobile crane
a Read the Operation and Maintenance Man-
ual of the crane carefully in advance and
operate the crane safely.
WD900-3
SAFETY SAFETY NOTICE

6. Precautions for using overhead hoist crane 14) If the hoist stops because of a power fail-
k When raising a heavy part (heavier than ure, turn the power switch OFF. When turn-
20 kg), use a hoist, etc. In Disassembly ing on a switch which was turned OFF by
and assembly, the weight of a part the electric shock prevention earth leakage
heavier than 20 kg is indicated after the breaker, check that the devices related to
mark of 4. that switch are not in operation state.
a The symbol 4 shows the weight of the 15) If you find an obstacle around the hoist,
parts with weight of 20 kg or more for conve- stop the operation.
nience of workers. But the weight can possi- 16) After finishing the work, stop the hoist at
bly be shown even if it is less than 20 kg in the specified position and raise the hook to
accordance with the work environment. Do at least 2 m above the floor. Do not leave
the work safely in response to the work envi- the sling installed to the hook.
ronment and the physical build, preexisting
condition, and physical condition of the oper- 7. Selecting wire ropes
ator. And obey the laws and regulations of 1) Select adequate ropes depending on the
each country. Before you start work, examine weight of parts to be hoisted, referring to
the wire ropes, brake, clutch, controller, rails, the table below.
over hoisting, ground fault interrupter for elec-
tric shock prevention, crane collision preven- Wire ropes
tion device, and power application caution (Standard “Z” twist ropes without galvanizing)
lamp, and examine the items about the (JIS G3525, No. 6, Type 6X37-A)
safety. Nominal
Allowable load
1) Before starting work, inspect the wire diameter of rope
ropes, brake, clutch, controller, rails, over mm kN ton
wind stop device, electric shock prevention 10 8.8 0.9
earth leakage breaker, crane collision pre- 12 12.7 1.3
vention device, and power application 14 17.3 1.7
warning lamp, and check safety. 16 22.6 2.3
2) Be sure not to touch the lifting tool and 18 28.6 2.9
lifted load directly. Use push-pull sticks or 20 35.3 3.6
tagline ropes.
25 55.3 5.6
3) Observe the signs for sling work.
30 79.6 8.1
4) Operate the hoist at a safe place.
40 141.6 14.4
5) Check the direction indicator plates (east,
west, south, and north) and the directions 50 221.6 22.6
of the control buttons without fail. 60 318.3 32.4
6) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging. a The allowable load is one-sixth of the
7) Do not raise or lower a load while the crane breaking strength of the rope used
is moving longitudinally or laterally. (Safety coefficient: 6).
8) Do not drag a sling.
9) When lifting up a load, stop it just after it 8. Precautions for disconnecting and connect-
leaves the ground and check safety, and ing hoses and tubes in air conditioner cir-
then lift it up. cuit
10) Consider the travel route in advance and lift 1) Disconnection
up a load to a safe height. k For the environment, the air condi-

11) Place the control switch on a position
where it will not be an obstacle to work and
passage.
12) After operating the hoist, do not swing the
control switch.
13) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.

WD900-3 00-7
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SAFETY SAFETY NOTICE

a Ask professional traders for collecting

and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you may
lose your sight and your skin may
be frozen. Accordin gly, p ut on
safety glasses, safety gloves and
safety clothes when recovering or
adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46)) to
its O-rings.

a Example of O-ring (Fitted to every joint of hoses

and tubes)

a For tightening torque, see the precautions for

installation in each section of "Disassembly and
assembly".

00-8 WD900-3
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SAFETY HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

q Prepare the latest information before starting work.
q Some attachments and optional parts in this shop manual may not be delivered to certain areas.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see
the engine volume of the engine model mounted on the machine.

1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.

00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.

01. Specification
This section explains the specifications of the machine.

10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disas-
sembly and service.

20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjust-
ing, and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.

30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and quan-
tity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

WD900-3 00-9
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SAFETY HOW TO READ THE SHOP MANUAL

2. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
Weight of parts of component or parts. Refer to this symbol when you
4
Weight handle heavy object for selection of the required equipment such as
crane and lifting tools, and for what kind of working posture to take.

3
Tightening Places that require special attention for tightening torque during
torque assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5
Oil, coolant Places where oil, etc. must be added, and capacity.

6
Drain Places where oil, etc. must be drained, and quantity to be drained.

3. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conven-
tionally used Gravitational System of units is indicated in parentheses { }.

00-10 WD900-3
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SAFETY EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.

1. Standard size and tolerance

q To be accurate, the finishing size of parts is
a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called the
“standard size” and the range of difference
f r o m t h e s ta n d a r d s i z e i s c a l le d t h e
“tolerance”.
q The tolerance with the symbols of + or ‒ is
indicated on the right side of the standard
size.

Example:
Standard size Tolerance
‒0.022
120
‒0.126

a The tolerance may be indicated in the text

and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (‒0.022/‒0.126)

q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and differ-
ent tolerances of the hole and shaft. The
tightness of fit is decided by the tolerance.
q Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
‒0.030 +0.046
60
‒0.076 +0

WD900-3 00-11
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SAFETY EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range from limit. The limit at which those parts cannot
the minimum clearance to the maximum be used is called the “clearance limit”.
clearance. q If the clearance between the parts exceeds
q When some parts are repaired, the clear- the clearance limit, they must be replaced
ance is generally adjusted to the standard or repaired.
clearance.
q A value of performance and function of new 6. Interference limit
p r o d u c ts o r e q u i v a l e n t i s c a l l e d t h e q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value of “interference limit”.
performance/function is set to the standard q The interference limit shows the repair limit
value. of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and toler-
ance table is smaller than that of the mating
shaft, the difference between those diame-
ters is called the “interference”.
q The range (A ‒ B) from the difference (A)
between the minimum size of the shaft and
the maximum size of the hole to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4. Repair limit and allowable value or allowable

dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various
tests or experiences in most cases, how-
ever, it must be judged after considering
the operating condition and customer's
requirement.

00-12 WD900-3
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SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COM-

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

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, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring harness

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. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about 10 times.

2) Defective crimping or soldering of connec-

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

WD900-3 00-13
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SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

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 connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other appro-
priate action before passing electricity
through it.

5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating 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 connector, wipe it off
with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.

00-14 WD900-3
(9)
SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnect-
ing.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw fully,
then hold the male and female con-
nectors in each hand and pull apart.
For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
a Never pull with one hand.

2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.

WD900-3 00-15
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SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the connec-
tor.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm the
inside of the wiring with a dryer,
but be careful not to make it too
hot as this will cause short cir-
cuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector cor-
rectly, and then insert it securely. For
connectors with the 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 har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In addi-
tion, if the wiring harness is
misaligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.

00-16 WD900-3
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SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

WD900-3 00-17
(9)
SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause defec-
tive contact, so remove all oil and
water from the compressed air
before blowing with air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n t a c t
restorer and reassemble.

00-18 WD900-3
(9)
SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector con-
tacts with your hand.
4) During rainy weather, do not leave the con-
troller in a place where it is exposed to rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the controller. Fit an arc weld-
ing ground close to the welding point.

5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connec-
tors before going on to the next step.
a If the power is turned ON with the con-
nectors still disconnected, unneces-
sary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related wir-
ing and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.

WD900-3 00-19
(9)
SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.

1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to check the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this. Do not simply drain oil out onto
the ground, but collect it and ask the customer
to dispose of it, or take it back with you for dis-
posal.

4. Do not let any dirt or dust get in during refill-

ing 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.

00-20 WD900-3
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SAFETY HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants 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 secondary flushing is car-
ried out with the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump,
contro l valve, etc.) or when ru nn ing the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot
remove, so it is an extremely effective device.

WD900-3 00-21
(9)
SAFETY HANDLING OF CONNECTORS NEWLY USED FOR ENGINES

HANDLING OF CONNECTORS NEWLY USED FOR ENGINES

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 ‒ 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in intake
q 125E-5 manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 ‒ 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 ‒ 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)

Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector
(1) toward you.
a Even if lock (L2) is pressed, connector
(1) cannot be pulled out toward you, if
part A does not float. In this case, float
part A with a small screwdriver while
press lock (L2), and then pull out con-
nector (1) toward you.

00-22 WD900-3
(9)
SAFETY HANDLING OF CONNECTORS NEWLY USED FOR ENGINES

3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)

Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.

q 114 engine

q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.

q 107 engine

a If the lock is on the underside, use flat-

head screwdriver [1] since you cannot
insert your fingers.
2) While pressing up lock (C) of the connector
with flat-head screwdriver [1], pull out con-
nector (3) in the direction of the arrow.

WD900-3 00-23
(9)
SAFETY HANDLING OF CONNECTORS NEWLY USED FOR ENGINES

q 95, 125 ‒ 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example)
Injection pressure control valve of fuel sup-
ply pump: PCV (SUMITOMO-2)

2) Connect the connector according to the fol-

lowing procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

00-24 WD900-3
(9)
SAFETY HOW TO READ ELECTRIC WIRE CODE

HOW TO READ ELECTRIC WIRE CODE

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)

1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thick-
ness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- ‒30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride

Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX ‒50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene

WD900-3 00-25
(9)
SAFETY HOW TO READ ELECTRIC WIRE CODE

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 ‒
Cov-
AV Standard ‒ ‒ ‒ ‒ ‒ ‒ ‒ 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 ‒ 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard ‒ ‒ ‒ ‒ ‒ ‒ ‒ ‒ ‒
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

“f” of nominal No. denotes flexible”.

00-26 WD900-3
(9)
SAFETY HOW TO READ ELECTRIC WIRE CODE

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG ‒ ‒ ‒ ‒ R ‒
Ground B ‒ ‒ ‒ ‒ ‒ B ‒
Start R ‒ ‒ ‒ ‒ ‒ R ‒
Light RW RB RY RG RL ‒ D ‒
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB ‒ L ‒
Type of
Br BrW BrR BrY BrB ‒ ‒ ‒
circuit
Lg LgR LgY LgB LgW ‒ ‒ ‒
O ‒ ‒ ‒ ‒ ‒ ‒ ‒
Others Gr ‒ ‒ ‒ ‒ ‒ ‒ ‒
P ‒ ‒ ‒ ‒ ‒ ‒ ‒
Sb ‒ ‒ ‒ ‒ ‒ ‒ ‒
Dg ‒ ‒ ‒ ‒ ‒ ‒ ‒
Ch ‒ ‒ ‒ ‒ ‒ ‒ ‒

WD900-3 00-27
(9)
 01 GENERAL

GENERAL ASSEMBLY DRAWING ..............................................................................................................01- 2

SPECIFICATIONS ........................................................................................................................................01- 3
WEIGHT TABLE............................................................................................................................................01- 6
LIST OF LUBRICANT AND WATER .............................................................................................................01- 8

WD900-3 01-1
GENERAL GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING

01-2 WD900-3
GENERAL SPECIFICATIONS

SPECIFICATIONS

Machine model WD900-3

Serial No. 50001 and up

Operating weight kg 100,000

Weight

Distribution (front) kg 50,000

Distribution (rear) kg 50,000
3
Blade capacity m 26.0
FORWARD 1st km/h 7.0
FORWARD 2nd km/h 12.3
FORWARD 3rd km/h 28.0
Travel speed
Performance

REVERSE 1st km/h 7.1

REVERSE 2nd km/h 12.4
REVERSE 3rd km/h 28.3
Max. rimpull kN {kg} 686.5 {70,000}
Gradeability deg 25

Min. turning Center of outside wheel mm 9,200

radius Outside portion of blade mm 11,285
Overall length mm 12,035
Overall width without blade mm 4,585
Blade width mm 6,470
Dimensions

Blade height mm 2,160

Overall height (top of ROPS cab) mm 5,215
Wheelbase mm 5,450
Tread mm 3,350
Min. ground clearance mm 480

WD900-3 01-3
GENERAL SPECIFICATIONS

Machine model WD900-3

Serial No. 50001 and up

Model SA12V140-1
4-cycle, water-cooled, V type,
Type 12-cylinder direct injection,
with 2-turbocharger, after-cooler
No. of cylinders - bore x stroke mm 12 – 140 x 165
Piston displacement l {cc} 30.48 {30,480}
Flywheel horsepower kW/rpm {HP/rpm} 637/2,000 {853/2,000}
Engine

Maximum torque Nm/rpm {kgm/rpm} 4,090/1,300 {417/1,300}

Performance Fuel consumption ratio g/kWh {g/HPh} 200 {145}
High idling speed rpm 2,220
Low idling speed rpm 650/850
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 75 A
Battery 12 V, 200 Ah x 4
3-element, 1-stage, single-phase
Torque converter
(TCA51-1A)
Power train

Planetary gear, multiple-disc,

Transmission
hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, single reduction, oil bath
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating
Axle, wheel

Rear axle Center pin support type, full-floating

Tire 45/65 R45 XLDD1 (L-4)
Wheel rim 36.00 x 45WTB
Inflation pressure kPa {kg/cm2} 667 {6.80}
Front/rear wheel braking,
Main brake separate front/rear wheel, wet disc,
Brakes

hydraulically actuated
Mounted on front axle input shaft, dry disc,
Parking brake
hydraulically release spring apply

01-4 WD900-3
GENERAL SPECIFICATIONS

Machine model WD900-3

Serial No. 50001 and up

Steering

Type Articulated type

system

Structure Fully hydraulically power steering

421
Torque converter, transmission pump l/min
(Gear type: SAR(4)112+SAR(3)100)
307
Steering pump l/min
(Fixed capacity piston pump: HPF76+71)
405
Switch pump l/min
(Fixed capacity piston pump: HPV95+95)
Additional oil cooler 51
l/min
Hydraulic pump

fan pump (Gear type: SAR(1)025)

delivery

67.8
Front brake cooling pump l/min
(Gear type: SBL(1)24)
67.8
Rear brake cooling pump l/min
(Gear type: SBR(1)24)
68
PPC pump l/min
(Gear type: SAR(1)032)
Hydraulic system

29
Brake pump l/min
(Gear type: SAR(1)014)
405
Work equipment pump l/min
(Variable capacity piston pump: HPV90+90)
2.5 {25}
Transmission valve MPa {kg/cm2}
(Spool type, electric control)
Control valve
Set pressure

31.4 {320}
Steering demand valve MPa {kg/cm2}
(Fully hydraulic type)
3.7 {38}
PPC valve MPa {kg/cm2}
(2-lever type)
31.4 {320}
Main control valve MPa {kg/cm2}
(2-spool type)
Reciprocating piston
Steering cylinder No. - bore x stroke mm
1 – 160 x 503
Cylinder

Reciprocating piston
Lift cylinder No. - bore x stroke mm
1 – 200 x 1,300
Reciprocating piston
Tilt cylinder No. - bore x stroke mm
2 – 225 x 240
equipment

Blade type Semi U-blade

Work

Blade frame type Outer frame

WD900-3 01-5
GENERAL WEIGHT TABLE

WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model WD900-3

Serial No. 50001 and up

Engine 3,200
Radiator 1,200
Torque converter 590
Transmission 2,300
Damper 178
Upper drive shaft 68.5
Center drive shaft 190
Front drive shaft 180
Rear drive shaft 190
Center support 154
Front axle 8,190
Rear axle 7,700
Front differential assembly 1,226
Rear differential assembly 1,256
Planetary carrier assembly (each) 238
Planetary hub assembly (each) 600
Axle pivot (Rear axle) 286
Wheel (each) 845
Tire (each) 2,130
Steering demand valve 58
Steering cylinder (each) 203
Hydraulic tank 823
Work equipment pump 167
Parking brake assembly 185
Torque converter charging + PPC + brake pump 49
Switch pump 141
Switch + additional oil cooler fan pump 151
Steering pump 141
Fender and guard assembly 1,393
PPC valve 5.5
Main control valve (each) 95
DC · CO valve 90
Lift cylinder (each) 621
Tilt cylinder 598
Fender and ladder assembly 1,720

01-6 WD900-3
GENERAL WEIGHT TABLE

Unit: kg

Machine model WD900-3

Serial No. 50001 and up

88 (Top)
Engine hood
28 (Side)
Front frame 9,966
Rear frame 9,855
Outer frame (L.H.) 1,136
Outer frame (R.H.) 1,148
H linkage 1,408
Y linkage 1,338
Support (L.H.) 1,909
Support (R.H.) 1,913
Blade 7,149
Counterweight 2,900
Fuel tank 780
Battery (each) 59
Cab 430
Air conditioner unit 55
Operator’s seat 48
Floor plate 348
ROPS support assembly 1,387

WD900-3 01-7
GENERAL LIST OF LUBRICANT AND WATER

LIST OF LUBRICANT AND WATER

01-8 WD900-3
(7)
GENERAL LIST OF LUBRICANT AND WATER

Note 1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.

Note 2: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differ-
ential).
If only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.

Note 3: When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer
than 12 hours/day, then the use of EO50-CD instead of AXO80 is recommended.
Squealing of the brakes may occur with EO50-CD, but there is no problem with the brake performance
or durability.

Note 4: If the machine is equipped with an automatic greasing system, see "Operation and Mainenance Man-
ual".

Note 5: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of
pins and bushings, the use of G2-T or G2-TE is recommended.

Note 6: Supercoolant (AF-NAC)

1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-
NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2
years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.

2) For details of the ratio when diluting super coolant with water, see "Operation and Mainenance Manual".
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more
Supercoolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F).
(never dilute with water)

3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Super-
coolant between 30% and 68%.

Supercoolant density table

°C Above -10 -15 -20 -25 -30

Minimum temperature
°F Above 14 5 -4 -13 -22
Density of Supercoolant % 30 36 41 46 50

WD900-3 01-9
(7)
 10 STRUCTURE AND FUNCTION
POWER TRAIN ....................................... 10- 2
POWER TRAIN SYSTEM ....................... 10- 3
ENGINE CONTROL ................................ 10- 4
SERVO CYLINDER ................................. 10- 5
RADIATOR AND COOLER...................... 10- 9
DAMPER ................................................. 10- 10
TORQUE CONVERTER AND
TRNSMISSION PIPING ..................... 10- 11
TRANSMISSION HYDRAULIC SYSTEM
DIAGRAM .......................................... 10- 12
TRANSMISSION HYDRAULIC CIRCUIT
DIAGRAM .......................................... 10- 13
TORQUE CONVERTER.......................... 10- 14
TRANSMISSION ..................................... 10- 19
TRANSFER ............................................. 10- 29
TRANSMISSION CONTROL VALVE....... 10- 30
TORQUE CONVERTER OIL COOLER... 10- 46
DRIVE SHAFT ......................................... 10- 47
CENTER SUPPORT................................ 10- 48
AXLE ....................................................... 10- 49
FINAL DRIVE .......................................... 10- 54
CENTER HINGE PIN .............................. 10- 55
AXLE MOUNT ......................................... 10- 56
TIRE AND WHEEL .................................. 10- 58
STEERING PIPING DIAGRAM ............... 10- 59
STEERING COLUMN.............................. 10- 61
STEERING PUMP ................................... 10- 62
SWITCH PUMP ....................................... 10- 67
STEERING DEMAND VALVE.................. 10- 70
STEERING UNIT (ORBIT-ROLL VALVE) 10- 81
PROPORTIONAL SOLENOID VALVE .... 10- 84
TWO-WAY RESTRICTOR VALVE ........... 10- 85
DIVERTER VALVE .................................. 10- 86
BRAKE PIPING ....................................... 10- 90
BRAKE CIRCUIT DIAGRAM ................... 10- 92
BRAKE VALVE ........................................ 10- 96
CHARGE VALVE ..................................... 10-108
ACCUMULATOR (FOR BRAKE) ............. 10- 113
SLACK ADJUSTER ................................. 10- 114
BRAKE .................................................... 10- 117
PARKING BRAKE.................................... 10- 118
SPRING CYLINDER................................ 10-121
PARKING BRAKE SOLENOID VALVE .... 10-122
HYDRAULIC PIPING............................... 10-124
WD900-3
WORK EQUIPMENT SOLENOID VALVE 10-126
WORK EQUIPMENT LEVER LINKAGE ..10-136
HYDRAULIC TANK ..................................10-138
MAIN PISTON PUMP...............................10-142
ES VALVE (Engine sensing valve) ...........10-154
SERVO VALVE.........................................10-156
PPC VALVE (Proportional
pressure valve) ...................................10-160
PPC RELIEF VALVE ................................10-164
ACCUMULATOR (FOR PPC VALVE) ......10-165
MAIN CONTROL VALVE..........................10-166
LUBRICATION OF WORK EQUIPMENT.10-174
WORK EQUIPMENT LINKAGE ...............10-176
CAB ..........................................................10-178
ROPS CANOPY .......................................10-179
AIR CONDITIONER .................................10-180
MACHINE MONITOR SYSTEM ...............10-183
MAIN MONITOR ......................................10-184
MAINTENANCE MONITOR .....................10-188
ENGINE STARTING CIRCUIT .................10-191
ENGINE STOP CIRCUIT .........................10-192
ELECTRICAL TRANSMISSION
CONTROL ..........................................10-193
BLADE CONTROL SWITCH
(KICK-DOWN, HOLD SWITCH) .........10-196
JOYSTICK STEERING SYSTEM.............10-197
TRANSMISSION AND JOYSTICK
STEERING CONTROLLER ................10-199
ELECTRIC PARKING BRAKE CONTROL10-201
BRAKE COOLING SYSTEM....................10- 211
55°C SPECIFICATION .............................10-220
10-1
STRUCTURE AND FUNCTION
POWER TRAIN
OUTLINE
• The power from engine (16) is transmitted from
the flywheel to damper (15) through the ring
gear. The damper alleviates the torsional vibra-
tion caused by the variation of the engine torque
and transmits the power to torque converter (11)
through upper drive shaft (14). The torque con-
verter converts the delivered torque according to
the variation in load on the oil used as the medi-
um, and transmits the power to the input shaft of
transmission (10). Then, the engine power is
transmitted to steering pump (12), main pump
(13), switch pump (18), and torque converter
charging pump + PPC pump + brake pump (19)
through the pump driving gear in torque convert-
er (11), thereby driving the pumps.
• In transmission (10), the five hydraulically-oper-
ated clutches are operated by the forward-re-
verse spool and the speed change spools in the
transmission valves, which are themselves acti-
vated by solenoid valves. Thus, the desired trav-
el speed can be selected from among the 3
forward and 3 reverse gear speeds.
10-2
POWER TRAIN
• The output shaft of transmission (10) transmits
the power to the output shaft of transfer (9)
through the gear. The power from the output
shaft of the transfer is transmitted to both the
front axle (5) and the rear axle (22).
In the front section of the chassis, the power is
transmitted to front axle (5) through center drive
shaft (7) and front drive shaft (6).
In the rear section, the power is transmitted to
rear axle (22) through rear drive shaft (25).
• The power transmitted to front axle (5) and rear
axle (22) is reduced through pinion and ring
gears in differential (24) and (1), and is transmit-
ted to the axle shafts.
• The power from the axle shafts is reduced
through final drive (20) and (3) and transmitted
to wheel (21) and (4) through the planetary carri-
er.
WD900-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM

POWER TRAIN SYSTEM

1. Front differential 11. Torque converter 20. Rear final drive

2. Front brake 12. Steering pump 21. Rear wheel
3. Front final drive 13. Main pump 22. Rear axle
4. Front wheel 14. Upper drive shaft 23. Rear brake
5. Front axle 15. Damper 24. Rear differential
6. Front drive shaft 16. Engine 25. Rear drive shaft
7. Center drive shaft 17. Additional oil cooler fan pump 26. Center support
8. Emergency steering pump (machine equipped with brade cooling sys- 27. Parking brake
9. Transfer tem or 55°C spec.)
10. Transmission 18. Switch pump
19. Torque converter charging pump (x 2)
+ PPC pump + brake pump

WD900-3 10-3
STRUCTURE AND FUNCTION ENGINE CONTROL

ENGINE CONTROL

1. Solenoid 5. Absorber
2. Accelerator pedal 6. Injection pump
3. Cable 7. Transmission oil filler
4. Servo cylinder

OUTLINE
1. An engine low idling selection mechanism is 2. A hydraulic assist engine control (servo cylinder
used, and when the engine low idle switch is (4)) is used to reduce the operating effort for the
operated, the engine low idling speed can be accelerator pedal.
switched in two stages.
1) The engine low idling speed is set to approx.
650 rpm. Use for normal operations such as
when waiting for a dump truck at low idling
o OFF.
2) The engine low idling speed is set to approx.
850 rpm.
Used on busy jobsites where it is needed to
reduce the cycle time o ON.

10-4 WD900-3
STRUCTURE AND FUNCTION SERVO CYLINDER

SERVO CYLINDER

1. Rod A. Oil outlet port (Drain to transmission oil filler)

2. Spring B. Oil inlet port (From oil filter)
3. Body
4. Piston
5. Yoke

OUTLINE
• The servo cylinder is installed to the engine con-
trol linkage.
This acts to reduce the operating force without
changing the amount of movement of the accel-
erator pedal cable and injection pump rod.

WD900-3 10-5
STRUCTURE AND FUNCTION SERVO CYLINDER

OPERATION

1. Accelerator pedal not depressed

Accelerator pedal (6) is not being depressed, so

the servo cylinder is not actuated.
The pressurized oil from the transmission oil fil-
ter passes through the middle of rod (1) and
flows to port A.

2. Accelerator pedal depressed

When accelerator pedal (6) is depressed,

cable (7) moves rod (1) to the left in the
direction of the arrow.
The oil from the transmission filter flows
from port A through the hole in piston (4)
and goes to chamber B.

10-6 WD900-3
STRUCTURE AND FUNCTION SERVO CYLINDER

When the oil flowing to chamber B reaches the
specified pressure, it overcomes the force of
spring (2) and moves piston (4) to the left in the
direction of the arrow.
Piston (4) continues to move until the hole in
piston (4) is closed.
As a result, the length of movement of rod (1)
becomes equal to the length of movement of the
piston, and the operating force is reduced by the
hydraulic pressure.

3. Accelerator pedal released

When accelerator pedal (6) is released,

cable (7) moves rod (1) to the right in the
direction of the arrow.
As a result, the oil at chamber B is drained.
When this happens, piston (4) is moved to
the right by spring (2) until the hole in piston
(4) is closed.

WD900-3 10-7
STRUCTURE AND FUNCTION SERVO CYLINDER

ENGINE LOW IDLING SELECT SYSTEM

OUTLINE
• By using the engine low idling selector device to
set the engine low idling speed to two stages, it
is possible to carry out operations more effi-
ciently.

OPERATION
Engine low idle switch OFF
When the engine low idle switch is OFF, no electric
current flows to solenoid (1), so the solenoid is not
actuated and the engine speed is set to 650 rpm.

Engine low idle switch ON

When the engine low idle switch is turned ON, elec-
tric current flows to solenoid (1), and the solenoid is
actuated.
The solenoid rod is connected by a link to accelera-
tor pedal (2), so the accelerator pedal is depressed
by an amount equal to the movement of the rod.
When this happens, the engine speed is set to
approximately 850 rpm.

10-8 WD900-3
STRUCTURE AND FUNCTION RADIATOR AND COOLER

RADIATOR AND COOLER

1. Radiator cap Specification

2. Water level sensor Core type : Model PF2-7
3. Fan guard Total heat dissipating area : 201.00 m2
4. Upper tank Cross-sectional area of water tubes: 288.52 cm2
5. Radiator
6. Hydraulic oil cooler
7. Lower tank

WD900-3 10-9
STRUCTURE AND FUNCTION DAMPER

DAMPER

1. Shaft FUNCTION
2. Breather • The damper reduces the torsional vibration
3. Rubber cushion caused by changes in the engine torque, and
4. Inner body acts to protect the units of the power train be-
5. Outer body yond the engine from the effects of torsional vi-
bration.

OPERATION
• The power of the engine is transmitted from the
flywheel to outer body (5). The torsional vibra-
tion of the engine is absorbed by rubber cushion
(3), passes through inner body (4) and shaft (1),
and is transmitted to the upper drive shaft be-
tween the torque converter.

10-10 WD900-3
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRNSMISSION PIPING

TORQUE CONVERTER AND TRNSMISSION PIPING

1. Accelerator pedal
2. Transmission control valve
3. Torque converter
4. Servo cylinder
5. Torque converter oil cooler
6. Torque converter charging pump (x 2)
7. Torque converter oil filter
8. Transmission oil level gauge
9. Transfer

WD900-3 10-11
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine running, F.R. lever in NEUTRAL, speed lever in 1st)

A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank

10-12 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

*1. 0.29 +0.1 +1 2
+0 MPa {3 +0 kg/cm }
*2. Serial No. 50001 – 50002: 2.45 +0.29
+0 MPa {25 +3 2
+0 kg/cm }
Serial No. 50003 and up: 2.65 +0.29
+0 MPa {27 +3 2
+0 kg/cm }

1. Transfer case 18. Modulating valve

2. Strainer 19. Quick return valve
3. Torque converter charging pump (SAR4-112) 20. Reducing valve
4. Torque converter charging pump (SAR3-100) 21. Solenoid valve
5. PPC pump (SAR1-032) 22. Emergency manual spool
6. Brake pump (SAR1-014) 23. Reverse spool
7. Torque converter oil filter 24. Forward spool
8. Torque converter oil filter 25. 2nd spool
9. Servo cylinder 26. 1st spool
10. Main relief valve 27. 3rd spool
11. Torque converter relief valve 28. Reverse clutch
12. Torque converter regulator valve 29. Forward clutch
13. Oil cooler 30. 2nd clutch
14. Lubrication relief valve 31. 1st clutch
15. Pilot oil filter 32. 3rd clutch
16. Pilot reducing valve 33. Torque converter
17. Priority valve 34. Transmission lubrication

WD900-3 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER

TORQUE CONVERTER

1. Torque converter regulator valve

2. Torque converter outlet oil pressure pick-up
(PT1/8)
3. Torque converter inlet oil pressure pick-up
(PT1/8)
4. Switch pump mounting
5. Main pump mounting
6. Coupling
7. Steering pump mounting
8. Torque converter charging pump + PPC pump +
brake pump mounting

A. Torque converter outlet port

B. Torque converter oil temperature
sensor mounting port
C. Torque converter inlet port
D. Drain port (to transmission)

10-14 WD900-3
STRUCTURE AND FUNCTION TORQUE CONVERTER

9. Turbine SPECIFICATIONS
10. Stator Model : TCA51-1A
11. PTO gear (Teeth 86) Type : 3-element, single stage, single phase
12. Housing Stall torque ratio : 2.84
13. Gear (Teeth 81)
14. Pump
15. Transmission input shaft
16. Gear (Teeth 81)

WD900-3 10-15
STRUCTURE AND FUNCTION TORQUE CONVERTER

Flow of motive force

• The torque converter is installed between the
damper and transmission. The motive force
from the damper passes through the drive shaft
and enters coupling (6).
Coupling (6), pump (14) and PTO gear (drive)
(11) are fixed with bolts. They are rotated
directly by the rotation of the engine. The motive
force of pump (14) uses oil to rotate turbine (9).
This transmits motive force to transmission input
shaft (15).
• The motive force of coupling (6) passes through
PTO gear (drive) (11) and is also used as the
motive force to drive the pump.

Flow of oil
• The oil pressure is adjusted by the torque con-
verter relief valve and then enters inlet port A,
passes through the oil passage in housing (12)
and flows to pump (14). In pump (14) centrifugal
force is applied. The oil enters turbine (9) and
the energy of the oil is transmitted to the turbine.
Turbine (9) is fixed to transmission input shaft
(15), so the motive force is transmitted to the
transmission input shaft (15).
The oil from turbine (9) is sent to stator (10) and
again enters the pump. However, part of the oil
passes from the stator through outlet port B and
is sent to regulator valve (1).
The oil sent to regulator valve (1) passes
through the oil cooler to be cooled, and is then
used to lubricate the transmission.

10-16 WD900-3
STRUCTURE AND FUNCTION TORQUE CONVERTER

TORQUE CONVERTER RELIEF VALVE

OUTLINE
• The torque converter relief valve is inside the
transmission valve, and acts to keep the oil en-
tering the torque converter at a constant pres-
sure. If the specified pressure is exceeded, it
drains the oil.

FUNCTION
• The oil from the pump passes through transmis-
sion main relief valve (1), enters port A, and
then flows to the torque converter.

• If the oil at port A exceeds the specified pres-

sure, the oil from orifice a of torque converter re-
lief valve (2) enters port B and moves torque
converter relief valve (2) to the left in the direc-
tion of the arrow.
As a result, the oil from port A flows from port C,
lubricates the transmission, and is drained.

WD900-3 10-17
STRUCTURE AND FUNCTION TORQUE CONVERTER

TORQUE CONVERTER REGULATOR VALVE

1. Valve body
2. Spring
3. Spool

A. Oil inlet port

(From torque converter)
B. Oil outlet port
(to oil cooler)

• The torque converter regulator valve is installed

in the output circuit of the torque converter to
regulate the hydraulic pressure inside the torque
converter to the specified pressure.

OPERATION
• The oil from the torque converter flows from port
A to port B. However, the hydraulic pressure at
port B is lower than the tension of spring (2), so
spool (3) does not move.

• When the hydraulic pressure at port B becomes

higher than the tension of spring (2), it pushes
spool (3) in the direction of the arrow, and the oil
at port A flows to port C.

10-18 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION

1. Transmission
2. Transmission control valve
3. Transfer
4. Oil filler
5. Transfer output coupling
6. Drain plug
7. Transfer output coupling

A. To torque converter charging pump

WD900-3 10-19
STRUCTURE AND FUNCTION TRANSMISSION

Serial No.: 50001 – 50006

10-20 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION

1. Input shaft
2. Reverse sun gear (Teeth 26)
3. Reverse ring gear (Teeth 90)
4. Gear (Teeth 90)
5. Reverse clutch
6. Planetary gear (Teeth 30)
7. Ring gear (Teeth 86)
8. Forward sun gear (Teeth 38)
9. Forward clutch
10. Planetary gear (Teeth 26)
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
13. Planetary gear (Teeth 26)
14. Ring gear (Teeth 140)
15. Ring gear (Teeth 90)
16. 2nd clutch
17. Planetary gear (Teeth 31)
18. 2nd ring gear (Teeth 140)
19. 2nd sun gear (Teeth 27)
20. Gear (Teeth 89)
21. 1st clutch
22. 1st sun gear (Teeth 27)
23. 1st ring gear (Teeth 89)
24. Planetary gear (Teeth 31)
25. 3rd clutch
26. Hub (Teeth 112)
27. Idle shaft
28. Output shaft
29. 1st carrier
30. 2nd carrier
31. Forward carrier
32. Reverse carrier

WD900-3 10-21
STRUCTURE AND FUNCTION TRANSMISSION

Serial No.: 50007 and up

10-22 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION

1. Input shaft
2. Reverse sun gear (Teeth 26)
3. Reverse ring gear (Teeth 90)
4. Gear (Teeth 90)
5. Reverse clutch
6. Planetary gear (Teeth 30)
7. Ring gear (Teeth 86)
8. Forward sun gear (Teeth 38)
9. Forward clutch
10. Planetary gear (Teeth 26)
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
13. Planetary gear (Teeth 26)
14. Ring gear (Teeth 140)
15. Ring gear (Teeth 90)
16. 2nd clutch
17. Planetary gear (Teeth 31)
18. 2nd ring gear (Teeth 140)
19. 2nd sun gear (Teeth 27)
20. Gear (Teeth 89)
21. 1st clutch
22. 1st sun gear (Teeth 27)
23. 1st ring gear (Teeth 89)
24. Planetary gear (Teeth 31)
25. 3rd clutch
26. Hub (Teeth 112)
27. Idle shaft
28. Output shaft
29. 1st carrier
30. 2nd carrier
31. Forward carrier
32. Reverse carrier

WD900-3 10-23
STRUCTURE AND FUNCTION TRANSMISSION

CLUTCH

OUTLINE
• The transmission consists of a 3-FORWARD, 3-
Speed range Clutch combination
REVERSE speed planetary gear transmission,
transfer, and transmission control valve. F1 F, 1st
• In the transmission, the motive force of the input F2 F, 2nd
shaft is changed by the combination of Forward F3 F, 3rd
or Reverse clutch with 1st, 2nd, 3rd clutch to
give FORWARD 1 – 3 or REVERSE 1 – 3 R1 R, 1st
speed, and is transmitted to the output shaft. R2 R, 2nd
R3 R, 3rd

OPERATION OF CLUTCH

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

Disengaged
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 transmit-
ted.

10-24 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION

FORWARD 1st

1 8 9 10 11 12 13 15 21 22 23 24 27 28

31 29

SEW01343

a The transfer shown in this figure is for serial No. 50001 – 50006

• In the case of FORWARD 1st, FORWARD • Ring gear (15) is being held in position, so the
clutch (9) and 1st clutch (21) are engaged. The rotation of carrier (31) is transmitted through
power from the torque converter transmitted to planet gear (13) to sun gear (12). It is also trans-
input shaft (1) is transmitted to output shaft (28). mitted through intermediate shaft (27) to sun
• FORWARD clutch (9) is actuated by the hydrau- gear (22).
lic pressure applied to the clutch piston and • Ring gear (23) is being held in position by 1st
holds ring gear (11) in position. 1st clutch (21) is clutch (21). For this reason, the rotation of sun
actuated by the hydraulic pressure applied to gear (22) is transmitted from carrier (29) through
the clutch piston and holds ring gear (23) in po- planet gear (24) to output shaft (28).
sition.
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (8) to plan-
et gear (10). Ring gear (11) is being held in posi-
tion by FORWARD clutch (9), so the rotation of
planet gear (10) rotates carrier (31).

WD900-3 10-25
STRUCTURE AND FUNCTION
FORWARD 2nd
1 8 9 10 11 12 13 15 16 17
31
a The transfer shown in this figure is for serial No. 50001 – 50006
• In the case of FORWARD 2nd, FORWARD
clutch (9) and 2nd clutch (16) are engaged. The
power from the torque converter transmitted to
input shaft (1) is transmitted to output shaft (28).
• FORWARD clutch (9) is actuated by the hydrau-
lic pressure applied to the clutch piston and
holds ring gear (11) in position. 2nd clutch (16)
is actuated by the hydraulic pressure applied to
the clutch piston and holds ring gear (18) in po-
sition.
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (8) to plan-
et gear (10).
• Ring gear (11) is being held in position by FOR-
WARD clutch (9), so the rotation of planet gear
(10) rotates carrier (31).
10-26
TRANSMISSION
18 19 22 23 24 27 28
30 29
SEW01344
• Ring gear (15) is being held in position, so the
rotation of carrier (31) is transmitted through
planet gear (13) to sun gear (12).
• It is also transmitted through intermediate shaft
(27) to sun gears (19) and (22). Ring gear (18) is
being held in position by 2nd clutch (16). For this
reason, the rotation of sun gear (19) is transmit-
ted through planet gear (17) to carrier (30). It is
then transmitted to ring gear (23).
• The rotation of ring gear (23) and the rotation of
sun gear (22) passes through planet gear (24)
and is transmitted to carrier (29). It is then trans-
mitted to output shaft (28).
WD900-3
STRUCTURE AND FUNCTION TRANSMISSION

FORWARD 3rd

1 8 9 10 11 12 13 15 25 26 27 28

31

SEW01345

a The transfer shown in this figure is for serial No. 50001 – 50006

• In the case of FORWARD 3rd, FORWARD • Ring gear (15) is being held in position, so the
clutch (9) and 3rd clutch (25) are engaged. The rotation of carrier (31) is transmitted through
power from the torque converter transmitted to planet gear (13) and goes from sun gear (12) to
input shaft (1) is transmitted to output shaft (28). intermediate shaft (27).
• FORWARD clutch (9) is actuated by the hydrau- • Intermediate shaft (27) and output shaft (28) are
lic pressure applied to the clutch piston and formed into one unit by 3rd clutch (25). For this
holds ring gear (11) in position. 3rd clutch (25) is reason, the rotation of intermediate shaft (27) is
actuated by the hydraulic pressure applied to transmitted to output shaft (28).
the clutch piston and engages output shaft (28)
and hub (26).
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (8) to plan-
et gear (10).
• Ring gear (11) is being held in position by FOR-
WARD clutch (9), so the rotation of planet gear
(10) rotates carrier (31).

WD900-3 10-27
STRUCTURE AND FUNCTION
REVERSE 1st
1 2 5 6 7 12 15
32 31
a The transfer shown in this figure is for serial No. 50001 – 50006
• In the case of REVERSE 1st, REVERSE clutch
(5) and 1st clutch (21) are engaged. The power
from the torque converter transmitted to input
shaft (1) is transmitted to output shaft (28).
• REVERSE clutch (5) is actuated by the hydrau-
lic pressure applied to the clutch piston and
holds carrier (32) in position. 1st clutch (21) is
actuated by the hydraulic pressure applied to
the clutch piston and holds ring gear (23) in po-
sition.
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (2) to plan-
et gear (6).
10-28
TRANSMISSION
21 22 23 24 27 28
29
SEW01346
• Carrier (32) is being held in position by RE-
VERSE clutch (5), so the rotation of planet gear
(6) rotates ring gear (7). The direction of rotation
of ring gear (7) is the opposite of the rotation of
the engine.
• The rotation of ring gear (7) is transmitted to car-
rier (31). Ring gear (15) is being held in position,
so the rotation of carrier (31) is transmitted
through sun gear (12) to intermediate shaft (27).
Ring gear (23) is being held in position by 1st
clutch (21). For this reason, the rotation of sun
gear (22) is transmitted from carrier (29) through
planet gear (24) to output shaft (28).
WD900-3
STRUCTURE AND FUNCTION TRANSFER

TRANSFER
Serial No. 50001 – 50006 Serial No. 50007 and up

1. Transmission output shaft OUTLINE

2. Transfer input gear (Teeth 32) • The transfer is installed at the power output end
3. Transfer idler gear (Teeth 33) of the transmission and is secured to the trans-
4. Idler gear (Teeth 34) mission case by bolts.
5. Output shaft
6. Front coupling TRANSMISSION PATH
7. Strainer • Output shaft (1) of the transmission is coupled to
8. Rear coupling transfer input gear (2) by a spline. The motive
9. Output gear (Teeth 44) force is transmitted to output shaft (5) through
idler gears (3), (4) and output gear (9).
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.

WD900-3 10-29
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE

1. Pilot oil filter A. Pilot reducing pressure pick-up

2. Main relief valve B. Modulating valve piston load pressure pick-up
3. Torque converter relief valve C. Torque converter relief pressure pick-up
4. Transmission solenoid valve D. Transmission lubricating pressure pick-up
5. Emergency manual spool E. Modulating pressure pick-up
6. Connector F. Modulating pressure pick-up
7. Lower valve (After quick return valve)
8. Upper valve
9. Breather

10-30 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

TRANSMISSION SOLENOID VALVE

10. REVERSE solenoid valve

11. FORWARD solenoid valve
12. 2nd solenoid valve
13. 1st solenoid valve
14. 3rd solenoid valve

STRUCTURE
• The transmission solenoid valve is installed to Actuation table for solenoid valve and clutch
the transmission together with the transmission
F R 1 2 3 4
valve. When the directional lever or speed con-
trol lever are operated, the solenoid valve is ac- F1 Q Q
tuated and moves the spool inside the F2 Q Q
transmission valve. F3 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q

WD900-3 10-31
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

LOWER VALVE

1. Transmission solenoid valve 10. Emergency manual spool

2. FORWARD spool 11. Priority valve
3. REVERSE spool 12. Pilot valve
4. Pilot oil filter 13. Load piston
5. Torque converter relief valve 14. Quick return valve
6. Main relief valve 15. Lubrication valve
7. 2nd spool 16. Pilot reducing valve
8. 1st spool 17. Modulating valve
9. 3rd spool

10-32 WD900-3
STRUCTURE AND FUNCTION
UPPER VALVE
OUTLINE
• The oil from the torque converter charging pump
enters port A of main relief valve, and passes
through priority valve (11) via by main relief
valve. It is then divided into three lines; there
are; to the clutch pistons, to pilot reducing valve
(16) and main relief valve. Priority valve (11)
acts to control the three lines so that pilot reduc-
ing valve (16) is the priority circuit.
• The oil flowing to pilot reducing valve (16) con-
trols the pilot pressure used to actuate the direc-
tional and speed spools. The oil regulated by
pilot reducing valve (16) presses through the or-
ifice in each spool and fills the spool.
WD900-3
TRANSMISSION CONTROL VALVE
• The other oil line flows to modulating valve (17)
and quick return valve (14). The action of modu-
lating valve (17) and quick return valve (14) rais-
es the clutch pressure smoothly. This reduces
the shock when actuating the FORWARD, RE-
VERSE and 1st, 2nd and 3rd speed clutches to
change gear.
• Lubrication valve (15) controls the lubrication oil
inside the transmission.
10-33
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

PILOT OIL FILTER

1. Oil filter head SPECIFICATION

2. Element Filtration area: 370 cm2
3. Case Mesh: 105 m

10-34 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

MAIN RELIEF VALVE

FUNCTION
• The main relief valve acts to supply the neces-
sary 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 fil-
ter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.

• When the pressure goes above the specified

level, oil passes through the orifice in relief valve
(1), pushes poppet (2), and moves relief valve
(1) to the left. The oil is relieved to the torque
converter, so the specified pressure is main-
tained.
a Specified pressure: 2.75 MPa {28 kg/cm2}

WD900-3 10-35
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

PILOT REDUCING VALVE

FUNCTION
• The pilot reducing valve acts to control the pres-
sure 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, pressu-

rized oil flows from orifice a of pilot reducing
valve (1) and goes to port D.
As a result, pilot reducing valve (1) moves to the
left, and port A and B are shut off, so the pres-
surized oil at port C is maintained at the same
pressure.
a Specified pressure: 1.96 MPa {20 kg/cm2}

10-36 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

TRANSMISSION SOLENOID VALVE

FUNCTION
• There is one solenoid valve installed for each di-
rectional and speed spool in the transmission
valve.
When the directional lever and speed control
levers in the operator’s compartment are oper-
ated, 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,
valve (1) shuts off the oil, so directional and
speed spool (2) does not move.

2) Solenoid valve ON
When the directional and gear shift lever are
operated, the solenoid valve 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 C becomes the high pres-
sure circuit and port A becomes the low pres-
sure circuit, and directional and speed spool (2)
is moved to the left, and the oil from the quick
return valve flows to the clutch.

WD900-3 10-37
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

PRIORITY VALVE

FUNCTION
• Priority valve (1) controls the minimum pressure
of pilot reducing valve (2). In addition, priority
valve (1) gives the oil flow to pilot reducing valve
(2) priority over the other circuit.

OPERATION
• The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).

• The oil entering port A flows from orifice a of pri-

ority 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 left. When
this happens, port A and port C are connected,
and the oil flows from port C to the modulating
valve (5).
a Specified pressure: 1.96 MPa {20 kg/cm2}

10-38 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

MODULATING VALVE AND QUICK RETURN VALVE

FUNCTION
The modulating valve, and quick return valve act
together to raise the transmission clutch pressure
smoothly. This reduces shock when shifting speed
range, and prevents the generation of peak torque in
the power train. Therefore, operator fatigue is
reduced to give better operating comfort, and at the
same time, the durability of the power train is
increased.

OPERATION
1. Immediately after shifting gear (point A)
When the gear shift lever is operated to engage
the clutch, the passage from the pump to the
clutch cylinder is opened and oil flows to the
clutch cylinder.
Using the force of this flow, quick return valve (2)
moves to the right in the direction of the arrow,
and connects port E and port G. When the back
pressure of piston (3) is removed, the tension of
springs (4) and (5) move modulating valve (1) to
the right in the direction of the arrow. At the
same time, piston (3) is returned to the left in the
direction of the arrow.

2. Hydraulic pressure starts to rise

When the oil sent under pressure from pump fills
the circuit from port A to the clutch cylinder, the
hydraulic pressure starts to rise.
The oil passing through orifice a of quick return
valve (2) moves quick return valve (2) to the left
in the direction of the arrow. As a result, the pas-
sage between port E and port G is closed.

WD900-3 10-39
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

In addition, the oil passes through orifice b of

modulating valve (1) and flows to port C to push
piston (6). In reaction to this, modulating valve
(1) compresses springs (4) and (5), and moves
to the left in the direction of the arrow. As a
result, modulating valve (1) restricts the passage
to port B.
The oil passing through orifice a of quick return
valve (2) passes through the center passage
and then flows from orifice c to port E, and to
back pressure port F of piston (3). For this rea-
son, piston (3) moves to the right in the direction
of the arrow and compresses springs (4) and
(5).

As the hydraulic pressure in the circuit rises, the

back pressure of piston (3) rises and piston (3)
moves to the right in the direction of the arrow.
The tension of springs (4) and (5) opens the
passage between port A and port B of modulat-
ing valve (1).
In addition, as the hydraulic pressure pushing
piston (6) rises, the reaction moves modulating
valve (1) to the left in the direction of the arrow
and compresses springs (4) and (5) to close port
A and port B.

3. Rise in hydraulic pressure completed

The operation described above is repeated con-
tinuously to increase the load on springs (4) and
(5). The hydraulic pressure rises gradually and
finally piston (3) comes into contact with the
valve stopper and does not move any further.
When this happens, modulating valve (1) stops
in a position where the passage to port B is kept
closed, and this completes the rise in hydraulic
pressure.

10-40 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

REDUCING VALVE

FUNCTION
• The reducing valve is in the circuit between the
quick return valve and the 3rd speed spool. It
acts to protect the 3rd clutch by reducing the hy-
draulic pressure acting on the 3rd clutch.
The maximum pressure of the oil in the circuit is
set by the transmission main relief pressure.

OPERATION (3rd speed spool actuated)

• The oil from quick return valve (1) enters port A,
flows from port B to the 3rd speed spool, and
the 3rd clutch is engaged.

• When oil fills the 3rd clutch, and the hydraulic

pressure rises, the oil passes from port B
through orifice a and enters port C.
The pressure of the oil pushes poppet (3), and
the reaction compresses spring (4) and moves
reducing spool (2) to the right in the direction of
the arrow.
• 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}.

WD900-3 10-41
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

EMERGENCY MANUAL SPOOL

FUNCTION
• If there is any failure in the electrical circuit of
the transmission control system, and the sole-
noid valve does not work, the emergency manu-
al spool is used. This spool is attached to each
directional and speed spool and is used to oper-
ate the transmission valve mechanically. (It is
used to drive the machine to a place where it
can be repaired.)
a Particular attention must be paid for when
using this spool.

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

2. When solenoid valve is abnormal:

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

10-42 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

TRANSMISSION LUBRICATION VALVE

FUNCTION
• The transmission lubrication valve protects the
transmission lubrication circuit from abnormally
high pressure.

OPERATION
• The oil from the oil cooler and torque converter
relief valve passes from port A and lubricates
the transmission. The oil entering port A passes
through orifice a and enters port B.

In this condition, if abnormally high pressure is

generated by the restriction in the lubricating cir-
cuit, the oil entering port B compresses spring
(2) and moves spool (1) to the left in the direc-
tion of the arrow. This opens port A and port C,
as the oil in the lubricating circuit is relieved to
port C. The hydraulic pressure at this point is 0.3
MPa {3 kg/cm2}

WD900-3 10-43
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE

HYDRAULIC CIRCUIT SCHEMATICS

FORWARD 1ST

A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank

10-44 WD900-3
STRUCTURE AND FUNCTION
OPERATION
• When the directional and speed control levers
are moved to FORWARD 1st, solenoid valves
(1) and (2) are opened.
• The oil from pumps (3) and (4) is divided into
three lines, but when the gears are being
changed, the oil flows mainly to each clutch.
• In one of the three lines, the oil passes from
main relief valve (5) through torque converter
(6). It then lubricates the transmission and re-
turns to the transfer case.
• One of the two oil lines flows from pilot reducing
valve (10) through the orifice of each speed
spool to the solenoid valve. However, solenoid
valves (1) and (2) of FORWARD spool (11) and
1st spool (12) are open, so the oil passing
through the orifice flows to the drain circuit. As a
result, a difference in pressure is created be-
tween port A and port B, and this overcomes the
force of springs. The port to the clutch is then
connected.
WD900-3
TRANSMISSION CONTROL VALVE
• The other oil line flows from priority valve (13) to
quick return valve (14). It then flows through ori-
fice a, and directional and speed spools (11)
and (12), and flows to the FORWARD clutch
and 1st clutch. When it starts to flow to the
clutch, it passes through orifice a and creates a
difference in pressure between port C and port
D. Quick return valve (14) moves to the right,
and the oil at the rear of modulating valve piston
(17) flows to drain circuit E. When each clutch is
filled with oil, the difference in pressure between
port C and port D disappears. The valve is
pushed back to the left by the difference in area
of the valves, and drain circuit E is closed.
At this point, each clutch is filled with oil, but the
oil has not reached the specified pressure. The
oil at port D flows through orifice b and reaches
the back of modulating piston (17). Piston (17)
moves to the right and the clutch pressure rises
slowly. When the modulating piston reaches the
end of its stroke, the clutch pressure reaches
the specified level, and the clutch is completely
engaged.
10-45
STRUCTURE AND FUNCTION torque converter oil cooler

TORQUE CONVERTER OIL COOLER

1. Torque converter oil cooler OUTLINE

• The oil which comes out from the torque con-
A. Oil inlet port verter outlet port is at a high temperature be-
(From torque converter regulator valve) cause of the energy used in transmitting the
B. Oil outlet port (To transmission lubricating) motive force. This torque converter oil passes
C. Water inlet port (From water pump) through oil cooler port A and enters the oil cool-
D. Water outlet port (To engine block) er. Here it is cooled by the engine cooling water.
The oil then flows out from oil outlet port B, lubri-
cates the transmission and returns to the trans-
fer case.

10-46 WD900-3
STRUCTURE AND FUNCTION
DRIVE SHAFT
1. Front drive shaft 4. Rear drive shaft
2. Center support 5. Upper drive shaft
3. Center drive shaft
OUTLINE
• The motive force from the engine passes
through the damper, upper drive shaft (5),
torque converter, transmission and transfer. Part
of this motive force passes through rear drive
shaft (4) and goes to the rear axle; the rest of
the motive force passes through center drive
shaft (3), center support (2) and front drive shaft
(1) and is sent to the front axle. In addition to
transmitting the motive force, the drive shafts
have the following purposes.
WD900-3
DRIVE SHAFT
• When the body is articulated, or when there is
shock from the road surface during traveling, or
when there is shock during operations, the axle
in front and behind the engine and transmission
change position.
To allow the motive force to be transmitted with-
out damage to parts of the machine when there
is shock or when the components move posi-
tion, the drive shafts have a universal joint and a
sliding joint. This allows them to handle changes
in angle and length.
10-47
STRUCTURE AND FUNCTION CENTER SUPPORT

CENTER SUPPORT

1. Front coupling FUNCTION

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

10-48 WD900-3
STRUCTURE AND FUNCTION AXLE

AXLE
FRONT AXLE

1. Front axle
2. Final drive
3. Brake
4. Front differential
5. Drain plug
6. Parking brake
7. Spring cylinder

WD900-3 10-49
STRUCTURE AND FUNCTION AXLE

FRONT DIFFERENTIAL

1. Bevel gear (Teeth 39)

2. Differential case
3. Differential side gear (Teeth 28)
4. Differential pinion gear (Teeth 22)
5. Shaft
6. Bevel pinion (Teeth 10)

10-50 WD900-3
STRUCTURE AND FUNCTION AXLE

REAR AXLE

1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug

WD900-3 10-51
STRUCTURE AND FUNCTION AXLE

REAR DIFFERENTIAL

1. Bevel pinion (Teeth 10)

2. Bevel gear (Teeth 39)
3. Shaft
4. Differential pinion gear (Teeth 22)
5. Differential side gear (Teeth 28)
6. Differential case
7. Coupling

10-52 WD900-3
STRUCTURE AND FUNCTION AXLE

OUTLINE
• The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted to
bevel gear (5). The bevel gear changes the di-
rection of the motive force by 90¡, and at the
same time reduces the speed. It then transmits
the motive force through differential (4) to axle
shaft (2).
1

2
3
4
5
SEW00077

When driving straight forward

• When the machine is driven straight forward, the
rotating speed of the left and right wheels is the 6
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).

3
2
4
SEW00078

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

3
2
4
SEW00079

WD900-3 10-53
STRUCTURE AND FUNCTION FINAL DRIVE

FINAL DRIVE

1. Axle shaft OUTLINE

2. Brake • To gain a large drive force, the final drive uses a
3. Planetary gear (Teeth 39) planetary gear system to reduce the speed and
4. Ring gear (Teeth 99) send drive force to the tires.
5. Drain plug
6. Housing OPERATION
7. Sun gear (Teeth 18) • The motive force transmitted from the differen-
8. Wheel tial through axle shaft (1) to sun gear (7) is
transmitted to planetary gear (3). The planetary
gear rotates around the inside of fixed ring gear
(4) and in this way transmits rotation at a re-
duced speed to planetary carrier. This motive
force is then sent to wheels (8) which are in-
stalled to planetary carriers.

10-54 WD900-3
STRUCTURE AND FUNCTION CENTER HINGE PIN

CENTER HINGE PIN

1. Front frame OUTLINE

2. Rear frame • The front frame and rear frame are joined by the
3. Rear axle center hinge pin through a bearing.
4. Front axle The steering cylinders adjust the angle of curva-
5. Upper hinge pin ture to the left and right of the front and rear
6. Lower hinge pin frame (in other words, they adjust the turning
radius).

WD900-3 10-55
STRUCTURE AND FUNCTION AXLE MOUNT

AXLE MOUNT

10-56 WD900-3
STRUCTURE AND FUNCTION AXLE MOUNT

1. Front frame Front axle

2. Rear frame • Front axle (4) receives the force directly during
3. Rear axle operations, so it is fixed directly to front frame
4. Front axle (1) by axle mounting bolts.
5. ROPS support
Rear axle
• Rear axle (3) has a structure which allows the
center of the rear axle to float, so that all tires
can be in contact with the ground when traveling
over soft ground.

WD900-3 10-57
STRUCTURE AND FUNCTION TIRE AND WHEEL

TIRE AND WHEEL

1. Tire OUTLINE
2. Rim • The tires act to absorb the shock that the ma-
3. Valve chine receives from the road surface, and at the
4. Lock ring same time, they provide drive force by rotating
5. Side ring in contact with the ground.
• Depending on the purpose of use, there are var-
ious types of tire available, so it is important to
select the correct tire to match the type of work
and bucket capacity.

SPECIFICATIONS
Item STD If equipped
Tire type 45/65-R45-LDD1 45/65-45-58PR
TRA code L4 L5
Nominal wheel 36.00 x 45WTB
Normal inflation
667 kPa {6.8 kg/cm2}
pressure

10-58 WD900-3
STRUCTURE AND FUNCTION STEERING PIPING DIAGRAM

STEERING PIPING DIAGRAM

STEERING WHEEL SPECIFICATION

1. Steering demand valve a Since the steering hydraulic circuit is shown

2. Steering unit (Orbit-roll valve) together with the work equipment circuit diagram,
3. Hydraulic tank see “WORK EQUIPMENT HYDRAULIC CIRCUIT
4. Steering pump DIAGRAM”.
5. Stop valve
6. Steering cylinder

WD900-3 10-59
STRUCTURE AND FUNCTION STEERING PIPING DIAGRAM

STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

1. Steering demand valve a Since the steering hydraulic circuit is shown

2. Steering unit (Orbit-roll valve) together with the work equipment circuit diagram,
3. Hydraulic tank see “WORK EQUIPMENT HYDRAULIC CIRCUIT
4. Steering pump DIAGRAM”.
5. Proportional solenoid valve
6. Stop valve
7. Steering cylinder

10-60 WD900-3
STRUCTURE AND FUNCTION STEERING COLUMN

STEERING COLUMN
STEERING WHEEL SPECIFICATION
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

1. Steering wheel
2. Steering column
3. Joint
4. Orbit-roll valve

WD900-3 10-61
STRUCTURE AND FUNCTION STEERING PUMP

STEERING PUMP
Serial No.: 50001 – 50006

SPECIFICATION
1. Shaft (front) 10. Cradle (rear)
Model : HPF 76 + 71
2. Cradle (front) 11. Shaft (rear) Rated delivery pressure : 31.4 MPa {320 kg/cm2}
3. Case (front) 12. Case (rear) Rated rpm : 2,120 rpm
4. Swash plate 13. End cap Theoretical delivery (front) : 76.2 cc/rev
5. Shoe 14. End cap (front) Theoretical delivery (rear) : 71.5 cc/rev
6. Piston 15. Servo piston Max. delivery : 161.6 + 151.6 l/min
7. Cylinder block 16. Collar
8. Valve plate 17. Collar
9. Impeller

OUTLINE
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the section
swash plate-type piston pumps and 1 impeller of the work equipment pump. The work equip-
pump between them. ment pump is of the variable displacement type,
• The front pump and rear pump are originally of however, since its rocker arm cam move.
the variable displacement type, but their dis-
placement is fixed since inserted collars (16)
and 17 disable servo piston (15) and fix rocker
cam (4).

10-62 WD900-3
STRUCTURE AND FUNCTION STEERING PUMP

WD900-3 10-63
STRUCTURE AND FUNCTION STEERING PUMP

Serial No.: 50007 and up

1. Shaft (front) 10. Cradle (rear) OUTLINE

2. Cradle (front) 11. Shaft (rear) • This pump consists of 2 fixed-displacement
3. Case (front) 12. Case (rear) swash plate-type piston pumps and 1 impeller
4. Swash plate 13. End cap (rear) pump between them.
5. Shoe 14. End cap (front) • The front pump and rear pump are originally of
6. Piston 15. Servo piston the variable displacement type, but their dis-
7. Cylinder block 16. Collar placement is fixed since inserted collars (16)
8. Valve plate 17. Collar and (17) disable servo piston (15) and fix swash
9. Impeller plate (4).
• For explanation of the operation, see the section
of the work equipment pump. The work equip-
SPECIFICATION ment pump is of the variable displacement type,
Model :HPF 76 + 71 however, since its swash plate (4) can move.
Rated delivery pressure :31.4 MPa {320 kg/cm2}
Rated rpm :2,120 rpm
Theoretical delivery (front) :76.2 cc/rev
Theoretical delivery (rear) :71.5 cc/rev
Max. delivery :161.6 + 151.6 l/min

10-64 WD900-3
STRUCTURE AND FUNCTION STEERING PUMP

WD900-3 10-65
STRUCTURE AND FUNCTION SWITCH PUMP

SWITCH PUMP

1. Additional oil cooler fan pump OUTLINE

• This pump consists of two fixed-displacement
SPECIFICATION swash plate piston pumps and 1 impeller pump
between them.
Switch pump STD If equipped
• Also additional oil cooler fan pump is installed
Model HPV 90 + 90 HPV 90 + 90 + 25 on the machine equipped with brake cooling
Rated delivery 31.4 MPa 31.4 MPa system or 55°C specification.
pressure {320 kg/ cm2} {320 kg/ cm2}
Rated rpm 2,120 rpm 2,124 rpm
Theoretical
97.4 cc/rev 97.4 cc/rev
delivery (front)
Theoretical
97.4 cc/rev 97.4 cc/rev
delivery (rear)
Max. delivery 206.5 + 206.5 l/min 206.9 + 206.9 l/min

WD900-3 10-67
STRUCTURE AND FUNCTION SWITCH PUMP

SWITHCH PUMP (HPF 90 + 90)

1. Shaft (front) 9. Impeller

2. Cradle (front) 10. Cradle (rear)
3. Case (front) 11. Shaft (rear)
4. Swash plate 12. Case (rear)
5. Shoe 13. End cap (rear)
6. Piston 14. End cap (front)
7. Cylinder block 15. Servo piston
8. Valve plate

10-68 WD900-3
STRUCTURE AND FUNCTION SWITCH PUMP

WD900-3 10-69
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

STEERING DEMAND VALVE

1. Overload relief valve

2. Surge cut relief valve
3. Steering spool
4. Demand spool
5. Main relief valve

A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)

10-70 WD900-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

OVERLOAD RELIEF VALVE

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring

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

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

• When the pressure at port A reaches the set

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

WD900-3 10-71
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

• 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 pres-

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

2. Operation of suction valve

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

10-72 WD900-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

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 maximum
pressure in the steering circuit when it is operat-
ed. In other words, when the valve is being op-
erated and the steering circuit goes above the
set pressure of this valve, it relieves the oil and
actuates the flow control spool of the demand
valve to drain the oil to the steering circuit.

WD900-3 10-73
STRUCTURE AND FUNCTION
OPERATION OF STEERING RELIEF VALVE
• When the pressure in the circuit rises and reach-
es the pressure set by spring (2) and adjustment
screw (1), pilot poppet (3) opens and drains the
oil.
• When this happens, the balance of the pressure
in pressure receiving chamber ( ) and pressure
receiving chamber ( ) is lost, and demand
spool (4) moves to the left.
10-74
STEERING DEMAND VALVE
• When demand spool (4) moves, the oil from the
steering pump is drained and the oil from the
switch pump is relieved to the main control
valve, so the steering circuit pressure is prevent-
ed from going above the set value.
WD900-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

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 cham-
and the oil from the switch pump enters port B. ber ( ) reaches a certain value (set by spring
• When steering spool (2) is at the neutral posi- (3)), notch f opens and the oil from the steering
tion, pressure receiving pressure chamber ( ) is pump goes to the drain circuit. Notch g is
connected to the drain circuit through orifice b, closed, so the oil from the switch pump all flows
and notch c is closed. to the main control valve.
• 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 ( ) and moves demand spool (1) to the
left.

WD900-3 10-75
STRUCTURE AND FUNCTION
WHEN STEERING SPOOL IS OPERATED
• Engine running at low speed
• When the steering is operated, oil flows from the
rotary valve to steering spool (2) and pushes
steering spool (2) to the right. The circuit be-
tween pressure receiving chamber ( ) and the
drain circuit is shut off, and at the same time,
notch c opens.
• As a result, the pressure in pressure receiving
chamber ( ) rises, and demand spool (1)
moves to the right until notch h closes.
• The passage from port B to the main control
valve is shut off, so the oil from the switch pump
pushes up pump merge-divider check valve (4)
and merges with the oil from the steering pump
at port A.
10-76
STEERING DEMAND VALVE
• The merged oil passes through notches c and d,
pushes load check valve (5), and flows to the
cylinder. The return oil from the cylinder passes
through notch e and flows to the drain circuit.
• When this happens, the pressure before
passing through notch c is sent to pressure re-
ceiving chamber ( ) and the pressure after
passing through notch c is sent to pressure re-
ceiving chamber ( ). Demand spool (1) is ac-
tuated so that the difference in pressure on
both sides of notch c is kept constant. There-
fore, an oil flow corresponding to the opening of
notch c is supplied to the cylinder port. These
pressure differences (control pressure) are set
by spring (3).
WD900-3
STRUCTURE AND FUNCTION
• Engine running at high speed
• There is no need for supply of extra oil from the
switch pump, so the steering pump pressure ris-
es until notch g closes and shuts off the merge
passage from port B.
• The pressure difference on both sides of notch c
is controlled only by notch f, and the excess oil
from the steering pump is drained from notch f
to the drain circuit. (At this point, notch g is
completely closed.)
WD900-3
STEERING DEMAND VALVE
• The oil from the steering pump passes through
notches c and d, pushes load check valve (5),
and flows to the cylinder. The return oil from the
cylinder passes through notch e and flows to the
drain circuit.
• Notch g is closed, so the oil from the switch
pump all flows from port B and is sent to the
main control valve.
10-77
STRUCTURE AND FUNCTION STEERING DEMAND VALVE

OPERATION OF STEERING VALVE

Neutral

• The steering is not being operated, so steering
spool (2) does not move.
• The oil from the steering pump enters port A.
The oil from the switch pump enters port B.
• When the pressure at ports A and B rises, de-
mand spool (1) moves to the left, so the oil from
the steering pump passes through port C of the
spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.

10-78 WD900-3
STRUCTURE AND FUNCTION
Turning right
• When the steering wheel is turned to the right,
the Orbit-roll valve is operated and steering
spool (2) moves to the left.
The oil from the steering pump enters port A,
then flows to steering spool (2) through demand
spool (1). The oil pushes open load check valve
(6) of the spool, and flows to the bottom end of
the left cylinder and the rod end of the right cyl-
WD900-3
STEERING DEMAND VALVE
inder to turn the machine to the right . The oil
from the left and right cylinders passes through
load check valve (5) of the steering spool and is
drained. The oil from the switch pump enters
port B, goes through demand spool (1), pushes
open check valve (4), and is merged with the oil
from the steering pump.
10-79
STRUCTURE AND FUNCTION
Turning left
• When the steering wheel is turned to the left, the
Orbit-roll valve is operated and steering spool
(2) moves to the right.
The oil from the steering pump enters port A,
then flows to steering spool (2) through demand
spool (1). The oil pushes open load check valve
(5) of the spool, and flows to the rod end of the
left cylinder and the bottom end of the right cyl-
10-80
STEERING DEMAND VALVE
inder to turn the machine to the left. The oil
from the left and right cylinders passes through
load check valve (6) of the steering spool and is
drained. The oil from the switch pump enters
port B, goes through demand spool (1), pushes
open check valve (4), and is merged with the oil
from the steering pump.
WD900-3
STRUCTURE AND FUNCTION STEERING UNIT (ORBIT-ROLL VALVE)

STEERING UNIT (ORBIT-ROLL VALVE)

STEERING WHEEL SPECIFICATION
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering cylinder (demand valve port Pb)
3. Check valve c. To steering cylinder (demand valve port Pa)
4. Spool d. From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin

WD900-3 10-81
STRUCTURE AND FUNCTION STEERING UNIT (ORBIT-ROLL VALVE)

OUTLINE

• The steering unit is directly connected to the

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

STRUCTURE

• Spool (4) is interconnected with the drive shaft

of the steering wheel and is connected to sleeve
(5) by neutral position spring (1) and center pin
(10) (when the steering wheel is at neutral, it
does not contact the spool).
• The top of drive shaft (9) is meshed with center
pin (10) and forms one unit with sleeve (5). The
bottom is meshed with the spline of gear (7) of
the gear set.
• Valve body (2) has four ports. These are con-
nected respectively to the pump circuit, tank cir-
cuit, 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 fail-
ure in the PPC pump, oil is sucked in directly
from the tank end by the check valve.

10-82 WD900-3
STRUCTURE AND FUNCTION STEERING UNIT (ORBIT-ROLL VALVE)

OPERATION

When turning

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

At neutral

• When the turning of the steering wheel is

stopped (the rotation of the spool is stopped),
the return force of neutral position spring (1)
returns spool (4) and sleeve (5) to the neutral
position, so the oil passage is shut off and the
oil stops flowing.
• When the non-reaction type steering valve is at
the neutral position, the steering cylinder and
spool (4) and sleeve (5) are blocked, so the
reaction from the machine is not transmitted to
the steering wheel.

WD900-3 10-83
STRUCTURE AND FUNCTION PROPORTIONAL SOLENOID VALVE

PROPORTIONAL SOLENOID VALVE

STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

A. To stop valve FUNCTION

B. To stop valve • The proportional solenoid valve controls the oil
P. From PPC pump flow to the stop valve with the electromagnetic
T. To hydraulic tank proportional valve that is controlled by the com-
mand current from the transmission and joy-
1. Solenoid a stick steering controller.
2. Solenoid b

10-84 WD900-3
STRUCTURE AND FUNCTION TWO-WAY RESTRICTOR VALVE

TWO-WAY RESTRICTOR 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 ori-
fice is installed in the oil line of the return circuit
from the cylinder. This applies pressure to the
returning oil, and regulates the movement of the
cylinder piston.

OPERATION
• When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and be-
tween poppet (1) and the poppet seat.

• When the oil is flowing to arrow i, the oil flows

only from orifice a inside poppet (1), so the flow
is controlled.

WD900-3 10-85
STRUCTURE AND FUNCTION DIVERTER VALVE

DIVERTER VALVE

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 steer-
5. Spool E. From hydraulic tank ing circuit, it drains the oil from the emergency
6. Valve body F. From steering circuit 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.

10-86 WD900-3
STRUCTURE AND FUNCTION DIVERTER VALVE

EMERGENCY STEERING RELIEF VALVE

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw

FUNCTION
Compared to the steering valve relief pressure of
31.4 MPa {320 kg/cm2 }, the rated pressure of the
emergency steering pump and diverter valve are
both 20.6 MPa {210 kg/cm2 }. Therefore, to protect
the emergency steering pump and diverter valve,
there is a relief valve in the piping from the diverter
valve to the steering valve. When the emergency
steering is being operated, and the hydraulic pres-
sure generated by the steering exceeds 20.6 MPa
{210 kg/cm2}, the relief valve is actuated.

OPERATION
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil pass-
es through the orifice in main valve (1) and fills
port B. Pilot poppet (3) is in contact with valve
seat (2).

• When the pressure inside port A and B reaches

the pressure set by the poppet spring (set pres-
sure), pilot poppet (3) opens and the hydraulic
pressure at port B escapes from port D to port
C. This lowers the pressure at port B.
• When the pressure at port B drops, the orifice of
main valve (1) generates a difference in pres-
sure between port A and port B. Main valve (1)
is opened by the pressure at port A and the oil
at port A is relieved.

WD900-3 10-87
STRUCTURE AND FUNCTION DIVERTER VALVE

HYDRAULIC CIRCUIT SCHEMATICS FOR EMERGENCY STEERING

Pump, engine working normally

(a) Sensor (f) Hydraulic tank (P1.)Emergency steering pump

(b) Relief valve (g) Oil cooler (P2.)Main pump
(c) From steering cylinder (h) Oil filter (P3.)Steering pump
(d) To steering cylinder (j) From orbit-roll valve (P4.)Switch pump
(e) To main control valve

When the steering pump and engine are working

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

10-88 WD900-3
STRUCTURE AND FUNCTION DIVERTER VALVE

Failure in pump or engine when machine is traveling

(a) Sensor (f) Hydraulic tank (P1.)Emergency steering pump

(b) Relief valve (g) Oil cooler (P2.)Main pump
(c) From steering cylinder (h) Oil filter (P3.)Steering pump
(d) To steering cylinder (j) From orbit-roll valve (P4.)Switch pump
(e) To main control valve

If there is a failure in the pump or engine when the

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

a The emergency steering pump is designed so

that it can rotate both directions.

WD900-3 10-89
STRUCTURE AND FUNCTION BRAKE PIPING

BRAKE PIPING

1. Front brake (right) 9. Charge valve

2. Brake valve (right) 10. Brake oil tank
3. Parking brake switch 11. Accumulators
4. Rear brake (right) 12. Brake valve (left)
5. Strainer 13. Front brake (left)
6. Slack adjuster (rear) 14. Parking brake spring cylinders
7. Torque converter charging (x 2), PPC, brake pump 15. Slack adjuster (front)
8. Rear brake (left) 16. Parking brake solenoid valve

10-90 WD900-3
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM

BRAKE CIRCUIT DIAGRAM

Serial No.: 50001 – 50006

10-92 WD900-3
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM

1. Torque converter charging (x 2), PPC, brake pump

1A.Torque converter charging pump
1B.Torque converter charging pump
1C.PPC pump
1D.Brake pump
2. Strainer
3. Accumulator charge valve
3A.Safety relief valve
3B.Relief valve
3C.Filter
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
16. Parking brake switch
17. Parking brake spring cylinder
18. Parking brake pilot lamp switch
19. Brake oil tank

WD900-3 10-93
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM

Serial No.: 50007 and up

10-94 WD900-3
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM

1. Torque converter charging (x 2), PPC, brake pump

1A.Torque converter charging pump
1B.Torque converter charging pump
1C.PPC pump
1D.Brake pump
2. Strainer
3. Accumulator charge valve
3A.Safety relief valve
3B.Relief valve
3C.Filter
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
16. Parking brake switch
17. Parking brake spring cylinder
18. Parking brake pilot lamp switch
19. Brake oil tank

WD900-3 10-95
STRUCTURE AND FUNCTION BRAKE VALVE

BRAKE VALVE
Serial No.: 50001 – 50006
BRAKE VALVE (RIGHT AND LEFT)

1. Brake pedal A. Pilot port

2. Rod B. To brake (left)
3. Pilot piston C. To brake (right)
4. Spool D. Drain
5. Upper cylinder E. From brake pump
6. Spool
7. Lower cylinder

10-96 WD900-3
STRUCTURE AND FUNCTION BRAKE VALVE

OUTLINE
• There are two brake valves installed in parallel
under the front of the operator’s compartment.
They are actuated when the pedal is depressed.
• When the right brake pedal is depressed, oil is
sent to the brake cylinder to actuate the brake.
In addition, pilot oil is sent to the left brake valve
and the brake is actuated in the same way as
when the left brake pedal is depressed.
• In addition, when the brake pedal is depressed,
the transmission cut-off switch “ON” acts to
actuate the transmission solenoid valve electri-
cally and shift the transmission to neutral.

WD900-3 10-97
STRUCTURE AND FUNCTION BRAKE VALVE

OPERATION
When brake is actuated
Upper
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3).
When spool (3) goes down, drain port a closes.
As a result, the oil from the pump and accumula-
tor flows from port A to port C, and actuates the
front left brake cylinder.

Lower
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3).
When spool (3) goes down, spool (5) is moved
down by plunger (6) and this closes drain port b.
As a result, the oil from the pump and accumula-
tor flows from port B to port D, and actuates the
front right brake cylinder.

When brake is actuated (interconnected with left

brake valve)
• When pedal (1) is depressed, spool (3) is
pushed down by rod (2) and spring (4), and
drain port a closes. As a result, the oil from the
pump and accumulator flows from port A to port
C.
• Port C of the right brake valve and port PP of the
left brake valve are connected, so the oil flowing
to port C flows to pilot port PP of the left brake
valve.
• The oil entering pilot port PP enters port G from
orifice d and pushes pilot piston (8). The piston
pushes the spring, so spool (3A) is pushed
down, and the brake is actuated in the same
way as when the left brake valve is depressed.

10-98 WD900-3
STRUCTURE AND FUNCTION BRAKE VALVE

Actuation of brake when upper valve fails

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

Actuation of brake when lower valve fails

• Even if there is leakage of oil from the lower pip-
ing, the upper portion is actuated normally.

When actuation is in balance

Upper
• When the front left brake cylinder is filled with
oil, and the pressure at port A and port C
becomes high, the oil entering port H through
orifice e of spool (3) acts against spring (4). As a
result, spool (3) is pushed up and port A and
port C are shut off. When this happens, drain
port a remains closed, so the oil stays in the
brake cylinder and the brake is kept applied.

Lower
• Spool (3) of the upper brake moves up. As a
result, at the same time that port A and port C
are shut off, the front right brake cylinder is also
filled with oil, and the pressure at port B and port
D becomes high. The oil entering port J through
orifice f of spool (5) pushes up spool (5) by the
amount of movement of spool (3), so port B and
port D are shut off. Furthermore, drain port b is
closed, so the oil stays in the brake cylinder and
the brake is kept applied.
• The pressure in the space in the upper portion
balances the operating effort of the pedal, and
the pressure in the space in the lower portion
balances the pressure in the space in the upper
portion. When spools (3) and (5) move the full
stroke, the circuits between ports A and C, and
between ports B and D are completely opened,
so the space in the upper and lower portions
and the oil pressure in the left and right brake
cylinders is the same as the oil pressure from
the pump.
Therefore, the braking effect can be controlled
by the amount the pedal is depressed until the
piston moves the full stroke.

WD900-3 10-99
STRUCTURE AND FUNCTION BRAKE VALVE

When brake is released

Upper
• When pedal (1) is let back and the operating
effort is removed from the top of the spool, spool
(3) is moved up by the back pressure from the
brake cylinder and the spool return spring. Drain
port a is opened, and the oil from the brake cyl-
inder flows to the brake oil tank return circuit, so
the front left brake is released.

Lower
• When the pedal is let back, upper spool (3) is
moved up, and at the same time, spool (5) is
moved by the back pressure from the brake cyl-
inder and the spool return spring. Drain port b is
opened, and the oil from the brake cylinder flows
to the brake oil tank return circuit, so the front
right brake is released.

10-100 WD900-3
STRUCTURE AND FUNCTION BRAKE VALVE

Serial No.: 50007 and up

BRAKE VALVE (RIGHT)

1. Brake pedal (Right and left brakes) A. Pilot port (Right brake)
2. Rod (Right brake) B. To front brake (Right brake)
3. Pilot piston (Right brake) C. To rear brake (Right brake)
4. Spool (Right brake) D. Drain (Right and left brakes)
5. Upper cylinder (Right brake) E. From brake pump (Right and left brakes)
6. Spool (Right brake) F. To pilot port (Left brake)
7. Lower cylinder (Right brake)
8. Rod (Left brake)
9. Spool (Left brake)
10. Cylinder (Left brake)

10-102 WD900-3
STRUCTURE AND FUNCTION BRAKE VALVE

BRAKE VALVE (LEFT)

OUTLINE
• There are two brake valves installed in parallel
under the front of the operator’s cab, and these
are actuated by depressing the pedal.
• When the right pedal is depressed, oil is sent to
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the trans-
mission solenoid valve electrically and set the
transmission to neutral.

WD900-3 10-103
STRUCTURE AND FUNCTION BRAKE VALVE

OPERATION

Brake applied (right brake valve)

Upper portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and
actuates the front brake cylinders.

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

Brake applied (left brake pedal)

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

10-104 WD900-3
STRUCTURE AND FUNCTION BRAKE VALVE

Applying brake when upper valve fails

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

Applying brake when lower valve fails

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

When actuation is balanced

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

WD900-3 10-105
STRUCTURE AND FUNCTION BRAKE VALVE

Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the front brake.

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

10-106 WD900-3
STRUCTURE AND FUNCTION CHARGE VALVE

CHARGE VALVE

A: To brake oil tank FUNCTION

ACC: Plug • The charge valve is actuated to maintain the oil
PP: To brake valve pressure from the pump at the specified pres-
P: From pump sure 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.

10-108 WD900-3
STRUCTURE AND FUNCTION CHARGE VALVE

1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
6. Filter

WD900-3 10-109
STRUCTURE AND FUNCTION CHARGE VALVE

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

2. When oil is supplied to accumulator

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

10-110 WD900-3
STRUCTURE AND FUNCTION CHARGE VALVE

2) When cut-out pressure is reached

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

3. Safety relief valve (R3)

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

WD900-3 10-111
STRUCTURE AND FUNCTION ACCUMULATOR (For brake)

ACCUMULATOR (For brake)

1. Valve
2. Top cover
3. Cylinder
4. Free piston

FUNCTION SPECIFICATIONS
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with ni- Charge amount: 6,000 cc
trogen gas between cylinder (3) and free piston Charging pressure: 3.43 MPa {35 kg/cm2} (at 50°C)
(4), and uses the compressibility of the gas to
absorb the pulse of the hydraulic pump or to
maintain the braking force and to make it possi-
ble to operate the machine if the engine should
stop.

WD900-3 10-113
STRUCTURE AND FUNCTION SLACK ADJUSTER

SLACK ADJUSTER

1. Piston SPECIFICATIONS
2. Cylinder Maximum available pressure: 5.9 MPa {60 kg/cm2}
3. Check valve (Safety valve set pressure:
4. Spring 0.97 MPa {9.9 kg/cm2})
5. Bleeder Normal pressure: 4.6 MPa {47 kg/cm2}
(Governor set pressure: 0.81 MPa {8.3 kg/cm2})
A. Inlet port (from brake valve)
B. Outlet port (to brake) Check valve cracking pressure:
1.1 ± 0.05 MPa {11.1 ± 0.5 kg/cm2}

FUNCTION
• The slack adjuster is installed in the brake oil
line from the brake valve to the brake piston. It
acts to keep the clearance between the brake
piston and discs constant even when the brake
discs are worn. In this way it acts to keep a con-
stant time lag when the brake is operated.

10-114 WD900-3
STRUCTURE AND FUNCTION SLACK ADJUSTER

OPERATION
1. Brake pedal depressed
The oil pumped out from brake valve (9) flows in from port P of the slack adjuster. From port P the oil is
divided and sent to left and right cylinders (2) and moves piston (4) a distance of stroke S to the right or left.

Because of this, an amount of oil corresponding to stroke S flows from port C to brake cylinder (7). When
this happens, the clearance between the brake piston and disc becomes 0, so no braking force is gener-
ated.

WD900-3 10-115
STRUCTURE AND FUNCTION SLACK ADJUSTER

If the oil pressure in brake valve (9) goes above a certain specified pressure, check valve (3) opens and the
oil flows through pilot circuit D and applies pressure to port C. This gives the braking force.
As a result, there is a constant time lag when the brake is applied.

2. Brake pedal released

When the brake is released, pressure is applied to the back of the brake piston because of the hydraulic
pressure of the brake. Piston (4) is moved back stroke S and the disc clearance returns to normal.

