SEN00235-14

WHEEL LOADER WA600 -6

SERIAL NUMBERS 60001 and up
 SEN00398-14

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

WA600-6 1
SEN00398-14 00 Index and foreword

Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00235-14

00 Index and foreword SEN00397-14

Index SEN00398-14 q
Foreword and general information SEN00415-03

01 Specification SEN00399-02
Specification and technical data SEN00400-02

10 Structure, function and maintenance standard SEN00401-07

Engine and cooling system SEN00402-01
Power train, Part 1 SEN00403-02
Power train, Part 2 SEN02455-01
Steering system SEN00404-03
Brake system SEN00405-01
Undercarriage and frame SEN00406-00
Hydraulic system, Part 1 SEN00407-01
Hydraulic system, Part 2 SEN02456-00
Work equipment SEN00408-03 q
Cab and its attachments SEN00409-01
Electrical system, Part 1 SEN01009-02
Electrical system, Part 2 SEN00410-02
Electrical system, Part 3 SEN00411-03

20 Standard value table SEN00566-03

Standard service value table SEN00552-03

30 Testing and adjusting SEN00567-06

Testing and adjusting, Part 1 SEN00553-05 q
Testing and adjusting, Part 2 SEN00554-04
Testing and adjusting, Part 3 SEN00555-06 q
Testing and adjusting, Part 4 SEN00556-05 q

40 Troubleshooting SEN00568-03
Failure code table and fuse locations SEN03364-01
General information on troubleshooting SEN00557-01

2 WA600-6
00 Index and foreword SEN00398-14

Troubleshooting by failure code (Display of code), Part 1 SEN00558-02

Troubleshooting by failure code (Display of code), Part 2 SEN00559-03
Troubleshooting by failure code (Display of code), Part 3 SEN00560-02
Troubleshooting by failure code (Display of code), Part 4 SEN00561-03
Troubleshooting by failure code (Display of code), Part 5 SEN00562-03
Troubleshooting by failure code (Display of code), Part 6 SEN00569-03
Troubleshooting by failure code (Display of code), Part 7 SEN00570-03
Troubleshooting by failure code (Display of code), Part 8 SEN00571-03
Troubleshooting by failure code (Display of code), Part 9 SEN00572-03
Troubleshooting by failure code (Display of code), Part 10 SEN00573-03
Troubleshooting by failure code (Display of code), Part 11 SEN00574-03
Troubleshooting of electrical system (E-mode) SEN00563-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00564-02
Troubleshooting of engine (S-mode) SEN00565-02

50 Disassembly and assembly SEN00583-06

General information on disassembly and assembly SEN01156-03
Engine and cooling system, Part 1 SEN01157-02
Engine and cooling system, Part 2 SEN01158-03 q
Power train, Part 1 SEN01160-02
Power train, Part 2 SEN01162-02
Power train, Part 3 SEN01164-03
Power train, Part 4 SEN01165-02
Brake system SEN01167-02
Undercarriage and frame SEN01169-02
Hydraulic system SEN01171-02
Work equipment SEN01174-02
Cab and its attachments SEN01175-02
Electrical system SEN01177-03

90 Diagrams and drawings SEN00414-06

Hydraulic diagrams and drawings SEN00412-03
Electrical diagrams and drawings SEN00413-04

WA600-6 3
SEN00398-14 00 Index and foreword

Table of contents 1
00 Index and foreword
Index SEN00398-14
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00415-03
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36

01 Specification
Specification and technical data SEN00400-02
Specification and technical data .................................................................................................. 2
Specification dimension drawing.............................................................................................. 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 10
Table of fuel, coolant and lubricants ........................................................................................ 12

10 Structure, function and maintenance standard

Engine and cooling system SEN00402-01
Engine and cooling system ......................................................................................................... 2
Engine mount and transmission mount ................................................................................... 2
Cooling system ........................................................................................................................ 6
Cooling fan pump..................................................................................................................... 10
Cooling fan motor .................................................................................................................... 18
Power train, Part 1 SEN00403-02
Power train, Part 1....................................................................................................................... 2
Power train............................................................................................................................... 2
Power train system diagram .................................................................................................... 3
Torque converter and transmission piping diagram ................................................................. 4
Torque converter...................................................................................................................... 6
Modulation clutch..................................................................................................................... 15
Torque converter regulator valve ............................................................................................. 16
Transmission............................................................................................................................ 18
Transfer.................................................................................................................................... 38
Transmission control valve ...................................................................................................... 40
ECMV ...................................................................................................................................... 43
Main relief valve and torque converter relief valve .................................................................. 50
Lubrication relief valve ............................................................................................................. 52
Power train, Part 2 SEN02455-01
Power train, Part 2....................................................................................................................... 2
Torque converter oil cooler ...................................................................................................... 2
Torque converter oil filter ......................................................................................................... 3
Drive shaft................................................................................................................................ 5
Center support ......................................................................................................................... 8
Axle.......................................................................................................................................... 10
Differential................................................................................................................................ 14
Limited slip differential ............................................................................................................. 23

