Wa500-3 LK SM Cebd005402

CEBM005402
Shop
Manual
WA500-3LK
WHEEL LOADER
SERIAL NUMBERS
WA500-3LK
A71001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
October 2004
Printed in USA
Copyright 2004 Komatsu

DataKom Publishing Division
00-1 2
FOREWORD
12
CONTENTS
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WA500-3LK
PRODUCT PUBLICATIONS INFORMATION

Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB009201
OPERATION AND MAINTENANCE MANUAL:
Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM008100
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM005402
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM022209
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT03-04
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
WA500-3LK pubinfok.fm
10/21/04
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM
AND RETURN TO
DataKom Publications and Training Division

440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO
ATTN.
TYPE or PRINT
ONLY
STREET ADDRESS
ORDER DATE
CITY, STATE, ZIP CODE

COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY.
PUBLICATION FORM NO.
PARTS BOOK
P-Paper
M-Microfiche
KDC91E 071403
PUBLICATION
DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
FOREWORD
The affected pages are indicated by using the following

marks. It is requested that necessary actions be taken to
these pages according to the table below.
Mark
Page
00-1
Rev
c
00-2
Mark
Mark
Mark
Indication
Action
New page to be added
Page to be replaced
Replace
( )
Page to be deleted
Discard
Page
Page
Rev
10-33
10-6
10-34
Page
Rev
00-19
10-5
00-20
Rev
Mark
Add
00-2-1
00-21
10-7
10-35
00-2-2
00-22
10-8
10-36
00-2-3
10-9
10-37
00-2-4
01-1
10-10
10-38
00-2-5
01-2
10-11
10-39
00-2-6
01-3
10-12
10-40
00-2-7
01-4
10-13
10-41
00-2-8
01-5
10-14
10-42
00-2-9
01-6
10-15
10-43
00-2-10
01-7
10-16
10-44
00-3
01-8
10-17
10-45
00-4
01-9
10-18
10-46
00-5
01-10
10-19
10-47
00-6
01-11
10-20
10-48
00-7
01-12
10-21
10-49
00-8
01-13
10-22
10-50
00-9
01-14
10-23
10-51
00-10
01-15
10-24
10-52
00-11
01-16
10-25
10-53
00-12
01-17
10-26
10-54
00-13
01-18
10-27
10-55
00-14
10-28
10-56
00-15
10-1
10-29
10-57
00-16
10-2
10-30
10-58
00-17
10-3
10-31
10-59
00-18
10-4
10-32
10-60
WA500-3LK
WA500-3LK
00-2-1 C
FOREWORD
Mark
Page
Rev
10-61
Page
Rev
10-94
10-127
10-160
10-62
10-95
10-128
10-161
10-63
10-96
10-129
10-162
10-64
10-97
10-130
10-163
10-65
10-98
10-131
10-164
10-66
10-99
10-132
10-165
10-67
10-100
10-133
10-166
10-68
10-101
10-134
10-167
10-69
10-102
10-135
10-168
10-70
10-103
10-136
10-169
10-71
10-104
10-137
10-170
10-72
10-105
10-138
10-171
10-73
10-106
10-139
10-172
10-74
10-107
10-140
10-173
10-75
10-108
10-141
10-174
10-76
10-109
10-142
10-175
10-77
10-110
10-143
10-176
10-78
10-111
10-144
10-177
10-79
10-112
10-145
10-178
10-80
10-113
10-146
10-179
10-81
10-114
10-147
10-180
10-82
10-115
10-148
10-181
10-83
10-116
10-149
10-182
10-84
10-117
10-150
10-183
10-85
10-118
10-151
10-184
10-86
10-119
10-152
10-185
10-87
10-120
10-153
10-186
10-88
10-121
10-154
10-187
10-89
10-122
10-155
10-188
10-90
10-123
10-156
10-189
10-91
10-124
10-157
10-190
10-92
10-125
10-158
10-191
10-93
10-126
10-159
10-192
00-2-2 C
Mark
Mark
Page
Rev
Mark
Page
Rev
WA500-3LK
FOREWORD
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
10-193
10-226
20-22
20-55
10-194
10-227
20-23
20-56
10-195
10-228
20-24
20-57
10-196
10-229
20-25
20-58
10-197
10-230
20-26
20-59
10-198
10-231
20-27
20-60
10-199
10-232
20-28
20-61
10-200
10-233
20-29
20-62
10-201
10-234
20-30
20-63
10-202
10-235
20-31
20-64
10-203
10-236
20-32
20-65
10-204
20-33
20-66
10-205
10-206
10-207
10-208
20-1
20-34
20-67
20-2
20-35
20-68
20-3
20-36
20-69
20-4
20-37
20-70
10-209
20-5
20-38
20-71
10-210
20-6
20-39
20-72
10-211
20-7
20-40
20-73
10-212
20-8
20-41
20-74
10-213
20-9
20-42
20-75
10-214
20-10
20-43
20-76
10-215
20-11
20-44
20-77
10-216
20-12
20-45
20-78
10-217
20-13
20-46
20-79
10-218
20-14
20-47
20-80
10-219
20-15
20-48
20-81
10-220
20-16
20-49
20-82
10-221
20-17
20-50
10-222
20-18
20-51
20-101
10-223
20-19
20-52
20-102
10-224
20-20
20-53
20-103
10-225
20-21
20-54
20-104
WA500-3LK
00-2-3 C
FOREWORD
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
20-105
20-158
20-216
20-507
20-106
20-159
20-217
20-508
20-107
20-160
20-218
20-509
20-108
20-161
20-219
20-510
20-109
20-162
20-220
20-511
20-110
20-163
20-221
20-512
20-111
20-164
20-222
20-513
20-112
20-165
20-223
20-514
20-113
20-166
20-224
20-515
20-114
20-167
20-225
20-516
20-115
20-168
20-226
20-517
20-116
20-169
20-227
20-518
20-117
20-170
20-228
20-519
20-118
20-171
20-229
20-520
20-119
20-172
20-230
20-521
20-120
20-173
20-231
20-522
20-121
20-174
20-232
20-523
20-122
Rev
20-524
20-123
20-201
20-401
20-525
20-124
20-202
20-402
20-526
20-125
20-203
20-403
20-527
20-126
20-204
20-404
20-528
20-127
20-205
20-405
20-529
20-128
20-206
20-406
20-530
20-207
20-407
20-531
20-150
20-208
20-408
20-532
20-151
20-209
20-152
20-210
20-501
20-153
20-211
20-502
20-533
20-534
20-154
20-212
20-503
20-601
20-155
20-213
20-504
20-602
20-156
20-214
20-505
20-603
20-157
20-215
20-506
20-604
00-2-4 C
WA500-3LK
FOREWORD
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
20-605
20-638
20-805
20-915
20-606
20-639
20-806
20-916
20-607
20-640
20-807
20-917
20-608
20-641
20-808
20-918
20-609
20-642
20-809
20-919
20-610
20-643
20-810
20-920
20-611
20-644
20-811
20-921
20-612
20-812
20-922
20-613
20-701
20-813
20-923
20-614
20-702
20-814
20-924
20-615
20-703
20-815
20-925
20-616
20-704
20-816
20-926
20-617
20-705
20-817
20-927
20-618
20-706
20-818
20-928
20-619
20-707
20-819
20-929
20-620
20-708
20-820
20-930
20-621
20-709
20-821
20-931
20-622
20-710
20-822
20-932
20-623
20-711
20-624
20-712
20-901
20-1201
20-625
20-713
20-902
20-1202
20-626
20-714
20-903
20-1203
20-627
20-715
20-904
20-1204
20-628
20-716
20-905
20-1205
20-629
20-717
20-906
20-1206
20-630
20-718
20-907
20-1207
20-631
20-719
20-908
20-1208
20-632
20-720
20-909
20-1209
20-633
20-910
20-1210
20-634
20-801
20-911
20-1211
20-635
20-802
20-912
20-1212
20-636
20-803
20-913
20-1213
20-637
20-804
20-914
20-1214
WA500-3LK
00-2-5 C
FOREWORD
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
20-1215
20-1248
20-1312
30-24
20-1216
20-1249
20-1313
30-25
20-1217
20-1250
20-1314
30-26
20-1218
20-1251
20-1315
30-27
20-1219
20-1252
20-1316
30-28
20-1220
20-1253
20-1317
30-29
20-1221
20-1254
20-1318
30-30
20-1222
20-1255
20-1319
30-31
20-1223
20-1256
20-1320
30-32
20-1224
20-1257
30-33
20-1225
20-1258
30-1
30-34
20-1226
20-1259
30-2
30-35
20-1227
20-1260
30-3
30-36
20-1228
20-1261
30-4
30-37
20-1229
20-1262
30-5
30-38
20-1230
20-1263
30-6
30-39
20-1231
20-1264
30-7
30-40
20-1232
20-1265
30-8
30-41
20-1233
20-1266
30-9
30-42
20-1234
20-1267
30-10
30-43
20-1235
20-1268
30-11
30-44
30-12
30-45
20-1236
20-1237
20-1301
30-13
30-46
20-1238
20-1302
30-14
30-47
20-1239
20-1303
30-15
30-48
20-1240
20-1304
30-16
30-49
20-1241
20-1305
30-17
30-50
20-1242
20-1306
30-18
30-51
20-1243
20-1307
30-19
30-52
20-1244
20-1308
30-20
30-53
20-1245
20-1309
30-21
30-54
20-1246
20-1310
30-22
30-55
20-1247
20-1311
30-23
30-56
00-2-6 C
WA500-3LK
FOREWORD
Mark
Page
Rev
30-57
Page
Rev
30-90
30-123
30-156
30-58
30-91
30-124
30-157
30-59
30-92
30-125
30-158
30-60
30-93
30-126
30-159
30-61
30-94
30-127
30-160
30-62
30-95
30-128
30-161
30-63
30-96
30-129
30-162
30-64
30-97
30-130
30-163
30-65
30-98
30-131
30-164
30-66
30-99
30-132
30-165
30-67
30-100
30-133
30-166
30-68
30-101
30-134
30-167
30-69
30-102
30-135
30-168
30-70
30-103
30-136
30-169
30-71
30-104
30-137
30-170
30-72
30-105
30-138
30-171
30-73
30-106
30-139
30-172
30-74
30-107
30-140
30-173
30-75
30-108
30-141
30-174
30-76
30-109
30-142
30-175
30-77
30-110
30-143
30-176
30-78
30-111
30-144
30-177
30-79
30-112
30-145
30-178
30-80
30-113
30-146
30-179
30-81
30-114
30-147
30-180
30-82
30-115
30-148
30-181
30-83
30-116
30-149
30-182
30-84
30-117
30-150
30-183
30-85
30-118
30-151
30-184
30-86
30-119
30-152
30-185
30-87
30-120
30-153
30-186
30-88
30-121
30-154
30-187
30-89
30-122
30-155
30-188
WA500-3LK
Mark
Mark
Page
Rev
Mark
Page
Rev
00-2-7 C
FOREWORD
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
30-189
30-222
30-255
40-19
30-190
30-223
30-256
40-20
30-191
30-224
30-257
40-21
30-192
30-225
30-258
40-22
30-193
30-226
30-259
40-23
30-194
30-227
30-260
40-24
30-195
30-228
30-261
40-25
30-196
30-229
30-262
40-26
30-197
30-230
30-263
40-27
30-198
30-231
30-264
40-28
30-199
30-232
30-265
40-29
30-200
30-233
30-266
40-30
30-201
30-234
30-267
40-31
30-202
30-235
30-268
40-32
30-203
30-236
40-33
30-204
30-237
40-1
40-34
30-205
30-238
40-2
40-35
30-206
30-239
40-3
40-36
30-207
30-240
40-4
40-37
30-208
30-241
40-5
40-38
30-209
30-242
40-6
40-39
30-210
30-243
40-7
40-40
30-211
30-244
40-8
40-41
30-212
30-245
40-9
40-42
30-213
30-246
40-10
40-43
30-214
30-247
40-11
40-44
30-215
30-248
40-12
40-45
30-216
30-249
40-13
40-46
30-217
30-250
40-14
40-47
30-218
30-251
40-15
40-48
30-219
30-252
40-16
40-49
30-220
30-253
40-17
40-50
30-221
30-254
40-18
40-51
00-2-8 C
WA500-3LK
FOREWORD
Mark
Page
Rev
40-52
90-2
40-53
90-3
40-54
90-4
40-55
90-5
40-56
40-57
40-58
40-59
40-60
Mark
Mark
Page
Rev
90-35
90-36
90-37
90-38
90-6
90-39
90-7
90-40
90-8
90-41
90-9
90-42
90-10
90-43
40-61
90-11
90-44
40-62
90-12
90-45
40-63
90-13
90-46
40-64
90-14
90-47
40-65
90-15
90-48
40-66
90-16
90-49
40-67
90-17
90-50
40-68
90-18
90-51
90-19
90-52
40-70
90-20
90-53
40-71
90-21
90-54
40-72
90-22
90-55
90-23
90-56
90-24
90-57
90-25
90-58
40-76
90-26
90-59
40-77
90-27
90-60
40-78
90-28
90-61
90-29
90-62
40-80
90-30
90-63
40-81
90-31
90-64
40-82
90-32
90-65
90-33
90-66
90-34
40-69
40-73
40-74
40-75
40-79
90-1
WA500-3LK
Page
Rev
Mark
Page
Rev
00-2-9 C
FOREWORD
Mark
Page
00-2-10 C
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
WA500-3LK
FOREWORD
SAFETY
12
00
00
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols
and
are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
00
GENERAL PRECAUTIONS
00
PREPARATIONS FOR WORK
Mistakes in operation are extremely dangerous. Read the

OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine

on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the
machine.
2.
2.
When carrying out any operation, always wear safety

shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
Always wear safety glasses when hitting parts with a
hammer.
Always wear safety glasses when grinding parts with a
grinder, etc.
Before starting work, lower blade, ripper, bucket or any

other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on
them.
3.
When disassembling or assembling, support the

machine with blocks, jacks or stands before starting
work.
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 or steps when getting on or off the
machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
3.
If welding repairs are needed, always have a trained,

experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more

workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator's compartment.
5.
6.
Keep all tools in good condition and learn the correct

way to use them.
Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
WA500-3LK
00
PRECAUTIONS DURING WORK
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or
removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
oil and water to cool before carrying out any work on
the oil or water circuits.
3.
Before starting work, remove the leads from the battery.

ALWAYS remove the lead from the negative (-) terminal first.
00-3
FOREWORD
SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is
being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4
WA500-3LK
FOREWORD
GENERAL
12
00
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WA500-3LK
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12
00
00
HOW TO READ THE SHOP MANUAL

VOLUMES
00
REVISIONS
Shop manuals are issued as a guide to carrying out repairs.

They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES

between the title page and SAFETY page.
Chassis volume:
Engine volume:
00
Issued for every machine model

Issued for each engine series
Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model,
it is necessary that chassis, engine, electrical and attachment
be available.
00
So that the shop manual can be of ample practical use,

important places for safety and quality are marked with the
following symbols.
Symbol Item
Special safety precautions are

necessary when performing the
work.
Caution
Special technical precautions or

other precautions for preserving
standards are necessary when
performing the work.
Weight
See the page number on the bottom of the page. File the
pages in correct order.
Following examples show how to read the page number:
Example:
Weight of parts or systems. Caution necessary when selecting

hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special attention for tightening torque during

assembly.
10 - 3
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel

must be added, and the capacity.
Drain
Places where oil or water must

be drained, and quantity to be
drained.
DISTRIBUTION AND UPDATING
FILING METHOD
1.
2.
Item number (10. Structure and Function)

Consecutive page number for each item
3.
Remarks
Safety
Any additions, amendments or other changes will be sent to

your distributors. Get the most up-to-date information before
you start any work.
00
SYMBOLS
Additional pages: Additional pages are indicated by a

hyphen (-) and numbered after the page number. File as
in the example.
Example:
10-4
10-4-1
10-4-2
Added pages
10-5
00
REVISED EDITION MARK
When a manual is revised, an edition mark (123) is

recorded on the bottom outside corner of the pages.
00-6
WA500-3LK
FOREWORD
HOISTING INSTRUCTIONS
12
00
00
HOISTING INSTRUCTIONS
HOISTING
can result. Hooks have maximum strength at the middle

portion.
WARNING! Heavy parts (25 kg or more)

must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol
1.
2.
00
If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
Check for removal of all bolts fastening the part to the
relative parts.
Check for existence of another part causing interface
with the part to be removed.
3.
WARNING! Slinging with one rope may

cause turning of the load during
hoisting, untwisting of the rope,
or slipping of the rope from its
original winding position on the
load, which can result in a
dangerous accident
WIRE ROPES
1.
Use adequate ropes depending on the weight of parts to

be hoisted, referring to the table below:
Wire ropes
(Standard Z or S twist ropes without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
4.
Do not sling a heavy load with ropes forming a wide

hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
2000 kg load at a lifting angle of 150
The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WA500-3LK
00-7
FOREWORD
00
PUSH-PULL TYPE COUPLER

WARNING! Before carrying out the following work,
release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.
WARNING! Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.
DISCONNECTION
1.
2.
3.
4.
Release the residual pressure from the hydraulic tank. For details, see
TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
Hold adapter (1) and push hose joint (2) into mating adapter (3). (See
Fig. 1)
The adapter can be pushed in about 3.5 mm.
Do not hold rubber cap portion (4).
After hose joint (2) is pushed into adapter (3), press rubber cap
portion (4) against (3) until it clicks. (See Fig. 2)
Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3)
Since some hydraulic oil flows out, prepare an oil receiving
container.
CONNECTION
1.
2.
Hold hose adapter (1) or hose (5) and insert it in mating adapter (3),
aligning them with each other. (See Fig. 4)
Do not hold rubber cap portion (4).
After inserting the hose in the mating adapter perfectly, pull it back to
check its connecting condition. (See Fig. 5)
When the hose is pulled back, the rubber cap portion moves
toward the hose about 3.5 mm. However, this does not indicate
abnormality.
00-8 1
WA500-3LK
FOREWORD
12
Type 2
1.
Type 3
Hold the mouthpiece of the tightening portion and push
body (2) in straight until sliding prevention ring (1)
contacts contact surface a of the hexagonal portion at the
male end.
Hold the mouthpiece of the tightening portion and push body (2)
in straight until sliding prevention ring (1) contacts surface a of
hexagonal portion at the male end.
2.
Hold in the condition in Step 1 and turn lever (4) to the right
(clockwise).
2.
Hold in the condition in Step 1 and push until cover (3)

male end.
3.
Hold in the condition in Steps 1 and 2, and pull out whole body 3.
(2) to disconnect it.
Hold in the condition in Steps 1 and 2, and pull out whole

body (2) to disconnect it.
Disassembly
1.
WA500-3LK
00-9 1
FOREWORD
Hold the mouthpiece of the tightening portion and push body (2)
in straight until sliding prevention ring (1) contacts contact
surface a of the hexagonal portion at the male end to connect it.
Hold the mouthpiece of the tightening portion and push

body (2) in straight until sliding prevention ring (1)
male end to connect it.
Connection
00-10 1
WA500-3LK
FOREWORD
COATING MATERIALS
12
00
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category
Code
LT-1A
Adhesives
LT-1B
Part No.
790-129-9030
790-129-9050
Container
150 g
Tube
20 g
(2 pes.)
Polyethylene
container
50 g
Polyethylene
container
Adhesive:
1 kg
Hardening
agent:
500 g
Can
LT-2
09940-00030
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
2g
Polyethylene
container
Three bond
179-129-9140
1735
Gasket
sealant
Quantity
Polyethylene
container
Aron-alpha
790-129-9130
201
50 g
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
LG-3
790-129-9070
1 kg
Main applications, features
Used to prevent rubber gaskets, rubber

cushions and cork plugs from coming out
Used in places requiring an immediately

effective, strong adhesive.
Used for plastics (except polyethylene,
polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and
non-metal.
Features: Resistance to heat, chemicals

Used for anti-loosening and sealant
purposes for bolts and plugs.
Used as adhesive or sealant for metal, glass

or plastic.
Used as sealant for machined holes.
Used as heat-resisting sealant for repairing

engine.
Quick hardening type adhesive.

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
rubbers, plastics and woods.
Quick hardening type adhesive.

Quick cure type (max. strength after
30 minutes).
Used mainly for adhesion of rubbers,
plastics and metals.
Features: Resistance to heat, chemicals

Used at joint portions subject to high
temperature.
Used as adhesive or sealant for gaskets and

packing of power train case, etc.
Features: Resistance to heat

Used as sealant for flange surfaces and bolts
at high temperature locations; used to
prevent seizure.
Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
Can
WA500-3LK
00-11 1
FOREWORD
Category
Code
LG-4
COATING MATERIALS
Part No.
790-129-9020
Quantity
200 g
Container
Tube
Main applications, features
LG-5
790-129-9080
1 kg
Polyethylene
container
Gasket
sealant
LG-6
09940-00011
250 g
Tube
Molybdenum
disulphide
lubricant
LG-7
150 g
Tube
Three bond
790-129-9090
1211
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYG2160CNCA
Various
Various
400 g (10 per

case)
Belows type
Molybdenum
disulphide lubricant
Grease
00-12 1
09920-00150
SYG2-400M
Features: Resistance to water, oil

Used as sealant for flange surface, thread.
Also possible to use as sealant for flanges
with large clearance.
Used as sealant for mating surfaces of final
drive case, transmission case.
Used as sealant for various threads, pipe
joints, flanges.
Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Features: Silicon based, resistant to heat,
cold.
Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case,
etc.
Features: Silicon based, quick hardening
type.
Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Used as heat-resisting sealant for repairing

engines.
Used as lubricant for sliding parts

(to prevent squeaking).
Used to prevent seizure or scuffing of the

thread when press fitting or shrink fitting.
Used as lubricant for linkage, bearings, etc.
General purpose type
Used for normal temperature, light load

bearing at places in contact with water or
steam.
Used for places with heavy load.
WA500-3LK
FOREWORD
STANDARD TIGHTENING TORQUE
12
00
00

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
10
13.2 1.4
1.35 0.15
13
31.4 2.9
3.20 0.3
10
17
65.7 6.8
6.70 0.7
12
19
112 9.8
11.5 1.0
14
22
177 19
18 2.0
16
24
279 29
28.5 3
18
27
383 39
39 4
20
30
549 58
56 6
22
32
745 78
76 8
24
36
927 98
94.5 10
27
41
1320 140
135 15
30
46
1720 190
175 20
33
50
2210 240
225 25
36
55
2750 290
280 30
39
60
3280 340
335 35
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
10
7.85 1.95
0.8 0.2
13
18.6 4.9
1.9 0.5
10
14
40.2 5.9
4.1 0.6
12
27
82.35 7.85
8.4 0.8
WA500-3LK
00-13 1
FOREWORD
12
TIGHTENING
00
TORQUE OF HOSE NUTS
Use these torques for hose nuts.

Thread diameter
Width across flat
mm
mm
Nm
kgm
02
14
19
24.5 4.9
2.5 0.5
03
18
24
49 19.6
52
04
22
27
78.5 19.6
82
05
24
32
137.3 29.4
14 3
06
30
36
176.5 29.4
18 3
10
33
41
196.1 49
20 5
12
36
46
245.2 49
25 5
14
42
55
294.2 49
30 5
Nominal No.
00
Tightening torque
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
00
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
14
65.7 6.8
6.7 0.7
12
17
112 9.8
11.5 1
16
22
279 29
28.5 3
TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
19
24.5 4.9
2.5 0.5
18
24
49 19.6
5 2
22
27
78.5 19.6
8 2
24
32
137.3 29.4
14 3
30
36
176.5 29.4
18 3
33
41
196.1 49
20 5
36
46
245.2 49
25 5
42
55
294.2 49
30 5
00-14 1
Tightening torque
WA500-3LK
FOREWORD
ELECTRIC WIRE CODE
12
00
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example:
05WB indicates a cable having a nominal number 05 and white coating with black stripe.
00
CLASSIFICATION BY THICKNESS
Copper wire
Nominal numNumber of Dia. Of strand Cross section
ber
strands
(mm)
(mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
26
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
CLASSIFICATION BY COLOR AND CODE

Priority
1
Circuits
Classification
Primary
00
Cable O.D.
(mm)
Auxiliary
WA500-3LK
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
Color
White &
Red
Black &
White
Red &
White
Yellow &
Red
Green &
White
Blue &
White
Code
WB
BY
RB
YB
GR
LR
Color
White &
Black
Yellow &
Black
Green &
Red
Blue & Red
Code
WL
BR
RY
YG
GY
LY
Color
White &
Blue
Black & Red
Red & Yellow
Yellow &
Green
Green &
Yellow
Blue &
Yellow
Code
WG
RG
YL
GB
LB
Color
White &
Green
Red &
Green
Yellow &
Blue
Green &
Black
Blue &
Black
Code
RL
YW
GL
Color
Red & Blue
Yellow &
White
Green &
Blue
Black & YelRed & Black

low
00-15 1
FOREWORD
CONVERSION TABLES
12
00
00
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2.
Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it
to 55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
3
1
00-16 1
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
WA500-3LK
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
WA500-3LK
00-17 1
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
00-18 1
1 L = 0.21997 U.K. Gal
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
WA500-3LK
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
1 kgm = 7.233 ft. lb.

0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63 1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1439.4
WA500-3LK
1432.1
00-19 1
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
00-20 1
1 kg/cm2 = 14.2233lb/in2
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
WA500-3LK
FOREWORD
CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
C
F
C
F
C
F
C
F
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
117.8
-37.2
.35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-27.8
-27.2
-26.7
-26.1
-19
-18
-17
-16
-15
-2.2
-0.4
1.4
3.2
5.0
-8.9
-8.3
-7.8
-7.2
-6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
-25.6
-25.0
-24.4
-23.9
-23.3
-14
-13
-12
-11
-10
6.8
8.6
10.4
12.2
14.0
-6.1
-5.6
-5.0
-4.4
-3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
-22.8
-22.2
-21.7
-21.1
-20.6
-9
-8
-7
-6
-5
15.8
17.6
19.4
21.2
23.0
-3.3
-2.8
-2.2
-1.7
-1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
-20.0
-19.4
-18.9
-18.3
-17.8
-4
-3
-2
-1
0
24.8
26.6
28.4
30.2
32.0
-0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
-17.2
-16.7
-16.1
-15.6
-15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
-14.4
-13.9
-13.3
-12.8
-12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
WA500-3LK
00-21 1
FOREWORD
CONVERSION TABLES
12
MEMORANDUM
00-22 1
WA500-3LK
01
GENERAL
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
FUEL, COOLANT AND LUBRICATNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15
WA500-3LK
01-1 1
GENERAL
DIMENSIONS
12
DIMENSIONS
With General Purpose

Bucket 4.3 m3 (5.6 yd3)
With Excavating Bucket

4.0 m3 (5.2 yd3)
With Spade Nose Rock

Bucket 4.0 m3 (5.2 yd3)
26.5 x 25
Tires
29.5 x 25
Tires
26.5 x 25
Tires
29.5 x 25
Tires
26.5 x 25
Tires
29.5 x 25
Tires
Tread
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
Width over tires
3.1 m
(10 ft 2 in)
3.2 m
(10 ft 6 in)
3.1 m
(10 ft 2 in)
3.2 m
(10 ft 6 in)
3.1 m
(10 ft 2 in)
3.2 m
(10 ft 6 in)
Wheelbase
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
Hinge pin height maximum
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
Hinge pin height - carry

position
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
Ground clearance
0.44 m
(1 ft 5 in)
0.49 m
(1 ft 7 in)
0.44 m
(1 ft 5 in)
0.49 m
(1 ft 7 in)
0.44 m
(1 ft 5 in)
0.49 m
(1 ft 7 in)
Hitch height
1.13 m
(3 ft 9 in)
1.18 m
(3 ft 11 in)
1.13 m
(3 ft 9 in)
1.18 m
(3 ft 11 in)
1.13 m
(3 ft 9 in)
1.18 m
(3 ft 11 in)
01-2 1
WA500-3LK
GENERAL
DIMENSIONS
12
With General Purpose
Bucket 4.3 m3 (5.6 yd3)
With Excavating Bucket

4.0 m3 (5.2 yd3)
With Spade Nose Rock

Bucket 4.0 m3 (5.2 yd3)
26.5 x 25
Tires
29.5 x 25
Tires
26.5 x 25
Tires
29.5 x 25
Tires
26.5 x 25
Tires
29.5 x 25
Tires
Overall height to top of

exhaust pipe
3.63 m
(11 ft 11 in)
3.68 m
(12 ft 1 in)
3.63 m
(11 ft 11 in)
3.68 m
(12 ft 1 in)
3.63 m
(11 ft 11 in)
3.68 m
(12 ft 1 in)
Overall height to top of

ROPS canopy
3.89 m
(12 ft 9 in)
3.94 m
(12 ft 11 in)
3.89 m
(12 ft 9 in)
3.94 m
(12 ft 11 in)
3.89 m
(12 ft 9 in)
3.94 m
(12 ft 11 in)
Dumping clearance at
maximum height & 45
dump angle
3.21 m
(10 ft 7 in)
3.27 m
(10 ft 9 in)
3.27 m
(10 ft 9 in)
3.32 m
(10 ft 11 in)
3.11 m
(10 ft 2 in)
3.16 m
(10 ft 4 in)
Reach @ 2.13 m (7 ft)

cutting edge clearance &
45 dump angle
2.03 m
(6 ft 8 in)
1.98 m
(6 ft 6 in)
1.99 m
(6 ft 7 in)
1.94 m
(6 ft 5 in)
2.08 m
(6 ft 10 in)
2.03 m
(6 ft 8 in)
Reach @ maximum
height & 45dump angle
1.37 m
(4 ft 6 in)
1.32 m
(4 ft 4 in)
1.32 m
(4 ft 4 in)
1.27 m
(4 ft 2 in)
1.46 m
(4 ft 10 in)
1.41 m
(4 ft 8 in)
Reach with lift arm horizontal & bucket level
2.81 m
(9 ft 3 in)
2.76 m
(9 ft 1 in)
2.73 m
(8 ft 11 in)
2.68 m
(8 ft 10 in)
2.95 m
(9 ft 8 in)
2.90 m
(9 ft 6 in)
Operating height - fully

raised
6.02 m
(19 ft 9 in)
6.07 m
(19 ft 11 in)
6.13 m
(20 ft 2 in)
6.18 m
(20 ft 4 in)
6.21 m
(20 ft 5 in)
6.26 m
(20 ft 7 in)
Overall length
8.97 m
(29 ft 5 in)
8.93 m
(29 ft 4 in)
8.89 m
(29 ft 2 in)
8.85 m
(29 ft 1 in)
9.12 m
(29 ft 11 in)
9.08 m
(29 ft 10 in)
Loader clearance circle at

outside corner of bucket
& bucket in carry position
14.39 m
(47 ft 3 in)
14.39 m
(47 ft 3 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
Digging depth at 0
0.175 m
(6.9 in)
0.125 m
(4.9 in)
0.115 m
(4.5 in)
0.065 m
(2.6 in)
0.125 m
(4.9 in)
0.075 m
(3.0 in)
Digging depth at 10
0.460 m
(1 ft 6 in)
0.410 m
(1 ft 4 in)
0.330 m
(1 ft 1 in)
0.290 m
(11.4 in)
0.385 m
(1 ft 3 in)
0.330 m
(1 ft 1 in)
Remark
All specifications are subject to change without notice.
WA500-3LK
01-3 1
GENERAL
SPECIFICATIONS
12
Weight
SPECIFICATIONS
Machine model
WA500-3LK
Serial number
A71001 and up
Operating weight
Distribution (front)
Distribution (rear)
Bucket capacity (piled)
Rated load
Performance
Travel speed:
FORWARD 1st
FORWARD 2nd
FORWARD 3rd
FORWARD 4th
REVERSE 1st
REVERSE 2nd
REVERSE 3rd
REVERSE 4th
Dimensions
Grade-ability
28,810 kg (63,515 lb)

13,360 kg (29,454 lb)
15,450 kg (34,061 lb)
4.3 m (5.6 yd)
75.9 kN (7,740 kg)
7.1 km/h (4.4 mph)
12.6 km/h (7.8 mph)
21.2 km/h (13.2 mph)
34.8 km/h (21.6 mph)
7.9 km/h (4.9 mph)
14.1 km/h (8.8 mph)
23.5 km/h (14.6 mph)
38.1 km/h (23.7 mph)
25 deg
Turning radius (bucket at carry - outside corner

of bucket)
7390 mm (24 ft 3 in)
Overall length
9320 mm (30 ft 6 in)
Overall width (Chassis)
3,190 mm (10 ft 5 in)
Bucket width (with bolt on cutting edge)
3460 mm (11 ft 4 in)
Overall height (top of cab)
3860 mm (12 ft 7 in)
Overall height (bucket raised)
6115 mm (20 ft 1 in)
Wheelbase
3600 mm (11 ft 10 in)
Tread
2400 mm (7 ft 10 in)
Minimum ground clearance
450 mm (1 ft 5 in)
Height of bucket hinge pin
4500 mm (14 ft 8 in)
Dumping clearance (tip of cutting edge)
3170 mm (10 ft 0 in)
Dumping reach (tip of cutting edge)
1365 mm 4 ft .5 in)
Bucket dump angle
45 deg
Bucket tilt angle (SAE carrying position)
48 deg
Digging depth (10 dump angle)
01-4 1
375 mm (14.7 in)
WA500-3LK
GENERAL
SPECIFICATIONS
Machine model
WA500-3LK
Serial number
A71001 and up
Model
Type
Engine
No. of cylinders - bore x stroke
Gross power @ 2100 rpm
235kW (315 HP)
Maximum torque (gross) @ 1400 rpm
Starting motor
Alternator
Battery
Torque converter
Power train
6 - 140 mm (5.5") x 165 mm (6.4")

15.2 L (15,200 cc)
Fuel consumption ratio
Axle, Wheel
4-cycle, water cooled, in line,direct injection, turbocharged, after-cooler
Piston displacement
High idle
Low idle
Brakes
Komatsu SA6D140E-3 diesel engine
Transmission
Reduction gear
1372 Nm (1011 lbf ft)

2300 rpm
725 rpm
245 g/kW h (180 g/HPh)
24 V, 11 kW
24 V, 50 A
12 V, 465 Ah x 2
3-element, single-stage, single-phase (TCA40-1C)
Planetary gear, constant-mesh multiple-disc, hydraulic actuated,
modulation type
Spiral bevel gear, splash lubrication
Differential
Straight bevel gear
Final drive
Planetary gear, single stage, splash lubrication
Drive type
Front / rear wheel drive
Front axle
Fixed frame full-floating type
Rear axle
Center pin support full-floating type
Tire
Wheel rim
29.5 - 25 - 22 pr tubeless (L3)

25.00 x 25 WTB
Inflation pressure Front tire
4.5 kgf/cm2 (64.0 lbf/in2)
Inflation pressure Rear tire
3.5 kgf/cm2 (49.8 lbf/in2)
Service brakes
Front / rear wheel braking, separate front/rear wheel, wet disc,

hydraulically actuated
Parking brake
Drive shaft, wet type disc brake, hydraulically released spring type
WA500-3LK
01-5 1
Steering system
GENERAL
SPECIFICATIONS
Machine model
WA500-3LK
Serial number
A71001 and up
Type
Structure
Hydraulic system
Hydraulic
Pump
Delivery
Work equipment
Articulated steering
Control valve
Fully hydraulic power steering
Work equipment pump
348 L (Gear type: SAR(4) - 160)
Switch pump
135 L (Gear type: SAR(3) - 63)
Steering pump
PPC pump
Set pressure for work equipment

Set pressure for steering
Cylinder
Linkage type
Bucket edge type
01-6 1
2 - Spool type 210 kg/cm2 (2986.9 lbf/in2)

Steering (Orbit-roll) valve type 210 kg/cm2 (2986.9 lbf/in2)
Boom cylinder qty. - bore x stroke
Reciprocating piston 2-200 x 839 (mm)
Bucket cylinder
stroke
qty. - bore x
Reciprocating piston 1-225 x 613 (mm)
Steering cylinder
stroke
qty. - bore x
Reciprocating piston 2 - 110 x 486 (mm)
Single link (Z-bar linkage)

Flat edge with bolt on cutting edge
WA500-3LK
GENERAL
WEIGHT TABLE
12
WEIGHT
TABLE
Machine model
WA500-3LK
Machine model
WA500-3LK
Serial No.
A71001 and up
Serial No.
A71001 and up
Engine
3,549 lb (1,610 kg)
Hydraulic tank
507 lb (230 kg)
Radiator
732 lb (332 kg)
Hydraulic pump
45 lb (20.3 kg)
Transmission with torque converter
2,524 lb (1,145 kg)
Switch and PPC pump
42 lb (19 kg)
Torque converter assembly
474 lb (215 kg)
Steering pump
27 lb (12.2 kg)
Transmission assembly
2,050 lb (930 kg)
PPC valve
8 lb (3.5 kg)
Damper
201 lb (91 kg)
Main control valve
210 lb (95 kg)
Upper drive shaft
40 lb (18 kg)
Steering cylinder (each)
104 lb (47 kg)
Center drive shaft
73 lb (33 kg)
Boom cylinder (each)
600 lb (272 kg)
Front drive shaft
99 lb (45 kg)
Bucket cylinder
631 lb (286 kg)
Rear drive shaft
86 lb (41 kg)
Engine hood (w/side panels)
496 lb (225 kg)
Center support
93 lb (42 kg)
Front frame
4,892 lb (2,219 kg)
Front axle assembly
4,277 lb (1,940 kg)
Rear frame
4,817 lb (2,185 kg)
Rear axle assembly
4,138 lb (1,877 kg)
Bucket link
234 lb (106 kg)
Axle pivot (Rear axle)
207/252 lb (94/114 kg)
Bellcrank
1,151 lb (522 kg)
Tire and wheel (each)
1,740 lb (789 kg)
Boom including bushings
4,449 lb (2,018 kg)
Wheel (each)
576 lb (261 kg)
Bucket with teeth
6,195 lb (2,810 kg)
Tire (each)
1,149 lb (521 kg)
Counterweight
4,954 lb (2,247 kg)
Front differential assembly
591 lb (268 kg)
Fuel tank
531 lb (241 kg)
Rear differential assembly
612 lb (278 kg)
Battery (each)
117 lb (53 kg)
Planetary carrier (each)
137 lb (62 kg)
Floor, dash, console
472 lb (214 kg)
Planetary hub (each)
227 lb (103 kg)
Cab (ROPS)
1,005 lb (456 kg)
Steering valve
52 lb (23.5 kg)
Air conditioner unit
117 lb (53 kg)
Orbit-roll valve
12 lb (5.3 kg)
Operators seat
119 lb (54 kg)
Brake valve (Tandem)
19 lb (8.5 kg)
Brake valve (Single)
12 lb (5.3 kg)
WA500-3LK
01-7 1
GENERAL
FUEL, COOLANT AND LUBRICATNTS
12
Reservoir
Kind of
fluid
Ambient Temperature
-22
-30
-4
-20
14
-10
32
0
50
10
68
20
Capacity
86
30
104
40
122F
50C
Specified
Refill
42 liters
11.1 gal
37 liters
9.8 gal
70 liters
18.5 gal
62 liters
16.4 gal
284 liters
75 gal
175 liters
46.2 gal
SAE 30
SAE 10W
Engine oil pan

with filter
SAE 10W-30
SAE 15W-40
Torque
converter,
transmission
case and oil
cooler
SAE 30W
Engine oil
SAE 10W
SAE 10W
Hydraulic
system
Drive axles (front & rear)
Axle oil
See "AXLE OIL " on page 01-11.
78 liters
20.6 gal
78 liters
20.5 gal
Pins
Grease
NLGI No. 2. See "GREASE" on page 01-12.
Lubricate as
instructed
---
Fuel tank
Diesel fuel
448 liters
118.3 gal
---
99 liters
26.2 gal
---
ASTM No. 2. See "DIESEL FUEL" on page

01-12.
ASTM No. 1
Cooling system Coolant
See "COOLANT SPECIFICATIONS" on page 01-13.
Other equipment will be necessary when operating the machine at temperatures below -20o C (-4o F). Consult your Komatsu
distributor for your needs.
API:
American Petroleum Institute
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8 1
WA500-3LK
GENERAL
12
ENGINE
OIL
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability. SAE 15W-40 multi-viscosity heavy duty engine oil meeting the
American Petroleum Institute (API) performance classification of CF-4 or CG-4 is recommended.
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.
A sulfated ash content of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control.
The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all
engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead
to excessive oil consumption.
The API service symbol displays the following information: the upper half of the symbol displays the appropriate oil
categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil
is recommended for most operating climates, refer to the table for oil viscosity recommendations for extreme climates.
Limited use of low viscosity oils, such as SAE 10W-30 is allowed to ease starting and provide sufficient oil flow at
ambient temperatures below -5C (+23F). However, continuous use of low viscosity oils can decrease engine life due to
wear.
Special "break-in" lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
"break-in" as specified for normal operation.
Remark
Single grade oil may be mixed with multigrade oil (SAE 10W-30, SAE 15W-40), but make sure the single
grade oil matches the temperature range in the table. We recommend genuine Komatsu oil which has
been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Use of fuels with high sulfur content necessitates more frequent oil changes.
Fuel sulfur content
Oil change interval
0.5 to 1.0 %
1/2 of regular interval
More than 1.0%
1/4 of regular interval
Additional information regarding lubricating oil availability throughout the world is available in the "E.M.A. Lubricating
Oils Data Book for Heavy Duty Automotive and Industrial Engines." The data book may be ordered from the Engine
Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone
number is (312) 644-6610.
WA500-3LK
01-9 1
GENERAL
12
Supplier
Engine Oil
[CD or CE]
SAE10W, 30, 40, 10W30,
15W40
(The 15W-40 oil marked *
is CE)
Gear oil
[GL-4 or GL-5]
SAE80, 90, 140
Grease
[Lithium base]
NLGI No. 2
Anti-freeze
Coolant
[ethylene glycol base]
Permanent Type
Komatsu
E010-CD
E030-CD
E010-30CD
E015-40CD
G090
G0140
G2-LI
G2-LI-S
Diesel sigma S super

diesel multi-grade
*Sigma turbo
Rotra MP
GR MU/EP
AGIP
Amoco
*Amoco 300
Multi-purpose gear oil
PYKON premium grease
Arcofleet S3 plus
Arco HD gear oil
Litholine HEP 2
Arco EP moly D
Vanellus C3
Gear oil EP
Hypogear EP
Energrease LS-EP2
Anti-freeze
*RPM delo 400

RPM delo 450
Universal thuban
Universal thuban EP
Marfak all-purpose 2
Ultra-duty grease 2
AF engine coolant
EP
EPX
Hypoy
Hypoy B
Hypoy C
MS3
Spheerol EPL2
Anti-freeze
Castrol
*Turbomax
*RX super
CRD
Chevron
*Delo 400
Universal gear
Ultra-duty grease 2
*Fleet motor oil
Universal gear lubricant
Super-sta grease
ARCO
BP
Caltex
Conoco
Glacelf
Gear oil GP
Gear oil GX
Beacon EP2
All-season coolant
Super duty motor oil

*Super Duty plus
Multi-purpose gear
lubricant
Gulfcrown EP2
Gulfcrown EP special
Anti-freeze and coolant
Delvac 1300
*Delvac super
10W-30, 15W-40
Mobilube GX
Mobilube HD
Mobilux EP2
Mobilgrease 77
Mobilgrease special
* Supreme duty fleet

motor oil
Multipurpose 4092
Multipurpose 4140
Multipurpose white grease

705
Anti-freeze and
707L White bearing
summer coolant
grease
Multiperformance 3C
Performance 3C
Exxon
(Esso)
Essolube D3
*Essolube XD-3
*Essolube XD-3 Extra
Exxon heavy duty
Gulf
Mobil
01-10 1
Tranself EP
Tranself EP type 2
ELF
Pennzoil
AF-ACL
AF-PTL
AF-PT (winter,
one-season type)
WA500-3LK
GENERAL
12
Supplier
Engine Oil
[CD or CE]
SAE10W, 30, 40, 10W30,
15W40
(The 15W-40 oil marked *
is CE)
Gear oil
[GL-4 or GL-5]
SAE80, 90, 140
Grease
[Lithium base]
NLGI No. 2
Anti-freeze
Coolant
[ethylene glycol base]
Permanent Type
Petrofine
FINA kappa TD
FINA potonic N
FINA potonic NE
Albania EP grease
Shell
Rimura X
Spirax EP
Spirax heavy duty
Albania EP grease
Sunoco GL5 gear oil
Sunoco ultra prestige 2EP

Sun prestige 742
Sunoco anti-freeze and

summer coolant
Sun
Texaco
*Ursa super plus

Ursa premium
Multigear
Multifak EP2
Starplex 2
Coda 2055 startex

anti-freeze coolant
Total
Rubia S
*Rubia X
Total EP
Total transmission TM
Multis EP2
Antigal/anti-freeze
Union
*Guardol
MP gear lube LS
Unoba EP
Veedol
*Turbostar
*Diesel star
MDC
Multigear
Multigear B
Mutligear C
Anti-freeze
-
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23C (-10F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with adequate low
temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
Remark
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL

Use API performance classification CE engine oil.
When using SAE 5W-20 engine oil in the work equipment hydraulic system in cold areas, return to SAE 10W when the cold
season ends.
AXLE OIL
For axle oil, use only the recommended oil as follows:
SHELL:
CALTEX:
CHEVRON:
TEXACO:
MOBIL:
*
DONAX TT or TD
RPM TRACTOR HYDRAULIC FLUID
TRACTOR HYDRAULIC FLUID
TDH OIL
MOBILAND SUPER UNIVERSAL
It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise may
result, durability should not be affected.
WA500-3LK
01-11 1
GENERAL
GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
DIESEL FUEL
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
Remark
The precise tolerances of diesel injection systems require that the fuel be kept clean and free of dirt and/or
water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.
For normal service above -12C (+10F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is
recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -12C (+10F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce fuel
economy.
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel.
However, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature.
Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt at 100C (212F) to provide adequate fuel system lubrication.
01-12 1
WA500-3LK
GENERAL
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled See SUPPLEMENTAL COOLANT
ADDITIVES on page 15. The coolant mixture must be drained and replaced at the specified service interval shown in the
"MAINTENANCE SCHEDULE CHART" in your ORPERATION AND MAINTENANCE MANUAL or every two years of
operation, whichever comes first.
WATER
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must
meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause
scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. "Softened" water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
Remark
Never use water alone in the cooling system because corrosion will occur.
ANTIFREEZE
In climates where the temperature is above -37C (-34F), use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is
required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should
not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain
corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
WA500-3LK
01-13 1
GENERAL
12
Remark
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system.
Sealer or anti-leak additives will cause plugging problems in the cooling system.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Approximate Freezing Point
Percentage of Antifreeze Concentration

by Volume
Specific Gravity at 60F (16C)
+32F (0C)
1.000
+20F (-7C)
15
1.025
+10F (-12C)
25
1.040
0F (-18C)
33
1.053
-10F (-23C)
40
1.062
-20F (-29C)
45
1.070
-30F (-34C)
48
1.074
-40F (-40C)
53
1.080
-50F (-46C)
56
1.083
-60F (-51C)
59
1.088
-70F(-57C)
62
1.092
-80F(-62C)
65
1.095
-90F(-68C)
67
1.097
-92F(-96C)
68
1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor SCA, to protect the engine cooling
system.
01-14 1
WA500-3LK
GENERAL
SUPPLEMENTAL COOLANT ADDITIVES

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal
operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and
attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners
which contain these additives must be added to maintain corrosion protection.
2.
SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.
3.
There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4.
SCA is recommended to inhibit corrosion in the cooling system for the following reasons:
Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over-concentration occurs
Provides engine protection in the following areas:
- Solder corrosion/bloom
- Copper corrosion/erosion/stress cracking
- Oil fouling
- Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion
- Seal and gasket degradation
Remark
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant
can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling
system components.
WA500-3LK
01-15 1
GENERAL
12
MEMORANDUM
01-16 1
WA500-3LK
10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
TORQUE CONVERTER AND TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
HYDRAULIC CIRCUIT FOR POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
TRANSMISSION CUTAWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
OPERATION OF CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
TRANMISSION CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
ECMV (ELECTRONIC CONTROL MODULATION VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
OUTLINE OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
ECMV AND PROPORTIONAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
ECMV AND FILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
ACTUATION OF ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
LUBRICATING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
PILOT FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
LIMITED SLIP (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TIRE AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
WA500-3LK
10-1 B

DEMAND VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
STEERING SPOOL AT NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
STEERING SPOOL OPERATED - ENGINE AT LOW SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
STEERING SPOOL OPERATED - ENGINE AT HIGH SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
FLOW AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
FLOW AMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
STEERING VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
RELIEF VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
ORBIT-ROLL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
STOP VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
DIVERTER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
BRAKE CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
RIGHT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
LEFT BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
ACCUMULATOR (FOR BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
MACHINES WITH STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
WORK EQUIPMENT LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
OIL FILTER BY-PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
ACCUMULATOR (FOR PPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
FOR BUCKET / BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
FOR OPTIONAL ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
PPC VALVE NEUTRAL POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
PPC VALVE POSITIONS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
ECSS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
2-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
FLOAT SELECTOR VALVE AND UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
BOOM AND DUMP SPOOLS AT HOLD POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
BOOM SPOOL AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
BOOM SPOOL AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
BOOM SPOOL AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
BUCKET SPOOL AT DUMP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
BUCKET SPOOL AT TILT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
10-2 B
WA500-3LK

WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
AIR CONDITIONING (GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
BASIC INFORMATION ON AIR CONDITIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
HUMIDITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
PRINCIPLE OF COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
REFRIGERANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
FREON-TYPE GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
REFRIGERATOR OIL (LUBE OIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
AIR CONDITONING CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
RECEIVER WITH SIGHT GLASS (LIQUID TANK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
MONITOR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
MAIN MONITOR DISPLAY FUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
MAIN MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
TROUBLE DATA DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
MAINTENANCE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
MAINTENANCE MONITOR DISPLAY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
MAINTENANCE MONITOR SWITCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . 10-183
SYSTEM STRUCTURE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
TRANSMISSION CONTROLLER POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
INPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
JOYSTICK TRANSMISSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
REMOTE POSITION, JOYSTICK STEERING CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
ECSS SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
CONNECTOR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
SPEEDOMETER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
ENGINE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
RADIATOR WATER LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
ENGINE OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
ENGINE WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
TORQUE CONVERTER OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
WA500-3LK
10-3 B

ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
PREHEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
ELECTRICAL TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
KICK-DOWN / HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
WHEN KICK-DOWN SWITCH IS OPERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
KICK-DOWN SWITCH OPERATION CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-219
ELECTRIC PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221
PARKING BRAKE EMERGENCY RELEASE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-223
EMERGENCY BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-223
PARKING SAFETY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
NEUTRALIZER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
ECSS WIRING DIAGRAM - FOLDOUT 10-225-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2 . . . . . . . . . . . . . . . . . . . . . . . . 10-233
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5) . . . . . . . . . . . . 10-233
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-10, (Sheet 2) (Part 3 of 4) . . . . . . . . . . 10-233
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-11, (Sheet 2) (Part 4 of 4) . . . . . . . . . . . 10-233
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
ENGINE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
ENGINE - FRAME - FLOOR HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235
10-4 B
WA500-3LK
GENERAL
12
GENERAL
OUTLINE
The power from the engine (1) is transmitted from the flywheel to damper (2) through the ring gear. The damper alleviates the
torsional vibration caused by the variation of the engine torque and transmits the power to torque converter (4) through drive
shaft (3). The torque converter converts the delivered torque according to the variation in the load on the oil used as the
medium, and transmits the power to the input shaft of transmission (10). The engine power then is transmitted to PPC pump
(7), steering pump (9), hydraulic pump (8), switch pump (6), and torque converter charging pump (5) through the pump driving gear in torque converter (4).
In transmission (10), the six hydraulic clutches are operated by the forward-reverse spool and the speed change spools in the
transmission valves, which are themselves activated by solenoid valves. Thus, the desired travel speed can be selected from
among the 4 forward and 4 reverse gear speeds.
A multiple disc parking brake is installed to the output shaft of transmission (10). At the front end, the power from the output
shaft passes through center drive shaft (12) and front drive shaft (14) and is transmitted to front differential (15), at the rear end
it is transmitted to rear differential (20) by rear drive shaft (19).
The power transmitted to front differential (15) and rear differential (20) is transmitted to the axle shafts.
The power from the axle shafts has its speed reduced by final drives (16) and (21), and it is then transmitted to tires (18) and
(23) through the planetary carrier.
WA500-3LK
10-5 B
GENERAL
12
1.
Engine
9.
2.
Damper
10. Transmission
18. Front tire
3.
Upper drive shaft
11. Parking brake
19. Rear drive shaft
4.
Torque converter
12. Center drive shaft
20. Rear differential
5.
Torque converter charging pump
13. Center support
21. Rear final drive
6.
Switch pump
14. Front drive shaft
22. Rear brake
7.
PPC pump
15. Front differential
23. Rear tire
8.
Hydraulic pump
16. Front final drive
10-6 B
Steering pump
17. Front brake
WA500-3LK
GENERAL
MEMORANDUM
WA500-3LK
10-7 B
RADIATOR AND OIL COOLER
12
1.
2.
3.
4.
5.
6.
7.
Radiator
Fan guard
Radiator coolant level sensor
Torque converter oil cooler (Water-cooled)
Hydraulic oil cooler
Sub-tank
Torque converter oil cooler (Air-cooled)
SPECIFICATIONS:
Radiator
Radiator core type: PF2-7 type
Total heat dissipation area: 101.87 m2
Cross-sectional area of water flow: 193.8 cm2
A.
B.
C.
D.
E.
F.
G.
H.
Coolant inlet port

Coolant outlet port
Hydraulic oil outlet port
Hydraulic oil inlet port
Torque converter oil outlet port
Torque converter oil inlet port (To port G)
Torque converter oil inlet port (From port F)
Torque converter oil outlet port (To Transmission)
Torque converter oil cooler
Type: PTO-OL (multiple disc type)
Heat dissipation area: 1.829 m2
Type: SF-2 (Air to Air)
Hydraulic oil cooler
Type: PTO-OL (multiple disc type)
10-8 B
WA500-3LK
12
WA500-3LK
10-9 B
DAMPER
12
DAMPER
1.
Coupling
5.
Bearing
2.
Output shaft
6.
Outer body
3.
Cover
7.
Rubber cushion
4.
Bearing
8.
Inner body
FUNCTION
The damper reduces the twisting and vibration caused by the variations in the engine torque, and acts to protect the engine and
other parts from such twisting and vibration.
10-10 B
WA500-3LK
DAMPER
12
OPERATION
The engine power is transmitted to the flywheel and outer body (6) and rubber cushion (7) absorbs the twist and vibration of
the engine. The engine power is then transmitted through the inner body (8) to output shaft (2). From here, the engine power is
transmitted through the coupling to the torque converter and drive shaft.
WA500-3LK
10-11 B
TORQUE CONVERTER AND TRANSMISSION PIPING
12
10-12 B
1.
Transmission
7.
Parking brake
2.
Torque converter
8.
3.
Transmission valve
4.
Torque converter oil cooler (Air-cooled)
5.
Torque converter oil cooler (Water -cooled)
6.
Oil filter
WA500-3LK
12
WA500-3LK
10-13 B
HYDRAULIC CIRCUIT FOR POWER TRAIN
12
HYDRAULIC CIRCUIT FOR POWER TRAIN
10-14 B
WA500-3LK
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
12
HYDRAULIC
CIRCUIT DIAGRAM FOR POWER TRAIN
1.
Transmission case
11. Pilot oil filter
22. Flow detector valve
2.
Strainer
12. Parking brake solenoid valve
23. Pressure control valve
3.
13. Parking brake emergency release

valve
24. FORWARD clutch
4.
Torque converter oil filter
14. Accumulator
25. REVERSE clutch
5.
Main relief valve
15. Parking brake
26. 3rd clutch
6.
Torque converter relief valve
16. FORWARD ECMV
27. 4th clutch
7.
Torque converter
17. REVERSE ECMV
28. 2nd clutch
8.
a. Oil cooler (water-cooled type)
18. 3rd ECMV
29. 1st clutch
8.
b. Oil cooler (air-cooled type)
19. 4th ECMV
9.
Transmission lubrication
20. 2nd ECMV
10. Lubrication relief valve
WA500-3LK
21. 1st ECMV
10-15 B
TORQUE CONVERTER AND PTO
12
10-16 B
WA500-3LK
12
Flow of motive force
The torque converter is installed between the damper and transmission.
The motive force from the damper passes through the drive shaft and enters
drive case (7). Drive case (7), pump (10) and PTO gear (drive) (13) are
fixed with bolts. They are rotated directly by the rotation of the engine.
The motive force of pump (10) uses oil to rotate turbine (8). This transmits
motive force to transmission input shaft (12).
The motive force of drive case (7) passes through PTO gear (drive) (13)
and is also used as the motive force to drive the gear pump.
Flow of oil
The oil pressure is adjusted by the torque converter relief valve and then
enters inlet port A, passes through the oil passage in housing (9) and flows
to pump (10). In pump (10) centrifugal force is applied. The oil enters turbine (8) and the energy of the oil is transmitted to the turbine.
Turbine (8) is fixed to transmission input shaft (12), so the motive force is
transmitted to the transmission input shaft (12).
The oil from turbine (8) is sent to stator (11) and again enters the pump.
However, part of the oil passes from the stator through outlet port B and is
sent to the cooler.
WA500-3LK
10-17 B
TRANSMISSION
12
TRANSMISSION
10-18 B
1.
Main relief, torque converter relief valve
6.
Parking brake
2.
Transmission valve
7.
Output coupling (front)
3.
Transmission input shaft
8.
Output coupling (rear)
4.
Transmission
9.
Oil filler port
5.
Transfer
10. Strainer
WA500-3LK
TRANSMISSION
12
A. To torque converter
I. Mount port for parking brake actuation pilot lamp
B. From torque converter case
J. To torque converter charging pump
C. Breather mount port
K. To REVERSE clutch
D. From oil filter
L. To 3rd clutch
E. Transmission main oil pressure port
M. To 1st clutch
F. To parking brake emergency release valve
N. To 2nd clutch
G. Lubricating oil pressure port
O. To 4th clutch
H. From oil cooler
P. To FORWARD clutch
WA500-3LK
10-19 B

12
TRANSMISSION
10-20 B
TRANSMISSION
CUTAWAY
WA500-3LK
TRANSMISSION
12
1.
Input shaft
11. No. 3 clutch
21. No. 6 gear (90 teeth)
2.
No. 1 sun gear (22 teeth)
12. No. 3 ring gear (75 teeth)
22. No. 6 clutch
3.
No. 1 planet gear (24 teeth)
13. No. 4 sun gear (33 teeth)
23. Output shaft
4.
No. 1 ring gear (75 teeth)
14. No. 4 planet gear (21 teeth)
24. No. 5 carrier
5.
No. 1 clutch
25. No. 3, 4 carrier
6.
No. 1 idler gear (70 teeth)
16. No. 4 clutch
7.
Lubrication relief valve
8.
No. 2 clutch
28. No. 2 carrier
9.
No. 3 sun gear (15 teeth) (Output

shaft)
29. No. 1 carrier
20. No. 5 clutch
Number of clutch discs and plates:

Clutch No.
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
WA500-3LK
Disc
4
4
3
3
3
3
Plate
4+1
4+1
2
2+1+1
2+1
2
10-21 B
TRANSMISSION
12
OUTLINE
The transmission consists of a 4-FORWARD, 4-REVERSE speed
planetary gear transmission, transfer, and transmission
control valve. In the transmission, the motive force of the input shaft is
changed by the combination of No.1 or No.2 clutch with No. 3, 4, 5 or 6
clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft
Speed range
Clutch combination
F1
No.2, No. 6
F2
No.2, No. 5
F3
No.2, No. 4
F4
No.2, No. 3
R1
No.1, No. 6
R2
No.1, No. 5
R3
No.1, No. 4
R4
No.1, No. 3
OPERATION OF CLUTCH
Engaged
The oil sent from the transmission control valve passes through the oil
passage inside the transmission. When it reaches the rear piston (1), it
moves the piston (1).
When the piston (1) moves, disc (2) and plate (3) are pressed together. Ring
gear (4) is meshed with disc (2), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission control valve is shut off, the
pressure of the oil is acting on the rear of piston (1) is reduced. The piston
is then pushed back to the right by return spring (5), and disc (2) and plate
(3) are separated. Ring gear (4) then rotates freely, and no motive force is
transmitted.
10-22 B
WA500-3LK
TRANSMISSION
12
FORWARD
1ST
In 1st FORWARD, No. 2 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (15) in position. No. 6
clutch is actuated by the hydraulic oil pressure applied to the clutch piston and holds gear (29) to carrier (32).
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). This carrier is connected to No. 5 carrier (32) through No. 4 ring gear (23), so when No. 6 clutch
is actuated, the rotation of carrier (32) is transmitted to gear (29) and rotates output shaft (31).
WA500-3LK
10-23 B

12
FORWARD
TRANSMISSION
2ND
In 2nd FORWARD, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter by
input shaft (2) is transmitted to output shaft (31).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (27) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is
transmitted to planetary gear (14) through sun gear (13).
on the inside ring gear (15). The rotation of carrier (33) is transmitted through ring gear (23) to carrier (32).
Ring gear (27) is held in position by No. 5 clutch, so the rotation of carrier (32) rotates planetary gear (26). The planetary gear
rotates on the inside of ring gear (27), and rotates sun gear (25). The sun gear rotates output shaft (31).
10-24 B
WA500-3LK
TRANSMISSION
12
FORWARD
3RD
In 3rd FORWARD, No. 2 clutch and No. 4 clutch are engaged. The motive force transmitted from the torque converter by
No. 2 clutch and No. 4 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (23) in position.
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to
planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch, so the rotation of planetary gear (14) rotates carriers (33) and (34), which is
on the inside ring gear (15). Ring gear (23) is held in position by No. 4 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (22) which rotates on the inside of ring gear (23), and rotates sun gear (21). The sun gear rotates output shaft
(31).
WA500-3LK
10-25 B

12
FORWARD
TRANSMISSION
4TH
In 4th FORWARD, No. 2 clutch and No. 3 clutch are engaged. The motive force transmitted from the torque converter by
No. 2 clutch and No. 3 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15)
and (19) in position.
on the inside ring gear (15). Ring gear (19) is held in position by No. 3 clutch, so the rotation of carrier (33) is transmitted to
planetary gear (18). The planetary (18) rotates on the inside of ring gear (19), and rotates sun gear (17), which forms one unit
with output shaft (31).
10-26 B
WA500-3LK
TRANSMISSION
12
REVERSE
1ST
In 1st REVERSE, No. 1 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input
shaft (2) is transmitted to output shaft (31).
No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks carrier (35) in position. No. 6 clutch
is actuated by the hydraulic pressure applied to the clutch piston and hold ring gear (29) in position.
Carrier (35) is held in position by No. 1 clutch, so the rotation of planetary gear rotates the ring gear. Ring gear (15) rotates in
the opposite direction from the input shaft. Ring gear (15) rotates carrier (34), and the rotation of carrier (34) rotates ring gear
(23), which then rotates carrier (32). Carrier (32) rotates No. 6 clutch (30). When No. 6 clutch is actuated, the rotation of carrier (32) is transmitted to gear (29) and rotates output shaft (31).
WA500-3LK
10-27 B
TRANMISSION CONTROL VALVE
12
1. ECMV for FORWARD clutch

2. ECMV for REVERSE clutch
3. ECMV for 3rd clutch
4. ECMV for 4th clutch
5. ECMV for 2nd clutch
6. Parking brake solenoid valve
7. ECMV for 1st clutch
8. Pilot filter
A, A : FORWARD clutch oil pressure port

B, B : REVERSE clutch oil pressure port
C, C : 3rd clutch oil pressure port
D, D : 4th clutch oil pressure port
E, E : 2nd clutch oil pressure port
F, F : 1st clutch oil pressure port
Remark
When measuring the clutch pressure accurately, such as, when measuring the modulating pressure,
measure A to F.
When measuring only the set pressure and modulating time, it is also possible to measure at
measurement ports A - F.
10-28 B
WA500-3LK
12
ECMV actuation table
Speed range
Clutch
FORWARD
REVERSE
3rd
Auto
Manual
F1
F2
F3
F4
4th
2nd
1st
R1
R2
R3
R4
Remark
When at manual N, the clutch of the speed range where the gear shift lever is placed, is ON.
WA500-3LK
10-29 B
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
12
A. To clutch
1. Connector
D. Drain port
2. Connector
P. From pump
T. Clutch drain port
10-30 B
WA500-3LK
12
3. Spring
7. Pin
4. Pressure control valve spool
8. Spring
5. Proportional solenoid
9. Flow detector valve spool
6. Fill switch
WA500-3LK
10-31 B

12
OUTLINE
OF ECMV
The ECMV (Electronic Control Modulation Valve) consist of two valves:

The pressure control valve and the flow detection valve.
Pressure control valve
The proportional solenoid receives the flow of electricity sent from the
transmission controller, and the pressure control valve converts this into
hydraulic pressure.
Flow detection valve
This valve is actuated by a trigger from the pressure control valve and has
the following functions:
1.
When the clutch is filled with oil, it sends a signal (fill signal) to the
controller to inform the controller that the filling is completed.
2.
While oil pressure is applied to the clutch, it outputs a signal (fill

signal) to the controller to inform the controller of the existence of the
oil pressure.
Range A:
Range B:
Range C:
Range D:
Range E:
Before shifting gear (when draining)

Fill starts (during trigger)
Fill completed
Pressure adjustment
During filling
ECMV AND PROPORTIONAL SOLENOID

There is one proportional solenoid installed to each ECMV. It generates
propulsion as shown in the diagram on the right according to the command
current from the transmission controller.
The propulsion generated by the proportional solenoid acts on the pressure
control valve spool and generates oil pressure as shown in the diagram on
the right. In this way, the command current is controlled and the propulsion
force varies to actuate the pressure control valve and control the oil flow
and oil pressure.
ECMV AND FILL SWITCH

There is one fill switch installed to each ECMV. When the filling of the
clutch is completed, the fill switch is turned on by the action of the flow
detection valve. With this signal, the oil pressure starts the build-up.
10-32 B
WA500-3LK
12
ACTUATION
OF ECMV
The ECMV is controlled by the command current from the transmission
controller to the proportional solenoid and the fill switch output signal. The
relationship between ECMV proportional solenoid command current and
the clutch input pressure and fill switch output signal is as shown in the
diagram on the right.
Range A:
Range B:
Range C:
Range D:
Range E:
1.
Before shifting gear (when draining)

Fill starts (during trigger)
Fill completed
Pressure adjustment
During filling
Before gear shifting (during draining) - Range A in graph.

When no current is flowing to proportional solenoid (5), proportional
solenoid (5) is pushed back by the reaction of pressure control valve
spring (3) through pressure control valve spool (4), so pressure control
valve (4) drains the oil at clutch port A through drain port T.
When this happens, there is no hydraulic force acting on flow
detection valve spool (9), so flow detection valve spool (9) is
separated from fill switch (6) by the reaction force of fill switch spring
(8).
WA500-3LK
10-33 B
12
2. Start of fill (when trigger command is input to pressure control valve) Range B in graph (See graph on page prior).
When there is no oil inside the clutch, if the trigger current is applied
to proportional solenoid (5) (if the maximum current is applied), the
proportional solenoid moves and pressure control valve spool (4)
moves to the left.
As a result, the circuit between pump port P and the pressure control
valve output port B opens, and oil passage through orifice a of flow
direction valve spool (9) and starts to fill the clutch.
3.
Filling completed (pressure control valve set to default pressure)

Range C in graph (See graph on page prior).
A. To reduce the transmission shock, action must be taken to prevent
peak pressure from being generated at clutch port A when the
filling is completed. In order to do this, the electric current in
proportional solenoid (5) is lowered to the default pressure before
the filling is completed and pressure control valve spool (4) is
moved to the right.
This allows a small amount of oil to leak from pressure control
valve output port B to drain port T. In this way, the generation of
peak pressure at clutch port A can be prevented when the filling is
completed.
B. When the clutch is filled with oil, the oil stops flowing from
pressure control valve output port B to clutch port A. The area
receiving the pressure on the left and right sides of orifice a of
flow detection valve spool (9) is different. The left side is larger,
so when the oil pressure on both sides of orifice a becomes equal,
fill switch spring (8) is compressed, and as a result, pin (7)
contacts fill switch (6) and sends the clutch fill completion signal
to the shift controller. At this point, the default pressure current is
flowing to proportional solenoid (5), and the oil pressure is set to
the default pressure setting by pressure control valve spool (4).
10-34 B
WA500-3LK
12
4. Adjusting pressure (Range D in graph)
When electric current flows to proportional solenoid (5), the solenoid
generates a force proportional to the current. The total of this
propulsion force of the solenoid and the propulsion force of the oil
pressure at the clutch port and the reaction force of pressure control
valve spring (3) is balanced. Flow detection valve spool (9) is pushed
to the right by the difference in the force of the oil pressure applied to
both sides of orifice a, and it continues to send the fill signal to the
shift controller.
WA500-3LK
10-35 B
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
12
1. Body
6. Main relief valve
A. Drain port (torque converter relief)
2. Torque converter relief valve
7. Valve spring
B. Drain port
3. Valve spring
8. Piston spring
C. From pump
4. Piston
9. Piston
D. Drain port
5. Piston spring
P1
Main relief oil pressure detection

port
P2
Torque converter inlet port relief oil

pressure detection port
E. To torque converter
OUTLINE
1.
2.
Main relief valve

Main relief valve (6) sets the pressure of the transmission oil.
Torque converter relief valve
Torque converter relief valve (2) acts to protect the torque converter
from abnormally high pressure. It relieves the pressure when the
pressure at the port of the torque converter goes above the inlet
specified pressure.
10-36 B
Specified pressure
Main relief pressure
35.9 kgf/cm2 (510.6 lbf/

in2) engine at rated speed
Torque converter inlet

port pressure
8.5 kgf/cm2 (120.8 lbf/in2)

cracking pressure
WA500-3LK
12
MAIN
RELIEF VALVE
OPERATION
The oil from the torque converter charging pump passes through the filter,
enters port A of the main relief valve, and then passes through orifice a and
enters port B. When the oil from the pump fills the circuit, the pressure
starts to rise. When the oil pressure in the circuit rises, the oil entering port
B pushes piston (4). The reaction compresses spring (7) and moves main
relief valve (6) to the left to open the passage between port A and port C.
When this happens, the oil from the pump is relieved from port A to port C
and flows from port C into the torque converter. The oil pressure at port A
at this point is 35.9 kgf/cm2 (510.6 lbf/in2) when the engine is at rated
speed.
TORQUE CONVERTER RELIEF VALVE

OPERATION
The oil relieved from the main relief valve flows from port C into the
torque converter, and at the same time, passes through orifice b and enters
port D. When the oil fills the circuit to the torque converter, the oil pressure
starts to raise.
When the oil pressure in the circuit to the torque converter rises, the oil
entering port D pushes piston (9). The reaction compresses spring (3), and
moves relief valve (2) to the right to open the passage between port C and
port E. When this happens, the oil from port C is relieved to port E and
flows to the transmission lubrication circuit. The oil pressure at port C at
this point is 8.5 kg/cm2 (120.8 lbf/in2) cranking (starting) pressure.
WA500-3LK
10-37 B
LUBRICATING RELIEF VALVE
12
LUBRICATING RELIEF VALVE
1. Piston
A. From oil cooler
2. Spring
B. Drain
3. REVERSE clutch housing
C. Drain
OUTLINE
The lubricating relief valve is assembled to the left face of the REVERSE
clutch housing, and protects the lubricating circuit and oil cooler
Unit: kgf/cm2 (lbf/in2)

Specified value
Pressure when normal
Cracking pressure
10-38 B
1.5 - 2.3 (21.3 - 32.7)

3.0 (42.6)
WA500-3LK
TORQUE CONVERTER OIL FILTER
12
TORQUE
CONVERTER OIL FILTER
OPERATION
The oil from the torque converter charging pump enters the filter inlet port
A and passes from the outside of element (2) to the inside. It then flows to
the outlet port B.
If the element (2) is clogged with dirt, or the oil temperature is low, the
pressure at the inlet port A rises. When this happens, the oil from the inlet
port A opens relief valve (1) and flows directly to the outlet port B. This
prevents damage to the pump or element (2).
WA500-3LK
10-39 B
PILOT FILTER
12
PILOT FILTER
SPECIFICATIONS
Filter mesh size: 10 m (1450 mesh)
Filtering area: 0.063 m2 (630 cm2)
Element pressure resistance: 4.9 MPa (50 kg/cm 2)
OUTLINE
The oil flows from the transmission case to pump to torque converter oil filter, and is then divided and flows to the torque
converter and transmission control valve.
There is a pilot filter installed at the inlet port of the transmission control valve, and this filters the dirt out of the oil flowing to
the control valve.
10-40 B
WA500-3LK
TRANSFER
12
TRANSFER
1. Transmission output shaft
5. Output shaft
2. Transfer input gear (teeth 28)
6. Front coupling
3. Transfer idler gear (teeth 45)
7. Rear coupling
4. Output gear (teeth 43)
8. Parking brake
OUTLINE
The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts.
TRANSMISSION PATH
Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output
gear (4) through idler gear (3) and output shaft (5).
Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive
shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft.
WA500-3LK
10-41 B
DRIVE SHAFT
12
DRIVE SHAFT
1. Front drive shaft
4. Rear drive shaft
2. Center support
5. Upper drive shaft
3. Center drive shaft
OUTLINE
The motive force from the engine passes through the damper, upper drive shaft (5), torque converter, transmission and transfer.
Part of this motive force passes through rear drive shaft (4) and goes to the rear axle: the rest of the motive force passes
through center drive shaft (3), center support (2) and front drive shaft (1) and is sent to the front axle. In addition to transmitting the motive force, the drive shafts have the following purposes.
When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during
operations, the axle in front and behind the engine and transmission change position.
To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the
components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in
angle and length.
10-42 B
WA500-3LK
CENTER SUPPORT
12
CENTER
SUPPORT
1. Front coupling
3. Grease fitting
2. Case
4. Rear coupling
FUNCTION
The center support is installed to the front frame between the center drive shaft and the front drive shaft.
With the articulating frame, this part is constantly twisting from side to side, so there is liable to be a large amount of stress on
the drive shafts. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts,
and improve the durability of the drive shafts.
WA500-3LK
10-43 B
AXLE
12
AXLE
FRONT
10-44 B
WA500-3LK
AXLE
12
REAR
WA500-3LK
10-45 B
DIFFERENTIAL
12
DIFFERENTIAL
NORMAL - (STANDARD)
FRONT
1. Slide gear (18 teeth)
4. Pinion (10 teeth)
2. Bevel pinion (9 teeth)
5. Shaft
3. Bevel gear (37 teeth)
10-46 B
WA500-3LK
DIFFERENTIAL
12
REAR
1. Bevel gear (37 teeth)
4. Pinion (10 teeth)
2. Shaft
5. Bevel pinion (9 teeth)
3. Slide gear (18 teeth)
WA500-3LK
10-47 B
DIFFERENTIAL
12
OUTLINE
The motive force from the drive shaft passes through bevel pinion (1) and
is transmitted to the bevel gear (5). The bevel gear changes the direction of
the motive force by 90 and at the same time reduces the speed. It then
transmits the motive force through the differential (4) to the sun gear shaft
(2).
WHEN DRIVING STRAIGHT FORWARD

When the machine is driven straight forward, the rotating speed of the left
and right wheels is the same, so the pinion gear (4) inside the differential
assembly (6) is sent through the pinion gear (4) and the side gear (3) and is
transmitted equally to the left and right sun gear shafts (2).
WHEN TURNING
When turning, the rotating speed of the left and right wheels is different, so
the pinion gear (4) and side gear (3) inside the differential assembly rotate
in accordance with difference between the rotating speed of the left and
right wheels. The motive force of the carrier (6) is then transmitted to the
sun gear shafts (2).
10-48 B
WA500-3LK
DIFFERENTIAL
12
LIMITED
SLIP (OPTION)
FRONT
1. Bevel gear (No. of teeth: 37)

2. Bevel pinion (No. of teeth: 9)
REAR
1. Bevel gear (No. of teeth: 37)

2. Bevel pinion (No. of teeth: 9)
WA500-3LK
10-49 B
DIFFERENTIAL
12
LIMITED SLIP (OPTION)
1.
Plate
5.
Cover
9.
Pressure ring
2.
Disc
6.
Slide gear
10. Case
3.
Washer
7.
Pinion
11. Bevel pinion
4.
Shaft
8.
Shaft
Operation of limited slip differential

The power transmitted from the transmission goes from bevel gear (11) to case (10), pressure ring (9), shaft (8), pinion (7), and
gear (6), and is then divided and sent left and right shafts (4). A brake mechanism consisting of disc (2) and plate (1) is
assembled at the rear face of side gear (6), and the brake torque is generated in proportion to the torque transmitted from
pressure ring (9) to shaft (8). In order for this brake torque to act to suppress the rotation in relation to side gear (6) and case
(10), it is made difficult for left and right side gears (6) to rotate mutually, and the action of the differential is suppressed.
10-50 B
WA500-3LK
DIFFERENTIAL
12
Mechanism for generation of brake torque of left and right side
gears (6)
Shaft (8) is supported by the cam surface cut into the mating surfaces of
left and right pressure rings (4). The power (= torque) transmitted from
pressure ring (4) to shaft (8) is transmitted by the cam surface, but force Fa
to separate left and right pressure rings (4) is generated in proportion to the
torque transmitted by the angle of this cam surface. This separation load Fa
acts as a brake on the rear face of left and right side gears (7) and
generates brake torque.
When travelling is straight line

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

wheels
[The road surface condition (friction coefficient) for the left and
right wheels and the load on the wheels are uniform, so there is no
misalignment of the center line of the load to the bucket].
The power from the transmission is divided uniformly to the left and
right by the limited slip differential. Under these conditions, the limit
for wheel slip for the left and right wheels is the same, so even if the
power from the transmission exceeds the wheel slip limit, the wheels
on both sides slip and the differential is not actuated.
No load is applied to the brake at the rear surface of the side gear.
WA500-3LK
10-51 B
DIFFERENTIAL
12
2. When there is imbalance between drive force of left and right wheels
[The road surface condition (friction coefficient) for the left and right
wheels and the load on the wheels are not uniform and the wheel on
one side tends to slip more than the wheel on the other side.]
Example 1: When wheel on one side is on soft ground surface during
digging operations
Example 2: When wheel on one side is on asphalt surface and wheel
on other side is on snow during snow clearing operations
Example 3: When imbalance is created in load on left and right wheels
by traveling on slope.
The power from the transmission is divided uniformly to the left and
right by the actuating gear. However, if the divided drive force exceeds
the wheel slip limit on the side where the wheel is slipping, a drive
force equal to the excess is sent through the brake at the rear face of
the side gear and the case to the brake on the opposite side (side where
wheel is locked), and is supplied to the wheel on the side which is
locked. If this excess drive force becomes greater than the braking
force, the differential starts to be actuated.
Difference in wheel drive force for each type of differential when
wheel on one side is slipping.
Wheel drive force (taken as 1 for wheel that is slipping)
Slipping wheel
Locked wheel
Total (proportional)
Limited slip
differential
(option)
2.64
3.64 (1.82)
Torque
proportioning
differential
(standard)
1.38
2.38 (1)
Normal
differential
2 (0.84)
On road surfaces where the wheel on one side is likely to slip, the limited slip differential increases the drive force 1.82 times
that of the torque proportioning differential supplied as standard.
When turning
The actuating gear built into the limited slip differential is the same as the gear used on the normal differential, so the
difference in rotation of the inside and outside wheels generated when turning can be generated smoothly.
10-52 B
WA500-3LK
DIFFERENTIAL
12
MEMORANDUM
WA500-3LK
10-53 B
FINAL DRIVE
12
FINAL DRIVE
1.
Axle shaft
4.
Planetary carrier
2.
Planetary gear (29 Teeth)
5.
Sun Gear (18 Teeth)
3.
Ring gear (78 Teeth)
6.
Wheel
OUTLINE
To gain a large drive force, the final drive uses a planetary gear system to reduce speed and send drive force to the tires.
10-54 B
WA500-3LK
FINAL DRIVE
12
OPERATION
The motive force transmitted from the differential through axle shaft (1) to
sun gear (5) is transmitted to planetary gear (2). The planetary gear rotates
around the inside of a fixed ring gear (3) and in this way transmits rotation
at a reduced speed to the planetary carrier (4). This motive force is then
sent to the wheels (6) which are installed to the planetary carriers (4).
WA500-3LK
10-55 B
AXLE MOUNT
12
AXLE MOUNT
10-56 B
WA500-3LK
AXLE MOUNT
12
1.
Front axle
4.
Rear frame
2.
Rear axle
5.
Axle mounting bolts
3.
Front frame
FRONT AXLE
The front axle (1) receives the force directly during operations, so it is fixed directly to the front frame (3) by axle mounting
bolts (5).
REAR AXLE
The rear axle (2) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the
ground when traveling over soft ground.
WA500-3LK
10-57 B
CENTER HINGE PIN
12
CENTER HINGE PIN
1.
Front axle
4.
Rear frame
2.
Rear axle
5.
Upper hinge pin
3.
Front frame
6.
Lower hinge pin
OUTLINE
The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5) and (6). The steering cylinders are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle
to give the desired angle, that is the desired turning radius.
10-58 B
WA500-3LK
TIRE AND WHEEL
12
TIRE
AND WHEEL
The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with
the ground to gain the power which drives the machine. Various types of tires are available to suit the purpose. Therefore it is
very important to select the correct tires for the type of work and bucket capacity.
1.
Tire
4.
Lock ring
2.
Rim
5.
Side ring
3.
Air valve
SPECIFICATIONS
Tire type:
TRA code:
Nominal size of wheel:
Nominal inflation pressure:
29.5 x 25, 22PR

L3
22.00 x 25WTB
FRONT tire: 4.5 kgf/cm (64.0 psi)
REAR tire: 3.5 kgf/cm (49.8 psi)
WA500-3LK
10-59 B
STEERING PIPING
12
STEERING PIPING
1.
Steering cylinder (R.H.)
5.
Hydraulic pump
9.
Stop valve (L.H.)
2.
Orbit-roll valve
6.
Oil cooler
10. Steering valve
3.
Stop valve (R.H.)
7.
Switch pump and PPC pump
11. Steering cylinder (L.H.)
4.
Hydraulic tank
8.
Steering pump
JOYSTICK STEERING ASSEMBLY DIAGRAM & STEERING LINE ASSEMBLY DIAGRAM

See Section 90 for illustration, Joystick Steering Assembly Diagram and Steering Line Assembly Diagram,
FOLDOUTS 10-54-1 thru 10-54-2.
10-60 B
WA500-3LK
STEERING COLUMN
12
STEERING
COLUMN
WA500-3LK
1.
Steering wheel
3.
Joint
2.
Steering column
4.
Orbit-roll valve
10-61 B
STEERING VALVE
12
STEERING VALVE
10-62 B
1.
Safety valve (with suction)
4.
Relief valve
2.
Check valve
5.
Demand spool
3.
Steering spool
WA500-3LK
STEERING VALVE
12
DEMAND
VALVE OPERATION
STEERING SPOOL AT NEUTRAL
The oil from the steering pump enters port A, and the oil from the switch pump enters port B. When steering spool (2) is at
neutral, pressure-receiving chamber II is connected to the drain circuit through orifice b, and notch c is closed. Notch c is
closed, so the pressure of the oil at port A and port B rises. This pressure passes through orifice a, goes to pressure-receiving
chamber I, and moves demand spool (1) to the left in the direction of the arrow.
When the pressure at pressure-receiving camber I reaches a certain value (set by spring {5}), notch f opens, and the oil from
the steering pump flows to the drain circuit. At the same time, notch g closes, and the oil from the switch pump all flows to the
main control valve.
WA500-3LK
10-63 B

12
STEERING
STEERING VALVE
SPOOL OPERATED - ENGINE AT LOW SPEED
When steering spool (2) is pressed (operated), pressure-receiving chamber III and the drain circuit are shut off, and at the same
time notch c opens. When this happens, the pressure in pressure-receiving chamber III rises, and demand spool (1) moves to
the right in the direction of the arrow until notch h closes. The passage from port B to the main control valve is shut off, so the
oil from switch pump pushes up merge check valve (3), and merges with the oil at port A from the steering pump.
The merged oil passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The oil returning
from the cylinder passes through notch e and enters the drain circuit. In this condition, the pressure before passing through
notch c goes to pressure-receiving chamber I, and the pressure after passing notch c goes to pressure-receiving chamber II.
Demand spool (1) moves to maintain the pressure difference on the two sides of notch c at a constant value. Therefore, a flow
corresponding to the amount of opening notch c is discharged from the cylinder port. These pressure differences (control
pressure) are set by spring (5).
10-64 B
WA500-3LK
STEERING VALVE
12
STEERING
SPOOL OPERATED - ENGINE AT HIGH SPEED
The extra oil from the switch pump is not needed, so the steering pump pressure rises until notch g closes, and shuts off the
merge passage at port B. The pressure difference on the two sides of notch c is controlled only by notch f, so the excess oil
from the steering pump is drained from notch f to drain the circuit (when this happens, notch g is completely closed).
The oil from steering pump passes through notch c and notch d, pushes up load check valve (4), and flows to the cylinder. The
oil returning from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the
switch pump is sent from port B to the main control valve.
WA500-3LK
10-65 B

12
FLOW
STEERING VALVE
AMP
1. Steering spool
5. Cap
A. From orbit-roll valve
2. Valve housing (body)
6. Bolt
B. From orbit-roll valve
3. Spring seat
7. Orifice
C. Passage (inside housing)
4. Return spring
FLOW AMP OPERATION

1.
Spool at neutral (Orbit-roll valve not actuated)
When the Orbit-roll valve is not actuated, both pilot port PiA and pilot port PiB are connected through the Orbit-roll to the
drain (return) circuit, so steering spool (1) is kept at neutral by return spring (4).
10-66 B
WA500-3LK

2.
STEERING VALVE
Spool actuated (oil flows to port PiA)
When oil flows to port PiA, the pressure inside the cap end A rises and moves steering spool (1) in the direction of the arrow.
The oil entering from port PiA passes through the hole in spring seat (3), through orifice (7) in steering spool (1), and then
flows to the opposite end (B end).
Port PiB is connected to the drain circuit through the Orbit-roll valve, so the oil flowing to end B is drained. The pressure
generated at port PiA is proportional to the amount of oil flowing in, so steering spool (1) moves to a position where the
opening of the flow amp notch balances the pressure generated with the force of return spring (4).
WA500-3LK
10-67 B
STEERING VALVE
12
3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)
If the steering wheel (steering [orbit-roll] valve) stops, the orbit-roll valve is set in neutral and the circuit to return to the tank
(drain circuit) is closed. Accordingly, the hydraulic pressure in port PiA between the steering valve and orbit-roll valve is
relieved through the groove of steering spool (1) into port PiB and the pressure in PiA becomes equal to that in PiB port. As a
result, spool (1) is returned to the neutral position by return spring (4).
10-68 B
WA500-3LK
STEERING VALVE
12
STEERING
VALVE OPERATION
NEUTRAL
The steering wheel is not being operated, so steering spool (1) does not move. The oil from the steering pump enters port A,
the oil from the switch pump enters port B.
When the pressure at ports A and B rises, demand spool (4) moves to the left in the direction of the arrow. The oil from the
steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and
flows to the main control valve.
WA500-3LK
10-69 B
STEERING VALVE
12
TURNING RIGHT
When the steering wheel is turned to the right, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the left in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (4) of the spool, and the oil flows to the bottom end of the left cylinder and the rod end of the right cylinder to
turn the machine to the right.
The oil from the left and right cylinders passes through load check valve (3) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.
10-70 B
WA500-3LK
STEERING VALVE
12
TURNING LEFT
When the steering wheel is turned to the left, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering
spool (1) moves to the right in the direction of the arrow.
The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open
load check valve (3) of the spool, and the oil flows to the bottom end of the right cylinder and the rod end of the left cylinder to
turn the machine to the left.
The oil from the left and right cylinders passes through load check valve (4) of the steering spool, and is drained.
The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with
the oil from the steering pump.
WA500-3LK
10-71 B

12
STEERING
STEERING VALVE
RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot popper
5. Valve seat
FUNCTION
The steering relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the
steering valve is actuated. When the steering valve is being actuated, if the steering circuit goes above the set pressure of this
valve, oil is relieved from this valve. When the oil is relieved, the flow control spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
10-72 B
WA500-3LK
STEERING VALVE
12
RELIEF
VALVE OPERATION
When the pressure in the circuit rises, and it reaches the pressure set by adjustment screw (1) and spring (2), pilot poppet (4)
opens, and the oil is drained. When this happens, the balance in pressure between pressure-receiving chamber I and
pressure-receiving chamber II is lost, so demand spool (6) moves to the left in the direction of the arrow.
When demand spool (6) moves, the oil from the steering pump is drained, and the oil from the switch pump is released to the
main control valve. This prevents the pressure in the steering circuit from going above the set value.
WA500-3LK
10-73 B

12
SAFETY
STEERING VALVE
VALVE (WITH SUCTION)

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
The safety valve is installed to the steering valve. It has the following two
functions:
1.
When the steering valve is at neutral, if any shock is applied to the

cylinder, and an abnormal pressure is generated, the oil is relieved
from the valve. In this way, it functions as a safety valve to prevent
damage to the cylinder or hydraulic piping.
2.
If negative pressure is generated at cylinder end, it functions as a

suction valve to prevent a vacuum from forming.
OPERATION
ACTING AS RELIEF VALVE
Port A is connected to the cylinder circuit and port B is connected to the
drain circuit. Oil passes through the hole in poppet (1) and acts on the
different areas of diameters d1 and d, so check valve poppet (3) and relief
valve poppet (2) are firmly seated in position.
When the pressure at port A reaches the set pressure of the relief valve,
pilot poppet (4) opens. The oil flows around pilot poppet (4), passes
through the drill hole, and flows to port B.
When pilot poppet (4) opens, the pressure at the back of poppet (1) drops,
so poppet (1) moves and is seated with pilot poppet (4).
10-74 B
WA500-3LK
STEERING VALVE
12
Compared with the pressure at port A, the internal pressure is low, so relief
valve poppet (2) opens. When this happens, the oil flows from port A to
port B, and prevents any abnormal pressure from forming.
ACTING AS SUCTION VALVE

When negative pressure is formed at port A, the difference in area of
diameters d3 and d4 causes check valve poppet (3) to open. When this
happens, the oil from port B flows to port A, and prevents any vacuum
from forming.
WA500-3LK
10-75 B

12
ORBIT-ROLL
STEERING VALVE
VALVE
1.
Needle bearing
5.
Rotor
9.
2.
Center spring
6.
Cover
10. Stator
3.
Drive shaft
7.
Center pin
11. Lower cover
4.
Valve body
8.
Sleeve
12. Check valve
10-76 B
Spool
WA500-3LK
STEERING VALVE
OUTLINE
The orbit-roll valve is connected directly to the shaft of the steering wheel.
It switches the flow of oil from the steering pump to the left and right
steering cylinders to determine the direction of travel of the machine.
The orbit-roll valve, broadly speaking, consists of the following
components: Rotary type spool (9) and sleeve (8), which have the function
of selecting the direction, and the Girotor set (a combination of rotor (5)
and stator (10)), which acts as a hydraulic motor during normal steering
operations, and as a hand pump (in fact, the operating force of the steering
wheel is too high, so it cannot be operated) when the steering pump or
engine have failed and the supply of oil has stopped.
STRUCTURE
Spool (9) is directly connected to the drive shaft of the steering wheel, and
is connected to sleeve (8) by center pin (7) (it does not contact the spool
when steering wheel is at neutral) and centering spring (2).
The top of drive shaft (3) is meshed with center pin (7), and forms one unit
with sleeve (8), while the bottom of the drive shaft is meshed with the
spline of rotor (5) of the Girotor.
There are four ports in valve body (4), and they are connected to the pump
circuit, tank circuit, and the circuits at the head end and bottom end of the
steering cylinders. The pump port and tank port are connected by the check
valve inside the body. If the pump or engine fail, the oil can be sucked in
directly from the tank by the check valve.
WA500-3LK
10-77 B
STEERING VALVE
12
CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with the sleeve ports used to
connect the suction and discharge ports of the Girotor.
If the steering wheel has been turned to the right, ports a, c, e, g, i, and k
are connected by the vertical grooves in the spool to the pump side. At the
same time, ports b, d, f, h, j, and l are connected to the head end of the left
steering cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the
Girotor set. They are connected to ports l, b, and d, so oil is sent to the
cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the
pump.
If the steering wheel is turned 90, changes to the condition shown in Fig.
2. In this case ports 1, 2, and 3 are the suction ports, and are connected to
ports i, k, and c. Ports 5, 6, and 7 are the discharge ports, and are connected
to ports d, f, and h.
10-78 B
WA500-3LK
STEERING VALVE
12
In this way the ports of the Girotor acting as delivery ports are connected to
ports which are connected to the end of the steering valve spool. The ports
acting as suction ports are connected to the pump circuit adjusting delivery
in accordance with angle of the steering wheel:
For every 1/7 turn of the steering wheel, the inner teeth of the Girotor gear
advances one position so the oil flow from the pump is adjusted by this
movement. In this way, the oil delivered from the pump is directly proportional to the amount the steering wheel is turned.
FUNCTION OF CENTER SPRING
Centering spring (2) consists of four layers of leaf springs crossed to form
an X shape. The springs are assembled in spool (9) and sleeve (8) as shown
in the diagram on the right. When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle variation) arises between the
spool and the sleeve. Because of this, the ports in the spool and sleeve are
connected and oil is sent to the cylinder. When the turning of the steering
wheel is stopped, the Girotor also stops turning, so no more oil is sent to
the cylinder and the oil pressure rises.
To prevent this, when the turning of the steering wheel is stopped, the
action of the centering spring only allows it to turn by an amount equal to
the difference in angle of rotation (angle variation) of the sleeve and spool,
so the steering wheel returns to the NEUTRAL position.
WA500-3LK
10-79 B
STOP VALVE
12
STOP VALVE
1. Boot
5. Spring
A. From orbit-roll
2. Wiper
6. Spool
B. To steering valve
3. Seal
7. Spring
DR. To drain
4. Poppet
10-80 B
WA500-3LK
DIVERTER VALVE
12
DIVERTER
VALVE
1.
2.
3.
4.
Spool
Valve body
Check valve
Check valve
A.
B.
C.
D.
E.
F.
G.
From steering pump

To steering valve
To hydraulic tank
Sensor mounting port
Ground driven steering pump port
Ground driven steering pump port
From hydraulic tank
FUNCTION
If the engine stops or the pump seizes while the machine is traveling, it becomes impossible to steer, the rotation of the
transmission is used to turn the ground driven steering pump to make steering possible.
WA500-3LK
10-81 B
DIVERTER VALVE
12
OPERATION
1.
Pump and engine are working normally
When the steering pump and engine are working normally, the hydraulic
pump, steering pump, and switch pump are rotated by the engine.
Therefore, oil is sent to the steering valve, and the machine can be steered.
In addition, the ground driven steering pump is rotated by the transmission,
so oil from port A of the diverter valve (1) pushes open check valve (2) and
enters port B.
Pressure oil from steering pump is flowing to port D, so it pushes spool (3)
in the direction of the arrow. As a result, the oil from port B flows to port C
and is drained to the hydraulic tank.
10-82 B
WA500-3LK
DIVERTER VALVE
12
2. Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when the machine is traveling, the
rotation of the wheels is transmitted through the transfer to rotate the
ground driven steering pump. The steering pump is not rotating, so no oil
pressure is formed at port D.
As a result, spool (3) is pushed in the direction of the arrow by spring (4).
The oil from the ground driven steering pump passes from port A through
port B and flows to the steering valve to make steering possible.
The ground driven steering pump is designed so that it can rotate both
directions.
WA500-3LK
10-83 B
BRAKE
12
BRAKE
BRAKE PIPING
10-84 B
1. Front brake (Right)
8. Front brake (Left)
2. Slack adjuster (Front)
9. Charge valve
3. Transmission
10. Emergency brake valve
4. Accumulator
11. Hydraulic tank
5. Slack adjuster (Rear)
12. Brake valve (Right)
6. Rear brake (Right)
13. Brake valve (Left)
7. Front brake (Left)
14. Emergency brake switch
WA500-3LK
BRAKE
12
WA500-3LK
10-85 B

12
BRAKE
10-86 B
BRAKE
CIRCUIT DIAGRAM
WA500-3LK
BRAKE
12
1. Hydraulic pump
6. Rear brake accumulator
15A.Parking brake emergency

release solenoid
1A. Switch pump
7. Front brake accumulator
16. Parking brake emergency

release switch
1B. PPC and brake pump
8. Emergency brake switch
17. Parking brake
2. Strainer
9. Left brake valve
18. Parking brake pilot lamp switch
3. Accumulator charge valve
10. Transmission cut-off switch
19. Parking brake solenoid
3A. Safety relief valve
11. Right brake valve
20. Parking brake valve
3B. PPC relief valve
12. Pilot lamp switch
21. Transmission pump
3C. Filter
13. Rear slack adjuster
22. Parking brake switch
4. Check valve
14. Front slack adjuster
5. Low pressure switch
15. Emergency parking brake

valve
WA500-3LK
10-87 B

12
BRAKE
BRAKE
VALVE
RIGHT BRAKE VALVE
1.
Brake pedal (left, right brake)
6.
Spool (right brake)
A. Pilot port (right brake)
2.
Rod (right brake)
7.
Lower cylinder (right brake)
B. To rear brake (right brake)
3.
Pilot piston (right brake)
8.
Rod (left brake)
C. To front brake (right brake)
4.
Spool (right brake)
9.
Spool (left brake)
D. Drain (left, right brake)
5.
Upper cylinder (right brake)
10. Cylinder (left brake)
10-88 B
E. To pilot port (left brake)
WA500-3LK
BRAKE
12
LEFT
BRAKE VALVE
Remark
Legend is at left.
OUTLINE
There are two brake valves installed in parallel under the front of the operators cab, and these are actuated by depressing the
pedal.
When the right pedal is depressed, oil is sent to the brake cylinders to apply the brakes.
When the left pedal is depressed, oil is sent to the right pedal to apply the brakes in the same way as when the right pedal is
depressed.
In addition, the left brake pedal operates the transmission cut-off switch to actuate the transmission solenoid valve electrically
and set the transmission to neutral.
WA500-3LK
10-89 B
BRAKE
12
OPERATION
BRAKE APPLIED (RIGHT BRAKE PEDAL)
Upper portion
When brake pedal (1) is depressed, the operating force is transmitted to
spool (3) through rod (2) and spring (4). When spool (3) goes down, drain
port a is closed, and the oil from the pump and accumulator flows from
port A to port C and actuates the rear brake cylinder.
Lower portion
When brake pedal (1) is depressed, the operating force is transmitted to
spool (3) through rod (2) and spring (4). When spool (3) goes down, spool
(5) is also pushed by plunger (6). When this happens, drain port b is closed,
and the oil from the pump and accumulator flows from port B to port C and
actuates the rear brake cylinder.
BRAKE APPLIED (LEFT BRAKE PEDAL)

When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring
(9), and drain port c is closed. The oil from the pump and the accumulator
flows from port E to port F.
Port F of the left brake valve and port PP of the right brake valve are
connected by a hose, so the oil flowing to port F flows to pilot port PP of
the right brake valve.
The oil entering pilot PP enters port G from orifice d, and pushes pilot
piston (11). The spring pushes spool (3) down, so the operation is the same
as when the right brake valve is depressed.
10-90 B
WA500-3LK
BRAKE
12
Applying brake when upper valve fails (right brake valve)
Even if there is leakage of oil in the upper piping, spool (5) is moved down
mechanically when pedal (1) is depressed, and the lower portion is actuated
normally. The upper brake is not actuated.
Applying brake when lower valve fails (right brake valve)
Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
When actuation is balanced