10-116 WD900-3
STRUCTURE AND FUNCTION BRAKE

BRAKE

1. Guide pin FUNCTION

2. Return spring • The brakes are wet-type multiple disc brakes,
3. Brake piston and are fitted to all four wheels.
4. Plate
5. Disc OPERATION
6. Floating seal • When the brake pedal is depressed, moves
brake piston (3) to the right, and presses disc (5)
and plate (4) together to hold them in position.
Disc (5) is rotating together with the wheel, so
when it is held in position, the rotation stops, the
brake is actuated, and the machine is stopped.
When the brake pedal is released, the pressure
at the rear face of piston (3) is released, and the
piston is moved to the left by the force of return
spring (2) to release the brake.

WD900-3 10-117
STRUCTURE AND FUNCTION PARKING BRAKE

PARKING BRAKE
Serial No.: 50001 – 50005

1. Spring cylinder OUTLINE

2. Caliper • The parking brake is a disc type and is installed
3. Disc on the front axle.
4. Caliper • The force of the spring inside spring cylinders
5. Spring cylinder (1) and (5) is used to apply the brake mechani-
6. Differential case cally; it is released by oil pressure.
• The parking brake caliper is fixed to the front dif-
ferential case.
The disc is installed to the differential yoke and
rotates together with the coupling.

10-118 WD900-3
STRUCTURE AND FUNCTION PARKING BRAKE

Serial No.: 50006 and up

1. Spring cylinder OUTLINE

2. Caliper • The parking brake is a disc type and is installed
3. Disc on the front axle.
4. Caliper • The force of the spring inside spring cylinders
5. Spring cylinder (1) and (5) is used to apply the brake mechani-
6. Differential case cally; it is released by oil pressure.
7. Spring • The parking brake caliper is fixed to the front dif-
ferential case.
The disc is installed to the differential yoke and
rotates together with the coupling.

WD900-3 10-119
STRUCTURE AND FUNCTION PARKING BRAKE

OPERATION

Parking
• When the parking brake switch is turned ON, the
solenoid valve is actuated and the oil pressure
from the brake pump is shut off by the solenoid
valve. The oil inside spring cylinder (1) is
drained to the brake oil tank from the solenoid
valve port.
Therefore, the piston and rod of spring cylinder
(1) are pushed by the force of the spring, so
lever (2) rotates and the parking brake is
applied.
• Lever (2) rotates piston shaft (3) and moves pis-
ton (4) in the axial direction, so the pad is
pushed against the disc, and the parking brake
is applied.

Traveling
• When the parking brake switch is turned OFF,
the solenoid valve is actuated and the valve
opens the drain port.
At the same time, the oil pressure from the
brake pump enters the bottom of the piston of
spring cylinder (1). It overcomes the force of the
spring and pushes the piston to rotate lever (2).
This rotates piston shaft (3), moves piston (4),
and releases the parking brake.
Therefore, hydraulic pressure is applied to the
spring cylinder and the parking brake is kept
released.

10-120 WD900-3
STRUCTURE AND FUNCTION SPRING CYLINDER

SPRING CYLINDER

1. Outer spring OUTLINE

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.

WD900-3 10-121
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE

PARKING BRAKE SOLENOID VALVE

1. Solenoid valve assembly FUNCTION

2. Block • When the parking brake switch is turned ON/
OFF, the solenoid valve is energized or deener-
B. Outlet port gized, so the brake oil pressure is taken to the
B1. Port for parking brake pilot lamp switch brake spring cylinder or removed from the brake
P. Inlet port cylinder to set the parking brake at the PARKED
T. Drain port position or TRAVEL position.
• Parking brake solenoid valve
Energized : TRAVEL
Deenergized : PARKED

10-122 WD900-3
STRUCTURE AND FUNCTION HYDRAULIC PIPING

HYDRAULIC PIPING

10-124 WD900-3
STRUCTURE AND FUNCTION HYDRAULIC PIPING

1. Hydraulic tank
2. Main piston pump
3. DE · CO valve
4. Main control valve
5. Steering demand valve
6. Switch piston pump
7. Torque converter charging, PPC, brake pump
8. PPC valve
9. Lift cylinder

A. To pitch cylinder (Right)

B. To pitch and tilt cylinder (Left)

• The work equipment system consists of the hy-

draulic circuit and steering circuit. The hydraulic
circuit controls the operation of the blade.
• The oil from hydraulic tank is sent from main
pump (2), and switch pump (6) through the
steering valve to main control valve (4). If the
blade and lift spools of the main control valve is
in neutral, the oil passes through the drain circuit
of the main control valve, is filtered by the filter
inside the hydraulic tank, and returns to the
tank.
• The blade or lift or boom spool in PPC valve is
activated by operating the work equipment con-
trol lever, causing each spool in the work equip-
ment valve to be hydraulically activated.
Thereby, the oil is allowed to flow from the work
equipment valve to lift cylinder, thus operating
the blade.
• The maximum pressure of the hydraulic circuit is
regulated by the relief valve inside the main con-
trol valve. There are two safety valves (with suc-
tion valve) and an unloader valve in the lift
cylinder circuit to protect the circuit.
• Even when engine is at rest, the blade can be
lowered to the ground because accumulator is
provided in the circuit.
• Hydraulic tank is a pressurized, sealed type and
has a breather with a relief valve. This acts to
pressurize the tank and at the same time pre-
vents negative pressure. This protects the pump
from cavitation.
• In the hydraulic tank there is pressurizing valve
installed to pressurize the hydraulic tank with air
pressure. It is used to carry out air bleeding of
the pump when changing the oil inside the tank
or when assembling after removing the piping of
the piston pump and pump.

WD900-3 10-125
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

WORK EQUIPMENT SOLENOID VALVE

SOLENOID VALVE (SOL a)

a. Solenoid valve assembly

b. Valve assembly
c. Port T
d. Port P
e. Port B
f. Port A
g. Port X
h. Port Y

10-126 WD900-3
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

OPERATION OF SOLENOID VALVE (a)

1. When power is turned off

Pressurized oil supplied through port PL flows
through port A of the solenoid valve into cham-
ber AS and moves the spool to the right to close
P, A, B and T of the master valve.
Chamber BS is opened since it is connected to
port T of the solenoid valve.

2. When power is turned on

Pressurized oil supplied through port PL flows
through port B of the solenoid valve into cham-
ber BS and moves the spool to the left to con-
nect BS and moves the spool to the left to
connect P of the master valve to A and connect
B to T.
Chamber AS is opened since it is connected to
port T of the solenoid valve.

WD900-3 10-127
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

SOLENOID VALVE (SOL b)

a. Solenoid valve assembly

b. Valve assembly
c. Port T
d. Port P
e. Port B
f. Port A
g. Port X
h. Port Y

10-128 WD900-3
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

OPERATION OF SOLENOID VALVE (b)

1. When power is turned off

Pressurized oil supplied through port PL flows
through port A of the solenoid valve into cham-
ber AS and moves the spool to the left to con-
nect P of the master valve to A and connect B to
T.
Chamber BS is opened since it is connected to
port T of the solenoid valve
The oil flows in ports T and A and flows out to
ports B and T.

2. When power is turned on

If the solenoid valve is turned on, pressurized oil
supplied through port PL flows through port B of
the solenoid valve into chamber BS and moves
the spool to the right to connect P of the master
valve to B and connect A to T.
Chamber AS is opened since it is connected to
port T of the solenoid valve.
If port T is connected to port A and port B is con-
nected to port P, the oil does not flow.

WD900-3 10-129
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

MERGE/DIVIDER VALVE

1. Spring FUNCTION
2. Cover This valve equally divides or merges the oil flowing
3. Sub-spool in it, irrespective of fluctuation of pressure differ-
4. Spool ence between ports A and B
5. Body

a. Port A
b. Port B
c. Port P

10-130 WD900-3
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

OPERATION OF MERGE/DIVIDER VALVE

1. When oil is divided

In the oil dividing state, the oil flowing in through
port P pushes sub-spools (3A and 3B) on ports
A and B side open and flows through the
chokes of the sub-spools and the oil path of
spool (4) into ports A and B. If there is pressure
difference between ports A and B, spool (4)
moves to the right or left according to the pres-
sure difference to adjust the width of the oil
paths to ports A and B so that the oil of the
same quantity will flow into both ports.
C: Solenoid valve b
D: Solenoid valve a

2. When oil is merged

In the oil merging state, the oil flows in from
ports A and B and moves the respective sub-
spools inward. Then, the oils from ports A and
B equally merge together while they flow
through the oil paths of the spools and chokes of
the sub-spools into port P. If there is pressure
difference between ports A and B, the spool
moves similarly to the oil dividing state to adjust
the width of the oil paths so that the oils of the
same quantity will flow into pot P.
C: Solenoid valve b
D: Solenoid valve a

WD900-3 10-131
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

Operation of right tilt

10-132 WD900-3
STRUCTURE AND FUNCTION
Tilting operation
1. Tilting to right
• The pressurized oil supplied from port A1 of
work equipment valve flows through port A
into the merge/divider valve.
One part of the divided pressurized oil flows
through port G into port C. The other part
does not flow into port J but flows through
port H into ports L and M, since solenoid
valve a is turned off and pilot spool (1) does
not work.
Since solenoid valve b is turned off, pilot
spool (2) does not work and the pressurized
oil flows through ports N and P and merges
in port C, then flows to the bottom side of left
tilt &pitch cylinder (3).
• On the other hand, the oil on the rod side of
left tilt & pitch cylinder (3) flows back through
ports D and B into the tank.
• Since the pressurized oil in ports E and F
does not flow at all, right pitch cylinder (4)
does not work. Consequently, the blade tilts
to the right.
WD900-3
WORK EQUIPMENT SOLENOID VALVE
2. Tilting to left
• The pressurized oil supplied from port B1 of
work equipment valve does not flow into port
K but flows through ports B and D into the
rod side of left tilt & pitch cylinder (3), since
solenoid valve a is turned off and pilot spool
(1) does not work.
• On the other hand, the oil on the bottom side
of tilt & pitch cylinder (3) is divided at port C.
One part of divided oil flows into port G and
the other part flows into ports N and P.
• Since solenoid valve b is turned off, pilot
spool (2) does not work and the pressurized
oil flows through ports L, M, H and merges in
the merge/divider valve and flows back into
the tank.
• Since the pressurized oil in ports E and F
does not flow at all, right pitch cylinder (4)
does not work. Consequently, the blade tilts
to the left.
10-133
STRUCTURE AND FUNCTION WORK EQUIPMENT SOLENOID VALVE

Operation of forward pitch

10-134 WD900-3
STRUCTURE AND FUNCTION
Pitching operation
1. Forward pitching
• The pressurized oil supplied from port A1 of
work equipment valve flows through port A
into the merge/divider valve.
One part of the divided oil flows through
ports G and C into the bottom side of left tilt
& pitch cylinder (3).
Pilot spool (1) works and the oil flows into
port J.
Then, the oil flows from port M through port
E into the bottom side of right pitch cylinder
(4).
At this time, solenoid valve b is turned on
and pilot spool (2) moves to open ports N, P,
Q and R.
• On the other hand, the oil on the rod side of
left tilt & pitch cylinder (3) flows through port
D into port B. The oil on the rod side of right
pitch cylinder (4) flows from port F through
solenoid valve a and merges, then flows
back through port B into the tank.
WD900-3
WORK EQUIPMENT SOLENOID VALVE
2. Rear pitching
• The pressurized oil supplied from port B1 of
work equipment valve flows into port B. One
part of this oil flows through port D into the
rod side of left tilt & pitch cylinder (3).
• The other part of the above oil flows into port
L, since solenoid valve a is turned on and pi-
lot spool (1) works. Then, it flows through
ports K and F to the rod side of right pitch cyl-
inder (4).
• On the other hand, the oil on the bottom side
of left tilt & pitch cylinder (3) flows from port
C to port G. The oil on the bottom side of
right pitch cylinder (4) flows from port E
through port H and merges in the merge/di-
vider valve, then flows back through port A
into the tank.
At this time, solenoid valve b is turned on
and pilot spool (2) moves to open ports N, P,
Q and R.
Consequently, the blade is pitched to the
rear.
10-135
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE

WORK EQUIPMENT LEVER LINKAGE

1. Work equipment control lever

2. PPC valve
3. Safety lever

10-136 WD900-3
STRUCTURE AND FUNCTION HYDRAULIC TANK

HYDRAULIC TANK

1. Filter bypass valve OUTLINE

2. Hydraulic filter • The oil from the hydraulic tank is sent from the
3. Strainer pump through the control valve to the cylinders.
4. Drain valve In the return circuit, the oil from various parts
5. Strainer merges. A part of oil is cooled in the oil cooler,
6. Breather passes through hydraulic filter (2) and returns to
7. Oil filler the tank.
• Hydraulic filter (2) filters all the oil in the circuit. If
A. Oil cooler return port hydraulic filter (2) becomes clogged, bypass
B. Main return port valve (1) acts to allow the oil to return directly to
C. Gear pump suction the tank. This prevents damage to filter (2). By-
D. Main piston pump suction port pass valve (1) is also actuated when negative
E. Emergency pump suction pressure is generated in the circuit.
F. Emergency pump return port

10-138 WD900-3
STRUCTURE AND FUNCTION HYDRAULIC TANK

OPERATION OF OIL FILTER BYPASS VALVE

When the filter is clogged.

Bypass valve (1) opens and the oil returns directly to
the tank without passing through the filter.
Bypass valve set pressure: 125 kPa {1.27 kg/cm2}

When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 25.5 kPa {0.26 kg/cm2}

WD900-3 10-139
STRUCTURE AND FUNCTION HYDRAULIC TANK

BREATHER

1. Body
2. Filter element
3. Poppet
4. Sleeve

FUNCTION
Preventing negative pressure inside the tank
The tank is pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when
the oil level drops during operations.
When this happens, the difference in pressure
between the tank and the outside atmospheric pres-
sure opens 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 tem-
perature rises. If the hydraulic pressure rises above
the set pressure, sleeve (4) is actuated to release
the hydraulic pressure inside the tank.

10-140 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

MAIN PISTON PUMP

Serial No.: 50001 – 50005
MODEL: HPV 90 + 90

1. ES valve (Engine sensing) OUTLINE

2. Front servo valve • These pump assemblies consist of two variable
3. Rear servo valve displacement swash-plate type pumps, two servo
4. Front main pump valve units, and impeller pump (built in between
5. Rear main pump the front main pump and the rear main pump), a
6. Control pump (BAR025) control pump and a relief valve.
7. Relief valve
8. Front servo valve assembly
9. Rear servo valve assembly

10-142 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

PISTON PUMP

1. Shaft (front) 9. Impeller Specification

2. Cradle (front) 10. Cradle (rear) Model : HPV 90 + 90
3. Case (front) 11. Shaft (rear) Rated delivery pressure: 34.3 MPa {350 kg/cm2}
4. Swash plate 12. Case (rear) Rated rpm : 2100 rpm
5. Shoe 13. End cap (rear) Theoretical delivery : front 97.4 cc/rev
6. Piston 14. End cap (front) rear 97.4 cc/rev
7. Cylinder block 15. Servo piston Max. delivery : 204.5 + 204.5 l/min
8. Valve plate

WD900-3 10-143
STRUCTURE AND FUNCTION MAIN PISTON PUMP

10-144 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

Serial No.: 50006 and up

MODEL: HPV95 + 95

1. ES valve (Engine sensing) OUTLINE

2. Front servo valve • These pump assemblies consist of two variable
3. Rear servo valve displacement swash-plate type pumps, two ser-
4. Front main pump vo valve units, and impeller pump (built in be-
5. Rear main pump tween the front main pump and the rear main
6. Control pump (BAR025) pump), a control pump and a relief valve.
7. Relief valve
8. Pump sub-assembly
9. Front servo valve assembly
10. Rear servo valve assembly
11. Impeller pump

10-146 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

PISTON PUMP

1. Shaft (front) SPECIFICATION

2. Cradle (front) Model : HPV 95 + 95
3. Case (front) Rated delivery pressure: 34.3 MPa {350 kg/cm2}
4. Swash plate Rated rpm : 2,100 rpm
5. Shoe Theoretical delivery : front 97.4 cc/rev
6. Piston rear 97.4 cc/rev
7. Cylinder block Max. delivery : 204.5 + 204.5 l/min
8. Valve plate
9. Impeller
10. Cradle (rear)
11. Shaft (rear)
12. Case (rear)
13. End cap (rear)
14. End cap (front)
15. Servo piston

WD900-3 10-147
STRUCTURE AND FUNCTION MAIN PISTON PUMP

10-148 WD900-3
STRUCTURE AND FUNCTION
FUNCTION
• The engine rotation and torque transmitted to
the pump shaft is converted into hydraulic ener-
gy, and pressurized oil is discharged according
to the load.
• It is possible to change the delivery amount by
changing the swash plate angle.
WD900-3
MAIN PISTON PUMP
STRUCTURE
• Cylinder block (7) is supported to shaft (1) by a
spline, and shaft (1) is supported by the front
and rear bearings.
• The tip of piston (6) is spherical, and shoe (5) is
caulked to it to form one unit. Piston (6) and
shoe (5) form a spherical bearing.
• Rocker cam (4) has plane surface A, and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
Rocker cam (4) brings high pressure oil at cylin-
drical surface B with cradle (2), which is secured
to the case, and forms a static pressure bearing
when it slides.
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• Cylinder block (7) seals the pressure oil to valve
plate (8) and carries out relative rotation. This
surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil in-
side each cylinder chamber of cylinder block (7)
is sucked in and discharged through valve plate
(8).
• Impeller (9) is connected to shaft (1) through the
spline boss (10) and rotates together with the
shaft. The oil sucked in through the suction port
is sent to the cylinder chamber by centrifugal
force to make suction easier.
10-149
STRUCTURE AND FUNCTION MAIN PISTON PUMP

OPERATION
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1),
and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves along
cylindrical surface B, so angle between cen-
ter line X of rocker cam (4) and the axial direc-
tion of cylinder block (7) changes. (Angle is
called the swash plate angle.)

1) Center line X of rocker cam (4) maintains swash

plate angle in relation to the axial direction of
cylinder block (7), and flat surface A moves as a
cam in relation to shoe (5). In this way, piston (6)
slides on the inside of cylinder block (7), so a dif-
ference between volume E and F is created
inside cylinder block (7). The suction and dis-
charge is equal to this difference E – F.
In other words, when cylinder block (7) rotates
and the volume of chamber E becomes smaller,
the oil is discharged during that stroke. On the
other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, the
oil is sucked in.

2) If center line X of rocker cam (4) is in line with

the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
umes E’ and F ’ ins ide cy linder bloc k ( 7)
becomes 0, so the pump does not carry out any
suction or discharge of oil.

10-150 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

2. Control of discharge amount

If swash plate angle becomes larger, the dif-
ference in volumes E and F becomes larger and
the discharge volume increases.
Swash plate angle is changed by servo piston
(15). Servo piston (15) moves in a reciprocal
movement ( ) in accordance with the com-
mand from the servo valve. This straight line
movement is transmitted through the rod of
rocker cam (4) to rocker cam (4), and rocker
cam (4), which is supported by the cylindrical
surface to cradle (10), slides in an oscillating
movement in direction ( ) along the cylindrical
surface.

WD900-3 10-151
STRUCTURE AND FUNCTION MAIN PISTON PUMP

CONTROL PUMP (BAR025)

1. Collar SPECIFICATION
2. Body Model : BAR 25
3. Housing Theoretical delivery : 25 cc/rev.
4. Drive gear Max. delivery pressure : 2.9 MPa {30 kg/cm2}
5. Driven gear

10-152 WD900-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP

RELIEF VALVE

1. Adjustment screw
2. Lock nut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring
6. Main valve

Set pressure: 2.9 MPa {30 kg/cm2}

(at 50 l/min)

FUNCTION
The relief valve is built in the body of control pump. It
relieves the oil delivered from the pump.

Flow of the oil

• Chamber A forms a pump circuit and chamber C
forms a tank drain circuit. The oil flows into
chamber B through the main relief valve orifice
to keep the chamber filled.
Pilot valve is set in the valve seat.

• If the pressure in chamber B reaches the pilot

valve spring force (set pressure), the pilot valve
moves, allowing the oil in chamber B to flow into
chamber C. In addition, the oil flows from cham-
ber A to B through orifices.

• If the oil flows through the orifice of valve (6), a

differential pressure occurs between the cham-
bers A and B, moving valve (6) to the left. This
allows the oil in chamber A to flow into chamber
C.

WD900-3 10-153
STRUCTURE AND FUNCTION ES VALVE (Engine sensing valve)

ES VALVE (Engine sensing valve)

1. Plug
2. Valve body
3. Shaft
4. Plug
5. Plug
6. Spool
7. Spool
8. Plug
9. Plug

10-154 WD900-3
STRUCTURE AND FUNCTION ES VALVE (Engine sensing valve)

FUNCTION
• This valve acts to control the delivery amount of
the hydraulic pump to match the changes in the
engine speed.
• A variable displacement piston pump is used for
the hydraulic pump to save energy by reducing
the consumption of hydraulic pressure when the
engine is running at low speed. At the same
time, it is also used to increase the engine ac-
celeration from low speed.
For this reason, a pressure difference valve is
used to detect the engine speed by using a
pressure difference system. The delivery (deliv-
ery per rotation) is then adjusted to match the
engine speed.

OPERATION When the pilot pressure difference reaches

• Oil from the PPC pump passes through pres- point a
sure difference valve (1) and is sent to the PPC
valve. Pilot pressure from the inlet and outlet
ports (ports A and B) of the pressure differential
valve is supplied to the ES valve (2).
The difference in pilot pressure becomes larger
as the flow from the PPC pump increases (in
other words, as the engine speed increases).
When the pilot pressure difference reaches
point a (0.12 MPa {1.24 kg/cm 2}), the ES valve
starts to operate, and actuates the servo valve
and servo cylinder to change the swash plate
angle of the pump.
When the swash plate angle is changed, the pis-
ton stroke also changes to change the delivery
of the pump (delivery per rotation).
Until the difference in pilot pressure reaches
0.31 MPa {3.2 kg/cm2}, the pump delivery (deliv-
When the pilot pressure difference reaches
ery per rotation) increases in proportion with the
point b
increase in the difference in pilot pressure (in
other words, the increase in the engine speed).
When the difference in pressure reaches 0.31
MPa {3.2 kg/cm 2 }, the pump delivery (delivery
per rotation) reaches the maximum.

WD900-3 10-155
STRUCTURE AND FUNCTION SERVO VALVE

SERVO VALVE

1. Sleeve
2. Body
3. Spool
4. Arm
5. Plug
6. Sleeve
7. Spool
8. Plug

10-156 WD900-3
STRUCTURE AND FUNCTION
OPERATION
1. Increasing of delivery amount (swash plate angle changes to the right)
• Input signal pressure Pi acts on chamber E in
the control piston from port D. Pressure Pc in
the charging pump is guided into port B.
• If input signal pressure Pi is raised a little, the oil
pressure acting on chamber E will increase ac-
cordingly. Control piston (9) therefore moves to
a position (rightward) where the force of spring
(10) is in balance with the oil pressure in cham-
ber E, thus allowing arm (4) to swing rightward
with servo piston (11) serving as the supporting
point. As a result, guide spool (12) moves to the
right.
WD900-3
SERVO VALVE
• With the movement of guide spool (12), port B
and port A connect to each other, allowing oil
pressure Pc, in the control pump to act on
chamber F in servo piston (11). Servo piston
(11) is then pushed rightward, increasing the
swash plate angle of the main piston pump.
Thus, the pump discharge is increased.
• Since arm (4) turns counterclockwise on pin
(13), guide spool (12) moves leftward, causing
port B, port C and drain port A to close. The
pump discharge, therefore, increases with the
change in input signal pressure Pi.
10-157
STRUCTURE AND FUNCTION
2. Decreasing of delivery amount (swash plate angle changes to the left)
• Next, let’s examine the case where servo piston
(11) is moved leftward. Assume that the servo
piston is in a balanced position at a certain loca-
tion. If Pi is decreased, control piston (9) moves
to a position where the oil pressure in chamber
E balances with the force of spring (10). Then,
arm (4) swings leftward, using servo piston (11)
as a support point, and cause, guide spool (12)
to move leftward.
10-158
SERVO VALVE
• With the movement of guide spool (12), port B
and port A are shut off and port A becomes
open to the drain.
On the other hand, port B and port C are con-
nected to each other, allowing the oil to flow into
chamber H in the servo cylinder. Servo piston
(11) is then pushed leftward by the force of
spring (14), decreasing the swash plate angle of
the main piston pump. Thus, the pump dis-
charge is decreased.
• Since arm (4) rotates clockwise on pin (13),
guide spool (12) moves rightward, shutting off
port B, port C and port A. The pump discharge,
therefore, decreases with the change in input
signal pressure Pi.
WD900-3
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)

PPC VALVE (Proportional pressure valve)

10-160 WD900-3
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)

P : From pump 1. Bolt 6. Center spring

T : To tank (drain) 2. Piston 7. Metering spring
P1 : To boom cylinder (Raise) 3. Plate 8. Valve
P2 : To bucket cylinder (Dump) 4. Collar 9. Body
P3 : To boom cylinder (Lower) 5. Retainer
P4 : To bucket cylinder (Tilt)

WD900-3 10-161
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)

OPERATION
1. Control lever at “neutral” (Fig. 1):
Ports PA1, P2, PB1 and P4 are connected to
drain chamber D through fine control hole f in
spool (10).

(Fig. 1)
2. Control lever operated slightly (fine control)
(Fig. 2):
When piston (4) starts to be pushed by plate (2),
retainer (7) is pushed. Valve (10) is also pushed
by spring (9) and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time
it is connected to pump pressure chamber PP,
and the pilot pressure of the control valve is sent
through fine control hole f to port P2 and PA1.
When the pressure at port P2 rises, valve (10) 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 P2 escapes to drain chamber
D.

Valve (10) moves up and down until the force of

spring (9) is balanced with the pressure of port
P2.
The position of valve (10) and body (11) (when
fine control hole f is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (10)
contacts the bottom of piston (4).
Therefore, spring (9) is compressed in propor-
tion to the travel of the control lever, so the pres-
sure at port P2 also rises in proportion to the
travel of the control lever. The spool of the con- (Fig. 2)
trol valve moves to a position where the pres-
sure of port PA1 (same as pressure at port P2)
and the force of the return spring of the control
valve are balanced.

10-162 WD900-3
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)

3. Control lever moved back from slightly oper-

ated position to neutral (Fine control) (Fig. 3):
When plate (2) starts to be pushed back, piston
(4) is pushed up by a force corresponding to the
force of centering spring (8) and the pressure at
port P2.
At the same time, fine control hole f of valve (10)
is connected to drain chamber D, so the oil at
port P2 escapes.
If the pressure at port P2 drops too far, valve
(10) is pushed down by spring (9). Fine control
hole f is shut off from drain chamber D, and at
almost the same time it is connected to pump
pressure chamber PP. The pump pressure is
supplied until the pressure at port P2 return to a
pressure equivalent to the position of the lever.
When the spool of the control valve returns, the
oil in drain chamber D flows in from fine control
hole f’ of the valve which has not moved. The
extra oil then flows through port P4 to chamber
PB1.

(Fig. 3)

4. Control lever operated to end of travel

(Fig. 4):
Plate (2) pushes piston (4) down, and piston (4)
forcibly pushes in valve (10).
Fine control hole f is shut off from drain chamber
D, and is connected to pump pressure chamber
PP.
Therefore, pressure oil from the charging pump
passes through fine control hole f, and flows
from port P2 to chamber PA1 to push the spool
of the control valve.
The oil returning from chamber A2 flows from
port PB1 through fine control hole f’ to drain
chamber D.

(Fig. 4)

WD900-3 10-163
STRUCTURE AND FUNCTION PPC RELIEF VALVE

PPC RELIEF VALVE

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw

Set pressure: 3.7 MPa {38 kg/cm2}

FUNCTION
• The PPC relief valve is between the PPC pump
and the PPC valve. When the PPC valve is not
being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and cir-
cuit from damage. (Sets maximum pressure in
the circuit).

OPERATION
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit.
The oil passes through the orifice of main valve
(1) and fills port B. Pilot poppet (3) is in close
contact with valve seat (2).

• If the pressure at ports A and B reach the pres-

sure set by the poppet spring, pilot poppet (3)
opens and the pressure oil at port B flows
through port D to port C. As a result, the pres-
sure at port B drops.

• If the pressure at port B drops, a pressure differ-

ence is generated between ports A and B due to
the orifice in main valve (1). Main valve (1) is
pushed open by the pressure at port A, and the
oil at port A is relieved.

10-164 WD900-3
STRUCTURE AND FUNCTION ACCUMULATOR (For PPC valve)

ACCUMULATOR (For PPC valve)

1. Cap
2. Nut
3. Body
4. Bladder
5. Oil port
6. Nut

SPECIFICATIONS
Type of gas : Nitrogen gas
Gas amount : 3,000 cc
Max. actuation pressure : 2.9 MPa {30 kg/cm2}
Min. actuation pressure : 1.2 MPa {12 kg/cm2}

FUNCTION
• The accumulator is installed between the hy-
draulic pump and PPC valve. An inflatable blad-
der is filled with nitrogen gas, and the
compressibility is used to store the pressure of
the oil. As a result, the boom and bucket can be
lowered under their own weight even after the
engine has been stopped.

OPERATION
• After the engine stops, when the PPC valve is a
NEUTRAL, chamber A (volume of nitrogen gas:
3,000 cc) inside the bladder is compressed by
chamber B.

• When the PPC valve is operated, the pressure

in chamber B drops below 2.9 MPa {30 kg/cm2}
and the pressure of the nitrogen gas in chamber
A makes the bladder expand. The actuating
pressure is 1.2 to 2.9 MPa {12 to 30 kg/cm2}.

WD900-3 10-165
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

MAIN CONTROL VALVE

Serial No.: 50001 – 50005 *1. For serial No. 50004 and up

1. Main relief valve PA1: From PA1 of PPC valve

2. Tilt and pitch spool return spring PA2: From PA2 of PPC valve
3. Lift spool return spring PB1: From PB1 of PPC valve
4. Lift spool PB2: From PB2 of PPC valve
5. Tilt and pitch spool A1 : To Tilt and pitch cylinder bottom side
6. Body A2 : To Lift cylinder rod side
7. Suction valve B1 : To Tilt and pitch cylinder rod side
8. Unloader valve B2 : To Lift cylinder bottom side
9. Float selector valve P : Pump port
10. Safety valve (with suction) P1 : From PA2 of PPC valve
P2 : From PB2 of PPC valve
T : Drain port (to hydraulic tank)

10-166 WD900-3
STRUCTURE AND FUNCTION
FUNCTION
• The two main control valves control the actua-
tion of the lift and the blade in the hydraulic sys-
tem. It has a tandem circuit which gives priority
to the blade circuit.
• The oil from the pump enters port P. The maxi-
mum pressure is set by main relief valve (1).
The oil passes through the bypass circuit of
blade spool (5) and lift spool (4). It then flows
from port T to the drain circuit, passes through
the filter and returns to the tank. If the blade and
lift spools are actuated, the oil flows to the blade
and lift cylinders.
WD900-3
MAIN CONTROL VALVE
*1. For serial No. 50004 and up
However, the circuit gives priority to the blade,
so when the blade spool is being operated, even
if the lift spool is operated, the tilt will not move.
• There are two safety valves (with suction valves)
(10) to protect the circuit if abnormal pressure is
generated in the blade circuit. If one of the two
safety valves is acting as a relief valve, the other
valve acts as a suction valve to make up any
lack of oil.
10-167
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

Serial No.: 50006 and up

1. Main relief valve PA1: From PA1 of PPC valve

2. Tilt and pitch spool return spring PA2: From PA2 of PPC valve
3. Lift spool return spring PB1: From PB1 of PPC valve
4. Lift spool PB2: From PB2 of PPC valve
5. Tilt and pitch spool A1 : To Tilt and pitch cylinder bottom side
6. Body A2 : To Lift cylinder rod side
7. Suction valve B1 : To Tilt and pitch cylinder rod side
8. Unloader valve B2 : To Lift cylinder bottom side
9. Float selector valve P : Pump port
10. Safety valve (with suction) P1 : From PA2 of PPC valve
P2 : From PB2 of PPC valve
T : Drain port (to hydraulic tank)

10-168 WD900-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

FUNCTION
• The two main control valves control the actua- • There are two safety valves (with suction valves)
tion of the lift and the blade in the hydraulic sys- (10) to protect the circuit if abnormal pressure is
tem. It has a tandem circuit which gives priority generated in the blade circuit. If one of the two
to the blade circuit. safety valves is acting as a relief valve, the other
• The oil from the pump enters port P. The maxi- valve acts as a suction valve to make up any
mum pressure is set by main relief valve (1). lack of oil.
The oil passes through the bypass circuit of
blade spool (5) and lift spool (4). It then flows
from port T to the drain circuit, passes through
the filter and returns to the tank. If the blade and
lift spools are actuated, the oil flows to the blade
and lift cylinders.
However, the circuit gives priority to the blade,
so when the blade spool is being operated, even
if the lift spool is operated, the tilt will not move.

WD900-3 10-169
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

RELIEF VALVE
Serial No.: 50001 – 50003

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

Set pressure: 31.4 MPa {320 kg/cm2}

FUNCTION
• The relief valve is installed at the inlet of the
main control valve. When the oil goes above the
set pressure, the relief valve drains the oil to the
tank. In this way, it sets the maximum pressure
in the hydraulic circuit and protects the circuit.

OPERATION
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil
passes through the orifice of main valve (1) and
flows to port B. Pilot poppet (3) is in close con-
tact with valve seat (2).
• When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of
pilot poppet spring (4), pilot poppet (3) opens,
and the pressurized oil from port B flows from
port D to port C, so the pressure at port B drops.
• When the pressure at port B drops, the orifice
effect of main valve (1) generates a difference in
pressure between port A and port B. The main
valve is pushed open and the oil from port A
passes through port C and flows to the drain cir-
cuit to release the abnormal pressure.

10-170 WD900-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

Serial No.: 50004 and up

1. Main valve
2. Piston
3. Piston spring
4. Poppet
5. Poppet spring
6. Plug with valve seat
7. Sleeve
8. Adjustment screw
9. Lock nut
10. Orifice

FUNCTION
• The relief valve is installed at the inlet of the
work equipment valve. When the oil pressure
rises above the specified level, this valve drains
the oil into the hydraulic tank to limit the maxi-
mum pressure of the work equipment circuit and
protect the circuit.

OPERATION
• Ports A and B are connected to the pump circuit
and drain circuit respectively. The oil pressure in
port A is applied through the hole of piston (3) to
port C.
• When the oil pressure is below the set relief
pressure, poppet (4) is in contact with the seat
of plug (6) and the oil does not flow from cham-
ber C into the drain circuit. Accordingly, the oil
pressure in port A is equal to that in chamber C.
• Since d2 < d3, main valve (2) is in contact with
the left side. The sectional areas are set in the
following order; d5 > d4 > d1 > d3 > d2.

• If the pump pressure is raised by spring (5) to

the relief pressure poppet (4) opens and the oil
in chamber C is drained through chamber D.
• If poppet (4) opens, the oil flows from A through
C to D.

• As the oil flows from A to C [hole through piston

(2)]. its pressure lowers. As a result, the pres-
sure in chamber C is lower than that in port A,
thus main valve (1) moves to the right.
• Then, the oil flows from port A to port B and lim-
its the maximum pressure to protect the circuit.

WD900-3 10-171
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

SAFETY VALVE (with suction valve)

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

Set pressure: 36.8 MPa {375 kg/cm2}

FUNCTION
• The safety valve (with suction valve) is in the
bucket cylinder circuit in the main valve. If shock
causes any abnormally high pressure in the cyl-
inder when the main valve is at neutral, the safe-
ty valve (with suction valve) releases the
abnormal pressure and protects the cylinder
from damage.
• This valve prevents generation of negative pres-
sure in the circuit.

OPERATION
As a safety valve
• Port A is the cylinder circuit and port B is the
drain circuit.
The pressure oil in port A flows to port D through
a hole in pilot piston (4). It also flows to port C
through an orifice consisting of the main valve
and pilot piston (4).
Pilot piston (4) is secured to the suction valve by
lock nut. The diameter of the cross section
(cross sectional area) gives a relationship of d2
> d1 > d3 > d4.

• If abnormally high oil pressure occurs in port A,

suction valve (1) is not actuated because of the
relationship d2 > d1.
However, because of the relationship d3 > d4 in
port A and C, the hydraulic pressure on main
valve (2) is equivalent to the area difference
between d3 and d4. If this pressure goes up to
the main valve spring force (set pressure), main
valve (2) is actuated, and the oil in port A flows
into port B.

10-172 WD900-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE

As a sunction valve
• If negative pressure is generated in port A, port
D also has negative pressure, because port D
and A are connected with each other. The tank
pressure in port B is applied to port E.
Hydraulic pressure a equivalent to the area dif-
ference between d2 and d1 is applied to the
safety valve because of the tank pressure in port
E. Therefore, hydraulic pressure e acts to open
the valve and hydraulic pressure a acts to close
suction valve (1).
• If the pressure in port A drops, (approaching
negative pressure) hydraulic pressure a be-
comes smaller than oil pressure e.
• When oil pressure e becomes larger than oil
pressure a + valve spring (5) force, suction valve
(1) opens, causing the oil to flow from port B into
port A. This prevents negative pressure from
building up in port A.

SUCTION VALVE

1. Main poppet
2. Sleeve
3. Spring

OPERATION
• If negative pressure is generated in port A
(boom cylinder rod end) (if the pressure is lower
than in port B in the tank circuit), main poppet
(1) opens because oil then flows from port B at
the tank end to port A at the cylinder port end.

WD900-3 10-173
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT

LUBRICATION OF WORK EQUIPMENT

1. Lift cylinder 8. Transmission A. Upper hinge pin

2. Front frame 9. Torque converter B. Lift cylinder bottom pin
3. Steering cylinder 10. Damper C. Lift cylinder rod pin
4. Pitch cylinder D. Tilt, pitch cylinder bottom pin
5. Tilt and pitch cylinder E. Tilt, pitch cylinder rod pin
6. Y-support F. Y-support pin
7. H-support G. H-support pin
H. Y-support pin
J. Steering cylinder pin (left)
K. Steering cylinder pin (right)

10-174 WD900-3
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT

L. Front axle support

M. Transmission trunnion
N. Rear axle support
P. Rear axle support

WD900-3 10-175
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

1. Y-support 5. Blade
2. Pitch cylinder 6. H-support
3. Frame 7. Lift cylinder
4. Tilt and pitch cylinder

10-176 WD900-3
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE

WD900-3 10-177
STRUCTURE AND FUNCTION CAB

CAB

1. Front glass
2. Front wiper
3. Door

10-178 WD900-3
STRUCTURE AND FUNCTION ROPS CANOPY

ROPS CANOPY

1. ROPS canopy
2. Cab

WD900-3 10-179
STRUCTURE AND FUNCTION AIR CONDITIONER

AIR CONDITIONER
AIR CONDITIONER PIPING

1. Air vent
2. Air vent
3. Condenser
4. Dry reservoir
5. Compressor
6. Air conditioner unit

10-180 WD900-3
STRUCTURE AND FUNCTION AIR CONDITIONER

AIR CONDITIONER COMPRESSOR

1. Refrigerant outlet port SPECIFICATIONS

2. Refrigerant inlet port Type : Piston pump type
3. Charge port on suction side Refrigerant used : R134a
4. Clutch
5. Relief valve

WD900-3 10-181
STRUCTURE AND FUNCTION AIR CONDITIONER

AIR CONDITIONER CONDENSER

1. Electric wiring
2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port

DRY RESERVOIR

1. Body
2. Drier
3. Filter

10-182 WD900-3
STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
OUTLINE
• The machine monitor system uses the sensors
and other devices installed to various parts of
the machine to observe the condition of the ma-
chine. It processes this information swiftly and
displays it on the monitor panel to inform the op-
erator of the condition of the machine.
• The machine monitor system consists of the
main monitor, maintenance monitor, sensors,
switches, relays, alarm buzzer, and power
source.
• The displays can be broadly divided into the fol-
lowing: Cautions displayed on the monitors (ab-
normalities in the machine where an alarm is
given) and normal conditions which are always
displayed on the instrument panel (pilot lamps
and readings for the gauges, speedometer, and
service meter).
WD900-3
MACHINE MONITOR SYSTEM
• There are also various switches built into the
monitor panel which function to operate the ma-
chine.
a The main monitor uses the network wiring to
send signals to the controller, and functions to
display the following information.
1) Shift indicator: 1st – 3rd, N, F, R
(F, R are optional)
(When auto shift, joystick steering are
installed)
2) HOLD (If equipped)
3) Failure action code, failure code, time
elapsed since failure (failure data display
mode)
10-183
STRUCTURE AND FUNCTION MAIN MONITOR

MAIN MONITOR

1. Check lamp OUTLINE

2. Caution lamp • The main motor has display function for the
3. Caution items speedometer and other gauges and a switching
3A. Emergency steering actuated function to control the electric components and
4. Pilot items controllers.
4A. Turn signal (left) • There is one CPU (Central Processing Unit) in-
4B. Turn signal (right) stalled internally, and this processes the signals
4C. Shift indicator from the sensors and outputs the display.
4D. Speedometer • A liquid crystal display and LEDs are used for
4E. Shift hold the display. The switches are embossed sheet
4F. Parking brake switches.
4G. Emergency steering normal
4H. Monitor pilop lamp (preheating, afterheating)
4I. Failure action code
5. Switches
5A. Auto grease switch
5B. Engine low idling switch
5C. Working lamp (front) switch
5D. Working lamp (rear) switch
5E. Transmission cut-off switch
5F. Auto shift, manual selector switch

10-184 WD900-3
STRUCTURE AND FUNCTION MAIN MONITOR

MAIN MONITOR DISPLAY FUNCTION

Display
Symbol Display item Display range Display method
category
When there is abnormality
Display flashes (for details, see MAINTE-
Check Check display on maintenance
NANCE MONITOR DISPLAY FUNCTION)
monitor
Emergency steer-
ing actuated (when
equipped with When actuated Display flashes
emergency
steering)
Caution Parking brake actuated,
Display flashes and buzzer sounds
transmission not at neutral
Caution When there is abnormality Display flashes (buzzer may also sound)
display on maintenance (for details, see MAINTENANCE MONI-
monitor TOR DISPLAY FUNCTION)

Turn signal
When operated Display lights up
(left, right)

Display lights up Buzzer sounds when

Parking brake When operated parking brake is applied and shift lever is
not at N
Emergency steer-
ing normal (when When normal (oil is flowing
Pilot equipped with emer-
Display lights up
in hydraulic circuit)
gency steering)

Lights up Lighting up time changes accord-

ing to engine water temperature when
Preheating When preheating
starting switch is turned ON (for details, see
PREHEATING CIRCUIT)

Shift hold
(Machine equipped When shift is held Display lights up
with auto shift)

Speed Digital display (display switches between

Travel speed 0 – 99 km/h
meter tachometer and speedometer)

Shift
Shift indicator 1–3N Digital display
indicator

When controller detects

failure and action by opera-
Digital display Buzzer sounds (For details
Failure Failure action tor is needed, CALL is dis-
of the travel data display mode, see TROU-
action code code played, or CALL and E TT
BLE DATA DISPLAY MODE)
(action code) are dis-
played in turn

F, R, display (when
Shift
equipped with joy- F, R Digital display
indicator stick steering)

WD900-3 10-185
STRUCTURE AND FUNCTION MAIN MONITOR

MAIN MONITOR SWITCH FUNCTION

Item Function Display Actuation

Lights up (goes out Auto-greasing control actuated (auto-

momentarily when matic greasing carried out at fixed inter-
switch is turned ON) val)
Forced greasing is carried out while
Auto-greasing switch is being pressed when display Flashes (slowly) Grease empty
is lighted up Abnormality in auto-greasing controller
Flashes (rapidly)
system
Goes out Auto-greasing controller not installed
Low idling speed set to approx. 850
Engine low idling speed is changed Lights up
Engine low rpm
between two stages each time switch
idling Low idling speed set to approx. 650
is pressed Goes out
rpm
Front working lamp lights up or goes Lights up Front working lamp lights up
Working lamp
out each time switch is pressed when
(front) Goes out Front working lamp goes out
side lamps are lighted up
Rear working lamp lights up or goes Lights up Rear working lamp lights up
Working lamp
out each time switch is pressed when
(rear) Goes out Rear working lamp goes out
side lamps are lighted up
Transmission cut-off function is actu- Lights up Cut-off function actuated
Transmission
ated or stopped each time switch is
cut-off Goes out Cut-off function stopped
pressed

Auto shift mode switches to manual Lights up Manual mode

Manual
mode when switch is pressed Goes out Auto shift mode

10-186 WD900-3
STRUCTURE AND FUNCTION MAIN MONITOR

TROUBLE DATA DISPLAY MODE

Item Switch operation Actuation

With engine stopped and starting switch turned All switch displays (LEDs) go out, and failure
ON, press 2nd switch from top on left side of main code is displayed on speedometer display and
monitor (switch below emergency steering dis- time elapsed since failure is displayed on failure
play) and working lamp (front) switch simulta- action code display.
neously for at least 5 seconds. 1) Failure code is a two-digit display given in
numbers or letters. The display for the failure
Method of now occurring flashes and the display for
switching to ON past failures lights up. If there is no failure,
trouble data CC is displayed (000 is displayed for time
display mode elapsed since failure)
2) The time elapsed since failure is to show
how long ago the failure occurred (the oldest
failure time is displayed. Any time greater
than 999H is displayed as 999H).
SDW00241
3) A maximum of 9 items are stored in memory
for the failure code.

Press working lamp (front) switch

Failure code and time elapsed since failure
change to next item.
ON

Method of Failure code

SPEED
sending failure x 100
RPM
code km/h
MPH Time elapsed
since failure

SDW01254
SDW00242

Press working lamp (rear) switch for at least 2

seconds

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

SDW00243

Press 2nd switch from top on left side of main

Resetting from
monitor (switch below emergency steering dis-
travel data Changes to normal display
play) and working lamp (front) switch simulta-
display mode
neously for at least 5 seconds, or start the engine.

WD900-3 10-187
STRUCTURE AND FUNCTION
MAINTENANCE MONITOR
1. Check items (Checks before starting)
1A. Engine coolant level
1B. Engine oil level
2. Caution items (warning items)
2A. Engine oil pressure
2B. Brake oil pressure
2C. Battery charge
2D. Air cleaner (L.H.)
2E. Air cleaner (R.H.)
2F. Transmission oil filter
3. Gauge items
3A. Fuel level
3B. Engine coolant temperature
3C. Torque converter oil temperature
4. Service meter
4A. Service meter numeric display
4B. Service meter RUN pilot lamp
5. Monitor module
6. Switch module
10-188
MAINTENANCE MONITOR
OUTLINE
• The maintenance monitor has a display function
for the caution items and gauges.
• The maintenance monitor consists of the moni-
tor module, switch module, service meter, case,
and other mechanisms.
• The monitor module has a built-in CPU (Central
Processing Unit). It processes the signal from
the sensors, and carries out the display and out-
put.
• A liquid crystal display and LEDs are used for
the display portions. The switches are em-
bossed sheet switches.
WD900-3
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 start-
ing switch is ON
Display when normal: OFF
Display when abnormal: Flashes
Check Engine oil level Below low level CHECK lamp flashes

Displays when engine is running

Above specified dif-
Transmission oil filter Display when normal: OFF
ferential pressure
Display when abnormal: Flashes

Engine coolant level Below low level

Displays when engine is running

Display when normal: OFF
Below specified pres-
Engine oil pressure Display when abnormal: Flashes
sure
CAUTION lamp flashes
Buzzer sounds
Below specified pres-
Brake oil pressure
sure

Engine coolant
Above 102°C Buzzer sounds if above 105°C
temperature

Caution
Torque converter oil
Above 120°C Buzzer sounds if above 130°C
temperature

Displays when engine is running

Display when normal: OFF
Fuel level Below low level
Display when abnormal: Flashes
CAUTION lamp flashes

When charge is
Battery charge Displays when engine is running
defective
Display when normal: OFF
Display when abnormal: Flashes
Above specified neg- CHECK lamp flashes
Air cleaner
ative pressure

Actuated when charge is normal

Service meter 0 – 9999.9h
Advances 1 for every hour
Service
meter
Service meter
— Lights up when service meter is running
indicator

WD900-3 10-189
STRUCTURE AND FUNCTION MAINTENANCE MONITOR

Display
Symbol Display item Display range Display method
category

All lamps light up below applicable level

Fuel level
Flashes when level is 1

One place lights up to show applicable

Engine coolant
Gauges level
temperature
Flashes when level is 6 or 7

One place lights up to show applicable

Torque converter oil
level
temperature
Flashes when level is 6 or 7

10-190 WD900-3
STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
FUNCTION
• There is a neutral safety circuit which prevents
the engine from being started if the directional
lever is not at the N portion. This is to ensure
safety when starting the engine.
• It is possible to start or stop the engine by turn-
ing the starting switch ON or OFF. An electrical
fuel-cut device (stop motor) is installed which
improves the ease of operation.
OPERATION
• When the directional lever is placed at N posi-
tion, the neutral contacts of the directional lever
switch are closed. In this condition, if the starting
switch is turned to the START position, electric
current flows as follows.
• ¥Electric current flows from the battery (+) o
starting switch terminal B o starting switch ter-
minal C o neutral relay terminals 5 – 3 o start-
ing motor terminal C o starting motor terminal E
o ground.
WD900-3
ENGINE STARTING CIRCUIT
• At the same time, electric current flows from
starting switch terminal BR o battery relay coil
o ground, and the switch of the battery relay
coil is closed.
• Electric current flows from the battery (+) o
starting switch terminal B o starting switch ter-
minal BR o engine stop motor relay coil o
ground. Electricity then flows in engine stop mo-
tor relay contacts (5) and (3).
When this happens, electricity flows from the
battery (+) o engine stop motor terminal B o
engine stop motor terminal P2 o engine stop
motor relay o engine stop motor terminal A o
ground. The engine stop motor is actuated, and
the fuel cut-off is canceled. A circuit is formed
from the battery (+) o battery relay o starting
motor terminal B, so the engine starts.
• If the directional lever is not at the N position,
the neutral relay is not actuated, so the circuit is
not formed and the engine does not start.
10-191
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT

ENGINE STOP CIRCUIT

OPERATION
• When the starting switch is turned OFF, current
stops flowing to the coil of the engine stop motor
relay. No electric current flows, so the continuity
between engine stop relay contact (3) and (5) is
shut off, and the circuit between contacts (3)
and (6) becomes continuous.
• When this happens, current flows from battery
(+) o engine stop motor terminal B o engine
stop motor terminal P1 o engine stop motor re-
lay (contact 3 and 6) o engine stop motor termi-
nal A o ground connection. When current flows
in the above circuit, the fuel supply is cut, and
the engine stops.

10-192 WD900-3
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL

ELECTRICAL TRANSMISSION CONTROL

1. Transmission cut-off selector switch 6. Maintenance monitor 11. Speed sensor

2. Parking brake switch 7. Relays 12. Transmission cut-off switch
3. Directional lever 8. Fuse boxes 13. Brake valve (left)
4. Speed lever 9. Transmission controller 14. Brake valve (right)
5. Kick-down switch 10. Transmission control valve

FUNCTION
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range
3 Kick-down switch
4 Transmission cut-off function
Transmission cut-off selector
5
function
6 Neutralizer
7 Neutral safety function
8 Warning function
Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch without
using the speed lever. If directional lever is operated to R or N, speed range
automatically returned to 2nd.
Transmission is shifted to neutral when brake is operated.
(Serial No.: 50001 – 50006: Right and left brake pedals
Serial No.: 50007 and up: Left brake pedal)
It is possible to select whether to actuate or not actuate the transmission cut-off
function. In this way, it is possible to obtain the same or greater ease of opera-
tion as on conventional loaders with the left brake when carrying out scooping
work or when loading or unloading the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking brake
applied, the transmission is shifted to neutral when the parking brake is applied.
If the directional lever is not at the N position, the engine will not start when the
starting switch is turned. This prevents the machine from starting suddenly. (For
details, see STARTING CIRCUIT.)
When traveling in reverse, the backup lamp lights up and the backup horn
sounds to warn people in the area.

WD900-3 10-193
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL

COMBINATION SWITCH

OUTLINE
• The directional lever has three positions and the
speed lever switch has three positions. As an
individual part, the switch does not have a
detent mechanism; the detent mechanism is in
the combination switch. Each switch is posi-
tioned by two pins, and is secured to the body
by three screws. When each lever is operated to
the desired position, the switch, which is inter-
connected by a shaft, acts to allow electric cur-
rent to flow to that circuit only.

General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd during opera-
3 Speed lever stopper
tions
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 same
8 Hazard switch
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

10-194 WD900-3
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL

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
IC (4) is positioned on the board to match each R
2
position.
• When directional lever (1) is operated to the F 1
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 mag-
netism detection circuit, so it detects the magne- 3
tism of magnet (3) and sends the F position
signal to the electric current amplification circuit. 4
6
In the electric current amplification circuit, a sig-
nal is output to actuate the transmission. 5
SEW00302

WD900-3 10-195
STRUCTURE AND FUNCTION BLADE CONTROL SWITCH (KICK-DOWN, HOLD SWITCH)

BLADE CONTROL SWITCH (KICK-DOWN, HOLD SWITCH)

1. Work equipment control lever

2. Hold switch
3. Tilt or pitch switch
4. Kick-down switch
5. Switch

1. KICK-DOWN SWITCH 3. TILT or PITCH SWITCH

When the speed control lever is in 2nd, and the This switch is used for PITCH operation of the
switch at the top of the blade control lever knob blade.
is pressed, the gear will shift down to 1st. To operate the blade to pitch, keep to press
down switch (4) and operate the blade control
This switch is used to increase the drawbar pull lever.
in digging operations. (When not pressing down the switch, the lever
works for TILT operation.)
2. HOLD SWITCH (Machine equipped with auto
shift)
To fix the gear shift range when using automatic
gear shifting, press the switch at the top of the
blade control lever knob. The speed range dis-
played on the transmission indicator on the main
monitor is fixed, and the HOLD display lights up.
If the switch is pressed again, the HOLD func-
tion is canceled and the display goes out
Use this function to set to the desired speed
range when traveling uphill or downhill, or when
carrying out grading.

10-196 WD900-3
STRUCTURE AND FUNCTION JOYSTICK STEERING SYSTEM

JOYSTICK STEERING SYSTEM

1. Joystick
2. Transmission and joystick steering controller
3. Proportional solenoid valve
4. Control pump
5. Stop valve
6. Steering demand valve
7. Steering cylinder

WD900-3 10-197
STRUCTURE AND FUNCTION JOYSTICK STEERING SYSTEM

1. Controller input signals

• Common signal input for shift down switch
(CN C5-5 terminal)
• Common signal input for hold/shift up switch
(CN C5-13 terminal)
Whether the joystick or the steering wheel is
in use is indicated by the above signals.

2. Up/down shift switch function

• Shift up switch: Normal shift up is output by
signal input
• Shift down switch: Normal shift down is out-
put by signal input
• Judgement of the input of the switch uses the
change in the ON/OFF condition of the sig-
nal.
(When the switch is pushed, it becomes ON
(GND).)
In addition, it always uses the latest signal to
judge shift up or down.
• The maximum speed range is set by the
transmission lever.

Range lever position Speed range used

3 3–1
2 2, 1
1 1

3. Main monitor display

10-198 WD900-3
STRUCTURE AND FUNCTION TRANSMISSION AND JOYSTICK STEERING CONTROLLER

TRANSMISSION AND JOYSTICK STEERING CONTROLLER

WD900-3 10-199
STRUCTURE AND FUNCTION TRANSMISSION AND JOYSTICK STEERING CONTROLLER

Connector signal

C1 C3A C4
Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 S/T SOL. cut relay Output 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — 2 Engine revolution sensor (+) Input
3 T/M 1 SOL. Output 3 S/T lever potentio meter Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
5 T/M 3 SOL. Output 5 NC — 5 NC —
6 GND Input Pressure sensor power sup- 6 NC —
6 Output
7 Power supply (+24V) Input ply 7 NC —
8 Back lamp relay Output 7 Potentio power supply Output 8 Flash write sig. Input
9 T/M R SOL. Output 8 NC — Engine rev./speed sensor (–
9 Output
10 T/M 2 SOL. Output 9 NC — )

11 NC — 10 Engine select Input 10 RS232C GND Input

12 GND Input 11 NC — 11 NC —

13 Power supply (+24V) Input 12 NC — 12 NC —

13 NC —
C2 C5
14 NC —
Pin Input/ Pin Input/
Name of signal 15 NC — Name of signal
No. output No. output
16 GND (for pressure sensor) Output
1 SOL. power supply (+24V) Input 1 GND (for Plus) Output
17 GND (for potentio) Output
2 S/T RH SOL. (+) Output 2 Speed sensor (+) Input
18 NC —
3 S/T LH SOL. (+) Output 3 GND Output
19 Neutralizer relay Input
4 F LED (S/T) Output 4 GND Output
20 Auto shift T/M option Input
5 R LED (S/T) Output Kick down SW/Shift down
5 Input
C3B SW
6 NC —
6 T/M cut off switch Input
7 N LED (S/T) Output Pin Input/
Name of signal 7 Joystick N (NC) Input
8 Neutral safety output (+) Output No. output
1 Joystick S/T Input 8 Joystick F (NC) Input
9 Caution relay (S/T) (+) Output
2 Machine select 1 Input 9 Joystick R (NC) Input
10 Caution (monitor) (+) Output
3 Machine select (EVEN parity) Input 10 GND (for Plus) Output
11 PGND Input
4 S-NET + Input 11 S/T lever neutral switch Input
12 SOL. power supply (+24V) Input
5 Direction F Input 12 NC —
13 S/T RH SOL. (–) Output
6 Direction R Input 13 Hold SW/ Shift up SW Input
14 S/T LH SOL. (–) Output
7 Range SW1 Input 14 Manual SW Input
15 NC —
8 Range SW3 Input 15 Joystick N (NO) Input
16 NC —
9 NC — 16 Joystick F (NO) Input
17 NC —
10 Machine select 2 Input 17 Joystick R (NO) Input
18 Neutral safety output (–) Output
19 Caution relay (S/T) (–) Output 11 NC — Joystick System Functional
20 NC — 12 S-NET + Input Selection Table
21 PGND Input 13 Direction N Input Engine
OFF ON
14 Joystick ON/OFF switch Input Pin
Machine Select Table 15 Range SW2 Input C3B-1 OPEN GND
Machine 16 Range SW4 Input
WD900-3 GND: Connect GND.
Pin
OPEN: Disconnect.
C3B-2 GND Automatic T/M Functional Selection
Table
C3B-10 GND Engine Selection Table
C3B-3 GND Machine
OFF ON Engine
Pin KOMATSU CUMMINS
Pin
GND: connect GND.
C3A-20 OPEN GND
OPEN: Disconnect. C3A-10 OPEN GND
GND: Connect GND. GND: Connect GND.
OPEN: Disconnect. OPEN: Disconnect.

10-200 WD900-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

ELECTRIC PARKING BRAKE CONTROL

OUTLINE
• When electric current flows to the parking brake 1. Parking brake display switch
valve (solenoid valve), the hydraulic pressure 2. Parking brake switch
from the accumulator is applied to the spring cyl- 3. Accumulators
inder to release the parking brake. 4. Emergency brake switch
On the other hand, if the electric current is 5. Low pressure switch
turned off, the oil pressure from the accumulator 6. Spring cylinders
is cut off, so the oil pressure inside the spring 7. Parking brake solenoid valve
cylinder passes through the parking brake valve 8. Neutralizer relay
and is drained, the parking brake is actuated by 9. Parking safety relay
the force of the spring.

WD900-3 10-201
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

FUNCTION
1. Applying and releasing parking brake
The parking brake is applied or released by using the parking brake switch (combination switch).

2. Emergency brake
If there is damage to the hydraulic circuit, and the pressure inside the accumulator drops and it is impossi-
ble to guarantee the braking force of the brake, the parking brake is automatically applied to act as an emer-
gency brake.

3. Parking brake safety

It is dangerous if the parking brake can be released simply by turning the starting switch ON after the auto-
matic parking brake has been applied. Therefore, to ensure safety, the system is designed so the brake
cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned
ON.

4. Neutralizer
The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this
problem, the caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken oper-
ation. In addition to this, when the parking brake is applied, the transmission is forcibly shifted to neutral to
make it impossible to driven the machine. However, the braking distance will become longer if the transmis-
sion is shifted to neutral when the emergency brake is applied. It may also be necessary to move the
machine if it stops in places where it is prohibited to stop (such as on railway crossings). To overcome this,
the circuits is designed so that the transmission is not shifted to neutral when the emergency brake is
applied.

PARKING BRAKE SWITCH

10-202 WD900-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

PARKING BRAKE SOLENOID VALVE

PARKING SAFETY RELAY

NEUTRALIZER RELAY

Relay actuation table

Terminal No.
Electricity 3 6 5
between 1 and 2
OFF
ON

EMERGENCY BRAKE SWITCH

WD900-3 10-203
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

OPERATION
1. STARTING SWITCH OFF

• When the starting switch is turned OFF, the bat-

tery relay is opened, so electricity does not flow
to the parking brake circuit. For this reason, if
the starting switch is at the OFF position, no
electric current flows to the parking brake sole-
noid valve, regardless of whether the parking
brake switch is ON (applied) or OFF (released),
so the parking brake is actuated.

10-204 WD900-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

2. STARTING SWITCH ON

2-1 When parking brake switch is ON (actuated) before starting switch is turned ON

• The electric current flows in circuit (1) from the

battery o starting switch o battery relay coil o
ground, so the battery relay is closed. When this
happens, electric current flows in circuit (2) from
the battery o battery relay o parking brake
switch terminal 1 – 3 o parking brake safety re-
lay terminal 1 – 2 o ground. In this way, the
parking safety relay is actuated and safety relay
terminals 3 – 5 are closed.
• When this happens, circuit (3) is formed from
the battery o battery relay o parking safety re-
lay terminal 5 – 3 o parking safety relay termi-
nal 1 – 2 o ground. From this point, the parking
safety relay is in the condition of circuit (3) until
the starting switch is turned OFF.
• In this condition, electric current does not flow to
the parking brake solenoid valve, so the parking
brake is actuated.
• In addition, in this condition, the trans-mission is
shifted to neutral by transmission controller.

WD900-3 10-205
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

2-2 When parking brake switch is OFF (released) before starting switch is turned ON

• Electric current flows in circuit (1) from the bat-

tery o starting switch o battery relay coil o
ground, so the battery relay is closed. However,
in this case, the parking brake switch is OFF (re-
leased), so the parking safety relay is not actuat-
ed. For this reason, the electric current does not
flow to the parking brake solenoid valve, so after
the automatic parking brake is applied, the park-
ing brake is not released automatically even
when the starting switch is turned ON.
• In addition, the electric current does not flow to
the transmission controller, so the machine does
not move.

10-206 WD900-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

3. PARKING BRAKE SWITCH OFF (RELEASED)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON

• If the parking brake switch is turned from ON

(actuated) to OFF (released), the circuit for ter-
minals 2 and 3 of the parking brake switch is
connected, and the parking brake safety relay is
also actuated. For this reason, electric current
flows in circuit (1) from the battery (+) o battery
relay o parking brake safety relay o parking
brake switch, and then flows to circuit (2).
(2) This circuit is formed from the emergency
brake switch o parking brake solenoid valve o
ground, and the parking brake is released.
• In addition, a signal is sent at the same time
from terminal 3 of the neutralizer relay to the
transmission controller to make it possible to
travel.

WD900-3 10-207
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

4. PARKING BRAKE SWITCH ON (ACTUATED)

• If the parking brake switch is turned ON (ap-

plied) after carrying out operations with the park-
ing brake switch OFF (released), the circuit in
the diagram above is formed.
• Electric current does not flow to the parking
brake solenoid valve, so the oil pressure from
the accumulator to the spring cylinder is shut off.
At the same time, the oil pressure inside the
spring cylinder passes through the parking
brake valve and is drained, so the parking brake
is applied by the force of the spring.
• In addition, at the same time, the neutralizer re-
lay is reset, so the circuit between terminals 3
and 5 is opened, and no electricity flows to the
transmission directional circuit, so the transmis-
sion is shifted to neutral.
As a result, the signal from terminal 3 to the
transmission controller is cut and the transmis-
sion is shifted to neutral.
In this way, the transmission is shifted to neutral
when the parking brake is applied. This makes it
impossible for the machine to travel with the
parking brake applied, and prevents the parking
brake from seizing.

10-208 WD900-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL

5. WHEN MAIN BRAKE OIL PRESSURE DROPS (EMERGENCY BRAKE ACTUATED)

• If the accumulator pressure drops, the emergen-

cy brake switch installed to the accumulator is
opened.
For this reason, the electric current stops flowing
to the parking brake solenoid valve, so the oil
pressure inside the spring cylinder is drained
and the parking brake is applied.
However, in this case, the condition is different
from the case where the parking brake switch is
ON (applied), because there is electric current
flowing to the neutralizer relay coil.
• For this reason, a signal is sent to the transmis-
sion controller, and it is possible to engage the
transmission clutch. In this way, it is possible to
use the engine brake when the emergency
brake is applied, so the braking distance be-
comes shorter. At the same time, if the emer-
gency brake has been applied and it is
necessary to move the machine (for example, if
the emergency brake is applied when the ma-
chine is on a railway crossing), it is possible to
move the machine by operating the transmis-
sion lever.

WD900-3 10-209
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

BRAKE COOLING SYSTEM

Serial No.: 50007 and up

BRAKE COOLING CIRCUIT *1: For Serial No. 50007 – 50008

WD900-3 10-211
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

ELECTRICAL CIRCUIT
Serial No.: 50007 – 50008

10-212 WD900-3
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

Serial No.: 50009 and up

WD900-3 10-213
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

BRAKE COOLING PIPING

1. Oil filter (Rear) 9. Oil cooler (Front)

2. Brake cooling pump (Front) (SBL(1)24) 10. Oil cooler (Rear)
3. Brake cooling pump (Rear) (SBR(1)24) 11. Rear axle
4. Fan switch (Rear) (Serial No. 50007 – 50008) 12. Front axle
5. Brake cooling oil temperature caution switch (Rear) 13. Relief valve
6. Fan switch (Front) (Serial No. 50007 – 50008) 14. Cooling fan motor
7. Brake cooling oil temperature caution switch (Front) 15. Magnet box (Rear)
8. Oil filter (Front) 16. Magnet box (Front)

10-214 WD900-3
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

A. Front axle oil inlet (From oil cooler) F. Oil cooler (Front) oil outlet (To front axle)
B. Front axle oil outlet (To pump) G. Oil cooler (Rear) oil inlet (From oil filter)
C. Rear axle oil inlet (From oil cooler) H. Oil cooler (Rear) oil outlet (To rear axle)
D. Rear axle oil outlet (To pump) J. Oil filter inlet (From pump)
E. Oil cooler (Front) oil inlet (From oil filter) K. Oil filter outlet (To oil cooler)

WD900-3 10-215
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

COOLING FAN DRIVE PIPING

10-216 WD900-3
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

1. Switch pump + cooling fan pump A. Fan motor inlet port

2. Relief valve B. Fan motor return port
3. Fan motor C. From hydraulic oil cooler
4. Shaft D. To hydraulic tank
5. Cooling fan E. From hydraulic tank
6. Solenoid valve F. Pump suction port
(Serial No.: 50007 – 50008) G. Pump discharge port

WD900-3 10-217
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

COOLING FAN DRIVE CIRCUIT

Serial No.: 50007 – 50008

Serial No.: 50009 and up

10-218 WD900-3
STRUCTURE AND FUNCTION BRAKE COOLING SYSTEM

1. Hydraulic tank
2. Switch pump + cooling fan pump
3. Solenoid valve
(Serial No.: 50007 – 50008)
4. Relief valve
(Set pressure: 14.7 MPa {150 kg/cm2}
5. Fan motor
6. Oil cooler
7. Hydraulic oil filter
8. Hydraulic oil cooler
9. Cold relief valve

WD900-3 10-219
STRUCTURE AND FUNCTION 55°C SPECIFICATION

55°C SPECIFICATION

10-220 WD900-3
STRUCTURE AND FUNCTION 55°C SPECIFICATION

1. Additional torque converter oil cooler A. To additional torque converter oil cooler
2. Torque converter oil cooler (from torque converter)
3. Torque converter B. Additional torque converter oil cooler inlet port
4. Orifice plate C. Additional torque converter oil cooler outlet port
5. Fan drive motor D. From additional torque converter oil cooler
6. Relief valve E. To torque converter oil cooler
7. Fan drive pump (from torque converter)
F. From transmission
(to torque converter oil cooler)
G. To torque converter oil cooler
(from transmission)
H. Torque converter oil cooler inlet pot
J. Torque converter oil cooler outlet port
K. To transmission
(from torque converter oil cooler)

WD900-3 10-221
STRUCTURE AND FUNCTION 55°C SPECIFICATION

HYDRAULIC CIRCUIT DIAGRAM

1. Hydraulic tank 8. Torque converter

2. Switch pump + cooling fan pump 9. Orifice
3. Relief valve (14.7 MPa {150 kg/cm2} 10. Additional torque converter oil cooler
4. Cooling fan pump 11. Torque converter oil cooler
5. Hydraulic oil filter 12. Transmission lubrication
6. Torque converter + PPC + brake pump 13. Transmission case
7. Transmission

10-222 WD900-3
 20 TESTING AND ADJUSTING

Standard value table for engine ..................................................................................................................20- 2

Standard value table for chassis .................................................................................................................20- 3
Standard value table for electrical parts......................................................................................................20- 8
TESTING AND ADJUSTING ......................................................................................................................20- 101
TROUBLESHOOTING ................................................................................................................................20- 201

a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.

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

k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k 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.
k Be careful not to get caught in the fan, fan belt or other rotating parts.

WD900-3 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Mchine model WD900-3

Engine SA12V140-1

Cate- Standard value

Item Measurement conditions Unit Service limit value
gory for new machine

High idling 2,220 ± 50 2,220 ± 50

Engine speed Low idling rpm 650 +50 650 +50

–30 –30

Rated speed 2,000 2,000

Air supply pressure kPa

At rated output 133 {1,000} 106 {800}
(boost pressure) {mmHg}

Whole speed range

Exhaust temperature °C Max. 650 700
(ambient temperature: 20°C)

At sudden acceleration Max. 4.0 6.0

Bosch
Exhaust gas color
index
At high idling Max. 2.0 3.0

Intake valve 0.43 —

Valve clearance
mm
(normal temperature)
Exhaust valve 0.80 —

Oil temperature: 40 – 60°C

Compression pressure MPa Min. 3.14 2.2
(Engine speed:
(SAE30 oil) {kg/cm²} {Min. 32} {22}
160 – 200 rpm)
Engine

(Water temperature:
Blow-by pressure kPa 1.47 2.94
Operating range)
(SAE30 oil) {mmH2O} {150} {300}
Rated output

(Water temperature:
0.25 – 0.39 0.18
Operating range)
{2.5 – 4.0} {1.8}
At high idling (SAE30)

MPa Min. 0.12 0.07

Oil pressure At low idling (SAE30)
{kg/cm²} {Min. 1.2} {0.7}

Min. 0.10 0.07

At low idling (SAE10W)
{Min. 1.0} {0.7}

Oil temperature Whole speed range (oil pan) °C 80 – 110 120

Fuel injection timing Before top dead center deg. 29 ± 1 29 ± 1

Deflection of one belt when

Alternator belt tension pressed with finger force of mm 20 20 – 22
approx. 59 N {approx. 6 kg}

Deflection when pressed

Air conditioner
with finger force of approx. mm 9 – 12.5 16.5
compressor belt tension
98 N {approx. 10 kg}

20-2 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS

(*1): AJSS specification
(*2): Steering wheel specification

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
N o FORWARD, • Engine stopped 8.4 ± 1.0 8.4 ± 4.0
Transmission

REVERSE • Measure at end of switch {0.86 ± 0.1} {0.86 ± 0.4}

switch (*1)

Operating 5.0 ± 1.0 5.0 ± 2.0

Upshift N {kg}
effort • Engine stopped {0.5 ± 0.1} {0.5 ± 0.2}
• Measure at center of lever knob 5.0 ± 1.0 5.0 ± 2.0
Downshift
{0.5 ± 0.1} {0.5 ± 0.2}
Operating N–FORWARD, • Engine stopped
Directional

–4.9 –0.5
lever (*2)

N{kg} 5.9 –2.9 {0.6 –0.3 } 16.7 {1.7}

effort REVERSE • Hook push-pull scale to point a
and measure.
N–FORWARD,
Travel mm 35 ± 10 35 ± 20
REVERSE

1st – 2nd 5.9 –4.9 –0.5

–2.9 {0.6 –0.3 } 16.7 {1.7}
Operating
N{kg}
Speed control

effort –4.9 –0.5

lever (*2)

2nd – 3rd 5.9 –2.9 {0.6 –0.3 } 16.7 {1.7}

1st – 2nd 35 ± 10 35 ± 20
Travel mm
2nd – 3rd 35 ± 10 35 ± 20

HOLD o RAISE • Low idling Max. 23.5 {2.4} 35.3 {3.6}

• Hydraulic oil temperature:
Operating effort

Lift HOLD o LOWER 45 – 55°C Max. 24.5 {2.5} 37.2 {3.8}

LOWER o FLOAT • Hook push-pull scale to center Max. 34.3 {3.5} 51.9 {5.3}
Work equipment control lever

of lever knob and measure. N{kg}

HOLD o Right tilt • Measure maximum value. Max. 23.5 {2.4} 35.3 {3.6}
Pitch
and tilt HOLD o
Max. 23.5 {2.4} 35.3 {3.6}
Forward pitch
HOLD o RAISE • Low idling 67 ± 15 67 ± 30
• Hydraulic oil temperature:
Lift HOLD o LOWER 45 – 55°C 53 ± 15 53 ± 30
• Hook push-pull scale to center
Travel

LOWER o FLOAT mm 67 ± 15 67 ± 30
of lever knob and measure.
HOLD o Right tilt • Measure maximum value. 60 ± 15 60 ± 30
Pitch
and tilt HOLD o
60 ± 15 60 ± 30
Forward pitch
• Engine stopped
Play deg. Max. 8 Max. 10
• Machine facing straight to front
• Flat, level, straight, dry, and 13.7 ± 4.9
Operating effort N {kg} 23.5 {2.4}
paved road {1.4 ± 0.5}
AJSS lever

• Engine speed: High idle

Operating angle deg. 86 ± 5 Max. 95
• Left lock – right lock

Low idle • Engine started Max. 6.6 Max. 7.6

Operating • Hydraulic oil temperature:
sec.
time Within operating range
High idle Max. 3.5 Max. 4.5
• Left lock – right lock

WD900-3 20-3
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value

• Engine stopped
Play mm Max. 20 20
• Play in direction of turning

• Flat, horizontal, straight, dry

paved road surface
• Hydraulic oil temperature:
Steering wheel

45 – 55°C 9.8 – 14.7 9.8 – 14.7

Operating effort N{kg}
• Hook push-pull scale to steer- {1.0 – 1.5} {1.0 – 1.5
ing wheel knob and measure.
• Measure effort taken to turn
steering wheel.
• Hydraulic oil temperature:
Low idling 45 – 55°C Max. 6.8 6.8
Operating
• Flat, horizontal, straight, dry sec.
time
paved road surface
High idling Max.5.0 5.0
• Left lock – right lock
• Put push-pull scale in contact at
point 150 mm from pedal ful-
crum a, and measure maximum
Operating effort value to end of stroke. N{kg} 59 {6.0} 88 {9.0}
• Low idling
• Engine water temperature:
Within operating range
Accelerator pedal

• Engine stopped
Low idling ( 1) 52 —
Operating angle

deg.

High idling ( 2) 35 —

Stopper height (L) mm 58 —

• Put push-pull scale in contact at

point 150 mm from pedal ful-
crum a, and measure maximum
294 ± 29
Operating effort value to end of stroke. N{kg} 421 {43}
{30 ± 3}
• Engine started
• Hydraulic oil temperature:
45 – 55°C
Brake pedal

• Engine stopped
Operating angle

Neutral ( 1) 45 —

deg.

Maximum ( 2) 15 —

Play mm 5 ± 0.5 —

20-4 WD900-3
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
• Tire inflation pressure:
A Specified value Max. 2.5 —
Insertion of wheel lock
ring
Tire

B mm Max. 4.0 —

Clearance of wheel
C 20 – 35 —
lock ring

• Engine water temperature:

Torque converter stall 2,040 ± 50 2,040 ± 50
Engine speed

Within operating range

• Torque converter oil temperature:
Hydraulic stall 60 – 80°C rpm 2,200 ± 100 2,200 ± 200
• Hydraulic oil temperature:
Torque converter stall 45 – 55°C
1,800 ± 200 1,800 ± 200
+ hydraulic stall (full stall) • Speed control lever: F3

Transmission main • Torque converter oil +0.29 +3 +0.29 +3

2.75 +0 {28 +0 } 2.75 +0 {28 +0 }
relief valve pressure temperature: 60 – 80°C

• Engine: High idling

• Torque converter oil 1.03 ± 0.01 1.03 ± 0.01
Pilot reducing pressure
temperature: 60 – 80°C {10.5 ± 1.0} {10.5 ± 1.0}
Transmission, torque converter

Modulate pressure
2.45 +0.29
+0 {25 +3 +0.29
+0 } 2.45 +0 {25 +3
+0 }
(excluding F3, R3)

Torque converter inlet 0.69 ± 0.10 0.59 ± 0.20

port pressure {7 ± 1} {6 ± 2}
MPa
{kg/cm2}
Torque converter outlet 0.49 ± 0.10 0.49 ± 0.10
port pressure {5 ± 1} {5 ± 1}

0.14 ± 0.06 0.14 ± 0.06

Lubrication valve pressure
{1.4 ± 0.6} {1.4 ± 0.6}

Reducing valve pressure 1.96 ± 0.10 1.96 ± 0.10

(for F3, R3) {20 ± 1} {20 ± 1}

• Hydraulic oil temperature:

45 – 55°C MPa 31.36 +0.49
–0.39 31.36 +0.98
–0.78
Steering relief pressure
• Engine full {kg/cm2} +5
{320 –4 }
+10
{320 –8 }
Steering

• Steering is relieved.
• Engine started
Emergency steering • Hydraulic oil temperature: MPa 20.58 ± 0.49 20.58 ± 0.98
relief pressure 45 – 55°C {kg/cm2} {210 ± 5} {210 ± 10}
• Machine speed: 24 km/h

WD900-3 20-5
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
• Brake oil
pressure 5.88 +0.49
+0 5.88 +0.98
–0.49
Charge cut-in pressure warning +5 +10
• Engine speed: {60 +0 } {60 –5 }
Accumulator

lamp: When
Low idling goes out MPa
• Brake oil 2
• When oil {kg/cm }
temperature:
45 – 55°C pressure 9.8 +0.98
+0 9.8 +1.47
–0.49
Charge cut-out pressure turns from +10 +15
increasing to {100 +0 } {60 –5 }
decreasing
+0.2 +0.2
• Hydraulic oil temperature: 3.72 +0 3.72 –0.2
PPC valve source pressure
45 – 55°C
(Orbit-roll source pressure) +2 +2
• Engine speed: High idling {38 +0 } {38 –2 }
Blade RAISE, +0.2 +0.2
MPa
PPC

FLOAT, • Hydraulic oil temperature: 3.72 +0 3.72 –0.2

PPC valve 45 – 55°C {kg/cm2}
Blade TILT, {38 +2 {38 +2
output • Engine speed: High idling +0 } –2 }
PITCH
pressure • Work equipment control lever:
Blade Full operating 2.54 ± 0.05 2.54 ± 0.05
LOWER {26 ± 0.5} {26 ± 0.5}
• Tire inflation pressure:
Specified pressure
• Flat, horizontal, straight, dry
paved road surface
• Speed when applying brake:
20 km/h, braking delay: 0.1
Performance mm Max. 7.5 —
second
• Brake pedal operating effort:
Wheel brake

Specified operating effort

(373 N {38 kg})
• Transmission cut-off switch: ON
• Measure stopping distance.
• Engine stopped
• Compress by pump to 4.2 – 5.2
MPa Max. 0.49
Drop in brake pressure MPa {43 – 53 kg/cm2} —
{kg/cm2} {Max. 5.0}
• Measure drop in brake pressure
after 5 minutes
Disc wear • Measure piston stroke mm 40.7 ± 1.4 Max. 46.3
• Tire inflation pressure:
Specified pressure
Performance • Flat dry paved road with — Stopped —
Parking brake

1/5 (11°20’) grade

• Machine at operating condition

Pad thickness • Including back metal 31.7 12.7

mm
Pad clearance • Total of each end 1.06 ± 0.18 Max. 2.1

20-6 WD900-3
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
+0.98 +0.98
31.4 –0.29 31.4 –1.27
Oil pressure

Blade relief pressure • High idling +10 +10

• Hydraulic oil temperature: MPa {320 –3 } {320 –13 }
45 – 55°C {kg/cm2} +0.98
31.4 –0.29
+0.98
31.4 –1.27
Blade tilt relief pressure • Relieve only measuring circuit
{320 +10
–3 } {320 +10
–13 }

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

• Engine water temperature:

2.5 ± 0.3 3.2
Within operating range
Work equipment speed

• No load
• Steering: Straight

Blade speed sec.

LOWER

4.5 ± 0.5 6.0

Work equipment

• Full throttle
• Hydraulic oil temperature:
45 – 55°C
• Engine water temperature:
Within operating range Front pitch
At full stroke

3.9
• No load 3.0 ± 0.3
PITCH

Rear pitch
3.1
2.4 ± 0.3
Work equipment speed

Blade speed sec.

Right tilt
At full stroke

2.5
1.9 ± 0.3
TILT

Left tilt
2.2
1.7 ± 0.3

WD900-3 20-7
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

Machine model WD900-3

Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
• Hydraulic oil temperature:
45 – 55°C
• Stop engine, leave for 5 min-
utes, then measure for next 15
minutes.
Work equipment

• Blade raise position.

Hydraulic drift of blade

mm Max. 120 120
cutting edge

20-7-1 WD900-3
(4)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

STEERING WHEEL SPECIFICATION

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
2) Insert T-adapter.

Measure
Between C1 (7), (13) – chassis

voltage
C1 3) Turn starting
Power supply Between C2 (1), (12) – chassis
C2 switch ON.
20 – 30 V
Between C1 (7), (13) – (6), (12)
Between C2 (1), (12) – (11), (21)

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Power supply Between (6) – (17)

C3A 20 – 30 V 3) Turn starting
(for signal) Between (6) – chassis switch ON.
4) Turn parking brake
switch ON
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure

2) Insert T-adapter.
Transmission & Joystick steering controller

voltage

Parking brake Turn parking brake

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

If the condition is as shown in the table below, it is 1) Turn starting

resistance
Measure

normal. switch OFF.

TR1 2) Disconnect
Solenoid (1st)
(male) Between (1) – (6) 5 – 15 z
connectors.
Between (1), (6) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
resistance
Measure

normal. switch OFF.

TR1 2) Disconnect
Solenoid (2nd)
(male) Between (2) – (6) 5 – 15 z
connectors.
Between (2), (6) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
resistance
Measure

normal. switch OFF.

TR1 2) Disconnect
Solenoid (3rd)
(male) Between (3) – (6) 5 – 15 z
connectors.
Between (3), (6) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
resistance
Measure

normal. switch OFF.

TR1 2) Disconnect
Solenoid (F)
(male) Between (4) – (6) 5 – 15 z
connectors.
Between (4), (6) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
resistance
Measure

normal. switch OFF.

TR1 2) Disconnect
Solenoid (R)
(male) Between (5) – (6) 5 – 15 z
connectors.
Between (5), (6) – chassis Max. 1 Mz 3) Connect T-adapter.

20-8 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.

resistance
Measure
Engine speed E03 Between (1) – (2) 500 – 1,000 z 2) Disconnect
sensor (male) connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-
adapter.
Measure in AC range. 1) Turn starting
Controller

Measure
voltage
Engine speed switch OFF.
C4 Between (2) – (9) Min. 0.5 V
sensor 2) Insert T-adapter.
3) Start engine.
Adjust 1) Screw in until the tip of sensor contacts gear,
Engine speed
— then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure

BC01 Between (1) – (2) 500 – 1,000 z 2) Disconnect

Speed sensor
(male) connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-
adapter.
1) Screw in until the tip of sensor contact gear,
Adjust

then turn back 3/4 – 1 turn.

Transmission & Joystick steering controller

Speed sensor — —
2) Sensor should work normally when adjusted as
above.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Speed control lever 2) Disconnect
Measure

Speed
voltage

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

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Speed control lever 2) Disconnect
Measure

Speed
voltage

Between 20 – 30 V connectors.
control lever at 2nd
(15) – 3) Turn starting
(2nd) Speed control lever chassis switch ON.
Max. 1 V
not at 2nd
Controller

C3B
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Speed control lever 2) Disconnect
Measure

Speed
voltage

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

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Directional lever 2) Disconnect
Measure
voltage

Directional Between 20 – 30 V connectors.

at F
lever (F) (5) – 3) Turn starting
Directional lever chassis switch ON.
Max. 1 V
not at F

WD900-3 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.