4 WA600-6
00 Index and foreword SEN00398-14

Final drive ................................................................................................................................ 28

Steering system SEN00404-03
Steering system........................................................................................................................... 4
Steering piping diagram........................................................................................................... 4
Steering column....................................................................................................................... 6
Joystick steering lever linkage................................................................................................. 7
Joystick EPC valve .................................................................................................................. 8
Lock valve................................................................................................................................ 9
Steering valve .......................................................................................................................... 10
Rotary valve............................................................................................................................. 13
Steering control valve .............................................................................................................. 16
Two-way restrictor valve .......................................................................................................... 32
Stop valve ................................................................................................................................ 33
Steering pump ......................................................................................................................... 34
Steering cylinder ...................................................................................................................... 48
Emergency steering piping diagram ........................................................................................ 50
Diverter valve........................................................................................................................... 51
Emergency steering pump....................................................................................................... 59
Brake system SEN00405-01
Brake system .............................................................................................................................. 2
Brake piping diagram............................................................................................................... 2
Brake ....................................................................................................................................... 4
Brake valve.............................................................................................................................. 8
Accumulator charge valve ....................................................................................................... 16
EPC relief valve ....................................................................................................................... 22
Accumulator (for brake) ........................................................................................................... 24
Slack adjuster .......................................................................................................................... 26
Parking brake .......................................................................................................................... 30
Parking brake solenoid valve................................................................................................... 32
Emergency parking brake release valve ................................................................................. 34
Brake cooling pump................................................................................................................. 35
Undercarriage and frame SEN00406-00
Undercarriage and frame ............................................................................................................ 2
Axle mount............................................................................................................................... 2
Center hinge pin ...................................................................................................................... 7
Hydraulic system, Part 1 SEN00407-01
Hydraulic system, Part 1 ............................................................................................................. 2
Hydraulic piping diagram ......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 4
Hydraulic tank .......................................................................................................................... 6
Work equipment hydraulic pump ............................................................................................. 8
Hydraulic system, Part 2 SEN02456-00
Hydraulic system, Part 2 ............................................................................................................. 2
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 16
Each function and operation of each valve.............................................................................. 21
Accumulator (for PPC circuit) .................................................................................................. 36
Triple pump.............................................................................................................................. 37
Work equipment SEN00408-03
Work equipment .......................................................................................................................... 2
Work equipment linkage .......................................................................................................... 2
Bucket...................................................................................................................................... 6
Bucket positioner and boom kick-out....................................................................................... 10
Work equipment lubrication ..................................................................................................... 11
Work equipment cylinder ......................................................................................................... 14

WA600-6 5
SEN00398-14 00 Index and foreword

Cab and its attachments SEN00409-01

Cab and its attachments.............................................................................................................. 2
ROPS cab................................................................................................................................ 2
Air conditioner.......................................................................................................................... 4
Electrical system, Part 1 SEN01009-02
Electrical system, Part 1.............................................................................................................. 2
Machine monitor system.......................................................................................................... 2
Machine monitor ...................................................................................................................... 8
Electrical system, Part 2 SEN00410-02
Electrical system, Part 2.............................................................................................................. 2
Work equipment control system .............................................................................................. 2
Transmission controller system ............................................................................................... 38
Electrical system, Part 3 SEN00411-03
Electrical system, Part 3.............................................................................................................. 2
Electric transmission control .................................................................................................... 2
Engine starting/stopping circuit................................................................................................ 4
Parking brake circuit ................................................................................................................ 7
Sensor ..................................................................................................................................... 11
VHMS controller related........................................................................................................... 33
Work equipment electric lever ................................................................................................. 37

20 Standard value table

Standard service value table SEN00552-03
Standard service value table for engine................................................................................... 2
Standard service value table for chassis ................................................................................. 3