Upper portion
When oil fills the rear brake cylinder and the pressure between port A and
port C becomes high, the oil entering port H from orifice e of spool (3)
pushes against spring (4). It pushes up spool (3) and shuts off the circuit
between port A and port C. When this happens, drain port a stays closed,
so the oil entering the brake cylinder is held and the brake remains applied.
Lower portion
When spool (3) in the upper portion moves up and the circuit between port
A and port C is shut off, oil also fills the front brake cylinder at the same
time, so the pressure in the circuit between port B and port D rises. The oil
entering port J from orifice f of spool (5) pushes up spool (5) by the same
amount that spool (3) moves, and shuts off port B and port D. Drain port b
is closed, so the oil entering the brake cylinder is held, and the brake is
applied.
The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is
balanced with the pressure in the space in the upper portion. When spools
(3) and (5) move to the end of their stroke, the circuits between ports A and
C and between ports B and D are fully opened, so the pressure in the space
in the upper and lower portions and the pressure in the left and right brake
cylinders is the same as the pressure from the pump. Therefore, up to the
point where the piston moves to the end of its stroke, the effect of the brake
can be adjusted by the amount that the pedal is depressed.
WA500-3LK
10-91 B
BRAKE
12
Brake released (right brake valve)
Upper portion
When brake pedal (1) is released and the operating force is removed from
the top of the spool, the back pressure from the brake cylinder and the force
of the spool return spring move spool (3) up. Drain port a is opened and the
oil from the brake cylinder flows to the hydraulic tank return circuit to
release the rear brake.
Lower portion
When the pedal is released, spool (3) in the upper portion moves up. At the
same time, the back pressure from the brake cylinder and the force of the
spool return spring move spool (5) up. Drain port b is opened and the oil
from the brake cylinder flows to the hydraulic tank return circuit to release
the front brake.
10-92 B
WA500-3LK
BRAKE
12
MEMORANDUM
WA500-3LK
10-93 B

12
CHARGE
BRAKE
VALVE
A.
ACC.
PP.
P.
T.
6.
To PPC valve
To brake valve
To brake valve
From pump
Drain
Filter
FUNCTION
The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and store it in the
accumulator.
When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load
on the pump.
10-94 B
WA500-3LK
BRAKE
12Operation
WA500-3LK
1.
Valve body
4.
PPC relief valve (R2)
2.
Main relief valve (R3)
5.
Relief valve (H1)
3.
Relief valve (R1)
10-95 B
BRAKE
12
OPERATION
1.
When no oil is being supplied to accumulator (cut-out condition)

The pressure at port B is higher than the set pressure of the relief valve
(R1), so piston (8) is forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so port C and port T are short circuited.
The spring chamber at the right end of spool (15) is connected to port
C of the relief valve (R1), so the pressure becomes the tank pressure.
The oil from the pump enters port P, pushes spool (15) to the right at a
low pressure equivalent to the load on spring (14), and flows from port
A to the PPC valve. At the same time, it also passes through orifices
(17), (18), and (16), and flows to the tank.
2.
When oil is supplied to accumulator

A. Cut-in condition
When the pressure at port B is lower than the set pressure of the
relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.
The spring chamber at the right end of spool (15) is also shut off
from port T, so the pressure rises, and the pressure at port P also
rises in the same way.
When the pressure at port P goes the pressure at port B
(accumulator pressure), the supply of oil to the accumulator starts
immediately. In this case, it is decided by the size (area) of orifice
(17) and the pressure difference (equivalent to the load on spring
(14)) generated on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed, and the remaining oil
flows to port A.
10-96 B
WA500-3LK
BRAKE
12
B. When cut-out pressure is reached
When the pressure at port B (accumulator pressure) reaches the
set pressure of the relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.
When the circuit is relieved, a pressure difference is generated
above and below piston (8), so piston (8) moves up, poppet (6) is
forcibly opened, and port C and port T are short circuited.
The spring chamber at the right end of spool (15) is connected to
port C of the relief valve (R1), so the pressure becomes the tank
pressure.
The pressure at port P drops in the same way to a pressure 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 tank circuit, so this sets the
maximum pressure in the brake circuit and protects the circuit.
WA500-3LK
10-97 B

12
ACCUMULATOR
BRAKE
(FOR BRAKE)
FUNCTION
The accumulator is installed between the charge valve and the brake valve.
It is charged with nitrogen gas between cylinder (3) and free
piston (4), and uses the compressibility of the gas to absorb the pulse of the
hydraulic pump or to maintain the braking force and to make it possible to
operate the brake if the engine should stop.
1.
2.
3.
4.
Valve
Top cover
Cylinder
Piston
SPECIFICATIONS:
Gas used:
Charge amount:
Charging pressure:
10-98 B
Nitrogen gas
4,000 cc
35 1.5 kgf/cm2 (at 50 C)
(497.8 21.3 lbf/in2[at 122 F])
WA500-3LK
BRAKE
12
SLACK
ADJUSTER
1.
Bleeder
4.
Piston
A. Inlet port
2.
Cylinder
5.
Spring
B. Outlet port
3.
Check valve
FUNCTION
The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to provide a fixed time lag
when the brake is applied.
SPECIFICATIONS
Piston actuation pressure:
Check valve cracking pressure:
Check valve closing pressure:
WA500-3LK
0.1 + 0.1 kg/cm2 (1.42 1.42 lbf/in2)

9.5 0.5 kg/cm2 (13.51 7.1 lbf/in2)
6.0 0.5 kg/cm2 (85.3 7.1 lbf/in2)
10-99 B
BRAKE
12
OPERATION
1.
When brake pedal is depressed

Before the brake is depressed, piston (4) is returned by the distance of
stroke S (full stroke). When the brake pedal is depressed, the oil
discharged from the brake valve flows from port P of the slack
adjuster and is divided to the left and right cylinders (2), where it
moves piston (4) by stroke S to the left and right.
When this is done, brake piston (7) moves by a distance of stroke S. In

this condition, the closer the clearance between the brake piston and
disc is to 0, the greater the braking force becomes.
If the brake pedal is depressed further, and the oil pressure discharged
from the brake valve goes above the set pressure, check valve (3)
opens and the pressure is applied to port C to act as the braking force.
Therefore, when the brake is applied, the time lag is a fixed value.
2.
When brake pedal is released

When the brake is released, piston (4) is returned by brake return
spring (8) by an amount equivalent to the oil for stroke S, and the
brake is released. In other words, return stroke T of brake piston (7) is
determined by the amount of oil for stroke S of the slack adjuster. The
time lag of the brake is always kept constant regardless of the wear of
the brake disc.
10-100 B
WA500-3LK
BRAKE
12
BRAKE
1.
Guide pin
5.
Outer gear (138 Teeth)
2.
Return spring
6.
Inner gear (105 Teeth)
3.
Cylinder
7.
Plate
4.
Brake piston
8.
Disc
FUNCTION
The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.
WA500-3LK
10-101 B
BRAKE
12
OPERATION
When the brake pedal is depressed, the pressure oil from the brake valve
moves brake piston (4) to the right in the direction of the arrow. This brings
disc (8) and plate (7) into contact, and friction is generated between the
disc and plate. The wheel is rotating together with the disc, so the machine
speed is reduced, and the machine is stopped by this friction.
When the brake pedal is released, the pressure at the back face of brake
piston (4) is released, so the piston is moved to the left in the direction of
the arrow by the force of return spring (2), and the brake is released.
10-102 B
WA500-3LK
PARKING BRAKE
12
PARKING
BRAKE
PARKING BRAKE CONTROL
1.
Parking brake switch
4.
Parking brake solenoid valve
2.
Parking brake emergency release switch
5.
Transmission (built-in parking brake)
3.
Transmission control valve
OUTLINE
See FOLDOUT 10-96 for electrical parking brake control diagram.
The parking brake is a wet-type multiple-disc brake built into the transmission. It is installed to the output shaft bearing, and
uses the pushing force of a spring to apply the brake mechanically and hydraulic power to release the brake.
When parking brake switch (1) installed in the operators compartment is switched ON, parking brake solenoid valve (4)
installed to the transmission control valve (3) shuts off the oil pressure and applies the parking brake. When the parking brake
switch is turned OFF, the oil pressure in the cylinder releases the parking brake.
When the parking brake is applied, the neutralizer relay shuts off the electric current to the transmission solenoid valve and
keeps the transmission at neutral.
Emergency release switch (2) for the parking brake is installed for use when moving the machine, if the machine has stopped
(the parking brake is automatically applied) because of trouble in the engine or drive system.
WA500-3LK
10-103 B

12
PARKING
PARKING BRAKE
BRAKE
1.
Output shaft
4.
Plate
2.
Piston
5.
Spring
3.
Disc
OUTLINE
The parking brake is a wet-type multiple-disc brake. It is actuated mechanically by a spring and applies the braking force to
output shaft (1) of the transmission.
The pushing force of spring (5) pushes piston (2), plate (4), and disc (3) into contact and applies the braking force to stop
output shaft (1).
10-104 B
WA500-3LK
PARKING BRAKE
12
PARKING
BRAKE SOLENOID VALVE
OPERATION
Parking brake applied (solenoid deactivated)
When the parking brake switch in the operators compartment is turned
ON, the solenoid is turned OFF and spool (6) is pushed to the left by spring
(5). When this happens, the passage between pump port P and parking
brake port A is closed, and the pressure oil from the pump does not flow to
the parking brake.
At the same time, the pressure oil from the parking brake flows from port A
to port T and is drained. As a result, the disc inside the parking brake is
pushed by the spring and the parking brake is applied.
When the parking brake switch is turned OFF, the solenoid is turned ON
and spool (6) is moved to the right. As a result, the pressure oil from the
pump passes from port P through the inside of spool (6), flows to port A
and then flows to the parking brake. At the same time, port T is closed, so
the oil is not drained. As a result, the spring inside the parking brake is
pushed back by the oil pressure and the parking brake is released.
WA500-3LK
10-105 B
PARKING BRAKE
12
PARKING
BRAKE EMERGENCY RELEASE

SOLENOID VALVE
1.
2.
Valve assembly
Solenoid valve
A:
B:
C:
T:
P:
To parking brake
From parking brake valve
From pilot circuit
Drain
From brake (accumulator circuit)
FUNCTION
The emergency release solenoid valve is installed between the transmission and the transmission control valve. If the engine
breaks down and no oil pressure is supplied from the transmission pump, it is possible to actuate the solenoid for the parking
brake release switch in the operators compartment. This allows the accumulator charge pressure in the brake circuit to flow to
the parking brake cylinder.
OPERATION
When the parking brake is emergency release is turned ON, solenoid
valve is actuated and the pressure stored in the accumulator enters
from port P. The circuit is switched by pilot pressure, so the oil flows from
port A to the parking brake, to release the parking brake.
10-106 B
WA500-3LK
HYDRAULIC
12
HYDRAULIC
HYDRAULIC PIPING
1.
Main control valve
6.
PPC valve
11. Radiator
16. Steering cylinder
2.
Bucket cylinder
7.
Solenoid valve
12. Oil cooler
17. Boom cylinder
3.
Steering valve
8.
Switch, PPC pump
13. Hydraulic pump
4.
Orbit-roll valve
9.
Check valve
14. Steering Pump
5.
Hydraulic tank
10. Accumulator
15. Cut-off valve
HYDRAULIC LINE ASSEMBLY

See Section 90 for illustration, Hydraulic Line Assembly, FOLDOUT 10-100-1 thru 10-100-3.
WA500-3LK
10-107 B
HYDRAULIC
12
OUTLINE
The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the
movement of the bucket and attachment.
The oil in hydraulic tank (5) is sent to the main control valve (1) by hydraulic pump (13). When the bucket and boom spools of
the main control valve are at HOLD, the oil passes through the drain circuit of the main control valve, is filtered by the filter
inside the hydraulic tank, and then returns to the tank.
When the work equipment control levers are operated, the bucket or boom spool of the PPC valve (6) moves, and the spools of
the main control valve are actuated by hydraulic pressure, so oil flows from the main control valve to boom cylinder (17) or
bucket cylinder (2) to move the boom or bucket.
Control of the maximum pressure in the hydraulic circuit is carried out by the relief valve inside the main control valve. A
safety-suction valve is installed to the bucket cylinder circuit to protect the circuit.
Accumulator (10) is installed in the PPC pilot circuit, so this makes it possible to lower the boom to the ground even when the
engine is stopped.
Hydraulic tank (5) is a pressurized sealed type and is equipped with a breather with relief valve. This compresses the inside of
the tank and also prevents negative pressure, so this prevents cavitation of the pump.
10-108 B
WA500-3LK
HYDRAULIC
12
HYDRAULIC
CIRCUIT DIAGRAM
MACHINES WITH STANDARD SPECIFICATIONS
WA500-3LK
10-109 B
HYDRAULIC
1.
Hydraulic tank
12. PPC valve
15. Bucket cylinder
2.
Oil filter
13. Main control valve
16. Orbit-roll valve
3.
Breather
13A. Main relief valve
17. Stop valve
4.
Switch, PPC pump
13B. Bucket spool
18. Steering valve
5.
13C. Safety valve with suction
18A. Demand spool
6.
Hydraulic pump
13D. Unloader valve
18B. Steering spool
7.
Steering pump
13E. Float selector valve
18C. Steering relief valve
8.
Strainer
13F. Boom spool
18D. Safety valve with suction
9.
Accumulator charge valve
13G. Suction valve
19. Steering cylinder
13H. Slow return valve
20. Cut-off valve
10. Check valve

11. Accumulator
10-110 B
14. Boom cylinder
21. Oil cooler
WA500-3LK
HYDRAULIC
12
HYDRAULIC CIRCUIT DIAGRAM
See Section 90 for illustration, Hydraulic Circuit Diagram, FOLDOUT 10-105.
WA500-3LK
10-111 B

12
WORK
HYDRAULIC
EQUIPMENT LEVER LINKAGE
1.
Boom lever
4.
Bucket lever
7.
Solenoid valve for boom lever
2.
Kick-down switch
5.
Attachment lever
8.
Safety lever lock
3.
Hold switch
6.
Solenoid valve for bucket lever
9.
PPC valve
10-112 B
WA500-3LK
HYDRAULIC
12
HYDRAULIC
TANK
WA500-3LK
10-113 B

12
OIL
HYDRAULIC
FILTER BY-PASS VALVE
OPERATION
When the filter is clogged
By-pass valve (1) opens and the oil returns directly to the tank without
passing through the filter.
By-pass valve set pressure: 1.27 kgf/cm2 (18.06 lbf/in2)
When negative pressure is formed in the return circuit

Valve (2) moves up and acts as a check valve.
By-pass valve set pressure: 0.26 kgf/cm2 (3.69 lbf/in2)
BREATHER
FUNCTION
Preventing negative pressure inside the tank
The tank is a pressurized, sealed type, so negative pressure is formed inside
the hydraulic tank when the oil level drops during operations. When this
happens, the difference in pressure between the tank and the outside
atmospheric pressure opens the poppet (3), and air from the outside is let
into the tank to prevent negative pressure.
Preventing rise in pressure inside the tank
When the hydraulic cylinders are being used, the oil level in the hydraulic
circuit changes and the temperature rises. If the hydraulic pressure rises
above set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.
10-114 B
WA500-3LK
HYDRAULIC
12
ACCUMULATOR
(FOR PPC VALVE)
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications:
Type of gas:
Nitrogen gas
Gas amount:
500 cc
Actuation Pressure:
Maximum: 35 kg/cm2 (497.8 lbf/in2)
Minimum: 12 kg/cm2 (170.6 lbf/in2)
FUNCTION
The accumulator is installed between the accumulator charge valve and the PPC valve. Even if the engine stops when the
boom is raised, it is possible to lower the boom and bucket under their own weight by using the pressure of the nitrogen gas
compressed inside the accumulator to send the pilot oil pressure to the main control valve to actuate it.
OPERATION
After the engine stops, if the PPC valve is at hold, chamber A inside the
bladder is compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure in chamber B goes below
30 kg/cm2 (426.7 lbf/in2). When this happens, the bladder is expanded by
the pressure of the nitrogen gas in chamber A, and the oil inside chamber B
is used as the pilot pressure to actuate the main control valve.
WA500-3LK
10-115 B

12
PPC
HYDRAULIC
VALVE
FOR BUCKET / BOOM
P = From PPC pump
P3 = To RAISE end of main control valve boom spool
P1 = To TILT end of main control valve bucket spool
P4 = To DUMP end of main control valve bucket
P2 = To LOWER end of main control valve boom spool
T = Drain
10-116 B
WA500-3LK
HYDRAULIC
12
WA500-3LK
1.
Bolt
4.
Collar
7.
Metering spring
2.
Piston
5.
Retainer
8.
Valve
3.
Plate
6.
Centering spring
9.
Body
10-117 B

12
FOR
HYDRAULIC
OPTIONAL ATTACHMENT
10-118 B
P = From PPC pump
P3 = To main control valve attachment spool
P2 = To main control valve attachment spool
T = Drain
WA500-3LK
HYDRAULIC
12
WA500-3LK
1.
Bolt
4.
Collar
7.
Metering spring
2.
Piston
5.
Retainer
8.
Valve
3.
Plate
6.
Centering spring
9.
Body
10-119 B

12
PPC
HYDRAULIC
VALVE NEUTRAL POSITION
The oil from the PPC pump enters port P of the PPC valve, but the circuit is closed by spool (8), so the oil is drained from the
relief valve (1). At the same time, the oil at port PA1 of the main control valve is drained from port f of spool (8). In addition,
the oil at port PB1 is drained from port g of spool (10).
10-120 B
WA500-3LK
HYDRAULIC
12
PPC
VALVE POSITIONS FUNCTIONS
The PPC valve supplies pressure oil from the charging pump to the side
face of the spool of each control valve according to the amount of travel of
the control lever. This pressure oil actuates the spool.
OPERATION
1.
Control lever at "hold". (Fig. 1)

Ports PA1, PA4, PB1, and P1 are connected to drain chamber D
through fine control hole (f) in valve (8).
2.
Control lever operated slightly (fine control) (Fig. 2)

When piston (2) starts to be pushed by plate (10), retainer (5) is
pushed. Valve (8) is also pushed by spring (7) and moves down. When
this happens, fine control hole (f) is shut off from drain chamber D. At
almost the same time it is connected to pump pressure chamber PP,
and the pilot pressure of the control valve is sent through fine control
hole (f) to port P4. When the pressure at port P4 rises, Valve (8) is
pushed back. Fine control hole (f) is shut off from pump pressure
chamber PP. At almost the same time it is connected to drain chamber
D, so the pressure at port P4 escapes to drain chamber D. Valve (8)
moves up and down until the force of spring (7) is balanced with the
pressure of port P4. The position of valve (8) and body (9) (when fine
control hole (f) is midway between drain chamber D and pump
pressure chamber PP) does not change until the head of valve (8)
contacts the bottom of piston (2).
Therefore, spring (7) is compressed in proportion to the travel of the
control lever, so the pressure at port P4 also rises in proportion to the
travel of the control lever. The spool of the control valve moves to a
position where the pressure of port PA1 (same as pressure at port P4)
and the force of the return spring of the control valve are balanced.
WA500-3LK
10-121 B
HYDRAULIC
12
3. Control lever moved back from slightly operated position to hold (Fine
control) (Fig. 3)
When plate (10) starts to be pushed back, piston (2) is pushed up by a
force corresponding to the force of centering spring (6) and the pressure at port P4. At the same time, fine control hole (f) of valve (8) is
connected to drain chamber D, so the oil at port P4 escapes. If the
pressure at port P4 drops too far, valve (8) is pushed down by spring
(7). Fine control hole (f) is shut off from drain chamber D, and at
almost the same time it is connected to pump pressure chamber PP.
The pump pressure is supplied until the pressure at port PA1 returns to
a pressure equivalent to the position of the lever. When the spool of the
control valve returns, the oil in drain camber D flows in from fine
control hole (f1) of the valve which has not moved. The extra oil then
flows through port P1 to chamber PB1.
4.
Control lever operated to end of travel (Fig. 4)

Plate (10) pushes piston (2) down, and piston (2) forcibly pushes in
valve (8). Fine control hole (f) is shut off from drain chamber D, and is
connected to pump pressure chamber PP. Therefore, pressure oil from
the charging pump passes through fine control hole (f), and flows from
port P4 to chamber PA1 to push the spool of the control valve. The oil
returning from chamber PB1 flows from port P1 through fine hole (f1)
to drain chamber D.
10-122 B
WA500-3LK
HYDRAULIC
12
PPC
RELIEF VALVE
1.
2.
3.
4.
5.
6.
Main valve
Spring
Valve seat
Pilot poppet
Spring
Screw
FUNCTION
The PPC relief valve is between the PPC brake pump and the PPC valve.
When the PPC pump is not being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved through this valve to
protect the pump and circuit from damage.
OPERATION
The relief valve is installed to the charge valve. Port A is connected to the
pump circuit, and port C is connected to the drain circuit.
The oil passes through the orifice of main valve (1) and fills port B. In
addition, pilot poppet (4) is seated in valve seat (3).
When the pressure at port A and B reaches the set pressure, pilot poppet (4)
opens and the oil pressure at port B escapes from port D to port C to lower
the pressure at port B.
When the pressure at port B goes down, a difference in pressure is
generated at ports A and B by the orifice in main valve (1). Main valve (1)
is opened by the pressure at port A, and the oil at port A is drained to port C to relieve the circuit.
WA500-3LK
10-123 B

12
CUT-OFF
HYDRAULIC
VALVE
1. Unload valve
C. Port C (from hydraulic pump)
2. Check valve
P. Port P (from steering valve)
3. Cut-off valve
T. Port1 T (to tank)
4. Screen
T1. Port T1 (to tank)
FUNCTION
The cut-off valve is installed between the switch pump and the main control valve. Depending on the operating condition, it
switches the oil from the switch pump to the main control valve or to the drain circuit.
The cut-off valve is operated by hydraulic pressure.
10-124 B
WA500-3LK
HYDRAULIC
12
OPERATION
Cut-off operation conditions
O: Cut-off (drain)
X: Not actuated (to main control valve)
More than
175 kg/cm2
(2489 lbf/in2)
Less than
175 kg/cm2
(2489 lbf/in2)
Kick-down
switch
ON
1.
When the work equipment valve is held.

The oil at the switch pump (the oil from the steering valve) presses up
check valve (1), merges with the oil from the work equipment pump
and flows to the work equipment valve.
2.
When the work equipment valve is activated.

A. When the work equipment pump pressure is lower than the cut-off
pressure.
As when the work equipment valve is held, the oil at the switch
pump (the oil from the steering valve) pushes up check valve (1),
merges with the oil from the work equipment pump and flows to
the work equipment valve.
B. When the work equipment pump pressure is higher than the
cut-off pressure.
When the cut-off pressure is reached, the pressure of the oil in
chamber a opens cut-off valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2) chamber c and is
drained. The oil in unload valve (3) chamber d passes through orifices e and f, and into chamber b causing the oil pressure in chamber d decrease, and unload valve (3) to open. Thus, the oil from
the switch pump is drained.
WA500-3LK
10-125 B

12
ECSS
HYDRAULIC
CONTROL VALVE
10-126 B
WA500-3LK
HYDRAULIC
12
1.
Spool
A.
To boom cylinder bottom side
2.
Solenoid valve
B.
To boom cylinder rod side
3.
Spool
M. To accumulator
4.
Valve body
P.
From hydraulic pump
SP. To accumulator
T.
Drain
FUNCTION
The E.C.S.S. control valve is installed in the front frame and turns ON and OFF the accumulator for the E.C.S.S. according to
the signals from the transmission & E.C.S.S. controller.
WA500-3LK
10-127 B

12
MAIN
HYDRAULIC
CONTROL VALVE
2-SPOOL
10-128 B
PA1.
From PPC valve P4
A1.
To bucket cylinder bottom end
PA2.
From PPC valve P2
A2.
To boom cylinder bottom end
PB1.
From PPC valve P1
B1.
To bucket cylinder head end
PB2.
From PPC valve P3
B2.
To boom cylinder head end
P.
From pump
D1.
Drain port
P1.
From PPC valve P2
D2.
Drain port
P2.
From PPC valve P3
T.
Drain port
WA500-3LK
HYDRAULIC
12
WA500-3LK
1.
Main relief valve
6.
Body
2.
Bucket spool return spring
7.
Suction valve
3.
Boom spool return spring
8.
Unloader valve
4.
Boom spool
9.
Safety valve (with suction)
5.
Bucket spool
10. Float selector valve
10-129 B
HYDRAULIC
12
3-SPOOL
A1.
To attachment cylinder
D1.
Drain port
PA2.
From PPC valve P4
A2.
To bucket cylinder bottom
D2.
Drain port
PA3.
From PPC valve P2
A3.
To boom cylinder bottom
P.
From pump
PB1.
From option PPC valve
B1.
To attachment cylinder
P1.
From PPC valve P2
PB2.
From PPC valve P1
B2.
To bucket cylinder head
P2.
From PPC valve P3
PB3.
From PPC valve P3
B3.
To boom cylinder head
PA1.
From option PPC valve
T.
Drain port
10-130 B
WA500-3LK
HYDRAULIC
12
WA500-3LK
1.
Main relief valve
7.
Attachment spool
2.
Attachment spool return spring
8.
Body
3.
Bucket spool return spring
9.
Unloader valve
4.
Boom spool return spring
10. Suction valve
5.
Boom spool
11. Safety valve (with suction)
6.
Bucket spool
12. Float selector valve
10-131 B
HYDRAULIC
12
OUTLINE
The main control valve controls the actuation of the boom attachments and the bucket in the hydraulic system. It has a tandem
circuit which gives priority to the bucket circuit.
The oil from the pump enters port P. The maximum pressure is set by the main relief valve. The oil passes through the by-pass
circuit of dump spool (5) and lift spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to
the tank. If the dump and lift spools are actuated, the oil flows to the dump and lift cylinders.
However, the circuit gives priority to the bucket, so when the dump spool is being operated, even if the lift spool is operated,
the lift arm will not move.
There are two safety valves (with suction valves) (10) to protect the circuit if abnormal pressure is generated in the bucket
circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up for any lack
of oil.
10-132 B
WA500-3LK
HYDRAULIC
12
RELIEF
VALVE
1.
2.
3.
4.
5.
6.
Main valve
Valve seat
Pilot poppet
Pilot poppet spring
Adjustment screw
Lock nut
Set pressure: 210 kg/cm2 (2986.9 lbf/in2)
FUNCTION
The relief valve is installed to the inlet portion of the main control valve. If
the oil goes above the set pressure, the relief valve drains the oil to the tank
to set the maximum pressure for the work equipment circuit, and to protect
the circuit.
OPERATION
Port A is connected to the pump circuit and port B is connected to the drain
circuit. The oil passes through the orifice of the main valve (1) and fills
port B. Pilot poppet (3) is seated in valve seat (2).
If the pressure port A and port B reaches the set pressure of pilot poppet
spring (4), pilot poppet (3) opens, and the oil pressure at port B escapes
from port D to port C, so the pressure at port B drops.
When the pressure at port B drops, a difference in pressure between port A
and port B is created by the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through port C, and flows to the
drain circuit to release the abnormal pressure.
The set pressure can be varied by changing the tension of pilot poppet
spring (4). To change the set pressure, remove cap nut, loosen lock nut (6)
and turn adjustment screw (5), to adjust the set pressure as follows:
Tighten to increase pressure
Loosen to decrease pressure
WA500-3LK
10-133 B

12
SAFETY
HYDRAULIC
VALVE (WITH SUCTION)

1.
2.
3.
4.
5.
6.
Suction valve
Main valve
Main valve spring
Pilot piston
Suction valve spring
Valve body
Set pressure: 230 kg/cm2 (3271.3 lbf/in2)
FUNCTION
The safety valve is in the bucket cylinder circuit inside the main control
valve. If any abnormal pressure is generated by any shock to the cylinder
when the main control valve is at the neutral position, this valve relieves
the abnormal pressure to prevent damage to the cylinder.
OPERATION
1.
Operation as safety valve.

Port A is connected to the cylinder circuit and port B is connected to
the drain circuit. The oil pressure at port A is sent to port D from the
hole in pilot piston (4). It is also sent to port C by the orifice formed
from main valve (2) and pilot piston (4). Pilot piston (4) is secured to
the safety valve, and the size of the cross-sectional surface
(cross-sectional area) has the following relationship: d2 > d1 > d3 > d4.
If abnormal pressure is created at port A, suction valve (1) is not
actuated because of relationship d2 > d1 , but the relationship between
port A and port C is d3 > d4, so main valve (2) receives oil pressure
equivalent to the difference between the areas of d3 and d4. If the oil
pressure reaches the force (set pressure) of main valve spring (3),
main valve (2) is actuated, and the oil from port A flows to port B.
10-134 B
WA500-3LK
HYDRAULIC
12
OPERATION AS SUCTION VALVE
If any negative pressure is generated at port A, port D is connected with
port A, so there is also a negative pressure at port D. The tank pressure of
port B is applied to port E, so the safety valve receives oil pressure a,
which is equal to the difference in the area of d2 and d1 because of the tank
pressure at port E. Therefore, oil pressure e moves the valve in the direction of opening, and oil pressure a acts to move suction valve (1) in the
direction of closing.
When the pressure at port A drops (and comes close to negative pressure),
it becomes lower than hydraulic pressure e. The relationship becomes oil
pressure e > oil pressure a + force of valve spring (5), and suction valve
(1) opens to let the oil from port B flow into port A and prevent any negative
pressure from forming at port A.
SUCTION VALVE
1.
2.
3.
Main poppet
Sleeve
Spring
FUNCTION
This valve acts to prevent any negative pressure from forming in the
circuit.
OPERATION
If any negative pressure is generated at port A (boom cylinder rod end)
(when a pressure lower than tank circuit port B is generated), main poppet
(1) is opened because of the difference in area between d1 and d2, and oil
flows from port B at the tank end to port A at the cylinder port end.
WA500-3LK
10-135 B

12
FLOAT
HYDRAULIC
SELECTOR VALVE AND UNLOAD VALVE
FUNCTION
The float selector valve and unload valve are inside the main control valve.
When the boom lever is operated to the FLOAT position, the float selector
valve detects this, and it acts to actuate the unload valve and set the boom
to the FLOAT position.
OPERATION
If the boom lever is pushed further from the LOWER position, it is set to
the FLOAT position and the PPC valve is set to the same condition as for
the LOWER position. The pressure at port A becomes high pressure and
the pressure at port B becomes low pressure.
The oil from the setting valve fills chamber F and chamber E.
If the difference in pressure between port A and port B becomes greater

than the specified pressure, float selector valve (2) is moved to the right,
and port C and port D open.
When port C opened, the oil pressure in chamber E drops, unload valve (4)
is moved up in the direction of the arrow, and the oil from the pump flows
to the drain circuit, and also flows to the rod end of the boom cylinders.
The oil at the bottom end of the boom cylinders is connected to the drain
circuit and forms the FLOAT position.
10-136 B
WA500-3LK
HYDRAULIC
12
BOOM
AND DUMP SPOOLS AT HOLD POSITION
OPERATION
The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).
Bucket spool (1) is at HOLD, so the by-pass circuit is open. The oil at port A passes around the spool and flows to port B.
Boom spool (2) is also at HOLD, so the by-pass circuit is open. The oil at port B passes around the spool and flows to port C
in the drain circuit. From here it passes through the filter and returns to the tank.
The oil from the PPC pump passes through check valve (13) and enters port L of the PPC valve. However, the boom and
bucket levers are at the HOLD position, so the oil returns from PPC relief valve (12) to the hydraulic tank.
WA500-3LK
10-137 B

12
BOOM
HYDRAULIC
SPOOL AT RAISE POSITION
OPERATION
When boom lever (3) is pulled, pressure oil from port L of the PPC valve flows to port N and port S. The oil in port T passes
through port M and flows to the drain circuit. The pressure oil in port S pushes the piston against the force of the spring and
moves boom spool (2) to the RAISE position.
The oil flows from the pump through the by-pass circuit of the bucket spool, and then flows to the by-pass circuit of boom
spool (2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port H to
port I, and goes to the bottom end of the cylinder.
At the same time, the oil at the rod end of the cylinder flows from port K to drain port C, and returns to the tank. Therefore, the
boom rises.
10-138 B
WA500-3LK
HYDRAULIC
12
BOOM
SPOOL AT LOWER POSITION
OPERATION
When boom lever (3) is pushed, pressure oil from port L of the PPC valve flows to port M and port T. In addition the oil at
port S is connected to the drain circuit. The pressure oil at port T pushes the piston against the force of the spring and moves
boom spool (2) to the LOWER position
The oil from the pump passes through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool
(2). The by-pass circuit is closed by the spool, so the oil pushes open check valve (10). The oil then flows from port J to port
K, and goes to the rod end of the cylinder.
At the same time, the oil at the bottom end of the cylinder flows from port I to drain port C, and returns to the tank. Therefore,
the boom goes down.
WA500-3LK
10-139 B

12
BOOM
HYDRAULIC
SPOOL AT FLOAT POSITION
OPERATION
When boom lever (3) is pushed to the FLOAT position, the spool of the PPC valve moves further from the LOWER position to
the FLOAT position. Pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W.
In addition, the pressurized oil at port S flows to port N.
The pressure oil at port T pushes the piston against the force of the spring and moves boom spool (2) to the LOWER position.
If the pressure difference between port W and port X goes above the specified level, valve (7) moves to the right and opens
ports C1 and C to connect them to the drain circuit. When port C1 is connected to the drain circuit, unload valve (8) moves up,
and the oil from the pump flows to the drain circuit.
Therefore, the oil at the rod end of the cylinder flows from port K, and then flows from unload valves (8) to the drain circuit.
At the same time, the oil at the bottom end of the cylinder flows from port I to port C, and then flows to the drain circuit.
Therefore, the boom is set to the FLOAT condition.
10-140 B
WA500-3LK
HYDRAULIC
12
BUCKET
SPOOL AT DUMP POSITION
OPERATION
When bucket lever (4) is pushed, pressure oil from port L of the PPC valve flows to port V via port Q. In addition, the oil at
port R is connected to the drain circuit. The pressure oil at port V pushes the piston against the force of the spring and moves
bucket spool (1) to the DUMP position.
The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) then flows from port F and enters port G, and goes to the rod end of the cylinder.
At the same time, the oil at the bottom end of the cylinder flows from port D to drain port C, and returns to the tank. Therefore,
the bucket is dumped.
WA500-3LK
10-141 B

12
BUCKET
HYDRAULIC
SPOOL AT TILT POSITION
OPERATION
When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows to port R via port P. The oil in port V is
connected to the drain circuit. The pressure oil at port R pushes the piston against the force of the spring and moves bucket
spool (1) to the TILT position.
The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve
(9) flows from port D to port E, and goes to the bottom end of the cylinder.
At the same time, the oil at the rod end of the cylinder flows from port G to drain port C, and returns to the tank. Therefore, the
bucket is tilted.
10-142 B
WA500-3LK
HYDRAULIC
12
MEMORANDUM
WA500-3LK
10-143 B
WORK EQUIPMENT
12
WORK EQUIPMENT
WORK EQUIPMENT LINKAGE
10-144 B
1.
Bucket
6.
Bucket link
2.
Bellcrank
7.
Bucket hinge pin
3.
Bucket cylinder
8.
Cord ring
4.
Boom cylinder
9.
Cord ring
5.
Boom
WA500-3LK
WORK EQUIPMENT
12
WA500-3LK
10-145 B
WORK EQUIPMENT
12
BUCKET
1.
2.
3.
10-146 B
Bucket
Tooth
Corner tooth
WA500-3LK
WORK EQUIPMENT
12
MEMORANDUM
WA500-3LK
10-147 B

12
BUCKET
10-148 B
WORK EQUIPMENT
POSITIONER AND BOOM KICK-OUT
WA500-3LK
WORK EQUIPMENT
12
BUCKET
POSITIONER
The bucket positioner is electrically actuated and is used to automatically
obtain the optimum digging angle for the bucket.
When the bucket is moved from the DUMP position to the TILT position,
and it reaches the desired angle, the dump lever is automatically moved
from the TILT position to the neutral.
Lever (4) is secured by bolts to dump cylinder rod (3). A proximity switch
(1) is fixed by bolts to the cylinder.
When the bucket is moved from the DUMP position to the TILT position,
the dump cylinder rod moves to the left. At the same time, lever (4) also
moves to the left. When it reaches the desired position, lever (4) separates
from proximity switch, and the bucket lever returns to neutral.
BOOM KICK-OUT
The boom kick-out is electrically operated and acts to stop the lift arm.
When the lift arm reaches the desired position before the maximum height,
the lift arm lever is returned to neutral.
Plate (5) is secured to the lift arm. A proximity switch (2) is fixed to the
frame. When the lift arm is moved from the LOWER position to the
RAISE position, the lift arm rises. When it reaches the desired position, the
proximity switch and plate come into contact and the lift arm lever is
returned to neutral.
WA500-3LK
10-149 B

12
PROXIMITY
WORK EQUIPMENT
SWITCH
FUNCTION
Proximity switches are installed by a support to the boom and bucket
cylinders. The lift arm RAISE position and the TILT BACK position can be
selected to match the operating conditions. When these positions are
reached, a pulse is generated from the switch, the electric current flows to a
magnet and the lift or dump lever is returned to the hold position. When this
happens, the main control valve is also returned to hold and the movement
of the lift arm or bucket stops.
OPERATION OF PROXIMITY SWITCH

BOOM RAISE
When the boom is lower than the set position for the boom kick-out, the detection unit (steel plate) is on the sensing surface of
the proximity switch. Electricity flows through the proximity switch. The relay switch is at OFF and the electric current of the
magnet switch coil is shut off.
10-150 B
WA500-3LK
WORK EQUIPMENT
12
When the boom lever is moved to the RAISE position, the lever cam and the
cam follower keep the lift spool in the RAISE position, so the boom arm
goes up.
KICK-OUT
When the boom goes up and reaches the set position for the kick-out (that is,
the detection unit (steel plate) is separated from the sensing surface of the
proximity switch), the proximity switch and relay circuit act to send electric
current to the magnet coil. This actuates the magnet, the cam is pulled out of
the cam detent, and the lift spool is returned to the neutral position by the
return spring.
WA500-3LK
10-151 B
WORK EQUIPMENT
12
ACTION OF PROXIMITY SWITCH FOR BOOM
Position
When detector is in position at detection

surface of proximity switch
When detector is separated from detection surface

of proximity switch
Proximity switch actuation display
Lights up
Goes out
Proximity switch load circuit

(relay switch circuit)
Current flows
Current shut off
Relay switch load circuit

(Solenoid circuit)
Current flows
Current shut off
10-152 B
WA500-3LK
WORK EQUIPMENT
12
BUCKET TILT
HOLD
When the bucket is dumped beyond the set position for the bucket leveler,
the sensor (steel plate) is above the detection surface of the bucket proximity
switch, so electric current flows in the proximity switch load circuit. The
positioner relay is turned ON and the current for the solenoid is shut off.
TILT
When the bucket lever is moved to the TILT position, the bucket spool is
held at the TILT position by the cam follower and cam on the lever, and the
bucket tilts.
WA500-3LK
10-153 B
WORK EQUIPMENT
POSITIONED
When the bucket tilts and reaches the set position for the bucket leveler (that
is, the detection unit (steel plate) is separated from the sensing surface of the
proximity switch), the proximity switch and relay circuit act to send electric
current to the magnet coil. This actuates the magnet, the cam is pulled out of
the cam detent, and the dump spool is returned to the neutral position by the
return spring.
ACTION OF PROXIMITY SWITCH FOR BUCKET

Position
Proximity switch actuation display
Positioner relay
Solenoid (for bucket)
10-154 B
When sensor is in position at detection

surface of proximity switch
When sensor is separated from detection surface of

proximity switch
Lights up
Goes out
Current flows
Current shut off
Current shut off
Current flows
WA500-3LK
CAB
12
CAB
WA500-3LK
10-155 B
ROPS CANOPY
12
ROPS CANOPY
1.
10-156 B
ROPS guard
2.
Cab
WA500-3LK
AIR CONDITIONER
12
AIR
CONDITIONER
AIR CONDITIONER PIPING
WA500-3LK
10-157 B

12
AIR
AIR CONDITIONER
CONDITIONING (GENERAL)
BASIC INFORMATION ON AIR CONDITIONERS

UNITS RELATED TO REFRIGERATION
HEAT
The kinetic energy of the molecular activity of a substance takes the form of heat. If a substance is given heat by any other
substance, its temperature will rise. If heat is taken away by another body, the temperature will decrease.
1.
Quantity of heat.
If the heat is transferred from one substance to another, the temperatures of both substances will change. The amount of
change in temperature will depend on the quantity of heat transferred. The quantity of heat is indicated in units of calories
(cal) or kilocalories (Kcal). One cal denotes the quantity of heat required to raise the temperature of 1g of water by 1
degree. One Kcal denotes the quantity of heat required to raise the temperature of 1 kg of water by 1 degree.
2.
Specific heat.
The quantity of heat required to raise or lower the temperature of substance varies depending on the type, weight, and
amount of change in temperature of the substance. The quantity of heat required to raise the temperature of one unit
weight of a substance by 1 degree is called the "specific heat" of the substance. The unit of the specific heat is "kcal/kg C.
The specific heat is often indicated with a numerical value without the unit.
The larger the specific heat of a substance, the more difficult it is for the substance to warm up and cool down. The
specific heat of water is 1, the largest value of any solid or liquid.
10-158 B
Substance
Specific heat (Kcal/kg C)
Water
1.0
Alcohol
0.57
Ice
0.49
Iron
0.11
Copper
0.09
Aluminum
0.21
WA500-3LK
AIR CONDITIONER
12
TEMPERATURE
When cooling or warming a substance, the units of warmth or coolness measurement are expressed as degrees C (Centigrade)
or F (Fahrenheit).
1. Scales of temperature.
The temperature at which water freezes at the standard barometric pressure
(1 barometric pressure) (the "freezing point"):
Centigrade . . . . . . . . . . . . . . . . 0 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F)
Temperature at which water boils at the standard barometric pressure (the
"boiling point"):
Centigrade . . . . . . . . . . . . . . . 100 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 212 degrees ( F)
On the Centigrade scale, the scale is equally divided into 100 graduations
ranging from 0 to 100 degrees. One graduation is 1 C. A temperature
below the freezing point (a subzero temperature) is indicated by a negative number, such as -a C.
On the Fahrenheit scale, the scale is divided into 180 graduations ranging from 32 to 212 degrees. One graduation is 1 F. A
temperature below 0 F is called subzero temperature and indicated by a negative number, such as -B F.
Relationship between the Centigrade and the Fahrenheit scales:
Centigrade and Fahrenheit temperatures can be converted according to the following formulas:
Centigrade temperature (C) = (F -32) x 5/9
Fahrenheit temperature (F) = C x 9/5 + 32
2.
Absolute temperature (Kelvin scale)

At zero degrees on the absolute scale ("absolute zero"), the molecular activity of all substances ceases. Absolute
temperature, lowest temperature in the natural world, often is for theoretical studies.
Relationships between the absolute temperature scale and the Centigrade and Fahrenheit temperature scales:
0 C is 273 K (on the Kelvin scale) in the absolute temperature system. One degree in the Kelvin scale equals one degree
in the Centigrade scale.
On the Fahrenheit temperature scale, 0 F is equivalent to 460 R (on the Rankine scale). One degree in the Rankine scale
is equivalent to one degree on the Fahrenheit scale.
Thus, their relationships are as follows:
Absolute temperature (K) = (C) + 273
0 K = -273 C.
Absolute temperature (R) = (F) + 460
0 R = -460 F.
WA500-3LK
10-159 B
AIR CONDITIONER
12
PRESSURE
The force acting on a unit area is called "pressure". Normally, the force
acting on a unit area of 1 cm2 is indicated in unit of kg.
Unit of pressure: kg/cm2.
1.
Absolute pressure.
The pressure actually imposed on the wall of a vessel by the gas inside
is called absolute pressure. The complete vacuum pressure, in
which no molecular activity occurs, is defined as the zero pressure.
The absolute pressure is used in the same manner as the absolute
temperature when treating problems theoretically. The unit of absolute
pressure is kg/cm2 abs.
2.
Gauge pressure.
The pressure measured with a pressure gauge at zero barometric pressure is called the gauge pressure. This pressure
indicates the difference between the absolute pressure and the atmospheric pressure. For a theoretical calculation, the
gauge pressure must be converted into the absolute pressure. In most cases, pressure refers to the gauge pressure. The unit
gauge pressure is kg/cm2 g, which distinguishes it from ordinary pressure.
3.
Atmospheric pressure.
This is the pressure of the air. The standard atmospheric pressure is 1.03 kg/cm2 abs. at sea level, equivalent to a mercury
column of 760 mm (Hg) or to a water column of 10.3 m. The relationship between the absolute pressure and the gauge
pressure is simple:
Absolute pressure = Gauge pressure + Atmospheric pressure.
Even if the gauge pressure of a gas in a container is zero, the gas is actually subject to a pressure of 1.03 kg/cm2 abs.
4.
Vacuum and the degree of the vacuum.

Normally, a pressure gauge has a red zone on its scale to indicate the
pressure below 0 kg/cm2. Any gas pressure indicated in the red zone is
below the atmospheric pressure.
The term "vacuum" refers to a given space filled with gas at a pressure
below the atmospheric pressure. A perfect vacuum refers to a space
completely empty of gas pressure (an absolute pressure of 0 kg/cm2
abs).
The degree of vacuum applies to the static pressure below the
atmospheric pressure and is indicated in terms of absolute pressure in
units of cm Hg. On the gauge scale, the atmospheric pressure is set at
zero and the perfect vacuum is set at 76 cm Hg. To convert the reading, h cm Hg, of the vacuum gauge into the absolute
pressure P kg/cm2 abs., the following formula is used:
P = 1.03 x (1 - h/76)
In this case, the degree of vacuum is (76-h) cm Hg.
10-160 B
WA500-3LK
AIR CONDITIONER
12
HUMIDITY
The amount of water contained in the air is called the humidity. Humidity is generally classified into absolute humidity and
relative humidity.
1.
Absolute humidity.
The absolute humidity is the weight of moisture per kg of dry air contained in the wet air, expressed in units of x kg/kg.
Practically, an air diagram is used to indicate the weight of moisture contained in 1 kg of wet air. For example, if 30 g of
moisture is contained in 1 kg of wet air, the absolute humidity on the air diagram is indicated as follows:
Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg.
2.
Relative humidity.
The ratio between the water partial pressure P (kg/cm2) of the wet air and the max. partial pressure Ps contained in the
water at that humidity (the water partial pressure of the saturated air) is called the "relative humidity".
That is, Relative humidity = P/Ps x 100 (%).
Generally, when we speak of humidity, we mean relative humidity. This is the humidity obtained from a home hygrometer
or a weather forecast.
PRINCIPLE OF COOLING
1.
Why do coolers cool?

We have all experienced the cold feeling when we are sweating and
the wind blows, or when we put a liquid like alcohol on our skin. This
feeling occurs because water and alcohol draw heat from the
surrounding area when evaporating and turning into gas. If we express
this another way, if we apply heat to a liquid it turns into gas. This is
called evaporation latent heat.
In a cooler, freon (R134a) is used instead of alcohol. When the liquid
freon (R134a) turns into gas, it takes latent heat from its surroundings.
However, if it is allowed to disperse as a gas, this is uneconomical. We
need a device which can collect this gas and turn it back into liquid before evaporating it again, and then repeat this cycle
continuously. A cooler is such a device. The fluid which turns into a liquid and then becomes a gas to cool the
surroundings is called the refrigerant.
2.
Refrigerator using evaporation latent heat

The liquid refrigerant freon (R134a) is sent under high pressure
through a valve where it is allowed to expand and is sent to the heat
exchanger. The refrigerant takes heat from the air in the room (or cab)
sucked in by low pressure vapor (moist vapor), turns into gas (super
heated vapor) and is discharged. The air which has lost its heat is
blown into the cooled room. This is the basic principle of the cooler,
but using only this device to cool is uneconomical and not very
practical.
WA500-3LK
10-161 B
AIR CONDITIONER
12
3. Refrigeration method (Vapor compression)
The refrigerant gas is compressed by a compressor (adiabatic
compression) and changes to high temperature and high compression.
It is then sent to the condenser and undergoes forced cooling in the
condenser to be turned to liquid. If this liquefied refrigerant is
expanded suddenly at the expansion valve, it changes into a low
temperature and low pressure mist and flows inside the evaporator.
The refrigerant, which enters the evaporator as a mist, passes through
the fins of the evaporator and takes latent evaporation heat from the
surrounding air. This causes it to evaporate and turn to its original
gaseous condition. In this way it acts to cool the surrounding air.
4.
Refrigerating cycle
The refrigerating cycle of an air conditioner consists of the
compressor, condenser, expansion valve, and evaporator as shown in
the diagram. Refrigerant is circulated in this sealed circuit
(refrigeration cycle), and heat is transferred from the low temperature
source (air inside the operator's compartment) to the high temperature
source (outside air) to give the cooling. This is called the evaporation
compression refrigeration system, the most widely used form of
cooling used for bus coolers, room air conditioners, and small
refrigerators.
A. Flow of refrigerant
i.
The liquid refrigerant which leaves the receiver is expanded suddenly at the expansion valve. It becomes a low
temperature, low pressure mist and flows to the evaporator.
ii.
The refrigerant mist which flows into the evaporator takes heat from the air (air inside the operator's
compartment) at the surface of the evaporator. It evaporates and is further heated, and is then sucked into the
compressor as a gaseous refrigerant.
The air inside the operator's compartment is sucked into the cooling unit by a fan, is cooled on the evaporator
surface, and is then sent out into the operator's compartment again.
iii. The gaseous refrigerant evaporated in the evaporator is sucked into the compressor.
iv. The gaseous refrigerant is compressed in the compressor, and is then sent to the condenser at high temperature
and high pressure.
v.
In the condenser, the gaseous refrigerant is cooled. It becomes a liquid refrigerant again and flows to the receiver.
By repeating the above steps (1) to (5), the heat is taken from the air at the surface of the evaporator, and heat is
dissipated to the air at the surface of the condenser to produce cooling inside the operator's compartment.
Remark
The temperature and pressure of the refrigerant vary according to the air flow and temperature of the front
surface of the condenser.
In this way, the refrigerant circulates during the refrigeration cycle to carry out the refrigeration action.
In refrigerators using the evaporation latent heat of the refrigerant at present used, if the gaseous refrigerant is not
liquefied at near normal temperature, it cannot take evaporation latent heat from the surrounding material to
carry out refrigeration (cooling).
10-162 B
WA500-3LK
AIR CONDITIONER
Generally speaking, for a gas to be liquefied, it must be

pressurized. However, if it is cooled at the same time as being
pressurized, it can be liquefied easily.
For this reason, compressors and condensers are needed in
the present refrigerating systems.
B. Properties of R-134a
Using R-134a as an example, let us explain how the refrigerant
can be liquefied.
High temperature (70 C), high pressure (15 kg/cm2) gaseous
refrigerant is compressed in the compressor. It then enters the
condenser where it is cooled and liquefied.
R-134a starts to liquefy at about 62 C at 15 kg/cm2, so the
temperature of the refrigerant need only be brought below 62 C.
WA500-3LK
10-163 B
AIR CONDITIONER
12
C. Temperature and pressure in the refrigeration cycle
1.
Receiver
4.
Compressor
2.
Evaporator
5.
Blower
3.
Condenser
6.
Expansion valve
In the refrigeration cycle, the refrigerant transforms from a liquid to a gas (evaporation) and from a gas to a liquid
(condensation). Both the temperature and pressure of the refrigerant vary throughout the refrigeration cycle.
The figure above indicates variations of the temperature and pressure in the refrigeration cycle. (The numbers in the
diagram are taken from the design values of a standard air conditioner, and are given only for reference. These values
vary depending on the conditions for the actual cycle).
10-164 B
WA500-3LK
AIR CONDITIONER
12
5. Heating cycle
The heating cycle uses cooling water taken from the engine cooling system.
A. The cooling water absorbs the heat from the engine, and its flow is controlled by the water valve to enter the heater
core.
B. In the heater core, the heat of the cooling water is transferred to the air at the surface of the core.
C. The heat is sent by the blower to the operator's compartment.
D. The cooling water which has given up its heat in the heater core returns to the engine.
By repeating the above steps (A) to (B), the inside of the operator's compartment is heated.
WA500-3LK
10-165 B
AIR CONDITIONER
12
REFRIGERANTS
The refrigerant plays the most important role in the refrigeration cycle. Various kinds of refrigerants are available for various
types of applications. The most critical characteristic of a refrigerant is the ease with it liquefies and vaporizes at normal or low
temperatures. However, only a few kinds of refrigerants are used in air conditioners, depending on various conditions, such as
the type of compressor, evaporation temperature (pressure), and condensation temperature (pressure).
Ammonia and freon type gases, which satisfy the requirements, are widely used. Air conditioners usually use "freon type"
gases because of their safety and the small size required for a refrigeration system.
FREON-TYPE GASES
Components in this system are compatible with Refrigerant 134a (CCL2F2 - Dichlorodifluoromethane). Use of other
refrigerants would not achieve performance characteristics, and more importantly, would, in most cases, chemically
deteriorate components.
SAFETY PRECAUTIONS
WARNING! The refrigerant R-134a can be a fire and health hazard if handled incorrectly. Avoid
contact with the substance and never expose it to extreme heat, sparks or open flame.
WARNING! The substance used in the air conditioning system, called R-134a is basically a safe,
nontoxic refrigerant. However, when it is exposed to an open flame, it changes to a very
highly poisonous and deadly phosgene gas. This phosgene gas will tarnish bright metal
surfaces.
WARNING! The liquid refrigerant will boil (or vaporize at -29.8 C (-21.7 F) at atmospheric pressure
(or when it is exposed to the air). It also evaporates so rapidly that the gas may displace
the oxygen in the area, if it happens to be a small enclosed area. Therefore, whenever
the system is worked on, a safe practice would be to work on it in a well ventilated area.
WARNING! The refrigerant, when exposed to the air, is approximately -29 C (-21 F). Upon contact
with the skin, the effect is just like frostbite. Treat the same as you would for frostbite.
WARNING! If the refrigerant contacts the eyes, immediately flush the eyes with water and continue to
do so until the temperature is above the freezing point. Consult an eye specialist
immediately. Blindness could result from an injury of this sort and it is highly
recommended that safety goggles be worn whenever servicing the system. If the air
conditioning system must be discharged, do it out of doors or in a well ventilated area
where no extreme heat or open flame is present. Release the refrigerant slowly as it will
suck the oil from the compressor if the system is opened too fast.
WARNING! Always use the correct type of hoses for the air conditioning system. Do not use any hose
which is not specified for refrigeration use. Never apply heat of any sort on any of the air
conditioning hoses or components of the system while it is charged. The extra heat could
cause the pressure of the refrigerant in the system to become excessive and cause a
dangerous rupture.
WARNING! Be sure the pressurized refrigerant containers are never exposed to or stored in an area
where the temperature could exceed 52 C (125 F).
WARNING! Do not discard empty refrigerant containers where they might be subjected to a temperature of 52 C (125 F) or higher.
10-166 B
WA500-3LK
AIR CONDITIONER
12
WARNING! Do not add alcohol or other liquid driers to the system to prevent freeze up. The
desiccant in the dryer prefers alcohol to water and will discharge moisture to absorb
alcohol.
WARNING! Refrigerant oil is the exception to the rule that water and oil do not mix. If left in an open
container it will absorb moisture and Refrigerant oil is the exception to the rule that water
and oil do not mix. If left in an open container it will absorb moisture and may cause
freeze-ups at the expansion valve or sludge build up.
REMEMBER:
A. Wear safety goggles.
B. Keep refrigerant away from heat, flame or sparks.
C. Do not smoke or have an open flame near when discharging refrigerant.
D. Work in a well ventilated area.
E. Avoid physical contact with refrigerant.
REFRIGERATOR OIL (LUBE OIL)

The lubricant used in air conditioners is generally called refrigerator oil. Its purpose in the compressor is to minimize wear of
the piston, cylinder walls, and other frictional parts like bearings, and to prevent them from seizing by removing the heat
created by friction. In addition, the substance helps prevent leakage of refrigerant by maintaining a uniform thin oil film on the
contact surface of parts.
Freon type refrigerant dissolves in oil better than ammonia does. When the freon is dissolved in oil, the freezing point of the
oil goes down, which causes no hindrance to the use of the oil at low temperatures. The flash point and the ignition point of the
refrigerant oil are ordinarily 160 C to 170 C and 200 C to 220 C, respectively.
The lube oil for air conditioners will contact refrigerant. Thus, the viscosity of the oil when mixed with refrigerant is an
important factor in the selection of the refrigerant oil. The lube oil used in air conditioners is a mineral oil refined from
petroleum, and various types are available. The refrigerant has a large effect on the durability of the compressor and therefore,
the oil must conform to that specified for each compressor.
Characteristics of SUNISO (SUNISO is a U.S. specification) refrigerator oil:.
1.
Chemical stability
The oil is resistant to chemical reactions with the refrigerant or any other substance in the system.
2.
Thermal stability
No carbon deposits are formed at high temperatures in the valve and delivery (discharge) portion of the compressor.
3.
Low wax content

The flocculent material does not separate from the oil-refrigerant mixture in the low temperature portion of the
refrigeration system.
4.
Low pour point

The oil in the refrigeration system does not freeze because the pour point is lower than the lowest temperature in the
system.
5.
High insulation resistance
WA500-3LK
10-167 B
AIR CONDITIONER
6.
Proper viscosity
Excessive wear of the compressor is prevented because the proper viscosity is maintained even at high temperatures.
Sufficient fluidity of the oil is maintained at low temperatures and a satisfactory oil film is formed at all times.
7.
Cleanliness of oil
No dust, or foreign matter that accelerate the deterioration of oil are mixed in the oil. Thus, the cylinder liners and
bearings will not get flawed and oil grooves will not get clogged.
AIR CONDITONING CONDENSER

FUNCTION
In a refrigeration system, the job of the condenser is to convert the heated,
high pressure gaseous refrigerant compressed in the compressor back into a
liquid refrigerant. Heat at the same time dissipates into the atmosphere. An
auxiliary fan helps force the heat exchange.
GENERAL DESCRIPTION
In the condenser, the quantity of heat to be emitted from the gaseous refrigerant depends on the quantity of heat absorbed from the room air in the
evaporator and the work to be done to compress the gas in the compressor.
Accordingly, the effect of the heat radiation on the cooling effect is so large
that the forced cooling is performed by two special cooling fans, in addition to the cooling fan for the engine radiator. This independent condenser
helps prevent overheating of the engine and does not effect engine performance.
1.
Refrigerant gas inlet port
10-168 B
2.
Fan
3.
Connector
4.
Refrigerant gas outlet port
WA500-3LK
AIR CONDITIONER
12
1. 2-Stage control of condenser fan motor
The electric fan of the condenser is controlled to two speeds by the
pressure of the refrigerant on the pressure side.
If the pressure of the refrigerant on the high pressure side rises above
18 kg/cm2, the pressure switch is turned ON and the fan motor runs at
high speed.
When the pressure of the refrigerant on the high pressure side drops
below 14 kg/cm2, the pressure switch is turned OFF and a resistor
reduces the voltage to make the fan motor run at low speed.
This extends the life of the fan motor, and also avoids the unnecessary
use of electricity.
2.
Pressure switch
This switches ON and OFF according to the pressure of the
refrigerant.
ON:
14 kg/cm2 (199 psi)
OFF: 18 kg/cm2 (266 psi)
Pressure switch (1)
3.
Defrosting device
Frost can build up on the evaporator fins if their temperature drops below freezing. Efficiency will suffer, so a thermistor
has been provided, attached to the evaporator fins, to signal when the fins are too cold. If so, the controller will turn off the
magnetic clutch, stopping the compressor.
WA500-3LK
10-169 B
AIR CONDITIONER
12
4. Magnetic clutch
The compressor pulley incorporates a magnetic clutch to connect and
disconnect from the engine. The clutch engages whenever current is
supplied to its magnet stator coil (air conditioning is switched on). The
drive belt then can power the compressor.
5.
Electric fan motor

This turns the electric fan and carries out the forced cooling of the
condenser.
Fan (1)
Fan motor (2)
10-170 B
WA500-3LK
AIR CONDITIONER
12
AIR
CONDITIONER COMPRESSOR
The compressor is a pump to raise the pressure of the refrigerant. As the
refrigerant pressure increases, so does its temperature, and the high
temperature refrigerant gas then will condense rapidly in the condenser by
releasing heat to the surroundings.
The compressor illustrated here, a swash plate type, operates paired pistons
on the swash plate. Rotation of the shaft and attached swash plate operates
the pistons in their bores. The swash plate and shoes convert rotary motion
of the shaft to reciprocating motion of the pistons.
Intake stroke: When the piston moves to the left, the right side of the piston
draws the refrigerant through the suction valve while the discharge valve is
held closed against the valve plate.
Discharge stroke: When the piston moves to the left, the left side of the piston forces out the refrigerant through the discharge valve while the suction
valve is held closed against the valve plate.
WA500-3LK
10-171 B

12
RECEIVER
AIR CONDITIONER
WITH SIGHT GLASS (LIQUID TANK)
The refrigerant liquefied in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the
evaporator according to the cooling load.
A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and a fusible
plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from inside the
refrigeration cycle.
If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the
expansion valve, and obstruct refrigerant flow.
10-172 B
1.
Body
3.
Drier
2.
Sight glass
4.
Drier
WA500-3LK
AIR CONDITIONER
12
1. Fusible plug
A fusible plug, also called a melt bolt, has a hole through its center
which is filled with special solder that melts at 103 to 110 C. If the
condenser cannot ventilate properly, and thoroughly dissipate the heat,
the special solder in the fusible plug will melt. The refrigerant escapes
to the open air before the pressure in the condenser and receiver can
increase enough to damage them.
When the special solder melts at 103 to 110 C, the pressure of the
refrigerant is approximately 30 kg/cm2.
WA500-3LK
10-173 B

12
AIR
AIR CONDITIONER
CONDITIONER UNIT
OUTLINE
In this all-season-type air conditioner unit, the air is cooled and
dehumidified through the evaporator and reheated to the proper
temperature through the heater for a comfortable cab atmosphere. In hot
weather, only the evaporator operates and in cold weather, mainly the
heater operates. In other seasons, particularly rainy and humid weather, the
heater and evaporator operate to dehumidify and heat the air.
1.
BLOWER SWITCH
Acts as the main switch and is used for controlling the air flow when
cooling or heating.
This switch controls the air flow to three levels:
Low Medium High
If the button is pushed to the OFF position, the air conditioner will
stop.
2.
AIR CONDITIONER SWITCH

Switching when cooling (power for compressor)
When the button is pressed, the switch is turned on and the pilot lamp lights up.
When the button is pressed again, the switch is turned off and the pilot lamp goes out.
If the air conditioner switch is turned on but the blower switch is still off, the air conditioner will not work (the pilot lamp
does not light up).
Turn the air conditioner switch on after turning the blower switch on.
3.
TEMPERATURE CONTROL
These buttons (arrow up or arrow down) control the temperature during cooling or heating.
Move the botton towards (up arrow) the Cool position to lower the temperature; move the lever towards (down arrow) the
WARM position to raise the temperature.
If the air conditioner switch and blower switch are turned on, and the lever is moved to the WARM position, the air
conditioner will give dehumidifying and heating.
4.
AIR SOURCE SELECTOR

This lever switches the source of air during cooling or heating.
FRESH (right - outside air is brought in) This is used for normal cooling and heating. Fresh air from the outside is used in
addition to the air inside the operator's compartment.
RECIRC (left - inside air is recirculated) This is used for quick cooling and heating.
In this position, only the air inside the operator's compartment is used.
10-174 B
WA500-3LK
MONITOR SYSTEMS
12
MONITOR
SYSTEMS
MACHINE MONITOR SYSTEM
OUTLINE
The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the
condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of
the condition of the machine.
The machine monitor system consists of the main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and
power source.
The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine
where an alarm is given), and normal conditions which are always displayed on the instrument panel (pilot lamps, readings for
the gauges, speedometer, and service meter).
There are also various switches built into the monitor panel which function to operate the machine. The main monitor uses the
network wiring to send signals to the controller and functions to display the following information:
Shift indicator: 1st - 4th, N, F, R (F and R are optional).
HOLD
Failure action code, failure code, time elapsed since failure (failure data display mode).
WA500-3LK
10-175 B

12
MAIN
MONITOR SYSTEMS
MONITOR
1.
Check lamp
4D. Shift indicator
5A. Not used
2.
Caution lamp
4E. Speedometer
5B. ECSS switch (option)
3.
Caution items
4F. Shift hold
5C. Working lamp (front) switch
3A. Ground driven steering actuated

(option)
4G. Parking brake
5D. Working lamp (rear) switch
4.
4H. Ground driven steering normal

(option)
5E. Transmission cut-off switch
4A. Turn signal (left)
4I. Not used
5F. Auto shift, manual selector switch
4B. Turn signal (fight)
4J. Failure action code
4C. High Beam
5.
Pilot items
Switches
OUTLINE
The main monitor has a display function for the speedometer and other gauges, and a switching function to control the electric
components and controllers.
There is one CPU (Central Processing Unit) installed internally, and this processes the signals from the sensors and outputs the
display.
A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches.
10-176 B
WA500-3LK
MONITOR SYSTEMS
12
MAIN
MONITOR DISPLAY FUCTION
WA500-3LK
10-177 B

12
MAIN
MONITOR SYSTEMS
MONITOR SWITCH FUNCTION
Item
Function
Display
Actuation
E.C.S.S. function is actuated or

stopped each time switch is
pressed
Lights up
E.C.S.S. function actuated
E.C.S.S.
Goes out
E.C.S.S. function stopped
Front working lamp lights up or

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

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

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

manual mode when switch is
pressed
Lights up
Manual mode
Manual
Goes out
Auto shift mode
10-178 B
WA500-3LK
MONITOR SYSTEMS
12
TROUBLE
DATA DISPLAY MODE
Item
Switch operation
Actuation
Method of switching to
trouble data display mode
With engine stopped and starting switch turned ON,

press 2nd switch from top on left side of main monitor
(switch below ground driven steering display) and
work lamp (front switch simultaneously for at least 5
seconds
All switch displays (LEDs) go out, and failure

code is displayed on speedometer display and
time elapsed since failure is displayed on failure action code display.
1. Failure code is two-digit display given in
numbers or letters. The display for the failure now occurring flashes and the display
for past failures lights up.
2. The time elapsed since failure is displayed as
a three-digit number to show how long ago
the failure occurred (the oldest failure time
is displayed. Any time greater than 999H is
displayed as 999H).
3. A maximum of 9 times are stored in memory
for the failure codes.
Method of sending failure

code
Press working lamp (front) switch
Failure code and time elapsed since failure

change to next item.
Clearing failure code
Press working lamp (rear) switch for at least 2 seconds
Failure code and time lapsed since failure

being displayed are cleared.
Failure code for problem now occurring
(flashing display cannot be cleared.
Resetting from travel data

display mode
Press 2nd switch from top on left side of main monitor

(switch below ground driven steering display) and
front working lamp switch simultaneously for at least
5 seconds, or start the engine.
Changes to normal display
WA500-3LK
10-179 B

12
MAINTENANCE
MONITOR SYSTEMS
MONITOR
OUTLINE
The maintenance monitor has a display function for the caution items and gauges, and switch functions to control the work
equipment controller.
The maintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms.
The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the
display and output.
A liquid crystal display and LEDs are used for the display portions. The switches are embossed sheet switches.
10-180 B
WA500-3LK
MONITOR SYSTEMS
12
MAINTENANCE
MONITOR DISPLAY FUNCTION
WA500-3LK
10-181 B

12
MAINTENANCE
MONITOR SYSTEMS
MONITOR SWITCH FUNCTION
Item
Function
Remote boom
positioner
LOWER
position setting
Sets stopping position in LOWER

direction for remote boom positioner
(boom position when switch is pressed is
recorded)
Flashes (2.5 sec)
Remote boom
positioner RAISE
position setting
Sets stopping position in RAISE direction

for remote boom positioner (boom
position when switch is pressed is
recorded)
Flashes (2.5 sec)
Selection of remote
boom
positioner
RAISE/LOWER
10-182 B
Sets remote boom positioner in stopping

direction (Switches function each time
switch is pressed)
Display
Goes out
Actuation
Sets stopping position
--Sets stopping position
Goes out
---
Goes out
Remote boom positioner function

Off
RAISE lights up
Remote boom positioner RAISE

stop function ON
LOWER lights up
Remote boom positioner LOWER

stop function ON
RAISE, LOWER light up
Remote boom positioner RAISE/

LOWER stop function ON
WA500-3LK
STRUCTURE AND FUNCTIONALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANS12

ALL-RANGE
ELECTRONIC CONTROL AUTOMATIC
TRANSMISSION SYSTEM
OUTLINE OF SYSTEM
The all-range electronic control automatic transmission system consist of the transmission controller, directional and speed
levers, engine speed sensor, speed sensor, and all-speed-range ECMV (transmission clutch modulation valve).
The transmission controller controls the shifting to the appropriate speed range according to the lever position and travel speed
signal.
To reduce shock when shifting gear (engaging the clutch), all-speed-range ECMV carries out modulation control.
A ECSS function and joystick steering control function are available as options, and these controls are possible if the function
is installed to the machine.
To improve durability, there is a safety function which prevents the machine from moving suddenly when the engine is started,
and a transmission protection function which protects the clutch when the direction of travel is changed.
The self-diagnostic function always observes the input and output condition, and displays the output condition on the two
7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality
occurs, it displays a failure code. Depending on the condition, it also displays a failure action code on the main monitor and
flashes the caution lamp to improve safety.
The transmission controller has a communications function, and it sends the speed range (N, 1st-4th) data to the main monitor,
which displays the speed range. (If the joystick mode is used, it also displays F and R.)
WA500-3LK
10-183 B

SYSTEM
10-184 B
STRUCTURE DIAGRAM
WA500-3LK

FUNCTION
1.
Auto-shift function.
Shifting the transmission up or down is carried out when the engine speed is above 1450 rpm. Shifting is decided by signals from the directional lever, speed lever, and travel speed sensor according to (Table 1 Automatic gear shift change
point table) recorded in the memory of the transmission controller.
A. Speed lever (1st - 4th).
This controls the maximum speed range (available speed range) for automatic gear shifting.
Example:
Speed lever at 4th: 2nd - 4th
Speed lever at 2nd: 2nd only
B. Directional lever N position.
To prevent the vehicle from moving accidentally, when the lever is at neutral position, only the 2nd clutch is engaged.
C. Directional lever F position.
When the directional lever is operated from N to F, the transmission turns ON the F and 2nd ECMVs (F2).
(Automatic start in 2nd)
i.
Shift up (when speed lever is at 4th) When the accelerator pedal is depressed to increase the engine speed and the
travel speed rises, when the travel speed reaches approximately 9.3 km/h, the ECMV 3rd is turned ON, and at the
same time, 2nd is turned OFF. (Shifting to F3)
When the travel speed rises further to approximately 17.6 km/h, the ECMV 4th is turned ON, and at the same
time, 3rd is turned OFF. (Shift to F4)
ii.
Shift down (speed lever at 4th)

When traveling in 4th, if the accelerator pedal is let back, and the travel speed comes down to approximately 15.6
km/h, the ECMV 3rd is turned ON, and 4th is turned OFF. (Shift to F3)
When the travel speed goes down to approximately 9.8 km/h, the ECMV 2nd is turned ON, and 3rd is turned
OFF. (Switches to F2)
D. Directional lever R position

Automatic gear shifting is carried out according to the travel speed between 2nd and 4th speeds (when the speed lever
is at 4th) in the same way as when the speed lever is at the F position.
E. Skip shift
When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accelerator pedal depressed, if the travel
speed is less than 8 km/h, the gear shifts down to 2nd to make it easier to accelerate. If the travel speed is more than 8
km/h, the speed range is maintained, and when the engine speed goes above 1450 rpm, the gear is shifted to a range
that matches the travel speed.
F.
2.
Gear shift prevention interval.

To prevent shift hunting after shifting gear, a time interval is set to maintain the speed range. The gear shift
prevention interval differs according to the shift pattern. For details, see [Table 1 Automatic gear shift change point
table].
Modulation control.
The modulation control acts to reduce the shock when shifting gear (when engaging the clutch). It uses the data for the
engine speed, transmission oil temperature, and gear shift pattern to control the clutch oil pressure (including the characteristics when starting) to match the condition of the hydraulic circuit to control all speed ranges to the optimum according
to the data in the transmission modulation table stored in the transmission controller memory. In addition, to reduce the
torque cut, it carries out modulation control of the ECMV at the side which switches OFF also.
The transmission modulation data table is set for each transmission oil temperature. In addition, it has a learning function
(transmission clutch piston data) to prevent any abnormal time lag when shifting gear.
WA500-3LK
10-185 B
STRUCTURE AND FUNCTIONALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANS3.
HOLD function.
When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes
down, the transmission does not shift down. However, when switching between forward and reverse, the transmission
normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the
travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling ground, or when
traveling downhill.)
4.
Kickdown function.
When operator turns the kick down switch ON, it overrides the auto shift and switches down forcibly to 1st if the
conditions (speed range, travel speed) in [Table 1 Automatic gear shift change point table, 5. Kickdown] are fulfilled.
5.
Travel mode.
A. Manual mode (option).
It is possible to switch between auto and manual shift. When using the manual mode, the gear is shifted according to
the operation of the speed lever. When traveling in F2, it is also possible to use the kick down function.
B. Joystick steering control function (option).
i.
If the machine is equipped with the joystick steering function, the operator can switch between steering wheel
and joystick steering mode as desired.
ii.
The transmission controller controls the signals from the travel system. (The steering system is controlled by the
work equipment controller.)
iii. When switching the steering between steering wheel and joystick steering, always stop the machine first, return
the speed lever to the N position, then switch the steering. When this is done, the transmission controller is set to
the neutral safety condition to prevent the machine from suddenly moving.
6.
Safety function.
A. Neutral safety.
When the engine is started, if the directional lever is at any position other than N, the transmission controller keeps
the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started,
the neutral safety is canceled.
B. Speed lever priority.
It is possible to shift down immediately by operating the speed lever, so the engine can be used as a brake when
traveling downhill.
C. Transmission protection.
When traveling in 3rd or 4th speed, the travel speed is controlled and a warning buzzer sounds to protect the
transmission when shifting between forward and reverse.
i.
Speed range control.

When the speed range control and travel speed fulfill the conditions for range I, the transmission shifts down to
2nd.When the speed range control and travel speed fulfill the conditions for range II, the speed range is
maintained and the transmission shifts down to 2nd according to the deceleration. (For details, see Fig. 1 F-R
selection gear shift pattern, table 1 Automatic gear shift change point table, 7. F-R selection.)
ii.
Alarm buzzer.
When the speed range control and travel fulfill the conditions for range III, the alarm buzzer sounds to warn the
operator. (If the engine speed is above 1700 rpm and the travel speed is above 13 km/h, or the travel speed is
above 14 km/h). (See Fig. 2 F-R selection alarm buzzer range.)
10-186 B
WA500-3LK
STRUCTURE AND FUNCTIONALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSD. Manual shift.

If the travel speed sensor is abnormal and it is impossible to detect the travel speed data, the transmission is set to
manual (shift) mode.
Table 1: Automatic gear shift change point table.
Item
Speed
range
Travel speed
(Km/h)
Gear shift
prevention interval
12
5.1 (5.3) or above
23
8.7 (9.2) or above
34
16.5 or above
43
Less than 14.5
32
Less than 9.2 (8.7)
2. Engine speed.
(less than 1450 rpm)
4 2
Less than 1.0
32
Less than 1.0
3. Engine speed.
(less than 1450 rpm
more than 1450 rpm)
42
Less than 8.0
32
Less than 8.0
4. Shift when HOLD is ON.
12
5.1
23
8.7
34
16.5
21
Whole range
31
Less than 12.0
41
Less than 12.0
6. FR selection (range I)
(F ) N _ R
(R ) N F
42
32
12
(Remark 1)
7. FR selection (range II)

(F ) N R
(R ) N F
4
3
(Remark 2)
16.5 or above
Less than 14.5 - 16.5
8. FR selection
(F ) N R
(R ) N F
4
3
2
16.5 or above
Less than 8.7 - 16.5
Less than 8.7
1. Basic shift change.
5. Shift down when kick down

is ON.
Remark 1
When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel
speed is less than 13 km/h.
Remark 2
When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed
is 16 km/h or above, the speed range maintained and the transmission shifts down to 2nd according to
deceleration.
WA500-3LK
10-187 B
7.
Self-diagnostic function
The transmission controller always observes the input and output signals of the automatic gear shifting system. It carries
out self diagnosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following
data to the main monitor.
A. Normal display:
Transmission controller LEDs display output range.
B. Failure code display:
If an abnormality is detected, the nature of the failure is displayed as a code. For details of failure code, see Table 2
Failure code table.
10-188 B
WA500-3LK

Table 2: Failure code table.
Code
Item
System
Main Monitor
Short Circuit
Disconnection
Action Code
10
Back-up alarm relay
None
11
None
---
---
---
12
F ECMV solenoid
Call
13
R ECMV solenoid
Call
14
1st ECMV solenoid
Call
15
2nd ECMV solenoid
Call
16
3rd ECMV solenoid
Call
17
4th ECMV solenoid
Call
18
None
---
---
---
19
Joystick direction switch
E00
20
Directional switch signal
Call
21
Range switch signal
None
22
Travel speed sensor
E00
23
Engine speed sensor
E00
24
Abnormality in memory (EEPROM)
---
---
None
25
Transmission oil temperature sensor
E01
26
F ECMV fill switch
Call
27
R ECMV fill switch
Call
28
1st ECMV fill switch
Call
29
2nd ECMV fill switch
Call
30
3rd ECMV fill switch
Call
31
4th ECMV fill switch
Call
32
F or R ECMV fill switch
E00
33
1st, 2nd, 3rd, or 4th ECMV fill switch
E00
WA500-3LK
10-189 B

8. Communications function
The transmission controller is equipped with a communications function using S-NET. It always maintains
communications with the main monitor, and when the engine is started, it receives model, ECSS availability, and tire
compensation data.
When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to
warn the operator in order to increase safety.
The failure code can recognize the codes recorded in the main monitor memory using the main monitor problem history
mode. For details of operating the main monitor, see the section on the main monitor.
9.
ECSS (option)
If the machine is equipped with a ECSS function, the operator can use this function by operating a switch.
When the engine is started, the availability of the ECSS function is transmitted from the main monitor, and the
troubleshooting function can also be actuated for the ECSS system.
TRANSMISSION CONTROLLER POWER SOURCE

When the starting switch is turned ON and the supply voltage is more than 20V, and +20V or more is supplied to the
transmission controller solenoid power source input, it is possible to drive each solenoid valve.
If the supply voltage is less than 19V, all outputs are turned OFF and the solenoids cannot carry out control (travel is
impossible).
INPUT SIGNALS
1.
Directional lever (F,N,R) signal

This signal is a +24V/OPEN digital signal, and when it is normal, one of F, N, or R signals (+24V) is input.
2.
Speed lever (1st - 4th) signal

This signal is a +24V/OPEN digital signal and +24V is input for the signal for the lever position.
3.
Kickdown switch
This signal is a +24V/OPEN digital signal and +24V is input when the kick down switch on the work equipment control
lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. 4.
4.
FORWARD switch
This signal is a +24V/OPEN digital signal and +24V is input when the HOLD switch on the work equipment control lever
is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point.
5.
Neutralizer relay signal

This signal is a +24V/OPEN digital signal and +24V is input when the parking brake switch is pressed.
When signal is OPEN, the transmission controller maintains the neutral condition.
6.
Transmission cut-off signal

This signal is a GND/OPEN digital signal, and when the transmission cut-off switch is operated (using the left brake), it
changes to GND. When it is actuated, the transmission controller changes to the neutral output condition, and when it is
restored, it sets to a suitable speed range for the travel speed at that point.
7.
Manual mode signal

This signal is a GND/OPEN digital signal, and when the manual mode switch is ON, GND is input.
10-190 B
WA500-3LK
STRUCTURE AND FUNCTIONALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANS8.
Fill switch (F, R, 1st - 4th signals)

This signal is a GND/OPEN digital signal, and is installed to each ECMV. The switch is operated by oil pressure.
When the ECMV is on, GND is input.
9.
Engine selection signal

This signal is a GND/OPEN digital signal, and when the engine is started, the type of engine mounted is judged from this
signal. (The speed conversion data is different.)
Table 3 Engine selection signal table

Input signal
Engine
Speed conversion data
GND
Komatsu
10. Memory clear signal

This signal is a GND/OPEN digital signal. It is normally OPEN. When clearing the memory, start the engine, then input
OPEN GND OPEN signals.
11. Engine speed sensor signal
This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for
control. When the engine speed is 1450 rpm or above, it is called the engine speed ON mode, and when the speed is less
than 1450 rpm, it is called the engine speed OFF mode.
Komatsu engine: Speed P (rpm) = Input frequency (Hz) x 60/6
12. Travel speed sensor signal
This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for
control.
To convert to the travel speed, the tire compensation data (communications data from the main monitor) are added. In
addition, the acceleration is also calculated to judge the travel speed for gear shifting.
Speed P (rpm) = Input frequency (Hz) x 60/ 59
Travel speed V (km/h) = Speed P (rpm)/ (101.6 x tire compensation value k) or Travel speed V (km/h) = Input
frequency (Hz)/(99.9 x tire compensation value k)
13. Transmission oil temperature sensor signal
This signal is an analog signal and converts 0 - 5 V inside the controller to temperature. This is used for selecting the modulation table when shifting gear.
14. Communications signal (S-NET)
This receives the following data set in the main monitor and is used for control.
A. Model selection
It selects the automatic gear shift change point data table for each model to use for shifting gear.
B. Tire compensation data
This adds the compensation value (covering a range from 0.86 to 1.14) to the speed data from the travel speed sensor
to obtain an accurate travel speed.
C. ECSS function selection This is a function selection signal and judges if the ECSS function exists. It controls the
ECSS system, including troubleshooting.
WA500-3LK
10-191 B

OUTPUT
SIGNALS
1. Transmission modulation valve (ECMV command current)

This signal is an electrical output (0 - 1A). There are six types of ECMV: R and F for direction, and 1st, 2nd, 3rd, and 4th for
each speed range. This valve is a pressure control valve and converts to a pressure matching the value of the current flowing to
the solenoid. Therefore, it controls the oil pressure for the clutch selected for each speed range and controls the engagement of
each independent clutch. In addition, only the 2nd clutch is actuated when the transmission is at neutral.
Table 4:
Combination of speed ranges and ECMV
ECMV/
Speed range
F1
F2
F3
F4
1st
2nd
3rd
4th
O
O
O
O
N
R1
R2
R3
R4
O
O
O
O
O = ON
2.
Backup lamp relay signal

This signal is a +24V digital (ON/OFF) output. It is actuated when the directional lever is placed at R and lights up the
backup lamp and caution lamp.
3.
F1 (cut-off) signal
This signal is a +24V digital (ON/OFF) output. This signal is output when the kick down is operated and sets the machine
to Fl.
4.
Engine speed signal

This outputs a signal at the same cycle as the engine speed sensor signal input to the transmission controller.
5.
Communications signal (main monitor display data)

For details of the display position and operation of the main monitor, see the section on the main monitor.
A. Speed range
1st speed range output:
2nd speed range output:
3rd speed range output:
4th speed range output:
Neutral:
[1]
[2]
[3]
[4]
[N]
B. F / R display
F / R are displayed in the joystick steering mode (option).
C. HOLD display
The pilot display is given on the main monitor when the HOLD function is ON.
10-192 B
WA500-3LK

LED
DISPLAY
When the engine is started, the display goes first to 1. Program quality display mode, and next to 2. Output speed range
display mode. However, if any abnormality is detected, it goes immediately to the troubleshooting mode.
1.
Program quality display mode.

When the power source is on, it switches once every second.
2.
Output speed range display mode.

LED display X. Y. (Both dots are out)
X: Direction ECMV drive condition FORWARD [F]: F, REVERSE [R]: A, Neutral: O
Y: Speed range ECMV drive condition 1 - 4.
3.
Troubleshooting display mode (currently existing failure)

A cycle of [E-(2 sec)], [Code (2 sec)] is repeated.
A. When there is one abnormal item.
WA500-3LK
10-193 B

B. When there are two abnormal items.
10-194 B
WA500-3LK
JOYSTICK TRANSMISSION SYSTEM
12
JOYSTICK
TRANSMISSION SYSTEM
1.
Combination of steering, transmission control functions

O: Function is employed
Steering wheel
Boom lever switch
Automatic
Joystick
Manual
Automatic
Manual
---
Kick-down function
Hold function
---
Up/down function
---
---
---
CN C5-5 input signal
Kick-down
Kick-down
Kick-down
Shift down
CN C5-13 input signal
Hold
Hold
Shift up
2.
Controller input signals

Common signal input for kick-down/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.
3.
Up/down shift switch function

Shift up switch: Normal shift up is output by signal input
Shift down switch: Normal shift down is output by signal input
Judgement of the input of the switch uses the change in the ON/OFF condition of the signal.
(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.
4.
Range lever position
Speed range used
4
3
2
1
4-1
3-1
2, 1
1
Main monitor display
WA500-3LK
10-195 B
STRUCTURE AND FUNCTION REMOTE POSITION, JOYSTICK STEERING CONTROLLER

12
REMOTE POSITION, JOYSTICK STEERING CONTROLLER
CONNECTOR SIGNALS
CN1
CN2
CN3
1 NETWARK signal
---
2 ---
Remote positioner upper set switch 2 ---
1 ---
3 ---
Remote positioner lower set switch 3 ---
4 ---
Positioner selector switch
4 Engine speed signal (+)
5 Dumping sol (+)
Boom RAISE pressure switch
5 ---
6 Steering left sol (+)
Boom LOWER pressure switch
6 Remote positioner upper stop LED
7 Steering right sol (+)
Engine selection
7 Remote positioner lower set LED
8 Power source input 24 V
Boom lever detent switch
8 Steering sol cut relay
9 GND
Signal GND output
10 Remote positioner upper set display
10 Potentiometer power source +5 V
9 --10 ---
11 ---
11 ---
11 ---
12 NETWORK signal
12 ---
12 Engine speed signal (-)
13 Sensor power source (+24 V)
13 ---
13 ---
14 ---
14 Joystick selection
14 Remote positioner lower stop display
15 Dumping sol (-)
15 ---
15 Caution buzzer output
16 Steering left/right sol (-)
16 Joystick function selection
16 Buzzer output
17 Sol power source input (+24 V)
17 Joystick neutral switch
18 Power source input +24 V
18
19 GND
19 Boom angle potentiometer
20 Boom lever kick-out
20 Joystick lever potentiometer
Remote positioner function

selection (N/A)
21 Steering N interlock relay
10-196 B
WA500-3LK
ECSS SYSTEM
12
ECSS
SYSTEM
1.
Main monitor
6.
2.
ECSS switch
3.
7.
Charge control solenoid valve (Sol 2)
6A. Main spool
8.
Accumulator
Combination switch
6B. Solenoid valve (Sol 1)
9.
Work equipment control valve
4.
Controller
6C. Charge valve
10. Boom cylinder
5.
Travel speed sensor
6D. Shut-off valve (for manual pressure

release)
1.
ECSS valve assembly
Electronically Controlled Suspension System (ECSS)

Accumulators charged with high pressure gas in this system is turned ON and OFF automatically by the controller according to the travel condition of the machine to give vertical elasticity to the work equipment. With this system, rolling of the
machine body is reduced during high speed travel to improve the operator comfort and prevent spill of the load. As a
result, the working efficiency is heightened.
WA500-3LK
10-197 B
ECSS SYSTEM
12
2. System
ECSS consists of the following electronic devices.
A. ECSS controller (Transmission ECSS controller)

B. Input devices: ECSS switch (System switch), Travel speed sensor,
speed range signal switch.
C. Output devices: Solenoid valve (Accumulator) 1, Charge control
solenoid valve 2.
ECSS is turned on and off with the ECSS switch on the main monitor.
If this system (switch) is turned ON, the ECSS LED on the main
monitor lights up
ECSS circuit
OPERATION
If the ECSS switch is turned on, the solenoid valve (Sol 1) is excited and the valve is changed, then the main spool is pushed
and the circuits between the lift cylinder bottom and accumulator and between the lift cylinder head and tank are connected.
A. Operating condition
This system operates when the speed range is 2nd through 4th and the travel speed is 5 km/h or higher.
B. Stopping of operation
When the travel speed is lowered to 3 km/h or the transmission is shifted into 1st or the ECSS switch is turned off, the
main spool is returned by the spring, and the circuits between the lift cylinder bottom and accumulator and between
the lift cylinder head and tank are disconnected.
C. Accumulator charge circuit

The accumulator charge circuit of ECSS prevents the boom from falling.
D. Charging of accumulator
The accumulator is charged by utilizing the oil pressure in the between the pump and work equipment valve when the
lift arm or bucket is operated. The charge pressure of the accumulators is 75 kgf/cm2 (1066.7 lbf/in2), which is
regulated with the charge valve in the ECSS valve.
E. No charging of accumulator
While ECSS is working, the accumulator cannot be charged since the charge control solenoid valve (Sol 2) is turned
off. The reason for this setting is to prevent the lift arm from rising when the accumulator is charged while the bucket
is operated.
10-198 B
WA500-3LK
ECSS SYSTEM
12
3. Contents of control
The controller receives the inputs in the left columns of the following table and gives the outputs in the right columns to
control the system.
O: ON
X: OFF
Inputs
Outputs
ECSS switch
(to turn on/off system)
Speed range
Travel speed
(Remark 1)
Solenoid 1
(Accumulator)
Solenoid 2
(Charge control)
OFF
All ranges
---
2nd or higher
Min. 5 km/h
---
---
---
---
---
2nd or higher
Max. 5 km/h
Remark 2
ON
4
5
Remark 1
ECSS is turned on and off with the ECSS switch on the main monitor. If this system is turned ON, the red
ECSS LED on the main monitor lights up.
The ON-OFF condition of the system is kept even after the engine is stopped and the starter switch is
turned OFF. When the starter switch is turned on the next time, the system is set in the previous condition.
Main monitor function
Starter switch OFF machine stops starter switch ON
(When system is turned ON system ON)
(When system is turned OFF system OFF)
Remark 2
When the output is turned off, and if the travel speed exceeds 5 km/h, the output is turned on.
When the output is turned on, it is kept turned on until the travel speed lowers to 3 km/h.
WA500-3LK
10-199 B
ECSS SYSTEM
12
4. Self diagnosis function
This system always observes the condition of the system and displays the condition of the system (see LED code in the
table below) of the controller self diagnostic display.
If any abnormality occurs in either the controller itself or in the input or output devices, the controller diagnoses this, turns
all outputs OFF and displays the error code (failure code) on the self diagnostic display and main monitor.
LED Code
LED display
Error code
d0
Content
System condition
Abnormality in solenoid 1, 2 (relief) system
Abnormality
A. Display on controller
See the section on the transmission controller (controller LED).
B. Display on main monitor
See the section on the trouble data display on the main monitor.
5.
Controller
The new ECSS controller is included inside the transmission controller.
10-200 B
WA500-3LK
ECSS SYSTEM
12
MEMORANDUM
WA500-3LK
10-201 B
TRANSMISSION CONTROLLER
12
10-202 B
WA500-3LK
12
CONNECTOR
SIGNALS
CNC1
CNC4
CNC3A
Joystick N output
NC
NC
Buzzer signal
NC
Engine speed
Relief solenoid
NC
NC
Engine speed output
NC
NC
Low pressure solenoid
NC
NC
GND
Pressure sensor power supply (+24v)
NC
Power supply (+24 V)
Potentio power supply
NC
F1 output
NC
NC
Damper solenoid 5
NC
GND (for rotate sensor)
10
High pressure solenoid
10
ENC select
10
NC
11
Back lamp relay
11
T/M oil temp. Sensor
11
Network (-)
12
GND
12
NC
12
Network (-)
13
Power supply (+24 V)
13
NC
CNC2
14
NC
GND (for plus)
Sol. power supply (+24V)
15
NC
Speed
ECMV 3 (+)
16
GND (for pressure sensor)
GND
NC
17
GND (for potentio)
GND
ECMV 4 (+)
18
NC
Kick down SW
NC
19
Joystick ON/OFF SW
T/M cut-off SW
NC
20
Pressure SW
Joystick N (NC)
ECMV F (+)
Joystick F (NC)
ECMV R (+)
Pressure SW B
Joystick R (NC)
ECMV 1 (+)
Fill SW F
10
GND (for plus)
10
ECMV 2 (+)
Fill SW 1
11
Fill SW 3
11
P GND
NC
12
Fill SW 4
12
Sol. power supply (+24V)
Direction F
13
Hold SW
13
ECMV 3 (-)
Direction R
14
Manual SW
14
NC
Range SW 1
15
Joystick N (NO)
15
ECMV 4 (-)
Range SW 3
16
Joystick F (NO)
16
NC
Damper SW
17
Joystick R (NO)
17
ECMV F (-)
10
Fill SW R
18
ECMV R (-)
11
Fill SW 2
19
ECMV 1 (-)
12
NC
20
ECMV 2 (-)
13
Direction N
21
P GND
14
Neutralizer relay
15
Range SW 2
16
Range SW 4
WA500-3LK
CNC5
CNC3B
10-203 B
SENSORS
12
SENSORS
FUNCTION
The sensors are a contact type sensor with one end grounded to the chassis. The signal from the sensor is input directly to the
monitor panel, and when the contacts are closed, the panel judges the signal to be normal. However, the engine oil pressure
uses a relay to reverse the sensor signal.
Sensor detection item
Sensor method
When normal
When abnormal
Speedometer sensor
Electromagnetic
Engine oil level
Contact
ON
OFF
Radiator water level
Contact
ON
OFF
Engine oil pressure
Contact
OFF
ON
Engine water temperature
Resistance
---
---
Torque converter oil temperature
Resistance
---
---
Engine speed sensor
Electromagnetic
---
---
Fuel level sensor
Resistance
---
---
SPEEDOMETER SENSOR
FUNCTION
The speedometer sensor is installed to the transmission output gear. A pulse voltage is generated by the rotation of the gear
teeth, and signal is sent to the machine monitor to display the travel speed.
1.
Connector
10-204 B
2.
Magnet
3.
Case
WA500-3LK
SENSORS
12
ENGINE
SPEED SENSOR
FUNCTION
The engine speed sensor is installed to the ring gear portion of the flywheel housing. A pulse voltage is generated by the
rotation of the gear teeth, and a signal is sent to the controller and monitor panel.
1.
Magnet
3.
Case
2.
Terminal
4.
Boot
5.
Connector
ENGINE OIL PRESSURE SENSOR

FUNCTION
This sensor is installed to the engine block and the diaphragm detects the oil pressure. If the pressure goes below the specified
pressure, the switch is turned ON, and a relay is actuated to turn the output OFF. This makes the maintenance monitor flash to
warn of the abnormality. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.
1.
Plug
3.
Contact
5.
Spring
2.
Contact ring
4.
Diaphragm
6.
Terminal
WA500-3LK
10-205 B

12
RADIATOR
SENSORS
WATER LEVEL SENSOR
FUNCTION
The sensor is installed to the top of the radiator. If the coolant goes below the specified level, the float goes down and the
switch is turned OFF. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.
1.
Float
2.
Sensor
3.
Connector
ENGINE OIL LEVEL SENSOR

FUNCTION
This sensor is installed to the side face of the oil pan. When the oil goes below the specified level, the float goes down and the
switch is turned OFF. This makes the maintenance monitor flash, and the check lamp to also light up at the same time to warn
of the abnormality.
10-206 B
1.
Connector
3.
Float
2.
Bracket
4.
Switch
WA500-3LK
SENSORS
12
FUEL
LEVEL SENSOR
FUNCTION
The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down as the level of the fuel changes.
As the float moves up and down, the arm actuates a variable resistance, and this sends a signal to the maintenance monitor to
display the fuel level. When the display the maintenance monitor reaches the specified level, the warning lamp flashes.
1.
Connector
4.
Body
2.
Float
5.
Spring
3.
Arm
6.
Contact
WA500-3LK
7.
Spacer
10-207 B

12
ENGINE
SENSORS
WATER TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR

FUNCTION
These sensors are installed to the engine cylinder block and transmission case. The change in the temperature changes the
resistance of the thermistor, and a signal is sent to the maintenance monitor to display the temperature. If the display on the
maintenance monitor reaches the specified position, the lamp flashes and the buzzer sounds to warn of the abnormality.
1.
Connector
10-208 B
2.
Plug
3.
Thermistor
WA500-3LK
ELECTRICAL
12
ELECTRICAL
ENGINE STARTING CIRCUIT
FUNCTION
The neutral safety circuit is employed so that the engine will be started safely, that is, the engine cannot start when the
forward-reverse lever is not in the N (Neutral) position.
OPERATION
If the forward-reverse lever is set in the N (Neutral) position, the neutral contacts of the forward-reverse lever are
"closed". If the starting switch is turned to the ON position, the neutral relay operates to "close" terminals 3 - 5. Then the
current flows from starting switch terminal BR through the battery relay coil to the ground to "close" the battery relay
switch. If the starting switch is turned to the START position, the current flows circuit B from the positive terminal of
the battery through starting switch terminal B, starting switch terminal C, neutral relay terminals 5 - 3, starting motor
terminal C, and starting motor terminal E to the ground.
The current flowing from starting switch terminal B to terminal C also flows as a starting motor signal to the engine
controller, which calculates the water temperature signal and other signals and sends the signals to the fuel supply pump
and injector to adjust the fuel injection rate properly.
The circuit from the battery through battery relay to starting motor terminal B is formed to start the engine. If the
forward-reverse lever is not in the N (Neutral) position, circuit B is not formed and the engine does not start.
WA500-3LK
10-209 B

12
ENGINE
ELECTRICAL
STOP CIRCUIT
FUNCTION
With the electric fuel injection rate controller, the operator can stop the engine by turning the starting switch from the ON
position to the OFF position. As a result, the controllability and operating performance are heightened.
OPERATION
If the starting switch is turned to the OFF position, starting switch terminals B and BR, and C and ACC are "opened"
respectively. At this time, the current to the engine controller is cut out and supply of the fuel is stopped to stop the engine.
10-210 B
WA500-3LK
ELECTRICAL
12
PREHEATING
CIRCUIT
AUTOMATIC PREHEATING SYSTEM
OUTLINE
The automatic preheating system is installed so that the engine will start easily in a cold district. This system shortens the
preheating time and sets the preheating time automatically according to the engine coolant temperature when then starting
switch is operated.
If the starting switch is turned to the ON position, a current flows in the ribbon heater to preheat the sucked air. The engine
controller determines the preheating time according to the coolant temperature measured by the engine coolant
temperature sensor.
During preheating, the preheating pilot lamp of the main monitor keeps lighting up. When preheating is finished, the
preheating pilot lamp goes off.
WA500-3LK
10-211 B
ELECTRICAL
12
OPERATION
If the starting switch is turned to the ON position, the heater relay operates to "close" the contacts according to the signal
from the engine controller.
The current flows from the battery through the battery relay and heater relay to the ribbon heater to preheat the sucked air.
When preheating is finished, the current from the engine controller to the heater relay is cut out and the heater relay
contacts are "opened".
During preheating, the current flows from starting switch terminal BR through preheating relay terminals 1 and 2 to the
engine controller to turn on the preheating relay coil and preheating pilot lamp of the main monitor. When preheating is
finished, the preheating relay is turned off and the preheating pilot lamp goes off.
10-212 B
WA500-3LK
ELECTRICAL
12
ELECTRICAL
TRANSMISSION CONTROL
1.
Transmission cut-off selector switch
6.
Maintenance monitor
11. Speed sensor
2.
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
Selection of F, R, and N positions
Using directional lever
Selection of speed range
Using speed lever
Kick-down switch
When traveling in F2, it is possible to shift down to 1st using this switch without using the speed lever. If direc-
Transmission cut-off function
Transmission cut-off selector function
tional lever is operated to R or N, speed range automatically returned to 2nd.