Measure
2) Insert T-adapter.

voltage
Directional Directional lever
Between 20 – 30 V 3) Turn starting
lever (R) at R
(6) – switch ON.
Directional lever chassis Max. 1 V
Controller

not at R
C3B
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure 2) Insert T-adapter.
voltage
Directional Directional lever
Between 20 – 30 V 3) Turn starting
lever (N) at N
(13) – switch ON.
Directional lever chassis Max. 1 V
not at N

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
JS3
resistance
Measure

System cut-off 2) Disconnect

System cut-off (male) Between 17 – 30 V connectors.
switch JS4 switch ON
JS3(1) – 3) Connect T-
(female) System cut-off JS4(1) adapter.
Max. 1 V
switch OFF

If the condition is as shown in the table below, it is 1) Turn starting

Transmission & Joystick steering controller

normal. switch OFF.

resistance
Measure

Joystick R.H. L27 Between (1) – (2) 10 – 20 z 2) Disconnect

solenoid (male) connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-
adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure

Joystick L.H. L26 Between (1) – (2) 10 – 20 z 2) Disconnect

solenoid (male) connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-
adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance

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

Measure

Joystick JS5 connectors.

neutral (N) switch (male) Not at N Max. 1 z
3) Connect T-
At N adapter.
Min. 1 Mz
Between (1) – chassis

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
resistance
Measure

Joystick JS2 Between (1) – (2) 0 – 2 kz ± 20% 2) Disconnect

potentiometer (male) connectors.
Between (2) – (3) 2 kz ± 20% 3) Connect T-
Between (3) – (1) 0 – 2 kz ± 20% adapter.

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Between 2) Set joystick col-
Measure voltage

20 – 30 V umn to joystick
Continue pushing N (7) – (3)
Controller

Joystick lever position.

switch Between
neutral (N) C5 Max. 1 V 3) Turn joystick
(15) – (3) ON/OFF switch
switch
Between ON.
Max. 1 V
(7) – (3) 4) Insert T-adapter.
Not to push N switch
Between 5) Turn starting
20 – 30 V
(15) – (3) switch ON.

20-10 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Between 2) Set joystick col-

Measure voltage
20 – 30 V umn to joystick
Continue pushing F (8) – (3)
position.
Joystick lever switch Between
C5 Max. 1 V 3) Turn joystick
F switch (16) – (3) ON/OFF switch
Between ON.
Max. 1 V
(8) – (3) 4) Insert T-adapter.
Not to push F switch
Between 5) Turn starting
20 – 30 V
(16) – (3) switch ON.
Transmission & Joystick steering controller

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Between 2) Set joystick col-
Measure voltage

20 – 30 V umn to joystick
Continue pushing R (9) – (3)
position.
Joystick lever switch Between
C5 Max. 1 V 3) Turn joystick
Controller

R switch (17) – (3) ON/OFF switch

Between ON.
Max. 1 V
(9) – (3) 4) Insert T-adapter.
Not to push R switch
Between 5) Turn starting
20 – 30 V
(17) – (3) switch ON.

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Neutralizer Parking brake is

C3A 20 – 30 V 3) Start engine.
relay released Between
Parking brake is (19) – (17)
Max. 1 V
applied

If the condition is as shown in the table below, it is 1) Turn starting

System net- normal. switch OFF.
Measure

work (S-NET) 2) Insert T-adapter.

voltage

Between (4), (12) – chassis 4–8V 3) Turn starting

(Between T/M C3B
controller and switch ON.
main monitor)

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
2) Insert T-adapter.
Blade control lever

Between
Measure voltage

20 – 30 V 3) Turn starting
Continue pushing (7) – (3)
Controller

Blade pitch switch ON.

N switch Between
select switch Max. 1 V
(15) – (3)
N
Between
Max. 1 V
(7) – (3)
Not to push N switch
Between
20 – 30 V
(15) – (3)

WD900-3 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Between 2) Insert T-adapter.

Measure voltage
20 – 30 V 3) Turn starting
Kick-down Continue pushing (8) – (3)
switch & switch ON.
F switch Between
shift-down Max. 1 V
(16) – (3)
switch
Between
F switch Max. 1 V
(8) – (3)
Not to push F switch
Between
20 – 30 V
(16) – (3)

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Between 2) Insert T-adapter.
Measure voltage

20 – 30 V 3) Turn starting
Continue pushing (9) – (3)
switch ON.
Controller

Shift-up R switch Between

Max. 1 V
switch R (17) – (3)
Between
Max. 1 V
(9) – (3)
Not to push R switch
Between
20 – 30 V
(17) – (3)
Blade control lever

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Neutralizer Parking brake is

20 – 30 V 3) Start engine.
relay released Between
Parking brake is (19) – (17)
Max. 1 V
applied

System net- If the condition is as shown in the table below, it is 1) Turn starting
Measure

work (S-NET) normal. switch OFF.

voltage

(Between T/M 2) Insert T-adapter.

controller and Between (4), (12) – chassis 4–8V 3) Turn starting
main monitor) switch ON.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure

Normal condition Max. 1 z 2) Disconnect

Transmission L12 Between connectors.
cut-off switch (male) L.H. brake pedal is (1) – (2) 3) Connect T-
Min. 1 Mz
depressed adapter.

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Controller

Measure

2) Insert T-adapter.
voltage

Manual Manual switch

C5 Between Max. 1 V 3) Turn starting
switch at ON
(14) – switch ON.
Manual switch chassis 20 – 30 V
at OFF

20-12 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting

Measure
normal. switch OFF.

voltage
Power supply L05 Between (1), (2) – chassis 2) Insert T-adapter.
20 – 30 V 3) Turn starting
Between (1), (2) – (3) switch ON.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Engine running 2) Insert T-adapter.

Measure
voltage
Charge Between 28 ± 2 V
L05 (At above 1/2 throttle)
(Alternator) (5) – (3)
Starting switch ON Max. 1 V
* If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure

Engine water 2) Disconnect

E05 Normal temperature Between
temperature Approx. 2 kz connectors.
(male) (25°C) (1) –
sensor 3) Connect
5°C chassis Approx. 4 kz
T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Directional switch Directional lever

L05 20 – 30 V 3) Turn starting
(N) at N Between
switch ON.
Directional lever (8) – (3)
Max. 1 V
not at N
Main monitor

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Starting switch C L09 Starting switch

Between 20 – 30 V
terminal (male) START
(3) –
Starting switch chassis Max. 1 V
OFF or ON

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Measure
voltage

Starting switch C Start engine 20 – 30 V 2) Insert T-adapter.

terminal Between
Starting switch (4) – (3) Max. 1 V
OFF or ON

If the condition is as shown in the table below, it is 1) Turn starting

L05 normal. switch OFF.
(*1) 20 – 30 V 2) Insert T-adapter.
Starting switch ON
Measure

Between o1V
voltage

Preheating switch (19) – (3)

ON Starting switch OFF Max. 1 V
*1.Voltage changes only when water temperature
is below 0°C, and time taken to change differs
according to water temperature.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
(*1) 1 V o 2) Insert T-adapter.
Starting switch ON
Measure

Between
voltage

Preheating switch 20 – 30 V
L06 (4) – (16)
output Starting switch OFF Max. 1 V
*1.Voltage changes only when water temperature
is below 0°C, and time taken to change differs
according to water temperature.

WD900-3 20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.

Measure
voltage
Starting switch L09 2) Insert T-adapter.
Starting switch ON Between 20 – 30 V
BR terminal (male) (2) –
Starting switch OFF chassis Max. 1 V

If the condition is as shown in the table below, it is 1) Turn starting

Measure
normal. switch OFF.

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

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
resistance
Measure

Parking brake 2) Disconnect

Parking brake F13 Max. 1 z connectors.
indicator switch (male) switch ON Between
3) Connect
Parking brake (1) – (2)
Min. 1 Mz T-adapter.
switch OFF
Main monitor

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
resistance
Measure

Low idling select B01 Between (1) – (2) 19 – 23 z 2) Disconnect

solenoid (male) connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect
T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Directional switch Directional lever

Between 20 – 30 V 3) Turn starting
(F) at F
(7) – switch ON.
Directional lever chassis Max. 1 V
not at F
L08
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure

2) Insert T-adapter.
voltage

Directional switch Directional lever

Between 20 – 30 V 3) Turn starting
(R) at R
(8) – switch ON.
Directional lever chassis Max. 1 V
not at R

If the condition is as shown in the table below, it is 1) Turn starting

Measure

normal. switch OFF.

voltage

Power supply L18 Between (1), (2) – chassis 2) Insert T-adapter.

20 – 30 V 3) Turn starting
Between (1), (2) – (3) switch ON.
If the condition is as shown in the table below, it is 1) Turn starting
Maintenance monitor

normal. switch OFF.

resistance
Measure

Engine water Normal temperature Approx. 2) Disconnect

E04 connectors.
temperature (25°C) Between 40 kz
(male) 3) Connect
sensor (1) – (2) Approx. T-adapter.
130°C
1.7 kz

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
resistance
Measure

Torque converter Normal temperature Approx. 2) Disconnect

T02 connectors.
oil temperature (25°C) Between 40 kz
(male) 3) Connect
sensor (1) – (2) Approx. T-adapter.
130°C
1.7 kz

20-14 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
2) Disconnect
Float connectors.
Approx. 4 z 3) Drain fuel.

resistance
raised

Measure
R05 to stopper 4) Remove fuel
Fuel level sensor
(male) level sensor.
Float 5) Connect
lowered Approx. 85 z T-adapter.
to stopper

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
resistance
Measure

Radiator water G06 Water level normal Max. 1 z 2) Disconnect

Between
level sensor (male) connectors.
Water level low (1) – (2) Min. 1 Mz 3) Connect
T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Engine oil pressure 2) Disconnect
when engine running: terminal.
resistance

Min. 1 Mz
Measure

above 0.07 MPa 3) Start engine.

Engine oil
E09 {0.7 kg/cm2} Between
pressure sensor
Engine oil pressure (1) – (3)
Maintenance monitor

when starting switch

Max. 1 z
ON:above 0.03 MPa
{0.3 kg/cm2}

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
BC04 Accumulator 2) Disconnect
(male) pressure: connectors.
BC05 Max. 1 z 3) Connect
resistance

Min. 5.39 ± 0.49 MPa

Measure

Brake T-adapter.
(male) {55 ± 5 kg/cm2}
accumulator low Between
BC06
pressure switch Depress brake and (1) – (2)
(male)
lower accumulator
BC07
pressure to below Min. 1 Mz
(male)
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Engine running 2) Insert T-adapter.
Measure
voltage

Charge Between 28 ± 2 V 3) Start engine.

L18 (above half throttle)
(Alternator) (12) – (3)
Starting switch ON Max. 1 V
* If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure

Engine oil level 2) Disconnect

Engine oil level R02 Between Max. 1 z terminal.
sensor (male) normal
(1) –
Engine oil level chassis Min. 1 Mz
abnormal

WD900-3 20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
B08 If the condition is as shown in the table below, it is 1) Turn starting
(female) normal. switch OFF.

R.H.
B09 2) Disconnect

continuity
Between

Check
Air cleaner (male) Air cleaner normal Continuity connectors.
B09 (1) – B08(1)
clogging sensor B06 3) Start engine.
Air cleaner clogged Between No
(female) 4) Check sensor
L.H.
or engine stopped B07 (1) – B06 (1) continuity
B07 side connector
(male) by using tester.
If the condition is as shown in the table below, monitor panel is normal. 1) Connect
T-adapter.
Table 1 (CHECK lamp & CAUTION lamp)
s

Connector Monitor item Measurement Sensor

Display
No. (input connector) conditions signal input
Engine water level Engine stopped Flashing 15 – 20 V
((8) – (3)) Starting switch ON Lighted OFF Max. 1 V
Engine oil level Engine stopped Flashing 15 – 20 V
((13) – (3)) Starting switch ON Lighted OFF Max. 1 V
CHECK lamp & Engine oil pressure Flashing 15 – 20 V
Engine start
CAUTION lamp ((10) – (3)) Lighted OFF Max. 1 V
L18 Brake oil pressure Flashing 15 – 20 V
Engine start
(male) ((11) – (3)) Lighted OFF Max. 1 V
Transmission oil filter Flashing 15 – 20 V
Engine start
((16) – (3)) Lighted OFF Max. 1 V
Battery charge Flashing Max. 10 V
Engine start
((12) – (3)) Lighted OFF Min. 12 V
Maintenance monitor

Air cleaner Flashing 15 – 20 V

Engine start
((14), (15) – (3)) Lighted OFF Max. 1 V

Table 2 (Gauge) 1) Turn starting

s

Display level resisitance switch OFF,

Gauge display position then insert
(monitor panel input resistance)
Starting switch ON Starting switch OFF dummy
resistance or
Fuel level measure
gauge resistance of
L18 (male) sensor.
Measure 2) Turn starting
resistance switch ON and
between check display.
(6) – (3)

Engine water
temperature
Gauge gauge
L18 (male)
Measure
resistance
between
(4) – (3)

Torque
converter oil
temperature
gauge
L18 (male)
Measure
resistance
between
(5) – (3)

20-16 WD900-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
Maintenance

BC02 normal. switch OFF.

resistance
Measure
monitor

Transmission oil (male) Fileter normal Max. 1 z 2) Disconnect

Between
filter sensor BC03 connectors.
Filter clogged (1) – (2) Min. 1 Mz
(male) 3) Connect
T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
BC08 Accumulator 2) Disconnect
Between
(male) pressure: connectors.
BC08 Max. 1 z
BC09 3) Connect

resistance
Min. 3.92 ± 0.49 MPa (1) – (2),
Emergency brake (male) Measure {40 ± 5 kg/cm2} BC09
T-adapter.
switch BC10 (1) – (2),
Depress brake and
(male) BC10
lower accumulator
BC11 (1) – (2),
pressure to below Min. 1 Mz
(male) BC11
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2} (1) – (2)
Others

If the condition is as shown in the table below, it is 1) Turn starting

normal. switch OFF.
Accumulator 2) Insert T-adapter.
pressure: 3) Turn starting
20 – 30 V switch ON.
Min. 3.92 ± 0.49 MPa
Measure
voltage

Emergency brake {40 ± 5 kg/cm2}

CBL1 Between
switch
Depress brake and (3) – (4)
lower accumulator
pressure to below Max. 1 V
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

WD900-3 20-17
 TESTING AND ADJUSTING
Precautions before work ........................................................................................................................................ 20-101-1
Table of tools for testing, adjusting and troubleshooting ............................................................................. 20-102
Measuring engine speed............................................................................................................................. 20-103
Measuring exhaust gas color ...................................................................................................................... 20-104
Adjusting valve clearance ........................................................................................................................... 20-105
Measuring compression pressure ............................................................................................................... 20-106
Measuring blow-by pressure ....................................................................................................................... 20-107
Testing and adjusting fuel injection timing................................................................................................... 20-108
Measuring engine oil pressure .................................................................................................................... 20-109
Measuring exhaust temperature ................................................................................................................. 20- 110
Measuring air supply pressure (boost pressure)......................................................................................... 20- 111
Testing and adjusting alternator belt tension............................................................................................... 20- 112
Testing and adjusting belt tension for air conditioner compressor .............................................................. 20- 113
Measuring accelerator pedal operating effort.............................................................................................. 20- 114
Measuring accelerator pedal operating angle ............................................................................................. 20- 115
Adjusting fuel control cable, linkage, and servo cylinder ............................................................................ 20- 116
Adjusting engine stopping motor cable ....................................................................................................... 20- 118
Testing of upper drive shaft sliding part ................................................................................................................. 20-118-1
Testing and adjusting torque converter and transmission oil pressure ....................................................... 20- 119
Procedure for operating emergency steering spool when transmission valve fails..................................... 20-121
Testing and adjusting steering oil pressure ................................................................................................. 20-123
Testing and adjusting emergency steering oil pressure .............................................................................. 20-124
Bleeding air from steering circuit................................................................................................................. 20-125
Testing and adjusting steering stop valve ................................................................................................... 20-126
Testing wheel brake performance ............................................................................................................... 20-127
Testing wheel brake oil pressure drop ........................................................................................................ 20-128
Measuring wear of wheel brake disc........................................................................................................... 20-130
Testing and adjusting accumulator charge cut-in and cut-out pressure ...................................................... 20-131
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...... 20- 132-1
Bleeding air from wheel brake circuit .......................................................................................................... 20-133
Testing parking brake performance............................................................................................................. 20-134
Measuring parking brake solenoid output pressure .................................................................................... 20-135
Checking and adjusting parking brake pad ................................................................................................. 20-136
Testing and adjusting PPC pressure ........................................................................................................... 20-137
Adjusting PPC valve linkage ....................................................................................................................... 20-138
Testing and adjusting work equipment hydraulic pressure ......................................................................... 20-139
Bleeding air from piston pump .................................................................................................................... 20-141
Bleeding air from work equipment circuit .................................................................................................... 20-142
Adjusting work equipment lever linkage...................................................................................................... 20-143
Releasing remaining pressure in hydraulic circuit....................................................................................... 20-144
Adjusting speedometer module of main monitor......................................................................................... 20-145
Adjusting joystick lever potentiometer......................................................................................................... 20-146
Adjusting joystick lever neutral detection switch ......................................................................................... 20-147

WD900-3 20-101
(9)
TESTING AND ADJUSTING PRECAUTIONS BEFORE WORK

PRECAUTIONS BEFORE WORK

Before you start, read the “SAFETY NOTICE” of the “SAFETY” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a
danger that you can get caught in the machine.
• Do not wear oversized clothes or accessories.
• Be sure to tie the long hair that comes out from the helmet.
k When you work together with more than one person, do the preparation that follows.
• Decide on the work procedure.
• Obey the specified signal during the work.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange
an observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not
to let the machine move.
• Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
• Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts,
there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.

20-101-1 WD900-3
(9)
 TABLE OF TOOLS FOR TESTING, ADJUSTING AND
TESTING AND ADJUSTING TROUBLESHOOTING

TABLE OF TOOLS FOR TESTING, ADJUSTING AND

TROUBLESHOOTING

Symbol
Check or measurement
Part No. Part name Remarks
item

Digital display L: 60 – 2,000 rpm

1 799-203-8001 Multi-tachometer H: 60 – 19,999 rpm
Engine speed A Kit part No.: 799-203-9000
2 6210-81-4111 Gear box
3 6215-81-3500 Tachometer drive
Water, oil, exhaust Digital temperature
B 799-101-1502 –99.9 to +1,299°C
temperatures gauge
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester
1 {25, 60, 400, 600 kg/cm2}
Oil pressure C 790-261-1203 Digital hydraulic tester Pressure gauge: 68.6 MPa {700 kg/cm2}
2 • 799-101-5160 • Nipple PT 1/8
3 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
Compression pressure D
2 795-502-1500 Adapter Kit part No.: 795-502-1205
1 799-201-1504 Blow-by checker —
Blow-by pressure E
2 799-201-1590 Gauge 0 – 9.8 kPa {0 – 1,000 mmH2O}
Commercially
Valve clearance F Feeler gauge —
available
1 799-201-9000 Handy smoke checker
Discoloration 0 – 70% (with standard color)
Exhaust color G Commercially
2 Smoke meter (Discoloration x 1/10 C Bosch index)
available
Air supply pressure
H 799-201-2201 Pressure gauge –101.3 – 199.9 kPa {–760 – 1,500 mmHg}
(boost pressure)
1 793-605-1001 Brake tester kit
Brake oil pressure J 2 790-101-1430 Coupler —
3 790-101-1102 Pump
79A-264-0020 0 – 294.2 N {0 – 30 kg}
Operating effort K Push-pull scale
79A-264-0090 0 – 490.3 N {0 – 50 kg}
Commercially
Operating angle of pedal L Angle gauge —
available
Commercially
Stroke, hydraulic drift M Scale —
available
Commercially
Work equipment speed N Stop watch —
available
Commercially
Measuring brake disc wear P Caliper gauge —
available

20-102 WD900-3
(5)
TESTING AND ADJUSTING TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Symbol
Check or measurement
Part No. Part name Remarks
item

Gas charging tool

1 792-610-1703
assembly
2 07000-11009 O-ring
3 792-610-2410 Bushing
4 792-610-1270 Hose
5 792-610-1400 Regulator
792-610-1310 Nipple (For Russia) GOST
Gas pressure check in the 792-610-1320 Nipple (For USA) CGA No. 351
accumulator and charging P ASA
792-610-1330 Nipple (For USA)
nitrogen gas B-571-1965
6 DIN 477-1963
NEN 3268-1966
792-610-1350 Nipple (For Germany)
SIS-SMS
2235/2238
BS341
792-610-1360 Nipple (For UK)
Part 1-1962
Commercially
7 Nitrogen gas cylinder
available
Moving machine when
there is failure in Q 793T-685-1110 Plate —
transmission valve
Measuring voltage,
R 79A-264-0211 Tester —
resistance value
1 799-601-7400 T-adapter assembly —
799-601-7310 SWP12P
Troubleshooting of wiring 799-601-7320 SWP16P
S
harness, sensors 2 799-601-7340 Adapter M8P
799-601-7380 JFC2P
799-601-3460 MS10P

WD900-3 20-102-1
(6)
TESTING AND ADJUSTING
MEASURING ENGINE SPEED
k When removing or installing the measuring
equipment, be careful not to touch any high tem-
perature parts.
k Before starting measurement, check that there
is no one in the surrounding area.
k Put blocks under the wheel to stop the machine
from moving.
a Measure the engine speed under the following
conditions.
• Water temperature: Within operating range
• Hydraulic temperature: 45 – 55°C
• Power train oil temperature: 60 – 80°C
1. Measuring low idling speed and high idling
speed
1) Remove cap (1) from the revolution take-out
port of engine.
2) Install gear box A2 and tachometer drive
A3.
3) Connect multi-tachometer A1.
4) Start the engine and measure the engine
speed at low idling and high idling.
a Check that the engine speed is in the stand-
ard range. If it is out of the standard range,
check the fuel control linkage for looseness,
play, etc.
WD900-3
MEASURING ENGINE SPEED
2. Measuring torque converter stall speed
1) Start the engine.
2) Turn the transmission cut-off switch OFF
and depress the left brake pedal fully. Check
that the transmission cut-off pilot lamp goes
out.
3) Turn speed control lever to 3rd.
Turn directional lever not at N.
4) Release the parking brake.
5) Run the engine at full throttle and measure
the engine speed when the torque converter
stalls.
3. Measuring hydraulic stall speed
1) Stick the reflective tape of multi-tachometer
A1 to a rotating part like a fan and set the
tachometer.
2) Start the engine and run at high idling.
3) Retract the lift cylinder or tilt and pitch cylin-
der and measure the engine speed when
the circuit is relieved.
4. Measuring torque converter stall + hydraulic
stall (full stall) speed
1) Stick the reflective tape of multi-tachometer
A1 to a rotating part like a fan and set the
tachometer.
2) Start the engine.
3) Turn the transmission cut-off selector switch
OFF and depress the left brake securely.
(Check that the transmission cut-off selector
pilot lamp is OFF.)
4) Place the gearshift lever at F4 or R4.
• For machines equipped with automatic
transmission, turn the main monitor
manual switch ON and place the speed
lever at F4 or R4.
5) Release the parking brake.
6) Run the engine at high idling and stall the
torque converter, and at the same time,
retract the lift cylinder or tilt and pitch cylin-
der and measure the engine speed when
the circuit is relieved.
20-103
TESTING AND ADJUSTING
MEASURING EXHAUST GAS
COLOR
• When measuring in the field when there is no air
or power supply, use handy smoke checker G1;
when recording official data, use smoke meter
G2.
a Raise the coolant temperature to the operating
range before measuring.
k 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 of tool G1
into the exhaust pipe, accelerate the engine
suddenly, and at the same time operate the
handle of tool G1 to catch the exhaust gas
on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2
1) Insert probe [1] into exhaust pipe, then
tighten the clip to secure it to the exhaust
pipe.
20-104
MEASURING EXHAUST GAS COLOR
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
a The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC power
supply.
a 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.
a Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the
exhaust gas color on top of unused filter
papers (10 sheets or more) inside the filter
paper holder, and read the indicated value.
WD900-3
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction.
While watching the movement of the intake
valve of the R6 cylinder, bring the R1 cylinder
into the top dead center position of the compres-
sion stroke and align the "R1.6 TOP" line on
vibration damper (2) with pointer (1).
a When the R1 cylinder comes near the top
dead center of the compression stroke, the
R6 intake valve will start to open.
4. Tighten locknut in position to secure adjustment

3 Locknut: 58.8 ± 5.9 Nm {6 ± 0.6 kgm}

screw.

5. Follow the same procedure to align the line with

the pointer and adjust the valve clearance of
each cylinder according to the firing order.
a Firing order:
R1 – L1 – R5 – L5 – R3 – L3 – R6 – L6 – R2 –
L2 – R4 – L4

3. Loosen locknut (6) of adjustment screw (5) of

R1 cylinder, insert the feeler gauge F corre-
sponding to the specified clearance between
crosshead (4) and rocker arm (3), and adjust the
clearance with the adjustment screw until the
thickness gauge can slide lightly.

WD900-3 20-105
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION 7. Disconnect the wiring of the engine stopping

motor, crank the engine with the starting motor
PRESSURE and measure the compression pressure.

a When carrying out performance test or trouble- a Measure the compression pressure at the
shooting, if it is thought that the piston, piston point where the pressure gauge indicator re-
ring, or cylinder liner are worn, measure the com- mains steady.
pression pressure. a When measuring the compression pressure,

k
measure the engine speed to confirm that it
When measuring the compression pressure, be is within the specified range.
careful not to touch the exhaust manifold or oth-
er hot parts, or to get caught in rotating parts,
such as the fan or fan belt.

1. Adjust the valve clearance.

a For details, see Adjusting valve clearance.

2. Warm up the engine so that the oil temperature

rises to 40 – 60°C.

3. Disconnect wiring connector (1).

4. Remove nozzle holder of cylinder to be mea-

sured.

5. Install adapter D2 and plate D3 of tool D on the

mount of the nozzle holder, then connect the
pressure gauge D1.

6. Set multi-tachometer A in position.

20-106 WD900-3
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY
PRESSURE
a Raise the water temperature to the operating
range before measuring.

1. Install blow-by checker E1 to the end of engine

blow-by hose (1) and (2), then connect gauge
E2 (0 – 9.8 kPa {0 – 1,000 mmH2O}).
a Since there are blow-by hoses respectively
on the right bank and left bank of the engine,
measure the blow-by pressure for each of
them.

2. Run the engine at high idling and relieve the

blade, and measure the blow-by pressure.

k When measuring, be careful not to touch

any hot parts or rotating parts.

CAUTION FOR MEASURING BLOW-BY

a Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-by
value is considered abnormal, check for
problems concerning defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, or prematurely dirty
or deteriorated oil.

WD900-3 20-107
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING

FUEL INJECTION TIMING
TESTING FUEL INJECTION TIMING

1. Disconnect fuel injection pipe (1) of R1 cylinder.

2. Remove delivery valve holder (2), then remove

delivery valve (3) and spring (4), and install only
delivery valve holder (2).

3. Place accelerator pedal at FULL position.

4. Operate priming pump and rotate crankshaft

slowly in normal direction. Check point where
fuel stops flowing from delivery valve holder (2).

5. Check that the fuel injection line on damper (5)

is aligned with pointer (6) at the position where
the fuel stops flowing:
a BEYOND injection timing line:
Timing RETARDED
a BEFORE injection timing line:
Timing ADVANCED
a If the test shows that the fuel injection timing is
incorrect, adjust as follows.

20-108 WD900-3
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

ADJUSTING FUEL INJECTION TIMING BY MEASURING ENGINE OIL

DELIVERY CHECK
PRESSURE
1. Turn crankshaft back for 30° to 40° from top
a Measure the engine oil pressure under the fol-
dead center.
lowing conditions.
• Water temperature: Within operating range
2. Rotate the crankshaft in the normal direction,
and align the fuel injection line on damper (5)
1. Remove engine oil pressure switch (1) from the
with pointer (6).
left bank of the engine (r ight si de of the
machine).
3. Loosen bolts (7) on the injection pump coupling
flange bolt.

2. Install nipple C2 and oil pressure gauge C3 (1.0

MPa {10 kg/cm2}).
4. Rotate the flange on the pump side little by little
while operating the priming pump (8) until no
fuel flows out of the delivery valve holder.

5. Tighten bolts (7) in oblong hole of coupling

flange of fuel injection pump.
a Check again that the fuel stops flowing from
the delivery valve holder at the point where
the pointer is aligned with the line on the
damper.

6. Remove delivery valve holder (2), assembly

delivery valve (3) and spring (4), then install
delivery valve holder (2) and fuel injection pipe

3 Delivery holder:
(1) again. 3. Start engine, and measure the oil pressure at
low idling and high idling.
32.4 ± 2.0 Nm {3.3 ± 0.2 kgm}

3 Sleeve nut:
7. Connect fuel injection pipe (1).

23.5 ± 1.0 Nm {2.4 ± 0.1 kgm}

WD900-3 20-109
TESTING AND ADJUSTING
MEASURING EXHAUST
TEMPERATURE
k The temperature sensor must be installed to the
exhaust system, so if the machine has been op-
erated, wait for the manifold temperature to drop
before installing the sensor.
a Raise water temperature to operating range.
1. Remove measuring plugs (3) and (4) (PT 1/8)
from right bank connector (1) and left bank con-
nector (2) between the turbocharger and
exhaust muffler.
a The right bank and left bank have two plugs re-
spectively. Remove either one from each side.
2. Install temperature sensors of digital tempera-
ture gauge B to both banks of engine.
• Temperature sensor
: 6215-11-8180 (Cable length 610 mm)
or
: 6215-11-8170 (Cable length 490 mm)
3. Connect to digital temperature gauge B with the
wiring harness (799-201-1110).
20-110
MEASURING EXHAUST TEMPERATURE
Measurement procedure
1. When measuring the maximum value during
troubleshooting
Carry out actual work and measure the maxi-
mum value during operation.
a Use the PEAK mode (it can store the maxi-
mum value in memory) of the temperature
gauge function.
Note: The exhaust temperature varies greatly
according to the ambient temperature
(temperature of the engine intake air), so
if any abnormal value is obtained, carry
out temperature compensation.
a Compensation = Measured value + 2 x
(standard ambient temperature – actual am-
bient temperature)
a The standard ambient temperature is tak-
en as 20°C.
2. When measuring periodically (during preventive
maintenance, etc.)
1) Raise the exhaust temperature to approx.
700°C by using full stall (torque converter
stall and hydraulic pump relief).
2) In the above condition, cancel the hydraulic
relief, and carry out only torque converter stall.
3) Note the stable temperature.
a If only torque converter stall is used
when measuring the exhaust tempera-
ture, torque converter will overheat be-
fore a stable value is obtained.
WD900-3
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

MEASURING AIR SUPPLY

PRESSURE (BOOST PRESSURE)
k Be careful not to touch any hot or rotating parts
when measuring or when removing or installing
the measuring tools.

1. Remove measuring plugs (3) and (4) (PT 1/8)

from air intake connector (1) for the right bank
air intake connector (2) for the left bank.
a The right bank and left bank have two plugs
respectively. Remove either one from each
side.

3. Carry out the torque converter stall operation at

engine full and read the gauge.

a The air supply pressure (boost pressure) should

be measured with the engine running at rated
output. However, when measuring in the field, a
similar value can be obtained by operating at
torque converter stall.

2. Install nipples C2 to both sides, then connect

pressure gauges H (–101.3 – 199.9 kPa {–760 –
1,500 mmHg}).

Note: Operate the engine at midrange speed or

above, and push to open the self-seal por-
tion of the hose to bleed the oil inside the
hose.
• Insert the hose into gauge then discon-
nect, repeat the action to open the self-
seal portion to bleed the oil.
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.

WD900-3 20-111
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

TESTING AND ADJUSTING ADJUSTING

ALTERNATOR BELT TENSION
TESTING
• Measure deflection a of the belt when each belt
is pushed with a force of approx. 59 N {approx. 6
kg} at a point midway between the alternator pul-
ley and the drive pulley.
a Deflection a of belt (standard value):
approx. 20 mm
1. Loosen the alternator assembly mounting bolts
and nuts (1), (2), (3) and lock nut (4).
2. Turn adjustment nut (5) to adjust the tension of
belt (6).
3. After positioning the alternator, secure it by tight-
ening lock nut (4), mounting bolts and nuts (1),
(2) and (3).

4. After adjusting the belt tension, check that

deflection is the standard value according to the
above procedure.

20-112 WD900-3
 TESTING AND ADJUSTING BELT TENSION FOR AIR
TESTING AND ADJUSTING CONDITIONER COMPRESSOR

TESTING AND ADJUSTING ADJUSTING

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
TESTING
• Measure deflection b of the belt when it is
pushed with a force of approx. 98 N {approx. 10
kg} at a point midway between the drive pulley
and the air conditioner compressor pulley.
a Deflection b of belt (standard value):
9 – 12.5 mm
1. Loosen mount bolts and nuts (1), (2), (3), lock-
nut (4).
2. Turn adjustment nut (5) to adjust the tension of
air conditioner compressor belt (6).
3. When the position of the air conditioner com-
pressor is correct, tighten locknut (4), mounting
bolts and nuts (1), (2), (3) to secure it in position.

4. After adjusting the belt tension, repeat the test-

ing procedure above to check that the deflection
is adjusted within the standard range.

WD900-3 20-113
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL OPERATING EFFORT

MEASURING ACCELERATOR ADJUSTING

PEDAL OPERATING EFFORT
MEASURING
1. Put push-pull gauge K in contact with the accel-
erator pedal at point 150 mm from pedal fulcrum
a.
2. Start the engine, push the pedal and measure
the maximum value when pushing from idling to
the end of the pedal travel (high idling).
1. Stop the engine.
2. Disconnect cable (1) at bottom of the accelera-
tor pedal, and check that the linkage move
smoothly.
3. Connect the cable (1) at the bottom of the pedal,
then disconnect at the connection for lever (2),
and check that cable (1) moves smoothly.
4. Leave cable (1) disconnect, and check that lever
(2) moves smoothly.

20-114 WD900-3
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL OPERATING ANGLE

5. Disconnect cable (3) from servo cylinder (4) and

lever (5), and check that cable (3) and lever (5)
MEASURING ACCELERATOR
move smoothly. PEDAL OPERATING ANGLE
a When carrying out this inspection, adjust or MEASURING
replace parts if necessary. Measure the op-
erating force again and check that it is within 1. Stop the engine.
the standard range. 2. Apply angle meter L to measure angle 1 for
a When operating force is heavy in spite of low idling and 2 for high idling.
there is no abnormality in this inspection,
check operation of servo cylinder (4).

ADJUSTING
Referring to "ADJUSTING FUEL CONTROL
CABLE, LINKAGE, AND SERVO CYLINDER",
adjust the angle of the accelerator pedal.

WD900-3 20-115
 ADJUSTING FUEL CONTROL CABLE, LINKAGE, AND
TESTING AND ADJUSTING SERVO CYLINDER

ADJUSTING FUEL CONTROL
CABLE, LINKAGE, AND
SERVO CYLINDER
1. Remove the cover at the bottom of the cab, then
open the inspection cover at the rear of the cab
and the engine inspection cover.
2. With the accelerator pedal at the low idling posi-
tion, loosen nut (2) and adjust so that the length
a is as shown below.
• Standard value: a = 148.4 mm
4. Remove rod (5) at the engine end, and adjust
the overall length to c.
• Standard value: c = 405.4 mm
5. Temporarily install rod (5), to governor lever (6),
then adjust the length of rod (5) so that engine
governor lever (6) contacts low idling stop bolt
(7) lightly, and tighten locknut (8).
a Install so that water drain hole d of the rod is
at the bottom.

6. Start the engine, gradually depress accelerator

3. Adjust joint (4) of the servo cylinder spool so
that the length of servo return spring (3) is b at
low idling.
• Standard value: b = 256 mm
pedal (10), adjust length e of stopper (11) so that
accelerator pedal (10) and stopper (11) are in
contact at the position where governor lever (6)
contacts high idling stopper bolt (9), then secure
with locknut (12).
• Reference value: e = Approx. 56 mm

20-116 WD900-3
 ADJUSTING FUEL CONTROL CABLE, LINKAGE, AND
TESTING AND ADJUSTING SERVO CYLINDER

7. Loosen locknut (13) and adjust the secondary

low idling by turning yoke (12) so that the clear-
ance f between lever (11) at the engine end and
air cylinder yoke (12) is as shown below when
the engine is topped.
• Standard value: f = 6.3 mm
a After completing the adjustment, check that
the engine speed is 850+50
+0 rpm when the
low idling speed is switched to secondary
low idling speed.

WD900-3 20-117
TESTING AND ADJUSTING
ADJUSTING ENGINE
STOPPING MOTOR CABLE
1. Temporarily install ball joint (3) to cable (2) of
engine stop motor (1) (screw in fully, then turn
back approx. 1/2 turns), then install the ball joint
to the stop lever of the injection pump.
2. Pull stop lever (4) of the injection pump by hand
to the engine stop position (no injection of fuel),
and temporarily assemble the cable to the
bracket. When this is done, secure the cable at
a point where stop lever (4) contacts engine
STOP stopper (5), and temporarily assemble to
the bracket (7) with locknut (6).
a Engine stop motor (1) is at the engine STOP
position with cable (2) pulled.
3. Adjust stop lever (4) of the injection pump and
STOP stopper (5) at the stop end so that clear-
ance a is 1.0 – 2.0 mm.
Adjust with nut (6) which secures the cable to
the bracket or carry out fine adjustment by
changing the depth that ball joint (3) is screwed
in.
4. Tighten all nuts and bolts.
20-118
ADJUSTING ENGINE STOPPING MOTOR CABLE
5. Turn the engine starting switch repeatedly to the
ON and OFF positions, and check that the
engine stop motor and cable work smoothly,
then carry out the following checks again.
1) Check visually that there is slack in the
engine stop motor cable when the engine is
running, and that the stop lever of the fuel
injection pump has returned fully to the RUN
position.
2) Check that the clearance between the stop
lever and stopper at the STOP end is 1.0 –
2.0 mm when the engine is stopped.
a With the engine stop motor, there are built-in
limit switches at both ends of the cable
stroke.
a Engine stop motor stroke: 35 mm
Fuel injection pump stop lever stroke: 30 mm
a When the engine is running, there is slack in
the engine stop motor cable, and the RUN
position is maintained by the action of a
spring (this is frequently built into the fuel in-
jection pump).
a There is a loose spring inside the engine
stop motor, and this absorbs the error in the
stop motor when the engine is stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump, so de-
pending on the machine model, this system
may not be possible to use.
With such models, there is a danger of prob-
lems arising with the injection pump if the
clearance between the stop lever and the
stopper at the STOP end is set to 0 when the
engine is stopped.
a Problems caused by improper adjustment of en-
gine stop motor cable
• When engine stop • Engine does not stop
motor cable is pulled
and clearance be-
tween stop lever and
STOP stopper is too
large.
• When cable is free • Engine does not give
and clearance be- full output because
tween stop lever and of drop in amount of
RUN stopper is too fuel injected
large
WD900-3
TESTING AND ADJUSTING TESTING OF UPPER DRIVE SHAFT SLIDING PART

TESTING OF UPPER DRIVE SHAFT SLIDING PART

When removing the upper drive shaft (the drive shaft
between the engine and transmission) for mainte-
nance of the engine, damper, transmission, etc., and
installing and using it again, check its sliding dis-
tance before installing.
4 Upper drive shaft: 68kg
(Sleeve yoke side (1): 26kg,
Spline yoke side (2): 42kg)

1. Extend and retract sleeve yoke side (1) while

locking spline yoke side (2), and check that dis-
tance (a) between mounting faces (s1) and (s2)
can change between 834 mm and 872 mm.
a Do not increase distance (a) between
mounting faces (s1) and (s2) to 872 mm or
more. If it is increased so, seal (3) may be
damaged.
a If the sliding range is abnormal, replace the
upper drive shaft.

WD900-3 20-118-1
(8)
 TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE

TESTING AND ADJUSTING

TORQUE CONVERTER AND
TRANSMISSION OIL
PRESSURE
Measurement conditions
• Coolant temperature: Inside operating range
• Torque converter oil temperature: 60 to 80°C

k Apply the parking brake and block the tires.

Measuring procedure
a The following preparatory work is necessary be-
fore measuring any oil pressure.
• Remove cover on upper side of the transmis-
sion.
• Turn transmission cut-off selector switch (2)
to OFF and use the left brake. (Check that
the pilot lamp is OFF).
• Remove the plug (P5) (PT 1/8) from the
measuring port of the transmission valve.
• Install nipple C2 and hydraulic tester C1 (2.5
MPa {25 kg/cm2})to the measuring port, pull
the gauge to the operator's compartment,
then start the engine and measure the pres-
sure.
a Check that there is no leakage of oil from any
joints.
3. Measuring modulating pressure
1) Remove plug (P2) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (5.9 MPa {60
kg/cm2}).
2) Run the engine at engine full and put the
directional lever in neutral, and measure the
pressure when the speed control lever is
operated.
a Measure pressure except F3 and R3.
4. Measuring torque converter inlet pressure
1) Remove plug (P10) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
2) Start the engine and measure the pressure
at engine full.

1. Transmission main relief valve pressure
1) Remove plug (P0) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (5.9 MPa {60
kg/cm2}).
2) Start the engine and measure the pressure
at 2000 rpm.
5. Measuring torque converter outlet pressure
1) Remove plug (P11) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
2) Start the engine and measure the pressure
at engine full.

2. Measuring pilot reducing pressure

1) Remove plug (P5) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
2) Run the engine at engine full and put the
directional lever in neutral, and measure the
pressure when the speed control lever is
operated.

WD900-3 20-119
 TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE

ADJUSTING PROCEDURE

k Always stop engine before adjusting hydraulic

pressure.

a If it is impossible to measure relief pressure ac-

culately, do not try to adjust pressure.
a If the main relief pressure is out of the standard
range, adjust it according to the following proce-
dure.

1. Adjusting of transmission main relief pressure

1) Loosen cap (1) to reduce spring tension.
2) Remove cover (2), and pull out plunger (3),
6. Measuring lubrication valve pressure then increase or decrease shims (4) to
1) Remove plug (P9) (PT 1/8), and install nip- adjust oil pressure.
ple C2 and hydraulic tester C1 (2.5 MPa {25 a Standard shim thickness: 6.0 mm
kg/cm2}). a Amount of adjustment for one shim (t =
2) Start the engine and measure the pressure 0.5 mm): approx. 11.8 kPa {0.12 kg/cm2}
at engine full. a To increase pressure, increase shims.
To decrease pressure, decrease shims.
7. Measuring reducing valve pressure
1) Remove plug (P3) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
2) Start the engine and measure the pressure
at engine full.

20-120 WD900-3
 PROCEDURE FOR OPERATING EMERGENCY STEERING
TESTING AND ADJUSTING SPOOL WHEN TRANSMISSION VALVE FAILS

PROCEDURE FOR
OPERATING EMERGENCY
STEERING SPOOL WHEN
TRANSMISSION VALVE FAILS
OUTLINE
• The transmission valve is controlled electrically.
Therefore, the emergency manual spool is in-
stalled to enable the machine to be moved if
there is any failure in the electrical system, or in
the solenoid valve and spool.
k The emergency manual spool is for use when
failure in the transmission control prevents the 3. Decide the direction to move the machine (for-
machine from being moved. It allows the ma- ward or in reverse), then move the emergency
chine to be moved from a dangerous place to a manual spool to the operating position.
place where repairs can be carried out safety.
The emergency manual spool must never be FORWARD: Rotate FORWARD clutch spool and
used except when the transmission control has 1st spool counterclockwise, and
broken down.
k
pull out approx. 10 mm to the oper-
When operating the emergency manual spool, ating position.
follow the correct order of operation exactly, and REVERSE: Rotate REVERSE clutch spool and
pay full attention to safety when moving the ma- 1st spool counterclockwise, and
chine.
k
pull out approx. 10 mm to the oper-
To prevent the machine from moving, lower the ating position.
blade to the ground, apply the parking brake,
and block the wheels.

OPERATION
1. Open cover on upper side of transmission.
k Always stop the engine before operating
spool.

2. Remove lock plate (2) of emergency manual

spool (1) of the transmission valve.
a Simply loosen the mounting bolts to remove
the lock plate (2).

4. Check that the area around the machine is safe,

remove the blocks from under the wheels.

5. Sit in the operator’s seat, and depress the left

brake pedal fully.

WD900-3 20-121
 PROCEDURE FOR OPERATING EMERGENCY STEERING
TESTING AND ADJUSTING SPOOL WHEN TRANSMISSION VALVE FAILS

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

release the brake pedal gradually to start the
machine.

k 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
and 3rd spool clockwise, and screw in approx.
10 mm to the OFF position.

7. After moving the machine, stop the engine,

apply the parking brake, and block the wheels.

8. Return the emergency manual spool to the neu-

tral position, and install the lock plate.

20-122 WD900-3
TESTING AND ADJUSTING
TESTING AND ADJUSTING
STEERING OIL PRESSURE
MEASURING
• Hydraulic oil temperature: 45 – 55°C
k
Install the safety bar to lock front frame and rear
frame.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the steering wheel 2 – 3 times to release the re-
maining pressure in the hydraulic piping.
1. Remove hydraulic oil pressure measurement
plug (2) (PT 1/8) from right-hand steering cylin-
der (1).
2. Install nipple C2, then install oil pressure mea-
surement gauge C1 (39.2 MPa {400 kg/cm2}).
WD900-3
TESTING AND ADJUSTING STEERING OIL PRESSURE
3. Start the engine and run it at the full speed. Turn
the steering wheel to the left and measure the
hydraulic pressure when the relief valve actu-
ates.
a When removing the oil pressure measure-
ment plug from left-hand steering cylinder,
turn the steering wheel to the right and
measure the oil pressure.
ADJUSTING
k
If the relief pressure is not normal, adjust the
steering relief valve according to the following
procedure.
k
Adjust the steering relief valve while the engine
is stopped.
Loosen lock nut (3), then turn adjustment screw
(4) to adjust.
a Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 17.8 MPa {181 kg/cm2}
a Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
a If it is impossible to measure relief pressure
accurately, do not try to adjust the pressure.
20-123
TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE

TESTING AND ADJUSTING 4. Remove plug (5) (PT 1/8) between diverter
valve and steering valve, and install nipple C2
EMERGENCY STEERING OIL and hydraulic tester C1 (39.2 Mpa {400 kg/
PRESSURE cm2}).

MEASURING
• Hydraulic oil temperature: 45 – 55°C
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the steering wheel 2 – 3 times to release the re-
maining pressure in the hydraulic piping.
k Fit the safety bar to lock the front frame and rear
frame.

1. Disconnect drive shaft (1) between transmission

and center support at transmission side.

2. Disconnect drive shaft (2) between transmission

and rear axle at transmission side.

5. Start engine, shift transmission gear shift lever

to F3 or R3 raise speedometer until 24 km/h.
3. Disconnect hose (3) to pilot port of diverter Turn the steering wheel to the right or left and
valve, replace elbow (4) by oil passage shut off measure the pressure when the relief valve is
elbow (for details, see next page), then connect actuated.
hose (3).
(As a result of this, oil pressure to pilot port of
diverter valve is shut off, emergency steering is
operating.)

20-124 WD900-3
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT

ADJUSTING BLEEDING AIR FROM

k Always stop the engine before adjusting the hy-
draulic pressure.
1. Remove capnut (6) of the relief valve.
STEERING CIRCUIT
a Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been re-
moved and installed again.

1. Start the engine and run at idling for approx. 5

minutes.

2. Run the engine at low idling and turn 4 – 5 times

to the left and right in turn.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.

3. Repeat Step 2 with the engine at full throttle.

2. Loosen locknut (7), then turn adjustment screw 4. Run the engine at engine slow and operate the
(8) to adjust. piston to the end of its stroke to relieve the cir-
a Amount of adjustment for 1 turn of adjust- cuit.
ment screw.
1 turn: Approx. 3.5 MPa {35.7 kg/cm2}
a Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
a If it is impossible to measure relief pressure
accurately, do not try to adjust the pressure.

a Preparatory of oil passage shut off elbow

Prepare elbow (07236-10210), insert pin (dia.: 5
mm) in drilled hole, then weld pin and elbow to
shut off passage.

WD900-3 20-125
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOP VALVE

TESTING AND ADJUSTING ADJUSTING

a If the clearance between the front frame and rear
STEERING STOP VALVE frame is not within the standard value, adjust as
follows.
STEERING WHEEL SPECIFICATION, 1. Loosen locknut (2), tighten stopper bolt (1), and
STEERING WHEEL AND JOYSTICK STEERING make sure that there is no contact with the
SPECIFICATION steering stop valve (3).
2. Start the engine, run at engine slow, then turn
TESTING the steering wheel slowly to bring the front frame
1. Set the front frame and rear frame facing and rear frame into contact.
straight. k When turning, be extremely careful not to
2. Check that locknut (2) of stopper bolt (1) is not get your arm or any other part of your body
loose. caught between the front frame and rear
frame.
3. Stop the engine, then loosen the stopper bolt
until it contacts the steering stop valve contact
surface.
4. Start the engine and run it at engine solw.
Return the steering wheel slowly. When dis-
tance b between stop valve (3) and head of
stopper bolt (1) becomes about 20 – 30 mm,
stop the engine.

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.
k Measure the clearance with the engine
stopped.
4. Before adjusting stopper bolt, check front frame
stopper does not come into contact with rear
frame stopper at steering end. If they come into
contact, adjust as shown below. 5. Loosen stopper bolt (1) 8.5 – 9 turns (length c:
a If they do not come into contact because of 14.9 – 15.8 mm), then tighten locknut (2).
lack of stopper, repair and then check above a Carry out the procedure in Steps 1 – 5 to ad-
for each steering end. just both the left and right sides.

6. Start the engine, turn the machine, and check that

clearance between the front frame and rear frame is
within the standard value for both the left and right
and that the steering stopper valve and stopper bolt
come into contact and the steering is stopped.

20-126 WD900-3
TESTING AND ADJUSTING TESTING WHEEL BRAKE PERFORMANCE

TESTING WHEEL BRAKE PERFORMANCE

a Test the performance of the wheel brake under

the following conditions.
• Road surface: Flat, horizontal, dry paved
surface.
• Travel speed: 20 km/h when brakes are ap-
plied
• Tire inflation pressure: Specified pressure
(235.4 kPa {2.4 kg/cm2})
• Operating effort of pedal: 373 N {38 kg}
• Operation delay time: 0.1 sec.

1. Start the engine, operate the directional lever to

F and the speed lever to 3rd, and drive the
machine.

2. Maintain the travel speed at 20 km/h, and depress

the brake pedal with the specified operating force.
a Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then travel at 20 km/h and apply the
brakes when the machine reaches the brak-
ing point.
a Switch the transmission cut-off switch ON
when carrying out this operation.
3. Measure the distance from the point where the
brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.

WD900-3 20-127
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP

TESTING WHEEL BRAKE OIL 3. Set brake tester kit J1 in position and connect
coupler J2 and pump J3.
PRESSURE DROP
k
4. Loosen bleeder (4), operate pump J3 to bleed
Apply the parking brake and put blocks securely the air, then tighten bleeder (4).
under the tires.

1. Remove the brake hose cover (1).

2. Remove hose (2) and nipple (3) from the brake

system to be measured.

k If the brake pedal is depressed when the

hose is disconnected, high-pressure oil will
spurt out. Never depress the brake pedal in
this condition.

5. Operate the pump to raise the oil pressure to the

specified pressure, then close the stop valve.
a Specified oil pressure:
4.2 – 5.2 MPa {43 – 53 kg/cm2}

6. Leave in this condition for 5 minutes, then check

the drop in pressure over the next 5 minutes.
a If the hose is moved during the inspection,
the pressure will change, so be careful not to
move the hose.
a After completion of the inspection, operate
the pump to release the oil pressure, then re-
move the brake tester kit.

20-128 WD900-3
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP

WD900-3 20-129
TESTING AND ADJUSTING MEASURING WEAR OF WHEEL BRAKE DISC

MEASURING WEAR OF
WHEEL BRAKE DISC
k Stop the machine on level ground and block the
tires.

1. Remove plug (1).

2. Depress the brake pedal fully to the end of its

stroke.

3. Measure depth a from the end face of the hous-

ing to the spring guide by using caliper gauge P.
a Keep the brake pedal depressed while
measuring.

Wear limit: a = 46.3 mm

(Reference: When machine is new, a = 40.7
± 1.4 mm)

a When the disc is near the wear limit, carry

out inspection frequently, regardless of the
maintenance interval.

20-130 WD900-3
 TESTING AND ADJUSTING ACCUMULATOR CHARGE
TESTING AND ADJUSTING CUT-IN AND CUT-OUT PRESSURE

TESTING AND ADJUSTING 3. Install adapter and nipple C2, then connect oil
pressure gauge C1 (39.2 MPa {400 kg/cm2}) .
ACCUMULATOR CHARGE
CUT-IN AND CUT-OUT
PRESSURE
MEASURING
a Brake oil temperature: 45 – 55°C
k Depress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulator circuit.

1. Remove the brake oil tank side cover (on the

front side of the machine body).

2. Disconnect hose (PP port) (2) from accumulator

charge valve (1) on the accumulator distribution
tube (3) side.

4. Measure the accumulator charge cut-in pres-

sure.
Start the engine, run the engine at engine slow,
and measure the oil pressure when the brake oil
pressure warning pilot lamp on the maintenance
monitor goes out and buzzer stops.

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 rises and becomes going
down.

WD900-3 20-131
 TESTING AND ADJUSTING ACCUMULATOR CHARGE
TESTING AND ADJUSTING CUT-IN AND CUT-OUT PRESSURE

ADJUSTING
Accumulator charge cut-out pressure
a 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 screw for the cut-
in pressure.

Loosen locknut (5) of cut-out valve (4) and adjust

cut-out pressure with the adjustment screw (6) as
follows.

a Adjustment screw
• To INCREASE cut-out pressure, turn
CLOCKWISE
• To DECREASE cut-out pressure, turn
COUNTERCLOCKWISE
a Pressure adjustment for one turn of adjustment

3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}

screw: 5.59 MPa {57 kg/cm2}

a After adjustment, check again the cut-in and cut-

out pressure according to the procedure men-
tioned in the previous page.

20-132 WD900-3
 TESTING OF ACCUMULATOR NITROGEN GAS
TESTING AND ADJUSTING PRESSURE AND PROCEDURE FOR CHARGING

TESTING OF ACCUMULATOR a In some cases, threaded portion height (B) of

gas valve (4) is short for depth (A) from the end
NITROGEN GAS PRESSURE face of adapter (5) of gas charging tool P1 to
AND PROCEDURE FOR packing (6). In this case, nitrogen gas may leak
CHARGING ACCUMULATOR through the threaded portion of gas valve (4). To
prevent this, securely install gas charging tool
WITH NITROGEN GAS P1.

a Testing and adjusting tools

Symbol Part No. Part name
1 792-610-1703 Gas charging tool assembly
2 07000-11009 O-ring
3 792-610-2410 Bushing
4 792-610-1270 Hose
5 792-610-1400 Regulator
P 792-610-1310 Nipple (For Russia)
792-610-1320 Nipple (For USA)
6 792-610-1330 Nipple (For USA)
792-610-1350 Nipple (For Germany)
792-610-1360 Nipple (For UK)
Commercially
7 Nitrogen gas cylinder
available Testing of accumulator nitrogen gas pressure
k Put on the appropriate protective equipment a The accumulators for the front brake, rear brake,
(goggles, leather gloves, protective clothes) so and parking brake have the same shape.
that the leaked nitrogen gas is not applied to a The accumulator can be tested similarly in an un-
your skin or clothes. Perform the work on the installed state as well.
windward side as much as possible. a Both old accumulator and new one are listed.
k When using the nitrogen gas indoors or on an ill- Confirm shape of accumulator and test.
ventilated location, ventilate the room, etc. and 1. Stop the engine, depress the brake pedal
observe the Industrial Safety and Health Law, repeatedly until its reaction force disappears in
Ordinance on Prevention of Anoxia, etc. order to completely release the oil pressure from
k The accumulator is charged with high-pressure the brake circuit.
nitrogen gas, and improper operation may cause a As a guide, by depressing the brake pedal
an explosion which will lead to serious injury or approximately 30 times, the reaction force of
death. When handling, always observe the fol- the brake pedal disappears and the oil pres-
lowing. sure is released.
• Do not bring open flame close to it or do not 2. Remove valve guard (2) and cap (3) from accu-
dispose of it in fire. mulator (1). (Old type accumulator)
• Do not perform drilling, welding or flame-cut-
ting.
• Do not hit or roll it, or subject it to any impact.
• When discarding it, gradually discharge the
filled nitrogen gas into the atmosphere out-
side by using gas charging tool P1.
k Be sure to charge the accumulator with nitrogen
gas.

Precautions for connecting gas charging tool P1

a The threaded portion of adapter (5) of gas charg-
ing tool P1 is coated with sealant. If the adapter
is removed without reason, it can cause gas
leakage. Never remove it.
a When connecting gas charging tool P1 to accu-
mulator (1), always fit O-ring P2, which is an ac-
cessory of gas charging tool P1, to gas valve (4),
and check for leakage.

WD900-3 20-132-1
(6)
 TESTING OF ACCUMULATOR NITROGEN GAS
TESTING AND ADJUSTING PRESSURE AND PROCEDURE FOR CHARGING

3. Remove plug (9) from accumulator (1).
(New type accumulator)
3) Fully turn handle (a) of gas charging tool P1
counterclockwise until it stops (to close pip-
ing between accumulator (1) and gas charg-
ing tool P1), and fully turn handle (b)
clockwise to close, then connect them.
a Since valve (7) on the hose connection
side of gas charging tool P1 is a check
valve (one-way valve), gas does not leak
from the hose connection port into the
atmosphere.
4) Connect gas charging tool P1 to gas valve
(4) of accumulator (1) or extension (8).
5) Cover valve (7) to prevent entry of rain,
snow, sand, or dust.

4. Connect gas charging tool P1 to gas valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Install attached O-ring P2 to gas valve (4).
(Old type accumulator)

Reference
• Handle (a): Turn counterclockwise to close the
valve, and clockwise to open the valve (to con-
nect the charge valve and accumulator)
a This valve is opened when tightened
• Handle (b): Turn counterclockwise to open the
valve (to open to the atmosphere), and clockwise
2) Install extension (8) attached to gas charge to close the valve (to disconnect from the atmos-
tool P1, to gas valve (4). phere)
(New type accumulator) a This valve is closed when tightened
a Do not attach O-ring P2. 5. Slowly turn handle (a) of gas charging tool P1
clockwise, and read the gauge value.
a Check the gas pressure by referring to the
following table, since the display varies de-
pending on the temperature at measure-
ment.
(The unit of values in the formula is °C)
Specified gas pressure =
Standard gas pressure x ((273 + t)/(273 + 50))
t: Gas temperature at measurement (°C)
Reference: "t" can be assumed to be the
ambient temperature.

20-132-2 WD900-3
(6)
 TESTING OF ACCUMULATOR NITROGEN GAS
TESTING AND ADJUSTING PRESSURE AND PROCEDURE FOR CHARGING

Table 1 Accumulator gas pressure table 6. When reducing the nitrogen gas pressure in the
Ambient Gas pressure accumulator after testing it
tempera-
MPa kg/cm2
Remarks a Initial state: Open handle (a)
ture °C 1) Slowly turn handle (b) counterclockwise,
15 3.06 31.2 and gradually release the nitrogen gas
16 3.07 31.3 through the threaded portion of handle (b).
17 3.08 31.4
18 3.09 31.5
Immediately after the gauge of gas charging
19 3.10 31.6 tool P1 reaches the specified gas pressure
20 3.11 31.8 in Table 1, turn handle (b) clockwise to close
21 3.12 31.9 the valve, and adjust the nitrogen gas pres-
22 3.14 32.0 sure in accumulator (1).
23 3.15 32.1 2) Go to step 8.
24 3.16 32.2
25 3.17 32.3
26 3.18 32.4
7. When charging the accumulator with nitrogen
27 3.19 32.5 gas after testing the nitrogen gas pressure in it
28 3.20 32.6 1) Close the valve by turning handle (a) coun-
29 3.21 32.7 terclockwise until it stops.
30 3.22 32.8 2) Gradually turn handle (b) counterclockwise,
31 3.23 32.9 and discharge the nitrogen gas remaining in
32 3.24 33.1 charging tool P1 through the threaded por-
33 3.25 33.2
34 3.26 33.3
tion of handle (b), then keep the valve open.
35 3.27 33.4 (To bleed air in the hose, open the piping
36 3.28 33.5 between handle (b) and atmosphere)
37 3.29 33.6 3) Go to "Procedure for charging accumulator
38 3.31 33.7 with nitrogen gas", step 4.6), and charge the
39 3.32 33.8 accumulator with nitrogen gas and adjust
40 3.33 33.9 the gas pressure.
41 3.34 34.0
42 3.35 34.1
43 3.36 34.2 8. After testing, close the valve by turning handle
44 3.37 34.4 (a) counterclockwise until it stops.
45 3.38 34.5
46 3.39 34.6 9. Remove gas charging tool P1 from accumulator
47 3.40 34.7 (1), and restore the machine.
48 3.41 34.8 1) Turn handle (b) counterclockwise to open
49 3.42 34.9
Standard temperature
the valve, and discharge the nitrogen gas
50 3.43 35.0 remaining in gas charging tool P1 through
Standard gas pressure
the threaded portion of handle (b).
2) Remove gas charging tool P1.
a Compare the gauge gas pressure with the 3) Remove extension (8). (New type accumu-
specified gas pressure in Table 1. When the lator)
gas pressure is too high, go to step 6, and
adjust the gas pressure.
a Compare the gauge gas pressure with the
specified gas pressure in Table 1. If the gas
pressure is insufficient, go to step 7, then
perform adjustment according to "Procedure
for charging accumulator with nitrogen gas".
a When the gas pressure is normal, go to step 8.

WD900-3 20-132-3
(6)

TESTING AND ADJUSTING
4) Remove O-ring P2 from gas valve (4) of
accumulator (1). (Old type accumulator)
10. Apply soapy water to gas valve (4) (previous
mentioned) of the accumulator, and check that
no nitrogen gas is leaking.
11. Install cap (3) and valve guard (2) to accumula-
3 Cap:
tor (1). (Old type accumulator)
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
12. Install plug (9) to accumulator (1).
3 Plug:
(New type accumulator)
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
20-132-4
(5)
TESTING OF ACCUMULATOR NITROGEN GAS
PRESSURE AND PROCEDURE FOR CHARGING
Procedure for charging accumulator with nitro-
gen gas
a The accumulator can be charged in uninstalled
state as well.
1. Stop the engine, depress the brake pedal
repeatedly until its reaction force disappears in
order to completely release the oil pressure from
the brake circuit.
a As a guide, by depressing the brake pedal
approximately 30 times, the reaction force of
the brake pedal disappears and the oil pres-
sure is released.
2. Remove valve guard (2) and cap (3) from accu-
mulator (1). (Old type accumulator)
3. Remove plug (9) from accumulator (1).
(New type accumulator)
WD900-3

TESTING AND ADJUSTING
4. Connect gas charging tool P1 and nitrogen cyl-
inder P7 to gas valve (4) of accumulator (1)
according to the following procedure.
1) Turn handle (a) of gas charging tool P1
counterclockwise until it stops. (Close the
piping between accumulator (1) and gas
charging tool P1)
2) Turn handle (b) counterclockwise for open-
ing. (To bleed air in the hose, open the pip-
ing between handle (b) and atmosphere)
3) Install attached O-ring P2 to gas valve (4).
(Old type accumulator)
4) Install extension (8) attached to gas charge
tool P1, to gas valve (4).
(New type accumulator)
a Do not attach O-ring P2.
5) Connect gas charging tool P1 to gas valve
(4) of accumulator (1) or extension (8).
6) Connect bushing P3 to gas charging tool
P1.
7) Turn handle (c) of regulator P5 until it stops
(closes), and connect regulator P5 to nitro-
gen gas cylinder P7.
a Use nipple P6 to connect the regulator,
depending on the specification of the ni-
trogen gas cylinder.
8) Connect hose P4 to bushing P3 and regula-
tor P5.
WD900-3
TESTING OF ACCUMULATOR NITROGEN GAS
PRESSURE AND PROCEDURE FOR CHARGING
Reference
• Handle (a): Turn counterclockwise to close the
valve, and clockwise to open the valve (to con-
nect the charge valve and accumulator)
a This valve is opened when tightened
• Handle (b): Turn counterclockwise to open the
valve (to open to the atmosphere), and clockwise
to close the valve (to disconnect from the atmos-
phere)
a This valve is closed when tightened
• Handle (c): Turn counterclockwise to close the
regulator (to stop discharge of gas), and clock-
wise to open the regulator (to discharge gas).
a This regulator is opened when tightened
5. Bleed air in the hoses according to the following
procedure.
1) Open valve (d) of nitrogen gas cylinder P7
until the pressure on the gas cylinder side of
regulator P5 becomes approximately 7 MPa
{70 kg/cm2}.
2) Slightly turn handle (c) clockwise to open,
and set the pressure on the hose side of
regulator P5 to 0.19 to 0.29 MPa {2 to 3 kg/
cm 2 }. When nitrogen gas starts leaking
through the threaded portion of handle (b),
turn handle (b) clockwise and close the
valve.
3) Turn handle (c) counterclockwise to close
the valve of regulator P5.
20-132-5
(6)
 TESTING OF ACCUMULATOR NITROGEN GAS
TESTING AND ADJUSTING PRESSURE AND PROCEDURE FOR CHARGING

6. Charge the accumulator with nitrogen gas Table 1 Accumulator charge gas pressure table
according to the following procedure. Ambient Gas pressure
a Keep valve (d) open as in the state of 5.1). tempera-
MPa kg/cm2
Remarks
1) Slowly turn handle (a) clockwise, and stop ture °C
when you feel a light reaction force. 15 3.06 31.2
a Do not turn handle (a) excessively, oth- 16 3.07 31.3
17 3.08 31.4
erwise it damages the accumulator 18 3.09 31.5
valve core and gas may leak. Operate 19 3.10 31.6
handle (a) carefully. 20 3.11 31.8
2) Slowly turn handle (c) clockwise to open the 21 3.12 31.9
valve of regulator P5, and add nitrogen gas 22 3.14 32.0
to the accumulator until the pressure gauge 23 3.15 32.1
of gas charging tool P1 indicates the speci- 24 3.16 32.2
25 3.17 32.3
fied gas pressure. 26 3.18 32.4
a During the work, turn handle (c) some- 27 3.19 32.5
times to close the valve of regulator P5 28 3.20 32.6
and stabilize the pressure, then check 29 3.21 32.7
the nitrogen gas pressure in accumula- 30 3.22 32.8
tor (1) with the gauge of gas charging 31 3.23 32.9
tool P1. 32 3.24 33.1
33 3.25 33.2
a Check the gas pressure by referring to 34 3.26 33.3
Table 1, since the gas pressure display 35 3.27 33.4
varies depending on the temperature at 36 3.28 33.5
measurement. 37 3.29 33.6
(The unit of values in the formula is °C) 38 3.31 33.7
Specified gas pressure = Standard gas 39 3.32 33.8
pressure x ((273 + t)/(273 + 50)) 40 3.33 33.9
41 3.34 34.0
t: Gas temperature at charge (°C) 42 3.35 34.1
Reference: "t" can be assumed to be the 43 3.36 34.2
ambient temperature. 44 3.37 34.4
3) When the gauge of gas charging tool P1 45 3.38 34.5
exceeds the specified gas pressure in Table 1 46 3.39 34.6
1] Turn handle (c) counterclockwise to 47 3.40 34.7
close the valve of regulator P5. 48 3.41 34.8
49 3.42 34.9
2] Slowly turn handle (b) counterclock- Standard temperature
wise, and gradually release the nitrogen 50 3.43 35.0
Standard gas pressure
gas through the threaded portion of
handle (b). Immediately after the gauge
of gas charging tool P1 reaches the
specified gas pressure in Table 1, turn
handle (b) clockwise to close the valve,
and adjust the nitrogen gas pressure in
accumulator (1).

20-132-6 WD900-3
(6)

TESTING AND ADJUSTING
7. When the nitrogen gas pressure in the accumu-
lator reaches the pressure in the table, remove
each tool according to the following procedure.
1) Turn handles (a) and (c) counterclockwise
to close the accumulator and valve of regu-
lator P5.
2) Close valve (d) of nitrogen gas cylinder P7.
3) Turn handle (b) counterclockwise to open
the valve, and discharge the nitrogen gas
remaining in gas charging tool P1 and hose
P4 through the threaded portion of handle
(b).
4) Remove hose P4, regulator P5, bushing P3,
and nipple P6.
5) Remove gas charging tool P1 from gas
valve (4) of accumulator (1).
6) Remove extension (8).
(New type accumulator)
7) Remove O-ring P2 from gas valve (4).
(Old type accumulator)
WD900-3
TESTING OF ACCUMULATOR NITROGEN GAS
PRESSURE AND PROCEDURE FOR CHARGING
8. Apply soapy water to gas valve (4) (previous
mention) of the accumulator, and check that the
nitrogen gas is not leaked.
9. Install cap (3) and valve guard (2) to accumula-
3 Cap:
tor (1).
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
10. Install plug (9) to accumulator (1).
3 Plug:
(New type accumulator)
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
11. Check that there is no reduction of the nitrogen
gas pressure within 1 week after the nitrogen
gas is charged.
a Check the functions within 5 minutes after
stopping the engine. (After 5 minutes or
longer of engine stop, the oil pressure of the
brake circuit is lowered and the correct test
cannot be performed.)
1) Stop the machine on a level ground, and set
the parking brake switch to "Park" position.
2) Start the engine, run it at medium speed for
a minute, and stop the engine.
3) Turn the starting switch to ON position.
Depress the brake pedal several times, and
count the number of times the brake is
depressed when the brake oil pressure cau-
tion lamp lights up.
20-132-7
(6)
 TESTING OF ACCUMULATOR NITROGEN GAS
TESTING AND ADJUSTING PRESSURE AND PROCEDURE FOR CHARGING

• When number of presses is 4 or less:

The accumulator gas pressure may be
low
• When number of presses is 5 or more:
The accumulator gas pressure is normal

Reference: How to discharge nitrogen gas when

discarding accumulator
a When discarding an uninstalled accumulator,
you need to discharge the nitrogen gas.
1. Connect gas charging tool P1 to gas valve (4) of
accumulator (1) or extension (8). For details,
see "Testing of accumulator nitrogen gas pres-
sure", 1 to 4.

2. Slowly turn handle (a) clockwise, and stop when

you feel a light reaction force.
a Do not turn handle (a) excessively, other-
wise it damages the accumulator valve core
and gas may leak. Operate handle (a) care-
fully.

3. Gradually tun handle (b) counterclockwise.

When nitrogen gas starts leaking through the
threaded portion of handle (b), leave the handle
as it is, and discharge the nitrogen gas.

4. When nitrogen gas stops leaking, leave handle

(a) as it is, and remove gas charging tool P1
from accumulator (1).

5. Remove extension (8).

(New type accumulator)

6. Remove O-ring P2 from gas valve (4).

(Old type accumulator)

7. Discard the accumulator.

a According to step 4, gas valve (4) of accumu-
lator (1) remains open.

20-132-8 WD900-3
(5)
TESTING AND ADJUSTING BLEEDING AIR FROM WHEEL BRAKE CIRCUIT

BLEEDING AIR FROM WHEEL
BRAKE CIRCUIT
a If brake circuit hoses were disconnected be-
cause of removing brake valve or axle, bleed air
as follows.
k Apply the parking brake and put blocks securely
under the tires.
k When engine is running, never bleed air from
5. Similarly, bleed air from the slack adjuster on the
opposite side and bleeder (3) of each wheel.
a If the accumulator pressure goes down, start
the engine and charge the accumulator.
a After completion of the air bleed operation,
run the engine at low idling, check the hy-
draulic oil level, and add oil if necessary.
a After bleeding air, perform "TESTING WHEEL
BRAKE PERFORMANCE".

slack adjuster because drive shift is rotating.

1. Start the engine and accumulate the pressure in

the accumulator (about 30 seconds at the high
idling speed).

2. Stop the engine and insert either end of vinyl

hoses [1] in bleeders (2) of slack adjuster (1),
then insert the other end in the container.

3. Depress the brake pedal, loosen the bleeder

screw, and bleed the air. Tighten the screw,
then release the brake pedal slowly.
a Carry out this operation with two workers:
one worker depresses the brake pedal, and
the other worker bleeds the air from the
bleeder screw.
a Use L.H. brake pedal.
a If brake oil level goes down, refill oil to keep
full.

4. Repeat this operation until no more bubbles

come out with the fluid from the vinyl hose, then
depress the pedal fully and tighten the bleeder
screw while the oil is flowing out.

WD900-3 20-133
TESTING AND ADJUSTING TESTING PARKING BRAKE PERFORMANCE

TESTING PARKING BRAKE

PERFORMANCE
a Measurement condition
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved surface with 1/5
(11°20’) gradient.
• Machine: In operating condition

1. Start the engine and drive the machine straight

up a 1/5 gradient with the bucket unloaded.

2. Depress the brake, place the directional lever in

neutral, then stop the engine.

3. Turn the parking brake switch ON, then slowly

release the brake pedal and keep the machine
must be kept stopped.
a The measurement must be made with the
machine facing either up or down the slope.

20-134 WD900-3
TESTING AND ADJUSTING MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE

MEASURING PARKING
BRAKE SOLENOID OUTPUT
PRESSURE
a Brake oil temperature: 45 – 55°C
k Put blocks securely under the tires.
k Depress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulator circuit.

1. Turn starting switch ON, then parking brake

switch OFF to release brake.

2. Remove front frame right sidecover. 5. Start engine and after accumulator charged,
turn parking brake switch ON.
3. Disconnect parking brake spring cylinder output
hose (1) from parking brake solenoid valve. 6. Measure oil pressure with the engine slow.

k After measuring parking brake oil pressure, de-

press the brake pedal at least 100 times with the
engine stopped to release the pressure inside
the accumulator circuit, and remove measuring
tools after turning parking brake switch OFF.

4. Connect nipple C2 and oil pressure gauge C1

(39.2 MPa {400 kg/cm2}).

WD900-3 20-135
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD

CHECKING AND ADJUSTING ADJUSTING

a If the measured value is not within the standard
PARKING BRAKE PAD value, adjust as follows.
k Block the tires securely.
1. Turn the starting switch ON, then turn the park-
ing brake switch OFF to release the brake.
MEASURING a If the main switch is turned OFF, so be care-
1. Turn the starting switch ON, and turn the parking ful the parking brake will be actuated.
brake switch (1) OFF to release the brake.
2. Turn adjustment bolt (4) of parking brake slack
2. Measure the thickness of the parking brake pad. adjuster (3) clockwise until parking brake pad (2)
Measure the thickness of the parking brake pad is lightly in contact with disc (3).
with thickness gauge F. a If the adjustment bolt is tightened too much
k When the starting switch is turned OFF, the
and parking brake pad (2) and disc (3) are
parking brake is applied, so be careful not to brought strongly into contact, it may cause
turn it OFF. the brake to squeak or the discs to overheat.
a Measure 4 pads.
a If the thickness is not within the standard val-
ue, replace the 2 parking brake pads as one
set.
a For details of removing the parking brake
pad, see "DISASSEMBLY AND ASSEM-
BLY".

3. Measure the parking brake pad clearance.

Insert thickness gauge F between disc (1) and
pad (2), then measure the clearances.
a The clearance value mentioned above indi-
cates the total value of both sides. (a + b)
k Note that the parking brake is actuated if the
starting switch is turned OFF. 3. Return adjustment bolt (1) 180° ± 30° (three
notch) counterclockwise. This will adjust the
total clearance on the left and right between
pad (2) and disc (1) to 1.06 ± 0.18 mm.

a After adjusting, measure the brake performance

again and check that it is within the standard val-
ue.

20-136 WD900-3
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC PRESSURE

TESTING AND ADJUSTING 2. Measuring PPC valve output pressure

1) Remove work equipment valve cover.
PPC PRESSURE 2) Remove plug (PT 1/8) (2) for blade LOWER
circuit oil pressure measuring, and install
a Hydraulic oil temperature: 45 – 55°C
k Loosen the oil filler cap slowly to release the
nipple C2 and oil pressure gauge C1 (5.9
MPa {60 kg/cm2}).
pressure inside the hydraulic tank.
k Operate the control levers 2 – 3 times to release
the pressure in the PPC accumulator circuit.

MEASURING
1. Measuring PPC relief pressure
1) Remove plug (PT 1/8) (1) for P port oil pres-
sure measuring from bottom of PPC valve
assembly.

2) Install nipple C2 and oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).

3) Start the engine and raise the blade. Pitch

the blade with the engine at the full speed
and measure the hydraulic pressure when
the relief valve operates.

3) Start engine and measure oil pressure with

the engine full throttle.

WD900-3 20-137
TESTING AND ADJUSTING ADJUSTING PPC VALVE LINKAGE

ADJUSTING ADJUSTING PPC VALVE

1. Adjusting PPC relief valve
LINKAGE
k Adjust the hydraulic pressure while the engine is
stopped.
k
1. Remove cover at the bottom of the work equip-
Gradually loosen the oil filler cap of the hydraulic ment control lever.
tank to release the pressure from the tank.
k Operate the work equipment control lever two – 2. Adjust dimension a from nut (1) of the PPC
three times to release the pressure from the ac- valve linkage to the top surface of the floor.
cumulator circuit for PPC. • Dimension a (target value): 54 mm
1) Remove the upper cover of the transmis-
sion. 3. Loosen nuts (2) and (3), then adjust the installed
2) Remove cap nut (3) of the PPC relief valve height of trunnion (5) so that there is no play in
beside the accumulator charge valve for lever (4).
PPC.
4. After adjusting, tighten nuts (2) and (3).

3) Loosen locknut (4) and adjust with the

adjustment screw (5).
a Adjustment screw
• To INCREASE, turn CLOCKWISE
• To DECREASE, turn COUNTERCLOCK-
WISE
a Pressure adjustment for one turn of adjust-
ment screw: 0.96 MPa {9.8 kg/cm2}

20-138 WD900-3
 TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING HYDRAULIC PRESSURE

TESTING AND ADJUSTING

WORK EQUIPMENT
HYDRAULIC PRESSURE
a Hydraulic oil temperature: 45 – 55°C

k Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.

MEASURING
1. Measuring work equipment relief pressure
1) Raise blade portion a approx. 30 – 50 mm.
2) Stop the engine, then operate the work
equipment control lever and check that the
bottom of the blade end-bit is in contact with
the ground.
k After lowering the blade to the ground, oper-
ate the work equipment control lever 2 – 3
times to release the remaining pressure in
the piping.

4) Start the engine and raise the blade, with

the engine at the full speed and measure
the hydraulic pressure when the relief valve
operates.
k After measuring, repeat the procedure
used when installing the oil pressure
gauge to release the pressure inside
the circuit, then remove the oil pressure
3) Remove plug (PT 1/8) (1) for blade RAISE gauge.
circuit hydraulic pressure measuring, and
install nipple C2 and oil pressure gauge C1
(39.2 MPa {40 kg/cm2}).

WD900-3 20-139
 TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING HYDRAULIC PRESSURE

ADJUSTING
Adjusting work equipment relief valve
k Adjust the hydraulic pressure while the engine is
stopped.
Loosen locknut (3) of work equipment relief valve
(2), then turn adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust as follows.
• To INCREASE the pressure, turn CLOCK-
WISE.
• To DECREASE the pressure, turn COUN-
TERCLOCKWISE.
a Amount of adjustment for one turn of adjustment
screw: 12.6 MPa {128 kg/cm2)
a After completion of the adjustment, repeat the
above procedure to measure the work equip-
ment relief pressure again.

20-140 WD900-3
TESTING AND ADJUSTING BLEEDING AIR FROM PISTON PUMP

BLEEDING AIR FROM PISTON 4. Loosen the mouthpiece of the case drain hose
(4), starting an engine at the condition of low
PUMP idling. Tighten the mouthpiece, confirming that
hydraulic oil flows from the mouthpiece.
a When replacing oil inside hydraulic tank or re-
moving piston pump or hydraulic pipings of pis-
ton pump, bleed air from piston pump to prevent
pump inner parts seizing as follows.

1. Check that the hydraulic tank is filled with

hydraulic oil.
a The cap of the hydraulic tank remains re-
moving, until the air bleeding of the piston
pump finishes.

2. Loosen plugs (1), (2) and (3) of piston pump

suction tube.

3. When oil overflows from plugs (1), (2) and (3) in

turn, and tighten plugs under air is bled com-
pletely. After that, in order to fill the inside of the
pump with the hydraulic oil, leave it for 10 min-
utes.

a Since the oil level in the hydraulic tank is higher

than positions (1), (2) and (3) above, air is bled
easily.

WD900-3 20-141
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT

BLEEDING AIR FROM WORK

EQUIPMENT CIRCUIT
a Bleed the air from the circuit as follows if the work
equipment control valve or work equipment cylin-
ders have been removed and installed again.

1. Start the engine and run at idling for approx. 5

minutes.

2. Run the engine at engine slow and raise and

lower the blade 4 – 5 times in turn.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.

3. Repeat Step 2 with the engine at full throttle.

4. Run the engine at engine slow and operate the

piston to the end of its stroke to relieve the cir-
cuit.

5. Repeat Steps 2 to 3 for the bucket cylinder also.

20-142 WD900-3
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE

ADJUSTING WORK EQUIPMENT LEVER LINKAGE

a 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.
a Carry out the adjustment with the engine stopped.
a Check that the operating effort of the work equip-
ment lever is within the standard value.
a Remove the side cover at the bottom of the work
equipment lever.

WD900-3 20-143

TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
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
dimension a from the center of trunnion (2)
to the top surface of the floor.
• Dimension a (target value): 54 mm
3) Install levers (4), (5) to trunnion (2) and secure
3 Bushing portion: Grease (G2-LI)
with nut (6).
2. Adjusting rod
1) Connect rod (7).
2) Operate work equipment lever (8) to the
LOWER position and adjust the lenght 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 posi-
tion.
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 posi-
tion, and adjust the mounting hole of spring
(13) so that it is the standard value.
a Measure the release effort with push-
pull scale J1.
• Standard release effort: 19.6 N {2 kg}
a Standard spring mounting hole: 2nd hole
from top.
20-144
ADJUSTING PPC VALVE LINKAGE
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
1. Releasing remaining pressure between each
hydraulic cylinder and control valve
a 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.
a When the levers are operated 2 – 3
times, the pressure stored in the PPC
accumulator is removed. Start the en-
gine, run at low idling for approx. 5 min-
utes, then stop the engine and operate
the control levers.
a Repeat the above operation 2 – 3 times
to release all the remaining pressure.
2. Releasing remaining pressure in brake accu-
mulator circuit
a If the piping between the accumulator and
accumulator check valve, and between the
accumulator and brake valve is to be discon-
nected, release the remaining pressure from
the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times
to release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure PPC accumu-
lator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, re-
lease the remaining pressure from the circuit
as follows.
• Operate the control lever 2 – 3 times to re-
lease all the remaining pressure.
WD900-3
TESTING AND ADJUSTING ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR

ADJUSTING SPEEDOMETER 3) After completing adjustment, fit the rubber

caps securely and install the main monitor.
MODULE OF MAIN MONITOR
Correction amount of switch 2 (for reference)
• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal for Switch position 0 1 2 3 4 5 6 7
the travel speed differs according to the ma- Correction
chine, so it is necessary to adjust the monitor for +14 +12 +10 +8 +6 +4 +2 0
amount (%)
use with the particular model.
Switch position 8 9 A B C D E F
ADJUSTMENT PROCEDURE
• Turn off the power, then remove the machine Correction
0 –2 –4 –6 –8 –10 –12 –14
amount (%)
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.

Switch 2 Switch 3
Switch 1
(speedo- (tacho-
Tire size (model
meter meter input
selection)
correction) selection)
45/65-45-46PR 0 7 0

WD900-3 20-145
TESTING AND ADJUSTING ADJUSTING JOYSTICK LEVER POTENTIOMETER

ADJUSTING JOYSTICK 3) Check the voltage between pins [2] and [3]
of the T-adapter.
LEVER POTENTIOMETER • Voltage between pins: DC 5V ± 0.05V
Adjust the voltage by turning the potentiom-
STEERING WHEEL AND JOYSTICK STEER- eter slowly so that the voltage between pins
ING SPECIFICATION [1] and [3] of the T-adapter become the
standard value.
PREPARATORY WORK • Voltage between pins: DC 2.5V ± 0.1V
Loosen the potentiometer mounting screws, remove (set value)
potentiometer connector CNJS2, then connect a T- After adjusting the voltage, tighten the poten-
adapter (X type 3-pin). tiometer mounting screws.
a Turn the starting switch OFF before doing this.

1. Adjusting neutral position

1) Set the joystick selector switch to the OFF
position and set the joystick lever to the N
position.

2) Turn the starting switch ON.

a Turn only to the ON position. Do not start
the engine.

20-146 WD900-3
TESTING AND ADJUSTING ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH

2. Adjusting left and right turning position

1) Operate the potentiometer to adjust the volt-
ADJUSTING JOYSTICK
age at the left and right turn positions. LEVER NEUTRAL DETECTION
SWITCH
Voltage between
Lever position
pins (1) and (3) STEERING WHEEL AND JOYSTICK STEERING
Left turn DC 0.83 V ± 0.1 V SPECIFICATION
Right turn DC 4.17 V ± 0.1 V
PREPARATORY WORK
After adjusting the neutral position with the
2) After adjusting the voltage, lock the stopper
potentiometer, set the lever to the neutral posi-
bolt in position.
tion and loosen the nut of the cam plate.

ADJUSTING
1) Set so that the tip of the roller of the neutral
detection switch contacts the concave por-
tion of the cam plate, then tighten the switch
mounting bolts.
a Never make the roller of the neutral de-
tection switch push into the concave por-
tion of the cam plate.

2) Tighten the nut so that the cam plate is not

at an angle.

WD900-3 20-147
 TROUBLESHOOTING
Precautions before work ........................................................................................................................ 20-201-1
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 location stereogram ................................................................................................................... 20-218
Connection table for connector pin numbers .............................................................................................. 20-224
T-branch box and T-branch table ................................................................................................................ 20-249
Explanation of functions of electric control mechanism .............................................................................. 20-252
Method of displaying action code and failure code ..................................................................................... 20-256
Chart of action codes and failure codes, and re-enaction........................................................................... 20-258
Transmission controller led display ............................................................................................................. 20-261
Method of using judgement table ................................................................................................................ 20-263
Method of using troubleshooting charts ...................................................................................................... 20-264
Method of using matrix troubleshooting tables............................................................................................ 20-266
Method of using troubleshooting charts ...................................................................................................... 20-302
Troubleshooting of transmission control system (T MODE)........................................................................ 20-401
Troubleshooting of main monitor system (M MODE) .................................................................................. 20-501
Troubleshooting of maintenance monitor system (K MODE) ...................................................................... 20-601
Troubleshooting of electrical system (E MODE) ......................................................................................... 20-701
Troubleshooting of hydraulic and mechanical system (H MODE)............................................................... 20-801
Troubleshooting of ajss (advanced joystick steering system) control system (A MODE) ........................... 20-851

WD900-3 20-201
(9)
TROUBLESHOOTING PRECAUTIONS BEFORE WORK

PRECAUTIONS BEFORE WORK

Before you start, read the “SAFETY NOTICE” of the “SAFETY” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a
danger that you can get caught in the machine.
• Do not wear oversized clothes or accessories.
• Be sure to tie the long hair that comes out from the helmet.
k When you work together with more than one person, do the preparation that follows.
• Decide on the work procedure.
• Obey the specified signal during the work.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange
an observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not
to let the machine move.
• Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
• Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts,
there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.

20-201-1 WD900-3
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k 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.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
any failure occurs:
• Parts that have no connection with the failure
or other unnecessary parts will be disassem-
bled.
• It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshoot-
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
4. Confirming failure
• Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measure-
ment that may make the problem worse.
5. Troubleshooting
• Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
causes of failure, then use the troubleshoot-
ing flowchart to locate the position of the fail-
ure exactly.
a The basic procedure for troubleshooting
is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or
information.
6. Measures to remove root cause of failure
• Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
failure will occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root
cause.

20-202 WD900-3
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

WD900-3 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1. Points to remember when handling electric

equipment

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, 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, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely 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 sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.

20-204 WD900-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the 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 electricity through it.

5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating 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.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.

WD900-3 20-205
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors

and wiring harnesses

• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a 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.
a 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.
a 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 WD900-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a 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.
a 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 wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.

• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c

WD900-3 20-207
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Drying wiring harness

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

If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move 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.
a 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 re-
lated parts too hot, as this will cause de-
formation or damage to the connector.

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.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.

20-208 WD900-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box

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

3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the 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
connected to the control box. Fit an arc
welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a 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.
a If there is any change, there is probably defective contact in that circuit.

WD900-3 20-209
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic

equipment

With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling 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
prepared dustproof workshop, and the perfor-
mance 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 enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect 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 refill-

ing 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 WD900-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants 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,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

WD900-3 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Remedy
standard
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil,
cooling water

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 (oil pan 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
equipment
Electrical

10. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
12. Check operation of instruments — Repair or replace
13. Check for abnormal noise, smell — Repair
mechanical
equipment
Hydraulic,

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
Electrics, electrical equipment

18. Check battery electrolyte level — Add or replace

19. Check for discolored, burnt, exposed wiring — Replace
20. Check for missing wiring clamps, hanging wiring — Repair
21. Check for water leaking on wiring (be particularly careful attention to — Disconnect
water leaking on connectors or terminals) — connector and dry
22. Check for blown, corroded fuses — Replace
23. Check alternator voltage (engine running at 1/2 throttle or above) —
(If the battery charge is low, the voltage may be approx. 25 V immedi- 28.5– 29.5 V Replace
ately after starting.)
24. Sound of actuation of battery relay — —
(when starting switch is turned ON, OFF)

20-212 WD900-3
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

CONNECTOR TYPES AND MOUNTING LOCATIONS

a The addresses cloumn in the table below shows the address in the connector arrangement drawing.
Connector Number
Type Device name Address
No. of pins
A4 X 2 Air conditioner REC & FRE air servomotor U-9
A5 M 2 Air conditioner thermistor X-6
A6 SWP 6 Air conditioner air mix servomotor X-6
A7 M 6 Air conditioner blower motor & resistor X-7
A8A S 10 Intermediate connector (Air conditioner) X-6
A8B S 8 Intermediate connector (Air conditioner) X-5
A9 YAZAKI 4 Air conditioner blower relay (MAIN) X-4
A10 YAZAKI 4 Air conditioner blower relay (M1) X-4
A11 YAZAKI 4 Air conditioner blower relay (M2) X-4
A12 YAZAKI 4 Air conditioner condenser relay X-3
A13 YAZAKI 4 Air conditioner blower relay (M1) X-5
A14 YAZAKI 2 Air conditioner condenser M1 (1) relay W-3
A15 YAZAKI 4 Air conditioner condenser M1 (2) relay W-2
A16 YAZAKI 4 Air conditioner magnetic clutch relay X-3
A17 AMP 16 Air conditioner control amplifier Q-1
A18 SWP 8 Air conditioner left detective servomotor S-1
A19 SWP 8 Air conditioner right detective servomotor N-4
A20 AMP 12 Air conditioner control amplifier R-1
A21 X 2 Air conditioner condenser Hi-Lo switch X-7
A22 YAZAKI 2 Air conditioner condenser Me switch X-8
AL01 Terminal 1 Battery relay L-5
AL02 Terminal 1 Battery relay L-5
AR01 Terminal 1 Battery relay L-6
AR02 Terminal 1 Battery relay K-9
AR03 Terminal 1 Battery relay K-9
ASS X 2 Air suspension seat W-8
B01 KES1 2 Low idling selector solenoid F-9
B02 KES1 2 Front window shield washer I-9
B03 KES1 2 Diode L-5
B04 KES1 2 Rear window shield washer I-9
B05 KES1 2 Diode I-9
B06 One-pin connector 1 Left dust indicator L-4
B07 One-pin connector 1 Left dust indicator L-4
B08 One-pin connector 1 Right dust indicator G-9
B09 One-pin connector 1 Right dust indicator G-9
B10 X 2 Air conditioner left condenser L-6
B11 X 1 Air conditioner left condenser L-6
B12 X 2 Air conditioner right condenser H-9
B13 X 1 Air conditioner right condenser H-9
BC01 X 2 Speed sensor F-1
BC02 X 2 Torque converter oil filter sensor I-2
BC03 X 2 Torque converter oil filter sensor H-1
BC04 X 2 Brake accumulator low pressure switch G-1
BC05 X 2 Brake accumulator low pressure switch H-1
BC06 X 2 Brake accumulator low pressure switch J-2
BC07 X 2 Brake accumulator low pressure switch J-2
BC08 X 2 Emergency brake switch G-1
BC09 X 2 Emergency brake switch H-1
BC10 X 2 Emergency brake switch I-2

WD900-3 20-213
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector Number
Type Device name Address
No. of pins
BR1 SWP 12 Intermediate connector K-3
C1 MIC 13 Transmission & joystick steering controller P-7
C2 MIC 21 Transmission & joystick steering controller N-6
C3A AMP040 20 Transmission & joystick steering controller O-7
C3B AMP040 16 Transmission & joystick steering controller P-7
C4 AMP040 12 Transmission & joystick steering controller O-6
C5 MIC 17 Transmission & joystick steering controller N-6
C01 M 6 Front wiper motor C-7
C02 YAZAKI 9 Cassette stereo & radio C-7
C03 M 2 Right front working lamp D-8
C04 M 2 Left front working lamp D-8
C05 KYORITSU 4 Warning lamp (Beacon) switch D-8
C06 KES1 2 Room lamp E-9
C07 M 4 Rear wiper motor K-7
C08 One-pin connector 1 Cigarette lighter C-7
C09 Terminal 1 Cigarette lighter D-8
C10 M 1 Power supply C-7
C11 X 2 Emergency brake switch J-2
C13 KES0 2 Left speaker G-9
C14 KES0 2 Right speaker F-9
C15 One-pin connector 1 Warning lamp (If equipped) —
C16 M 2 Left side working lamp G-9
C17 M 2 Right side working lamp E-8
CBL1 SWP 8 Intermediate connector U-1
CL1 S 12 Intermediate connector N-4
CL2 S 10 Intermediate connector (Air conditioner) N-3
CL3 M 6 Intermediate connector (Air conditioner) N-3
CL4 M 6 Intermediate connector N-4
CL18 — 1 Right power window regulator —
CL19 — 1 Left power window regulator —
CL20 — 1 Right power window regulator —
CL21 — 1 Left power window regulator —
D19 Solenoid valve AE-2
E02 Terminal 1 Starting motor Z-3
E03 X 2 Engine speed sensor Z-3
E03 SWP 8 Engine stop motor L-5
E04 X 2 Engine water temperature sensor (Monitor) AB-7
E05 AMP250 1 Engine water temperature sensor (Timer) AB-7
E06 X 2 Starting motor Y-3
E07 X 2 Starting motor Y-3
E08 X 1 Air compressor magnetic clutch AC-7
E09 Terminal 1 Engine oil pressure switch Z-3
E10 Terminal 1 Right heater relay Z-7
E11 Terminal 1 Right heater relay Z-7
E12 Terminal 1 Left heater relay AC-3
E13 Terminal 1 Left heater relay AD-4
E14 KES 2 Diode Y-5
E15 KES 2 Diode Y-4
E16 KES 2 Diode Y-5
E17 KES 2 Diode Y-4
E18 KES 2 Diode AD-5
E19 KES 2 Diode AB-2

20-214 WD900-3
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector Number
Type Device name Address
No. of pins
E20 Terminal 1 Alternator AD-6
E21 Terminal 1 Alternator AD-7
E22 Terminal 1 Alternator AD-6
ER1 SWP 12 Intermediate connector Y-6
ER2 L 2 Intermediate connector Y-4
ER3 L 2 Intermediate connector AA-3
F01 M 4 Intermediate connector A-5
F02 M 3 Intermediate connector A-5
F03 M 3 Intermediate connector A-3
F04 M 4 Intermediate connector A-3
F05 X 3 — —
F06 X 3 — —
F07 Terminal 1 Horn C-1
F08 Terminal 1 Horn D-1
F09 Terminal 1 Horn A-5
F10 Terminal 1 Horn A-4
F11 X 2 Parking brake solenoid B-1
F13 X 2 Parking brake indicator switch C-1
F14 X 2 Pitch, tilt select solenoid A-1
FF+ Themo switch (For fan) (front) AJ-6
FF– Themo switch (For fan) (front) AJ-6
FL Flasher unit AJ-2
FL+ Themo switch (For lamp) (front) AJ-6
FL– Themo switch (For lamp) (front) AJ-6
FLR Caution lamp relay AJ-3
FL1 S 12 Intermediate connector X-5
FL2 SWP 6 Intermediate connector W-2
FS1 L 2 Intermediate connector W-8
FS2 S 12 Intermediate connector W-8
FS3 M 6 Intermediate connector V-9
FS4 L 2 Intermediate connector V-9
FS5 M 6 Intermediate connector V-9
FS6 M 4 Intermediate connector U-9
G01 M 6 Right rear combination lamp I-9
G02 M 2 Right working lamp K-8
G03 M 2 Right working lamp J-9
G04 Terminal 1 Backup buzzer L-6
G05 Terminal 1 Backup buzzer L-6
G06 X 2 Radiator water level sensor J-9
G07 M 2 Left working lamp K-8
G08 M 2 Left working lamp L-6
G09 M 6 Left rear combination lamp L-8
GND M 1 Right front combination lamp B-6
GND M 1 Left front combination lamp D-1
GND Additional brake cooling harness AE-3
GR1 SWP 12 Intermediate connector K-8
GRE SWP 6 Auto grease T-1
HEAD M 2 Right head lamp A-6
HEAD M 2 Left head lamp A-2
INJ Caution lamp AJ-4
JL1 S 8 Joystick steering —
JL2 S 8 Joystick steering —

WD900-3 20-215
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector Number
Type Device name Address
No. of pins
L01 M 6 Parking brake switch O-2
L02 SWP 6 Lighting & dimmer switch P-1
L03 SWP 6 Turn signal & hazard switch O-2
L04 SWP 14 Directional & shift switch P-1
L05 AMP040 20 Main monitor N-5
L06 AMP040 16 Main monitor N-2
L07 AMP040 12 Main monitor N-4
L08 AMP040 8 Main monitor O-2
L09 M 4 Starting switch O-2
L10 S 10 Front & rear wiper switch P-1
L12 X 2 Transmission cut-off switch R-1
L15 M 4 Kickdown switch & shift-up switch P-7
L16 KES1 2 — —
L17 KES1 2 — —
L18 AMP040 16 Sub-monitor Q-8
L19 AMP040 8 Sub-monitor Q-8
L20 S 6 Blade control lever connector O-7
L21 KES1 2 Sub-monitor R-8
L22 KES1 2 Sub-monitor R-9
L26 X 2 Joystick steering left solenoid (If equipped) S-1
L27 X 2 Joystick steering right solenoid (If equipped) S-1
L39 KES1 6 Joystick steering ON/OFF solenoid [Steering wheel and joystick specification] R-8
L40 — 7 Right power window switch Q-8
L41 — 7 Left power window switch P-8
L42 One-pin connector 1 Caution buzzer S-9
L43 One-pin connector 1 Caution buzzer S-9
L44 — 6 Wiper relay T-9
L46 KES1 4 Flasher unit T-9
L48 — 5 Bucket relay M-7
L49 — 5 Boom relay N-7
L50 — 5 Low idling selector relay P-8
L51 — 6 Side working lamp relay N-9
L52 — 5 Hazard relay M-7
L53 — 5 Stop lamp relay M-7
L54 — 5 Backup lamp relay N-9
L55 — 5 Horn relay N-7
L56 — 5 Preheater relay O-9
L57 — 5 Neutral relay M-7
L58 — 5 Neutralizer relay M-8
L59 — 5 Parking brake safety relay M-9
L60 — 6 Front working lamp relay N-9
L61 — 6 Rear working lamp relay N-9
L62 — 5 Engine stop relay M-9
L63 One-pin connector 1 Horn switch P-1
L64 — 5 Engine oil pressure relay M-8
L65 — 5 Joystick steering caution relay N-7
L66 — 5 Joystick steering selector relay P-7
L67 — 5 Joystick steering cut-out solenoid relay P-8
L71 — 5 Left power window RAISE relay P-9
L72 — 5 Left power window LOWER relay P-8
L73 — 5 Right power window RAISE relay O-9
L74 — 5 Right power window LOWER relay O-9

20-216 WD900-3
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS

Connector Number
Type Device name Address
No. of pins
L79 — 5 Left dust indicator relay M-9
L80 — 5 Right dust indicator relay M-8
L81 X 2 Stop lamp switch Q-1
LM1 S 10 Management monitor X-8
LR1 SWP 14 Intermediate connector V-1
LR2 SWP 12 Intermediate connector V-2
LR3 SWP 16 Intermediate connector T-1
LR4 M 4 Intermediate connector U-1
LR5 L 2 Intermediate connector U-1
R01 X 2 Emergency steering indicator switch G-1
R02 X 1 Engine oil level sensor L-4
R03 KES 2 Diode L-4
R04 KES 2 Diode L-4
R05 X 2 Fuel level sensor L-5
R06 Terminal 1 Slow-blow fuse AA-2
R07 Terminal 1 Slow-blow fuse AB-2
R08 Terminal 1 Slow-blow fuse AC-3
R09 Terminal 1 Slow-blow fuse AC-3
R11 Terminal 1 Battery L-5
RA1 X 3 Battery relay L-6
RA2 X 2 Battery relay L-5
RF Intermediate connector AE-1
RF+ Themo switch (for fan) (rear) AJ-7
RF– Themo switch (for fan) (rear) AJ-7
RL+ Themo switch (for lamp) (rear) AJ-7
RL– Themo switch (for lamp) (rear) AJ-7
SEL1 M 4 Machine selection Q-1
SMALL M 1 Right front combination lamp B-7
SMALL M 1 Left front combination lamp E-1
T01 MS 10 Transmission solenoid J-3
T02 X 2 Torque converter oil temperature sensor F-9
TR1 SWP 8 Intermediate connector H-9
TURN M 1 Right front combination lamp B-6
TURN M 1 Left front combination lamp F-1
WORK M 2 Right working lamp A-6
WORK M 2 Left working lamp A-1
+24V Power 24V AI-1

WD900-3 20-217
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

CONNECTOR LOCATION STEREOGRAM

20-218 WD900-3
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

WD900-3 20-219
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

20-220 WD900-3
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

WD900-3 20-221
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

20-222 WD900-3
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM

WD900-3 20-223
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a 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.

X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010

2 799-601-7020

Part No.: 08055-00282 Part No.: 08055-00292

3 799-601-7030

Part No.: 08055-00381 Part No.: 08055-00391

4 799-601-7040

Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
• Electric wire size: 2.0 • Electric wire size: 2.0
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-224 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

6 799-601-7050

Part No.: 08055-10681 Part No.: 08055-10691

8 799-601-7060

Part No.: 08055-10881 Part No.: 08055-10891

12 799-601-7310

Part No.: 08055-11281 Part No.: 08055-11291

14 799-601-7070

Part No.: 08055-11481 Part No.: 08055-11491

WD900-3 20-225
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

16 799-601-7320

Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
• Electric wire size: 1.25 • Electric wire size: 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-226 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080

2 799-601-7090

Part No.: 08056-00271 Part No.: 08056-00281

3 799-601-7110

Part No.: 08056-00371 Part No.: 08056-00381

4 799-601-7120

Part No.: 08056-00471 Part No.: 08056-00481

6 799-601-7130

Part No.: 08056-00671 Part No.: 08056-00681

8 799-601-7340

Part No.: 08056-00871 Part No.: 08056-00881

WD900-3 20-227
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10
799-601-7150
(White)

Part No.: 08056-11071 Part No.: 08056-11081

12
799-601-7350
(White)

Part No.: 08056-11271 Part No.: 08056-11281

16
799-601-7330
(White)

Part No.: 08056-11671 Part No.: 08056-11681

20-228 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

10
—
(Blue)

— —

12
799-601-7160
(Blue)

Part No.: 08056-11272 Part No.: 08056-11282

16
799-601-7170
(Blue)

Part No.: 08056-11672 Part No.: 08056-11682

WD900-3 20-229
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —

5 799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)

9 799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)

13 799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)

20-230 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

17 799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)

21 799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)

WD900-3 20-231
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 799-601-7180

— Housing part No.: 79A-222-3430 (Q’ty: 5)

12 799-601-7190

— Housing part No.: 79A-222-3440 (Q’ty: 5)

16 799-601-7210

— Housing part No.: 79A-222-3450 (Q’ty: 5)

20 799-601-7220

— Housing part No.: 79A-222-3460 (Q’ty: 5)

a Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-232 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-7510

— Part No.: 08195-10210

12 799-601-7520

— Part No.: 08195-12210

14 799-601-7530

— Part No.: 08195-14210

18 799-601-7540

— Part No.: 08195-18210

20 799-601-7550

— Part No.: 08195-20210

WD900-3 20-233
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

— —

Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

9 —

— —

Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-3460

— —

20-234 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part No.:08027-10310 Part No.:08027-10360

4 —

Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

WD900-3 20-235
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 —

Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

Connector for relay (Socket type)

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

5 799-601-7360

— —

6 799-601-7370

— —

20-236 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 —

— —

WD900-3 20-237
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Metri-Pack connector
No.of
pins T-adapter
Female terminal (socket)
Part No.

2 —

— —

3 —

— —

Metri-Pack connector
No.of
pins T-adapter
Male terminal (pin)
Part No.

4 —

— —

20-238 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

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 termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female termial)

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
(2) Pin (female terminal) Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106

WD900-3 20-239
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9230

18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

Pin (male terminal) Pin (female termial)

799-601-9240

18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102

20-240 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9250

24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

Pin (male terminal) Pin (female termial)

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
(6) Pin (female terminal) Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106

WD900-3 20-241
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

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
(7) Pin (female terminal) Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106

20-242 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male termial) Pin (female terminal)

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
(9) Pin (female terminal) Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106

WD900-3 20-243
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.

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

Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

20-244 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.

8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090

Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140

Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)

WD900-3 20-245
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DTM Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

799-601-9010
2

Part No.: 08192-02200 Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]

DTHD Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

1 —

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)

20-246 WD900-3
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Deutch connector
No.of
pins T-adapter
Receptacle Plug
Part No.

2 —

— —

WD900-3 20-247
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

ECONOSEAL CONNECTOR
No.of
pins T-adapter
Female terminal (Socket) Male terminal (Pin)
Part No.

2 —

— —

3 —

— —

4 —

— —

8 —

— —

12 —

— —

20-248 WD900-3
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or

—
Part No. No. of pins
part name

799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P

WD900-3 20-249
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or

—
Part No. No. of pins
part name

799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P

20-250 WD900-3
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

TRANSMISSION CONTROL SYSTEM

20-252 WD900-3
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

MAIN MONITOR SYSTEM

WD900-3 20-253
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

MAINTENANCE MONITOR SYSTEM

20-254 WD900-3
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

JOYSTICK STEERING CONTROL SYSTEM

WD900-3 20-255
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE

METHOD OF DISPLAYING
ACTION CODE AND FAILURE
CODE
1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each control
system. The nature of the troubleshooting is dis-
played as the failure action code, failure code, and
the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the net-
work circuit. (Only the engine controller uses a spe-
cial parallel signal.)

2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01
+ CALL (E01 and CALL are displayed alter-
nately), and CALL. If a failure occurs suddenly,
one of these codes is shown on the speedome-
ter display.

3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which con-
troller has failed, so carry out troubleshooting for
the applicable controller.

4. Saving failure code

The transmission and joystick steering 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
deleted and the new item is saved.
a 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.

20-256 WD900-3
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE

5. Switch operation procedure and actuation

Switch operation Actuation

Trouble data memory

mode display
1) Stop engine. • The failure code is dis-
2) Turn starting switch ON. played on the speedom-
3) Push operation mode eter display and the
switch (1) and head time elapsed since fail-
lamp switch (2) simulta- ure is displayed on the
neously and keep action code display.
pressed for at least 5 • If there is no failure, the
seconds. speedometer display
shows [CC] and the
action code display
shows [0000].
Going to nest failure
code
4) Press head lamp switch • The failure code and
(2). time elapsed since fail-
ure are displayed in turn
(when this is done, the
failure code for the lat-
est failure is displayed
first).
• If the failure still exists,
the display flashes; if
the failure has been
restored, the display
lights up.
Clearing failure code
5) Keep rear lamp switch • The failure code and
(3) pressed for at least elapsed time on the dis-
2 seconds. play are cleared.
• If the failure still exists,
the failure code is not
cleared.
Quitting trouble data
memory display mode
6) Push operation mode • The display returns to
switch (1) and head the normal display.
lamp switch (2) simulta-
neously and keep
pressed for at least 5
seconds. Or start the
engine.

WD900-3 20-257
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION

CHART OF ACTION CODES AND FAILURE CODES, AND

RE-ENACTION
STEERING WHEEL SPECIFICATION
1. Transmission control system codes table
Failed system Re-enaction
Action Failure Alarm
Item Short Discon- Short Discon- memory
code code buzzer
circuit nection circuit nection
— 10 Back lamp relay Q Q t a Q ×
12 F solenoid Q Q t a Q Q
13 R solenoid Q Q t a Q Q
14 1st solenoid Q Q t a Q Q
CALL
15 2nd solenoid Q Q t a Q Q
16 3rd solenoid Q Q t a Q Q
20 Directional switch signal Q Q a a Q Q
— 21 Range switch signal Q Q a a Q Q
22 Travel speed sensor × Q × a Q Q
E00
23 Engine speed sensor × Q × a Q ×

• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a : Turn stating switch ON (with engine stopped)
Q : Start engine
t : Carry out operation to actuate actuator.

2. Action code table

Action Transmission control system Joystick control system Action
Action by operator
code Problem system Action of machine Problem system Action of machine buzzer
Disconnection in Automatic gear-
travel speed sen- shifting not carried
tion possible at
sor system out (changes to — —
manual
manual gearshift-
E00 ing)(OP) No
Disconnection in Gearshifting not Normal operation
engine speed sen- carried out in Auto — — possible at man-
sor system mode. (OP) ual
Shift lever system Become neutral
disconnection, and cannot travel
— —
short circuit with (Judges controller
GND, short circuit input as N)
F, R solenoid sig- Become neutral Stop travelling
nal system dis- and cannot travel immediately,
connection, short (Output off) — — Turn starting
CALL Yes
circuit with GND, switch OFF,
short circuit Call service after
1st, 2nd, 3rd sole- Become neutral action above.
noid system dis- and cannot travel
connection, short (Output off) — —
circuit with GND,
short circuit

20-258 WD900-3
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION

STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

1. Transmission control system codes table

Failed system Re-enaction
Action Failure Alarm
Item Short Discon- Short Discon- memory buzzer
code code
circuit nection circuit nection
— 10 Back lamp relay Q Q t a Q ×
12 F solenoid Q Q t a Q Q
13 R solenoid Q Q t a Q Q
CALL 14 1st solenoid Q Q t a Q Q
15 2nd solenoid Q Q t a Q Q
16 3rd solenoid Q Q t a Q Q
E00 19 Joystick directional switch signal Q Q a a Q Q
CALL 20 Directional switch signal Q Q a a Q Q
— 21 Range switch signal Q Q a a Q Q
22 Travel speed sensor × Q × a Q Q
E00
23 Engine speed sensor × Q × a Q ×

• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a : Turn stating switch ON (with engine stopped)
Q : Start engine
t : Carry out operation to actuate actuator.

2. Joystick control system codes table

Failed system Re-enaction
Action Failure Alarm
Item Short Discon- Short Discon- memory
code code buzzer
circuit nection circuit nection
None 56 Joystick caution relay output Q × a t Q ×
57 Steering right solenoid (detect when output) Q Q t t Q Q
58 Steering left solenoid (detect when output) Q Q t t Q Q
59 Steering right solenoid (short circuit on hot side) Q × a a Q Q
E00 60 Steering left solenoid (short circuit on hot side) Q × a a Q Q
61 Steering solenoid cut relay output Q Q a t Q Q
62 Joystick neutral switch abnormal Q Q a a Q Q
63 Joystick potentiometer abnormal Q Q a a Q Q

• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a : Turn stating switch ON (with engine stopped)
Q : Start engine
t : Carry out operation to actuate actuator.
• If any abnormality is detected, the joystick caution system operates.
• Send E59 and E60 signals at a same time because monitor cannot distinguish E59 and E60.
• For E56, monitor cannot detect disconnection because E56 is normally closed.

WD900-3 20-259
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION

3. Action code table

Action Transmission control system Joystick control system Action
Action by operator
code Problem system Action of machine Problem system Action of machine buzzer
Disconnection in Automatic gear-
travel speed sen- shifting not carried
Normal operation
sor system out (changes to
— — possible at man-
manual gearshift-
ual
ing)(OP)

Disconnection in Gearshifting not

engine speed sen- carried out in Auto
Normal operation
sor system mode. (OP)
E00 — — No possible at man-
ual

Breakage, short Set to neutral

circuit with chas- position. (Can be
Normal operation
sis ground or changed to steer-
— — possible at steer-
short circuit of joy- ing wheel mode.)
ing wheel mode
stick FNR signal
line
Shift lever system Become neutral
disconnection, and cannot travel
short circuit with (Judges controller
— —
GND, short circuit input as N)

F, R solenoid sig- Become neutral

Stop travelling
nal system dis- and cannot travel
immediately, Turn
connection, short (Output off)
CALL — — Yes starting switch
circuit with GND,
OFF, Call service
short circuit
after action above.

1st, 2nd, 3rd sole- Become neutral

noid system dis- and cannot travel
connection, short (Output off)
— —
circuit with GND,
short circuit

20-260 WD900-3
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DISPLAY

TRANSMISSION CONTROLLER LED DISPLAY

The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and
input/output errors. The display shows two characters at the same time, and changes these in turn to give the
display.
a When the engine is started, “Program part No. display mode” appears, follwed by “Output speed range dis-
play mode”. If there is any abnormality in the controller, it changes to “Troubleshooting mode”.
a The failure mode is saved to memory by the main monitor.

Table 1 (Output speed range display mode)

Display Content Display Content
0. 1° Neutral, 1st F. 3° FORWARD, 3rd
0. 2° Neutral, 2nd A. 1° REVERSE, 1st
0. 3° Neutral, 3rd A. 2° REVERSE, 2nd
F. 1° FORWARD, 1st Neutral safety condition or
E. 0°
F. 2° FORWARD, 2nd abnormality in selection signal

WD900-3 20-261
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE

METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the
electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to
decide which troubleshooting table
(E–QQ, H–QQ, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which trouble-
shooting table to go to.
a The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system
(M–QQ, K–QQ).
(See troubleshooting of the machine monitor system)

[Method of using judgement table]

• A Q mark is put at the places where the failure mode and self-diagnostic display match, so check if an error
code is displayed on the graphic display portion of the monitor panel.
• If an error code is displayed:
Go to the troubleshooting code at the bottom of the judgement table (E–QQ, etc.).
• If there is a problem but no error code is displayed:
Go to the troubleshooting code on the right of the judgement table (H–QQ).
• For failure modes where no Q mark is given, go directly to the troubleshooting code on the right of the
judgement table.

WD900-3 20-263
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
S–QQ Troubleshooting of engine system
T–QQ Troubleshooting of transmission control system
M–QQ Troubleshooting of main monitor system
K–QQ Troubleshooting of maintenance monitor system
E–QQ Troubleshooting of electrical systems
H–QQ Troubleshooting of hydraulic, mechanical system
J–QQ Troubleshooting of joystick steering control system
A–QQ Troubleshooting of AJSS (Advanced Joystick Steering System) 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) General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top of the
page and marked with a.
The precautions marked a are not given in the , but must always be followed when carrying out the
check inside the .
(3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, compo-
nent, 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.
(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 column on the right.
• Below the there are the methods for inspection or measurement, and the judgement values. If the
judgement values below the are correct or the answer to the question inside the is YES, follow
the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the judgement
values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is
danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before
starting inspection or measurement, always read the instructions carefully, and start the work in order
from Item 1).
(5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
(6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number con-
nection. When carrying out troubleshooting, see this chart for details of the connector pin number and
location for inspection and measurement of the wiring connector number appearing in the troubleshoot-
ing flow chart.

20-264 WD900-3
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

<Example>
(1) M-5 Turn signal display does not light up
(2) a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is
not blown.
a) L.H turn signal display does not light up
(3) a)Divided into sections a) and b)
b) R.H. turn signal display does not light up
(4) Flow charta) L.H. turn signal display does not light up

Cause Remedy

1 YES
Defective main monitor Replace
Is voltage
between L06 (14)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (14) and L33 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up

Cause Remedy

1 YES
Defective main monitor Replace
Is voltage
between L06 (15)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (15) and L31 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn R.H. turn signal ON.

M-5 Related electrical circuit diagram

WD900-3 20-265
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES

METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the
causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main
components, such as the steering system and work equipment hydraulic system. Follow the procedure given
below and carry out troubleshooting to locate the problems accurately and swiftly.

Step 1. Questioning the operator
The questions to ask the operator are given below
the failure symptom. If the answers to the questions
match the information given, follow the arrow to
reach the probable cause of the failure.
Consider the contents of the questions and consult
the table while proceeding to Steps 2 and 3 to grasp
the true cause.
1. Steering does not work i Symptom [Example]
Ask the operator about the following points.
• Did the steering suddenly stop working o
Breakage in steering equipment
• Had the steering gradually been becoming
heavy? o Internal wear of steering equipment,
defective seal

Step 2. Checks before troubleshooting 2. Checks before starting [Example]

Before starting the main troubleshooting and mea-
suring the hydraulic pressure, first check the Checks • Is the oil level in the hydraulic tank correct?
before Starting items, and check for oil leakage and Is the type of oil correct?
loose bolts. These checks may avoid time wasted • Is there any leakage of oil from the steering
valve or Orbit-roll?
on unnecessary troubleshooting.
• Has the safety bar been removed from the
The items given under Checks before Starting are
frame?
items which must be considered particularly for that
symptom before starting troubleshooting.

Step 3. Using cross-reference table [Example 1]

1) Operate the machine to carry out the checks in
No.
the troubleshooting item column.
Mark the items where the results match the
symptom.
a It is not necessary to follow the troubleshoot-
ing checks in order; follow an order which is
easiest to carry out troubleshooting.
Remedy
Problems
1 Steering does not work to the left or right.
Same as Item 1, but abnormality in actuation of
2
work equipment.
3 Steering can lnly be operated to one side.
4 Steering wheel is heavy and cannot be turned.

2) Find the appropriate cause from the cause col- [Example 2]

umn. If the symptom appears, the Q marks on
that line indicate the possible causes. (For item
No. 2 in the table on the right, the possible
causes are c or e.)
If there is only one Q:
Carry out the other troubleshooting items (where
the same cause is marked with Q), check if the
symptom appears, then repair.
If there are two Q:
Go on to Step 3) to narrow down the possible
causes.

20-266 WD900-3
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES

3) Operate the machine and check the trouble-

shooting items other than those in 1).
Operate the machine and check the items in the
same way as in 1), and if the symptom appears,
mark that item. (In the chart on the right, the
symptom appears again for item 5).

4) Find the appropriate cause from the cause col-

umn. In the same way as in Step 2), if the symp-
tom appears, the Q marks on that line indicate
the possible causes. (For item No. 5 in the table
on the right, the possible causes are b or e.)

5) Narrow down the possible causes.

There is one common cause among the causes
located in Steps 2) and 4). (One cause marked
Q appears on the line for both items.) This
cause is common to both the symptoms in trou-
bleshooting Steps 1) and 3).
a The causes which are not common to both
troubleshooting items (items which are not
marked Q for both symptoms) are unlikely
causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c or
e, and the cause for Troubleshooting Item 5
are b or e, so cause e is common to both.)

6) Repeat the operations in Steps 3), 4) and 5)

until one cause (one common cause) remains.
a If the causes cannot be narrowed down to
one cause, narrow the causes down as far
as possible.

7) Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the remedy
column.
The symbols given in the remedy column indi-
cate the following:
X: Replace, E: Repair, A; Adjust, C: Clean

WD900-3 20-267
 TROUBLESHOOTING OF ENGINE
(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............................................................................................................................ 20-307
(1) Engine does not turn....................................................................................................................... 20-307
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is no fuel injection for the bank on one side) ..... 20-308
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) ..................................... 20-309
S-3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................... 20-310
S-4 Engine stops during operations (For V type engine, including cases where one bank stops) ..............20-311
S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-312
S-6 Engine lacks output (no power) (With V-type engine, for cases where there is injection
for only one bank, go to troubleshooting S-2-(2) or S-4.) ..................................................................... 20-313
S-7 Exhaust gas is black (incomplete combustion) .................................................................................... 20-314
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................................... 20-315
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-316
S-10 Fuel consumption is excessive........................................................................................................... 20-317
S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-318
S-12 Oil pressure lamp lights up (drop in oil pressure) ............................................................................... 20-319
S-13 Oil level rises ...................................................................................................................................... 20-320
S-14 Water temperature becomes too high (overheating) .......................................................................... 20-321
S-15 Abnormal noise is made..................................................................................................................... 20-322
S-16 Vibration is excessive ......................................................................................................................... 20-323

WD900-3 20-301
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

Using troubleshooting chart for engine-
related failure
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 using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.

[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user’s
level.

[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the user
and the results of (C) that he has obtained from his
own inspection.

[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].

20-302 WD900-3
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

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 Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q 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.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
ence for locating the cause of the failure.
However, do not use this when making cal-
culations to narrow down the causes.
2. Use the E in the Cause column as refer-
ence for [Degree of use (Operated for long
period)] in the [Questions] section as refer-
ence.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.

WD900-3 20-303
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

• 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 [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel

20-304 WD900-3
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

WD900-3 20-305
TROUBLESHOOTING S-1

S-1 Starting performance is poor (Starting always takes time)

Legend
General causes why starting performance is poor Q : Possible causes
• Defective electrical system (judging from Question and check items)
w : Most probable causes
• Insufficient supply of fuel (judging from Question and check items)
• Insufficient intake of air E : Possible causes due to length of use
• Improper selection of fuel (used for a long period)
q : Items to confirm the cause.
(At ambient temperature of –10°C [–14°F] or below, use
ASTM D975 No. 1, and –10°C [–14°F] or above, use ASTM
D975 No. 2 diesel fuel.)
a Battery charging rate
Charging rate
Ambient 100% 90% 80% 75% 70%
temperature
20°C [–68°F] 1.28 1.26 1.24 1.23 1.22
0°C [–32°F] 1.29 1.27 1.25 1.24 1.23
–10°C [–14°F] 1.30 1.28 1.26 1.25 1.24

• The specific gravity should exceed the value

for the charging rate of 70% in the above table.
• In cold weather the specific gravity must exceed
the value for the charging rate of 75% in the above table.

20-306 WD900-3
TROUBLESHOOTING S-2

S-2 Engine does not start

(1) Engine does not turn

General causes why engine does not turn

• Internal parts of engine seized
a If internal parts of the engine are
seized, carry out troubleshooting
for “Engine stops during opera-
tions”.
• Failure in power train
• Defective electrical system

WD900-3 20-307
TROUBLESHOOTING S-2

(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is no fuel injection for the bank on one side)

General causes why engine turns but no exhaust gas comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Standards for use of fuel
Ambient temprature
Type of fuel –22 –4 –14 32 50 68 86 104°F
–30 –20 –10 0 10 20 30 140°C

ASTM D975 No.2

Diesel oil
ASTM D975A
No.1

20-308 WD900-3
TROUBLESHOOTING S-2

(3) Exhaust gas comes out but engine does not start
(Fuel is being injected)

General causes why exhaust gas comes out but

engine does not start
• Lack of rotating force due to defective electrical
system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel

WD900-3 20-309
TROUBLESHOOTING S-3

S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up smoothly

• Insufficient intake of air
• Insufficient supply of fuel
• Improper condition of fuel injection
• Improper fuel used

20-310 WD900-3
TROUBLESHOOTING S-4

S-4 Engine stops during operations

(For V type engine, including cases where one bank stops)

General causes why engine stops during operations

• Seized parts inside engine
• Insufficient supply of fuel
• Overheating
a If there is overheating and insuffi-
cient output, carry out trouble-
shooting for overheating.
• Failure in power train
a If the engine stops because of a
failure in the power train, carry out
troubleshooting for the chassis.

WD900-3 20-311
TROUBLESHOOTING S-5

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly

• Air in fuel system
• Defective governor mechanism

20-312 WD900-3
TROUBLESHOOTING S-6

S-6 Engine lacks output (no power)

(With V-type engine, for cases where there is
injection for only one bank, go to troubleshooting S-2-(2) or S-4.)
General causes why engine lacks output
• Insufficient intake of air
• Insufficient supply of fuel
• Improper condition of fuel injection
• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overheating
a If there is overheating and insufficient
output, carry out troubleshooting for
overheating.

WD900-3 20-313
TROUBLESHOOTING S-7

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black

• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel

20-314 WD900-3
TROUBLESHOOTING S-8

S-8 Oil consumption is excessive (or exhaust gas is blue)

a Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)

General causes why oil consumption is excessive

• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
a Judge the oil consumption by comparing it
with the fuel consumption during the same
period.
More than 0.5%: Check the engine
More than 1.0%: There is some abnormality

WD900-3 20-315
TROUBLESHOOTING S-9

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly

• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper combustion
• Improper oil used
• Operation under excessive load

20-316 WD900-3
TROUBLESHOOTING S-10

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection
• Excessive injection of fuel

WD900-3 20-317
TROUBLESHOOTING S-11

S-11 Oil is in cooling water, or water spurts back, or water level goes down

General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system

20-318 WD900-3
TROUBLESHOOTING S-12

S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating

a Standards for use of oil

Type of oilSelection of oil SAE number
Type of according to ambient temperature
oil –22 –4 –14 32 50 68 86 1104°F
–30 –20 –10 0 10 20 30 140°C

SAE 30

Engine SAE 10W

oil SAE 10W-30
SAE 15W-40

WD900-3 20-319
TROUBLESHOOTING S-13

S-13 Oil level rises

a If there is oil in the cooling water, carry out trou-

bleshooting for “Oil is in cooling water”.

General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component

20-320 WD900-3
TROUBLESHOOTING S-14

S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high

• Lack of cooling water (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature of power train
a Carry out troubleshooting for chassis.
a Check that the maintenance monitor panel coolant
level caution lamp is not lighted up.
a When the maintenance monitor panel water tempera-
ture gauge is normal, go to troubleshooting of
machine monitor system (M mode).

WD900-3 20-321
TROUBLESHOOTING S-15

S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external

noise.

General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion noise
• Air sucked in from intake system

20-322 WD900-3
TROUBLESHOOTING S-16

S-16 Vibration is excessive

a If there is abnormal noise together with the

vibration, carry out troubleshooting for
“Abnormal noise is made”.

General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion

WD900-3 20-323
 TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM (T MODE)
Judgement table for transmission control system related parts .................................................................. 20-402
Action taken by controller when abnormality occurs and problems on machine......................................... 20-404
Electrical circuit diagram for transmission control system........................................................................... 20-408
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp
relay) is displayed .............................................................................................................................. 20-410
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is
displayed............................................................................................................................................ 20- 411
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is
displayed............................................................................................................................................ 20-412
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is
displayed............................................................................................................................................ 20-413
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is
displayed............................................................................................................................................ 20-414
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is
displayed............................................................................................................................................ 20-415
T-7 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed..... 20-416
T-8 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed............................................................................................................................................ 20-418
T-9 Failure code [21] (Short circuit, disconnection in range switch system) is displayed......................... 20-422
T-10 Failure code [22] (Disconnection in travel speed sensor system) is displayed.................................. 20-425
T-11 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed ........... 20-426
T-12 Shift-up signal system (Joystick (If equipped) manual shift) and hold signal system
(Auto-shift (If equipped)) .................................................................................................................... 20-427
T-13 Kick-down signal system and shift-down signal system (Joystick (If equipped) manual shift)........... 20-427
T-14 Transmission cut-off signal system .................................................................................................... 20-428
T-15 Neutralizer signal system................................................................................................................... 20-429
T-16 Buzzer signal system ......................................................................................................................... 20-430
T-17 Network system ................................................................................................................................. 20-431
T-18 Transmission controller power source system ................................................................................... 20-432
T-19 Short circuit in travel speed sensor system ....................................................................................... 20-433
T-20 Abnormality in machine selection wiring harness .............................................................................. 20-434

WD900-3 20-401
 JUDGEMENT TABLE FOR TRANSMISSION CONTROL
TROUBLESHOOTING SYSTEM RELATED PARTS

JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

RELATED PARTS
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
Self-diagnosis display (Display of abnormality)

Troubleshooting code when no abnor-mality display is given

Short circuit, disconnection in Joystick directional switch system

Short circuit, disconnection in engine speed sensor system

Location of failure

Short circuit, disconnection in directional switch sytem

Short circuit, disconnection in back lamp relay system

Abnormality in network signal system or main monitor

Short circuit, disconnection in 2nd solenoid system
Short circuit, disconnection in 3rd solenoid system
Short circuit, disconnection in 1st solenoid system

Short circuit, disconnection in shift switch system

Abnormality in transmission cut-off signal system

Short circuit, disconnection in R solenoid system
Short circuit, disconnection in F solenoid system

Abnormality in kickdown switch signal system

Disconnection in travel speed sensor system

Abnormality in alarm buzzer signal system

Abnormality in neutralizer signal system

Abnormality in network signal system

Failure mode

Failure
code
Transmission control error
10 12 13 14 15 16 19 20 21 22 23 — — — — — —

1 Travel is impossible Q Q Q Q Q E E E E-1, H-1

Directional lever and direction of travel are
2 Q
different
Machine travels forward when directional
3 Q Q
lever is not at F
Machine travels in reverse when directional
4 Q Q
lever is not at R
5 There is excessive gearshifting shock Q Q H-2, H-3

6 There is shift funting when travering Q

There is shift funting when shifting gear speed
7 Q
lever
8 Speed range cannot be controlled with Q
9 Back lamp and buzzer do not work Q
10 Kickdown does not work Q T-12, E-9

11 Transmission is not cut off with left brake Q T-14, E-12

It is possible to travel even when parking
12 Q T-15, E-5
brake is applied
If F-R lever is operated when traveling at high
13 Q T-16
speed, alarm buzzer does not sound
14 Alarm buzzer continues to sound Q T-16, J-1
Main monitor does not display transmission
15 controller information Q T-17
(alarm buzzer, failure code, etc)
Diagnosis 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 — — — — — —

20-402 WD900-3

TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
OCCURS AND PROBLEMS ON MACHINE
Failure code Abnormal system
Short circuit, disconnection
10
in back lamp relay
Short circuit, disconnection
12
in F solenoid system
Short circuit, disconnection
13
in R solenoid system
Short circuit, disconnection
14
in 1st solenoid system
Short circuit, disconnection
15
in 2nd solenoid system
Short circuit, disconnection
16
in 3rd solenoid system
20-404
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
OCCURS AND PROBLEMS ON MACHINE
Nature of abnormality
1) Defective back lamp relay
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (8) and L54 (1)
3) Defective contact or disconnection in wiring harness between back
lamp relay L54 (female) (2) and chassis ground
4) Defective transmission & joystick controller
1) Defective F solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (2) – TR1 (4) – T01 (4)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (1)
4) Defective transmission & joystick controller
1) Defective R solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (9) – TR1 (5) – T01 (3)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (1)
4) Defective transmission & joystick controller
1) Defective 1st solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (3) – TR1 (1) – T01 (8)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission & joystick controller
1) Defective 2nd solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between transmission
& joystick controller C1 (female) (10) – TR1 (2) – T01 (7)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission & joystick controller
1) Defective 3rd solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (5) – TR1 (3) – T01 (6)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission controller
WD900-3
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Action by controller Problem that appears Troublesh

Condition when normal
when abnormality is on machine when ooting
(voltage, current, resistance)
detected there is abnormality code

1) Resistance of relay coil: 200 – 400 z Neutral Back lamp is not

2) Voltage between transmission & joystick controller (F, R, 1st, 2nd, 3rd actuated when driving
C1 (8) and chassis ground at neutral: Less than 1 V solenoid output: off) in reverse
3) Resistance in wiring harness between
T-1
transmission & joystick controller C1 (female) (8)
and L54 (female) (1): Max. 1 z
4) Resistance in wiring harness between back lamp
relay L54 (female) (2) and chassis ground: Max. 1 z
1) Resistance between transmission & joystick Neutral It is impossible to travel
controller C1 (female) (2) and chassis ground: 5 – (F, R, 1st, 2nd, 3rd
15 z solenoid output: off)
2) Voltage between transmission & joystick controller T-2
C1 (2) and chassis ground at neutral: Less than 1 V

1) Resistance between transmission & joystick Neutral It is impossible to travel

controller C1 (female) (9) and chassis ground: 5 – (F, R, 1st, 2nd, 3rd
15 z solenoid output: off)
2) Voltage between transmission & joystick controller T-3
C2 (8) and chassis ground at neutral: Less than 1 V

1) Resistance between transmission & joystick Neutral It is impossible to travel

controller C1 (female) (3) and chassis ground: 5 – (F, R, 1st, 2nd, 3rd
15 z solenoid output: off)
2) Voltage between transmission & joystick controller T-4
C2 (9) and chassis ground at neutral: Less than 1 V

1) Resistance between transmission & joystick Neutral It is impossible to travel

controller C1 (female) (10) and chassis ground: 5 (F, R, 1st, 2nd, 3rd
– 15 z solenoid output: off)
2) Voltage between transmission & joystick controller T-5
C2 (10) and chassis ground at neutral: Less than
1V

1) Resistance between transmission & joystick Neutral It is impossible to travel

controller C1 (female) (5) and chassis ground: 5 – (F, R, 1st, 2nd, 3rd
15 z solenoid output: off)
2) Voltage between transmission & joystick T-6
controller C2 (2) and chassis ground at neutral:
Less than 1 V

WD900-3 20-405
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Failure code Abnormal system Nature of abnormality

1) Defective joystick directional lever F, N, R switch

Short circuit, disconnection
19
in joystick directional 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 C5 (female) (8) – JS1 (2) – joystick
lever connector (4) or short circuit with chassis ground in wiring harness
between C5 (female) (16) – JS1 (3) – joystick lever connector (3)
4) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5 (female) (7) – JS1 (4) – joystick lever
connector (4) or short circuit with chassis ground in wiring harness
between C5 (female) (15) – JS1 (5) – joystick lever connector (5)
5) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5 (female) (9) – JS1 (6) – joystick
lever connector (6) or short circuit with chassis ground in wiring harness
between C5 (female) (17) – JS1 (7) – joystick lever connector (7)

1) Defective directional lever

2) Defective combination switch power source Short circuit with power
source, short circuit with chassis ground, defective contact,
disconnection in the following wiring harness
Short circuit, disconnection
3) Wiring harness between transmission & joystick controller C3B
20 in directional switch signal
(female) (5) and L04 (2)
system
4) Wiring harness between transmission & joystick controller C3B
(female) (13) and L04 (3)
5) Wiring harness between transmission & joystick controller C3B (female)
(6) and L04 (4) 6)Defective transmission & joystick controller

1) Defective directional lever

Short circuit, disconnection
21
in shift switch signal system
Disconnection in speed
22
sensor system
Short circuit, disconnection
23 in engine speed sensor
system
2) Defective combination switch power source Short circuit with power
source, short circuit with chassis ground, defective contact,
disconnection in the following wiring harness
3) Wiring harness between transmission & joystick controller C3B
(female) (7) and L04 (5)
4) Wiring harness between transmission & joystick controller C3B
(female) (15) and L04 (6)
5) Wiring harness between transmission & joystick controller C3B
(female) (8) and L04 (7)
6) Defective transmission & joystick controller
1) Defective speed sensor
2) Defective adjustment of speed sensor mount
3) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5 (female) (2) – CBL1 (6) – C01 (1)
4) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5 (female) (10) – CBL1 (7) – C01 (2)
5) Defective transmission & joystick controller
1) Defective engine speed sensor
2) Defective adjustment of engine speed sensor mount
3) Defective contact or disconnection in wiring harness between
transmission & joystick controller C4 (female) (2) – LR3 (14) – ER1
(10) – E03 (1)
4) Defective contact or disconnection in wiring harness between
transmission & joystick controller C4 (female) (9) – LR3 (15) – ER1
(17) – E03 (2)
5) Defective transmission & joystick controller

20-406 WD900-3
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Action by controller Problem that appears Troublesh

Condition when normal
when abnormality is on machine when ooting
(voltage, current, resistance)
detected there is abnormality code

1) Resistance between joystick directional lever Neutral Cannot travel in joystick

connector (8) and chassis ground: Less than 1 z (F, R, 1st, 2nd, 3rd mode (possible in
The following conditions are when the switch is not solenoid output: off) steering wheel mode)
pressed
2) Resistance between transmission & joystick
controller C5 (female) (8) and chassis ground:
Less than 1 z
3) Resistance between transmission & joystick
T-7
controller C5 (female) (7) and chassis ground:
Less than 1 W and resistance between C5
(female) (15) and chassis ground: Min. 1 Mz
4) Resistance between transmission & joystick
controller C5 (female) (9) and chassis ground:
Less than 1 W and resistance between C5
(female) (17) and chassis ground: Min. 1 Mz

1) Voltage between combination switch L04 (1) and • Shifts to neutral It is impossible to travel
chassis ground: 20 – 30 V immediately when
2) Voltage for only 1 system in accordance with short circuit with
position of directional lever: 20 – 30 V (Others: power supply is
Less than 1 V) detected
F:Between transmission & joystick controller C3B • When there is no T-8
(5) – chassis ground signal (disconnec-
N:Between transmission & joystick controller C3B tion), holds previous
(13) – chassis ground signal condition for 2
R:Between transmission & joystick controller C3B seconds
(6) – chassis ground
1) Voltage between combination switch L04 (1) and • If 2 signals are input, 1) Auto-shift limit is
chassis ground: 20 – 30 V 2)Voltage for only 1 it judges speed range different from range
system in accordance with position of range lever: position in order of position selected by
20 – 30 V (Others: Less than 1 V) priority 3i2i1 operator (OP)
1st: Between transmission & joystick controller • When there is no sig- 2) Impossible to shift
C3B (7) – chassis ground nal (disconnection), gear in manual mode T-9
2nd:Between transmission & joystick controller holds previous signal
C3B (15) – chassis ground condition (speed
3rd: Between transmission & joystick controller range position)
C3B (8) – chassis ground

1) Resistance between travel speed sensor C01 (1) 1) Switches to manual 1) Does not carry out
and (2): 500 – 1,000 z mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick controller 2) Shifts gear 2) Switches to manual
C5 (female) (2) and (10): Min. 0.5 V according to shift T-10
operation of range
lever

1) Resistance between engine speed sensor E03 (1) 1) Does not carry out
and (2): 100 – 500 z auto-shift (OP)
1) Switches to manual
2) Voltage between transmission & joystick controller 2) Switches to manual
mode (OP)
C4 (female) (2) and (9) shift
2) Shifts gear
T-11
according to
operation of range
lever

WD900-3 20-407
 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROL SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROL SYSTEM

20-408 WD900-3
 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROL SYSTEM

WD900-3 20-409
TROUBLESHOOTING T-1

T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in
backup lamp relay) is displayed
Steering wheel specification,
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

T-1 Related electrical circuit diagram

20-410 WD900-3
TROUBLESHOOTING T-2

T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in
F solenoid) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (1) and disconnection in wiring
3 chassis ground
Is resistance harness between T01 Repair or
normal?
• Max. 1 z
(female) (1) and chassis replace
YES between C1 NO
(female) (2) and ground
• Turn starting
2 chassis ground
switch OFF. Short circuit with chassis
normal?
• Min. 1 Mz
Is resistance • Disconnect T01. ground or another part in
YES Repair or
between C1 harness between C1
(female) (2) and T01
• Turn starting NO replace
(female) (2) and T01
1 (female) (4) normal? switch OFF.
(female) (4)
• Disconnect C1
Is resistance between
• Max. 1 z and T01. Defective contact or
T01 (male) (1) and (4)
disconnection in wiring Repair or
and between (1), (4)
• Turn starting
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (2) and T01
• Between (1) and and T01. (female) (4)
(4): 5 – 15 z Defective F solenoid Replace
• Between (1), (4) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. Defective transmission &
5 YES
joystick steering Replace
Is voltage between controller
C1 (female) (2) and
A chassis ground
Short circuit with power
normal?
source in wiring harness Repair or
• Turn starting NO between C1 (female) (2) replace
switch ON. and T01 (female) (4)
• Disconnect C1
and T01.
• Max. 1 V

T-2 Related electrical circuit diagram

WD900-3 20-411
TROUBLESHOOTING T-3

T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in
R solenoid) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

4 YES
Go to A
Is resistance
YES between T01
Defective contact or
(female) (1) and
3 chassis ground
disconnection in wiring
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 z NO
(female) (1) and chassis replace
(female) (9) and ground
chassis ground
• Turn starting
2 switch OFF.
normal? Short circuit with chassis
Is resistance • Min. 1 Mz • Disconnect T01. ground or another part in Repair or
YES between C1 harness between C1
• Turn starting NO replace
(female) (9) and T01 (female) (9) and T01
1 (female) (3) normal? switch OFF.
(female) (3)
• Disconnect C1
• Max. 1 z
Is resistance between
and T01. Defective contact or
T01 (male) (1) and (3) Repair or
and between (1), (3) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (9) and T01
• Between (1) and and T01. (female) (3)
(3): 5 – 15 z Defective R solenoid Replace
• Between (1), (3) NO
and chassis ground: Min. 1
Mz
• Turn starting switch OFF. 5 YES Defective transmission &
• Disconnect T01. joystick steering Replace
Is voltage between controller
C1 (female) (9) and
A chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (9) replace
• Turn starting and T01 (female) (3)
switch ON.
• Disconnect C1
and T01.

T-3 Related electrical circuit diagram

20-412 WD900-3
TROUBLESHOOTING T-4

T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in
1st solenoid) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (2) and disconnection in wiring
3 chassis ground
Is resistance harness between T01
normal? Repair or
• Max. 1 z
YES between C1 (female) (2) and chassis replace
(female) (3) and
NO ground
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
normal?
• Min. 1 Mz
Is resistance • Disconnect T01. ground or another part in
YES Repair or
between C1 harness between C1
(female) (3) and T01
• Turn starting NO replace
(female) (3) and T01
1 (female) (8) normal? switch OFF.
(female) (8)
• Disconnect C1,
• Max. 1 z
Is resistance between
T01 (male) (2) and (8) T01 and L05. Defective contact or Repair or
and between (2), (8) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (3) and T01
• Between (2) and and T01. (female) (8)
(8): 5 – 15 z Defective 1st solenoid Replace
• Between (2), (8) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (3)
A and chassis
ground normal?
Short circuit with power
source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (3) replace
• Turn starting and T01 (female) (8)
switch ON.
• Disconnect C1,
T01 and L05.

T-4 Related electrical circuit diagram

WD900-3 20-413
TROUBLESHOOTING T-5

T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in
2nd solenoid) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (2) and disconnection in wiring
3 chassis ground
Is resistance harness between T01
normal? Repair or
• Max. 1 z
(female) (2) and chassis
YES between C1 NO replace
(female) (10) and ground
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
Is resistance normal?
• Min. 1 Mz • Disconnect T01. ground or another part in
YES between C1 harness between C1 Repair or
(female) (10) and • Turn starting NO replace
(female) (10) and T01
T01 (female) (7) switch OFF.
1 normal?
(female) (7)
• Disconnect C1,
• Max. 1 z
Is resistance between
T01 (male) (2) and (7) T01 and L05. Defective contact or
Repair or
and between (2), (7) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (10) and T01
• Between (2) and and T01. (female) (7)
(7): 5 – 15 z Defective 2nd solenoid Replace
• Between (2), (7) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (10) and
A chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (10) replace
• Turn starting and T01 (female) (7)
switch ON.
• Disconnect C1,
T01 and L05.

T-5 Related electrical circuit diagram

20-414 WD900-3
TROUBLESHOOTING T-6

T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in
3rd solenoid) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

4 YES
Go to A
Is resistance
YES between T01
Defective contact or
(female) (2) and
3 chassis ground
disconnection in wiring
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 z NO
(female) (2) and chassis replace
(female) (5) and ground
chassis ground
• Turn starting
2 switch OFF.
normal? Short circuit with chassis
Is resistance
• Min. 1 Mz • Disconnect T01. ground in harness Repair or
YES between C1 between C1 (female) (5)
• Turn starting NO replace
(female) (5) and T01
switch OFF. and T01 (female) (6)
1 (female) (6) normal?
• Disconnect C1,
• Max. 1 z Defective contact or
Is resistance between
T01 (male) (2) and (6) T01 and L05. Repair or
• Turn starting disconnection in wiring
and between (2), (6) harness between C1 replace
and chassis ground switch OFF. NO
• Disconnect C1 (female) (5) and T01
normal?
and T01. (female) (6)
• Between (2) and
(6): 5 – 15 z Defective 3rd solenoid Replace
• Between (2), (6) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (5) and
A chassis ground
Short circuit with power
normal?
source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (5) replace
• Turn starting and T01 (female) (6)
switch ON.
• Disconnect C1,
T01 and L05.

T-6 Related electrical circuit diagram

WD900-3 20-415
TROUBLESHOOTING T-7

T-7 Failure code [19] (Short circuit, disconnection in joystick directional switch sys-
tem) is displayed
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Table 1 Voltage on each position of joystick lever

Pushed switch
F N R
Terminals
JS1 (male) (8) – (2) Between C5 (8) and chassis 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (8) – (3) Between C5 (16) and chassis Max. 1 V 20 – 30 V 20 – 30 V
JS1 (male) (8) – (4) Between C5 (7) and chassis Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (8) – (5) Between C5 (15) and chassis 20 – 30 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (7) Between C5 (17) and chassis 20 – 30 V 20 – 30 V Max. 1 V

T-7 Related electrical circuit diagram

20-416 WD900-3
TROUBLESHOOTING T-8

T-8 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed
Steering wheel specification,
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

20-418 WD900-3
TROUBLESHOOTING T-8

Table 1
Directional lever position
Terminal F N R

Between L04 (2) – chassis 20 – 30 V Max. 1 V Max. 1 V

Between L04 (3) – chassis Max. 1 V 20 – 30 V Max. 1 V
Between L04 (4) – chassis Max. 1 V Max. 1 V 20 – 30 V

WD900-3 20-419
TROUBLESHOOTING T-8

T-8 Related electrical circuit diagram

20-420 WD900-3
TROUBLESHOOTING T-9

T-9 Failure code [21] (Short circuit, disconnection in range switch system) is dis-
played
Steering wheel specification,
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

YES

6
Is resistance between
YES C3B (female) (8) –
chassis and between
C3B (female) (8) and
5 (15) normal?
Is voltage • Min. 1 MΩ
YES between C3B (7) • Disconnect L04,
and chassis C3B. NO
4 normal? • Turn starting
Is resistance • 20 – 30 V switch OFF.
YES between C3B • Turn starting
(female) (7) – chassis
and between C3B switch ON. NO
3 (female) (7) – (8), (15) • Set speed control
Is resistance • Min. 1 MΩ lever to 1st.
YES between L04
• Disconnect L04,
(female) (10) and
chassis ground C3B. NO
2 normal? • Turn starting
Is voltage • Max. 1 Ω switch OFF.
YES between L04 (1) • Turn starting
and chassis switch OFF. NO
1 ground normal? • Disconnect L04.
Is resistance • 20 – 30 V
between L04 • Turn starting
(female) (1) and
switch ON.
chassis ground NO
normal?
• Min. 1 MΩ
• Disconnect FS2,
L04. NO
• Turn starting
switch OFF.

20-422 WD900-3
TROUBLESHOOTING T-9

Table 1
Directional lever position
Terminal F N R

Between L04 (5) – chassis 20 – 30 V Max. 1 V Max. 1 V

Between L04 (6) – chassis Max. 1 V 20 – 30 V Max. 1 V
Between L04 (7) – chassis Max. 1 V Max. 1 V 20 – 30 V

WD900-3 20-423
TROUBLESHOOTING T-9

T-9 Related electrical circuit diagram

20-424 WD900-3
TROUBLESHOOTING T-10

T-10 Failure code [22] (Disconnection in travel speed sensor system) is displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

T-10 Related electrical circuit diagram

WD900-3 20-425
TROUBLESHOOTING T-11

T-11 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed

a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

T-11 Related electrical circuit diagram

20-426 WD900-3
TROUBLESHOOTING T-12, T-13

T-12 Shift-up signal system (Joystick (If equipped) manual shift) and hold signal system
(Auto-shift (If equipped))
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

T-13 Kick-down signal system and shift-down signal system (Joystick (If equipped)
manual shift)

T-12, T-13 Related electrical circuit diagram

WD900-3 20-427
TROUBLESHOOTING T-14

T-14 Transmission cut-off signal system

a Check that the parking brake works normally.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

T-14 Related electrical circuit diagram

20-428 WD900-3
TROUBLESHOOTING T-15

T-15 Neutralizer signal system

a Check that the parking brake works normally.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

T-15 Related electrical circuit diagram

WD900-3 20-429
TROUBLESHOOTING T-16

T-16 Buzzer signal system

a Check that the main monitor and alarm buzzer works normally.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

Cause Remedy

2 YES Defective transmission &

joystick steering Replace
Is resistance
between C2 controller
YES
(female) (10) and Defective contact or
1 L08 (female) (6)
disconnection in wiring
Is resistance normal? Repair or
harness between C2
between C2 • Disconnect C1 NO replace
(female) (10) and L08
(female) (10) and and L08. (female) (6)
chassis normal? • Max. 1 z
• Disconnect C1 Short circuit with chassis
Repair or
and L08. ground in wiring harness
NO replace
• Min. 1 Mz betwen C2 (female) (10)
and L08 (female) (6)

T-16 Related electrical circuit diagram

20-430 WD900-3
TROUBLESHOOTING T-17

T-17 Network system

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

T-17 Related electrical circuit diagram

WD900-3 20-431
TROUBLESHOOTING T-18

T-18 Transmission controller power source system

a Check that fuse II (6) is normal.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).

T-18 Related electrical circuit diagram

20-432 WD900-3
TROUBLESHOOTING T-19

T-19 Short circuit in travel speed sensor system

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

Defective transmission &

2 YES Replace
joystick steering
Is resistance controller
YES between C5 Short circuit in wiring
1 (female) (2) and harness betwen C5 (female)
(1) normal? (2) – L07 (female) (1) – BC01
Is resistance (male) (1) or short circuit in Repair or
between C5 • Min. 1 Mz NO wiring harness between C5 replace
(female) (2) and • Turn starting switch OFF. (female) (1) – L07 (female)
(2) – BC01 (female) (2)
chassis normal? • Disconnect C5, BC01 and
• Min. 1 Mz L07. Short circuit in wiring
harness betwen C5 (female) Repair or
• Turn starting NO (2) – TM2 (9) – CN3 (female) replace
switch OFF. (2), or short circuit in
between C5 (female) (2) and
• Disconnect C5, L07 (female) (1)
BC01 and L07.

T-19 Related electrical circuit diagram

WD900-3 20-433
TROUBLESHOOTING T-20

T-20 Abnormality in machine selection wiring harness

a Check that machine selection connector is properly selected.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Table 1

Machine model
WD900-3
Connector

Between C3B (female) (2) and C1 (female) (6), (12) Max. 1 z

Between C3B (female) (3) and C1 (female) (6), (12) Max. 1 z
Between C3B (female) (10) and C1 (female) (6), (12) Max. 1 z

T-20 Related electrical circuit diagram

20-434 WD900-3
 TROUBLESHOOTING OF MAIN MONITOR SYSTEM
(M MODE)
Trouble data display.................................................................................................................................... 20-503
Electrical circuit diagram for main monitor system...................................................................................... 20-506
M-1 Main monitor does not work.............................................................................................................. 20-508
M-2 When starting switch is turned ON (within 3 seconds) and engine is started immediately,
all lamps stay lighted up ................................................................................................................... 20-509
M-3 Speedometer display does not work properly................................................................................... 20-510
M-4 Abnormality in shift indicator ............................................................................................................. 20- 511
a) Displays N even when directional switch is at F ........................................................................... 20- 511
b) Displays N even when directional switch is at R .......................................................................... 20-511
c) Does not display N even when directional switch is at N (Display 1st – 3rd)................................ 20-512
d) Does not display 1st even when gear shift lever is at 1st position
(Directional lever is at F or R position).......................................................................................... 20-512
e) Does not display 2nd even when gear shift lever is at 2nd position
(Directional lever is at F or R position).......................................................................................... 20-512
f) Does not display 3rd even when the gear shift lever is at 3 rd position
(Directional lever is at F or R position).......................................................................................... 20-513
M-5 High beam display does not light up ................................................................................................. 20-514
M-6 Turn signal display does not light up................................................................................................. 20-515
a) L.H. turn signal display does not light up ...................................................................................... 20-515
b) R.H. turn signal display does not light up ..................................................................................... 20-515
M-7 Abnormality in parking display .......................................................................................................... 20-516
a) Parking lamp display does not light up ......................................................................................... 20-516
b) Parking lamp display stays lighted up .......................................................................................... 20-516
M-8 Abnormality in preheating system..................................................................................................... 20-517
a) Does not carry out preheating ...................................................................................................... 20-517
b) Always carries out preheating for 45 seconds .............................................................................. 20-518
c) Preheating stays on ...................................................................................................................... 20-518
d) Preheating time becomes shorter, or there is variation ................................................................ 20-519
M-9 Night lighting does not light up.......................................................................................................... 20-521
M-10 Abnormality in front working lamp..................................................................................................... 20-522
a) Neither monitor display nor front working lamp light up................................................................ 20-522
b) Working lamp lights up but monitor display does not light up....................................................... 20-522
M-11 Abnormality in rear working lamp ..................................................................................................... 20-524
a) Neither monitor display nor rear working lamp light up ................................................................ 20-524
b) Rear working lamp lights up but monitor display does not light up............................................... 20-524
c) Monitor display lights up but rear working lamp does not light up ................................................ 20-524

WD900-3 20-501
M-12 Abnormality in transmission cut-off ................................................................................................... 20-526
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not
switched and display does not change ......................................................................................... 20-526
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out
but cut-off function is actuated when pedal is depressed ............................................................. 20-526
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off
function is always actuated ........................................................................................................... 20-526
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off
switch ON or OFF) ........................................................................................................................ 20-526
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function
is not actuated............................................................................................................................... 20-527
M-13 Abnormality in low idling selection .................................................................................................... 20-528
a) When monitor switch (Low idle selector switch) is turned ON, the low idling speed does not
rise and display does not change ................................................................................................. 20-528
b) When the monitor switch (Low idle selector switch) is turned ON, the monitor lights up but the
low idling speed does not rise....................................................................................................... 20-528
c) When the monitor switch (Low idle selector switch) is turned OFF, the monitor goes off but the
low idling speed does not lower .................................................................................................... 20-529
M-14 Abnormality in emergency steering normal display .......................................................................... 20-530
M-15 Abnormality in emergency steering actuation display....................................................................... 20-531
a) Emergency steering actuation display does not light up............................................................... 20-531
b) Emergency steering actuation display stays lighted up ................................................................ 20-531
M-16 Abnormality in parking brake dragging warning ................................................................................ 20-532
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes
even when directional lever is at N ............................................................................................... 20-532
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 .................................................... 20-532
M-17 Abnormality in parking brake dragging warning (When joystick steering mode
(If equipped))..................................................................................................................................... 20-534
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes
even when directional lever is at N .............................................................................................. 20-534
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................................................................ 20-534
M-18 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously,
or they are not actuated .................................................................................................................... 20-536
a) Actuated continuously................................................................................................................... 20-536
b) Not actuated ................................................................................................................................. 20-536
M-19 Abnormality in buzzer ....................................................................................................................... 20-537
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) .......... 20-537
b) Buzzer always sounds .................................................................................................................. 20-537
M-20 Condition of monitor switches is not stored in memory..................................................................... 20-538
M-21 Abnormality in failure display mode .................................................................................................. 20-539
a) Does not enter failure display mode ............................................................................................. 20-539
b) Count for time elapsed since failure in failure display mode does nor advance ........................... 20-539
M-22 Buzzer is not made to sound by transmission & joystick steering controller..................................... 20-540
M-23 Failure code is not sent to main monitor (abnormality in network) (If equipped) .............................. 20-541

20-502 WD900-3
(4)
TROUBLESHOOTING TROUBLE DATA DISPLAY

TROUBLE DATA DISPLAY

1. Outline
The speedometer 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, failure
code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)

2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01
+ CALL (E01 and CALL are displayed alter-
nately), and CALL. If a failure occurs suddenly,
one of these codes is shown on the speedome-
ter display.

3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which con-
troller has failed, so carry out troubleshooting for
the applicable controller.
For failure that have occurred and been reset,
the failure code and the time elapsed since fail-
ure are displayed to make it easy to check fail-
ures that are not occurring at present.
The failure codes for failures that are now occur-
ring flash, and the codes for failures that are not
occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode,
see STRUCTURE AND FUNCTION for the main
monitor.
NOTE: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
For the correspondence between the failure
codes for each controller and the failed system,
see Item 4.

WD900-3 20-503
TROUBLESHOOTING TROUBLE DATA DISPLAY

4. Action code table

Transmission control system Joystick control system

Action Action Action by
code buzzer operator
Problem system Action of machine Problem system Action of machine

Automatic
Disconnection in
gearshifting not
travel speed sensor Normal operation
carried out
system — — possible at
(changes to manual
manual
gearshifting)
(If equipped)
Disconnection in Gearshifting not
engine speed carried out in Auto Normal operation
E00 No
sensor system mode. (If equipped) — — possible at
manual

Breakage, short
Set to neutral
circuit with chassis Normal operation
position. (Can be
— — ground or short possible at wheel
changed to steering
circuit of joystick steering mode
wheel mode.)
FNR signal line
Shift lever system Become neutral
disconnection, and cannot travel
short circuit with (Judges controller — —
GND, short circuit input as N)

Stop travelling
F, R solenoid signal Become neutral
immediately, Turn
system and cannot travel
starting switch
CALL disconnection, (Output off) — — Yes
OFF, Call service
short circuit with
after action
GND, short circuit
above.
1st, 2nd, 3rd Become neutral
solenoid system and cannot travel
disconnection, (Output off) — —
short circuit with
GND, short circuit

20-504 WD900-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

20-506 WD900-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM

a This circuit diagram is made by extracting the part of the main monitor system from the general circuit
diagram.

WD900-3 20-507
TROUBLESHOOTING M-1

M-1 Main monitor does not work

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

YES
Defective main monitor Replace
1

Is voltage Defective contact or

between L05 (1), disconnection in wiring
2 YES Repair or
(2) – (3) normal? harness between L05
Is resistance replace
between L05 (female) (1), (2) and FS2
• 20 – 30 V (female) (9)
(female) (3) and
• Turn starting NO chassis ground
switch ON. Defective contact or
normal? Repair or
disconnection in wiring
• Turn starting NO harness between L05 replace
switch OFF. (female) (3) and LR4
• Disconnect L05. (male) (3)
• Max. 1 z

M-1 Related electrical circuit diagram

20-508 WD900-3
TROUBLESHOOTING M-2

M-2 When starting switch is turned ON (within 3 seconds) and engine is started
immediately, all lamps stay lighted up

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

M-2 Related electrical circuit diagram

WD900-3 20-509
TROUBLESHOOTING M-3

M-3 Speedometer display does not work properly

a When error code is not displayed.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that the gap between the speed sensor and gear is normal.

M-3 Related electrical circuit diagram

20-510 WD900-3
TROUBLESHOOTING M-4

M-4 Abnormality in shift indicator

a Check that error code is not displayed.

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that the transmission shifts.
a The steering system must be in the steering wheel mode.

a) Displays N even when directional switch is at F

b) Displays N even when directional switch is at R

WD900-3 20-511
TROUBLESHOOTING M-4

c) Does not display N even when directional switch is at N (Display 1st – 3rd).

d) Does not display 1st even when gear shift lever is at 1st position (Directional lever is at F or R
position).

e) Does not display 2nd even when gear shift lever is at 2nd position (Directional lever is at F or R
position).

20-512 WD900-3
TROUBLESHOOTING M-4

f) Does not display 3rd even when the gear shift lever is at 3 rd position (Directional lever is at F or R
position).

M-4 Related electrical circuit diagram

WD900-3 20-513
TROUBLESHOOTING M-5

M-5 High beam display does not light up

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb is not blown.

M-5 Related electrical circuit diagram

20-514 WD900-3
TROUBLESHOOTING M-6

M-6 Turn signal display does not light up

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.

a) L.H. turn signal display does not light up

b) R.H. turn signal display does not light up

M-6 Related electrical circuit diagram

WD900-3 20-515
TROUBLESHOOTING M-7

M-7 Abnormality in parking display

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Parking lamp display does not light up

Cause Remedy

3 YES Defective main monitor Replace

Is resistance
YES between F13
(female) (2) and Defective contact or
2 chassis ground disconnection in wiring
Is voltage normal? harness between F13 Repair or
YES between L06 (11) • Max. 1 z NO (female) (2) and chassis replace
and chassis • Turn starting ground
1 ground normal? switch OFF.
Defective contact or
Is resistance • Disconnect F13. Repair or
• 20 – 30 V disconnection in wiring
between F13 • Turn starting NO harness between L06 replace
(male) (1) and (2) switch ON. (female) (11) – F13
normal? • Turn parking (female) (1)
• Max. 1 z switch ON. Defective parking brake Replace
• Disconnect F13. NO indicator switch
• Turn starting
switch ON.
• Turn parking
switch ON.

b) Parking lamp display stays lighted up

Cause Remedy

2 YES
Defective main monitor Replace
Is voltage
YES between F13 (1)
1 and chassis Short circuit with power
ground normal? source in harness Repair or
Is resistance
between F13 •0–2V NO between L06 (female) replace
(male) (1) and (2) • Turn starting (11) – F13 (female) (1)
normal? switch ON.
• Max. 1 z
• Turn parking switch OFF. Defective parking brake
Replace
• Disconnect F13. NO indicator switch
• Turn starting
switch ON.
• Turn parking
switch OFF.

M-7 Related electrical circuit diagram

20-516 WD900-3
TROUBLESHOOTING M-8

M-8 Abnormality in preheating system

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Does not carry out preheating

a Check that the water temperature is below 5°C.
(1) Monitor display also does not light up

(2) Only monitor display lights up

WD900-3 20-517
TROUBLESHOOTING M-8

b) Always carries out preheating for 45 seconds

a Check that the water temperature is above – 10°C

c) Preheating stays on

20-518 WD900-3
TROUBLESHOOTING M-8

d) Preheating time becomes shorter, or there is variation

Table 1 (Tolerance ± 0.5 kz)

Temperature (°C) –30 –20 0 20 40 60 80 90
Resistance value (kz) 19.5 12.1 5.11 2.39 1.21 0.695 0.381 0.295

WD900-3 20-519
TROUBLESHOOTING M-8

M-8 Related electrical circuit diagram

20-520 WD900-3
TROUBLESHOOTING M-9

M-9 Night lighting does not light up

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulbs are not blown.
a Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between FS2 (female) (5) and L05 (female) (16).

M-9 Related electrical circuit diagram

WD900-3 20-521
TROUBLESHOOTING M-10

M-10 Abnormality in front working lamp

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.

a) Neither monitor display nor front working lamp light up

b) Working lamp lights up but monitor display does not light up

c) Monitor display lights up but front working lamp

does not light up

20-522 WD900-3
TROUBLESHOOTING M-10

M-10 Related electrical circuit diagram

WD900-3 20-523
TROUBLESHOOTING M-11

M-11 Abnormality in rear working lamp

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.

a) Neither monitor display nor rear working lamp light up

b) Rear working lamp lights up but monitor display does not light up

c) Monitor display lights up but rear working lamp

does not light up

20-524 WD900-3
TROUBLESHOOTING M-11

M-11 Related electrical circuit diagram

WD900-3 20-525
TROUBLESHOOTING M-12

M-12 Abnormality in transmission cut-off

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) When monitor switch (transmission cut-off switch) is pressed,

cut-off function is not switched and display does not change

b) When monitor switch (transmission cut-off switch) is OFF,

monitor display goes out but cut-off function is actuated when
pedal is depressed

c) When monitor display is turned off (transmission cut-off switch

turned OFF), cut-off function is always actuated

d) Cut-off function is always actuated regardless of monitor

display (transmission cut-off switch ON or OFF)

20-526 WD900-3
TROUBLESHOOTING M-12

e) Monitor display lights up (transmission cut-off switch turned

ON), but cut-off function is not actuated

M-12 Related electrical circuit diagram

WD900-3 20-527
TROUBLESHOOTING M-13

M-13 Abnormality in low idling selection

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) When monitor switch (Low idle selector switch) is turned

ON, the low idling speed does not rise and display does not
change

b) When the monitor switch (Low idle selector switch) is turned

ON, the monitor lights up but the low idling speed does not
rise

20-528 WD900-3
TROUBLESHOOTING M-13

c) When the monitor switch (Low idle selector switch) is turned

OFF, the monitor goes off but the low idling speed does not
lower

M-13 a), b), c) Related electrical circuit diagram

WD900-3 20-529
TROUBLESHOOTING M-14

M-14 Abnormality in emergency steering normal display

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Emergency steering normal display does not light up

Cause Remedy

1 YES
Defective main monitor Replace
Is voltage
between L05 (10)
and chassis Defective contact or
ground normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (10) – chassis
switch ON.

M-14 Related electrical circuit diagram

20-530 WD900-3
TROUBLESHOOTING M-15

M-15 Abnormality in emergency steering actuation display

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Emergency steering actuation display does not light up

Cause Remedy

2 YES
Defective main monitor Replace
Is resistance
YES between L05
(female) (11) and
1 chassis ground Short circuit with chassis
Is resistance normal? ground in harness Repair or
between R01 • Min. 1 Mz NO between L05 (female) replace
(male) (1) and (2) • Turn starting switch OFF. (11) and R01 (female) (1)
normal? • Disconnect L05 and R01.
• Min. 1 Mz Defective emergency
Replace
• Turn starting NO steering indicator switch
switch ON.
• Disconnect R01.

b) Emergency steering actuation display stays lighted up

Cause Remedy

2 YES
Defective main monitor Replace
Is voltage
YES between L05 (11)
1 and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance Repair or
harness between L05
between R01 • 20 – 30 V NO replace
(female) (11) and chassis
(male) (1) and (2) • Turn starting ground
normal? switch ON.
• Max. 1 z Defective emergency
Replace
• Start engine. NO steering indicator switch
• Disconnect R01.

M-15 Related electrical circuit diagram

WD900-3 20-531
TROUBLESHOOTING M-16

M-16 Abnormality in parking brake dragging warning

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at 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
a Check that the synchronous flash is normal.

20-532 WD900-3
TROUBLESHOOTING M-16

M-16 Related electrical circuit diagram

WD900-3 20-533
TROUBLESHOOTING M-17

M-17 Abnormality in parking brake dragging warning (When joystick steering mode
(If equipped))

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at 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
a Check that the synchronous flash is normal.

20-534 WD900-3
TROUBLESHOOTING M-17

M-17 Related electrical circuit diagram

WD900-3 20-535
TROUBLESHOOTING M-18

M-18 When parking brake dragging warning is given, buzzer and CAUTION lamp are
actuated continuously, or they are not actuated

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Actuated continuously

Cause Remedy

YES
Defective main monitor Replace
1

Does buzzer stop

and lamp go out? 2 YES Defective maintenance
Replace
monitor (sub monitor)
• Turn starting Does buzzer stop
switch ON. and lamp go out? Defective contact or
NO disconnection in wiring
• Connect L07 Repair or
(male) (6) to harness between L07
• Turn starting NO replace
chassis ground. (female) (6) and L19
switch ON. (female) (5)
• Connect L19
(female) (5) to
chassis ground.

b) Not actuated

Cause Remedy

YES
Defective main monitor Replace
1

Do buzzer and
lamp work? 2 YES Defective maintenance
Replace
monitor (sub monitor)
• Turn starting Do buzzer and
switch ON. NO lamp work? Short circuit with power
• Disconnect L07. source in harness Repair or
• Turn starting NO between L07 (female) (6) replace
switch ON. and L19 (female) (5)
• Disconnect L19.

M-18 Related electrical circuit diagram

20-536 WD900-3
TROUBLESHOOTING M-19

M-19 Abnormality in buzzer

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)

Cause Remedy

Defective contact or
YES disconnection in wiring
Repair or
harness between L06
1 replace
(female) (8) and L43
(male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
• Turn starting L42 (female) (1)
switch ON. and chassis Defective contact or
NO disconnection in wiring
• Contact L43 ground normal? Repair or
(female) to harness between L42
• 20 – 30 V NO replace
chassis ground. (female) (1) and FS2
• Turn starting (female) (9)
switch ON.

b) Buzzer always sounds

Cause Remedy

YES Defective main monitor Replace

1
Does buzzer stop
when L06 is See troubleshooting (K
YES
disconnected? mode) for maintenance —
2
monitor
• Turn starting Does buzzer stop
Short circuit with chassis
switch ON. when L19 is
NO 3 YES ground in harness Repair or
• Disconnect L06. disconnected?
between L06 (female) (8) replace
Does buzzer stop and L43 (male) (1)
• Turn starting when L43 is
switch ON. NO disconnected?
• Disconnect L19.
Defective buzzer Replace
• Turn starting NO
switch ON.
• Disconnect L43.