Transmission is shifted to neutral when left brake is operated
It is possible to select whether to actuate or not actuate the transmission cut-off function. In this way, it is possible
to obtain the same or greater ease of operation as on conventional loaders with the left brake when carrying out
scooping work or when loading or unloading the machine from a trailer.
6
Neutralizer
Neutral safety function
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.)
Warning function
WA500-3LK
When traveling in reverse, the backup lamp lights up and the backup horn sounds to warn people in the area.
10-213 B
ELECTRICAL
COMBINATION SWITCH
OUTLINE
The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does
not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is
secured to the body by three screws.
When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric
current to flow to that circuit only.
General locations, function
Directional lever switch
Switches between F, R, and N
Speed lever switch
Selects speed range
Speed lever stopper
Stopper used to prevent speed lever from entering 3rd or 4th during operations
Turn signal indicators
Direction indicator lamps used when turning left or right
Self cancel
Turn signal indicator lever automatically returns to central position after machines turns left
or right
Lamp switch
Switches on clearance lamp, head lamp, parking lamp, etc.
Dimmer switch
Selects high beam for travel and low beam for passing
Hazard switch
Makes both left and right turn signal indicator lamps flash at the same time
Emergency flashing pilot lamp
Flashes at the same time as the emergency flashing lamp flashes
Applies or releases parking brake
10
10-214 B
WA500-3LK
ELECTRICAL
12
OPERATION
Directional lever (1) and shaft (2) of the speed lever of the combination
switch form one unit with magnet (3), and magnet (3) also moves together
with lever (1).
Control switch (5) with built-in hole IC (4) is installed at the bottom of
magnet (3), and hole IC (4) is positioned on the board to match each position.
When directional lever (1) is operated to the F position, magnet (3) is
immediately above hole IC (4) for the F position of the control switch. The
magnetism from magnet (3) passes through the gap and case (6), and
magnetism is applied to hole IC (4).
When this happens, hole IC (4) is inside a magnetism detection circuit, so it
detects the magnetism of magnet (3) and sends the F position signal to the
electric current amplification circuit. In the electric current amplification
circuit, a signal is output to actuate the transmission.
WA500-3LK
10-215 B

12
KICK-DOWN
ELECTRICAL
/ HOLD SWITCH
1.
2.
3.
4.
5.
Kick-down switch
Spring
Spring
Hold switch
Wiring harness
KICK-DOWN SWITCH
OPERATION
The kick-down (shifting down from 2nd 1st) is actuated only when
traveling in F2.
When traveling in F2, if it is desired to shift down to 1st without operating
the speed lever, operate the kick-down switch on the boom lever to ON to
shift down to F1.
After this, even if the kick-down switch is pressed, the transmission is kept
at F1.
Cancellation (or not actuated)
When directional lever is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF
HOLD SWITCH
The hold switch is installed to the boom lever, and when the hold switch is pressed, the speed range displayed on the main
monitor transmission indicator is held.
Press the hold switch again to cancel.
10-216 B
WA500-3LK
ELECTRICAL
12
KICK-DOWN
ELECTRICAL CIRCUIT DIAGRAMS
NORMAL OPERATION
(When directional lever is at F and speed lever is at 2nd)
1.
When directional lever is at F.

If the directional lever is set to the F position, the electric current flows from battery (+) directional lever terminals 1 2 transmission controller FORWARD CNC3B terminal 5, and then flows from CNC2 terminal 7 F solenoid
CNC2 terminal 17 as the FORWARD output signal, and the FORWARD solenoid valve is actuated.
If the parking brake is placed at the RELEASED position, electricity flows from battery (+) parking brake safety relay
terminals 5 - 3 parking brake switch terminals 3 - 2 neutralizer relay terminals 1 - 2 ground, and terminals 3 - 5 of
the neutralizer relay are connected.
2.
When speed lever is at 2nd.

When the speed lever is at the 2nd position, the signal is in put to transmission controller 2nd CNC3B terminal 15, and
electricity flows as the 2nd signal from CNC2 terminal 10 2nd solenoid CNC2 terminal 20, and the 2nd solenoid is
actuated.
WA500-3LK
10-217 B

12
WHEN
ELECTRICAL
KICK-DOWN SWITCH IS OPERATED
(Operation with speed lever at F2 position)

(When kick down switch is pressed ON)
When the kick-down switch is pressed, the main monitor network signal (-) enters from CNL08 terminal 2 to controller CNC5
terminal 5. The kick-down circuit is formed inside the controller and the solenoid output signal flows from CNC2 terminal 7
and terminal 9 to the F solenoid and 1st solenoid, the solenoid valves are actuated, and the speed range is set to F1.
This kick-down circuit continues to be actuated even if the kick-down switch is returned. (Self-hold circuit)
In this way, if the kick-down switch is pressed when the speed lever is at F2, the transmission is automatically shifted to F1. At
the same time, the self-hold function of the kick-down circuit keeps the condition at F1 even if the switch is released or is
pressed several times.
10-218 B
WA500-3LK
ELECTRICAL
12
KICK-DOWN
SWITCH OPERATION CANCELED
(When directional lever is set to N or R)
If the directional lever is operated to the R position, the contact of terminal F of the lever is turned off, so the electricity stops
flowing from battery (+) speed lever switch terminals 1 - 2 transmission controller.
The FORWARD circuit inside the transmission controller is opened, so electricity stops flowing to the kick-down circuit. As a
result, the kick-down self-hold circuit is canceled and the 1st solenoid stops actuating. (Even if the directional lever is set to
the N position, the same operation as above is carried out and the kick-down circuit is canceled.)
The FORWARD circuit is also opened, so the F solenoid also stops actuating.
When the directional lever is set to the R position, current flows from battery speed lever terminals 1 - 4 transmission
controller CNC3B terminal 6 CNC 2-8 terminal (Reverse circuit formations R (+) signal inside controller) R solenoid
controller (-) CNC2 terminal 18, and the REVERSE solenoid valve is actuated.
At the same time, electricity flows from transmission controller 2nd signal (+) CNC2 terminal 10 2nd solenoid CNC2
terminal 20, and the 2nd solenoid valve is actuated to set to R2.
WA500-3LK
10-219 B
ELECTRICAL
12
MEMORANDUM
10-220 B
WA500-3LK
ELECTRICAL
12
ELECTRIC
PARKING BRAKE CONTROL
1.
Parking brake emergency release

switch
5.
9.
2.
Neutralizer relay
6.
10. Accumulator
3.
Parking brake safety relay (parking

brake emergency release relay)
7.
Parking brake (built into transmission)
4.
8.
Parking brake emergency release

valve
Charge valve
OUTLINE
The parking brake is a wet type multiple disc brake built into the transmission. When electricity flows to the parking brake
solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder and releases the parking
brake.
When the flow of electricity is stopped, the hydraulic pressure from the transmission pump is shut off. The hydraulic pressure
inside the parking brake cylinder passes through the parking brake solenoid valve and is drained. The force of the brake spring
then applies the parking brake.
WA500-3LK
10-221 B
ELECTRICAL
12
FUNCTION
1.
Applying and releasing parking brake

The parking brake is applied or released by using the parking brake switch (combination switch).
2.
Automatic parking brake

When the engine stops (when the starting switch is OFF), the parking brake is automatically applied to prevent the
machine from running away when the operator is away from his seat.
3.
Emergency brake
If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be
ensured, the parking brake is applied automatically to act as an emergency brake.
4.
Parking brake safety

It is dangerous if the parking brake can be released simply by turning the starting switch ON after the automatic parking
brake has been applied. Therefore, to ensure safety, the system is designed so the brake cannot be released unless the
starting switch is turned ON and then the parking brake switch is also turned ON.
5.
Neutralizer
The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this problem, the
caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. In addition to this,
when the parking brake is applied, the transmission is forcibly shifted to neutral to make it impossible to drive the
machine.
However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is
applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on
railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the
emergency brake is applied.
6.
Parking brake emergency release solenoid valve

If the supply of pressure oil from the transmission pump should stop because of some failure, it is possible to actuate the
emergency relief solenoid valve with the parking brake emergency release switch in the operators compartment. This
sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake.
10-222 B
WA500-3LK
ELECTRICAL
12
PARKING
BRAKE EMERGENCY RELEASE SWITCH
EMERGENCY BRAKE SWITCH
WA500-3LK
10-223 B

12
PARKING
ELECTRICAL
SAFETY RELAY
NEUTRALIZER RELAY
10-224 B
WA500-3LK
ELECTRICAL
12
OPERATION
1.
Starting switch OFF

When the starting switch is turned OFF, the battery relay is opened, so electricity does not flow to the parking brake
circuit. For this reason, if the starting switch is at the OFF position, no electric current flows to the parking brake solenoid
valve, regardless of whether the parking brake switch is ON (applied) or OFF (released), so the parking brake is actuated
(Automatic parking brake).
WA500-3LK
10-225 B
ELECTRICAL
12
2. Starting switch ON
A. When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit from the battery + starting switch battery relay coil ground, so the
battery relay is closed. When this happens, electric current flows in circuit from the battery + battery relay
parking brake switch terminal 1 - 3 parking brake safety relay terminal 1 - 2 ground. In this way, the parking
safety relay is actuated and safety relay terminals 3 - 5 are closed.
When this happens, circuit is formed from the battery + battery relay parking safety relay terminal 5 - 3
parking safety relay terminal 1 - 2 ground. From this point, the parking safety relay is in the condition of circuit
until the starting switch is turned OFF.
In this condition, electric current does not flow to the parking brake solenoid valve, so the parking brake is actuated.
In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric current does not flow to the
transmission directional circuit, and the transmission is shifted to neutral.
10-226 B
WA500-3LK
ELECTRICAL
12
B. When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit from the battery + starting switch battery relay coil ground, so the battery
relay is closed. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not
actuated. For this reason, the electric current does not flow to the parking brake solenoid valve, so after the automatic
parking brake is applied, the parking brake is not released automatically even when the starting switch is turned ON.
In addition, the electric current does not flow to the transmission directional circuit, so the machine does not move.
WA500-3LK
10-227 B
ELECTRICAL
12
3. Parking brake switch OFF (released)
When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
If the parking brake switch is turned from ON (actuated) to OFF (released), the circuit for terminals 2 and 3 of the parking
brake switch is connected, and the parking brake safety relay is also actuated. For this reason, electric current flows in
circuit from the battery + battery relay parking brake safety relay parking brake switch, and then flows to
circuits and given below.
This circuit is formed from the emergency brake switch parking brake solenoid valve ground, and the parking
brake is released.
This circuit is formed from the battery + battery relay neutralizer relay terminal 3 - 5 transmission directional
circuit, so when the directional lever is operated, the machine will move.
10-228 B
WA500-3LK
ELECTRICAL
12
4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied) after carrying out operations with the parking brake switch OFF
(released), the circuit in the diagram below is formed.
Electric current does not flow to the parking brake solenoid valve, so the oil pressure from the transmission pump to the
parking brake cylinder is shut off. At the same time, the oil pressure inside the parking brake cylinder passes through the
parking brake valve and is drained, so the parking brake is applied by the force of the spring.
In addition, at the same time, the neutralizer relay is reset, so the circuit between terminals 3 and 5 is opened, and no
electricity flows to the transmission directional circuit, so the transmission is shifted to neutral. This kind of neutralizer
relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts
the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the
parking brake still applied.
WA500-3LK
10-229 B
ELECTRICAL
12
5. When main brake oil pressure drops (emergency brake actuated)
OPERATION
If the oil pressure in the main brake line drops, the emergency brake switch installed to the accumulator is opened.
For this reason, the electric current stops flowing to the parking brake solenoid valve, so the oil pressure inside the parking
brake cylinder is drained and the parking brake is applied.
However, in this case, the condition is different from the case where the parking brake switch is ON (applied), because
there is electric current flowing to the neutralizer relay coil.
For this reason, electric current flows to the transmission directional circuit, and it is possible to engage the transmission
clutch. In this way, it is possible to use the engine brake when the emergency brake is applied, so the braking distance
becomes shorter. At the same time, if the emergency brake has been applied and it is necessary to move the machine (for
example, if the emergency brake is applied when the machine is on a railway crossing), it is possible to move the machine
by operating the transmission lever.
10-230 B
WA500-3LK
ELECTRICAL
12
6. Parking brake emergency release
OPERATION
If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake
cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored in
the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time,
electric current flows to the emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the
parking brake.
The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position
after the emergency release.
WA500-3LK
10-231 B
ELECTRICAL
12
7. Function of parking brake neutralizer relay
OUTLINE
When the parking brake is being actuated, the transmission is held at neutral to prevent the parking brakes from dragging
if the machine is operated by mistake.
OPERATION
A. When the parking brake is actuated (ON), electricity flows from the battery relay parking brake switch terminals
1 - 3 parking brake safety relay terminal 1 ground. As a result, the safety relay coil is actuated, and safety relay
terminals 3 and 5 are connected to form the circuit.
B. When the parking brake switch is OFF (released) and the engine is started, the circuit in Item A is not formed, so the
parking brake switch must be turned ON.
C. When the parking brake is being actuated, electricity does not flow to the neutralizer relay coil, so neutralizer relay
terminal 3 and terminal 5 are separated and no electricity flows to the transmission directional circuit. In this way,
when the parking brake is applied, the transmission is held at neutral.
10-232 B
WA500-3LK
ELECTRICAL
12
ELECTRICAL
DIAGRAM
See Section 90 for;
ECSS WIRING DIAGRAM - FOLDOUT 10-225-1

JOYSTICK STEERING WIRING DIAGRAM - FOLDOUT 10-225-2
ELECTRICAL CIRCUIT DIAGRAM - FOLDOUT 10-225-3, (Sheet 1) (Part 1 of 5)
ENGINE FLOOR HARNESS DIAGRAM - FOLDOUT 10-225-12
CAB ELECTRICAL DIAGRAM - FOLDOUT 10-225-13
WA500-3LK
10-233 B

12
ENGINE
10-234 B
ELECTRICAL
HARNESS DIAGRAM
WA500-3LK
ELECTRICAL
12
ENGINE
- FRAME - FLOOR HARNESS DIAGRAM
WA500-3LK
10-235 B
ELECTRICAL
12
MEMORANDUM
10-236 B
WA500-3LK
20
TESTING, ADJUSTING AND

TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5

STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
COMPONETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
BLEEDING AIR FROM FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . 20-28
BLOW-BY PRESSURE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
COMPRESSION PRESSURE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . 20-28
EXHAUST TEMPERATURE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . 20-28
FUEL PRESSURE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
HANDLING EQUIPMENT IN FUEL CIRCUIT (REFER TO ENGINE SHOP MANUAL) . . . . . . . . 20-28
INTAKE AIR PRESSURE (BOOST PRESSURE) (REFER TO ENGINE SHOP MANUAL) . . . . . . 20-28
LEAKAGE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . 20-28
OIL PRESSURE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
PERFORMANCE TEST STANDARDS (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . 20-28
RELEASING REMAINING PRESSURE IN FUEL SYSTEM (REFER TO ENGINE
SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
RUN-IN STANDARD (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
SPEED SENSOR (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (REFER TO ENGINE
SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (REFER TO ENGINE
SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (REFER TO ENGINE SHOP
MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
VALVE CLEARANCE (REFER TO ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
REDUCED CYLINDER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
AIR CONDITIONER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
TORQUE CONVERTER STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
SHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
OPERATING FORCE OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
TRAVEL OF SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
OPERATING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
HYDRAULIC CIRCUIT FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
TRANSMISSION VALVE FAILS - MOVING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
MEASURING PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
MEASURING OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
MEASURING OPERATING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
WA500-3LK
20-1 1
TESTING AND ADJUSTING
TABLE OF CONTENTS
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
STEERING STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
PEDAL PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
TESTING BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
MANUAL RELEASE METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
TESTING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
LEVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
BOOM KICK-OUT POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
INITIAL TEACHING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
RELEASING REMAINING HYDRAULIC OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-78
ADJUSTING JOYSTICK LEVER POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-81
TROUBLESHOOTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
ELECTRICAL CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL
MECHANISM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING SYSTEMS OF:
D MODE - ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) . . . . . . . . . . . . . . . 20-401
E MODE - CHASSIS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
H MODE - HYDRAULIC AND MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601
J MODE - JOYSTICK STEERING CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
20-2 2
WA500-3LK
TABLE OF CONTENTS
K MODE - MAINTENANCE MONITOR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801

M MODE - MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
T MODE - TRANSMISSION CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1201
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1301
For further detail information, refer to Engine Shop Manual.

Heed the following precautions when referring to the Standard Value Tables for testing, adjusting and troubleshooting:
A. The standard values in tables are those established for a new machine and are given as reference values for
the point at which the machine is shipped from the factory. These values should be used only as a guide
when estimating wear after the machine is operated and when carrying out repairs.
B. Permissible values shown in the tables are estimations based on the results of test performed on the
machines shipped from the factory, so they should be used together with the information on the repair condition and other information such as the operating history of the machine itself when judging the condition of
the machine.
C. These standard values do not form a basis for judging claims.
WARNING! Before testing, adjusting, or troubleshooting, park the machine on level ground,
install the safety bar, and use blocks to prevent the machine from moving.
WARNING! When working with others, always use signals and keep unauthorized people
away from the machine.
WARNING! Wait for the engine coolant water to cool before checking the coolant level. If the
radiator cap is removed while the coolant is still hot, the coolant will spurt out and
cause burns. Be careful to stay away from the fan, fan belt and other moving
parts
WA500-3LK
20-3 2

12
MEMORANDUM
20-4 1
WA500-3LK
STANDARD VALUE TABLE FOR ENGINE - IN CHASSIS
12
STANDARD
VALUE TABLE FOR ENGINE - IN CHASSIS
Machine model
WA500-3LK
Engine model
Komatsu SA6D140E-3
Item
Measure condition
Unit
High idle
Engine speeds
rpm
Low idle
Standard value for

new machine
Service limit value
2300 50
2300 100
725 50
725 75
Rated speed
kW/rpm
250 / 2100
250 / 2100
Intake manifold pressure
At T.C. stall and W.O.T. (Wide Open

Throttle)
mm Hg
800 min.
670 min.
Intake air restriction
At T.C. stall and W.O.T. at restriction

indicator port
mm H2O
New element: 380
762 max.
Lubricating oil pressure

with SAE 15W-40 oil &
coolant temperature in
operating range
Minimum at low idle
kgf/cm2
(lbf/in2)
1.2
17.0
.08
1.13
Minimum at high idle
kgf/cm2
(lbf/in2)
340
49.7
2.1
29.8
Fuel filter inlet restriction
Maximum restriction at high idle
mm Hg
220 max.
220 max.
Blow-by pressure
Coolant temperature in operating range:

Service Tool orifice size: 7.67 mm
At T.C. stall and W.O.T.
mm H2O
150 max.
300 max.
Exhaust back pressure
Maximum at T.C. stall and W.O.T.
mm Hg
105 max.
105 max.
Coolant temperature
Maximum operating temperature at engine

outlet
C/ F
100 / 212 max.
100 / 212 max.
Valve clearance
Engine cold:
Intake valves
Exhaust valves
mm
0.35
0.57
0.35
0.57
Alternator belt
Deflection when pressed with finger force

of approximately 98 N (22 lbf)
mm
13 - 16
13 - 16
Air conditioner
compressor belt tension
Deflection when pressed with finger force

of approximately 58.8 N (13.2 lbf)
mm
10 - 15
10 - 15
For further detailed information, refer to Engine Shop Manual.
WA500-3LK
20-5 1

12
STANDARD
STANDARD VALUE TABLE FOR CHASSIS
VALUE TABLE FOR CHASSIS
Item
Machine model
WA500-3LK
Engine model
Komatsu SA6D140E-3
Measurement condition
Engine stall speeds:
Coolant temperature in operating range

Torque converter oil temperature in
operating range
Hydraulic oil at normal operating
temperature
Torque converter
Hydraulic
Full
Accelerator pedal:
Operating force
Operating angle:
x1
x2
Stopper height (L)
Item
Standard value for

new machine
Service limit value
2140 100
2140 100
2180 100
2180 150
1820 100
1820 200
N (lbf)
24.5 4.9 @ 48
(5.5 1.1 @ 48)
53.9 @ 35
(12.1 @ 35)
Max. 97 (21.8)
degree
degree
48
34 - 35
mm
55.8
Unit
rpm
---
Unit
Standard value for

new machine
Service limit value
N (lbf)
5.88 + 4.9 / - 2.94

(1.32 + 1.10 / 0.66)
Max. 16.66
(3.74)
N (lbf)
5.88 + 4.9 / - 2.94

(1.32 + 1.10 / 0.66)
Max. 16.66
(3.74)
mm
35 10
35 20
mm
35 10
35 20
Shift lever operating force and stroke

Directional lever operating force
N-F
N-R
Speed lever operating force
1st - 2nd
2nd - 3rd
3rd - 4th
Directional lever travel
N-F
N-R
Speed lever travel
1st - 2nd -3rd -4th
20-6 1
Measure at center of lever knob

Engine stopped
WA500-3LK

Standard value for
new machine
Service limit value
Oil pressure of torque converter and

transmission.
Torque converter outlet port oil pressure
4 1
(56.8 14.22)
4 1
(56.8 14.22)
Torque converter inlet port oil pressure
0.83 0.1
(8.5 1)
0.83 0.1
(8.5 1)
33.5 2
476.4 28.4)
35.5 1.5
(476.4 21.3)
33.5 2
476.4 28.4)
35.5 1.5
(476.4 21.3)
33 1.5
(469.3 21.3)
36 1.5
(512.0 21.3)
33 1.5
(469.3 21.3)
36 1.5
(512.0 21.3)
2.15 0.85
(30.5 12.0)
2.15 0.85
(30.5 12.0)
Max. 2.5
Max. 4.0
2 - 10
mm
N (lbf)
Max. 50
12.25 2.45
(2.75 0.55)
50 - 100
Max. 19.6 (4.4)
Sec.
Sec.
Max. 5.5
Max. 3.1
Max. 6.5
Max. 4.5
Turns
3.6 0.4
Max. 4.5
mm
25 2
Item
ECMV output (clutch) oil pressure

1st
Torque converter oil

temperature: 60 - 80 C
2nd, 3rd, 4th, F-R
Engine speed: High idling
Main relief valve

Low idling
Unit
kgf/cm2
(lbf/in2)
Manual switch ON
High idling
Lubrication pressure (oil cooler outlet
port)
Tire inflation pressure
Specified pressure
Tire and wheel
Fitting of wheel lock ring
(A)
(B)
Clearance of wheel lock ring
(C)
mm
Steering wheel
Steering wheel play
Steering wheel operating force
Operating time of steering wheel
Low idle
High idle
Road surface: Flat, horizontal,

dry, paved surface:
Hydraulic temp.:45 - 55 C
Turning speed
Engine speed: High idling
Clearance between front and rear frame
Engine speed: 1200 rpm
WA500-3LK
Machine posture:
Facing straight
20-7 1
12
Testing and measuring item
Steering oil pressure
Main relief oil pressure
Standard value for

new machine
Service limit value
210 +10/-3
(43.0 + 0.014/-0.004)
210 +10/-3
(43.0 + 0.014/-0.004)
38 +4/-2
(0.054 +0.005/-0.002)
38 +4/-2
(0.054 +0.005/-0.002)
N (lbf)
294 29.4
(66.0 6.60)
Max. 421.4
(94.7)
degree
45
mm
15 +1/-0
60 +5/-0
853.4 +71.1/-0
60 +5/-0
853.4 +71.1/-0
100 +10/-0
(1422.3 +142.2/-0)
100 +10/-0
(1422.3 +142.2/-0)
kgf/cm2
(lbf/in2)
6.0 0.1
(85.3 1.4)
6.0 0.1
(85.3 1.4)
mm
Max. 5
Max. 5
kgf/cm2
(lbf/in2)
Max. 5
(71.1)
mm
2.2 - 5.5
Unit
Hydraulic temperature: 45 - 55 C
Engine speed: High idle
kgf/cm2
(lbf/in2)
Orbit-roll output pressure

Brake pedal
Operating force
Operating angle
Engine speed: Low idle

Hydraulic temperature: 45-55C
Play
Accumulator
Charge cut-in pressure
Point where brake oil pressure warning lamp goes out
Hydraulic temperature: 45-55C
Charge cut-out pressure
Point where oil pressure is going up
and then starts to go down
Warning buzzer pressure
Actuating starting
Actuating stopping
Coolant temperature:
Inside operating range
Brake performance
Road surface: Flat, horizontal, dry,

paved surface
Speed when applying brakes: 20
km/h
Time lag when pressing the pedal:
0.1 sec.
Brake pedal operating force: 294
29.4 N (30 3 kg)
Tire inflation pressure:
Specified pressure
Drop in brake oil pressure
Test pressure:
53 kg/cm2/5 min.
Wear of brake disc
Piston stroke
Parking brake performance
Tire inflation pressure:

Specified pressure
Road surface:
Flat, dry, paved surface with 1/5
(1120') gradient
Machine:
In operating condition
Thickness of pad
With back plate
Clearance between
disc and pad
20-8 1
Total of both side
kgf/cm2
(lbf/in2)
No
machine
movement
mm
Max. 5
(71.1)
Max. 8.5
No
machine
movement
31.7
12.7
1.06 0.18
Max. 2.3
WA500-3LK

Testing and measuring item

Dump and lift control levers

Lift arm control lever operating force
Hold _ Raise
Raise _ Hold
Hold _ Lower
Lower _ Hold
Lower _ Float
Float _ Hold
Dump control lever operating force
Hold _ Dump
Hold _ Tilt
Tilt _ Hold
Unit
kg
Lift arm control lever travel

Hold _ Raise
Hold _ Lower
Hold _ Float
mm
Relief oil pressure

PPC valve
Main control valve
Operating speeds
Lift arm lifting time
Lift arm lowering time
Bucket dumping time
Bucket tilt back time
(Full stroke)
Bucket tilt back time
(Horizontal position of bucket)
Steering position: Neutral
Bucket: empty
sec.
Stop engine, leave for 5 minutes,
then measure for next 15 minutes.
Lift arm horizontal
Bucket horizontal
Bucket: empty
mm
Retraction of dump cylinder rod
Bucket positioner
Clearance of switch
Boom kick-out
Clearance of switch
WA500-3LK
Max. 2.5
2-4
Max. 2.5
2-4
2-4
Max. 2.5
Max. 2.5
2-4
Dump control lever travel

Hold _ Dump
Hold _ Tilt
Hydraulic drift of lift arm and bucket

Retraction of lift cylinder rod
Standard value for

new machine
kgf/cm2
(lbf/in2)
mm
Service limit value
Max. 3.5
Max. 6
Max. 3.5
Max. 6
Max. 6
Max. 3.5
Max. 3.5
Max. 6
52 - 82
34 - 64
52 - 82
37 - 97
19 - 79
37 - 97
45 - 75
45 - 75
30 - 90
30 - 90
210 5
(2986.9 71.1)
210 5
(2986.9 71.1)
6.8 - 7.4
3.0 - 4.0
1.4 - 2.0
Max. 8.9
Max. 4.8
Max. 2.4
1.9 - 2.5
Max. 3.0
1.3 - 1.9
Max. 2.3
Max. 40
Max. 40
Max. 20
Max. 20
3-5
3-5
20-9 1
12
Inspection
method
Measurement
conditions
Name of component
Connector
number
Main power
supply
CN4
If condition is as shown in the table below, it is

Measure voltage normal
Between CN4 (8), (19) - (9), (20)
20 - 30 V
Turn starting switch ON.
Power supply
CN7

Between CN7 (5), (13) - (6), (14)
20 - 30 V
Key switch ACC

power supply
CN4

Between CN4 (8), (19) - (7), (18)
20 - 30 V
Key switch
terminal C signal
Acceleration
sensor
potentiometer
Judgement table

normal
CN4
Measure voltage
Between CN4 (8), (19) - (2)
CN1
20 - 30 V

normal
Measure voltage
4.6 - 5.4 V
Between CN1 (11) - (4)
1. When starting switch is

turned to ON
position.
2. When starting switch is
turned to START
position.
0.3 - 4.5 V
Engine controller

normal
Accelerator limit
switch
Ne speed sensor
CN4
CN1
Ne
Measure voltage
Measure
resistance
Acceleration sensor voltage is above

3.8 V
15 - 30 V
Acceleration sensor voltage is below

3.8 V
Max. 1 V

normal
Turn starting switch OFF

85 - 210
Between Ne (2) - (1)
G speed sensor
CN2
G
Measure
resistance

normal
Turn starting switch OFF

1 - 2
Between G (2) - (1)
Common rail
pressure sensor
CN1
CN2
J011

normal
0.3 - 4.7 V
Measure voltage
Turn starting switch ON

4.6 - 5.4 V
Between J011 (3) - (1)

Between J011 (3) - (2)
Boost pressure
sensor
CN1
CN2
J011
0.3 - 4.7 V

normal
0.3 - 4.7 V
Measure voltage
Turn starting switch ON

4.6 - 5.4 V
Between J011 (6) - (4)

Between J011 (6) - (5)
20-10 1
0.3 - 4.7 V
WA500-3LK

Name of component
Water temperature
sensor (Low)
Connector
number

Inspection
method
CN
Measure
TWL_DT2 resistance
Measurement
conditions
Judgement table
normal
0.3 - 9 K
1. Turn starting switch

OFF.
2. 10 - 100C (20 - 212F)
Between YWH_DT2 (2) - (1)

Fuel temperature
sensor
CN2
THL_DT2
Measure
resistance

normal
Between CN2 (10) - (11)
0.3 - 9 K

OFF.
2. 10 - 100C (20 - 212F)
Between THL_DT2 (2) - (1)
Injector #1
CN6
CN1_DT2
Measure
resistance

normal
Between CN1_DT2 (2) - (1)
Injector #2
CN6
CN2_DT2
Measure
resistance
Engine controller
CN6
CN3_DT2
Measure
resistance
CN6
CN4_D72
Measure
resistance
CN7
CN5_DT2
Measure
resistance
CN7
CN6_DT2
Measure
resistance
CN7
PCV1
Measure
resistance
Turn starting switch OFF.
0.4 - 1.1
0.4 - 1.1

normal
Supply pump #1
0.4 - 1.1

normal
Injector #6

normal
Injector #5
0.4 - 1.1

normal
Injector #4

normal
Injector #3
0.4 - 1.1
0.4 - 1.1

normal
Between CN7 (11) - (10)

2.35 - 5.3
Between PCV2 (2) - (1)1
Supply pump #2
CN7
PCV2
Measure
resistance

normal

2.35 - 5.3
Between PCV2 (2) - (1)
WA500-3LK
20-11 1

Name of component
Connector
number

Inspection
method
Measurement
conditions
Judgement table
If the condition is as shown in the table below, it is
normal
Power source
C1
C2
Between C1 (7), (18) - chassis

Measure voltage
Between C2 (1), (12) - chassis

Between C1 (7), (13) - (6), (12)
20 - 30 V

OFF
2. Insert T-adapter
3. Turn starting switch ON
Between C2 (1), (12) - (11), (21)

Power source
(signal)
Transmission & Travel Damper Controller
Parking brake
switch
ECMV solenoid
(1st)
ECMV solenoid
(2nd)
ECMV solenoid
(3rd)
ECMV solenoid
(4th)
ECMV solenoid
(F)
ECMV solenoid
(R)
20-12 1
C3A
If the condition is as shown in the table below, it is 1. Turn starting switch

normal
OFF
Measure voltage
2. Insert T-adapter
Between (6) - (17)
20 - 30 V
4. Apply parking brake
Between (6) - chassis
L01
If the condition is as shown in table below, the sen1. Turn starting switch
sor is normal
OFF
Measure voltage
Parking brake ON, Between (1) - (3), 20 - 30 V
2. Insert T-adapter
Parking brake OFF, Between (1) - (3), Max. 1 V
CN4
(male)
CN6
(male)
CN12
(male)
CN8
(male)
CN16
(male)
CN14
(male)
Measure
resistance
If condition is as shown in the table below, the sen1. Turn starting switch
sor is normal
OFF
Between (1) - (2)
5 - 15
2. Disconnect connector
3. Connect T-adapter
Between (1), (2) - chassis
Min. 1 M
Measure
resistance
If the condition is as shown in the table below, the

sensor is normal
OFF
Between (1) - (2)
5 - 15
Min. 1 M
Measure
resistance

sensor is normal
OFF
Between (1) - (2)
5 - 15
Measure
resistance
If condition is as shown in the table below, it is nor1. Turn starting switch

mal
OFF
Between (1) - (2)
5 - 15
Min. 1 M
Measure
resistance

sensor is normal
OFF
Between (1) - (2)
5 - 15
Min. 1 M
Measure
resistance

normal
OFF
Between (1) - (2)
5 - 15
Min. 1 M
WA500-3LK
Name of component
Connector
number

Inspection
method
Measurement
conditions
Judgement table
normal
1st - CN5
(male)
2nd - CN7
(male)
3rd - CN13
(male)
4th - CN9
(male)
Speed lever at measurement

|position:
Measure
resistance

Speed lever not at measurement
position:
ECMV fill switch
F - CN17
(male)
R - CN15
(male)
Max. 1
Min. 1
If the condition is as shown in the table below, it is 1. Turn starting switch

normal
OFF
Directional lever at measurement
position:
4. Start engine
Max. 1
5. Place directional lever
at N
6. Turn manual switch ON
Measure
resistance
Directional lever not at

measurement position:
Min. 1
Transmission oil
temperature sensor
Transmission oil
temperature
(controller)
WA500-3LK
CN11
(male)
C2

OFF
2. Insert T-adapter
Measure
resistance
Measure
resistance
If condition is as shown in the table below, the

sensor is normal
Normal temperature (25 C)
3.8 - 4.8
100 C Between (1) - chassis
3.6 - 3.9

OFF
4. Start engine
5. Turn transmission cutoff (lamp OFF)
6. Turn parking brake
switch OFF
7. Depress brake
OFF

normal
OFF
2.
Disconnect
connector
4.4
4.6
Between (11) - (17)
100 C Between (11) - (17)
2.1 - 2.3
20-13 1

Name of component
Engine speed
sensor
Engine speed
(controller)
Connector
number
E04
(male)
C4
(male)

Inspection
method
Measure
resistance
Measure voltage
Measurement
conditions
Judgement table

sensor is normal
OFF
Between (1) - (2)
500 - 1000 2. Disconnect connector
Between (1) - (2 - chassis)
Min. 1 M
normal
Measure with AC range
Between (2) - (9)
Max. 0.5 V

OFF
3. Start engine

sensor is normal
Engine speed
Adjust
1. Screw in until speed sensor contacts ring gear,

then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as

above.
CN3
(male)
Measure
resistance

normal
Between (1) - (2)
Between (1) - (2 - chassis)

OFF
500 - 1000 2. Disconnect connector
Min. 1 M

sensor is normal
Speed
-
Adjust
1. Screw in until speed sensor contacts ring gear,

then turn back 3/4 - 1 turn
2. Sensor should work normally when adjusted as

above.
20-14 1
WA500-3LK
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
sensor is normal
Speed lever
(1st)
Speed lever at 1st.

20 - 30 V
Speed lever not at 1st.

Max. 1 V

normal
Speed lever
(2nd)
Speed lever at 2nd.

20 - 30 V
Speed lever not at 2nd.

Max. 1 V

sensor is normal
Speed lever at 3rd.
20 - 30 V
Speed lever not at 3rd.

Max. 1 V

normal
Controller
Speed lever
(3rd)
Speed lever
(4th)
C3B
Directional
lever
(F)
Speed lever at 4th.

20 - 30 V
Speed lever not at 4th.

Measure voltage Between (16) - chassis
Max. 1 V

OFF
If the condition is as shown in the table below, the 3. Start engine
sensor is normal
Directional lever at F
20 - 30 V
Speed lever not at F.

Max. 1 V

normal
Directional
lever
(R)
Directional lever at R
20 - 30 V
Speed lever not at R.

Max. 1 V

sensor is normal
Directional
lever
(N)
S-NET
between
transmission
and main
controller
WA500-3LK
Directional lever at N
20 - 30 V
Speed lever not at N.

Max. 1 V

sensor is normal
4-8V
20-15 1
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
normal
L15
(male)
Measure
resistance
Hold Switch
Kick-down switch ON
Between (1) - (2)
Max. 1
Kick-down switch OFF

Between (1) - (2)
Min. 1 M

sensor is normal
Hold switch ON
Between (3) - (4)
Max. 1
Hold switch OFF

Between (3) - (4)
Min. 1 M

normal
Transmission
cut-off switch
Controller
Kick-down Switch
L12
(male)
Measure
resistance
When operated normally

Between (1) - (2) - chassis
Max. 1
When left brake is depressed

Min. 1 M

sensor is normal
Manual
Switch
Power source
C5
CN3
(male)
Manual switch ON
Measure voltage
20 - 30 V
Manual switch OFF

Max. 1 V

OFF
2. Insert T-adapter

OFF

OFF

OFF
2. Insert T-adapter

normal
OFF
Measure voltage
2. Insert T-adapter
20 - 30 V
Between (1) - (2) - (3)
Main Monitor

sensor is normal
Charge (alternator)
L05
Engine running (at above 1/2

Measure voltage throttle.
Between (5) - (3)
Starting switch ON
Between (5) - (3)
28 2 V

OFF
2. Insert T-adapter
Max. 1 V
* If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
Engine water
temperature
sensor

sensor is normal
TWH
(female)
Measure
resistance
Normal temperature 25C (77F)

Between (1) - (2)
5C (41F)
Between (1) - (2)
20-16 1

Approximately
OFF
2 k
Approximately
4 k
WA500-3LK
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
sensor is normal
Directional switch
(N)
L05
Measure
voltage
Directional lever at N
Between (8) - (3)
20 - 30 V
Directional lever not at N

Between (8) - (3)
Max. 1 V

OFF
2. Insert T-adapter

normal
Starting switch
terminal C
L09
(male)
Measure
voltage
Starting switch at start

20 - 30 V
Starting switch at OFF or ON

Max. 1 V

OFF
2. Insert T-adapter

sensor is normal
Starting switch
terminal C
L04
Measure
voltage
Engine started
Between (4) - (3)
20 - 30 V
Starting switch OFF or ON

Between (4) - (3)
Max. 1 V
Main Monitor Related

normal
Starting switch
terminal BR
L09
(male)
Measure
voltage
Starting switch ON
20 - 30 V
Starting switch OFF

Max. 1 V

OFF
2. Insert T-adapter

OFF

sensor is normal
Starting switch
terminal BR
L07
Measure
voltage
Starting switch ON
20 - 30 V
Starting switch OFF

Max. 1 V

normal
Parking brake
indicator switch
CN19
(male)
Measure
resistance
Parking brake ON
Between (1) - (2)
Max. 1
Parking brake OFF

Min. 1 M

sensor is normal
Directional switch
(F)
L08
Measure
voltage
Directional lever at F
20 - 30 V
Directional lever not at F

Max. 1 V

sensor is normal
Directional switch
(R)
WA500-3LK
L08
Measure
voltage
Directional lever at R
20 - 30 V
Directional lever not at R

Max. 1 V

OFF
2. Insert T-adapter

OFF

OFF
2. Insert T-adapter

OFF
2. Insert T-adapter
20-17 1
12
Name of component
Power source
Connector
number
L18
Inspection
method
Measure
voltage
Measurement
conditions
Judgement table

normal
OFF
2. Insert T-adapter
20 - 30 V
Between (1), (2) - (3)
sensor is normal
Engine water
temperature sensor
E06
(male)
Measure
resistance
50 C
Between (A) - (B)
100C
Between (A) - (B)

Approxiately
OFF
19
Approxiately
3.6
Maintenance Monitor Related

normal
Torque converter
oil temperature
sensor
CN18
(male)
Measure
resistance

Between (1) - (2)
130 C
Between (1) - (2)
Fuel level sensor
R07
(male)
Measure
resistance

Approxiately
OFF
40
Approxiately
1.7
If the condition is as shown in the table below, the 1. Turn starting switch
sensor is normal
OFF
Approxiately 2. Disconnect connector
Float raised to stopper
3. Drain fuel
4
4. Remove fuel level
sensor
Approxiately
Float lowered to stopper
85
normal
Radiator water
level sensor
G01
(male)
Measure
resistance
Water level normal

Between (1) - (2)
Max 1
Water level low

Between (1) - (2)
Min. 1 M

OFF

sensor is normal
Engine oil pressure
sensor
E11
Measure
resistance
Engine oil pressure: Min. 1.3 kgf/

cm2 (18.4 lbf/in2) (Start engine) Min. 1 M
Between (A) - (C)
Engine oil pressure: Max. 0.7 kgf/
cm2 (9.9 lbf/in2) (Starting switch Max. 1
ON) Between (A) - (C)
20-18 1

OFF
4. Start engine
WA500-3LK
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
sensor is normal
Brake
accumulator low
pressure switch
B08
(male)
B13
(male)
Measure
resistance
Accumulator pressure:
Min. 55 5 kgf/cm2 (782.2 +71.1 Max. 1
lbf/in2) Between (1) - (2)
Depress brake and lower accumulator pressure to below 45 5 kg/cm2
(640.0 71.1 lbf/in2) Between (1) - Min. 1 M
(2)

OFF

normal
Charge (alternator)
L18
Measure
voltage
Engine running (at above 1/2

throttle)
Between (12) -(3), (14)
28 2 V
Starting switch ON
Between (12) -(3), (14)
Max. 1 V

OFF
2. Insert T-adapter
3. Start engine
*If the battery is old, or after starting in cold areas,

the voltage may not rise for some time.
sensor is normal
Engine oil level
sensor
E10
(male)
Measure
resistance
Oil level normal

Between (1) - (2)
Max. 1
Oil level abnormal

Between (1) - (2)
Min. 1 M

OFF
Measurement
conditions
normal
Dust indicator
WA500-3LK
E19
(male)
E20
(female)
Measure
continuity
Air cleaner normal

Between E19 (1) - E20 (1)
Continuity
Air cleaner clogged or engine

stopped - No continuity
No continuity
Between E19 (1) - E20 (1)
20-19 1
12
WARNING! Check carefully that there is no one in the surrounding area before starting inspection.
When carrying out operations during inspection, raise the work equipment control lever stand for operations, and
lower it when traveling.
Turn the starting switch OFF before inserting the T-adapter, or making any connections.
Name of component
Measurement
conditions
Judgement table
If the condition is as shown in Table 1, the monitor panel is normal
Table 1 (CHECK, CAUTION portion)
Connector
No.
CHECK,
CAUTION
portion
L18
(male)
Monitor item
(input connector)
Display
Sensor
signal input
Engine water level

(8) - (3), (14)
Engine stopped,
Starting switch ON
Flashing
15 - 20 V
OFF
Max. 1 V
Engine oil level

(13) - (3), (14)
Engine stopped,
Starting switch ON
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
Max. 10 V
Engine oil pressure

(10) - (3), (14)
Start engine
Brake oil pressure

(11) - (3), (14)
Start engine
Battery charge
(12) - (3), (14)
Start engine
Air cleaner
(15) - (3), (14)
20-20 1
Measurement
conditions
Start engine
OFF
Min. 12 V
Flashing
15 - 20 V
OFF
Max. 1 V
WA500-3LK
Name of component
Judgement table
Measurement
conditions
Table 2 (Gauge portion)
Gauge
portion
WA500-3LK

OFF, then insert
dummy resistance or
measure resistance of
sensor.
ON and check display
20-21 1
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
sensor is normal
Parking brake
emergency cancel
switch
L90
Measure
voltage
Parking brake emergency cancel

switch ON
Between (1) - (2) and (3) - (4)
20 - 30 V

switch OFF
Between (1) - (2) and (3) - (4)
Max. 1 V

OFF
2. Insert T-adapter

normal
Parking brake
emergency cancel
solenoid
B14
Measure
voltage

switch ON
Between (1) - (2)
20 - 30 V

switch ON
Between (1) - (2)
Max. 1 V

OFF
2. Insert T-adapter
Others

sensor is normal
Emergency brake
switch
B09, B10
(male)
Measure
resistance
Accumulator pressure: Min. 40

5 kg/cm2 (568.9 71.1 lbf/in2)
Between B09 (1) - B10 (2)
Max. 1
Depress brake and lower accumulator pressure to below37 5 kg/

Min. 1 M
cm2 (526.2 71.1 lbf/in2)
Between B09 (1) - B10 (2)

OFF

normal
Emergency brake
switch
BR1
Measure
voltage
Accumulator pressure: Min. 40

5 kg/cm2 (568.9 71.1 lbf/in2)
Between (7) - (8)
20 - 30 V
Depress brake and lower accumulator pressure to below 37 5 kg/

Max. 1 V
cm2 (526.2 71.1 lbf/in2)
Between B09 (1) - B10 (2)

OFF
2. Insert T-adapter

sensor is normal
Bucket positioner
proximity switch
20-22 1
F05
Measure
voltage
Between
When
screwdriver is
brought close
When
screwdriver is
not brought
close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V

OFF
2. Insert T-adapter
WA500-3LK
12
Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
sensor is normal
F06
Measure
voltage
Others
Boom kick-out
proximity switch
Boom kick-out
solenoid
Bucket positioner
solenoid
WA500-3LK
L16
L17
Between
When
screwdriver is
brought close
When
screwdriver is
not brought
close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V

OFF
2. Insert T-adapter
Measure
resistance

normal
OFF
Between (1), (2)
19 - 23
Min. 1 M
Measure
resistance

sensor is normal
OFF
Between (1), (2)
19 - 23
Min. 1 M
20-23 1

Name of component
Power source
voltage
Connector
number
L28

Inspection
method
Measure
voltage

sensor is normal
OFF
Between (8), (17), (18) - (9), (18)
2. Insert T-adapter
When actuated
20 - 30 V
When not actuated
Damping solenoid
Joystick Controller
Boom angle
potentiometer
F28
(male)
Boom lever
RAISE pressure
switch
L27
(male)
L27
Measure
voltage
Between (1) - (2)
15 - 25
Min. 1 M
Between (2) - (3)
4 - 5 k
Between (3) - (1)
0 - 5 k
1.Turn starting switch

OFF.
2 Disconnect connector.
sensor is normal
0 - 5 k
Between (1) - (2)
If the condition is as shown in the table below, the 1. Turn starting switch
sensor is normal
OFF
Between (19) - (9)
2. Insert T-adapter
0.3 - 4.7 V
When actuated
sensor is normal
Boom lever operation
F21
(male)
Not at RAISE
At RAISE
Measure
resistance
Boom lever
LOWER pressure
switch
F22
(male)
Not at LOWER
At LOWER
Joystick L
(left) solenoid
CNR
(male)
CNL
(male)
Max. 1
Min. 1 M
1.Turn starting switch

OFF.
2
Disconnect
connector.
sensor is normal
Boom lever operated between (1) - (2)

Joystick R
(right) solenoid
Max. 1 V

sensor is normal
Measure
resistance
Boom angle
potentiometer
Measurement
conditions
Judgement table
Max. 1
Min. 1 M
Measure
resistance

normal
OFF
Between (1) - (2)
10 - 20
Min. 1 M
Measure
resistance

sensor is normal
OFF
Between (1) - (2)
10 - 20
Min. 1 M
normal
Joystick neutral
switch
NEUTRAL
Measure
resistance
Joystick neutral switch between (1) - (3)

Not at N
At N
20-24 1
Max 1

OFF
Min. 1 M
WA500-3LK
Joystick Controller
Name of component
Joystick
potentiometer
Joystick
potentiometer
WA500-3LK
Connector
number
Inspection
method
L27
Measure
voltage

normal
OFF
Between (20) - (9)
2. Insert T-adapter
When actuated
0.5 - 4.5 V
Measure
resistance

sensor is normal
OFF
Between (1) - (2)
0-5
Between (2) - (3)
4-5
4. Start engine
Between (3) - (1)
0-5
JS7
(male)
Judgement table
Measurement
conditions
20-25 1

No.

Tool Description
Check or Measurement item
Tool Number
799-203-8001
799-203-9000
(Kit)
Remarks
Digital display
L: 60 - 20,000 rpm
H: 60 - 19,999 rpm
Engine speeds
Digital Optical Tachometer
Intake manifold pressure
Pressure gauge
See Engine Shop Manual
Intake air restriction
Water manometer
Lubricating oil pressure
Pressure gauge
Fuel filter inlet restriction
Vacuum gauge
Blow-by pressure
Tool, adapter & manometer
Exhaust back pressure
Mercury manometer
Coolant temperature
Digital temperature gauge
Valve clearance
Feeler gauge
10
Alternator, fan & water pump drive

belts
11
Exhaust gas color
12
Brake oil pressure
13
Operating effort
Push-pull scale
14
Stroke, hydraulic drift
Scale
15
Work equipment speed
Stop watch
16
Measuring brake disc wear
Calipers
17
18
19
Commercially
available
---
Tension gauge
ST-1138
---
Smoke detector
799-201-9000
Smoke meter
Commercially
available
Brake test kit
793-520-1805
Nipple
793-520-1851
Discoloration
0-70% with standard color
% x 1/10 ~ Bosch index
79A-264-0020
0 - 294.2 N (0 - 30 kg)
79A-264-0090
0 - 490.3 N (0 - 50 kg)
Commercially
available
---
Commercially available
---
Commercially
available
---
Moving machine when there is failure

Plate
in transmission valve
793T-685- 1110
---
Measuring voltage, resistance value
Tester
79A-264-0210
---
T-adapter
assembly
799-601-7400
---
Troubleshooting of wiring, harness,

sensors
20-26 1
Adapter
799-601-7310
SWP12P
799-601-7320
SWP16P
799-601-7340
M8P
799-601-7380
JFC2P
WA500-3LK
SKETCHES OF SPECIAL TOOLS
12
SKETCHES
OF SPECIAL TOOLS
TOOL N
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
WA500-3LK
20-27 1
ENGINE
ENGINE
COMPONETS
BLEEDING AIR FROM FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)
BLOW-BY PRESSURE (REFER TO ENGINE SHOP MANUAL)
COMPRESSION PRESSURE (REFER TO ENGINE SHOP MANUAL)
EXHAUST TEMPERATURE (REFER TO ENGINE SHOP MANUAL)
FUEL PRESSURE (REFER TO ENGINE SHOP MANUAL)
HANDLING EQUIPMENT IN FUEL CIRCUIT (REFER TO ENGINE SHOP MANUAL)
INTAKE AIR PRESSURE (BOOST PRESSURE) (REFER TO ENGINE SHOP MANUAL)
LEAKAGE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)
OIL PRESSURE (REFER TO ENGINE SHOP MANUAL)
PERFORMANCE TEST STANDARDS (REFER TO ENGINE SHOP MANUAL)
RELEASING REMAINING PRESSURE IN FUEL SYSTEM (REFER TO ENGINE SHOP MANUAL)
RUN-IN STANDARD (REFER TO ENGINE SHOP MANUAL)
SPEED SENSOR (REFER TO ENGINE SHOP MANUAL)
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING (REFER TO ENGINE
SHOP MANUAL)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (REFER TO ENGINE SHOP
MANUAL)
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) (REFER TO ENGINE SHOP MANUAL)
VALVE CLEARANCE (REFER TO ENGINE SHOP MANUAL)
20-28 1
WA500-3LK
ENGINE
12
HANDLING
ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT
WARNING! With the engine controller, a high voltage

circuit (110 - 130 V) is used for the fuel
injector drive. As a result, a high voltage
circuit is connected to the wiring harness
and connector from the controller to the
fuel injector.
Normally, high voltage is output from the controller to the fuel injector
only when the engine is running. When the engine is stopped, the
output stops.
WARNING! If the high voltage circuit is touched
directly, there is danger of electrocution,
so observe the following precautions
when carrying out inspection.
1.
The connectors, including those for the high voltage circuit, are as follows.
Controller connector: L86, L87
Intermediate connector: LR8, ER3
Injector connector: CN1, CN2, CN3, CN4, CN5, CN6
Terminal at head of injector (inside head cover)
2.
When disconnecting or connecting the applicable connector, always turn the starting switch OFF before starting.
3.
When a T-adapter has been inserted or connected to the applicable connector to carry out troubleshooting, never start the
engine.
If the starting switch is operated, operate it only to OFF or ON. Never turn it to the START position.
WA500-3LK
20-29 1

12
REDUCED
ENGINE
CYLINDER MODE
OPERATION
Reduced cylinder mode operation means setting the fuel injectors of a single cylinder or multiple cylinders electrically to
the NO INJECTION condition to run the engine on a reduced number of cylinders. It has the following purposes and
effects.
The reduced cylinder mode operation must be carried out when the engine is mounted on the machine.
In addition, when carrying out reduced cylinder mode operation, it is necessary to operate switches or the panel on the
machine mounting the engine, so see the shop manual for the machine for details of the method of operation.
1.
The reduced cylinder mode operation is used when it is thought that one of the engine cylinders is not giving normal
output (combustion). It is a method to determine which cylinder is not operating normally.
2.
With the reduced cylinder mode operation, if there is no change in the engine speed and output from the present condition
(engine running on all cylinders), even when a cylinder is set to NO INJECTION, it means that this cylinder is the cause
of the problem. Such problems may occur for the following reasons.
Leakage from cylinder head gasket
Defective injection by the fuel injector
Defective piston, piston ring, cylinder liner
Defective valve mechanism (dynamic valve)
Defective electrical system
3.
With the common rail type fuel injection system, the fuel injector for each cylinder is operated individually by electronic
control. So compared with the mechanical type fuel injection system, it is possible to carry out the reduced cylinder mode
operation with simple operation of the switches. This makes it easier to narrow down the location of the problem.
20-30 1
WA500-3LK
ENGINE
12
METHOD OF REDUCED CYLINDER MODE
1.
Remove the cover of the right console box.
2.
Start and check the reduced cylinder mode operation according to the
following procedure.
A. Connect switch box Q to controller (CN3) and start the engine.
B. Set the engine in the reduced cylinder mode by operating the
switches (shown in the following chart). Check that the engine
operates according to the following chart.
C. Check that the display of the controller LED changes. This LED displays "00" normally but displays the reduced
cylinder No. in the reduced cylinder mode. Cylinder No.1: "01" - Cylinder No. 6 "06".
D. Measure the engine speed as a voltage output of the controller with a tester. The conversion ratio of the engine speed
to output voltage is 1,000 (rpm)/1.0 (V). That is, when the output voltage is 1.85 V, for example, the engine speed is
1,850 rpm.
Since this output terminal is used as a check terminal for the other items, however, it outputs a voltage corresponding
to the engine speed only in the "reduced cylinder mode".
E. Run the engine in the reduced cylinder mode with each cylinder selected to see if any cylinder is not fired.
JUDGING ABNORMAL CYLINDER
The engine speed in the reduced cylinder mode does not change depending on the selected cylinder.
All the cylinders are fired.
The engine speed in the reduced cylinder mode changes depending on the selected cylinder.
When a cylinder is selected in the reduced cylinder mode, if the engine speed does not change, that cylinder is not fired.
WA500-3LK
20-31 1
ENGINE
12
DISPLAY OF REDUCED CYLINDER MODE
Perform the following operation with the cylinder selector switch and reduced cylinder mode switch.
TIMING CHART OF REDUCED CYLINDER MODE OPERATION
20-32 1
WA500-3LK
ENGINE
12
ALTERNATOR
BELT TENSION
1.
Inspecting
Measure deflection a when the belt is pressed with a finger at a point
midway between the alternator pulley and drive pulley.
Pushing force: Approximately 961 N (216 lbf)
Deflection (one belt): 13 - 16 mm (0.511 - 0.629 in)
2.
Adjusting
This makes a clearance of 0.75 - 1.00 mm (0.029 - 0.039 in)
between the tip of the sensor and the tip of the gear tooth.
If the deflection is not within the specified range, adjust as
follows.
A. Loosen 2 mount bolts of alternator (1) and 1 lock bolt of the bar.
B. Loosen locknut (2), move alternator (1) with adjustment nut (3),
and adjust the tension of belt (4).
Deflection (one belt): 13 - 16 mm (0.511 - 0.629 in)
C. Tighten locknut (2).
D. Tighten 2 mount bolts of alternator (1) and 1 lock bolt of the bar.
After adjusting, check the belt tension again.
WA500-3LK
20-33 1

12
FAN
ENGINE
BELT TENSION
TESTING
Measure deflection b of the belt when it is pushed with a force of approximately 961 N (216 lbf) at a point midway between the fan pulley and the
crank pulley.
Deflection b of belt:
13 - 15 mm (new part)
17 - 39 mm (when tension is adjusted)
ADJUSTING
Loosen locknut (2) of tension pulley (1), then turn adjustment bolt (3) to
adjust the tension of belt (4).
20-34 1
WA500-3LK
ENGINE
12
AIR
CONDITIONER BELT
1.
Testing
Measure deflection c of the belt when it is pushed with force of
approximately 58.8 N (13.22 lbf) at a point midway between the fan
pulley and the air conditioner compressor pulley.
Deflection c of belt (standard value): 10 - 15 mm
2.
Adjusting
A. Loosen mount bolt and nut, and the adjustment plate bolt and nut.
B. Move the position of the air conditioner compressor to adjust the
tension of the belt.
C. When the position of the air conditioner compressor is correct,
tighten adjustment plate bolt and nut, and the mounting bolt and
nut to secure it in position.
D. After adjusting the belt tension, repeat the testing procedure above
to check that the tension is adjusted within the standard value.
WA500-3LK
20-35 1
TORQUE CONVERTER STALL SPEEDS
12
TORQUE CONVERTER STALL SPEEDS

Measurement conditions
Coolant temperature: Inside operating range
Engine oil temperature: minimum 80 C (176 F)
Hydraulic oil temperature: 45 - 55C (113 - 131F)
Torque converter oil temperature: 70 - 90C (158 - 194F)
Check that the low and high idle speeds are at the standard value.
Before measuring at each stall speed, install tachometer (A), using the
instructions that came with it.
1.
Measuring torque converter stall

A. Start engine and run at low idle.
B. Put the directional lever in FORWARD or REVERSE, and speed
control lever in the highest speed range.
C. Using the brake, stop the machine and measure the engine speed
when the accelerator pedal is fully depressed.
Turn the transmission cut-off selector switch (1) to the OFF
position and use the left brake. (Check that the pilot lamp is
OFF).
Do not run at the stall speed for more than 20 seconds and do
not let the torque converter oil temperature raise above 120C
(248F).
Turn the parking brake switch OFF (release).
20-36 1
WA500-3LK
SHIFT LEVERS
12
SHIFT
LEVERS
Measurement conditions:
Engine stopped
Torque converter oil temperature: 60 - 80 C (140 - 176 F)
Measure at center of lever knob
OPERATING FORCE OF SPEED LEVER

Install push-pull scale l2 or a spring balance to the center of the control
lever knob, and measure the operating force when the lever is pulled in the
direction of operation.
Carry out the measurement for each speed range.
TRAVEL OF SPEED LEVER

Make a mark (1) at the center of the control lever knob, and measure the
travel when the lever is operated in the direction of operation.
WA500-3LK
20-37 1
ACCELERATOR PEDAL
12
ACCELERATOR PEDAL
OPERATING FORCE
1.
Measuring procedure
A. Put push-pull scale "A" in contact with the accelerator pedal at
point 150 mm from pedal fulcrum "a".
The center of push-pull scale must be in contact with a point
150 mm from the pedal fulcrum.
B. Start the engine, push the pedal in the direction of operation and
measure the maximum value when pushing from low idle to the end of the pedal travel (high idling).
Remark
There is no testing and adjustment (unit is electronically controlled).
20-38 1
WA500-3LK
ACCELERATOR PEDAL
12
OPERATING
ANGLE
1.
Measuring procedure
A. Stop the engine.
B. Put angle gauge "A" in contact with the accelerator pedal, then
measure the operating angle from low idle to high idle, and
calculate operating angle a = a1 - a2.
2.
Adjusting procedure
A. Remove the cover under the cab, and open the inspection cover on
the right side of the engine.
B. Loosen nut (1) and adjust bolt (2) so that pedal stroke angle is 13.
Remark
See drawing on previous page.
WA500-3LK
20-39 1
TORQUE CONVERTER AND TRANSMISSION
12

OIL PRESSURE
Coolant temperature: Inside operating range.
Torque converter oil temperature: 60 - 80C
Manual switch ON
WARNING! Apply the parking brake and block the
tires.
1.
Measuring main relief pressure

A. Remove the cover at the front of the engine and the cover at the
rear of the operators compartment.
B. Remove oil pressure measurement plug (PT1/8) (1), then install
oil pressure gauge C1 60 kgf/cm2 (853.4 lbf/in2).
C. Start the engine and measure the oil pressure with the engine at
low idling and high idling.
2.
Adjusting main relief valve

WARNING! Adjust the main relief valve with the
engine stopped.
If the main relief pressure is not within the standard value, adjust as
follows:
A. Remove plug (1) and washer (2).
B. Remove inner spring (3) and outer spring (4).
C. Adjust by changing the thickness of shim (5).
Standard shim thickness: 3.0 mm (0.5 x 6)
Amount of adjustment for one shim: 0.4 kg/cm2 (5.68 lbf/in2).
20-40 1
WA500-3LK

3.
Measuring torque converter relief (inlet port) pressure

oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.)
4.
Measuring torque converter outlet port pressure

A. Remove the cover at the left side of the transmission.
B. Remove oil pressure measurement plug (1) at the bottom of the
torque converter oil temperature sensor, then install oil pressure
gauge C1 60 kg/cm2 (853.4 lbf/in2).
high idling. (If the pressure is not affected by any adjustments, it
may indicate possible need for repair.
WA500-3LK
20-41 1
12
5. Measuring ECMV output (clutch) pressure
B. Remove the oil pressure measurement plug for the clutch to be
measured.
Plug for measuring 1st clutch pressure: (1)
Plug for measuring 2nd clutch pressure: (2)
Plug for measuring 3rd clutch pressure: (3)
Plug for measuring 4th clutch pressure: (4)
Plug for measuring reverse clutch pressure: (5)
Plug for measuring forward clutch pressure: (6)
Gasket sealant (LG-5)
C. Install oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).
D. Start engine and measure the 1st, 2nd, 3rd, and 4th clutch
pressures under the following conditions at high idling.
i.
Leave the directional lever at neutral.
ii.
Turn the main monitor manual switch ON.
iii. Place the gear shift lever at the speed range to be measured.
E. Start the engine and measure the forward and reverse clutch
pressures under the following conditions at high idling.
WARNING! Put blocks under the tires and depress
the brake securely.
F.
Turn the transmission cut-off selector switch OFF (lamp off).

i.
Turn the parking brake switch OFF.
ii.
Depress the brake.
iii. Turn the main monitor manual switch ON and place the
gearshift lever in 4th.
iv. Keep the brake depressed and place the directional lever at
F or R.
G. Measuring lubricating oil pressure (oil cooler outlet port)
i.
Remove the cover at the left side of the rear frame.
ii.
Remove the oil pressure measurement plug (1), then, install

oil pressure gauge C1 60 kg/cm2 (853.4 lbf/in2).
20-42 1
WA500-3LK
iii. Start the engine and measure the oil pressure with the engine at high idling. (If the pressure is not affected by any
adjustments, it may indicate possible need for repair.)
HYDRAULIC CIRCUIT FLUSHING

Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the life of the torque
converter and transmission, and will cause internal damage. To prevent this, flush the system to remove the dirt or metal
particles in the hydraulic circuit.
1.
Flush the circuit if the following conditions apply.

A. If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are
circulating in the hydraulic circuit.
B. When the torque converter and transmission have been overhauled or repaired.
2.
Install the flushing element.

A. Drain the oil from the filter case.
B. Remove the two transmission oil filters, then install two flushing elements (561-15-55670).
After flushing the system, assemble the parts that were removed, and the parts inside the case.
3.
Fill the transmission case with oil.

Add fresh oil through the oil filler port to the specified level, and run the engine to circulate the oil through the system.
Then check the level again.
Transmission case: 62 liters

4.
Carry out flushing as follows.

A. After starting the engine, run the engine for approximately 20 minutes at low idling without operating the speed lever
or directional lever.
From time to time, raise the engine speed to approximately 1500 rpm.
If the ambient temperature is low and the engine coolant temperature gauge does not enter the green range,
continue the warming-up operation longer.
B. Travel or carry out actual operations for at least 20 minutes.
Use all the speed ranges (FORWARD, REVERSE, and 1st - 4th).
C. Repeat the procedure in 4-A, and run the engine at low idling for approximately 20 minutes.
WA500-3LK
20-43 1
12
5. Replace the flushing element.
A. Using the procedure in step 2-A, replace the flushing element with the standard element (424-16-11140).
WARNING! If the flushing element is used for a long time, there will be premature clogging, so always
replace the flushing element with the standard element.
B. Add oil and check the level again.
6.
Replace the transmission fail safe filter.

A. Use a wrench to turn portion (A) of fail safe filter case (1) to
remove it.
If there is any dirt inside the filter case, wash the case.
B. Remove element (2) and replace with a new element.
C. Install new O-ring (3) to the outside circumference of the case.
Coat the outside circumference of the O-ring with a small
amount of grease.
D. Install the case.
Case: 39.2 Nm (28.9 lbf ft)
20-44 1
WA500-3LK
12
TRANSMISSION
VALVE FAILS - MOVING MACHINE
If the machine cannot be moved because of a failure in any part of the
transmission valve system (electrical system, solenoid valves, spools,
etc.), it is possible to move the machine by installing plate N.
WARNING! Plate N is only for emergency use when
the machine cannot be moved by any
other means because of a failure in the
transmission control valve system. DO
NOT install plate N to the ECMV except
when there has been a failure and it is
necessary to move the machine from a
dangerous working area to a safe place
for repairs.
WARNING! When carrying out this operation keep

strictly to the procedure and pay careful
attention to safety when moving the
machine.
WARNING! To prevent the machine from moving,
lower the work equipment completely to
the ground, apply the parking brake, and
put blocks under the tires.
WARNING! Carry out the operation with the engine
stopped.
WARNING! Be careful not to burn yourself if the oil is
hot.
1.
Remove the cover at the bottom of the operators cab, and the cab at
the bottom of the step on the left side.
2.
Remove valve cover (1).

Wash the area around the ECMV, clean and remove all dirt and
mud.
3.
Disconnect wiring connectors (2) thru (13).

For details of precautions when removing the wiring connectors, see Section 30, TRANSMISSION CONTROL
VALVE, REMOVAL.
WA500-3LK
20-45 1
12
4. Depending on the direction for moving the machine (forward or
reverse), remove the following 2 ECMV solenoids (14) and install
plate N.
FORWARD: F solenoid and 2nd solenoid
REVERSE: R solenoid and 2nd solenoid
If there is any mistake in the selection of the solenoid to
remove, there is danger that the transmission may be
damaged.
Install plate N with the protruding surface facing the ECMV.
Check also that there is an O-ring installed to the mating
surface.
Be careful not to let any dirt or mud get inside the removed
solenoid or valve
5.
Depress the left brake pedal securely.
6.
Start the engine, release the parking brake, then release the brake pedal
gradually to allow the machine to start, then move the machine.
WARNING! Remove the blocks from under the tires.
WARNING! When the engine is started, the

transmission is also engaged to start the
machine. To ensure safety when
starting the engine, check carefully that
the direction of travel and area around the
machine are safe, and always keep the
brake pedal depressed when starting.
WARNING! After moving the machine, stop the
engine, apply the parking brake, put
blocks under the tires.
20-46 1
WA500-3LK
STEERING WHEEL
12
STEERING
WHEEL
MEASURING PLAY
Engine speed: Stopped
Machine posture: Facing straight forward
Method of measurement
A. Move the steering wheel 2 or 3 times lightly to the left and right,
check that the steering mechanism is at the neutral position, then
make a mark on the outside frame of the machine monitor.
B. Turn the steering wheel to the right, and make a mark at the
position where the operating force starts to become heavy (when
the steering valve lever starts to move).
C. Turn the steering wheel to the left in the opposite direction from
Step 2, and make a mark at the point where the operating force
becomes heavy (when the steering valve lever starts to move).
Then measure the distance in a straight line between the marks
made in Step 2 and Step 3.
MEASURING OPERATING FORCE

Road surface: Flat, horizontal, dry paved surface
Engine water temperature: Within green range on engine water
temperature gauge
Hydraulic oil temperature: 45 - 55 C (113 - 131 F)
Tire inflation pressure: Specified pressure
Engine speed: Low idling (bucket empty)
Measurement method
A. Install push-pull scale l2 to the steering wheel knob.
B. Start the engine.
After starting the engine, raise the bucket approximately 400 mm and remove the safety bar.
C. Pull push-pull scale l2 in the tangential direction and measure the value when the steering wheel moves smoothly.
Avoid measuring when the steering wheel starts to move.
WA500-3LK
20-47 1

12
MEASURING
STEERING WHEEL
OPERATING TIME
temperature gauge
Engine speed: Low and high idling
Measurement method
A. Start the engine.
After starting the engine, raise the bucket approximately 400 mm and remove the safety bar.
B. Operate the steering wheel to the end of its stroke to turn the machine to the left or right.
C. Measure the time taken to operate the steering wheel to the end of the stroke to the right (left).
Operate the steering wheel as quickly as possible without using force.
Carry out the measurements both at low idling and high idling, and to both the left and right.
20-48 1
WA500-3LK
STEERING OIL PRESSURE
12
STEERING
OIL PRESSURE
WARNING! Install the safety bar to the frame.
MEASURING
1.
Measuring steering relief pressure

A. Remove oil pressure measurement plug (PT1/8) (1) from the
elbow at the right steering cylinder head end, then install oil
pressure gauge C1 400 kgf/cm2 (5689.3 lbf/in2).
B. Start the engine, run the engine at high idling, then turn the
steering wheel to the right and measure the pressure when the
relief valve is actuated.
When removing the oil pressure measurement plug on the left
steering cylinder, turn the steering wheel to the left.
2.
Measuring steering pilot pressure

A. Disconnect pilot hose (2) or (3) from steering valve (1).
B. Install the adapter and oil pressure gauge 60 kgf/cm2
(853.4 lbf/in2) inside tool C1.
C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.
Hose (2): Turn steering to right

Hose (3): Turn steering to left
WA500-3LK
20-49 1
STEERING OIL PRESSURE
12
3. Measuring Orbit-roll output pressure
A. Disconnect Orbit-roll output hose (1) or (2).
B. Install the adapter and oil pressure gauge 60 kgf/cm2
(853.4 lbf/in2) inside tool C1.
C. Start the engine and measure the oil pressure when the steering
wheel is turned with the engine running at high idling.
Hose (1): Turn steering to right
Hose (2): Turn steering to left
ADJUSTING
WARNING! Always stop the engine before adjusting
the pressure.
1.
Adjusting steering relief valve

A. Loosen locknut (2) of steering relief valve (1), then turn
adjustment nut (3) to adjust.
Turn the adjustment screw to adjust the set pressure as
follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE

Pressure adjustment for one turn of adjustment screw:
Approximately 151 kg/cm2 (2147.7 lbf/in2)
20-50 1
WA500-3LK
STEERING STOP VALVE
12
STEERING
STOP VALVE
TESTING
1.
Set the front and rear frames facing straight.
2.
Check that locknut (2) of stopper bolt (1) is not loose.
3.
Start the engine, and check that there is a clearance between the front
frame stopper and rear frame stopper when the steering is turned to the
right or left.
WARNING! Measure the clearance with the engine
stopped.
Measure the clearance between the front frame and rear frame
when steering stop valve contact surface (3) and stopper bolt (1)
coming into contact and the turning stops. - Standard clearance a:
40 5 mm
ADJUSTING
If the clearance between the front frame and rear frame is not within the
standard value, adjust as follows.
1.
Loosen locknut (2), tighten stopper bolt (1), and make sure that there is no contact with the steering stop valve.
2.
Start the engine, run at low idling, then turn the steering wheel slowly to bring the front and rear frames into contact.
When turning, be extremely careful not to get your arm or any other part of your body caught between the front and rear
frames.
3.
Stop the engine, then loosen the stopper bolt until it contacts the steering stop valve contact surface.
4.
Set the front and rear frames facing straight.
5.
Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2).
Carry out the procedure in Steps 1 - 5 to adjust both the left and right sides.
6.
Start the engine, turn the machine, and check that clearance a between the front and rear frames is within the standard
value for both the left and right and that the steering stopper valve and stopper bolt come into contact and the steering is
stopped.
WA500-3LK
20-51 1
BRAKE PEDAL
12
BRAKE PEDAL
temperature gauge
Engine speed: Low idling
OPERATING FORCE
1.
Install push gauge (1) to the operator's foot.

Align the center of the push gauge with the center of the pedal.
2.
Start the engine, run at low idling, and measure the operating force
when the pedal is depressed.
TRAVEL
1.
Install push gauge (1) to the operator's foot.

Align the center of the push gauge with the center of the pedal.
2.
Start the engine, and measure pedal angle a1 when running at low
idling, and pedal angel a2 when the pedal is depressed with a force of
294 N (66 lbf)
Install angle gauge (2) to the brake pedal when measuring.
PEDAL PLAY
1.
Start the engine.
2.
Push the brake pedal lightly by hand, and measure pedal angle a3 when
the pedal starts to become heavy.
20-52 1
WA500-3LK
BRAKE PERFORMANCE
12
BRAKE
PERFORMANCE
Travel speed: 20 km/h when brakes are applied
Delay in applying brakes: 0.1 sec.
MEASUREMENT METHOD
1.
Start the engine and move the machine.
2.
Set the speed lever to the highest speed position and drive the machine.
3.
When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force.
Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
Switch the transmission cut-off switch ON when carrying out this operation.
4.
Measure the distance from the point where the brakes were applied to the point where the machine stopped.
Repeat this measurement three times and take the average.
WA500-3LK
20-53 1
TESTING BRAKE OIL PRESSURE
12
TESTING BRAKE OIL PRESSURE

WARNING! Put blocks securely under the tires.
1.
Inspecting
A. Remove bleeder screw (1), then install oil pressure gauge tool 1
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.
B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.
C. Depress the left brake and measure the brake oil pressure.
2.
Measuring drop in brake piston pressure

A. Remove bleeder screw (1), then install oil pressure gauge tool l
400 kgf/cm2 (2942 lbf/in2), the joint, bleeder screw, and nipple.
B. Connect hose (2) to the bleeder screw and bleed the air from the
brake circuit. For details, see BLEEDING AIR.
C. Stop engine, depress the left brake pedal, leave for 5 min. with the
oil pressure at 50 kgf/cm2 (711 lbf/in2), and measure the drop in
Be careful not to move the brake pedal for 5 minutes.
After completing the operation, bleed the air from the brake
circuit again.
20-54 1
WA500-3LK
BRAKE DISC WEAR
12
BRAKE
DISC WEAR
Brake oil pressure: 50 5 kg/cm2 (711 71 lbf/in2)
WARNING! Park the machine on horizontal ground
and put blocks securely under the tires.
Measurement Method
1.
Remove plug (1).
2.
Depress the brake pedal fully.
3.
Use calipers M to measure depth a from the end face of the housing to
the spring guide.
When measuring, keep the brake pedal depressed.
4.
Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain
the brake oil.
After draining the brake oil, check that the brake piston has
returned to the end of its stroke.
5.
Measure depth b from the end face of the housing to the spring guide
pin.
Calculating Piston Stroke

S=a-b
WA500-3LK
S = Max. 8.5 mm
20-55 1
PARKING BRAKE
12
PARKING BRAKE
Performance
Road surface: Flat, dry, paved surface with 1/5 (1120') gradient.
Machine: In operation condition
Measuring Procedure
1.
Start the engine, set the machine facing in a straight line, then drive the
machine up a 1/5 grade slope with the bucket empty.
2.
Depress the brake, stop the machine, set the directional lever to the
neutral position, then stop the engine.
3.
Turn the parking brake switch ON, then slowly release the brake pedal,
and the machine must not move at all.
Carry out the measurement in two ways. Once with the machine
facing uphill, and once more with the machine facing downhill.
20-56 1
WA500-3LK
PARKING BRAKE
12
OIL
PRESSURE
1.
Measuring parking brake inlet port

A. Remove the transmission side cover.
oil pressure gauge C1 60 kgf/cm2 (853 lbf/in2)
C. Turn the parking brake switch OFF.
D. Start the engine and measure with the engine running at low idling
and high idling.
2.
Measuring parking brake pilot pressure

top of the transmission.
B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).
C. Start the engine and measure at high idling.
WA500-3LK
20-57 1
PARKING BRAKE
12
3. Measuring parking brake solenoid valve output pressure
top of the transmission.
B. Disconnect hose (1), then install adapter and oil pressure gauge in
tool C1 60 kgf/cm2 (853 lbf/in2).
C. Turn the parking brake switch OFF.
D. Start the engine and measure at high idling.
20-58 1
WA500-3LK
PARKING BRAKE
12
DISC
WEAR
If the parking brake effect becomes weak, measure the wear of the
parking brake disc as follows.
the ground and put blocks under the tires.
WARNING! Always stop the engine before carrying
out this procedure.
1.
Drain oil from the transmission case.
Transmission case: 62 liters (16.37 gal)

2.
Remove one of two plugs (1) on each side.
3.
Using calipers M, measure depth a from the end face of cage (2) to
piston (3).
Standard depth a: Max. 40.3 mm
4.
If depth a is greater than the specified value, remove parking brake

disc (4), and check thickness W of the disc. For details, see
DISASSEMBLY AND ASSEMBLY, PARKING BRAKE DISC,
REMOVAL.
Dimension W: Min. 3.2 0.1 mm
If the thickness of the parking brake disc is below the standard
value, replace it.
WA500-3LK
20-59 1

12
MANUAL
PARKING BRAKE
RELEASE METHOD
The parking brake is controlled by hydraulic pressure, so if there

should be any failure in the transmission and it becomes impossible to
release the parking brake, it is possible to release it manually to move
the machine.
WARNING! The manual release of the parking brake
is designed only to move the machine
from a dangerous working area to a safe
place where repairs can be carried out.
This method must not be used except
when there has been a failure
the ground and put blocks under the tires.
WARNING! Always stop the engine before carrying
out this procedure.
1.
Remove two plugs (1).

After releasing the parking brake, coat the plugs with gasket
sealant (LG-5), then tighten the plugs.
2.
Remove two cage mounting bolts (2), then screw them into the plug
mount gradually in turn.
When bolts (2) are screwed in, piston (3) is pulled and the parking
brake is released.
20-60 1
WA500-3LK
PPC VALVE
12
PPC
VALVE
OIL PRESSURE
Hydraulic oil temperature: 45 - 55 C (113 - 131 f)
MEASURING
1.
Measuring PPC pump pressure

A. Remove the cover at the top of the pump.
oil pressure gauge C1 400 kgf/cm2 (2942 lbf/in2).
C. Start the engine and measure the oil pressure at high idling.
2.
Measuring PPC valve basic pressure (orbit-roll basic pressure)

A. Disconnect hose (1), then install the adapter and oil pressure
gauge 60 kgf/cm2 (853 lbf/in2) in tool C1.
B. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.
WA500-3LK
20-61 1
PPC VALVE
12
3. Measuring PPC valve output pressure
WARNING! Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
WARNING! Operate the control levers several times
to release the pressure in the PPC
accumulator circuit.
A. Remove the main control valve cover.

B. Remove oil pressure detection plug (PT1/8) (1) of the circuit to be
measured, then install oil pressure gauge C1 60 kgf/cm2 (853 lbf/
in2).
Plug A: Boom LOWER, boom FLOAT
Plug B: Boom RAISE
Plug C: Bucket DUMP
Plug D: Bucket TILT
C. Start the engine, run the engine at high idling, then operate the
work equipment control lever and measure the oil pressure.
ADJUSTING
1.
Adjusting PPC relief valve

Loosen locknut (2) of PPC relief valve (1), then turn adjustment screw
(3) to adjust.
Turn the adjustment screw to adjust as follows:
To INCREASE the pressure, turn clockwise.
To DECREASE the pressure, turn counter clockwise.
Amount of adjustment - for one turn of adjustment screw:
18.3 kg/cm2 (260 lbf/in2)
Locknut: 83.4 4.9 Nm (61.5 3.6 lbf ft)
After completion of the adjustment, re-check the accumulator
charge cut-in pressure and cut-out pressure again. Refer to
ACCUMULATOR CHARGE PRESSURE.
20-62 1
WA500-3LK
PPC VALVE
12PPC
ADJUSTING
LINKAGE
1.
Remove cover (1) at the bottom of the work equipment control lever.
2.
Adjust dimension a from nut (1) of the PPC valve linkage to the top
surface of the floor.
Dimension a (target value): 54 mm
3.
Loosen nuts (2) and (3), then adjust the installed height of trunnion (5)
so that there is no play in lever (4).
4.
After adjusting, tighten nuts (2) and (3).
WA500-3LK
20-63 1
ACCUMULATOR
12
ACCUMULATOR
CHARGE PRESSURE
MEASURING
WARNING! Stop the engine, then depress the brake
pedal at least 100 times to release the
pressure inside the accumulator circuit.
1.
Disconnect accumulator inlet port hose (1), then install the adapter and
oil pressure gauge 400 kg/cm2 (2942 lbf/in2) in tool C1.
2.
Measure the accumulator charge cut-in pressure. Start the engine, run
at low idling, and measure the oil pressure when the brake oil pressure
warning pilot lamp on the maintenance monitor goes out.
3.
Measure the accumulator charge cut-out pressure. After the

accumulator charge cut-in, the pressure rises. Measure the oil pressure
at the point where the oil pressure gauge indicator suddenly drops after
rising.
ADJUSTING
When the accumulator charge cut-out pressure is adjusted, the cut-in
pressure also changes because of the valve area ratio. For this reason,
there is no cut-in pressure adjustment nut.
1.
Loosen locknut (2) of the accumulator charge cut-out valve (1), then
turn adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows:
Amount of adjustment - for one turn of adjustment screw:
57 kg/cm2 (810 lbf/in2)
Locknut: 10.78 0.98 Nm (7.9 0.72 lbf ft))

After completion of the adjustment, repeat the above procedure
for test to check the accumulator charge cut-in pressure and
cut-out pressure again.
20-64 1
WA500-3LK
WORK EQUIPMENT
12
WORK
EQUIPMENT
HYDRAULIC PRESSURE
WARNING! Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
1.
Measuring main control valve basic pressure (hydraulic pump

pressure)
A. Remove the cover at the rear of the operators cab.
B. Remove oil pressure measurement plug (PT1/8) (1) in the
hydraulic pump tube, then install oil pressure gauge C1
(60 kg/cm2 (853 psi)).
2.
Measuring work equipment relief pressure

A. Raise bucket portion a approximately 30 - 50 mm and set portion
b in contact with the ground.
B. Stop the engine, then operate the work equipment control lever
and check that the bottom surface of the bucket (both portion a
and portion b is in contact with the ground.
After lowering the bucket to the ground, operate the work
equipment control lever several times to release the
remaining pressure in the piping.
C. Remove the cover at the top of the main control valve.

D. Remove oil pressure measurement plug (PT1/8) (1), then install
oil pressure gauge C1 400 kgf/cm2 (2942 lbf/in2).
WA500-3LK
20-65 1
WORK EQUIPMENT
12
E. Start the engine, raise the lift arm approximately 400 mm, run the
engine at high idling, tilt the bucket back, then measure the oil
pressure when the relief valve is actuated.
WARNING! After measuring, repeat the procedure
used when installing the oil pressure
gauge to release the pressure inside the
circuit, then remove the oil pressure
gauge.
ADJUSTING
1.
Adjusting work equipment relief valve.

A. Loosen locknut (2) of work equipment relief valve (1), then turn
adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows.
Amount of adjustment for one turn of adjustment screw:
52.9 kg/cm2 (752 lbf/in2)
Locknut: 39.2 9.8 Nm (28.9 7.2 lbf ft)

After completion of the adjustment, repeat the above procedure to
measure the work equipment relief pressure again.
20-66 1
WA500-3LK

12
CUT-OFF
WORK EQUIPMENT
VALVE
TESTING FUNCTION
In some cases the Cut-Off Valve, which unloads the Switch Pump when the Loader circuit reaches a set pressure (175 kg/cm2
[2489 lbf/in2]), fails to function. The following procedure outlines a method to test the hydraulic function to determine if the
Cut-Off valve is working. This method is intended only to determine if the valve is unloading. If it is indicated that the unload
function is not working, further tests must be conducted to determine the failure mode and root cause of valve malfunction.
PROCEDURE
1.
This procedure requires two people to conduct the test.
2.
With the machine at operating temperature, operate the machine in the following manner.
3.
Park the machine on a level surface in an area where there is ample light to view the center hinge area.
4.
Set the parking brake, extend the bucket cylinder to full stroke (bucket rolled back), and run the engine at low throttle.
5.
While standing clear of the machine, the second person takes a

position to one side at a location that allows clear view of the center
hinge area where the hydraulic hoses pass through. The Loader and
Switch hoses must be identified. On the WA500-3, it is easier to view
from the right side with the machine steered to the left.
6.
Keeping the engine at low throttle and bucket cylinder extended to full
stroke (bucket rolled back), meter the bucket cylinder control lever in
the curl (extend) direction so that the loader circuit pressure rises to
relief. During this operation the hydraulic hoses will flex as the
pressure increases in the circuit. At a point between mid-stroke and
end-stroke of the bucket control lever, the system pressure will reach a
level that should activate the Cut-Off valve in the Switch Pump circuit.
7.
As the Cut-Off valve actuates, the pressure in the Switch Pump circuit will drop immediately. The switch circuit hose
passing through the center hinge area can be seen to relax from its flexed condition. This is observed as a sudden
movement or "sag" in the hose. The Loader circuit hose will remain flexed.
8.
The person on the ground will be able to detect this relaxation by careful observation.
9.
If this is observed, the Cut-Off valve is activating. If the Switch Pump hose does not relax, the Cut-Off valve is
malfunctioning and further hydraulic testing on the Cut-Off valve is required.
WA500-3LK
20-67 2
WORK EQUIPMENT
12
MEMORANDUM
20-68 2
WA500-3LK

12
LEVER
WORK EQUIPMENT
LINKAGE
ADJUSTING
Always stop the engine before adjusting the work equipment lever
linkage.
Check that the operating effort of the work equipment control lever is
within the standard value.
1.
Do as follows to set solenoid (1) in a pulled condition.

A. Disconnect wiring connectors (F05) (2) and (F06) (3).
F05:
Proximity switch for bucket positioner
F06:
Proximity switch for boom kick-out
B. Connect a T-adapter, then connect the terminals between (1)
and (2).
Check that the solenoid is pulled l2 mm.
2.
With the solenoid pulled, move solenoid (1) so that clearances a

between boom lever cam (4) and boom lever cam follower (5) and
between bucket lever cam (6) and bucket lever cam follower (7) are
each 0 - 0.5 mm.
Carry out the adjustment with the boom and bucket levers at the
HOLD position.
3.
Operate the boom lever and adjust distance c between the pins of rod
(8) so that clearance b between the notches at both ends of boom lever
cam (4) and boom lever cam follower (5) is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
4.
Operate the bucket lever and adjust distance c between the pins of rod
(8) so that clearance d between the notches (1 place) bucket lever cam
(6) and bucket lever cam follower (7) is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
WA500-3LK
20-69 1
BUCKET POSITIONER
12
BUCKET POSITIONER
TESTING
1.
Start the engine, operate the bucket and actuate proximity switch (1),
then stop the engine and measure clearance a between the proximity
switch and angle (2).
Standard clearance a: 3 - 5 mm
2.
Run the engine at mid-range speed (1500 rpm), actuate the proximity
switch, and check that the bucket angle is 0 - 1 facing down when the
bucket is lowered to the ground. Measure dimension b between the
center of the proximity switch to the tip of the angle.
Measure three times and take the average.
Standard dimension b: 15 mm
ADJUSTING
1.
If dimension a is not within the standard value, adjust as follows:

A. Adjust mounting nut (4) so that clearance c between the tip of the
switch protector (3) and the sensing surface of proximity switch
(1) is the standard value.
Standard clearance c: 0.5 - 1.0 mm
Mount nut: 17.15 2.45 Nm (12.6 1.8 lbf ft))

B. Adjust with washer (5) and shim (6) so that clearance a between
the sensing surface of proximity switch (1) and angle (2) is the
standard value.
Adjust with shim (6) so that clearance a is within the standard
value for the whole stroke of the angle.
Secure in position, making sure that the center of proximity
switch sensing surface and the angle do not move away from
the center.
After adjusting, operate the bucket lever and check that the
proximity switch is actuated normally.
2.
If the bucket angle and dimension b are not within the standard value,
move angle (2) to adjust.
20-70 1
WA500-3LK
BOOM KICK-OUT POSITIONER
12

WARNING! Always be sure to apply the safety lock to
work equipment control lever.
TESTING
1.
Start the engine, operate the boom lever to actuate proximity switch
(1), then stop the engine and measure dimension a between the center
of proximity switch (1) and the top of plate (2).
Standard clearance a: 0 - 5 mm
2.
Measure dimension b between the proximity switch sensing surface

and the plate.
Standard dimension b: 3 - 5 mm
ADJUSTING
1.
If the dimension a is not within the standard value, move the plate to
adjust.
2.
If dimension b is not within the standard value, adjust proximity

switch mounting nut (3).
Mounting nut: 17.15 2.45 Nm (12.6 1.8 lbf ft)

After adjusting, operate the boom lever and check that the proximity switch is actuated normally.
WA500-3LK
20-71 1
12
Proximity switch actuation pilot lamp (red)
The proximity switch is equipped with a pilot lamp which shows when it is
being actuated, so use this when adjusting.
Proximity switch
actuation
pilot lamp
Detector position
Lights up
When detector is positioned at detection surface
of proximity switch
Goes out
When detector has moved away from detection surface of
proximity switch
Bucket
positioner
Boom kick-out
20-72 1
WA500-3LK
12
INITIAL TEACHING METHOD
The transmission controller is equipped with a learning function to self compensate so that it provides a constant gear
shifting feeling to match the changes in the transmission clutches occurring with the wear.
If the transmission is overhauled or replaced, the transmission controller keeps the control command values learned to
match the previous transmission. For this reason, transmission shock or abnormal noise may occur. After operating the
machine for a short time, the controller will learn to match the condition of the new transmission and will gradually return
to the normal condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to
reset the learning data and to carry out initial learning as follows.
1.
Method for resetting learning control data

Do as follows to return all the previously learned control data in
the controller to the default values.
A. Check that the starting switch is at the OFF position.
B. Remove the cover at the right side of the work equipment control
box.
C. Disconnect wiring connector (C3B) (1) and connect T-adapter P
to the controller only (leave the harness hanging).
D. Turn the starting switch ON.
Do not start the engine.
E. Short circuit between terminals No. (1) to (16) for at least one second, then return them to free condition.
2.
Initial learning method

To adjust the controller learning control data for each clutch from the default settings to the optimum values, first
carry out the above Step 1 "Method of resetting learned control data", then do as follows.
A. Stall the torque converter. For details, see ENGINE SHOP MANUAL.
B. Operate the speed lever and directional lever as follows.
N F1 F2 F3 F4 N R1 N
Operate the levers with the engine running at low idling, the transmission cut-off selector switch at OFF, and the
manual switch at ON.
It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.
WA500-3LK
20-73 1
12
C. When the torque converter oil temperature gauge rises to the 2nd level on the maintenance monitor, return engine
to low idling.
Target value for torque converter oil temperature: 40 - 50 C (104 - 122 F)
There is no problem if oil temperature gauge goes down to the lst level.
D. Operate the speed lever and directional lever twice in succession as follows:
N F1 F2 F3 F4 F3 F2 F1 N R1 N
Operate the levers with engine running at low idling, transmission cutoff selector switch at OFF, and the manual
switch at ON.
Hold for the following periods of time for each speed range.
Speed range 4 only: 3 seconds
Other speed ranges: 2 seconds
After carrying out gear shifting operation in Step B, if engine is stopped before carrying out the gear shifting
operation in Step D, repeat Step B again.
It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.
WARNING! Check area around the machine to be sure it is safe and depress the left brake securely
when shifting gear.
20-74 1
WA500-3LK
MAIN MONITOR
12
MAIN MONITOR
ADJUSTMENT PROCEDURE
The speedometer on the main monitor is a common part for all machines, the input signal for the travel speed differs
according to the machine, so it is necessary to adjust the monitor for use with a particular model.
In addition, the tire diameter also differs according to the size of tires used, so it is necessary the monitor to give the
correct travel speed.
It is also necessary to change the switches if the machine has E.C.S.S. (Electronically Controlled Suspension System)
installed.
1.
On the back of the monitor panel are 4 switches identified as

DIP SW1 (1), DIP SW2 (2), DIP SW3 (3), and DIP SW4 (4).
The settings of these switches has an effect on the speedometer
readout and ride control.
2.
When the rubber caps are removed, a rotary switch can be seen
inside. Using a flat-blade screwdriver, turn the dipswitch to adjust
the settings per the tables on the following pages.
WA500-3LK
20-75 1

3.
MAIN MONITOR
DIP SW1, DIP SW2, and DIP SW3 are rotary switches.
DIP SW1
Controls model and whether the monitor

displays miles per hour (mph) or kilometers per
hour (Km/h).
DIP SW2
Adjusts for different tire sizes, so speedometer

readout is correct.
DIP SW3
Sets monitor panel to display either engine

speed (rpm) or road speed, not both.
DIP SW1, DIP SW2, and DIP SW3 SWITCH SETTINGS

DIP SW3
Tire Size
DIP SW1
DIP SW2
Speedometer
Tachometer
(See Note)
29.5 x 25
km/h
29.5 x 25
mph
The tachometer feature will only work on loaders equipped with the "Autoshift" transmission.
4.
DIP SW4 is a combination of 4 small ON/OFF switches.
DIP SW4
Setting is for ride control (E.C.S.S.)
DIP SW4 SWITCH SETTINGS

Switch No.
Without ECSS
With ECSS
ON
ON
ON
ON
ON
OFF
OFF
OFF
20-76 1
WA500-3LK
BLEEDING AIR
12
BLEEDING AIR
WARNING! Put blocks securely under the tires
1.
Bleeding air from brake system

A. Remove cap (1) of the bleeder screw, insert a vinyl hose into the
screw, and insert the other end in a container.
B. Start the engine.
C. Depress the brake pedal, then loosen the bleeder screw and bleed the air.
This operation is carried out with two workers. One worker operates the brake pedal while the other bleeds the
air from the bleeder screw.
When depressing the brake pedal, use the left pedal.
D. When no more air bubbles come out with the fluid from the hose, depress the pedal fully and tighten the bleeder
screw while the oil is still flowing.
Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level
in the oil tank and add more oil if necessary.
To bleed the air completely, bleed the air first from the cylinder which is farthest from the brake pedal.
2.
Bleeding air from the hydraulic cylinders.

A. Start the engine and run at idling for approximately 5 minutes.
B. Run the engine at low idling, the raise and lower the boom 4 - 5 times in succession.
Operate the piston rod to a point approximately 100 mm before the end of its stroke. Do not relieve the circuit
under any circumstances.
C. Run the engine at full throttle and repeat step B. After that, run the engine at low idling, and operate the piston rod to
the end of its stroke to relieve the circuit.
D. Repeat steps B and C to bleed the air from the bucket cylinder.
When the cylinder has been replaced, bleed the air before connecting the piston rod.
WA500-3LK
20-77 1
RELEASING REMAINING HYDRAULIC OIL PRESSURE
12
RELEASING REMAINING HYDRAULIC OIL PRESSURE

1.
Releasing remaining pressure between each hydraulic cylinder and control valve.
If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining
pressure from the circuit as follows:
A. Stop the engine.
B. Release the oil filler cap slowly to release the pressure inside the tank.
C. Operate the control levers.
When the levers are operated 2 - 3 times, the pressure stored in the PPC accumulator is removed. Start the
engine, run at low idling for approximately 5 minutes, then stop the engine and operate the control levers.
Repeat the above operation 2 - 3 times to release all the remaining pressure.
2.
Releasing remaining pressure in brake accumulator circuit.

If the piping between the brake accumulator and emergency parking brake valve, between the accumulator and check
valve, and between the accumulator and brake valve is to be disconnected, release the remaining pressure from the
circuit as follows.
Stop the engine.
Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit.
3.
Releasing remaining pressure PPC accumulator circuit.

If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from
the circuit as follows:
Repeat the above operation 2 - 3 times to release all the remaining pressure.
20-78 1
WA500-3LK
ADJUSTING JOYSTICK LEVER POTENTIOMETER
12

PREPARATORY WORK
Loosen the potentiometer mounting screws, remove potentiometer
connector CN JS2, then connect a T-adapter (X type 3-pin)
Turn the starter switch OFF before doing this.
ADJUSTING
1.
Adjusting neutral position

A. Set the joystick selector switch to the OFF position and set the
joystick lever to the N position.
B. Turn the starter switch ON.
Turn only to the ON position. Do not start the engine.
C. Check the voltage between pins c and d of the T-adapter.

Voltage between pins: DC 5V 0.05V Adjust the voltage by
turning the potentiometer slowly so that the voltage between
pins b and d of the T-adapter become the standard value.
Voltage between pins: DC 2.5V 0.1V (set value)
After adjusting the voltage, tighten the potentiometer screws.
WA500-3LK
20-79 1
12
2.
Adjusting the left turn and right turn potentiometer output.

A. Operate the Joystick lever to adjust the voltage output from the
potentiometer at the full stroke left turn and right turn positions.
Lever position
Voltage between pins (1) and (3)
Left turn,
Full stroke (Approximately 20)
DC 0.83 0.1 V
Right turn,
Full stroke (Approximately 20)
DC 4.17 0.1 V
B. After adjusting the voltage, lock the stopper bolt in position.
20-80 1
WA500-3LK
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION
12
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH

PREPARATORY WORK
After adjusting the neutral position with the potentiometer, set the lever to the neutral position and loosen the nut of the cam
plate.
ADJUSTING
1.
Set so that the tip of the roller of the neutral detection switch contacts
the concave portion of the cam plate, then tighten the switch mount
bolts.
Never make the roller of the neutral detection switch push into the
concave portion of the cam plate.
2.
Tighten the nut so that the cam plate is not at an angle.
WA500-3LK
20-81
ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION
12
MEMORANDUM
20-82
WA500-3LK
TROUBLESHOOTING GENERAL
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-112
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
JUDGEMENT OF POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
PRECAUTIONS WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
METHODS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING
PARTS DURING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
PREVENTING RECURRENCE OF TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
OIL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
CLEANING FRAGMENTS OF DAMAGED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
CATEGORY OF TROUBLESHOOTING CODE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE. . 20-120
METHOD OF USING MATRIX TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
METHOD OF USING ENGINE RELATED CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
WA500-LK
20-101
TROUBLESHOOTING
12
MEMORANDUM
20-102
WA500-LK
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLE-
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and
parking brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the
agreed signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out
and cause burns, so wait for the engine to cool down before starting
troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating
parts.
WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the
battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil,
water or air, always release the internal pressure first. When installing measuring
equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a
short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure
that would produce the reported symptoms.
1.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the
user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2.
Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F.
Has the same kind of failure occurred before?
WA500-LK
20-103
TROUBLESHOOTING
3.
POINTS TO REMEMBER WHEN TROUBLE-
Check before troubleshooting.

A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.
Confirming the failure.

A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5.
Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i.
Start from the simple points.
ii.
Start from the most likely points.
iii. Investigate other related parts or information.

6.
Measures to remove root cause of failure.

A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-104
WA500-LK
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLE-
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA500-LK
20-105
TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS 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 hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRIC

EQUIPMENT
1.
Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and disconnecting
one wire from another wire, and protector or tubes used for protecting
the wiring. Compared with other electrical components fitted in boxes
or cases, wiring harnesses are more likely to be affected by the direct
effects of rain, water, heat, or vibration. Furthermore, during
inspection and repair operations they are frequently removed and
installed again, so they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely careful when handling
wiring harnesses.
2.
Main failures occurring in wiring harness

A. Faulty contact of connectors
(faulty contact between male and female).
Problems with faulty contact are likely to occur because the
male connector is not properly inserted into the female
connector, or because one or both of the connectors is
deformed or the position is not correctly aligned, or
because there is corrosion or oxidation of the contact
surfaces.
B. Defective compression or soldering of connectors
The pins of the male and female connectors are in contact
at the compressed terminal or soldered portion, but there
is excessive force on the wiring, and the plating peels to
cause improper connection or breakage.
20-106
WA500-LK
TROUBLESHOOTING
12
C. Disconnections in wiring
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or the
soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector

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

If oil or grease are stuck to the connector and an oil film is formed
on the mating surface between the male and female pins, the oil
will not let the electricity pass, and this will cause a defective
contact.
If there is oil or grease or dirt stuck to the connector, wipe it off
with a dry cloth or blow dry with air, and spray it with a contact
restorer.
When wiping the mating portion of the connector, be careful
not to use excessive force or deform the pins.
If there is water or oil present, it will increase the
contamination of the points, so clean with air until all water
and oil has been removed.
WA500-LK
20-107
TROUBLESHOOTING
12
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors
i.
Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors and
not the wires. For connectors held by a screw, loosen the
screw fully, then hold the male and female connectors in each
hand and pull apart. For connectors which have a lock
stopper, press down the stopper with your thumb and pull the
connectors apart.
ii.
When removing the connectors from the clips, pull the

connector in a parallel direction to the clip.
If the connector is twisted to the left and right or up and
down, the housing may break.
iii. When disconnecting male and female connectors, release the

lock and pull in parallel with both hands.
Never try to pull apart with one hand.
20-108
WA500-LK
TROUBLESHOOTING
12
iv. Action to take after removing connectors.
After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
B. Connecting connectors
i.
Check the connector visually.