M-19 Related electrical circuit diagram

WD900-3 20-537
TROUBLESHOOTING M-20

M-20 Condition of monitor switches is not stored in memory

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

1 YES
Defective main monitor Replace
Is voltage
between L07 (10)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L07 Repair or
• 20 – 30 V NO (female) (10) and L09 replace
• Turn starting (female) (2)
switch ON.

M-20 Related electrical circuit diagram

20-538 WD900-3
TROUBLESHOOTING M-21

M-21 Abnormality in failure display mode

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Does not enter failure display mode

b) Count for time elapsed since failure in failure display mode does nor advance

M-21 Related electrical circuit diagram

WD900-3 20-539
TROUBLESHOOTING M-22

M-22 Buzzer is not made to sound by transmission & joystick steering controller

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

2 YES See troubleshooting of

transmission controller Replace
Is resistance between system (T mode)
YES L08 (female) (6) and
1 C2 (female) (10) Defective contact or
normal? disconnection in wiring Repair or
Does buzzer sound
• Max. 1 z.
harness between L08 replace
when C2 (female) NO (female) (6) and C2
(10) is grounded to • Turn starting
chassis? (female) (10)
switch OFF.
• Disconnect L01 and C1.
• Turn starting Defective main monitor Replace
switch ON. NO
• Disconnect C1.
• Connect C1
(female) (2) to
chassis ground.

M-22 Related electrical circuit diagram

20-540 WD900-3
TROUBLESHOOTING M-23

M-23 Failure code is not sent to main monitor (abnormality in network) (If equipped)

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Set dipswitch 3 at the rear of the main monitor to "F".

M-23 Related electrical circuit diagram

WD900-3 20-541
TROUBLESHOOTING OF MAINTENANCE MONITOR
SYSTEM (K MODE)
Electrical circuit diagram for maintenance monitor system ......................................................................... 20-602
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for
3 seconds, maintenance monitor dose not work .............................................................................. 20-604
a) No lamps on maintenance monitor light up .................................................................................. 20-604
b) Some lamps do not light up .......................................................................................................... 20-604
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out
(even after 3 seconds) ...................................................................................................................... 20-605
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds),
no lamps on maintenance monitor go out......................................................................................... 20-606
K-4 When starting switch is turned ON (engine stopped), CHECK items flash....................................... 20-608
a) Engine oil level display flashes ..................................................................................................... 20-608
b) Engine water level display flashes................................................................................................ 20-609
K-5 When starting switch is turned ON (engine started), CAUTION items flash ..................................... 20-610
a) Engine oil pressure display flashes (Check that the engine oil puressure is correct.).................. 20-610
b) Battery charge level display flashes ............................................................................................. 20- 611
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)........................ 20-612
d) Air cleaner (R.H.) clogging display flashes (Check that the air cleaner (R.H.) is not clogged.).... 20-614
e) Air cleaner (L.H.) clogging display flashes (Check that the air cleaner (L.H.) is not clogged.) ..... 20-615
f) Transmission oil filter display flashes (The transmission oil filter must not be clogged.) ............... 20-616
K-6 CAUTION items are flashing but buzzer does not sound ................................................................. 20-617
K-7 There is no abnormality in monitor display but caution buzzer sounds ............................................ 20-618
K-8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes........................ 20-619
a) CHECK lamp ................................................................................................................................ 20-619
b) CAUTION lamp............................................................................................................................. 20-619
K-9 There is no abnormality in maintenance monitor display but CHECK lamp or CAUTION lamp
lights up ............................................................................................................................................ 20-620
a) CHECK lamp ................................................................................................................................ 20-620
b) CAUTION lamp............................................................................................................................. 20-620
K-10 Only night lighting of maintenance monitor does not light up when lighting switch is turned ON ..... 20-621
K-11 Night lighting lights up even when lighting switch is turned OFF ...................................................... 20-622
K-12 Service meter does not work ............................................................................................................ 20-623
K-13 Service meter is running even when engine is stopped ................................................................... 20-623
K-14 Abnormality in gauge display ............................................................................................................ 20-625
a) Abnormality in fuel gauge ............................................................................................................. 20-625
b) Abnormality in engine water temperature gauge .......................................................................... 20-626
c) Abnormality in torque converter oil temperature gauge ................................................................ 20-627

WD900-3 20-601
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM

ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR

SYSTEM

20-602 WD900-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM

a This circuit diagram is made by extracting the part of the maintenance monitor system from the general cir-
cuit diagram.

WD900-3 20-603
TROUBLESHOOTING K-1

K-1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor dose not work

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) No lamps on maintenance monitor light up

Cause Remedy

Defective monitor
YES
module of maintenance Replace
monitor

Defective contact or
1 disconnection in wiring
Repair or
YES harness between L18
Is voltage replace, or
3 (female) (1), (2) – fuse I-
between L18 (1), replace fuse
10 – FS1 (male) (2), or
(2) – (3) normal? Is voltage between
YES FS1 (female) (2) blown fuse I-10
• 20 – 30 V and chassis
• Turn starting ground normal? Defective contact or
2
switch ON. disconnection in wiring Repair or
Is resistance • 20 – 30 V
between L18
harness between FS1 replace, or
• Disconnect FS1. (female) (2) – battery
(female) (3),(9),L19 NO replace fuse
NO • Turn starting relay, or blown slow
(8) and chassis
ground normal?
switch ON. blow fuse (120A)
• Max. 1 z
• Turn starting Defective contact or Repair or
switch OFF. NO disconnection in wiring replace
• Disconnect L18, harness between L18 (3),
L19. (9), L19 (female) (8) –
chassis ground

b) Some lamps do not light up

Cause Remedy

Defective monitor
module of maintenance Replace
monitor

20-604 WD900-3
TROUBLESHOOTING K-2

K-2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out (even after 3 seconds)

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

Defective monitor
module of maintenance Replace
monitor

K-1, K-2 Related electrical circuit diagram

WD900-3 20-605
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

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

20-606 WD900-3
TROUBLESHOOTING K-3

K-3 Related electrical circuit diagram

WD900-3 20-607
TROUBLESHOOTING K-4

K-4 When starting switch is turned ON (engine stopped), CHECK items flash

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Engine oil level display flashes

a Before starting troubleshooting, check the engine oil level again.
(Check that the engine oil level is correct.)

K-4 a) Related electrical circuit diagram

20-608 WD900-3
TROUBLESHOOTING K-4

b) Engine water level display flashes

a Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)

K-4 b) Related electrical circuit diagram

WD900-3 20-609
TROUBLESHOOTING K-5

K-5 When starting switch is turned ON (engine started), CAUTION items flash

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Engine oil pressure display flashes

(Check that the engine oil puressure is correct.)

K-5 a) Related electrical circuit diagram

20-610 WD900-3
TROUBLESHOOTING K-5

b) Battery charge level display flashes

K-5 b) Related electrical circuit diagram

WD900-3 20-611
TROUBLESHOOTING K-5

c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)

Cause Remedy

4 YES
Go to A
Is resistance
YES between BC07
3 (male) (1) and (2) Defective brake
Is resistance normal? accumulator oil pressure
YES between BC06 • Max. 1 z NO (low pressure) switch
Replace
(male) (1) and (2) • Start engine. (SW4)
2
normal? • Disconnect BC07. Defective brake
• Max. 1 z
Is resistance
accumulator oil pressure
YES between BC05 Replace
• Start engine. NO (low pressure) switch
(male) (1) and (2)
1 • Disconnect BC06. (SW3)
normal?
• Max. 1 z
Is resistance Defective brake
between BC04 accumulator oil pressure Replace
• Start engine.
(low pressure) switch
(male) (1) and (2) • Disconnect BC05. NO
normal? (SW2)
• Max. 1 z Defective brake
• Start engine. accumulator oil pressure Replace
• Disconnect BC04. NO (low pressure) switch
(SW1)
Defective monitor
6 YES
module of maintenance Replace
Is resistance
between L18
monitor
YES
(female) (11) and Defective contact or
5 BC04 (female) (1)
Is resistance
disconnection in wiring
normal?
harness between L18 Repair or
between BC04
• Max. 1 z NO (female) (11) and BC04 replace
A (female) (2) and
chassis ground
• Turn starting (female) (1)
normal? switch OFF.
Defective contact or
• Max. 1 z
• Disconnect L18 and BC04.
disconnection in wiring Repair or
• Turn starting NO harness between BC04 replace
switch OFF. (female) (2) and chassis
• Disconnect BC04. ground

20-612 WD900-3
TROUBLESHOOTING K-5

K-5 c) Related electrical circuit diagram

WD900-3 20-613
TROUBLESHOOTING K-5

d) Air cleaner (R.H.) clogging display flashes (Check that the air cleaner (R.H.) is not clogged.)

K-5 d) Related electrical circuit diagram

20-614 WD900-3
TROUBLESHOOTING K-5

e) Air cleaner (L.H.) clogging display flashes (Check that the air cleaner (L.H.) is not clogged.)

K-5 e) Related electrical circuit diagram

WD900-3 20-615
TROUBLESHOOTING K-5

f) Transmission oil filter display flashes (The transmission oil filter must not be clogged.)

K-5 f) Related electrical circuit diagram

20-616 WD900-3
TROUBLESHOOTING K-6

K-6 CAUTION items are flashing but buzzer does not sound

a Buzzer does not sound when battery charge or engine oil level is abnormal.
a ßBefore carrying out troubleshooting, check that all the related connectors are properly connected.
a ßAlways connect any disconnected connectors before going on to the next step.
a Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in wiring
harness between fuses I-10 to FS2 (9) and L42 (1).

Cause Remedy

Defective contact or
disconnection in wiring
3 YES
harness between L19 Replace
Does buzzer sound (female) (4) and L43
YES When L43 (female) (male) (1)
2 (1) is connected to
chassis ground ?
Does buzzer sound Defective buzzer Replace
YES When L19 (female) • Turn starting NO
(4) is connected to switch ON.
1 chassis ground ? • Disconnect L43.
Is voltage between
Defective monitor
• Disconnect L19. module of maintenance Replace
L42 (female) (1)
and chassis • Turn starting NO monitor
ground normal? switch ON.
Defective contact or
• 20 – 30 V disconnection in wiring
Repair or
• Disconnect L42. harness between FS2
NO replace
• Turn starting (female) (9) and L42
switch ON. (female) (1)

K-6 Related electrical circuit diagram

WD900-3 20-617
TROUBLESHOOTING K-7

K-7 There is no abnormality in monitor display but caution buzzer sounds

a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before carrying out troubleshooting, check that buzzer stays sounded when L06 is disconnected.

Cause Remedy

Defective monitor
2 YES
module of maintenance Replace
Is resistance
monitor
YES between L19
(female) (4) and Short circuit with chassis
1 chassis ground
Is resistance ground in wiring harness
normal? Repair or
between L19 (female) (4)
• Min. 1 Mz
between L43
NO replace
(female) (1) and – L43 (male) (1) – L06
chassis ground • Turn starting switch OFF. (female) (8)
normal? • Disconnect L06, L19 and
L43.
• Min. 1 Mz Defective buzzer
NO Replace
• Turn starting
switch OFF.
• Disconnect L42
and L43.

K-7 Related electrical circuit diagram

20-618 WD900-3
TROUBLESHOOTING K-8

K-8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes

a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) CHECK lamp

Cause Remedy

Defective monitor
YES
module of maintenance Replace
1
monitor
Does CHECK lamp
light up when L19 Defective contact or
(female) (2) is disconnection in wiring
connected to 2 YES Repair or
Does CHECK lamp harness between L19
chassis ground ? replace
light up when L06 (female) (2) and L06
• Disconnect L19. (female) (10)
(male) (10) is
• Turn starting NO connected to
switch ON. chassis ground ?
Defective main monitor Replace
• Disconnect L06. NO
• Turn starting
switch ON.

b) CAUTION lamp

K-8 Related electrical circuit diagram

WD900-3 20-619
TROUBLESHOOTING K-9

K-9 There is no abnormality in maintenance monitor display but CHECK lamp or

CAUTION lamp lights up

a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) CHECK lamp

Cause Remedy

Defective monitor
1 YES
module of maintenance Replace
Is resistance
between L19 monitor
(female) (2) and
chassis ground Short circuit with chassis
normal? ground in wiring harness Repair or
• Min. 1 Mz NO between L19 (female) (2) replace
• Turn starting and L06 (female) (10)
switch OFF.
• Disconnect L06
and L19.

b) CAUTION lamp

Cause Remedy

Defective monitor
1 YES
module of maintenance Replace
Is resistance
between L19 monitor
(female) (3) and
chassis ground Short circuit with chassis
normal? ground in wiring harness Repair or
• Min. 1 Mz NO between L19 (female) (3) replace
and L06 (female) (9)
• Turn starting
switch OFF.
• Disconnect L06
and L19.

K-9 Related electrical circuit diagram

20-620 WD900-3
TROUBLESHOOTING K-10

K-10 Only night lighting of maintenance monitor does not light up when lighting
switch is turned ON

a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Cause Remedy

1 YES Disconnection in wiring

Replace
Is voltage harness of lamp holder
between
L21(female) (1) Defective contact or
and (2) normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between L21 replace
• Disconnect L21. (female) (1) and FS2 (5)
• Turn starting
switch ON.
• Turn lamp switch
ON.

K-10 Related electrical circuit diagram

WD900-3 20-621
TROUBLESHOOTING K-11

K-11 Night lighting lights up even when lighting switch is turned OFF

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

Switch Continuity

ON YES
OFF NO

K-11 Related electrical circuit diagram

20-622 WD900-3
TROUBLESHOOTING K-12, K-13

K-12 Service meter does not work

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

K-13 Service meter is running even when engine is stopped

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

WD900-3 20-623
TROUBLESHOOTING K-12, K-13

K-12, K-13 Related electrical circuit diagram

20-624 WD900-3
TROUBLESHOOTING K-14

K-14 Abnormality in gauge display

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Abnormality in fuel gauge

a Before carrying out troubleshooting, check the fuel level again. (Check that the fuel level is correct.)

(1) Little or nothing is displayed in display area Cause Remedy

YES Defective fuel level

Replace
sensor

1
Defective monitor
Does fuel gauge 3 YES
module of maintenance Replace
show FULL when Is resistance between
L18 (female) (6) and monitor
short connector
is connected to YES chassis ground
normal when short
R05 (female)? connector is Defective contact or
2 connected to R05? disconnection in wiring
• Disconnect R05.
• Max. 1 z
Is resistance Repair or
• Connect short harness between R05
between R05 replace
connector to R05 • Turn starting NO (female) (1) and L18
(female) (2) and
(female). NO chassis ground switch OFF. (female) (6)
• Turn starting normal? • Connect short connector
• Max. 1 z
Defective contact or
switch ON. to R05 (female).
disconnection in wiring
• Turn starting • Disconnect L18. Repair or
harness between R05
switch OFF. NO replace
(female) (2) and chassis
• Disconnect R05. ground

(2) Display always shows FULL and does not move Cause Remedy

YES Defective fuel level

Replace
1 sensor
Do all display areas
on fuel gauge go
out when R05 is YES Defective monitor
disconnected? module of maintenance Replace
Is resistance 2
between R05
monitor
• Disconnect R05.
(female) (1) and
• Turn starting NO Short circuit with chassis
chassis ground
switch ON. normal? ground in wiring harness Repair or
• Min. 1 Mz NO between R05 (female) (1) replace
• Turn starting switch OFF. – L18 (female) (6)
• Disconnect L18 and R05.

K-14 a) Related electrical circuit diagram

WD900-3 20-625
TROUBLESHOOTING K-14

b) Abnormality in engine water temperature gauge

(1) Nothing is displayed in display area

Cause Remedy

YES Defective engine water

Replace
1 temperature sensor
Does engine water
temperature gauge
show minimum Defective monitor
level when E04 is
2 YES
module of maintenance Replace
disconnected? Is resistance
monitor
• Disconnect E04. between E04
(female) (1) and
• Turn starting NO Short circuit with chassis
chassis ground
switch ON. normal? ground in wiring harness Repair or
• Min. 1 Mz NO between E04 (female) (1) replace
• Turn starting – L18 (female) (4)
switch OFF.
• Disconnect L18
and E04.

(2) Display shows lowest level and does not move

Cause Remedy

YES Defective engine water

Replace
temperature sensor

1
When short Defective monitor
connector is
3 YES
module of maintenance Replace
connected to E04 Is resistance
(female), does between L18
monitor
engine water (female) (4) and
temperature gauge
display area rise one YES chassis ground
stage at a time, and normal when short
finally do all lamps connector is Defective contact or
2 connected to E04 disconnection in wiring
• Disconnect E04. Repair or
Is resistance (female)?
harness between E04
• Max. 1 z
• Connect short between E04 replace
connector to E04 NO (female) (1) – L18
(female) (2) and
(female). NO • Turn starting switch OFF. (female) (4)
chassis ground
• Turn starting normal?
• Connect short connector to
switch ON. E04 (female). Defective contact or
• Turn starting
• Disconnect L18. disconnection in wiring
switch OFF. Repair or
• Disconnect E04. harness between E04
replace
• Max. 1 z NO (female) (2) – chassis
ground

K-14 b) Related electrical circuit diagram

20-626 WD900-3
TROUBLESHOOTING K-14

c) Abnormality in torque converter oil temperature gauge

(1) Nothing is displayed in display area

Cause Remedy

YES Defective torque

converter oil temperature Replace
1
sensor
Does torque converter
oil temperature gauge
show minimum level Defective monitor
when T02 is
2 YES
module of maintenance Replace
disconnected? Is resistance
monitor
• Disconnect T02. between T02
(female) (1) and Short circuit with chassis
• Turn starting NO chassis ground ground in wiring harness
switch ON. normal? Repair or
between T02 (female) (1)
• Turn starting NO replace
– L18 (female) (5) (contact
switch OFF. with chassis ground)
• Disconnect L18
and T02.
• Min. 1 Mz

(2) Display shows lowest level and does not move

Cause Remedy

Defective torque
YES
converter oil temperature Replace
sensor

1
When short Defective monitor
connector is 3 YES
module of maintenance Replace
connected to T02, Is resistance
does torque between L18
monitor
converter oil (female) (5) and
temperature gauge
display area rise one YES chassis ground
stage at a time, and normal when short
finally do all lamps connector is Defective contact or
2 connected to T02 disconnection in wiring
• Disconnect T02. Repair or
Is resistance (female)?
• Connect short harness between T02
• Max. 1 z
between T02 replace
connector to T02 NO (female) (1) – L18
(female) (2) and
(female). NO • Turn starting switch OFF. (female) (5)
chassis ground
• Turn starting normal? • Connect short connector to
switch ON. • Max. 1 z T02 (female). Defective contact or
• Turn starting • Disconnect L18. disconnection in wiring
harness between T02 Repair or
switch OFF. replace
• Disconnect T02. NO (female) (2) – chassis
ground

K-14 c) Related electrical circuit diagram

WD900-3 20-627
 TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)

Electrical circuit diagram for power supply, engine starting, engine stopping and preheating .................... 20-702
Electrical circuit diagram for parking brake ................................................................................................. 20-704
E-1 Engine does not start ........................................................................................................................... 20-706
a) Starting motor does not turn ............................................................................................................ 20-706
b) Starting motor turns (STD spec.) ..................................................................................................... 20-710
E-2 Engine does not stop (STD spec.) ....................................................................................................... 20-712
E-3 Engine Stops when machine is traveling (STD spec.) ......................................................................... 20-713
E-4 Abnormality in preheating system ........................................................................................................ 20-715
a) Does not carry out preheating ......................................................................................................... 20-715
b) Always carries out preheating for 45 seconds ................................................................................. 20-716
c) Preheating stays on ......................................................................................................................... 20-716
d) Preheating time becomes shorter, or there is fluctuation................................................................. 20-717
E-5 Parking brake does not have effect ...................................................................................................... 20-719
a) Parking brake has no effect when parking brake switch is turned ON............................................. 20-719
b) Parking brake has no effect when brake pressure (accumulator pressure) drops
(Does not work as emergency brake) .............................................................................................. 20-719
E-6 Parking brake is applied when machine is traveling............................................................................. 20-720
E-7 Parking brake is released when starting switch is turned ON .............................................................. 20-722
E-8 Transmission does not change to neutral when parking brake is applied
(but parking brake works normally) ...................................................................................................... 20-722
E-9 Kick-down switch does not work .......................................................................................................... 20-724
a) Kick-down switch does not work even though gear shift works normally ........................................ 20-724
b) Kick-down cannot be canceled ........................................................................................................ 20-725
E-10 Abnormality in lighting up of front working lamp ................................................................................. 20-726
E-11 Abnormality in lighting up of rear working lamp .................................................................................. 20-726
E-12 Abnormality in transmission cut-off..................................................................................................... 20-726
E-13 Abnormality in low idling selection...................................................................................................... 20-726
E-14 Abnormality in parking brake dragging warning ................................................................................. 20-726
E-15 Abnormality in buzzer ......................................................................................................................... 20-726

WD900-3 20-701
 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING

ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE

STARTING, ENGINE STOPPING AND PREHEATING

20-702 WD900-3
 ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING

a This circuit diagram is made by extracting the parts of the power supply, engine starting, engine stopping,
and preheating systems from the general circuit diagram.

WD900-3 20-703
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

a This circuit diagram is made by extracting the part of the parking brake system from the general circuit dia-
gram.

20-704 WD900-3
TROUBLESHOOTING E-1

E-1 Engine does not start

a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to
the original condition before going on to the next check.

a) Starting motor does not turn

20-706 WD900-3
TROUBLESHOOTING E-1

WD900-3 20-707
TROUBLESHOOTING E-1

20-708 WD900-3
TROUBLESHOOTING E-1

WD900-3 20-709
TROUBLESHOOTING E-1

b) Starting motor turns (STD spec.)

20-710 WD900-3
TROUBLESHOOTING E-1

WD900-3 20-711
TROUBLESHOOTING E-2

E-2 Engine does not stop (STD spec.)

a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a 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.

20-712 WD900-3
TROUBLESHOOTING E-3

E-3 Engine Stops when machine is traveling (STD spec.)

a Check if the starting motor turns. If it does not turn, check E-1 a) Starting motor does not turn.

WD900-3 20-713
TROUBLESHOOTING E-1, E-2, E-3

E-1, 2, 3 Related electrical circuit diagram

20-714 WD900-3
TROUBLESHOOTING E-4

E-4 Abnormality in preheating system

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.

a) Does not carry out preheating

a Check that the water temperature is below 5°C.
1) Monitor display also does not light up

2) Only monitor display lights up

WD900-3 20-715
TROUBLESHOOTING E-4

b) Always carries out preheating for 45 seconds

a Check that the water temperature is above – 10°C

c) Preheating stays on

20-716 WD900-3
TROUBLESHOOTING E-4

d) Preheating time becomes shorter, or there is fluctuation

Table 1 (Tolerance ± 0.5 kz)

Temperature (°C) –30 –20 0 20 40 60 80 90
Resistance (kz) 19.5 12.1 5.11 2.39 1.21 0.695 0.381 0.295

WD900-3 20-717
TROUBLESHOOTING E-4

E-4 Related electrical circuit diagram

20-718 WD900-3
TROUBLESHOOTING E-5

E-5 Parking brake does not have effect

a Check that the brake hydraulic system is normal.

a When carrying out troubleshooting of the brake system, stop the machine on level ground.
a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a Always connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.

a) Parking brake has no effect when parking brake switch is turned ON

b) Parking brake has no effect when brake pressure (accumulator pressure) drops (Does not work as
emergency brake)

Cause Remedy

1 YES Defective parking brake

Replace
Is resistance solenoid
between CBL1
(female) (3) and Defect of all four
(4) normal? emergency brake
Replace
• Start engine NO switches (SW1, SW2,
(Charge SW3, SW4)
accumulator).

WD900-3 20-719
TROUBLESHOOTING E-6

E-6 Parking brake is applied when machine is traveling

a When carrying out troubleshooting of the brake system, stop the machine on level ground.
a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE QE(
QE ).
a Always connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.

2 YES
Is resistance
YES between F11
(female) (2) and
chassis ground
normal?
• Disconnect L59. NO
• Turn starting
switch OFF.
• Max. 1 z YES

1
Is voltage between 4 YES
F11 (female) (1) Does condition
and chassis become normal
YES
ground normal? when L59 is
replaced with other
• 20 – 30 V relay of same type?
• Start engine • Replace parking
(Charge brake safety relay
accumulator). (L59) with other 5
relay of same Does condition
become normal when
type.
BC08, BC09, BC10 and
• Start engine NO C11 are connected to
(Charge short connector?
accumulator). • Connect short
3 YES
connector to
Is resistance of
BC08 (female), 7
L01 (male) (1), (2)
BC09 (female),
NO and (3) as shown BC10 (female) Is resistance
in Table 1? YES between L59
and C11 (female).
• Disconnect L01. (female) (1) and (3)
• Start engine
• Turn starting 6 normal?
(Charge with
switch OFF. brake oil Is voltage between • Max. 1 z
• Turn parking pressure). L59 (female) (5) • Turn starting
brake switch ON/ NO and chassis switch OFF. NO
OFF. ground normal? • Disconnect L59.
• 20 – 30 V
• Turn starting
switch ON. NO
• Disconnect L59.

NO

Table 1
Between Between
Operation
L01 (2) – (3) L01 (1) – (3)
ON (Parking) Min. 1 Mz Max. 1z
OFF (Traveling) Max. 1 z Min. 1 Mz

20-720 WD900-3
TROUBLESHOOTING E-6

WD900-3 20-721
TROUBLESHOOTING E-7, E-8

E-7 Parking brake is released when starting switch is turned ON

a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE QE(
QE ).
a Always, connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.

E-8 Transmission does not change to neutral when parking brake is applied (but
parking brake works normally)

20-722 WD900-3
TROUBLESHOOTING E-6, E-7, E-8

E-6, E-7, E-8 Related electrical circuit diagram

WD900-3 20-723
TROUBLESHOOTING E-9

E-9 Kick-down switch does not work

a 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE QE(
QE ).
a Always, connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.

a) Kick-down switch does not work even though gear shift works normally

20-724 WD900-3
TROUBLESHOOTING E-9

b) Kick-down cannot be canceled

E-9 Related electrical circuit diagram

WD900-3 20-725
TROUBLESHOOTING E-10, E-11, E-12, E-13, E-14, E-15

E-10 Abnormality in lighting up of front working lamp

a Go to Troubleshooting M-10.

E-11 Abnormality in lighting up of rear working lamp

a Go to Troubleshooting M-11.

E-12 Abnormality in transmission cut-off

a Go to Troubleshooting M-12.

E-13 Abnormality in low idling selection

a Go to Troubleshooting M-13.

E-14 Abnormality in parking brake dragging warning

a Go to Troubleshooting M-16, 17.

E-15 Abnormality in buzzer

a Go to Troubleshooting M-18.

20-726 WD900-3
 TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
H-1 Machine does not move ....................................................................................................................... 20-802
H-2 Machine lacks power or speed (every speed range) ........................................................................... 20-803
H-3 Excessive time lag when starting machine or shifting gear.................................................................. 20-804
H-4 Torque converter oil temperature is high .............................................................................................. 20-805
H-5 Steering does not turn .......................................................................................................................... 20-806
H-7 Turning, response of steering is poor................................................................................................... 20-808
H-8 Turning, response of steering is poor [machine with joystick (If equipped)]......................................... 20-809
H-11 Steering wheel shakes or jerks............................................................................................................20-811
H-13 Turning radius is different between left and right at maximum steering ............................................. 20-813
H-14 Wheel brakes do not work or braking effect is poor ........................................................................... 20-814
H-15 Wheel brakes are not released or brakes drag .................................................................................. 20-815
H-16 Blade does not rise ............................................................................................................................ 20-816
H-17 Blade moves slowly or does not have sufficient lifting power............................................................. 20-817
H-18 When raising blade, becomes slow at certain height ......................................................................... 20-818
H-19 Lift cylinder cannot hold down blade .................................................................................................. 20-818
H-20 Blade has large amount of hydraulic drift........................................................................................... 20-818
H-21 Blade fluctuates while working ........................................................................................................... 20-819
H-22 Blade drops momentarily when lever is operated from HOLD to RAISE ........................................... 20-819
H-23 Blade does not tilt back ...................................................................................................................... 20-820
H-24 Blade moves slowly or has insufficient tilt back power....................................................................... 20-821
H-25 Blade movement becomes slow during tilt back ................................................................................ 20-822
H-26 Lift cylinder cannot hold down bucket ................................................................................................ 20-822
H-27 Blade has large amount of hydraulic drift........................................................................................... 20-822
H-28 Blade control lever does not move smoothly ..................................................................................... 20-823

WD900-3 20-801
TROUBLESHOOTING H-1

H-1 Machine does not move

Ask the operator the following points

• Did the machine suddenly stop moving?
Yes = Component seized or damaged
• Was there any abnormal noise when the
machine stopped moving?
Yes = Component broken.

Checks before troubleshooting

• Is oil level in transmission case correct?
• Is monitor display normal?
• Is drive shaft broken?

Note 1: If the solenoid valve and hydraulic pressure The following symbols are used to indicate the action to
are normal, the "m" in the Causes column be taken when a cause of failure is located.
indicates that the valve spool does not work.
Note 2: If the transmission clutch pressure is low, X: Replace E: Repair
but the cause cannot be found in the above A: Adjust C: Clean
table, a possible cause is cracks in the valve
or transmission.

20-802 WD900-3
TROUBLESHOOTING H-2

H-2 Machine lacks power or speed (every speed range)

Checks before troubleshooting

• Is oil level transmission case correct?
• Is there any leakage of oil from joints of
piping or valves?
• Is parking brake or wheel brake dragged?

Checking for abnormalities

• Engine high idling speed
• Torque converter stall speed
• Machine travel speed
• Transmission clutch pressure (both
high pressure and low pressure)
• Pressure at outlet port of torque con-
verter pump
• Pilot reducing pressure

WD900-3 20-803
TROUBLESHOOTING H-3

H-3 Excessive time lag when starting machine or shifting gear

Checks before troubleshooting

• Is oil level in transmission case correct?
• Is there any leakage of oil from joints of
piping or valves?

20-804 WD900-3
TROUBLESHOOTING H-4

H-4 Torque converter oil temperature is high

Ask the operator the following points
• Does torque converter oil temperature go
up during torque converter stall, and
down when the torque converter is not
installed?
Yes = Normal (incorrect selection of gear
speed)

Checks before troubleshooting

• Is oil level in transmission case correct?
• Is transmission filter clogged?

Checking for abnormalities

a If the oil temperature is normal but the oil
temperature gauge is outside the operat-
ing range, the oil temperature gauge is
defective.

WD900-3 20-805
TROUBLESHOOTING H-5

H-5 Steering does not turn

Ask the operator the following points

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?

Checks before troubleshooting

• Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
frame?

a There is a close connection between the steering circuit and the work equip-
ment circuit, so if any abnormality is felt in the steering, check the operation of
the work equipment also.

20-806 WD900-3
TROUBLESHOOTING H-6

H-6 Steering does not turn [machine with joystick (If equipped)]

Ask the operator the following points

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?

Checks before troubleshooting

• Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
frame?
• Is the operation of the steering and the
steering mode switch correct?

a There is a close connection between the steering circuit and the work equipment cir-
cuit, so if any abnormality is felt in the steering, check the operation of the work
equipment also.

WD900-3 20-807
TROUBLESHOOTING H-7

H-7 Turning, response of steering is poor

Ask the operator the following points

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?
• Was there previously any symptom, such
as difficulty in steering?
Yes = Wear of related equipments, defec-
tive seal

Checks before troubleshooting

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?

a There is a close connection between the steering circuit and the work equipment cir-
cuit, so if any abnormality is felt in the steering, check the operation of the work
equipment also.

20-808 WD900-3
TROUBLESHOOTING H-8

H-8 Turning, response of steering is poor [machine with joystick (If equipped)]

Ask the operator the following points

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when
this happened? Where did the noise
come from?
• Was there previously any symptom,
such as difficulty in steering?
Yes = Wear of related equipment, de-
fective seal

Checks before troubleshooting

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?

a 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.

WD900-3 20-809
TROUBLESHOOTING H-9, H-10

H-9 Steering is heavy

Checking for abnormalities

• Is the steering difficult to turn?
Yes = Go to H-8 or H-9
• Measure the operating effort and turning
speed, and check the STANDARD VAL-
UE TABLE to see if they are abnormal.

Ask the operator the following points

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there previously any symptom,
such as heavy steering?
Yes = Wear of related equipment, defec-
tive seal

Checks before troubleshooting

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?
• Is the tire inflation pressure correct?

H-10 Joystick lever is heavy [machine with joystick (If equipped)]

Causes and Remedy

• Abnormality of joystick lever (x)
(The joystick lever is an electrically operated lever, so if the operating effort is large, the abnormality is in the
joystick lever.)

20-810 WD900-3
TROUBLESHOOTING H-11

H-11 Steering wheel shakes or jerks

Checking for abnormalities

• Is the steering difficult to turn?
Yes = Go to H-8
• Is there any abnormal noise from around
the steering equipment?

Checks before troubleshooting

• Is the steering wheel play correct?
• Is there any abnormality in the connec-
tion between the steering shaft and the
Orbit-roll?
• Is the tire inflation pressure correct?

WD900-3 20-811
TROUBLESHOOTING H-12

H-12 Steering wheel shakes or jerks [machine with joystick (If equipped)]

Checking for abnormalities

• Is the steering difficult to turn?
Yes = Go to H-9
• Is there any abnormal noise from around
the steering equipment?

Checks before troubleshooting

• Is any failure code for the electrical sys-
tem displayed on the main monitor?
• Is the steering wheel play correct?
• Is there any abnormality in the connec-
tion between the steering shaft and the
Orbit-roll?
• Is the tire inflation pressure correct?

20-812 WD900-3
TROUBLESHOOTING H-13

H-13 Turning radius is different between left and right at maximum steering

Cause and remedy

E)
• Defective adjustment of stop valve (E

WD900-3 20-813
TROUBLESHOOTING H-14

H-14 Wheel brakes do not work or braking effect is poor

Checking for abnormalities

• Measure the actual brake performance,
and check if there is actually an abnor-
mality or whether it is just the feeling of
the operator. For details, see TESTING
AND ADJUSTING, Measuring brake
performance.

Ask the operator the following points.

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when
this happened? Where did the noise
come from?
• Did the problem gradually appear?
Yes = Wear of related equipments, de-
fective seal

Checks before troubleshooting

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?
• Is the brake pedal play correct?
• Is there any leakage of oil from the
brake tube?
Is there any deformation of the tube?
• Is the tire inflation pressure and tread
pattern correct?

20-814 WD900-3
TROUBLESHOOTING H-15

H-15 Wheel brakes are not released or brakes drag

Ask the operator the following points.

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?

Checks before troubleshooting

• Does the brake pedal come back fully?
• Is the parking brake still applied (ON)?

WD900-3 20-815
TROUBLESHOOTING H-16

H-16 Blade does not rise

Ask the operator the following points

• Did the problem suddenly fail to rise?
o Seizure or damage to various units.
• Was unusual noise produced? (Where did
it emanate from?)
• Were there previous signs of the blade
slowing down?
o Wear of parts of flattening of spring.

Checks before troubleshooting

• Is oil level in hydraulic tank correct?
• Is travel of blade control lever and spool
correct?

20-816 WD900-3
TROUBLESHOOTING H-17

H-17 Blade moves slowly or does not have sufficient lifting power

Checks before troubleshooting

• Is the travel of the blade control lever and
also the spool of the work equipment control
valve correct?
• Seizure of work equipment linkage bushing.
(Does emits abnormal noise)

Fault check
There is a strong relationship between faults
involving lifting force and lifting speed. Such
faults appear initially in the from of insufficient
lifting speed. Measure the lifting speed of the lift
arm when loaded and refer to the standard
value table to determine whether or not there is
a fault.

WD900-3 20-817
TROUBLESHOOTING H-18, H-19, H-20

H-18 When raising blade, becomes slow at certain height

Checks before troubleshooting

• External deformation of lift cylinder.

Cause
• Swollen or internally damaged lift cylinder tube.
a Regarding other faults occurring during boom rise, refer to item “H-17 Blade moves slowly or
does not have sufficient lifting power”.

H-19 Lift cylinder cannot hold down blade

Refer to item “H-17 Blade moves slowly or does not have sufficient lifting power”.

Checks before troubleshooting

• Is travel of blade control lever and also the spool of work equipment control valve correct?

Cause
• Defective lift cylinder rod side suction valve seat of work equipment control valve
• Oil leakage from lift cylinder piston seal

H-20 Blade has large amount of hydraulic drift

Ask the operator the following points

• Did the hydraulic drift suddenly become large?
o Dirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
o Worn parts.

Checks before troubleshooting

• Is the blade spool in the hold position?
o Seized ring bushing, defective spool detent.

Troubleshooting and cause

• When measuring hydraulic drift, internal leakage of lift cylinder makes oil leakage noise.
o Damaged cylinder packing.
• When measuring hydraulic drift, lift cylinder does not make oil leakage noise.
o Defective oil sealing of blade raise-lower spool.
o Defective check valve between pipings.

20-818 WD900-3
TROUBLESHOOTING H-21, H-22

H-21 Blade fluctuates while working

During excavation or ground leveling when the blade control lever is in the “HOLD” position, the bucket
and blade move up and down in accordance with the terrain.

Troubleshooting and cause

Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the lift cyl-
inder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item “H-20 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-19 Lift cylinder cannot
hold down blade”.
3. If the 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 o
the trouble is due to the generation of a vacuum in the cylinder.
a If a vacuum is generated frequently o defective suction valve on lift cylinder rod side.

H-22 Blade drops momentarily when lever is operated from HOLD to RAISE

The blade drops momentarily under its own weight when the blade control lever is gradually shifted from
the “HOLD” position to the “RAISE” position while the engine is at low idling. When the control 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.

WD900-3 20-819
TROUBLESHOOTING H-23

H-23 Blade does not tilt back

Ask the operator the following points

• Did the blade suddenly cease to move?
o Seized or damaged equipment.
• Was any abnormal noise emitted (where
did it emanate from?)
• Was there previous signs of the blade
slowing down?
o Worn parts or flattening of spring.

Checks before troubleshooting

• Is the travel of the blade control lever and
spool correct?

20-820 WD900-3
TROUBLESHOOTING H-24

H-24 Blade moves slowly or has insufficient tilt back power

Checks before troubleshooting

• Is the travel of the blade control lever
and the work equipment control valve
spool correct?
• Seizure of bushing in blade linkage?
(Does emits abnormal noise?)

Fault checks
• Check deficient tilt force by performing
actual work.
• Measure the operating speed of the
blade and check it against the standard
value table to determine whether or not
it is normal.

WD900-3 20-821
TROUBLESHOOTING H-25, H-26, H-27

H-25 Blade movement becomes slow during tilt back

Checks before troubleshooting

• External deformation of lift cylinder.

Cause
• Swollen or internally damaged lift cylinder tube.
• As to other faults which occur when operating blade, refer to item “H-24 Blade moves slowly or
has insufficient tilt power”.

H-26 Lift cylinder cannot hold down bucket

Refer to item “H-24 Blade moves slowly or has insufficient tilt power”.

Checks before troubleshooting

• Is the travel of lift spool of work equipment control valve correct?

Cause
• Defective seat of safety valve (with suction valve) of the rod side of lift cylinder of work equipment
valve.
• Oil leakage from seal of lift cylinder piston.

H-27 Blade has large amount of hydraulic drift

Ask the operator the following points

• Did the hydraulic drift suddenly become large?
oDirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
oWorn parts.

Checks before troubleshooting

• Is the blade spool in the hold position?
oSeized ring bushing, faulty spool detent.

Fault check
• Use the standard value table to check whether or not the hydraulic drift of the blade is actually large.

Cause
• Oil leakage in lift cylinder
• Defective seating of safety valve (with suction valve) at bottom side.
• Defective oil sealing of blade raise-lower spool.
• Defective check valve between pipings.

20-822 WD900-3
TROUBLESHOOTING H-28

H-28 Blade control lever does not move smoothly

Fault check
Using the standard value table, check
whether or not the operating effort of the
lever is large.

WD900-3 20-823
 TROUBLESHOOTING OF JOYSTICK STEERING
CONTROL SYSTEM
(J MODE)

JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL SYSTEM RELATED PARTS................... 20-852
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 20-854
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING CONTROL SYSTEM............................ 20-858
J-1 Failure code [56] (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed............................................................................................ 20-860
J-2 Failure code [57] (Disconnection or short circuit with chassis ground in
steering lever angle sensor system) is displayed.................................................................................. 20861
J-3 Failure code [58] (Deviation of steering lever angle sensor and frame angle sensor signals)
is displayed........................................................................................................................................... 20-862
J-4 Failure code [59] (Disconnection or short circuit with chassis ground in
frame angle sensor system) is displayed ............................................................................................. 20-863
J-5 Failure code [60] (Disconnection or short circuit with chassis ground in
steering lever lock pressure switch system) is displayed ..................................................................... 20-864
J-6 Failure code [62] (Disconnection or short circuit with chassis ground in
steering neutral interlock relay system) is displayed ............................................................................ 20-866
J-7 Failure code [63] (Disconnection, short circuit with chassis ground, or
short circuit with power source in steering main pressure control EPC solenoid system) is displayed 20-868
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentiometer) is displayed ... 20-869
J-9 Abnormality in console switch (adjustment of steering lever angle sensor and
frame angle sensor is impossible)........................................................................................................ 20-870
J-10 Abnormality in joystick steering ON-OFF circuit.................................................................................. 20-871
J-11 Disconnection in steering right solenoid.............................................................................................. 20-872
J-12 Disconnection in steering left solenoid................................................................................................ 20-873

WD900-3 20-851
 JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL
TROUBLESHOOTING SYSTEM RELATED PARTS

JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL

SYSTEM RELATED PARTS
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, disconnection in steering solenoid cut relay output

Short circuit, disconnection in joystick steering neutral switch
Short circuit, disconnection in joystick caution relay output

Short circuit in steering right solenoid (power supply side)

Short circuit in steering left solenoid (power supply side)
Troubleshooting

Short circuit, disconnection in joystick potentiometer

code when no

Abnormality in power supply, power supply voltage

abnormality
display is given

Failure mode

Abnormality in joystick ON-OFF circuit

Failure
code

Transmission & joystick

Steering controller
56 57 58 59 60 61 62 63 — —

1 Buzzer does not stop Q T-16

H-6, H-8, H-10,
2 Steering does not turn to left Q Q Q Q
H-12, J-9, J-12
H-6, H-8, H-10,
3 Steering does not turn to right Q Q Q Q
H-12, J-9, J-11
4 Steering is always turned to left Q Q Q

5 Steering is always turned to right Q Q Q J-9, J-10

6 Both steering and transmission do not work at all Q Q

Troubleshooting code when no error code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 — —

20-852 WD900-3
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
JOYSTICK CONTROL SYSTEM

Failure code Abnormal system Nature of abnormality

1) Defective caution relay

2) Short circuit with ground, defective contact, or disconnection in wiring
harness between C2 (female) (9) – L65 (1)
3) Short circuit with ground, defective contact, or disconnection in wiring
harness between C2 (female) (19) – L65 (2) – chassis ground
56 Joystick caution relay
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 follow-
ing 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)
7) Defective transmission & joystick steering controller

1) Defective steering left solenoid

2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between C2 (female) (3) – (14)
Short circuit with ground, defective contact, or disconnection in the follow-
ing wiring harness
4) Wiring harness between C2 (female) (3) – L26 (14)
58 Steering left solenoid
5) Wiring harness between C2 (female) (14) – L67 (3)
6) Wiring harness between L67 (female) (5) – L26 (1)
7) Defective transmission & joystick controller

1) Defective steering right solenoid

Short circuit with power
59 source in steering right
solenoid circuit
2) Short circuit with power source in wiring harness between C2 (female)
(2) – L27 (2)
3) Defective transmission & joystick steering controller

1) Defective steering left solenoid

Short circuit with power
60 source in steering left sole-
noid circuit
2) Short circuit with power source in wiring harness between C2 (female)
(3) – L26 (2)
3) Defective transmission & joystick steering controller

20-854 WD900-3
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Problem that appears on Trouble-

Condition when normal Action by controller when
machine when there is shooting
(voltage, current, resistance) abnormality is detected
abnormality code

1) Joystick caution relay: ON (voltage between C2 Caution output: OFF Joystick caution actuated
(9) – (19): 20 – 30 z)
2) Resistance of relay coil between C2 (female)
(9) – (19): 200 – 400 z
3) Resistance of wiring harness between C2 J-1
(female) (9) – L65 (female) (1): Less than 1 z
4) Resistance of wiring harness between L65
(female) (2) – C2 (19): Less than 1 z

1) Steering solenoid cut relay: ON (voltage Steering right, left sole- Impossible to use joy-
between C2 (2) and chassis ground: 20 – 30 V) noid output: OFF stick and joystick caution
2) Resistance of steering right solenoid: 10 – 20 z and steering solenoid cut actuated
3) Resistance between C2 (female) (2), (13) – relay output: OFF
chassis ground: Min. 1 Mz Resistance of the and caution relay output:
following wiring harness: Less than 1 z OFF J-2
4) Wiring harness between C2 (female) (2) – L27
(female) (2) 5)Wiring harness between C2
(female) (13) – L67 (female) (3)
6) Wiring harness between L67 (female) (5) – L27
(female) (1)

1) Steering solenoid cut relay: ON (voltage Steering right, left sole- Impossible to use joy-
between C2 (3) – chassis ground: 20 – 30 V) noid output: OFF stick and joystick caution
2) Resistance of steering left solenoid: 10 – 20 z and steering solenoid cut actuated
3) Resistance between C2 (female) (3), (14) – relay output: OFF
chassis ground: Min. 1 Mz Resistance of the and caution relay output:
following wiring harness: Less than 1 z OFF
J-3
4) Wiring harness between C2 (female) (3) – L26
(female) (2)
5) Wiring harness between C2 (female) (14) – L67
(female) (3)
6) Wiring harness between L67 (female) (5) – L27
(female) (1)

When joystick lever is at neutral Steering right, left sole- Impossible to use joy-
Voltage between C2 (female) (2) – chassis ground: noid output: OFF stick and joystick caution
Less than 1 V and steering solenoid cut actuated
relay output: OFF
and caution relay output: J-4
OFF

When joystick lever is at neutral Steering right, left sole- Impossible to use joy-
Voltage between C2 (female) (3) – chassis ground: noid output: OFF stick and joystick caution
Less than 1 V and steering solenoid cut actuated
relay output: OFF
and caution relay output: J-5
OFF

WD900-3 20-855
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Failure code Abnormal system Nature of abnormality

1) Defective steering solenoid relay

2) Short circuit with ground, defective contact, or disconnection in wiring
harness between C1 (female) (1) – L67 (female) (1)
3) Short circuit with ground, defective contact, or disconnection in wiring
61 Steering solenoid cut relay harness between JS5 (3) – chassis ground
4) Defective transmission & joystick steering controller

1) Defective joystick neutral switch

2) Short circuit with ground, defective contact, or disconnection in wiring
harness between C5 (female) (11) – JS5 (female) (1)
3) Defective contact or disconnection in wiring harness between JS5 (3)
62 Joystick neutral switch – chassis ground
4) Defective transmission & joystick steering controller

1) Defective boom angle potentiometer

2) Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between C3A (female) (3)
– JS2 (1)
3) Short circuit with power source, defective contact, or disconnection in
63 Joystick potentiometer wiring harness between C3A (female) (7) – JS2 (2)
4) Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between C3A (female)
(17) – JS2 (female) (3)
5) Defective transmission & joystick steering controller

20-856 WD900-3
(6)
 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

Problem that appears on Trouble-

Condition when normal Action by controller when
machine when there is shooting
(voltage, current, resistance) abnormality is detected
abnormality code

Resistance between C5 (female) (11) – chassis Steering right, left sole- Impossible to use joystick
ground: Min. 1 Mz (joystick at neutral), Less than noid output: OFF and joystick caution actu-
1 z (joystick angled ± 5 – 15° from neutral) and steering solenoid cut ated
relay output: OFF
and caution relay output: J-6
OFF

Voltage between C3A (female) (3) – (17): 0.5 – 4.5 V Steering right, left sole- Impossible to use joystick
(voltage when joystick is at neutral: Approx. 2.5 V) noid output: OFF and joystick caution actu-
and steering solenoid cut ated
relay output: OFF
and caution relay output: J-7
OFF

1) Steering solenoid cut relay: ON (voltage Steering right, left sole- Impossible to use joy-
between C1 (1) – chassis ground: 20 – 30 V) noid output: OFF stick and joystick caution
2) Resistance of relay coil between C1 (female) and steering solenoid cut actuated
(1) – chassis ground: 200 – 400 z relay output: OFF
3) Resistance of wiring harness between C1 and caution relay output:
(female) (1) – L67 (female) (1): Less than 1 z OFF J-8
4) Resistance of wiring harness between steering
solenoid cut relay L67 (female) (2) – chassis
ground: Less than 1 z

WD900-3 20-857
(6)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL

ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING

CONTROL SYSTEM

20-858 WD900-3
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL

a This circuit diagram is made by extracting the part of the transmission & joystick steering controller from the
general circuit diagram.

WD900-3 20-859
TROUBLESHOOTING J-1

J-1 Failure code [56] (Short circuit, disconnection in caution relay output) is
displayed

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting any connector.

J-1 Related electrical circuit diagram

20-860 WD900-3
TROUBLESHOOTING J-2

J-2 Failure code [57] (Short circuit in steering right solenoid (detected when signal
is output)) is displayed

a 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.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.

J-2 Related electrical circuit diagram

WD900-3 20-861
TROUBLESHOOTING J-3

J-3 Failure code [58] (Short circuit in steering left solenoid (detected when signal is
output)) is displayed
a 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.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the
next step.
a When the joystick steering lever is not being used, leave it at the
neutral position and turn the joystick steering selector switch ON.

J-3 Related electrical circuit diagram

20-862 WD900-3
TROUBLESHOOTING J-4

J-4 Failure code [59] (Short circuit in steering right solenoid (power supply side)) is
displayed

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.

J-4 Related electrical circuit diagram

WD900-3 20-863
TROUBLESHOOTING J-5

J-5 Failure code [60] (Short circuit in steering left solenoid (power supply side)) is
displayed

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket
adapter).

J-5 Related electrical circuit diagram

20-864 WD900-3
TROUBLESHOOTING J-6

J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay
output) is displayed

a 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.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.

20-866 WD900-3
TROUBLESHOOTING J-6

J-6 Related electrical circuit diagram

WD900-3 20-867
TROUBLESHOOTING J-7

J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral circuit)
is displayed

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.

J-7 Related electrical circuit diagram

20-868 WD900-3
TROUBLESHOOTING J-8

J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentio-
meter) is displayed

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a After connecting the T-adapter, turn the starting switch ON.

J-8 Related electrical circuit diagram

WD900-3 20-869
TROUBLESHOOTING J-9

J-9 Abnormality in power supply, power supply voltage

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse I (10) is normal.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.

J-9 Related electrical circuit diagram

20-870 WD900-3
TROUBLESHOOTING J-10

J-10 Abnormality in joystick steering ON-OFF circuit

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse I (11) is normal.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.
a Always connect any disconnected connectors before going on to the next step.

J-10 Related electrical circuit diagram

WD900-3 20-871
TROUBLESHOOTING J-11

J-11 Disconnection in steering right solenoid

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.

J-11 Related electrical circuit diagram

20-872 WD900-3
TROUBLESHOOTING J-12

J-12 Disconnection in steering left solenoid

a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steer-
ing selector switch ON.

J-12 Related electrical circuit diagram

WD900-3 20-873
 30 DISASSEMBLY AND ASSEMBLY

PRECAUTIONS BEFORE WORK .................30- 2-1 DISASSEMBLY AND ASSEMBLY OF

METHOD OF USING MANUAL ..................... 30- 3
PRECAUTIONS WHEN CARRYING OUT
OPERATION ............................................ 30- 5
SPECIAL TOOL LIST..................................... 30- 7
SKETCHES OF SPECIAL TOOLS ................ 30- 13
REMOVAL AND INSTALLATION OF
STARTING MOTOR ................................. 30- 21
REMOVAL AND INSTALLATION OF
ALTERNATOR .......................................... 30- 22
REMOVAL AND INSTALLATION OF
ENGINE OIL COOLER ............................. 30- 23
REMOVAL AND INSTALLATION OF
FUEL INJECTION PUMP FOR
RIGHT BANK............................................ 30- 25
REMOVAL AND INSTALLATION OF
FUEL INJECTION PUMP FOR
RIGHT BANK............................................ 30- 25
REMOVAL AND INSTALLATION OF
WATER PUMP.......................................... 30- 26
REMOVAL AND INSTALLATION OF
NOZZLE HOLDER ................................... 30- 27
REMOVAL AND INSTALLATION OF
TURBOCHARGER ................................... 30- 28
REMOVAL AND INSTALLATION OF
ENGINE FRONT SEAL ............................ 30- 29
REMOVAL AND INSTALLATION OF
ENGINE REAR SEAL............................... 30- 31
REMOVAL AND INSTALLATION OF
CYLINDER HEAD .................................... 30- 33
REMOVAL AND INSTALLATION OF
RADIATOR ............................................... 30- 38
REMOVAL AND INSTALLATION OF
ENGINE .................................................... 30- 40
REMOVAL AND INSTALLATION OF
DAMPER .................................................. 30- 45
DISASSEMBLY AND ASSEMBLY OF
DAMPER .................................................. 30- 46
REMOVAL AND INSTALLATION OF
TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY .................. 30- 50
DISASSEMBLY AND ASSEMBLY OF
TORQUE CONVERTER........................... 30- 57
TORQUE CONVERTER VALVE .............. 30- 64
DISASSEMBLY AND ASSEMBLY OF
TRANSMISSION ...................................... 30- 65
REMOVAL AND INSTALLATION OF
TRANSMISSION VALVE .......................... 30- 89
DISASSEMBLY AND ASSEMBLY OF
TRANSMISSION VALVE .......................... 30- 90
DISASSEMBLY AND ASSEMBLY OF
TRANSFER .............................................. 30- 94
DISASSEMBLY AND ASSEMBLY OF PTO... 30-107
REMOVAL AND INSTALLATION OF
CENTER SUPPORT ................................ 30-112
DISASSEMBLY AND ASSEMBLY OF
CENTER SUPPORT ................................ 30-114
DISASSEMBLY AND ASSEMBLY OF
DRIVE SHAFT.......................................... 30-118
REMOVAL AND INSTALLATION OF
FRONT AXLE........................................... 30-121
REMOVAL AND INSTALLATION OF
REAR AXLE ............................................. 30-123
REMOVAL AND INSTALLATION OF
DIFFERENTIAL........................................ 30-128
DISASSEMBLY AND ASSEMBLY OF
DIFFERENTIAL........................................ 30-130
DISASSEMBLY AND ASSEMBLY OF
FINAL DRIVE ........................................... 30-138
REMOVAL AND INSTALLATION OF
ORBIT-ROLL ............................................ 30-143
REMOVAL AND INSTALLATION OF
EMERGENCY STEERING PUMP ........... 30-145
REMOVAL AND INSTALLATION OF
DIVERTER VALVE ................................... 30-146
DISASSEMBLY AND ASSEMBLY OF
DIVERTER VALVE ................................... 30-147
REMOVAL AND INSTALLATION OF
ACCUMULATOR CHARGE VALVE ......... 30-149
DISASSEMBLY AND ASSEMBLY OF
ACCUMULATOR CHARGE VALVE ......... 30-150
REMOVAL AND INSTALLATION OF
STEERING STOP VALVE ........................ 30-152
REMOVAL AND INSTALLATION OF
STEERING CYLINDER............................ 30-153

WD900-3 30-1
(9)
DISASSEMBLY AND ASSEMBLY

REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF

STEERING VALVE...................................30-155
REMOVAL AND INSTALLATION OF
BRAKE VALVE..........................................30-157
REMOVAL AND INSTALLATION OF
SLACK ADJUSTER ..................................30-158
DISASSEMBLY AND ASSEMBLY OF
SLACK ADJUSTER ..................................30-159
REMOVAL AND INSTALLATION OF BRAKE 30-161
DISASSEMBLY AND ASSEMBLY OF
BRAKE......................................................30-162
REMOVAL AND INSTALLATION OF
PARKING BRAKE CALIPERS ..................30-167
DISASSEMBLY AND ASSEMBLY OF
PARKING BRAKE CALIPERS ..................30-168
REMOVAL AND INSTALLATION OF
PARKING BRAKE PAD ..................................30-170
REMOVAL AND INSTALLATION OF
PARKING BRAKE SPRING CYLINDER...30-171
REMOVAL AND INSTALLATION OF
BRAKE OIL TANK ....................................30-172
REMOVAL AND INSTALLATION OF
HYDRAULIC PUMP ASSEMBLY .............30-173
REMOVAL AND INSTALLATION OF
SERVO CYLINDER ..................................30-176
REMOVAL AND INSTALLATION OF
HYDRAULIC TANK AND
FILTER CASE ASSEMBLY.......................30-177
REMOVAL AND INSTALLATION OF
PPC VALVE ..............................................30-179
DISASSEMBLY AND ASSEMBLY OF
PPC VALVE ..............................................30-181
REMOVAL AND INSTALLATION OF
WORK EQUIPMENT CONTROL VALVE..30-182
WORK EQUIPMENT CONTROL VALVE . 30-184
REMOVAL AND INSTALLATION OF CAB .... 30-187
REMOVAL AND INSTALLATION OF
FLOOR FRAME ....................................... 30-189
REMOVAL AND INSTALLATION OF
CENTER HINGE PIN ............................... 30-192
REMOVAL AND INSTALLATION OF
WORK EQUIPMENT ................................ 30-200
REMOVAL AND INSTALLATION OF
LIFT CYLINDER ASSEMBLY................... 30-203
REMOVAL AND INSTALLATION OF
PITCH & TILT CYLINDER ........................ 30-204
REMOVAL AND INSTALLATION OF
AIR CONDITIONER UNIT ........................ 30-205
REMOVAL AND INSTALLATION OF
AIR CONDITIONER COMPRESSOR ...... 30-207
REMOVAL AND INSTALLATION OF
RECEIVER TANK..................................... 30-208
REMOVAL AND INSTALLATION OF
AIR CONDITIONER CONDENSER ......... 30-209
REMOVAL AND INSTALLATION OF
TRANSMISSION AND
STEERING CONTROLLER ..................... 30-210
REMOVAL AND INSTALLATION OF
MAIN MONITOR....................................... 30-211
REMOVAL AND INSTALLATION OF
FUEL TANK .............................................. 30-213
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT ................................. 30-215
REMOVAL AND INSTALLATION OF
AJSS LEVER SWITCH ASSEMBLY ........ 30-216

30-2 WD900-3
(9)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS BEFORE WORK

PRECAUTIONS BEFORE WORK

Before you start, read the “SAFETY NOTICE” of the “SAFETY” to understand the content fully.
k Before you start the inspection and maintenance work, take the measures that follow. There is a
danger that you can get caught in the machine.
• Do not wear oversized clothes or accessories.
• Be sure to tie the long hair that comes out from the helmet.
k When you work together with more than one person, do the preparation that follows.
• Decide on the work procedure.
• Obey the specified signal during the work.
k Keep only those persons who need to access the machine during the maintenance. Also, arrange
an observer if necessary. An accident can occur if unapproved persons touch the machine.
k Before you refill liquid (fuel, coolant, or oil) or repair the machine, do the measures that follow not
to let the machine move.
• Stop the machine on a level ground, and fully lower the work equipment to the ground in a stable posture.
• Fix the machine with chocks.
k Immediately after the machine is stopped, the parts or liquids (fuel, coolant, oil, etc.) are hot. There-
fore, wait until the temperature dropped, and start the work. If you touch high-temperature parts,
there is a danger that you get burned.
k Before you use the testing tools and special tools, read the manuals and understand them carefully.

WD900-3 30-2-1
(9)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

METHOD OF USING MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES

SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for
removal or installation of parts are listed.
• List of the special tools contains the following
kind of information.
1) Necessity
t: Special tools which cannot be substi-
tuted, should always be used.
q: Special tools which are very useful if
• Except where otherwise instructed, install parts
is the reverse order of removal.
• Instructions and precautions for installing parts
are shown with [*1] mark in the INSTALLATION
Section, identifying which step the instructions
are intended for.
• Marks shown in the INSTALLATION Section
stand for the following.

k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly
developed for this model. a This mark gives guidance or precau-
R: Tools with upgraded part numbers, tions when doing the procedure.
remodeled from already available tools 2 This mark stands for a specific coating
for other models. agent to be used.
3 This mark
Blank: Tools already available for other mod-
els, used without any modification. indicates the specified
torque.
5
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the This mark indicates an amount of oil or
special tool is presented in the section of water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not SKETCHES OF SPECIAL TOOLS
interchangeable with those made by Komatsu in • Various special tools are illustrated for the con-
Japan e.g. 79*T - xxx - xxxx. venience of local manufacture.

REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.

k This mark indicates safety-related pre-

cautions which must be followed when
doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.

6 This mark shows oil or water to be

drained.

WD900-3 30-3
(1)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS ASSEMBLY

• Special tools which are deemed necessary for
disassembly and assembly are listed in this sec-
tion.
• List of the special tools contains the following
kind of information.
• Section titled ASSEMBLY contain procedures,
precautions and the know-how for the work, as
well as the amount of oil or water to be added.
• Various symbols used in the ASSEMBLY Sec-
tion are explained and listed below.

k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools 2 This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
3 This mark
developed for this model.
R: Tools with upgraded part numbers, indicates the specified
remodeled from already available tools torque.
for other models. 5 This mark indicates an amount of oil or
Blank: Tools already available for other mod- water to be added.
els, used without any modification.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the SKETCHES OF SPECIAL TOOLS
special tool is presented in the section of • Various special tools are illustrated for the con-
Sketches for Special Tools. venience of local manufacture.
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not
interchangeable with those made by Komatsu in
Japan e.g. 79*T - xxx - xxxx.

DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.

k This mark indicates safety-related pre-

cautions which must be followed when
doing the work.
a This mark gives guidance or precau-
tions when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
drained.

30-4 WD900-3
(1)
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 pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting 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 enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628

2) Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part 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
12 07049-01215 12 10 15
øD

ød

14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
L
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 DEW00401
24 07049-02430 24 20 30

27 07049-02734 27 22.5 34

WD900-3 30-5
(1)
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.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic 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 cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a 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 reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

30-6 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

a Tools with part number 79QT-QQQ
QQQ-QQQQ
QQQ QQQQ cannot be supplied (they are items to be locally manufactured).

a Necessity: t ........... Cannot be substituted, must always be installed (used)

q............Extremely useful if available or can be substituted with commercially available part
a 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 oth-
er models
Blank: ...Tools already available for other models, can be used without any modification

a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

Removal, installation of
1 790-331-1110 Wrench t 1
cylinder head
795-602-2200 Installer KIT t 1 Press fitting of front seal
• 795-602-2210 • Installer t 1 Press fitting of oil seal
• 795-502-2220 • Installer t 1 Press fitting of sleeve
2
• 01050-32250 • Bolt t 1
• 01050-32240 • Bolt t 6
Disassembly, assembly of • 01640-22232 • Washer t 6
A
engine
795-602-2300 Installer KIT t 1 Press fitting of rear seal
• 795-602-2320 • Installer t 1 Press fitting of oil seal
• 795-502-2120 • Sleeve t 1 Press fitting of sleeve
3
• 01050-32055 • Bolt t 5
• 01050-22040 • Bolt t 5
• 01640-22032 • Washer t 10
4 795-931-1100 Puller q 1 Removal of rear seal
790-101-5401 Push tool KIT (C) t 1
• 790-101-5521 • Plate 1 Press fitting of bearing in
1
• 790-101-5421 • Grip 1 cover

Disassembly, assembly of • 01010-51240 • Bolt 1

B
damper 793T-812-1110 Plate t 1 N Q
Press fitting of bearing in
2 790-101-5421 Grip t 1
cover
01010-51240 Bolt t 1
3 790-101-7190 Push tool t 1 Press fitting of shaft
790-901-5000 Unit repair stand t 1 For Japan
790-901-5200 Unit repair stand t 1 For overseas countries
1
790-901-5110 Bracket t 1
790-901-5120 Plate t 1
Disassembly, assembly of Removal, installation of
C 2 791-381-1011 Wrench t 1
torque converter round nut
Press fitting of shaft
3 790-201-2870 Spacer t 1
bearing
Press fitting of shaft
4 790-201-2760 Spacer t 1
bearing

WD900-3 30-7
(1)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

790-201-2250 Plate t 1 Press fitting of shaft

5
• 790-201-2760 • Spacer t 1 bearing inner race
790-101-5401 Push tool KIT (C) t 1
• 790-101-5481 • Plate 1 Press fitting of housing
6
• 790-101-5421 • Grip 1 bearing outer race
• 01010-51240 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
Disassembly, assembly of • 790-101-5461 • Plate 1 Press fitting of retainer oil
C 7
torque converter • 790-101-5421 • Grip 1 seal
• 01010-51240 • Bolt 1
Press fitting of pump
8 790-201-2740 Spacer t 1
shaft collar, bearing
790-101-5401 Push tool KIT (C) t 1
• 790-101-5431 • Plate 1 Press fitting of front
9 housing bearing outer
• 790-101-5421 • Grip 1 race
• 01010-51240 • Bolt 1
Check of operation of
1 799-301-1600 Push tool KIT (C) t 1
clutch
793T-815-1110 Push tool t 1 N Q Press fitting of clutch
2 shaft main bearing, sub
790-210-2760 Spacer t 1 bearing
790-101-5401 Push tool KIT (C) t 1
• 790-101-5461 • Plate 1 Press fitting of bushing in
3
• 790-101-5421 • Grip 1 cover
Disassembly, assembly of
D • 01010-51240 • Bolt 1
transmission
790-101-5621 Plate t 1 Press fitting of main
4 • 790-101-5421 • Grip t 1 bearing outer race in
• 01010-51240 • Bolt t 1 cage

790-101-5201 Push tool KIT (B) t 1

• 790-101-5321 • Plate 1 Press fitting of transfer
5
• 790-101-5221 • Grip 1 gear bearing inner race
• 01010-51225 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5521 • Plate 1 Press fitting of bearing
6
• 790-101-5421 • Grip 1 outer race in cage
• 01010-51240 • Bolt 1
793T-815-1120 Plate t 1 N Q Press fitting of bearing
7 790-101-5421 Grip t 1 outer race in transfer
Disassembly, assembly of output shaft cage
transfer
D 01010-51240 Bolt t 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5491 • Plate 1 Press fitting of bearing
8 inner race in rear side
• 790-101-5421 • Grip 1 coupling
• 01010-51240 • Bolt 1
Press fitting of transfer
9 790-201-2750 Push tool t 1
gear bearing inner race

30-8 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

790-101-7200 Centering tool t 1

1 790-101-7230 • Shaft 1 Centering of transmis-
10
2 790-101-7240 • Guide 1 sion and support
3 01010-31230 • Bolt 1
793-116-1030 Push tool t 1
Press fitting of oil seal to
11 790-101-5221 Grip t 1
rear output shaft cage
01010-51225 Bolt t 1
793-116-1040 Push tool t 1
Press fitting of dust seal
12 790-101-5221 Grip t 1
to rear output shaft cage
01010-51225 Bolt t 1
Disassembly, assembly of
D 793-116-1010 Push tool t 1
transfer Press fitting of oil seal to
13 790-101-5221 Grip t 1
front output shaft cage
01010-51225 Bolt t 1
793-116-1020 Push tool t 1
Press fitting of dust seal
14 790-101-5221 Grip t 1
to front output shaft cage
01010-51225 Bolt t 1
15 790-201-2430 Push tool t 1 Press fitting of bearing
outer race to front output
16 790-201-2480 Push tool t 1 shaft cage
790-101-5621 Push tool t 1 Press fitting of bearing
17 790-101-5221 Grip t 1 outer race to transfer
01010-51225 Bolt t 1 input gear cage

790-101-7180 Push tool t 1

Press fitting of center
1 790-101-5421 Grip t 1
support oil seal
01010-51240 Bolt t 1
790-101-7140 Push tool t 1
2 790-101-5421 Grip t 1 Press fitting of bearing
Disassembly, assembly of 01010-51240 Bolt t 1
E
center support 792-715-1300 Push tool t 1
Press fitting of main
3 790-101-5421 Grip t 1
bearing outer race
01010-81235 Bolt t 1
790-101-5621 Plate t 1
Press fitting of sub
4 790-101-5421 Grip t 1
bearing outer race
01010-51240 Bolt t 1
790-501-2000 Engine repair stand t 1 Disassembly, assembly
1
790-901-5110 Bracket t 1 of differential
790-101-2300 Push tool q 1
• 790-101-2310 • Block 1
Disassembly, assembly of • 790-101-2350 • Leg 2
H
differential • 790-101-2360 • Plate 4 Removal of pinion shaft
2
• 790-101-2430 • Adapter 2 bearing
• 02215-11622 • Nut 2
790-101-2102 Puller (294 kN {30 ton}) q 1
790-101-1102 Hydraulic pump q 1

WD900-3 30-9
(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

793T-822-1130 Push tool t 1 N Q Press fitting of pinion

3
793T-822-1140 Push tool t 1 N Q bearing inner race
Press fitting of bearing in
4 793T-822-1150 Push tool t 1 N Q
sleeve
793T-822-1110 Plate t 1 N Q
793T-822-1120 Spacer t 1 N Q Press fitting of oil seal,
Disassembly, assembly of 5
H • 790-101-5421 • Grip t 1 dust seal in cage
differential
• 01010-51240 • Bolt t 1
792-340-1120 Nut, wrench t 1 Removal, installation of
6
796-550-1310 Wrench t 1 sleeve round nut
792-525-3000 Micrometer t 1
Adjusting preload of side
7 790-425-1670 Adapter t 1
bearing
790-425-1660 Wrench t 1
792-633-1300 Fixture t 4
Removal, installation of
1 01010-81430 Bolt t 4
brake
01641-21423 Washer t 4
791-585-1510 Installer t 1
792-530-1700 Push tool t 1
• 791-580-1610 • Plate 1
• 791-580-1620 • Arm 4
• 792-530-1630 • Stud 4 Installation of floating
2
• 791-580-1640 • Plate 1 seal
• 791-585-1650 • Plate 4
• 01010-51425 • Bolt 8
Disassembly, assembly of
J • 01640-21426 • Washer 4
brake and final drive
• 01541-21670 • Nut 4
793T-833-1110 Plate t 1 N Q
Press fitting of oil seal in
3 • 790-101-5421 Grip t 1
hub
• 01010-51240 Bolt t 1
790-438-1060 Nipple t 1 Check for brake oil
4
793-520-1805 Brake tester t 1 leakage
790-101-5401 Push tool KIT (C) t 1
• 790-101-5541 • Plate 1 Press fitting of bearing
5 • 790-101-5451 • Plate 1 and carrier spacer in
• 790-101-5421 • Grip 1 planetary gear

• 01010-51240 • Bolt 1

30-10 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

790-101-2501 Push puller t 1

• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
• 790-101-2540 • Washer 1
• 790-101-2610 • Leg 2
• 790-101-2570 • Plate 4 Press fitting of upper
1
• 790-101-2740 • Adapter 2 center hinge bearing
• 790-101-2560 • Nut 2
790-101-7340 Push tool t 1
790-101-7350 Guide t 1
790-201-1310 Spacer t 1
• 790-101-2102 Puller (294 kN {30 ton}) t 1
• 790-101-1102 Hydraulic pump t 1
790-201-1970 Plate t 1
Press fitting of upper
2 • 790-101-5021 Grip t 1
retainer dust seal
• 01010-50816 Bolt t 1
Disassembly, assembly of 790-101-2300 Push tool t 1
K
center hinge • 790-101-2310 • Plate 1
• 790-101-2320 • Screw 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2390 • Leg 2
• 790-101-2360 • Plate 4 Press fitting of lower
3
• 02215-11622 • Nut 2 center hinge
790-101-7330 Adapter t 2
790-201-1310 Spacer t 1
790-101-7310 Push tool t 1
790-101-7320 Grip t 1
• 790-101-2102 • Puller (294 kN {30 ton}) t 1
• 790-101-1102 • Hydraulic pump t 1
793T-846-1110 Plate t 1 N Q
Press fitting of lower
4 • 790-101-5221 • Grip t 1
retainer dust seal
• 01010-51225 • Bolt t 1
Removal, installation of
5 790-450-1110 Adapter t 1
center hinge shaft
1 790-502-1003 Cylinder repair stand q 1 Repair of hydraulic cylinder
790-720-1000 Expander t 1
Installation of piston
2 796-720-1680 Ring t 1
rings of all cylinders
Removal, installation of 07281-01589 Clamp t 1
U
hydraulic cylinder 796-720-1710 Ring t 1 Installation of piston
3
07281-02709 Clamp t 1 rings of lift cylinder
796-720-1730 Ring t 1 Installation of piston
4
07281-03209 Clamp t 1 rings of dump cylinder

WD900-3 30-11
(5)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/Remodel
Necessity
Symbol

Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks

790-201-1500 Push tool KIT t 1

• 790-201-1660 • Plate 1 Press fitting of dust seal
5
• 790-101-5201 • Grip 1 of steering cylinder
• 01010-50816 • Bolt 1
792-103-3601 Push tool t 1 Press fitting of dust seal
6
792-103-0400 Grip t 1 of lift cylinder
791-863-1140 Push tool t 1
Press fitting of dust seal
7 • 790-101-5221 • Grip t 1
of dump cylinder
• 01010-51225 • Bolt t 1
Removal, installation of
U 790-201-1702 Push tool KIT t 1
hydraulic cylinder
• 790-201-1851 • Push tool 1 Press fitting of roll
8 bushing of steering
• 790-101-5021 • Grip 1 cylinder
• 01010-50816 • Bolt 1
792-103-4102 Push tool t 1
Press fitting of roll
9 • 790-101-5421 • Grip t 1
bushing of lift cylinder
• 01010-81235 • Bolt t 1
792-625-1300 Push tool t 1 Press fitting of roll
10 • 790-101-5421 • Grip t 1 bushing of dump
• 01010-81235 • Bolt t 1 cylinder

793T-870-1110 Sleeve t 1 N Q
793T-870-1120 Plate t 1 N Q
791-745-2110 Adapter t 1
790-438-1110 Screw t 1
Removal of work equipment pin 790-101-2540 Washer t 1 Removal of bucket hinge
and removal, installation of 1
bushing 02215-11622 Nut t 1 pin and bucket link pin
01010-81655 Bolt t 3
01640-21626 Washer t 3
790-101-2102 Puller t 1
V 790-101-1102 Puller (294 kN {30 ton}) t 1
793T-870-1130 Sleeve t 1 N Q
793T-870-1140 Plate t 1 N Q
793T-870-1150 Plate t 1 N Q

Removal of work equipment pin 01580-13024 Nut t 2 Removal, installation of

and removal, installation of 2 01643-33080 Washer t 2 bushing of lift arm end
bushing 791-650-1240 Spacer t 2 (bucket hinge)

791-650-1230 Bolt t 1
790-314-1000 Puller (785 kN {80 ton}) t 1
790-101-1102 Pump (294 kN {30 ton}) t 1

30-12 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

B2 PLATE

D2 PUSH TOOL

WD900-3 30-13
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

D7 PLATE

H5 PLATE

30-14 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

H5 SPACER

H3 PUSH TOOL

WD900-3 30-15
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

H3 PUSH TOOL

H4 PUSH TOOL

30-16 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

J3 PLATE

K4 PLATE

WD900-3 30-17
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

V1 SLEEVE

V1 PLATE

30-18 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

V2 SLEEVE

V2 PLATE

WD900-3 30-19
(1)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

V2 PLATE

30-20 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL AND INSTALLATION INSTALLATION

OF STARTING MOTOR • Carry out installation in the reverse order to
removal.
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove side cover (1).

2. Remove fuel control lever (2) together with

bracket (3).

3. Disconnect connectors (4) (ER1, 2, 3).

4. Disconnect connectors (5) (ER06, 07).

5. Disconnect cables (6) and (7).

6. Remove starting motors (8) and (9).

WD900-3 30-21
(1)
DISASSEMBLY AND ASSEMBLY ALTERNATOR

REMOVAL AND INSTALLATION INSTALLATION

OF ALTERNATOR • Carry out installation in the reverse order to
removal.
REMOVAL
k Disconnect the cable from the negative (–) ter-
3 Terminal mounting nut:
[*1]
minal of the battery.
Terminal R: 1.9 – 2.5 Nm {0.19 – 0.25 kgm}
1. Open side cover (1). Terminal E: 3.2 – 4.4 Nm {0.33 – 0.45 kgm}
Terminal B: 16.1 – 22.1 Nm {1.65 – 2.25 kgm}

3 Lock bolt:
[*2]

54 – 123 Nm {5.5 – 12.5 kgm}

[*3]
a Adjust the deflection of the belt to the speci-
fied dimension. For details, see TESTING
AND ADJUSTING, Testing and adjusting al-
ternator belt tension.

2. Disconnect connectors (2) (E20, 21, 22). [*1]

3. Loosen locknuts (3).

4. Remove lock bolt (4).

5. Remove lock bolt (5) and turn down adjustment

bolt (6) toward the air conditioner compressor.
[*2]

6. Loosen the alternator mounting bolt, then

remove drive belt (7). [*3]

7. Remove the mounting bolt, then remove alterna-

tor (8).

30-22 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER

REMOVAL AND INSTALLATION INSTALLATION

OF ENGINE OIL COOLER • Carry out installation in the reverse order to
removal.
REMOVAL
1. Open the left cover. [*1]
a Install fuel injection pump for right bank ac-
2. Loosen radiator drain valve and drain cooling cording to REMOVAL AND INSTALLATION
water. OF FUEL INJECTION PUMP FOR RIGHT
a If the coolant contains antifreeze, dispose of BANK.
it correctly.
a Tighten drain valve and add water to the
3. Remove fuel injection pump (1) assembly for specified level, and then run the engine to
right bank. [*1] circulate the water then check the water level
a For details, see REMOVAL AND INSTALLA- of reservoir tank.
TION OF FUEL INJECTION PUMP FOR
RIGHT BANK (WITHOUT GOVERNOR).

4. Remove front oil cooler assembly (2).

5. Remove rear oil cooler assembly (3).

WD900-3 30-23
(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR LEFT BANK

REMOVAL AND INSTALLATION 9. Remove coupling lock bolt (9).

OF FUEL INJECTION PUMP

FOR LEFT BANK
(WITH GOVERNOR)

REMOVAL
k Close valve between fuel tank and fuel filter.

1. Open left side cover.

2. Remove cover (1).

DEW3906

3. Remove control rods (2).

10. Remove mounting bolts, then remove fuel injec-
4. Disconnect injection pump lubrication tubes (3). tion pump.
a When removing fuel injection pump, be care-
5. Disconnect fuel hoses (4). ful not to drop the key.
6. Disconnect air tube (5). 4 Fuel injection pump: 30 kg
7. Disconnect fuel injection tubes (6). [*1]
INSTALLATION

• Carry out installation in the reverse order to

removal.

3 Sleeve nut: 24 ± 1 Nm {4 ± 0.1 kgm}

[*1]

a Check fuel injection timing according to

TESTING AND ADJUSTING FUEL INJEC-
TION TIMING.

8. Remove mounting bolts at injection pump end to

remove rack control rod (7).

30-24 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR RIGHT BANK

REMOVAL AND INSTALLATION 7. Remove coupling lock bolts (6).

OF FUEL INJECTION PUMP

FOR RIGHT BANK
(WITHOUT GOVERNOR)

REMOVAL
k Close valve between fuel tank and fuel filter.

1. 1.Open left side cover.

2. Remove lower cover (1) of coupling part.

3. Disconnect injection pump lubrication tubes (2).

8. Remove mounting bolts, then remove fuel injec-
4. Disconnect fuel hoses (3). tion pump.
a When removing the fuel injection pump, be
5. Disconnect fuel injection tubes (4). [*1] careful not to drop key.

4 Fuel injection pump: 23 kg

INSTALLATION

• Carry out installation in the reverse order to

removal.

3 Sleeve nut: 24 ± 1 Nm {2.4 ± 0.1 kgm}

[*1]

a Check fuel injection timing according to

TESTING AND ADJUSTING FUEL INJEC-
TION TIMING.
6. Remove mounting bolts at injection pump end to
remove rack control rod (5).

WD900-3 30-25
(1)
DISASSEMBLY AND ASSEMBLY WATER PUMP

REMOVAL AND INSTALLATION INSTALLATION

OF WATER PUMP • Carry out installation in the reverse order to
removal.
REMOVAL
1. Open left side cover. a Tighten drain valve and add water to speci-
fied level, and then run the engine to circu-
2. Loosen drain valve and drain cooling water. late water, then c heck water level of
a If cooling water contains antifreeze, dispose reservoir tank.
of it correctly.

3. Remove cover (1).

4. Remove corrosion resistor (2).

5. Disconnect hoses (3).

6. Disconnect bypass pipe (4).

7. Remove water pump (5).

4 Water pump: 22 kg

30-26 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER

REMOVAL AND INSTALLATION 5. Fully screw forcing screw [1] (10 mm, P = 1.5) in
the nozzle holder, then pull out nozzle holder (8)
OF NOZZLE HOLDER by levering it up with a bar.
a When pulling out the nozzle holder, clean
REMOVAL around it so that foreign matter will not enter
k Stop the machine on level ground and lower the the empty hole.
work equipment completely to the ground, then a Check that the gasket is fitted to the nozzle
put blocks under the wheels to prevent the ma- end.
chine from moving.

1. Remove the engine hood.

2. emove head cover mounting bolt (1), then

remove head cover (2). [*1]

3. Remove lock nut (4), then pull out connection

(5). [*2]

4. Remove bolt (6), then remove holder (7). [*3]

INSTALLATION

• Carry out installation in the reverse order to

removal.

3 Head cover mounting bolt:

[*1]

3.9 ± 0.1 Nm {0.4 ± 0.1 kgm}

3 Connection: 37 ± 3 Nm {3.8 ± 0.3 kgm}

[*2]

3 Lock nut: 39 ± 5 Nm {4.0 ± 0.5 kgm}

3 Bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

[*3]

WD900-3 30-27
(1)
DISASSEMBLY AND ASSEMBLY TURBOCHARGER

REMOVAL AND INSTALLATION 10. Disconnect lubrication oil inlet hoses (11).

OF TURBOCHARGER 11. Disconnect lubrication oil outlet hoses (12).

REMOVAL 12. Remove the mounting bolts or nuts, then

k Stop the machine on level ground and lower the remove turbochargers (13). [*1]

4 Turbocharger: 22 kg (1 piece)
work equipment completely to the ground.

k Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove mufflers (1).

2. Remove handrail (2).

3. Sling and remove engine hood (3).

INSTALLATION

• Carry out installation in the reverse order to

removal.

[*1]
a Replace the removed gaskets with new gas-

3 Mounting bolt: 49 ± 5 Nm {5.0 ± 0.5

4. Disconnect air cleaner connecting hose. kets.

5. Disconnect Komaclone tubes (5). kgm}

6. Remove mufflers (6).

7. Disconnect connectors (7).

8. Remove bolts (8), then remove exhaust elbows (9).

a Check the number of the shims.

9. Remove elbows (10).

a Check the number of the shims.

30-28 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION
OF ENGINE FRONT SEAL
SPECIAL TOOLS
Symbol
Part No. Part Name
795-602-2200 Installer KIT
• 795-602-2210 • Installer
• 795-502-2220 • Installer
A 2
• 01050-32250 • Bolt
• 01050-32240 • Bolt
• 01640-22232 • Washer
REMOVAL
1. Remove the radiator. For details, see REMOVAL
AND INSTALLATION OF RADIATOR.
2. Remove mounting bolts (1), then remove
damper and crank pulley (2).
3. Take care not to damage crankshaft (3), remove
seal (4) with a screwdriver, etc.
WD900-3
ENGINE FRONT SEAL
INSTALLATION
1. Front oil seal and sleeve
1) When the seal contact face of the crank-
shaft is not worn
• Press fit the oil seal to the end of the
New/remodel
Necessity
gear case cover by 11mm with tool A2
Sketch
Q'ty
a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 –
80%.
t 1 a Tighten the mounting bolts evenly.
t 1 2) When the seal contact face of the crank-
t 1
shaft is worn
• If the position of the oil seal can be
t 1
changed, press fit a new oil seal to a
t 6 place at which its lip does not touch the
t 6 worn groove.
a Measure the position of the worn
groove, then press fit the new oil
seal with tool A2 to a place where
there is not a worn groove.
3) When the position of the oil seal cannot be
changed
• Press fit sleeve (5) to the crankshaft.
a Remove rust and mud from sleeve
fitting portion of the crankshaft.
a Thinly apply sealant (LG-7) over the
inside of sleeve (5), then install the
sleeve to the end of crankshaft (3) in
parallel by hitting it lightly with a
wooden or plastic hammer.
30-29
(1)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

2. Install damper and crank pulley (2).

a Press fit the sleeve to the depth of Tighten mounting bolts (1) in the order given in
5mm from the crankshaft end with the diagram below.
tool A2 a Apply engine oil (SAE-30CD) to the mount-

a Press fit the sleeve by tightening the
bolts alternately.
• Press fit the seal.
a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 –
80%.
a Press fit front seal (6) to the depth of
13mm with tool A2
3 Mounting bolt
ing bolts.
1st step: 74 ± 20 Nm {7.5 ± 2.0 kgm}
2nd step: 245 – 20 Nm {25 ± 2 kgm}
3rd step: 745 – 20 Nm {76 ± 2 kgm}
a If the mounting bolts are tightened with an
impact wrench, their threads may be broken.
Accordingly, tighten them with a hand tool.

30-30 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

REMOVAL AND INSTALLATION INSTALLATION

OF ENGINE REAR SEAL 1. Rear oil seal and sleeve
1) When the seal contact face of the crank-
SPECIAL TOOLS shaft is not worn
• Press fit the oil seal to the crankshaft

New/remodel
Necessity
end by 21mm with tool A3
Symbol

Sketch
a Fill the space between lips on the out-

Q'ty
Part No. Part Name
side with grease (G2-LI) up to 50 – 80%.
a Tighten the mounting bolts evenly.
795-602-2300 Installer KIT t 1
• 795-602-2320 • Installer t 1 2) When the seal contact face of the crank-
shaft is worn
• 795-502-2120 • Sleeve t 1
3 • If the position of the oil seal can be
A • 01050-32055 • Bolt t 5 changed, press fit a new oil seal to a
• 01050-22040 • Bolt t 5 place at which its lip does not touch the
• 01640-22032 • Washer t 10 worn groove.
4 795-931-1100 Puller q 1 a Measure the position of the worn
groove, then press fit the new oil seal
with tool A3 to a place where there is not
REMOVAL
a worn groove.
1. Remove the torque converter and transmission.
For details, see REMOVAL AND INSTALLA-
TION OF TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY.

2. Remove mounting bolts (1), then remove fly-

wheel (2).

3) When the position of the oil seal cannot be

changed
• Press fit sleeve (5) to the crankshaft.
a Remove rust and mud from sleeve fitting
portion of the crankshaft.
a Thinly apply sealant (LG-7) over the in-
side of sleeve (5), then install the sleeve
3. Taking care not to damage crankshaft (3), to the end of crankshaft (3) in parallel by
remove seal (4) with a screwdriver, etc. hitting it lightly with a wooden or plastic
hammer.
a Press fit the sleeve to the depth of 14
mm from the crankshaft end with tool A3
a Press fit the sleeve by tightening the
bolts alternately.

WD900-3 30-31
(1)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

2. Install flywheel (2).

1) Tighten mounting bolts (1) in the order given
in the diagram below.
a Apply engine oil (SAE-30CD) to the

3 Mounting bolt
mounting bolts.

1st step: 98 ± 20 Nm {10 ± 2 kgm}

2nd step: 294 ± 20 Nm {30 ± 2 kgm}
3rd step: 539 ± 20 Nm {55 ± 2 kgm}
a If the mounting bolts are tightened with
an impact wrench, their threads may be
broken. Accordingly, tighten them with a
hand tool.

4) Press fit the seal.

a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 – 80%.
a Press fit front seal (6) to the depth of
21mm with tool A3

2) Measure the radial runout and facial runout

with dial gauge [1].
• Radial runout: Max. 0.30 mm
• Facial runout: Max. 0.30 mm

30-32 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL AND INSTALLATION 4. Disconnect drain tubes (4).

OF CYLINDER HEAD
SPECIAL TOOLS

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

A 1 790-331-1110 Wrench t 1

REMOVAL
k 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- 5. Disconnect flange bolts (5).
chine from moving.
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Drain the engine cooling water.

6 Engine cooling water: Approx. 310 l

2. Remove engine hood (1).

4 Engine hood : Approx. 300 kg

6. Remove U-bolts (6), then remove mufflers (7).

3. Disconnect clamps (3) of Komaclone tubes (2).

7. Remove air intake connectors (8).

WD900-3 30-33
(1)
DISASSEMBLY AND ASSEMBLY
8. Disconnect turbocharger lubrication oil tubes
(9).
9. Disconnect turbocharger drain tubes (10).
10. Remove turbochargers (11).
11. Disconnect fuel injection tube clamps (12).
12. Disconnect boost compensator tube (13).
13. Disconnect electrical intake air heater wire (14).
14. Disconnect aftercooler tubes (15) and (16).
30-34
(1)
CYLINDER HEAD
15. Temporarily sling the air intake manifold and
aftercooler assembly (18), then remove mount-
ing bolts. [*2]
a Set the guide bolt to the mounting hole at the
bottom of the air intake manifold to prevent
[*1] the electrical intake air heater from falling.
16. Remove the air intake manifold, aftercooler (18)
and electrical intake air heater.
4 Air intake manifold and aftercooler assem-
bly: 50 kg
17. Remove exhaust manifold (19). [*3]
4 Exhaust manifold : 30 kg
WD900-3
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

18. Remove fuel injection tube (20). [*4] 27. Remove rocker arm housing (29). [*12]

19. Remove spill tube (21). [*5] 28. Remove the mounting bolts, then remove cylin-
der head (30). [*13]

4 Cylinder head : 19 kg
20. Remove air vent tube (22). [*6]

21. Remove head cover (23). [*7]

22. Remove connection tube (24). [*8]

23. Remove nozzle holder (25). [*9]

24. Remove rocker arms (26). [*10]

25. Remove push rods (27).

26. Remove crossheads (28). [*11]

WD900-3 30-35
(1)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

3 Fuel injection tube:

INSTALLATION [*4]

• Carry out installation in the reverse order to 23 – 25 Nm {2.3 – 2.5 kgm}

removal.

3 Spill tube: 10 – 13 Nm {1.0 – 1.3 kgm}

[*5]

2 Mounting nut: Lubricant (LM-P)

[*1]

3 Mounting nut: 49 ± 5 Nm {5.0 ± 0.5 kgm}

3 Air vent tube: 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*6]

3 Mounting bolt: 59 – 74 Nm {0 – 5 kgm}

[*2]

3 Head cover: 15 – 34 Nm {1.5 – 3.5 kgm}

[*7]
a Tighten the mounting bolts in the order given
in the diagram below.

3 Connection tube:
[*8]

3 Connection tube lock nut:

34 – 39 Nm {3.5 – 4.0 kgm}

34 – 44 Nm {3.5 – 4.5 kgm}

3 Nozzle holder mounting bolt:

[*9]

59 – 74 Nm {6.0 – 7.5 kgm}

3 Rocker arm mounting bolt:

[*10]

93 – 103 Nm {9.5 – 10.5 kgm}

2 Mounting bolt: Lubricant (LM-P)

[*3]
3 Mounting bolt: 44 – 54 Nm {4.5 – 5.5 kgm}
a Tighten the mounting bolts in the order given
in the diagram below.
[*11]
a Adjustment of crosshead
i) Hold upper face of the crosshead lightly
and screw in adjustment screw.
ii) After the adjustment screw comes into
contact with the valve stem, screw in an
additional 20° (or 30° when the engine
is being reassembled).
a When the engine is disassembled and as-

3 Crosshead: 59 ± 6 Nm {6.0 ± 0.6 kgm}

sembled, be sure to adjust the crosshead.

3 Rocker arm housing:

[*12]

98 ± 5 Nm {10.0 ± 0.6 kgm}

30-36 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

[*13] Step Procedure

a Tighten the mounting bolts in the order given
1st step Tighten to 147± 10 Nm {15 ± 1 kgm}

2 Mounting bolt: Lubricant (LM-P)

in the diagram below.
2nd step Tighten to 216 ± 5 Nm {22 ± 0.5 kgm}
3 Mounting bolt: Tighten by 2 – 3 turns 3rd step Mark bolt head, then tighten it by 90° +30°
+0
first with the hand, then tighten further
according to the following procedure. a Tighten bolt [7] to 62 ± 4 Nm {75 ± 0.75 kgm}.
i) 1st step: a After tightening each bolt, make a punch
137 – 157 Nm {14 – 16 kgm} mark on it to indicate the number of times
ii) 2nd step: tightened.
211 – 221 Nm {21.5 – 22.5 kgm} a Do not use a bolt having five punch marks,
iii) 3rd step: but replace it with new one.
Tighten by 90° +30°
+0 with wrench A1.

• If wrench A1 is not used, tighten the mounting

bolts according to the following procedure.

A1

• Refilling with water

CEP00354
Add water up to the water filler. Run the engine
to circulate the water through the system. Then,
check the water level in the reservoir tank again.

WD900-3 30-37
(1)
DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL AND INSTALLATION 5. Remove radiator grille.

OF RADIATOR 4 Grille: Approx. 30 kg

REMOVAL 6. Disconnect connector (7) (CN-GR1).

k Stop the machine on level ground and install the a After disconnecting the radiator water level
safety bar to the frame. Lower the work equip- sensor wiring connector (CN-G06), move the
ment to the ground and stop the engine. Then connector towards the radiator.
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
a Disconnect the cable from the negative (–)
terminal of the battery.

1. Draining water
Loosen drain valve (1) and drain cooling water.
a If the coolant contains antifreeze, dispose of
it correctly.

6 Cooling water: 301 l

7. Sling radiator guard (8) temporarily, remove

mounting bolts, then lift off.

4 Radiator guard: Approx. 225 kg

2. Remove exhaust assembly (2) and then remove

hand guard (3), (4).

3. Remove side cover (5).

4. Remove engine hood (6). 8. Disconnect water drain hose (9) from radiator.

4 Exhaust assembly: 44 kg (2 pieces) 9. Loosen clamp of lower hose (10).

4 Engine hood: 88 kg 10. Disconnect hose (11).

30-38 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
11. Loosen hose clamps of tubes (12) and (13).
a Disconnect hose (14) from the radiator.
12. Disconnect hydraulic cooler hoses (15), (16).
13. Remove fan guard (17) from radiator.
14. Remove radiator supports (18) of both sides.[*1]
WD900-3
RADIATOR
15. Sling radiator (19) temporarily, remove mounting
bolts, then lift off.
a Raise the radiator slightly and check that the
lower and upper hoses have come out, then
lift off the radiator.
a Be careful not to let the fan hit the radiator core.
4 Radiator: 710 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Mounting bolt: 549 ± 59 Nm {56 ± 6 kgm}
[*1]
• Refilling with water and oil
a Tighten drain valve (1), then add engine
cooling water through the water filler of the
radiator to the specified level.
5 Engine cooling water: 301 l
a Add oil through the oil filler of the hydraulic
tank to the specified level.
a Run the engine to circulate the water and oil
through the system. Then, check the water
level and oil level again.
30-39
(1)
DISASSEMBLY AND ASSEMBLY ENGINE

REMOVAL AND INSTALLATION

OF ENGINE
REMOVAL
k Stop the machine on level ground and install the
safety bar to the frame. Lower the work equip-
ment to the ground and stop the engine and ap-
ply the parking brake, then put blocks under the
wheels to prevent the machine from moving.
a Disconnect the cable from the negative (–)
terminal of the battery.
a Collect the air conditioner gas (R134a) with
tool X.
7. Disconnect air conditioner hose (8).
1. Loosen drain valve (1), and drain engine cooling
water. 8. Disconnect heater hose clamp (9) from the bulk-
a If antifreeze solution is mixed in the engine head.
cooling water, handle the engine cooling wa-
ter as a chemical, and do not disposal of it
carelessly.

6 Engine cooling water: 301 l

2. Disconnect engine oil drain valve (2) from the

fuel tank.

9. Disconnect air conditioner hose (10).

10. Disconnect transmission breather (11).

11. Disconnect drive shaft (12). [*1]

a After disconnecting the drive shaft, sling it
with ropes, etc.

3. Remove hand guards (3) and (4).

4. Remove exhaust tube (5).

5. Remove side cover (6).

6. Remove engine hood (7).

4 Exhaust assembly: 22 kg x 2 pieces

4 Engine hood: 88 kg

4 Side hood: 55 kg

30-40 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ENGINE

12. Loosen clamp of tube hose (13). 16. Sling air cleaner and bulkhead assembly (18A)
temporarily, then remove mounting bolts, and
13. Disconnect engine stop cable (14) and electric lower.

4 Air cleaner, bulkhead: 19.3 kg

wiring connector (15).

14. Disconnect fuel control cable (16) at servo cylin-

der end. a Remove bar (18B) first.

17. Disconnect hose (19) for heater from engine,

and remove clamp from bar (20), then move
hose towards front, and disconnect bar.

15. Loosen hose clamp between air cleaner and tur-

bocharger, and remove left and right hoses (17).

18. Remove air conditioner hose (21) from com-

pressor, and remove clamp from bar (20) and
(22), remove hose, then disconnect bar.

WD900-3 30-41
(1)
DISASSEMBLY AND ASSEMBLY ENGINE

a Disconnect the both ends of fuel hoses (23), 22. Remove tubes (27) and (28), and disconnect
(24). hose (29).

19. Disconnect connectors (25) (CN-GR1). 23. Disconnect tube (30), tube (31) (between water
a After disconnecting the radiator water level pump and torque converter cooler), and tube
sensor wiring, move the connector towards (32) (between torque converter cooler and
the radiator. engine).

20. Sling radiator guard (26) temporarily, then 24. Disconnect left and right blow-by hose (33).
remove mounting bolts, and lift off.

4 Radiator guard: 225 kg

25. Disconnect fuel hose (34).

21. Remove radiator grille.

4 Grille: 30 kg

30-42 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ENGINE

26. 2Disconnect ground connection cable (35). 31. Sling engine temporarily, and remove left and
right front mounting bolts (42). [*2]
27. Disconnect cable (36) from starting motor.

32. Remove left and right rear mounting bolts (43).

28. Disconnect connectors (37) (CN-ER1), (38) [*3]
(CN-ER2), and (39) (CN-ER3).

29. Disconnect ground connection cable (40).

33. Lift off engine (44).

a Be careful not to hit any parts when lifting off.
a Check that all hoses and wires are discon-
30. Remove fan guard (41). nected.

4 Engine: Approx. 3,500 kg

Sling fan temporarily and remove mounting
bolts, then secure fan to bar at top of radiator
with wire.
a Be careful not to damage the radiator core
with the fan.

WD900-3 30-43
(1)
DISASSEMBLY AND ASSEMBLY ENGINE

34. Lift off fan (45) from radiator. INSTALLATION

a Be careful not to damage the radiator core
with the fan. • Carry out installation in the reverse order to

4 Fan: 63 kg
removal.

[*1]
a Check that the sliding range of the drive shaft is
normal before installing the drive shaft. For de-
tails, see TESTING AND ADJUSTING, Testing

3 Drive shaft mounting bolt:

of upper drive shaft sliding part.

157 – 196 Nm {16.0 – 20.0 kgm}

3 Engine rear mounting bolt:

[*2]

770 – 1,030 Nm {78 – 105 kgm}

3 Engine front mounting bolt:

[*3]

770 – 1,030 Nm {78 – 105 kgm}

30-44 WD900-3
(8)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION
OF DAMPER
REMOVAL
k 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.
1. Remove the engine hood and bulkhead. For
details, see REMOVAL AND INSTALLATION OF
ENGINE .
2. Sling upper drive shaft (1) temporarily and remove
the mounting bolts, then lift off the shaft.
a Make match marks on the couplings.
4 Upper drive shaft: 68 kg
3. Remove mounting bolts (2), then remove
damper cover (3). [*2]
4 Damper cover: 113 kg
4. Loosen the upper two bolts of damper (5), then
sling temporarily and remove mounting bolts (4).
[*3]
5. Slowly sling and lift off damper (5).
4 Damper: 178 kg
WD900-3
DAMPER
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Check that the sliding range of the drive shaft is
normal before installing the upper drive shaft. For
details, see TESTING AND ADJUSTING, Test-
3 Upper drive shaft mounting bolt:
ing of upper drive shaft sliding part.
157 – 196 Nm {16 – 20 kgm}
[*2]
a Apply gasket sealant to the damper cover as-
2 Damper cover assembly mounting face:
[*1] sembly mounting face.
3 Damper cover mounting bolt:
Gasket sealant (LG-8)
98 – 123 Nm {10.0 – 12.5 kgm}
3 Damper mounting bolt:
[*3]
245 – 309 Nm {25.0 – 31.5 kgm}
30-45
(9)
DISASSEMBLY AND ASSEMBLY DAMPER

DISASSEMBLY AND ASSEMBLY

OF DAMPER
SPECIAL TOOLS

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-101-5401 Push tool KIT (C) t 1

• 790-101-5521 • Plate 1
1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1 4) Face cover (1) in the opposite direction, and
B
793T-812-1110 Plate t 1 N Q remove bearing (6) and spacer (7).
2 790-101-5421 Grip t 1 a Bearing (6) cannot be used again after it
01010-51240 Bolt t 1 has been removed. Always replace it in
the same way as oil seals (2) and (8).
3 790-101-7190 Push tool t 1

DISASSEMBLY
1. Cover
1) Remove oil seal (2) from cover (1).
2) Remove stopper snap rings (4) and (5) of
shaft (3).
3) Pull out shaft (3) from cover (1).
a After pulling out shaft (3), remove oil seal
(8).

2. Damper
1) Remove mounting bolts (9), and using forc-
ing screws, remove flange (10).
a Tighten the 3 forcing screws evenly.

30-46 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY DAMPER

a Do not remove spacer (11) unless nec- Assembly

essary. 1. Damper
1) Install flange (15) under outer body (13),
then install inner body (14).
a Align the bolt mounting holes of the bot-

2 Contact surface of flange and outer

tom flange and outer body.

body: Gasket sealant (LG-8)

2) Remove rubber (12).

2) Assemble rubber (12) between inner body

2 Outside circumference of inner

(14) and outer body (13).

body (14):

2 Inside circumference of outer body

Grease (G2-LI)

(13):
Grease (G2-LI)

3) Remove inner body (14) and flange (15)

from outer body (13).
a Screw in the mounting bolts, tap with a
hammer and remove.

WD900-3 30-47
(9)
DISASSEMBLY AND ASSEMBLY DAMPER

3) Coat all of the clearance (a) between inner

2 All of the clearance (a):

body and rubbers equally with grease (G2-LI).

Grease (G2-LI)
Amount of grease:
70 ± 4 cc {61.8 – 68.4 g}

2) Using tool B2, press fit oil seal (8) in cover

(1).
a Press fit the oil seal so that the lip sur-

2 Outside surface of oil seal:

face is on the bearing side.

Adhesive (Loctite648)
4) Install flange (10), and tighten mounting 3) Coat clearance (a) between oil seal (8) and

2 Contact surface of flange and outer 2 Clearance (a) between oil seal and
bolts (9). the bearing with grease.

3 Mounting bolt:
body: Gasket sealant (LG-8) bearing: ENS grease
Amount of grease:

2 Lip of oil seal: ENS grease

278 ± 31 Nm {28.3 ± 3.2 kgm} 80 ± 4 cc {70.7 – 78.1 g}

2. Cover
1) Using tool B1, press fit bearing (6) and
spacer (7) in cover (1).
a When press fitting the bearing, check
that the inside diameter of the spacer
and the inside diameter of the bearing

2 Outside circumference of bearing

are aligned.

outer race:

2 Bearing: ENS grease

Adhesive (Loctite648)

Amount of grease:
70 ± 7 cc {58.6 – 71.6 g}

30-48 WD900-3
(9)
DISASSEMBLY AND ASSEMBLY DAMPER

4) Install stopper snap ring (5) of bearing (6) to 2 Clearance (b) between oil seal and
cover (1). bearing: ENS grease
5) Using tool B1, press fit oil seal (2) in cover Amount of grease:

2 Lip of oil seal: ENS grease

(1). 160 ± 8 cc {141.4 – 156.2 g}
a Press fit the oil seal so that the lip sur-

2 Outside surface of oil seal:

face is on the bearing side. 9) Remove plug (16), then apply grease

2 Grease area (d) between bearings:

through plug hole.
Adhesive (Loctite648)
ENS grease
Amount of grease:

3 Plug: 7.4 ± 2.5 Nm {0.75 ± 0.25 kgm}

700 ± 30 cc {623.1 – 678.9 g}

2 Shaft spline portion (portion (e)):

Molybdenum disulphide
lubricant (LM-P)
a Leave to dry naturally for 2 – 3 minutes
after coating LM-P, then install shaft and
cover assembly to damper assembly.

2 Portion (f): ENS grease

10) Coat portion (f) with grease.

Amount of grease:
30 ± 2 cc {26.5 – 29.3 g}
a Always keep to the specified amount for
2 Inside of inner race of bearing (6):
6) Using tool B3, press fit shaft (3) in cover (1).
grease in the grease areas ((a), (b), (d),
Adhesive (Loctite648) (f)).
a Always remove all other grease com-
pletely before using ENS grease. Do not
mix it with any other grease.
Use a different grease gun for each type
of grease.
a ENS grease Part No.: 427-12-11871 (2
kg can)

7) Assemble snap ring (4) to shaft (3).

8) Coat clearance (b) between oil seal (2) and

the bearing with grease.

WD900-3 30-49
(9)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

REMOVAL AND INSTALLATION 3. Disconnect drain hose (3) of the right-hand

brake valve.
OF TORQUE CONVERTER
4. Disconnect hoses (4) and (5) between the accu-
AND TRANSMISSION mulator and right-hand brake valve.
ASSEMBLY 5. Disconnect accelerator cable (6). [*1]
a Loosen the locknut and pull out the pin to dis-
SPECIAL TOOLS
connect the cable.
6. Pull window washier hose (7) out of the floor

New/remodel
Necessity
frame, then disconnect clamp (8) and move it
Symbol

Sketch
Q'ty
Part No. Part Name toward the frame.

790-101-7200 Centering tool t 1

1 790-101-7230 • Shaft 1
D 10
2 790-101-7240 • Guide 1
3 01010-31230 • Bolt 1

REMOVAL
k 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
k Loosen the oil filler cap of the hydraulic tank 7. Remove clamp (9), then disconnect left-hand
gradually to release the pressure in the hydraulic brake drain tube (10).
tank.
k Release remaining pressure in PPC circuit. For 8. Disconnect hoses (11) and (12) between the left
detail, see TESTING AND ADJUSTING "Re- hand brake valve and slack adjuster.
leasing remaining pressure in hydraulic circuit".
k Release remaining pressure in brake acccumu- 9. Disconnect hoses (13) and (14) between the
lator circuit. For detail, see TESTING AND AD- accumulator and left-hand brake valve.
JUSTING "Releasing remaining pressure in
hydraulic circuit". 10. Disconnect pilot hose (to shuttle valve) (15).
k Disconnect the cable from the negative (–) ter-
minal of the battery
1. Remove front, rear, right and left side covers (1)
under the cab.
2. Remove the cab (2). For details, see REMOVAL

3 Cab: 400 kg
AND INSTALLATION OF CAB.

11. Disconnect hose (16) between the accumulator

and orbit-roll.

12. Disconnect hose (17) between the orbit-roll and

right-hand stopper valve.

30-50 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

13. Disconnect drain hose (18) of the orbit-roll.

14. Disconnect hose (19) between the orbit-roll and

left-hand stopper valve.

15. Disconnect pilot hose (to shuttle valve) (20).

16. Disconnect hoses (21) and (22) between the

right-hand brake valve and slack adjuster.

25. Disconnect heater hose (34).

a Close the hot water outlet valve on the en-
gine side.

26. Disconnect air conditioner hose (35). [*2]

a Collect the new Freon with tool X1.
a Since the adapter is brittle, apply two span-
ners to it to disconnect each hose.

27. Disconnect connector (36), then remove wire

17. Disconnect hoses (23) (Raise lift arm), (24) clamp (37) and move it toward the body.
(Dump), (25) (Lower lift arm) and (26) (Tilt) a Connector: CN-CL2, CL3, A4, A5, A6, A7,
between the PPC valve and control valve. A8A, A8B

18. Disconnect hose (27) between the PPC valve

and PPC pump.

19. Disconnect PPC valve drain hose (28).

20. Disconnect hose clamp (29).

28. Disconnect connector (38), then remove wire

clamp (39).
a Connector: CN-FL1, FL2, CL1, LR1, LR2,
LR3, LR4, LR5, GRE

21. Disconnect brake oil drain block (30) from the

floor frame.

22. Disconnect brake shuttle valve (31) from the

floor frame.

23. Disconnect hose clamp (32).

24. Disconnect ground cable (33).

WD900-3 30-51
(4)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

34. Disconnect steering pump suction tube (48).

29. Remove 4 mounting nuts (40) of the floor frame
mount. [*3] 35. Disconnect steering pump drain hose (49).

30. Sling the floor frame (41) and lift off.

a While slinging the floor frame slowly, check
that all the clamps and harnesses are dis-
connected.

36. Disconnect discharge tubes of the pumps for

brake (50), PPC (51), torque converter, trans-
mission (52) and (53).

31. Remove transmission top cover (42), then

remove bracket (43).

32. Disconnect transmission breather (44).

37. Disconnect switch pump suction tube (54).

38. Disconnect loader pump suction tube (55).

33. Disconnect the suction tubes of the pumps for

torque converter, transmission (45), PPC (46)
and brake (47).

30-52 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

39. Disconnect switch pump discharge hose (56). 49. Remove the mounting bolts, then remove emer-
gency steering pump (68).

4 Emergency steering pump: 50 kg

40. Loader pump discharge hose (57).

41. Remove bracket (58).

42. Disconnect control pump suction tubes (59) and (60).

43. Disconnect steering pump discharge tube (61).

44. Disconnect switch pump drain hose (62) and

loader pump drain hose (63).

50. Remove hoses (69) and (70) of the sight gauge.

a Remove the drain hose of the engine control
servo cylinder from the oil feed tube.

45. Sling upper drive shaft (63) temporarily and

remove the mounting bolts, then lift off the shaft.
[*4]
a Make match marks on the couplings.

4 Upper drive shaft: 68 kg

51. Remove hose (71) of the torque converter

cooler.
a Disconnect speedometer sensor connector
(72) (CM-C01).

46. Disconnect emergency steering pump drain

hose (64).

47. Disconnect emergency steering pump discharge

hose (65) and suction hose (66).

48. Remove bracket (67).

WD900-3 30-53
(8)
DISASSEMBLY AND ASSEMBLY
52. Remove transmission lubrication tube (73).
53. Remove hose (74) between the torque con-
verter filter and transmission.
54. Remove tube (75) between the torque converter
and torque converter cooler.
a Disconnect torque converter oil temperature
sensor wiring (76) from the connector.
55. Remove transmission solenoid valve wiring (77)
from the connectors.
a When removing the connector, be careful
not to damage the case of the threaded
parts.
30-54
(1)
TORQUE CONVERTER AND TRANSMISSION
56. Sling rear drive shaft (78) temporarily and
remove the mounting bolts, then sling and lift off
the shaft. [*5]
a When slinging the drive shaft, install suffi-
ciently long slings on left and right sides of
the transmission.
4 Rear drive shaft: 186 kg
57. Sling center drive shaft (79) temporarily and
remove the mounting bolts, then sling and lift off
the shaft. [*6]
4 Center drive shaft: 186 kg
58. Sling transmission and torque converter assem-
bly (80) temporarily.
a Set the slings as short as possible.
WD900-3
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

59. Remove the mounting bolts of the trunnion (81). INSTALLATION

[*7]
a Secure the trunnion to the torque converter
with wires.
a If shims are installed between the frame and
trunnion, check its quantity and thickness.
a Disconnect trunnion greasing hose (82) from
the trunnion.
• Carry out installation in the reverse order to
removal.
[*1]
a Adjust the length of the accelerator cable.
For details, see TESTING AND ADJUST-
ING, Adjusting length of accelerator cable.

[*2]
a When connecting each hose, do not twist it.
a Be careful not to let dirt, dust, water, etc. in
each hose.
a Charge with new Freon gas (R134a) by us-
ing tool X1.

3 Mounting nut:
[*3]

245 – 309 Nm {25.0 – 31.5 kgm}

[*4]
60. Remove mount bracket (83) and mounting bolt a Check that the sliding range of the drive shaft is
(84) on the front side. [*8] normal before installing the drive shaft. For de-
a Keep mount bracket (83) on the front side re- tails, see TESTING AND ADJUSTING, Testing

3 Upper drive shaft:

moved. of upper drive shaft sliding part.
a Be careful not to lose the pin between the
transmission and bracket. 157 – 196 Nm {16.0 – 20.0 kgm}

3 Center drive shaft:

[*5]

342 – 427 Nm {35.0 – 43.5 kgm}

3 Rear drive shaft:

[*6]

342 – 427 Nm {35.0 – 43.5 kgm}

3 Trunnion mounting bolt:

[*7]

490.4 – 608.0 Nm {50.0 – 62.0 kgm}

a Check the parallelism and adjust the shims.
Parallelism: 0.15 mm max.

61. Moving the transmission and torque converter

(80) toward the engine, sling and lift it off slowly.

4 Transmission and torque converter

assembly: 2,880 kg

WD900-3 30-55
(8)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION

1) Set the transmission to the frame, then

tighten the front and rear mounting bolts
temporarily.
2) Install tools D10-1, D10-2 and D10-3 to
the upper and lower center hinge pins,
then install dial gauge [1] to the coupling
on the transmission side to measure the
parallelism of the coupling and shaft
D10-1.
3) Insert the shim in the mount.
4) Position the transmission and tighten
the mounting bolts.

3 Bracket mounting bolt:

[*8]

3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

824 – 1,030 Nm {84 – 105 kgm}

30-56 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

DISASSEMBLY AND ASSEMBLY 1. Valve

1) Remove tubes (2) and (3), and block (4).
OF TORQUE CONVERTER 2) Remove valve assembly (5).
SPECIAL TOOLS 3) Remove tube (6) and block (7).

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-901-5000 Unit repair stand t 1

790-901-5200 Unit repair stand t 1
1
790-901-5110 Bracket t 1
790-901-5120 Plate t 1
2 791-381-1011 Wrench t 1
3 790-201-2870 Spacer t 1
4 790-201-2760 Spacer t 1
790-201-2250 Plate t 1 2. PTO
5
• 790-201-2760 • Spacer t 1 1) Remove holder (8) and coupling (9).
790-101-5401 Push tool KIT (C) t 1
• 790-101-5481 • Plate 1
C 6
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5461 • Plate 1
7
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
8 790-201-2740 Spacer t 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5431 • Plate 1
9 2) Using eyebolts [1] (Dia. = 16 mm, Pitch =
• 790-101-5421 • Grip 1
2.0 mm), sling PTO assembly temporarily.
• 01010-51240 • Bolt 1 3) Screw in forcing screws [2], and lift off PTO
assembly (10).
DISASSEMBLY
Preparatory work
• Remove torque converter and PTO assembly.
For details, see DISASSEMBLY AND ASSEM-
BLY OF TRANSMISSION.
• Set torque converter and PTO assembly (1) on
tool C1.
4 Torque converter, PTO assembly: 610 kg

WD900-3 30-57
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

3. Turbine · case assembly iv) Remove bearing (20) from case (19).
1) Remove plug (11), and drain oil inside drive v) Remove bearing (21) from input shaft.
case.
2) Leave 2 bolts on opposite sides, and remove
all remaining pump mounting bolts (12).
3) Set case side at top, and remove 2 remain-
ing mounting bolts.
4) Using eyebolts [3] (Dia = 16 mm, Pitch = 2.0
mm), lift off turbine · case assembly (13).

4. Stator
1) Remove snap ring (22).
2) Remove stator (23).

5) Disassemble turbine · case assembly as fol-

lows.
i) Remove mounting bolts, then remove
input shaft (14) and gear (15).
ii) Remove snap ring (16) and plate (17).

5. Pump assembly
1) Using tool C2, loosen nut (24).
a Leave the nut in position to prevent the
bearing and pump from flying off.

iii) Using 2 forcing screws [4] (Dia. = 10 mm,

Pitch = 1.25 mm) remove turbine (18).
a Use the forcing screws to push the
inner race of the bearing.

30-58 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

2) Remove 2 plugs (25) at stator shaft end. 2) Remove stator shaft (32) from rear housing
3) Remove inner race of bearing from hole (33).
where plug was removed, then remove
pump assembly (26).

3) Remove seal ring (34).

4) Remove sleeve (35).
4) Remove bolts, then remove collar (27),
pump (28) and guide (30).
5) Remove bearing (29) from guide (30).

6. Stator shaft
1) Remove 8 mounting bolts (31).

WD900-3 30-59
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

ASSEMBLY 3) Operate repair stand, rotate torque con-

verter case 90°, install stator shaft (32), then
Preparatory work tighten 8 mounting bolts (31) from opposite

2 Mounting bolt: Adhesive (LT-2)

• Clean all parts, and check for dirt or damage. side.

3 Mounting bolt:
Coat the sliding surfaces of all parts with engine
oil before installing.
• Set torque converter rear housing (33) on tool 275 ± 29 Nm {28 ± 3 kgm}
C1.

2. Pump assembly
1. Stator shaft 1) Using push tool C8 (outside diameter: 195
1) Expand fit sleeve (35) to stator shaft. mm), press fit bearing (29) in guide.
2) Install seal ring (34) to stator shaft.
a Make the protrusion of the seal ring from
the shaft uniform.

2) Install guide (30) and retainer (27) to pump

2 Mounting bolt: Adhesive (LT-2)

(28).

3 Mounting bolt:
69 ± 5 Nm {7.0 ± 0.5 kgm}

30-60 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

3) Using push tool C5, press fit inner race (36)

to stator shaft.
4) Set pump assembly (26) in position, be
careful not to damage the seal ring.
a Coat the seal ring with grease (G2-LI),
make the amount of protrusion from the
shaft uniform, and fix in position.
5) Using push tool C5, press fit inner race (36)
to stator shaft.
a Be careful to install the inner race facing
in the correct direction.

2 Nut: Adhesive (LT-2)

8) Using tool C2, install nut (24) to stator shaft.

3 Nut: 613 ± 25 Nm {62.5 ± 2.5 kgm}

6) Set pump. Be careful not to damage the

seal ring while setting pump.
a Coat the seal ring with grease (G2-LI),
make the amount of protrusion from the
shaft uniform, and fix in position.
7) Using push tool C5, press fit inner race (36)
to stator shaft. 3. Stator
a Be careful to install inner race facing in 1) Align spline, and install stator (23).
the correct direction. 2) Install snap ring (22).

WD900-3 30-61
(1)
DISASSEMBLY AND ASSEMBLY
4. Turbine case assembly
1) Using push tool C5, press fit bearing (20) in
case (19).
2) Set turbine (18) in push tool C3 (outside
diameter: 105 mm, height: 165 mm).
3) Using push tool C4 (inside diameter: 110
mm), press fit case (19) to turbine (18).
4) Fit plate (17) and install snap ring (16).
5) Using push tool C9 (inside diameter: 90
mm), press fit bearing (21) in pilot.
30-62
(1)
TORQUE CONVERTER
6) Install gear (15).
2 Mounting bolt: Adhesive (LT-2)
7) Install pilot (14).
3 Mounting bolt:
275 ± 29 Nm {28 ± 3 kgm}
8) Using eyebolts [3] (Dia. = 16 mm, Pitch =
2.0 mm), raise turbine case assembly (13),
align oil groove of case with drain hole of
pump (2 places), then install.
2 Mounting bolt: Adhesive (LT-2)
9) Tighten pump mounting bolts temporarily.
WD900-3
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER

10) Rotate repair stand 90° and tighten mount- 2) Install coupling (9).

3 Mounting bolt: 3 Mounting bolt:

ing bolts (12). 3) Fit O-ring and install holder (8).

54 ± 5 Nm {5.5 ± 0.5 kgm} 275 ± 29 Nm {28 ± 3 kgm}

11) Tighten drain plug (11).

3 Plug: 7.4 ± 2.5 Nm {0.75 ± 0.25 kgm}

12) Tighten 2 plugs (25).

6. Valve assembly
1) Fit O-ring and install block (7) and tube (6).
5. PTO assembly 2) Fit O-ring and install valve assembly (5).

3 Valve assembly mounting bolt:

1) Fit O-ring, then using eyebolts [1] (Dia. = 16 3) Fit block (4) and install tubes (3) and (2).
mm, Pitch = 2.0 mm), install PTO assembly

3 Tube mounting bolt:

(10). 49 ± 5 Nm {5.0 ± 0.5 kgm}
a Be careful not to damage the oil seal
when installing. 25 ± 5 Nm {2.5 ± 0.5 kgm}
a Mount PTO assembly after adjusting
mounting position. If move PTO assem-
bly after mounting, O-ring will be twisted
and gone out of groove.

WD900-3 30-63
(1)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE

DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER VALVE

DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY OF TORQUE CONVERTER VALVE

VALVE
a Clean all parts, and check for dirt or damage.
1. Remove cover (1), then remove valve (2), spring Coat the sliding surfaces of all parts with engine
(3) and valve (4). oil before installing.
2. Remove cover (5), then remove spring (6), valve
(7) and washer, shim (8). 1. Assemble washer, shim (8), valve (7) and spring
(6), then fit O-ring and install cover (5).
2. Assemble valve (4), spring (3), and valve (2),
then install cover (1).

30-64 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

DISASSEMBLY AND ASSEMBLY DISASSEMBLY

OF TRANSMISSION 1. Torque converter assembly
Using eyebolts, remove torque converter
SPECIAL TOOLS assembly (1) from transmission assembly (2).

4 Torque converter assembly: 650 kg

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

1 799-301-1600 Push tool KIT (C) t 1

793T-815-1110 Push tool t 1 N Q
2
790-210-2760 Spacer t 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5461 • Plate 1
3
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5621 Plate t 1
4 • 790-101-5421 • Grip t 1
2. Control valve assembly
• 01010-51240 • Bolt t 1
1) Remove 11 mounting bolts.
790-101-5201 Push tool KIT (B) t 1 • The length of the bolts is different, so
• 790-101-5321 • Plate 1 check before removing.
5
• 790-101-5221 • Grip 1 • Remove only the bolts marked a in the
• 01010-51225 • Bolt 1 diagram.
790-101-5401 Push tool KIT (C) t 1
• 790-101-5521 • Plate 1
D 6 • 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
793T-815-1120 Plate t 1 N Q
7 790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-101-5401 Push tool KIT (C) t 1
• 790-101-5491 • Plate 1
8
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-5401 Push tool KIT (C) t 1 2) Using eyebolts [1] (Dia. = 10 mm, Pitch =
• 790-101-5561 • Plate 1 1.5 mm), lift off control valve assembly (3).
9

4 Control valve assembly: 110 kg

• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
790-101-7200 Centering tool t 1
1 790-101-7230 • Shaft 1
10
2 790-101-7240 • Guide 1
3 01010-31230 • Bolt 1

WD900-3 30-65
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

3. Sleeve 5. Tie bolts

Remove sleeve (4). 1) Using tool D1, check the operation of the
piston before disassembling.

4. Transmission case
1) Raise transfer and transmission assembly, 2) Remove tie bolts (16).
and put transfer (14) at bottom.

4 Transfer, transmission assembly:

2,200 kg

6. Plate
Using eyebolts [1] (Dia. = 12 mm, Pitch = 1.75
mm), lift off plate (17).

2) Using eyebolts [4] (Dia. = 16 mm, Pitch = 4 Plate: 30 kg

2.0 mm), lift off transmission case (15).

4 Transmission case: 125 kg

30-66 WD900-3
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

7. Spring 10. Shaft, No. 1 carrier assembly

Remove spring (18). 1) Using eyebolts [4] (Dia. = 12 mm, Pitch =
a This spring is different from the other 1.75 mm), lift off shaft and No. 1 carrier
springs, so keep it separately in a safe place. assembly (23).

8. Spring, disc, plate 2) Disassemble shaft and No. 1 carrier assem-

Remove spring (19), disc (20), and plate (21). bly as follows.
a There are springs between each plate. i) Remove snap ring (24).
ii) Remove gear (25).

9. No. 1 ring gear

Remove ring gear (22). iii) Remove collar (27) from shaft and car-
rier assembly (26).

WD900-3 30-67
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

iv) Remove snap ring (28), then remove

shaft assembly (29) from carrier assem-
bly (30).

x) Remove pin, then remove thrust washer

(36), planetary gear (37), needle bear-
ing (38), and spacer (39).
v) Remove bearing (31). a When removing the pin, be careful
not to lose the ball.

vi) Remove sun gear (32).

vii) Remove bearing (33).
11. No. 2 ring gear
1) Remove mounting bolts (40), then remove
plate (41).
2) Remove ring gear (42).

viii) Remove bearing (34).

ix) Remove snap ring (35).

30-68 WD900-3
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

12. No. 1 piston, housing 15. Guide Pin

1) Using eyebolts [1] (Dia. = 12 mm, Pitch = Remove guide pin (50).
1.75 mm), lift off piston and housing (43).

4 Piston, housing: 65 kg
16. Ring gear
Remove ring gear (51).

2) Remove piston (45) from housing (44).

17. No.2 piston, housing

1) Using eyebolts [1] (Dia. = 12 mm, Pitch =
13. Spring 1.75 mm), lift off piston and housing (52).

4 Piston, housing: 65 kg
Remove spring (46).
a This spring is different from the other
springs, so keep it separately in a safe place.
2) Remove piston (54) from housing (53).

14. Spring, disc, plate

Remove spring (47), disc (48), and plate (49).
a There are springs between each plate.

WD900-3 30-69
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

18. No. 2, 3 carrier assembly
1) Remove snap ring (55).
2) Using puller, pull out bearing press-fit por-
tion of No. 2 and 3 carrier assembly (56).
3) Using eyebolts [1] (Dia. = 12 mm, Pitch =
1.75 mm), lift off carrier assembly (56).
iii) Remove pin, then remove thrust washer
(60), planetary gear (61), and needle
bearing (62).
a When removing the pin, be careful
not to lose the ball.

4 Carrier assembly: 90 kg

iv) Remove bearing (63).

19. Ring gear, plate

4) Disassemble No. 2 and 3 carrier assembly 1) Remove ring gear (64).
as follows. 2) Using eyebolts (Dia. = 12 mm, Pitch = 1.75
i) Remove sun gear (57). mm), lift off plate (65).
ii) Remove mounting bolts (58), then
remove retainer (59).

30-70 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

20. No. 3 piston, housing 22. Spring, disc, plate

1) Remove collar (66). Remove spring (71), disc (72), and plate (73).
a There are springs between each plate.

2) Using eyebolts [1] (Dia. = 12 mm, Pitch =

1.75 mm), lift off piston and housing (67). 23. No. 3 ring gear

4 Piston, housing: 65 kg
Remove ring gear (74).

3) Remove piston (69) from housing (68).

24. No. 4 piston, housing

1) Using eyebolts [1] (Dia. = 12 mm, Pitch =
1.75 mm), lift off piston and housing (75).

4 Piston, housing: 65 kg
21. Spring
Remove spring (70).
a This spring is different from the other
springs, so keep it separately in a safe place. 2) Remove piston (77) from housing (76).

WD900-3 30-71
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

25. Spring 29. Shaft assembly

Remove spring (78). 1) Remove shaft assembly (84).
a This spring is different from the other
springs, so keep it separately in a safe place.

2) Remove snap ring (85).

3) Set in press, then using push tool D4 (Inside
26. Spring, disc, plate diameter: 80 mm, Length: 400 mm), remove
Remove spring (79), disc (80), and plate (81). bearing (86).
a There are springs between each plate.

27. Guide pin

Remove guide pin (82).

30. No. 4 ring gear, carrier assembly

1) Using eyebolts [1] (Dia. = 12 mm, Pitch =
1.75 mm), lift off ring gear and carrier
assembly (87).

4 Ring gear, carrier assembly: 80 kg

28. Plate
Remove plate (83).

30-72 WD900-3
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DISASSEMBLY AND ASSEMBLY
2) Disassemble No. 4 ring gear and carrier
assembly as follows.
i) Remove bearing assembly (88) from
ring gear and carrier assembly (87).
ii) Remove collar (91) from bearing (90).
iii) Remove mounting bolts (92), then
remove retainer (93).
iv) Remove snap ring (94), then remove
ring gear (95).
WD900-3
TRANSMISSION
v) Remove pin, then remove thrust washer
(96), planetary gear (97), and needle
bearing (98).
a When removing the pin, be careful
not to lose the ball.
31. Sun gear
Remove sun gear (99).
32. Cover assembly
1) Turn over transfer assembly.
4 Transfer assembly: 1,100 kg
2) Remove mounting bolts (5), then using forc-
ing screws [2] (Dia. = 12 mm, Pitch = 1.75
mm), remove cover assembly (6).
30-73
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

3) Remove snap ring (8) from cover (7), then
remove bushing (9).
34. Inner race
Using puller [6], pull out rotating clutch assembly
(120), then remove inner race (121).
a When pulling out the rotating clutch assem-
bly, fit a block under the rotating clutch to
prevent it from falling.

33. Collar assembly

1) Remove snap ring (10).
2) Using puller [3], remove collar assembly (11).
a When using the puller, remove the out-
side seal ring (1 piece). Serial No.: 50001 – (T/M No. 101138)

Serial No.: (T/M No. 101139) and up

30-74 WD900-3
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

35. Rotating clutch assembly FINE DISASSEMBLY OF ROTATING CLUTCH

1) Raise transfer assembly (122), and disas- ASSEMBLY
semble rotating clutch assembly.

4 Transfer assembly: 1,100 kg

36. No. 5 carrier assembly
1) Remove mounting bolts (101).
2) Using eyebolts [1] (Dia. = 12 mm, Pitch =
2) Remove flange (100) of bearing. 1.75 mm), sling carrier assembly (102), then
using forcing screws (Dia. = 12 mm, Pitch =
Serial No.: 50001 – (T/M No. 101138) 1.75 mm), lift off carrier assembly.

4 Carrier assembly: 65 kg

Serial No.: (T/M No. 101139) and up

3) Disassemble carrier assembly as follows.

i) Remove snap ring (103).
ii) Remove collar (104).
iii) Remove bearing (105).

WD900-3 30-75
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

iv) Remove pin (106), then remove thrust
washer (107), planetary carrier (108),
and needle bearing (109).
a When removing the pin, be careful
not to lose the ball.
39. Retainer, pressure plate
1) Remove mounting bolts (115), then remove
retainer (116).
2) Remove pressure plate (117).

40. Bearing
37. Sun gear, No. 5 ring gear Using puller [7], remove bearing (118).
1) Remove sun gear (110).
2) Remove ring gear (111). 41A.Inner race
Serial No. : 50001 – (T/M No. 101138)
Remove inner race (119).

41B.Bearing
Serial No. : (T/M No. 101139) and up
Remove inner race (119A).

38. Spring, disc, plate

Remove spring (112), disc (113), and plate (114).
a There are springs between each plate.

30-76 WD900-3
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

ASSEMBLY 2. Bearing
1) Install 2 seal rings to drum.
a Precautions when assembling 2) Press fit bearing (118).
• Coat the rotating and sliding surfaces of all
parts with engine oil (SAE10W) before in-
stalling.
• Coat the seal rings and roller bearings with
grease (G2-LI), then install them, making
sure that they are not off center.
• Align the notches on the discs when install-
ing.
• Check that the snap rings are fitted securely.
a Clean all parts, and repair any damage.

FINE ASSEMBLY OF ROTATING CLUTCH

ASSEMBLY

a Before assembling, coat plug (121) with LT-2 3. Pressure plate, retainer
and tighten it into shaft (120) until its head is flush 1) Fit seal ring to pressure plate (117), then
with the end of shaft (120) and then bend 2 parts install to drum.
(parts a) and install pin (122). 2) Fit retainer (116) and tighten mounting bolts

3 Mounting bolt:
(115).

66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

1A. Inner race

Serial No.: 50001 – (T/M No. 101138)
Using push tool D2 (Inside diameter = 123 mm,
Length = 270 mm), press fit inner race (119). 4. Spring, disc, plate
Install spring (112), disc (113), and plate (114).
1B. Bearing a There are springs between each plate.
Serial No.: (T/M No. 101139) and up a Number of discs: 6
Heat bearing (119A) and install it by shrink fit. Number of plates: 5
a Do not heat bearing (119A) higher than
120°C.

WD900-3 30-77
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DISASSEMBLY AND ASSEMBLY TRANSMISSION

5. No. 5 ring gear, sun gear 2) Using eyebolts [1] (Dia = 12 mm, Pitch =
1) Install ring gear (111). 1.75 mm), raise carrier assembly (102) and
2) Install sun gear (110). install.

3 Mounting bolt:
3) Tighten mounting bolts (101).

110 ± 12 Nm {11.25 ± 1.25 kgm}

6. No. 5 carrier assembly

1) Assemble carrier assembly as follows.
i) Install needle bearing (109), planetary
gear (108), and thrust washer (107),
then knock in pin (106).
a Be careful not to forget the ball when
installing.
7. Rotating clutch assembly
1) Install flange (100) of bearing.
2) Raise transfer assembly (122), and connect
rotating clutch assembly.
Serial No.: 50001 – (T/M No. 101138)

ii) Heat bearing (105) and install it by Serial No.: (T/M No. 101139) and up
shrink fit.
a Do not heat bearing (105) higher
than 120°C.
iii) Fit 2 seal rings to collar (104) and
install.
iv) Install snap ring (103).

30-78 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

8. Inner race 9. Cover assembly

Using push tool D5 (inside diameter: 103 mm, 1) Set in press, then using push tool D3 (out-
length: 70 mm), press fit inner race (121) to side diameter: 135 mm), press fit bushing
rotating clutch (120). (9) in cover (7).
a Press fit the inner race at approx. 20°C, and 2) Install snap ring (8).
be extremely careful that the bearing roller
does not fall over.
Serial No.: 50001 – (T/M No. 101138)

3) Fit O-ring and install cover assembly (6),

then tighten mounting bolts (5).
Serial No.: (T/M No. 101139) and up

8A. Collar assembly 10. Sun gear

1) Install 2 seal rings to collar. 1) Turn over transfer assembly.

4 Transfer assembly: 1,100 kg

2) Using push tool D6 (inside diameter: 83
mm), press fit collar assembly (11).
a Align the collar assembly exactly with
the position of the dowel pin and press fit 2) Install sun gear (99).
gradually.
3) Install snap ring (10).

WD900-3 30-79
(1)
DISASSEMBLY AND ASSEMBLY
11. No. 4 ring gear, carrier assembly
1) Assemble No. 4 ring gear and carrier
assembly as follows.
i) Assemble needle bearing (98) in plane-
tary gear (97), fit thrust washers (96) to
both ends and set to carrier.
ii) Fit ball (120) and push in pin (121).
a Be careful not to forget the ball when
installing to the shaft.
iii) Fit snap ring (94) to ring gear (95), and
install ring gear.
iv) Fit retainer (93) and tighten with mount-
ing bolts (92).
a Check that the snap ring installed to
the ring gear is set securely between
3 Mounting bolt:
the retainer and the carrier.
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30-80
(1)
TRANSMISSION
v) Heat bearing (90) and install it to collar
(91) by shrink fit.
a Do not heat the bearing higher than
120°C.
a Install a seal ring on the collar.
vi) Cool the outer race of bearing (88) and
fit bearing (88) to ring gear and carrier
assembly (87) by expansion fit.
a Install seal rings to the ring gear and
carrier assembly.
2) Cool only the outer race of bearing (105).
Then, using eyebolts [1] (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install ring gear
and carrier assembly (87) to bearing (105)
by expansion fit.
WD900-3
DISASSEMBLY AND ASSEMBLY TRANSMISSION

12. Plate 14. Guide pin

Align with dowel pin, and install plate (83). Install guide pin (82).

15. Disc, spring plate

Install disc (80), spring (79), and plate (81).
a There are springs between each plate.
a Number of discs: 5
Number of plates: 4

13. Shaft assembly

1) Install snap ring (85).
2) Heat bearing (86) and install it to the shaft
by shrink fit.
a Do not heat bearing (86) higher than
120°C.
16. Spring
Install spring (78).
a This spring is different from the other
springs, so be careful to distinguish it when
installing.
a Free height of spring: 91 mm

3) Tap shaft assembly (84), and press fit bear-

ing.

WD900-3 30-81
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

17. No. 4 piston, housing 20. Spring

1) Fit seal ring, then install piston (77) in hous- Install spring (70).
ing (76). a This spring is different from the other
a Install the seal ring with the groove fac- springs, so be careful to distinguish it when
ing the housing as shown in the diagram. installing.
2) Using eyebolts [1] (Dia. = 12 mm, Pitch = a Free height of spring: 91 mm
1.75 mm), align with dowel pin, raise piston
and housing (75), and install.
a When installing, check through the clear-
ance between the piston and the transfer
that spring (78) has not fallen over.

21. No. 3 piston, housing

1) Fit seal ring, then install piston (69) in hous-
ing (68).
a Install the seal ring with the groove fac-
ing the housing as shown in the diagram.
18. No. 3 sun gear 2) Using eyebolts (Dia. = 12 mm, Pitch = 1.75
Install ring gear (74). mm), align with dowel pin, raise piston and
housing (67), and install.
a When installing, check through the
clearance between the piston and the
housing that spring (70) has not fallen
over.
3) Install collar (66).

19. Disc, spring, plate

Install disc (72), spring (71), and plate (73).
a There are springs between each plate.
a Number of discs: 4
Number of plates: 3

30-82 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
22. Plate, ring gear
1) Using eyebolts (Dia. = 12 mm, Pitch = 1.75
mm), align with dowel pin, then raise plate
(65) and install.
2) Install ring gear (64).
23. No. 2, 3 carrier assembly
1) Assemble No. 2 and 3 carrier assembly as
follows.
i) Heat bearing (63) and install it by shrink
fit.
a Do not heat bearing (63) higher than
120°C.
ii) Assemble needle bearing (62) in plane-
tary gear (61), and fit thrust washers
(60) to both ends, then set in carrier.
iii) Fit ball (122) and push in pin (123).
a Be careful not to forget the ball when
installing the shaft.
WD900-3
TRANSMISSION
iv) Fit retainer (59) and tighten mounting
3 Mounting bolt:
with bolts (58).
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
v) Cool only the outer race of bearing (63).
Then, using eyebolts [1] (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install car-
rier assembly (56) to bearing (63).
vi) Insert seal ring in collar, then assemble
to shaft.
a When the seal ring is assembled to
the collar, install so that the narrow
width a of the seal ring and collar is
at the bottom.
vii) Install sun gear (57).
viii) Install snap ring (55).
30-83
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

24. No. 2 piston, housing 28. Spring

1) Fit seal ring, then install piston (54) in hous- Install spring (46).
ing (53). a This spring is different from the other springs,
a Install the seal ring with the groove fac- so be careful to distinguish it when installing.
ing the housing as shown in the diagram. a Free height of spring: 108.5 mm
2) Using eyebolts [1] (Dia. = 12 mm, Pitch =
1.75 mm), align with dowel pin, raise piston
and housing (52), and install.

29. No. 1 piston, housing

1) Fit seal ring, then install piston (45) in housing (44).
a Install the seal ring with the groove fac-
25. Ring gear ing the housing as shown in the diagram.
Install ring gear (51). 2) Using eyebolts [1] (Dia. = 12 mm, Pitch =
1.75 mm), align with dowel pin, raise piston
26. Guide pin and housing (43), and install.
Install guide pin (50). a When installing, check through the clear-
ance between the housing and the piston
that spring (46) has not fallen over.

27. Disc, spring, plate

Install disc (48), spring (47), and plate (49).
a There are springs between each plate. 30. No. 2 ring gear
a Number of discs: 6 1) Fit snap ring (42A) to ring gear (42), and
Number of plates: 5 install ring gear.

30-84 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

2) Fit plate (41), and tighten with mounting bolts (40). v) Heat bearing (33) and install it by shrink
a Check that the snap ring installed to the fit.
ring gear is set securely between the a Do not heat bearing (33) higher than

3 Mounting bolt:
plate and the carrier. 120°C.
vi) Install sun gear (32).
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

31. Shaft, No. 1 carrier assembly vii) Heat bearing (31) and install it to the
1) Assemble shaft and No. 1 carrier assembly shaft by shrink fit.
as follows. a Do not heat bearing (31) higher than
i) Assemble needle bearing (38) and 120°C.
spacer (39) in planetary gear (37), fit
thrust washers (36) to both ends and set
to carrier.
ii) Fit ball (124) and push in pin (125).
a Be careful not to forget the ball when
installing to the shaft.

viii) Cool only the outer race of bearing (31).

Then, press fit shaft assembly (29) to
the carrier assembly (30) and install
snap ring (28).

iii) Install snap ring (35).

iv) Heat bearing (34) and install it by shrink fit.
a Do not heat bearing (34) higher than
120°C.

WD900-3 30-85
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

ix) Fit seal ring and install collar (27) to 32. No. 1 ring gear
shaft and carrier assembly (26). Install ring gear (22).

x) Install gear (25). 33. Disc, spring, plate

xi) Install snap ring (24). Install disc (20), spring (19), and plate (21).
a There are springs between each plate.
a Number of discs: 6
Number of plates: 5

2) Cool only the outer race of bearing (33).

Then, using eyebolts [4] (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install shaft and
No. 1 carrier assembly (23).
34. Spring
Install spring (18).
a This spring is different from the other
springs, so be careful to distinguish it when
installing.
a Free height of spring: 108.5 mm

30-86 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

35. Plate 38. Transmission case

Using eyebolts [1] (Dia. = 12 mm, Pitch = 1.75
mm), raise plate (17) and install.
a When installing, check through the clear-
ance between the plate and the piston that
spring (18) has not fallen over.
Fit O-ring, then using eyebolts [4] (Dia. = 12
mm, Pitch = 1.75 mm), raise transmission case
(15) and install.

39. Sleeve
36. Tie bolts 1) Raise transfer and transmission assembly

3 Tie bolt: 373 ± 20 Nm {38 ± 2 kgm}

Install 17 tie bolts (16). and set in upright position.

4 Transfer, transmission assembly:

2,200 kg
2) Fit O-ring and install sleeve (4).

37. Piston operation check

Using tool D1, check stroke of each piston.
a Air pressure: 0.3 – 0.5 MPa {3 – 5 kg/cm2}
Unit:mm 40. Control valve assembly
Piston Standard stroke 1) Fit gasket, then using eyebolts [1] (Dia. = 10
mm, Pitch = 1.5 mm), install control valve
No. 1 7.6
assembly (3).
No. 2 8.6
a Align the hole position of the gasket at
No. 3 7.0 the mating surface.
No. 4 7.2

WD900-3 30-87
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION

2) Tighten 11 mounting bolts.

• Tighten the mounting bolts marked a
uniformly in turn so that there is no defor-

3 Mounting bolt:
mation of the valve.

49 ± 5 Nm {5.0 ± 0.5 kgm}

41. Torque converter assembly

Using eyebolts, install torque converter assem-
bly (1) to transmission (2).

30-88 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE

REMOVAL AND INSTALLATION INSTALLATION

OF TRANSMISSION VALVE
REMOVAL
k Stop the machine on level ground and install the
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
1. Transmission valve
Set transmission valve (3) in mounting position,
and tighten mounting bolts.
a Align the position of the holes of the gasket
at the mating surface exactly.
a Tighten the mounting bolts on opposite side
in turn to prevent the valve from being dis-

3 Mounting bolt:
wheels to prevent the machine from moving. torted.
k Loosen the oil filler cap of the hydraulic tank
gradually to release the pressure in the hydraulic 50 ± 5 Nm {5.0 ± 0.5 kgm}
tank.
k Disconnect the cable from the negative (–) ter-
2. Electric wiring
Connect transmission solenoid valve wire (2) to
minal of the battery. transmission valve.
a When connecting the connector, be careful
1. Cover not to deform the thread case.
Open platform cover (1).
3. Cover
Close platform cover (1).

2. Electric wiring
Disconnect transmission solenoid valve wire (2)
from transmission valve.

3. Transmission valve
Using eyebolts, lift off transmission valve (3).

4 Transmission valve: 96 kg

WD900-3 30-89
(4)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE
DISASSEMBLY, ASSEMBLY OF UPPER VALVE
DISASSEMBLY OF UPPER VALVE
1. Remove cover (1), then remove valve (2), spring
(3), valves (4) and (5), shim (6), and springs (7)
and (8).
a Check the number and thickness of the
shims, and keep in a safe place.
2. Remove plug (9), then remove spring (10),
valves (11) and (12), spring (13), and valve (14).
3. Remove plug, pull out pin (15), then remove
stopper (16).
4. Remove cover (17), then remove valve (18),
spring (19), valves (20) and (21), and shims (22)
and (23).
a Check the number and thickness of the
shims, and keep in a safe place.
30-90
(1)
TRANSMISSION VALVE
5. Remove cover (24), then remove piston (25),
shim (26), and springs (27) and (28).
a Check the number and thickness of the
shims, and keep in a safe place.
6. Using bolts (Dia. = 10 mm, Pitch = 1.5 mm),
remove stopper (29), then remove valve (30).
7. Remove cover (31), then remove boss (32).
8. Remove plug (33), then remove spring (34),
valves (35) and (36), spring (37), and valve (38).
9. Remove cover (39), then remove valve (40) and
spring (41).
10. Remove plug, pull out pin (42), then remove
stopper (43).
WD900-3
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE

ASSEMBLY OF UPPER VALVE

a Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.

1. Set stopper (43) in valve body (44), knock in pin

(42), and install plug.

2. Assemble spring (41) and valve (40) in valve

body (44), then fit O-ring and install cover (39).

3. Set valve (36), spring (37), and valve (38) in

valve (35), assemble valve (35) and spring (34)
in valve body (44), then fit O-ring and install plug

3 Plug: 128 ± 20 Nm {13 ± 2 kgm}

(33).

4. Fit O-ring and assemble boss (32) in valve body

(44), then align with dowel pin and install cover
(31).

5. Assemble valve (30) in valve body (44), then fit

O-ring and install stopper (29).

6. Set shim (26) in piston (25), assemble in valve

body, then fit O-ring and install cover (24).
a Standard shim thickness: 0.5 mm × 4

7. Set shims (22) and (23), and springs (28) and

(27) in valve (21), assemble valves (21) and
(20), spring (19) and valve (18) in valve body
(44), then fit O-ring and install cover (17).
a Standard shim thickness: 0.5 mm × 4 (both
large and small shims)

8. Set stopper (16) in valve body (44), and knock in

pin (15), then install plug.

9. Set valve (12), spring (13), and valve (14) in valve

(11), assemble valve (11) and spring (10) in valve

3 Plug: 128 ± 20 Nm {13 ± 2 kgm}

body (44), then fit O-ring and install plug (9).

10. Set shim (6), and springs (7) and (8) in valve (5),
assemble valves (5) and (4), spring (3), and
valve (2) in valve body (44), then fit O-ring and
install cover (1).
a Standard shim thickness: 0.5 mm × 6

WD900-3 30-91
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE

DISASSEMBLY, ASSEMBLY OF LOWER VALVE

DISASSEMBLY OF LOWER VALVE

1. Remove solenoid valve assembly, then remove

spring (1).

2. Remove cover (2), then using bolts (Dia. = 10

mm, Pitch = 1.5 mm), remove stopper (3).

3. Remove valve (4).

ASSEMBLY OF LOWER VALVE

a Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.

1. Assemble valve (4) in valve body (5).

2. Fit O-ring and assemble stopper (3) in valve

body (5), then install cover (2).

3. Assemble spring (1) in valve body (5), and

install solenoid valve assembly.

30-92 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE

DISASSEMBLY, ASSEMBLY OF RELIEF VALVE

DISASSEMBLY OF RELIEF VALVE

1. Remove cover (1), then remove valve (2), spring

(3), valves (4) and (5), and shim (6).
a Check the number and thickness of the
shims, and keep in a safe place.

2. Remove plug (7), then remove springs (8) and

(9).

ASSEMBLY OF RELIEF VALVE

a Clean all parts, and check for dirt or damage.

Coat the sliding surfaces of all parts with engine
oil before installing.

1. Set springs (8) and (9) in plug (7), and install to

valve body (10).

2. Set shim in valve (5), and assemble valves (5)

and (4), spring (3), and valve (2) in valve body
(10), then install cover (1).
a Standard shim thickness:
0.5 mm × 12 (Main relief valve)
0.5 mm × 2 (Torque converter relief valve)

WD900-3 30-93
(1)
DISASSEMBLY AND ASSEMBLY TRANSFER

DISASSEMBLY AND ASSEMBLY

OF TRANSFER
SPECIAL TOOLS

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-101-5401 Push tool KIT (C) t 1

• 790-101-5521 • Plate 1
6
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
793T-815-1120 Plate t 1 N Q 3A) Serial No.: 50001 – (T/M No. 101138)
7 790-101-5421 Grip t 1 Set in press, then using push tool D6 (out-
01010-51240 Bolt t 1 side diameter: 185 mm), remove bearing (5)
from cage (4).
790-101-5401 Push tool KIT (C) t 1
• 790-101-5491 • Plate 1
8
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
9 790-201-2750 Push tool t 1
793-116-1030 Push tool t 1
11 790-101-5221 Grip t 1
D 01010-51225 Bolt t 1
793-116-1040 Push tool t 1
12 790-101-5221 Grip t 1
01010-51225 Bolt t 1
793-116-1010 Push tool t 1
13 790-101-5221 Grip t 1 3B) Serial No.: (T/M No. 101139) and up
01010-51225 Bolt t 1 Using notch a, remove outer race (5A) from
793-116-1020 Push tool t 1 cage (4).
14 790-101-5221 Grip t 1
01010-51225 Bolt t 1
15 790-201-2430 Push tool t 1
16 790-201-2480 Push tool t 1
790-101-5621 Push tool t 1
17 790-101-5221 Grip t 1
01010-51225 Bolt t 1

DISASSEMBLY
a Clean all parts and repair any burrs.

1. Transmission assembly
Disassemble transmisison assembly.
For details, see DISASSEMBLY AND ASSEM-
BLY OF TRANSMISSION.

2. Cage
1) Remove snap ring (1), then remove mount-
ing bolts (2).
2) Using forcing screws [1] (Dia. = 12 mm, Pitch
= 1.75 mm), remove cage assembly (3).

30-94 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

3. No. 1 gear 5. Cage assembly

Using eyebolts [3] (Dia. = 12 mm, Pitch = 1.75 1) Remove mounting bolts (10), then screw in
mm), lift off gear (6). forcing screws [1] (Dia. = 12 mm, Pitch =

4 Gear: 40 kg
1.75 mm) and remove fitting portion of cage.

2) Using eyebolt [3] (Dia. = 12 mm, Pitch =

4. Snap ring, bearing 1.75 mm), lift off cage assembly (11).
Serial No.: 50001 – (T/M No. 101138) a The cage is thick, so raise it vertically.

4 Cage assembly: 40 kg
1) Remove snap ring (7).
2) Remove spacer (8).
3) Using push tool [4] (outside diameter: 162
mm), remove bearing (9) form cage. 3) Remove bearing (13) from cage (12).

Serial No.: (T/M No. 101139) and up

1) Remove spacer (8).
2) Remove the bolts (11 pieces). Then, using
eyebolts (2 pieces) (Dia. = 12 mm, Pitch =
1.75 mm), remove the cage assembly.
3) Using push tool [4] (outside diameter: 162
mm), remove bearing (9) form cage.

6. No. 3 gear
1) Using eyebolts [3] (Dia. = 12 mm, Pitch =
1.75 mm), lift off gear assembly (14).

4 Gear assembly: 50 kg

WD900-3 30-95
(5)
DISASSEMBLY AND ASSEMBLY
2) Remove bearing inner race (16) from gear
(15).
3) Remove bearing inner race (17) from gear
(15).
7. Coupling, cage assembly
1) Remove mounting bolt (18), then remove
holder (19).
a Width across flats of mounting bolt: 55
mm
2) Remove coupling cage mounting bolts (64).
a Make match marks on the spline of the
shaft and the coupling.
30-96
(5)
TRANSFER
3) Screw in forcing screws [1] (Dia. = 12 mm,
Pitch = 1.75 mm) and remove fitting portion
of cage.
a Check the number and thickness of
shims (20), and keep in a safe place.
4) Using eyebolts [3] (Dia. = 12 mm, Pitch =
1.75 mm), lift off coupling and cage assem-
bly (21).
4 Coupling, cage assembly: 55 kg
5) Disassemble coupling and cage assembly
as follows.
i) Set in press, then using push tool D8
(outside diameter: 135 mm), remove
coupling (23) from cage (22).
ii) Remove oil seal (24) from cage (22).
iii) Remove bearing (25) from cage (22).
WD900-3
DISASSEMBLY AND ASSEMBLY TRANSFER

6) Remove collar (26). 9. Cage assembly

1) Turn over transfer.

4 Transfer: 770 kg

2) Remove mounting bolts (30).

3) Screw in forcing screws [1] (Dia. = 12 mm,
Pitch = 1.75 mm) and remove fitting portion
of cage.

8. Strainer assembly
1) Remove cover (27).
2) Remove spring (28).

4) Using eyebolts [3] (Dia. = 12 mm, Pitch =

1.75 mm), lift off cage assembly (31).

4 Cage assembly: 30 kg

3) Remove strainer assembly (29).

5) Remove bearing (33) from cage (32).

WD900-3 30-97
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

10. No. 2 gear assembly 12. Cage assembly

1) Using eyebolts (Dia. = 12 mm, Pitch = 1.75 1) Remove mounting bolts (39).
mm), lift off gear assembly (34). 2) Using forcing screws [1] (Dia. = 12 mm,

4 Gear assembly: 50 kg
Pitch = 1.75 mm), remove cage assembly
(40).

2) Remove bearing inner races (36) and (37) 3) Remove bearing (42) from cage (41).
from gear (35). 4) Remove cover (43) from cage (41).

11. Bearing 13. Coupling assembly

Remove bearing (38). 1) Remove mounting bolts (44), then remove
holder (45).
a Width across flats of mounting bolt: 55
mm
2) Lift off coupling assembly (46).
a Support the block under the shaft.

30-98 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

3) Remove inner race (48) from coupling (47). 15. No. 4 gear, shaft assembly
1) Using holder (45) and mounting bolts (44),
lift off No. 4 gear and shaft assembly (55).

4 No. 4 gear, shaft assembly: 90 kg

14. Cage assembly

1) Remove mounting bolts (49), then screw in
forcing screws (Dia. = 12 mm, Pitch = 1.75
mm) and remove fitting portion of cage.
2) Using eyebolts [3] (Dia. = 12 mm, Pitch = 2) Lift off gear (57) from shaft (56).

4 Gear: 60 kg
1.75 mm), lift off cage assembly (50).

4 Cage assembly: 45 kg
3) Remove spacer (58) from shaft (56).

3) Remove oil seal (52) from cage (51).

4) Remove snap ring (53) from cage (51), then
remove bearing (54).

WD900-3 30-99
(5)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
1. No. 4 gear, shaft assembly
1) Install spacer (58) to shaft (56).
2) Raise gear (57) and install to shaft (56).
3) Using holder (45) and mounting bolts (44),
raise No. 4 gear, shaft assembly (55) and
install.
a Support the block under the shaft.
2. Rear side cage
1) Set in press, then using push tool D7 (out-
side diameter: 249.5 mm), press fit bearing
(54) in cage (51), and install snap ring (53).
30-100
(5)
TRANSFER
2) Horizontally set oil seal (52-1) to cage (51),
and press fit it with push tool D11 gradually
and horizontally while preventing it from
2 Oil seal fitting surface:
leaning.
Gasket sealant (LG-5)
a Apply the gasket sealant thinly over the
inside surface of the cage (51) and wipe
off the projected part.
a If the oil seal leans while it is being press
fitted, it may be deformed. Press fit it
straight while checking not to lean.
a Dimension "a" is 16.7 to 16.8 mm.
3) Horizontally set dust seal (52-2) to cage
(51), and press fit it with push tool D12 grad-
ually and horizontally while preventing it
from leaning.
a When installing dust seal (52-2), direct
its lip out.
a If the dust seal leans while it is being
press fitted, it may be deformed. Press fit
it straight while checking not to lean.
a Dimension "b" is 6.3 to 6.4 mm.
WD900-3
DISASSEMBLY AND ASSEMBLY TRANSFER

4) Apply or fill grease to/into the oil seal and 3. Rear side coupling
dust seal lip as shown in the following figure. 1) Set in press, then using push tool D8 (inside
Portion "a": Apply grease (G2-S or G2-LI) to diameter: 140 mm), press fit inner race (48)
the lip ends (4 places). in coupling (47).
Portion "b": Fill grease (G2-S or G2-LI) into
the spaces "between the main lip
and dust lip of oil seal", "between
the dust seal and oil seal", and
"between the double lips of dust
seal" up to 40 to 60%.
Excessively applied grease can
be mistaken for oozing oil. Take
care.
Wipe off the grease forced in or
out.
Portion “c”: Grease may be forced out into
the space between oil seal and
dust seal.
2) Raise coupling assembly (46) and install.
3) Fit O-ring and holder (45), and tighten with

3 Mounting bolt:
mounting bolts (44).

2,210 ± 150 Nm {225 ± 15 kgm}

5) Fit O-ring, then using eyebolts [3] (Dia. = 12

mm, Pitch = 1.75 mm), raise cage assembly
(50) and install.
6) Tighten with mounting bolts (49).

4. Cage assembly
1) Fit O-ring and install cover (43) to cage (41).

WD900-3 30-101
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

2) Using push tool D6 (outside diameter: 169.5 6. No. 2 gear assembly

mm), press fit bearing (42) in cage (41).
1) Set in press, then using push tool D9 (inside
diameter: 81 mm), press fit inner race (37) in
gear (35).
2) Set in press, then using push tool D9 (inside
diameter: 81 mm), press fit inner race (36) in

2 Inner race: Adhesive (LT-2)

gear (35).

a After press fitting, wipe off the projected

adhesive.

3) Fit cage assembly (40) and tighten with

mounting bolts (39).

a After press fitting, when the inner race is

at the room temperature, check that the
clearance between the gear and inner
race is 0.04 mm or less at 2 places.

5. Bearing
Using push tool D6 (outside diameter: 169.5
mm), press fit bearing (38).

3) Using eyebolts (Dia. = 12 mm, Pitch = 1.75

mm), raise gear assembly (34) and install.

30-102 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

7. Cage assembly 8. Snap ring, bearing

1) Set in press, then using push tool D6 (out- Serial No.: 50001 – (T/M No. 101138)
side diameter: 169.5 mm), press fit bearing 1) Install snap ring (7).
(33) in cage (32).

2) Using push tool D6 (outside diameter: 169.5

2) Fit O-ring, then using eyebolts [3] (Dia. = 12 mm), press fit bearing (9).
mm, Pitch = 1.75 mm), raise cage assembly
(31) and install.

9. Strainer assembly
1) Turn over transfer.

4 Transfer: 700 kg
3) Tighten with mounting bolts (30).

2) Install strainer assembly (29).

WD900-3 30-103
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

3) Install spring (28).

a Insert the spring securely in the groove
at the top of the strainer.
4) Fit O-ring and install cover (27).

ii) Horizontally set dust seal (24-2) to cage

(22), and press fit it with push tool D14
gradually and horizontally while pre-
venting it from leaning.
10. Front side coupling, cage assembly a When installing the dust seal, direct
1) Install collar (26). its lip out.
a If the dust seal leans while it is being
press fitted, it may be deformed.
Press fit it straight while checking
not to lean.
a Dimension "b" is 1.8 to 1.9 mm.

2) Assemble coupling and cage assembly as

follows.
i) Horizontally set oil seal (24-1) to cage
(22), and press fit it with push tool D13
gradually and horizontally while pre-

2 Oil seal press fitting surface:

venting it from leaning. iii) Set in press, then using push tool D15
(outside diameter: 224 mm), press fit
Liquid gasket (LG-5) (Thinly bearing outer race (25-a) in cage (22).
apply to inside of cage (22),
and wipe off excess.)
a If the oil seal leans while it is being
press fitted, it may be deformed.
Press fit it straight while checking
not to lean.
a Dimension "a" is 12.2 to 12.3 mm.

30-104 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

iv) Install bearing spacer (25-b).

v) Install bearing (25-c).

viii) Set in press, press fit coupling (23) in

cage (22).

vi) Set the cage on the press, and press fit

bearing outer race (25-d) by using push
tool D16 (259 mm in outside diameter).

11. Adjusting coupling, cage assembly

vii) Apply or fill grease to/into the oil seal
and dust seal lip as shown in the follow-
ing figure.
Portion "a": Apply grease (G2-S or G2-
LI) to the lip ends (4 places).
Portion "b": Fill grease (G2-S or G2-LI)
1) Fit O-ring, then using eyebolts [3] (Dia. = 12
mm, pitch = 1.75 mm), raise coupling and
cage assembly (21) and install.
a Install the front and rear couplings of the
output shaft to the splines so that the
phase difference will be 10° or less when
the output shaft is assembled.
2) Fit holder (19), and tighten with mounting
bolt (18), then measure clearance between

3 Mounting bolt:
into the spaces "between cage and case with feeler gauge [13].
the main lip and dust lip of
oil seal", "between the dust 2,210 ± 150 Nm {225 ± 15 kgm}
seal and oil seal", and
"between the double lips of
dust seal" up to 40 to 60%.
Excessively applied grease
can be mistaken for oozing
oil. Take care.
Wipe off the grease forced
in or out.
Portion “c”: Grease may be forced out
into the space between oil
seal and dust seal.

WD900-3 30-105
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

3) Remove mounting bolt (18) and holder (19), 2) Set in press, then using push tool D9 (inside
then using forcing screw [1] (Dia. = 12 mm, diameter: 81 mm), press fit inner race (16)
Pitch = 1.75 mm), insert shim (20) with thick- to gear (15).
ness of measured clearance + (0 ± 0.05) mm.

3) After press fitting, when the inner race is at

4) Tighten coupling cage mounting bolt (64). the room temperature, check that the clear-
5) Fit holder (19) and tighten with mounting ance between the gear and inner race is

3 Mounting bolt: 2 Inner race: Adhesive (LT-2)

bolt (18). 0.04 mm or less at 2 places.

2,210 ± 150 Nm {225 ± 15 kgm} After press fitting, wipe off the pro-
jected adhesive.

12. No. 3 gear

1) Set in press, then using push tool D9 (inside 4) Using eyebolts [3] (Dia. = 12 mm, Pitch = 1.75
diameter: 81 mm), press fit inner race (17) in mm), raise gear assembly (14) and install.
gear (15).

30-106 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

13. Cage assembly 15. No. 1 gear

1) Set in press, then using push tool D6 (out- 1) Install spacer (8).
side diameter: 169.5 mm), press fit bearing 2) Using eyebolts [3] (Dia. = 12 mm, Pitch =
(13) in cage (12). 1.75 mm), raise gear (6) and install.

2) Fit O-ring, then using eyebolts [3] (Dia. = 12
mm, Pitch = 1.75 mm), raise cage assembly
(11) and install.
3) Tighten with mounting bolts (10).
16. Cage assembly
Serial No.: 50001 – (T/M No. 101138)
1A) Set in press, then using push tool D17 (out-
side diameter: 214.5 mm), press fit bearing
(5) in cage (4).

14. Bearing Serial No.: (T/M No. 101139) and up

1) Turn over the transfer. 1B) Set in press, then using push tool D17 (out-

4 Transfer: 700 kg
side diameter: 214.5 mm), press fit outer
race (5A) in cage (4).
2) Install bearing (9) to the cage by expansion
fit.
3) After installing the bearing, tighten the bolts
(11 pieces).

WD900-3 30-106-1
(5)
DISASSEMBLY AND ASSEMBLY TRANSFER

2) Install snap ring (1).

3) Fit cage assembly (3) and tighten with
mounting bolts (2).

17. Transmission assembly

Assemble transmission assembly.
For details, see ASSEMBLY OF TRANSMIS-
SION.

18. Adjusting speedometer sensor

1) Screw in sensor (68) until it contacts outside
surface of gear (69).
a Before installing the sensor, check that
the gear is at the outside surface com-
pared with the mounting surface.
2) After sensor (68) contacts gear (69), turn it
back 3/4 – 1 turn and secure with locknut (70).
a Be careful that the outlet direction of the
sensor harness is not the opposite direc-

2 Sensor thread: Adhesive (LT-2)

tion to the sensor connector clamp.

3 Sensor locknut:
39 ± 10 Nm {4 ± 1 kgm}

30-106-2 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY PTO

DISASSEMBLY AND ASSEMBLY 2. Snap ring

Remove snap ring (3).
OF PTO
DISASSEMBLY
Preparatory work
• Remove PTO. For details, see DISASSEMBLY
AND ASSEMBLY OF TORQUE CONVERTER.

a The procedure for disassembly and assembly of

the gear and shaft assemblies is the same, but
for gear and shaft assemblies I, II, III and IV, the
shaft and bearing are different.

3. Bearing
1) Turn over PTO case assembly (4).
2) Remove bearing (5).

1. Retainer
1) Using forcing screws [1] (Dia. = 10 mm,
Pitch = 1.25 mm), remove retainer (1).
2) Remove oil seal (2).

4. Shaft assembly
1) Remove snap ring (6).
2) Using push tool [1] (outside diameter: 60
mm), tap shaft assembly and remove.

WD900-3 30-107
(1)
DISASSEMBLY AND ASSEMBLY PTO

3) Remove snap ring (7). 7. Snap ring, bearing

4) Set shaft assembly in position, then using 1) Turn over case.
push tool [2], pull out bearing (8) from shaft 2) Remove snap ring (13).
(9). 3) Turn over case again, and remove bearing
a Push tool [2] (14).
Unit: mm
Gear, shaft Push tool outside
assembly No. diameter
I, II, III 70
IV 65

5. Inner race
Remove inner race (10).

6. Spacer, gear
1) Lift up gear (11) and remove.
2) Remove spacer (12).
a Gear (11) must be installed facing in the
correct direction, so remember the direc-
tion.

30-108 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY PTO

ASSEMBLY 2. Spacer, gear

1) Install spacer (12).
Preparatory work 2) Set gear (11) in position.
• Clean all parts, and check for dirt or damage. a Be careful to install gear (11) facing in
Coat the sliding surfaces of all parts with engine the correct direction.
oil before installing.

a The procedure for disassembly and assembly of

the gear and shaft assemblies is the same, but
for gear and shaft assemblies I, II, III and IV, the
shaft and bearing are different.

3. Shaft assembly
1) Using push tool [4], press fit bearing (8) in
shaft.
a Push tool [4]
Unit: mm
Gear, shaft Push tool outside
1. Bearing, snap ring assembly No. diameter
1) Using push tool [6] (outside diameter = 115 I, II, III 80
mm), press fit bearing (14).
IV 75

2) Install snap ring (13).

WD900-3 30-109
(1)
DISASSEMBLY AND ASSEMBLY PTO

2) Install snap ring (7). 6. Retainer

2 Oil seal press-fitting surface:

3) Using push tool [5], press fit shaft assembly 1) Press fit oil seal (2) to retainer.
(9).
a Push tool [5] Gasket sealant (LG-4)
Unit: mm 2) Fit O-ring, then using guide bolts [7] (Dia. =
Gear, shaft Push tool outside 10 mm, Pitch = 1.25 mm), install retainer

2 Lip of oil seal: Grease (G2-LI)

assembly No. diameter (1).
I, II, III 155
IV 120

7. Inner race
1) Turn over PTO case assembly (4).
2) Set bottom of shaft on stand [8].
4. Snap ring a Set the PTO case assembly so that
Install snap ring (3). there is no play.

5. Bearing
Using push tool [6] (outside diameter: 145 mm),
press fit bearing (5) in case.

3) Using push tool [9] (inside diameter: 70

mm), press fit inner race (15).

30-110 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY PTO

4) Install snap ring (6).

a Check that the gear rotates smoothly.

WD900-3 30-111
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

REMOVAL AND INSTALLATION 2) Lift off front drive shaft (2).

a Move the drive shaft towards the front
[*2]

OF CENTER SUPPORT differential, move the center support end

to the side and remove the pilot portion
SPECIAL TOOLS at the differential end.

4 Front drive shaft: 173 kg

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-101-7200 Centering tool t 1

1 790-101-7230 • Shaft 1
D 10
2 790-101-7240 • Guide 1
3 01010-31230 • Bolt 1

REMOVAL
k Stop the machine on level ground and turn the
steering wheel fully to the left lock. Lower the
work equipment to the ground and stop the en-
gine. Then apply the parking brake and put
blocks under the wheels.
1. Drive shaft
1) Lift off center drive shaft (1).
4 Center drive shaft: 186 kg
2. Center support
Sling center support (3) temporarily, remove
mounting bolts, then lift off. [*3]
[*1] a If there are shims inserted between the cent-
er support and frame, check the number of
shims and use as a guide when assembling.
a When lifting off, be careful not to damage the
steering cylinder rod.