Check that there is no oil, dirt, or water stuck to the connector pins (mating portion).
Check that there is no deformation, faulty contact, corrosion, or damage to the connector pins.
Check that there is no damage or breakage to the outside of the connector.
If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this
will cause short circuits.
If there is any damage or breakage, replace the connector.
ii.
Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment of

the wiring harness.
For connectors fitted with boots, correct any protrusion or the
boot. In addition, if the wiring harness is misaligned, or the
clamp is out of position, adjust it to its correct position.
When blowing with dry air, there is danger that the oil in
the air may cause improper contact, so clean with properly filtered air.
WA500-LK
20-109
TROUBLESHOOTING
12
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and check
that there is no looseness of the clamp.
C. Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a
dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i.
Disconnect the connector and wipe off the water with a dry
cloth.
If the connector is blown dry with air, there is the risk that
oil in the air may cause a faulty contact, so avoid
blowing with air.
ii.
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
Hot air from the dryer can be used, but be careful not to
make the connector or related parts too hot, as this will
cause deformation or damage to the connector.
iii. Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and carry
out a continuity test to check for any short circuits between
pins caused by water.
After completely drying the connector, spray it with contact restorer and reassemble.
20-110
WA500-LK
TROUBLESHOOTING
12
HANDLING
CONTROL BOX
1.
The control box contains a microcomputer and electronic control

circuits.
This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.
2.
Do not open the cover of the control box unless necessary.
3.
Do not place objects on top of the control box.
4.
Cover the control connectors with tape or a vinyl bag.
5.
Do not leave the control box in a place where it is exposed to rain.
6.
Do not place the control box on oil, water, or soil, or in any hot place,
even for a short time.
(Place it on a suitable dry stand)
7.
Precautions when carrying out arc welding

When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
WA500-LK
20-111
TROUBLESHOOTING
12
POINTS
TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the

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

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

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the equipment.
It is also difficult to confirm the performance after repairs, so it is
desirable to use unit exchange. Disassembly and maintenance of
hydraulic equipment should be carried out in a specially prepared dust
proof workshop, and the performance should be confirmed with
special test equipment.
3.
Seal or cover all openings of disconnected piping

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag, this
could cause particles or dirt to get into the system.
Drain all oil into a container and not unto the ground and be sure to
follow the proper environmental regulation for any disposal of oil.
4.
Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around
it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that
has collected during storage, so this is an even more effective method.
20-112
WA500-LK
TROUBLESHOOTING
12
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. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is carried out with the
specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump, control valve, etc.) or
when running the machine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the ultra fine (about 3)
particles that the filter built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
WA500-LK
20-113
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Hydraulic,
mechanical
equipment
Electrical
equipment
Lubricating oil, cooling water
Item
Electrical equipment
Remedy
1. Check fuel level, type of fuel
Add fuel
2. Check for impurities in fuel
Clean, drain
3. Check hydraulic oil level
Add oil
4. Check hydraulic filter (Torque converter, transmission oil)
Replace
5. Check brake oil level
Add oil
6. Check engine oil level
Add oil
7. Check coolant level
Add coolant
8. Check dust indicator for clogging
Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
10. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring
Repair or replace
12. Check operation of instruments
Repair or replace
13. Check for abnormal noise, smell
Repair
14. Check for oil leakage
Repair
15. Carry out air bleeding
Bleed air
16. Check effect of parking brake, wheel brake
Adjust, repair or
replace
23 - 26 V
Repair or replace
17. Check battery voltage (engine stopped)
20-114
Judgement
standard
18. Check battery electrolyte level
Add or replace
19. Check for discolored, burnt, exposed wiring
Repair or replace
20. Check for missing wiring clamps, hanging wire
Repair
21. Check for water leaking on wiring (pay particular attention to

water leaking on connectors or terminals)
Disconnect
connector and dry
Replace
22. Check for blown, corroded fuses

23. Check alternator voltage (engine running at 1/2 throttle or above)
(If the battery charge is low, the voltage may be approximately. 25V
immediately after charging
24. Sound of actuation of battery relay
(when starting switch is turned ON, OFF
27.5 - 29.5 V
-
Check, repair or
replace
Replace
WA500-LK
TROUBLESHOOTING
JUDGEMENT OF POWER TRAIN
12
JUDGEMENT OF POWER TRAIN

To judge if any abnormality in the power train is in the electrical system of the transmission or in the transmission itself, use
the following judgement flow chart. If the abnormality is in the electrical system, carry out troubleshooting for E-5, and if the
abnormality is in the transmission system, go to troubleshooting T-1 - T-4.
Testing transmission solenoid

WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower
the bucket to the ground and stop the engine. Then apply the parking brake and
put blocks under the wheels to prevent the machine from moving.
1.
Install a T-adapter checker to connector CNFT1, and check the voltage between the connector pins and the chassis ground.
2.
Turn the start switch ON.

Do not start the engine under any circumstances.
3.
Turn the parking brake switch ON OFF (release).
4.
When using the foot brake, press the right brake so that the transmission cut-off is not turned off.
WA500-LK
20-115
TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING
12

SAFETY
WARNING! Stop the machine on level ground, and check that the safety pins and parking brake are
correctly applied, and that the tires are blocked.
WARNING! When working in groups, use agreed upon signals and do not allow unauthorized persons near machine.
WARNING! Be careful not to get burned by hot parts or get caught in rotating parts.
WARNING! Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wiring.
WARNING! Always release the pressure before removing the plugs or caps of any place under
hydraulic or air pressure, and connect all measuring tools correctly.
METHODS FOR TROUBLESHOOTING

Just because a failure occurs, do not immediately start to disassemble the machine.
The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be
unknown.
As a result,
The customer and operator will lose confidence in you.
Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems, use the following procedure when troubleshooting.
1.
Ask the customer and operator the following questions about the breakdown.
A. Was there anything unusual before the machine broke down?
B. Have there been any other problems apart from the one reported?
C. Did the breakdown occur suddenly, or had there been signs of trouble before?
D. What was the machine doing when break down occurred?
E. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?
F.
2.
Had the same kind of failure occurred before?
Check the following items which can be checked simply by visual checks etc.
A. Check oil level.
B. Check for leakage of oil from piping or hydraulic equipment.
C. Check travel of control levers.
D. Check stroke of spool in control valves.
20-116
WA500-LK
TROUBLESHOOTING
3.
Reenact the failure and check the condition of the machine (particular conditions at the time of failure).
A. Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or
by feeling.
B. Compare extent of failure with standard values.
C. Check safety before carrying out any check.
D. Did not make any check or measurement that will make the condition worse.
4.
Try to locate the possible causes for the failure.

The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical
control.
In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as
follows;
Transmission itself, or transmission control valve.
Transmission electric control.
To decide which of the two is the location of the failure, refer to JUDGMENT ON POWER TRAIN.
5.
Carry out troubleshooting using the troubleshooting charts.

There are the following two types of troubleshooting charts.
A. TROUBLESHOOTING TABLE
POWER TRAIN
STEERING SYSTEM
BRAKE AND AIR SYSTEM
WORK EQUIPMENT SYSTEM
B. TROUBLESHOOTING FLOW CHART

ELECTRICAL SYSTEM
The troubleshooting charts consist of:
i.
Items which can be checked easily.
ii.
Items which are likely to be the cause of such failures.
Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points.
Check related items.
Check that there are no other failures or breakdowns.
6.
Investigate causes of breakdown

Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur
again. To investigate and remove the original cause, see "Actions to take to prevent failures from occurring again".
WA500-LK
20-117
TROUBLESHOOTING
12
PRECAUTIONS
WHEN REMOVING, INSTALLING, DISASSEMBLING OR

ASSEMBLING PARTS DURING TROUBLESHOOTING
Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting".
When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and
bottom.
Check the match marks, or make match marks to prevent mistakes when installing.
If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the
part to see if there is any problem with it and remove the problem before trying to disassemble the part.
When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before
coating with gasket sealant.
20-118
WA500-LK
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
12
PREVENTING RECURRENCE OF TROUBLE
The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment.
However, it is not able to establish the root cause of the damage or failure.
Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention
what action should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to the following items.
Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the
Shop Manual.
HYDRAULIC EQUIPMENT
OIL CHECKS
The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign
matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and
then take appropriate action.
1.
Oil checks
Check for water contamination.
Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate.
Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank
and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a
contamination checker.
Viscosity check
Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory.
2.
Check of contamination point

If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is
necessary to find out where the contamination is occurring and also to take steps to prevent it.
Water:
Oil storage tank, breather, etc.
Sand:
Oil replenishing or replacing method, etc.
Rubber:
Cylinder packing, etc.
Metal:
Wear or damage to hydraulic equipment such as pump and motor, as well as transmission
and torque converter, etc.
3.
Oil cleaning and replacement

If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil
refresher or replace it.
If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher.
When washing the oil, also wash or replace the strainer and replace the filter.
CLEANING FRAGMENTS OF DAMAGED PARTS

If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil.
In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other
foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the
engine or hydraulic equipment.
WA500-LK
20-119
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
12
METHOD OF USING TROUBLESHOOTING CHARTS

CATEGORY OF TROUBLESHOOTING CODE NUMBER
Troubleshooting code No.
Troubleshooting of Component
D - 00
ECSS (Electronically Controlled Suspension System)
E - 00
Chassis Electrical System - See Remark
H - 00
Hydraulic and Mechanical System
J - 00
Joystick Steering Controller System
K - 00
Maintenance Monitor System
M - 00
Main Monitor System
S - 00
Engine System - See ENGINE SHOP MANUAL
T - 00
Transmission Controller System
Remark
Troubleshooting code number E-00 Engine Electrical System are found in the ENGINE SHOP MANUAL.
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH

TROUBLESHOOTING MODE.
1.
Troubleshooting code number and problem.

The title of the troubleshooting chart gives the troubleshooting code, service code and failure mode (problem with the
machine). (See Example (1)).
2.
Distinguishing conditions.
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small
letters (for example, (a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in the failure
mode. (See Example (2)).
3.
Method of following troubleshooting chart.
Check or measure the item inside

, and according to the answer, follow either the YES line or the NO line to
go to the next
condition box. (Note: The number at the top right corner of the
condition box is an index
number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause
column. Check the cause and take the action given in the Remedy column on the right. (See Example (3))
Below the
condition box, there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the
condition box are correct or the answer to the question inside the
condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to the question in NO,
then follow the NO line.
Below the
condition box is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is
the danger that it may cause mistaken judgement or the equipment may be damaged. Therefore, before starting
inspection or measurement, always read the instructions carefully, and start the work in order from the first item 1.
20-120
WA500-LK
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
12
4. General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the
top of the page and marked with a !.(See Example (4)).
The precautions marked ! are not given in the
condition box, but must always be followed when carrying out the
check inside the condition box.
5.
Troubleshooting tools
When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING,
ADJUSTING AND TROUBLESHOOTING.
6.
Installation position, pin number.

A diagram or chart is given for the connector type, installation position, and connector pin number connection. When
carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and
measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode
(problem).
< Example >

(1) M-15 Abnormality in buzzer
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
(3)
(4)
! Before carrying out troubleshooting, check that all the related connectors are properly inserted.
! Always connect any disconnected connectors before going on to the next step.
WA500-LK
20-121
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLE-
12
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of 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 2. Checks before troubleshooting

Before starting the main troubleshooting and measuring the
hydraulic pressure, first check the Checks before Starting
items, and check for oil leaks and loose bolts. These checks
may avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting are items
which must be considered particularly for that symptom
before starting troubleshooting.
Step 3. Using cross-reference table
A. Operate the machine to carry out the checks in the
troubleshooting item column.
Mark the items where the results match the
symptom.
It is not necessary to follow the troubleshooting checks in order; follow an order which is
easiest to carry out troubleshooting.
B. Find the appropriate cause from the cause column.
If the symptom appears, the O, 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 O:
Carry out the other troubleshooting items (where
the same cause is marked with check if the symptom appears, then repair.
If there are two O:
Go on to Step 3) to narrow down the possible
causes.
20-122
1.
Steering does not work
Symptom [Example]
Ask the operator about the following points.

Did the steering suddenly stop working? Breakage in
steering equipment
Did the steering gradually become heavy? Internal wear
of steering equipment, defective seal.
Checks before starting [Example]
Is the oil level in the hydraulic tank correct?
Is the type of oil correct?
Are there any oil leaks from the steering control valve?
Has the safety bar been removed from the frame?
[Example 1]
Remedy
No. Problem
1 Steering does work to the left or right.

as item 1, but abnormality in actuation of
2 Same
work equipment.
3 Steering can only be operated to one side.
4 Steering wheel is heavy and cannot be turned.
[Example 2]
Causes
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.
Problems
1
2
3
4
5
Remedy
a b c d e
X C
A X
O O O O
O
O
O
O
O
O
WA500-LK
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLE-
12
Causes
3) Operate the machine and check the troubleshooting items

other than those in 1).
Operate the machine and check the items in the same way
as in 1) and if the symptom appears, mark that item. (In
the chart on the right, the symptom appears again for item
5).
Remedy
Problems
4) Find the appropriate cause from the cause column. In the

same way as in Step 2), if the symptom appears, the O
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.)
6) Repeat the operations in Steps 3), 4) and 5) until one

cause (one common cause) remains.
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 common cause,
take the action given in the remedy column.
The symbols given in the remedy column indicate the
following:
X: Replace
: Repair
A: Adjust
C: Clean
WA500-LK
X C X A X
O O O O
O
O
O
O
O
Applicable troubleshooting item located in Step 3).

Applicable troubleshooting item located in Step 1).
Causes
Ignore these causes
Remedy
Problems
1
2
3
4
5
Remedy
Problems
1
2
3
4
5
Common causes
a b c d e
X C X A X
O O O O
O
O
O
O
Causes
5) Narrow down the possible causes.

There is one common cause among the causes located in
Steps 2) and 4). (One cause marked O, appears on the line
for both items.) This cause is common to both the
symptoms in troubleshooting Steps 1) and 3).
The causes which are not common to both
troubleshooting items (items which are not marked O
for both symptoms) are unlikely causes, so ignore them.
(In the example given on the right, the causes for
Troubleshooting Item 2 are c or e, and the causes for
Troubleshooting Item 5 are b or e, so cause e is
common to both.)
1
2
3
4
5
a b c d e
a b c d e
Action to take
X C X A X
O O O O
O
O
O
O
O
O
20-123
TROUBLESHOOTING
METHOD OF USING ENGINE RELATED
12
METHOD OF USING ENGINE RELATED CHARTS

Using troubleshooting charts for engine-related failure
This troubleshooting chart is divided into three sections:
questions, check items, and troubleshooting.
The questions and check items are used to pinpoint high
probability causes that can be located from the failure
symptoms or simple inspection without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are used to
check the high probability causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the
items where answers can be obtained from the user. The items
in (B) are items that can be obtained from the user, depending
on the user level.
[Check items]
The serviceman carries out simple inspection to narrow down
the causes. The items under (C) in the chart on the right
correspond to this.
The service man narrows down the causes from information
(A) that he has obtained from the user and the results of (C)
that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in order of probability, starting
with the causes that have been marked with having the highest
probability from information gained from [Questions] and
[Check items]
Causes
(A)
Questions
(1) (2) (3)
(B)
(b)
(c)
(d)
Check items
(C)
(a)
(e)
Troubleshooting
20-124
ii
iii
WA500-LK
TROUBLESHOOTING
12
The basic method of using the troubleshooting chart is as follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with O, and these,
causes that have high probability are marked with a .
Check each of the [Questions] and [Check items] in turn and mark
the O or the in the chart for items where the problem appeared.
The vertical column (Causes) that has the highest number of points
is the most probable cause, so start troubleshooting for that item to
ake final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions Section, ask the user, and mark the Cause
column with
to use as reference for locating the
cause of the failure. However, do not use this when
making calculations to narrow down the causes.
2. Use the
in the Cause column as reference for
[Degree of use (operated for long period)] in the
[Questions] section as reference.As a rule do not use
it when calculating the points for locating the cause,
but it can be included if necessary to determine the
order for troubleshooting.
WA500-LK
Confirm recent repair history
Degree of use
Defective injection pump (excessive injection)
Improper injection timing
Clogged seized injection nozzle
Worn piston ring, cylinder
Clogged air cleaner element
Seized turbocharger, interference
Causes
Operated for long period
20-125
TROUBLESHOOTING
12 Example of troubleshooting when exhaust gas is black

Let assume that [Clogged air cleaner] is taken to be the cause of the black gas. Three symptoms have causal relationship
with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us
explain here the method of using this causal relationship to pin point the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
Insufficient intake of air
Improper condition of fuel injection
Excessive injection of fuel
20-126
O O
O O O
Defective injection pump (rack, plunger seized)
Air leaks between turbo charger and head
Crushed clogged muffler
improper valve clearance
Defective injection pump (excessive injection)
Improper injection timing
Defective contact of valve, valve seat
O
O
O
O
Replace
Replace
Repair
Replace
Adjust
Adjust
Adjust
Replace
Replace
Replace
Clean
Check items
O O
Troubleshooting
Remedy
Clogged seized injection nozzle
Worn piston ring, cylinder
O
O
Questions
: Most probable causes (judging from questions and check items)

: Possible causes do to length of use (used for a long period)
: Items to confirm the cause
Confirm recent repair history
Degree of use
Operated for long period
Suddenly became black
Color of exhaust gas
Gradually became black
Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Air leaks between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinder does not change when operating on reduced cylinders
When check is made using delivery method, timing found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked, it is found to be outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not return
Clogged air cleaner element
Legend
O: Possible causes (judging from questions and check items)
Seized turbocharger, interference
Causes
WA500-LK
TROUBLESHOOTING
12
Five causes
Step 1
Clarify the relationship between the three symptoms
in the [Questions] and [Check items] section and the
five Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of O and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect.
(1) Clogged air cleaner element:----------------- O
(2) Air leaks between turbocharger and head:--O O
(3) Clogged, seized injection nozzle:------------O
(4) Defective contact of valve, valve seat:------O
(5) Worn piston ring, cylinder:-------------------O
Step 3
The calculation in Step 2 show that the closet relationship is with [clogged air cleaner element]. Follow this
column down to the troubleshooting area and carry
out the troubleshooting item marked The Remedy
is given as [clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA500-LK
20-127
TROUBLESHOOTING
12
MEMORANDUM
20-128
WA500-LK
TROUBLESHOOTING CONNECTORS
12
CONNECTOR ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-153
CONNECTOR NUMBERS, TYPES AND PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-163
WA500-3LK
20-151
TROUBLESHOOTING
12
MEMORANDUM
20-152
WA500-3LK
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
12
CONNECTOR ARRANGEMENT DIAGRAM

See foldouts in Section 90.
Connector Arrangement Diagram - FOLDOUT 20-153-1 Sheet 1 (Part 1 of 5)
3D Connector Arrangement Diagram - FOLDOUT 20-153-6 Sheet 2 (Part 1 of 2)
3D Connector Arrangement Diagram - FOLDOUT 20-153-7 Sheet 2 (Part 2 of 2)
WA500-3LK
20-153
TROUBLESHOOTING
CONNECTOR NUMBERS, TYPES AND PINS
12

The address column in the table below shows the address in the connector arrangement diagram.
Connector
Number
Type
No. of pins
Place of use
A10
Blower relay (Hi)
A11
Blower relay (M2)
A12
Condenser relay
A13
Blower relay (M1)
A14
Condenser relay (Hi)
A14
Relay
Relay
A15
Hi / Lo switch
A15
Magnet clutch relay
A15
Compressor clutch relay
A15
Compressor clutch relay
A14
A16
SWP
12
Air conditioner controller
A17
SWP
16
Air conditioner controller
A18
SWP
L.H. detection servo motor
A19
SWP
R.H. detection servo motor
A4
Air servo motor
A5
Thermistor
A6
SWP
Air mix servo motor
A7
Blower motor and resistor
A8A
10
Intermediate connector (air conditioner relay)
A8B
Intermediate connector (air conditioner relay)
Blower relay (Main)
A9
AF1
Solenoid 1 (relief) (ECSS)
AF2
Solenoid 5 (charge) (ECSS)
Air suspension seat
Condenser
B03
Window washer
B04
Window washer
B05
Diode
B06
Diode
Condenser (lower)
ASS
B01
B07
20-154 1
WA500-3LK
TROUBLESHOOTING
Connector
Number
Type
No. of pins
B08
Brake accumulator low pressure switch
B09
Emergency brake switch
B10
Emergency brake switch
B11
Condenser (Hi/Low)
B12
Condenser (Hi/Low)
B13
Brake accumulator low pressure switch
B14
Parking brake emergency release solenoid
BR1
SWP
14
Intermediate connector
C01
Front wiper motor
Radio
C02
Place of use
C03
Front working lamp
C04
Front working lamp
C05
Warning lamp switch
C06
Room lamp
Rear wiper motor
C08
Cigar lighter
C09
Cigar lighter
13
Transmission and ECSS controller
C11
Door switch (RH room) lamp
C12
Door switch (LH) room lamp
C13
Ground
C16
Working lamp (side LH)
C17
Working lamp (side RH)
21
Memory clear switch
C07
C1
C2
MIC
MIC
C38G
C3A
AMP040
20
C3B
AMP040
16
C4
AMP040
12
C5
MIC
17
CL1
12
Intermediate connector (working lamp, radio)
CL18
CL19
CL2
(M) Intermediate (window regulator)
CL20
WA500-3LK
20-155 1
TROUBLESHOOTING
Connector
Number
Type
CL26
No. of pins
Place of use
CL3
Intermediate connector (air conditioner)
CL4
Intermediate connector (power windows)
CL2
10
Intermediate connector (air conditioner)
Radio connection
CN14
CN10
Parking brake solenoid
CN11
CN12
JFC
3rd solenoid (Transmission)
CN13
3rd fill switch (Transmission)
CN14
JFC
R solenoid (Transmission)
CN15
R fill switch (Transmission)
CN16
JFC
F solenoid (Transmission)
CN17
F fill switch (Transmission)
CN18
Torque converter oil temperature sensor (monitor)
CN19
Parking brake indicator switch
CN3
Speed sensor
CN4
JFC
1st solenoid (Transmission)
CN5
1st fill switch (Transmission)
CN6
JFC
2nd solenoid (Transmission)
CN7
2nd fill switch (Transmission)
CN8
JFC
4th solenoid (Transmission)
CN9
4th fill switch (Transmission)
CNL
Joystick solenoid (L)
CNR
Joystick solenoid (R)
D01
Diode (for neutral switch)
D02
Diode (for neutral switch)
D1
Diode (ECSS)
D2
Diode (ECSS)
E01
Slow blow fuse (120A)
E02
E07
Heater relay
E08
Heater relay
E09
Heater relay
Air conditioner compressor
E12
20-156 1
WA500-3LK
TROUBLESHOOTING
Connector
Number
Type
No. of pins
E13
Starting motor
E14
Ground start motor
E15
Alternator terminal B
E16
Alternator terminal R
E17
Alternator terminal E
ECSS
SWP
Place of use
Engine - CN1
Boost pressure sensor
Engine - CN1
Common rail fuel pressure sensor
Engine - CN2
Boost pressure sensor
Engine - CN2
Common rail fuel pressure sensor
Engine - IJ1
No. 1 fuel injector
Engine - IJ2
No. 2 fuel injector
Engine - IJ3
No. 3 fuel injector
Engine - IJ4
No. 4 fuel injector
Engine - IJ5
No. 5 fuel injector
Engine - IJ6
No. 6 fuel injector
Engine - POH
Oil pressure high-pressor switch
Engine - POL
Oil pressure low-pressor switch
Engine - PV1
Fuel supply pump PCV1
Engine - PV2
Fuel supply pump PCV2
Engine - SG
G revolution sensor
Engine - SNE
NE revolution sensor
Engine - TFL
Fuel temperature sensor
Engine - TWH
Water temperature high-temperature sensor
Engine - TWL
Water temperature low-temperature sensor

14
Intermediate connector (air conditioner, engine water temperature

sensor)
ER2
31
Intermediate connector (engine controller)
ER3
31
ER1
SWP
EST
Remove when installing emergency steering
F01
Head lamp (RH)
F02
Front combination lamp (RH)
F03
Front combination lamp (LH)
F04
Head lamp (LH)
F05
Proximity switch for bucket
WA500-3LK
20-157 1
TROUBLESHOOTING
Connector
Number
Type
No. of pins
F06
Proximity switch for boom kick-out
F07
Horn
F08
Horn
F09
Horn
F10
Horn
Place of use
F11
Switch pump cut-off solenoid
F12
KES 1
Diode
FR1
10
FR2
Intermediate connector (boom, bucket SIG)
FS1
Power source
FS2
12
Fuse
FS3
Fuse
FS4
Power source
FS5
Fuse
FS6
Fuse
GND1
GRD (opt.)
GND2
GRD (opt.)
GR1
Intermediate connector (working lamp)
GRE
SWP
Grease
JL57
DT2
JL58
DT2
JL59
DT1
Power (engine controller)
JL60
DT1B
Ground (engine controller)
JL61
DT2B
Ground (engine controller)
JS1
Buzzer (J/S)
JS10
Selector switch
JS11
Steering neutral interlock relay
JS12
Intermediate connector (joystick switch)
JS14
Intermediate connector (joystick lever switch)
JS3
1-pin connector
Cut-off switch power source
JS4
1-pin connector
Cut-off switch GND
Joystick ON-OFF switch
Neutral switch
Potentiometer
JS5
JS6
JS7
20-158 1
WA500-3LK
TROUBLESHOOTING
Connector
Number
Type
No. of pins
Place of use
JS8
Caution relay
JS9
Solenoid cut relay
JSA (male)
1-pin connector
Intermediate connector (neutral)
JSB (male)
1-pin connector
Intermediate connector (neutral)
JSC
1-pin connector
Neutral (J/S)
JSD
1-pin connector
Neutral (J/S)
L01
SWP
L02
SWP
Light and dimmer switch
L02
Yazaki
Radio
L03
SWP
Turn signal and hazard switch
L04
SWP
14
F/R and speed switch
L05
AMP040
20
Main monitor
L06
AMP040
16
Main monitor
L07
AMP040
12
Main monitor
L08
AMP040
Main monitor
L09
Starting switch
L10
10
Wiper switch
L12
Transmission cut-off switch
L13
Accelerator potentiometer
L14
Accelerator limit switch
L15
Kick-down and hold switch
L16
Boom kick-out solenoid
L17
Bucket positioner solenoid
L18
AMP040
16
Maintenance monitor
L19
AMP040
Maintenance monitor
L20
AMP040
16
Maintenance monitor
L21
Maintenance monitor
L25
24
Engine throttle controller
L26
MIC
21
Work equipment and joystick controller
L27
MIC
20
L28
MIC
16
L32
L32
Intermediate connector (power source, GND)
L33
Intermediate connector (boom kick-out output)
WA500-3LK
20-159 1
TROUBLESHOOTING
Connector
Number
Type
L34
No. of pins
Place of use
Opt. equipment control
L34
Intermediate connector (network, buzzer output) (Opt.)
L42
1-pin connector
Caution buzzer
L43
1-pin connector
Caution buzzer
L44
Wiper relay
L46
Flasher unit
L48
Bucket relay
L49
Boom relay
L52
Hazard relay
L53
Stop lamp relay
L54
Back-up lamp relay
L55
Horn relay
L56
Pre-heat relay
L57
Neutral relay
L58
Neutralizer relay
L59
Parking brake safety relay
L60
Front working lamp relay
L61
Rear working lamp relay
L62
Engine stop relay
L63
1-pin connector
Horn switch
L64
KES 0
Engine oil pressure relay
L80
KES 0
Dust indicator relay
L81
AMP070
12
Engine controller
L81
Stop lamp switch
Switch pump cut-off relay
L82
L82
AMP070
18
Engine controller
L84
AMP070
20
Engine controller
L86
AMP070
10
Engine controller
L87
AMP070
14
Engine controller
L90
L91
ECSS relay
L92
Relay pwr window LH - up
L93
Relay pwr window LH - down
L94
Relay pwr window RH - up
20-160 1
WA500-3LK
TROUBLESHOOTING
Connector
Number
Type
L95
No. of pins
Place of use
Relay pwr window RH - down
L96
Yazaki
Power window switch (RH)
L97
Yazaki
Power window switch (LH)
LL1
12
Intermediate (to Engine Gov. controller floor harness)
LL2
Engine controller signal ground
LL2
14
Intermediate (to Engine Gov. floor harness)
LL3
E16 control power
LM1
10
MDC monitor panel
LR1
12
Intermediate connector (lamp)
LR11
SWP
14
Intermediate connector (boom switch) (opt. not available)
LR2
SWP
14
LR4
SWP
14
Intermediate connector (monitor related)
LR5
Intermediate connector (power source, GND)
LR6
Intermediate connector (power source)
LR7
31
LR8
31
OP1
1-pin connector
Fuse outlet
OP2
1-pin connector
Fuse outlet (power source)
OP4
Key on (opt.)
OP5
Key on (opt.)
PWR1
Motor pwr window regulator LH
PWR1
Motor pwr window regulator RH
PWR2
Motor pwr window regulator LH
PWR2
Motor pwr window regulator RH
R01
Diode
R02
Diode
R03
Diode
R04
Diode
R07
Fuel level sensor
R08
Rear combination lamp (LH)
R09
Rear combination lamp (RH)
R10
Ground for tail lights
R10
Ground for tail lights
Battery
R11
WA500-3LK
Terminal
20-161 1
TROUBLESHOOTING
Connector
Number
Type
No. of pins
R12
Terminal
Battery relay (key switch BR)
R13
Terminal
Battery relay
R15
Terminal
R17
Terminal
R18
1-pin connector
License lamp
R19
1-pin connector
License lamp (GND)
RES
Resistance (diode J/S)
RPM
RPM select
RPM1
RPM (opt.)
RPM2
RPM (opt.)
Place of use
SEL
Engine select
SEL2
Joystick function selection
SEL3
Remote positioner select
T02
Diode
TAC
Tachograph
TM1
SWP
14
Intermediate connector (transmission)
TM2
SWP
16
Intermediate connector (transmission)
20-162 1
WA500-3LK
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
WA500-3LK
20-163
TROUBLESHOOTING
12
20-164
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-165
TROUBLESHOOTING
12
20-166
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-167
TROUBLESHOOTING
12
20-168
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-169
TROUBLESHOOTING
12
20-170
WA500-3LK
12
WA500-3LK
20-171
12
20-172
WA500-3LK
12
WA500-3LK
20-173
12
MEMORANDUM
20-174
WA500-3LK
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ECM
12
(ELECTRIC CONTROL MECHANISM)
EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL MECHANISM) . . . . . . . . . . . . . . . . 20-202

TRANSMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202
MAIN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
MAINTENANCE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) CONTROL SYSTEM . . . . . . 20-214
JOYSTICK STEERING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
METHOD OF DISPLAYING ACTION AND FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
CONTROLLERS AND FAILURE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
MAIN MONITOR FAILURE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-226
TRANSMISSION CONTROLLER LED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-229
ERROR CODE DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
WA500-3LK
20-201 1
TROUBLESHOOTING
12
EXPLANATION OF FUNCTIONS OF ECM (ELECTRIC CONTROL

MECHANISM)
TRANSMISSION CONTROL SYSTEM
20-202
WA500-3LK
TROUBLESHOOTING
12
1. Function of equipment at input end.
A. F/R switch.
This detects the condition of operation of directional lever and inputs it to the controller as a digital (ON-OFF) signal.
(On machines equipped with joystick, the signal from the joystick switch is also input.)
B. Speed range switch.
This detects the condition of operation of speed lever and inputs it to the controller as a digital (ON-OFF) signal.
C. Manual selector switch.
This detects the condition of operation of the manual selector switch and inputs it to the controller as a digital (ONOFF) signal.
D. Transmission cut-off selector switch.
This detects the condition of operation of the transmission cut-off switch, and controls the signal of the ON-OFF
signal from CUT-OFF oil pressure switch to the controller signal.
E. Hold switch.
This detects the condition of operation of the hold switch or shift up switch (when using the joystick) and inputs it to
the controller as a digital (ON-OFF) signal.
F.
Kick-down switch.
This detects the condition of operation of the kick-down switch or shift-down switch (when using the joystick) and
inputs it to the controller as a digital (ON-OFF) signal.
G. Engine speed sensor.

This detects the speed of the engine flywheel as the engine speed and inputs it to the controller as a pulse (rotation)
signal.
H. Cut-off oil pressure switch.
This detects the condition of operation of the left brake pedal from the brake circuit oil pressure, and inputs it to the
controller as a digital (ON-OFF) signal. (When the main monitor cut-off switch is ON.)
I.
Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the controller as a pulse
(rotation) signal. (The speed sensor is also used with the main monitor system.)
J.
Transmission oil temperature sensor.

This detects the temperature of the transmission oil and inputs it to the controller as a analog (resistance) signal.
K. Speed range switch. (F, R, 1st, 2nd, 3rd, 4th)

This detects the condition of actuation of the ECMV flow detection valve and inputs it to the controller as a digital
(ON-OFF) signal.
L. Neutralizer relay.
This detects the condition of actuation of the parking brake and inputs it to the controller as a digital (ON-OFF)
signal.
2.
Limit function of controller (outlet port).

A. Auto-shift function:
This calculates the optimum speed range from the signals from the switches and sensors, and outputs it to the ECMV
as an analog (current) signal in order to shift up or down.
WA500-3LK
20-203
TROUBLESHOOTING
12
B. Modulation control function:
This calculates the optimum modulation pattern from the signals from the switches and sensors in order to reduce the
shock when shifting up or down, and outputs it to the ECMV of both the clutch to be engaged and the clutch to be
disengaged as an analog (current) signal.
C. Hold function:
When the hold switch is turned ON, it outputs a signal to the ECMV to stop the auto-shift and hold it at the same
speed range.
D. Kick-down function:
When the kick-down switch is turned ON, if it matches the control conditions, the signal is output to the ECMV to
shift down to 1st.
E. Manual shift function:

When the manual shift is turned ON, the signal is output to the ECMV to shift the speed to the selected speed range
with the shift lever.
For machines with joysticks, when operating in the manual mode, the hold switch becomes the shift-up switch and
the kick- down switch becomes the shift-down switch, so the transmission is shifted up or down within the range of
the speeds selected by the speed range switch (the range of speeds self-between 1st and the selected speed range).
F.
Parking brake neutralizer function:

To prevent seizure of the parking brake, the signal from the neutralizer relay stops the out-put of the directional signal
to the ECMV and holds the transmission at neutral even if the directional lever is operated to F or R.
G. Back-up lamp drive function:

The signal from the directional switch is sent to the back-up lamp relay as a digital (ON- OFF) signal.
H. Buzzer function:
The signal is sent through the main monitor to the alarm buzzer as a digital (ON-OFF) signal according to the
condition of the input signal.
I.
Self-diagnostic function:
The controller always observes the directional switch, speed range switch, speed sensor, engine speed sensor,
transmission oil temperature sensor, the 6 ECMV fill switches at the input side, and the 8 ECMV solenoids at the
output side to check that no abnormality occurs in the back-up lamp relay systems.
J.
Network communication with main monitor:

i.
The controller communicates the actuated speed range through the network.
ii.
The controller communicates the actuated F/R position through the network. (Machines with joystick.)
iii. It communicates the condition of actuation of the hold mode through the network.
iv. If any abnormality is detected by the self-diagnostic function, it communicates the details of the abnormality
through the network.
3.
Functions of output equipment.

A. ECMV solenoid valve. (F, R, 1st, 2nd, 3rd, 4th)
The solenoid receives the signal from the controller, is driven, and controls the transmission clutch oil pressure.
B. Back-up lamp relay.
The relay receives the signal from the controller, is driven, and turns the power for the back-up lamp relay ON-OFF.
20-204
WA500-3LK
TROUBLESHOOTING
12
4. Main monitor display.
For details, see MAIN MONITOR.
WA500-3LK
20-205
TROUBLESHOOTING
12
MAIN
20-206
MONITOR SYSTEM
WA500-3LK
TROUBLESHOOTING
12
1. Functions of equipment at input end
A. Parking brake oil pressure switch
This detects the condition of actuation of the parking brake and inputs it to the main monitor as a digital (ON-OFF)
signal.
B. Engine speed sensor.
This detects the speed of the engine flywheel as the engine speed and inputs it to the main monitor as a pulse
(rotation) signal.
C. Speed sensor.
This detects the speed of the transmission output shaft as the travel speed and inputs it to the main monitor as a pulse
(rotation) signal. (The speed sensor is also used with the transmission control system.)
D. Engine water temperature sensor.
This detects the temperature of the engine cooling water and inputs it to the main monitor as an analog (resistance)
signal.
E. Transmission directional switch.
This detects the condition of operation of the directional lever to the N position and inputs it to the main monitor as
a digital (ON-OFF) signal. (The transmission directional switch is also used for the transmission control system.)
F.
Emergency steering detection switch.

This detects the condition of actuation of the emergency steering hydraulic circuit and inputs into the main monitor as
a digital (ON- OFF) signal.
G. Turn signal, hazard switch.

This detects the condition of operation of the turn signal and hazard switch, and inputs it to the main monitor as a
digital (ON-OFF) signal.
H. Dimmer switch.
This detects the condition of operation of the dimmer switch and inputs it to the main monitor as a digital (ON-OFF)
signal.
I.
Head lamp relay/rear lamp relay.

This detects the condition of actuation of the relay from the secondary outlet voltage of the head lamp relay and rear
lamp relay, and inputs it to the main monitor as a digital (ON-OFF) signal.
J.
Preheating relay.
Optional equipment, detects actuation of the relay from the secondary outlet voltage of the preheating relay, and
inputs it to the main monitor as a digital (ON-OFF) signal.
K. Maintenance monitor.
i.
CHECK lamp signal.

This inputs the CHECK lamp drive signal (the output signal from the maintenance monitor) to the main monitor
as a digital (ON-OFF) signal.
ii.
CAUTION lamp signal.

This inputs the CAUTION lamp drive signal (the output signal from the maintenance monitor) to the main
monitor as a digital (ON-OFF) signal.
iii. Lamp synchronous signal.

This inputs the lamp synchronous signal (the output signal from the maintenance monitor) to the main monitor as
a digital (ON-OFF) signal.
WA500-3LK
20-207
TROUBLESHOOTING
12
L. Starting switch.
i.
Terminal BR.
This detects the condition of operation of the starting switch to the ON position and inputs it to the main monitor
as a digital (ON-OFF) signal.
ii.
Terminal C.
This detects the condition of operation of the starting switch to the START position and inputs it to the main
monitor through the neutral relay as a digital (ON-OFF) signal.
M. Alternator (terminal R).

This detects the condition of electricity generated by the alternator and inputs it to the main monitor as an analog
(voltage) signal.
2.
Network communication with controllers.

A. With transmission, ECSS controller.
i.
The speed range (1 - 4) now being used is communicated.
ii.
The directional position (F, N, R) now being selected is communicated (machines with joystick).
iii. When the hold function is actuated, the actuation signal is communicated.
iv. If any abnormality occurs in the transmission control system or ECSS control system, the details of the
abnormality are communicated.
B. With work equipment, joystick controller:
If any abnormality occurs in the transmission control system or joystick control system, the details of the abnormality
are communicated.
3.
Functions of main monitor

A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)
B. Speedometer function:
The speedometer is displayed on the meter portion by the signal from the speed sensor. (When the system is set to the
tachometer display specification, the tachometer is displayed on the meter portion by the signal from the engine speed
sensor.)
C. Transmission shift indicator function:
The speed range or directional N is displayed on the shift indicator portion by the network communication from the
transmission and ECSS controller.
D. Transmission directional indicator function:
(Machines with joystick) The directional F or R is displayed at the bottom of the speedometer portion by the network
communication from the transmission and ECSS controller. (Even on machines with joystick, the directional N is
displayed on the shift indicator portion.)
E. Hold indicator function
When the hold mode is actuated, the hold indicator is lighted up by the network communication from the
transmission and ECSS controller.
20-208
WA500-3LK
TROUBLESHOOTING
12
F.
Turn signal pilot lamp function:

The left or right turn signal pilot lamps are made to flash (in the case of hazard the lamps on both sides flash) by the
signal from the turn signal and hazard switch.
G. Hi beam pilot lamp function:

When the Hi beam is used, the Hi beam pilot lamp is lighted up by the signal from the dimmer switch.
H. CHECK lamp function:
The CHECK lamp is made to flash by the CHECK lamp signal from the maintenance monitor. When this happens,
the flashing of the lamp on the maintenance monitor and flashing of the CHECK lamp are synchronized by the flash
synchronous signal from the maintenance monitor.
I.
CAUTION lamp function:

The CAUTION lamp is made to flash by the CAUTION lamp signal from the maintenance monitor. When this
happens, the flashing of the lamp on the maintenance monitor and the flashing of the CAUTION lamp are
synchronized by the flash synchronous signal from the maintenance monitor.
J.
Emergency steering indicator function:

The emergency steering pilot lamp is made to flash by the signal from the emergency steering detection switch.
K. ECSS switch function (machines equipped with ECSS):

For details, see ECSS CONTROL SYSTEM.
L. Working lamp switch function (front, rear):
The condition of operation of the working lamp switch is output to the working lamp relay as a digital (ON-OFF)
signal. At the same time, the indicator is lighted up by the signal from the working lamp relay.
M. Parking brake dragging warning function:
If the directional lever (switch) is set to the F or R position when the parking brake is still applied (ON), the
CAUTION lamp flashes and the alarm buzzer sounds intermittently.
N. Action code and failure code display function:
If an abnormality signal is received by network communication from the controllers, the action code (normally
displayed) or failure code (when failure code is displayed) are displayed on the speedometer portion. At the same
time, when the abnormality code is received, the total hours of operation of the machine is calculated by the signal
from the alternator terminal R, and this is displayed as the elapsed time since failure on the failure mode display.
4.
Functions of equipment at output end.

A. Alarm buzzer:
This receives the signal from the main monitor and generates the alarm sound. (The alarm buzzer is also used for the
maintenance monitor system.)
B. Front, rear working lamp relay:
This receives the signal from the controller and switches the power for the front or rear working lamp relay ON-OFF
according to the switching of the relay.
WA500-3LK
20-209
TROUBLESHOOTING
12
MAINTENANCE
20-210
MONITOR SYSTEM
WA500-3LK
TROUBLESHOOTING
12
1. Functions of equipment at input end.
A. Fuel level sensor:
This detects the fuel level in the fuel tank and inputs it to the maintenance monitor as an analog (resistance) signal.
B. Engine water temperature sensor:
This detects the temperature of the engine cooling water and inputs it to the maintenance monitor as an analog
(resistance) signal.
C. Torque converter oil temperature sensor:
This detects the temperature of the torque converter oil and inputs it to the maintenance monitor as an analog
(resistance) signal.
D. Engine water level switch:
This detects the level of the engine cooling water in the radiator reservoir tank and inputs it to the maintenance
monitor as a digital (ON-OFF) signal.
E. Engine oil level switch:
This detects the level of the oil in the engine oil pan and inputs it to the maintenance monitor as a digital (ON-OFF)
signal.
F.
Brake accumulator low-pressure switch:

This detects the oil pressure in the wheel brake accumulator circuit and inputs it to the maintenance monitor as a
digital (ON-OFF) signal.
G. Engine oil pressure switch:

This detects the engine oil pressure inputs it to the maintenance monitor as a digital (ON- OFF) signal.
H. Air cleaner clogging switch:
This detects the clogging condition of the air cleaner and inputs it to the maintenance monitor as a digital (ON-OFF)
signal.
2.
I.
Alternator (terminal R):

This detects the condition of generation of electricity by the alternator and inputs it to the maintenance monitor as an
analog (electricity generation) signal.
J.
Starting switch (terminal C):

This detects the condition of operation of the starting switch to the START position and inputs it through the neutral
relay to the maintenance monitor as a digital (ON-OFF) sensor.
Control functions of maintenance monitor.

A. Self-check function:
When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1
second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the
self check, the self check stops.)
B. Fuel gauge:
The fuel gauge is displayed and the pilot lamp flashes or goes out according to the signal from the fuel level sensor.
C. Engine water temperature gauge:
The engine water temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal from
the engine water temperature sensor.
WA500-3LK
20-211
TROUBLESHOOTING
12
D. Torque converter oil temperature gauge:
The torque converter oil temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal
from the torque converter oil temperature sensor.
E. Engine water level pilot lamp:
The pilot lamp flashes or goes out according to the signal from the engine water level signal.
F.
Engine oil level pilot lamp:

The pilot lamp flashes or goes out according to the signal from the engine oil level sensor.
G. Brake oil pressure caution lamp:

The caution lamp flashes or goes out according to the signal from the brake accumulator low-pressure switch.
H. Engine oil pressure caution lamp:
The caution lamp lights up, flashes, or goes out according to the signal from the engine oil pressure switch.
I.
Battery charge caution lamp:

The caution lamp lights up, flashes, or goes out according to the signal from alternator terminal R.
J.
Air cleaner clogging caution lamp:

The caution lamp flashes or goes out according to the signal from the air cleaner clogging sensor.
K. Service meter:
The service meter is driven by the signal from the engine oil pressure switch.
L. Output to main monitor:
The CHECK lamp signal, CAUTION lamp signal, and flash synchronous signal are output to the main monitor as a
digital (ON-OFF) signal according to the condition of the input signal.
M. Alarm buzzer function:
The digital (ON-OFF) signal is output to the alarm buzzer according to the condition of the input signal.
3.
Functions of equipment at output end.

A. Main monitor:
This receives the signal from the maintenance monitor and makes the CHECK lamps or CAUTION lamps flash.
B. Alarm buzzer:
This receives the signal from the maintenance monitor and makes the buzzer sound. (The alarm buzzer is also used
for the main monitor system.)
20-212
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-213
TROUBLESHOOTING
12
ECSS
(ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)

CONTROL SYSTEM
This system has functions in the transmission controller, and judges the function by the select signal from the main monitor
when the engine is started.
20-214
WA500-3LK
TROUBLESHOOTING
12
1. Functions of equipment at input end High.
A. ECSS actuation switch:
This detects the condition of actuation of the ECSS switch and inputs it to the controller as a digital (ON-OFF) signal.
B. Output speed range signal:
This detects the condition of the output speed range. (The ECSS system carries out control with the same controller as
the transmission control system, so the speed range switch signal is also used inside the controller.)
C. Speed sensor:
This detects the speed of the transmission output shaft as the travel speed (speed) and inputs it to the controller as a
pulse (rotation) signal. (The ECSS system carries out control with the same controller as the transmission control
system, so the speed sensor signal is also used inside the controller.)
D. Charge oil pressure switch:
This detects the basic oil pressure of the damper circuit and inputs it to the controller as a digital (ON-OFF) signal.
E. Boom bottom oil pressure switch:
This detects the oil pressure of the boom cylinder bottom circuit and inputs it to the controller as a digital (ON-OFF)
signal.
F.
2.
Pressure release switch:

This switch is the drive power to the selector solenoid (SOL4) by the operation of the pressure release switch. (The
signal from the pressure release switch does not pass through the controller, and is output directly to the selector
solenoid (SOL4). It is actuated at the same time has the normal return solenoid valve (SOL1).)
Control function of controller

A. Damper function:
To prevent pitching and bouncing of the bucket, the input signals from the switches and sensors are output as a digital
(ON-OFF) signal to the relief solenoid (SOL1), High-1) pressure solenoid (SOL2), Low-pressure solenoid (SOL3),
and pressure release solenoid (SOL4).
B. Accumulator charge function:
To prevent the oil pressure in the accumulator circuit from dropping and the boom from going down when the damper
function is actuated, the signal from the charge oil pressure sensor is output to the charge solenoid (SOL5) as a digital
(ON-OFF) signal.
C. Pressure release function:
The pressure release switch signal drives the pressure release solenoid (SOL4) to release the remaining pressure in
the boom cylinder circuit during the disassembly and assembly operation. (The pressure release switch signal does
not pass through the controller, it can be input directly to the pressure release solenoid (SOL4).)
D. Self-diagnostic function:
The controller always observes the system to check that no abnormality has occurred in the systems for the four
solenoids at the output end.
E. Network communication with main monitor:
If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality through the
network. (The ECSS system carries out control with the same controller as the transmission control system, so the
network communication circuit is used in both systems.)
WA500-3LK
20-215
TROUBLESHOOTING
12
3. Functions of equipment at output end.
A. Return solenoid valve (SOL1):
This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom
cylinder head circuit and the hydraulic tank.
B. High-pressure solenoid valve (SOL2):
cylinder bottom circuit and the high-pressure accumulator.
C. High-pressure solenoid valve (SOL3):
cylinder bottom circuit and the low-pressure accumulator.
D. Pressure release check solenoid valve (SOL4):
The return solenoid valve (SOL1) and the pressure release check solenoid valve (SOL4) are turned ON-OFF through
the relay. The valve receives the signal from the controller or the pressure release switch, and the solenoid is driven to
open or close the circuit between the boom cylinder bottom circuit and the damper (high-pressure, low-pressure
accumulator) circuit.
E. Accumulator pressure solenoid valve (SOL5):
This receives the signal from the controller, and the solenoid is driven to open or close the circuit between the
hydraulic pump circuit and the damper (high-pressure, low-pressure accumulator) circuit.
4.

For details, see MAIN MONITOR SYSTEM.
20-216
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-217
TROUBLESHOOTING
12
JOYSTICK
STEERING CONTROL SYSTEM
This section describes only the items related to steering in the joystick steering control system. For details of the transmission,
see TRANSMISSION CONTROL SYSTEM.
20-218
WA500-3LK
TROUBLESHOOTING
12
1. Functions of equipment at input end.
A. Joystick ON-OFF switch:
This detects the condition of operation of the joystick ON-OFF switch and inputs it to the controller as a digital
(ON-OFF) signal.
B. System cut-off switch:
This detects the slide position of the joystick lever stand and inputs it to the controller as a digital (ON-OFF) signal.
C. Joystick neutral switch:
This detects the neutral position of the steering lever and inputs it to the controller as a digital (ON-OFF) signal.
D. Joystick potentiometer:
This detects the angle of operation of the steering lever and inputs it to the controller as an analog (current) signal.
2.
Control functions of controller.

A. System cut-off function:
This actuates or stops the system according to the signals from the system cutoff switch and joystick ON-OFF switch.
Joystick neutral interlock function When starting the engine, if the joystick is not at the neutral position, the engine
cannot be started.
B. Steering function:
This calculates the signal from the steering potentiometer and outputs an analog (current) signal corresponding to this
to the left and right steering solenoids.
C. Solenoid stop function:
If any abnormality occurs in the system, this outputs a signal to the solenoid cut relay as a digital (ON-OFF) signal.
D. Buzzer drive function:
If any abnormality occurs in the system, this turns the digital (ON-OFF) signal to the caution relay OFF and actuates
the buzzer.
E. Self-diagnostic function:
The controller always observes the condition to check that there is no abnormality in the joystick potentiometer and
joystick neutral switch systems at the input end and the left and right steering solenoids, solenoid cut relay, and
caution relay systems at the output end.
F.
3.
Network communication with main monitor:

If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality to the main
monitor through the network. (The joystick control system carries out control with the same controller as the work
equipment control system, so the network communication circuit is used in both systems.)
Functions of equipment at output end

A. Left, right steering solenoid valve:
This receives the signal from the controller and drives the solenoid to control the solenoid valve output pressure
effortlessly.
B. Steering neutral interlock relay:
This receives the signal from the controller and drives the solenoid to drive the neutral safety relay when the engine is
started.
WA500-3LK
20-219
TROUBLESHOOTING
12
C. Solenoid cut relay:
This receives the signal from the controller and drives the solenoid to switch the circuit at the return side of the
steering solenoid ON-OFF.
D. Caution relay:
This receives the signal from the controller and drives the relay to switch the alarm buzzer circuit ON-OFF.
4.

For details, see MAIN MONITOR SYSTEM.
20-220
WA500-3LK
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION AND
12
METHOD OF DISPLAYING ACTION AND FAILURE CODE

1.
Outline
The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of
the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals
between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine
controller uses a special parallel signal.)
2.
Display of failure action code

This code informs the operator directly of the abnormality, and takes
action, such as stopping the machine immediately. There are three
types of action code: E00, E0N + CALL (E0N and CALL are
displayed alternately), and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer display.
3.
Failure code and time elapsed since failure

The failures detected by each controller are changed to a code and
displayed. It is possible to tell from this code which system in which
controller has failed, so carry out troubleshooting for the applicable
controller.
4.
Saving failure code

The transmission controller writes the failure codes to memory.
A. A total of 9 failure codes can be saved in memory.
B. The data that is saved to memory is as follows:
i.
Failure code
ii.
Time elapsed since failure (up to 1000 hours)
C. The failures are saved in the order that they occur. If a failure code
already exists in the memory, the repeat failure code is not saved.
D. If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved.
It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the
main monitor set switch.
WA500-3LK
20-221
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION AND
12
5. Switch operation procedure actuation
Switch operation
Trouble data memory mode display
1. Stop engine
3. Push operation mode switch (1) and
head lamp switch (2) simultaneously
and keep pressed for at least 5
seconds.
Actuation
The failure code is displayed on
the speedometer display and the
time elapsed since failure is displayed on the action code display.
If there is no failure, the
speedometer display shows [CC]
and the action code
display shows [0000].
Going to next failure code
The failure code and time elapsed
4. Press head lamp switch (2).
since failure are
displayed in turn (when this is
done, the failure code for the latest failure is displayed first).
If the failure still exists, the
display flashes; if the failure has
been restored, the display lights
up.
Clearing failure code
The failure and elapsed time on
5. Keep rear lamp switch (3) pressed for the display are cleared.
at least 2 seconds.
If the failure still exists, the failure code is not cleared.
Quitting trouble data memory display The display returns to the
mode
normal display.
6. Push operation mode switch (1) and
head lamp switch (2) simultaneously
and keep pressed for at least 5
seconds. Or start the engine.
20-222
WA500-3LK
TROUBLESHOOTING
CONTROLLERS AND FAILURE CODES
12
CONTROLLERS
AND FAILURE CODES
1.
After an error occurs, turn starting switch OFF and if the display goes out, it is possible to re-enact the problem as follows.
For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING SELF
DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY.
Marks:
= Turn starting switch ON (with engine stopped)
= Turn starting switch OFF
= Carry out operation to actuate actuator
O = Possible cause
X = Non-Applicable
TRANSMISSION / ECSS CONTROLLER
A. TRANSMISSION CONTROL SYSTEM
Main monitor action

code
Failure
code
None
10
12
Failed system
Recreate
Short
circuit
Disconnection
Short
circuit
Disconnection
Memory
Alarm buzzer
Back-up lamp
F ECMV solenoid
13
R ECMV solenoid
14
1st ECMV solenoid
15
2nd ECMV solenoid
16
3rd ECMV solenoid
17
4th ECMV solenoid
E00
19
Joystick directional switch
CALL
20
Directional switch signal
None
21
Range switch signal
22
Travel speed sensor
23
Engine speed sensor
None
24
EEP ROM abnormality
E01+
CALL
25
26
F ECMV fill switch
27
R ECMV fill switch
28
1st ECMV fill switch
29
2nd ECMV fill switch
30
3rd ECMV fill switch
31
4th ECMV fill switch
32
F, R ECMV fill switch
33
1st, 2nd, 3rd, 4th ECMV fill switch
CALL
E00
CALL
E00
Item
E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.
WA500-3LK
20-223 1
TROUBLESHOOTING
12
B. ECSS CONTROL SYSTEM
Main monitor action
code
Failure
code
None
d0
2.
Failed system
Item
ECSS relay
Recreate
Short
circuit
Disconnection
Short
circuit
Disconnection
Memory
Alarm buzzer
JOYSTICK CONTROLLER
Failed system
Main monitor action

code
Failure
code
None
56
Caution relay
57
Steering solenoid (R)
58
Steering solenoid (L)
59
CALL
E00
Item
Recreate
Disconnection
Short
circuit
Disconnection
Memory
Alarm buzzer
Steering solenoid (R)
60
Steering solenoid (L)
61
Cut relay (sit solenoid)
62
Neutral switch
63
Potentiometer
Short
circuit
E59 and E60 cannot be distinguished, so they are issued at the same time.
Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
20-224 1
WA500-3LK
TROUBLESHOOTING
12
3. ENGINE CONTROLLER
Remark
See ENGINE SHOP MANUAL for engine fault codes.
Marks:
= Turn starting switch ON (with engine stopped)
= Turn starting switch OFF
= Start engine
= Carry out operation
O = Possible cause
X = Non-Applicable
Failure Code
Action
Code Monitor Controller
E-56
E-7A
CALL
90
E-7C
E-80
E-1b
E-1c
E-31
E-3c
E-3d
E-51
E-54
E-57
E-5A
E-6A
E-70
E-71
E01
E-74
+
91
E-75
CALL
E-77
E-79
E-7b
E-7d
E-81
E-82
E-83
E-84
E-85
E-86
E-8A
E-8b
None
99
E-22
WA500-3LK
Item
Abnormality in power supply system 1
Abnormality in common rail high pressure 2
No pressure from fuel supply pump 2
Defective controller
Abnormality in Ne speed sensor system
Abnormality in G sped sensor system
Abnormality in throttle sensor system
Abnormality in boost pressure sensor system
Abnormality in fuel temp. sensor system
Abnormality in preheater relay coil system
Short circuit in starting switch C signal system
Abnormality in power supply system 2
Abnormality in Q adjustment switch system
Abnormality in low water temp. sensor system
Excess current in fuel supply pump PCV1 system
Excess current in fuel supply pump PCV2 system
Disconnection in fuel supply pump PCV1 system
Disconnection in fuel supply pump PCV2 system
Abnormality in common rail fuel pressure sensor system
Abnormality in common rail high pressure 1
No pressure from fuel supply pump 1
Abnormal fuel pressure in common rail
Disconnection in fuel injector system 1
Short circuit in fuel injector system 1, 2 or 3
Short circuit in fuel injector system 4, 5 or 6
Overrun
Failed system
Recreate
Memor
Short Open Short Open
O
O
X
X
O
X
X
O
X
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
X
O
O
O
O
X
X
O
O
O
O
O
X
O
O
X
O
O
O
O
O
O
O
O
O
X
X
O
X
X
O
X
X
X
O
O
X
O
O
X
O
X
O
O
X
O
O
X
O
O
O
O
O
O
O
X
X
Alarm
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
20-225 1
TROUBLESHOOTING
RELATIONSHIP OF ELECTRONIC CONTROL
12
RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM

If an error is displayed on the main monitor portion (normally the speedometer display) of the machine monitor, follow the
corresponding table when carrying out the self diagnostic troubleshooting below.
ECSS
Problem
system
Condition of
machine
Problem
system
Condition
of machine
Problem
system
---
---
---
---
Disconnection,
short circuit or
abnormality in
engine speed
sensor system
Engine speed
taken as 2100
rpm (there is
gear shifting
shock)
---
---
---
---
---
Disconnection
in fill switch
Clutch is
engaged without fill signal
(there is shock)
---
---
---
---
---
---
---
---
---
---
---
---
Condition
of machine
Disconnection, short
circuit or Returns to
short cir- neutral (poscuit with
sible to
ground in
manual
joystick
switch)
FNR signal
system
Does not shift

Disconnection gear automatiin travel speed cally (switches
sensor system to manual gear
shifting)
Short circuit between

Boom
damping
movement is
solenoid and
slow
+ side power
supply 24 V
Electronic
governor
system
Joystick
control system
Problem
system
Condition
of machine
---
---
---
---
---
---
---
---
---
---
---
---
---
---
Power
supply
Not cut
when starting switch is
turned OFF
Deterioration in
emission
---
---
---
---
---
---
---
---
---
Supply
pump drive
circuit
---
---
---
---
---
---
---
---
Supply
pump
Deterioration in
emission
---
---
---
---
---
---
---
---
Common
rail pressure
abnormal
(1st stage)
Normal
operation
Deterioration in
emission,
increase in
noise
---
---
---
---
---
---
---
---
Impossible
to control
common
rail, drop in
pressure (1st
stage)
---
---
---
---
---
---
---
---
Drop in outDisconnecput, increase

tion in TWV
in noise
---
---
---
---
---
---
---
---
Short cir- Drop in outcuit in TWV

put
20-226 1
Alarm buzzer
Condition of
machine
Work equipment
control system
Action
by
operator
Normal
work
possible with
manual
operation
No
Problem
system
Impossible to
select suitable
Short circuit in gear shift data
transmission
for transmisoil temperasion oil temture sensor
perature (there
is gear shifting
shock)
E01 + CALL
Option
Transmission
control system
Normal
work
possible, but
there is
gear
shifting
shock
Yes
E00
Error code
MAIN MONITOR FAILURE DISPLAY
Travel
under
own
power
possible,
move to
safe
place,
then call
service
WA500-3LK
Problem
system
Condition of
machine
---
---
---
---
---
---
---
---
WA500-3LK
---
---
---
---
---
---
---
---
---
Work equipment
control system
ECSS
Problem
system
---
---
---
---
---
---
---
---
---
Condition of
machine
---
---
---
---
---
---
---
---
---
Problem
system
---
---
---
---
---
---
---
---
---
Condition
of machine
---
---
---
---
---
---
---
---
---
Joystick
control system
Problem
system
---
---
---
---
---
---
---
---
---
Condition
of machine
Electronic
governor
system
Problem
system
Condition
of machine
---
Drop in outBoost pres- put, black

sure sensor smoke when
accelerating
---
DeterioraCommon tion in emisrail pressure

sion,
sensor
increase in
noise
---
Ne sensor
Engine
speed unstable, engine
stops
---
G sensor
Normal
operation,
but no
backup
when Ne is
abnormal
---
Water temperature
(low temperature)
system
Deterioration in
exhaust gas
color, drop
in starting
ability
---
Fuel injection amount

adjustment
switch signal
Output
excessive,
insufficient
---
Accelerator
sensor
Impossible
to control
accelerator
pedal
---
Drop in
starting abilPreheating
ity when
relay coil
temperature
is low
---
Engine
Short ciracceleration
cuit in startimpossible,
ing switch
black smoke
Alarm buzzer
Option
Transmission
control system
---
E01 + CALL

Action
by
operator
Yes
Error code
TROUBLESHOOTING
Travel
under
own
power
possible,
move to
safe
place,
then call
service
20-227 1
Problem
system
Condition of
machine
Becomes neutral, travel
impossible
(modulation
output OFF)
Work equipment
control system
ECSS
Problem
system
---
Condition of
machine
---
Problem
system
Condition
of machine
Wiring harRemote
ness on
positioner
damping
function
solenoid
stopped,
return side
possible
short circuit
burning out
with power
of control
source
Joystick
control system
Electronic
governor
system
Problem
system
Condition
of machine
Problem
system
Condition
of machine
---
---
Power
supply
Engine stops
Becomes neuDisconnection,
tral, travel
short circuit
impossible
with ground,
(judges concircuit in shift
troller input as
lever system
N)
---
---
---
---
---
---
Drop in performance,
deterioration in emisDrive circuit
sion, engine
stops, black
smoke,
white smoke
Disconnection,
short circuit
Becomes neuwith ground, or
tral, travel
short circuit in
impossible
F, R ECMV (ECMV output
solenoid signal
OFF)
system
---
---
---
---
---
---
Common
rail pressure Injection
abnormal pump stops
(2nd stage)
---
Impossible
to control
common
rail, drop in
pressure
(2nd stage)
Disconnection,
short circuit
Becomes neuwith ground or
tral, travel
short circuit
impossible
with speed
(ECMV output
range ECMV
OFF)
solenoid signal
system
20-228 1
---
---
---
---
---
Alarm buzzer
Option
Transmission
control system
Fill switch
short circuit
with ground
CALL

Action
by
operator
Yes
Error code
TROUBLESHOOTING
Stop
machine
turn
starting
switch
OFF, do
same as
above,
then call
service
Injection
pump stops
WA500-3LK
TROUBLESHOOTING
TRANSMISSION CONTROLLER LED DIS-
12
TRANSMISSION
CONTROLLER LED DISPLAY
The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and input/output
errors. The display shows two characters at the same time, and changes these in turn to give the display.
When the engine is started, Program part No. display mode" appears, followed by "Output speed range display mode". If
there is any abnormality in the controller, it changes to "Troubleshooting mode". The failure mode is saved to memory by the
main monitor.
1.
Method of displaying failure codes for transmission controller
Table 1 (Output speed range display mode)

Display
0.1.
0.2.
0.3.
0.4.
F.1.
F.2.
F.3.
WA500-3LK
Content
NEUTRAL, 1st
NEUTRAL, 2nd
NEUTRAL, 3rd
NEUTRAL, 4th
FORWARD, 1st
FORWARD, 2nd
FORWARD, 3rd
Display
F.4.
A.1.
A.2.
A.3.
A.4.
F.F.
Content
FORWARD, 4th
REVERSE, 1st
REVERSE, 2nd
REVERSE, 3rd
REVERSE, 4th
Neutral safety condition
20-229 1
TROUBLESHOOTING
ERROR CODE DISPLAYS
12
ERROR CODE DISPLAYS

1.
Error code displays

A. The engine controller displays the appropriate error code for the
abnormality in display window (1) of the controller using seven
segments with two alphanumeric digits.
B. When the starting switch is turned ON, the display check displays
[88], then displays [E] to show the occurrence of an error and a
2-digit code repeately.
C. If there are multiple service codes in memory, the display returns to
the first display after completing all the displays.
D. To prevent mistakes when reading, the numerals and letters are
displayed as follows:
Numerals: 0 1 2 3 4 5 6 7 8 9
Alphabet: A b C d E
E. When recreating an abnormality or after completion of repair of an
abnormality, keep the start switch at the ON position and
connect the No. 4 pin circuit of connector (2) CN4 to the ground.
20-230 1
WA500-3LK
TROUBLESHOOTING
ERROR CODE DISPLAYS
12
WA500-3LK
20-231 1
TROUBLESHOOTING
ERROR CODE DISPLAYS
12
2. Precautions for troubleshooting
A. Precautions to be taken when trouble repaired itself
When a connector is disconnected and a T-adapter is inserted for troubleshooting or when the T-adapter is removed
and the connector is re-installed, if the error code or "E" for error code is not displayed, the trouble may have been
repaired. The probability is that the same trouble will occur again. Consequently, follow up the condition of the
machine.
B. Handling of error codes
When displaying error codes for troubleshooting, take notes of all displayed items and delete those items, then reproduce the trouble and start the troubleshooting according to the error codes displayed at this time.
Troubles caused by a wrong operation, disconnection of a connector, etc. may be saved in the memory. In this
case, you can avoid unnecessary work by performing the above operation.
After finishing the troubleshooting, be sure to delete all saved error codes.
C. Handling of connectors
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
D. Handling of high-voltage circuit of engine controller
WARNING! The controller has a high-voltage circuit
(110 - 130 V) to drive the fuel injector.
This circuit is connected to the wiring
harness and connectors between the
engine controller and fuel injector.
The engine controller outputs the high voltage to the fuel
injector only while the engine is running and stops outputting
if the engine stops.
WARNING! If you touch the high-voltage circuit
directly, you may get an electric shock. To
avoid this, observe the following precautions.
When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn OFF the starting
switch.
If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit, do not start the
engine.
You may turn the starting switch to the OFF or ON position, but you must not turn it to the START position.
20-232 1
WA500-3LK
TROUBLESHOOTING OF ECSS (D MODE)
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)

JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
D-1 ECSS DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
A. ERROR CODE (d0) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
B. NO ABNORMALITY DISPLAY IS GIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
1. DOES NOT WORK AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
D-2 ECSS CANNOT BE CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407
WA500-3LK
20-401
TROUBLESHOOTING
JUDGEMENT TABLE FOR CONTROLLER
12
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

ECSS Control System
Failure code
d0
Abnormal system
Nature of abnormality
ECSS relay
1. ECSS relay.
2. Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 (1).
3. Defective contact or disconnection in wiring harness between ECSS relay
L90 (female) (2) and chassis ground.
4) Defective transmission controller.
Condition when normal (voltage, current, resistance)
1) Resistance of relay coil: 200 - 400

2) Resistance of wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90
(female) (1): Max. 1
3) Voltage between transmission controller C1 (3) and
chassis ground: Less than 1 V (Command OFF); 20
V or above (Command ON).
4) Resistance of wiring harness between ECSS relay
L90 (female) (2) and chassis ground: Max. 1
20-402
Action by
controller when
abnormality is
detected
Problem that
appears on machine
when there is
abnormality
ECSS function:
OFF
Swaying (pitching,
bouncing) of
machine when
traveling at high
speed (2nd - 4th)
Troubleshooting
code
D-1
a)
WA500-3LK
TROUBLESHOOTING
JUDGEMENT TABLE FOR CONTROLLER
12
MEMORANDUM
WA500-3LK
20-403
TROUBLESHOOTING
D-1 ECSS DOES NOT WORK
12
Carry out troubleshooting with the starting switch ON.
Check that the ECSS switch on the main monitor is ON.
A. ERROR CODE (D0) IS DISPLAYED

Cause
4
Yes
Yes Is resistance between

L90 (female) (2) and
chassis normal?
3
chassis normal?
2
Is resistance between
Yes chassis normal when
C1 (male) (3) is
grounded to chassis?
1
Is troubleshooting code
displayed when L90 is
replaced with another
relay of the same type?
1)
2)
3)
20-404
1) Max. 1.
2) Turn starting switch
OFF.
3) Disconnect L90
and C1.
No
1) Max. 1.
OFF.
No
3) Disconnect L90
and C1.
Turn starting switch

OFF.
Interchange with
another relay of same
type.
No
ECSS switch: ON
1) Max. 1.
OFF.
No
3) Disconnect L90.
Remedy
Defective ECSS controller Replace
Defective contact or
disconnection in wiring
harness between L90
(female (2) and chassis.
Repair or
replace
Short circuit with ground

in wiring harness between Repair or
C1 (female) (3) and L90 replace
(female) (1) and chassis
harness between C1
(female (3) and L90
(female (1)
Repair or
replace
Defective ECSS relay
Replace
WA500-3LK
TROUBLESHOOTING
D-1 A. Related electrical circuit diagram
WA500-3LK
20-405
TROUBLESHOOTING
12
B.
NO ABNORMALITY DISPLAY IS GIVEN
1. DOES NOT WORK AT ALL
Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
Cause
2
1
chassis normal when
C3B (male) (9) is
1)
2)
3)
Max. 1.
OFF.
Disconnect L06.
Yes
Yes Is voltage between C3B

(9) and chassis normal?
1) Max. 1.
ON.
3) Main monitor ECSS
switch: ON.
No
No
Remedy
Defective main monitor
Go to troubleshooting
of main monitor
harness between L06
(female (7) and C3B
(female (9)
Repair or replace
D-1 B. Related electrical circuit diagram
20-406
WA500-3LK
TROUBLESHOOTING
D-2 ECSS CANNOT BE CANCELED
12
Cause
2
Yes
Yes Is voltage between C3B

normal?
1
C3B (female) (9) and
chassis normal?
1)
2)
3)
Max. 1.
OFF.
Disconnect L06.
1) 20 - 30 V
ON.
3) Main monitor ECSS
switch: OFF.
No
No
Remedy
Go to troubleshooting
of main monitor
Short circuit with ground

in wiring harness between Repair or replace
C3B (female) (9) and L06
(female) (7)
D-2. Related electrical circuit diagram
WA500-3LK
20-407
TROUBLESHOOTING
12
MEMORANDUM
20-408
WA500-3LK
TROUBLESHOOTING OF CHASSIS
ELECTRICAL SYSTEM (E MODE)
Remark
Troubleshooting of the ENGINE electrical system (E MODE) is found in the ENGINE SHOP MANUAL.
E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502

A. STARTING MOTOR DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
B. STARTING MOTOR TURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
E-2 ENGINE DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
E-5 PARKING BRAKE DOES NOT HAVE EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON
(ACTUATED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT
WORK AS EMERGENCY BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON . . . . . . . . . . . . . . . 20-520
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS
APPLIED (BUT PARKING BRAKE WORKS NORMALLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
E-9 KICK-DOWN SWITCH DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY DURING
NORMAL GEAR SHIFT OPERATIONS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
B. KICK-DOWN IS NOT CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
E-10 BOOM KICK-OUT CANNOT BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-530
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-16 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
WA500-3LK
20-501
TROUBLESHOOTING
E-1 ENGINE DOES NOT START
12
When connecting or disconnecting T-adapter (or socket adapter) or short connector to carry out checks, always turn the
starting switch OFF before starting.
When connecting T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
A. STARTING MOTOR DOES NOT TURN

Yes
3
Yes Is voltage between
starting motor
terminal (B) and
chassis normal?
Yes
1) 20 - 30 V
2) Turn starting
switch OFF.
5
battery relay terminals
and chassis normal?
1) 20 - 30 V.
ON.
3) Check voltage
between chassis and
both terminals
connected by thick No
cable.
2
Yes Is there continuity
between starting
motor terminal (E)
and chassis?
1)
4
Does battery relay
make sound of
No actuation?
Turn starting
switch OFF.
1)
Starting switch
ONOFF.
Yes
6
1
No
Is voltage between
E13 (female) (1)
and chassis
normal?
1)
2)
3)
4)
No
No
No
20-502
Is voltage between
both connection
terminals of R12
and R13 of
battery relay
normal?
1) 20 - 30 V
2) Turn starting
switch OFF.
20 - 30 V
Disconnect E13.
Directional
lever: Neutral
Turn starting
switch to
START.
WA500-3LK
TROUBLESHOOTING
12
Cause
Remedy
Defective starting motor
disconnection in cable
Repair or
between battery relay and replace
starting motor
If answer is NO for
both terminals:
disconnection in
wiring harness
between battery and
battery relay
If answer is NO for
one terminal:
Defective battery
relay
Defective battery relay
Yes
8
R13 (female) and
chassis normal?
7
1) Max. 1.
OFF.
3) Disconnect R13.
Repair or
replace
Replace
harness between starting Replace
switch terminal BR - L09
(2) - LR4 (9) - R03 (diode)
(2), (1) - R12 female)
harness between R13 and
chassis ground
Repair or
replace
Replace
disconnection in starting
motor ground cable
Repair or
replace
Go to A on next page
Is voltage between
starting switch
terminal BR and
chassis normal?
Replace
1) 20 - 30 V
ON.
No
WA500-3LK
No
20-503
TROUBLESHOOTING
12
Yes
a
Yes
11
L57 (female) (5)
and chassis normal?
9
Does starting
motor rotate
A when neutral
relay is
replaced?
1)
2)
3)
1)
2)
3)
Replace
neutral relay
(L57) with
stop lamp
relay (L53).
FR lever:
Neutral
Turn starting
switch to
START.
20 - 30 V.
Disconnect
L57.
Turn starting
switch to
START.
13
1)
2)
Is voltage between
starting switch
terminal B and
No chassis normal?
1)
2)
20 - 30 V.
Turn starting
switch OFF.
20 - 30 V.
No
Turn starting
switch to START.
No
16
Is voltage between
L57 (female) (1)
No and (2) normal?
3)
Yes

L04 (3) and chassis
normal?
10
1)
2)
Yes

starting switch
terminal C and
12
chassis normal?
1)
2)
Disconnect L57.
Directional
lever: Neutral
Turn starting
switch to
START.
15
3)

L04 (female) (1)
and chassis normal?
1)
2)
3)
4)
20 - 30 V.
Connect Tadapter to L04.
No
Directional lever:
N
Turn starting
switch ON.
20 - 30 V.
Disconnect L04.
Turn starting
switch ON.
Does battery relay

make sound of
No actuation?
1)
14
Yes
Starting switch
ONOFF.
1) 20 - 30 V.
2) Turn starting
i
switch ON.
No
3) Check voltage
of both lines
between
chassis and 2
terminals
where thick
Yes
cable is
j
connected.
19
1) Max. 1.
2) Turn starting
switch OFF.
3) Disconnect L57.
Are both voltages

between battery
No relay R12 and
R13 connection
terminals normal?
1)
2)
20 - 30 V.
Turn starting
switch OFF.
No
No
20-504
18
Yes Are both voltages

between battery
relay terminals
and chassis
normal?
17
Is resistance
between L57
No (female) (2) and
chassis normal?
WA500-3LK
TROUBLESHOOTING
12
Cause
a
Defective neutral relay
Remedy
Replace
harness between L57 (female) Repair or
(3) - LR4 (8) - R01, R02
replace
(diode) - ER1 (10) - E13
(female) (1)
harness between starting
switch terminal C - L09 (3) L57 (female) (5)
Repair or
replace
Defective starting switch
Replace
switch terminal B - L09 (1) FS3 (4) - fuse I-12, FS3 (6) LR5 (1) - R17 - slow blow
fuse 30A - battery relay
Repair or
replace
Repair or
harness between L04 (female) replace
(3) and L57 (female) (1)
Defective directional lever

switch
disconnection in wiring harness between battery relay slow blow fuse 80A - R15 LR6 (1) - FS1 (2) fuse I-9 FS2 (8) - L04 (female) (1)
If answer is NO for
both terminals:
disconnection in
wiring harness
between battery and
battery relay
If answer is NO for
one terminal:
Defective battery
relay
Yes
21
20

R13 (female) and chassis
normal?
1)
2)
Is voltage between starting

switch terminal BR and
chassis normal?
1)
2)
3)

ON.
20 - 30 V.
No
WA500-3LK
Max. 1.
OFF.
Disconnect R13.
No
Replace
Repair or
replace
Repair or
replace
Replace
Repair or
switch terminal BR - L09 (2) - replace
LR4 (9) - R03 (diode) (2), (1)
- R12 (female)
harness between R13 and
chassis ground
Repair or
replace
Defective starting switch
Replace
Repair or
(2) - LR5 (2) - chassis ground
20-505
TROUBLESHOOTING
12
B.
STARTING MOTOR TURNS
Yes
4
Yes
1
3
Does engine stop

motor work?
1)
2)
3)
20 - 30 V.
Connect Tadapter to E03.
Turn starting
switch ON.
1) Max. 1.
2) Turn starting
switch OFF.
3) Disconnect E03.
No
Yes
Yes
5
Does engine stop
No motor when engine
stop relay is
replaced
Is voltage between
E03 (female) (4)
No and chassis normal?
20 - 30 V.
Disconnect E03.
Turn starting
switch OFF.
1) Max. 1.
2) Turn starting
switch ON.
3) Disconnect
L62.
No
No
20-506
Yes Is resistance
between L62
(female) (2) and
chassis normal?
1) Replace engine
6
stop relay (L62)
with stop lamp
Is voltage between
relay (L53).
L62 (female) (1)
2) Turn starting
switch ON
1) 20 - 30 V.
OFF and check
2) Disconnect L62.
visually.
3) Turn starting
switch ON.
1)
2)
3)
E03 (female) (8) and
chassis normal?

E03 (7) and chassis
normal?
1) Turn starting
switch ON
OFF and check
visually.
Yes
No
WA500-3LK
TROUBLESHOOTING
12
Cause
Remedy
Defective adjustment of
wire between engine stop
solenoid and lever
Replace
Defective engine stop

solenoid
Replace
Repair or
harness between E03 (female)
replace
(8) - ER2 (5) - ER1 (10) chassis ground

relay
Replace

solenoid
Replace
8
e
Yes
(7) normal?
ON.
2) Disconnect E03.
No
harness between E03 (female) Repair or
(5) - ER2 (3) - LR3 (5) - L62 replace
(female) (5), or between E03
(female (7) - ER2 (4) - LR3
(6) - L62 (female) (3)
Repair or
(2) chassis ground
Repair or
Blown fuse I-14, or defective

contact or disconnection in
Repair or
wiring harness between F2
(female) (11) - LR3 (3) - ER2 replace
(1) - E03 (female (4)
WA500-3LK
20-507
TROUBLESHOOTING
12
E-1 Related electrical circuit diagram
20-508
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-509
TROUBLESHOOTING
E-2 ENGINE DOES NOT STOP
12
When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn
the starting switch OFF before starting.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
Cause
Yes
1
Yes
Does engine stop motor

work?
ON OFF and check
visually.

motor
Replace
2
Is voltage between
E03 (7) and (8)
No normal?
1) 20 - 30 V.
2) Connect Tadapter to E03,
engine stop
motor connector
(8 pin).
3) Turn starting
switch OFF.
harness between E03 (female)
(3) - ER2 (2) - LR3 (4) - L62 Repair or
(female) (6), or between L62 replace
(female) (3) - LR3 (6) - ER2
(4) - E03 (female) (7), or
defective relay L62)
Yes
3
Is voltage between
E03 (3) and (8)
No normal?
1)
2)
3)
20 - 30 V.
Turn starting
switch OFF.
Connect Tadapter to E03.
Yes
Is voltage between
E03 (4) and (8)
No normal?
1)
2)
20-510
Remedy
Defective adjustment
between engine stop motor Adjust
and stop lever
20 - 30 V.
Connect T-adapter
to E03.
No

motor
Replace
harness between E03 (female) Repair or
(4) - ER2 (1) - LR3 (3) - FS2 replace
(female) (11), or blown fuse
I-14
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-511
TROUBLESHOOTING
E-3 ENGINE STOPS WHEN MACHINE IS
12
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING
Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
Cause
1
Yes
Does engine stop motor

work?
ON OFF and
No
check visually.
2
Does voltage
between E03 (7) and
(8) switch between 0
V and 20 - 30 V?
1) Connect Tadapter to E03.
2) Turn starting
switch ON
OFF.
20-512
Remedy
Defective adjustment
between engine stop motor Adjust
and stop lever
Yes
Yes
Is voltage between L62

(female) (2) and
No (female) (1) normal?
1)
2)
3)
20 - 30 V.
Disconnect L62
(engine stop relay.
ON.
No

motor
Replace

relay
Replace
Repair or
replace
switch terminal BR - L09 (2) L62 (female) (1)
WA500-3LK
TROUBLESHOOTING
E-3 ENGINE STOPS WHEN MACHINE IS
12
WA500-3LK
20-513
TROUBLESHOOTING
E-5 PARKING BRAKE DOES NOT HAVE EF-
12
E-5 PARKING BRAKE DOES NOT HAVE EFFECT
When carrying out troubleshooting of the brake system, stop the machine on flat ground.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA().
A. PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS

TURNED ON (ACTUATED)
Cause
Yes
Defective parking brake

switch
1
Does connection
become normal when
L01 is disconnected?
1)
2
No (3) normal?
1) Disconnect L01.
2) Turn starting
switch OFF.
3) Disconnect L58.
4) Disconnect L59.
Replace
Contact of wiring harness Repair or

at L01 (female) (2) end
replace
and (3) end
Yes
Start engine
(charge brake oil
pressure).
Remedy
Yes
Is voltage between
CN10 (female) (1) and
No chassis normal?
1) Max. 1 V.
2) Start engine.
(Charge brake oil
pressure).
3) Turn parking brake
switch ON.
No

solenoid
Replace

at L01 (female) (2) end
replace
B. PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS

(DOES NOT WORK AS EMERGENCY BRAKE)
Cause
1
Yes
Does condition become

normal when B09 is
disconnected?
1)
2)

ON.
Turn parking brake
switch ONOFF.
2
normal when B10 is
No disconnected?
1)
2)
20-514
Yes

ON.
Turn parking brake
switch ONOFF.
No
Remedy

switch (B09)
Replace

switch (B10)
Replace

solenoid
Replace
WA500-3LK
TROUBLESHOOTING
E-5 PARKING BRAKE DOES NOT HAVE EF-
12
MEMORANDUM
WA500-3LK
20-515
TROUBLESHOOTING
E-6 PARKING BRAKE IS APPLIED WHEN
12
E-6 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING
When carrying out troubleshooting of the brake system, stop the machine on flat ground.
2
Yes

CN10 (female) (2)
and chassis normal?
1) Max. 1.
2) Turn starting
switch OFF.
3) Disconnect L59.
No
Yes
Is voltage between
CN10 (female) (1)
and chassis normal?
Yes Does connection

become normal
when parking brake
safety relay is
replaced?
1) 20 - 30 V.
2) Start engine.
(Charge brake oil
pressure).
3
c
Yes
1) Replace parking
brake safety relay
(L59) with stop
lamp relay (L53).
2) Start engine.
(Charge brake oil
pressure)
Is continuity of L01
(male) (1)(2)(3) as
No shown in Table 1.
5
Does condition
become normal
No when B09 and B10
are connected to
short connector?
1) Turn starting
switch OFF.
2) Operating parking
brake switch
ON/OFF.
3) Disconnect L01.
1) Connect short
connector to B09
(female) and B10
(female).
2) Start engine.
(Charge brake oil
pressure)
Yes
7
Yes Is resistance
between L59
(female) (1) and
(3) normal?
6
Is voltage between
L59 (female) (5)
1) Max. 1
2) Turn starting
switch OFF.
3) Disconnect L59.
No
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Disconnect L59.
No
No
20-516
WA500-3LK
TROUBLESHOOTING
12
Table 1
Operation
Between (2) - (3)
Between (1) - (3)
ON (Parking)
Min. 1 M
Max. 1
OFF (Travel)
Max. 1
Min. 1 M
Cause
Remedy

solenoid
Replace
harness between CN10
Repair or
replace

safety relay
Replace

switch
Replace
Yes
11
10 Yes Is voltage between
B10 (female) (1) and
chassis normal?

chassis normal?
9
chassis normal?
8
e
1) Max. 1.
OFF.
3) Disconnect L59.
Is voltage between
L59 (female) (1)
and chassis
normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Turn parking
brake switch
ON.
4) Disconnect
L59.
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Turn parking
brake switch
ONOFF.
4) Disconnect B09.
No
No
No
1) 20 - 30 V.
ON.
No
switch ONOFF.
4) Disconnect B10.
or
harness between B10 (female) Repair
replace
(2) - BR1 (8) - LR4 (14) - TH2
(11) - CN10 (female)
Repair or
harness between B09 (female) replace
(2) and B10 (female) (1)
or
harness between B09 (female) Repair
replace
(1) - BR1 (7) - LR4 (13) - L01
(female) (2)
Repair or
(2) and chassis
(1) and L01 (female) (3), or
replace
between FS2 (female) (7) and
L01 (female) (1)
Repair or
Repair or
(5) and FS2 (7) - fuse I-9

switch
WA500-3LK
Replace
20-517
TROUBLESHOOTING
12
E-6 Related electrical diagram
20-518
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-519
TROUBLESHOOTING
E-7 PARKING BRAKE IS RELEASED WHEN
12
E-7 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS

TURNED ON
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOL( ).
Cause
Yes
1
Is problem removed
when parking safety
switch (L59) is
replaced?
1) Replace parking
brake safety relay
(L59) with stop
lamp relay (L53).
ON.
3) Start engine.
(Stop engine after
charging brake oil
pressure)
20-520
Yes
2
Does it become
normal when L01 is
No disconnected?
1) Disconnect L01.
2) Turn starting
switch ON.
3) Start engine.
(Stop engine
after charging
brake oil
pressure)
Yes
3
Remedy

safety relay
Replace

switch
Replace

between L59 (5) and
replace
(female) (3)(1)
Is there continuity
between L59 (female)
No (3) and (5)?
switch OFF.
OFF.
3) Disconnect L59.
No

between L01 (female) (1) replace
and (2)
WA500-3LK
TROUBLESHOOTING
E-7 PARKING BRAKE IS RELEASED WHEN
12
WA500-3LK
20-521
TROUBLESHOOTING
E-8 TRANSMISSION DOES NOT CHANGE TO
12
E-8 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN

PARKING BRAKE IS APPLIED (BUT PARKING BRAKE
WORKS NORMALLY)
Cause
1
Yes
Is voltage between
neutralizer relay L58
(female) (5) - chassis
normal?
1) Max. 1 V.
No
2) Disconnect neutralizer
relay L58.
ON.
4) Shift directional lever
between F, N, and R,
and check each
voltage.
20-522
Remedy
Defective neutralizer relay Replace
Short circuit with power

source in wiring harness
between L58 (female) (5)
and C3A (female) (6)
Repair or
replace
WA500-3LK
TROUBLESHOOTING
E-8 TRANSMISSION DOES NOT CHANGE TO
12
WA500-3LK
20-523
TROUBLESHOOTING
E-9 KICK-DOWN SWITCH DOES NOT WORK
12
After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to original
A. KICK-DOWN SWITCH DOES NOT WORK (SHIFT WORKS CORRECTLY

DURING NORMAL GEAR SHIFT OPERATIONS)
Cause
4
Yes
3 Yes Is resistance between

L08 (male) (2), (4)
and GND normal?
L08 (female) (2), (4)
No
1) Max. 1.
2 Yes and GND normal
when L15 (female)
OFF.
(2) is grounded to
3) Disconnect L08.
chassis?
Yes C5 (female) (5) and
GND normal when
No
L15 (female) (1) is
1) Max. 1.
OFF.
1
3) Disconnect L15
and L08.
1) Max. 1
4) Ground L15
L15 (male) (1) and (2)
(female) (2) to
OFF.
normal?
chassis.
3) Disconnect L15
and C5.
No
1) Max. 1
4) Ground L15
(female) (1) to
OFF.
chassis.
3) Disconnect L15.
4) Press kick-down
switch.
No
Remedy
Repair or
replace
Defective transmission
controller
Repair or
replace
Repair or
(2) and L08 (female) (2), (4)
Repair or
Defective kick-down
switch
Replace
B. KICK-DOWN IS NOT CANCELED

Cause
Yes
1
normal when L15 is
disconnected?
Is voltage between
No L15 (female) (2),
L08 (female) (2), (4)
- GDN normal?
1) Max. 1.
OFF.
No
3) Disconnect C5 and L08.

4) Turn kick-down switch OFF.
5) Ground C5 (female) (5) to chassis.
1) Max. 1 V.
OFF.
No
3) Disconnect C5 and
L08.
20-524
Yes

L08 (female) (2), (4) GDN normal when C5
(female) (5) is
2
Remedy
Defective kick-down
switch
Replace
controller
Repair or
replace
Defective contact, or short

circuit in wiring harness
between C5 (female) (5) - L15 Repair or
(female) (1) and in wiring
replace
harness between L15 (female)
(2) - L08 (female) (2)

between L15 (female) (2) L08 (female) (2), (4)
Repair or
replace
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-525
TROUBLESHOOTING
E-10 BOOM KICK-OUT CANNOT BE USED
12
Before carrying out troubleshooting, check that all related connectors are properly inserted.
Check that fuse I (10) is normal. If it is blown, check for a short circuit with ground in the wiring harness between
fuse I (10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)
Yes
Yes
1
Does condition
become normal
when L49 is
replaced with a
relay of same type?
1)
5
F06 (1) and chassis
ground normal?
Interchange with
a relay of same
type.
1) 20 - 30 V.
2) Turn starting
switch ON.
Yes Is resistance
between F06
(female) (3) and
chassis ground
normal?
3
Yes Is resistance
between L16
(female) (1) and (2)
normal?
2
1) 20 - 30 V.
2) Turn starting
switch ON.
No
3) Bring a screwdriver close to
boom kick-out
proximity
switch.
No
1) Max. 1.
2) Turn starting
switch OFF.
3) Disconnect F06.
1) 19 - 23 1.
2) Disconnect L16.
No
Is voltage between
No each pin of F06 as
shown in Table 1?
1) See Table 1.
2) Turn starting
switch ON.

L49 (2) and
chassis ground
normal?
No
No
Table 1
When screwdriver is close
When screwdriver is not close
Between (1) and (2)
20 - 30 V
Max. 3 V
Between (1) and (3)
20 - 30 V
0 - 30 V
Between (2) and (3)
Max. 3 V
20 - 30 V
20-526
WA500-3LK
TROUBLESHOOTING
12
Cause
a
Defective boom relay
Yes
7
b
chassis ground
normal?
No
1) Max. 1.
OFF.
3) Disconnect L16.
Remedy
Replace
Repair or
Repair or
(2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO6 (female)
(2)
harness between fuse I (10) FS2 (10) - L49 (female) (3),
Repair or
between FS2 (10) - LR2 (1) - replace
FR12 (1) - F06 (female) (1), or
between FS2 (10) - L32 (1) L33 (1) - L49 (female) (1)
Repair or
harness between F06 (female) replace
(3) and chassis ground
Defective boom kick-out

solenoid
Replace
Defective boom
proximity switch
Replace
WA500-3LK
20-527
TROUBLESHOOTING
12
20-528
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-529
TROUBLESHOOTING
E-11 ABNORMALITY IN BUCKET POSITION-
12
E-11 ABNORMALITY IN BUCKET POSITIONER FUNCTION
Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between
fuse I (10) - FS2 (10) - L48 (1) (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1).
Yes
Yes
1
Does condition
become normal
when L48 is
replaced with a
relay of same type?
1)
5
F05 (1) and chassis
ground normal?
Interchange with
a relay of same
type.
1) 20 - 30 V.
2) Turn starting
switch ON.
Yes Is resistance
between F05
(female) (3) and
chassis ground
normal?
3
Yes Is resistance
between L17
(female) (1) and (2)
normal?
2
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Bring a screwdriver close to
bucket
positioner
proximity
switch.
No
No
1) Max. 1.
2) Turn starting
switch OFF.
3) Disconnect F05.
1) 19 - 23 1.
2) Disconnect L17.
No
Is voltage between
No each pin of F05 as
shown in Table 1?
1) See Table 1.
2) Turn starting
switch ON.