4 Center support: 169 kg

30-112 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

INSTALLATION 3) Adjust the shims on the center support

mounting face.
• Carry out installation in the reverse order to 4) Position the center support and tighten the

3 Center support mounting bolt:

removal. mounting bolts.

3 Center drive shaft:

[1] 820 – 1,030 Nm {84 – 105 kgm}

342 – 427 Nm {35.0 – 43.5 kgm}

3 Front drive shaft:

[2]

342 – 427 Nm {35.0 – 43.5 kgm}

3 Center support mounting bolt:

[3]

820 – 1,030 Nm {84 – 105 kgm}

a Check the parallelism and adjust the shims.
Parallelism: 0.15 mm max.
1) Set the center support to the frame, then
tighten the mounting bolts temporarily.

2) Install tools D10-1, D10-2 and D10-3 to the

upper and lower center hinge pins, then
install dial gauge [1] to the coupling on the
center support side to measure the parallel-
ism of the coupling and shaft.

WD900-3 30-113
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

DISASSEMBLY AND ASSEMBLY 2. Coupling

Remove center bolt (3), then remove holder (4),
OF CENTER SUPPORT O-ring and coupling (5).
SPECIAL TOOLS a Check the number and thickness of the
shims between the holder and shaft.

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-101-7180 Push tool t 1

1 790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-101-7140 Push tool t 1
2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
E
792-715-1300 Push tool t 1
3 790-101-5421 Grip t 1
01010-81235 Bolt t 1 3. Retainer
790-101-5621 Plate t 1 Remove mounting bolts, then remove retainer
(6).
4 790-101-5421 Grip t 1
a Remove the O-ring at the mating face of re-
01010-51240 Bolt t 1 tainer (6) and case (7).

DISASSEMBLY
1. Retainer
Remove mounting bolts (2) of retainer (1).
a Rotate the coupling and remove all mounting
bolts.
a Turn over the center support.

4. Shaft
1) Set shaft and case assembly (8) on press
stand.
2) Remove shaft (9) with press.
a Be extremely careful as the shaft will drop
out suddenly.

30-114 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

3) Remove bearing cone (10) and retainer (1) ASSEMBLY

from shaft.
a Remove O-ring (11) from retainer. 1. Bearing cup
Install bearing cup (13) to the case.

2. Oil seal
Install oil seals (12) to retainers (1) and (6) with

2 Outside of oil seal: Grease (G2-LI)

tool E1.

5. Oil seal
Remove oil seal (12) from retainers (1) and (6).

6. Case
Remove bearing cup (13) from case.

3. Bearing cone
1) Install retainer (1) to the shaft, then press fit
bearing cone (10) with tools E2.
a After installing the bearing, check that

2 Lip of seal: Grease (G2-LI)

there is not a clearance at the shaft end.

2 Inner circumfernce of bearing:

Grease (G2-LI)
2) Install O-ring (11) to the retainer.

WD900-3 30-115
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

4. Case 2) Tighten retainer (1) with mounting bolts (2).

3 Mounting bolt:
1) Using tools E3 and E4, press fit outer race a Be careful not to get the O-ring caught.
of bearings (10) and (14) to case (7).
2) Install case (7) to the shaft. 110.8 ± 11.8 Nm {11.3 ± 1.2 kgm}
3) Press fit bearing cone (14) with tool E2, then
install O-ring (15).
a Fill the inner circumference of the case
with grease.
a When press fitting bearing (14), be care-
ful not to apply excessive force.

6. Coupling
1) Select shim as follows.
• Rotate case (7) and tighten bolt (3) until
starting torque is (7.9 – 11.8 Nm {0.8 –
1.2 kgm}).
• Measure clearance a between holder (4)
and shaft (9) at holes in holder at 3 plac-
es, take the average clearance, and se-
lect shims of a thickness equal to the
average clearance + 0.1 to 0.15.
a To measure the clearance, first meas-
ure the thickness of the holder.

5. Retainer
1) Secure retainer (6) to case (7).

3 Mounting bolt:
a Be careful not to get the O-ring caught.

110.8 ± 11.8 Nm {11.3 ± 1.2 kgm}

30-116 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT

2) Assemble coupling (5), install O-ring (16),

shim (17) selected above, and holder (9),
then tighten bolt (3).
a Rotate the case and tighten the bolts to

3 Mounting bolt:
the specified torque.

2,750 ± 290 Nm {280 ± 30 kgm}

(width across flats: 55 mm)

a Align the spline of the shaft and coupling

so that the match marks are aligned.

7. End play
Check that end play is within specified range.
a End play: 0.05 – 0.15 mm
a Carry out greasing after installing the center
support to the chassis.

WD900-3 30-117
(1)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

DISASSEMBLY AND ASSEMBLY 2) Remove bearing (7), seal (8) and Delrin
washer (9) from bearing cap.
OF DRIVE SHAFT
DISASSEMBLY
1. Splined yoke
Loosen retainer (1) and remove splined yoke
(2).

4. Sleeve yoke
1) Remove mounting bolts (11) from sleeve
yoke (10), then remove bearing assembly
(4).
a Make match marks on the yoke and
bearing.
2. Bearing
Remove mounting bolts (3), then remove bear-
ing assembly (4).
a Make match marks on the yoke and bearing.

2) Remove bearing cap (5) from bearing

assembly.

3. Bearing cap
1) Remove bearing cap (5) from bearing
assembly.
a Remove strap (6) of cap.

30-118 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

3) Remove bearing (7), seal (8), and Delrin ASSEMBLY

washer (9) from bearing cap.
1. Bearing cap
1) Install bearing (7), and seal (8) to bearing

2 Bearing, seal: Grease (G2-LI)

cap (5).

2) Assemble Delrin washer (9) and bearing

2 Bearing cap: Grease (G2-LI)

cap (5) to bearing assembly (4).

2. Bearing
Assemble bearing assembly (4) to sleeve yoke
(10).
a Align the match marks correctly.
a Wipe the mounting face of the bearing cap

3 Mounting bolt:
with a clean cloth.

385 ± 41 Nm {39.3 ± 4.2 kgm}

WD900-3 30-119
(1)
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT

3. Splined yoke 4) Align match marks, insert splined yoke in

1) Assemble bearing (7) and seal (8) in bear- sleeve yoke (10), and secure with retainer

2 Bearing seal: Grease (G2-LI)

ing cap (5). (1).
a Check that the yokes are facing in the
same direction.
a If the spline is worn, replace the whole
drive shaft assembly.

2) Assemble Delrin washer (9) and bearing

cap (5) to bearing assembly (4).
a Do not weld the strap. The heat when

3 Bearing cap mounting bolt (11):

welding will damage the bearing. a Upper drive shaft

214 ± 7 Nm {21.8 ± 0.7 kgm}

3) Assemble bearing assembly (4) to splined

yoke (2).
a Align the match marks carefully.
a Wipe the mounting face of the bearing

3 Mounting bolt:
cap with a clean cloth.

385 ± 41 Nm {39.3 ± 4.2 kgm}

30-120 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FRONT AXLE

REMOVAL AND INSTALLATION 1. Tires, wheels

Sling left and right tires and wheels (3) tempo-
OF FRONT AXLE rarily, remove mounting nuts, then lift off.

REMOVAL 4 Tire, wheel: 3,505 kg

k Stop the machine on level ground and install the
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.

• Before removing the front axle, remove the work

equipment.
• Block the rear tires and apply the parking brake
securely.
• Insert blocks [1] between the top face (1) of the
rear axle housing and frame (2). (both left and
right)

2. Drive shaft
Lift off front drive shaft (4). [*1]
a Make match marks on the drive shaft cou-
pling to act as a guide when assembling.
a Move the drive shaft towards the front differ-
ential, then move the center support end to
the side and remove the pilot portion at the
differential end.

4 Front drive shaft: 173 kg

• Jack up the machine and set blocks [2] under

the front frame on the left and right.

WD900-3 30-121
(1)
DISASSEMBLY AND ASSEMBLY FRONT AXLE

3. Brake hoses 5. Front axle

Disconnect brake hoses (5) and (6) from con- 1) Sling axle (8) temporarily, remove mounting
nection of tube. bolts, then use hoist and jack to maintain
a Fit covers after disconnecting the piping. balance, and lower on top of roller. [*3]

4 Front axle: 8,190 kg

a Fix chains around the axle as shown in

the figure.
2) Pull out front axle (8) from chassis.

4. Parking brake hose

Disconnect hose (7) from parking brake cylinder.
[*2]
a Check that the parking brake is actuated.
a Disconnect the air hoses from the left and
right parking brake cylinder.
a Reference drawing of rollers to move
axle sideway.

INSTALLATION

• Carry out installation in the reverse order to

removal.

3 Front drive shaft:

[*1]

343 – 427 Nm {35.0 – 43.5 kgm}

[*2]
a Bleed air from the brake circuit. For details,
see TESTING AND ADJUSTING, Bleeding
air from wheel brake circuit.

3 Front axle mounting bolt:

[*3]

3,170 – 3,870 Nm {323 – 395 kgm}

30-122 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY REAR AXLE

REMOVAL AND INSTALLATION • Disconnect cable (8) for left and right
ground connections.
OF REAR AXLE
REMOVAL
k Stop the machine on level ground and install the
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.

• Disconnect the cable from the negative (–) ter-

minal of the battery.
• Put blocks under the front wheels to prevent the
machine from moving, and apply the parking
brake securely.
3) Remove under cover (9). [*1]
1. Counterweight 4) Remove left and right mounting bolts (10),
1) Remove left and right steps (1), and covers then lift counterweight (11) off. [*2]

4 Counterweight (11): 2,500 kg

(2) and handrail (3).

2) Electric wiring, battery cables

• Remove battery cable (4) from left and a Pull out the disconnected battery cables
right battery relays. and wirings (12) and (13) to the left and
• Disconnect wiring (5) for left and right right from holes.
lights at connector.
• Disconnect wiring (6) for left and right re-
lays at connector.
• Disconnect cable (7).

WD900-3 30-123
(1)
DISASSEMBLY AND ASSEMBLY
2. Fuel tank
1) Loosen drain valve and drain fuel.
6 Fuel : 1,200 l
2) Remove engine oil drain valve (14), cooling
water drain valve (15) of torque converter
cooler, and cooling water drain valve (16)
from fuel tank.
3) Disconnect fuel hoses (17) and (18).
a Remove the clamps of the fuel hoses,
left and right engine blowby hoses and
engine block water drain hoses.
3. Frame support
4) Disconnect wiring (19) for fuel unit from con-
nector.
30-124
(1)
REAR AXLE
5) Sling fuel tank (20) temporarily, remove
mounting bolts, then lift off. [*3]
a Fix the lifting tool to the lifting hooks, be
careful to maintain the balance, and lift
off slowly.
a Check that all the fuel has been drained.
a Lay a pallet under the tank, set blocks in
position in line with the fuel tank, then
pull out the fuel tank from the chassis.
a For details, see REMOVAL AND IN-
STALLATION OF FUEL TANK.
4 Fuel tank : 786 kg
Jack up rear frame and set stand under frame.
a Insert blocks [1] between the top face of the
rear axle housing and frame (both left and
right).
a For safety, put steel sheets under the stand.
WD900-3
DISASSEMBLY AND ASSEMBLY REAR AXLE

4. Tire, wheel 7. Rear axle, support

Sling left and right rear tire and wheel (21) tem- 1) Remove mounting bolts, then remove thrust
porarily, remove mounting nuts, then lift off. [*4] cover (26). [*7]

4 Tire, wheel : 3,565 kg 4 Thrust cover : 119 kg

a Remove grease tube.

5. Drive shaft
Sling rear drive shaft (22) temporarily, remove
mounting bolts, then lift off. [*5] a Thrust cover (26) is heavy, so handle it
a Use a lifting tool of ample length for the drive as follows and use fixed signals when re-
shaft, and lift up from both ends of the trans- moving.
mission. • Leave one bolt in position at the bot-

4 Rear drive shaft : 186 kg

tom, and use this bolt as a pivot to
rotate the cover carefully.
• Hold the cover with a pallet, remove
the 1 remaining bolt, then remove
the cover carefully.

6. Brake piping
1) Remove cover (23). [*6]
2) Disconnect tube (24) from slack adjuster.
3) Remove support lubrication tube (25).

WD900-3 30-125
(1)
DISASSEMBLY AND ASSEMBLY REAR AXLE

2) Remove thrust washer (27), thrust plate (28) 5) Move rear axle approx. 250 mm to front,
and thrust washer (29). remove from rear support, then using hoist

4 Thrust plate : 76 kg
and jack to maintain balance, lower rear
axle.

4 Rear axle and support : 7,986 kg

a Lay steel sheets under the part being

lowered, and lower one end of the axle
on to the roller.
6) Pull out rear axle and support (31) from the
body.

3) Sling rear axle temporarily.

a Fit a chain around the axle and be care-
ful to maintain the balance.

8. Front support
1) Remove front support (32) from rear axle.
a Be careful not to damage the O-ring (or
seal).

4 Front support : 286 kg

4) Secure front support (30) to rear axle with

wire, and remove front support mounting
bolts. [*8]

30-126 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
2) Remove retainer (33), O-ring (or seal) (34),
and bushing (35) from front support (32).
a For machines where the bushing and
support are stuck together, remove
bushing (35) in the procedure for Step
10.
9. Rear support
Remove O-ring (or seal) (36) and bushing (37)
from rear support.
a For machines where the bushing and sup-
port are stuck together, remove bushing (37)
in the procedure for Step 10.
10. Procedure for removing bushing
1) Insert tip of a knife between bushing and
support, separate bushing and support
around whole circumference, then remove
bushing.
a If the adhesive is hard, and it is difficult
to separate the bushing and support,
heat the bushing to 100°C with boiling
water or with a small torch, then try again
to separate the bushing and support.
2) Coat adhesion portion (where it is held to
the support) with adhesive removing liquid,
wait for 2 – 3 minutes, then remove adhe-
2 Portion with hardened adhesive :
sive.
Adhesive removing liquid
(part No. 427-46-11890)
WD900-3
REAR AXLE
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Undercover mounting bolt:
[*1]
490 – 608 Nm {50 – 62 kgm}
3 Counterweight mounting bolt:
[*2]
1,510 – 1,910 Nm {155 – 195 kgm}
3 Fuel tank mounting bolt:
[*3]
1,510 – 1,910 Nm {155 – 195 kgm}
3 Hub nut: 736 – 912 Nm {75 – 93 kgm}
[*4]
3 Rear drive shaft:
[*5]
343 – 427 Nm {35.0 – 43.5 kgm}
[*6]
a Bleed air from the rear brake. For details,
see TESTING AND ADJUSTING, Bleeding
air from wheel brake circuit.
2 Thrust washer: Lubricant (G2-LI)
[*7]
3 Thrust washer mounting bolt:
3 Thrust cover:
824 – 1,030 Nm {84 – 105 kgm}
824 – 1,030 Nm {84 – 105 kgm}
2 Bushing: Lubricant (G2-LI)
[*8]
3 Retainer mounting bolt:
3 Front support mounting bolt:
157 – 196 Nm {16 – 20 kgm}
3,170 – 3,870 Nm {323 – 395 kgm}
30-127
(4)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

REMOVAL AND INSTALLATION 4. Remove snap ring, then remove sun gear (2).
a When removing the sun gear, pull out the
OF DIFFERENTIAL torque shaft slightly to remove.

REMOVAL
1. Remove axle assembly and set on block [1]. For
details, see REMOVAL AND INSTALLATION OF
AXLE ASSEMBLY.

4 Front axle assembly: 8,190 kg

4 Rear axle assembly: 7,700 kg

5. Raise torque shaft (3), and pull out from spline

of differential assembly.
a Remove the torque shaft on the opposite
side in the same way.

2. Remove drain plug of final case and drain plug

at bottom of differential case, and drain oil from
final drive case.
a There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful
when draining.

6 Final drive case: Approx. 360 l

3. Remove final drive case cover (1).
6. When removing front differential assembly,
remove parking brake assembly as follows.
1) Loosen the adjustment bolt, and remove the
plate.
2) Pull out pin, and remove cylinder assembly
(4).
3) Remove brake pad assembly (5).
4) Remove cover (6) and disc (7), then remove
bracket. [*1]

30-128 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
7. Remove holder, then remove coupling (8). [*2]
a Check the number and thickness of the
shims assembled inside the holder, and
keep in a safe place.
4 Coupling: 40 kg
8. Remove mounting bolts, pull out differential
assembly (9) slightly, then using lifting hooks [2]
adjust balance with bar and remove differential
assembly.
4 Differential assembly: 1,250 kg
k When pulling out the differential assembly,
support the bottom of the differential as-
sembly with a garage jack.
WD900-3
DIFFERENTIAL
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}
2 Holder mounting bolt: Adhesive (LT-2)
[*2]
3 Holder mounting bolt:
2,750 ± 290 Nm {280 ± 30 kgm}
[*3]
Adjustment of shim of shaft
a Adjust the shim of the shaft when the differ-
ential or axle housing is replaced.
1) Install shaft and tighten the mounting bolts
e v e n l y, t h e n m e a s u r e t h e c l e a r a n c e
between the axle housing and shaft.
3 Mounting bolt:
[*3] a Do not assemble shims.
[*4] 3.9 ± 1.0 Nm {0.4 ± 0.1 kgm}
2) Prepare shim having thickness of measured
clearance a + 0.1 ± 0.05 mm, then insert it.
a Thickness of shim: Clearance a + (0.1 ±
3 Mounting bolt:
0.05 mm)
280 ± 29 Nm {28.5 ± 3.0 kgm}
2 Mounting bolt: Adhesive (LT-2)
[*4]
3 Mounting bolt:
932 ± 98 Nm {95 ± 10 kgm}
30-129
(1)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

DISASSEMBLY AND ASSEMBLY 1. Remove case (2).

OF DIFFERENTIAL 4 Case: 45 kg
SPECIAL TOOLS
2. Remove oil seal (3) from case.

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

790-501-2000 Engine repair stand t 1

1
790-901-5110 Bracket t 1
790-101-2300 Push tool q 1
• 790-101-2310 • Block 1
• 790-101-2350 • Leg 2
• 790-101-2360 • Plate 4
2
• 790-101-2430 • Adapter 2
• 02215-11622 • Nut 2
790-101-2102 Puller (294 kN {30 ton}) q 1 3. Fit the coupling (4) temporarily, and remove pin-
790-101-1102 Hydraulic pump q 1 ion and cage assembly (5).

4 Coupling, pinion, cage assembly: 180 kg

793T-822-1130 Push tool t 1 N Q
H 3
793T-822-1140 Push tool t 1 N Q
4 793T-822-1150 Push tool t 1 N Q a Check the number and thickness of the
793T-822-1110 Plate t 1 N Q shims, and keep in a safe place.
793T-822-1120 Spacer t 1 N Q
5
• 790-101-5421 • Grip t 1
• 01010-51240 • Bolt t 1
792-340-1120 Nut, wrench t 1
6
796-550-1310 Wrench t 1
792-525-3000 Micrometer t 1
7 790-425-1670 Adapter t 1
790-425-1660 Wrench t 1

DISASSEMBLY
• Preparatory work 4. Disassemble pinion and cage assembly as follows.
Set differential assembly (1) to tools H1. 1) Remove coupling, and sling cage (6) tempo-

4 Differential assembly: 1,250 kg

rarily, then using tools H2 and [1], pull out
bearing (7), and remove cage.
a If tools H2 and [1] are not used, support
the flange surface of the cage, push the
pinion shaft with a press to disassemble.

30-130 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

2) Remove outer race (8). 8. Disassemble differential gear case assembly as

3) Remove bearing (11) from pinion shaft (10). follows.
1) Remove mounting bolts (16), then remove
case (17).

4 Case: 85 kg

2) Remove bearing (18) and thrust washer

from case.

5. Remove left and right locks, then loosen the nut

(12) with a bar to a point where it can be turned
by hand.

6. Remove mounting bolts (13), then remove cap

(14).

3) Remove bevel gear (19).

4) Remove pinion gear assembly (20) together
with cross shaft (21).

4 Pinion gear, cross shaft: 110 kg

7. Remove differential gear case assembly (15).

4 Differential gear case assembly:

1,250 kg

WD900-3 30-131
(1)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

a Disassemble pinion gear assembly as follows.

1) Raise lock plate, hold pinion gear assembly
(20) with press, then using wrench H6,
loosen lock nut (22) and remove.
2) Push shaft (23) with press, and remove pin-
ion gear (24) and bearing (25).

9. Remove bevel gear (30).

10. Remove thrust washer (31).

11. Remove mounting bolts, and using eyebolts

(Dia. = 24 mm, Pitch = 3.0 mm), remove bevel
3) Remove collar (26). gear.

4 Bevel gear: 320 kg

4) Remove bearing (27) from shaft.

DEW04447

5) Remove outer races (28) and (29).

30-132 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

ASSEMBLY 2) Press fit bearing (27) in shaft.

a Coat the rotating surfaces of the bearing roller,

inner race and outer race rollers with engine oil
before installing.

1. Using the eyebolts (Dia. = 24 mm, Pitch = 3.0

2 Mounting bolt: Adhesive (LT-2)

mm), install the bevel gear.

3 Mounting bolt:
932 ± 98 Nm {95 ± 10 kgm}

2. Install thrust washer (31).

a Align the thrust washer with the dowel pin
when installing.
3) Assemble collar (26).
3. Install bevel gear (30).

DEW04447

4) Assemble pinion gear (24) and bearing (25)

a Assemble pinion gear as follows. in shaft.
1) Install outer races (29) and (28). 5) Fit lock plate and tighten lock nut (22) with
wrench H6.

3 Lock nut:
a Bend the lock plate securely.

981 ± 98 Nm {100 ± 10 kgm}

WD900-3 30-133
(1)
DISASSEMBLY AND ASSEMBLY
a Assemble differential gear case assembly as fol-
lows.
1) Assemble pinion gear assembly (20) in
cross shaft (21), and install to case.
a Align the notch in the pinion gear with
the cross shaft dowel pin when installing.
2) Install bevel gear (19).
a Move the bevel gear and check that the
pinion gear assembly rotates smoothly.
3) Install thrust and bearing to case.
a Align the thrust with the dowel pin when
installing.
2 Mounting bolt: Adhesive (LT-2)
4) Install case, and tighten mounting bolts.
3 Mounting bolt:
932 ± 98 Nm {95 ± 10 kgm}
30-134
(4)
DIFFERENTIAL
4. Tighten nut (12) temporarily, and put differential
gear case assembly (15) in differential case.
a Align the nut with the groove in the differen-
tial case, then check that it rotates smoothly
by hand.
2 Mounting bolt: Adhesive (LT-2)
5. Install cap (14) and tighten mounting bolts (13).
3 Mounting bolt:
1,716 ± 196 Nm {175 ± 20 kgm}
a Check the match mark on the bearing cap
when installing.
a When tightening the bolts, rotate the bevel
gear 20 – 30 times to settle the bearing be-
fore tightening.
WD900-3
DISASSEMBLY AND ASSEMBLY
a Adjust the preload of the bevel gear as follows.
1) Using tool D7, measure distance D.
2) Adjust with the nut so that the increase in
distance D is 0.39 ± 0.15 mm.
a The increase becomes the amount of
deflection of the case from before giving
preload to after giving preload.
a If the increase deflection is greater than the
standard distance, return to the position be-
fore adjusting with the adjustment nut.
When returning the adjustment nut, rotate the
bevel gear, and tap the bearing cap and bev-
el gear with a plastic hammer to check that
there is no clearance at b. Then adjust again.
a Assemble pinion and cage assembly as follows.
1) Install bearing (11) to pinion shaft (10).
a Check that there is no clearance between
the bearing inner race and the pinion.
2) Install outer race (8) to cage.
WD900-3
DIFFERENTIAL
3) Install pinion shaft to cage (6).
4) Install bearing (7).
5) Install coupling (4), and tighten holder with
mounting bolt to 323.6 ± 19.6 Nm {33 ± 2.0
kgm} temporarily, then measure clearance
between holder and pinion.
a Add 0.11 mm to the measured value for
the clearance to decide the shim thick-
ness.
6) Insert shim and rotate cage while tightening
holder mounting bolts to specified tightening
2 Mounting bolt: Adhesive (LT-2)
torque.
3 Mounting bolt:
2,750 ± 290 Nm {280 ± 30 kgm}
30-135
(1)
DISASSEMBLY AND ASSEMBLY
a Rotate the cage 20 – 30 times, then using
push-pull scale [1], check the starting torque.
a Starting torque:
22.6 ± 6.9 Nm {2.3 ± 0.7 kgm}
a Check that the bearing roller big end and
inner race lip are in contact.
a Adjust tooth contact as follows.
6. Fit O-ring and assemble shim, then install pinion
and cage assembly (5) to differential case.
a If the shim was disassembled, assemble the
same number and thickness of shims that
2 Mounting bolt: Adhesive (LT-2)
was removed.
3 Mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}
30-136
(1)
DIFFERENTIAL
7. Adjusting tooth contact, backlash
a Adjust backlash as follows.
1) Move bevel gear with adjustment nut.
When adjusting the bevel gear, do not
change the preload of the bearing.
Always turn the adjustment nuts at both
ends the same amount in the same
direction.
2) Put dial gauge H7 at right angles in con-
tact with the face of the tooth at the out-
side of the bevel gear.
Turn the adjustment nut and adjust until
the movement of the gauge indicator is
0.43 – 0.61 mm.
a Adjust at 3 or 4 places. Keep the pin-
ion gear locked when measuring.
1) Adjust the position of the bevel pinion by
changing the shims between the differential
case and bearing cage.
2) Adjust tooth contact between pinion gear
and bevel gear.
For details, see Adjusting tooth contact.
3) Adjust tooth contact
Coat face of 7 or 8 teeth of bevel pinion
lightly with red lead (minimum).
Hold the bevel gear by hand to brake it, and
rotate the bevel pinion forward and back-
ward and inspect the pattern left on the
teeth.
WD900-3
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL

Adjust the tooth contact as follows.

Tooth contact Cause Procedure for adjustment

Adjust the bevel pinion by adjusting the shims
Correct contact at the bevel pinion cage.
The tooth contact pattern should start Adjust the bevel gear in the same way as when
from about 5 mm from the toe of the adjusting backlash.
bevel gear and cover about 50% of the
length of the tooth.
It should be in the center of the tooth
DEW00910 height.

Bevel pinion is too far from bevel gear. 1. Reduce shims at

bevel pinion to
bring closer to 2
bevel gear.
2. Move bevel gear
further away from
bevel pinion and
DEW00904 adjust backlash 1 DEW00908

correctly.
Bevel pinion is too close to bevel gear. 1. Increase shims at
bevel pinion to
move away from 2
bevel gear.
2. Move bevel gear
closer to bevel
pinion and adjust
DEW00905 backlash cor- 1 DEW00909

rectly.
Bevel gear is too close to bevel pinion. 1. Reduce shims at
bevel pinion to
bring closer to 2
bevel gear.
2. Move bevel gear
further away from
bevel pinion and
DEW00906 adjust backlash 1 DEW00908

correctly.
Bevel gear is too far from bevel pinion. 1. Increase shims at
bevel pinion to
move away from 2
bevel gear.
2. Move bevel gear
closer to bevel
pinion and adjust
1 DEW00908
DEW00907 backlash cor-
rectly.

8. After adjusting tooth contact and backlash, install

2 Mounting bolt: Adhesive (LT-2)

left and right locks.

WD900-3 30-137
(1)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

DISASSEMBLY AND ASSEMBLY 3. Remove final drive case cover (2).

OF FINAL DRIVE
SPECIAL TOOLS

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

792-633-1300 Fixture t 4
J 1 01010-81430 Bolt t 4
01641-21423 Washer t 4

DISASSEMBLY
k Stop the machine on level ground and install the
4. Remove snap ring, then remove sun gear (3).
a Pull out the torque shaft approx. 150 mm,
safety bar on the frame. then push in the sun gear approx. 10 mm,
Lower the work equipment to the ground and and remove the snap ring.
stop the engine. Then apply the parking brake
and put blocks under the wheels to prevent the
machine from moving.

1. Loosen wheel nut, jack up machine with work

equipment, insert stand under axle, then sling
wheel assembly temporarily, remove wheel nut,
and lift off wheel assembly (1).

4 Wheel assembly: 3,565 kg

5. Remove torque shaft (4).

4 Torque shaft: 105 kg

a Remove retainer (5).

2. Remove drain plug of final drive case, and drain

oil from final drive case.
a There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful
when draining.

6 Final drive case: Approx. 360 l

30-138 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

6. Remove 3 hexagonal bolts, then using eyebolts
[1] (Dia. = 12 mm, Pitch = 1.75 mm), lift off car-
rier case assembly (6).
a When pulling out the carrier case assembly,
insert a bar in the casting hole at the bottom
of the case, and adjust the balance when
pulling out.
7. Using tool J1, secure wheel hub (13) and float-
ing seal case (14).
a Secure tool J1 at 4 places on opposite sides
to prevent uneven contact of the floating
seal.

4 Carrier case assembly: 390 kg

8. Remove retainer (15), then remove shim (16).

a Check the number and thickness of the shims,
and keep in a safe place.
a Disassemble carrier case assembly as follows.
1) Remove mounting bolts (7), then remove
retainer (8).
2) Using a copper hammer, knock out
shaft, then remove pinion gear (9) and
bearing form carrier case.

9. Lift off ring gear assembly (17).

a When pulling out the ring gear assembly, in-
sert a bar in the casting hole at the bottom of
the case, and adjust the balance when pull-
ing out.

3) Remove the bearing from pinion gear, 4 Ring gear assembly: 240 kg
then remove cup (10), spacer (11), and
snap ring (12).
a Keep the bearing and cup as set.

WD900-3 30-139
(1)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

10. Remove lock plate, then remove ring gear (19) ASSEMBLY
from ring gear hub (18).

4 Ring gear hub: 95 kg

1. Install stud bolts
• Install stud bolts (1) (53 pieces) to wheel hub

4 Ring gear: 150 kg

(2) according to the following procedure,
while preventing scuffing.
1) Check that the nut side is with identification
mark "E" or is stepped.
a When tightening, do not coat grease or
oil on the screw portion.
2) Install 2 nuts to the nut side of each stud
bolt.
3) Tighten the 2 nuts so that they are pressed
to each other (Turn the bottom one counter-
clockwise and the top one clockwise).
4) Install the stud bolt by turning only the top
nut in the tightening direction.
5) Tighten the stud bolt to the incomplete
thread portion.
• Tightening (protrusion) distance: 98 – 100

3 Stud bolt:
11. Replace wheel hub stud bolts mm
a If any stud bolts are damaged or elongated,
replace all of them. 238 – 335Nm {24.3 – 34.2 kgm}
Remove stud bolts (double nut)
• Remove stud bolts (1) (53 pieces) from
wheel hub (2) according to the following pro-
cedure.
1) Check that the threaded holes of wheel hub
(2) are free from damage.
2) Install 2 nuts to each stud bolt.
3) Tighten the 2 nuts so that they are pressed
to each other (Turn the bottom one coun-
terclockwise and the top one clockwise).
4) Remove the stud bolt by turning only the
bottom nut in the loosening direction.

2. Install ring gear (19) to ring gear hub (18), and

2 Mounting bolt: Adhesive (LT-2)

secure with lock plate.

3 Mounting bolt:
88.3 ± 9.8 Nm {9.0 ± 1.0 kgm}
a Clean all the grease and oil from the bolt
thread and mounting hole.

30-140 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

3. Adjust wheel bearing as follows.

1) Align ring gear assembly (17) with spline of
axle shaft, and tighten retainer (15) with 3
bolts temporarily.
a Measure thickness of the retainer before
installing.
a Remove tool J1, rotate the hub 20 – 30
times, then tighten the mounting bolts

3 Mounting bolt:
uniformly to the specified torque.

186 ± 5 Nm {19 ± 0.5 kgm}

4) Using tool J1, secure wheel hub (13) and

floating seal case (14).
a Secure tool J1 at 4 places on opposite
sides to prevent uneven contact of the
floating seal.

2) Using calipers [1] or depth micrometer through

measuring hole of retainer, measure distance
a from retainer to end face of axle shaft.
3) Remove the 3 bolts tightened temporarily, and
then remove retainer (15) and measure its
thickness b.

5) Remove retainer, and fit selected shim (16)

and retainer, then tighten mounting bolts.
a Remove tool J1, rotate the hub 5 – 6
times, then tighten the mounting bolts

2 Mounting bolt: Adhesive (LT-2)

uniformly to the specified torque.

3 Mounting bolt:
932 ± 98 Nm {95 ± 10 kgm}
a After tightening the bolts, rotate the hub
and check for any abnormality in the ro-
tation of the bearing rollers.

a Measure at 2 places and take the average.

a Difference C between measured values
= a – b + 0.3 mm (Round the measure-
ment up to the nearest 0.1 mm).
a Select the combination of shims to give
the required thickness with the minimum
number of shims.

WD900-3 30-141
(6)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

4. Assemble planetary carrier as follows.

1) Install snap ring (12) and spacer (11) to pin-
ion gear.
2) Press fit cup (10), and assemble the bear-
ing.

6. Raise torque shaft (4) and set in mounting posi-

tion temporarily.

7. Align spline and push torque shaft (4) in mount-

ing position of differential assembly.
3) Set pinion gear (9) and bearing in carrier a Leave the torque shaft protruding approx.
case, assemble shaft, then press fit shaft 150 mm, install the snap ring to the sun gear,
with copper hammer. then push in completely.

2 Mounting bolt: Adhesive (LT-2)

4) Tighten retainer (8) with mounting bolts (7).

3 Mounting bolt:
8. Install retainer (5) and sun gear (3), and secure
with snap ring.
275 ± 29 Nm {28 ± 3 kgm} a When aligning the tooth faces of the sun
gear and carrier gear, raise the torque shaft
slightly to align.

5. Fit O-ring, then using eyebolts [1] (Dia. = 12

mm, Pitch = 1.75 mm), raise carrier case
assembly (6), align tooth faces of planetary gear
and ring gear, then set in mounting position and
tighten 3 hexagonal bolts.
a When installing the carrier case assembly,
insert a bar in the casting hole at the bottom
of the case to adjust the balance when in-
stalling.

30-142 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE

9. Fit O-ring and install final case cover (2).

10. Tighten drain plug of final case, and add oil until
it flows out from level plug.

5 Final drive case: Approx. 360 l

11. Raise wheel assembly (1), install to wheel hub,

then temporarily tighten nuts.
Jack up machine with work equipment, remove
stand from under axle, then lower machine.

3 Wheel nut: 824 ± 88 Nm {84 ± 9 kgm}

12. Tighten wheel nuts fully.

WD900-3 30-142-1
(4)
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL

REMOVAL AND INSTALLATION 4. Disconnect hose (4) of the accumulator.

OF ORBIT-ROLL 5. Disconnect hose (5) of the right-hand stop

valve.
REMOVAL
k Stop the machine on level ground and lower the 6. Disconnect hose (6) of the left-hand stop valve.
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma- 7. Disconnect drain hose (7).
chine from moving.
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove cover (1) from the steering column.

8. Remove mounting bolt (8), then remove orbit-

roll (9) and bracket together.[*2]

2. Loosen joint lock bolt (2). [*1]

9. Loosen lock bolt (10), then remove joint (11).

10. Remove bolt (12), then remove bracket (13)

from orbit-roll (9).
3. Remove cover (3) under the cab.

WD900-3 30-143
(1)
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL

INSTALLATION

• Carry out installation in the reverse order to

removal.

3 Joint lock bolt:

[*1]

55.9 ± 7.8 Nm {5.7 ± 0.8 kgm}

3 Bracket mounting bolt:

[*2]

51.9 ± 7.8 Nm {5.3 ± 0.8 kgm}

• Bleeding air
Bleed air from the steering circuit. For details,
see TESTING AND ADJUSTING, "Bleeding air
from steering circuit".

30-144 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING PUMP

REMOVAL AND INSTALLATION INSTALLATION

OF EMERGENCY STEERING • Carry out installation in the reverse order to
PUMP removal.

REMOVAL
k Lower the work equipment completely to the
ground, then put blocks under the wheels to pre-
vent the machine from moving.

1. Disconnect hoses (1) and (2) of the diverter

valve.

2. Disconnect return hose (3).

3. Remove mounting bolt (4), then remove emer-

gency steering pump (5).

4 Emergency steering pump: 49 kg

WD900-3 30-145
(7)
DISASSEMBLY AND ASSEMBLY DIVERTER VALVE

REMOVAL AND INSTALLATION

OF DIVERTER VALVE
REMOVAL
k Lower the work equipment completely to the
ground, then put blocks under the wheels to pre-
vent the machine from moving.

k Gradually loosen the cap of the hydraulic tank to

release the pressure from the tank.

1. Drain hydraulic oil from the hydraulic tank.

6 Hydraulic oil: 725 l INSTALLATION

2. Disconnect hose (1) of the hydraulic tank.
3. Disconnect tube (2) of the steering valve.
4. Disconnect hoses (3) and (4) of the emergency
steering pump.
• Carry out installation in the reverse order to
removal.
• Refilling with oil (hydraulic tank)
1) Add hydraulic oil through the oil filler port to
the specified level.

5. Disconnect tube (5) of the hydraulic tank. 5 Hydraulic oil: 725 l

2) Before starting the engine, bleed air from
the steering pump, switch pump and loader
pump. (For details, see Testing and adjust-
ing, "Bleeding air from piston pump".)
3) Let the oil circulate in the piping by starting
the engine. Then check the oil level again.

• Bleeding air
Bleed air from steering circuit. For details, see
Testing and adjusting, "Bleeding air from steer-
ing circuit".

6. Disconnect connector (6) (R01).

7. Disconnect hose (7) of the steering pump.

8. Disconnect hose (8) of the hydraulic tank.

9. Remove the mounting bolt, then remove diverter

valve (9).

4 Diverter valve : Approx. 70 kg

30-146 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY DIVERTER VALVE

DISASSEMBLY AND ASSEMBLY 4) Remove cover (11) from valve body (2),
then remove spring (12) and check valve
OF DIVERTER VALVE (13).
5) Remove O-ring (14) from cover (11), then
DISASSEMBLY remove backup ring (15).
1. Remove mounting bolt (1), then disconnect
selector valve (3) from check valve (2).

3. Disassembly of selector valve

1) Remove O-ring (17) and spool (18) from
2. Disassembly of check valve valve body (3).
1) Remove spring (5) and check valve (4) from
valve body (2).

2) Remove cover (19) from valve body, then

remove spring (20) and retainer (21).
2) Remove cover (6) from valve body (2), then 3) Remove O-ring (22) from cover (19).
remove spring (7) and check valve (8).
3) Remove O-ring (9) and backup ring (10)
from cover (6).

WD900-3 30-147
(1)
DISASSEMBLY AND ASSEMBLY DIVERTER VALVE

ASSEMBLY 2. Assembly of selector valve

1) Install spool (17) to valve body (3).
1. Assembly of check valve 2) Install O-ring (18) to valve body (3), then

3 Mounting bolt:
1) Assemble check valve (8) and spring (7) to install cover (16).
valve body (2).
2) Install backup ring (10) and O-ring (9) to 98 – 123 Nm {10.0 – 12.5 kgm}
cover (6), then install them to valve body (2).

3) Assemble retainer (21) and spring (20) to

3) Assemble check valve (13) and spring (12) valve body (3).
to valve body (2). 4) Install O-ring (22) to cover (19), then install

3 Mounting bolt:
4) Install backup ring (15) and O-ring (14) to them to valve body (3).
cover (11), then install them valve body (2).
58.8 – 73.6 Nm {6.0 – 7.5 kgm}

5) Assemble check valve (4) and spring (5) to

valve body (2).
6) Install the O-ring to selector valve body (3),

3 Mounting bolt: 98.1 Nm {10 kgm}

then install bolt (1) to check valve (2).

30-148 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE

REMOVAL AND INSTALLATION INSTALLATION

OF ACCUMULATOR CHARGE • Carry out installation in the reverse order to
VALVE removal.

REMOVAL • Bleeding air

k Lower the work equipment completely to the
Bleed air from the brake accumulator circuit. For
details, see TESTING AND ADJUSTING, Bleed-
ground, then put blocks under the wheels to pre-
ing air from wheel brake circuit.
vent the machine from moving.

k Loosen the oil filler cap of the brake oil tank

gradually to release the pressure in the brake oil
tank.

k Depress the brake pedal at least 100 times to re-

lease the pressure from the accumulator.

k Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove tube (1) of the accumulator.

2. Disconnect hose (2) of the brake tank.

3. Disconnect hose (3) of the accumulator.

4. Disconnect hose (4) of the hydraulic tank.

5. Disconnect tube (5) of the brake pump.

6. Remove mounting bolt, then remove accumula-

tor charge valve (6).

WD900-3 30-149
(4)
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE

DISASSEMBLY AND ASSEMBLY 14. Remove snap ring (29) from valve body (1), then
remove filter (30).
OF ACCUMULATOR CHARGE
VALVE
DISASSEMBLY
1. Remove PPC relief valve (2) from valve body
(1).

2. Remove O-ring (3) and 2 backup rings (4) from

the PPC relief valve.

3. Remove plug (6) from valve body (1), then

remove spring (8) and spool (9).

4. Remove the O-ring from plug (6).

5. Remove bushing (10) from valve body (1).

6. Remove snap ring (11), filter (12) and O-ring

(13) from bushing (10).

7. Remove locknut (14) from valve body (1), then

remove adjustment screw (15).

8. Remove retainer (16), spring (17), shim (18) and

O-ring (19) from adjustment screw (15).

9. Remove plug (20) from valve body (1), then

remove retainer (21), piston (22) and valve seat
(23).

10. Remove O-ring (24) from plug (20).

11. Remove locknut (14) from valve body (1), then

remove adjustment screw (15).

12. Remove ball (25), spring (26), shim (18) and O-

ring (19) from adjustment screw (15).

13. Remove plug (27) from valve body (1), then

remove orifice (28).

30-150 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE

ASSEMBLY 13. Install O-ring (5), backup ring (4) and ring (3) to
PPC relief valve (2), then install them to valve

3 PPC relief valve:

1. Insert filter (30) in valve body (1), then install body (1).
snap ring (29).
79 – 88 Nm {8 – 9 kgm}

2 Orifice: Loctite (#241)

2. Install orifice (28) to valve body (1).

3 Orifice:
3.14 – 3.9 Nm {0.32 – 0.40 kgm}

2 Plug: ThreeBond (#1305)

3. Install plug (27).

4. Install O-ring (19) to adjustment screw (15), then

set shim (18), spring (26) and ball (25), and
install them to valve body (1).

3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}

5. Install locknut (14) to adjustment screw (15).

6. Install valve seat (23), piston (22) and retainer

(21) to valve body (1). Install O-ring (24) to plug

2 Plug: 30.4 – 37.3 Nm {3.1 – 3.8 kgm}

(20), then install them.

7. Assemble O-ring (19) to adjustment screw (15).

Set shim (18) and spring (17) and retainer (16),
then install them to valve body (1).

3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}

8. Install locknut (14) to adjustment screw (15).

9. Insert filter (12) in bushing (10), then install snap

ring (11).

10. Install O-ring (13) to bushing (10), then install

3 Bushing:
them to valve body (1).

29.4 – 39.2 Nm {3.0 – 4.0 kgm}

11. Assemble spring (7) to spool (8), then insert

them in valve body (1).

12. Install O-ring (9) to plug (6), then install them to

3 Plug: 53.9 – 68.6 Nm {5.5 – 7.0 kgm}

valve body (1).

WD900-3 30-151
(1)
DISASSEMBLY AND ASSEMBLY STEERING STOP VALVE

REMOVAL AND INSTALLATION INSTALLATION

OF STEERING STOP VALVE • Carry out installation in the reverse order to
removal.
REMOVAL
k Stop the machine on level ground and lower the a Check the stop valve. For details, see TESTING
work equipment completely to the ground, then AND ADJUSTING, Adjustment of stop valve.
put blocks under the wheels to prevent the ma-
chine from moving.

1. Disconnect hose (1) of the steering valve.

2. Disconnect hose (2) of the orbit-roll.

3. Disconnect drain hose (3).

4. Remove mounting bolt (4), then remove steering

stop valve (5).

30-152 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

REMOVAL AND INSTALLATION 6. Start the engine, then retract piston (13).
a Check the number of the shims.
OF STEERING CYLINDER
REMOVAL
k Fully extract the piston rod of the steering cylin-
der to be removed and lower the work equip-
ment completely to the ground, then put blocks
under the wheels to prevent the machine from
moving.

1. Remove bolt (1) and loosen bolt (2), then slowly

turn cover (3) toward the rear of the machine
body.
a Turn the cover around bolt (2).
a Since the available space is narrow, work
carefully. 7. Temporarily sling steering cylinder (14).

8. Disconnect hose (15) on the bottom side.

9. Disconnect hose (16) on the head side.

2. Remove mounting bolts (4) and (5), then remove

plate (6).

10. Remove bolts (17) and (18), then remove plate

(19).

11. Disconnect the remote tube, then remove grease

nipple (20).

12. Remove bolt (21), then remove plate (22).

13. Remove taper bushings (23) and (24), then pull

out pin (25). [*2]

3. Disconnect the remote tube, then remove grease

nipple (7).

4. Remove bolt (8), then remove plate (9).

5. Remove taper bushings (10) and (11), then pull

out pin (12). [*1]

WD900-3 30-153
(1)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER

14. Sling and remove steering cylinder (14). INSTALLATION

a When slinging, be careful not to interfere
with the remote grease tube, etc. • Carry out installation in the reverse order to
a Check the number of the shims. removal.

4 Steering cylinder : 210 kg [*1] [*2]

1) Do not put grease or other lubricants on the
contact faces of the pin and taper bushing.
2) When installing the taper bushing, set its slit
in the lateral direction of the machine body.
k When aligning the position of the pin hole, use a
bar. Never insert your fingers in the pin hole.
a Adjust the clearance of the cylinder mounting
portions to the following values.
• Bottom side: a, b = 3 mm max.

• Head side: a, b = 1 mm max.

• Bleeding air
Bleed air from the steering circuit. For details,
see TESTING AND ADJUSTING, "Bleeding air
from steering circuit".

30-154 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION
OF STEERING VALVE
REMOVAL
k Stop the machine on level ground and install the
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the steering wheel and the control levers 2 – 3
times to release the remaining pressure in the
hydraulic piping.
1. Step
Remove step (1) on cab front.
WD900-3
STEERING VALVE
2. Hydraulic piping
Disconnect the following tubes from steering
demand valve.
• Remove tube (2) between steering demand
valve (P2 port) and switch pump.
• Remove tube (3) between steering demand
valve (P1 port) and steering pump.
• Remove tube (4) between steering demand
valve (P, B port) and work equipment valve.
a Remove the bolts of bracket (5) for fixing
tube (4) in advance.
• Remove tube (6) between steering demand
valve (A port) and steering cylinder.
• Remove tube (7) between steering demand
valve (B port) and steering cylinder.
• Remove tube (8) between steering demand
valve (T port) and return port of hydraulic oil
tank.
• Remove tubes (9) and (10) between orbit-roll
and steering demand valve pilot circuit.
a Remove the tube clamp in advance.
30-155
(1)
DISASSEMBLY AND ASSEMBLY STEERING VALVE

3. Steering demand valve INSTALLATION

Sling steering demand valve temporarily,
remove mounting bolts (11), then remove steer- • Carry out installation in the reverse order to
ing demand valve (12). removal.

4 Steering demand valve: 66 kg • Refilling with oil (Hydraulic tank)

1) Add hydraulic oil through the oil filler of the
4. Bracket hydraulic tank to the specified level.
Remove bracket (13) from steering demand 2) Before starting the engine, bleed air from
valve (12). the steering pump, switch pump and loader
pump.
a See TESTING AND ADJUSTING, "Bleed-
ing air from piston pump".
3) Run the engine to circulate the oil through
the system. Then, check the oil level again.

• Bleeding air
Bleed air from the steering circuit. For details,
see TESTING AND ADJUSTING, "Bleeding air
from steering circuit".

30-156 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY BRAKE VALVE

REMOVAL AND INSTALLATION 7. Remove pedal (11).

OF BRAKE VALVE 8. Remove boot (12).

REMOVAL
k 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.
k Loosen the oil filler cap of the brake oil tank gradu-
ally to release the pressure in the brake oil tank.
k Release remaining pressure in brake acccumu-
lator circuit. For detail, see TESTING AND AD-
JUSTING "Releasing remaining pressure in
hydraulic circuit".

1. Remove the U-bolt, then disconnect drain tube

(2). 9. Remove 4 bolts (13), then remove brake valve
a Move the drain tube and hose toward the (14).
frame. a This work must be done by two workers. Re-
move the valve under the floor frame.
2. Disconnect hose (3) of the front brake.

3. Disconnect hose (4) of the shuttle valve.

4. Disconnect pilot hose (5) (of the shuttle valve).

5. Disconnect hose (6) of the accumulator.

INSTALLATION

• Carry out installation in the reverse order to

removal.

• Bleeding air
6. Pull out snap pin (9), then pull out pins (7) and Bleed air from the brake circuit. For details, see
(8). TESTING AND ADJUSTING, Bleeding air from
a Be careful not to lose L-pin (10). wheel brake circuit.

WD900-3 30-157
(4)
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER

REMOVAL AND INSTALLATION INSTALLATION

OF SLACK ADJUSTER
REMOVAL
k 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.
k Loosen the oil filler cap of the brake oil tank
gradually to release the pressure in the brake oil
tank.
• Carry out installation in the reverse order to
removal.
• Bleeding air
Bleed air from the brake circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
wheel brake circuit.

1. Disconnect tubes (1) and (2) of the brake valve.

a After removing the tubes, loosen the clamp.

2. Disconnect hoses (3) and (4) of the brakes on

left and right sides.

3. Remove mounting bolt (5), then remove bracket

(6) and slack adjuster (7) together.

30-158 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER

DISASSEMBLY AND ASSEMBLY 3. Piston

1) Remove spring (5) and O-ring (6).
OF SLACK ADJUSTER 2) Push out piston (7) and remove O-ring.
a Gently push out the piston with a rod (di-
DISASSEMBLY ameter 10 mm) when remove it.
1. Bleeder a Pay attention not to give damage to
Remove bleeder (2) from body (1). screw portion with the rod.

2. Cylinder
Remove mounting bolts, then disconnect body
(1) from cylinders (3) and (4).
k Cylinder has spring tension inside. Carefully
remove them holding two parts together.
4. Poppet
a Do not disassemble poppet unless neces-
sary.
If disassembled, replace poppet and cylin-
der as assembly.
1) Remove cover (8) from cylinder (4), then
remove plug (9), spring (10) and poppet
(11).
a Remove the poppet by air blowing
through the oil hole of the cylinder.
a Hold the oil port of the cylinder by hand
and pay attention not to blow air hard.
a If replace poppet (11) or cylinder (4), re-
place them as a set.
2) Remove O-ring (12) from the poppet.

WD900-3 30-159
(1)
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER

ASSEMBLY 2) Install cylinders (4) and bracket (3) to body

(1).
1. Poppet
1) Fit O-ring (12) to poppet (11). 4. Bleeder
2) Install poppet (11), spring (10), plug (9) and Install bleeder (2).
cover (8), then assemble into the cylinder
(4).

2. Piston
1) Fit O-ring (13) to piston (7).
2) Insert piston (7) into cylinder (4).
a Confirm that the piston moves smoothly.

3. Cylinder
1) Install O-ring (6) and spring (5) to cylinder.
a Spring installation load: 43.1N {4.4 kg}

30-160 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY BRAKE

REMOVAL AND INSTALLATION a Bearing (3) will fall out, so remove the bear-
ing while removing the wheel hub.
OF BRAKE
4 Bearing: 45 kg
SPECIAL TOOLS
4 Wheel hub: 90 kg

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

792-633-1300 Fixture t 4
J 1 01010-81430 Bolt t 4
01641-21423 Washer t 4

REMOVAL
k Stop the machine on level ground and install the
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving. 4. Sling brake (4) temporarily, and remove mount-
ing bolts, then remove brake. [*2]
1. Remove ring gear. a Bearing (5) will fall out, so remove the bear-
For details see DISASSEMBLY AND ASSEM- ing while removing the brake.

4 Bearing: 43 kg
BLY OF FINAL DRIVE.

4 Brake : 380 kg
2. Disconnect brake tube (1).

3. Sling wheel hub (2) temporarily, remove mount-

ing nut, then remove wheel hub. [*1] INSTALLATION

• Carry out installation in the reverse order to

removal.

2 Mounting bolt: Adhesive (LT-2)

[*1]

3 Mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}

2 Mounting bolt: Adhesive (LT-2)

[*2]

3 Mounting bolt:
932 ± 98 Nm {95 ± 10 kgm}

WD900-3 30-161
(1)
DISASSEMBLY AND ASSEMBLY BRAKE

DISASSEMBLY AND ASSEMBLY a Disassemble cylinder as follows.

1) Screw in eyebolts [1] (Dia. = 16 mm, Pitch
OF BRAKE = 2.0 mm), push in spring with bar [2],
SPECIAL TOOLS then pull out pin (2).
2) Remove spring (3), shaft (4), and washer.

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

792-633-1300 Fixture t 4
1 01010-81430 Bolt t 4
01641-21423 Washer t 4
791-585-1510 Installer t 1
792-530-1700 Push tool t 1
• 791-580-1610 • Plate 1
J • 791-580-1620 • Arm 4
• 792-530-1630 • Stud 4
2
• 791-580-1640 • Plate 1 3) Remove piston (5).
• 791-585-1650 • Plate 4
• 01010-51425 • Bolt 8
• 01640-21426 • Washer 4
• 01541-21670 • Nut 4

DISASSEMBLY
1. Remove mounting bolts, and screw in eyebolts
[1] (Dia. = 16 mm, Pitch = 2.0 mm), then lift off
cylinder assembly (1).

4 Cylinder assembly: 140 kg

2. Removal plates and discs

1) Remove stopper bolts, then remove plates
(6).

30-162 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY BRAKE

2) Remove discs (7). 6. Remove mounting bolts, then remove hub (12)
from outer drum.

3. Remove tool J1.

7. Remove oil seal (13).

8. Remove floating seal (14).

4. Screw in eyebolts [1] (Dia. = 16 mm, Pitch = 2.0

mm), then lift off outer drum (8).

4 Outer drum: 240 kg

5. Knock out retainer (10) through removal hole in

inner gear (9), then remove together with float-
ing seal (11).

WD900-3 30-163
(5)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY
1. Using tools J2, install floating seal (14) to hub.
a When assembling the floating seal, clean the
surface of the O-ring with alcohol and as-
semble without twisting.
a Use a new part for the O-ring.
2. Install oil seal (13).
a Tap the oil seal with a plastic hammer to in-
2 Lip of oil seal: Grease (G2-LI)
stall uniformly.
3. Fit O-ring and install hub (12) to outer drum.
2 Mounting bolt: Adhesive (LT-2)
a Use a new part for the O-ring.
3 Mounting bolt:
For M14: 177 ± 19 Nm {18 ± 1.9 kgm}
For M20: 549 ± 59 Nm {56 ± 6 kgm}
30-164
(6)
BRAKE
4. Using tools J2, install floating seal (11) to
retainer (10).
a When assembling the floating seal, clean the
surface of the O-ring with alcohol and as-
semble without twisting.
a Use a new part for the O-ring.
5. Fit O-ring to inner gear (9), align with dowel pin and
install retainer (10) together with floating seal (11).
a When installing the retainer to the inner gear,
tap the end of face of the retainer with a cop-
per hammer to install.
a Use a new part for the O-ring.
6. Using eyebolts [1] (Dia. = 16 mm, Pitch = 2.0 mm),
install outer drum (8) to inner gear.
a Coat the sliding surface of the floating seal
thinly with engine oil, and be careful not to
damage the floating seal when installing the
outer drum.
WD900-3
DISASSEMBLY AND ASSEMBLY BRAKE

7. Using tool J1, fix inner gear and outer gear. 9. Fit O-ring (20) to hub (21), and tighten discs (7)
a Center the inner gear and outer gear, and and plates (6) with stopper bolts (22).
tighten with tool J1. a Use a new part for the O-ring (20).

8. Assemble discs (7) and plaes (6). a Assemble cylinder as follows.

a Align the notched teeth at 6 places around 1) Assemble seal rings to cylinder (15) and
the circumference of the discs and plates piston (5), and set piston (5) at bottom.
when assembling. a Coat to each seal ring with engine
oil.

2) Align return spring guide shaft hole of

piston (5) and cylinder (15), then press
fit piston (5).
a Assemble so that casting holes A’
(bleeder side) and B’ (plug side) of
the piston are in the positions shown
in the figure below.
a When press fitting the piston, tap
with a plastic hammer. Do not hit
with a steel or copper hammer.

WD900-3 30-165
(5)
DISASSEMBLY AND ASSEMBLY BRAKE

10. Fit O-ring, then screw in eyebolts [1] (Dia. = 16

mm, Pitch = 2.0 mm), install cylinder assembly
(1).

2 Mounting bolt: Adhesive (LT-2)

a Use a new part for the O-ring.

3 Mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}

3) Turn over cylinder (15), and set so that

piston (5) is facing down on the pads [2]
above blocks [1].
a Use pads to prevent damage to the
side face of the piston.
a When installing plug (16) and bleed-
er (17), coat the thread with gasket

2 Plug thread and bleeder

sealant, and install.

thread:
Gasket sealant (LG-5)

4) Assemble washer, shaft (4), and spring

(3) to piston from cylinder end.
5) Screw in eyebolts [1] (Dia. = 16 mm,
Pitch = 2.0 mm), compress spring with
bar [2], then install pin (2) in shaft.

30-166 WD900-3
(5)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS

REMOVAL AND INSTALLATION 6. Remove plate (8). [*1]

a Remove cover (9). [*2]
OF PARKING BRAKE a After removing the plate, remove pad (10).
CALIPERS a Sling the calipers so that they will not fall.

REMOVAL 7. Remove parking brake calipers (11).

k Stop the machine on level ground and lower the
a The parking brake calipers must be removed
by two workers.
work equipment completely to the ground, then
4 Parking brake caliper : 40 kg
put blocks under the wheels to prevent the ma-
chine from moving.
k Loosen the oil filler cap of the brake oil tank
gradually to release the pressure in the brake oil
tank.
k Release remaining pressure in brake acccumu-
lator circuit. For detail, see TESTING AND AD-
JUSTING "Releasing remaining pressure in
hydraulic circuit".

1. Release the parking brake and turn adjustment

bolt (1) counterclockwise to set the yoke free.

2. Pull out pin (3), then disconnect the yoke from

adjuster (4).

3. Remove cover (5).

INSTALLATION
4. Apply the parking brake, then disconnect hose
(6). • Carry out installation in the reverse order to
a Before disconnecting the hose, check that removal.
any pressure is not remaining in the brake
2 Mounting bolt: Adhesive (LT-2)
cylinder. [*1]

5. Remove the mounting bolt, then remove spring 3 Mounting bolt:

cylinder (7). 820 – 1,030 Nm {84 – 105 kgm}

2 Mounting bolt: Adhesive (LT-2)

[*2]

3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}

WD900-3 30-167
(4)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS

DISASSEMBLY AND ASSEMBLY 4. Remove piston shaft (8) and thrust bearing (9)
from piston.
OF PARKING BRAKE
CALIPERS
DISASSEMBLY
1. Remove snap ring (1), then pull out adjuster (2).

5. Remove piston (11) and piston seal (12) from

calipers (10).

2. Remove washers (3) and (4), and seal (5).

3. Remove bolt, then remove cap (6) and gasket

(7).

30-168 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS

ASSEMBLY 4. Install seal (5) and washers (3) and (4).

2 Seal: Grease (G2-LI)

a Fit the seal securely in the groove.
1. Assemble piston seal (12) in calipers (10), and

2 Piston, piston seal: Grease (G2-LI)

insert piston (11).

5. Assemble adjuster (2) and secure with snap ring

(1).
2. Screw piston shaft (8) into piston, and install
thrust bearing (9).
a Be careful to install the thrust bearing facing

2 Thrust bearing: Grease (G2-LI)

in the correct direction.

3 Mounting bolt:
3. Fit gasket (7) and install cap (6).

177 ± 20 Nm {18 ± 2 kgm}

WD900-3 30-169
(1)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD

REMOVAL AND INSTALLATION INSTALLATION

OF PARKING BRAKE PAD • Carry out installation in the reverse order to
removal.
REMOVAL
k Stop the machine on level ground and install the
2 Mounting bolt: Adhesive (LT-2)
[*1]

3 Mounting bolt:
safety bar on the frame. Lower the work equip-
ment to the ground and stop the engine. Then
put blocks under the wheels to prevent the ma- 490 – 608 Nm {50 – 62 kgm}
chine from moving.

2 Mounting bolt: Adhesive (LT-2)

a Turn the main switch ON, and release the [*2]

3 Mounting bolt:
parking brake.

1. Turn adjustment bolt (1) in counterclockwise 820 – 1,030 Nm {84 – 105 kgm}
direction to increase clearance between pad
and disc.

2. Remove cover (2). [*1]

3. Loosen mounting bolts of plate (3). [*2]

a Sling to prevent calipers (4) from falling.

4. Move plate to side carefully so that pad does not

fall, then remove pad (5).
a When removing the front pad, first remove
the rear pad and move the calipers to the
front, then remove the front pad.
a Remove the pad of the parking brake cali-
pers on the right side in the same way.

30-170 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY PARKING BRAKE SPRING CYLINDER

REMOVAL AND INSTALLATION INSTALLATION

OF PARKING BRAKE SPRING • Carry out installation in the reverse order to
CYLINDER removal.

REMOVAL
k 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.
k Loosen the oil filler cap of the brake oil tank gradu-
ally to release the pressure in the brake oil tank.
k Release remaining pressure in brake acccumu-
lator circuit. For detail, see TESTING AND AD-
JUSTING "Releasing remaining pressure in
hydraulic circuit".

1. Release the parking brake and turn adjustment

bolt (1) counterclockwise to set the yoke (2)
free.

2. Pull out pin (3), then disconnect yoke (2) from

adjuster (4).

3. Apply the parking brake, then disconnect hose (5).

a Check that no pressure is remaining in the
brake cylinder.
a After removing the hose, cover the hole to
prevent dust from entering.

4. Remove the mounting bolt (6), then remove

parking brake spring cylinder (7).

WD900-3 30-171
(4)
DISASSEMBLY AND ASSEMBLY BRAKE OIL TANK

REMOVAL AND INSTALLATION 5. Disconnect hose (6) of the parking brake sole-
noid valve.
OF BRAKE OIL TANK
6. Disconnect hoses (7) and (8) of the charge
REMOVAL valve.
k Lower the work equipment completely to the a There is a clamp on the tank side.
ground, then put blocks under the wheels to pre-
vent the machine from moving.

1. Drain oil from the brake oil tank.

6 Brake oil: 27 l

2. Remove front cover (1) and side covers (2) and

(3).

7. Remove the mounting bolts, then sling and

remove brake oil tank (9).

4 Brake oil tank: 36 kg

3. Disconnect drain hose (4).

4. Remove suction tube (5).

INSTALLATION

• Carry out installation in the reverse order to

removal.

• Refilling with oil

Add oil to the center of the upper sight gauge.
a Bleed air from the brake line, referring to
TESTING AND ADJUSTING, Bleeding air
from wheel brake circuit. Then, check the oil
level again.

30-172 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

REMOVAL AND INSTALLATION 4. Loader pump

1) Disconnect suction tube (2).
OF HYDRAULIC PUMP 2) Disconnect two hoses (3) between the switch-
ASSEMBLY ing pump E.S. valve and loader pump E.S.
valve.
REMOVAL
k 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.
k Release remaining pressure in work equipment
circuit. For detail, see TESTING AND ADJUST-
ING "Releasing remaining pressure in hydraulic
circuit".

1. Draining oil
Drain hydraulic oil from the hydraulic tank.

6 Hydraulic oil: 725 l

3) Remove bracket (4), then disconnect control
pump discharge tube (5).
2. Remove step (1) from the rear of the cab.
4) Disconnect clamp (6).
5) Disconnect two discharge hoses (7).
6) Disconnect drain hose (8).
7) Sling loader pump (9) and lift it off.

4 Loader pump: Approx. 160 kg

3. For the location of each PTO pump, see the fig-

ure.

WD900-3 30-173
(7)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

5. Switching pump
1) Disconnect two discharge hoses (10).
2) Disconnect control pump discharge tube (11).
4) Disconnect tube (20) of the accumulator
charge valve.
5) Disconnect tube (21) of the PPC.
6) Disconnect tubes (22) and (23) of the torque
converter and transmission.
7) Sling 4-unit pump assembly (24) and lift it off.

4 4-unit pump assembly:

Approx. 60 kg

3) Disconnect suction tube (12).

4) Disconnect drain hose (13).
5) Disconnect two hoses (14) of the loader
pump E.S. valve.
6) Sling switching pump (15) and lift it off.

4 Switching pump: Approx. 160 kg

7. Steering pump assembly
a Remove the loader pump in advance.
1) Disconnect drain hose (25).
2) Disconnect two discharge tubes (26). [*1]

6. 4-unit (Torque converter, transmission, PPC,

brake) pump assembly
a Remove the switching pump in advance.
1) Disconnect suction tubes (16) and (17) of
the torque converter and transmission.
2) Disconnect suction tube (18) of the PPC pump.
3) Disconnect suction tube (19) of the brake
pump.

30-174 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY
a Serial number: 50001- 50105
3) Remove bracket (27) with discharge tubes
(26).
4) Disconnect suction tube (28).
5) Sling steering pump (29) and lift it off.
4 Steering pump: 145 kg
a Serial number: 50106 and up
6) Remove brackets (30) and (31) together
with discharge tube (26). [*4]
7) Remove brackets (32) and (33). [*5]
8) Disconnect suction tube (28). [*6]
9) Sling and remove steering pump (29).
4 Steering pump: 145 kg
WD900-3
HYDRAULIC PUMP
INSTALLATION
[*2] • Carry out installation in the reverse order to
[*3] removal.
a Serial number: 50001 - 50105
a To "Lightly tighten a tube or a bracket" means to
tighten the tube or bracket to a degree that they
move when they are tapped.
[*1], [*2], [*3]
1. Lightly tighten both of discharge tubes (26) on
the pump side.
a Do not connect on the hose side at this time.
2. Lightly tighten suction tube (28).
3. Lightly tighten bracket (27).
4. Check that no force is applied to discharge tube
(26).
a If any force is applied to discharge tube (26),
eliminate it by moving discharge tube (26)
and bracket (27). If it is still not eliminated,
eliminate it by moving steering pump (29).
5. Tighten suction tube (28) to the specified
torque.
6. Tighten both of discharge tubes (26) on the
pump side to the specified torque.
7. Tighten bracket (27) to the specified torque.
8. Install hoses (40) and (41) to discharge tube
(26).
30-175
(7)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

a Serial number: 50106 and up 9. Install hoses (40) and (41) to discharge tube
a To "Lightly tighten a tube or a bracket" means to (26).
tighten the tube or bracket to a degree that they a Install hose (41) at approximately 25° up-
move when they are tapped. ward, and check that clearance to the frame
[*1], [*4], [*5], [*6] is at least 30 mm.
1. Lightly tighten both of discharge tubes (26) on
the pump side to steering pump (29).
a Do not connect on the hose side at this time.
2. Lightly tighten suction tube (28).
3. Lightly tighten brackets (30) to (33).
4. Check that no force is applied to discharge tube
(26).
a If any force is applied to discharge tube (26),
eliminate it by moving discharge tube (26)
and brackets (30) to (33).
5. Tighten suction tube (28) to the specified
torque.
6. Tighten both of discharge tubes (26) on the
pump side to the specified torque.
• Refilling with oil (hydraulic tank)
1) Add hydraulic oil to the specified level.

5 Hydraulic tank: 725 l

2) Before starting the engine, bleed air from
the steering pump, switch pump and loader
pump. (For details, see Testing and adjust-
ing, "Bleeding air from piston pump".)
3) Run the engine to circulate the oil through
the system. Then, check the oil level again.

• Bleeding air
Bleed air from each part. For details, see TEST-
ING AND ADJUSTING, "Bleeding air from work
7. Check that there is no gap in contact faces (A), equipment circuit", "Bleeding air from steering
(B), (C), or (D) of brackets (30) to (33). circuit" and "Bleeding air from wheel brake cir-
a If there is any gap in (A), (B), (C), or (D), cuit".
eliminate it by moving each bracket.
8. Tighten mounting bolts (34) to (39) of brackets
(30) to (33) in this order to the specified torque.
a Tighten in the order of suction tube (28),
brackets, and discharge tube.

30-175-1 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY SERVO CYLINDER

REMOVAL AND INSTALLATION 8. Remove the mounting bolt from bracket (7),
then remove servo cylinder (8).
OF SERVO CYLINDER a Mark off the position of the servo cylinder so
that it will be installed to the same position.
REMOVAL
k Stop the machine on level ground and lower the
work equipment completely to the ground, then
apply the parking brake and stop the engine.

1. Open step (1).

INSTALLATION
• Carry out installation in the reverse order to
removal.

2. Disconnect drain hose (2) of the transmission. a Check the engine speed. For details, see DE-
PRESSING ANGLE OF ACCELERATOR PEDAL.
3. Disconnect hose (3) of the oil filter.

4. Pull out the pin of cable (4) of the fuel pump,

then disconnect the cable.

5. Pull out the pin of cable (5) of the accelerator

pedal, then disconnect the cable.

6. Remove spring (6).

7. Remove bracket (7).

a If the position of the bracket changes, the en-
gine speed may change. Accordingly, mark
off the position of the bracket with a pen be-
fore removing it.

30-176 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE ASSEMBLY

REMOVAL AND INSTALLATION 2. Remove step (3) on the top of the hydraulic
tank.
OF HYDRAULIC TANK AND
FILTER CASE ASSEMBLY 4 Step: 150 kg

REMOVAL 3. Remove ladder (4) from hydraulic tank (11).

k Stop the machine on level ground and lower the
4 Ladder: 45 kg
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma-
chine from moving.

a Observe the following points to protect the hy-

draulic equipment when disassembling and as-
sembling it.
• Before disassembling any part, clean the
machine body, particularly around that part.
• When disassembling and assembling the hy-
draulic equipment, do not let dust in the hy-
draulic circuit.
• Perfectly clean the parts, particularly the cir-
cuits and parts in the trouble section.
• Before disassembling or after cleaning the
4. Disconnect tube (5) between the hydraulic tank
hydraulic equipment, mask the all openings
and hydraulic pump from the hydraulic tank.
of the piping and hydraulic parts.

k Loosen the oil filler cap to release the pressure

5. Disconnect tube (6) between the hydraulic tank
and PPC pump from the hydraulic tank.
from the hydraulic tank, then operate the steer-
ing wheel and work equipment control lever 2 –
3 times to release the pressure from the piping.

1. Draining oil
Remove plug (1), then loosen plug (2) and drain
hydraulic oil.

6 Hydraulic oil: 725 l

6. Disconnect tubes (7) and (8) between the hydrau-

lic tank and diverter valve from the hydraulic tank.

WD900-3 30-177
(7)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE ASSEMBLY

7. Disconnect return tube (9) between the work INSTALLATION

equipment valve and hydraulic tank from the
hydraulic tank. • Carry out installation in the reverse order to
removal.

3 Mounting bolt:
[*1]

820 – 1,030 Nm {84 – 105 kgm}

• Refilling with oil

1) Add hydraulic oil to the specified level.

5 Hydraulic oil: 725 l

8. Disconnect return tube (10) between the oil
cooler and hydraulic tank from the hydraulic
tank.
2) Before starting the engine, bleed air from
the steering pump, switch pump and loader
pump. (For details, see TESTING AND
ADJUSTING, "Bleeding air from piston
pump".)
3) Run the engine to circulate the oil through
the system. Then, check the oil level again.

• Bleeding air
Bleed air from the each portion. For details, see
TESTING AND ADJUSTING, "Bleeding air from
work equipment circuit" and "Bleeding air from
steering circuit".

9. Temporarily sling hydraulic tank and filter case

assembly (11).

10. Remove mounting bolts (12) and (13), then

remove hydraulic tank and filter case assembly
(11). [*1]

4 Hydraulic tank and filter case assembly:

900kg

30-178 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY PPC VALVE

REMOVAL AND INSTALLATION 2. Remove nut (2), then disconnect rod (3).

OF PPC VALVE
REMOVAL
k Stop the machine on level ground and install the
safety bar to the frame. Lower the work equip-
ment to the ground and stop the engine and ap-
ply the parking brake, then put blocks under the
wheels to prevent the machine from moving.

a Observe the following points to protect the hy-

draulic equipment when disassembling and as-
sembling it.
• Before disassembling, clean the machine
body, particularly around disassembling por- 3. Pull out pin (4), then disconnect plate (5) from
tions. lever (7).
• When disassembling and assembling the hy-
draulic equipment, do not let dust get into the 4. Remove nut (6), then remove lever (7).
hydraulic circuit. a Similarly, remove the nut and lever on the
• Perfectly clean the parts, particularly the cir- opposite side.
cuits and parts in the trouble section.
• Before disassembling or after cleaning the
hydraulic equipment, mask the all openings
of the piping and hydraulic parts.

k Loosen the oil filler cap to release the pressure

from the hydraulic tank, then operate the work
equipment control lever over TILT and NEU-
TRAL at least 40 times to release the pressure
from the accumulator and piping.

1. Cover
Remove the cover form the rear of the cab and
console box cover (1) from the right side of the
operator’s seat.

WD900-3 30-179
(1)
DISASSEMBLY AND ASSEMBLY PPC VALVE

5. Disconnect hose (8) between the PPC valve INSTALLATION

and control valve. (Identification color: Yellow)
• Carry out installation in the reverse order to
6. Disconnect hose (9) between the PPC valve removal.
and control valve. (Identification color: Blue)
• Refilling with oil
7. Disconnect hose (10) between the PPC valve Add oil to the specified level of the hydraulic
and control valve. (Identification color: Green) tank.

8. Disconnect hose (11) between the PPC valve

and control valve. (Identification color: Red)

9. Disconnect hose (12) between the PPC valve

and accumulator. (Identification color: White)

10. Disconnect PPC valve drain hose (13).

11. Remove mounting bolt (14), then remove PPC

valve (15).
a Plug the disconnected hoses to prevent dirt
from entering them.

30-180 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY PPC VALVE

DISASSEMBLY AND ASSEMBLY

OF PPC VALVE
DISASSEMBLY
1. Remove bolt (1), then remove plate (2).

2. Remove seal (3), then remove collar (4).

3. Remove piston (5).

4. Disassembly of piston
Remove the following parts from piston assem-
bly (6).
1) Push down retainers (8), and remove collar
(7).
2) Remove retainers (8), main spring (9),
spring (10), shim (11), and piston (12).

5. Remove snap ring (13).

6. Remove retainer (14), spring (15), and valve

(16) from body (17).

ASSEMBLY

1. Assembly of piston
Assemble the following parts to piston (12).
1) Assemble shim (11), spring (10), and main
spring (9).
2) Push down retainer (8), and install collar (7).

2. Assemble valve (16), spring (15), and retainer

(14) to body (17).

3. Install snap ring (13).

4. Assemble piston assembly (6).

5. Install piston (5), then install collar (4) and seal

(3).

6. Align with dowel pin, and install plate (2), then

3 Bolt: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}

install bolt (1).

WD900-3 30-181
(1)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE

REMOVAL AND INSTALLATION 3. Hydraulic piping

Disconnect the following hydraulic piping from
OF WORK EQUIPMENT work equipment control valve.
CONTROL VALVE • Hoses (1A) and (2) between steering de-
mand valve and work equipment control
REMOVAL valve. Disconnect them on the side of the
k Stop the machine on level ground and install the
work equipment control valve.
• Hoses (3) and (4) between work equipment
safety bar on the frame. Lower the work equip-
control valve and bucket cylinder. Discon-
ment to the ground and stop the engine. Then
nect them on the side of the work equipment
apply the parking brake and put blocks under the
control valve.
wheels to prevent the machine from moving.
• Tubes (7) between work equipment control
valve and the hydraulic oil tank. Disconnect
a To keep the hydraulic circuits clean and to pro-
them on the side of the work equipment con-
tect the hydraulic equipment, be careful of the
trol valve.
following points when disassembling or assem-
a Remove the clamp before removing the
bling.
tube.
• Before disassembling, wash the machine.
• Tubes (5) and (6) between work equipment
Be particularly careful to completely clean
control valve and the lift cylinder. Disconnect
the area that is to be disassembled.
them on the side of the work equipment con-
• Do not let dirt or dust get into the hydraulic
trol valve.
circuits when disassembling or assembling.
a Remove the clamp before removing the
• Carry out thorough flushing of the parts, and
tube.
be particularly careful to do this thoroughly
a Cover pipings disconnected with blind
for the circuits or parts that have failed.
plugs to prevent dust in them.
• When disassembling or after flushing, al-
ways mask the openings of the piping or hy-
draulic equipment completely.
k Loosen the filler cap to remove the pressure in
the hydraulic oil tank, and repeat shifting the op-
eration lever for the work equipment between tilt
and neutral 40 times or more to remove the re-
maining pressure in the accumulator and the
pipings.

1. Draining oil
Drain hydraulic oil from the hydraulic tank.

6 Hydraulic oil: 725 l

2. Cover
Remove cover (1) from the front frame.

30-182 WD900-3
(7)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE

4. PPC piping 5. Work equipment control valves

Disconnect the following PPC pipings from the Screw eyebolts into work equipment control
work equipment control valve. valves, remove mounting bolts, then raise work
• Tubes (8) and (9) between PPC valve and equipment control valves (13) and (14) and
the dump spool piston remove to outside of frame.

4 Work equipment control valve:

• Tubes (10) and (11) between PPC valve and
the lift spool piston
• Hose (12) between work equipment control 90 kg (1 piece)
valve and the hydraulic oil tank
a Cover pipings disconnected with blind a When raising the valve, be careful not to hit
plugs to prevent dust in them. the valve against the frame. Also be careful
a Attach tag plate and others to tubes dis- not to get your fingers caught.
connected to distinguish attaching posi-
tions.

INSTALLATION
• Refilling with oil
1) Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.

5 Hydraulic oil: 725 l

2) Before starting the engine, bleed air from

the piston pump circuit. For details, see
TESTING AND ADJUSTING, "Bleeding air
from piston pump".
3) After bleeding air, run the engine to circulate
the hydraulic oil through the system. Then,
check the oil level again.

• Bleeding air
Bleed air from the work equipment circuit. For
details, see TESTING AND ADJUSTING,
"Bleeding air from work equipment circuit".

WD900-3 30-183
(7)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE

DISASSEMBLY AND ASSEMBLY 8. Remove elbows (19) and (20) from cases (21)
and (26).
OF WORK EQUIPMENT
CONTROL VALVE 9. Remove case (21) from valve body (1), then
remove springs (22) and (23), retainer (24) and
DIASSEMBLY spool (25).
1. Remove hose (2), T-piece (3) and valve (4) from 10. Remove case (26) from valve body (1), then
valve body (1). remove springs (27) and (28) and retainer (29).
2. Remove hose (5), T-piece (6) and joint (7) from 11. Remove plug (30) from valve body (1).
valve body (1).

3. Remove suction valve (8) and 2 safety valves

(9) having the suction tube from valve body (1).
a Since the safety valve cannot be adjusted
actually, do not disassemble it.

4. Remove plug (10) from the valve body.

5. Remove main relief valve (11) from valve body

(1).

12. Loosen nut (33) of main relief valve (11), then

divide it into holder (31A) and sleeve (32A).

6. Remove plate (12) from valve body (1), then

remove spring (13) and check valve (14).

7. Remove flange (15) from valve body (1), then

remove spring (16), seal (17) and valve (18).
13. Remove nut (33) from holder (31A).

14. Remove nut (34) from holder (31A), then

remove screw (35), retainer (36), spring (37)
and puppet (38).

30-184 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY
15. Remove seat (39) and backup ring (40) from
sleeve (32A).
16. Remove snap ring (41) from sleeve (32A), then
remove valve (42), spring (43) and backup ring
(44).
a If sleeve (32) or valve (42) has any trouble,
replace as a set, since those parts are not
supplied independently.
WD900-3
WORK EQUIPMENT CONTROL VALVE
ASSEMBLY
1. Assembly of sleeve (32A)
1) Install backup ring (44), spring (43) and
valve (42) to sleeve (32), then secure them
with snap ring (41).
2) Install the O-ring to seat (39), then install
them and backup ring (40) together to
sleeve (32).
2. Assembly of holder (31A)
1) Install the O-ring and puppet (38), spring
(37), retainer (36) and screw (35) to holder
(31).
2) Install nut (33) to holder (31A).
3. Install holder (31A) to sleeve (32A), then lock
them with nut (33).
30-185
(1)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE

3 Main relief valve (11):

4. Insert retainer (29), springs (28) and (27) in 10. Install main relief valve (11) to valve body (1).
valve body (1). Install the O-ring to case (26),
then install them to the valve body. 324 ± 44 Nm {33.0 ± 4.5 kgm}

3 Plug (10): 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}

5. Insert spool (25), retainer (24) and springs (23) 11. Install plug (10) to valve body (1).
and (22). Install the O-ring to case (21), then
install them to the valve body.
12. Install safety valve (9) having the suction tube to

3 Safety valve having suction tube (9):

6. Install elbows (19) and (20) to cases (21) and valve body (1).

3 Elbows (19), (20):

(26).
186 ± 10 Nm {19 ± 1 kgm}
90.7 ± 12.3 Nm {9.25 ± 1.25 kgm}

3 Suction valve (8):

13. Install suction valve (8) to valve body (1).

3 Plug (30): 152 ± 24 Nm {15.5 ± 2.5 kgm}

7. Install plug (30) to valve body (1).
186 ± 10 Nm {19 ± 1 kgm}

14. Install joint (7) and T-piece (6) to valve body (1),
then connect hose (5) between elbow (20) and
T-piece (6).
a When clamping the hose, be careful not to
twist it.

15. Install valve (4) and T-piece (3) to valve body

(1), then connect hose (2) between elbow (19)

3 Valve (4): 68.7 ± 9.8 Nm {7.0 ± 1.0 kgm}

and T-piece (3).

3 T-pieces (3), (6):

3 Hoses (2), (5):

34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}
8. Insert valve (18), seal (17) and spring (16) in

3 Joint (7): 34.3 ± 4.9 Nm {3.5 ± 0.5 kgm}

valve body (1), then install the O-ring to flange 49.0 ± 19.0 Nm {5.0 ± 2.0 kgm}
(15).

9. Insert check valve (14) and spring (13) in valve

body (1), then install the O-ring to plate (12).

30-186 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CAB

REMOVAL AND INSTALLATION 5. Remove 2 steering post lock bolts (5).

OF CAB
REMOVAL
k Stop the machine on level ground, install the
safety bar on the frame, and put blocks under
the wheels to prevent the machine from moving.

1. Remove covers (1) at bottom of floor frame.

6. Remove plastic mounting bolts and pull up rub-

ber boot (6) at bottom of steering post.

2. Remove right cover (2) inside cab.

7. Remove 4 bolts (7), then tip steering post over

fully towawds operator's seat.
a At the same time, set the colum tilt lever to
the unlock position and tip the steering col-
umn over fully towards the operator's seat.

3. Disconnect electric wiring connectors (3).

Connectors: CN-CL1, CL2, CL3

4. DIsconnect window washer hose (4).

WD900-3 30-187
(1)
DISASSEMBLY AND ASSEMBLY CAB

8. Remove 2 cab mounting bolts (8) and 4 mount- INSTALLATION

ing bolts (9) each at intermediate position and
rear. • Carry out installation in the reverse order to
removal.

[*1]
• When installing the cab assembly, do not for-
get to install the seal.

2 Seal:
a Coat the seal uniformly with adhesive.

Adhesive (Cemedyne 366E)

9. Raise cab assembly (10) slowly and keep hori-

zontal when lifting off. [*1]
a Be careful that there is no interference with
the electric wiring at the rear right of the floor
frame.
a Cover the steering post and plastic cover
with a sheet to prevent any damage.

4 Cab: 400 kg

30-188 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

REMOVAL AND INSTALLATION 3. Disconnect drain hose (3) of the right-hand

brake valve.
OF FLOOR FRAME
4. Disconnect hoses (4) and (5) between the accu-
REMOVAL mulator and right-hand brake valve.
k Stop the machine on level ground and lower the
work equipment completely to the ground, then 5. Disconnect accelerator cable (6). [*1]
put blocks under the wheels to prevent the ma- a Loosen the locknut and pull out the pin to dis-
chine from moving. connect the cable.
k Loosen the oil filler cap of the hydraulic tank
gradually to release the pressure in the hydraulic 6. Pull window washer hose (7) out of the floor
tank. frame, then disconnect clamp (8) and move it
k Release remaining pressure in PPC circuit. For toward the frame.
detail, see TESTING AND ADJUSTING "Re-
leasing remaining pressure in hydraulic circuit".
k Release remaining pressure in brake acccumu-
lator circuit. For detail, see TESTING AND AD-
JUSTING "Releasing remaining pressure in
hydraulic circuit".
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Remove front, rear, right and left side covers (1)

under the cab.