L48 (2) and
chassis ground
normal?
No
No
Table 1
When screwdriver is close
When screwdriver is not close
Between (1) and (2)
20 - 30 V
Max. 3 V
Between (1) and (3)
20 - 30 V
0 - 30 V
Between (2) and (3)
Max. 3 V
20 - 30 V
20-530
WA500-3LK
TROUBLESHOOTING
12
Cause
a
Defective bucket relay
Yes
7
b
chassis ground
normal?
No
1) Max. 1.
OFF.
3) Disconnect L17.
Remedy
Replace
Repair or
Repair or
(2) - L32 (2) - L33 (2) - LR2 replace
(2) - FR2 (2) - FO5 (female)
(2)
harness between fuse I (10) FS2 (10) - L48 (female) (3),
Repair or
between FS2 (10) - LR2 (1) - replace
FR12 (1) - F05 (female) (1), or
between FS2 (10) - L32 (1) L33 (1) - L48 (female) (1)
Repair or
harness between F05 (female) replace
(3) and chassis ground
Defective bucket
positioner solenoid
Replace
Defective bucket
proximity switch
Replace
WA500-3LK
20-531
TROUBLESHOOTING
12
20-532
WA500-3LK
TROUBLESHOOTING
E-12 ABNORMALITY IN LIGHTING UP OF
12
E-12 ABNORMALITY IN LIGHTING UP OF FRONT WORKING LAMP
Go to Troubleshooting M-10.
E-13 ABNORMALITY IN LIGHTING UP OF REAR WORKING LAMP
Go to Troubleshooting M-11
E-14 ABNORMALITY IN TRANSMISSION CUT-OFF
Go to Troubleshooting M-12.
E-15 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
Go to Troubleshooting M-13, M-14.
E-16 ABNORMALITY IN BUZZER
Go to Troubleshooting M-15, M-18.
20-533
WA500-3LK
E-16 ABNORMALITY IN BUZZER
12
MEMORANDUM
20-534
WA500-3LK
TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEMS (H MODE)
12
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
H-1 MACHINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES,
DOES NOT SHIFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR . . . . . . . . . . . . . . . . 20-612
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR . . . . . . . . . . . . . 20-615
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-6 STEERING WHEEL DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-7 STEERING DOES NOT TURN (MACHINE WITH JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-8 TURNING, RESPONSE OF STEERING IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-9 TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK) . . . . . . . . . . . . 20-622
H-10 STEERING IS HEAVY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-11 JOYSTICK STEERING IS HEAVY (MACHINES EQUIPPED WITH JOYSTICK) . . . . . . . . . . . 20-624
H-12 STEERING WHEEL SHAKES OR JERKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
H-13 STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE WITH JOYSTICK) . . . 20-626
H-14 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT
MAXIMUM STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-627
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-629
H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR . . . . . . . . . . . . . . . . . . . . 20-629
H-16 WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG . . . . . . . . . . . . . . . . . . . . . . . . . . 20-631
H-17 PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR . . . . . . . . . . . . . . . . . 20-632
H-18 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING EMERGENCY
RELEASE SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-633
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-634
H-19 NEITHER BOOM NOR BUCKET MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-634
H-20 BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER . . . . . . . . . . . . . . . . . . . . . . . . . . 20-635
H-21 BOOM DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-636
H-22 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-636
H-23 BOOM IS SLOW OR BOOM LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-637
H-24 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-637
H-25 BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM FLOAT . . . . . . . . 20-638
H-26 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM
HOLD TO RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-639
H-27 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-639
H-28 EXCESSIVE HYDRAULIC DRIFT OF BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-640
H-29 BUCKET DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-641
H-30 BUCKET IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-642
H-31 EXCESSIVE HYDRAULIC DRIFT OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-643
H-32 ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING [MACHINES
WITH ECSS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-644
WA500-3LK
20-601 1
TROUBLESHOOTING
POWER TRAIN
12
POWER TRAIN
H-1 MACHINE DOES NOT START
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Clutch seized, part broken Was there any abnormal noise when this happened?
Where did the noise come from?
Checks before troubleshooting
Does the main monitor function properly?
Is any failure code for the electrical system displayed on the main monitor?
Does not start in certain transmission ranges
Abnormal noise comes from charging pump or transmission

filter when transmission oil temperature is low
Machine does not move when transmission oil temperature

rises
Metal particles (aluminium, copper, iron, etc.) stuck to

transmission filter or strainer
When torque converter stall speed is measured - Speed is high
in all speed ranges
When torque converter stall speed is measured - Speed is high

in certain speed ranges
When ECMV output (clutch) oil pressure is measured - Oil

pressure is low in all speed ranges
When ECMV output (clutch) oil pressure is measured - Oil

pressure is low in certain speed ranges
X
o
10 When ECMV output (clutch) oil pressure is measured Gauges fluctuates, oil pressure is not stable
Parking
brake
Transmission
Defective parking brake piston seal
Does not start in any transmission range
Defective operation of parking brake solenoid valve
Oil leakage from sleeve (between housing and clutch case)

(except 1st)
Defective rear shaft seal ring (1st only)
Defective seal applicable clutch piston
Wear, seizure of applicable clutch
Breakage inside transmission
EC
M
V
11 When torque converter relief (inlet port) oil pressure is

measured, it is found to be low
Legend: X: Replace : Correct A: Adjust C: Clean
Defective operation of applicable ECMV
Main relief
valve
Clogged fail-safe filter
Breakage inside torque converter
Problems
Drop in set pressure of main relief valve
Defective charging pump
No.
Remedy
Air sucked in at suction end of pump
T/
C
Clogged strainer
Torque converter
charging pump
Defective PTO
Defective operation of torque converter relief valve
Causes
Is the transmission oil level correct? Is the type of oil

correct?
Is the transmission oil deteriorated? Does the oil smell of
burning?
Is the transmission filter or strainer clogged? Is there any
damage or leakage of oil that can be seen externally?
Is the drive shaft broken?
Is the wheel brake or parking brake locked?
Method of determining defective clutch and ECMV (check using failure code)
20-602 1
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
For details of the method for checking the failure code display, see "Method of displaying action code and failure code" and
"Action code and failure code table and re-enaction".
When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it
and tighten the mounting bolts to the specified tightening torque.
Carry out the following troubleshooting with the manual mode for starting the engine.
Table of clutch
combinations
Speed
Auto
Manual
F1
F2
F3
F4
R1
R2
R3
R4
Clutch
2nd
O
O
1st
3rd
4th
Remark
At N in the manual mode, the clutch for the speed range (marked O) selected by the speed lever is ON.
WA500-3LK
20-603 1
TROUBLESHOOTING
POWER TRAIN
12
Defective actuation of R clutch ECMV
Defective actuation of 3rd clutch ECMV
Defective actuation of 4th clutch ECMV
(1) The failure code is not displayed as R1 - R4; it is displayed as F1 - F4
26 O
After troubleshooting item (1), if the failure code is 26, when the F fill switch
(2) connector (CN17) is disconnected, the failure code display will go out: If the
failure code is 32, when any ECMV except F is replaced, the failure code
display will go out.
32
(1) The failure code is not displayed as F1 - F4; it is displayed as R1 - R4
27
After troubleshooting item (1), if the failure code is 26, when the R fill switch
failure code is 32, when any ECMV except R is replaced, the failure code
28
(1) The failure code is not displayed as F2, F3, or F4; it is displayed as F1
28
Causes
Transmission
No.
Problems
O
O
O
29
O
O
30
O
O
After troubleshooting item (1), if the failure code is 26, when the 3rd fill switch
33
failure code is 32, when any ECMV except 3rd is replaced, the failure code
After troubleshooting item (1), if the failure code is 26, when the 2nd fill switch
33
failure code is 32, when any ECMV except 2nd is replaced, the failure code
ECVM
After troubleshooting item (1), if the failure code is 26, when the 1st fill switch
33
failure code is 32, when any ECMV except 1st is replaced, the failure code
31
Defective actuation of 2nd clutch ECMV
Defective actuation of F clutch ECMV
Remedy
Defective actuation of 1st clutch ECMV
Worn, seized 4th clutch disc, or worn piston seal
Worn, seized 3rd clutch disc, or worn piston seal
Worn, seized 2nd clutch disc, or worn piston seal
Worn, seized R clutch disc, or worn piston seal
Worn, seized F clutch disc, or worn piston seal
Worn, seized 1st clutch disc, or worn piston seal
Causes
O
O
After troubleshooting item (1), if the failure code is 26, when the 4th fill switch
33
failure code is 32, when any ECMV except 4th is replaced, the failure code
Remark
20-604 1
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
MEMORANDUM
WA500-3LK
20-605 1
TROUBLESHOOTING
POWER TRAIN
12
H-2
TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS

POWER ON SLOPES, DOES NOT SHIFT GEAR
Yes = Related equipment broken
Was there any abnormal noise when this happened?
Did the problem gradually appear?
Yes = Wear of related parts, defective seal
Checking for abnormalities
Measure digging operations and speed when traveling on level ground and on slopes, and check if there is actually an
abnormality or whether it is just the feeling of the operator.
Is the failure code for the electrical system displayed on the monitor?
Is the transmission oil level correct? Is the type of oil correct?
Is the transmission filter or strainer clogged?
Is there any oil leaking from the joints of the piping or valves around the torque converter or transmission?
Is there any dragging of the wheel brake or parking brake?
Is the tire inflation pressure and tread pattern correct?
Is the method of operation correct?
Remark
If it is judged that there is a drop in the engine performance, go to troubleshooting of the engine system (S mode).
20-606 1
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
Torque
converter
charging pump

No.
Remedy
Problems
Abnormality in all transmission ranges
C
X
Torque
converter
cooler
Torque
converter
Main relief
valve
Abnormality in certain transmission ranges

When oil temperature is low, abnormal noise comes from charging
pump or transmission filter
Torque converter oil overheats
Transmission oil level changes
Metal particles stuck to transmission filter or strainer
When engine low idling, high idling speeds are measured, speed is
found to be abnormal
When torque converter stall speed is measured - Speed is found to be

high

low
10 When ECMV output (clutch) oil pressure is measured - When oil
Clogged breather
Oil leakage from sleeve (between housing and clutch case) (except 1st)

n
Defective seal of applicable clutch piston
pressure is found to be low (Items 11 - 13 are normal)
A: Adjust
14 When torque converter relief (inlet port) oil pressure is measured, oil
: Correct
low in certain speed ranges
15 When torque converter outlet port pressure is measured, oil pressure is

found to be low (Item 14 is normal)
12 When ECMV output (clutch) oil pressure is measured - Oil pressure is

13 When ECMV output (clutch) oil pressure is measured - Gauges
fluctuates, oil pressure is not stable
temperature rises, oil pressure goes down

low in all speed ranges
Parking
brake
Transmission
X: Replace
ECMV
Legend:
Defective operation of torque converter relief valve
Oil leakage inside torque converter
Broken oil cooler, piping (beyond torque converter outlet port)
Clogged oil cooler, piping (beyond torque converter outlet port)
Clogged strainer
Causes
C: Clean
Go to "Method of determining defective clutch and ECMV (check using failure code)".
WA500-3LK
20-607 1
TROUBLESHOOTING
POWER TRAIN
12
Continued from page 20-607.
Drop in engine performance
Defective seal on shaft for hydraulic pumps for work

equipment and steering systems (hydraulic oil leaking
into transmission case)
Causes
No.
Remedy
Problems
Note
Others
Abnormality in all transmission ranges
Abnormality in certain transmission ranges
When oil temperature is low, abnormal noise comes from charging

pump or transmission filter
Metal particles stuck to transmission filter or strainer
When engine low idling, high idling speeds are measured, speed is
found to be abnormal

high

low
10 When ECMV output (clutch) oil pressure is measured - When oil

temperature rises, oil pressure goes down

low in all speed ranges

low in certain speed ranges
13 When ECMV output (clutch) oil pressure is measured - Gauges

fluctuates, oil pressure is not stable
14 When torque converter relief (inlet port) oil pressure is measured, oil
pressure is found to be low (Items 11 - 13 are normal)
15 When torque converter outlet port pressure is measured, oil pressure is

found to be low (Item 14 is normal)
Legend:
X: Replace
20-608 1
: Correct
A: Adjust
C: Clean
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
"Action code and failure code table and re-enaction"
Table of clutch
combinations
Speed
Auto
Manual
F1
F2
F3
F4
R1
R2
R3
R4
Clutch
1st
2nd
O
O
3rd
4th
Remark
WA500-3LK
20-609 1
TROUBLESHOOTING
POWER TRAIN
12
No.
Problems
26 O
32
27
(CN15) is disconnected, the failure code display will go out: If the
(2) connector
28
28
O
O
O
29
O
O
33
30
O
O
33
(2) connector
33
5
ECVM
31
(2) connector
33
20-610 1
Transmission
Remedy
Causes
Causes
O
O
O
O
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
H-3
EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR

Where did the noise come from? Did the problem gradually appear?
Is the travel speed slow, is the thrusting force weak, does the machine lack power
when traveling uphill, is it impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2
Is there any oil leaking from the joints of the piping or valves around the torque converter or
transmission?
Torque converter charging

pump

No.
Remedy
Shock is excessive in certain transmission ranges

Oil pressure is low in all speed ranges
X: Replace
Oil leakage from sleeve

(between housing and clutch case)
X
Legend:

X
Defective return (disengagement)

of applicable clutch piston
Oil pressure is low in certain speed ranges

Gauges fluctuates, oil pressure is not
stable
: Correct A: Adjust C: Clean
Defective operation of applicable clutch piston
When ECMV output (clutch) oil pressure is

measured
Parking
brake
Transmission
Shock is excessive in every transmission range
ECMV
1
3
Problems
C
X
Clogged strainer
Causes
X
k
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by dirt.
Go to Method of determining defective clutch and ECMV (check using failure code).
WA500-3LK
20-611 1
TROUBLESHOOTING
POWER TRAIN
12
Table of clutch
combinations
Speed
Auto
Manual
F1
F2
F3
F4
R1
R2
R3
R4
Clutch
1st
2nd
O
O
3rd
4th
Remark
20-612 1
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
No.
Problems
26 O
32
27
(2) connector
28
28
O
O
O
29
O
O
33
30
O
O
33
(2) connector
33
5
ECVM
31
(2) connector
33
WA500-3LK
Transmission
Remedy
Causes
Causes
O
O
O
O
20-613 1
TROUBLESHOOTING
EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR

Where did the noise come from? Did the problem gradually appear?
Is the travel speed slow, is the thrusting force weak, does the machine lack power
when traveling uphill, is it impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2
Is there any oil leaking from the joints of the piping or valves around the torque converter or
transmission?
Torque
converter
charging pump

No.
1
Remedy
Problems
Time lag is excessive in every transmission range
C
X
When ECMV output (clutch) oil pres- Oil pressure is low in all speed ranges
sure is measured
Oil leakage from sleeve (between housing

and clutch case)
X

X
Defective seal of applicable clutch piston
Time lag is excessive in certain transmission ranges
Transmission
When transmission oil temperature is low, abnormal noise comes from charging pump
or transmission filter
ECMV
Main
relief
valve
Clogged strainer
Causes
12
H-4
POWER TRAIN
Parking
brake
X
j
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by dirt in the spool.
Go to Method of determining defective clutch and ECMV (check using failure code).
20-614 1
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
Table of clutch
combinations
Speed
Auto
Manual
F1
F2
F3
F4
R1
R2
R3
R4
Clutch
1st
2nd
O
O
3rd
4th
Remark
WA500-3LK
20-615 1
TROUBLESHOOTING
POWER TRAIN
12
No.
Problems
26 O
32
27
(2) connector
28
28
O
O
O
29
O
O
33
30
O
O
33
(2) connector
33
5
ECVM
31
(2) connector
33
20-616 1
Transmission
Remedy
Causes
Causes
O
O
O
O
WA500-3LK
TROUBLESHOOTING
POWER TRAIN
12
H-5
TORQUE CONVERTER OIL TEMPERATURE IS HIGH
Does oil temperature rise during torque converter stall and go down when
there is no load?
Yes = Improper selection of transmission range
Does oil temperature rise only when carrying out
scooping work?
Yes = Improve method of operation
Measure the torque converter oil temperature. Is it
actually high?
No = Defective oil transmission gauge
Are the radiator water level and fan belt tension correct?
Remark
If it is judged that there is a drop in the engine
performance, go to troubleshooting of the engine system
(S mode in the engine shop manual).
Remedy

No.
Drop in engine performance
Defective seal on shaft for hydraulic pumps for work equipment

and steering systems (hydraulic oil leaking into transmission case)
Clogged breather
Oil leakage inside torque converter
Broken oil cooler, piping (beyond torque converter outlet port)

X
C
X
Abnormality in travel speed, thrusting force, and grade ability in all transmission
ranges
Abnormality in travel speed, thrusting force, and grade ability in certain transmission ranges
Metal particles stuck to transmission strainer or torque converter filter
When engine low idling, high idling speeds are measured, speed is found to be
abnormal
When torque converter stall speed is measured, it is found to be high
12 When torque converter relief (inlet port) oil pressure is measured, oil pressure is
found to be low (Items 9 - 11 are normal)
WA500-3LK
Others
13 When torque converter outlet port pressure is measured, oil pressure is found to
be low (Item 12 is normal)
Transmission
When oil temperature rises, oil pressure goes down

When ECMV
output (clutch) oil Oil pressure is low in all speed ranges
10 pressure is
measured
11
Gauge fluctuates, oil pressure is not stable
Main
relief
valve
Torque
converter
C
X
When oil temperature is low, abnormal noise comes from charging pump or trans
mission filter
Problems
Torque
converter
cooler
Remark
Torque
converter
charging pump
Clogged oil cooler, piping (beyond torque converter outlet port)
Clogged strainer
Causes
20-617 1
TROUBLESHOOTING
STEERING SYSTEM
12
STEERING SYSTEM
H-6 STEERING WHEEL DOES NOT TURN
Is the steering shaft broken?
Is the stop valve stopper properly adjusted?
Hydraulic Charge Orbit

pump
valve
roll
Remedy
No.
Problems
Steering wheel turns only in one direction (left or right)
Steering wheel is heavy in both directions (left and right)
Work equipment moves
Work equipment does not move
Abnormal noise comes from around PTO
Abnormal noise comes from around PPC pump or hydraulic tank
When steering relief

pressure is measured
Steering wheel does not turn in both directions (left and right)
Stop
valve
Steering valve
X
h
Oil pressure is low or there is no pressure in both directions

(left or right)
Defective piston seal
Defective safety / suction valve
Defective actuation of steering spool
Defective actuation of demand spool
Defective stop valve
Defective Orbit-roll
Defective charge valve
Defective PPC pump
Defective steering and switch pump
Causes
Cylinder
X
i
Oil pressure is low or there is no pressure in one direction (left

or right)
10 When orbit-roll output pressure is measured, oil pressure is found to be low or there is
no oil pressure
11 When PPC valve (orbit- Oil pressure is low

roll) basic pressure is
12 measured
There is no oil pressure
Legend: X: Replace : Correct A: Adjust
C: Clean
Remark
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt
in the steering, check the operation of the work equipment also.
20-618 1
WA500-3LK
TROUBLESHOOTING
STEERING SYSTEM
12
H-7
STEERING DOES NOT TURN (MACHINE WITH JOYSTICK)

Is the steering shaft broken?
Is the stop valve stopper properly adjusted?
Is the operation of the steering and the steering mode switch correct?
Hydraulic pump Charge

valve

No.
1
2
3
Remedy
Problems
When steering
mode switch is
switched
orbitroll
Steering wheel does not turn in both directions (left and right)
Steering wheel turns only in one direction (left or right)
Steering wheel is heavy in both directions (left and right)
Steering wheel is heavy in one direction (left or right)
Steering valve
Valve
Cylinder
C
X
11 Abnormal noise comes from around PPC pump or hydraulic tank
12 When steering
relief pressure is (left and right)

measured
13
or right)
14 When orbit-roll out put pressure is measured, oil pressure is found to be low or
there is no oil pressure
15 When joystick solenoid valve output pressure is measured, oil pressure is found
to be low or there is no oil pressure
16 When PPC valve Oil pressure is low

(orbit-roll) basic
17 pressure is meaThere is no oil pressure
sured
Legend: X: Replace : Correct
10 Abnormal noise comes from around PTO
A: Adjust
Defective 2-way restrictor valve
Defective actuation of joystick solenoid valve
Defective actuation of stop valve

Stop
valve
Steering does not move (joystick mode only)
Joystick
Steering does not move (steering wheel mode only)

Steering does not move in either mode
Clogged filter
Defective orbit-roll
Defective PPC pump
Defective PTO
Causes
C: Clean
Remark
WA500-3LK
20-619 1
TROUBLESHOOTING
TURNING, RESPONSE OF STEERING IS POOR

Charge Orbitvalve
roll
Hydraulic pump

No.
Remedy
Problems
Turning response of steering is poor in one direction (left or right)
Steering wheel is heavy in both directions
Abnormal noise comes from around steering pump or hydraulic tank
Abnormal noise comes from around switch pump or hydraulic tank
Steering valve
Defective main relief valve
Stop
valve
Turning response of steering is poor in both directions
10 When steering
11 relief pressure is
measured
Defective switch pump
Defective steering pump
Defective PPC pump
Defective PTO
Causes
12
H-8
STEERING SYSTEM
Cylinder

or right)
12 When orbit-roll output pressure is measured, oil pressure is found to be low
13 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be
low
Remark
20-620 1
WA500-3LK
TROUBLESHOOTING
STEERING SYSTEM
12
H-9
TURNING, RESPONSE OF STEERING IS POOR (MACHINE WITH JOYSTICK)
Was there previously any symptom, such as difficulty in steering?
Yes = Wear of related equipment, defective seal
Hydraulic pump

No.
1
Remedy
Problems
C
X
Joystick
Stop
valve
Valve Cylinder
Steering valve
Turning response of steering is poor in both directions
Turning response of steering is poor in one direction (left or right)
Steering wheel is heavy in both directions
11 Abnormal noise comes from around steering pump or hydraulic tank
15 When orbit-roll output pressure valve output pressure is measured, oil pressure
is found to be low
16 When joystick solenoid valve output pressure is measured, oil pressure is

found to be low
17 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found
to be low
Remark
WA500-3LK
12 Abnormal noise comes from around switch pump or hydraulic tank

13 When steering Oil pressure is low in both directions
relief pressure
14 is measured
Oil pressure is low in one direction (left or right)
Orbitroll
Charge
valve
When steering Abnormality only in steering wheel mode

mode switch is Abnormality only in joystick mode
switched
Abnormality in both modes
Clogged filter
Defective steering pump
Defective PPC pump
Defective PTO
Causes
20-621 1
TROUBLESHOOTING
STEERING IS HEAVY
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 VALUE TABLE to see if they are abnormal.
Was there previously any symptom, such as heavy steering?
Yes = Wear of related equipment, defective seal
Is the tire inflation pressure correct?

No.
Remedy
Stop valve
Steering
valve
Others
Problems
Steering is heavy when turned in both directions
Steering is heavy when turned on one direction (left or right)
Steering is heavy even when joint between steering shaft and orbit-roll is disconnected
5
6
20-622 1

Oil pressure is low in both directions
Oil pressure is low in one direction (left or right)
When orbit-roll output pressure is measured, oil pressure is found to be low

Interference of steering wheel or steering shaft
Orbit-roll
Causes
12
H-10
STEERING SYSTEM
WA500-3LK
TROUBLESHOOTING
STEERING SYSTEM
12
H-11
JOYSTICK STEERING IS HEAVY (MACHINES EQUIPPED WITH JOYSTICK)
Causes and remedy
Abnormality of joystick (X)
Remark
The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in the joystick; see
J-MODE Joystick Steering Controller System.
WA500-3LK
20-623 1
TROUBLESHOOTING
STEERING WHEEL SHAKES OR JERKS

Is the steering difficult to turn?
Yes = Go to H-8
Is there any abnormal noise from around the steering
equipment?
Is the steering wheel play correct?
Is there any abnormality in the connection between the
steering shaft and the Orbit-roll?
Charge
valve
Remedy
No.
Orbit-roll Stop valve
X
c
Problems
Steering wheel shakes or jerks in both directions
Steering wheel shakes or jerks in one direction (left or right)
During operations or when traveling (when steering), steering wheel shakes or jerks in
both directions
one direction (left or right)
Steering wheel jerks or there is excessive shock when steering is operated to the end of
the stroke
Work equipment also jerks

Oil pressure is unstable in both directions
Cylinder
X
g
Steering valve
X
h
Oil pressure is unstable in one direction (left or right)
9 When orbit-roll output Oil pressure is unstable in both directions

10 pressure is measured Oil pressure is unstable in one direction (left or right)
11 When PPC valve (orbit-roll basic pressure is measured oil pressure is found to be
unstable
20-624 1
Defective charging valve
Causes
12
H-12
STEERING SYSTEM
WA500-3LK
TROUBLESHOOTING
STEERING SYSTEM
12
H-13
STEERING SHAKES OR THERE IS EXCESSIVE SHOCK (MACHINE
WITH JOYSTICK)
Checking for abnormalities Is the steering difficult to turn?
Yes = Go to H-9
Is there any abnormal noise from around the steering
equipment?
Is any failure code for the electrical system displayed on
the main monitor?
Is the steering wheel play correct?
Is there any abnormality in the connection between the
steering shaft and the Orbit-roll?
1
2
3
4
Problems
When steering mode
switch is switched
Abnormally in both modes
Steering wheel shakes or jerks in one direction (left or right)

both directions
one direction (left or right)
Steering wheel jerks or there is excessive shock when steering is operated to end of its
stroke
Confirm recent repair
Steering valve
Stop
valve
valve
Cylinder
14 When joystick solenoid Oil pressure is unstable in both directions

valve output pressure is
15 measured
16 When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be
unstable
WA500-3LK
Joystick
Abnormally only in joystick mode
12 When orbit-roll output

13 pressure is measured
Orbitroll
Abnormally only in steering wheel mode
Steering wheel shakes or jerks in both directions
10 When steering relief

11 pressure is measured
No.
Remedy
Charge
valve
Causes
20-625 1
TROUBLESHOOTING
STEERING SYSTEM
12
H-14
TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT AT

MAXIMUM STEERING
Causes and Remedy
Defective adjustment of stop valve (X)
20-626 1
WA500-3LK
TROUBLESHOOTING
STEERING SYSTEM
12
MEMORANDUM
WA500-3LK
20-627 1
TROUBLESHOOTING
BRAKE SYSTEM
12
BRAKE SYSTEM
H-15 WHEEL BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
Measure the actual brake performance, and check if there is
actually an abnormality or whether it is just the feeling of the
operator. For details, see TESTING AND ADJUSTING,
Measuring brake performance.
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?

No.
Remedy
Problems
Brake
valve
Slack
adjuster
Wheel brake
Breakage inside brake
Defective actuation of brake piston
Defective brake piston seal
Breakage inside brake
Defective slack adjuster
Piston
seal
Defective right brake valve
Charge
valve
Defective left brake valve
Defective piston seal or defective

bleeding of gas from accumulator
PPC pump
Defective accumulator charge valve
Defective PPC pump
Defective PTO
Causes
Others
Brake has no effort only when left brake pedal is depressed
Left brake pedal is light when it is depressed
Right brake pedal is light when it is depressed
Left brake pedal is heavy when it is depressed
Right brake pedal is heavy when it is depressed
Abnormality large operating force is needed to obtain specified

braking force
Abnormal noise is heard from brake when brake is applied
Work equipment, steering also do not work
Movement of work equipment, steering is slow

11 Abnormal noise comes from around PPC pump or hydraulic tank
12 Many metal particles are found in oil drained from axle case
13 When accumulator charge pressure is measured, oil pressure is found
to be low
14 Brake stops having effect immediately when engine is stopped
15 There is a time lag before brake takes effect

17 When drop in brake piston pressure is measured, it is found to be
excessive
18 When wear of brake disc is measured, it is found to be excessive
19 When air is bled from brake line, air comes out.
Legend: X: Replace : Correct A: Adjust
20-628 1
16 When brake oil pressure is measured, it is found to be low
C: Clean
WA500-3LK
TROUBLESHOOTING
BRAKE SYSTEM
12
Remark
The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and
steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work
equipment and steering also. (The circuit set pressure is different).
WA500-3LK
20-629 1
TROUBLESHOOTING
WHEEL BRAKES ARE NOT RELEASED OR BRAKES DRAG

Does the brake pedal come back fully?
Is the parking brake still applied?
Brake valve

No.
Problems
Machine cannot travel at all
Machine can travel a small amount
When remaining pressure is released from brake accumulator

circuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator

circuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows

out and brake is released
When air bled plug is loosened, a large amount of oil flows

out
When brake disc wear is measured and brake pedal is

released, piston returns
20-630 1
Remedy
When brake disc wear is measured and brake pedal is

released, piston does not return
Slack adjuster
Seized brake disc, plate
Defective right brake valve
Defective left brake valve
Causes
Defective actuation of slack adjuster
12
H-16
BRAKE SYSTEM
Wheel brake
WA500-3LK
TROUBLESHOOTING
BRAKE SYSTEM
12
H-17
PARKING BRAKE DOES NOT WORK OR BRAKING EFFECT IS POOR

Is parking brake emergency release switch open? (Normally it is open)
Is parking brake mechanical release operation being carried out?
Problems
Parking brake does not work when engine is stopped
When parking brake disc wear is measured, disc thickness is found to be less than specified
value
When parking brake inlet

port pressure is measured
WA500-3LK
Parking brake
There is oil pressure when parking brake switch is ON
There is no oil pressure when parking brake switch is ON

(normal)
When parking brake solenoid There is no oil pressure when parking brake switch is ON
valve output pressure is mea- (normal)
sured
There is oil pressure when parking brake switch is ON
Worn brake disc
Valve
Defective actuation of parking brake piston
SOL
Defective brake spring
Defective parking brake emergency release valve
No.
Remedy
Defective parking brake solenoid valve

Causes
20-631 1
TROUBLESHOOTING
BRAKE SYSTEM
12
H-18
PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS (INCLUDING

EMERGENCY RELEASE SYSTEM)
Checking for abnormalities:
Is there any abnormality in the power train system?
Yes = Carry out Troubleshooting H-1 - H-4
(Power train hydraulic system)
Problems
When emergency release switch is turned ON, parking brake is released (not released with parking brake
switch)
When manual method for release of parking brake is carried out, parking brake is released (not released
with parking brake switch or emergency release switch)
3
4
5
When parking brake inlet port pressure is

measured (when parking brake switch is
operated)
Parking
brake
Wheel
Emergency brake switch for wheel

brake has been actuated
Valve
Seized wheel brake disc, plate
SOL
Oil pressure is normal

Oil pressure is low
When parking brake output pressure is

Oil pressure is normal
measured (when emergency release switch
Oil pressure is low
is operated)
When parking brake solenoid valve output pressure is measured, oil pressure is found to be low
Defective parking brake emergency release valve
No.
Remedy
Defective parking brake solenoid valve

Causes
When oil pressure is wheel brake piping is measured, oil pressure is found to be less than emergency brake
actuation pressure 37 5 kgf/cm2 (526 71 lbf/in2)
Remark
The power train main relief pressure is used for the parking brake release pressure, so if any abnormality is felt in the
parking brake release system, check the condition of actuation of the power train (the emergency release circuit uses
the wheel brake circuit presure).
20-632 1
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
WORK
EQUIPMENT
H-19 NEITHER BOOM NOR BUCKET MOVE

Hydraulic pump

No.
Remedy
Problems
Defective PPC pump
Defective PTO
Causes
Charge
valve
Control
valve
X
e
Steering also does not work
Abnormal noise comes from around PPC pump or hydraulic tank
When PPC valve output pressure is measured, oil pressure is found to be normal
When PPC valve (orbit-roll) basic pressure is measured, oil pressure is low or there is no oil pressure
Remark
WA500-3LK
20-633 1
TROUBLESHOOTING
BOTH BOOM AND BUCKET ARE SLOW OR LACK POWER

No.
Remedy
Problems
Boom and bucket movement takes approximately 1.5 times stand value
Boom and bucket movement takes approximately 3 times standard value
Steering works normally
Response of steering is also poor
Abnormal noise comes from around hydraulic pump or hydraulic tank
When PPC valve output pressure is measured, oil pressure is found to be normal
When PPC valve (orbit-roll) basic pressure is measured, oil pressure is found to be low
Defective cut-off valve
Defective actuation of demand valve
Charge
valve
Control
valve
Steering
valve
Cut0off
valve
Hydraulic pump
Defective hydraulic pump
Defective PPC pump
Defective PTO
Causes
12
H-20
WORK EQUIPMENT
Remark
20-634 1
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
H-21
BOOM DOES NOT MOVE

PPC
valve

No.
Remedy
Problems
Does not move in both directions
Does not move in one direction (RAISE or LOWER)
X
a
Control valve
X
e
Defective travel lever linkage
Defective cylinder seal
Boom Others
Defective suction valve
Defective unload valve
Defective actuation of load check valve
Defective actuation of boom spool
Defective PPC valve
Causes
When boom relief

pressure is measured Oil pressure is low or there is no pressure in one direction (RAISE or LOWER)
When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure
When operating effort of boom control lever is measured, lever is found to be heavy
When travel of boom control lever is measured, it is found to be short

H-22 NOT USED
WA500-3LK
20-635 1
TROUBLESHOOTING
BOOM IS SLOW OR BOOM LACKS POWER

PPC
valve

No.
Remedy
Problems
Does not move in one direction (RAISE or LOWER)
X
a
Control valve
When boom relief

pressure is measured Oil pressure is low in one direction (RAISE or LOWER)
When PPC valve output pressure is measured, oil pressure is found to be low
When hydrulic drift of boom is measured, it is found to be excessive
When operating effort of boom control lever is measured, lever is found to be heavy

X
e
Defective travel lever linkage
Boom Others
Defective suction valve
Defective actuation of boom spool
Defective PPC valve
Causes
Defective unload valve
12
H-23
WORK EQUIPMENT
H-24 NOT USED
20-636 1
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
H-25
BOOM CANNOT BE SET TO FLOAT OR CANNOT BE RELEASED FROM
FLOAT

Can other operations of boom (RAISE, HOLD, LOWER)
be carried out normally?

No.
1
2
3
4
5
Remedy
Problems
When PPC valve output pressure is measured (boom control Oil pressure is normal
lever at FLOAT position)
Oil pressure is low
When PPC valve output pressure is measured (boom control Oil pressure is normal
lever at LOWER position)
Oil pressure is low
WA500-3LK
Control valve
X
a
Others
A
d
Defective control valve
Defective actuation of float selector valve
PPC
valve
Defective actuation of unload valve
Defective PPC valve
Causes
20-637 1
TROUBLESHOOTING
WORK EQUIPMENT
12
H-26
BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED

FROM HOLD TO RAISE
With the engine running at low idling, if the boom control lever is gradually moved from HOLD to RAISE, the boom
moves down momentarily under its own weight.
If the control lever is operated fully to the RAISE position, the condition becomes normal.
Causes and Remedy
Defective slow return check valve for control valve boom spool (X) or () (C)
H-27 NOT USED
20-638 1
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
H-28
EXCESSIVE HYDRAULIC DRIFT OF BOOM


No.
1
2
Remedy
Problems
When boom control lever is operated in

Hydraulic drift increases
RAISE direction from boom maximum raise
No change in hydraulic drift
with engine stopped (See Remark)
Defective oil tightness of boom spool
Causes
Control valve
Cylinder
Remark
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
WA500-3LK
20-639 1
TROUBLESHOOTING
BUCKET DOES NOT MOVE

PPC valve
Remedy
No.
Problems
Does not move in one direction (TILT or DUMP)
X
a
When bucket relief

When PPC valve output pressure is measured, oil pressure is found to be low or there is no pressure
When operating effort of bucket control lever is measured, lever is found to be heavy
When travel of bucket control lever is measured, it is found to be short

20-640 1
X
d
Defective control lever linkage
Control valve

Oil pressure is low or there is no pressure in one direction (TILT or DUMP)
Defective actuation of bucket spool
Defective PPC valve
Causes
12
H-29
WORK EQUIPMENT
Cylinder
Others
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
H-30
BUCKET IS SLOW OR LACKS POWER

PPC valve

No.
1
Remedy
Problems
Does not move in one direction (TILT or DUMP)
When bucket relief pressure is

measured
When PPC valve output pressure is measured, oil pressure is found to be low
When hydraulic drift of bucket is measured, it is found to be excessive
When operating effort of bucket control is measured, lever is found to be heavy
When travel of bucket control lever is measured, it is found to be short

WA500-3LK
X
d
Defective control lever linkage
Control valve

Oil pressure is low in one direction (TILT or DUMP)
Defective actuation of bucket spool
Defective PPC valve
Causes
Cylinder
others
20-641 1
TROUBLESHOOTING
EXCESSIVE HYDRAULIC DRIFT OF BUCKET

Defective oil tightness of bucket spool
Causes

No.
1
2
Remedy
Problems
When bucket control lever is operated in DUMP direction Hydraulic drift increases
with engine stopped (See Remark)
No change in hydraulic drift
12
H-31
WORK EQUIPMENT
Control valve
Cylinder
Remark
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
20-642 1
WA500-3LK
TROUBLESHOOTING
WORK EQUIPMENT
12
H-32
ECSS DOES NOT WORK, AND THERE IS PITCHING AND BOUNCING
[MACHINES WITH ECSS]
Ask the operator the following questions

Is operation of ECSS switch correct?
Solenoid valve

No.
Remedy
Problems
Defective speed sensor
Defective seal, leakage of gas from low pressure accumulator
Defective actuation of controller
Sensor
d2
d3
--
--
--
--
ECSS does not work when traveling loaded
ECSS does not work when traveling unloaded
When ECSS is actuated when traveling loaded, boom drops greatly (more than
30 cm [11.8 in])
ECSS does not work at all

Legend: X: Replace
WA500-3LK
Controller
d1
A: Adjust
Accumulator
d0
Speed 5 km/h (3.1 mi/h) for start of actuation of ECSS is greatly out of
adjustment
: Correct
Defective seal, leakage of gas from high pressure accumulator
Defective action of charge solenoid valve (SOL5)
Defective actuation of low pressure solenoid valve (SOL3)
Defective actuation of high-pressure solenoid valve (SOL2)
Defective actuation of relief solenoid valve (SOL1)
Causes
C: Clean
20-643 1
TROUBLESHOOTING
WORK EQUIPMENT
12
MEMORANDUM
20-644 1
WA500-3LK
TROUBLESHOOTING OF JOYSTICK STEERING

CONTROLLER SYSTEM (J MODE)
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . . . . . . . 20-703
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
JOYSTICK CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN CAUTION RELAY OUTPUT)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (DETECTED WHEN
OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (DETECTED WHEN
OUTPUT)) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT SOLENOID (HOT END)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT SOLENOID (HOT END)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
J-6 FAILURE CODE [61] (SHORT CIRCUIT, DISCONNECTION IN STEERING SOLENOID CUT
RELAY OUTPUT) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
J-7 FAILURE CODE [62] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING
NEUTRAL SIGNAL) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
J-8 FAILURE CODE [63] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK STEERING
LEVER POTENTIOMETER SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-717
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
J-12 DISCONNECTION IN STEERING LEFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
WA500-3LK
20-701
TROUBLESHOOTING
12
MEMORANDUM
20-702
WA500-3LK
TROUBLESHOOTING
JUDGEMENT TABLE FOR JOYSTICK CON-
12
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM

RELATED PARTS
WA500-3LK
20-703
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR

JOYSTICK CONTROLLER SYSTEM
Failure
code
56
57
58
59
60
20-704
Abnormal system
Joystick caution relay system
Steering (R) (right) solenoid

system
Steering (L) (left) solenoid

system
1.
Defective caution relay
2.
Short circuit with ground, defective contact, or disconnection in wiring harness

between work equipment controller L28 (female) (13) and JS8 (1)
3.
Defective contact or disconnection in wiring harness between caution relay J8

(female) (2) and chassis ground
4.
Defective work equipment controller
1.
Defective R solenoid
2.
Defective steering solenoid cut relay
3.
Short circuit in wiring harness between work equipment controller L26 (female) (6)
and (16)
Short circuit with ground, defective contact, or disconnection in the following wiring
harness:
4.
Wiring harness between work equipment controller L26 (female) (6) and R (2)
5.
Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6.
Wiring harness between steering solenoid cut relay JS9 (5) and R (1)
7.
1.
Defective L solenoid
2.
Defective steering solenoid cut relay
3.
Short circuit in wiring harness between work equipment controller L26 (female) (7)
and (16)
Short circuit with ground, defective contact, or disconnection in the following wiring harness:
4.
Wiring harness between work equipment controller L26 (female) (7) and L (2)
5.
Wiring harness between work equipment controller L26 (female) (16) and JS9 (3)
6.
Wiring harness between steering solenoid cut relay JS9 (5) and L (1)
7.
Short circuit with power source

in wiring harness between
steering (R) (right) solenoid
system
1.
2.
Short circuit with power source in wiring harness between work equipment
controller L26 (female) (6) and R (2)
3.
Short circuit with power source

in wiring harness between
steering (L) (left) solenoid system
1.
Defective L solenoid
2.
Short circuit with power source in wiring harness between work equipment
controller L26 (female) (7) and L (2)
3.
WA500-3LK
TROUBLESHOOTING
12

1.
Joystick caution relay: ON (voltage between L28 (15) and

chassis ground: 20 - 30 V)
2.
Resistance of relay coil between work equipment controller

L28 (female) (13) and J chassis ground: 200 - 400
3.
Resistance of wiring harness between work equipment

controller L28 (female) (13) and caution relay JS8 (female)
(1): Less than 1
4.
Resistance of wiring harness between caution relay JS8

(female) (2) and chassis ground: Less than 1
1.
Steering solenoid cut relay: ON (voltage between L26 (8)

and chassis ground: 20 - 30 V)
2.
Resistance of steering R solenoid: 10 - 20
3.
Resistance between work equipment controller L26

(female) (6), (16) and chassis ground: Min. 1M
Action by controller
abnormality is detected
Problem that appears

on machine when
there is abnormality
Troubleshooting
code
Caution output: OFF
Joystick caution
actuated
J-1
Steering R, L solenoid
output: OFF and steering
solenoid cut relay output:
OFF and caution relay:
OFF
Impossible to use
joystick and joystick
caution actuated
J-2
OFF
Impossible to use
caution actuated
J-3
Joystick lever at neutral

Voltage between work equipment controller L26 (female) (6)
and chassis ground: Less than 1 V
OFF
Impossible to use
caution actuated
J-4
Joystick lever at neutral

and chassis ground: Less than 1 V
OFF
Impossible to use
caution actuated
J-5
Resistance of the following wiring harness: Less than 1

4.
Wiring harness between work equipment controller L26

(female) (6) - R (female) (2)
5.

(female) (16) - JS9 (female) (3)
6.
Wiring harness between steering solenoid cut between JS9

(female) (5) and L (female (1)

2.
Resistance of steering L solenoid: 10 - 20
3.
Resistance between work equipment controller L26

(female) (7), (16) and chassis ground: Min. 1M
Resistance of the following wiring harness: Less than 1

4.

(female) (7) - L (female) (2)
5.

(female) (16) - JS9 (female) (3)
6.
Wiring harness between steering solenoid cut between JS9

(female) (5) and L (female (1)
WA500-3LK
20-705
TROUBLESHOOTING
12
Failure
code
61
62
63
20-706
Abnormal system
Steering solenoid. cut relay

system
1.
Defective steering solenoid relay
2.

between work equipment controller L26 (female) (8) and JS9 (1)
3.
Defective contact or disconnection in wiring harness between NEUTRAL SW (1)

and chassis ground
4.
1.
Defective joystick neutral SW
2.

between work equipment controller L27 (female) (17) - D01 (2), (1) - NEUTRAL
SW (3)
3.
Defective contact or disconnection in wiring harness between NEUTRAL SW (1)

and chassis ground
4.
1.
Defective boom angle potentiometer
2.
Short circuit with power source, short circuit with ground, defective contact, or
disconnection in wiring harness between work equipment controller L27 (female)
(20) and JS7 (1)
3.
(9) and JS7 (2)
4.
(10) and JS7 (3)
5.
Joystick neutral SW system
Joystick potentiometer system
WA500-3LK
TROUBLESHOOTING
12

Resistance between work equipment controller L27 (female)
(17) and chassis ground: Min. 1 M Less than 1

and L27 (9): 0.5 - 4.5 V (voltage when joystick is at neutral:
Approx. 2.5 V)
1.

2.
Resistance of relay coil between work equipment controller

L28 (female) (8) and chassis ground: 200 - 400
3.
Resistance of wiring harness between work equipment

controller L28 (female (8) and JS9 (female) (1)
4.
Resistance of wiring harness between steering solenoid cut

relay JS9 (female) (2) and chassis ground: Less than 1
WA500-3LK
abnormality is detected

on machine when
there is abnormality
Troubleshooting
code
OFF
Impossible
to
use
oystick and joystick
caution actuated
J-6
OFF
Impossible to use
caution actuated
J-7
OFF
Impossible to use
caution actuated
J-8
20-707
TROUBLESHOOTING
J-1 FAILURE CODE [56] (SHORT CIRCUIT,
12
J-1 FAILURE CODE [56] (SHORT CIRCUIT, DISCONNECTION IN

CAUTION RELAY OUTPUT) IS DISPLAYED
When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector
switch ON.
Always turn the starting switch OFF before disconnecting any connector
Cause
Yes
1
3
Is resistance
between L28
(female) (18) and
chassis normal?
1. Disconnect L28
2. 200 - 400
Yes
2
No
JS8 (male) (1) and
(2) normal?
1. Disconnect JS8
2. 200 - 400
Yes
JS8 (female) (2) and
chassis normal?
1. Disconnect JS8
2. Max. 1
No
No
Remedy
Defective joystick boom

controller
Replace
harness between JS8(1)
and JS1(15)
Repair or
replace
harness between JS8(2) LGL(2) - L23 (female)
(10)
Repair or
replace
Defective caution lamp

relay
Replace
J-1 Related electrical circuit diagram
20-708
WA500-3LK
TROUBLESHOOTING
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN
12
J-2 FAILURE CODE [57] (SHORT CIRCUIT IN STEERING RIGHT

SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no
longer displayed on the monitor display, the problem has been removed.
switch ON.
Cause
4
Yes

(16) normal?
3
L26 (female) (16)
and chassis normal?
2
chassis normal?
1
is failure code
displayed when
JS9 is replaced
with other relay of
same type?
1. Turn starting
switch OFF.
2. Interchange
with another relay
of same type.
3. Turn starting
switch ON.
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L26
and CNR
No
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L26.
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect JS9
and L26
No
No
No
Defective joystick
controller
Remedy
Replace
Short circuit in wiring

harness between L26
(female) (6) and CNR
or
(female) (2) and between Repair
L26 (female) (16) and JS9 replace
(female) (1)
Short circuit with chassis
ground in writing harness Repair or
and JS9 (female) (3)
ground in writing harness
and CNR (female) (2)
Repair or
replace
Defective steering
solenoid cut relay
Replace
WA500-3LK
20-709
TROUBLESHOOTING
12
J-3 FAILURE CODE [58] (SHORT CIRCUIT IN STEERING LEFT

SOLENOID (DETECTED WHEN OUTPUT)) IS DISPLAYED
switch ON.
Cause
4
Yes

3
(16) normal?
L26 (female) (16)
2
and chassis normal?
L26 (female) (17)
1
and chassis normal?
Is failure code
displayed when
JS9 is replaced
with other relay of
same type?
1. Turn starting
switch OFF.
2. Interchange
with other relay of
same type.
3. Turn starting
switch ON.
20-710
1. Min. 1 M.
2. Turn starting
switch) OFF.
3. Disconnect L26
and CNL.
1. Min. 1 M.
2. Turn starting
switch) OFF.
3. Disconnect JS9
and L26.
No
No
1. Min. 1 M.
2. Turn starting
switch) OFF.
3. Disconnect L26.
No
No
Remedy
Defective joystick
controller
Replace

harness between L26
(female) (7) and CNL
or
(female) (2) and between Repair
L26 (female) (16) and JS9 replace
(female) (1)
ground in wiring harness Repair or
and JS9 (female) (30
ground in wiring harness
and CNL (female) (2)
Repair or
replace
Defective steering
solenoid cut relay
Replace
WA500-3LK
TROUBLESHOOTING
12
J-4 FAILURE CODE [59] (SHORT CIRCUIT IN STEERING RIGHT

SOLENOID (HOT END) IS DISPLAYED
switch ON.
Cause
1
Yes
Is voltage between
L26 (female) (6)
and chassis
normal?
1. Max. 1V.
2. Turn starting
switch ON.
WA500-3LK
No
Remedy
Defective joystick steering Replace

controller
source in wiring power
or
between L26 (female) (6) - Repair
CNR (female) (2) or CNR replace
(female) (1) - JS9 (female)
(5)
20-711
TROUBLESHOOTING
12
J-5 FAILURE CODE [60] (SHORT CIRCUIT IN STEERING LEFT

SOLENOID (HOT END) IS DISPLAYED
switch ON.
Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause
1
Yes
Is voltage between
L26 (female) (6)
and chassis
normal?
1. Max. 1V.
2. Turn starting
switch ON.
20-712
No
Remedy

controller
source in wiring power
or
between L26 (female) (7) - Repair
CNL (female) (2) or CNL replace
(female) (1) - JS9 (female)
(5)
WA500-3LK
TROUBLESHOOTING
12

STEERING SOLENOID CUT RELAY OUTPUT) IS DISPLAYED
switch ON.
Cause
4
chassis normal?
1. Max. 1 .
chassis normal?
2. Turn starting
switch OFF.
2
1. Max. 1 M.
3. Disconnect JS9.
2. Turn starting
switch OFF.
3. Disconnect L26
and JS9.
chassis normal when
JS9 (female) (1) is
1
No
Is failure code
displayed when
JS9 is replaced
with another relay
of same type?
1. Turn starting
switch OFF.
2. Interchange
with another relay
of same type.
3. Turn starting
switch ON.
WA500-3LK
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L26
and JS9.
No
No
Yes
No
Remedy

controller
harness between JS9
(female) (2) - JS12 (2) LR (3) - chassis ground
Repair or
replace

and JS9 (female) (1)
Repair or
replace
harness between L28
(female) (8) and JS9
(female) (1)
Repair or
replace
Defective steering
solenoid cut relay
Replace
20-713
TROUBLESHOOTING
12

JOYSTICK STEERING NEUTRAL SIGNAL) IS DISPLAYED
switch ON.
Turn the starting switch ON.
Cause
2
Yes

L27 9female) (17)
and chassis normal?
1. disconnect L27.
2. Operate joystick
lever fully to left or
right.
3. Max. 1.
1
Is resistance
between L27
(female) (17) and
chassis normal?
No
1. Disconnect L27.
2. Max. 1.

chassis normal?
JS6 9male) (1) and
1. Disconnect JS6.
(3) normal?
2. Max. 1 .
1. Disconnect JS6.
2. Operate joystick
lever fully to left or
right.
3. Max. 1.
No
No
JS6 9male) (1) and
(3) normal?
1. Disconnect JS6.
2. Max. 1.
20-714
Yes
No
Yes
No
Remedy
Defective joystick
steering controller
Replace
harness between JS6
(female) (3) - D01 - L27
(female) 917)
Repair or
replace
harness between JS6
(female) (1) - JS12 (2) LR5 (3) - chassis ground
Repair or
replace
Defective neutral switch
Replace

between JS6 (female) (3) - replace
D01 - L27 (female) (17)
Defective neutral switch
Replace
WA500-3LK
TROUBLESHOOTING
12

JOYSTICK STEERING LEVER POTENTIOMETER SYSTEM) IS DISPLAYED
switch ON.
After connecting the T-adapter, turn the starting switch ON.

Cause
Defective joystick
potentiometer, neutral
position misaligned
Yes
2
Yes Does voltage
between L27 (20)
and (9) change?
1
Is voltage between
L27 (10) and (9)
normal?
1. Operate joystick
lever to left or right.
2. 0.5 - 4.5 V.
No
3
Does voltage
between JS7 (male)
(1) and (3) change?
1. Turn starting
switch OFF.
2. Disconnect JS7.
3. Operate joystick
lever to left and
right.
4. 0.2 - 5 k.
1. 4.9 - 5.1 V.
No
Yes
No
Remedy
Replace,
adjust
neutral
position
again

source, short circuit with
ground, defective contact Repair or
or disconnection in wiring replace
harness between L27
(female) (1)
Defective joystick
potentiometer
Replace
Defective remote boom & Replace

joystick steering controller
WA500-3LK
20-715
TROUBLESHOOTING
J-9 ABNORMALITY IN POWER SOURCE,
12
J-9 ABNORMALITY IN POWER SOURCE, VOLTAGE
Check that fuse I (11) is normal.
switch ON.
Cause
1
Yes
Is voltage between
L26 (female) (8),
(18) and chassis
normal?
No
1. 20 - 30 V.
2. Turn starting
switch ON.
20-716
Remedy

controller
Repair or
harness betwen L26
(female) (8), (18) - L32 (1) replace
- FS2 (10) - fuse I (11)
WA500-3LK
TROUBLESHOOTING
J-10 ABNORMALITY IN JOYSTICK STEER-
12
J-10 ABNORMALITY IN JOYSTICK STEERING ON-OFF SIGNAL

SYSTEM
Check that fuse I (11) is normal.
switch ON.
Cause
Yes

controller
1. 20 - 30 V.
2. Turn starting
switch ON.
No
L27 (female) (14)
and chassis normal
when S4 (male) is
1. Turn starting
switch OFF.
2. disconnect S4 and
L27.
3. Max. 1
WA500-3LK
Yes

JS3 (female) and
2
chassis normal?
Is voltage between
l27 (female) (14)
and chassis
normal?
Remedy
1. 20 - 30 V.
2. Turn starting
switch ON.
No
No
Defective system cut-off

switch
Replace
Repair or
harness between fuse I
(11) - FS2 (10) - L32 91) - replace
JS3 (female)
harness between L27
Repair or
(female) (14) - JS5 (1), (2) replace
- S4 (male) or defective
joystick ON - OFF switch
20-717
TROUBLESHOOTING
J-11 DISCONNECTION IN STEERING RIGHT
12
J-11 DISCONNECTION IN STEERING RIGHT SOLENOID
switch ON.
Cause
4
chassis normal when
CNR (female) (1) is
L26
(female)
(15)
2 Yes
and chassis normal
when JS9 (female)
1. Max. 1 .
(3) is grounded to
2. Turn starting
chassis?
switch OFF.
Yes L26 (female) (6) and
3. Disconnect JS9.
chassis normal when
1
1. Max. 1 .
CNR (female) (2) is
2.
Turn
starting
switch OFF.
No
Is resistance
3. Disconnect L26
between CNR
and JS9.
1. Max. 1 .
(male) (1) and (2)
2. Turn starting
normal?
switch OFF.
3. Disconnect L26.
1. Max. 1 .
No
2. Turn starting
switch OFF.
3. Disconnect
CNR.
No
20-718
Yes
No
Remedy

controller
harness between JS9
(female) (1)
Repair or
replace
harness between L26
(female) (3)
Repair or
replace
harness between L26
9female) (6) and CNR
(female) (20
Repair or
replace

right solenoid valve
WA500-3LK
J-12 DISCONNECTION IN STEERING LEFT
12
J-12 DISCONNECTION IN STEERING LEFT SOLENOID
switch ON.
Cause
4
chassis normal when
CNL (female) (1) is
L26
(female)
(16)
2 Yes
and chassis normal
when JS9 (female)
1. Max. 1 .
(3) is grounded to
2. Turn starting
chassis?
switch OFF.
3. Disconnect JS9.
chassis normal when
1
1. Max. 1 .
CNR (female) (2) is
2.
Turn
starting
switch OFF.
No
Is resistance
3. Disconnect L26
between CNL
and JS9.
1. Max. 1 .
(male) (1) and (2)
2. Turn starting
normal?
switch OFF.
3. Disconnect L26.
1. Max. 1 .
No
2. Turn starting
switch OFF.
3. Disconnect
CNL.
No
WA500-3LK
Yes
No
Remedy

controller
harness between JS9
(female) (1)
Repair or
replace
harness between L26
(female) (3)
Repair or
replace
harness between L26
9female) (7) and CNL
(female) (20
Repair or
replace

right solenoid valve
20-719
J-12 DISCONNECTION IN STEERING LEFT
12
MEMORANDUM
20-720
WA500-3LK
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM (K-MODE)
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE
MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR
DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803
A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803
B. SOME LAMPS DO NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR
LIGHT UP BUT DO NOT GO OUT (EVEN AFTER 3 SECONDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-804
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS
TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON MAINTENANCE MONITOR GO OUT . . . . 20-805
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH . . . . . 20-806
A. ENGINE OIL LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
B. ENGINE WATER LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH . . 20-808
A. ENGINE OIL PRESSURE DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
B. BATTERY CHARGE LEVEL DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
C. BRAKE OIL PRESSURE DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
D. AIR CLEANER DISPLAY FLASHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER DOES NOT SOUND . . . . . . . . . . . . . 20-812
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT CAUTION BUZZER SOUNDS . . . . 20-813
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION
LAMP) DOES NOT FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
A. CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
B. CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT
WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
A. CHECK LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
B. CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON . . . . . . . . . . . 20-816
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF . . . . . . . . . . . . . . . . . . . . . . 20-817
K-12 SERVICE METER DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED . . . . . . . . . . . . . . . . . . . . . . . 20-819
K-14 ABNORMALITY IN GAUGE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
A. ABNORMALITY IN FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
B) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . 20-821
C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE . . . . . . . . . . . . . . . . 20-822
WA500-3LK
20-801 1
TROUBLESHOOTING
12
MEMORANDUM
20-802 1
WA500-3LK
TROUBLESHOOTING
K-1
12
K-1
WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON
MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,
MAINTENANCE MONITOR DOES NOT WORK
A. NO LAMPS ON MAINTENANCE MONITOR LIGHT UP

Yes
Is voltage between
L18 (1), (2) - (3)
normal?
Yes
1. 20 - 30 V.
2. Turn starting
switch ON.
3
Yes
2
L18 (female) (3),
(14), L19 (8) and
chassis ground
normal?
1. Max. 1.
2. Turn starting
switch ON.
3. Disconnect L18.
Remedy
Defective monitor module Replace

of maintenance monitor
No
Cause
Is voltage between
FS1 (female) (20 and
chassis ground
normal?
1. 20 - 30 V.
2. Disconnect FS1.
3. Turn starting
switch ON.
No
No
harness between L18
(female) (1), (2) - FS2 (9)
- fuse I (10) - FS1 (male)
(2) or blown fuse I - 10
Repair or
replace or
replace
fuse
harness between FS1
(female) (2) - LR6 (1) slow blow fuse - battery
relay or blown slow blow
fuse (80A)
Repair or
replace or
replace
fuse
harness between L18 (1),
(14), L19 (female) (8) Lr4 (12) - chassis ground
Repair or
replace
B. SOME LAMPS DO NOT LIGHT UP

Cause
Remedy

WA500-3LK
20-803 1
TROUBLESHOOTING
K-2
12
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON

MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT (EVEN
AFTER 3 SECONDS)
Cause
Remedy

K-1, 2 Related electrical circuit diagram
20-804 1
WA500-3LK
TROUBLESHOOTING
K-3
12
K-3
WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING
SWITCH IS TURNED ON (WITHIN 3 SECONDS), NO LAMPS ON
MAINTENANCE MONITOR GO OUT
1
When starting
engine, is voltage
between L19
(female) (1) and
chassis ground
normal?
Cause
Yes
No
1. 20 - 30 V.
2. Disconnect L19.
3. Start engine.
4. Measure when
starting motor is
turning (starting
switch at START)
Remedy

harness between L19
(female) (1) and neutral
relay
Repair or
replace
K-3 Related electrical circuit diagram
WA500-3LK
20-805 1
TROUBLESHOOTING
K-4
12
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE

STOPPED), CHECK ITEMS FLASH
A. ENGINE OIL LEVEL DISPLAY FLASHES
Before starting troubleshooting, check the engine oil level to make sure it is correct.
Cause
2
Yes
1
Is resistance
between ER2
(male) (22) and
chassis ground
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect
ER2.
Yes
L18 (female) (13)
and chassis ground
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L18.
No
No
Remedy

Repair or
harness between L18
replace
(female) (13) - LL1(9) LR7(22) - ER2 (male) (22)
Defective engine oil level Replace
sensor
K-4 A. Related electrical circuit diagram
20-806 1
WA500-3LK
TROUBLESHOOTING
K-4
12 ENGINE WATER LEVEL DISPLAY FLASHES

B.
Before starting troubleshooting, check the engine water level again. (Check that the water level is correct).
Cause
3
Yes
2
Yes
1
Is resistance
between G01
(male) (2) and (1)
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect
G01.
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect G01.
chassis ground
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L18.
G01 (female) (1) and
chassis ground
normal?
No
No
Yes
No
Remedy

disconnection in writing
harness between L18
(female) (8) - LR4(10) GR1 (3) - G01 (female)
(1)
Repair or
replace
disconnection in writing
harness between G01
(female) (2) - GR1(2) chassis ground
Repair or
replace
Defective radiator water

level sensor
Replace
K-4 B. Related electrical circuit diagram
WA500-3LK
20-807 1
TROUBLESHOOTING
K-5
12
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE

STARTED), CAUTION ITEMS FLASH
A. ENGINE OIL PRESSURE DISPLAY FLASHES

Cause
Yes
1
Yes
Does display go
out when E11 is
disconnected?
1. Start engine.
2. Disconnect E11.
No
Does condition
become normal
when engine oil
pressure relay L64 is
interchanged?
1. Interchange
engine oil pressure
relay L64 with a
normal relay.
Yes
3
No
Is voltage between
E11 and chassis
ground normal?
1. 20 - 30 V.
2. disconnect E11.
3. Start engine.
Yes
L18 (female) (10)
and chassis ground
normal?
1. Max. 1.
2. Disconnect L18.
3. Turn starting
switch OFF.
No
No
Remedy
Defective engine oil

pressure switch
Replace
Defective engine oil

pressure relay
Replace

Repair or
harness between L18
(female) (10) - L64 (3) (6) replace
- LR5(2) - chassis ground
Contact of ground with
wiring harness between
ring terminal - LR7(12) - Replace
ER2 (male) (12) - LL1(10)
- L64 (female) (2)
K-5 A. Related electrical circuit diagram
20-808 1
WA500-3LK
TROUBLESHOOTING
K-5
12 BATTERY CHARGE LEVEL DISPLAY FLASHES

B.
Cause
2
Yes
1
Is voltage between
alternator terminal I and chassis
ground normal?
1. 20 - 30 V.
2. Start engine.
Yes
Is voltage between
L18 (female) (12)
and chassis ground
normal?
1. 20 - 30 V.
2. Start engine.
No
No
Remedy

harness between L18
(female) (12) - LR4(6) ER1(9) - alternator
terminal I
Repair or
replace
Defective alternator
Replace
K-5 B. Related electrical circuit diagram
WA500-3LK
20-809 1
TROUBLESHOOTING
12
C.
K-5
BRAKE OIL PRESSURE DISPLAY FLASHES
Remark
Check that the oil pressure is correct.
Cause
4
Yes

L18 (11) and chassis
ground normal?
3
Yes
1
Is resistance
between B08
(male) (1) and (2)
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect B08.

B13 (male) (1) and
(2) normal?
1. Max. 1 .
2. Start engine.
3. Disconnect B13.
1. Max. 1 .
2. Start engine.
3. Disconnect
B08.
chassis ground
normal?
No
No
1. Start engine.
2. Max. 3 V.
No
No
Remedy

Repair or
harness between L18
replace
(female) (11) - LR2(8) BR1(6) - B08 (female) (1)
harness between B08
Repair or
(female) (2) - B13
replace
(female) (1) or between
B13 (female) (2) - BR1(4)
- chassis ground
Defective brake
accumulator charge oil
Replace
pressure switch (B13 end)
Defective brake
accumulator charge oil
Replace
pressure switch (B08 end)
K-5 C. Related electrical circuit diagram
20-810 1
WA500-3LK
TROUBLESHOOTING
K-5
12 AIR CLEANER DISPLAY FLASHES

D.
Remark
Check that there is no clogging of the air cleaner.
Cause
1
Yes
Does display go
out when AC is
disconnected?
Yes
1. Start engine.
2. Disconnect E19.
No
Does display go out

when dust indicator
relay L80 is
interchanged?
No
Is voltage between
ER2 (male) (28) and
chassis ground
normal?
1. turn starting
switch ON.
2. Disconnect ER2.
3. 20 - 30 V.
From A
Yes
L18 (female) (15)
and chassis ground
normal?
No
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L18.
Yes
chassis ground
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L80.
No
No
Remedy
Defective dust indicator

sensor
Replace
Defective dust indicator

relay
Replace
To A
---
harness between L80
(female) (5) - LR5 (2) chassis ground
Repair or
replace

between ER2 (male) (28) - Repair or
LR7 (28) - LL1 (11) - L80 replace
(female) (2) (short circuit
or contact with chassis
ground)
harness between L18
(female) (15) and L80
(female) (3)
Repair or
replace
K-5 D. Related electrical circuit diagram
WA500-3LK
20-811 1
TROUBLESHOOTING
K-6
12
K-6 CAUTION ITEMS ARE FLASHING BUT CAUTION BUZZER

DOES NOT SOUND
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL
Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness
between fuse I-10 - FS2 (9) - L42.
Cause
2
Yes
1
Is voltage between
L42 (female) (1)
and chassis ground
normal?
1. 20 - 30 V.
2. Disconnect L42.
3. Turn starting
switch ON.
Yes
Does buzzer sound

when L19 (female)
(4) is connected to
chassis ground?
1. Turn starting
switch ON.
Yes
Does buzzer sound

when L43 (female)
(1) is connected to
chassis ground?
1. Turn starting
switch ON.
No

3
No
Remedy
No
harness between L19
(male) (1)
Replace
Defective buzzer
Replace
or
harness between fuse I-10 Repair
replace
- FS2 (9) - L42 (female)
(1)
20-812 1
WA500-3LK
TROUBLESHOOTING
K-7
12
K-7
THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT
CAUTION BUZZER SOUNDS
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause
2
Yes
1
Is resistance
between L43
(female) (1) and
chassis ground
normal?
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L42
and L43.
Yes
chassis ground normal?
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L06,
L19, and L43.
No
No
Remedy

between L19 (female) (4) - Repair or
L43 (male) (1) - L06
replace
(female) (8) (contact with
chassis ground)
Defective buzzer
Replace
WA500-3LK
20-813 1
TROUBLESHOOTING
K-8
12
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP

(CHECK LAMP, CAUTION LAMP) DOES NOT FLASH
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
A. CHECK LAMP
Cause
1
Does CHECK
lamp light up
when L19
(female) (2) is
connected to
chassis ground?
Yes

2
No
1. Disconnect L19.
2. Turn starting
switch ON.
Remedy
Does CHECK lamp

light up when L06
(male) (10) is
connected to chassis
ground?
Yes
No
harness between L19
(female) (10)
Repair or
replace
Replace
1. Disconnect L06.
2. Turn starting
switch ON.
B. CAUTION LAMP
Cause
1
Does CHECK
lamp light up
when L19
(female) (3) is
connected to
chassis ground?
1. Disconnect L19.
2. Turn starting
switch ON.
Yes

2
No
Remedy
Does CHECK lamp

light up when L06
(male) (9) is
connected to chassis
ground?
Yes
No
harness between L19
(female) (9)
Repair or
replace
Replace
1. Disconnect L06.
2. Turn starting
switch ON.
K-8 A & B Related electrical diagram
20-814 1
WA500-3LK
TROUBLESHOOTING
K-9
12
K-9
THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR
DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP)
LIGHTS UP
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Always connect any disconnected connectors before going on to the next step
A. CHECK LAMP
Cause
1
Yes
chassis ground
normal?
No
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L06
and L19.
Remedy

and L06 (female) (10)
Repair or
replace
Cause
Remedy
B. CAUTION LAMP
1
Yes
chassis ground
normal?
No
1. Min. 1 M.
2. Turn starting
switch OFF.
3. Disconnect L06
and L19.

Repair or
replace
K-8 A & B Related electrical circuit diagram
WA500-3LK
20-815 1
TROUBLESHOOTING
K-10
12
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP

SWITCH IS TURNED ON
Remark
Only lighting of maintenance monitor does not light up.
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause
1
Yes
Is voltage between
(2) normal?
1. 20 - 30 V.
2. disconnect L21.
3. Turn starting
switch ON.
4. Turn lamp switch
ON.
No
Remedy
Disconnection in wiring
harness of lamp holder
Replace
harness between L21
(female) (1) and FS2 (5)
Repair or
replace
20-816 1
WA500-3LK
TROUBLESHOOTING
K-11
12
K-11
NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS
OFF
Cause
2
Is lamp switch
normal?
1. Turn starting
switch OFF.
2. disconnect L02.
3. Check that
continuity
between L02
(male) (1) and (5)
is as shown in
table below when
lamp switch is
turned ON-OFF.
Yes
Contact of +24V with siring harness between FS2 Repair or

(male) (4) - fuse box - FS2 replace
(5) - L21 (female) (1)

FS2 (female) (4) and
chassis ground
normal?
1. Max. 1V.
2. disconnect FS2.
3. Turn lamp switch
OFF.
4. Turn starting
switch ON.
Remedy
Contact of +24V with siring harness between L02 Repair or

(female) (5) and FS2
replace
(female) (4)
No
Defective lamp switch
No
Switch
Continuity
ON
Yes
OFF
No
Replace
WA500-3LK
20-817 1
TROUBLESHOOTING
K-12
12
K-12 SERVICE METER DOES NOT WORK
Cause
Yes
2
alternator terminal R
and chassis ground
normal?
1
Is voltage between
L22 (female) (2)
and (1) normal?
1. 20 - 30 V.
2. Start engine.
No
chassis ground
normal?
1. Turn starting
switch OFF.
2. Disconnect L22.
No
Yes
No
Remedy
Defective service meter
Replace
harness between L22
(female) (2) - LR4 (6) ER1 (9) - alternator
terminal R
Repair or
replace
harness between L22
Repair or
replace
Replace
20-818 1
WA500-3LK
TROUBLESHOOTING
K-13
12
K-13
SERVICE METER IS RUNNING EVEN WHEN ENGINE IS
STOPPED
Cause
Yes
Defective service meter
1
Is voltage between
L22 (female) (2)
and (1) normal?
No
Remedy
Yes
Is voltage between
alternator terminal R
and chassis ground
normal?
1. Max. 3 V.
2. Turn starting
switch ON.
No
Replace
Contact of +24V with

or
L22 (female) (2) - LR4 (6) Repair
replace
- ER1 (9) - alternator
terminal R
Replace
WA500-3LK
20-819 1
TROUBLESHOOTING
K-14
12
K-14 ABNORMALITY IN GAUGE ITEMS
A. ABNORMALITY IN FUEL GAUGE
Before carrying out troubleshooting, check the fuel level and make sure the level is correct.
15. Little or nothing is displayed in display area.

Cause
Yes
Defective fuel sensor
2
Yes
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect R07.
Does fuel gauge

show FULL when
short connector is
connected to R07
(female)?
R07 (female) (2) and
chassis ground
normal?
No
chassis ground
normal when short
connector is
connected to R07?
Yes
No
1. Max. 1 .
2. Turn starting switch OFF.
3. Connect short connector to R07 (female).
4. Disconnect L18.
No
Remedy
Replace

harness between R07
(female) (1) - LR4 (10) L18 (female) (6)
Repair or
replace
harness between R07
ground
Repair or
replace
16. Display always shows FULL and does not move.

Cause
1
Yes
Do all display
areas on fuel
gauge go out when
R07 is
disconnected?
No
Remedy
Defective fuel sensor

2
Yes
R07 (female) (1) and
chassis ground
normal?
No
Replace

harness between R07
(female) (1) - LR4 (10) L18 (female) (6)
Repair or
replace
K-14A Related electrical circuit diagram
20-820 1
WA500-3LK
TROUBLESHOOTING
K-14
12 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE

B)
17. Nothing is displayed in area.
Cause
1
Does engine coolant
temperature gauge show
minimum level when
E06 is disconnected?
1)
2)
Disconnect E06.
ON.
Yes
Remedy
Defective engine coolant

temperature sensor
2
Yes

No E06 (female) (1) and
chassis ground
normal?
1) Min. 1 M.
OFF.
3) Disconnect L18 and
E06.
Replace

between E06 (female) (1) - replace
ER1 (6) - LR4 (1) - L18
(female) (4)
No
18. Displayed shows lowest level and does not move.

Cause
1
When short connector is
connected to E06
(female), does engine
coolant temperature
gauge display area rise
one stage at a time, and
finally do all lamps go
out?
1)
2)
3)
Disconnect E06.
Connect short
connector to E06
(female).
ON.
Yes
Remedy

temperature sensor
3

chassis ground normal
2
when short connector is
connected to E06
(female)?
No chassis ground
1) Max. 1.
normal?
OFF.
3) Connect short
connector to E06
1) Turn starting
(female).
switch OFF.
2) Max. 1.
E06.
3) Disconnect E06.
No
Yes
No
Replace

Repair or
harness between E06
replace
(female) (1) - ER1 (6) LR4 (1) - L18 (female) (4)
harness between E06
(female) (2) - ER1 (7) chassis ground
Repair or
replace
K-14B Related electrical circuit diagram
WA500-3LK
20-821 1
TROUBLESHOOTING
12
C)
K-14
ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE
19. Nothing is displayed in area.

Cause
1
Does torque converter
oil temperature gauge
show minimum level
when CN18 is
disconnected?
1)
2)
Yes
Defective torque converter Replace

oil temperature sensor
2
Disconnect CN18.
ON.
Remedy
Yes

No CN18 (female) (1) and
chassis ground
normal?
1) Min. 1 M.
OFF.
CN18.

between CN18 (female)
(1) - TM2 (8) - L18
(female) (5)
No
Repair or
replace
20. Displayed shows lowest level and does not move.

Cause
1
When short connector is
connected to CN18
(female), does torque
converter oil
temperature gauge
display area rise one
stage at a time, and
finally do all lamps go
out?
1)
2)
3)
Disconnect E06.
Connect short
connector to E06
(female).
ON.
Yes
Remedy

temperature sensor
3

chassis ground normal
2
when short connector is
connected to E06
(female)?
No chassis ground
1) Max. 1.
normal?
OFF.
3) Connect short
connector to E06
1) Turn starting
(female).
switch OFF.
2) Max. 1.
E06.
3) Disconnect E06.
No
Yes
No
Replace

Repair or
harness between E06
replace
(female) (1) - ER1 (6) LR4 (1) - L18 (female) (4)
harness between E06
(female) (2) - ER1 (7) chassis ground
Repair or
replace
K-14C Related electrical circuit diagram
20-822 1
WA500-3LK
TROUBLESHOOTING OF MAIN MONITOR

SYSTEM (M MODE)
M-1 MAIN MONITOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY,
ALL LAMPS STAY LIGHTED UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-904
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-905
M-4 ABNORMALITY IN SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAYS R
WHEN DIRECTIONAL LEVER IS AT F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-906
D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND DISPLAY F
WHEN DIRECTIONAL LEVER IS AT R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-907
E. DOES NOT DISPLAY 1ST - 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-907
M-5 HIGH BEAM DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
M-7 ABNORMALITY IN PARKING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
B. PARKING LAMP DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
M-8 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-911
M-9 NIGHT LIGHTING DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
M-10 ABNORMALITY IN FRONT WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-914
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . 20-914
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . 20-914
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . 20-914
M-11 ABNORMALITY IN REAR WORKING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-916
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP . . . . . . . . . . . . . . . . . 20-916
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . 20-916
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP . . . . . . . . . . . 20-916
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS PRESSED,
CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES NOT CHANGE . . . . . . . . . . . . 20-918
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF,
MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION IS ACTUATED
WHEN PEDAL IS DEPRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF
SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED . . . . . . . . . . . . . . . . . . 20-918
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF
MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF) . . . . . . . . . . . . . . . . . . . 20-918
E. MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH TURN ON),
BUT CUT-OFF FUNCTION IS NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-919
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS
(INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN WHEN
DIRECTIONAL LEVER IS AT N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND
CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS
WA500-3LK
20-901
TROUBLESHOOTING
AT POSITION OTHER THAN N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION
LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED . . . . . . . . . . . . . . 20-922
A. ACTUATED CONTINOUSLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
B. NOT ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
M-15 ABNORMALITY IN BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON
(FOR 3 SECONDS) (DURING SELF-CHECK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
B. BUZZER ALWAYS SOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-923
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY . . . . . . . . . . . . . . . . . . . . 20-924
M-17 ABNORMALITY IN FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
A. DOES NOT ENTER FAILURE DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY
MODE DOES NOT ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . 20-926
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 20-927
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . 20-927
B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-927
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY . . . . . . . . . . . . . . . . . . . . . 20-928
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . 20-928
B. EMERGENCY STEERING DISPLAY STAYS LIT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-928
M-21 NOT USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-929
M-22 ABNORMALITY IN ECSS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK . . . . . . . . . . . . . . 20-930
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) . . . . . . . 20-931
20-902
WA500-3LK
TROUBLESHOOTING
M-1 MAIN MONITOR DOES NOT WORK
12
M-1 MAIN MONITOR DOES NOT WORK
Cause
Yes
1
Is voltage between
L05 (1), (2) - (3)
normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Yes
chassis ground
normal?
1. Turn starting
switch OFF.
2. Disconnect L05.
3. Max. 1 .
No
Remedy
Replace
harness between L05
(female) (1), (2) and FS2
(female) (9)
Repair or
replace
harness between L05
(female) (3) and LR5
(male) (3)
Repair or
replace
M-1 Related electrical circuit diagram
WA500-3LK
20-903
TROUBLESHOOTING
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
12
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS

STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP
Cause
1
Yes
Is voltage between
L05 (4) and
chassis ground
normal?
1. 20 - 30 V.
2. Turn starting
switch to START.
No
Remedy
Replace
harness between L05
(female) (3)
Repair or
replace
20-904
WA500-3LK
TROUBLESHOOTING
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
12
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY
Check that the gap between the speed sensor and gear is normal.
Cause
2
Yes
1
Is resistance
between CN3
(male) (1) and (2)
normal?
1. 500 - 1 k.
2. Turn starting
switch OFF.
3. Disconnect
CN3.
Yes
(2) normal?
1. 500 - 1 k.
2. Turn starting
switch OFF.
3. Disconnect L07.
No
Yes
Remedy
Replace
Defective contact or disconnection L07 (female)

(1), (2) - TM2 (9), (10) CN3 (female) (1), (2)
Repair or
replace
Replace
WA500-3LK
20-905
TROUBLESHOOTING
M-4 ABNORMALITY IN SHIFT INDICATOR
12
Check that the transmission shifts.
A. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT F

Cause
1
Yes
Is voltage between
L08 (7) and
chassis ground
normal?
No
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Directional
lever: F
Remedy
Replace
Defective contact or disconnection in wiring har- Repair or

ness between L08 (female) replace
B. DISPLAYS N EVEN WHEN DIRECTIONAL LEVER IS AT R

Cause
1
Yes
Is voltage between
L08 (8) and
chassis ground
normal?
No
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Directional
lever: R.
Remedy
Replace

C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND

DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F
Cause
1
Yes
Is voltage between
L08 (8) and
chassis ground
normal?
No
1. 0 - 5 V.
2. Turn starting
switch ON.
3. Directional
lever: N
20-906
Remedy
Replace

and L04 (female) (4) or
defective transmission
lever
Repair or
replace
WA500-3LK
TROUBLESHOOTING
12
D.
DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N, AND

DISPLAY F WHEN DIRECTIONAL LEVER IS AT R
Cause
1
Yes
Is voltage between
L08 (7) and
chassis ground
normal?
No
1. 0 - 5 V.
2. Turn starting
switch ON.
3. Directional
lever: N
Remedy
Replace

and L04 (female) (2) or
lever
Repair or
replace
Cause
Remedy
E. DOES NOT DISPLAY 1ST - 4TH

1
Is there
abnormality in
S-NET?
Yes
No
See Troubleshooting of
transmission controller
system (T-mode)
---
Replace
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Speed lever: 1.
WA500-3LK
20-907
TROUBLESHOOTING
M-5 HIGH BEAM DOES NOT LIGHT UP
12
M-5 HIGH BEAM DOES NOT LIGHT UP
Before starting troubleshooting, check that the lamp bulb is not blown.
Cause
Yes
1
Is voltage L06
(12) and chassis
ground normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
Yes
L06 (female) (13)
and chassis ground
normal?
No
1. Max. 1 .
3. Disconnect L06.
4. Dimmer switch: HI beam
No
Remedy
Replace

20-908
WA500-3LK
TROUBLESHOOTING
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
12
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP
Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
A. LH TURN SIGNAL DISPLAY DOES NOT LIGHT UP

Cause
1
Yes
Is voltage between
L06 (14) and
chassis ground
normal?
No
1. Repeats 0 V and 20 - 30 V.
2. Turn starting switch ON.
3. Turn LH turn signal ON.
Remedy
Replace
harness between L06
(female) (4)
Repair or
replace
B. RH TURN SIGNAL DISPLAY DOES NOT LIGHT UP

Cause
1
Is voltage between
L06 (15) and
chassis ground
normal?
Yes
No
1. Repeats 0 V and 20 - 30 V.
3. Turn RH turn signal ON.
Remedy
Replace
harness between L06
(female) (3)
Repair or
replace
WA500-3LK
20-909
TROUBLESHOOTING
M-7 ABNORMALITY IN PARKING DISPLAY
12
M-7 ABNORMALITY IN PARKING DISPLAY
A. PARKING LAMP DISPLAY DOES NOT LIGHT UP

Cause
Yes
2
Yes
1
Is resistance
between CN19
(male) (1) and (2)
normal?
1. Max. 1 .
2. Disconnect
CN19.
3. Turn starting
switch ON.
4. Turn parking
switch ON.
Is voltage between
ground normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Turn parking
switch ON.
Yes
CN19 (female) (2)
and chassis ground
normal?
No
1. Max. 1 .
3. Disconnect CN19.
No
No
Remedy
Replace
harness between CN19
ground
Repair or
replace
harness between L06
(female) (11) - TM2 (7) CN19 (female) (1)
Repair or
replace

indicator switch
Replace
B. PARKING LAMP DISPLAY STAYS LIT UP

Cause
2
Yes

CN19 (1) and chas1
sis ground normal?
Is resistance
between CN19
(male) (1) and (2)
normal?
1. Max. 1 .
2. Disconnect
CN19.
3. Turn starting
switch ON.
4. Turn parking
switch OFF.
1. 0 - 2 V.
2. Turn starting
switch ON.
3. Turn parking
switch OFF.
No
No
Remedy
Replace

source in harness between Repair or
L06 (female) (11) - TM2 replace
(7) - CN19 (female) (1)
indicator switch
Replace
20-910
WA500-3LK
TROUBLESHOOTING
M-8 NOT USED
12
M-8 NOT USED
WA500-3LK
20-911
TROUBLESHOOTING
M-9 NIGHT LIGHTING DOES NOT LIGHT UP
12
Before starting troubleshooting, check that the lamp bulbs are not blown.
Check that fuse I - 6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness
between FS2 (female) (5) and L05 (female) (16).
Cause
1
Yes
Is voltage between
L05 (16) and
chassis ground
normal?
No
1. 20 - 30 V.
3. Turn small lamp switch ON.
Remedy
Replace
harness between L05
(female) (16) and FS2 (5)
Repair or
replace
20-912
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-913
TROUBLESHOOTING
M-10 ABNORMALITY IN FRONT WORKING LAMP
12
Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP

Cause
Yes
1
Is voltage between
L60 (1) and
chassis ground
normal?
Yes
3
1. 0 - 3 V.
2. Turn starting
switch ON.

L60 (6) and chassis
2
ground normal?
No
Is voltage between
L60 (2), (5) and
chassis ground
normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
1. 0 - 3 V.
2. Turn starting
switch ON.
No
No
Yes
Is voltage between
L06 (1) and chassis
ground normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Remedy
harness between L60
(female) (1) - L05 (17) CL1 (female) (7)
Repair or
replace
Defective front working

lamp relay
Replace
harness between L06
(female) (6)
Repair or
replace
Replace
harness between L60
(female) (1)
Repair or
replace
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause
1
Yes
Is voltage between
L05 (17) and
chassis ground
normal?
No
1. 20 - 30 V.
2. Turn starting
switch ON.
Remedy
Replace
harness between L05
(female) (1)
Repair or
replace
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause
Remedy
harness between L60 (1) - Repair or
CL1 (7) - C03 (female)
replace
(1), C04 (female) (1) or
blown working lamp bulb
20-914
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-915
TROUBLESHOOTING
M-11 ABNORMALITY IN REAR WORKING LAMP
12
Before starting troubleshooting, check that the monitor lighting is lighted up.
A. NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP

Cause
Yes
1
Is voltage between
L61 (1) and
chassis ground
normal?
Yes
3
1. 0 - 3 V.
2. Turn starting
switch ON.

L61 (6) and chassis
2
ground normal?
No
Is voltage between
L61 (2), (5) and
chassis ground
normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
1. 0 - 3 V.
2. Turn starting
switch ON.
No
No
Yes
Is voltage between
L06 21) and chassis
ground normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Remedy
harness between L61
(female) (1) - L05 (18) LR1 (female) (12)
Repair or
replace
Defective rear working

lamp relay
Replace
harness between L06
(female) (6)
Repair or
replace
Replace
harness between L61
(female) (2)
Repair or
replace
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT
UP
Cause
1
Yes
Is voltage between
L05 (18) and
chassis ground
normal?
No
1. 20 - 30 V.
2. Turn starting
switch ON.
Remedy
Replace
harness between L05
(female) (1)
Repair or
replace
C. MONITOR DISPLAY LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT
UP
Cause
Remedy
harness between L61 (1) - Repair or
LR1 (12) - G02 (female) replace
(1), G04 (female) (1) or
blown working lamp bulb
20-916
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-917
TROUBLESHOOTING
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF
12
A. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS

PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY DOES
NOT CHANGE
Cause
Remedy
Replace
B. WHEN MONITOR SWITCH (TRANSMISSION CUT-OFF SWITCH) IS OFF,

MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION IS ACTUATED
WHEN PEDAL IS DEPRESSED
Cause
1
Yes
Is voltage between
L06 (3) and
chassis ground
normal?
1. 0 - 3 V.
2. Turn starting
switch ON.
3. disconnect L12.
No
Remedy
harness between L06
(female) (3) and C5
(female) (60
Repair or
replace
Replace
C. WHEN MONITOR DISPLAY IS TURNED OFF (TRANSMISSION CUT-OFF

SWITCH TURNED OFF), CUT-OFF FUNCTION IS ALWAYS ACTUATED
Cause
2
Yes
1
Is resistance
between L12
(male) (1) and (2)
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L12.
Yes
chassis ground
normal?
1. Max. 1 .
2. Turn starting
switch OFF.
3. Disconnect L12.
No
No
Remedy
harness between L12
(female) (1) and C5
(female) (6)
Repair or
replace
harness between L12
ground
Repair or
replace
cut-off switch
Replace
D. CUT-OFF FUNCTION IS ALWAYS ACTUATED REGARDLESS OF

MONITOR DISPLAY (TRANSMISSION CUT-OFF SWITCH ON OR OFF)
Cause
1
Yes
Is voltage between
C5 (6) and chassis
ground normal?
1. Max. 3 V.
20-918
No
Remedy
controller
Replace

ness between C5 (female) replace
(6) and L06 (female) (3),
L12 (female) (1)
WA500-3LK
TROUBLESHOOTING
12
E.
MONITOR DISPLAY LIGHTS UP (TRANSMISSION CUT-OFF SWITCH

TURN ON), BUT CUT-OFF FUNCTION IS NOT ACTUATED
Cause
1
Yes
Does cut-off
function work
when L12 is
disconnected?
1. Disconnect L06. No
2. Turn starting
switch ON.
Yes
Does cut-off
function work when
L06 is disconnected?
1. Disconnect L06.
2. Turn starting
switch ON.
No
Yes
Is voltage between
C5 (6) and chassis
ground normal?
1. Disconnect L12.
2. Turn starting
switch ON.
3. 20 - 30 V.
No
Remedy
cut-off switch
Replace
Replace
controller
Replace

L06 (female) (3) - C5
replace
(female) (6) - L12
(female) (10
WA500-3LK
20-919
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING

12
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS

(INTERMITTENTLY) AND CAUTION LAMP FLASHES WEVEN WHEN
DIRECTIONAL LEVER IS AT N.
Cause
1
Yes
Is voltage between
L05 (8) and
chassis ground
normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
3. Directional
lever: N.
No
Remedy
Replace
harness between L05
(female) (8) - JSA
(female) (1) - L04
(female) (3)
Repair or
replace
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND

CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER
IS AT POSITION OTHER THAN N
Check that the synchronous flash signal is normal.
Cause
1
Yes
Is voltage between
L05 (8) and
chassis ground
normal?
1. 0 - 5 V.
2. Turn starting
switch ON.
3. Directional
lever: Other than
N.
20-920
No
Yes
L05 (male) 98) and
(3) normal?
1. 3 - 4 k.
2. Turn starting
switch OFF.
3. Disconnect L05.
Remedy
No
Replace

between L05 (female) (8) - Repair or
JSB (male) (1), JSA
replace
(female) (1) - L04
(female) (3) or defective
directional lever
Replace
WA500-3LK
TROUBLESHOOTING M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING

12
WA500-3LK
20-921
TROUBLESHOOTING
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,
12
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN,

BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY,
OR THEY ARE NOT ACTUATED
A. ACTUATED CONTINOUSLY
Cause
2
Yes
1
1. Turn starting
switch ON.
2. Connect L07 (6)
to chassis ground.
Does buzzer stop

and lamp go out?
1. Turn starting
switch ON.
2. Connect L19
(female) (5) to
chassis ground.
Does buzzer stop

and lamp go out?
Yes
No
No
Remedy
Defective maintenance
monitor
Replace
harness between L07
(female) (5)
Repair or
replace
Replace
B. NOT ACTUATED
Cause
2
Yes
1
Does buzzer and
lamp work?
1. Turn starting
switch ON.
2. Disconnect L07
Yes
Does buzzer and

lamp work?
1. Turn starting
switch ON.
2. Disconnect L19.
No
No
Remedy
Defective maintenance
monitor
Replace

L07 (female) (6) and L19 replace
(female) (5)
Replace
20-922
WA500-3LK
TROUBLESHOOTING
M-15 ABNORMALITY IN BUZZER
12
M-15 ABNORMALITY IN BUZZER
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS AT ON (FOR 3

SECONDS) (DURING SELF-CHECK)
Cause
Yes
1
Does buzzer
sound?
1. Turn starting
switch ON.
2. Contact L43
(female) to
chassis ground.
Yes
Is voltage between
L42 (female) and
No chassis ground
normal?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Remedy
harness between L06
(male) (1)
Repair or
replace
Defective buzzer
Replace
harness between L42
(female) (1) and FS2
(female) (9)
Repair or
replace
B. BUZZER ALWAYS SOUNDS

Cause
1
Yes
Does buzzer stop

when L06 is
disconnected?
1. Disconnect L06.
2. Turn starting
switch ON.

2
Yes
Does buzzer stop

when L19 is
No disconnected?
1. Disconnect L19.
2. Turn starting
switch ON.
Remedy
Go to Troubleshooting for
Maintenance Monitor
3
Yes
Does buzzer stop

when L43 is
No disconnected?
1. Disconnect L43.
2. Turn starting
switch ON.
Replace
No
---

L06 (female) (8) and L43 replace
(male) (1)
Defective buzzer
Replace
WA500-3LK
20-923
TROUBLESHOOTING
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN
12
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN

MEMORY
Cause
1
Yes
Is voltage between
L07 (10) and
chassis ground
normal?
1. 20 - 30 V.
2. turn starting
switch ON.
No
Remedy
Replace
harness between L07
(female) (2)
Repair or
replace
20-924
WA500-3LK
TROUBLESHOOTING
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
12
M-17 ABNORMALITY IN FAILURE DISPLAY MODE
A. DOES NOT ENTER FAILURE DISPLAY MODE

Cause
1
Yes
Is voltage between
L05 (5) and
chassis ground
normal?
1. 0 - 5 V.
2. Turn starting
switch ON.
No
Remedy
Replace

between L05 9female) (5) Repair or
- LR4 (6) - ER1 (9) replace
alternator terminal R, or
defective alternator
B. COUNT FOR TIME ELAPSED SINCE FAILURE IN FAILURE DISPLAY

MODE DOES NOT ADVANCE
Cause
1
Yes
Is voltage between
L05 (5) and
chassis ground
normal?
1.20 - 30 V.
2. Start engine.
No
Remedy
Replace
harness between L05
(female) (5) - LR4 (6) ER1 (9) - alternator
terminal R or defective
alternator
Repair or
replace
WA500-3LK
20-925
TROUBLESHOOTING M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION CON-
M-18 BUZZER IS NOT MADE TO SOUND BY TRANSMISSION

CONTROLLER
Cause
2
Yes
chassis ground
normal when C1
1
No
(female) (2) is
Does buzzer sound
when C1 (female)
1. Max. 1.
(2) is grounded to
chassis?
3. disconnect L01 and C1
1. Turn starting
switch ON.
2. Disconnect C1.
3. Connect C1
(female) (2) to
chassis ground.
No
Remedy
Go to Troubleshooting of
Transmission Controller
System (T Mode)
Replace
harness between L08
(female) (6) and C1
(female) (2)
Repair or
replace
Replace
20-926
WA500-3LK
TROUBLESHOOTING
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL DIS-
12
M-19 ABNORMALITY IN EMERGENCY STEERING NORMAL

DISPLAY
A. EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP

Cause
2
Yes

1
ground normal?
Is emergency
steering selection
connector
disconnected?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Remedy
Replace
harness between L05
(female) (10) and EST
(female) (2)
Repair or
replace
Defective disconnection of
emergency steering
Disconnect
selector connector
No
B. EMERGENCY STEERING NORMAL DISPLAY STAYS LIT UP

Cause
2
Yes

1
ground normal?
Is emergency
steering selection
connector
disconnected?
1. 0 - 2 V.
2. Turn starting
switch ON.
No
No
Remedy
Replace
harness between L05
(female) (2)
Repair or
replace
Disconnect
emergency steering
selector connector
WA500-3LK
20-927
TROUBLESHOOTINGM-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION DIS12
M-20 ABNORMALITY IN EMERGENCY STEERING ACTUATION

DISPLAY
A. EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP

Cause
2
Yes

1
ground normal?
Is emergency
steering selection
connector
disconnected?
1. 20 - 30 V.
2. Turn starting
switch ON.
No
Remedy
Replace
harness between L05
(female) (1)
Repair or
replace
emergency steering
Disconnect
selector connector
No
B. EMERGENCY STEERING DISPLAY STAYS LIT UP

Cause
2
Yes

1
ground normal?
Is emergency
steering selection
connector
disconnected?
1. 0 - 2 V.
2. Turn starting
switch ON.
No
No
Remedy
Replace

L05 (female) (11) and EST replace
(female) (1)
emergency steering
Disconnect
selector connector
20-928
WA500-3LK
TROUBLESHOOTING
M-21 NOT USED
12
M-21 NOT USED
WA500-3LK
20-929
TROUBLESHOOTING
M-22 ABNORMALITY IN ECSS SYSTEM
12
M-22 ABNORMALITY IN ECSS SYSTEM
ECSS: Electronic Controlled Suspension System.
A. DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED

Cause
Remedy
Replace
B. MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK
2
Yes

C3B (9) and chassis
1
ground normal?
Is voltage between
L06 (7) and
chassis ground
normal?
1. Max. 3 V.
2. Turn starting
switch ON.
1. Max. 3 V.
2. Turn starting
switch ON.
No
No
Cause
Remedy
Go to Troubleshooting for
ECSS Controller System
(D Mode)
---
harness between L06 (7)
and C3B (9)
Repair or
replace
Replace
20-930
WA500-3LK
TROUBLESHOOTING
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)
Set dipswitch 3 at the rear of the main monitor to "F".
MDC: Multiple Display and Condition.
Cause
2
1 Yes
Is voltage between
L08 (male) (1) and
(2) normal?
1. Repeats 0 V and
12 V.
2. Turn starting
switch ON.
3. Disconnect L08.
Yes
Is voltage normal
between pins of
connectors in table
below?
1. Repeats 0 V and
12 V.
2. Turn starting
switch ON.
3. Disconnect
connector to be
measured.
No
No
Remedy
Applicable controller is
defective
Replace
harness between L08
(female) (1) (3), L08
(female) (2) (4) applicable connector pins
Repair or
replace
Replace
WA500-3LK
20-931
TROUBLESHOOTING
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNOR-
12
MEMORANDUM
20-932
WA500-3LK
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (T MODE)
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS . . . . . . . . . 20-1204
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS
ON MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1206
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION, SHORT CIRCUIT WITH
POWER SOURCE IN BACK-UP LAMP RELAY) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1212
POWER SOURCE IN F SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1214
POWER SOURCE IN R SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1216
POWER SOURCE IN 1ST SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1218
POWER SOURCE IN 2ND SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1220
POWER SOURCE IN 3RD SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1222
POWER SOURCE IN 4TH SOLENOID) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1224
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN JOYSTICK DIRECTIONAL
SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1226
T-9 FAILURE CODE [20] (SHORT CIRCUIT, DISCONNECTION IN DIRECTIONAL SWITCH
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1228
T-10 FAILURE CODE [21] (SHORT CIRCUIT, DISCONNECTION IN RANGE SWITCH
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1232
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED SENSOR SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1236
T-12 FAILURE CODE [23] (SHORT CIRCUIT, DISCONNECTION IN ENGINE SPEED
SENSOR SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1238
T-13 FAILURE CODE [24] (SHORT CIRCUIT, DISCONNECTION IN EEP ROM) IS DISPLAYED . . . . 20-1240
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL TEMPERATURE
SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1241
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1242
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1243
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1244
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1245
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1246
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1247
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL SWITCH SYSTEM)
IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1248
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR 4TH ECMV FILL
SWITCH SYSTEM) IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1250
T-23 HOLD SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1253
WA500-3LK
20-1201
TROUBLESHOOTING
T-24 KICK-DOWN SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1254
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1255
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1256
T-27 BUZZER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1257
T-28 NETWORK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1258
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1259
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1260
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM . . . . . . . . . . . . 20-1261
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1262
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1263
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1264
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1265
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1266
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1267
Remark
See Electrical Diagram in section 90.
20-1202
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-1203
TROUBLESHOOTING
JUDGEMENT TABLE FOR TRANSMISSION
12
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER

SYSTEM RELATED PARTS
Short circuit in 4th ECMV fill switch system
Short circuit in 3rd ECMV fill switch system
Short circuit in 2nd ECMV fill switch system
Short circuit in 1st ECMV fill switch system
Short circuit in R ECMV fill switch system
Short circuit in F ECMV fill switch system
Short circuit in transmission oil temperature system
Short circuit, disconnection in memory (EEP ROM)
Short circuit, disconnection in engine speed sensor system
Disconnection in travel speed sensor system
Short circuit, disconnected in range switch system
Short circuit, disconnected in directional switch system
Short circuit, disconnected in joystick directional switch system
Short circuit, disconnected in 4th ECMV solenoid
Short circuit, disconnected in 3rd ECMV solenoid
Short circuit, disconnected in 2nd ECMV solenoid
Short circuit, disconnected in 1st ECMV solenoid
Short circuit, disconnected in R ECMV solenoid
Short circuit, disconnected in F ECMV solenoid
Short circuit, disconnection in back-up lamp relay
Self diagnostic display (abnormality display)

(Location of failure)
Transmission controller error

(Failure code)
X
Directional lever and direction of travel are different
Machine travels forward when directional lever is not at F
Machine travels in reverse when directional lever is not at R
Shifts down regardless of travel speed
Shifts up regardless of travel speed
Speed range is not same as position of lever
There is excessive shock while shifting gears
X
X
X
X
X
X
X
10 There is shift hunting when traveling
11 There is shift hunting when shifting gears
12 Speed range can not be controlled with speed lever

13 Back-up lamp and buzzer do not work
T-20
T-19
Auto-shifting is not carried out
T-18
T-17
10 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31
Travel is impossible
T-16
Failure mode
T-15
No.
X
X
14 Shift can not be held

15 Kick-down does not work
16 When kick-down is actuated, there is no scooping power
17 Transmission is not cut off with left brake
18 It is possible to travel even when parking brake is applied
19 If F-R lever is operated when traveling at high speed, alarm
buzzer does not sound
20 Alarm buzzer continues to sound
21 Main monitor does not display transmission controller
information (alarm buzzer, fail code, etc.)
20-1204
T-14
T-13
T-12
T-11
T-10
T-9
T-8
T-7
T-6
T-5
T-4
T-3
T-2
Troubleshooting code when no error code is displayed
T-1
22 Gear shifting speed is abnormal (tire compensation)
WA500-3LK
WA500-3LK
T-22
T-21
32 33
-
Abnormality in network signal system or main monitor
Abnormality in network signal system
Abnormality in alarm buzzer signal system
Abnormality in neutralizer signal system
Abnormality in transmission cut-off signal system
Abnormality in kick-down switch signal system
Abnormality in hold switch signal system
Disconnection in 1st, 2nd, 3rd, or 4th ECMV fill switch system
Disconnection in F or R ECMV fill switch system
TROUBLESHOOTING
JUDGEMENT TABLE FOR TRANSMISSION
12
Self diagnostic display

(abnormality display)
X
X
Troubleshooting code
when no abnormality
display is given
Transmission controller error

(Failure code)
X
X
E-1, H-1
X
X
H-2, H-3
T-24, E-9
T-23
T-25
T-27, H-17, E-5
T-26
T-28
T-28, J-1
T-29
20-1205
TROUBLESHOOTING
12
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
1. TRANSMISSION CONTROLLER SYSTEM
Failure
Code
Abnormal System
Nature of Abnormality
1)
2)
10
Back-up lamp relay

3)
4)
1)
2)
12
Abnormality in F ECMV system
3)
4)
1)
2)
13
Abnormality in R ECMV system
3)
4)
1)
2)
14
Abnormality in 1st ECMV system

3)
4)
1)
2)
15
Abnormality in 2nd ECMV system

3)
4)
1)
2)
16
Abnormality in 3rd ECMV system
3)
4)
20-1206
Defective back-up lamp.

Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission controller C1
(female) (11) and L54 (1).
defective contact or disconnection in wiring harness between back-up lamp
relay L54 (female) (2) and chassis ground.
Defective transmission controller.
Defective F ECMV.
(female) (7) - TM2 (4) - CN16 (1).
Short circuit with chassis ground, defective contact, disconnection in wiring
harness between transmission controller C2 (female) (17) - TM2 (5) - CN16
(2).
Defective R ECMV.
(female) (8) - TM2 (1) - CN14 (1).
(2).
Defective 1st ECMV.

(female) (9) - TM1 (1) - CN4 (1).
harness between transmission controller C2 (female) (19) - TM1 (2) - CN4 (2).
Defective 2nd ECMV.

(female) (10) - TM1 (4) - CN6 (1).
harness between transmission controller C2 (female) (20) - TM1 (5) - CN6 (2).
Defective 3rd ECMV.

(female) (2) - TM1 (7) - CN12 (1).
(2).
WA500-3LK
TROUBLESHOOTING
12
when abnormality is
detected

on machine with
abnormality
Troubleshooting
Code
Resistance of relay coil: 200 - 400 .

Voltage between transmission controller C1 (11) and chassis
ground at neutral: Less than 1 V.
Resistance in wiring harness between transmission controller
C1 (female) (11) and L54 (female) (1): Max. 1 .
Resistance in wiring harness between back-up lamp relay L54
(female) (2) and chassis ground: Max. 1 .
Neutral
(All ECMV outputs: OFF)
Back-up lamp is not

actuated when driving in
reverse.
T-1
Resistance of solenoid between transmission controller C2

(female) (7) and (17): 10 - 20 .
Resistance between transmission controller C2 (female) (7),
(17) and chassis ground: Min. 1 M.
C2 (female) (7), (17) - TM2 (4), (5) - CN16 (1), (2):
Less than 1 .
Neutral
It is impossible to travel.
T-2

(female) (8) and (18): 10 - 20 .
C2 (female) (8), (18) - TM2 (1), (2) - CN14 (1), (2):
Less than 1 .
Neutral
T-3

(female) (9) and (19): 10 - 20 .
C2 (female) (9), (19) - TM1 (1), (2) - CN4 (1), (2):
Less than 1 .
Neutral
T-4

(female) (10) and (20): 10 - 20 .
C2 (female) (10), (20) - TM1 (4), (5) - CN6 (1), (2):
Less than 1 .
Neutral
T-5

(female) (2) and (13): 10 - 20 .
C2 (female) (2), (13) - TM1 (7), (8) - CN12 (1), (2):
Less than 1 .
Neutral
T-6
1)
2)
a
3)
4)
1)
2)
b
3)
4)
1)
2)
c
3)
4)
1)
2)
d
3)
4)
1)
2)
e
3)
4)
1)
2)
f
3)
4)
WA500-3LK
20-1207
TROUBLESHOOTING
Failure
Code
Abnormal System
1)
2)
17
19
Abnormality in 4th ECMV system
Abnormality in joystick directional switch
4)
Defective 4th ECMV.

(female) (4) - TM1 (10) - CN8 (1).
(2).
1)
2)
Defective joystick directional lever F, N, R switch.

Disconnection between directional lever connector (8) and chassis ground.
3)
When the wiring harness is in any of the following conditions with switch not
pressed:
3) Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (8) - JS14 (2) - joystick lever connector (2), or short
circuit with chassis ground in wiring harness between C5 (female) (16) - JS14
(3) - joystick lever connector (3).
circuit with chassis ground in wiring harness between C5 (female) (15) JS14 (5) - joystick lever connector (5).
circuit with chassis ground in wiring harness between C5 (female) (7) JS14 (7) - joystick lever connector (7).
1)
2)
20
Abnormality in directional switch signal

system
21
Abnormality in range switch signal system
22
Disconnection in speed sensor

4)
5)
1)
2)
3)
23
Abnormality in engine speed sensor system

4)
5)
20-1208
Defective directional lever.

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 controller C3B (female) (7) and L04 (5).
1)
2)
3)
Defective directional lever.

Defective combination switch power source.
Short circuit with power source, short circuit with chassis ground, defective contact,
disconnection in the following wiring harness:
1)
2)
Defective speed sensor.

Defective adjustment of speed sensor mount.
Defective contact or disconnection in wiring harness between transmission
controller C5 (female) (2) - TM2 (9) - CN3 (1).
Defective engine speed sensor.

Defective adjustment of engine speed sensor mount.
Short circuit with chassis ground, defective contact or disconnection in wiring
harness between transmission controller C4 (female) (2) - LR3 (7) - ER2 (6) E04 (2).
controller C4 (female) (9) - LR3 (8) - ER2 (7) - E04 (3).
WA500-3LK
TROUBLESHOOTING
12
when abnormality is
detected

on machine with
abnormality
Troubleshooting
Code
Neutral
T-7
Neutral
Can not travel in joystick

mode (possible in
steering wheel mode)
T-8
Voltage between combination switch L04 (1) and chassis ground:

20 - 30 V.
Voltage for only 1 system in accordance with position of directional
lever: 20 - 30 V (Others: Less than 1 V)
F: Between transmission controller C3B (5) - chassis ground.
N: Between transmission controller C3B (13) - chassis ground.
R: Between transmission controller C3B (6) - chassis ground.
Shift to neutral
immediately when short
circuit with power source
is detected.
When there is no signal
(disconnection), holds
previous signal condition
for 2 seconds.
It is impossible to travel
T-9
Voltage between combination switch L04 (1) and chassis ground:

20 - 30 V.
Voltage for only 1 system in accordance with position of directional
lever: 20 - 30 V (Others: Less than 1V)
1st: Between transmission controller C3B (7) - chassis ground.
2nd: Between transmission controller C3B (15) - chassis ground.
3rd: Between transmission controller C3B (8) - chassis ground.
4th: Between transmission controller C3B (16) - chassis ground.
If signals are input, it

judges speed range
position in order of
priority 4321.
When there is no signal
(disconnection), holds
previous signal condition
(speed range position).

1)
2)
g
3)
4)
1)
2)
i
1)
2)
j
Resistance of solenoid between joystick directional lever connector

(8) and chassis ground: Less than 1 V.
The following conditions are when the switch is not pressed:

2) Voltage between transmission controller C5 (female) (8) and chassis
and resistance between C5 (female) (16) and chassis ground:
Min. 1 M.
3) Resistance between transmission controller C5 (female) (7), and
chassis ground: Less than 1 V.
Min. 1 M.
4) Resistance in wiring harness between transmission controller
C5 (female) (9) and chassis ground: Less than 1 .
Min. 1 M.
1)
Resistance of solenoid between transmission controller C2 (female)

(4) and (15): 10 - 20
C2 (female) (4), (15) - TM1 (10), (11) - CN8 (1), (4):
Less than 1 .
1)
2)
Resistance between speed sensor CN3 (1) and (2): 500 - 1,000 .
Voltage between transmission controller C5 (female) (2) and (10):
Min. 0.5 V.
1)
Resistance between engine speed sensor E04 (2) and (3):

100 - 500 .
Voltage between transmission controller C4 (female) (2) and (9):
Min. 0.5 V.
2)
WA500-3LK
1)
2)
Switches to manual
mode.
Shifts gear according
to operation of speed
lever
It is possible to travel with

engine speed taken as
2,100 rpm.
1)
2)
1)
2)
Auto-shift limit is
different from
range position
selected by
operator.
Impossible to shift
gear in manual
mode.
T-10
Does not carry out

auto-shift.
Switches to manual
shift.
T-11
There is gearshifting
shock.
T-12
20-1209
TROUBLESHOOTING
12
Failure
Code
Abnormal System
24
Abnormality in memory (EEPROM)
25
Short circuit in transmission oil temperature

sensor system.
1)
1)
2)
Defective transmission oil temperature sensor.

Short circuit with chassis ground in wiring harness between transmission
controller C3A (female) (11) - TM2 (13) - CN11 (1).
Defective F ECMV fill switch.

controller C3B (female) (2) - TM2 (6) - CN17 (1).
Defective R ECMV fill switch.

Defective 1st ECMV fill switch.

Defective 2nd ECMV fill switch.

Defective 3rd ECMV fill switch.

Defective 4th ECMV fill switch.

4)
Defective fill switch.

F ECMV fill switch:
R ECMV fill switch:
1)
Defective fill switch.
3)
26
Short circuit in F ECMV fill switch system.
1)
2)
3)
27
Short circuit in R ECMV fill switch system.
1)
2)
3)
28
Short circuit in 1st ECMV fill switch system.
1)
2)
3)
29
Short circuit in 2nd ECMV fill switch

system.
1)
2)
3)
30
Short circuit in 3rd ECMV fill switch

system.
1)
2)
3)
31
Short circuit in 4th ECMV fill switch

system.
1)
2)
3)
1)
2)
32
33
20-1210
Disconnection in F or R ECMV fill switch

system
Disconnection in 1st, 2nd, 3rd, or 4th ECMV

fill switch system
3)
Defective contact or disconnection in the following wiring harness:

2) 1st ECMV fill switch:
Between transmission controller C3B (female) (3) - TM1 (3) - CN5 (1).
3) 2nd ECMV fill switch:
Between transmission controller C3B (female) (11) - TM1 (6) - CN7 (1).
4) 3rd ECMV fill switch:
Between transmission controller C5 (female) (11) - TM1 (9) - CN13 (1).
5) 4th ECMV fill switch:
Between transmission controller C5 (female) (12) - TM1 (12) - CN9 (1).
6) Defective transmission controller.
WA500-3LK
TROUBLESHOOTING
12
when abnormality is
detected
1)
Shock when shifting gear is reduced by learning function.
Stops learning function and

uses default data
shock.
T-13
1)
Resistance between transmission oil temperature sensor CN11 (1)

and (2): 38 - 48 k {approx. 25 C (77 F)}
Voltage between transmission controller C3A (female) (11) and
(17): 1 - 5 V.
Uses low temperature data

for transmission oil
temperature when shifting
gear
shock.
T-14
1)
Resistance between transmission controller C3B (female) (2) and

chassis ground at neutral (F ECMV: OFF): Min. 1 M.
Neutral
T-15
1)

chassis ground at neutral (R ECMV: OFF): Min. 1 M.
Neutral
T-16
1)

chassis ground at neutral (1st ECMV: OFF): Min. 1 M.
Neutral
T-17
1)

chassis ground at neutral (2nd ECMV: OFF): Min. 1 M.
Neutral
T-18
1)
Resistance between transmission controller C5 (female) (11) and

chassis ground at neutral (3rd ECMV: OFF): Min. 1 M.
Neutral
T-19
1)

chassis ground at neutral (4th ECMV: OFF): Min. 1 M.
Neutral
T-20
1)

chassis ground at FORWARD (F ECMV: ON): Less than 1 .
chassis ground at REVERSE (R ECMV: ON): Less than 1 .
Uses data without fill

switch signal when shifting
gear
shock.
T-21

chassis ground when traveling at 1st (1st ECMV: ON):
Less than 1 .
chassis ground when traveling at 2nd (2nd ECMV: ON):
Less than 1 .
chassis ground when traveling at 3rd (3rd ECMV: ON):
Less than 1 .
chassis ground when traveling at 4th (4th ECMV: ON):
Less than 1 .
Uses data without fill

switch signal when shifting
gear
shock.
T-22
2)
2)
1)
2)
v
3)
4)
WA500-3LK

on machine with
abnormality
Troubleshooting
Code
20-1211
TROUBLESHOOTING
T-1 FAILURE CODE [10] (SHORT CIRCUIT,
12
T-1 FAILURE CODE [10] (SHORT CIRCUIT, DISCONNECTION,

SHORT CIRCUIT WITH POWER SOURCE IN BACK-UP LAMP
RELAY) IS DISPLAYED
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
Cause
4
Yes

3
chassis ground
normal?
No
1) Min. 1 M.
2 Yes C1 (female) (11) and
chassis normal when
OFF.
L54 (female) (1) is
L54.
chassis ground
1) Max. 1 .
normal?
No
OFF.
1
L54.
1) Max. 1 .
Is troubleshooting code
10 displayed when the
OFF.
relay is interchanged
3) Disconnect L54.
with a relay of same
type?
OFF.
2) Interchange relay with
of same type.
ON.
4) Directional lever: R
No
No
5
A
Yes
Is voltage between C1
(female) (11) and
chassis normal?
OFF.
L54.
3) Less than 0.1 V.
No
Remedy
Go to A

between C1 (female) (11) replace
harness between C1
(female) (1)
Repair or
replace
harness between L54
Repair or
replace
Defective back-up lamp

relay
Replace
controller
Replace

Replace
between C1 (female) (11) or replace
T-1 Related electrical circuit diagram
20-1212
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-1213
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN F SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN16 (female) (1)
and chassis normal
when C2 (female)
(7) is grounded to
3
chassis?
1)
2)
C2 (female) (17) and
2
chassis ground
3)
normal?
CN16 (female) (2)
1) Min. 1 M.
Yes and chassis normal
when C2 (female)
No
OFF.
(17) is grounded to
chassis?
CN16.
1
1) Max. 1 .
OFF.
CN16.
No
CN16 (male) (1) and
(2), and between (1), (2)
and chassis normal?
1) Between (1) and (2):
5 - 15 .
2) Between (1), (2) and
chassis: Min. 1 M.
OFF.
4) Disconnect CN16.
No
Max. 1 .
OFF.
Disconnect C2 and
CN16.
Remedy
Go to A
harness between C2
Repair or
replace

- TM2 (5) - CN16 (female)
(2)
harness between C2
Repair or
replace
Defective F solenoid
Replace
controller
Replace
No
7
Yes
Yes Is voltage between C2

normal?
6
C2 (female) (7) and
(17) normal?
5
A C2 (female) (7) and
chassis normal?
1) 5 - 15 .
OFF.
CN16.
No
1) Min. 1 M.
OFF.
CN16.
No
20-1214

OFF.
CN16.
3) Less than 0.1 V.
No

Replace
between C2 (female) (7) - or repair
TM2 (4) - CN16 (1)

between C2 (female) (17)
- TM2 (5) - CN16 (female) Repair or
(2) and wiring harness
replace
between C2 (female) (7) TM2 (4) - CN16 (female)
(1)

between C2 (female) (7) - replace
TM2 (4) - CN16 (female)
(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1215
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN R SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN14 (female) (1)
and chassis normal
when C2 (female)
(8) is grounded to
3
chassis?
Yes
2
CN14 (female) (2)
when C2 (female)
(18) is grounded to
chassis?
No
1) Max. 1 .
OFF.
CN14.
chassis normal?
1) Min. 1 M.
No
OFF.
CN14.
1) Max. 1 .
OFF.
CN14.
No
CN14 (male) (1) and
and chassis normal?
5 - 15 .
chassis: Min. 1 M.
OFF.
4) Disconnect CN14.
Remedy
Go to A
harness between C2
Repair or
replace

(2)
harness between C2
Repair or
replace
Replace
controller
Replace
No
7
Yes

normal?
6
C2 (female) (8) and
(18) normal?
5
chassis normal?
1) 5 - 15 .
OFF.
CN14.
No
1) Min. 1 M.
OFF.
CN14.
No
20-1216

OFF.
CN14.
3) Less than 0.1 V.
No

Replace
TM2 (1) - CN14 (1)

replace
(1)

(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1217
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN 1ST SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN4 (female) (1)
and chassis normal
when C2 (female)
(9) is grounded to
3
chassis?
No
1) Max. 1 .
OFF.
CN4.

2
chassis ground
normal?
CN4 (female) (2)
1) Min. 1 M.
when C2 (female)
No
OFF.
(19) is grounded to
chassis?
CN4.
1
1) Max. 1 .
OFF.
CN4.
CN4 (male) (1) and (2),
and between (1), (2) and
chassis normal?
5 - 15 .
chassis: Min. 1 M.
OFF.
4) Disconnect CN4.
No
Remedy
Go to A
harness between C2
Repair or
replace

(2)
harness between C2
Repair or
replace
Defective 1st solenoid
Replace
controller
Replace
No
7
Yes

normal?
6
C2 (female) (9) and
(19) normal?
5
chassis normal?
1) 5 - 15 .
OFF.
CN4.
No
1) Min. 1 M.
OFF.
CN4.
No
20-1218

OFF.
CN4.
3) Less than 0.1 V.
No

Replace
TM1 (1) - CN4 (1)

replace
(1)

(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1219
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN 2ND SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN6 (female) (1)
and chassis normal
when C2 (female)
(10) is grounded to
3
chassis?
No
1) Max. 1 .
OFF.
CN6.

2
chassis ground
normal?
CN6 (female) (2)
1) Min. 1 M.
when C2 (female)
No
OFF.
(20) is grounded to
chassis?
CN6.
1
1) Max. 1 .
OFF.
CN6.
CN6 (male) (1) and (2),
chassis normal?
5 - 15 .
chassis: Min. 1 M.
OFF.
4) Disconnect CN6.
No
Remedy
Go to A
harness between C2
Repair or
replace

(2)
harness between C2
Repair or
replace
Defective 2nd solenoid
Replace
controller
Replace
No
7
Yes

(female) (10) and chassis normal?
6
(20) normal?
5
chassis normal?
1) 5 - 15 .
OFF.
CN6.
No
1) Min. 1 M.
OFF.
CN6.
No
20-1220

OFF.
CN6.
3) Less than 0.1 V.
No

Replace
between C2 (female) (10) or repair
- TM1 (4) - CN6 (1)

replace
(1)

(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1221
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN 3RD SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN12 (female) (1)
and chassis normal
when C2 (female)
(2) is grounded to
3
chassis?
No
1) Max. 1 .
OFF.
CN12.

2
chassis ground
normal?
CN12 (female) (2)
1) Min. 1 M.
when C2 (female)
No
OFF.
(13) is grounded to
chassis?
CN12.
1
1) Max. 1 .
OFF.
CN12.
CN12 (male) (1) and
and chassis normal?
5 - 15 .
chassis: Min. 1 M.
OFF.
4) Disconnect CN12.
No
Remedy
Go to A
harness between C2
Repair or
replace

(2)
harness between C2
Repair or
replace
Defective 3rd solenoid
Replace
controller
Replace
No
7
Yes

normal?
6
C2 (female) (2) and
(13) normal?
5
chassis normal?
1) 5 - 15 .
OFF.
CN12.
No
1) Min. 1 M.
OFF.
CN12.
No
20-1222

OFF.
CN12.
3) Less than 0.1 V.
No

Replace
TM1 (7) - CN12 (1)

replace
(1)

(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1223
TROUBLESHOOTING
12

SHORT CIRCUIT WITH POWER SOURCE IN 4TH SOLENOID) IS
DISPLAYED
Cause
4
Yes

CN8 (female) (1)
and chassis normal
when C2 (female)
(4) is grounded to
3
chassis?
No
1) Max. 1 .
OFF.
CN8.

2
chassis ground
normal?
CN8 (female) (2)
1) Min. 1 M.
when C2 (female)
No
OFF.
(15) is grounded to
chassis?
CN8.
1
1) Max. 1 .
OFF.
CN8.
CN8 (male) (1) and (2),
chassis normal?
5 - 15 .
chassis: Min. 1 M.
OFF.
4) Disconnect CN8.
Remedy
Go to A
harness between C2
Repair or
replace

(2)
Repair or
harness between C2
(female) (15) - TM1 (11) - replace
CN8 (female) (2)
No
Defective 4th solenoid
Replace
controller
Replace
No
7
Yes

normal?
6
C2 (female) (4) and
(15) normal?
5
chassis normal?
1) 5 - 15 .
OFF.
CN8.
No
1) Min. 1 M.
OFF.
CN8.
No
20-1224

OFF.
CN8.
3) Less than 0.1 V.
No

Replace
TM1 (10) - CN8 (1)

replace
(1)

(1)
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1225
TROUBLESHOOTING
12
T-8 FAILURE CODE [19] (SHORT CIRCUIT, DISCONNECTION IN

JOYSTICK DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
Cause
4
Yes

C5 (female) (7), (8),
(9), (15), (16), (17)
and chassis as shown
in Table 1?
3
1) Turn starting switch No
ON.

JS15 (female) (8)
and chassis normal?
2
JS15 (1) and chassis
normal?
1
Is voltage between JS15
(8) and terminals (2),
(3), (4), (5), (6), and (7)
as shown in Table 1?
1) 20 - 30 V.
ON.

ON.
1) Min. 1 M.
OFF.
3) Disconnect JS15.
Remedy
controller
Replace
Short circuit, short circuit

with chassis ground,
defective contact, or
Repair or
replace
harness between JS15
(female) (2), (3), (4), (5),
(6), (7) - C5 (female) (7),
(8), (9), (15), (16), (17)
Defective contact, or
harness between JS15
(female) (8) - JS14 (8) LR5 (2) - chassis
No
Repair or
replace
Short circuit, short circuit

with chassis ground,
Repair or
replace
harness between C3A
(male) (6) - JS14 (1) - LR5
(1) - chassis
No
Defective joystick lever
No
Replace
Table 1: Voltage of each direction position of joystick lever.

Terminal
When directional switch is pressed

F
JS15 (male) (8) - (2)
Between C5 (8) and chassis
20 - 30 V
Max. 1 V
Max. 1 V
JS15 (male) (8) - (3)
Max. 1 V
20 - 30 V
20 - 30 V
JS15 (male) (8) - (4)
Max. 1 V
20 - 30 V
Max. 1 V
JS15 (male) (8) - (5)
20 - 30 V
Max. 1 V
20 - 30 V
JS15 (male) (8) - (6)
Max. 1 V
Max. 1 V
20 - 30 V
JS15 (male) (8) - (7)
20 - 30 V
20 - 30 V
Max. 1 V
20-1226
WA500-3LK
TROUBLESHOOTING
12
WA500-3LK
20-1227
TROUBLESHOOTING
12

DIRECTIONAL SWITCH SYSTEM) IS DISPLAYED
Yes
6
Is resistance
between C3B
Yes (female) (6) and
chassis, and
between C3B
(female) (6) and
(13) normal?
5
C3B (5) and chassis
normal?
4
Is resistance
between C3B
chassis, and
between C3B
(female) (5) and
(6), (13) normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Directional lever:
F
1) Min. 1 M.
2) Disconnect L04,
C3B, and JSA.
3) Turn starting
switch OFF.
1) Min. 1 M.
2) Disconnect L04,
C3B, and JSA.
3) Turn starting
switch OFF.
No
No

L04 (1) and chassis
normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
No
2
Yes Is resistance
between L04
(female) (1) and
chassis normal?
1
Is resistance
between L04 (male)
(1) and (2), (3), and
(4) as shown in
Table 1?
1) Min. 1 M.
2) Disconnect FS2
and L04.
3) Turn starting
switch OFF.
1) Disconnect L04.
2) Turn starting
switch OFF.
No
No
20-1228
No
WA500-3LK
TROUBLESHOOTING
Cause
10
Yes

C3B (13) and chassis
normal?
Yes Is failure code
displayed when L57
1) 20 - 30 V.
No
8
is replaced with
relay of same type?
ON.
3) Directional lever: N
normal?
OFF.
2) Interchange with
No
1) Min. 1 M.
7
relay of same type.
2) Disconnect L04,
3)
Turn
starting
switch
C3B,
L57,
and
L05.
Is voltage between
ON.
C3B (6) and
OFF.
chassis normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
R
No
Remedy
controller
Replace
harness between L04
(female) (3) and C3B
(female) (13)
Repair or
replace
Defective neutral relay
Replace

Repair or
and C3B (female) (13),
between L04 (female) (3) - replace
JSA (1) - L05 (female) (8),
and between JSA (female)
harness between L04
(female) (6)
Repair or
replace

and C3B (female) (6), or
short circuit in wiring
harness between L04
(female) (4) - C3B
(female) (6) and wiring
harness between L04
(female) (13)
Repair or
replace
harness between L04
(female) (5)
Repair or
replace
No

short circuit wiring
harness between L04
Repair or
(female) (2) - C3B
replace
harness between L04
(female) (4) - C3B
(female) (6), and between
L04 (female) (3) and C3B
(female) (13)
or
harness between fuse I (9) Repair
replace
- FS2 (8) - L04 (female)
(1)

between FS2 (female) (8)
Repair or
replace
Defective directional and

speed switch
Replace
WA500-3LK
20-1229
TROUBLESHOOTING
12
Table 1
Terminal
Directional Position
F
L04 (male) (1) - (2)
Max. 1
Min. 1 M
Min. 1 M
L04 (male) (1) - (3)
Min. 1 M
Max. 1
Min. 1 M
L04 (male) (1) - (4)
Min. 1 M
Min. 1 M
Max. 1
20-1230
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-1231
TROUBLESHOOTING
12

RANGE SWITCH SYSTEM) IS DISPLAYED
Yes
6
Is resistance
between C3B
chassis, and
between C3B
(female) (8) and
(15) (16) normal?
5
C3B (7) and chassis
normal?
4
Is resistance
between C3B
chassis, and
between C3B
(female) (7) and
(8), (15) (16)
normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Speed lever: 1st
1) Min. 1 M.
2) Disconnect L04
and C3B.
3) Turn starting
switch OFF.
1) Min. 1 M.
2) Disconnect L04
and C3B.
3) Turn starting
switch OFF.
No
No

L04 (1) and chassis
normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
No
2
Yes Is resistance
between L04
(female) (1) and
chassis normal?
1
Is resistance
between L04 (male)
(1), (5), (6), (7), and
(8) as shown in
Table 1?
1) Min. 1 M.
2) Disconnect FS2
and L04.
3) Turn starting
switch OFF.
1) Disconnect L04.
2) Turn starting
switch OFF.
No
No
20-1232
No
WA500-3LK
TROUBLESHOOTING

Cause
10
Yes

normal?
9
7
a

normal?
C3B (female) (15)
1) 20 - 30 V.
Yes and chassis, and
between C3B
ON.
(female) (15) and
3) Speed lever: 2nd
(16) normal?
Is voltage between
C3B (8) and
chassis normal?
1) 20 - 30 V.
2) Turn starting
switch ON.
3) Speed lever: 3rd
1) Min. 1 M.
2) Disconnect L04
and C3B.
OFF.
No
No
No
1) Min. 1 M.
2) Disconnect L04
No
and C3B.
OFF.
Remedy
Go to A

and C3B (female) (16)
Repair or
replace
harness between L04
(female) (15)
Repair or
replace

Repair or
harness between L04
replace
(female) (6) - C3B
harness between L04
(female) (8) - C3B
(female) (16)
harness between L04
(female) (8)
Repair or
replace

harness between L04
Repair or
(female) (7) - C3B
replace
(female) (8), between L04
(female) (6) - C3B
L04 (female) (8) - C3B
(female) (16)
harness between L04
(female) (7)
Repair or
replace

harness between L04
Repair or
(female) (5) - C3B
(female) (7), between L04 replace
(female) (6) - C3B
(female) (15), between
(female) (16)
or
harness between fuse I (9) Repair
replace
- FS2 (8) - L04 (female)
(1)

between FS2 (female) (8)
Repair or
replace
Defective speed switch
Replace
WA500-3LK
20-1233
TROUBLESHOOTING
11
From A
1) 20 - 30 V.
ON.
3) Speed lever: 4th.
20-1234
Yes
Is voltage between C3B

(16) and chassis
normal?
No
WA500-3LK
TROUBLESHOOTING
12
Cause
Remedy
controller
Replace
harness between L04
(female) (16)
Repair or
replace
Table 1
Terminal
Directional Position
1st
2nd
3rd
4th
L04 (male) (1) - (5)
Max. 1
Min. 1 M
Min. 1 M
Min. 1 M
L04 (male) (1) - (6)
Min. 1 M
Max. 1
Min. 1 M
Min. 1 M
L04 (male) (1) - (7)
Min. 1 M
Min. 1 M
Max. 1
Min. 1 M
L04 (male) (1) - (8)
Min. 1 M
Min. 1 M
Min. 1 M
Max. 1
WA500-3LK
20-1235
TROUBLESHOOTING
T-11 FAILURE CODE [22] (DISCONNECTION
12
T-11 FAILURE CODE [22] (DISCONNECTION IN TRAVEL SPEED

SENSOR SYSTEM) IS DISPLAYED
Cause
3
Yes

chassis normal when
CN3 (female) (2) is
2
1)
2)
C5 (female) (2) and
chassis normal when
1
3)
CN3 (female) (1) is
CN3 (male) (1) and (2),
1) Max. 1 .
2) Disconnect C3, C5,
chassis normal?
No
and L07.
OFF.
500 - 1000 .
chassis: Min. 1 M.
No
3) Disconnect CN3.
OFF.
Max. 1 .
Disconnect C3, C5,
and L07.
OFF.
No
Remedy
controller
Replace
harness between C5
Repair or
replace
Repair or
harness between C5
CN3 (female) (2)
Replace
20-1236
WA500-3LK
TROUBLESHOOTING
T-11 FAILURE CODE [22] (DISCONNECTION
12
MEMORANDUM
WA500-3LK
20-1237
TROUBLESHOOTING
12

ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED
Cause
4
Yes

C4 (female) (9) and
chassis normal when
3
E04 (female) (3) is
Is
resistance
between
Yes
C4 (female) (2) and
No
1) Max. 1 .
chassis normal?
2
2) Disconnect C4,
1)
Min.
1
M
E04,
and
L07.
.
2) Disconnect C4,
C4 (female) (2) and
OFF.
E04, and L07.
chassis normal when
E04 (female) (2) is
OFF.
1
E04 (male) (2) and (3)
normal?
1) 100 - 500 .
2) Disconnect CN3.
OFF.
1) Max. 1 .
2) Disconnect C4,
E04, and L07.
OFF.
No
No
Yes

C4 (female) (2) and (9)
normal?
5
From A
1) Min. 1 M.
2) Disconnect C4, E04,
and L07.
OFF.
1) Min. 1 M.
2) Disconnect C4, E04,
and L07.
OFF.
No
20-1238
Go to A
Repair or
harness between C4
replace
(female) (9) - LR3 (8) ER2 (7) - E04 (female) (3)
between C4 (female) (2) - Repair or
LR3 (7) - ER2 (6) - E04
(female) (2), and between replace
C4 (female) (2) and L07
(female) (3)
Repair or
harness between C4
replace
(female) (2) - LR3 (7) ER2 (6) - E04 (female) (2)
No
C4 (female) (9) and
chassis normal?
Remedy
No
Defective engine speed

sensor
Replace
controller
Replace

LR3 (7) - ER2 (6) - E04
(female) (2), and between replace
C4 (female) (9) - LR3 (8) ER2 (7) - E04 (female) (3)
LR3 (8) - ER2 (7) - E04
(female) (3)
WA500-3LK
TROUBLESHOOTING
WA500-3LK
20-1239
TROUBLESHOOTING
12

EEP ROM) IS DISPLAYED
Cause
Remedy
controller
20-1240
Replace
WA500-3LK
TROUBLESHOOTING
T-14 FAILURE CODE [25] (SHORT CIRCUIT
12
T-14 FAILURE CODE [25] (SHORT CIRCUIT IN TRANSMISSION OIL

TEMPERATURE SYSTEM) IS DISPLAYED
Cause
3
Yes
2
C3A (female) (11)
and chassis normal?
1
CN11 (male) (1) and
chassis normal?
38 - 48 k (normal
temperature: 25o C
[77o F])
chassis: Min. 1 M.
OFF.
4) Disconnect CN11.
1) Min. 1 M.
OFF.
3) Disconnect C3A
and CN11.
C3A (female) (11) and
(17) normal?
1) Min. 1 M.
OFF.
3) Disconnect C3A
and CN11.
No
No
Yes
No
Remedy
controller
Replace

harness between C3A
(female) (11) - TM2 (13) - Repair or
replace
C3A (female) (17) - TM2
(14) - CN11 (female) (2)
between C3A (female)
(11) - TM2 (13) - CN11
(female) (1)
Repair or
replace
Defective transmission oil Replace

temperature sensor
WA500-3LK
20-1241
TROUBLESHOOTING
12
T-15 FAILURE CODE [26] (SHORT CIRCUIT IN F ECMV FILL

SWITCH SYSTEM) IS DISPLAYED
Cause
2
Yes

chassis normal?
1
CN17 (male) (1) and
chassis normal?
1) Min. 1 M.
2) Disconnect CN17.
OFF.
1) Min. 1 M.
2) Disconnect C3B and
CN17.
OFF.
No
No
Remedy
controller
Replace

between C3B (female) (2) replace
(1)
Defective F ECMV fill
switch
Replace
20-1242
WA500-3LK
TROUBLESHOOTING
12
T-16 FAILURE CODE [27] (SHORT CIRCUIT IN R ECMV FILL

Cause
2
Yes

chassis normal?
1
CN15 (male) (1) and
chassis normal?
1) Min. 1 M.
2) Disconnect CN15.
OFF.
1) Min. 1 M.
CN15.
OFF.
No
No
Remedy
controller
Replace

between C3B (female)
(10) - TM2 (3) - CN15
(female) (1)
Repair or
replace
Defective R ECMV fill

switch
Replace
WA500-3LK
20-1243
TROUBLESHOOTING
12
T-17 FAILURE CODE [28] (SHORT CIRCUIT IN 1ST ECMV FILL

Cause
2
Yes

chassis normal?
1
chassis normal?
1) Min. 1 M.
2) Disconnect CN5.
OFF.
1) Min. 1 M.
CN5.
OFF.
No
No
Remedy
controller
Replace

between C3B (female) (3) replace
(1)
Defective 1st ECMV fill
switch
Replace
20-1244
WA500-3LK
TROUBLESHOOTING
12
T-18 FAILURE CODE [29] (SHORT CIRCUIT IN 2ND ECMV FILL

Cause
2
Yes

chassis normal?
1
chassis normal?
1) Min. 1 M.
2) Disconnect CN7.
OFF.
1) Min. 1 M.
CN7.
OFF.
No
No
Remedy
controller
Replace

between C3B (female)
(11) - TM1 (6) - CN7
(female) (1)
Repair or
replace
Defective 2nd ECMV fill

switch
Replace
WA500-3LK
20-1245
TROUBLESHOOTING
12
T-19 FAILURE CODE [30] (SHORT CIRCUIT IN 3RD ECMV FILL

Before carrying out troubleshooting, check that all the related connectors are property inserted.
Cause
2
Yes

chassis normal?
1
chassis normal?
1) Min. 1 M.
2) Disconnect CN13.
OFF.
1) Min. 1 M.
CN13.
OFF.
No
No
Remedy
controller
Replace

(1)
Defective 3rd ECMV fill
switch
Replace
20-1246
WA500-3LK
TROUBLESHOOTING
12
T-20 FAILURE CODE [31] (SHORT CIRCUIT IN 4TH ECMV FILL

Cause
2
Yes

chassis normal?
1
chassis normal?
1) Min. 1 M.
2) Disconnect CN9.
OFF.
1) Min. 1 M.
CN9.
OFF.
No
No
Remedy
controller
Replace

(1)
Defective 4th ECMV fill
switch
Replace
WA500-3LK
20-1247
TROUBLESHOOTING
12
T-21 FAILURE CODE [32] (SHORT CIRCUIT IN F OR R ECMV FILL

Cause
Yes
Remedy
controller
Replace

switch
Replace

switch
Replace
harness between C3B
Repair or
replace
harness between C3B
Repair or
replace
Yes
2
C3B (female) (2)
and chassis normal
when CN15 (female)
(1) is grounded to
chassis?
1
chassis normal when
CN17 (female) (1) is
1) Max. 1 .
OFF.
3) Disconnect C3B.
1) Max. 1 .
OFF.
3) Disconnect C3B.
Yes Is E32 displayed

when CN15 (female)
3
(1) is grounded to
chassis?
Is E32 displayed
when CN17 (female)
(1) is grounded to
chassis?

OFF.
2) Disconnect CN17
3) Start engine
4) Transmission cutoff switch: OFF
5) Parking brake
switch: OFF
6) Depress brake.
7) Directional lever: F
No
No
No

OFF.
2) Disconnect CN15 No
3) Start engine
4) Transmission cutoff switch: OFF
5) Parking brake
switch: OFF
6) Depress brake.
7) Directional lever: R
20-1248
WA500-3LK
TROUBLESHOOTING
12
MEMORANDUM
WA500-3LK
20-1249
TROUBLESHOOTING
12
T-22 FAILURE CODE [33] (SHORT CIRCUIT IN 1ST, 2ND, 3RD, OR

4TH ECMV FILL SWITCH SYSTEM) IS DISPLAYED
Yes
6
5
when CN5 (female)
4
(1) is grounded to
chassis?
Is resistance
between C5
chassis normal
2
when CN13
(female) (1) is
grounded to
chassis?
Is resistance
between C3B
chassis normal
when CN7 (female)
(1) is grounded to
chassis?
1
Is resistance
between C3B
(female) (3) and
chassis normal
when CN5 (female)
(1) is grounded to
chassis?
1) Max. 1 .
2) Turn starting
switch OFF.
3) Disconnect CN7
and C3B.
1) Max. 1 .
2) Turn starting
switch OFF.
3) Disconnect CN5
and C3B.
20-1250
1) Max. 1 .
2) Turn starting
switch OFF.
3) Disconnect CN9
and C5.
No

when CN7
(female) (1) is
grounded to
chassis?
1) Turn starting
switch OFF.
2) Disconnect
CN7.
3) Start engine.
4) Directional
lever: N
5) Speed lever:
2nd
1) Turn starting
switch OFF.
2) Disconnect CN5.
3) Start engine.
N
5) Speed lever: 1st No
No
1) Max. 1 .
2) Turn starting
switch OFF.
3) Disconnect CN13
and C5.
No
No
Is resistance
between C5
chassis normal
when CN9 (female)
3
(1) is grounded to
chassis?
No
WA500-3LK
TROUBLESHOOTING
12
Cause
8
Yes
Remedy
controller
Replace

switch
Replace

switch
Replace

switch
Replace

switch
Replace
Repair or
harness between C5
CN9 (female) (1)
harness between C5
Repair or
replace
harness between C3B
Repair or
replace
harness between C3B
Repair or
replace
7 Yes Is E33 displayed when

CN9 (female) (1) is
Is E33 displayed
when CN13
(female) (1) is
OFF.
grounded to
2) Disconnect CN9.
chassis?
3) Start engine.
1) Turn starting
5) Speed lever: 4th
switch OFF.
2) Disconnect
CN13.
3) Start engine.
No
N
5) Speed lever: 3rd
WA500-3LK
No
20-1251
TROUBLESHOOTING
12
20-1252
WA500-3LK
TROUBLESHOOTING
T-23 HOLD SWITCH SYSTEM
12
T-23 HOLD SWITCH SYSTEM
Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
Cause
Yes
controller
1
Is resistance between C5
(female) (13) and
chassis normal?
1)
2)
Disconnect C5.
Hold switch
ON: Max. 1 .
OFF: Min. 1 M.
Yes
No L15 (male) (3) and (4)
normal?
1)
2)
Disconnect L15.
Hold switch
ON: Max. 1 .
OFF: Min. 1 M.
No
Remedy
Replace

ground, defective
contact, or disconnection Repair or
in wiring harness between replace
(female) (3)
Defective hold switch
Replace
WA500-3LK
20-1253
TROUBLESHOOTING
T-24 KICK-DOWN SWITCH SYSTEM
12
T-24 KICK-DOWN SWITCH SYSTEM
Cause
Yes
controller
1
(female) (5) and
chassis normal?
1)
2)
Disconnect C5.
Hold switch
ON: Max. 1 .
OFF: Min. 1 M.
Yes
normal?
1)
2)
Remedy
Disconnect L15.
Hold switch
ON: Max. 1 .
OFF: Min. 1 M.
No
Replace

ground, defective
(female) (1)
Defective kick-down
switch
Replace
20-1254
WA500-3LK
TROUBLESHOOTING
T-25 TRANSMISSION CUT-OFF SIGNAL
12
T-25 TRANSMISSION CUT-OFF SIGNAL SYSTEM
Cause
Yes
controller
1
(female) (6) and
chassis normal?
1)
2)
Disconnect C5.
Transmission cut-off
switch
ON: Max. 1 .
OFF: Min. 1 M.
Yes
normal?
Disconnect L12.
Transmission cut-off
switch
ON: Max. 1 .
OFF: Min. 1 M.
Replace
1) Short circuit with

chassis ground,
disconnection in
wiring harness
between C5 (female)
(6) and L12 (female)
(1)
2) Short circuit with
chassis ground,
disconnection in
wiring harness
between C5 (female)
(6) and L06 (female)
(3)
1)
2)
Remedy
No
cut-off switch
Repair or
replace
Replace
WA500-3LK
20-1255
TROUBLESHOOTING
T-26 NEUTRALIZER RELAY SIGNAL SYS-
12
T-26 NEUTRALIZER RELAY SIGNAL SYSTEM
Check that the parking brake works normally.

Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.
Cause
Yes
1
Is voltage between C3B

(14) and (9) normal?
1) Insert T-adapter.
ON.
3) Parking brake switch:
ONOFF.
4) 20 - 30 V.
Yes
2
No L58 (female) (2) and
chassis normal?
1) Disconnect L58.
2) Max. 1 .
Is voltage between
chassis normal?
1) Disconnect C3A,
C3B, and L58.
2) Short circuit L58
(female) (3) and
(5).
3) Max. 1 .
1) Disconnect L58.
ON.
3) Parking brake
switch: ONOFF. No
4) 20 - 30 V.
No
controller
Replace
Defective neutralizer relay Replace
Yes C3A (female) (6)
and C3B (female)
3
(14) normal?
Yes
Remedy
No
harness between C3A
Repair or
(female) (6) - L58
replace
(female) (5), L58 (female)
(3) - C3B (female) (14)
ground, defective contact,
or disconnection in wiring Repair or
harness between L58
replace
(female) (2)
harness between L58
Repair or
replace
20-1256
WA500-3LK
TROUBLESHOOTING
T-27 BUZZER SIGNAL SYSTEM
12
T-27 BUZZER SIGNAL SYSTEM
Check that the main monitor and alarm buzzer work normally.
Cause
3

C1 (female) (2) and
chassis normal?
C1 (female) (2) and
1)
Disconnect C1 and
chassis normal?
1
L08.
1) Disconnect C1.
2) 4k - 7k.
2) Make short circuit
between L08, and
normal?
chassis.
3) Max. 1 .
1) Disconnect C1, L08,
and RES.
3) Min. 1 M.
No
No
Yes
No
controller
Remedy
Replace
Short circuit, defective

C1 (female) (2) - L34 (5) RES (female) (1)
Repair or
harness between C1
(female) (2) L08 (female) replace
(6)
L08 (female) (6), L34
replace
(male) (5) - RES (female)
(1)
WA500-3LK
20-1257
TROUBLESHOOTING
T-28 NETWORK SYSTEM
12
T-28 NETWORK SYSTEM
Cause
2
Yes

C3B (female) (4),
1
(12) and chassis
normal?
C3B (female) (4), (12)
and chassis normal?
1) Min. 1 M.
OFF.
3) Disconnect C3B, L08,
L34, and LM1.
No
1) Max. 1 .
OFF.
3) Disconnect C3B, L08,
L34, and LM1.
4) Make short circuit
between L08 (female)
(1), (3), and chassis.
No
Remedy
controller
Replace
harness between C3B
or
(female) (4), (12), and L08 Repair
replace
(female) (1, (3), or L34
(male) (1), or LM1 (male
(5))
between C3B (female) (4), Repair or
(12), and L08 (female) (1), replace
(3), or L34 (male) (1), or
LM1 (male) (5)
20-1258
WA500-3LK
TROUBLESHOOTING
T-29 TRANSMISSION CONTROLLER POW-
12
T-29 TRANSMISSION CONTROLLER POWER SOURCE SYSTEM
Check that fuse (II) is normal.

Cause
Yes
controller
1
(7), (13), C2 (1), (12) C1 (6), (12), C2 (11),
(21) normal?
1)
2)
20 - 30 V.
ON.
Remedy
Yes
2
No C1 (female) (6), (12)
and C2 (female) (11),
(21) - chassis normal?
1) Max. 1 .
OFF.
C2.
No
Replace
Short circuit with ground,

defective contact, or disconnection in wiring
Repair or
harness between C1
(female) (7), (13) and C2 replace
(female) (1), (12) - FS5
(female) (6)
harness between C1
(female) (6), (12) and C2
(female) (11), (21) -LR5
(female) (3) - chassis
Repair or
replace
WA500-3LK
20-1259
TROUBLESHOOTING
T-30 SHORT CIRCUIT IN TRAVEL SPEED
12
T-30 SHORT CIRCUIT IN TRAVEL SPEED SENSOR SYSTEM
Cause
Yes
2
C5 (female) (2) and
(10) normal?
1
normal?
1) Min. 1 M.
OFF.
3) Disconnect C5, CN3,
and L07.
1) Min. 1 M.
OFF.
3) Disconnect C5, CN3,
and L07.
No
No
Remedy
controller
Replace

harness between C5
(female) (2) - L07
(female) (1) - TM2 (9) or
CN3 (male) (1) and wiring Repair
replace
harness between C5
(female) (10) - L07
harness between C5
(female) (2) - TM2 (9) Repair or
replace
between C5 (female) (2) L07 (female) (1)
20-1260
WA500-3LK
TROUBLESHOOTING
T-31 DISCONNECTION IN TRANSMISSION
12
T-31 DISCONNECTION IN TRANSMISSION OIL TEMPERATURE

SENSOR SYSTEM
Cause
4
Yes
3
CN11 (male) (1) - (2)
and between (1), (2)
chassis normal?
C3A (female) (17)
and chassis normal?
C3A (female) (17)
1)
2)
when CN11 (female)
2
(2) is grounded to
3)
chassis?
Yes C3A (female) (17)
1) Max. 1 .
and chassis normal
when CN11 (female)
No
OFF.
1
(1) is grounded to
3) Disconnect C3A.
chassis?

3.8 - 4.8 (normal
temperature: 25o C
[77o F])
3.6 - 3.9 (100o C
[212o F]
chassis: Min. 1 M.
OFF.
4) Disconnect CN11.
1) Max. 1 .
OFF.
3) Disconnect C3A.
No
No
Yes
No
Min. 1 M.
OFF.
Disconnect C3A
and CN11.
Remedy
controller
Replace

between C3A (female)
(17) - TM2 (14) - CN11
(female) (2)
Repair or
replace
Repair or
harness between C3A
CN11 (female) (2)
Repair or
harness between C3A
CN11 (female) (1)
Defective transmission oil Replace
temperature sensor
WA500-3LK
20-1261
TROUBLESHOOTING
T-32 DISCONNECTION IN F ECMV FILL
12
T-32 DISCONNECTION IN F ECMV FILL SWITCH SYSTEM
Cause
2
Is voltage between
CN17 (1) and chassis
normal?
Yes

chassis normal when
1
1) 20 - 30 V.
OFF.
3) Disconnect CN17.
4) Start engine.
5) Transmission cut-off
switch: OFF (lamp
out).
OFF
7) Depress brake.
1) Max. 1 .
2) Disconnect C3B.
OFF.
No
No
Remedy
controller
Replace
harness between C3B
Repair or
replace

switch
Replace
20-1262
WA500-3LK
TROUBLESHOOTING
T-33 DISCONNECTION IN R ECMV FILL
12
T-33 DISCONNECTION IN R ECMV FILL SWITCH SYSTEM
Cause
2
Is voltage between
normal?
Yes

chassis normal when
1
1) 20 - 30 V.
OFF.
3) Disconnect CN15.
4) Start engine.
5) Transmission cut-off
switch: OFF (lamp
out).
OFF
7) Depress brake.
1) Max. 1 .
2) Disconnect C3B.
OFF.
No
No
Remedy
controller
Replace
harness between C3B
Repair or
replace

switch
Replace
WA500-3LK
20-1263
TROUBLESHOOTING
T-34 DISCONNECTION IN 1ST ECMV FILL
12
T-34 DISCONNECTION IN 1ST ECMV FILL SWITCH SYSTEM
Cause
2

chassis normal when
1
CN5 (female) (1) is
Is voltage between CN5
1) Max. 1 .
2) Disconnect C3B.
1) 20 - 30 V.
OFF.
OFF.
3) Disconnect CN5.
4) Start engine.
No
6) Manual switch: ON
7) Speed lever: 1st.
Yes
No
Remedy
controller
Replace
harness between C3B
Repair or
replace

switch
Replace
20-1264
WA500-3LK
TROUBLESHOOTING
T-35 DISCONNECTION IN 2ND ECMV FILL
12
T-35 DISCONNECTION IN 2ND ECMV FILL SWITCH SYSTEM
Cause
2

chassis normal when
1
CN7 (female) (1) is
1) Max. 1 .
2) Disconnect C3B.
1) 20 - 30 V.
OFF.
OFF.
3) Disconnect CN7.
4) Start engine.
No
7) Speed lever: 2nd.
Yes
No
Remedy
controller
Replace
harness between C3B
Repair or
replace

switch
Replace
WA500-3LK
20-1265
TROUBLESHOOTING
T-36 DISCONNECTION IN 3RD ECMV FILL
12
T-36 DISCONNECTION IN 3RD ECMV FILL SWITCH SYSTEM
Cause
2
Is voltage between
normal?
Yes

chassis normal when
1
1) 20 - 30 V.
OFF.
3) Disconnect CN13.
4) Start engine.
7) Speed lever: 3rd.
1) Max. 1 .
2) Disconnect C5.
OFF.
No
No
Remedy
controller
Replace
harness between C5
Repair or
replace

switch
Replace
20-1266
WA500-3LK
TROUBLESHOOTING
T-37 DISCONNECTION IN 4TH ECMV FILL
12
T-37 DISCONNECTION IN 4TH ECMV FILL SWITCH SYSTEM
Cause
2

chassis normal when
1
CN9 (female) (1) is
1) Max. 1 .
2) Disconnect C5.
1) 20 - 30 V.
OFF.
OFF.
3) Start engine.
4) Disconnect CN9.
No
7) Speed lever: 4th.
Yes
No
Remedy
controller
Replace
Repair or
harness between C5
CN9 (female) (1)
switch
Replace
WA500-3LK
20-1267
TROUBLESHOOTING
T-37 DISCONNECTION IN 4TH ECMV FILL
12
MEMORANDUM
20-1268
WA500-3LK
TROUBLESHOOTING AIR CONDITIONING

(DENSO)
AIR CONDITIONER / HEATER (DENSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1302
VISUAL AND AUDIBLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1302
TROUBLESHOOTING WITH MANIFOLD GAUGE (REFRIGERATION CYCLE) . . . . . . . . . . . . . . 20-1303
NORMAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1303
INSUFFICIENT REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1303
REFRIGERANT FAILS TO CIRCULATE (SYSTEM CLOGGED) . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
MOISTURE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
COMPRESSOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1304
EXCESSIVE REFRIGERANT OR INSUFFICIENT CONDENSER COOLING . . . . . . . . . . . . . . . 20-1305
AIR IN THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1305
EXPANSION VALVE OPENS TOO FAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1305
TROUBLESHOOTING THE ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1306
BLOWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1306
ELECTRICAL CIRCUIT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1308
COOLER CIRCUIT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
AIR CONDITIONER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
MAGNETIC CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1310
CONDENSER FAN OPERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1311
ERROR MESSAGE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1314
A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER . . . . . . . . . . . . . . . . . . . 20-1314
B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER . . . . . . . . . . . . . . . . . . . 20-1314
C. FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS . . . . . . . . . . . . . . . 20-1315
D. PROBLEM - NO HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1315
E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF, WHEN THE
POWER IS TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1315
F. PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS DEFROST
BUTTON IS PUSHED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1316
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1318
WIRE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1319
INSPECTION AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1320
WA500-3LK
20-1301
TROUBLESHOOTING
AIR CONDITIONER / HEATER (DENSO)
12

VISUAL AND AUDIBLE INSPECTION
Is the drive belt loose?

Are condenser fins blocked, clogged, or covered with dirt or dust? (Condenser and air conditioner efficiency both will
suffer).
Is the air filter clogged? (Clogged air filter will reduce air flow and lower the cooling capacity).
Are oil stains present in the refrigeration cycle connections and joints? (Stains are evidence of compressor oil, usually
accompanied by refrigerant).
Does the system contain the correct refrigerant quantity as seen in the sight glass? (Only a small quantity of bubbles
appear).
Is the system louder than usual? (Abnormal noise).
20-1302
Component
Check these items
Compressor
Shaft, cylinder head
Magnetic clutch
Worn or damaged bearing.

Contact between stator and rotor.
Loose mounting screw on stator.
Blower motor
Upside down blower motor

Loose blower mounting
V-belt
Improper tension
Idle pulley
Worn mounting
Worn or damaged bearing
Piping parts
Improper fastening or mounting of

bracket or clamp
Incorrect clearance.
WA500-3LK
TROUBLESHOOTING
12
TROUBLESHOOTING
WITH MANIFOLD GAUGE (REFRIGERATION CYCLE)
Trouble often can be detected and diagnosed for repair with the help of a manifold gauge. The manifold gauge unit
indicates the refrigeration system pressure on both sides (high and low pressure sides) simultaneously on the two dials.
Remark
Be sure air has been purged from the charging hoses of the manifold gauge by using the refrigerant pressure in the
system.
NORMAL CONDITIONS
After engine warm-up, check the following conditions
Engine speed
1500 rpm
A/C inlet temperature
30-35oC (85-95oF)
Blower speed
HI
Temperature control
Maximum cooling
Remark
Gauge indications before A/C operation, both high and low
pressure sides: 5-8 kg/cm (71-114 psi).
INSUFFICIENT REFRIGERANT
Problem
Cause
Pressure low on both

low pressure side
and the high
pressure side.
Quantity of
refrigerant is too
small.
Bubbles visible in
sight glass.
Gas leakage
Air output is not

cool.
20-1303
Check and
remedy
Check for gas leak
and repair.
Replenish
refrigerant.
If pressure near 0,
evacuate air after
repairing leak.
WA500-3LK
TROUBLESHOOTING
12
REFRIGERANT
FAILS TO CIRCULATE (SYSTEM
CLOGGED)
Problem
Vacuum is
immediately
indicated on low
pressure side
(completely
clogged).
Cause
Clogging of A/C
system.
Check and
remedy
-Check condition of
receiver, expansion
valves, etc.
-A temperature
difference occurs
between IN and
OUT of the
defective parts.
Vacuum gradually
indicated on low
pressure side
(partially clogged).
-Evacuate air after

repair.
MOISTURE IN SYSTEM
Problem
Normal operation at
first; vacuum on low
pressure side is
indicated after time.
Cause
Moisture in
expansion valve
freezes.
Check and
remedy
-Check condition of
expansion valve, etc.
-Replace receiver (or
dryer)
-Evacuate air after
repair.
COMPRESSOR FAILURE
Problem
Pressure on low
pressure side is high;
pressure on high
pressure side is low.
When the A/C is
turned off, the low
and high pressure
sides quickly
equalize.
20-1304
Cause
Compressor defect.
Check and
remedy
-Check compressor
condition.
-Compressor unit is
cool to the touch if
there is a
compression
malfunction.
WA500-3LK
TROUBLESHOOTING
12
EXCESSIVE
REFRIGERANT OR INSUFFICIENT
CONDENSER COOLING
Problem
Check and
remedy
Cause
Pressure high on
both sides.
Excessive
refrigerant.
Bubbles not visible

in the sight glass.
Poor condenser
cooling.
-Check refrigerant
quantity and slowly
vent excess if
overcharged.
-Check and repair
condenser fan.
Poor cooling
performance.
-Check engine
cooling system.
AIR IN THE SYSTEM

Problem
Pressure is high on
both sides.
Check and
remedy
Cause
Air has entered into
the system.
-Replace refrigerant.
-Evacuate the air
after repairs.
Low pressure is hot

to the touch.
Bubbles are visible
in the sight glass.
EXPANSION VALVE OPENS TOO FAR

Problem
Pressure is high on
both sides.
Frost
(condensation)
appears on low
pressure side piping.
20-1305
Cause
Expansion valve
fault (problem
frequently occurs
after replacing
expansion valves).
Check and
remedy
-Check condition of
expansion valves.
-Check temperature
sensing bulb
condition and
installation.
WA500-3LK
TROUBLESHOOTING
TROUBLESHOOTING THE ELECTRICAL
12
TROUBLESHOOTING THE ELECTRICAL CIRCUIT

The flow charts on the following pages break down air conditioning problems into two categories: blower-related problems
and cooling equipment related problems. Check for blower troubles first, including such items as gauge fuse, circuit breaker,
heater relay, blower motor, blower resistor, and blower switch. Then check other air conditioning electrical components like
air conditioner fuse and switch, magnetic clutch and relay, sensors and wiring (input to amplifier) and amplifier. Cooler circuit
troubleshooting steps are shown on the next flow chart.
BLOWER TROUBLESHOOTING
Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart.
Descriptions of the inspection methods can be found on the pages that follow the flow chart.
20-1306
WA500-3LK
TROUBLESHOOTING
12
20-1307
WA500-3LK
TROUBLESHOOTING
12
ELECTRICAL
CIRCUIT CHECKS
HEATER RELAY
Steps 4 and 5
Turn on the ignition switch and check input voltage at terminal 5 and 3.
If no voltage (0V), there should be open circuit between heater relay and
gauge fuse, or between heater relay and the battery. Inspect the
continuity with a circuit tester or ohmmeter. Repair or replace as
necessary.
Standard:
terminal No. 1-3 continuity

terminal No. 2-4 continuity
terminal No. 4-5 no continuity
Applying the battery voltage between terminal Nos. 1 and 3, check

continuity between terminal 4 and 5 (point is closed).
BLOWER SWITCH
Step 6
If the blower doesnt operate correctly, remove the blower switch
connector and check the continuity between the terminals with each
switch position. If all conditions are good reconnect the blower switch.
Check continuity between the heater relay terminals and the blower
switch terminals as follows.
1.
Check continuity between the heater relay terminal 1 and blower

switch terminal 12, and between blower switch terminal 9 and
vehicle ground.
2.
Check the resistance between the heater relay terminal 4 and

blower switch terminal 9 with each blower switch position.
When changing blower switch position from OFF to HI, the resistance
value should change from a high value to a low value.
20-1308
WA500-3LK
TROUBLESHOOTING
12
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit
have been ruled out. Details about these procedures appear on the pages that follow.
20-1309
WA500-3LK
TROUBLESHOOTING
12
COOLER
CIRCUIT TROUBLESHOOTING
AIR CONDITIONER SWITCH

Step 1 and 2
Turn on blower switch and air conditioner switch, check voltage of the
amplifier at terminal 10. If 12 volts is not present (battery voltage),
wiring between the air conditioner fuse and amplifier input terminals is
faulty (open circuit), or the A/C switch is defective.
MAGNETIC CLUTCH RELAY

Step 4 and 4-1
Check that continuity exists between terminal no. 1 and 3 but not
between terminals 2 and 4. Apply battery voltage between terminal 1
and 3, check continuity between terminals 2 and 4 (the point is closed).
20-1310
WA500-3LK
TROUBLESHOOTING
12
CONDENSER
FAN OPERATION CIRCUIT
Step 2-2
Turn on the blower switch and A/C switch. Then inspect the condenser
fan operation.
Conditions
A/C
switch
Magnetic
Clutch
Coolant
Temperature
Refrigerant
pressure
Below 83o C
ON or
OFF
OFF
Above 90o C
ON
Below 12.5 kg/cm2

(178 psi)
Below 83o C
(181o F)
Above 15.5 kg/cm2

(221 psi)
Above 90o C
Below 12.5 kg/cm2

(178 psi)
ON
(194o F)
HI
LO
(181o F)
Below 83o C
ON
Stop
(181o F)
(194o F)
ON
Fan
speed
H!
Above 15.5 kg/cm2

(221 psi)
Under low coolant temperature and low thermal load (low room and
ambient temperature) conditions, fan rotates at low speed with the
magnetic clutch on, while as the coolant temperature increases, fan
starts high speed rotation.
In case of high thermal load, the fan rotates at high speed also.
Check four relays used in the condenser fan operation.
a. Engine main relay (identical to the heater relay).
b. Condenser fan relay (3), identical to magnetic clutch relay.
c. Condenser fan relay (2) differs slightly from the heater relay in the
terminal layout. Check continuity as follows: continuity between
terminals 5 and 2, 1 and 3. No continuity between terminals 1 and
4.
Applying battery voltage between terminals 5 and 2, check the
continuity between terminals 1 and 4 (point is closed). Note that the
diode permits current flow between terminal 5 and terminal 2 in only
one direction.
20-1311
WA500-3LK
TROUBLESHOOTING
12
If the thermistor signal is wrong, check resistance of the thermistor. Its
resistance characteristics are shown in the illustration.
Idle speed check

When the air conditioner switch is turned ON, idle speed should
increase. Make sure the speed changes.
20-1312
WA500-3LK
TROUBLESHOOTING
12
20-1313
WA500-3LK
TROUBLESHOOTING
ERROR MESSAGE TABLES
12
Setup: Controller set on Temp. 60o F (16o C), defrost off, and fan on high.
A. PROBLEM - EO ERROR MESSAGE DISPLAY ON THE CONTROLLER

Possible Cause
Inspection
1. Open electric condenser power

circuit.
Check electric condenser circuit

breaker for power, voltage, and
continuity.
2. Defective electric condenser relay

(circuit).
Check for output voltage on the yellow

wire, at the relay coil. Check the
voltage and continuity across the relay
contacts.
3. Open electric condenser voltage

detection circuit.
Remedy
a.
b.
Repair wiring.
Replace open circuit breaker.
a.
b.
Repair the connections / wiring.

Replace the defective relay.
Check for input voltage on the brown

wire, at the controller.
a.
Repair the wiring or connector.
4. Improper wiring installation.
Applicable to systems without an EC.
a.
See note #3.
5. Defective controller.
Check for output voltage on the yellow

a.
Replace the controller.
B. PROBLEM - E1 ERROR MESSAGE DISPLAY ON THE CONTROLLER

Possible Cause
Inspection
Remedy
Check the refrigerant pressures with

gauges.
High side greater than:
320 psig (R12), or 350 psig
(R134a).
Low side less than:
3 - 6 psig.*
a.
Check for output voltage on the green

wire at the compressor. Check the wire
connections. Check for continuity
across the pressure switch(es) and
thermostat. Check continuity of clutch
solenoid to the ground.
a.
b.
3. Opened pressure switch detection

circuit.
Check for an input voltage on the tan

a.
Repair the connections/ wiring.
Check for output voltage on the green

1. Abnormal A/C refrigerant

pressure(s).
* Cool weather operation may cause
low pressure short cycling.
2. Opened compressor clutch circuit.
20-1314
b.
c.
c.
Check the condenser operation for

air and refrigerant blockage.
Leak check system, repair the
leaks and recharge the system.
Relocate the low pressure switch
to the evaporator outlet.
Repair the connections/wiring.
Replace the defective switch(es)
or the thermostat.
Replace the defective compressor
clutch.
WA500-3LK
TROUBLESHOOTING
12
C.
FALSE E1 ERROR MESSAGE / COLD WEATHER CHARGING PROBLEMS
Occurs particularly when vapor charging in cold weather.
1.
E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction side
pressure must rise above 45 psig to reset the E1 error message.
2.
When the system is fully charged, the E1 error message should not appear under normal operating conditions.
3.
In order to continue charging, by-pass the LPS, turn the controller off then on, and set the controller to 60o F (16o C).
This will reset the controller and force into the air conditioning mode.
4.
If the LPS cant be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the
compressor clutch solenoid. Take care not to short out the controller clutch circuit.
5.
E1 error message may occur while charging, when the compressor is wired hot.
D. PROBLEM - NO HEAT
Possible Cause
Inspection
Remedy
1. Opened heat solenoid circuit. Poor

connection, loss of voltage.
Check for an output voltage on the

white wire, at the heat solenoid valve.
Check solenoid continuity to the
ground.
a.
Repair connections/wiring.
2. Defective heat solenoid or improper

installation.
Check for coolant blockages in the

heat solenoid valve and hoses. Check
the direction of coolant flow (feel the
hoses).
a.
b.
Repair or replace the valve.

Reverse the coolant hoses to the
valve.
Check for output voltage on the white

a.
E. PROBLEM - NO DISPLAY, THE BLOWER FAN WILL NOT TURN OFF,

WHEN THE POWER IS TURNED ON
Possible Cause
1. Fan wires shorted to ground or
vehicle chassis.
20-1315
Inspection
Disconnect controller from the
external harness, Individually check
continuity of the orange and black fan
wires to ground, in the external
harness.
Remedy
a.
Disconnect the ground and repair

the shorted wiring.
WA500-3LK
TROUBLESHOOTING
12
F.
PROBLEM - COMPRESSOR CLUTCH WILL NOT ENGAGE, UNLESS

DEFROST BUTTON IS PUSHED.
Possible Cause
Inspection
Remedy
a.
b
1. Defective preset thermostat inside

evaporator. Opened preset
thermostat circuit. Broken
thermostat wiring. Evaporator coil
temperature too cold for A/C
operation.
Push, hold defrost / temperature

decrease buttons simultaneously.
Check display for OP or CL
readout. Disconnect red leads, and
check for continuity across thermostat
terminals.
2. Ambient cab temperature too cool

{below 60o F (16o C)}.
Set controller at 68-70o F (20-21o C),

in A/C mode. Warm-up ambient
temperature probe with fingers or heat
gun.
a.
3.
Push, hold temp. Decrease/increase

buttons simultaneously. Display will
read 40o F (4o C) if probe is defective.
Disconnect the controller, check for
continuity across black probe leads.
Check resistance of thermistor.
a.
Opened ambient cab temperature

probe (thermistor).
20-1316
c.
b.
b.
c.
If CL, go to step 2.
If OP, repair connections or
wiring to preset thermostat.
Replace preset thermostat.
Verify if compressor clutch will

pull in or not.
If not go to step 3.
If display reads 49o F (9o C), at
room temperature, replace
thermistor.
Repair connections/wiring.
If 10k 20%, thermistor is
good. If 100k-1M , replace
thermistor.
WA500-3LK
TROUBLESHOOTING
12
Notes:
1.
Wire colors may vary with installation. Refer to the wiring schematic.
2.
For 24V controllers, resistor (R17) must be clipped and removed from the circuit board, refer to illustration. If resistor
is not clipped on 24V system, the controller display will light up, but the blower fan will not turn on.
3.
For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together,
on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.
4.
Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in
damage to the controller.
5.
Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short
cycling of the compressor.
6.
Eagle climate controllers are designed to use normally closed heat solenoid valves.
7.
Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more.
The current drain from the controllers memory may result in a dead vehicle battery. An optional ignition relay may be
installed to disable the controllers memory function, when the key switch is turned off.
20-1317
WA500-3LK
TROUBLESHOOTING
WIRING DIAGRAM
12
WIRING DIAGRAM
20-1318
WA500-3LK
TROUBLESHOOTING
WIRING DIAGRAM
12
NOTES:
1.
Position the ambient temperature probe near waist high level, out of air flow and sun load.
2.
Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st
and 2nd rows, to a depth of the coil height minus 1 inch.
WIRE CHART
Socket
Size
Color
10GA
Red
Battery positive in
18GA
Red
1/2 evaporator coil thermostat in
18GA
Black
18GA
Red
1/2 evaporator coil thermostat in
N/A
N/A
Not used
18GA
Black
14GA
Orange
Fan positive out
16GA
Dk.
Green
Clutch out
18GA
Dk.
Blue
Ignition switch in
10
14GA
Black
Fan negative out
11
18GA
Brown
Condenser blown fuse in
12
16GA
White
Heat solenoid out
13
18GA
Tan
Pressure switch detect in
14
16GA
Yellow
Condenser fan relay out
15
12GA
Black
Battery negative in
16
N/A
N/A
20-1319
Wire function
Connector Detail
1/2 ambient thermistor in
1/2 ambient thermistor in
Not used
WA500-3LK
TROUBLESHOOTING
12
INSPECTION
WIRING DIAGRAM
AREAS
Body ground
Fuse blows easily.
No blower operation.
Heater relay, blower motor, blower

resistor, blower switch.
Blower speed does not change.
Blower resistor, blower switch.
No compressor operation.
Magnetic clutch and relay,

compressor, heater relay, A/C
switch, A/C amplifier.
A/C lamp does not light.
A/C lamp flashes (only for

compressor with lock sensor).
No A/C operation (cooled air

does not come out).
Cab temperature does not

decrease (insufficient cooling).
Warm air does not come out.
10
No condenser fan operation.
11
No engine idle speed increase

when A/C switch is turned on.
Problem
20-1320
Servomotors
Wire harness
No.
Fuse
Connectors
Sensor circuit
Main inspection areas
Engine speed signal lines, A/C

amplifier, A/C switch.
X
Compressor, drive belt, A/C

amplifier, magnetic clutch.
Water temperature switch (for

variable compressor type) A/C
amplifier.
Engine coolant volume, A/C
temperature control, heater radiator.
Other inspection items
Relays (for condenser fan, radiator

fan), condenser fan motor, condenser
fuse.
Idle-up actuator, vacuum hose line,
air conditioner amplifier.
WA500-3LK
30
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ALTERNATOR (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
CYLINDER HEAD (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE FRONT SEAL (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE OIL COOLER (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE REAR SEAL (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . 30-16
FUEL INJECTION PUMP (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . 30-16
NOZZLE HOLDER (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
STARTING MOTOR (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
THERMOSTAT (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
TURBOCHARGER (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
WATER PUMP (REFER TO THE ENGINE SHOP MANUAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
WA500-3LK
30-1b

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
TRANSMISSION CONTROL VALVE (ECMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
REMOVAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
INSTALLATION (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
REMOVAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
INSTALLATION (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-126
DISASSEMBLY DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
FINE DISASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-130
FINE ASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 30-131
FINE ASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
ASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
DISSASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
FINE DISASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-141
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-142
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
FINE ASSEMBLY OF PINION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-145
ASSEMBLY OF DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
DISASSEMBLY OF FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-153
ASSEMBLY OF FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
STEERING ORBITAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
ENSURE A CLEAN WORKING ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-174
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-174
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-185
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
30-21
WA500-3LK

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
BRAKE ASSEMBLY (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-193
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-199
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-223
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-235
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-245
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-250
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-252
FLOOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-253
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-253
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-255
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
WA500-3LK
30-31

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-259
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-260
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-260
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-261
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-262
RECEIVER TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-263
COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-264
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-264
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265
MAIN MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-266
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-266
INSTALLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-267
30-41
WA500-3LK
METHOD OF USING MANUAL
METHOD OF USING MANUAL

1.
When removing or installing unit assemblies

A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal
operation; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked
, and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example
Explanation
(COMPONENT) REMOVAL
Title of operation
WARNING!
Safety precautions to observe when performing an operation
1. XXX
Text of or name of procedural step
A.
Text of procedural step if 1 was procedural name
Technique or important point

Reference to a special technique during assembly or installation (note that
this symbol is right-aligned).
(COMPONENT) INSTALLATION
Title of operation
Overall directive
Installation is the reverse of removal.
Special technique during assembly or installation (note that this symbol is

left-aligned).
(Component/assembly)
Specification
2.
General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.
3.
Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure,
see the SPECIAL TOOL LIST later in this section.
WA500-3LK
30-51
PRECAUTIONS DURING OPERATION

12
Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK
If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1.
Hoses and tubes using sleeve nuts
Nominal
number
Plug (nut end)
02
07376-50210
07221-20210 (Nut), 07222-00210 (Plug)
03
07376-50315
07221-20315 (Nut), 07222-00312 (Plug)
04
07376-50422
07221-20422 (Nut), 07222-00414 (Plug)
05
07376-50522
07221-20522 (Nut), 07222-00515 (Plug)
06
07376-50628
07221-20628 (Nut), 07222-00616 (Plug)
10
07376-51034
07221-21034 (Nut), 07222-01018 (Plug)
12
07376-51234
07221-21234 (Nut), 07222-01219 (Plug)
2.
Sleeve nut (elbow end) Use the two items below

as a set
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
30-61
WA500-3LK

3.
If the part is not under hydraulic pressure, the following corks can be
used:
Nominal
number
Part Number
06
Dimensions
D
07049-00608
L
8
08
07049-00811
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press-fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
WA500-3LK
30-71

12
PRECAUTIONS
WHEN COMPLETING THE OPERATIONS
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS
To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
Do not use seal tape for the thread of the plug mounts or connections.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air comes out from
the plugs.
D. After completing bleeding the air, tighten the plugs.
Plug: 11.3 1.5 Nm (8.33 1.10 lbf ft)
E. After repair or long storage, follow the same procedure.
30-81
WA500-3LK
SPECIAL TOOL LIST
12
SPECIAL
TOOL LIST
Remark
Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
Remark
:. . . . . . . . . . . . Cannot be substituted, should always be installed (used)
: . . . . . . . . . . .Extremely useful if available, can be substituted with commercially
available part
Necessity:
Remark
New/remodel:
N: . . . . . . . . .Tools with new part numbers, newly developed for this model
R: . . . . . . . .Tools with upgraded part numbers, remodeled from items already
available for other models
Blank: . . . . Tools already available for other models, used without any
modification
Remark
Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
Component
Symbol
Installation of
engine cylinder
head
A
3
Assembly of
damper
Disassembly,
assembly of PTO
WA500-3LK
Qty
New
Remodeled
Sketch
795-521-1110
Push tool
790-101-5221
Grip
01010-51225
Bolt
01050-31640
Bolt
795-931-1210
Sleeve jig
795-931-1220
Sleeve jig
01050-31625
Bolt
01050-31645
Bolt
793T-615-1230
Push tool
793T-615-1240
Spacer
790-101-5421
Grip
01010-51240
Bolt
790-102-1871
Wrench
790-201-2730
Spacer
791-520-4140
Screw
02215-11622
Nut
01643-32780
Washer
790-101-2102
Puller (294.2
kN {30 ton})
790-101-1102
Pump
790-501-5200
Repair stand
790-901-2110
Bracket
790-310-2160
Plate
Nature of work, remarks

Tightening of head
assembly
6
Disassembly,
assembly of
torque converter
assembly
Necessity
Wrench
2
B
Part Name
790-331-1110
2
Installation of
engine front seal,
rear seal
Part Number
Press fitting of front seal
Press fitting of front sea
Press fitting of oil seal and

dust seal
Removal, installation of
round nut
Press fitting of PTO gear

bearing inner race
30-91

Component
Symbol
Part Number
799-301-1500
Oil leak tester
796-514-2000
Remover
796-515-2140
Adapter
790-201-1702
Push tool kit
790-201-1741
Push tool
790-101-5021
Grip
01010-50816
Bolt
790-452-1200
Pilot ring tool
Centering of body and

upper cover
790-452-1100
Installer set
Press fitting of spacer
790-520-2510
Bracket
790-520-2610
Plaste
differential assembly
790-501-5000
Repair stand
100V
790-501-5200
Repair stand
220V, 240V
790-901-2110
Bracket
793-310-2160
Plate
793T-622-1120
Push tool
793T-622-1130
Spacer
790-101-5421
Grip
01010-51240
Bolt
792-525-1000
Micrometer
792-525-1230
Adapter
1
2
793T-622-1110
Plate
790-101-5421
Grip
01010-51240
Bolt
793T-622-1150
Fixture
793-520-1805
Brake tester
793-520-1851
Bolt
793-520-2680
791-580-1600
791-580-1610
Plate
791-580-1620
Arm
791-580-1640
Plate
791-580-1650
Plate
01010-51425
Bolt
01541-21670
Nut
01640-21426
Washer
Disassembly,
assembly of final
drive assembly
30-101
Checking actuation of
clutch piston
Removal of No.3 planet
gear shaft
Removal fitting of No.3,

No.4 carrier bushing
Disassembly,
assembly of
differential
assembly
Qty
Removal,
installation of
differential
assembly
Disassembly,
assembly of
brake assembly
Sketch
Necessity
Disassembly,
assembly of
orbital steering
valve
New
Remodeled
Part Name
1
Disassembly,
assembly of
transmission
assembly
SPECIAL TOOL LIST
Adjusting preload of
bearing
N
Installer
Push tool
10 792-530-1630
Stud
Press fitting of dust seal

and oil seal of coupling
cage
Press fitting of oil seal of

outer drum
wheel hub
Checking leakage of brake
oil
4
1
Installation of floating seal

(gear end)
793-520-2680
Installer
791-580-1600
Push tool
793-622-1210
Arm
793-622-1220
Plate
791-580-1640
Plate
792-530-1630
Stud
01010-21425
Bolt
01640-21426
Washer
01580-01613
Nut
Installation of floating seal

(hub end)
WA500-3LK

Component
Symbol
New
Remodeled
Sketch
Bar
793-520-2640
Push tool
793-520-2530
Guide
790-101-2300
Push puller
790-101-2310
Block
02215-11622
Nut
790-101-2102
Puller (294.2
kN {30 ton})
790-101-1102
Pump
793-520-2550
Guide
01010-31480
Bolt
01643-31445
Washer
793-520-2640
Push tool
790-101-2102
Puller (294.2
kN {30 ton})
790-101-1102
Pump
790-502-1003
or
790-502-2000
Repair stand
790-101-1102
Pump
790-330-1100
Wrench
assembly
cylinder head
790-302-1290
Socket (width
across flats
60 mm)
Removal, installation of nut
1
X
2
3
WA500-3LK
Qty
793-520-2630
Disassembly,
assembly of
accumulator
Necessity
Disassembly,
assembly of
hydraulic cylinder assemblies
Part Name
Removal,
installation of
center hinge pins
Part Number
SPECIAL TOOL LIST
Press fitting bearing of top

center hinge portion
Press fitting bearing of

bottom center hinge portion
790-201-1500
Push tool kit
Press fitting of dust seal
790-201-1580
Plate
Steering cylinder
790-201-1670
Plate
Boom cylinder
790-201-1680
Plate
Bucket cylinder
790-101-5021
Grip
01010-50816
Bolt
790-201-1702
Push tool kit
790-201-1771
Push tool
Steering cylinder
790-201-1861
Push tool
Boom cylinder
790-201-1871
Push tool
Bucket cylinder
790-101-5021
Grip
01010-50816
Bolt
790-720-1000
Expander
796-720-1660
Ring
07281-01159
Clamp
796-720-1690
Ring
07281-02169
Clamp
796-720-1720
Ring
07281-02429
Clamp
790-102-2303
Wrench
assembly
790-102-2303
Wrench
assembly
790-102-4310
Pin
790-720-1000
Expander
796-720-1660
Ring
07281-01159
Clamp
792-610-1700
Charging tool
All cylinders
Press fitting of roll bushing
All cylinders
Expansion of piston ring
Steering cylinder
Boom cylinder
Bucket cylinder
round head
Expansion of piston ring
Charging with N2 gas
30-111

Component
Charging air
conditioning with
R134a freon gas
Symbol
Part Number
1
799-703-1200
799-703-1100
799-703-1110
799-703-1120
30-121
799-703-1400
SPECIAL TOOL LIST

Part Name
Service tool
kit
Vacuum
pump
Gas leak
tester
New
Remodeled
Sketch
Necessity
Qty
110V
220V
240V
WA500-3LK
12
SKETCHES
OF SPECIAL TOOLS
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3-2 SPACER
H6 FIXTURE
WA500-3LK
30-131
12
H5-1 PLATE
H3-1 PUSH TOOL
30-141
WA500-3LK
12
B1-2 SPACER
B1-1 PUSH TOOL
WA500-3LK
30-151
ENGINE
ENGINE
COMPONENTS
ALTERNATOR (REFER TO THE ENGINE SHOP MANUAL)
CYLINDER HEAD (REFER TO THE ENGINE SHOP MANUAL)
ENGINE FRONT SEAL (REFER TO THE ENGINE SHOP MANUAL)
ENGINE OIL COOLER (REFER TO THE ENGINE SHOP MANUAL)
ENGINE REAR SEAL (REFER TO THE ENGINE SHOP MANUAL)
FUEL INJECTION PUMP (REFER TO THE ENGINE SHOP MANUAL)
NOZZLE HOLDER (REFER TO THE ENGINE SHOP MANUAL)
STARTING MOTOR (REFER TO THE ENGINE SHOP MANUAL)
THERMOSTAT (REFER TO THE ENGINE SHOP MANUAL)
TURBOCHARGER (REFER TO THE ENGINE SHOP MANUAL)
WATER PUMP (REFER TO THE ENGINE SHOP MANUAL)
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar to the front and rear frames.
Lower the bucket to the ground and stop the engine. Apply the parking brake and put
blocks under the wheels to prevent the machine from moving.
WARNING! Pressure in the hydraulic system must be released. Loosen oil filler cap slowly to release
pressure inside the hydraulic tank. Operate steering wheel and control levers several
times to release remaining pressure in the hydraulic piping.
WARNING! Disconnect cable from the negative (-) terminal of the battery
1.
Remove engine hood assembly. For details, refer to "ENGINE

HOOD REMOVAL".
2.
Remove radiator assembly. For details, refer to "RADIATOR

REMOVAL".
3.
Remove bulkhead. For details, refer to "BULKHEAD

REMOVAL".
4.
Bleed air from the hydraulic system.

Remove cover (1), loosen plug (2) on top of hydraulic tank
filler, and bleed air from the tank.
30-161
WA500-3LK

5.
ENGINE
Remove muffler.
A. Remove two fasteners (3) attaching the muffler drain tube
on the right side of engine, then remove the drain tube (4).
Fasteners (3): 14mm across flats.
B. Sling muffler (5), remove two mounting clamps (6), then lift
muffler off the machine.
Muffler clamp nuts: 17mm across flats
Muffler: 31 kg (68 lbs)
C. Cap turbocharger exhaust outlet pipe to prevent dirt or foreign
objects from entering.
6.
Remove air cleaner.

A. Sling air cleaner assembly (7), loosen hose clamps for
turbocharger inlet tube at air cleaner housing end.
B. Remove two band clamps mounting air cleaner, and lift
assembly off the machine.
Band clamps: 17mm across flats
Air cleaner: 32 kg (71 lbs)
C. Cap turbocharger inlet pipe to prevent dirt or foreign objects
from entering.
7.
Electrical connections and wires.

A. Disconnect two cannon plugs (8) of engine harness from the
main harness.
B. Disconnect red cable (9) from starter motor to starter relay.
(At starter motor end).
C. Disconnect black ground cable (10) from starter motor to
frame. (At frame end).
WA500-3LK
30-171
ENGINE
D. Slow-Blow fuse.
i.
Remove the rear slow-blow fuse box (11) from the chassis.
E. Disconnect one yellow wire (12) and one white wire (13) from
the engine harness.
8.
Remove two bolts (14) and disconnect engine oil drain valve (15)
located on right side of machine from the fuel tank
Fasteners (14): 14mm across flats.
9.
Remove crankcase vent tube (16) located on right side of the

engine, then remove engine block coolant drain hose (17) located
on left side of the engine.
30-181
WA500-3LK
ENGINE
10. Disconnect fuel spill return hose (18), fuel suction hose (19), and
fuel return hose (20) on the right side of machine at the engine end.
Cap hoses and fuel inlet/outlet connections to prevent dirt or
foreign objects from entering the fuel system.
11. Remove vent tube (21) on top of the fuel tank.
Cap nipple on the fuel tank to prevent dirt or foreign objects
from entering the tank.
12. Disconnect heater hoses (not illustrated) from the engine
13. Disconnect switch pump suction tube (22) and outlet hose (23),
then remove switch pump + PPC pump (24).
14. Disconnect hydraulic pump suction tube (25) and outlet tube (26),
then remove hydraulic pump (27).
15. Disconnect steering pump outlet hose (28), remove tube (29) at
pump end.
16. Disconnect damper lubrication tubes (30) and (31).

17. Disconnect drive shaft (32) and remove spacer (33).
Make match marks to prevent the coupling from being
installed in a different direction.
18. Remove two rear engine mounting bolts (34), two nuts (35), four
washers (36), and four rubber mounts (37) from each side of the
engine.
19. Remove two front engine mounting bolts (38), two nuts (39), four
washers (40), and four rubber mounts (41) from each side of the
engine.
20. Using a hoist, slowly lift engine about 100 mm (4 in) and check that
all electrical wires and hoses are disconnected, then completely
remove engine from the machine.
WA500-3LK
30-191
ENGINE
12
INSTALLATION
1.
Install the engine assembly in the reverse order to removal.

When assembling engine mounting bolts never use grease, oil,
or soapy water on the rubber mounts (37) or (41).
Engine mounting bolts:
Rear (34): 662 - 828 Nm (448 - 611 lbf ft)
Front (38): 662 - 828 Nm (448 - 611 lbf ft)
2.
Be careful not to damage the engine oil drain hose when

installing the engine assembly
Connect drive shaft (32).

Match marks to prevent the coupling from being installed in a
different direction.
Mounting bolts (32): 98 - 123 Nm (72 - 91 lbf ft)
3.
Install bulkhead. For details, refer to "BULKHEAD

INSTALLATION".
4.
Install radiator assembly. For details, refer to "RADIATOR

INSTALLATION".
Install so that the clearances between the fan and fan guard at
the left and right, and the top and bottom are the same.
5.
Install engine hood assembly. For details, refer to "ENGINE HOOD INSTALLATION".
6.
Refilling with oils and coolant.

Tighten radiator drain valve, add engine coolant through the radiator filler neck to the specified level.
Coolant: 99 liters (26.2 gal.)
Check and if necessary add engine oil through the oil filler to the specified level.
Check and if necessary add transmission oil through the oil filler to the specified level.
Check and if necessary add hydraulic oil through the oil filler in the hydraulic oil tank to the specified level.
Run the engine (to operating temperature) and heater to circulate the oil and engine coolant through the system.
Recheck the engine oil, coolant, and transmission oil levels again. Add oil or coolant if required.
30-201
WA500-3LK
ENGINE
12
MEMORANDUM
WA500-3LK
30-211
RADIATOR
RADIATOR
REMOVAL
WARNING! Stop the machine on level ground and install the safety bar to the front and rear frames.
Lower the bucket to the ground and stop the engine. Apply the parking brake and put
blocks under the wheels to prevent the machine from moving.
1.
Remove engine hood assembly, see ENGINE HOOD REMOVAL.
2.
Open radiator drain valve (1), and drain coolant.

After coolant is completely drained from the radiator, close
drain valve and disconnect drain hose from drain valve (1).
3.
Remove aeration hose (2) and return hose (3).
4.
Disconnect recovery tank line (4).
5.
Remove fan guard (5).
6.
Disconnect radiator outlet hose (6).
7.
Disconnect torque converter cooler outlet and inlet hoses (7).
8.
Disconnect hydraulic cooler outlet and inlet hoses (8).
30-221
WA500-3LK

9.
RADIATOR
Remove cover (9) at front bottom of radiator.
10. Loosen radiator mounting bolts (10).
11. Sling radiator assembly (11) and remove mounting bolt (10).
Disconnect supports from radiator, loosen supports at frame,
and rotate out of way.
Support bolts: 30mm across flats
12. Lift off radiator assembly.

Sling the radiator assembly, and lift off while moving radiator
to the rear and up.
Be careful, and make sure the cooling fan does not interfere
with the radiator core.
Radiator assembly: 332 kg (732 lb)
INSTALLATION
Carry out installation in the reverse order to removal.

Rotate and connect supports to radiator then tighten supports at frame.
Radiator mounting bolts: 490 - 608 Nm (361 - 448 lbf ft)
Radiator support bolts: 490 - 608 Nm (361 - 448 lbf ft)
Install so that the clearances between the fan and fan guard at the left and right, and the top and bottom are the same.
Tighten radiator drain valve, add engine coolant through the radiator filler neck to the specified level.
Check and if necessary add transmission oil through the oil filler to the specified level.
Check and if necessary add hydraulic oil through the oil filler in the hydraulic oil tank to the specified level.
Run the engine (to operating temperature) and heater to circulate the oil and engine coolant through the system.
Recheck the engine oil, coolant, and transmission oil levels again. Add oil or coolant if required.
WA500-3LK
30-231
DAMPER
DAMPER
REMOVAL
WARNING! Stop the machine on level ground and
install the safety bar to the front and rear
frames. Lower the bucket to the ground
and stop the engine. Apply the parking
brake and put blocks under the wheels to
prevent the machine from moving.
1.
Remove engine hood assembly. For details, see ENGINE HOOD

REMOVAL.
2.
Remove bulkhead assembly. For details, see BULKHEAD REMOVAL.
3.
Disconnect switch pump suction tube (1) and outlet hose (2), then
remove switch pump + PPC pump (3).
4.
Disconnect hydraulic pump suction tube (4) and outlet tube (5), then
remove hydraulic pump (6).
5.
Disconnect steering pump outlet hose (7), remove tube (8) at pump end.
6.
Disconnect damper lubrication tubes (9) and (10).
7.
Disconnect drive shaft (11).
8.
Pull out flange (12).
9.
Remove mounting bolt (13).
Remove the mounting bolt, insert a guide bolt, then sling the
cover and push the cover out with forcing screws.
10. Lift off cover assembly (14).

Cover: 32 kg (71 lb)
11. Sling damper assembly (15), then remove mounting bolt (16) and insert
guide bolt.
Pull out the damper assembly using forcing screws.
Damper assembly: 60 kg (132 lb)
30-241
WA500-3LK
DAMPER
INSTALLATION
Mounting bolts: 110.7 12.7 Nm (82 9 lbf ft)
WA500-3LK
30-251
DAMPER
12
DISASSEMBLY
1.
Cover assembly.
A. Remove elbows (1) and (2).
B. Remove mounting bolts, then using forcing screws, remove

cover (3).
Tighten the two forcing screws uniformly.
C. Remove oil seal (4) and o-ring (5) from cover (3).
D. Turn over cover (6), then pull out shaft (7).
Cover: 29 kg (64 lb)
30-261
WA500-3LK
DAMPER
E. Remove snap rings (8) and bearing (9) from shaft (7).
F.
2.
Remove snap rings (10). (11), and oil seal (12) from cover (6).
Damper.
A. Remove spacer (14).
B. Using forcing screws, remove flange (13).

Tighten the two forcing screws evenly.
WA500-3LK
30-271
DAMPER
C. Remove inner body (15) and rubber (16).
D. Remove snap ring (17) and oil seal (18) from the inner body.
E. Remove flange (20) from outer body (19).

Screw in the mounting bolts, then tap with a hammer to
remove.
30-281
WA500-3LK
DAMPER
ASSEMBLY
1.
Damper assembly.
A. Install flange (20) at bottom of outer body (19).
Contact surface of flange and outer body: Gasket

sealant (LG-4).
B. Press fit oil seal (18) in the inner body (15), then assemble
snap ring (17).
Fit the snap ring securely in the groove. Set the oil seal
with the sleeve on the snap ring side, and fit it close in
contact with the snap ring.
Inside surface portion (hatched portion) of inner body
(15): Lithium base molybdenum disulphide extreme
pressure grease.
Fill the circumference uniformly with grease.
Lip of oil seal: Lithium base molybdenum disulphide

extreme pressure grease.
Brand of Lithium base molybdenum disulphide extreme pressure
grease.
Kyoto Oil Malleolus No.2 or equivalent.
Show Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or equivalent.
C. Assemble inner body (15) in outer body (19), then assemble

rubber (16).
Whole surface of rubber: Grease (G2-LI)
Outer surface of inner body: Grease (G2-LI)
Inner surface of outer body: Grease (G2-LI)
Between inner body and rubber: Grease (G2-LI)
WA500-3LK
30-291
DAMPER
Fill clearance b at four places evenly with 270 g (9.5 oz)

of grease.
D. Install flange (13), and tighten mounting bolts.
Contact surface of flange and outer body: Gasket

sealant (LG-4).
Mounting bolts: 66.6 6.9 Nm (49 5 lbf.ft.)
2.
Cover assembly.
A. Fit snap ring (11), then fit snap ring (10) after press fitting the oil
seal (12) in cover (6).
Press fit the oil seal with the lip face on the bearing side.
B. Assemble snap rings (8) and bearing (9) to shaft (7).
Bearing portion C (hatched portion): Lithium base

molybdenum disulphide extreme pressure grease.
Remark
Do not leave any space when filling with grease.
Brand of Lithium base molybdenum disulphide extreme
pressure grease.
30-301
WA500-3LK
DAMPER
C. Press fit shaft (7) into cover (6).
D. Press fit oil seal (4) into cover (3), and install o-ring (5).
Oil seal portion d (hatched portion): Lithium base
pressure grease.
WA500-3LK
30-311
DAMPER
E. Set cover (3) on mounting position, and tighten the mounting bolts.
F.
Install elbows (1) and (2).

Elbow (1) and (2): Thread tightener (LT-2).
Elbow (1) and (2): 3.9 1.0 Nm (3 1 lbf ft)
Be careful of the direction of elbow (2).
30-321
WA500-3LK

3.
DAMPER
Greasing.
A. Assemble damper to the engine, and connect the grease hose, then
fill the inside of the damper with grease (310g) from portion e.
Damper portion e (hatched portion): Lithium base

pressure grease.
WA500-3LK
30-331
TORQUE CONVERTER AND TRANSMIS-

REMOVAL
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then apply the parking brake and put blocks
under the wheels to prevent the machine from moving.
WARNING! Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate
the control levers several times to release the remaining pressure in the hydraulic piping.
1.
Drain oil.
Hydraulic oil: 120 liter (31.7 gal)
Transmission: 62 liter (16.4 gal)

2.
Remove bulkhead assembly. For details, see BULKHEAD REMOVAL.
3.
Remove floor frame assembly. For details, see FLOOR FRAME REMOVAL.
4.
Remove drive shaft between switch + PPC pump, loader pump, and engine - torque converter.
For details, see HYDRAULIC PUMP REMOVAL.
5.
Disconnect drive shaft (1) between transmission and rear differential

at the transmission end.
6.
Disconnect drive shaft (2) between transmission and center support

at the differential end.
7.
Disconnect hose (3) from oil cooler on left side of transmission and
hose (4) leading to transmission valve.
8.
Disconnect transmission oil outlet tube (5).
30-341
WA500-3LK

9.
Disconnect hoses (6) and (7) leading to steering valve at right side
of transmission.
10. Disconnect hose (8) to loader control valve.
11. Disconnect hydraulic tank outlet hose (9).

12. Remove clamps (10) and (11), then remove tube (12).
13. Disconnect hoses (13) and (14) leading to emergency brake valve
from transmission control valve.
14. Disconnect grease supply hose (15) at bottom of transmission support.
15. Disconnect connectors (16), (17), and (18) at bottom left of floor
frame (LR1 - 6 and TM1, 2).
16. Disconnect (19) at left side of center of machine (FR1, 2).
WA500-3LK
30-351
17. Remove filler tube (20).
18. Remove two mount bolts (21) at torque converter end.
19. Disconnect parking brake hose (22) at bottom left of transfer.

20. Remove four mount bolts (23) at transfer end.
21. Raise transmission assembly (24) and remove cushion.
22. Remove mounting bolts (26), then remove bracket (27).
Remove bracket (27) and move transmission assembly to the

left while slowly raising the assembly.
30-361
WA500-3LK
INSTALLATION
Adjust mount at the transfer end as shown in diagram to the right.
Drive shaft: 110.7 12.7 Nm (81 9 lbf ft)
Mount bolt: 744.8 83.3 Nm (549 61 lbf ft)
Bracket mounting bolts: 274.4 29.4 Nm (202 22 lbf ft)
REFILLING HYDRAULIC TANK AND TRANSMISSION CASE WITH OIL.
Add transmission oil through the oil filler to the specified level.
Add hydraulic oil through the oil filler in the hydraulic oil tank to the specified level.
Run the engine (to operating temperature) to circulate the oil through the system.
Recheck the oil levels again, and add oil if required.
WA500-3LK
30-371
DISCONNECTION
1.
Remove torque converter and transmission assembly. For details,

see TORQUE CONVERTER, TRANSMISSION REMOVAL.
2.
Disconnect suction tube (1).
3.
Remove flange (2).
4.
Remove tube (3) between torque converter and transfer.
5.
Remove support (4).
6.
Disconnect connector (5).
7.
Remove mounting bolts (6), then lift off torque converter

assembly (7).
Using a lever block set, set with the torque converter end at the top.
After setting the assembly in position, check that it is stable,
before removal of the lifting tool.
CONNECTION
Carry out connection in the reverse order to disconnection.

Make the protrusion from the shaft equal.
Be careful when pushing in. If the assembly is pushed in by force,
seal ring (8) may be damaged.
Input shaft seal ring: G2-LI
Torque converter mounting bolts: 110.7 12.7 Nm (81 9 lbf ft)
30-381
WA500-3LK
TORQUE CONVERTER
TORQUE CONVERTER
DISASSEMBLY
1.
Disconnect torque converter and PTO assembly from transmission

assembly.
For details, see TORQUE CONVERTER, TRANSMISSION
DISCONNECTION.
2.
PTO assembly
A. Set tool C to torque converter and PTO assembly (1).
B. Remove holder (2) and coupling (3).
C. Using eye bolts a, sling PTO assembly.

D. Using forcing screw b, lift off PTO assembly (4).
E. Disassemble PTO assembly as follows.

i.
Remove retainer (5).
ii.
Remove oil seal (6) from retainer (5).
iii. Remove bearing (7).
WA500-3LK
30-391
TORQUE CONVERTER
iv. Using tool B2, remove nut (8).

v.
Using puller d, push out gear (9).

At this point, put in contact with the bearing outer race
and push the gear out. Do not remove the gear.
vi. Remove bearing (10a).

vii. Using snap ring pliers, remove snap ring (11)
viii. Remove spacer (12).
ix. Using gear puller e, pull out outer races (13a) and (13b)
approx. 10 mm (0.394 in).
x.
Remove gear (9), then remove outer races (13a) and (13b)
and spacer (14).
xi. Remove spacer (40) and bearing (10b) from gear (9).
3.
Turbine case assembly

A. Leave two pump mounting bolts (15) on diagonally opposite
sides and remove other mounting bolts.
B. Set with case at top and remove remaining two mounting bolts.
C. Using eye bolt c, remove turbine and case assembly (16).
30-401
WA500-3LK
TORQUE CONVERTER
D. Disassemble turbine and case assembly as follows.

i.
Remove shaft (17) and gear (18).
ii.
Using snap ring pliers, remove snap ring (19).
iii. Remove spacer (20).
iv. Insert two round bars f from 8.5 drill hole and remove
turbine assembly (21).
v.
Push the inner race of the bearing with a forcing screw.
vi. Using snap ring pliers, remove snap ring (23) from case (22).
vii. Using push tool g, remove bearing (24).
4.
Stator
A. Remove snap ring (25).
B. Remove stator (26).
WA500-3LK
30-411

5.
TORQUE CONVERTER
Stator shaft, pump assembly.

A. Remove 10 mounting bolts (27).
B. Remove stator shaft and pump assembly (28) from housing (29).
C. Disassemble stator shaft and pump assembly as follows.

i.
Remove two plugs (31) of stator shaft (30).
ii.
Using round bar h, knock out bearing inner race from

hole where plug has been removed, then remove pump
assembly (32).
iii. Remove bolts, then remove retainer (33), pump (34), and
guide (35).
iv. Remove bearing (36) from guide (35).
30-421
WA500-3LK
TORQUE CONVERTER
ASSEMBLY
1.
Stator shaft, pump assembly.

A. Assemble stator shaft and pump assembly as follows:
i.
Using push tool j, press fit bearing (36) {outside

diameter: 120 mm (4.724 in)} to guide (35).
After press fitting the bearing, apply drops (6 cc)
of engine oil (EO10-CD or EO30-CD) and rotate
10 times.
ii.
Align with oil groove and install guide (35) and retainer (33)
to pump (34).
Mounting bolt: Thread tightener (LT-2)
Mounting bolt: 59 - 74 Nm (44 - 55 lbf ft)
iii. Install seal ring (39) to stator shaft (30).

Apply grease to the seal ring and make the protrusion from
the shaft uniform.
iv. Using push tool k, press fit pump assembly (32) to stator
shaft (30).
WA500-3LK
30-431

v.
TORQUE CONVERTER
Install two plugs (31) to stator shaft (30).

Do not coat the plugs with adhesive.
Plug: 3 - 6 Nm (2 - 4 lbf ft)
B. Set housing (29) to tool C.

C. Install stator shaft and pump assembly (28).
2.
Stator.
A. Install stator (26).
B. Using snap ring pliers, install snap ring (25).
3.
Turbine case assembly.

A. Assemble turbine case assembly as follows:
i.
Using push tool g, press fit bearing (24) to case (22).
ii.
Using snap ring pliers, install snap ring (23).
30-441
WA500-3LK
TORQUE CONVERTER
iii. Using push tool l, press fit turbine assembly (21) to

case (22).
Support the inner race of the case bearing and press fit
the turbine assembly.
After press fitting, apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) and rotate 10 times.
iv. Install spacer (20).

v.
vi. Using push tool m, press fit inner race (37) to shaft (17).
vii. Install gear (18) and shaft (17) to case (22).

WA500-3LK
30-451
TORQUE CONVERTER
B. Using eyebolt c, install turbine and case assembly (16), then

tighten 24 mounting bolts (15).

4.
PTO assembly.
A. Assemble PTO assembly as follows:
i.
Using push tool (n), press fit bearing (10b) {inside diameter:
50 mm (1.969 in)} to gear (9).
ii.
Set gear (9) to each pump mount portion of housing (38).
Gear (spline portion): Grease (G2-LI)
iii. Using push tool p, press fit outer race (13b) {outside
diameter: 90 mm (3.543 in).
Be careful of the mounting direction.
30-461
WA500-3LK
TORQUE CONVERTER
iv. Install spacer (14).
v.
Using push tool p, press fit outer race (13a) {outside

diameter: 90 mm (3.543 in)}.
Be careful of mounting direction.
vi. Fit spacer (40), the using puller q, press fit bearing (10a)
{inside diameter: 50 mm (1.969 in)}.
vii. Install spacer (12).

viii. Using snap ring pliers, install snap ring (11).
WA500-3LK
30-471
TORQUE CONVERTER
ix. Using tool B2, tighten mounting nut (8).

Mounting nut: Thread tightener (LT-2)
Mounting nut: 392 - 441 Nm (289 - 325 lbf ft)
After tightening the mounting nut, apply drops (6 cc)
of engine oil (EO10-CD or EO30-CD) to bearings
(10a) and (10b) and rotate 10 times. Then check the
tightening torque of the mounting nut again.
x.
Using push tool r, press fit bearing (7) (outside diameter:

130 mm) to coupling mount portion of housing (38).
After tightening the mounting nut, apply drops (6 cc)
of engine oil (EO10-CD or EO30-CD) to bearings (7)
and rotate 10 times.
xi. Using push tool, press fit oil seal (6) to retainer (5).
Lip of oil seal: Grease (G2-LI)
Coat the oil seal press-fitting surface of the retainer
with gasket sealant (LG-5).
When coating with gasket sealant, coat the hole in
the housing thinly, and wipe off all gasket sealant that
is squeezed out.
xii. Fit O-ring and install retainer (5).

O-ring: Grease (G2-LI)
B. Fit O-ring, then using eyebolts a, install PTO assembly (4).
30-481
WA500-3LK
TORQUE CONVERTER
C. Fit O-ring and install coupling (3) and holder (2).

WA500-3LK
30-491
TRANSMISSION
TRANSMISSION
DISASSEMBLY
1.
Torque converter and PTO assembly.

A. Disconnect torque converter and PTO assembly. For details,
see TORQUE CONVERTER, TRANSMISSION
DISCONNECTION.
2.
Cover.
Remove cover (1) from top of transmission control valve.
3.
Main relief valve.

Remove main relief valve (3).
4.
Transmission control valve.

A. Remove wiring harness (4).
Disconnect the ECMV solenoid connector. For details,
see TRANSMISSION CONTROL VALVE ASSEMBLY
(ECMV ASSEMBLY) REMOVAL.
B. Remove parking brake hose (5).
C. Lift off transmission control valve assembly (6).
Remove the bolts at the positions marked by arrows in the
diagram on the right.
5.
Lubrication tube.
Remove lubrication tube (7) from front of transfer.
6.
Sleeves.
A. Using eyebolt a, remove four sleeves (8) {length: 74mm
(2.913 in)} and 1 sleeve (9) {length: 79mm (3.110 in)}.
30-501
WA500-3LK

7.
TRANSMISSION
Transmission, transfer assembly.

A. Using eyebolts b and chain block, raise transmission and transfer
assembly (10), then set on block c with transfer assembly at
bottom.
B. Using eyebolts d, sling transmission assembly (11), then using

forcing screw e, disconnect from transfer assembly.
8.
Transmission assembly.
A. Remove 6 mounting bolts (12) from output shaft end of
transmission case assembly (11).
B. Set transmission case assembly (11) on block c.

C. Remove 15 mounting bolts (13) from input shaft of transmission
case assembly (11).
WA500-3LK
30-511
TRANSMISSION
D. Remove two tie bolts (14) shown in diagram on the right,

and install eyebolts f.
E. Lift off transmission assembly (16) from transmission case
(15), and set to g.
9.
Checking actuation of clutch piston.

A. Install four sleeves (8) and 1 sleeve (9) to transmission
assembly (16).
B. Using tool D1, check actuation of piston before disassembling.
C. After checking actuation of piston, remove four sleeves (8)
and 1 sleeve (9).
10. Input shaft, No. 1 carrier, housing assembly.

A. Remove remaining 10 tie bolts (14).
B. Using eyebolts h, remove input shaft and No. 1 carrier and
housing assembly (17), and put on block c.
C. Disassemble input shaft, No. 1 carrier and housing assembly

(17) as follows:
i.
ii.
Remove No. 2 sun gear (20).
30-521
WA500-3LK
TRANSMISSION
iii. Support housing (21), then using push tool i, push input
shaft (22) with press and remove.
iv. Using snap ring pliers, remove snap ring (166) from input
shaft (22).
v.
Remove seal ring (167).
vi. Using snap ring pliers, remove snap ring (25).

Remove from the bearing inner race end.
vii. Support housing (21), then using push tool j, push No. 1
carrier assembly (26) with press and remove.
viii. Remove spacer (27).
ix. Using snap ring pliers, remove snap ring (169).

x.
Remove bearing (170).
xi. Remove seal ring (171).
WA500-3LK
30-531
TRANSMISSION
D. Disassemble No. 1 carrier assembly as follows:

i.
Remove snap ring (23).
ii.
Remove No. 1 ring gear (24).
iii. Remove shaft (29) and ball (173) from No. 1 carrier.
Be careful not to lose ball (173).
iv. Remove two thrust washers (174), needle bearing (175),
and planetary gear (176).
v.
Remove sun gear (30) and spacer (31).
vi. Using push tool k, remove spacer and bearing assembly (32).
vii. Using snap ring pliers, remove snap ring (33) from spacer
and bearing assembly (32).
viii. Using push tool l, remove bearing (34).
ix. Using snap ring pliers, remove snap ring (36) from No. 1
carrier.
x.
30-541
Using push tool m, remove bearing (37).
WA500-3LK
TRANSMISSION
11. No 1 spring.
Remove No. 1 spring (38).
12. No 1 plates, springs, No 1 discs.