2. Remove cab (2). For details, see REMOVAL

AND INSTALLATION OF CAB .

4 Cab : 400 kg
7. Remove clamp (9), then disconnect left-hand
brake drain tube (10).

8. Disconnect hoses (11) and (12) between the

left-hand brake valve and slack adjuster.

9. Disconnect hoses (13) and (14) between the

accumulator and left-hand brake valve.

10. Disconnect pilot hose (to shuttle valve) (15).

WD900-3 30-189
(4)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

11. Disconnect hose (16) between the accumulator 21. Disconnect brake oil drain block (30) from the
and orbit-roll. floor frame.

12. Disconnect hose (17) between the orbit-roll and 22. Disconnect brake shuttle valve (31) from the
right-hand stopper valve. floor frame.

13. Disconnect drain hose (18) of the orbit-roll. 23. Disconnect hose clamp (32).

14. Disconnect hose (19) between the orbit-roll and 24. Disconnect ground cable (33).
left-hand stopper valve.

15. Disconnect pilot hose (to shuttle valve) (20).

16. Disconnect hoses (21) and (22) between the

right-hand brake valve and slack adjuster.

25. Disconnect heater hose (34).

a Close the hot water outlet valve on the en-
gine side.

26. Disconnect air conditioner hose (35). [*2]

a Collect the new Freon with tool X1.
17. Disconnect hoses (23) (Raise lift arm), (24) a Since the adapter is brittle, apply two span-
(Dump), (25) (Lower lift arm) and (26) (Tilt) ners to it to disconnect each hose.
between the PPC valve and control valve.
27. Disconnect connector (36), then remove wire
18. Disconnect hose (27) between the PPC valve clamp (37) and move it toward the body.
and PPC pump. a Connector: CN-CL2, CL3, A4, A5, A6, A7,
CA8A, A8B
19. Disconnect PPC valve drain hose (28).

20. Disconnect hose clamp (29).

30-190 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME

28. Disconnect connector (38), then remove wire INSTALLATION

clamp (39).
• Carry out installation in the reverse order to
a Connector: CN-FL1, FL2, CL1, LR1, LR2,
removal.
LR3, LR4, LR5, GRE
[*1]
a Adjust the length of the accelerator cable.
For details, see TESTING AND ADJUST-
ING, Adjusting length of accelerator cable.

[*2]
a When connecting each hose, do not twist it.
a Be careful not to let dirt, dust, water, etc. get
into hoses.
a Charge with new Freon gas (R134a) by us-
ing tool X1.

3 Mounting nut:
[*3]
29. Remove 4 mounting nuts (40) of the floor frame
245 – 309 Nm {25.0 – 31.5 kgm}
mount. [*3]
• Bleeding air
30. Sling and lift off floor frame (41).
Bleed air from the brake circuit. For details, see
a While slinging the floor frame slowly, check
TESTING AND ADJUSTING, Bleeding air from
that all the clamps and harnesses are dis-
wheel brake circuit.
connected.

4 Floor frame : 240 kg

WD900-3 30-191
(4)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

REMOVAL AND INSTALLATION REMOVAL

OF CENTER HINGE PIN a Before starting the work, remove the bucket.
k Stop the machine on level ground and install the
SPECIAL TOOLS
safety bar to the frame. Lower the work equip-
ment to the ground and stop the engine and ap-

New/remodel
Necessity
Symbol

ply the parking brake, then put blocks under the

Sketch
Q'ty
Part No. Part Name wheels to prevent the machine from moving.
k Loosen the oil filler cap to release the pressure
from the hydraulic tank, then operate the work
790-101-2501 Push puller t 1 equipment control lever over TILT and NEU-
• 790-101-2510 • Block 1 TRAL at least 40 times to release the pressure
• 790-101-2520 • Screw 1 from the accumulator and piping.
a Disconnect the cable from the negative (–)
• 791-112-1180 • Nut 1
terminal of the battery.
• 790-101-2540 • Washer 1
• 790-101-2610 • Leg 2 1. Floor frame
• 790-101-2570 • Plate 4 Remove the floor frame. For details, see
1 REMOVAL AND INSTALLATION OF FLOOR
• 790-101-2740 • Adapter 2
FRAME.
• 790-101-2560 • Nut 2
790-101-7340 Push tool t 1 2. Steering cylinder pin
790-101-7350 Guide t 1 Remove lock plates (1) of the right-hand and
790-201-1310 Spacer t 1 left-hand steering cylinder pins, then pull out the
• 790-101-2102 Puller (294 kN {30 ton}) t 1 pins (2) downward. [*1]
a Remove the bushings.
• 790-101-1102 Hydraulic pump t 1
K 790-101-2300 Push tool t 1
• 790-101-2310 • Plate 1
• 790-101-2320 • Screw 1
• 790-101-2330 • Nut 1
• 790-101-2340 • Washer 1
• 790-101-2390 • Leg 2
• 790-101-2360 • Plate 4
3
• 02215-11622 • Nut 2
790-101-7330 Adapter t 2
790-201-1310 Spacer t 1
790-101-7310 Push tool t 1
790-101-7320 Grip t 1
• 790-101-2102 • Puller (294 kN {30 ton}) t 1
• 790-101-1102 • Hydraulic pump t 1
5 790-450-1110 Adapter t 1

30-192 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

3. Hydraulic piping 5. PPC piping, brake piping

Disconnect the following hoses from the joints
on the rear frame side.
• Hose (3) between switch pump and steering
valve
• Hose (4) between loader pump and work
equipment valve
• Hose (5) between steering pump and steer-
ing valve
• Hose (6) between oil cooler and steering
valve
• Hose (7) between work equipment valve and
hydraulic tank
• Hose (8) between diverter valve and steering
valve
Disconnect the following hoses from the tubes.
• Hoses (10) (Raise lift arm), (11) (Lower lift
arm), (12) (Dump) and (13) (Tilt) between
PPC valve and control valve
• Hoses (14) and (15) between brake valve
and slack adjuster
• Hose (17) between parking brake solenoid
valve drain hose (16), parking brake sole-
noid valve and accumulator charge valve
• Hoses (18) (right side) and (19) (left side) be-
tween stop valve and steering valve
a Attach a tag to each hose for identification.
a Disconnect the clamps of each hose.

4. Drive shaft
Sling and remove center drive shaft (9). [*2]

4 Center drive shaft: 186 kg

WD900-3 30-193
(1)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

6. Supporting of frame 7. Lower hinge pin

1) Adjust the height of the rear frame with 1) Remove the mounting bolts, then remove
hydraulic jacks, and place blocks [1]. retainer (20). [*3]
a Apply the hydraulic jacks and place the a Check the quantity and thickness of the
blocks on left and right sides of the shims inserted between the retainer and
frame. frame.
2) Place blocks [2] under the front frame by
using jacks.

2) Install eyebolts to lower hinge pin (21), then

lift off pin.

3) Place blocks [3] under the counterweight. 4 Lower hinge pin: 68 kg

4) Move the hydraulic hoses to the right side of
the machine by using lever blocks. a Remove bolt (22) of the hinge pin, and
install the eyebolt.

3) Remove spacer (23).

30-194 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

8. Upper hinge pin 10. Lower hinge

1) Remove mounting bolts (24) and (25), then 1) Remove mounting bolt, then remove retainer
remove retainer (26). [*4] (29). [*5]
a There are shims between the retainer
and the frame, so check the number and
thickness of the shims, and keep in a
safe place.

2) Install eyebolt K5 to upper hinge pin (27),

and lift off.

4 Upper hinge pin: 40 kg

2) Remove dust seal (30) from retainer.

9. Disconnecting frame
Remove safety bar, pull out front frame to front 3) Remove spacer (31) from front frame.
and disconnect frames.
a Be careful not to let the spacer at the upper
of the lower hinge bite into the rear frame.
a Be careful to maintain the balance when car-
rying out the operation.
a Move the frame about 100 mm at a time.
a Remove spacer (28) from the rear frame.

WD900-3 30-195
(1)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

4) Remove plate (32) from front frame, then 2) Remove dust seal (36) from retainer.
remove dust seal (33).

3) Remove plate (37) from front frame, then

5) Remove bearing (34). remove dust seal (38).

4) Remove bearing (39).

11. Upper hinge
1) Remove retainer (35). [*6]
a There are shims between the retainer
and the frame, so check the number and
thickness of the shims, and keep in a
safe place.

30-196 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

INSTALLATION a Assemble the steering cylinder pin according

to the following procedure.
• Carry out installation in the reverse order to
1. After tightening the upper taper collet and
removal.
the steering cylinder pin, tighten the lower
taper collet and the steering cylinder pin.
[*1]
a Adjust clearance d to the specification val-
2. Tightening of the upper bolt
ues with shims.
a Check "4. Precautions" in advance.
Clearance d: 3.0 max.
k When aligning the position of the pin hole,
1) Tighten bolts (1), (2) and (3) by using

3 Bolt (1), (2), (3):

ratchet wrench.
use a bar. Never put your fingers on the pin
hole.
39 Nm {4 kgm}
a Tightening torque of 39 Nm {4 kgm}:
Tighten to the operating effort of 20
kg by using ratchet wrench of L =
200.
Then, tighten them at 3 places clock-
wise in the order of (1), (2), (3), (1), (2),

3 Bolt (1), (2), (3):

(3) by using ratchet wrench.

39 Nm {4 kgm}
2) Tighten bolts once clockwise in the
order of (1), (2), (3) by using torque

3 Bolt (1), (2), (3):

wrench.

98 Nm {10 kgm}
3) Hit any position of (A) or (B) or (C) twice
by using plastic hammer so that the
clearance between taper collet and
frame (part Y of the figure) becomes
even, and taper collet does not slant.
Hit each part of (A), (B), (C) twice by
using plastic hammer. Perform this for 2
times.
4) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

98 Nm {10 kgm}
5) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

147 Nm {15 kgm}

6) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

177 Nm {18 kgm}

7) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

196 Nm {20 kgm}

WD900-3 30-197
(3)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

8) Loosen bolt (1) temporarily, apply adhe-

sive to it, and tighten it.
Loosen bolt (2) temporarily, apply adhe-
sive to it, and tighten it.
Loosen bolt (3) temporarily, apply adhe-

2 Bolt (1), (2), (3):

sive to it, and tighten it.

3 Bolt (1), (2), (3):

Adhesive (LOCTITE #262)

177 Nm {18 kgm}

9) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

177 Nm {18 kgm} Upper left front

Upper right front

Upper left rear

Upper right rear

30-197-1 WD900-3
(3)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

3. Tightening of the lower bolt

a Check "4. Precautions" in advance.
1) Tighten bolts (1), (2) and (3) by using

3 Bolt (1), (2), (3):

ratchet wrench.

39 Nm {4 kgm}
a Tightening torque of 39 Nm {4 kgm}:
Tighten to the operating effort of 20
kg by using ratchet wrench of L =
200.
Then, tighten them at 3 places clock-
wise in the order of (1), (2), (3), (1), (2),

3 Bolt (1), (2), (3):

(3) by using ratchet wrench.
Lower left front
39 Nm {4 kgm}
2) Tighten bolts once clockwise in the
order of (1), (2), (3) by using torque

3 Bolt (1), (2), (3):

wrench.

98 Nm {10 kgm}
3) Hit each part of (E), (F), (G) twice by
using plastic hammer. Perform this for 2
times.
4) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

98 Nm {10 kgm}
5) Tighten bolts clockwise in the order of Lower right front

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

147 Nm {15 kgm}

6) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

177 Nm {18 kgm}

7) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

196 Nm {20 kgm}

8) Loosen bolt (1) temporarily, apply adhe-
sive to it, and tighten it.
Loosen bolt (2) temporarily, apply adhe- Lower left rear
sive to it, and tighten it.
Loosen bolt (3) temporarily, apply adhe-

2 Bolt (1), (2), (3):

sive to it, and tighten it.

3 Bolt (1), (2), (3):

Adhesive (LOCTITE #262)

177 Nm {18 kgm}

9) Tighten bolts clockwise in the order of

3 Bolt (1), (2), (3):

(1), (2), (3). Perform this for 3 times.

177 Nm {18 kgm}

Lower right rear

WD900-3 30-197-2
(3)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

4. Precautions 5) The height to start hitting the plastic

1) Install taper collet (4) so that its slit (part
B) faces inside of machine.
2) Note that there is no clearance or slant
between the frame and the collet (part
Y) when they are assembled temporar-
hammer (dimension H) is 150 mm.
6) Degrease the bolts and holes before
starting the work.
7) Apply LM-P to the inner surface of bush-
ing on cylinder side and to the dust seal

2 Part a:
ily before tightening. lip before installing the pin. (Part a)
3) The above mentioned clearance or slant
must not be found both during and after Lubricant (LM-P)
tightening. Install dust seal (5) with its lip out. (View
4) Use plastic hammer [1] of the following P)
size. 8) Do not allow adhesion of lubricant as
• Dimension grease, etc. to the pin and the taper
L: 320 mm face of the collet. (Part b)
D: 38mm

30-197-3 WD900-3
(3)
DISASSEMBLY AND ASSEMBLY
3 Drive shaft mounting bolt:
[*2]
343 – 427 Nm {35.0 – 43.5 kgm}
2 Outer circumference of lower hinge pin:
[*3]
Lubricant (LM-P)
a Install the retainer to the lower hinge pin
without using shims, then tighten it to the
specified torque.
a Jack up the front frame until the spacer
reaches the rear frame hinge.
a Tap the lower hinge pin head with a copper
hammer so that the mounting bolt will be
tightened to the specified torque, then tight-
en the bolt to the specified torque.
a Before installing the retainer, measure its
3 Mounting bolt:
thickness to select shims.
Shaft 1,520 – 1,910 Nm {155 – 195 kgm}
Frame 842 – 1,030 Nm {84 – 105 kgm}
a Remove the all outside mounting bolts and
measure clearance c between the retainer
and frame at three holes, then calculate the
average.
Select shims so that the average clearance
will be 0.08 – 0.18mm.
a The thickness of the shims must not exceed
the clearance measured at the three places.
a Remove the grease from the mounting bolts
2 Mounting bolt: Adhesive (LT-2)
and mounting holes completely.
3 Mounting bolt:
Shaft 1,520 – 1,910 Nm {155 – 195 kgm}
Frame 842 – 1,030 Nm {84 – 105 kgm}
WD900-3
CENTER HINGE PIN
[*4]
a Install the retainer (2) to the upper hinge pin
2 Adhesive: LT-2
(1) with bolts (3).
3 Mounting bolt:
549.0 ± 59.0 Nm {56.0 ± 6.0 kgm}
a Apply lubricant to the outer circumference
2 Outer circumference of hinge pin:
(e) of upper hinge pin (1) and install the pin.
Lubricant (LM-P)
a Do not allow any lubricant to attach to taper
surface (f) of upper hinge pin (1).
a Tighten bolts (4) lightly.
a Tighten each bolt (4) once in the order of (A),
(B), (C), (D), (E), and (F).
Then, tighten each of it three times in the
2 Adhesive: (LT-2)
order of (A), (C), (E), (B), (D), and (F).
3 Mounting bolt:
98.1 ± 9.8 Nm {10.0 ± 1.0 kgm}
a Furthermore, tighten each bolt (4) once in
the order of (A), (B), (C), (D), (E), and (F).
Then, tighten each of it in the order of (A),
(C), (E), (B), (D), and (F) until all of the bolts
cannot be turned.
Mounting bolt:
549.0 ± 59.0 Nm {56.0 ± 6.0 kgm}
a Check that the clearance (g) between the re-
tainer and the bushing is within 3 to 7 mm. If
the clearance (g) is 3 mm or less, remove the
grease because it may have attached to ta-
per surface (f) of the upper hinge pin (1), and
tighten bolts (4) again.
a If the clearance (g) is 7 mm or more, loosen
bolts (4) because they may have been tight-
ened insufficiently, and tighten them again.
30-197-4
(3)
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN

a Tighten the 10 mounting bolts of the retainer,

and measure clearance b between the re-
tainer and hinge at 4 places. Then, select
shims so that clearance b will be 0.08 –
0.18mm less than the measured value.
a The thickness of the shims must not exceed
the clearance measured at the four places.
a After selecting shims, tighten the retainer to

3 Mounting bolt (For adjusting shims):

the specified torque.

3 Mounting bolt:
245 ± 25 Nm {25.0 ± 2.5 kgm}

[*5] 927 ± 103 Nm {94.5 ± 10.5 kgm}

a Press fit the bearing and spacer to the front a Press fit so that the lip of the dust seal is fac-

2 Dust seal lip face: Lubricant (G2-LI)

frame with tool K3. ing outside.
a Be careful that the bearing is not at an angle.
a Fill inside of the bearing with grease suffi- a Install the spacer with the more chamfered

2 Inside of spacer: Lubricant (G2-LI)

ciently. side on the bearing side.
a When installing the bearing, be sure to re-
member to install the spacer.
a The clearance of the bearing is adjusted, so
do not change the combination of bearing
and the spacer. When replacing, replace as
a set.
a Press fit so that the lip of the dust seal is fac-

2 Dust seal lip face: Lubricant (G2-LI)

ing outside.

30-198 WD900-3
(2)
DISASSEMBLY AND ASSEMBLY
[*6]
a Install tool K1 to the top of the front frame up-
per hinge, then set the bearing. Press fit the
bearing to the press fit part from above.
a Be careful that the bearing is at an angle.
a Fill inside of the bearing with grease suffi-
ciently.
a When installing the bearing, be sure to re-
member to install the spacer.
a The clearance of bearing h is adjusted, so do
not change the combination of it and the
spacer. When replacing, replace as a set.
a Press fit so that the lip of the dust seal is fac-
2 Dust seal lip face: Lubricant (G2-LI)
ing outside.
a Tighten the six mounting bolts of the retain-
er, and measure clearance a between the re-
tainer and hinge at four places. Then, select
shims so that clearance b will be 0.08 –
0.18mm less than the measured value.
a The thickness of the shims must not exceed
the clearance measured at the four places.
a After selecting shims, tighten the retainer to
the specified torque.
WD900-3
CENTER HINGE PIN
3 Mounting bolt (For adjusting shims):
3 Mounting bolt:
78.5 ± 7.9 Nm {8.0 ± 0.8 kgm}
549 ± 59 Nm {56 ± 6 kgm}
a Press fit so that the lip of he dust seal is fac-
2 Dust seal lip face: Lubricant (G2-LI)
ing outside.
• Refilling with oil
Add oil through the oil filler of the hydraulic tank
to the specified level.
5 Hydraulic oil: Approx. 550 l
a After bleeding air, run the engine to circulate
the hydraulic oil through the system. Then,
check the oil level again.
• Bleeding air
Bleed air from the brake system.
a Bleed air from the brake circuit. For details,
see TESTING AND ADJUSTING, "Bleeding
air from wheel brake circuit".
a Bleed air from the work equipment circuit. For
details, see TESTING AND ADJUSTING,
"Bleeding air from work equipment circuit".
a Bleed air from the piston pump circuit. For
details, see TESTING AND ADJUSTING,
"Bleeding air from piston pump".
a Bleed air from the steering circuit. For de-
tails, see TESTING AND ADJUSTING,
"Bleeding air from steering circuit".
• Charging with gas
a Charge the air conditioner with gas (R134a).
a Standard quantity of gas to be supplied:
1.5 – 1.6kg
a Before charging with the gas, be sure to
evacuate the system by the repeated evacu-
ation method.
a Be sure that Freon liquid stay out of the re-
frigerating system, and prevent mistakes
such as placing the Freon can upside down.
a Do not start the compressor before charging
the system with the gas.
a Check that proper quantity of the gas is supplied.
a Check the quantity of the compressor oil.
(Standard quantity of oil: 150 +14
+0 CC ND-OIL8)
30-199
(4)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL AND INSTALLATION 3. Sling Y-link (4), remove lock bolt (5), and pull out
blade pin (6).
OF WORK EQUIPMENT
4. Remove lock bolt (7), plate (8), shim (9), and
REMOVAL bushing (10). [*1]
k Stop the machine on level ground and lower the a If shims are inserted, record its quantity.
work equipment completely to the ground, then
put the safety bar on the frame and set blocks
under the wheels to prevent the machine from
moving.

1. Set blocks [1] and [2] under the left and right
straight frame.

5. Remove lock bolt (11) and pull out pin (12). [*2]
a If shims are inserted, record its quantity.

2. Sling lift cylinder (1), remove lock bolt (2), and

pull out head pin (3).
a 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.

6. Lift off the Y-link.

4 Y-link: 1,338 kg

7. Sling H-link (13), remove lock bolt (14), and pull

out the cord ring and pin (15). [*3]
a If shims are inserted, record its quantity.

8. Lift off the H-link.

4 H-link: 1,408 kg

30-200 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

9. Remove covers (16) and (17). 11. Remove left and right trunnion caps (20).
a Make match marks on the left and right trun-
nion caps.

12. Start engine, and move machine slowly in reverse

to disconnect work equipment assembly from
machine.

13. Sling bar (21), remove lock bolt (22), pull out pin
(23), remove lock bolt (24), and pull out pin (25).

14. Lift off the link.

4 Link: 249 kg

10. Disconect hoses (18) and (19) from connector.

WD900-3 30-201
(1)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

15. Sling trunnion (26) and remove mounting bolts INSTALLATION

(27).
• Carry out installation in the reverse order to
removal.
16. Lift off the trunnion.
a Take care not to damage the spherical sur- • Refilling with oil
face. Add oil to the specified level. Run the engine to

4 Trunnion: 139 kg
circulate the oil through the system. Then, check
the oil level again.
k When aligning the pin holes, use a bar. Never in-
17. Sling trunnion support (28), remove lock bolt sert your fingers in the pin holes.
(29), and pull out pin (30).
[*1]
a Remove lock bolt (31), and pull out pin (32).
a Protrusion of bushing a = 0.21 – 1.65 mm
18. Lift off the trunnion support.

4 Trunnion support: 1,913 kg (R.H.)

1,909 kg (L.H.)

[*2]
a Clearance b = Max. 1.5 mm

[*3]
a Take care that the cord ring will not be caught.
a When installing Y-link (4) and H-link (13),
match the stamps on them to each other.

30-202 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER

REMOVAL AND INSTALLATION 4. Disconnect grease tube (6) for the bottom-side
pin.
OF LIFT CYLINDER ASSEMBLY
REMOVAL
k Stop the machine on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels.

k Loosen the filler cap to release the pressure

gradually from the hydraulic tank, then operate
the work equipment lever three to four times to
decrease the pressure within the piping up to the
ambient pressure level.

1. Remove bracket (1) and clip (2).

5. Pull out bottom-side pin (7).
2. Disconnect head-side tube (3) and bottom-side a Pull it up to the position where the piston can
tube (4) for the lift cylinder. be removed.
a Disconnect the hoses with confirmation to a Sling the cylinder temporarily.
exlstence of the remainde compressed air.
6. Sling and remove lift cylinder assembly (8).

4 Lift cylinder assembly: 621 kg

3. Remove the lock bolt and pull out head side pin
(5).
a Pull it up to the position where the piston can
be removed.
a Sling the cylinder temporarily.
INSTALLATION
• Carry out installation in the reverse order to
removal.

k Use stick, bar or similar tool to align the holes for

the pin and never put a finger into hte hole.

WD900-3 30-203
(1)
DISASSEMBLY AND ASSEMBLY PITCH & TILT CYLINDER

REMOVAL AND INSTALLATION INSTALLATION

OF PITCH & TILT CYLINDER • Carry out installation in the reverse order to
removal.

k When aligning the position of the pin hole, use a

REMOVAL
k Stop the machine on level ground and lower the bar. Never put your fingers in the pin hole.
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma-
chine from moving.

k Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Disconnect hose (1) on the pitch and tilt cylinder

head side and tube (2) on the bottom side.
a Checking the residual pressure, disconnect
the hoses.

2. Pull out bottom pin (3).

a Pull out the pin until the cylinder can be re-
moved.
a Sling the cylinder temporarily.

3. Pull out head pin (4).

a Pull out the pin until the cylinder can be re-
moved.
a Sling the cylinder temporarily.

4. Lift off pitch and tilt cylinder assembly (5).

4 Pitch and tilt cylinder assembly: 598 kg

30-204 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT

REMOVAL AND INSTALLATION 4. Remove cover (3).

OF AIR CONDITIONER UNIT 5. Remove air conditioner unit cover (3), console
SPECIAL TOOLS box cover (4) and box (5).

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

799-703-1200 Service tool KIT 1

799-703-1110 Vacuum pump (220V) 1
X 1
790-703-1120 Vacuum pump (240V) 1
790-703-1400 Gas leak detector t 1

REMOVAL
k Stop the machine on level ground and lower the
6. Remove fuse box (6) from the air conditioner
work equipment completely to the ground, then
unit, then move it toward the right-hand console
put blocks under the wheels to prevent the ma-
box.
chine from moving.
7. Disconnect connectors (7) (LC3) and (8) (LC2).
1. Remove the cab . For details, see REMOVAL
AND INSTALLATION OF CAB .
8. Disconnect two refrigerant tubes (9).
2. Connect refrigerant collector X1 to adapter (1) of
the air conditioner compressor hose, then col-
lect the new Freon gas (R134a).

9. Disconnect two heater hoses (10).

a Be careful, since the tube on the unit side is
soft.
3. Remove operator‘s seat (2).

4 Operator‘s seat : 40 kg

WD900-3 30-205
(1)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT

10. Remove mounting bolt (11), then remove air INSTALLATION

conditioner unit (12).
a Remove the air conditioner unit by pulling it • Carry out installation in the reverse order to
out to the left. removal.

• Charging with gas

Charge the air conditioner circuit with new Freon
gas (R134a) by using refrigerant charger X1.

30-206 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

REMOVAL AND INSTALLATION 8. Remove four mounting bolts (9), then remove air
conditioner compressor (10).
OF AIR CONDITIONER
COMPRESSOR
SPECIAL TOOLS

New/remodel
Necessity
Symbol

Sketch
Q'ty
Part No. Part Name

799-703-1200 Service tool KIT 1

799-703-1110 Vacuum pump (220V) 1
X 1
790-703-1120 Vacuum pump (240V) 1
790-703-1400 Gas leak detector t 1

REMOVAL
k Disconnect the cable from the negative (–) ter-
INSTALLATION

minal of the battery. • Carry out installation in the reverse order to

removal.
1. Collect the new Freon gas (R134a) with tool X1.
• Charging with gas
Charge the air conditioner with new Freon gas
(R134a) by tool X1.

2. Disconnect connector (1) (CN-E08).

3. Disconnect two hoses (2).

4. Loosen locknut (3) and drive belt adjustment nut

(4).

5. Loosen mounting bolt (5).

6. Loosen adjustment nut (4), then remove drive belt

(6) from the pulley.

7. Remove bolt (7), then disconnect block (8) from

the air conditioner compressor.

WD900-3 30-207
(1)
DISASSEMBLY AND ASSEMBLY RECEIVER TANK

REMOVAL AND INSTALLATION INSTALLATION

OF RECEIVER TANK • Carry out installation in the reverse order to
removal.

New/remodel
Necessity
Symbol

Sketch
[*1]

Part No. Part Name
799-703-1200 Service tool KIT
799-703-1110 Vacuum pump (220V)
X 1
790-703-1120 Vacuum pump (240V)
790-703-1400 Gas leak detector
Q'ty
a Before connecting each hose, check that the
O-ring is free from damage and deteriora-
tion.
1
1 • Charging with gas
1 a Charge the air conditioner circuit with air
t 1 conditioner gas (R134a) by using refrigerant
charger X1.

REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
k Collect the new Freon gas (R134a). For details,
see REMOVAL AND INSTALLATION OF AIR
CONDITIONER COMPRESSOR.

1. Open snap (1).

2. Disconnect hose (2) of the air conditioner con-

denser.

3. Disconnect hose (3) of the air conditioner unit.

[*1]

4. Remove two U-bolts (4), then remove receiver

tank (5).

30-208 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER

REMOVAL AND INSTALLATION 3. Left-hand condenser

1) Disconnect connectors (5).
OF AIR CONDITIONER a Connectors: CN-B12, CN-B13
CONDENSER 2) Disconnect hose (6) between the right-hand
condenser and receiver tank. [*1]
3) Disconnect hose (7) between both condens-

New/remodel
Necessity
ers.
Symbol

Sketch
Q'ty
Part No. Part Name a Since the adapter is brittle, apply two
spanners to it to disconnect each hose.
4) Remove the mounting bolts (8), then remove
799-703-1200 Service tool KIT 1 left-hand condenser (9).
799-703-1110 Vacuum pump (220V) 1
X 1
790-703-1120 Vacuum pump (240V) 1
790-703-1400 Gas leak detector t 1

REMOVAL
k Stop the machine on level ground and put blocks
under the wheels to prevent the machine from
moving.
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Collect the new Freon gas (R134a). For details,

see REMOVAL AND INSTALLATION OF AIR
CONDITIONER COMPRESSOR. INSTALLATION

2. Right-hand condenser • Carry out installation in the reverse order to

1) Disconnect connectors (1). removal.
a Connectors: CN-B10, CN-B11
2) Disconnect hose (2) between both condens- [*1]
ers. [*1] a When connecting each hose, do not twist it.
3) Disconnect hose (3) of the air conditioner a Be careful not to let dirt, dust, water, etc. in
compressor. each hose.
a Since the adapter is brittle, apply two a Charge the air conditioner circuit with new
spanners to it to disconnect each hose. Freon gas (R134a) by using tool X1.
4) Remove the mounting bolts, then remove
right-hand condenser (4).

WD900-3 30-209
(1)
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND STEERING CONTROLLER

REMOVAL AND INSTALLATION INSTALLATION

OF TRANSMISSION AND • Carry out installation in the reverse order to
STEERING CONTROLLER removal.

REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.

1. Open the right-hand door of the cab, then remove

the cover out of the control stand case.

2. Disconnect connectors (1), (2), (3), (4), (5) and

(6).
(1) = C1, (2) = C3B, (3) = C3A, (4) = C4, (5) =
C2, (6) = C5

3. Remove mounting bolts (7), then remove trans-

mission and steering controller (8).

30-210 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY MAIN MONITOR

REMOVAL AND INSTALLATION 5) Remove steering post cover (8) and mount-
ing bolt cap, then remove mounting bolt (9).
OF MAIN MONITOR a Turn down the steering post cover for-
ward.
REMOVAL
k Stop the machine on level ground and install the
safety bar to the frame. Lower the work equip-
ment to the ground and stop the engine and ap-
ply the parking brake, then put blocks under the
wheels to prevent the machine from moving.

k Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Removal of surrounding steeling column

1) Remove dashboards (1) and (2).
2) Remove steering post covers (3) and (4).

2. Remove bracket (10) on the back side of the

main monitor.

3) Remove steering post cover (5).

4) Remove steering post cover (6) and mount-
ing bolt cap (7), then remove the bolt.
3. Remove main monitor (11) and eight mounting
bolts (12).
a When removing the main monitor, be careful
not to give a large shock to it.

WD900-3 30-211
(1)
DISASSEMBLY AND ASSEMBLY MAIN MONITOR

4. Disconnect connectors (13), (14), (15) and (16) INSTALLATION

from the main monitor (11), then remove the
main monitor. [*1] • Carry out installation in the reverse order to
(13) = CN-L05 removal.
(14) = CN-L07
(15) = CN-L06 [*1]
(16) = CN-L08 a Apply the locks of the connectors securely.

30-212 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL AND INSTALLATION 8. Disconnect fuel hoses (11) and (12).

a Disconnect the hoses on the engine side.
OF FUEL TANK
REMOVAL
k 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.

1. Drain the fuel.

6 Fuel: Approx. 1,300 l

2. Remove step (1) and covers (2) and (3).

3. Disconnect engine oil drain valve (4), torque 9. Disconnect fuel gauge connector (13) (CN-R05).
converter cooling water drain valve (5) and cool- a This connector is just above the drain valve.
ing water drain valve (6) from the fuel tank.

10. Remove cover (14) installed between the fuel

4. Remove side cover (7). tank and counterweight.

5. Remove handrail (8).

6. Remove fuel cut valve cover (9).

7. Remove step (10).

WD900-3 30-213
(1)
DISASSEMBLY AND ASSEMBLY FUEL TANK

11. Temporarily sling fuel tank (15), then remove INSTALLATION

mounting bolts (16). [*1]

4 Fuel tank : 786 kg

• Carry out installation in the reverse order to
removal.

3 Fuel tank mounting bolt:

[*1]

1,520 – 1,910 Nm {155 – 195 kgm}

• Bleeding air
Bleed air from the fuel line. For details, see
TESTING AND ADJUSTING, Bleeding air from
each portion.

12. Set block [1] under the fuel tank.

13. Slowly lower fuel tank (15).

a Pull the fuel tank out of under the machine
body.

30-214 WD900-3
(1)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL AND INSTALLATION INSTALLATION

OF COUNTERWEIGHT
REMOVAL
k Stop the machine on level ground, install the
safety bar on the frame, and put blocks under
the wheels to prevent the machine from moving.
• Carry out installation in the reverse order to
removal.
3 Counterweight mounting bolt:
[*1]
1,510 – 1,910 Nm {155 – 195 kgm}

1. Sling counterweight (1), then remove mounting

bolts, and lift off.
a When lifting off the couterweight, be careful
to maintain the balance.

4 Counterweight: 2,500 kg

WD900-3 30-215
(1)
DISASSEMBLY AND ASSEMBLY AJSS LEVER SWITCH ASSEMBLY

REMOVAL AND 3. Remove bolts (5) (3 pieces) and washers (6) (2

pieces), and remove clamps (7), (9) and (9a)
INSTALLATION OF AJSS which are fixing wiring harness (8).
LEVER SWITCH ASSEMBLY
REMOVAL
k Before starting the removal work, be sure to per-
form the works described in "Section 30, DISAS-
SEMBLY AND ASSEMBLY", "PRECAUTIONS
WHEN CARRYING OUT OPERATION".
k Disconnect the cable from the negative (-) termi-
nal of the battery. (If the machine is equipped
with the battery disconnect switch, turn it to OFF
position.)

1. Remove bolts (1) (4 pieces).

2. Move cover (2) to a place where it is not a hin-
drance to work.
a Pass the cover (2) to shaft (4) of AJSS lever
(3) and fix with tape, etc.

4. Remove screws (11) (2 pieces) and collars (12)

(2 pieces) at portion (a) on the back of knob
(10).

30-216 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY
5. Push up wiring harness (8) passed through shaft
(4) toward knob (b).
6. Disconnect connectors (15) and (16), and
remove AJSS lever cover (17) and switch
assembly together.
7. Remove screw (18), and disconnect relay unit
(19).
8. Remove directional selector switch (20) and
hooks (c) (3 pieces) of horn switch (21), and
remove AJSS lever switch assembly (22).
WD900-3
AJSS LEVER SWITCH ASSEMBLY
INSTALLATION
1. Install AJSS lever switch assembly (22) accord-
ing to the following procedure.
2. Install upshift switch (23) and downshift switch
(24) of switch assembly (22) to AJSS lever
cover (17).
a Color of upshift switch cable:
Blue/black, green/yellow
a Color of downshift switch cable:
Green/black, brown/white
3. Install relay unit (19) with screw (18).
a Confirm that the relay unit does not catch the
3 Screw (18):
harness.
0.7 to 0.9 Nm {0.07 to 0.09 kgm}
a Install upshift switch (23) and downshift
switch (24) to the center of mounting hole.
a Check that rubber boot (27) is not tensed or
deformed.
30-217
(4)
DISASSEMBLY AND ASSEMBLY AJSS LEVER SWITCH ASSEMBLY

a The shape of the directional switch differs

according to the machine serial number.

5. Install horn switch (26) to AJSS lever cover (17).

a Check that hook (f) of horn switch (26) is in-
stalled securely.

4. Install directional selector switch (20) to AJSS

lever cover (17).
a Check that hooks (d) (2 pieces) of directional
selector switch (20) are installed securely.
a Check that height (e) of rubber boot (25)
above cover (17) is even all around the pe-
riphery. If it is not, even it out by moving di-
rectional selector switch (20) back and forth
2 to 3 times to fit.
Height (e) of rubber boot (25): 1.5 mm 6. Connect wiring harness (8) which is passing
through shaft (4) to connectors (16) and (15).
a Connect connector (16) (4-pole) first, then
connect connector (15) (6-pole).
a Check that locks (g) of connectors (16) and
(15) are set normally.

30-218 WD900-3
(4)
DISASSEMBLY AND ASSEMBLY AJSS LEVER SWITCH ASSEMBLY

9. Install clamps (7), (9) and (9a) with bolts (5) (3

pieces) and washers (6) (2 pieces), and fix wir-
ing harness (8).

7. Install collars (12) (2 pieces) to back (a) of knob

(10).
a Install the collar (12) with the small diameter
end first.
8. Install cover (17) with screws (11) (2 pieces).
a Install horn switch (21) to the center of the
mounting hole and eliminate clearance

3 Screw (11)
around it.

0.8 ± 0.1 Nm {0.08 ± 0.01 kgm}

WD900-3 30-219
(4)
DISASSEMBLY AND ASSEMBLY AJSS LEVER SWITCH ASSEMBLY

10. Install cover (2) with bolts (1) (4 pieces).
Check of operation
1. Connect the negative (-) terminal of the battery.
(If the machine is equipped with the battery dis-
connect switch, turn it to ON position.)
2. Start the engine, operate AJSS lever and each
switch as follows, and check their operations.
Steering operation
• Operate AJSS lever to the right and left, and
check that the machine turns in the operating
direction of AJSS lever.
Directional operation
• Set directional selector switch (20) to each
position (N, F, R), and check that the travel
direction changes according to the operation
of directional selector switch.
Upshift and downshift operations
• Operate upshift switch (23) and downshift
switch (24), and check that gear is shifted ac-
cording to the switch operation.
Horn switch operation
• Operate horn switch (21), and check that the
horn sounds according to the horn switch op-
eration.

30-220 WD900-3
(4)
 40 MAINTENANCE STANDARD
ENGINE MOUNT ..........................................................................................................................................40- 2
TRANSMISSION MOUNT ............................................................................................................................40- 3
DAMPER.......................................................................................................................................................40- 4
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP ................................................................40- 6
TORQUE CONVERTER ...............................................................................................................................40- 8
TORQUE CONVERTER REGULATOR VALVE ............................................................................................40- 9
TRANSMISSION (1/2) ..................................................................................................................................40- 10
TRANSMISSION (2/2) ..................................................................................................................................40- 12
TRANSFER...................................................................................................................................................40- 14
TRANSMISSION CONTROL VALVE ............................................................................................................40- 16
DRIVE SHAFT ..............................................................................................................................................40- 21
CENTER SUPPORT .....................................................................................................................................40- 22
DIFFERENTIAL (1/2) ....................................................................................................................................40- 23
DIFFERENTIAL (2/2) ....................................................................................................................................40- 24
FINAL DRIVE ................................................................................................................................................40- 26
AXLE MOUNT...............................................................................................................................................40- 28
CENTER HINGE PIN....................................................................................................................................40- 30
STEERING COLUMN ...................................................................................................................................40- 32
STEERING DEMAND VALVE .......................................................................................................................40- 34
DIVERTER VALVE ........................................................................................................................................40- 36
STEERING CYLINDER MOUNT ..................................................................................................................40- 37
EMERGENCY STEERING PUMP ................................................................................................................40- 38
BRAKE VALVE..............................................................................................................................................40- 40
SLACK ADJUSTER ......................................................................................................................................40- 43
BRAKE ..........................................................................................................................................................40- 44
PARKING BRAKE .........................................................................................................................................40- 46
PPC VALVE...................................................................................................................................................40- 48
PPC RELIEF VALVE .....................................................................................................................................40- 50
STEERING PUMP ........................................................................................................................................40- 51
SWITCH PUMP ............................................................................................................................................40- 52
MAIN PISTON PUMP ...................................................................................................................................40- 54
CONTROL PUMP .........................................................................................................................................40- 56
MAIN CONTROL VALVE ..............................................................................................................................40- 58
HYDRAULIC CYLINDER ..............................................................................................................................40- 62
WORK EQUIPMENT LINKAGE ....................................................................................................................40- 66
BRAKE COOLING PUMP .............................................................................................................................40- 71

WD900-3 40-1
MAINTENANCE STANDARD ENGINE MOUNT

ENGINE MOUNT

40-2 WD900-3
MAINTENANCE STANDARD TRANSMISSION MOUNT

TRANSMISSION MOUNT

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between trunnion size Shaft Hole clearance limit
1
and torque converter case
–0.100 +0.072 0.100 –
230
–0.172 0 0.242
Clearance between O.D. of Replace
0 +0.035
2 shaft and I.D. of rubber cush- 63 0 – 0.065
–0.030 0
ion
Clearance between O.D. of
+0.115 +0.054 –0.115 –
3 rubber cushion and I.D. of 97
+0.080 0 –0.026
bracket hole
Standard shim thickness: 1.5 mm (parallelism of coupling mating
4 Thickness of mount shim joint of transmission output shaft and sensor of sensor pin: Max. —
0.5 mm

WD900-3 40-3
MAINTENANCE STANDARD DAMPER

DAMPER

40-4 WD900-3
MAINTENANCE STANDARD DAMPER

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between bearing size Shaft Hole clearance limit
1
and shaft
+0.015 0 –0.035 –
95 0.025
+0.003 –0.020 –0.003
Clearance between bearing 0 –0.008 –0.033 –
2 170 0.030
and housing –0.025 –0.033 0.017
Clearance between inner +0.035 +0.099 0.029 –
3 94.3 0.1 Replace
body and shaft +0.013 +0.064 0.086
Standard size Tolerance Repair limit
Wear of surface in shaft and
4 0
oil seal 115 –0.140
–0.087
Wear of surface in sleeve and 0
5 140 –0.160
oil seal –0.100
6 Backlash of spline 0.068 – 0.263

WD900-3 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP

TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP

40-6 WD900-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP

Unit: mm

No. Check item Criteria Remedy

Model Standard clearance Clearance limit

SAR4 – 112 0.11 – 0.16 0.19
Clearance between rotor and
1 SAR3 – 100 0.13 – 0.18 0.22
shaft
SAR1 – 32 0.10 – 0.15 0.19
SAR1 – 14 0.10 – 0.15 0.19
SAR4 – 112 0.06 – 0.140 0.20
Clearance between inside SAR3 – 100 0.06 – 0.149 0.20
2 diameter of plain bearing and
outside diameter of gear shaft SAR1 – 32 0.06 – 0.119 0.20 Replace

SAR1 – 14 0.06 – 0.149 0.20

SAR4 – 112 0
21 –0.5

SAR3 – 100 0
14 –0.5
3 Insertion depth of pin
SAR1 – 32 0
10 –0.5

SAR1 – 14 0
10 –0.5

4 Rotating torque of spline shaft 20.6 – 36.3 Nm {2.1 – 3.7 kgm} —

Standard Repair limit
Revolution Discharge
Model discharge discharge
(rpm) pressure
(l/min) (l/min)
2.9 MPa
SAR4 – 112 2,200 242 222
{30 kg/cm2}
Discharge
— Oil: EO10-CD 2.9 MPa —
SAR3 – 100 2,200 210 183
Temperature: 45 to 55°C {30 kg/cm2}
2.9 MPa
SAR1 – 32 2,200 68 57
{30 kg/cm2}
9.8 MPa
SAR1 – 14 2,200 29 24
{100 kg/cm2}

WD900-3 40-7
MAINTENANCE STANDARD TORQUE CONVERTER

TORQUE CONVERTER

Unit: mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Inside diameter of seal ring
1 +0.040 Repair
surface of retainer 170 170.5
0 chrome plat-
ing or replace
Inside diameter of seal ring +0.035
2 85 85.1
surface of sleeve 0
0
Width and thick- Width 4.45 4.05
3 –0.1
ness of seal ring
Thickness 6.0 ±0.1 5.5 Replace
Backlash of PTO gear
4 0.20 – 0.52
(Drive gear)

40-8 WD900-3
MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE

TORQUE CONVERTER REGULATOR VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
1
poppet and spool
–0.020 +0.021 0.020 –
22 0.08
–0.030 0 0.051
Clearance between –0.035 +0.016 0.035 –
2 40 0.08
spool and body –0.045 0 0.061
Standard size Repair limit Replace

Installation Installation Installation

Free length Free length
3 Poppet spring length load load
22.4 N 20.6 N
43.9 21 42
{2.28 kg} {2.1 kg}
Spool spring 107.9 N 98.1 N
4 172 92 167
{11 kg} {10.0 kg}

WD900-3 40-9
MAINTENANCE STANDARD TRANSMISSION (1/2)

TRANSMISSION (1/2)

5 16 6 15 17 7 8 9 13

12 1 2 10 11 14 3 4
kgm 66.7±6.9Nm kgm 6.7±6.9Nm kgm 66.7±6.9Nm kgm 66.7±6.9Nm
{6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm}
kgm 110.3±12.3Nm SEW01600
{11.25±1.25kgm}

a The transfer shown in this figure is for serial No. 50001 – (T/M No. 101138)

40-10 WD900-3
MAINTENANCE STANDARD TRANSMISSION (1/2)

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation
Free length Free length
1 R clutch springs (12 pieces) length load load
114.7 N 97.1 N
91 78 85.5
{11.7 kg} {9.9 kg}
139.3 N 108.9 N
2 F clutch springs (12 pieces) 108.5 92 102
{14.2 kg} {11.1 kg}
123.6 N 104.9 N
3 2nd clutch springs (12 pieces) 91 77 85.5
{12.6 kg} {10.7 kg}
194.2 N 164.8 N
4 1st clutch springs (12 pieces) 91 69 85.5
{19.8 kg} {16.8 kg}

Thickness of assembled 6 Standard size Tolerance Repair limit

5
discs and 5 plates for R clutch 61.4 — 59.5
Thickness of assembled 6
6 61.4 — 59.0
discs and 5 plates for F clutch
Thickness of assembled 4
7 discs and 3 plates for 2nd 39.0 — 37.4
clutch
Thickness of assembled 5
8 50.8 — 48.8
discs and 4 plate for 1st clutch Replace
Thickness of assembled 6
9 discs and 5 plates for 3rd 61.4 — 59.0
clutch
10 Thickness of 1 disc 5.4 ±0.1 5.0
11 Thickness of 1 plate 5.8 ±0.1 5.3
–0.01
Wear of seal ring Width 3.0 –0.03 2.6
12
for input shaft Thickness 3.5 ±0.100 3.35
–0.01
Wear of seal ring Width 3.0 –0.03 2.8
13
for output shaft Thickness 4.3 ±0.120 4.15
–0.01
Wear of seal ring Width 4.0 –0.03 3.5
14
for 2nd carrier Thickness 5.0 ±0.15 4.85
–0.01
Wear of seal ring Width 4.0 –0.04 3.5
15
for F carrier Thickness 5.0 ±0.15 4.85
–0.01
Wear of seal ring Width 3.0 –0.03 2.6
16
for R carrier Thickness 4.0 ±0.12 3.85
–0.01
Wear of seal ring Width 3.0 –0.03 2.6
17
for idler shaft Thickness 4.0 ±0.12 3.85

WD900-3 40-11
MAINTENANCE STANDARD TRANSMISSION (2/2)

TRANSMISSION (2/2)

1 2 3 4 5 6 7 8 9 10

SEW01601
a The transfer shown this figure is for serial No. 50001 – (T/M No. 101138)
Unit: mm

No. Check item Criteria Remedy

Backlash between reverse

1 0.15 – 0.40
sun gear and planetary gear
Backlash between reverse
2 0.15 – 0.39
planetary gear and ring gear
Backlash between forward
3 0.15 – 0.40
sun gear and planetary gear
Backlash between forward
4 0.15 – 0.40
planetary gear and ring gear
Backlash between sun gear
5 0.15 – 0.40
and planetary gear
Replace
Backlash between planetary
6 0.15 – 0.40
gear and ring gear
Backlash between 2nd sun
7 0.15 – 0.40
gear and planetary gear
Backlash between 2nd plane-
8 0.15 – 0.39
tary gear and ring gear
Backlash between 1st sun
9 0.15 – 0.40
gear and planetary gear
Backlash between 1st plane-
10 0.15 – 0.39
tary gear and ring gear

40-12 WD900-3
MAINTENANCE STANDARD TRANSFER

TRANSFER
Serial No.: 50001 – 50006

Unit: mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Oil seal sliding surface of out-
1 0
put shaft coupling (R) 170 169.8
–0.10
Oil seal sliding surface of out- 0
2 170 169.8
put shaft coupling (F) –0.10
Standard clearance Clearance limit
Clearance between output
3 –0.05 – 0.05
cover and case 1 Replace
After installed shim
Backlash between input gear
4 0.23 – 0.59
and idler gear
Backlash between output gear
5 0.23 – 0.59
and idler gear
Backlash between 2nd shaft
6 0.23 – 0.59
gear and 3rd shaft gear

40-14 WD900-3
MAINTENANCE STANDARD TRANSFER

Serial No.: 50007 and up

Unit: mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Oil seal sliding surface of out-
1 0
put shaft coupling (R) 170 169.8
–0.10
Oil seal sliding surface of out- 0
2 170 169.8
put shaft coupling (F) –0.10
Standard clearance Clearance limit
Clearance between output
3 –0.05 – 0.05
cover and case 1 Replace
(After installed shim)
Backlash between input gear
4 0.23 – 0.59
and idler gear
Backlash between output gear
5 0.23 – 0.59
and idler gear
Backlash between 2nd shaft
6 0.23 – 0.59
gear and 3rd shaft gear

WD900-3 40-15
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

TRANSMISSION CONTROL VALVE

UPPER VALVE

40-16 WD900-3
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between pilot size Shaft Hole clearance limit
1
reducing valve spool and body
–0.035 +0.013 0.035 –
28 0.08
–0.045 0 0.058
Clearance between priority –0.035 +0.013 0.035 –
2 28 0.08
valve and body –0.045 0 0.058
Clearance between quick –0.035 +0.013 0.035 –
3 19 0.08
return valve spool and body –0.045 0 0.058
Clearance between modulat- –0.035 +0.016 0.035 –
4 35 0.08
ing valve spool and body –0.045 0 0.061
Clearance between reducing –0.035 +0.013 0.035 –
5 28 0.08
valve spool and body –0.045 0 0.058
Clearance between lubrication –0.035 +0.013 0.035 –
6 28 0.08
valve spool and body –0.045 0 0.058
Standard size Repair limit
Installation Installation Installation Replace
Free length Free length
7 Priority valve spring (Large) length load load
164.7 N 156.9 N
41.5 31.0 40.3
{16.8 kg} {16.0 kg}
130.4 N 123.6 N
8 Priority valve spring (Small) 35.0 31.0 34.0
{13.3 kg} {12.6 kg}
163.8 N 155.9 N
9 Pilot reducing valve spring 68.7 54.0 66.6
{16.7 kg} {15.9 kg}
319.7 N 304.0 N
10 Reducing valve spring 86.0 54.0 83.4
{32.6 kg} {31.0 kg}
Modulating valve spring 266.7 N 253.0 N
11 80.0 71.5 77.6
(Small) {27.2 kg} {25.8 kg}

Modulating valve spring 688.3 N 654.1 N

12 100 76.0 97.0
(Large) {70.2 kg} {66.7 kg}

116.7 N 110.8 N
13 Lubrication valve spring 74.5 48.0 72.3
{11.9 kg} {11.3 kg}

Shim adjustment for pilot

14 One shim will charge the pressure by 31.4 kPa {0.32 kg/cm2}
reducing valve

Thickness of shim Large 1 (One shim will charge the pressure by 37.3 kPa {0.38 kg/cm2}
15 for modulating
valve Small 1 (One shim will charge the pressure by 41.2 kPa {0.42 kg/cm2}

Thickness of shim for priority Adjust

16 3 (One shim will charge the pressure by 136.3 kPa {1.39 kg/cm2}
valve

Adjustment of shim for reduc-

17 One shim will charge the pressure by 28.4 kPa {0.29 kg/cm2}
ing valve

Adjustment of shim for lubrica-

18 One shim will charge the pressure by 3.9 kPa {0.04 kg/cm2}
tion valve

WD900-3 40-17
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

LOWER VALVE

40-18 WD900-3
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between forward size Shaft Hole clearance limit
1
spool and body
–0.035 +0.013 0.035 –
22 0.08
–0.045 0 0.058
Clearance between first –0.035 +0.013 0.035 –
2 22 0.08
speed spool and body –0.045 0 0.058
Clearance between second –0.035 +0.013 0.035 –
3 22 0.08
speed spool and body –0.045 0 0.058
Clearance between third –0.035 +0.013 0.035 –
4 22 0.08
speed spool and body –0.045 0 0.058
Clearance between reverse –0.035 +0.013 0.035 –
5 22 0.08
spool and body –0.045 0 0.058
Clearance between main –0.035 +0.016 0.035 –
6 45 0.08
relief valve spool and body –0.045 0 0.061
Replace
Clearance between torque
–0.035 +0.016 0.035 –
7 converter relief valve spool 45 0.08
–0.045 0 0.061
and body
Standard size Repair limit
Springs for FORWARD, Installation Installation Installation
Free length Free length
8 REVERSE, first, second, and length load load
third speeds
113.8 N 107.9 N
78 45 75
{11.6 kg} {11 kg}
Torque converter relief valve 517.8 N 492.3 N
9 206.5 143 200
spring {52.8 kg} {50.2 kg}
681.6 N 647.2 N
10 Main relief valve spring (inner) 185 138 179
{69.5 kg} {66.0 kg}
926.7 N 880.6 N
11 Main relief valve spring (outer) 160 97 155
{94.5 kg} {89.8 kg}
Thickness of main relief valve Standard shim thickness: 6.0
12
shim (One shim will charge the pressure 11.8 kPa {0.12 kg/cm2})
Adjust
Thickness of torque converter Standard shim thickness: 1.0
13
relief shim (One shim will charge the pressure 6.9 kPa {0.07 kg/cm2})

WD900-3 40-19
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE

SOLENOID VALVE

40-20 WD900-3
(4)
MAINTENANCE STANDARD DRIVE SHAFT

DRIVE SHAFT

WD900-3 40-21
MAINTENANCE STANDARD CENTER SUPPORT

CENTER SUPPORT

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between case and size Shaft Hole clearance limit
1
bearing
0 –0.022 –0.051 –
230 0.011
–0.030 –0.051 0.008
Clearance between case and 0 –0.022 –0.051 – Replace
2 215 0.011
bearing –0.030 –0.051 0.008
Clearance between coupling +0.052 0 –0.007 –
3 130 –0.024
shaft and bearing +0.027 –0.025 –0.027
Clearance between coupling +0.045 0 –0.065 –
4 120 –0.020
shaft and bearing +0.023 –0.020 –0.023
Standard size Tolerance Repair limit
5 Wear of oil seal surface 0 Repair
160 –0.20
–0.100 chrome plat-
ing or replace
0
6 Wear of oil seal surface 160 –0.20
–0.100
7 End play of coupling shaft 0.05 – 0.15 Replace

40-22 WD900-3
MAINTENANCE STANDARD DIFFERENTIAL (1/2)

DIFFERENTIAL (1/2)

Unit: mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 Thickness of side gear washer
9.0 — 8.5
Thickness of pinion gear Replace
2 10.75 — 10.25
washer sleeve
0
3 Wear of oil seal surface 150 —
–0.100

WD900-3 40-23
(4)
MAINTENANCE STANDARD DIFFERENTIAL (2/2)

DIFFERENTIAL (2/2)

40-24 WD900-3
MAINTENANCE STANDARD DIFFERENTIAL (2/2)

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance of bearing outer size clearance limit
Shaft Hole
1 race in differential gear
assembly 0 +0.036 –0.016 –
280 —
–0.035 –0.016 0.071
Clearance of bearing inner
+0.074 0 –0.049 –
2 race in differential gear 180 —
+0.049 –0.025 –0.099
assembly
Clearance of outer race of pin- 0 0 –0.046 –
3 215 —
ion shaft bearing –0.030 –0.046 0.030
Clearance of inner race of pin- 0 0 –0.020 –
4 120 —
ion shaft bearing –0.022 –0.020 0.022
Clearance of outer race of pin- 0 0 –0.052 –
5 290 —
ion shaft bearing –0.035 –0.052 0.035
Clearance of inner race of pin- +0.040 0 –0.015 –
6 160 —
ion shaft bearing +0.015 –0.025 –0.065
Clearance of differential pinion 0 –0.028 –0.003 –
7 160 —
gear outer race bearing –0.025 –0.068 –0.068
Clearance of differential pinion +0.013 0 –0.028 –
8 90 —
gear inner race bearing –0.009 –0.015 0.009
Clearance of differential pinion 0 –0.028 –0.010 –
9 140 —
gear outer race bearing –0.018 –0.068 –0.068 Replace
Clearance of differential pinion +0.013 0 –0.028 –
10 90 —
gear inner race bearing –0.009 –0.015 0.009
Clearance between differen- 0 +0.057
11 330 0 – 0.114 —
tial carrier and cage –0.057 0
Clearance between spider 0 +0.030
12 70 0 – 0.060 —
and differential pinion bushing –0.030 0
13 Backlash of bevel gear 0.43 – 0.61
14 Backlash of differential gear 0.31 – 0.40
Free rotating torque of pinion
22.6 Nm {2.3 kgm}
15 gear
Preload of pinion bearing 21 kN {2,140 kg}
Free rotating torque of bevel
25.5 Nm {2.6 kgm}
16 gear
Preload of side bearing 28 kN {2,860 kg}
17 Rear face runout of bevel gear 0.13
Standard thickness of shims
18 Clearance "a" + (0.1± 0.05)
for stop shaft
Standard thickness of shims
19 2.0
for differential cage

WD900-3 40-25
MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

40-26 WD900-3
(4)
MAINTENANCE STANDARD FINAL DRIVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing
+0.018 0 –0.038 –
100 —
+0.003 –0.020 –0.003
Clearance between planetary 0 –0.028 –0.003 –
2 180 —
gear and bearing –0.025 –0.068 –0.068
Clearance between axle –0.017 0 –0.018 –
3 300 —
housing and bearing –0.069 –0.035 0.069
Clearance between wheel hub 0 –0.045 –0.108 –
4 460 —
and bearing –0.045 –0.018 0
Clearance between axle –0.018 0 –0.022 –
5 320 — Replace
housing and bearing –0.075 –0.040 0.075
Clearance between wheel hub 0 –0.045 –0.108 –
6 480 —
and bearing –0.045 –0.108 0

Thickness of retainer at ring Standard size Tolerance Repair limit

7
gear hub mount 30 ±0.1 29.6

Backlash between planet gear Standard clearance Clearance limit

8
and sun gear 0.26 – 0.58 1.0
Backlash between planet gear
9 0.30 – 0.78 1.2
and ring gear
Thickness of standard shim
10 2.0
for wheel hub

WD900-3 40-27
MAINTENANCE STANDARD AXLE MOUNT

AXLE MOUNT

40-28 WD900-3
MAINTENANCE STANDARD AXLE MOUNT

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance of shaft and hole size clearance limit
Shaft Hole
1 (Front support side)
(Before press-fit bushing) +4.8 +0.155 –4.80 –
470.2
+0.8 0 –0.645
Clearance of shaft and hole
–0.068 +1.021 0.323 –
2 (Front support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
Clearance of shaft and hole
+4.800 +0.155 –4.80 –
3 (Rear support side) 470.2
+0.800 0 –0.645
(Before press-fit bushing)
Replace
Clearance of shaft and hole
–0.068 +1.021 0.323 –
4 (Rear support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
Standard size Clearance limit
5 Thickness of thrust washer
8 ±0.2
–0.21
6 Thickness of thrust plate 37
–0.35
7 Thickness of rear bushing 5 ±0.1
8 Thickness of front bushing 5 ±0.1

WD900-3 40-29
MAINTENANCE STANDARD CENTER HINGE PIN

CENTER HINGE PIN

40-30 WD900-3
MAINTENANCE STANDARD CENTER HINGE PIN

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between lower size Shaft Hole clearance limit
1
hinge pin and bushing
–0.043 +0.070 0.043 –
146.05 —
–0.068 0 0.138
Clearance between lower –0.043 +0.063 0.043 –
2 146.05 1.0
hinge pin and spacer (small) –0.068 0 0.131
Clearance between lower –0.043 +0.025 0.043 –
3 146.05 —
hinge pin and bearing –0.068 0 0.093
Clearance between lower –0.043 +0.063 0.043 –
4 146.05 1.0
hinge pin and spacer (large) –0.068 0 0.131
Clearance between lower
–0.050 +0.077 0.050 –
5 hinge spacer (large) and 206.0 —
–0.122 0 0.199
bushing
Clearance between front
+0.025 –0.067 –0.138 –
6 frame and upper hinge bear- 234.95 —
0 –0.113 –0.067
ing
Clearance between upper –0.043 +0.063 0.043 –
7 127 —
hinge pin and rear frame –0.068 0 0.131
Clearance between upper –0.043 +0.025 0.043 –
8 127 —
hinge pin and bearing –0.068 0 0.093
Replace
Clearance between front +0.025 –0.078 –0.155 –
9 304.8 —
frame and lower hinge bearing 0 –0.130 –0.078
Clearance between rear +0.310 +0.063 0.043 –
10 170 —
frame and bushing +0.210 0 0.131
Clearance at press-fitted part –0.043 +0.063 –0.310 –
11 146.05 —
of seal of upper hinge pin –0.068 0 –0.147
Clearance at press-fitted part +0.260 +0.072 –0.260 –
12 210 —
of seal of lower hinge pin +0.160 0 –0.088
Clearance between lower
+0.186 +0.063 –0.186 –
13 hinge bushing and frame 161.0 —
+0.146 0 –0.083
(upper)
Clearance between lower
+0.242 +0.072 –0.242 –
14 hinge bushing and frame 226.0 —
+0.196 0 –0.124
(lower)

Height of lower hinge spacer Standard size Tolerance Repair limit

15
(small) 73 ±0.1 —
Height of lower hinge spacer
16 155.5 ±0.1 —
(large)
Thickness for lower hinge and
17 32 ±0.8 —
retainer
Shim thickness for lower
18 1.93
hinge and retainer
Shim thickness for lower
19 2.20 Adjust
hinge and retainer
Shim thickness for upper
20 2.31
hinge and retainer

WD900-3 40-31
MAINTENANCE STANDARD STEERING COLUMN

STEERING COLUMN

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between steering size Shaft Hole clearance limit Replace
1
shaft and column bushing bushing
–0.080 +0.150 0.050 –
19 —
–0.080 +0.050 0.230

40-32 WD900-3
MAINTENANCE STANDARD STEERING DEMAND VALVE

STEERING DEMAND VALVE

40-34 WD900-3
MAINTENANCE STANDARD STEERING DEMAND VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free Installation Installation Free Load
1 Steering spool return spring length length load length limit
74.5 N 58.8 N
41.8 38.0 —
{7.6 kg} {6 kg}
8.8 N 7.0 N
2 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
410 N 328 N
3 Demand spool return spring 90.8 83.0 —
{41.8 kg} {33.4 kg} Replace
182.4 N 145.1 N
4 Surge cut relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
182.4 N 145.1 N
5 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
590 N 471 N
6 Overload relief valve spring 39.5 35.7 —
{60.2 kg} {40.8 kg}
8.8 N 7.0 N
7 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}

WD900-3 40-35
MAINTENANCE STANDARD DIVERTER VALVE

DIVERTER VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between body and size Shaft Hole clearance limit
1
spool
–0.023 +0.015 0.020 –
40 —
–0.005 +0.007 0.03
Standard size Repair limit
Installation Installation Installation
Free length Free length Replace
2 Spool spring length load load
216.7 N 205.9 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.6 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}

40-36 WD900-3
MAINTENANCE STANDARD STEERING CYLINDER MOUNT

STEERING CYLINDER MOUNT

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between mounting
pin and bushing connection of size Shaft Hole clearance limit
1
steering cylinder rod and
–0.036 +0.307 0.256 –
frame 110 1.0
–0.090 +0.220 0.397
Clearance between mounting
pin and bushing at connec- –0.036 +0.020 0.036 –
2 110 1.0
tion of steering cylinder bot- –0.090 0 0.110
tom and frame
Replace
Standard clearance
Connection of steering cylin- Width of boss Width of hinge
3 (Clearance a + b)
der and front frame
0
93 –0.2 116 ± 1.5 0.5 – 3.7
Connection of steering cylin- After adjusting with
4 110 +0.8
+0 116 ± 1.5
der rod and rear frame shim: Less than 1.0
Standard size Tolerance Repair limit
5 Width of spacer
10.5 ±0.5 —

WD900-3 40-37
MAINTENANCE STANDARD EMERGENCY STEERING PUMP

EMERGENCY STEERING PUMP

MODEL: SAM(3)100 + 100

Unit: mm

No. Check item Criteria Remedy

Clearance between gear case Pump model Standard clearance Clearance limit
1
and side plate gear SAM(3)100 0.10 – 0.15 0.19
Clarance between inside
2 diameter of plain bearing and SAM(3)100 0.020 – 0.043 0.075
Replace
outside diameter of gear shaft
Standard clearance Tolerance
3 Insertion depth of pin 0
14
–0.5
4 Rotating torque of spline shaft 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
Standard Repair limit
Revolution
Discharge Pump model Pressure discharge discharge
(rpm) —
— Oil: EO10-CD (l/min) (l/min)
Temperature: 45 to 55°C SAM(3)100 20.6 MPa
2,000 352 312
+ 100 {210 kg/cm2}

40-38 WD900-3
MAINTENANCE STANDARD BRAKE VALVE

BRAKE VALVE
RIGHT AND LEFT (Serial No.: 50001 – 50006)
RIGHT (Serial No.: 50007 and up)

40-40 WD900-3
MAINTENANCE STANDARD BRAKE VALVE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between pedal size Shaft Hole clearance limit
1
mount hole and bracket hole
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
Clearance between roller and –0.025 +0.1 0.175 –
2 10 0.25
pin –0.075 0 0.025
Standard size Tolerance Repair limit
3 Outside diameter of roller 0
30 29.2
–0.5
Standard size Repair limit
Installation Installation Installation Replace
Free length Free length
4 Control spring length load load
30.6 N
34 30 33 —
{3.12 kg}
0N
5 Control spring 46 46 45 —
{0 kg}
60.8 N
6 Return spring 86.2 58 78 —
{6.2 kg}
17.7 N
7 Spring 17 16.5 16.2 —
{1.8 kg}
16.7 N
8 Return spring 31.5 19.5 28 —
{1.7 kg}

WD900-3 40-41
MAINTENANCE STANDARD BRAKE VALVE

LEFT (Serial No.: 50007 and up)

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between pedal size Shaft Hole clearance limit
1
mount hole and bracket hole
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
Clearance between roller and –0.025 +0.1 0.175 –
2 10 0.25
pin –0.075 0 0.025
Standard size Tolerance Repair limit
3 Outside diameter of roller 0
30 29.2
–0.5
Standard size Repair limit Replace
Installation Installation Installation
Free length Free length
4 Control spring length load load
3.82 N
34 33.5 33 —
{0.39 kg}
12.8 N
5 Control spring 47.7 46 46.7 —
{1.3 kg}
60.8 N
6 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
7 Return spring 31.5 19.5 28 —
{1.7 kg}

40-42 WD900-3
MAINTENANCE STANDARD SLACK ADJUSTER

SLACK ADJUSTER

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between body and size Shaft Hole clearance limit
1
piston
–0.030 +0.074 0.030 –
80 0.250
–0.076 0 0.150
Standard size Repair limit
Replace
Installation Installation Installation
Free length Free length
2 Slack adjuster spring length load load
117.7 N
246 88 — —
{12 kg}
123.6 N
3 Check valve spring 44.8 38 — —
{12.6 kg}

WD900-3 40-43
MAINTENANCE STANDARD BRAKE

BRAKE

40-44 WD900-3
MAINTENANCE STANDARD BRAKE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free Installation Installation Free Installation
1 Return spring length length load length load
999.3 N 887.5 N
114.0 98.8 112.3
{101.9 kg} {90.5 kg}
Standard size Repair limit
2 Thickness of plate
2.4 2.15
3 Thickness of disc 5.1 4.6
Total thickness of plate and
4 107.4 100.4
disc
Standard size Tolerance Repair limit
Wear of contact surface of oil Replace
5 0
seal 580 —
–0.175
Wear of surface in contact +0.110
6 585 —
with piston seal 0
Wear of surface in contact +0.110
7 630 —
with piston seal 0

Deformation of friction surface Standard Repair limit

8
of plate and disc Max. 0.45 0.70
Backlash between outer gear
9 0.21 – 0.64
and plate
Backlash between inner gear
10 0.21 – 0.64
and disc

WD900-3 40-45
MAINTENANCE STANDARD PARKING BRAKE

PARKING BRAKE

40-46 WD900-3
MAINTENANCE STANDARD PARKING BRAKE

Unit: mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Remaining
thickness of fric- 22.2 — 3.7
1 Wear of pad Replace
tion material
Including back-
31.7 — 12.7
ing plate
2 Face runout of disc 0.6 — 1.2
–0.10
3 Wear of rod connecting pin 12.7 —
–0.17
Rebuild
Thickness of plate
Wear of disc must be under
4 25 ±0.7 23 mm
(Thickness of disc)
Less than 23 mm Replace
Clearance between pad and
5 disc 1.06 ±0.18 2.1
(Total of both sides) Adjust
Clearance between brake body
6 0.36 – 1.0
and plate

WD900-3 40-47
MAINTENANCE STANDARD PPC VALVE

PPC VALVE

40-48 WD900-3
MAINTENANCE STANDARD PPC VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation
Centering spring Free length Free length
1 length load load
(Right tilt, lower)
5.4 N
39.9 34.5 — —
{0.55 kg} Replace if
Centering spring 21.1 N damaged or
2 56.7 34.5 — — deformed
(Left tilt, raise) {2.15 kg}
33.3 N
3 Metering spring 33.5 29.4 — —
{3.4 kg}
14.7 N
4 Return spring 28.2 17.5 — —
{1.5 kg}

WD900-3 40-49
MAINTENANCE STANDARD PPC RELIEF VALVE

PPC RELIEF VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation
Free length Free length
1 Main valve spring length load load
19.6 N 15.7 N Replace
47 27 —
{2.0 kg} {1.6 kg}
58.4 N 47.1 N
2 Poppet spring 33.6 30.5 —
{5.95 kg} {4.8 kg}

40-50 WD900-3
MAINTENANCE STANDARD STEERING PUMP

STEERING PUMP
MODEL: HPF76 + 71

WD900-3 40-51
MAINTENANCE STANDARD SWITCH PUMP

SWITCH PUMP
Serial No.: 50001 – 50006

MODEL: HPF90 + 90

40-52 WD900-3
MAINTENANCE STANDARD SWITCH PUMP

Serial No.: 50007 and up

MODEL: HPV95 + 95

WD900-3 40-53
MAINTENANCE STANDARD MAIN PISTON PUMP

MAIN PISTON PUMP

Serial No.: 50001 – 50006

MODEL: HPV90 + 90

40-54 WD900-3
MAINTENANCE STANDARD MAIN PISTON PUMP

Serial No.: 50007 and up

MODEL: HPV95 + 95

WD900-3 40-55
MAINTENANCE STANDARD CONTROL PUMP

CONTROL PUMP
MODEL: BAR025

Unit: mm

No. Check item Criteria Remedy

Standard clearance Tolerance

1 Top clearance of gear
0.090 – 0.130 0.145
2 Side clearance of gear 0.055 – 0.075 0.105 Replace

Clearance between gear shaft

3 0.045 – 0.076 0.13
and bushing
Standard Repair limit
Pump Revolution
Discharge Pressure discharge discharge
model (rpm)
— Oil: EO10-CD (l/min) (l/min) —
Temperature: 45 to 55°C 2.9 MPa
BAR25 3,200 72 68
{30 kg/cm2}
Tightening torque for housing
— 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} Tighten
case mounting bolt

40-56 WD900-3
MAINTENANCE STANDARD MAIN CONTROL VALVE

MAIN CONTROL VALVE

Serial No.: 50001 – 50005 *1. For Serial No.: 50004 and up

40-58 WD900-3
MAINTENANCE STANDARD MAIN CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation
Free length Free length
1 Spool return spring length load load
431.5 N 345.2 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
0N
2 Spool return spring 77.0 77.0 — —
{0 kg}
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 —
{6.28 kg} {5.0 kg}
Main valve spring of relief valve 86.3 N 69.0 N
52.4 38.0 —
(Serial No.: 50001 – 50003) {8.80 kg} {7.04 kg}
4
Main valve spring of relief valve 5.6 N 4.5 N
12.0 12.1 —
(Large) (Serial No.: 50004 and up) {0.57 kg} {0.46 kg}
18.8 N 14.7 N Replace
5 Check valve spring 78.2 52.0 —
{1.92 kg} {1.5 kg}
Suction valve spring of safety 6.9 N 5.9 N
6 27.9 18.0 —
valve {0.70 kg} {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 —
{0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 —
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 —
{5.0 kg} {4.0 kg}
Pilot poppet spring of relief 319.7 N 256.0 N
10 30.7 26.9 —
valve {32.6 kg} {26.1 kg}
Main valve spring of relief valve 2.3 N 1.9 N
11 10.45 6.3 —
(Small) (Serial No.: 50004 and up) {0.236 kg} {0.19 kg}

WD900-3 40-59
MAINTENANCE STANDARD MAIN CONTROL VALVE

Serial No.: 50006 and up

40-60 WD900-3
MAINTENANCE STANDARD MAIN CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Installation Installation Installation
Free length Free length
1 Spool return spring length load load
431.5 N 345.2 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
0N
2 Spool return spring 77.0 77.0 — —
{0 kg}
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 —
{6.28 kg} {5.0 kg}
Main valve spring of relief valve 5.6 N 4.5 N
4 12.0 12.1 —
(Large) {0.57 kg} {0.46 kg}
18.8 N 14.7 N
5 Check valve spring 78.2 52.0 —
{1.92 kg} {1.5 kg} Replace
Suction valve spring of safety 6.9 N 5.9 N
6 27.9 18.0 —
valve {0.70 kg} {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 —
{0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 —
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 —
{5.0 kg} {4.0 kg}
Pilot poppet spring of relief 319.7 N 256.0 N
10 30.7 26.9 —
valve {32.6 kg} {26.1 kg}
Main valve spring of relief 2.3 N 1.9 N
11 10.45 6.3 —
valve (Small) {0.236 kg} {0.19 kg}

WD900-3 40-61
MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
STEERING CYLINDER

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between piston rod size Shaft Hole clearance limit
1
and bushing
–0.036 +0.265 0.085 –
100 —
–0.090 +0.049 0.355
Replace
Clearance between piston rod –0.036 +0.307 0.256 – bushing
2 110 —
mounting pin and bushing –0.090 +0.220 0.397
Clearance between cylinder
–0.036 +0.020 0.036 –
3 bottom mounting pin and 110 —
–0.090 0 0.110
bushing
Standard size Tolerance Repair limit
4 Cylinder bore +0.3 Replace
160 —
0
Tightening torque of cylinder
5 461 ± 142 Nm {47.0 ± 14.5 kgm}
head mounting bolt
Retighten
Tightening torque of piston
6 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
mounting bolt

40-62 WD900-3
MAINTENANCE STANDARD HYDRAULIC CYLINDER

LIFT CYLINDER

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between rod and size Shaft Hole clearance limit
1
bushing
–0.043 +0.256 0.083 –
130 0.662
–0.106 +0.040 0.362
Replace
Clearance between piston rod –0.036 +0.054 0.036 – bushing
2 115 1.0
mounting pin and bushing –0.090 +0.106 0.144
Clearance between cylinder
–0.036 +0.054 0.036 –
3 bottom mounting pin and 115 1.0
–0.090 +0.106 0.144
bushing
+0.200
4 Cylinder bore 200 — — — Replace
+0.200
Tightening torque of cylinder
5 1.15 ± 0.12 kNm {117.5 ± 12.5 kgm}
head mounting bolt
Retighten
Tightening torque of piston
6 117 ± 19.6 Nm {18 ± 2 kgm}
mounting bolt

WD900-3 40-63
MAINTENANCE STANDARD HYDRAULIC CYLINDER

TILT, PITCH CYLINDER

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between rod and size Shaft Hole clearance limit
1
bushing
–0.043 +0.228 0.091 –
160 0.634
–0.106 +0.048 0.334
Replace
Clearance between piston rod –0.043 +0.263 0.243 – bushing
2 140 1.0
mounting pin and bushing –0.106 +0.200 0.369
Clearance between cylinder
–0.043 +0.395 0.338 –
3 bottom mounting pin and 140 1.0
–0.106 +0.295 0.501
bushing
+0.200
4 Cylinder bore 250 — — — Replace
+0.200
Tightening torque of cylinder
5 1.96 ± 0.2 kNm {200 ± 20 kgm}
head mounting bolt
Retighten
Tightening torque of piston
6 277 ± 31.9 Nm {28.25 ± 3.25 kgm}
mounting bolt

40-64 WD900-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

40-66 WD900-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

WD900-3 40-67
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between bearing size clearance limit
Shaft Hole
1 and pin at joint of lift cylinder
rod and blade –0.036 +0.054 0.036 –
115 1
–0.090 +0.347 0.144
Clearance between bearing
–0.036 +0.054 0.036 –
2 and pin at joint of support and 95 1
–0.090 +0.347 0.144
blade
Clearance between bushing
–0.300 +0.103 0.363 –
3 and pin at joint of frame and 120 2
–0.500 +0.063 0.603
blade
Clearance between bearing
–0.043 +0.263 0.243 –
4 and pin at joint of tilt, pitch cyl- 140 2
–0.106 +0.200 0.369
inder and blade
Clearance between bushing
–0.043 +0.245 0.188 –
5 and pin at joint of support and 140 1
–0.106 +0.145 0.351
front frame
Clearance between bushing
–0.043 +0.395 0.338 –
6 and pin at joint of tilt, pitch cyl- 140 2
–0.106 +0.295 0.501
inder and frame
Clearance between bushing
–0.036 +0.054 0.036 –
7 and pin at joint of lift cylinder 115 1
–0.090 +0.295 0.144
bottom and front frame
Clearance between bushing –0.043 +0.245 0.188 –
8 140 1
and pin at joint of support –0.106 +0.145 0.351 Replace
Clearance between bearing
9 and bushing at joint of lift cyl- 180 — — — —
inder and blade
Clearance between bearing
10 and bushing at joint of support 240 — — — —
and blade
Clearance between pin and
–0.036 +0.300 0.236 –
11 boss at joint of lift cylinder bot- 115 2
–0.090 +0.200 0.390
tom and front frame
Clearance between bearing
12 and bushing at joint of tilt, 180 — — — —
pitch cylinder and blade
Clearance between pin and
–0.036 +0.300 0.236 –
13 boss at joint of cylinder rod 115 1
–0.090 +0.200 0.390
and blade
Clearance between pin and
–0.036 +0.300 0.036 –
14 boss at joint of frame and 95 1
–0.090 +0.200 0.390
blade
Clearance between pin and
–0.300 +0.300 0.300 –
15 boss at joint of frame and 120 2
–0.500 +0.200 0.800
blade
Clearance between pin and
–0.043 +0.300 0.106 –
16 boss at joint of tilt, pitch cylin- 140 2
–0.106 +0.200 0.243
der and blade

40-68 WD900-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

Unit: mm

No. Check item Criteria Remedy

Clearance between pin and

–0.043 +0.350 0.293 –
17 boss at joint of support and 140 2
–0.106 +0.250 0.456
front frame
Clearance between pin and
–0.043 +0.350 0.293 –
18 boss at joint of tilt, pitch cylin- 140 2
–0.106 +0.250 0.456
der and frame
Clearance between pin and –0.043 +0.350 0.293 –
19 140 2
boss at joint of support –0.106 +0.250 0.456
Tolerance Replace
Clearance between bearing Standard Standard Clearance
20 and bushing at joint of lift cyl- size Shaft Hole clearance limit
inder bottom and front frame
180 — — — —
Clearance between bushing
–0.300 +0.323 0.549 –
21 and pin at joint of frame and 120 2
–0.500 +0.249 0.823
joint
Clearance between pin and –0.300 +0.300 0.300 –
22 120 2
boss at joint of frame and joint –0.500 +0.320 0.800
Width between Standard clearance
Joint of bucket cylinder and Width of hinge
23 bosses (Clearance a + b)
blade
141 +0.5
+0 140 +0.050
–0.190 0.95 – 1.69
24 Joint of support and frame — 190 +0.050
–0.190 —
25 Joint of frame and blade 240 +0.5
+0 240 –0.2
–0.4 0.2 – 0.9
Joint of tilt, pitch cylinder and
26 111 +0.5
+0 110 –0
–0.25 0 – 1.75
blade
Joint of support and front Adjust
27 120 ± 1 116 ± 0.8 2.2 – 5.8
frame
Joint of tilt, pitch cylinder and
28 164 ± 1.5 160 +0
–0.5 2.5 – 6
frame
29 Joint of support 120 ± 1 116 ± 0.8 2.2 – 5.8
Joint of lift cylinder bottom and
30 140 +2.0
+0.5 140 +0.050
–0.190 0.45 – 2.19
front frame
31 Joint of frame and joint 240 +0.3
+0.1 240 –0.2
–0.4 0.3 – 0.7

WD900-3 40-69
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

CUTTING EDGE AND END BIT

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Cutting edge height
406 344
2 End bit (outside) height 490 365 Replace
3 End bit (inside) height 393 344
4 End bit width 765 622
Tightening torque for mount-
5 1,950 – 2,490 Nm {199 – 254 kgm} Retighten
ing bolt

40-70 WD900-3
MAINTENANCE STANDARD BRAKE COOLING PUMP

BRAKE COOLING PUMP

MODEL: SBL(1)24
MODEL: SBR(1)24

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside diam- Replace
2 eter of plain bearing and outside 0.060 – 0.119 0.20
diameter of gear shaft

Standard size Tolerance Repair limit

3 Depth for knocking in pin –0.5
10 —
–0.5
4 Rotating torque of spline shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Rotating Delivery Standard Delivery —
Discharge amount speed pressure delivery amount amount limit
(rpm) {MPa (kg/cm2)} (l/min) (l/min)
– Oil: EO 10-CD
Oil temperature: 45 – 55°C 20.6
3,000 67.8 62.6
{210}

WD900-3 40-71
 90 OTHERS
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/2) .....................................................................90- 3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/2) .....................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/7) ......................................................................................................90- 7
ELECTRICAL CIRCUIT DIAGRAM (2/7) ......................................................................................................90- 9
ELECTRICAL CIRCUIT DIAGRAM (3/7) ......................................................................................................90- 11
ELECTRICAL CIRCUIT DIAGRAM (4/7) ......................................................................................................90- 13
ELECTRICAL CIRCUIT DIAGRAM (5/7) ......................................................................................................90- 15
ELECTRICAL CIRCUIT DIAGRAM (6/7) ......................................................................................................90- 17
ELECTRICAL CIRCUIT DIAGRAM (7/7) ......................................................................................................90- 19

WD900-3 90-1
(1)
 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/2) *1. For Serial No. 50001 – 50006 a On the machines serial No. 50006 and up, the
*2. For Serial No. 50007 and up pilot circuits (PA2 and PB2) in which the oil
STEERING WHEEL SPECIFICATION
from PPC valve to lift spool are reversed.

WD900-3 90-3
 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/2) *1. For Serial No. 50001 – 50006 a On the machines serial No. 50006 and up, the
*2. For Serial No. 50007 and up pilot circuits (PA2 and PB2) in which the oil
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
from PPC valve to lift spool are reversed.

WD900-3 90-5
 ELECTRICAL CIRCUIT DIAGRAM (1/7)
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (1/5)

WD900-3 90-7
 ELECTRICAL CIRCUIT DIAGRAM (2/7)
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (2/5)

WD900-3 90-9
 ELECTRICAL CIRCUIT DIAGRAM (3/7)
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (3/5)

WD900-3 90-11
 ELECTRICAL CIRCUIT DIAGRAM (4/7)
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (4/5)

WD900-3 90-13
 ELECTRICAL CIRCUIT DIAGRAM (5/7)
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (5/5)

WD900-3 90-15
ELECTRICAL CIRCUIT DIAGRAM (6/7)
WORK EQUIPMENT LEVER ELECTRIC DIAGRAM
a This section gives only information related to the wheel dozer.

WD900-3 90-17
ELECTRICAL CIRCUIT DIAGRAM (7/7)
TAKE-OFF POWER ELECTRIC DIAGRAM

WD900-3 90-19