Remove four No. 1 plates (39), 20 springs (41), and four
No. 1 discs (40).
13. Guide pins, plate.

Remove five guide pins (42) and plate (43).
14. Valve, spring.

Remove valve (44) and spring (45).
WA500-3LK
30-551
TRANSMISSION
15. No 1, No 2 piston, housing assembly.

A. Using eyebolts n, lift off No. 1 and No. 2 piston and
housing assembly (46).
Tap with a copper hammer to pull out the dowel pin,
then remove.
When raising the housing assembly, be careful not to drop
the No. 2 piston.
B. Using eyebolt o, remove No. 1 piston (48) from No. 1
housing (47).
C. Turn over No. 1 housing, then remove No. 2 piston (52).

D. Remove seal ring (49) from No. 1 piston (48).
E. Remove seal ring (53) from No. 2 piston (52).
F.
Remove seal rings (50) and (51) from No. 1 housing (47).
16. Plate.
Remove plate (54).
17. No. 2 springs.

Remove 10 No. 2 springs (164).
30-561
WA500-3LK
TRANSMISSION
18. No. 2 discs, springs, No. 2 plates.

Remove four No. 2 discs (55), 20 springs (56), and four No. 2
plates (57).
19. Spacer.
A. Using snap ring pliers, remove snap ring (58).
B. Remove spacer (59).
20. No. 2 carrier, housing assembly.

A. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).
B. Using snap ring pliers, remove snap ring (61) from bearing
inner end.
C. Support No. 2 housing assembly (62), then using push tool q,

push No. 2 carrier assembly (63) with press and remove.
Push the No. 2 carrier.
WA500-3LK
30-571
TRANSMISSION
D. Disassemble No. 2 housing assembly (62) as follows:

i.
ii.
Support No. 2 housing (65), then using push tool r, push

bearing (66) with press and remove.
iii. Remove seal ring (67) from No. 2 housing (65).
E. Disassemble No. 2 carrier assembly (63) as follows:

i.
Remove spacer (68).
ii.
Remove ring gear (69).
iii. Insert thin rods into four holes (70) for removing snap
ring, then push snap ring (71), and remove No. 2 carrier
assembly (163) from ring gear (72).
30-581
WA500-3LK
TRANSMISSION
iv. Remove shaft (73) and ball (74) from No. 2 carrier (163).
v.
Remove two thrust washers (75), needle bearing (76),

and planetary gear (77).
21. No. 3 springs.


Remove three No. 3 discs (79), 20 springs (80), and two No. 3
plates (81).
23. No 3 piston.
A. Remove No. 3 piston (82).
B. Remove seal ring (158).
24. Guide pins.
Remove five guide pins (162).
25. No. 3 ring gear.
26. No. 3, No. 4 housing, No. 4 piston assembly.

A. Using eyebolts s, liftoff No. 3 and No. 4 housing and piston
assembly (159).
then remove.
B. Turn over No. 3 and No. 4 housing (84), and remove No. 4
piston (86).
WA500-3LK
30-591
TRANSMISSION
C. Remove seal ring (87) from No. 4 piston (86).

D. Remove two seal rings (85) from No. 3 and No. 4 housing (84).
27. No. 4 springs.

plates (91).
29. No. 3, No. 4 carrier assembly.

A. Using bar t, push up No. 3 and No. 4 carrier assembly (92)
and remove.
B. Disassemble No. 3 and No. 4 carrier assembly as follows:

i.
Using tool D2, pull out No. 3 shaft (93) and remove.
ii.
Remove two thrust washers (95), needle bearing (96), and

No. 3 planetary gear (97).
30-601
WA500-3LK
TRANSMISSION
iii. Using round bar, knock pin (98) into No. 4 shaft (99).
iv. Using round bar u, knock out No. 4 shaft (99) from No. 3
carrier end and remove.
v.
Remove two thrust washers (100), needle bearing (101),

and No. 4 planetary gear (102).
vi. Using push tool v, push bearing (103) with press and remove.
vii. Remove bushing (161).

viii. Remove No. 3 and No. 4 seal ring (104).
WA500-3LK
30-611
TRANSMISSION
30. No. 4 sun gear.

B. Remove spacer (106) and No. 4 sun gear (107).

A. Remove snap ring (108).
B. Remove No. 4 ring gear (109).
32. No. 5 housing, No. 5 piston assembly.

A. Using eyebolts w, lift off No. 5 housing and No. 5 piston
assembly (110).
When raising the housing, be careful not to drop the No. 5
piston.
B. Using eyebolt o, remove No. 5 piston (112) from No. 5
housing (181).
C. Remove seal ring (113) from No. 5 piston (112).

D. Remove seal ring (111) from No. 5 housing (110).
30-621
WA500-3LK
TRANSMISSION
33. No. 5 plate.

Remove No. 5 plate (114).
34. No. 5 springs.
35. No. 5 discs, springs, No. 5 plate.
Remove two No. 5 discs (116), 10 springs (117), and No. 5 plate (118).
36. Guide pins.

Remove 5 guide pins (119).
38. No. 5 plate.
Remove No. 5 plate (121).
39. No. 5 carrier assembly.

A. Remove nine mounting bolts (122).
B. Remove No. 5 carrier assembly (123).
then remove.
C. Remove spacer (124) from No. 5 carrier assembly (123).
D. Disassemble No. 5 carrier assembly (123) as follows.

i.
WA500-3LK
30-631

ii.
TRANSMISSION
Remove shaft (125) and ball (126).

iii. Remove two thrust washers (127), needle bearing (128), and
planetary gear (129).
40. No. 5 sun gear.

Remove No. 5 sun gear (130).
41. Spring, pin.

Remove spring (131) and pin (132).
plates (135).
43. No. 6 piston.

A. Remove No. 6 piston (136).
B. Remove seal ring (156).
44. Guide pins.

Remove five guide pins (153).
45. Seal ring.
Remove seal ring (154) from housing (149).
30-641
WA500-3LK
TRANSMISSION
46. No 6 hub.
Remove No. 6 hub (137).
47. Output shaft.

A. Support cage, then push output shaft (139) with press and remove.
B. Remove two seal rings (140) from output shaft (139).
48. Cage assembly.

B. Support No. 6 housing assembly (143), then using push tool x,
push cage assembly (144) with press and remove.
C. Using push tool nn, push bearing (145) with press and remove
from cage (146).
D. Remove two seal rings (147).
WA500-3LK
30-651
TRANSMISSION
49. No. 6 housing assembly.

B. Using push tool y, remove bearing (150), bushing (151), and

ball (152) from housing (149).
30-661
WA500-3LK
TRANSMISSION
ASSEMBLY
1.
No. 6 housing assembly.

A. Using push tool z, press fit bearing (150) to No. 6 housing (149).
B. Using push tool aa, press fit bushing (151) and ball (152) to
No. 6 housing (149).
C. Using snap ring pliers, install snap ring (148).

2.
Cage assembly.
A. Install two seal rings (147) to cage (146).
Seal ring: Grease (G2-LI)
B. Using push tool bb, No. 6 housing assembly (143) to cage

assembly (144) with press.
Push the inner race of bearing (150).

3.
Output shaft.
A. Install two seal rings (140) to output shaft (139).
WA500-3LK
30-671
TRANSMISSION
B. Using push tool cc, press fit bearing (145) to output shaft (139)
with press.
C. Set No. 6 housing assembly (143) to g.
D. Using push tool dd, press fit output shaft and bearing
assembly (155).
Push bearing (145) of the output shaft.
4.
Seal ring.
Install seal ring (154) to No. 6 housing (149).
Set the groove of the seal ring facing the direction receiving
the pressure.
5.
Guide pin.
Install guide pin (153).
6.
No. 6 piston.
Install seal ring (156) to No. 6 piston (136).
the pressure.
7.
No. 6 gear.
A. Install No. 6 gear (137).
30-681
WA500-3LK
TRANSMISSION
B. Install No. 6 piston (136).
8.
No. 6 plates, springs, No. 6 discs.

Install two No. 6 plates (135), 15 springs (134), and three No. 6
discs (133).
9.
Pin, spring.
Install pin (132) and spring (131).
10. No. 5 sun gear.

Install No. 5 sun gear (130).
A. Assemble No. 5 carrier assembly as follows:
i.
Assemble needle bearing (128) to planetary gear (129),

put washers (127) to both ends, then set to No. 5 carrier.
Align the center of each part with the shaft hole.
ii.
Install shaft (125) and ball (126).

Check that the gear rotates smoothly.
WA500-3LK
30-691
TRANSMISSION
C. Align position of dowel pin and install No. 5 carrier

assembly (123).
Tap with a copper hammer to knock in the dowel pin.
D. Install 9 mounting bolts (122).
E. Assemble spacer (124).
12. No. 5 housing assembly.
A. Assemble No. 5 housing assembly as follows:
i.
Install No. 5 ring gear (120) to No. 5 plate (121).
ii.
lnstall guide pins (119).
iii. Install two No. 5 discs (116), 10 springs (117), and No. 5
plate (118).
iv. Install 10 No. 5 springs (115).
v.
Install No. 5 plate (114).
vi. Install seal ring (113) to No. 5 piston (112).

Set the groove of the seal ring facing the direction
receiving the pressure.
vii. Install seal ring (111) to No. 5 housing (181).

viii. Install No. 5 piston (112) to No. 5 housing.
30-701
WA500-3LK
TRANSMISSION
ix. Align position of dowel pin and install No. 5 housing and
No. 5 piston assembly (110).
Be careful not to drop the No. 5 piston. Tap with a
copper hammer to knock in the dowel pin.
B. Fit clamps ee to No. 5 housing assembly (157) to hold in position.

C. Using eyebolts w, install No. 5 housing assembly (157).

A. Install No. 4 ring gear (109).
B. Install snap ring (108).

Install three No. 4 discs (89), 15 springs (90), and two No. 4
plates (91).
15. Springs.
Install 10 springs (88).
WA500-3LK
30-711
TRANSMISSION
16. No. 4 piston.

the pressure.
17. No. 3 piston.
the pressure.

18. No. 3, No. 4 housing.
A. Install two seal rings (85) to No. 3 and No. 4 housing (84).
B. Install No. 3 piston (82) and No. 4 piston (86) to No. 3 and
No. 4 housing (84).
C. Using eyebolts s, lift off No. 3 and No. 4 housing assembly (159).
When raising the housing, be careful not to drop the No. 4
piston.
19. No. 4 sun gear, spacer.

A. Install No. 4 sun gear (107) and spacer (106).
20. No. 3, No. 4 carrier assembly.
A. Assemble No. 3 and No. 4 carrier assembly as follows:
i.
Install seal ring (104) to No. 3 and No. 4 carrier (160).

30-721
WA500-3LK

ii.
TRANSMISSION
Using tool D3, press fit bushing (161) to No. 3 and No. 4
carrier (160).
iii. Using push tool ee, press fit bearing (103) to No. 3 and
No. 4 carrier (160).
iv. Assemble needle bearing (101) to No. 4 planetary gear

(102), put thrust washers (100) to both ends, then set to
No. 4 carrier.
v.
Align roll pin hole and install No. 4 shaft (99).

The deviation between the position of the No. 4 shaft
and carrier roll pin hole must be less than 0.2 mm
(0.008 in).
vi. Install roll pin (98).

Install so that the side of the roll pin with the slit is
facing the planetary gear.
vii. Assemble needle bearing (96) to No. 3 planetary gear (97),
and put thrust washers (95) to both ends, then set to No. 4
carrier.
viii. Install No. 3 shaft (93) and ball (94).
WA500-3LK
30-731
TRANSMISSION
B. Install No. 3 and No. 4 carrier assembly (92).

Put plate ff to No. 3 and No. 4 carrier assembly (92), then
press fit the bearing inner race portion to the output shaft.

Install No. 3 ring gear (83).
22. Guide pins.
Install guide pins (162).

Install three No. 3 discs (79), 20 springs (80), and two No. 3
plates (81).
24. No. 3 springs.
Install 10 No. 3 springs (78).
25. No. 2 carrier, housing assembly.

A. Assemble No. 2 carrier assembly as follows:
i.
Set snap ring to No. 2 carrier (163) and install ring gear (72).
ii.
Set snap ring (71) in groove of ring gear (72).
30-741
WA500-3LK
TRANSMISSION
iii. Assemble needle bearing (76) to planetary gear (77), put

thrust washers (75) to both ends, then set to No. 2 carrier.
iv. Install shaft (73) and ball (74).
v.
Install spacer (68) and ring gear (69) to No. 2 carrier

assembly.
B. Assemble No. 2 housing assembly as follows:

i.
Install seal ring (67) to No. 2 housing (65).

ii.
Support No. 2 housing (65), then using push tool gg,

press fit bearing (66) with press.
iii. Using snap ring pliers, install snap ring (64).
WA500-3LK
30-751
TRANSMISSION
C. Support No. 2 carrier assembly (63), then using push tool hh,
press fit No. 2 housing assembly (62) with press.
Press fit the bearing inner race.
D. Using snap ring pliers, install snap ring (61).

E. Using eyebolts p, lift off No. 2 carrier and housing assembly (60).
26. Spacer.
A. Install spacer (59).
27. No. 2 plates, springs, No. 2 discs.

Install four No. 2 plates (57), 20 springs (56), and four No. 2
discs (55).
30-761
WA500-3LK
TRANSMISSION
Assemble discs (55), springs (56), and plates (57) in the

order shown in the diagram.
28. No. 2 springs.

29. Plate.
Install plate (54).
30. No. 1 piston, housing assembly.

A. Install seal ring (49) to No. 1 piston (48).
the pressure.
B. Install seal ring (53) to No. 2 piston (52).
the pressure.
C. Install seal rings (50) and (51) to No. 1 housing (47).
the pressure.
D. Install No. 1 piston (48) and No. 2 piston (52) to No. 1
housing (47).
WA500-3LK
30-771
TRANSMISSION
E. Using eyebolts n, lift off No. 1 piston and housing assembly (46).
When raising the housing assembly, be careful not to drop
No. 2 piston.
31. Spring, valve.

Install spring (45) and valve (44).

A. Using push tool ii, press fit bearing (37) to No. 1 carrier (165).
C. Assemble needle bearing (175) to planetary gear (176), put

thrust washers (174) to both ends, then set to No. 1 carrier.
Align center of each part with the shaft hole.
D. Install shaft (29) and ball (173).
E. Set No. 1 ring gear (24) to No. 1 carrier assembly.
F.
30-781
WA500-3LK
TRANSMISSION
33. Input shaft.

A. Install seal ring (167) to input shaft (22).
C. Support No. 1 carrier assembly (26), then using push tool i,
press fit input shaft (22) with press.
Press fit until snap ring (166) of the input shaft contacts
the bearing.
34. Spacer, sun gear.
Install spacer (31) and sun gear (30).
35. Bearing, spacer.
A. Using push tool jj, press fit bearing (34) to spacer (136).
B. Using push tool kk, press fit spacer and bearing assembly (32).
After assembling, check that the bearing rotates easily.
36. No. 2 sun gear.

A. Install No. 2 sun gear (20).
37. Input shaft, No. 1 carrier assembly.
Raise input shaft and No. 1 carrier assembly (168) and install.
WA500-3LK
30-791
TRANSMISSION
38. Guide pins.

Install five guide pins (42).
39. Plate.
Install plate (43).
40. No. 1 plates, springs, No. 1 discs.

Install four No. 1 plates (39), 20 springs (41), and four No. 1
discs (40).
Assemble in the order shown in the diagram.
41. No. 1 springs.

30-801
WA500-3LK
TRANSMISSION
42. Housing.
A. Install seal ring (171) to housing (21).
B. Using push tool al, press fit bearing (170).
D. Install spacer (27) to No.1 carrier assembly.
E. Install housing (21).
Fit eyebolt an to the input shaft, then fit wire and apply
slight tension to the wire, then press fit the housing.
F.
G. Install 10 tie bolts (14).

Tie bolt: 157 - 177 Nm (116 - 131 lbf ft)
Do not install the two tie bolts at position where eyebolts

are installed.
43. Checking actuating condition and travel of piston.

A. Install four sleeves (8) and 1 sleeve (9) to transmission
assembly (16).
B. Using tool D1, check actuating condition and travel of piston.
Air pressure: 3 - 5 kg/cm2 (42 - 71 psi)
Piston
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
Travel
4 mm (0.158 in)
5.5 mm (0.217 in)
3.5 mm (0.138 in)
4.5 mm (0.177 in)
3 mm (0.118 in)
4.2 mm (0.165 in)
C. Remove four sleeves (8) and 1 sleeve (9) from transmission

assembly (16).
WA500-3LK
30-811
TRANSMISSION
44. Transmission assembly.

A. Install dowel pin (171) from output shaft end.
B. Install eyebolts f at positions shown by arrows in diagram on right.
C. Put transmission case (15) on block c.
D. Raise transmission assembly (16) and install to transmission
case (15).
Align the position of the mounting bolt hole on the top of

the transmission.
Check that dowel pin (171) has entered the transmission
case.
E. Remove eyebolts f, and install remaining two tie bolts (14).
Tie bolt: 157 - 177 Nm (116 - 131 lbf ft)
F.
Install six mounting bolts (12) to output shaft end.
G. Install 15 mounting bolts (13) to input shaft end.

45. Transmission case assembly.

A. Set transfer assembly (172) to block c.
B. Fit O-ring, then using eyebolts d, raise transmission case (11)
and install.
30-821
WA500-3LK
TRANSMISSION
46. Sleeves.
Fit O-ring and install four sleeves (8) (length: 74 mm {2.913 in}) and
1 sleeve (9) (length: 79 mm {3.110 in}).
47. Lubrication tube.
Install lubrication tube (7) to transfer.
48. Transmission control valve.

A. Fit O-ring to transmission case and valve seat, then raise
transmission control valve assembly (6) and install.
Tighten mounting bolts in positions shown in diagram on
the right.
Check that there is an O-ring fitted to rear of the transmission
case.
B. Install parking brake hose (5).
C. Install wiring harness (4).

Install the ECMV solenoid connector. For details,
see TRANSMISSION CONTROL VALVE (ECMV
ASSEMBLY) INSTALLATION.
49. Main relief valve.
Fit O-ring and install main relief valve (3).
Tie bolt: 44 -54 Nm (33 - 40 lbf ft)
49. Cover.
Install cover (1) to top of transmission control valve.
50. Torque converter, PTO assembly.
Connect torque converter and PTO assembly to transmission
assembly. For details, see TORQUE CONVERTER AND
TRANSMISSION CONNECTION.
WA500-3LK
30-831
TRANSFER
TRANSFER
DISASSEMBLY
1.
Transmission.
Remove transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.
2.
Parking brake assembly.

Remove parking brake assembly. For details, see PARKING BRAKE
DISASSEMBLY.
3.
Input shaft cage assembly.

A. Using forcing screws a, remove input shaft cage assembly (1).
B. Remove shims (2).
Check the number and thickness of the shims at each
mounting position, and keep in a safe place.
4.
Input shaft gear assembly.

A. Remove input shaft gear assembly (3).
B. Remove bearings (4) and (5) from input shaft gear assembly (6).
5.
Outer race.
A. Using push tool b, remove outer race (7) from input shaft
cage (34).
B. Remove outer race (35).
30-841
WA500-3LK

6.
TRANSFER
Strainer.
A. Remove cover (8).
B. Remove spring (9).

C. Remove strainer (10).
7.
Intermediate shaft cage assembly.

A. Turn over transfer.
B. Using forcing screws c, remove intermediate cage assembly (11)
and shims (12).
Check the number and thickness of the shims at each
mounting position, and keep in a safe place.
8.
Intermediate shaft gear assembly.

A. Remove intermediate shaft gear assembly (14).
B. Remove two bearings (16) from intermediate shaft gear (15).
WA500-3LK
30-851

9.
TRANSFER
Outer race.
A. Remove outer race (13) from intermediate cage (32).
B. Remove outer race (17) from transfer case.
10. Coupling.
Remove holder (18) and coupling (19).
11. Cover.
A. Using forcing screws c, remove cover assembly (22) and
shims (23).
B. Remove dust seal (25) and oil seal (26) from cover(35).
30-861
WA500-3LK
TRANSFER
12. Output shaft.

Using tool D4, remove output shaft (20) and spacer (21).
13. Cage.
A. Using forcing screws d, remove cage and bearing assembly (27).
B. Using push tool e, remove outer races (28a) and (28b),
collar (28c), and bearings (28d) and (28e) from cage (29).
The two bearings are not interchangeable, so keep them
as separate sets.
14. Spacer.
Remove spacer (30).
15. Output shaft gear.
Remove output shaft gear (31).
WA500-3LK
30-871
TRANSFER
ASSEMBLY
1.
Outer race.
Using push tool f, press fit outer race (17) to transfer case.
2.
Intermediate shaft gear assembly.

A. Using push tool g, press fit two bearings (16) to intermediate
shaft gear.
B. Install intermediate gear assembly (14).
3.
Intermediate shaft cage assembly.

A. Using push tool h, press fit outer race (13) to intermediate
shaft cage (32).
B. Fit O-ring and install shims (12) and intermediate shaft cage
assembly (11).
Standard shim thickness: 2 mm (0.078 in)
4.
Adjusting preload of intermediate shaft bearing.

A. Remove cover (33).
30-881
WA500-3LK
TRANSFER
B. Using tool D6 and torque wrench, measure preload of intermediate

shaft.
C. Adjust shims as follows:
i.
Adjust with shims (12) so that preload is 0.29 - 0.54 Nm

(0.214 - 0.398 lbf ft).
ii.
After adjusting, add a further 0.1 mm of shim.

There are four types of shim thickness: t=0.15 mm
(0.006 in), t=0.2 mm (0.008 in), t=0.3 mm (0.012 in),
and t=1.0 mm (0.039 in)
Check that there is no play in the gear. If there is any
play, adjust the shims again.
D. After adjusting preload, remove intermediate shaft cage assembly

(11), shims (12), and intermediate shaft gear assembly (14).
5.
Outer race.
A. Using push tool i, press fit outer race (35) to transfer case.
B. Using push tool i, press fit outer race (7) to input shaft cage (34).
6.
Input shaft gear assembly.

A. Using push tool j, install bearings (4) and (5) to input shaft gear (6).
B. Install input shaft gear assembly (3).
7.
Input shaft cage assembly.

Install shims (2) and input shaft cage assembly (1).
Standard shim thickness: 2 mm (0.078 in)
WA500-3LK
30-891

8.
Adjusting preload of input shaft bearing.

Using tool D7 and torque wrench, measure preload of input shaft.
If measurement is not within standard, adjust with shim (2).
Preload standard value: 0.1 - 0.98 Nm (0.074 - 0.723 lbf ft)
There are four types of shim thickness: t=0.15 mm (0.006 in),
t=0.2 mm (0.008 in), t=0.3 mm (0.012 in), and t=1.0 mm (0.039 in)
Check that there is no play in the gear. If there is any play,
adjust the shims again.
Reference: Standard value for preload when assembling input
shaft and intermediate shaft (measure at input shaft end):
0.2 - 1.27 Nm (0.148 - 0.937 lbf ft)
9.
Output shaft gear.

Assemble output shaft gear (31) to transfer case.
TRANSFER
10. Spacer.
Install spacer (30).
11. Outer race.

Using push tool k, press fit outer race (28a) to cage (29).
12. Output shaft.
Assemble output shaft (20) and spacer (21), and support with block l.
13. Cage assembly.

Fit O-ring and install cage assembly (36).
30-901
WA500-3LK
TRANSFER
14. Bearing.
A. Using tool D5, press fit bearing (28d).
B. Press fit bearing (28e) in same way.
15. Outer race.

A. Install collar (28c).
B. Using push tool l, press fit outer race (28b).
16. Cover.
A. Using push tool l, press fit oil seal (26) and dust seal (27) to
cover (37).
Oil seal: Grease (G2-LI)
Oil seal press-fitting surface:
Gasket sealant (Three Bond 1110B)
Dust seal: Grease (G2-LI)

When coating with gasket sealant, coat the inside surface
of the hole in the housing thinly, and wipe off all the
gasket sealant that is squeezed out.
B. Adjust shims as follows:
i.
Fit O-ring and install shims (23) and cover assembly (22).
Do not tighten the mounting bolts.
ii.
Put feeler gauge between shims (23) and cover assembly

(22) and measure clearance, adjust number of shims so that
clearance is 0.05 - 0.10 mm (0.002 - 0.004 in), then tighten
mounting bolts.
Standard shim thickness: 0.25 mm (0.010 in).
WA500-3LK
30-911
TRANSFER
17. Coupling.
A. Install coupling (19).
B. Fit O-ring and install holder (18).

18. Intermediate shaft gear assembly.
Install intermediate shaft gear assembly again.
For details, see steps 2, 3, and 4.
Assemble the shims adjusted in step 4.
30-921
WA500-3LK
PARKING BRAKE
PARKING BRAKE
DISASSEMBLY
1.
Transmission.
Disconnect transmission assembly from transfer. For details, see
TRANSMISSION DISASSEMBLY.
2.
Coupling.
Remove holder (1) and coupling (2).
3.
Sleeve.
A. Remove flange (3).
B. Using eyebolt I, remove sleeve (4).
4.
Parking brake assembly.

A. Remove 12 mounting bolts (5).
Do not remove four mounting bolts (6).
B. Using forcing screws a, disconnect parking brake assembly (7).
C. After removing forcing screws a from parking brake (7),

fit eyebolts b and lift off.
WA500-3LK
30-931

5.
PARKING BRAKE
Cover assembly.
A. Remove cover assembly (8).
B. Disassemble cover assembly as follows.
i.
Remove dust seal (9) and oil seal (10).
ii.
Remove bearing (11).
iii. Remove dowel pin (29).
6.
Springs.
Remove 18 outer springs (12) and 18 inner springs (13).
7.
Spacer assembly.
A. Remove spacer assembly (14).
B. Using push tool c, remove inner race (15) from spacer (16).
8.
Piston.
A. Using eyebolts d, lift off piston (17).
B. Remove seal rings (18) and (19).
30-941
WA500-3LK

9.
PARKING BRAKE
Snap ring.
10. Plates, springs, discs.

Remove 9 plates (21), 8 springs (22), and 8 discs (23).
11. Gear.
Remove gear (24).
12. End plate.
Remove end plate (25).
13. Housing.
Using snap ring pliers, remove snap ring (26) from housing (27).
WA500-3LK
30-951
PARKING BRAKE
ASSEMBLY
1.
Cover.
A. Assemble cover assembly as follows:
i.
Using push tool f, press fit bearing (11).
ii.
Install two dowel pins (29).
iii. Using push tool, press fit oil seal (10) and dust seal (9).
Oil seal: Grease (G2-LI)

Oil seal press-fitting surface:
Gasket sealant (Three Bond 1110B)
Dust seal: Grease (G2-LI)
When coating with gasket sealant, coat the inside surface of

the mount thinly, and wipe off all the gasket sealant that is
squeezed out.
2.
Spacer assembly.
A. Using push tool e, press fit inner race (15) to spacer (16).
B. Install spacer assembly (14) to cover assembly (8).
3.
Springs.
Install 18 outer springs (12) and 18 inner springs (13) to cover
assembly (8).
4.
Piston.
A. Install seal rings (18) and (19) to piston (17).
Set the groove of the seal ring facing the direction shown in
the diagram on the right.
B. Set piston (17) on outer spring (12) and inner spring (13).
Align the position of the hole in piston (17) and dowel pin
(27) of the cover assembly.
30-961
WA500-3LK

5.
PARKING BRAKE
Housing.
A. Using snap ring pliers, install snap ring (20) to housing (27).
B. Fit O-ring and install housing (27) to cover assembly (8), then
tighten four mounting bolts (6).
Be careful not to twist the piston against housing (27), and
tighten the bolts uniformly a little at a time.
6.
Plugs.
A. Remove two plugs (28).
B. Tighten two mounting bolts of parking brake assembly together
with washers to mounting portion of plug (28).
Tighten the bolts a little at a time in turn.
The piston is pulled when the bolts are tightened.
7.
Gear.
Install gear (24).
Be careful of the direction of mounting.
8.
Plates, springs, discs.

Install 9 plates (21), 8 springs (22), and 8 discs (23).
WA500-3LK
30-971

9.
PARKING BRAKE
End plate.
Install end plate (25).
10. Snap ring.

11. Mounting bolts.
Remove two mounting bolts installed in Step 6B, then install two
plugs (28).
Loosen the two mounting bolts a little at a time in turn.
Plug: Gasket sealant (LG-5)
12. Parking brake assembly.
Using eyebolts b, fit O-ring, raise parking brake assembly (7)
and install.
When installing, gradually mesh the spline on the inside of
spacer assembly (14) and gear (24) with the spline of the
output shaft, and install.

13. Sleeve.
A. Fit O-ring and install sleeve (4).
B. Fit O-ring and install flange (3).
30-981
WA500-3LK
PARKING BRAKE
14. Coupling.
A. Install coupling (2).
B. Fit O-ring and install holder (1).

15. Transmission.
Connect transmission assembly and transfer. For details,
see TRANSMISSION ASSEMBLY.
WA500-3LK
30-991
TRANSMISSION CONTROL VALVE (ECMV)
TRANSMISSION CONTROL VALVE

(ECMV)
REMOVAL
install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
put blocks under the wheels to prevent
the machine from moving.
1.
Remove cover (1) between bulkhead and cab.
2.
Remove transmission top cover (2).
3.
Disconnect solenoid connector (3) and fill connector (4).

When disconnecting solenoid connector, hold the ECMV body
lightly with one hand, and hold connector housing with the other
hand as shown in diagram on the right. Then lift up connector
housing lightly in direction A and in this condition, pull it in
direction B to disconnect. Do not use force when pulling out
the wiring.
4.
Remove four mounting bolts (5), then remove ECMV assembly (6).
INSTALLATION

Clean around the valve before installing the ECMV assembly.
When fitting the solenoid connector, align lock and guide as
shown in diagram on the right, and push in. Do not twist
when inserting.
ECMV mounting bolt: 31.4 3.9 Nm (23 3 lbf ft)
30-1001
WA500-3LK
CENTER SUPPORT
CENTER SUPPORT
REMOVAL
install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
put blocks under the wheels to prevent
the machine from moving.
1.
Disconnect center drive shaft (1) from center support. Set a block
under the drive shaft when removing.
Center drive shaft: 36.4 kg (80.1 lb)

2.
Sling front drive shaft (2) and disconnect from center support.
Front drive shaft: 44 kg (97 lb)

3.
Disconnect grease tube.
4.
Sling center support (4), remove mounting bolts, then remove.
If there are shims between the center support and frame, check
the number and thickness of the shims and use as a guide when
assembling.
Center support: 43 kg (94.8 lb)
WA500-3LK
30-1011
CENTER SUPPORT
INSTALLATION
Center drive shaft mounting bolt:

110.7 12.7 Nm (801 91 lbf ft)
Front drive shaft mounting bolt:

110.7 12.7 Nm (801 91 lbf ft)
Center support mounting bolt

548.8 58.8 Nm (405 43 lbf ft)
30-1021
WA500-3LK
CENTER SUPPORT
DISASSEMBLY
1.
Coupling
Remove center bolt (1), then remove retainer (2), O-ring (3), and
coupling (4).
2.
Retainer
Remove mounting bolts (5) or retainer.
Remove all mounting bolts while rotating coupling.
3.
Shaft
A. Set shaft case assembly (6) on press stand.
B. Push out shaft (7) with press.
Be careful because the shaft will fall out suddenly.
C. Remove spacer (8), bearing cone (9) and retainer (5) from shaft.
WA500-3LK
30-1031

4.
CENTER SUPPORT
Oil seal
A. Remove oil seal (10)and O-ring (11) from retainer.
B. Remove oil seal (12) from case.
5.
Case
Remove bearing cone (13) and bearing outer race (14) and (15).
30-1041
WA500-3LK
CENTER SUPPORT
ASSEMBLY
1.
Bearing outer race

Assemble bearing outer race (14) and (15), in case (16).
2.
Oil seal
Assemble oil seal (10) in retainer (5).
Outer circumference of oil seal: Grease (G2-LI)
3.
Bearing cone
Assemble retainer (5) shaft and press fit bearing cone (9).
After assembling bearing, check that there is no clearance at tip
of shaft.
Assemble spacers.
Lip of seal: Grease (G2-LI)
Inner circumference of bearing: Grease (G2-LI)

4.
Case
A. Assemble O-ring (11) in retainer. Insert O-ring completely in
groove.
WA500-3LK
30-1051
CENTER SUPPORT
B. Stand shaft and insert case (16).

Fill a and b of case and inner circumference of oil seal
completely with grease.
5.
Retainer
Secure retainer (5) in case.
Be careful that O-ring does not get caught or damaged when
installing.
Mounting bolt: 65.7 6.9 Nm (49 5 lbf ft)
6.
Bearing seal
A. Press fit bearing (13) to shaft.
B. Assemble oil seal (12) in case.
Dimension of seal press fit and outer edge of case: 0.5
mm
(0.020 in)
Seal: Grease (G2-LI)
7.
Coupling
Assemble coupling (4), install O-ring (3) and retainer (2), and secure
center bolt (1).
Center bolt: 931 98 Nm (687 7 lbf ft)
30-1061
WA500-3LK

8.
CENTER SUPPORT
Inspection of end play

Check that end play is within specified range.
End play: Less than 0.22 mm (0.009 in).
If end play is 0, with the seal and bearing coated with grease
check that the free rotating torque is less than 3.9 Nm (3 lbf ft).
WA500-3LK
30-1071
DRIVE SHAFT
DRIVE SHAFT
DISASSEMBLY
1.
Shaft
A. Remove shaft (2)
Make match marks a before removing to ensure that the
direction of the spider assembly does not change.
Cover (1) and (1A) is caulked with a punch at four places,

so it must not be removed unless necessary.
When removing cover (1) and (1A) be extremely careful
not
to damage cover (1), (1A) and yoke (3).
When removing the caulking, raise the caulking with a
screwdriver.
B. Remove mounting bolts (4), then remove spider assembly (5).

Make match marks on yoke and spider.
30-1081
WA500-3LK
DRIVE SHAFT
C. Remove bearing caps (6) from spider assembly.

Remove strap (7) of cap.
D. When replacing bearing (8), seal (9), and derling washer (10)
from bearing cap (6), replace whole cap assembly.
2.
Yoke
A. Remove mounting bolts (11) from yoke (3), then remove spider
assembly (12).
Stamp match marks on the yoke and spider.
B. Remove bearing caps (13) from spider assembly.
WA500-3LK
30-1091
DRIVE SHAFT
C. When replacing bearing (14), seal (15), and derling washer (16)
from bearing cap (13) replace whole cap assembly.
30-1101
WA500-3LK
DRIVE SHAFT
ASSEMBLY
1.
Yoke
A. Install bearing (14), and seal (15) to bearing cap (13).
Bearing, seal: Grease (G2-LI)
B. Assemble washer (16), and bearing cap (13) to spider

assembly (12)
Be careful not to damage bearing with heat when welding
strap.
Bearing cap: Grease (G2-LI)
C. Assemble spider assembly (12) to yoke (3).

Carefully align match marks.
Clean the mounting face of the bearing cap by wiping with
a clean cloth.
Mounting bolts: 142.2 9.8 Nm (105 7 lbf ft)
2.
Shaft
A. Assemble bearing (8) and seal (9) in bearing cap (6).
Bearing seal: Grease (G2-LI)
WA500-3LK
30-1111
DRIVE SHAFT
B. Assemble washer (10)and bearing cap (6) to spider assembly (5).

Be careful not to damage bearing with heat when welding
strap.
Bearing cap: Grease (G2-LI)
C. Assemble spider assembly (5) to shaft (2).

Carefully align match marks.
Clean the mounting face of the bearing cap by wiping with
a clean cloth.
D. Align match marks a, then install shaft (2) to yoke (3).

Check that the direction of the spider assembly is the same.
If the spline is worn, replace the whole drive shaft assembly.
Spline: Grease (G2-LI)
30-1121
WA500-3LK
DRIVE SHAFT
E. lf cover (1) and (1A) has been removed, do as follows:

Front and rear drive shaft.
Insert seal and retainer to cover (1) and shaft (2), assemble
cover (1), then caulk with a punch on diagonally opposite
sides.
Center drive shaft.
Insert shaft (2) to cover (1A), assemble cover (1A), then
caulk with a punch on diagonally opposite sides.
WA500-3LK
30-1131
FRONT AXLE
FRONT AXLE
REMOVAL
WARNING! Stop the machine on level ground, install
the safety bar on the frame, and put
blocks under the wheels to prevent the
machine from moving.
1.
Insert blocks and between top face (1) of left and right rear axle
housings and frame (2).
2.
Start engine, operate work equipment to raise front axle, then set
block under front frame on left and right sides and operate work
equipment to lower frame.
Check that the front wheels can be removed, then lower the work
equipment to the ground.
3.
Sling left and right wheels (3), remove hub nuts, then lift off.
Tire, wheel: 660 kg (1452 lb)

4.
Disconnect front drive shaft (4) at differential end.
Make counter marks to act as a guide when assembling.
5.
Disconnect brake tube (5) from slack adjuster.
6.
Remove brake tubes (6) and (7).

Seal the brake system with blind plugs after the piping
is disconnected.
30-1141
WA500-3LK

7.
Sling one side of front axle assembly (8) and set garage jack to other
side.
8.
Remove mounting bolts (9).
9.
Operate crane and garage jack to lower the axle assembly.

Be careful not to let the slack adjuster on top of the axle housing
hit the frame.
FRONT AXLE
Front axle assembly: 1850 kg (4070 lb)

10. Pull out front axle assembly from chassis.
INSTALLATION
Hub nut: 470.4 49.0 Nm (347.2 36.2 lbf ft)
Drive shaft mounting bolt: 110.7 12.7 Nm (82 9 lbf ft)
Axle mounting bolt: 2744.0 294.0 Nm (2025 217 lbf ft)
REFILLING FRONT AXLE WITH OIL
Add oil through the oil filler to the specified level.
WA500-3LK
30-1151
REAR AXLE
REAR AXLE
REMOVAL
1.
Jack up chassis, set block under rear frame, and support bottom of
counterweight with stand .
2.
Sling left and right wheels (1), then remove hub nut and lift off.
3.
Disconnect rear drive shaft (2) from rear axle.

Rear drive shaft: 37 kg (81.4 lb)
4.
Disconnect hose (3) between brake pedal and slack adjuster at slack
adjuster end.
5.
Disconnect tubes (4) and (5) between slack adjuster and left and right
wheel brakes.
Be sure to remove the brake tube before removing the axle. There
is danger that it may be crushed.
30-1161
WA500-3LK

6.
Disconnect grease tubes (6) and (7) from axle support at rear end.
7.
Disconnect grease tube (8) from axle support at front end.

Remove the clamps of the brake hose from the support.
8.
Secure axle support and rear axle with chain.
9.
Remove mounting bolts, then using garage jack to maintain balance,

lower axle assembly.
REAR AXLE
Rear axle assembly: 1710 kg (3762 lb)

10. Pull out rear axle assembly (9) from chassis.
Support both ends of the axle with jacks.
WA500-3LK
30-1171
REAR AXLE
11. Remove front support (10) from rear axle.

Be careful not to damage the packing.
Front support: 95 kg (209 lb)
12. Remove packings (11) and (12) from front support.
13. Remove bushing (13) from front support.

Remove all dirt and oil from the bushing mounting surface
inside the front support.
14. Sling rear support, and remove thrust cap (14).
30-1181
WA500-3LK
REAR AXLE
15. Remove thrust washer (15), thrust plate (16), and thrust washer (17)
from rear axle.
16. Lift off rear support (18).

Rear support: 115 kg (253 lb)
17. Remove packing (19) from rear support.
WA500-3LK
30-1191
REAR AXLE
18. Remove bushing (20) from rear support.

Remove all dirt and oil from the bushing mounting surface inside
the rear support.
INSTALLATION
Hub nut: 471 49 Nm (347 36 lbf ft)
Rear support mounting bolt: 1568 196 Nm (1157 145 lbf ft)
Soak a cloth with primer for Loctite Prism adhesive, then wipe the adhesion surface at the bushing end.
Adhesion surface at rear support end:
Instant adhesive Loctite Prism 411 (approximately 3g)
Install the bushing within five minutes of coating it with primer.

Do not mix the primer with adhesive when using it.
Be careful to install the packing with the lip facing in the correct direction.
Lip of packing: Grease (G2-LI)
Rear axle mount portion: Grease (G2-LI)
30-1201
WA500-3LK
REAR AXLE
Front support mounting bolt: 1,568 196 Nm (1157 145 lbf ft)
Coat the bushing the same as the rear axle.

Lip of packing: Grease (G2-LI)
Front axle mount portion: Grease (G2-LI)
Thrust cap mounting bolt: 279.3 29.4 Nm (206 22 lbf ft)
Thrust plate mounting bolt: 279.3 29.4 Nm (206 22 lbf ft)
REFILLING REAR AXLE WITH OIL
Add oil through the oil filler to the specified level.
WA500-3LK
30-1211
DIFFERENTIAL
DIFFERENTIAL
REMOVAL (FRONT)
1.
Remove drain plugs (1) and (2), and drain oil.
Axle oil: 78 liters (20.6 gal)

2.
Operate work equipment to raise front axle, then set stand under left
side of axle.
3.
Sling left wheel (3), then remove hub nut and lift off.

4.
Remove left and right final drive covers (4).
5.
Using forcing screws , pull out drive shaft (5) approx. 200 mm
(7.874 in) together with sun gear (6).
30-1221
WA500-3LK

6.
Remove front drive shaft (7).
7.
DIFFERENTIAL
Sling the drive shaft and lower it slowly.
Remove two mounting bolts of differential (8), and install guide

bolt.
Screw in the guide bolt fully and check that all the threads have
entered the hole.
First, screw in the guide bolt, then remove the remaining
mounting bolts.
8.
Set lever block to differential case (9), and set so that differential
assembly does not fall over.
Fit both ends of a lever block to the front frame inspection window.
9.
Pull out differential (8) approx. 20 mm from axle housing (10) along
guide bolts.
Be careful not to damage the O-ring.
10. Install tools H1-1 and H1-2 to garage jack, and insert between
differential and axle housing, then install differential to tool H1-1.
11. Adjust lever block and height of jack, and remove differential
assembly slowly.
Differential assembly: 282 kg (620.4 lb)
12. Operate jack and pull out differential assembly (8) to outside of chassis.
13. Remove O-ring (11).
WA500-3LK
30-1231
DIFFERENTIAL
INSTALLATION (FRONT)
Drain valve: 151.9 24.5 Nm (112 18 lbf ft)
Hub nut: 470.4 49.0 Nm (347 36 lbf ft)
Differential mounting bolt: 548.8 58.8 Nm (405 44 lbf ft)
30-1241
WA500-3LK
DIFFERENTIAL
REMOVAL (REAR)
1.
Remove rear axle assembly from chassis. For details, see REAR
AXLE REMOVAL.
Do not remove the rear support from the rear axle.
2.
Remove plug (1) and drain axle oil.

Set so that the drain plug is at the bottom.
Axle oil: 78 liter (20.6 gal)
3.
Remove cover (2).
4.
Using forcing screws, pull out drive shaft (3).

Pull the drive shaft out approx. 200 mm (7.874 in).
5.
Using eyebolts, lift off rear differential assembly (4).

Rear differential assembly: 282 kg (620.4 lb)
Remove the O-ring from the housing mating surface.
WA500-3LK
30-1251
DIFFERENTIAL
INSTALLATION (REAR)

Differential mounting bolt: Thread tightener (LT-2)
Differential mounting bolt: 548.8 58.8 Nm (405 43 lbf ft)
Adjusting shims on shaft

1.
Adjust the shims on the shaft if the differential assembly or axle

housing have been replaced.
2.
Tighten mounting bolts of shaft (5) uniformly, then measure clearance

a between axle housing and shaft.
Do not assemble the shims.
Tighten the mount bolts to 3.9 0.1 Nm (3 lbf ft)
3.
Add 0.1 0.05 mm (0.004 0.002 in) to the measurement for

clearance a, then select a shim within that range and assemble it.
Shim thickness: Clearance a + 0.1 0.05 mm (0.004 0.002 in)
30-1261
WA500-3LK
DIFFERENTIAL
DISASSEMBLY DIFFERENTIAL GEAR

ASSEMBLY
1.
Set differential assembly (1) on special tools H2-1, H2-2, and H-3.
Differential assembly: 230kg (506 lb)
2.
Pinion assembly
A.
Remove case (2).
B. Remove oil seal (3) and dust seal (3A) from case.
C. Screw in jack screw (Thread dia. = 18 mm, Pitch = 1.75 mm),

and lift out pinion assembly (4).
Check number of shims (5).
WA500-3LK
30-1271

3.
DIFFERENTIAL
Differential gear case assembly

A. Remove left and right locks (6), and with a bar, turn nut (7) until
it become loose.
B. Remove mounting bolts (9) of cap (8).
C. Remove nut and lift out differential gear case assembly (10).
30-1281
WA500-3LK
DIFFERENTIAL
12
FINE
DISASSEMBLY OF PINION ASSEMBLY
4.
Bearing, collar, cage

A. Support cage (11), push shaft with press and tack out pinion.
B. Remove bearing (12) and collar from cage.
C. Remove outer races (13) and (14) from cage (11).
5.
Pinion, bearing
A. Remove snap ring (15), then remove bearing (16).
B. Remove bearing (17).
WA500-3LK
30-1291
DIFFERENTIAL
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE

ASSEMBLY
6.
Bevel gear (large)

Remove mounting bolts, using eye-bolts c (Thread dia. = 16 mm,
Pitch = 2.0 mm), lift off bevel gear (18).
7.
Bevel gear (small)

Remove thrust plate (19) and bevel gear (20).
Pinion gear, cross shaft
Remove pinion gear (21), cross shaft (22), and washer (23) as one unit.
8.
9.
Bevel gear (small)

Remove bevel gear (24) and thrust plate.
10. Bearing
Remove bearing (26) from case (25).
30-1301
WA500-3LK
DIFFERENTIAL
12
FINE
ASSEMBLY OF DIFFERENTIAL GEAR CASE
ASSEMBLY
1.
Bearing
Using press fit kit d {120 mm (4.724 in) inner diameter}, press fit
bearing (26) to case (25).
2.
Bevel gear (small)

Install thrust and small bevel gear (24) in case.
Align thrust with dowel pin and install.
3.
Pinion gear, cross shaft

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

Install bevel gear (20) and thrust plate (19).
WA500-3LK
30-1311

5.
DIFFERENTIAL
Bevel gear (large)

Using eye-bolts (thread dia. = 16 mm, Pitch = 2.0 mm), lift and
install bevel gear (18).
Align pin hole of thrust and dowel pin on case side and install.
FINE ASSEMBLY OF PINION ASSEMBLY

6.
Bearing
A. Using press fit kit e (26 mm inner diameter), install pinion
bearing (17).
B. Using press fit kit f {55 mm (2.165 in) inner diameter}, install
bearing (16).
Rotating surface of bearing: Engine oil (EO30-CD)
C. Install snap ring (15).
7.
Cage
A. Install outer races (14) and (13).
B. lnstall cage (11) to pinion assembly.
30-1321
WA500-3LK

8.
Collar
Install collar (27).
9.
Bearing
Using press fit kit e (76 mm inner diameter), install bearing (12).
DIFFERENTIAL
ASSEMBLY OF DIFFERENTIAL GEAR

ASSEMBLY
Set differential case on special tools H1-I, H2-2, and H2-3.
10. Pinion assembly

A. Assemble shims removed when disassembled.
Standard shims thickness: 2.1 mm (0.083in).
B. Using eye-bolts f (Thread dia.=12mm, Pitch 1.75 mm), install
pinion assembly (4).
C. Install oil seal (3) and dust seal (3A) to case.
Rear Lip of dust seal: Grease (G2-LI)
D. Fit O-ring to case, and install case (2).

WA500-3LK
30-1331
DIFFERENTIAL
E. Insert coupling (28), fit O-ring and tighten holder.

Mounting bolt: 921 98 Nm (608 72 lbf ft)
Fit the balancer to bolt hole of coupling, and measure
the rotating torque: Rotating torque: Max. 50.0 N (11.22
lbf)
11 Differential gear assembly

Sling differential gear assembly (10) and install case.
12. Nut, cap

A. Align nut (7) with differential case groove and install.
B. Install cap (8) and tighten (9).

Mounting bolt:
Check match marks on bearing cup before installing.
Rotate bevel gear 20 - 30 times to settle in, then tighten bolt.
30-1341
WA500-3LK
DIFFERENTIAL
Bearing pre-load adjustment steps are as follows.

C. Install tool H4-1 and H4-2 to cap on both sides.
D. Measure clearance a between tool H4-2 with tool H4-1.
E. Add 0.26 0.07 mm (0.010 0.003 in) to measurement

dimension and set scale on tool H4-1.
The added dimension becomes the amount of bending of
the
case, given before pre-load and given after pre-load.
F.
Tighten adjusting nut with bar until increased amount becomes

0.26 0.07 mm (0.010 0.003 in).
Caution for pre-load adjustment

When adjusting nut is overtightened (in case the amount of
increased bending surpasses the standard measurement), return
adjusting nut to position before adjusting. Then, while rotating
bevel gear, lightly tap bearing cap and bevel gear with plastic
hammer, and check that there is no clearance in position b.
WA500-3LK
30-1351
DIFFERENTIAL
13. Adjusting tooth contact, backlash

Adjust the backlash, and at the same time adjust tooth contact.
A. Adjust backlash as follows:
i.
Movement of bevel gear is done with adjusting nut (7).

At this time, so as not to change pre-load pressurization
of bearing, turn nuts on both sides, the same amount each,
in same direction.
Put dial gauge in vertical contact with forward and

reverse sides of outer edge of bevel gear tooth face, and
while turning adjusting nut, adjust until gauge meter
fluctuation becomes 0.3 - 0.4 mm (0.012 - 0.016 in).
Measure at three or four places, and keep the pinion gear fixed
when measuring.
ii.
B. Adjust tooth contact as follows:

i.
Adjust bevel pinion by adjusting shims between differential

case and bearing cage.
ii.
Adjusting tooth contact

For details, see ADJUSTING TOOTH CONTACT.
30-1361
WA500-3LK
DIFFERENTIAL
C. Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the
pinion gear forward and backward and inspect the pattern left on the teeth.
Tooth contact
Cause
Correct contact
The tooth contact pattern should start
from about 5 mm from the toe of the
bevel gear and cover about 50% of the
length of the tooth.
It should be in the center of the tooth
height.
Bevel pinion is too far from bevel gear.
Bevel pinion is too close to bevel gear.
Bevel gear is too close to bevel pinion
Bevel gear is too far from bevel pinion.
Procedure for adjustment
Adjust the bevel pinion by adjusting the shims at the bevel

pinion cage.
Adjust the bevel gear in the same way as when adjusting
backlash.
1.
Reduce shims at bevel

pinion to bring closer to
bevel gear.
2.
Move bevel gear further

away from bevel pinion
and adjust backlash
correctly.
1.
Increase shims at bevel

pinion to move away from
bevel gear.
2.
Move bevel gear closer to

bevel pinion and adjust
backlash correctly.
1.

bevel gear.
2.

and adjust backlash
correctly.
1.

pinion to move away
from bevel gear.
2.

backlash correctly.
When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and
right. Always keep the same total thickness of shims.
WA500-3LK
30-1371
DIFFERENTIAL
14. Lock
After adjusting tooth contact and backlash, install lock (6).
30-1381
WA500-3LK
DIFFERENTIAL
12
DISSASSEMBLY
OF LIMITED SLIP DIFFERENTIAL ASSEMBLY
1.
Set differential assembly (1) on special tools H2-1, H2-2 and H-3.
Differential assembly: 230 kg (507 lb)
2.
Pinion assembly
A. Remove case (2).
B. Remove oil seal (3) and dust seal (3A) from case.
C. Screw in forcing screw b (Thread dia. = 18 mm, Pitch = 1.75

mm) and fit out pinion assembly (4).
Check for the number of shims (5) used.
WA500-3LK
30-1391
DIFFERENTIAL
12
3. Differential gear case assembly
A. Remove left and right locks (6) and with a bar, turn nut (7) until it
becomes loose.
B. Remove mount bolts (9) of cap (8).
C. Remove nut and lift out differential gear case assembly (10).
30-1401
WA500-3LK
DIFFERENTIAL
12
FINE
DISASSEMBLY OF PINION ASSEMBLY
4.
Bearing, collar, cage

A. Support cage (11), push shaft with press and tack out pinion.
B. Remove bearing (12) and collar from cage.
C. Remove outer races (13) and (14) from cage (11).
5.
Pinion, bearing
A. Remove snap ring (15), then remove bearing (16).
B. Remove bearing (17).
WA500-3LK
30-1411
DIFFERENTIAL
12
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE
ASSEMBLY
6.
Bevel gear (large)

Remove mount bolts, using eye-bolts c (Thread dia. = 16 mm, Pitch =
2.0 mm) lift off bevel gear (18).
7.
Cover
A. Remove bearing (19).
B. Remove mount bolts (20-1) and detach cover (20).

C. Remove thrust washer (21), disc (22), plate (22-1), pressure ring
(23) and side gear (24).
Remove them on both sides.
D. Take out shaft and pinion gear assembly from flange half (25) and
remove pinion gear from shaft.
30-1421
WA500-3LK
DIFFERENTIAL
12
8. Bevel gear (small)
Remove bevel gear (26) and thrust plate.
9.
Bearing
Remove bearing 928) from case (27).
ASSEMBLY OF LIMITED SLIP DIFFERENTIAL ASSEMBLY

1.
Ring gear
A. Press fit bearing (28) to flange half (25).
B. Mount flange half (25) to ring gear (29).

Mount bolt: Adhesive (LT-2)
Mount bolt: 490 - 608 Nm (361.4 - 448.4 lbf ft)
WA500-3LK
30-1431
DIFFERENTIAL
12
2. Slide gear, disc plate (lower part)
A. Mount thrust washer (21) to flange half.
Fit the washer to the pin in the case with reliability.
Thrust washer: Apply grease (G2-LI) to its sides
B. Mount two plates and two discs in order of the plate (22-1) and
disc (22).
Select four plates from 425-22-27450, 425-22-27460 and
425-22-27470 and mount two at each of right and left sides.
The difference between thickness of the right and left plates should be 0.1 mm or less.
Disc: Apply Shell DONAX TD to both sides
C. Mount pressure ring (33) and assembly side gear (24).

3.
Bevel gear (large)

Using eye-bolts c (Thread dia. = 16 mm, Pitch = 2.0 mm), lift and
install bevel gear (18).
Align pin hole of thrust and dowel pin on case side and
install.
30-1441
WA500-3LK
DIFFERENTIAL
12
FINE
ASSEMBLY OF PINION ASSEMBLY
4.
Bearing
A. Using press fit kit e (26 mm inner diameter), install pinion
bearing (17).
B. Using press fit kit f (55 mm inner diameter), install bearing (16).
Rotating surface of bearing: Engine oil (EO30-CD)
C. Install snap ring (15).
5.
Cage
A. Install outer races (14) and (13).
B. Install cage (11) to pinion assembly.
6.
Collar
Install collar (30).
7.
Bearing
Using press fit kit e (76 mm inner diameter), install bearing (12).
WA500-3LK
30-1451

12
ASSEMBLY
DIFFERENTIAL
OF DIFFERENTIAL ASSEMBLY
Set differential case on special tools H1-1, H2-2 and H2-3.

8.
Pinion assembly
A. Assemble shims (5) removed when disassembled.
Standard shim thickness: 2.1 mm.
B. Using eye-bolts f (Thread dia. = 12 mm, Pitch = 1.75 mm),
install pinion assembly (4).
C. Remove oil seal (3) and dust seal (3A) to case.

Lip of dust seal: Grease (G2-LI)
D. Fit O-ring to case and install case (2).

Mount bolt: Thread tightener (LT-2)
Mount bolt: 279.3 29.4 Nm (206 21.6 lbf ft)
9.
Pinion gear
Mount pinion gear (24-2) to shaft (24-1) and assemble it to flange half.
Fit the corner part of the shaft into the groove of the pressure
ring with reliability.
30-1461
WA500-3LK
DIFFERENTIAL
12
10. Side gear, disc plate (upper part)
A. Assemble side gear (24) and pressure ring (23) inside case.
Fit the corner part of the cross shaft into the groove of the
pressure ring with reliability.
Rotate the side gear (forward and back) two to three times to
conform.
B. Mount two disks and two plates in order of disc (22) and plate
(22-1).
Disc: Apply Shell DONAXTD to both sides.
11. Adjustment
Adjust clearance between the disc, plate. Measure distance A between
top surfaces of flange half and plate and distance B between cover
mounting surface and faucet joint and calculate clearance between
plates.
Clearance between plates (discs): A - B = 0.2 - 0.8 mm
When the clearance is outside the standard range, replace the
plates to assure the correct clearance.
The difference between the thickness of right and left plates
should be 0.1 mm or less.
12. Cover
A. Press fit bearing (19) to cover (20).
B. Mount selected thrust washer (21) to cover (20).
Thrust washer: Apply grease (G2-LI) to both sides
C. Mount cover (20) and tighten it with bolt (20-1).

Mount bolt: 113.0 9.8 Nm (83.3 7.2 lbf ft)
WA500-3LK
30-1471
DIFFERENTIAL
12
13. Measurement of differential torque
Secure (stop rotation of) side gear at ring gear side of differential
assembly and measure the rpm of side gear opposite side.
Differential torque: 14.7 Nm (10.8 lbf ft) or less
Freely rotate the differential except the side gear.
Any shape of measuring tool is acceptable, except that it conforms
measuring conditions and can secure the side gear.
14. Differential gear assembly

Sling differential gear assembly (10) and install case.
15. Nut, cap

A. Align nut (7) with differential case groove and install.
30-1481
WA500-3LK
DIFFERENTIAL
12
B. Install cap (8) and tighten (9).
Mount bolt: Thread tighener (LT-2)
Mount bolt: 931 98 Nm (686.6 72.2 lbf ft)
BEARING PRE-LOAD ADJUSMENT STEPS ARE A FOLLOWS:

1.
Install tool H4-1 and H-2 to cap on both sides.
2.
Measure clearance "a" between tool H4-2 with tool H4-1.
3.
Add 0.26 0.07 mm to measurement dimension and set scale on tool

H4-1.
The added dimension becomes the amount of bending of the case,
given before pre-load and given after pre-load.
4.
Tighten adjusting nut with bar until increased amount becomes 0.26
0.07 mm.
WA500-3LK
30-1491
DIFFERENTIAL
12
Caution for pre-load adjustment
When adjusting nut is overtightened, in case the amount of increased
bending surpasses the standard measurement, return adjusting nut to
the position before adjusting. Then while rotating bevel gear, lightly
tap bearing cap and bevel gear with plastic hammer and check that
there is no clearance in position b.
16. Adjust tooth contact, backlash

Adjust the backlash and at the same time adjust tooth contact
A. Adjust backlash as follows:
i.
Movement of bevel gear is done with adjusting nut (7). At

this time, so as not to change pre-load pressurization of bearing, turn nuts on both sides, the same amount each, in same
direction.
ii.
Put dial gauge d in vertical contact with forward and reverse

sides of outer edge of bevel gear tooth face and while turning
adjusting nut, adjust until gauge meter fluctuation becomes
0.3 - 0.4 mm.
Measure at 3 or 4 places and keep the pinion gear when measuring.
B. Adjust tooth contact as follows:

i.
Adjust bevel pinion by adjusting shims between differential

case and bearing cage.
ii.
Adjusting tooth contact

For details, see ADJUSTING TOOTH CONTACT.
30-1501
WA500-3LK
DIFFERENTIAL
12
C. Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the
pinion gear forward and backward and inspect the pattern left on the teeth.
Tooth contact
Cause
Correct contact
The tooth contact pattern should start
from about 5 mm from the toe of the
bevel gear and cover about 50% of the
length of the tooth.
It should be in the center of the tooth
height.
Bevel pinion is too far from bevel gear.
Bevel pinion is too close to bevel gear.
Bevel gear is too close to bevel pinion
Bevel gear is too far from bevel pinion.
Procedure for adjustment
Adjust the bevel pinion by adjusting the shims at the bevel

pinion cage.
Adjust the bevel gear in the same way as when adjusting
backlash.
1.

bevel gear.
2.

and adjust backlash
correctly.
1.

pinion to move away from
bevel gear.
2.

backlash correctly.
1.

bevel gear.
2.

and adjust backlash
correctly.
1.

pinion to move away
from bevel gear.
2.

backlash correctly.
When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and
right. Always keep the same total thickness of shims.
WA500-3LK
30-1511
DIFFERENTIAL
12
17. Lock
After adjusting tooth contact and backlash, install lock (6).
30-1521
WA500-3LK
DIFFERENTIAL
12
DISASSEMBLY
OF FINAL DRIVE ASSEMBLY
1.
Tire assembly
Loosen hub nut, raise chassis with work equipment or jack, insert
support stand under axle, then sling tire assembly, remove hub nuts,
and lift off tire assembly (1).
Tire assembly: 660 kg (1452 lb)

2.
Draining oil
Remove drain plug (2) and drain oil.
Set so that the drain plug is at the bottom.
Axle oil: 78 liter (20.6 gal) (front and rear)
3.
Cover
Remove mounting bolts (3), then remove cover (4).
4.
Drive shaft
Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75 mm) in drive
shaft, then pull out drive shaft assembly (5) and remove.
5.
Planetary carrier assembly

Remove mounting bolts (6), then using eyebolt (Thread dia.=12
mm, Pitch=1.75 mm), lift off planetary carrier assembly (7).
Use a bar to adjust the position of the center of gravity when
removing.
Planetary carrier assembly: 90 kg (198.42 lb)
WA500-3LK
30-1531

6.
DIFFERENTIAL
Ring gear
A. Using tool H6, secure wheel hub (8) and brake housing (9).
Install tool H6 at three places at equal distances.
Do not remove tool H6 until assembly Step 3.
B. Remove mounting bolts (10), then remove retainer (11) and

ring gear (12).
Check the number and thickness of shims on the inside of
the retainer.
Ring gear: 50 kg (110 lb)
7.
Disassembly of planetary carrier

Using press, pull out shaft (13), then remove pinion gear (14).
Lock ball (15) is fitted in the shaft, so be careful not to lose the ball.
Write the serial number on the case and be careful not to mix the
removed parts with other parts.
The bearings and other parts have settled as a set, so make
identification marks and be careful not to mix with other parts.
30-1541
WA500-3LK
8.
DIFFERENTIAL
Disassembly of ring gear

A. Remove lock plates (18) from ring gear hub (17), then remove
ring gear (19)
B. Pull out bearing (20) from ring gear hub (17).
WA500-3LK
30-1551

12
ASSEMBLY
1.
DIFFERENTIAL
OF FINAL DRIVE ASSEMBLY
Assembly of ring gear

A. Press fit bearing (20) on ring gear hub (17).
After press fitting the bearing, check that there is not
clearance between the rib and bearing.
B. Set ring gear hub (17) on ring gear (19), then install lock
plates (18).
Install the lock plates with the wider ones on the inside.
Remove all grease and oil from the bolt.

2.
Assembly of planetary carrier

Set pinion gear (14) in carrier case, insert ball (15) in shaft (13),
then press fit.
Press fit so that the hole for the lock ball is on the outside
circumference, then stop with the hole at the front and align
the holes.
After press fitting the shaft, check that the gear rotates smoothly.
30-1561
WA500-3LK

3.
DIFFERENTIAL
Wheel bearing adjustment

A. Insert ring gear assembly (12) in axle housing, fit retainer (11)
tighten temporarily with mounting bolts (10), and remove tool H6.
B. Measure thickness b of retainer before installing. Do not insert

shims in the retainer when tightening temporarily.
Rotate the wheel hub 20 - 30 times and tighten the bolts to
a uniform torque.
C. Using a depth micrometer or dial gauge, insert through

measuring hole of retainer (21) and measure clearance a from
retainer to face of housing.
Measure at two places and take the average.
0.3 mm (0.012 in) added to measured value difference
C = a - b, becomes shim thickness.
Use the smallest number of shims which gives the
required thickness.
WA500-3LK
30-1571
DIFFERENTIAL
D. After installing tool H6 to brake housing and wheel hub,

remove retainer, insert the required number of shims and
retainer, then tighten mounting bolts.
When assembling shims, after installing tool H6, always
tighten the mounting bolts uniformly to the specified
tightening torque.
4.
Planetary carrier
Fit O-ring, using eye-bolts (2) (Thread dia. = 12 mm, Pitch = 1.75 mm)
sling planetary carrier assembly (7), set in mounting position and
tighten mounting bolts (6).
Because balance is bad, adjust the center of gravity with a bar
and install.
5.
Axle shaft
Screw in bolt b (Thread dia. = 12 mm, Pitch= 1.75 mm) in axle
shaft and insert axle shaft assembly (5).
If the position of the sun gear does not match, rotate the wheel
hub to align.
6.
Cover
Fit O-ring, install final drive cover (4), then tighten mounting bolts (3).
Mount bolt: 68.6 9.8 Nm (51 7 lbf ft)
30-1581
WA500-3LK

7.
DIFFERENTIAL
Refilling with oil

Tighten drain plug (2), then remove level plug, and add oil through
oil filter to specified level. Set the machine so that the level plug of
the final drive is at the bottom when refilling with oil.
Axle oil: Approx. 78 liter (20.6 gal) (each)
8.
Tire assembly
Raise tire assembly (1), set to wheel hub, and tighten temporarily
with wheel nuts. Then jack up chassis with work equipment and jack,
remove stand under axle, lower chassis to ground and tighten wheel
nuts to specified torque.
Wheel nut: 470 49.0 Nm (347 36 lbf ft)
(Width across flats: 30 mm)
WA500-3LK
30-1591

12
STEERING
STEERING ORBITAL VALVE
ORBITAL VALVE
REMOVAL
1.
Remove cover (1) from steering column.
2.
Remove joint lock bolt (2).
3.
Disconnect four hoses (3).

Mark the hoses and their destinations to facilitate reassembly.
4.
Remove three mounting bolts (4), then remove orbital steering valve
assembly (5).
5.
Remove joint lock bolt (6), then remove joint assembly (7).
6.
Remove bolt (8), then remove bracket (9).
INSTALLATION
Joint lock bolt: 55.9 7.8 Nm (41 6 lbf ft)
Bracket mounting bolt: 51.9 7.8 Nm (38 6 lbf ft)
30-1601
WA500-3LK
DISASSEMBLY
ENSURE A CLEAN WORKING ENVIRONMENT
1.
Dirt or debris in the hydraulic system will cause premature wear and erratic operation. Keep all dirt and dust out of the
hydraulic circuit.
2.
Use a clean work bench when disassembling or assembling the equipment.
3.
Remove dirt from the exterior of the unit before disconnecting any piping.
4.
Always wipe dirt off the unit before placing it on the work bench.
5.
After disassembling, wash with a clean petroleum-base solvent, and blow dry with clean air. Always ensure that there
are no impurities in the solvent or air.
If any other solvent is used, it may lead to deterioration of the rubber seal. Never wipe any part with a cloth or
apply steam to the unit.
The solvent is flammable. Keep flames and sparks away.
PREPARATORY WORK
1.
Fit blind plugs in the five ports in the valve body, clean the outside,
then remove the blind plugs.
2.
Install tube nut to one of the ports.
3.
Install in a vise with the end cover at the top.

Do not clamp the valve body directly in the vise, which could
damage or break the unit.
4.
Remove 7 mounting bolts (1), insert screwdriver between end cover

assembly (2) and sleeve (3), then remove end cover assembly (2).
After removing, check that there is no damage to the edge of the
hole in the end cover.
WA500-3LK
30-1611

5.
Remove commutator (5) and washer (6).

Do not remove pin (4).
6.
Using two mounting bolts (1), remove commutator ring (7) and
manifold (8).
7.
Using two mounting bolts (1), remove rotor set (9) and wear plate
(10) in the same way as commutator ring and manifold.
8.
Insert screwdriver between sleeve (3) and valve body (11), then
remove sleeve (3).
9.
Remove drive link(12).
10. Remove ball (13).

11. Remove rod (14), roller (15), rod (16), and spring (17).
30-1621
WA500-3LK
12. Install in vise with input shaft (18) at the top, and make counter
marks with a punch in upper cover (19) and valve body (11).
13. Remove four mounting bolts (20), then grip input shaft (18), move it
up, and remove input shaft, upper cover, and valve spool assembly (23).
The valve spool is fitted in the body with an extremely small

clearance, so if a horizontal force is applied, it will be impossible
to remove it. When removing the valve spool from the housing,
never apply any excessive force.
14. Remove upper cover assembly (22) from input shaft and valve spool
assembly (23), then remove shim (24) and spacer (25).
Check the number and thickness of the shims, and keep in a
safe place.
15. Remove seal (26) and snap ring (27), then remove spacer (28),
seal (29), and seal ring (30) from upper cover (19).
WA500-3LK
30-1631
Seal (29) and seal ring (30) may form one unit.
16. Remove snap ring (31), thrust washer (32), thrust bearing (33),
thrust washer (34), and wave washer (35) from input shaft (18).
17. Use punch pin (3) (3.0 mm dia, 16 mm length), to remove needle
roller (36) from input shaft (18).
Cushion the input shaft with a wooden block to prevent damage
when striking with the hammer.
30-1641
WA500-3LK
12
18. Set valve spool (37) facing bottom, then remove torsion bar (38)
and spacer (39) from input shaft and valve spool assembly.
Do not remove needle roller (40) from the torsion bar.
19. Set valve spool (37) facing bottom, then rotate input shaft (18) until
drive link (41) comes out.
20. Set valve spool (37) facing bottom, then rotate input shaft (18)
clockwise to a point where ball comes out.
Ball (42) may come out by itself, so be careful not to lose it.
Do not remove ball retaining spring (43) unless it is to be

replaced. When removing it, hold the flat end with pliers and
pull up until it comes completely out from valve spool (37).
When doing this, be careful not to damage the outside of the
valve spool or the control edge.
WA500-3LK
30-1651
ASSEMBLY
Before assembly, wash all parts with clean petroleum based solvent
and dry with air. Never wipe with a cloth.
Check carefully that there is no debris or paint on the edge of the
lapped surface.
If there are no special instructions, do not coat any parts with oil
when assembling.
1.
Set thrust washer (34), thrust bearing (33), and thrust washer (32) to
input shaft (18), and install snap ring (31).
2.
Install wave washer (35) to thrust bearing (33) and thrust washer (34).
3.
Install ball (42) inside valve spool (37).
4.
To mesh the groove and ball, rotate counterclockwise and insert

input shaft (18) into valve spool (37).
Keep the spool horizontal when doing this.
5.
Fit center portion of torsion bar (38) between thrust washer (34)
and valve spool (37).
30-1661
WA500-3LK
The positioning of the valve spool and input shaft is carried out
by inserting the torsion bar.
6.
Check spline of input shaft (18) and drive link (41), and align spline
of valve spool (37), then install drive link (41).
If the drive link and input shaft do not mesh, rotate the input
shaft slightly to carry out the meshing.
When inserting the drive link, make sure that the torsion bar is
securely held in position.
If the drive link is assembled correctly, there will be a clearance
of 8.89 mm (0.350 in) between the thrust washer and valve spool.
If the relationship between the spool, drive link, and input shaft
is not correct, the steering unit will not work properly.
7.
Measure diameter L of pin (40) of torsion bar (38) at several points

and check that the difference does not exceed 0.025 mm (0.010 in).
8.
Set spacer (39) to torsion bar (38), then insert in valve spool and
input shaft assembly (23).
WA500-3LK
30-1671

9.
Using pin (outside diameter: 3 mm), align pin hole of input shaft
(18) and torsion bar (38).
10. Using pin (1), knock pin (36) 0.8 mm in from end face of input shaft.
11. Install spacer (25) on valve spool and input shaft. If there is a lip at
one end inside the spacer, install so that the lip surface is facing the
wave washer.
12. Install input shaft and valve spool assembly (23) to valve body (11).
The clearance is extremely small, so if any sideways pressure is
applied during assembly, it will not work properly.
13. Set shim (24) on top of thrust washer, fit seal, align counter marks of
upper cover (19), then install and tighten mounting bolts (20)
temporarily.
14. Set tool F1 in position, and install so that valve body and upper
cover are centered.
15. Tighten mounting bolts (20) and remove tool F1.
30-1681
WA500-3LK
16. Measure width w of groove of drive link (12) at several places and
check that the difference does not exceed 0.025 mm.
17. Pull input shaft down, align drive link (12) with spline of valve spool,
then rotate spool so that end face of spool and valve body are level
with each other.
18. Align pin (40) and drive link (12) and install.
19. Using depth gauge , measure installed height h of end face of

valve body and valve spool.
WA500-3LK
30-1691
If installed height h = Within 0.063 mm it is not necessary to

adjust shim.
If installed height h = 0.064 mm or more, repeat Steps 12
through 19 to adjust the shim height so that h = Within 0.063 mm.
20. Install ball (13).

21. Set rod (17) to spring (16), then fit to valve body (11) and install
roller (15) and rod (14).
22. Fit seal to valve body.
23. Before installing rotor, check rotor as follows.

A. Set the pin end of end cover assembly at top and spline end of
rotor assembly (9) at bottom, then check that rotor rotates freely
inside stator.
B. Measure thickness of rotor and stator, and check that the

difference is less than 0.18 mm (0.007 in).
C. Using feeler gauge (7), check that the clearance of the rotor
from the stator is less than 0.18 mm (0.007 in).
30-1701
WA500-3LK
24. Using guide pin , install wear plate (10), rotor assembly (9), and
manifold (8).
25. Fit seal to end cover assembly (2).
26. Set sleeve (3) and end cover assembly (2) in position, tighten
mounting bolts (1) uniformly, then install sleeve, and remove end
cover assembly.
27. Fit washer (6) to end cover assembly (2), and install commutator (5).
Install the commutator so that the concave part is at the end
cover assembly end.
Determine the position so that the oval hole of the commutator

is in line with one of the bolt holes of the end cover assembly.
WA500-3LK
30-1711
28. Install commutator ring (7).

29. Rotate input shaft so that tip of drive shaft is aligned with oval hole
in commutator.
30. Set end cover assembly (2) on sleeve (3), then tighten five mounting
bolts uniformly.
Mounting bolt: 6.9 0.6 Nm (61 6 lbf in)
31. Set input shaft end facing top, then install seal ring (30) and seal (29).
Install the seals from the small diameter end.
Seal ring (30) and seal (29) are stuck together and are supplied
as one unit.
Coat the new seal with oil and install from the lip end.
When doing this, coat the inside with a small amount of grease.
32. Using tool F2, install spacer (28) from small diameter end.
33. Install snap ring (27).
34. Fit seal (26) to input shaft, and fit to upper cover.
30-1721
WA500-3LK
12
MEMORANDUM
WA500-3LK
30-1731
STEERING CYLINDER
12
STEERING CYLINDER
REMOVAL
WARNING! Pressure in the hydraulic system must be

released. Loosen oil filler cap slowly to
release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release remaining
pressure in the hydraulic piping.
1.
Remove bolts (1), loosen bolt (2), then rotate cover (3) carefully
towards rear of machine.
Rotate the cover using bolt (2) as the fulcrum.
The operating space is confined, so be extremely careful when

carrying out the operation.
2.
Disconnect bottom hose (4).
3.
Disconnect grease tube (5).
4.
Remove mounting bolt (6), then pull out pin (7).

Note the number and thickness of the shims to use as a guideline
when assembling.
5.
Disconnect head hose (8).
30-1741
WA500-3LK

6.
Remove mounting bolt (9), then pull out pin (10).

Note the number and thickness of the shims to use as a guideline
when assembling.
7.
Using lever block, lift off steering cylinder (11).

Carry out the removal operation for the cylinder using two workers.
Be careful not to damage the cylinder rod.
STEERING CYLINDER
Steering cylinder: 47 kg (103.4 lb)
INSTALLATION

Adjust the shims so that the clearance is specified value.
Clearance a + b = Less than 1.0 mm (0.039 in) (The specified value
is the same for both the rod end and the bottom end.)
WARNING! Align position of the pin hole with a bar.
Never insert a finger into the pin hole.
WA500-3LK
30-1751
STEERING CYLINDER
DISASSEMBLY
1.
Set cylinder assembly (1) in tool U1.
2.
Raise lock of cylinder head (2), then using tool U2, remove cylinder
head (2) from cylinder.
3.
Pull cylinder head and piston rod assembly (3) out from cylinder (4),
then lift off.
Oil will come out when the piston rod assembly is removed from
the cylinder, so catch it in a container.
4.
Remove cylinder (4) from tool U1.
5.
Set cylinder head and piston rod assembly in tool U1, and, using
power wrench and socket U3, loosen nut (5).
Power wrench: x 16
Socket U3: Width across flats: 60 mm
6.
Remove nut (5), then remove piston assembly (6), and cylinder head
assembly (7) from rod (8).
30-1761
WA500-3LK

7.
STEERING CYLINDER
Disassembly of piston assembly

A. Remove wear ring (9).
B. Remove piston ring (10) from piston (11).
8.
Disassembly of cylinder head assembly

A. Remove snap ring (16), then remove dust seal (17).
B. Remove rod packing (18).

C. Remove buffer ring (19).
D. Remove O-ring (20) and backup ring (21).
E. Remove O-ring (22).
F.
Remove bushing (23) from cylinder head (24).
WA500-3LK
30-1771
STEERING CYLINDER
ASSEMBLY
Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing. Be careful not
to damage the rod packing, dust seals or O-ring when assembling.
1.
Assembly of cylinder head assembly

A. Using tool U5, press fit bushing (23) to cylinder head (24).
Be extremely careful not to deform the bushing when press
fitting.
B. Install buffer ring (19).

C. Install rod packing (18).
Be careful to install rod packing (18) facing in the correct
direction.
D. Using push tool, install dust seal (17) to cylinder head (24).
E. Install snap ring (16).
F.
Install O-ring (22).
G. Install backup ring (21) and O-ring (20).

Do not try to force the backup ring into position.
Warm it in water 50 - 60C (122 - 140F) before fitting it.
2.
Assembly of piston assembly

A. Using tool U6-1, expand piston ring (10).
Place the piston ring on the expander and turn the handle
8 - 10 times to expand the ring.
B. Remove piston ring (10) from tool U6-1, and assemble on
piston (11).
C. Fit tool U6-2, on piston ring, then using clamp U6-3, contact
piston ring.
D. Assemble wear ring (9).
30-1781
WA500-3LK

3.
Set piston rod (8) in tool U1.
4.
Assemble cylinder head assembly (7) and piston assembly (6) on rod,
then fit nut (5).
5.
Using power wrench and socket U3 tighten piston nut (5).
STEERING CYLINDER
Power of power wrench (1): X16

Width across flats of nut (5): 60 mm
Tightening torque of nut: 1765 176 Nm
(1302 132 lbf ft)
6.
Remove piston rod and head assembly from tool U1.
7.
Set cylinder (4) in tool U1.
8.
Raise piston rod and head assembly (3), and assemble in cylinder (4).
9.
Using tool U2, tighten cylinder head nut (2).

Cylinder head nut: 932.0 93.2 Nm (687 69 lbf ft)
10. Bend lock into notch on cylinder side.

11. Remove cylinder assembly from tool U1.
WA500-3LK
30-1791
STEERING VALVE
STEERING VALVE
REMOVAL
1.
Remove bolt (1), loosen bolt (2),then rotate cover (3) carefully
towards rear of machine.
2.
Remove side cover (4).
3.
Remove mounting bolts (5), and disconnect bracket (6).
4.
Remove mounting bolts (7), and disconnect bracket (8).
5.
Disconnect hose (9) between cut-off valve and hydraulic tank.
6.
Disconnect hoses (10) and (11) between cut-off valve and loader circuit.
7.
Disconnect hose (12) between steering valve and cut-off valve.

Hose (12) is at the rear of the cut-off valve.
30-1801
WA500-3LK

8.
Disconnect tubes (13) between steering valve and steering cylinder.
9.
Disconnect tube, (14) between steering valve and hydraulic tank.
STEERING VALVE
10. Disconnect hose (15) between stop valve and steering valve.
11. Disconnect hose (16) between stop valve and steering valve.
It is connected to both ends of the steering valve.
12. Disconnect hose (17) between steering valve and steering pump.
13. Disconnect tube (18) between switch pump and steering valve.
14. Disconnect hose (19) between steering valve and cut-off valve.
15. Remove mounting bolt (20).
16. Using guide bolt (1), pull out steering valve assembly (21) together
with bracket approx. 200 mm (7.874 in) to center of machine.
Remove the cut-off valve at this point.
WA500-3LK
30-1811
STEERING VALVE
17. Lift off steering valve assembly (21) together with bracket.
INSTALLATION
Install the cut-off valve after lowering the steering valve assembly together with the bracket to the mounting position.
After installing the cut-off valve, use the guide bolt to move close to the frame and install.
30-1821
WA500-3LK
STEERING VALVE
12
MEMORANDUM
WA500-3LK
30-1831
BRAKE VALVE
BRAKE VALVE
REMOVAL
1.
Remove clamp (1) at front of brake valve.
2.
Disconnect hose (2) between valve and hydraulic tank.
3.
Disconnect hoses (3) and (4) between accumulator and valve.
4.
Fit a wrench to the joint to stop it from turning.
5.
Remove hoses (5) between R.H. brake valve and slack adjuster.
6.
Remove clamp (6).
7.
Disconnect hose (7) between R.H. brake valve and L.H. brake valve.
8.
Disconnect hose (8) between valve and hydraulic tank.
9.
Disconnect hose (9) between accumulator and valve.
10. Remove pedal (10).
11. Pull out snap pin (11), then pull out pin (12).
Be careful not to lose L-shaped pin (13).
30-1841
WA500-3LK
BRAKE VALVE
12. Remove mounting bolts (14), then remove brake valve assembly (15).
Carry out the operation with two workers and remove the valve
assembly from under the floor plate.
INSTALLATION
Reverse the removal procedure to install a brake valve assembly.
WA500-3LK
30-1851
SLACK ADJUSTER
SLACK ADJUSTER
REMOVAL
1.
Remove cover (1) on top of front frame.
2.
Disconnect tube (2) between brake valve and slack adjuster.
3.
Disconnect tube (3) between slack adjuster and left and right brake
pistons.
4.
Remove mounting bolts, then remove slack adjuster (4).

INSTALLATION
Tube: 80.9 12.3 Nm (60 9 lbf ft)
Tube: 68.6 9.8 Nm (51 7 lbf ft)
30-1861
WA500-3LK
SLACK ADJUSTER
DISASSEMBLY
1.
Bleeder
Remove bleeder (2) from body (1).
2.
Cylinder
Remove mounting bolts, then disconnect body (1) and cylinder (4)
together with bracket (3).
WARNING! There is spring tension inside the cylinder,
so hold the contact surfaces and be
careful when removing.
3.
Piston
A. Remove spring (5) and O-ring (6).
B. Remove piston (7), then remove O-ring
Use a rod of 10 mm (0.394 in) diameter and push out the
piston slowly.
Be careful not to damage the thread with the rod.
4. Poppet
Do not disassemble the poppet unless necessary. If it is disassembled,
replace the whole cylinder assembly.
A. Remove cover (8) from cylinder (4), then remove plug (9),
spring (10) and poppet (11).
When removing the poppet, blow in air from the oil hole in
the cylinder.
Hold the oil port of the cylinder by hand, and do not pump
in air suddenly.
Be careful not to change the combination of poppet (11)
and cylinder (4).
When replacing, replace the poppet and cylinder as an assembly.
B. Remove O-ring (12) from poppet.
WA500-3LK
30-1871
SLACK ADJUSTER
ASSEMBLY
1.
Poppet
A. Fit O-ring (12) on poppet (11).
B. Install poppet (11), spring (10), plug (9) and cover (8), then
assemble cylinder (4).
2.
Piston
A. Install O-ring (13) on piston (7).
B. Insert piston (7) in cylinder (4).
Check that the piston moves smoothly.
3.
Cylinder
A. Install O-ring (6) and spring (5) in cylinder.
Installed load of spring 43.1 Nm (9.68 lbf)
B. Install body (1) and cylinder (4) together with bracket (3).
4.
Bleeder
Install bleeder (2).
30-1881
WA500-3LK
BRAKE ASSEMBLY (FRONT AND REAR)
BRAKE ASSEMBLY (FRONT AND

REAR)
REMOVAL
1.
Remove final drive assembly. For details, see FINAL DRIVE

DISASSEMBLY.
2.
Disconnect brake tube (1).
3.
Set tool H6 in position, and sling brake and wheel hub assembly,
remove mounting bolts (2), then lift off brake and wheel hub
assembly (3).
Brake, wheel hub assembly: 280 kg (617.3 lb)

4.
Remove bearing (5) and retainer (6) from axle (4).
INSTALLATION
Brake tube: 68.6 9.8 Nm (51 7 lbf ft)

Brake, wheel hub mounting bolt: 548.8 58.8 Nm (405 43 lbf ft)
WA500-3LK
30-1891
DISASSEMBLY
1.
Cylinder
Using eyebolt b (Thread dia. = 16 mm, Pitch = 2.0 mm), lift out
cylinder (1).
Disassemble cylinder with following steps:

A. Screw in eyebolts b (Thread dia.=16 mm, Pitch 2.0 mm),
push in spring with bar c, then pull out pin (2).
B. Remove spring (3) and shaft (4).
C. Remove piston (5).
2.
Plate, disc
A. Remove plate (6).
30-1901
WA500-3LK
B. Remove disc (7).

i.
When removing the disc and plates, put match marks on the
inner gear and disc, and outer gear and plate before removing.
ii.
The discs are made of soft material, so be careful not to

damage them during removal.
iii. Remove discs and plates alternately.
3.
Gear assembly
A. Remove tool H6.
B. Using eyebolt (Thread dia.=12 mm, Pitch =1.75 mm), lift off
gear (8).
C. Remove plate (9) from gear (8).
D. Remove floating seal (10) and oil seal (11) from gear (8).
WA500-3LK
30-1911

4.
Floating seal, outer race

A. Remove floating seal (12) from hub (13).
B. Remove outer races (14) and (15) from hub (13).
30-1921
WA500-3LK
ASSEMBLY
1.
Outer race, floating seal

A. Using push tool , press fit outer race (15) to hub (13).
B. Using push tool , press fit outer race (14) to hub (13).
C. Using tool H9, install floating seal (12) to hub (13).

Seal contact surface: Engine oil (EO30-CD)
Assemble O-ring (12) to floating seal.
Use alcohol to completely remove any white blooming
from
the surface of the O-ring.
Remove all oil and grease from the floating seal and hub
O-ring contact surface.
Tighten tool H9 uniformly to prevent twisting of the floating

seal O-ring. After press fitting, measure height at four
places
around the circumference and check that the difference in
dimension t at all four places is within 1 mm (0.039 in).
2.
Gear assembly
A. Using tool H5, install oil seal (11) to gear (8).
Mating surface of oil seal hub: Thread tightener

(Loctite #648)
WA500-3LK
30-1931
B. Using tool H8, install floating seal (10) to gear (8).

Seal contact surface: Engine oil (E030-CD)
Assemble O-ring (10) to floating seal.
Use alcohol to completely remove any white blooming
from
the surface of the O-ring.
Remove all oil and grease from the floating seal and
retainer
O-ring contact surface.
Tighten tool H8 uniformly to prevent twisting of the floating

seal O-ring. After press fitting, measure height t at four
places
around the circumference and check that the difference in
dimension t at all four places is within 1 mm (0.039 in).
3.
Assemble plate (9), then using eyebolt (Thread dia. = 12 mm,

Pitch = 1.75 mm), raise gear (8) and install.
4.
Install tool H6.
30-1941
WA500-3LK

5.
Disc, plate
A. Install disc (7).
B. Install plate (6).

Align notched portion of outer teeth of plate and assemble.
Align the counter marks on the disc and inner gear, and
plate and outer gear, then assemble the plates and discs in
turn.
6.
Cylinder
Assemble cylinder with following steps:
A. Set piston (5) at bottom.
B. Install shaft (4) and spring (3).

C. Screw in eyebolts b (Thread dia. = 6 mm, Pitch = 2.0 mm),
push in spring with bar c, then install pin (2).
WA500-3LK
30-1951
D. Fit O-ring and using eyebolts (Thread dia. = 16 mm,

Pitch = 2.0 mm), match with guide bolt (1) and lift and install
cylinder assembly.
30-1961
WA500-3LK
MEMORANDUM
WA500-3LK
30-1971
HYDRAULIC PUMP
HYDRAULIC PUMP
(SWITCH & PPC, LOADER, TORQUE CONVERTERTRANSMISSION, STEERING)
REMOVAL

1.
Remove engine hood assembly

For details, see ENGINE HOOD REMOVAL.
2.
Remove bulkhead assembly.

For details, see BULKHEAD REMOVAL.
3.
SWITCH + PPC pump assembly.

A. Disconnect hose (1) and tube (2).
B. Remove mounting bolt (3).
C. Lift off pump assembly (4).
4.
Loader pump assembly.

A. Remove bolts (5), and disconnect tube (6) together with hose.
B. Disconnect hose (7).
C. Remove U-bolts (8), then remove bracket (9).

D. Remove bolt (10), then remove tube (11).
E. Remove bolt (12), then remove pump assembly (13).
F.
Disconnect tube (14).
30-1981
WA500-3LK

5.
HYDRAULIC PUMP
Steering pump assembly.

A. Remove drive shaft assembly (15).
B. Disconnect brake tube (16).
C. Remove bolt (17), then remove pump assembly (18)
6.
Transmission/torque converter pump assembly

A. Disconnect hose (19).
B. Disconnect tube (20).
C. Remove mounting bolt (21), then remove pump assembly (22).
INSTALLATION
Brake tube: 110.7 12.7 Nm (81 9 lbf ft)
WA500-3LK
30-1991
HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL

Remove cover (1).

Loosen plug (2) on top of the hydraulic tank filler and bleed air from
the tank.
1.
Remove plug (3), then loosen valve (4) and drain hydraulic oil.
Hydraulic oil: 175 liters (46.23 gal)
2.
Sling ladder floor (5), then remove mounting bolts and lift off.
Be careful of the center of gravity when lifting off the ladder.
Ladder floor: 90 kg (198 lb)
3.
Disconnect main suction tube (6).
4.
Disconnect return tube (7) from cooler.
5.
Disconnect main return tube (8).
30-2001
WA500-3LK

6.
Disconnect hose (9) between brake valve and hydraulic tank.
7.
Disconnect stop valve, charge valve, PPC, orbital steering valve, and
drain hoses (10).
8.
Sling hydraulic tank, then remove mounting bolts (11)

and (12).
9.
Lift off hydraulic tank assembly (13).
HYDRAULIC TANK
Hydraulic tank assembly: 240 kg (308 lb)
INSTALLATION
Plug: 11.8 1.0 Nm (9 7 lbf ft)
Hydraulic tank bolt: 277.3 32.3 Nm (205 24 lbf ft)
WA500-3LK
30-2011
HYDRAULIC FILTER
HYDRAULIC FILTER
REMOVAL
1.
Remove cover (1).
2.
the tank, then remove mounting bolts, and remove cover (3).
WARNING! The cover is under pressure from a

spring. Remove the cover slowly and
carefully.
3.
Remove spring (4).
4.
Remove bypass valve (5).
5.
Remove filter (6).
INSTALLATION
Plug: 11.8 1.0 Nm (9 7 lbf ft)
30-2021
WA500-3LK
PPC VALVE
PPC VALVE
REMOVAL

Remove cover (1).

the tank.
1.
Remove console box cover (3) on right side of operator's seat.
2.
Disconnect rods (4).
3.
Disconnection of hoses from PPC valve

A. Disconnect hoses P1 (5) and P4 (6) for bucket control
B. Disconnect hoses P3 (7) and P2 (8) for boom control
C. Disconnect hose (9) from PPC pump
D. Remove eyebolt (10) of return hose leading to hydraulic tank.
E. After disconnecting the hoses, fit tags to distinguish them.
4.
Remove mounting bolts (11), then remove PPC valve assembly (12).
INSTALLATION
Plug: 11.8 1.0 Nm (9 7 lbf ft)
WA500-3LK
30-2031
PPC VALVE
DISASSEMBLY
1.
Remove bolt (1).
2.
Remove plate (2).
3.
Remove seal (3), then remove collar (4).
4.
Remove valve assembly and center spring (7) from valve body (10).
5.
Remove collar (11), then remove retainer (6), shim (12), and
spring (8) from valve (9).
ASSEMBLY
1.
Push shim (12), spring (8), and retainer (6) into valve (9), and install
collar (11).
2.
Install center spring (7) and valve assembly to valve body (10).
3.
Install spool (5).
4.
Fit O-ring and install collar (4).
5.
Install seal (3).
6.
Fit plate (2) and install bolt (1).

Bolt: 44.1 4.9 Nm (326 36 lbf ft)
30-2041
WA500-3LK
MAIN CONTROL VALVE
12
MAIN
CONTROL VALVE
REMOVAL
1.
Open cover (1).
2.
Loosen plug (2) on top of the hydraulic tank filter and bleed air from
tank.
3.
Remove bucket cylinder assembly. For details, see BUCKET

CYLINDER REMOVAL.
4.
Remove bolt (3), then remove cover (4).
5.
Remove bolt (5), and loosen bolt (6), then rotate cover (7) carefully
to right.
Rotate the cover on the right side of the chassis to the left.
6.
Disconnect hose (13) for bucket spool between PPC valve (P1) and
main control valve (PB1).
WA500-3LK
30-2051

7.
Disconnect hose (14) for boom spool between PPC valve (P3) and
main control valve (PB2).
8.
Disconnect hose (15) for bucket spool between PPC valve (P4) and
main control valve (PA1).
9.
Disconnect hose (16) for boom spool between PPC valve (P2) and
main control valve (PA2).
Remove the hose clamp.
After disconnecting the hose, move it to the rear of the machine.
After disconnecting the hoses, fit tags to distinguish them.
MAIN CONTROL VALVE
10. Disconnect hose (17) between main control valve and hydraulic tank.
11. Remove tube (18) between main control valve and bucket cylinder
together with hose.
12. Remove tube (19) between main control valve and boom cylinder.
13. Disconnect tube (20) from manifold.
14. Remove bracket (21) of tube.
15. Disconnect hose (22) between steering valve and main control valve
from main control valve.
16. Disconnect tube (23) between hydraulic tank and main control valve
30-2061
WA500-3LK
MAIN CONTROL VALVE
17. Remove tube (24) between main control valve and bucket cylinder
together with hose.
18. Disconnect tube (25) between main control valve and boom cylinder
19. Loosen the tube clamp.
20. Remove mounting bolts and rotate main control valve (26) 90.
21. Using eyebolts, lift off main control valve.

Be careful of the slack adjuster bleed screw when removing.
Main valve: 91 kg (200.2 lb)
INSTALLATION
Plug: 11.8 1.0 Nm (9 7 lbf ft)
TO REFILL WITH OIL (HYDRAULIC TANK), ADD HYDRAULIC OIL

THROUGH THE OIL FILLER TO THE SPECIFIED LEVEL.
Run engine to circulate oil through the system.

Then recheck the oil level and add if required.
WA500-3LK
30-2071
MAIN CONTROL VALVE
DISASSEMBLY
30-2081
WA500-3LK

1.
MAIN CONTROL VALVE
Spool assembly
A. Remove sleeve (1), then remove case (2).
B. Remove spring (3) and retainer (4).
C. Remove spring (5) and retainer (6).
D. Remove piston (7), spring (8), and spacer (9).
E. Remove spool assembly (10).
Disassemble spool assembly. Remove plugs (12) and (13) from spool (11).
WA500-3LK
30-2091

2.
MAIN CONTROL VALVE
Main relief valve

A. Remove main relief valve assembly (14).
B. Disassemble main relief valve assembly.
i.
Loosen nut (15), and pull out adjustment screw (16), then
remove retainer (17), spring (18), spacer (19), and poppet (20).
Before loosening nut (15), measure the protrusion of
screw (16) from the end face of the nut.
ii.
Loosen nut (21), then remove holder (22), seat (23), and
backup ring (24).
iii. Remove snap ring (25), then remove retainer (26), valve (27),
and spring (28) from sleeve (29).
iv. Remove backup ring (30) from sleeve.
If there is any abnormality in the sleeve or valve, replace
as an assembly.
3.
Safety valve assembly with suction

Remove safety valve assembly (31).
The safety valve cannot be adjusted when it is on the machine, so
do not disassemble it.
30-2101
WA500-3LK

4.
MAIN CONTROL VALVE
Suction valve assembly

A. Remove suction valve assembly (32).
B. Disassemble suction valve assembly (32).
i.
Remove valve (33) together with seal (34).
ii.
Remove seal (34) from valve (33).
iii. Remove spring (35) from sleeve (36).

If there is any abnormality in the sleeve or valve, replace
as an assembly.
5.
Selector valve assembly

A. Remove selector valve assembly (37).
6.
i.
Remove sleeve (38) together with seat (39).

Seat (39) is press fitted to sleeve (38) (press fitting load:
1,177 - 7,845 N (120 -800 kg), so if there is any
abnormality replace as an assembly. (The same applies
for the sleeve.)
ii.
Remove nipple (40), then remove shim (41), spring (42), and
piston (43).
Check the number and thickness of the shims, and keep
in a safe place.
Check valve assembly

A. Remove plate (44), then remove spring (45) and check valve (46).
B. Remove flange (47), then remove spring (48), seal (49), and
valve (50).
WA500-3LK
30-2111
MAIN CONTROL VALVE
ASSEMBLY
30-2121
WA500-3LK

1.
MAIN CONTROL VALVE
Check valve assembly

A. Assemble valve (50), seal (49), and spring (48) in valve body (51),
then fit O-ring and install flange (47).
Flange surface: Thread tightener (LT-2)
B. Assemble check valve (46) and spring (45) in valve body, then fit
O-ring and install plate (44).
Bolts: 88.2 9.8 Nm (65 7 lbf ft)
2.
Selector valve assembly

A. Assemble selector valve assembly.
B. Assemble piston (43), spring (42), and shim (41) in sleeve (38),
then fit O-ring and install nipple (40).
Nipple: 22.1 2.5 Nm (163 18 lbf ft)
C. Fit O-ring and install selector valve assembly (37).
Selector valve: 68.6 9.8 Nm (51 7 lbf ft)
3.
Suction valve assembly

A. Assemble suction valve assembly.
i.
Assemble spring (35) in sleeve (36).
ii.
Assemble seal (34) in valve (33), and install to sleeve (36).
iii. Fit O-ring and install suction valve assembly (32).

Suction valve assembly: 186.2 9.8 Nm (130 7 lbf ft)
4.
Safety valve assembly with suction

Fit O-ring and install safety valve assembly (31).
Safety valve: 186.2 9.8 Nm (130 7 lbf ft)
WA500-3LK
30-2131

5.
MAIN CONTROL VALVE
Main relief valve assembly

A. Assemble main relief valve.
i.
Install backup ring (30) and O-ring to sleeve (29).
ii.
Assemble spring (28), valve (27), and retainer (26) in sleeve

(29), and install snap ring (25).
iii. Fit backup ring (24) and O-ring, and assemble seat (23) in
sleeve.
iv. Screw nut (21) into holder (22), then fit O-ring and assemble
in sleeve, and tighten nut.
Holder: 39.2 9.8 Nm (29 7 lbf ft)
Nut thread: Thread tightener (LT-2)

Nut: 152.0 24.5 Nm (112 18 lbf ft)
v.
Assemble poppet (20), spacer (19), spring (18), and retainer

(17), and screw in adjustment screw (16). Adjust protrusion
from end face of nut (15) to same dimension as at time of
disassembly, then tighten with nut (15).
Nut: 39.2 4.9 Nm (29 4 lbf ft)
B. Fit O-ring and install main relief valve assembly (14).

Main relief valve: 323.6 44.1 Nm (239 33 lbf ft)
6.
Spool assembly
A. Assembly of spool assembly.
B. Install plugs (13) and (12) to spool (11).
Nut: 24.5 4.9 Nm (18 4 lbf ft)
C. Assemble spool assembly (10) in valve body.
D. Assemble spacer (9), spring (8), and piston (7).
E. Assemble retainer (6), spring (5), retainer (4), and spring (3), then
fit O-ring and install case (2) and sleeve (1).
30-2141
WA500-3LK
BUCKET CYLINDER
12
BUCKET
CYLINDER
REMOVAL
WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks
under the wheels to prevent the machine from moving.
1.
Disconnect connector (1) for bucket positioner.
2.
Disconnect grease tube (2) from bottom pin.
3.
Disconnect head hose (3).
4.
Disconnect bottom hose (4).
5.
Sling cylinder then remove lock bolt, and remove head pin (5).Sling
from two points and be careful of the center of gravity.
6.
Remove lock bolt, then remove bottom pin (6).
If there are shims, check the number and thickness of the shims.
WA500-3LK
30-2151

7.
BUCKET CYLINDER
Remove bucket cylinder assembly (7).

Bucket cylinder assembly: 286 kg (629.2 lb)
INSTALLATION
When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin (6) and lock with the bolt.
Clearance a + b = Less than 1.0 mm (0.039 in)
30-2161
WA500-3LK
BUCKET CYLINDER
DISASSEMBLY
1.
Set cylinder assembly (1) tool U1.
2.
Remove mounting bolts (2) of cylinder head.
3.
then lift off.
4.
Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).
5.
Remove O-ring (10) and backup ring (11) from piston rod (9).
WA500-3LK
30-2171

6.

Remove wear ring (12) and piston ring (13) from piston (14).
7.
Disassembly of cylinder assembly
BUCKET CYLINDER
A. Remove O-ring (15)and back up ring(16).

B. Remove snap ring, then remove dust seal (17).
C. Remove rod packing (18).

D. Remove bushing (19).
30-2181
WA500-3LK
BUCKET CYLINDER
ASSEMBLY
Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.
1.

A. Using push tool U5, press fit bushing (19) on cylinder head (20).
Be careful not to deform the bushing when press fitting.
B. Assemble rod packing (18).

Be careful to install the rod packing facing in the correct
direction.
C. Assemble buffer ring (21).
D. Assemble backup ring (16) and O-ring (15) in order.
Do not try to force the backup ring into position. Heat the
backup ring in warm water (50C to 60C) before fitting it.
E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.
WA500-3LK
30-2191

2.
BUCKET CYLINDER

Set the piston ring on the expander and turn the handle 8 11
times to expand the ring.
B. Remove piston ring from tool U6-1, and assemble on piston (14).
C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.
D. Assemble wear ring (12) on piston.
3.
Assemble O-ring (10) and backup ring (11) on piston rod (9).
4.
Assemble cylinder head assembly (8) and piston assembly (7) on

piston rod.
Coat backup ring (11) with grease so that it does not stick out,
and assemble carefully.
5.
Assemble spacer (6), then tighten piston bolts (5).

Piston bolt: Adhesives (LT-2)
Piston bolt: 176.5 19.6 Nm (130 15 lbf ft)
30-2201
WA500-3LK

6.
Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).
7.
Tighten cylinder head mounting bolts (2).
BUCKET CYLINDER
Cylinder head mounting bolt: 662 74 Nm

(501 543 lbf ft)
8.
Remove cylinder assembly (1) from tool U1.
WA500-3LK
30-2211
BOOM CYLINDER
BOOM CYLINDER
REMOVAL

1.
Lift off fender (1).

Fender: 25 kg (55 lb)
2.
Sling boom cylinder, then remove lock bolt, and remove pin (3).
Start the engine and operate the control lever to retract the
cylinder rod of the cylinder where the pin has been removed.
After stopping the engine, release the remaining pressure from
the hydraulic piping.
3.
Disconnect head hose (4) and bottom hose (5).
4.
Fit lifting tool to bottom of boom cylinder (2), then use lever block
to pull out to rear of machine.
5.
Using forcing screws, remove bottom pin (6).
If there are shims, check the number and thickness of the shim.
30-2221
WA500-3LK

6.
BOOM CYLINDER
Lift off boom cylinder assembly (2).

Boom cylinder assembly: 272 kg (598.4 lb)
INSTALLATION
When aligning the pin hole at the bottom end, assemble shims so that
the total clearance between cylinder and frame is within specified
value, then assemble pin and lock with the bolt.
Clearance a + b = Less than 1.0 mm (0.039 in)
WA500-3LK
30-2231
BOOM CYLINDER
DISASSEMBLY
1.
Set cylinder assembly (1) tool U1.
2.
Remove mounting bolts (2) of cylinder head.
3.
then lift off.
4.
Remove piston bolts (5), then remove spacer (6), piston assembly (7)
and cylinder head assembly (8).
5.
Remove O-ring (10) and backup ring (11) from piston rod (9).
30-2241
WA500-3LK

6.

Remove wear ring (12) and piston ring (13) from piston (14).
7.
Disassembly of cylinder assembly
BOOM CYLINDER
A. Remove O-ring (15)and back up ring(16).

B. Remove snap ring, then remove dust seal (17).
C. Remove rod packing (18).

D. Remove bushing (19).
WA500-3LK
30-2251
BOOM CYLINDER
ASSEMBLY
Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
U-packings, dust seals, or O-rings when assembling.
1.

A. Using push tool U5, press fit bushing (19) on cylinder head (20).
Be careful not to deform the bushing when press fitting.
B. Assemble rod packing (18).

Be careful to install the rod packing facing in the correct
direction.
C. Assemble buffer ring (21).
D. Assemble backup ring (16) and O-ring (15) in order.
Do not try to force the backup ring into position. Heat the
backup ring in warm water 50 - 60 C (122 - 140 F) before
fitting it.
E. Using push tool U4, install dust seal (17) to cylinder head, then
secure with snap ring.
30-2261
WA500-3LK

2.
BOOM CYLINDER

Set the piston ring on the expander and turn the handle 8 11
times to expand the ring.
B. Remove piston ring from tool U6-1, and assemble on piston (14).
C. Fit tools U6-2, on piston ring, then using clamp U6-3, compress
piston ring.
D. Assemble wear ring (12) on piston.
3.
Assemble O-ring (10) and backup ring (11) on piston rod (9).
4.
Assemble cylinder head assembly (8) and piston assembly (7) on

piston rod.
Coat backup ring (11) with grease so that it does not stick out,
and assemble carefully.
5.
Assemble spacer (6), then tighten piston bolts (5).

Piston bolt: Adhesives (LT-2)
Piston bolt: 176.5 19.6 Nm (130 15 lbf ft)
WA500-3LK
30-2271

6.
Set cylinder (4) in tool U1, then raise piston rod and head assembly
(3), and assemble in cylinder (4).
7.
Tighten cylinder head mounting bolts (2).
BOOM CYLINDER
Cylinder head mounting bolt: 662 74 Nm

(501 543 lbf ft)
8.
Remove cylinder assembly (1) from tool U1.
30-2281
WA500-3LK
CENTER HINGE PIN
CENTER HINGE PIN

REMOVAL

1.
Open cover (1) and loosen plug (2) on top of hydraulic tank to
prevent oil from flowing out from tank.
2.
Remove bolt (3), then remove cover (4).
3.
Remove plug (5), then loosen valve (6) and drain hydraulic oil.
When draining the hydraulic oil, drain to the level of the bottom of
each pipe.
Hydraulic oil: 140 liter (36.9 gal)
(level at bottom of piping)
4.
Remove covers (7) and (8) at bottom of cab.
WA500-3LK
30-2291

5.
Remove left and right steering cylinder pins (9).
6.
CENTER HINGE PIN
If there are shims between the pin and frame, check the number
and thickness.
Remove guard (10), then remove center drive shaft (11).
Center drive shaft assembly: 31 kg (68.2 lb)

7.
Disconnect hose (12) between brake valve and slack adjuster.
8.
Disconnect connectors (13) FR1 and (14) FR2.

Disconnect the clamps under the floor.
9.
Disconnect hoses (15) and (16) between steering valve and stop
valve at steering valve end.
10. Disconnect hose (17) between steering valve and oil cooler.
11. Disconnect hose (18) between work equipment control valve and
hydraulic tank.
12. Disconnect hose (19) between work equipment control valve and
loader pump.
30-2301
WA500-3LK
CENTER HINGE PIN
13. Disconnect bypass hose (20) from hydraulic circuit at top of tank.
14. Disconnect hoses P1 (21) and P4 (22) for bucket control.
15. Disconnect hoses P3 (23) and P2 (24) for boom control.
Disconnect the clamps at the rear frame end.
16. Using hydraulic jack to rear frame, insert block while adjusting
height.
Put support stands under the left and right side of the frame.
17. Put support stand under counterweight.
18. Using jack under front frame, insert block .
19. Remove mounting bolts, then remove retainer (25).
If there are shims between the retainer and frame, check the
number and height.
WA500-3LK
30-2311
CENTER HINGE PIN
20. Adjust height carefully so that lower hinge pin (26) can be removed
easily by hand.
21. Remove spacer (27).
23. Using puller, remove upper hinge pin (29) and spacer(30).
30-2321
WA500-3LK
CENTER HINGE PIN
24. Remove safety bar, then pull out front frame towards front and
disconnect frame.
Be careful not to let the spacer at the top of the lower hinge get
caught in the rear frame.
Carry out the operation carefully and pay attention to maintaining
the balance.
Move approx. 100 mm (3.9 in) at a time.

number and thickness.
26. Remove dust seal (32) from retainer (31).
27. Remove spacer (33) and dust seal (34) from front frame.
WA500-3LK
30-2331
CENTER HINGE PIN
28. Remove bearing (35).
29. Remove retainer (36).
number and thickness.
30. Remove dust seal (37) from retainer.

Remove dust seal (38) at the frame end.
31. Remove bearing (39).
30-2341
WA500-3LK
CENTER HINGE PIN
INSTALLATION
Plug: 11.8 1.0 Nm (9 7 lbf ft)
Adjust the shims so that the clearance is the specified value.

Clearance a + b = Less than 1.0 mm (0.039 in).
Drive shaft mounting bolt: 110.7 12.7 Nm

(752 94 lbf ft)
Outer circumference of hinge pin: Grease (G2-LI)
Measure clearance c between retainer and frame at four places on the inside circumference, and select a shim thickness
to make the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the measured value.
When adjusting the shim, temporarily tighten the retainer mounting bolts to act as a stopper.
When tightening the mounting bolts, first tighten the retainer mounting bolts to the specified torque, then tighten the pin
mounting bolts.
After selecting the shim, assemble the retainer to the specified torque.
Remove all oil and grease from the mounting bolts and mount holes.
Mounting bolt: Thread tightener (Loctite 262)

Mounting bolt (48) when adjusting shims: 276.3 29.4 Nm (206 22 lbf ft)
Mounting bolt (48): 276.3 29.4 Nm (206 22 lbf ft)
Mounting bolt (49) when adjusting shims: 382.2 34.3 Nm (282 25 lbf ft)
WA500-3LK
30-2351
CENTER HINGE PIN
Assemble spacer (30), insert upper hinge (29), then tap three times
with a copper hammer to settle the parts.
Never coat spacer (30) with grease.
Outer circumference of hinge pin: Grease (G2-LI)
Mounting bolt (46): Thread tightener (Loctite 262)

Grease on spacer (28) may prevent the mounting bolts being tightened
to the specified tightening torque. Remove any grease and tighten again.
Use tool K2 to press fit the bearing and spacer to the frame. Make
sure the bearing is not at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be sure to assemble the spacer.
The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is facing the outside.
Measure clearance a between retainer (31) and hinge at four places

on the inside circumference, and select a shim thickness to make
the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the measured
value.
Mounting bolt (when adjusting shims):
98.0 9.8 Nm (72 7 lbf ft)
30-2361
WA500-3LK
CENTER HINGE PIN
Using tool K1, press fit the bearing and spacer to the frame.
When press fitting the bearing, be careful that the bearing is not at an
angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be careful not to forget to assemble the
spacer.
The clearance of the bearing is adjusted, so do not change the
combination of bearing and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is facing the outside.
Measure clearance a between retainer (36) and the hinge at four

places on the inside circumference, and select a shim thickness to
make the value 0.08 - 0.18 mm (0.003 - 0.007 in) less than the
measured value.
Mounting bolt (when adjusting shims):

58.8 5.9 Nm (43 4 lbf ft)
Mounting bolt: 176.4 19.6 Nm (130 15 lf ft)
After completion of mounting the hinge pin, fill with oil and bleed the air.
A. Tighten the plug on the top of the hydraulic tank filter, then add hydraulic oil through oil filler to the specified level.
Plug on top of filter: 11.8 1.0 Nm (9 1 lbf ft)
Hydraulic oil: Approx. 140 liter (36.9 gal)
B. Run the engine to circulate the oil through the system. Then check the oil level again.
C. Bleed the air from the brake system. For details, see TESTING AND ADJUSTING.
WA500-3LK
30-2371
WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
1.
Remove mounting pin (1) of bucket link.
Remove cord ring.

Tie the bucket link to the tilt lever with wire.
Mounting pin: 25 kg (55 lb)
2.
Remove mounting pin (2) of bucket hinge.
Remove cord ring.

3.
Move machine to rear and disconnect bucket.
4.
Temporarily sling bucket cylinder (3), pull pin (4), then disconnect
cylinder rod and tilt lever.
Attach lifting tool to bucket cylinder and secure in the rear.
Bucket cylinder: 285 kg (627 lb)
5.
Attach lever block to boom cylinder (5), pull machine to rear

and remove mounting pin (6).
Boom cylinder: 272 kg (599 lb)
30-2381
WA500-3LK

6.
WORK EQUIPMENT
Temporarily sling bellcrank (7) and bucket link, remove mounting

pin (8), then lift out from boom (9).
Remove with the bucket link still fitted.
Three technicians are required for removal of mounting pin
operation.
Bellcrank and bucket link: 615 kg (1365 lb)
Mounting pin: 59 kg (129.8 lb)
7.
Temporarily sling bucket link (10), remove mounting pin (11), then
lift out from bellcrank (7).
Remove cord ring.

Bucket link: 103 kg (226.6 lb)
Note the number of shims at this location for reference when

installing.
8.
Remove boom kick out switch (13).
9.
Temporarily sling boom (9), pull out mounting pin of boom, then lift
out boom.
Shims are installed at connecting point of front frame and boom,
so check the number of shims.
Boom: 2,025 kg (4,455 lb)
WA500-3LK
30-2391
WORK EQUIPMENT
10. Pull out dust seal (14) and bushing (15) from boom (9).
11. Pull out dust seal (16) and bushing (17) from bellcrank (7)
30-2401
WA500-3LK
WORK EQUIPMENT
12. Pull out dust seal (18) and bushing (19) from bucket link (10).
After long use, wear can make the pin difficult to remove. A
puller (pin puller jig) such as the one shown here can be helpful
when removing a pin.
WA500-3LK
30-2411
WORK EQUIPMENT
INSTALLATION
WARNING! Align the position of the pin hole with a
bar. Never insert a finger into the pin hole.
Clearance g + h = Less than 1.0 mm (0.039 in).

Be careful not to get cord ring (22) caught.
Clearance e + f = Less than 1.0 mm (0.039 in).

Secure the bucket link and bellcrank with wire.

Insert shims so that the clearance is equal on the left and right.
Clearance c + d = Less than 1.0 mm (0.039 in).
Align the hole in the boom mount and the front frame, then insert
shims to make the clearance equal on the left and right.
Clearance a + b = Less than 1.0 mm (0.039 in).
After assembling the pin, set the support stand to the tip of the boom.
Grease each pin.
30-2421
WA500-3LK
WORK EQUIPMENT
MEMORANDUM
WA500-3LK
30-2431
BULKHEAD
BULKHEAD
REMOVAL
1.
Remove engine hood assembly (1). For details, see ENGINE

HOOD REMOVAL.
2.
Remove bulkhead left side cover (2).

Disconnect the connector (BR1) at the bottom at the engine end
of the left side of the bulkhead.
Reach in at the point marked by the arrow, and disconnect the
connector (BR1).
3.
Remove bulkhead hood (3).
4.
Remove floor plate (4).
5.
Remove covers (5) and (6).
6.
Disconnect hose (7) at receiver tank end.
7.
Disconnect hose (8) at condenser end.
Disconnect the accelerator control cable at the fuel pump end.
30-2441
WA500-3LK

8.
Disconnect brake hoses (9), (10), and (11).
9.
Disconnect emergency brake valve connecting hoses (12), (13),

and (14).
BULKHEAD
10. Disconnect accumulator charge valve connecting hoses (15), (16),

and (17).
11. Disconnect PPC pump connecting hose (18).
12. Disconnect PPC accumulator inlet hose (19).
13. Disconnect window washer hoses (20).
14. Disconnect transmission breather (21).
After disconnecting the hoses, fit tags to distinguish them.
15. Remove four mounting bolts (22) and (23).

16. Lift off bulkhead assembly (24).
Bulkhead assembly: 220 kg (484 lb)
INSTALLATION

When installing the hoses, be careful not to let dirt, dust, or moisture
get inside the hoses.
Using a gas charger (X3), charge with new freon gas (R134a).
WA500-3LK
30-2451
ENGINE HOOD
12
ENGINE HOOD
REMOVAL
WARNING! Stop the machine on level ground, set
the parking brake, install the safety bar
on frame, and put blocks under wheels
to prevent the machine from moving.
1.
Open access doors on left and right sides of the machine.
2.
Remove four mounting bolts (1), sling and remove exhaust

stack (2).
Mounting bolts (1): 19mm across flats.
3.
Loosen clamp on hose (3), remove four mounting bolts (4), and
remove air cleaner hood (5).
4.
Remove four bolts (6) and radiator grille (7).

Remove baffle plate on both sides of the radiator.
Four baffle plate mounting bolts: 17mm across flats.
5.
Disconnect head lamp connector (8).
6.
Disconnect water level sensor connector (9).
7.
Disconnect three clamps for radiator sub-tank hose inside hood on

the left side.
8.
Remove hood mounting bolts, six upper bolts (10), two middle
bolts, and six lower bolts (11) with six collars (12).
Upper bolts (10) located on top of hood at bulkhead:
17mm across flats
Middle bolts (17mm across flats) are located on firewall about
203 mm (8 in) above lower mounting bolt (11)
Lower bolts (11) with collars are located at rear by firewall,
and in front and back of radiator: Mounting bolts (1): 30mm
across flats
30-2461
WA500-3LK

9.
ENGINE HOOD
Disconnect air conditioner compressor.

A. Disconnect two clamps for air conditioner compressor hoses
inside hood just above the right side access doors.
Clamp bolts: 14mm across flats
B. Disconnect electrical connector (13).
C. Loosen two mounting bracket pivot bolts (14).
Pivot bolts (14): 19mm across flats.
D. Loosen lock nut (15) and adjustment bolt (16), then remove
belt (17) from compressor.
Lock nut (15): 24mm across flats.
Adjusting bolt (16): 24mm across flats.
E. Remove four mounting bolts (18) from compressor and lay off
to the side, being careful not to twist or damage the hoses.
10. Remove four plastic caps located on top of the hood and install four
lifting eyes and attach chain (13).
11. Slowly lift engine hood (14) approximately 150 mm (6 in), check
that there is no interference, then lift off completely.
Use a lever block to maintain the balance when lifting off.
Engine hood assembly: 225 kg (496 lb)
WA500-3LK
30-2471
ENGINE HOOD
12
INSTALLATION
1.
Slowly lift engine hood (14) and set into place, be careful not to
damage radiator.
Check that radiator coolant level sensor wire is placed so it can
be connected to harness.
2.
Remove hood mounting bolts, six upper bolts (10), two middle
bolts, and six lower bolts (11) with six collars (12).
Upper bolts (10) located on top of hood at bulkhead:
17mm across flats
Middle bolts (17mm across flats) are located on firewall about
203 mm (8 in) above lower mounting bolt (11)
Lower bolts (11) with collars are located at rear by firewall,
and in front and back of radiator: Mounting bolts (1): 30mm
across flats
3.
Connect head lamp connector (8).
4.
Connect water level sensor connector (9).
5.
Attach clamps for radiator sub-tank hose inside hood on the left
side.
6.
Attach air conditioner compressor.

A. Add four mounting bolts (18) to mount compressor, being
careful not to twist, or damage, the hoses. Make sure there no
interference with hoses.
Bolt (20): 27 - 34 Nm (20 - 25 lbf ft)
B. Attach belt (17) to compressor. Using lock nut (15) and
adjustment bolt (16) to adjust tension of belt.
30-2481
WA500-3LK
ENGINE HOOD
C. Proper belt deflection is 10 mm (25/64 in.) while applying

approximately 58 N (13 lbf) of force on the belt between
compressor drive pulley and magnetic clutch.
Remark
If a new belt is installed, recheck belt tension after running the
machine for one hour, it probably will require adjustment
D. Connect electrical connector (13) to the engine harness.

E. Tighten two mounting bracket pivot bolts (14).
F.
Attach air conditioning hose clamps in two places inside the

engine hood on the right side.
Hose clamp bolts: 14mm across flats.
7.
Attach exhaust stack (2) with four mounting bolts (1).

8.
Attach air cleaner hood (5) with four mounting bolts (4) and clamp
hose (3).
9.
Attach radiator grille (7) with four bolts (6).

Attach baffle plates on both sides of the radiator.
Four baffle plate mounting bolts: 17mm across flats.
WA500-3LK
30-2491
CAB
12
CAB
REMOVAL
1.
Remove covers (1) at bottom of floor frame.
2.
Remove right cover (2) inside cab.
3.
Disconnect electric wiring connectors (3).
4.
Disconnect window washer hose (4).
5.
Remove two steering post lock bolts (5).
30-2501
WA500-3LK

6.
Remove plastic mounting bolts and pull up rubber boot (6) at bottom
of steering post.
7.
Remove four bolts (7), then tip steering post over fully towards
operator's seat.
At the same time, set the column tilt lever to the unlock position
and tip the steering column over fully toward the operator's seat.
8.
Remove two cab mounting bolts (8) and four mounting bolts (9) each
at intermediate position and rear.
9.
Raise cab assembly (10) slowly and keep horizontal when lifting off.
Be careful that there is no interference with the electric wiring at
the rear right of the floor frame
.
CAB
Cover the steering post and plastic cover with a sheet to prevent
any damage.
WA500-3LK
30-2511
CAB
INSTALLATION
When installing the cab assembly, be sure to install the seal.

Coat the seal uniformly with adhesive.
Seal: Adhesive (Cemedyne 366E)
30-2521
WA500-3LK
FLOOR FRAME
FLOOR FRAME
REMOVAL
1.
Remove cab assembly.

For details, see CAB REMOVAL.
2.
Remove left and right ladders (1) and (2).

Ladder: 90 kg (198 lb)
3.
Remove floor plate (4) and cover (3) of bulkhead.
4.
Disconnect wiring connectors (5) (TM1, 2, LR1-6).
5.
Disconnect ground connection (6).
6.
Disconnect hoses (7) between brake valve and slack adjuster.
7.
Disconnect hose (9) between orbital steering valve (8) and

hydraulic tank.
8.
Disconnect hose (10) between orbital steering valve (8) and

accumulator.
9.
Disconnect hoses (11) between orbital steering valve (6) and stop valve.
10. Disconnect return hose (12) between orbital steering valve and
hydraulic tank.
11. Disconnect return hose (13) coming from PPC valve.
12. Disconnect return hose (14) coming from brake valve.
After disconnecting the hose, install a blind plug to prevent
contamination.
WA500-3LK
30-2531
FLOOR FRAME
13. Remove mounting bolts (15), then remove brake hose bracket (16).
14. Disconnect PPC hoses (17).
The hoses are fitted with self-seal couplings.
15. Disconnect hose (18) from accumulator.
16. Disconnect accumulator charge valve connecting hoses (19) and (20).
17. Disconnect PPC accumulator connecting hose (21).
18. Disconnect two window washer hoses (22).
19. Disconnect two hoses (23) from brake valve.
20. Disconnect air conditioner compressor hose (24).
There are hose clamps at two places inside the engine hood.
Remove the hose clamps.
21. Remove clamp (25) and joint (26), then remove accelerator cable (27).
22. Disconnect heater hoses (28) and (29).

Hose (29) is installed under the connector at the suction end of
the water pump.
Open radiator drain valve, and drain coolant.
30-2541
WA500-3LK
FLOOR FRAME
23. Remove floor frame mount mounting nuts (30) (four places).
24. Lift off floor frame assembly (31).

Check that all the clamps and wiring harnesses have been
disconnected.
Floor frame assembly: 280 kg (617 lb)
INSTALLATION

When installing the hoses, be careful to prevent dirt, dust, or moisture
from getting inside the hoses.
Mount nut: 277.3 32.3 Nm (203 24 lbf ft)
REFILLING WITH COOLANT
Tighten radiator drain valve and add coolant through water filler to the specified level.
Run the engine to circulate the coolant through the system. Then check the water level again.
WA500-3LK
30-2551
COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL
1.
Sling counterweight (19), then remove mounting bolts, and lift off.
When lifting off the counterweight, be careful to maintain the balance.

Counterweight: 1500 kg (3300 lb)
INSTALLATION
Counterweight mounting bolt: 1568 196 Nm (1157 144 lbf ft)
30-2561
WA500-3LK
COUNTERWEIGHT
12
MEMORANDUM
WA500-3LK
30-2571
FUEL TANK
FUEL TANK
REMOVAL
1.
Loosen drain valve (1) and drain fuel.

Check the fuel level before draining.
Fuel (when full): 486 liters (128.3 gal)
2.
Remove engine oil drain valve (2) from fuel tank.
3.
Disconnect hose (3) between injection pump and fuel tank.
4.
Disconnect hose (4) between fuel tank and feed pump.
5.
Disconnect spill hose (5).
6.
Disconnect connector (6) for fuel level sensor.
7.
Remove hoses (7) of blow-by and muffler.
8.
Sling fuel tank assembly (8), then remove mounting bolts and slowly
lower the tank.
Put a pallet under the tank, then be careful to maintain the

balance of the tank assembly, and lower it on to the pallet.
Fuel tank assembly: 246 kg (541.2 lb)
Before pulling out the fuel tank assembly, remove breather

tube (9).
The bottom surface of the tank is not flat, and there is danger
that it may slip, so be extremely careful when handling it.
30-2581
WA500-3LK
FUEL TANK
INSTALLATION
Fuel tank mounting bolt: 931.0 98.0 Nm (686 72 lbf ft)
Be careful of breather tube (9) when raising the tank.
WA500-3LK
30-2591
AIR CONDITIONER UNIT

REMOVAL
WARNING! Disconnect cable from negative (-)
terminal of the battery.
1.
Remove cab assembly. For details, see CAB REMOVAL.
2.
Remove connector (1)
3.
Install freon gas collector and regenerator to plug (2), and collect
refrigerant.
4.
Remove operator's seat (3).

Operator's seat assembly: 40 kg (88 lb)
5.
Remove rear console box (4).
6.
Remove console box cover (5).
7.
Remove console box (6).
8.
Disconnect connector (7) (CL3).
9.
Disconnect connector (8) (CL2).
10. Disconnect tubes (9).

11. Disconnect heater hoses (10).
30-2601
WA500-3LK
12. Remove mounting bolt (11), then remove air conditioner unit
assembly (12).
Pull the unit out to the left and remove it.
INSTALLATION

WA500-3LK
30-2611
CONDENSER
CONDENSER
REMOVAL
1.
Disconnect connector (1) (E1 2).
2.
Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.
3.
Remove bulkhead cover (3).
4.
Disconnect connectors (4) (B07 and B12).
5.
Disconnect hose (5) between condenser and air conditioner compressor.
Always fit a wrench to the condenser end.
6.
Disconnect connectors (6) (B01 and B11).
7.
Disconnect hose (7) between top and bottom condensers.
8.
Disconnect hose (8) between receiver tank and condenser.
9.
Remove mounting bolts (9), then remove condenser assembly (10).
INSTALLATION

When installing the hoses, be careful not to let dirt, dust, or moisture
get inside the hoses.
30-2621
WA500-3LK
RECEIVER TANK
RECEIVER TANK
REMOVAL
1.
Disconnect connector (1) (E1 2).
2.
Install freon gas collector and regenerator to plugs (2), and collect
refrigerant.
3.
Remove bulkhead cover (3).
4.
Disconnect hose (4) between air conditioner compressor and

receiver tank
5.
Disconnect hose (5) between receiver tank and condenser.
6.
Remove U-bolts (6), then remove receiver tank assembly (7).
INSTALLATION

When installing the hoses, be careful not to let dirt, dust, or
moisture get inside the hoses.
WA500-3LK
30-2631
COMPRESSOR ASSEMBLY
12
COMPRESSOR ASSEMBLY
REMOVAL
1.
Disconnect electrical connector b.
2.
Install freon gas collector and regenerator to plugs c, and collect

refrigerant.
3.
Remove the air conditioner compressor.

A. Disconnect two clamps for air conditioner compressor hoses
inside hood just above the right side access doors.
Clamp bolts: 14mm across flats
B. Disconnect two air conditioner compressor hoses d.
Cap hoses and compressor to prevent dirt, dust, or
moisture from entering the hoses.
C. Loosen two mounting bracket pivot bolts e.
Pivot bolts e: 19mm across flats.
D. Loosen lock nut f and adjustment bolt g, then remove belt
h from compressor.
Lock nut f: 24mm across flats.
Adjusting bolt g: 24mm across flats.
E. Remove four mounting bolts i and remove the compressor.
Mounting bolts i: 13mm across flats.
30-2641
WA500-3LK
COMPRESSOR ASSEMBLY
12
INSTALLATION
1.
Attach air conditioner compressor.

A. Add four mounting bolts i to mount the compressor.
Bolt (20): 27 - 34 Nm (20 - 25 lbf ft)
B. Attach belt h to compressor. Using lock nut f and
adjustment bolt g to adjust tension of belt.
C. Proper belt deflection is 10 mm (25/64 in.) while applying

approximately 58 N (13 lbf) of force on the belt between
compressor drive pulley and magnetic clutch.
Remark
If a new belt is installed, recheck belt tension after running the
machine for one hour, it probably will require adjustment
D. Connect two air conditioner compressor hoses d.

When installing the hoses, be careful not to let dirt,
dust, or moisture get inside the hoses or compressor.
E. Tighten two mounting bracket pivot bolts e.
Pivot bolts (4): 19mm across flats.
F.
Attach air conditioning hose clamps in two places inside the

engine hood on the right side.
Hose clamp bolts: 14mm across flats.
G. Connect electrical connector b) to the engine harness.

H. Recharge the system thru plugs c with refrigerant.
Using a gas charger (X3), charge with new freon gas
(R134a).
WA500-3LK
30-2651
MAIN MONITOR
12
MAIN MONITOR
REMOVAL
1.
After disconnecting the battery cable from the negative (-) terminal,
remove dashboards (1) and (2).
2.
Remove steering post cover mounting bolts (3) and (4).
3.
Remove steering post cover (5).
4.
Remove mounting bolt caps (7) from steering post cover (6), them
remove bolts.
5.
Remove mounting bolt caps (9) from steering post cover (8), them
remove bolts and tip cover forward.
6.
Remove bracket (10) at back of the main monitor.
30-2661
WA500-3LK

7.
Remove eight mounting bolts (12), when removing main monitor

(11), be careful not to subject it to any strong shock.
8.
Disconnect wiring connectors (13), (14), (15), and (16) from the
monitor.
MAIN MONITOR
INSTALLING
Install the monitor in the reverse order of removal, and be sure to

lock connectors securely.
For adjustment procedures, see TESTING AND ADJUSTING in
section 20.
WA500-3LK
30-2671
MAIN MONITOR
12
MEMORANDUM
30-2681
WA500-3LK
40
ENGINE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3

TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
TORQUE CONVERTER AND PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
LUBRICATION RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
CENTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
DIFFERENTIAL, NORMAL - (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
DIFFERENTIAL, LIMITED SLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
STEERING COLUMN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40
STEERING VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
STEERING CYLINDER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
LEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
SAR(4)-160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
SWITCH, PPC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
SAR(3)-63 + SAR(1)-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
PPC VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
FOR BUCKET AND BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
FOR AUXILIARY ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
CUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
2 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
BUCKET LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
WA500-3LK
40-1 1
12
MEMORANDUM
40-2 1
WA500-3LK
ENGINE MOUNT
12
ENGINE
MOUNT
No.
1
Check Item
Clearance between engine mounting bracket and adjusting bolt
Criteria
Remedy
3.0 - 7.0 mm
(0.118 - 0.276 in)
Adjust
Torque Values
Item
Nm
lbf ft
745 83
550 62
WA500-3LK
40-3 1
TRANSMISSION MOUNT
TRANSMISSION MOUNT
40-4 1
WA500-3LK
No.
Check Item
TRANSMISSION MOUNT
Criteria
Remedy
Shim thickness: 0.5 mm (0.020 in)

(Decide the shim thickness so that the misalignment between the damper
output shaft and input shaft is less than 2.0 mm (0.079 in)
Adjust
Thickness of shim for mounting
There must be a clearance of at least 2 mm (0.079 in) between stopper and

Clearance between stopper and bracket
bracket around the whole circumference.
Torque Values
Item
Nm
lbf ft
745 83
550 62
277 32
204 24
WA500-3LK
40-5 1
TORQUE CONVERTER CHARGING PUMP

SAR(3)-80
No.
Check Item
Criteria
Remedy
Standard Clearance
Clearance Limit
Clearance between gear case and side

plate, gear
0.10 - 0.15 mm
(0.004 - 0.006 in)
0.19 mm
(0.008 in)
Clearance between inside

diameter of plain bearing and
outside diameter of gear shaft
0.06 - 0.149 mm
(0.002 - 0.006 in)
0.20 mm
(0.008 in)
Insertion depth of pin
Rotating torque of spline shaft
14 +0
-0.5 mm
Replace
(0.006 +0
-0.002 in)
6.9 - 11.8 Nm
(5 - 9 lbf ft)
Discharge
Oil: E010-CD
Temperature: 45 - 55 C
(113 - 131 F)
Revolution (rpm)
Pressure
Standard
discharge
Repair limit
discharge
2500
35.9 kg/cm2
(511 psi)
192 L/min
(51 gal/min)
176 L/min
(47 gal/min)
Torque Values
Item
Nm
lbf ft
277 31
204 24
40-6 1
WA500-3LK
12
MEMORANDUM
WA500-3LK
40-7 1
DAMPER
DAMPER
40-8 1
WA500-3LK
DAMPER
12
No.
Check item
Criteria
Tolerance
Standard size
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
Clearance between bearing

and shaft
40 mm
(1.575 in)
-0.009 to
-0.034 mm
(-0.0004 to
-0.0013 in)
-0.012 mm
(-0.0005 in)
-0.003 to
-0.034 mm
(-0.0001 to
-0.0013 in)
0.05 mm
(0.002 in)

and housing
80 mm
(3.150 in)
-0.013 mm
(-0.0005 in)
-0.030 mm
(-0.0012 in)
-0.013 to
-0.030 mm
(-0.0005 to
-0.0012 in)
0.035 mm
(0.0014 in)

and shaft
75 mm
(2.953 in)
+0.012 to
-0.007 mm
(+0.0005 to
-0.0003 in)
-0.015 mm
(-0.0006 in)
-0.007 to
-0.027 mm
(-0.0003 to
-0.0011 in)
0.025 mm
(0.0010 in)

and cover
130 mm
(5.118 in)
-0.018 mm
-0.0007 in)
+0.007 to
+0.018 mm
(+0.0003 to
+0.0007 in)
0.007 to
0.036 mm
(0.0003 to
0.0014 in)
0.05 mm
(0.002 in)
Clearance between retainer

and cover
135 mm
(5.315 in)
-0.014 to
-0.054 mm
(-0.0006 to
-0.002 in)
+0.04 mm
(+0.0015 in
0.014 to
0.094 mm
(0.0006 to
0.004 in)
0.13 mm
(0.005 in)
Replace
Standard size
Tolerance
Repair limit
Wear of surface in coupling

and oil seal
95 mm
(3.740 in)
-0.087 mm
(-0.003 in)
-0.12 mm
(-0.005 in)
Wear of surface in shaft and

oil seal
105 mm
(4.134 in)
-0.087 mm
(-0.003 in)
-0.12 mm
(-0.005 in)
Backlash of spline (shaft,

coupling, and body)
0.071 - 0.177 mm
(0.003 - 0.007 in)
Torque Values
Item
Nm
lbf ft
110 12
814 9
66 7
49 5
4 1
3 1
88 34
65 25
WA500-3LK
40-9 1
40-10 1
WA500-3LK
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
Inside diameter of seal ring surface of retainer
120 mm
(4.724 in)
+0.035 mm
(+0.0014 in)
120.5 mm
(4.744 in)
Inside diameter of seal ring surface of sleeve
65 mm
(2.559 in)
+0.025 mm
(+0.0010)
65.1 mm
(2.563 in)
Width
3.95 mm
(0.156 in)
-0.1 mm
(-0.0039 in)
3.55 mm
(0.140 in)
Thickness
4.6 mm
(0.181 in)
0.1 mm
(0.0039 in)
4.14 mm
(0.163 in)
Width and thickness of seal
Backlash of PTO gear (drive gear)
Repair
chrome
plating or
replace
Replace
0.18 - 0.49 mm
(0.007 - 0.019 in)
Torque Values
Item
Nm
lbf ft
110 12
814 9
66 7
49 5
4 1
3 1
88 34
65 25
WA500-3LK
40-11 1
TRANSMISSION
TRANSMISSION
Torque Values
Item
Nm
lbf ft
167 10
123 7
110 12
81 9
40-12 1
WA500-3LK
TRANSMISSION
12
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation load
No. 1 clutch spring (X 10)
66 mm
(2.598 in)
56.5 mm
(2.224 in)
132.4 N
(29.8 lbf)
62.0 mm
(2.441 in)
112.8 N
(25.4 lbf)
59 mm
(2.323 in)
52.5 mm
(2.067 in)
63.7 N
(14.3 lbf)
55.5 mm
(2.185 in)
53.9 N
(12.1 lbf)
39.8 mm
(1.567 in)
33.5 mm
(1.319 in)
87.3 N
(19.6 lbf)
37.4 mm
(1.472 in)
74.5 N
(16.8 lbf)
39.8 mm
(1.567 in)
35.9 mm
(1.41 in)
54.1 N
(12.1 lbf)
37.4 mm
(1.472 in)
46.0 N
(10.3 lbf)
39.8 mm
(1.567 in)
35.0 mm
(1.377 in)
66.6 N
(14.9 lbf)
37.4 mm
(1.472 in)
56.6 N
(12.7 lbf)
No. 6 clutch spring (10 each)
39.8 mm
(1.567 in)
34.2 mm
(1.346 in)
77.5 N
(17.4 lbf)
37.4 mm
(1.472 in)
65.7 N
(14.8 lbf)
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
Thickness of 4 discs and 3 plates for No. 1

clutch
40 mm
(1.57 in)
0.28 mm
(0.011 in)
36.8 mm
(1.448 in)

clutch
40 mm
(1.57 in)
0.28 mm
(0.011 in)
36.8 mm
(1.448 in)

clutch
25 mm
(0.98 in)
0.22
(0.0086 in)
22.6 mm
(0.8897 in)
10

clutch
25 mm
(0.98 in)
0.22
(0.0086 in)
22.6 mm
(0.8897 in)
11

clutch
21.4 mm
(0.8425 in)
0.22 mm
(0.0086 in)
19.0 mm
(0.7480 in)
12

clutch
25 mm
(0.98 in)
0.22
(0.0086 in)
22.6 mm
(0.8897 in)
13
Thickness of 1 disc
5 mm
(0.1968 in)
0.1 mm
(0.0039 in)
4.2 mm
(0.1653 in)
14
Thickness of 1 plate (No. 1 - 4, 6 clutch)
5 mm
(0.1968 in)
0.1 mm
(0.0039 in)
4.2 mm
(0.1653 in)
15
Thickness of 1 plate (No. 5 clutch)
3.2 mm
(0.1259 in)
0.1 mm
(0.0039 in)
2.9 mm
(0.1141 in)
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance limit
16
Clearance between
transmission input shaft
bearing and housing
90 mm
(3.543 in)
0 to -0.015 mm
(0 to -0.0006 in)
+0.016 to
-0.006 mm
(+0.0006 to
-0.0002 in)
+0.031 to
-0.006 mm
(+0.0012 to
-0.0002 in)
+0.037 mm
(+0.0015 in)
17
Clearance between
transmission output shaft
bearing and carrier
72 mm
(2.835 in)
0 to -0.013 mm
(0 to -0.0005 in)
+0.013 to
-0.006 mm
(+0.0005 to
-0.0002 in)
+0.026 to
-0.006 mm
(+0.0010 to
-0.0002 in)
+0.031 mm
(+0.0012 in)
18
Clearance between
transmission output shaft
bearing and housing
100 mm
(3.937 in)
0 to -0.015 mm
(0 to -0.0006 in)
+0.016 to
-0.006 mm
(+0.0006 to
-0.0002 in)
+0.031 to
-0.006 mm
(+0.0012 to
-0.0002 in)
+0.037 mm
(+0.0015 in)
WA500-3LK
Replace
Replace
Remedy
Replace
40-13 1
TRANSMISSION
12
40-14 1
WA500-3LK
No.
TRANSMISSION
Check item
Criteria
Tolerance
Repair limit
Width
3.0 mm
(0.118 in)
-0.01 to
-0.03 mm
(-0.0004 to
-0.0012 in)
2.7 mm
(0.1062 in)
Thickness
2.7 mm
(0.1062 in)
0.1 mm
(0.0039 in)
2.55 mm
(0.1003 in)
Width
3.0 mm
(0.118 in)
-0.01 to
-0.03 mm
(-0.0004 to
-0.0012 in)
2.7 mm
(0.1062 in)
Thickness
3.1 mm
(0.1220 in)
0.1 mm
(0.0039 in)
2.95 mm
(0.1161 in)
Wear of transmission input shaft seal ring
Wear of transmission output shaft seal ring
Backlash between No. 1 sun gear and planet gear
0.13 - 0.32 mm
(0.005 - 0.013 in)
Backlash between No. 1 planet gear and ring gear and inside teeth
0.15 - 0.38 mm
(0.006 - 0.015 in)
0.13 - 0.32 mm
(0.005 - 0.013 in)
0.15 - 0.38 mm
(0.006 - 0.015 in)
0.12 - 0.30 mm
(0.005 - 0.012 in)
0.15 - 0.38 mm
(0.006 - 0.015 in)
0.13 - 0.32 mm
(0.005 - 0.013 in)
10
0.15 - 0.38 mm
(0.006 - 0.015 in)
11
0.14 - 0.35 mm
(0.006 - 0.014 in)
12
0.15 - 0.38 mm
(0.006 - 0.015 in)
WA500-3LK
Remedy
Standard
size
Replace
40-15 1
TRANSFER
TRANSFER
Torque Values
Item
Nm
lbf ft
745 83
550 62
110 12
81 9
69 10
51 7
40-16 1
WA500-3LK
TRANSFER
12
No.
Check item
Criteria
Standard
size
Remedy
Tolerance
Standard
clearance
Shaft
Hole
85 mm
(3.347 in)
+0.045 to
+0.023 mm
(+0.002 to
+0.001 in)
-0.020 mm
(-0.0008 in)
-0.023 to
-0.065 mm
(-0.001 to
(-0.003 in)
Clearance between drive gear bearing and cage
150 mm
(5.906 in)
-0.018 mm
(-0.0007 in)
-0.012 to
-0.052 mm
(-0.0005 to
-0.002 in)
0.006 to
-0.052 mm
(0.0002 to
-0.002 in)
Clearance between drive gear bearing and cage
150 mm
(5.906 in)
-0.018 mm
(-0.0007 in)
-0.040 mm
(-0.002 in)
0.018 to
-0.040 mm
(-0.0007 to
-0.002 in)
Clearance between idler gear and bearing
95 mm
(3.740 in)
+0.059 to
-0.037 mm
(+0.002 to
-0.002 in)
-0.020 mm
(-0.0008 in)
-0.037 to
-0.079 mm
(-0.002 to
-0.003 in)
Clearance between drive gear bearing and case

(cover)
170 mm
(6.693 in)
-0.025 mm
(-0.002 in)
-0.040 mm
(-0.002 in)
0.025 to
-0.020 mm
(0.001 to
-0.002 in)
Clearance between output shaft and bearing
80 mm
(3.150 in)
+0.039 to
-0.020 mm
(+0.0002 to
-0.0008 in)
-0.015 mm
(-0.0006 in)
-0.020 to
-0.054 mm
(-0.0008 to
-0.002 in)
Clearance between output shaft bearing and cage
140 mm
(5.512 in)
-0.018 mm
(-0.0007 in)
-0.012 to
-0.052 mm
(-0.0005 to
-0.002 in)
0.006 to
-0.052 mm
(0.0002 to
-0.002 in)
Clearance between spacer and bearing
95 mm
(3.740 in)
+0.045 to
+0.023 mm
(+0.002 to
+0.001 in)
-0.020 mm
(-0.0008 in)
-0.023 to
-0.065 mm
(-0.023 to
-0.003 in)
Clearance between output shaft bearing and housing
170 mm
(6.693 in)
-0.025 mm
(-0.002 in)
-0.012 to
-0.052 mm
(-0.0005 to
-0.002 in)
0.013 to
-0.052 mm
(-0.0005 to
-0.002 in)
Clearance between drive gear and bearing
Standard
size
Tolerance
Repair limit
94.8 mm
(3.732 in)
10
Coupling oil seal contact surface
95 mm
(3.740 in)
-0.087 mm
(-0.003 in)
11
Clearance between cage and case
2 (Shim)
Preload: 0.1 - 1.0 Nm

(0.07 - 0.7 lbf ft)
(Drive gear as individual part)
12
Clearance between cover and case
2 (Shim)

(0.22 - 0.41 lbf ft)
Then add 0.1 mm (0.0039 in) of shim (idler
gear as individual part)
13
Clearance between cage and cover
0.25 mm
(0.010 in)
(Shims)

(0.4 - 0.7 lbf ft)
(Output shaft as individual part)
14
Backlash between drive gear and idler gear
0.17 - 0.44 mm (0.007 - 0.017 in)
15
Backlash between idler gear and driven gear
0.17 - 0.44 mm (0.007 - 0.017 in)
WA500-3LK
Replace
Adjust
Replace
40-17 1
MAIN RELIEF, TORQUE CONVERTER RE-
No.
Check item
Criteria
Standard
size
Clearance between main relief

valve and valve body
Clearance between torque

converter valve and valve body
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.013 mm
(+0.0005 in)
0.035 to
0.058 mm
(0.0014 to
0.0023 in)
0.08 mm
(0.003 in)
+0.013 mm
(+0.0005 in)
0.035 to
0.058 mm
(0.0014 to
0.0023 in)
0.08 mm
(0.003 in)
Shaft
Hole
25 mm
(0.984 in)
-0.035 to
-0.045 mm
(-0.0014 to
-0.0018 in)
22 mm
(0.866 in)
-0.035 to
-0.045 mm
(-0.0014 to
-0.0018 in)
Standard size
Replace
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
Main relief valve spring (outer)
128 mm
(5.039 in)
75.3 mm
(2.965 in)
509 N
(114 lbf)
124.2 mm
(4.890 in)
483 N
(109 lbf)
Main relief valve spring (inner)
108 mm
(4.252 in)
75.3 mm
(2.965 in)
402 N
(90 lbf)
104.8 mm
(4.126 in)
382 N
(86 lbf)
Main relief valve spring
50 mm
(1.969 in)
42 mm
(1.654 in)
153 N
(34 lbf)
48.5 mm
(1.910 in)
145 N
(33 lbf)
40-18 1
WA500-3LK
LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
No.
Check item
Criteria
Standard size
Lubrication relief valve spring
WA500-3LK
Remedy
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
26 mm
(1.023 in)
23.7 mm
(0.933 in)
11.8 N
(2.65 lbf)
25.2 mm
(0.9921 in)
10.8 N
(2.42 lbf)
Replace
40-19 1
DRIVE SHAFT
DRIVE SHAFT
40-20 1
WA500-3LK
DRIVE SHAFT
12
Torque Values
Item
Nm
lbf ft
549 59
405 44
110 12
81 9
144 12
106 9
WA500-3LK
40-21 1
CENTER SUPPORT
CENTER SUPPORT
No.
Check item
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Clearance between case and bearing
140 mm
(5.512 in)
-0.018 mm
(-0.0007 in)
-0.036 to
-0.061 mm
(-0.0014 to
-0.0024 in)
-0.018 to
-0.061 mm
(-0.0007 to
-0.0024 in)
-0.015 mm
(-0.0006 in)
Clearance between case and bearing
130 mm
(5.118 in)
-0.018 mm
(-0.0007 in)
-0.036 to
-0.061 mm
(-0.0014 to
-0.0024 in)
-0.018 to
-0.061 mm
(-0.0007 to
-0.0024 in)
-0.015 mm
(-0.0006 in)
Clearance between coupling shaft and

bearing
80 mm
(3.150 in)
+0.051 to
+0.032 mm
(+0.0020 to
+0.0013 in)
-0.015 mm
(-0.0006 in)
0.032 to
0.066 mm
(0.0013 to
0.0026 in)
0.029 mm
(0.0011 in)
Clearance between coupling shaft and

bearing
75 mm
(2.953 in)
+0.051 to
+0.032 mm
(+0.0020 to
+0.0013 in)
-0.015 mm
(-0.0006 in)
0.032 to
0.066 mm
(0.0013 to
0.0026 in)
0.029 mm
(0.0011 in)
Standard size
Tolerance
Repair limit
Wear of oil seal surface
95
(3.740 in)
-0.087 mm
(-0.003 in)
-0.018 mm
(-0.0007 in)
105 mm
(4.134 in)
-0.087 mm
(-0.003 in)
-0.018 mm
(-0.0007 in)
End play of coupling shaft
40-22 1
Replace
Repair
chrome
plating or
replace
Preload max: 3.9 Nm (2.9 lbf ft)
WA500-3LK
CENTER SUPPORT
Torque Values
Item
Nm
lbf ft
932 98
687 72
66 7
49 5
WA500-3LK
40-23 1
DIFFERENTIAL, NORMAL - (STANDARD)
40-24 1
WA500-3LK
12
No.
Check item
Criteria
Standard size
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance of side bearing (outer race) in differential

gear assembly
180 mm
(7.087 in)
-0.025 mm
(-0.0010 in)
+0.054 to
+0.014 mm
(+0.0021 to
+0.0006 in)
0.014 to
0.079 mm
(0.0006 to
0.0031 in)
Clearance of side bearing (inner race) in differential

gear assembly
120 mm
(4.724 in)
+0.045 to
+0.023 mm
(+0.0018 to
+0.0009 in)
-0.020 mm
(-0.0008 in)
-0.023 to
-0.065 mm
(-0.0009 to
-0.0026 in)
Clearance of pinion shaft bearing (outer race)
171.45 mm
(6.75 in)
+0.025 mm
(+0.0010 in)
+0.026 to
-0.014 mm
(+0.0010 to
-0.0006 in)
0.026 to
-0.039 mm
(0.0010 to
-0.0015 in)
Clearance of pinion shaft bearing (inner race)
76.2 mm
(3.00 in)
+0.064 to
+0.038 mm
(+0.0025 to
+0.0015 in)
+0.013 mm
(+0.0005 in)
-0.025 to
-0.064 mm
(0.0010 to
-0.0025 in)
Clearance of pinion shaft bearing (inner race)
76.2 mm
(3.00 in)
+0.030 to
+0.011 mm
(+0.0012 to
+0.0004 in)
+0.013 mm
(+0.0005 in)
0.002 to
-0.030 mm
(-0.00000 to
-0.00118 in)
0.012 to
0.049 mm
(0.0005 to
0.0019 in)
Clearance of pilot bearing (outer race)
120 mm
(4.724 in)
-0.015 mm
(-0.0006 in)
+0.034 to
+0.012 mm
(+0.0013 to
+0.0005 in)
Clearance of pilot bearing (inner race)
55 mm
(2.165 in)
+0.039 to
+0.020 mm
(+0.0015 to
+0.0008 in)
-0.010 to
-0.025 mm
(-0.0004 to
-0.0010 in)
-0.030to
-0.064 mm
(-0.0012 to
-0.0025 in)
Clearance between differential carrier and cage
210 mm
(8.268 in)
-0.020 to
-0.060 mm
(0.0008 to
-0.0024 in)
+0.046 to
+0.010 mm
(+0.0018 to
+0.0004 in)
0.030 to
0.106 mm
(0.0012 to
0.0042 in)
Clearance between spider and differential pinion

bushing
40 mm
(1.575 in)
-0.025 to
-0.050 mm
(0.0010 to
-0.0020 in)
+0.160 to
+0.110 mm
(+0.0063 to
+0.0043 in)
0.135 to
0.210 mm
(0.0053 to
0.0083 in)
10
Backlash of bevel gear
0.30 - 0.41 mm (0.0012 - 0.0016 in)

0.30 - 0.41 mm (0.0012 - 0.0016 in)
11
Backlash of differential gear
12
End play of pinion gear
Max. 0.064 mm (0.0025 in)
13
Free rotating torque of bevel gear
Max. 8.34 Nm {6.15 lbf ft)
14
Rear face runout of bevel gear
15
Standard thickness of shims for stop shaft
WA500-3LK
Replace
0.1 mm (0.0039 in)

Clearance "a" + (0.1 0.05 mm / 0.0039 0.002 in)
40-25 1
12
40-26 1
WA500-3LK
12
No.
Check item
Thickness of side gear washer
Criteria
Remedy
Standard
size
Tolerance
Repair limit
4 mm
(0.158 in)
+0.05 to
-0.05 mm
(+0.002 to
-0.002 in)
3.8 mm
(0.150 in)
1.35 mm
(0.053 in)
-
Thickness of pinion gear washer
1.5 mm
(0.059 in)
+0.09 to
-0.01 mm
(+0.004 to
-0.0004 in)
100 mm
(3.937 in)
-0.087 mm
(-0.0034 in)
Replace
Torque Values
Item
Nm
lbf ft
549 59
405 44
927 103
684 76
4 1 (see note 1)
3 0.74 (see note 1)
13 10 (see note 2)
83 7 (see note 2)
277 32
204 24
31 3
23 3
907 123
669 191
note 1
1st step when measuring clearance with no shim.
note 2
1st step when measuring clearance with shim installed.
WA500-3LK
40-27 1
DIFFERENTIAL, LIMITED SLIP
12
Torque Values
Item
Nm
lbf ft
117.7 4.9
86.8 3.6
927 103
684 75
549 59
404 43
277 32
204 23
907 122.5
669 90.3
80.9 3.4
59 2.5
40-28 1
WA500-3LK
12
No.
Unit: mm (in)
Check item
Criteria
Remedy
Tolerance
Standard
size
Shaft
Hole
180
(7.08)
0 to -0.025
(0 to -0.00098)
Clearance of side bearing inner

race in differential gear assembly
120
(4.72)
Clearance of outer race of pinion

shaft bearing
Standard clearance
Clearance
limit
+0.026 to
+0.014
(+0.0010
+0.00055)
0.014 to 0.051
(0.00055 to 0.0020)
---
+0.045 to
+0.023
(+0.0017 to
+0.00090)
0 to -0.025
(0 to -0.00098)
-0.023 to -0.065
(-0.00090 to -0.00255)
---
171.45
(6.75)
+0.025 to 0
(+0.00098 to 0)
+0.026 to
-0.014
(+0.0010 to
+0.00055)
0.026 to 0.039
(0.0010 to +0.00153)
---
Clearance of inner race of pinion

shaft bearing
76.2
(3.0)
+0.064 to
+0.038
(0.00251 to
+0.00149)
+0.013 to 0
-0.025 to -0.064
(+0.00051 to 0) (-0.00098 to -0.00251)
---
Clearance of inner race of pinion

shaft bearing
76.2
(3.0)
+0.030 to
+0.011
(+0.00118 to
+0.0118)
+0.013 to 0
(+0.00051 to 0)
0.002 to -0.030
(0 to -0.00118)
---
Clearance of inner race of pilot

bearing
55
(2.16)
+0.039 to
+0.020
(+0.00153 to
+0.00078)
-0.010 to
-0.025
(-0.000393 to
-0.00098)
-0.030 to -0.064
(0.00118 to -0.00251)
---
Clearance between differential

carrier and cage
210
(8.26)
-0.020 to -0.060
(-0.00078 to 0.00236)
+0.046 to
+0.010
(+0.00181 to
+0.000393)
0.030 to 0.106
(0.00118 to 0.00417)
---
Backlash of bevel gear
0.30 - 0.45 (0.00118 - 0.01771)
Backlash of differential gear
0.30 - 0.41 (0.00118 - 0.016141)
10
End play of pinion gear
11
Free rotating torque of bevel gear
12
Rear face runout of bevel gear
13
Standard thickness of shims for

stop shaft
Clearance of side bearing outer

race in differential gear assembly
Max. 0.64 (0.02519)

Max. 8.34 Nm (6.15 lbf ft)
0.1 (0.00393)
Clearance "a" +{0.1 0.05} ("a" +[0.00393 0.00196])
Standard size
14
Thickness of plate
Replace
Tolerance
Standard clearance
0.025 (0.000984)
3.6 (0.14173)
0.035 (0.001377)
3.915 (0.15413)
3.705 (0.14586)
3.785 (0.14901)
3.855 (0.15177)
15
Thickness of disc
16
Clearance of disc, plate (End play)
17
Thickness of washer
3.96 (0.15590)
0.2 (0.001377)
3.8 (0.14960)
18
100 (3.93701)
0 to -0.087 (0 to -0.003425)
---
WA500-3LK
3.965 (0.15610)
0.2 - 0.8 (0.00787 - 0.03149)
40-29 1
FINAL DRIVE
FINAL DRIVE
Torque Values
Item
Nm
lbf ft
31 3
23 3
172 74
12754
110 12
81 9
277 32
204 24
69 10
51 7
40-30 1
WA500-3LK
FINAL DRIVE
12
No.
Check item
Criteria
Standard
size
Clearance between planetary shaft

and bearing
Clearance between ring gear hub

and bearing
Tolerance
Remedy
Standard
clearance
Clearance
limit
-0.015 mm
(-0.0006 in)
-0.002 to
-0.030 mm
(-0.0006 to
-0.0012 in)
-0.030 mm
(-0.0012 in)
-0.004 to
-0.063 mm
(-0.0002 to
-0.0025 in)
Shaft
Hole
55 mm
(2.165 in)
+0.015 to
+0.002 mm
(+0.000590 to
+0.0006 in)
190 mm
(7.480 in)
+0.033 to
+0.004 mm
(+0.0013 to
+0.0002 in)
Standard
size
Tolerance
Repair limit
22 mm
(0.866 in)
0.1 mm
(0.0039 in)
21.5 mm
(0.847 in)
Thickness of spacer
Backlash between planet gear and

sun gear
0.18 - 0.43 mm (0.007 - 0.017 in)
Backlash between planet gear and

ring gear
0.18 - 0.54 mm (0.007 - 0.021 in)
Thickness of shim for wheel hub
WA500-3LK
Replace
2.0 mm (0.079 in)
40-31 1
AXLE MOUNT
AXLE MOUNT
40-32 1
WA500-3LK
AXLE MOUNT
12
No.
Check item
Criteria
Standard size
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
Clearance of shaft and hole front

support side (after press fitting
bushing)
310 mm
(12.205 in)
-0.056 to
-0.137 mm
(-0.002 to
-0.005 in)
+0.489 mm
(+0.019 in)
0.056 to
0.626 mm
(0.002 to
0.025 in)
1.6 mm
(0.063 in)

support side (before installing
bushing)
320.2 mm
(12.606 in)
+2.30 to
-0.80 mm
(+0.090 to
-0.032 in)
+0.089 mm
(+0.004 in)

support side (after press fitting
bushing)
260 mm
(10.236 in)
-0.056 to
-0.137 mm
(-0.002 to
-0.005 in)
+0.481 to
-0.008 mm
(+0.019 to
-0.0003 in)
0.048 to
0.618 mm
(0.002 to
0.024 in)
1.6 mm
(0.063 in)

support side (before installing
bushing
270.2 mm
(10.638 in)
+2.30 to
-0.80 mm
(+0.090 to
-0.032 in)
+0.081 mm
(+0.003 in)
Standard size
Tolerance
Repair limit
Thickness of wear plate
20 mm
(0.787 in)
-0.10 to
-0.25 mm
(-0.0039 to
-0.010 in)
Thickness of wear plate
5 mm
(0.197 in)
+0.1 to
-0.3 mm
(+0.0039 to
-0.012 in)
Thickness of rear bushing
5 mm
(0.197 in)
0.1 mm
(0.0039 in)
Thickness of front bushing
5 mm
(0.197 in)
0.1 mm
(0.0039 in)
note
Replace (see
note)
Replace
The bushings must be in contact with the support at both the front and rear
Torque Values
Item
Nm
lbf ft
2746 294
2025 217
1569 196
1157 145
277 32
204 24
WA500-3LK
40-33 1
CENTER HINGE PIN
CENTER HINGE PIN
40-34 1
WA500-3LK
CENTER HINGE PIN
12
No.
Check item
Criteria
Standard size
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance between lower hinge pin and rear

frame
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
+0.054 mm
(+0.002 in)
0.036 to
0.112 mm
(0.001 to
0.004 in)
Clearance between lower hinge pin and spacer

(small)
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
+0.054 mm
(+0.002 in)
0.036 to
0.112 mm
(0.001 to
0.004 in)
Clearance between lower hinge pin and

bearing
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
-0.020 mm
(-0.001 in)
0.016 to
0.058 mm
(0.001 to
0.002 in)
Clearance between lower hinge pin and spacer

(large)
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
+0.054 mm
(+0.002 in)
0.036 to
0.112 mm
(0.001 to
0.004 in)
Clearance between rear frame and spacer

(large)
130 mm
(5.118 in)
-0.043 to
-0.106 mm
(-0.002 to
-0.004 in)
+0.063 mm
(+0.003 in)
0.043 to
0.169 mm
(0.002 to
0.007 in)
Clearance between front frame and upper

hinge bearing
155 mm
(6.102 in)
-0.025 mm
(-0.001 in)
-0.048 to
-0.088 mm
(-0.002 to
-0.004 in)
-0.023 to
-0.088 mm
(-0.001 to
-0.004 in)
Clearance between upper hinge pin and rear

frame
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
+0.054 mm
(+0.002 in)
0.036 to
0.112 mm
(0.001 to
0.004 in)
Clearance between upper hinge pin and

bearing
100 mm
(3.937 in)
-0.036 to
-0.058 mm
(-0.001 to
-0.002 in)
-0.020 mm
(-0.001 in)
0.016 to
0.058 mm
(0.001 to
0.002 in)
Clearance between front frame and lower

hinge bearing
160 mm
(6.299 in)
-0.025 mm
(-0.001 in)
-0.050 to
-0.090 mm
(-0.002 to
-0.004 in)
-0.025 to
-0.090 mm
(-0.001 to
-0.004 in)
10
Clearance between rear frame and bushing
125 mm
(4.921 in)
-0.043 to
-0.106 mm
(-0.002 to
-0.004 in)
+0.063 mm
(+0.003 in)
0.043 to
0.169 mm
(0.002 to
0.007 in)
11
Clearance at press fitted part of seal of upper

hinge pin
115 mm
(4.528 in)
+0.280 to
+0.180 mm
(+01011 to
+0.007 in)
+0.054 mm
(+0.002 in)
-0.126 to
-0.280 mm
(-0.005 to
-0.011 in)
12
Clearance at press fitted part of seal of lower

hinge pin
135 mm
(5.315 in)
+0.310 to
+0.210 mm
(+0.012 in
+0.008 in)
+0.063 mm
(+0.003 in)
-0.147 to
-0.310 mm
(-0.006 in
-0.012 in)
Standard size
Tolerance
13
Height of lower hinge spacer (small)
35 mm (1.387 in)
0.1 (0.0039 in)
14
Height of lower hinge spacer (large)
101.5 mm (3.996 in)
0.1 (0.0039 in)
WA500-3LK
Replace
Replace
40-35 1
No.
Check item
CENTER HINGE PIN

Criteria
Remedy
15
Shim thickness for lower hinge and retainer
2.3 mm (0.090 in)
16
Shim thickness for lower hinge and retainer
1.6 mm (0.063 in )
17
Shim thickness for upper hinge and retainer
1.6 mm (0.063 in )
Adjust
Torque Values
Item
Nm
lbf ft
177 20
131 15
59 6 (see note 1)
44 4 (see note 1)
177 20 (see note 2)
131 15 (see note 2)
98 10 (see note 1)
72 7 (see note 1)
277 32 (see note 1)
204 24 (see note 1)
277 32 (see note 2)
204 24 (see note 2)
385 42
284 31
note 1
When adjusting shim
note 2
Final value
40-36 1
WA500-3LK
CENTER HINGE PIN
MEMORANDUM
WA500-3LK
40-37 1
STEERING COLUMN
STEERING COLUMN
40-38 1
WA500-3LK
No.
STEERING COLUMN
Check item
Criteria
Standard size
Clearance between steering shaft and column

bushing
19 mm
(0.748 in)
Remedy
Tolerance
Shaft
Hole
Standard
clerance
-0.080 mm
(-0.003 in)
+0.150 to
+0.050 mm
(+0.006 to
+0.002 in)
0.050 to
0.230 mm
(0.002 to
0.010 in)
Replace
Torque Values
Item
Nm
lbf ft
34 5
25 4
44 10
33 7
29 3
21 2
52 8
38 5
55 7
41 5
WA500-3LK
40-39 1
STEERING PUMP
STEERING PUMP
SAR(3)-080
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
Clearance between gear case and side plate,

gear
0.10 - 0.15 mm
(0.004 - 0.006 in)
0.19 mm
(0.007 in)
Clearance between inside diameter of plain

bearing and outside diameter of gear shaft
0.06 - 0.149 mm
(0.002 - 0.006 in)
0.20 mm
(0.008 in)
insertion depth of pin
Discharge:
E010-CD
(113 - 131 F)
+0
Replace
+0
mm (0.55 -0.02 in)

7 - 12 Nm (5 - 9 lbf ft)
14 -0.5
Revolution
(RPM)
Discharge
pressure
Standard
discharge
Repair limit
discharge
2500
210 kg/cm
(2987 psi)
184 L/min.
(49 gal/min)
170 L/min.
(45 gal/min
Torque Values
Item
Nm
lbf ft
277 32
204 24
40-40 1
WA500-3LK
STEERING VALVE
STEERING VALVE
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
Steering spool return spring
37.2 mm
(1.465 in)
32 mm
(1.260 in)
57 N
(13 lbf)
45 N
(10 lbf)
Load check valve spring
20.9 mm
(0.823 in)
13.2 mm
(0.520 in)
9 5 N
(2 1 lbf)
8N
(2 lbf)
Demand spool return spring
75.2 mm
(2.961 in)
68.5 mm
(2.697 in)
136 N
(31 lbf)
112 N
(25 lbf)
Relief valve spring
24.0 mm
(0.945 in)
22.19 mm
(0.874 in)
182 N
(41 lbf)
145 N
(33 lbf)
Check valve return spring
21.6 mm
(0.850 in)
17.0 mm
(0.669 in)
2N
(0.5 lbf)
2N
(0.45 lbf)
WA500-3LK
Replace
40-41 1
STEERING CYLINDER MOUNT
No.
Check item
Criteria
Standard size
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance between mounting pin and

bushing connection of steering cylinder
rod and frame
60 mm
(2.362 in)
0 to
-0.074 mm
(0 to
-0.003 in)
+0.200 to
+0.100 mm
(+0.008 to
+0.004 in)
0.100 to
0.248 mm
(0.004 to
0.010 in)
Clearance between mounting pin and

bushing connection of steering cylinder
bottom and frame
60 mm
(2.362 in)
0 to
-0.074 mm
(0 to
-0.003 in)
+0.200 to
+0.100 mm
(+0.008 to
+0.004 in)
0.100 to
0.248 mm
(0.004 to
0.010 in)
Width of boss
Width of hinge
Standard clearance
(Clearance a + b)
74 1 mm
(2.913 0.039 in)
2.2 - 5.0 mm
(0.087 - 0.197 in)
74 1 mm
(2.913 0.039 in)
3.0 - 5.5 mm
(0.118 - 0.217 in)
Connection of steering cylinder and

front frame
Connection of steering cylinder and

rear frame
40-42 1
mm
70 +0.8
0
(2.756 +0.032
in)
0
0
mm
70 -0.5
0
(2.756 -0.020
in)
Replace
Max. 1.0 mm
(0.030 in) after
adjusting shim
WA500-3LK
12
MEMORANDUM
WA500-3LK
40-43 1
BRAKE VALVE
BRAKE VALVE
RIGHT
40-44 1
WA500-3LK
No.
BRAKE VALVE
Check item
Criteria
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
Clearance between pedal mount

hole and bracket hole
10 mm
(0.394 in)
-0.025 to
-0.075 mm
(-0.001 to
-0.003 in)
+0.1 mm
(+0.004 in)
0.175 to
0.025 mm
(0.007 to
0.001 in)
0.25 mm
(0.010 in)
Clearance between roller and pin
10 mm
(0.394 in)
-0.025 to
-0.075 mm
(-0.001 to
-0.003 in)
+0.1 mm
(+0.004 in)
0.175 to
0.025 mm
(0.007 to
0.001 in)
0.25 mm
(0.010 in)
Outside diameter of roller
Standard
size
Tolerance
Repair limit
30 mm
(1.181 in)
-0.5 mm (0.020 in)
29.2 mm (1.150 in)
Standard size
Replace
Repair limit
Free length
Test height
Test load
Free length
21.8 mm
(0.858 in)
93.2 N
(21 lbf)
33 mm
(1.299 in)
Control spring
34 mm
(1.339 in)
Control spring
46.3 mm
(1.823 in)
34.3 mm
(1.350 in)
459.0 N
(103 lbf)
45.3 mm
(1.784 in)
Return spring
86.2 mm
(3.394 in)
58 mm
(2.284 in)
60.8 N
(14 lbf)
78 mm
(3.071 in)
Spring
17 mm
(0.669 in)
15 mm
(0.591 in)
69.6 N
(16 lbf)
16.2 mm
(0.638 in)
Return spring
31.5 mm
(1.240 in)
19.5 mm
(0.768 in)
16.7 N
(3.75 lbf)
28 mm
(1.102 in)
Test load
Torque Values
Item
Nm
lbf ft
66 7
49 5
152 25
112 18
8 2
6 1.5
WA500-3LK
40-45 1
BRAKE VALVE
LEFT
40-46 1
WA500-3LK
No.
BRAKE VALVE
Check item
Criteria
Standard
size
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
Clearance between pedal mount

hole and bracket hole
10 mm
(0.394 in)
-0.025 to
-0.075 mm
(-0.001 to
-0.003 in)
+0.1 mm
(+0.004 in)
0.175 to
0.025 mm
(0.007 to
0.001 in)
0.25 mm
(0.010 in)
Clearance between roller and pin
10 mm
(0.394 in)
-0.025 to
-0.075 mm
(-0.001 to
-0.003 in)
+0.1 mm
(+0.004 in)
0.175 to
0.025 mm
(0.007 to
0.001 in)
0.25 mm
(0.010 in)
Outside diameter of roller
Standard
size
Tolerance
Repair limit
30 mm
(1.181 in)
-0.5 mm (0.020 in)
29.2 mm (1.150 in)
Standard size
Replace
Repair limit
Free length
Test height
Test load
Free length
21.8 mm
(0.858 in)
93.2 N
(21 lbf)
33 mm
(1.299 in)
Control spring
34 mm
(1.339 in)
Control spring
46.3 mm
(1.823 in)
34.3 mm
(1.350 in)
459.0 N
(103 lbf)
45.3 mm
(1.784 in)
Return spring
86.2 mm
(3.394 in)
58 mm
(2.284 in)
60.8 N
(14 lbf)
78 mm
(3.071 in)
Spring
17 mm
(0.669 in)
15 mm
(0.591 in)
69.6 N
(16 lbf)
16.2 mm
(0.638 in)
Return spring
31.5 mm
(1.240 in)
19.5 mm
(0.768 in)
16.7 N
(3.75 lbf)
28 mm
(1.102 in)
Test load
Torque Values
Item
Nm
lbf ft
66 7
49 5
152 25
112 18
8 2
6 1.5
WA500-3LK
40-47 1
SLACK ADJUSTER
SLACK ADJUSTER
No.
Check item
Criteria
Standard
size
Clearance between body and piston
55 mm
(2.165 in)
Tolerance
Shaft
Hole
-0.030 to
-0.076 mm
(-0.001 to
-0.003 in)
+0.074 mm
(+0.003 in)
Remedy
Standard
clearance
Clearance
limit
0.030 to
0.150 mm
(0.001 to
0.006 in)
0.25 mm
(0.010 in)
Standard size
Replace
Repair limit
Free length
Test length
Test load
Free length
Test load
38 mm
(1.496 in)
43.2 N
(10 lbf)
33 mm
(1.299 in)
66.7 N
(15 lbf)
Spring
198 mm
(7.795 in)
Spring
39.2 mm
(1.543 in)
Torque Values
Item
Nm
lbf ft
56 7
41 5
66 7
49 5
40-48 1
WA500-3LK
SLACK ADJUSTER
12
MEMORANDUM
WA500-3LK
40-49 1
BRAKE
BRAKE
40-50 1
WA500-3LK
No.
BRAKE
Check item
Criteria
Remedy
Standard size
Return spring
Repair limit
Free length
Install length
Install load
Free length
Install load
80.2 mm
(3.158 in)
69.9 mm
(2.752 in)
600.2 N
(135 lbf)
72.2 mm
(2.843 in)
539.4 N
(121 lbf)
Standard size
Tolerance
Repair limit
0.08 mm
(0.003 in)
2.0 mm
(0.079 in)
Thickness of plate
2.3 mm
(0.091 in)
Thickness of disc
3.8 mm
(0.150 in)
0.1 mm
(0.004 in)
3.5 mm
(0.137 in)
Total thickness of plates and discs
51.1 mm
(2.011 in)
1.52 mm
(0.059 in)
46.0 mm
(1.811 in)
Wear of piston seal contact surface
42.0 mm
(1.654 in)
+0.097 mm
(+0.004 in)
Wear of piston seal contact surface
38.3 mm
(1.509 in)
+0.089 mm
(+0.004 in)
Backlash between outer gear and

plate
0.21 - 0.65 mm
(0.008 - 0.026 in)
Backlash between inner gear and

disc
0.31 - 0.74 mm
(0.012 - 0.029 in)
Replace
Torque Values
Item
Nm
lbf ft
177 20
130 15
549 59
405 44
WA500-3LK
40-51 1
PARKING BRAKE
PARKING BRAKE
No
Check item
Criteria
Remedy
Standard size
Free length Install length
Repair limit
Install load
Free length Install load
Parking brake spring (outside)
77.7 mm
(3.158 in)
54.0 mm
(2.126 in)
1425 22 N
(320 5 lbf)
69.9 mm
(2.752 in)
1258 N
(283 lbf)
Parking brake spring (inside)
77.8 mm
(3.063 in)
54.0 mm
(2.126 in)
535 5.3 N
(120 1 lbf)
70.0 mm
(2.756 in)
482 N
(108 lbf)
Standard size
Tolerance
Repair limit
Thickness
4.0 mm
(0.158 in)
0.05 mm
(0.002 in)
3.9 mm
(0.154 in)
Distortion
0.15 mm
(0.006 in)
0.6 mm
(0.024 in)
Thickness
3.2 mm
(0.126 in)
0.1 mm
(0.004 in)
35.0 mm
(1.378 in)
Depth of
lining groove
0.45 mm
(0.018 in)
+0.175 mm
(+0.007 in)
0.235 mm
(0.009 in)
Thickness of
lining
0.7 mm
(0.028 in)
+0.075 mm
(+0.003 in)
Separation of plate
Brake disc
Load of wave spring
40-52 1
Replace
WA500-3LK
HYDRAULIC PUMP
HYDRAULIC PUMP
SAR(4)-160
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
Clearance between gear case and side plate,

gear
0.11 - 0.16 mm
(0.004 - 0.006 in)
0.19 mm
(0.007 in)
Clearance between inside diameter of plain

bearing and outside diameter of gear shaft
0.06 - 0.140 mm
(0.002 - 0.006 in)
0.20 mm
(0.008 in)
Discharge:
E010-CD
(113 - 131 F)
+0
14 -0.5
Replace
+0
mm (0.55 -0.02 in)

9.8 - 14.7 Nm (7 - 11 lbf ft)
Revolution
(RPM)
Discharge
pressure
Standard
discharge
Repair limit
discharge
2200
210 kg/cm2
(2987 psi)
328 L/min.
(87 gal/min)
303 L/min.
(80 gal/min
Torque Values
Item
Nm
lbf ft
177 20
130 15
WA500-3LK
40-53 1
SWITCH, PPC PUMP
SWITCH, PPC PUMP

SAR(3)-63 + SAR(1)-28
No.
Check item
Criteria
Clearance between gear case

and side plate gear
Clearance between inside

diameter of plain bearing and
outside diameter of gear shaft
Model
Standard clearance
Clearance
SAR(3)-63
0.10 - 0.15 mm
(0.004 - 0.006 in)
0.19 mm
(0.007 in)
SAR(1)-28
0.10 - 0.15 mm
(0.004 - 0.006 in)
0.19 mm
(0.007 in)
SAR(3)-63
0.06 - 0.149 mm
(0.002 - 0.006 in)
0.20 mm
(0.008 in)
SAR(1)-28
0.06 - 0.149 mm
(0.002 - 0.006 in)
0.20 mm
(0.008 in)
Standard size
Tolerance
SAR(3)-63
10 mm
(0.394 in)
-0.5 mm
(-0.020 in)
SAR(1)-28
10 mm
(0.394 in)
-0.5 mm
(-0.020 in)
Discharge:
E010-CD
45o - 55o C
(113o - 131o F)
Remedy
SAR(3)-63
Replace
6.9 - 11.8 Nm (5 - 9 lbf ft)
SAR(1)-28
2.0 - 4.9 Nm (1.5 - 4 lbf ft)

Revolution
(rpm)
Discharge
pressure
Standard dis- Repair limit discharge

charge
SAR(3)-63
2500
210 kg/cm2
(2987 psi)
145 L/min
(38 gal/min)
134 L/min
(35 gal/min)
SAR(1)-28
2500
38 kg/cm2
(541 psi)
67 L/min
(18 gal/min)
60 L/min
(16 gal/min)
Torque Values
Item
Nm
lbf ft
177 20
130 15
113 10
83 7
40-54 1
WA500-3LK
PPC VALVE
PPC VALVE
FOR BUCKET AND BOOM
No
Check item
Criteria
Standard size
Free length
X O.D.
Install
length
Remedy
Repair limit
Install load Free length Install load
Centering spring
(bucket DUMP, boom LOWER)
52.8 x 12.3 mm
(2.079 x 0.484 in)
36.0 mm
(1.417 in)
29.4 N
(7 lbf)
23.5 N
(5 lbf)
Centering pin
(bucket TILT, boom RAISE)
52.8 x 12.3 mm
(2.079 x 0.484 in)
36.0 mm
(1.417 in)
39.2 N
(9 lbf)
31.4 N
(7 lbf)
Metering spring
31.4 x 7.4 mm
(1.236 x 0.291 in)
29.4 mm
(1.158 in)
16.7 N
(4 lbf)
13.7 N
(3 lbf)
Replace
spring if
damaged or
deformed
Torque Values
Item
Nm
lbf ft
44.1 4.9
33 4
17.7 3.9
13 3
WA500-3LK
40-55 1
PPC VALVE
FOR AUXILIARY ATTACHMENT
No
Check item
Criteria
Standard size
Free length
X O.D.
Install
length
Remedy
Repair limit
Centering spring
(bucket DUMP, boom LOWER)
52.8 x 12.3 mm
(2.079 x 0.484 in)
36.0 mm
(1.417 in)
29.4 N
(7 lbf)
23.5 N
(5 lbf)
Centering pin
(bucket TILT, boom RAISE)
52.8 x 12.3 mm
(2.079 x 0.484 in)
36.0 mm
(1.417 in)
39.2 N
(9 lbf)
23.5 N
(5 lbf)
Metering spring
31.4 x 7.4 mm
(1.236 x 0.291 in)
29.4 mm
(1.158 in)
16.7 N
(4 lbf)
13.7 N
(3 lbf)
Replace
spring if
damaged or
deformed
Torque Values
Item
Nm
lbf ft
44.1 4.9
33 4
17.7 3.9
13 3
40-56 1
WA500-3LK
CUT-OFF VALVE
CUT-OFF VALVE
No
Check item
Criteria
Standard size
Free length
Install
length
Remedy
Repair limit
Unload valve spring
36.95 mm
(1.455 in)
3.0 mm
(0.118 in)
35.3 N
(8 lbf)
28.4 N
(6 lbf)
Check valve spring
33 mm
(1.299 in)
2.0 mm
(0.079 in)
16.7 N
(4 lbf)
1.4 N
(0.32 lbf)
Replace
Torque Values
Item
Nm
lbf ft
66.2 7.4
49 6
2.21 0.25
147.1 9.8
109 7
34.3 4.9
25 4
WA500-3LK
40-57 1
MAIN CONTROL VALVE
MAIN CONTROL VALVE

2 SPOOL VALVE
40-58 1
WA500-3LK
MAIN CONTROL VALVE
12
No
Check item
Criteria
Standard size
Free length
Install
length
Remedy
Repair limit
Bucket spool return spring (large)
64.4 mm
(2.535 in)
62.2 mm
(2.449 in)
190 N
(43 lbf)
152 N
(34 lbf)
Bucket spool return spring (small)
18.6 mm
(0.732 in)
14.9 mm
(0.587 in)
112.8 N
(25 lbf)
90 N
(20 lbf)
Boom spool return spring (large)
64.4 mm
(2.535 in)
62.7 mm
(2.469 in)
149 N
(34 lbf)
119.6 N
(27 lbf)
Boom spool return spring (small)
18.6 mm
(0.732 in)
15.2 mm
(0.598 in)
104 N
(23 lbf)
83.4 N
(19 lbf)
89.2 mm
(3.512 in)
82.0 mm
(3.228 in)
616 N
(139 lbf)
554 N
(125 lbf)
42.0 mm
(1.654 in)
42.0 mm
(1.654 in)
82.4 mm
(3.244 in)
82.0 mm
(2.228 in)
182.4 N
(41 lbf)
163.8 N
(37 lbf)
42.0 mm
(1.654 in)
42.0 mm
(1.654 in)
Main valve spring
52.3 mm
(2.059 in)
38.0 mm
(1.496 in)
86.3 N
(19 lbf)
68.6 N
(15 lbf)
10
Check valve spring
78.2 mm
(3.079 in)
52.0 mm
(2.047 in)
18.8 N
(4 lbf)
14.7 N
(3 lbf)
11
Suction valve spring of safety valve
27.9 mm
(1.098 in)
18.0 mm
(0.709 in)
6.9 N
(2 lbf)
5.9 N
(1 lbf)
12
27.9 mm
(1.098 in)
18.0 mm
(0.709 in)
6.9 N
(2 lbf)
5.9 N
(1 lbf)
13
Float selector valve spring
53.0 mm
(2.087 in)
42.1 mm
(1.657 in)
137 N
(31 lbf)
123.6 N
(28 lbf)
14
Unloader valve spring
82.7 mm
(3.256 in)
47.0 mm
(1.850 in)
49 N
(11 lbf)
39 N
(9 lbf)
15
Relief valve poppet spring
49.3 mm
(1.941 in)
43.3 mm
(1.705 in)
209.9 N
(47 lbf)
167.7 N
(38 lbf)
Replace
Torque Values
Item
Nm
lbf ft
321 47
237 34
152 25
112 18
88 10
65 7
186 10
137 7
69 10
51 7
22 3
16 2
WA500-3LK
40-59 1
MAIN CONTROL VALVE
12
3-SPOOL
40-60 1
WA500-3LK
MAIN CONTROL VALVE
12
No
Check item
Criteria
Standard size
Free length
Install
length
Remedy
Repair limit
Attachment spool return spring (large)
64.4 mm
(2.535 in)
62.2 mm
(2.449 in)
190 N
(43 lbf)
152 N
(34 lbf)
Attachment spool return spring (small)
18.6 mm
(0.732 in)
14.9 mm
(0.587 in)
112.8 N
(25 lbf)
90 N
(20 lbf)
64.4 mm
(2.535 in)
62.2 mm
(2.449 in)
190 N
(43 lbf)
152 N
(34 lbf)
18.6 mm
(0.732 in)
14.9 mm
(0.587 in)
112.8 N
(25 lbf)
90 N
(20 lbf)
64.4 mm
(2.535 in)
62.7 mm
(2.469 in)
149 N
(34 lbf)
119.6 N
(27 lbf)
18.6 mm
(0.732 in)
15.2 mm
(0.598 in)
104 N
(23 lbf)
83.4 N
(19 lbf)
89.2 mm
(3.512 in)
82.0 mm
(3.228 in)
616 N
(139 lbf)
554 N
(125 lbf)
42.0 mm
(1.654 in)
42.0 mm
(1.654 in)
82.4 mm
(3.244 in)
82.0 mm
(2.228 in)
182.4 N
(41 lbf)
163.8 N
(37 lbf)
10
42.0 mm
(1.654 in)
42.0 mm
(1.654 in)
11
Attachment spool return spring (large)
82.4 mm
(3.244 in)
82.0 mm
(2.228 in)
182.4 N
(41 lbf)
68.6 N
(15 lbf)
12
Attachment spool return spring (small)
42.0 mm
(1.654 in)
42.0 mm
(1.654 in)
13
Main valve spring
52.3 mm
(2.059 in)
38.0 mm
(1.496 in)
86.3 N
(19 lbf)
68.6 N
(15 lbf)
14
Check valve spring
78.2 mm
(3.079 in)
52.0 mm
(2.047 in)
18.8 N
(4 lbf)
14.7 N
(3 lbf)
15
Suction valve spring of safety valve
27.9 mm
(1.098 in)
18.0 mm
(0.709 in)
6.9 N
(2 lbf)
5.9 N
(1 lbf)
16
27.9 mm
(1.098 in)
18.0 mm
(0.709 in)
6.9 N
(2 lbf)
5.9 N
(1 lbf)
17
Float selector valve spring
53.0 mm
(2.087 in)
42.1 mm
(1.657 in)
137 N
(31 lbf)
123.6 N
(28 lbf)
18
Unloader valve spring
82.7 mm
(3.256 in)
47.0 mm
(1.850 in)
49 N
(11 lbf)
39 N
(9 lbf)
19
Relief valve poppet spring
49.3 mm
(1.941 in)
43.3 mm
(1.705 in)
209.9 N
(47 lbf)
167.7 N
(38 lbf)
Replace
Torque Values
Item
Nm
lbf ft
321 47
237 34
152 25
112 18
88 10
65 7
186 10
137 7
69 10
51 7
22 3
16 2
WA500-3LK
40-61 1
HYDRAULIC CYLINDERS
HYDRAULIC CYLINDERS
40-62 1
WA500-3LK
No
HYDRAULIC CYLINDERS
Check item
Clearance between rod and

bushing
Clearance between piston

rod mounting pin and
diameter of hole
Clearance between cylinder

bottom mounting pin and
bushing
Cylinder bore
Criteria
Cylinder
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Steering
55 mm
(2.165 in)
-0.030 to
-0.076 mm
(-0.001 to
-0.003 in)
+0.151 to
+0.006 mm
(+0.006 to
+0.0002 in)
0.036 to
0.227 mm
(0.001 to
0.009 in)
0.327 mm
(0.013 in)
Boom
110 mm
(4.331 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.274 to
+0.060 mm
(+0.010 to
+0.002 in)
0.096 to
0.364 mm
(0.004 to
0.014 in)
0.469 mm
(0.018 in)
Bucket
120 mm
(4.724 in)
-0.043 to
-0.106 mm
(-0.002 to
-0.004 in)
+0.203 to
+0.048 mm
(+0.008 to
+0.002 in)
0.091 to
0.309 mm
(0.004 to
0.012 in)
0.469 mm
(0.018 in)
Steering
60 mm
(2.362 in)
-0.074 mm
(-0.003 in)
+0.174 to
+0.100 mm
(+0.007 to
+0.004 in)
0.100 to
0.248 mm
(0.004 to
0.010 in)
1.0 mm
(0.039 in)
Boom
120 mm
(4.724 in)
+0.100 mm
(+0.004 in)
Bucket
120 mm
(4.724 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
Steering
60 mm
(2.362 in)
-0.074 mm
(-0.003 in)
+0.174 to
+0.100 mm
(0.00685 to
0.00393)
0.100 to
0.248 mm
(0.004 to
0.010 in)
1.0 mm
(0.039 in)
Boom
120 mm
(4.724 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
Bucket
120 mm
(4.724 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
Standard size
Tolerance
Repair limit
Steering
110 mm
(4.331 in)
+0.150
(+0.006 in)
Boom
200 mm
(7.874 in)
+0.200
(+0.008 in)
Bucket
225 mm
(7.874 in)
+0.200
(+0.008 in)
Replace
Torque Values
Item
Nm
lbf ft
932 93
687 69
177 18
131 13
466 142
344 105
177 20
131 15
662 74
488 54
WA500-3LK
40-63 1
BUCKET LINKAGE
BUCKET LINKAGE
40-64 1
WA500-3LK
BUCKET LINKAGE
12
No
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Clearance between pin and

bushing at both ends and bucket
link
110 mm
(4.331 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 to
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of boom and
bucket
110 mm
(4.331 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 to
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of and frame
120 mm
(4.724 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 to
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of bucket cylinder
bottom and frame
120 mm
(4.724 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 in
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of bucket cylinder
rod and lever
120 mm
(4.724 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 to
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of tilt lever and
frame
140 mm
(5.512 in)
-0.043 to
-0.106 mm
(-0.002 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 in
0.016 in)
1.0 mm
(0.039 in)

bushing at joint of boom cylinder
bottom and frame
120 mm
(4.724 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.395 to
+0.295 mm
(+0.016 to
+0.012 in)
0.338 to
0.501 mm
(0.013 to
0.020 in)
1.0 mm
(0.039 in)

bushing at joint of boom cylinder
rod
120 mm
(4.724 in)
-0.036 to
-0.090 mm
(-0.001 to
-0.004 in)
+0.307 to
+0.220 mm
(+0.012 to
+0.009 in)
0.256 to
0.397 mm
(0.010 to
0.016 in)
1.0 mm
(0.039 in)
Width between bosses
Width of
hinge
Standard clearance
(Clearance a + b)
Joint of bucket cylinder and frame
143 mm
(5.630 in)
140 mm
(5.512 in)
3.0 mm
(0.118 in)
10
Joint of boom and frame
153 mm
(6.024 in)
150 mm
(5.906 in)
3.0 mm
(0.118 in)
11
Joint of boom and bucket
180 mm
(7.087 in)
176.8 mm
(6.961 in)
3.2 mm
(0.126 in)
12
Joint of bucket link and bucket
145 mm
(5.709 in)
142 mm
(5.591 in)
3.0 mm
(0.118 in)
13
Joint of tilt lever and bucket link
144 mm
(5.670 mm)
142 mm
(5.591 in)
2.0 mm
(0.079 in)
14
Joint of tilt lever and frame
240 mm
(9.449 in)
237 mm
(9.331 in)
3.0 mm
(0.118 in)
15
Joint of tilt lever and bucket

cylinder
143 mm
(5.630 in)
140 mm
(5.512 in)
3.0 mm
(0.118 in)
16
Joint of boom cylinder and boom
125 mm
(4.921 in)
122 mm
(4.803 in)
3.0 mm
(0.118 in)
17
Joint of boom cylinder and frame
123 mm
(4.843 in)
120 mm
(4.724 in)
3.0 mm
(0.118 in)
WA500-3LK
Replace, also if
other parts are
biting into pin
Insert shims on
both sides to
make clearance
on both left and
right sides less
than 1.5 mm
(0.059 in)
40-65 1
BUCKET
BUCKET
No.
Check item
Wear of bucket tooth
Thickness of shims for tooth (Clearance between tooth and bucket)
Tightening torque of mounting bolt for bucket tooth
Tightening torque of mounting bolt for corner tooth
40-66 1
Croteria
Remedy
Standard size
Repair limit
61 mm
(2.402 in)
23 mm
(0.906 in)
Replace
Max. 0.5 mm
(Max. 0.020 in)
Adjust
1040 157 Nm
(767 116 lbf ft)
Retighten
WA500-3LK
BUCKET POSITIONER AND BOOM KICK-
12
BUCKET
POSITIONER AND BOOM KICK-OUT
No.
Check item
Clearance of bucket positioner switch
Clearance of boom kick-out switch
WA500-3LK
Criteria
Remedy
3 - 5 mm
(0.118 - 0197 in)
Adjust
40-67 1
ROPS CAB
12
ROPS CAB
Torque Values
Item
Nm
lbf ft
927 103
684 76
40-68 1
WA500-3LK
90
OTHERS
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

ECSS WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
JOYSTICK STEERING WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 of 5)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
ENGINE FLOOR HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25

CAB ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5)
. . . . . . . . . . . . . . . . . . . . . . . . 90-29
. . . . . . . . . . . . . . . . . . . . . . . . 90-31
. . . . . . . . . . . . . . . . . . . . . . . . 90-33
. . . . . . . . . . . . . . . . . . . . . . . . 90-35
. . . . . . . . . . . . . . . . . . . . . . . . 90-37
3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2) . . . . . . . . . . . . . . . . . . . . . 90-39

3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2) . . . . . . . . . . . . . . . . . . . . . 90-41
PARKING BRAKE CONTROL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
HYDRAULIC LINE ASSEMBLY (PART 1 OF 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
WA500-3LK
90-1 1
OTHERS
12
MEMORANDUM
WA500-3LK
90-2 1
OTHERS
FOLDOUT 10-225-1
12
ELECTRICAL DIAGRAMS
ECSS WIRING DIAGRAM
WA500-3LK
90-3 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-4
WA500-3LK
OTHERS
12
JOYSTICK
WA500-3LK
FOLDOUT 10-225-2
STEERING WIRING DIAGRAM
90-5 b
OTHERS
MEMORANDUM
MEMORANDUM
90-6
WA500-3LK
OTHERS
FOLDOUT 10-225-3
WA500-3LK
90-7 b
OTHERS
MEMORANDUM
MEMORANDUM
90-8
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-4
CIRCUIT DIAGRAM (SHEET 1) (PART 2 of 5)
90-9 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-10
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-5
90-11 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-12
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-6
90-13 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-14
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-7
90-15 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-16
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-8
90-17 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-18
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-9
90-19 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-20
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-10
90-21 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-22
WA500-3LK
OTHERS
12
ELECTRICAL
WA500-3LK
FOLDOUT 10-225-11
90-23 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-24
WA500-3LK
OTHERS
12
ENGINE
FOLDOUT 10-225-12
FLOOR HARNESS DIAGRAM
WA500-3LK
90-25 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-26
WA500-3LK
OTHERS
12
CAB
FOLDOUT 10-225-13
ELECTRICAL DIAGRAM
WA500-3LK
90-27 b
OTHERS
MEMORANDUM
MEMORANDUM
90-28
WA500-3LK
OTHERS
FOLDOUT 20-153-1
WA500-3LK
90-29 B
OTHERS
MEMORANDUM
MEMORANDUM
90-30
WA500-3LK
OTHERS
FOLDOUT 20-153-2
WA500-3LK
90-31 B
OTHERS
MEMORANDUM
MEMORANDUM
90-32
WA500-3LK
OTHERS
12
CONNECTOR
WA500-3LK
FOLDOUT 20-153-3
ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5)
90-33 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-34
WA500-3LK
OTHERS
12
CONNECTOR
WA500-3LK
FOLDOUT 20-153-4
90-35 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-36
WA500-3LK
OTHERS
12
CONNECTOR
WA500-3LK
FOLDOUT 20-153-5
90-37 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-38
WA500-3LK
OTHERS
12
3D
FOLDOUT 20-153-6
WA500-3LK
90-39 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-40
WA500-3LK
OTHERS
12
3D
FOLDOUT 20-153-7
WA500-3LK
90-41 b
OTHERS
MEMORANDUM
12
MEMORANDUM
90-42
WA500-3LK
OTHERS
12
PARKING
FOLDOUT 10-96
BRAKE CONTROL DIAGRAM
1.
2.
Neutralizer relay
3.
Parking brake safety relay (parking brake emergency release relay)
4.
5.
6.
7.
Parking brake (built into transmission)
8.
Parking brake emergency release valve
9.
Charge valve
10. Accumulator
WA500-3LK
90-43 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-44
WA500-3LK
OTHERS
FOLDOUT 10-105
12
HYDRAULIC
CIRCUIT DIAGRAM
WA500-3LK
90-45 B
OTHERS
MEMORANDUM
MEMORANDUM
90-46
WA500-3LK
OTHERS
12
JOYSTICK
WA500-3LK
FOLDOUT 10-54-1-1
STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)
90-47 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-48
WA500-3LK
OTHERS
12
JOYSTICK
WA500-3LK
FOLDOUT 10-54-1-2
90-49 B
OTHERS
MEMORANDUM
MEMORANDUM
90-50
WA500-3LK
OTHERS
12
JOYSTICK
WA500-3LK
FOLDOUT 10-54-1-3
90-51 B
OTHERS
MEMORANDUM
MEMORANDUM
90-52
WA500-3LK
OTHERS
12
STEERING
WA500-3LK
FOLDOUT 10-54-2-1
LINE ASSEMBLY DIAGRAM (PART 1 OF 3)
90-53 B
OTHERS
MEMORANDUM
MEMORANDUM
90-54
WA500-3LK
OTHERS
12
STEERING
WA500-3LK
FOLDOUT 10-54-2-2
90-55 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-56
WA500-3LK
OTHERS
12
STEERING
WA500-3LK
FOLDOUT 10-54-2-3
90-57 B
OTHERS
MEMORANDUM
12
MEMORANDUM
90-58
WA500-3LK
OTHERS
12
HYDRAULIC
WA500-3LK
FOLDOUT 10-100-1
LINE ASSEMBLY (PART 1 OF 3)
90-59 B
OTHERS
MEMORANDUM
MEMORANDUM
90-60
WA500-3LK
OTHERS
12
HYDRAULIC
WA500-3LK
FOLDOUT 10-100-2
90-61 B
OTHERS
MEMORANDUM
MEMORANDUM
90-62
WA500-3LK
OTHERS
12
HYDRAULIC
WA500-3LK
FOLDOUT 10-100-3
90-63 B
OTHERS
MEMORANDUM
MEMORANDUM
90-64
WA500-3LK

Wa500-3 LK SM Cebd005402

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Wa500-3 LK SM Cebd005402

Hochgeladen von

Copyright:

Verfügbare Formate

CEBM005402

Copyright 2004 Komatsu

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

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

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

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

PRODUCT PUBLICATIONS INFORMATION

PARTS BOOK - PAPER:

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

DataKom Publications and Training Division

CITY, STATE, ZIP CODE

PUBLICATION FORM NO.

CURRENT PRICES WILL BE CHARGED

The affected pages are indicated by using the following

New page to be added

PREPARATIONS FOR WORK

Mistakes in operation are extremely dangerous. Read the

Before adding oil or making repairs, park the machine

Before carrying out any greasing or repairs, read all the

When carrying out any operation, always wear safety

Before starting work, lower blade, ripper, bucket or any

When disassembling or assembling, support the

If welding repairs are needed, always have a trained,

When carrying out any operation with two or more

Keep all tools in good condition and learn the correct

PRECAUTIONS DURING WORK

Before starting work, remove the leads from the battery.

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES

Issued for every machine model

Electrical volume: Each issued as one to cover all models

So that the shop manual can be of ample practical use,

Special safety precautions are

Special technical precautions or

Weight of parts or systems. Caution necessary when selecting

Places that require special attention for tightening torque during

Places to be coated with adhesives and lubricants etc.

Places where oil, water or fuel

Places where oil or water must

DISTRIBUTION AND UPDATING

Item number (10. Structure and Function)

Any additions, amendments or other changes will be sent to

Additional pages: Additional pages are indicated by a

REVISED EDITION MARK

When a manual is revised, an edition mark (123) is

can result. Hooks have maximum strength at the middle

WARNING! Heavy parts (25 kg or more)

If a part cannot be smoothly removed from the machine

WARNING! Slinging with one rope may

Use adequate ropes depending on the weight of parts to

Do not sling a heavy load with ropes forming a wide

The allowable load value is estimated to be 1/6 or 1/7 of

PUSH-PULL TYPE COUPLER

PUSH-PULL TYPE COUPLER

PUSH-PULL TYPE COUPLER

Hold in the condition in Step 1 and push until cover (3)

Hold in the condition in Steps 1 and 2, and pull out whole

Hold the mouthpiece of the tightening portion and push

PUSH-PULL TYPE COUPLER

Main applications, features

Used to prevent rubber gaskets, rubber