30 Testing and adjusting

Testing and adjusting, Part 1 SEN00553-05
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Sketches of special tools ......................................................................................................... 9
Measuring engine speed ......................................................................................................... 10
Measuring exhaust gas color................................................................................................... 12
Measuring exhaust temperature .............................................................................................. 13
Adjusting valve clearance ........................................................................................................ 15
Testing compression pressures ............................................................................................... 17
Measuring blow-by pressure.................................................................................................... 20
Measuring engine oil pressure................................................................................................. 21
Testing EGR valve and bypass valve drive oil pressure .......................................................... 22
Measuring intake air (boost) pressure ..................................................................................... 24
Handling fuel system equipment.............................................................................................. 25
Releasing residual pressure in fuel system ............................................................................. 25
Testing fuel pressures.............................................................................................................. 26
Testing return rate and leakage ............................................................................................... 27
Bleeding air from fuel circuit .................................................................................................... 30
Testing leakage in fuel system................................................................................................. 32
Handling reduced cylinder mode operation ............................................................................. 33
Handling no-injection cranking operation................................................................................. 33
Handling controller voltage circuit............................................................................................ 34
Replacing and adjusting alternator and air conditioner compressor belt tension .................... 35
Adjusting modulation clutch speed sensor and speed sensor................................................. 36
Measuring directional lever and gear shift lever (Steering wheel specification) ...................... 38
Testing and adjusting power train oil pressure......................................................................... 39
Flushing procedure for torque converter and transmission hydraulic circuit............................ 53
Method of moving machine when transmission valve is broken.............................................. 55
Adjusting steering stop valve ................................................................................................... 57

6 WA600-6
00 Index and foreword SEN00398-14

Testing and adjusting, Part 2 SEN00554-04

Measuring operating effort of AJSS lever (AJSS specification)............................................... 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) 4
Testing and adjusting steering stopper bolt (AJSS specification) ............................................ 6
Testing and adjusting steering wheel (Steering wheel specification)....................................... 8
Testing steering oil pressure.................................................................................................... 10
Bleeding air from steering cylinder circuit................................................................................ 14
Testing hydraulic drive fan ....................................................................................................... 15
Bleeding air from hydraulic drive fan circuit............................................................................. 18
Measuring brake pedal ............................................................................................................ 20
Measuring brake performance................................................................................................. 21
Testing and adjusting accumulator charge pressure ............................................................... 22
Testing of accumulator nitrogen gas pressure and procedure for charging
accumulator with nitrogen gas.......................................................................................... 24
Testing wheel brake oil pressure ............................................................................................. 30
Measuring wear of wheel brake disc ....................................................................................... 32
Bleeding air from wheel brake circuit....................................................................................... 33
Releasing residual pressure in brake accumulator circuit ....................................................... 34
Testing parking brake performance ......................................................................................... 35
Measuring parking brake oil pressure ..................................................................................... 36
Testing wear of parking brake disc .......................................................................................... 39
Method of releasing parking brake manually ........................................................................... 40
Measuring and adjusting work equipment control lever .......................................................... 41
Measuring work equipment oil pressure.................................................................................. 42
Bleeding air from work equipment circuit................................................................................. 47
Releasing residual pressure in work equipment circuit ........................................................... 48
Moving machine for removing operator cab ............................................................................ 50
Testing and adjusting bucket positioner................................................................................... 52
Testing and adjusting lift arm position detecting lever ............................................................. 54
Checking proximity switch operation indication lamp .............................................................. 55
Preparations for work on troubleshooting of electric system ................................................... 56
Procedure for testing diodes.................................................................................................... 60
Testing and adjusting, Part 3 SEN00555-06
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller ................................................ 2
Special functions of machine monitor (EMMS)........................................................................ 5
Testing and adjusting, Part 4 SEN00556-05
VHMS controller initial setting procedure ................................................................................ 2
Precautions for replacing VHMS controller.............................................................................. 22
Pm-clinic inspection table ........................................................................................................ 28

40 Troubleshooting
Failure code table and fuse locations SEN03364-01
Failure codes list...................................................................................................................... 2
Fuse locations ......................................................................................................................... 15
General information on troubleshooting SEN00557-01
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Testing before troubleshooting ................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Information contained in troubleshooting table ........................................................................ 6
Phenomena looking like troubles and troubleshooting Nos..................................................... 8
Connection table for connector pin numbers ........................................................................... 10
T- branch box and T- branch adapter table ............................................................................. 45
Troubleshooting by failure code (Display of code), Part 1 SEN00558-02
Failure code [1500L0] (TORQFLOW transmission: Double meshing)..................................... 3
Failure code [15B0NX] (Transmission filter: Clogged)............................................................. 4

WA600-6 7
SEN00398-14 00 Index and foreword

Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) .... 6
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) ... 8
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) .... 10
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)... 12
Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON) ............ 14
Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF) ........... 16
Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON)............. 18
Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF)............ 20
Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON) ............ 22
Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF) ........... 24
Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON) ............ 26
Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF) ........... 28
Failure code [15W0NT] (Transmission modulation clutch: Overheating)................................. 30
Failure code [2F00MA] (Parking brake: Malfunction) .............................................................. 31
Failure code [2G42ZG] (Front accumulator: Low oil pressure)................................................ 34
Troubleshooting by failure code (Display of code), Part 2 SEN00559-03
Failure code [2G43ZG] (Rear accumulator: Low oil pressure) ................................................ 4
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) .................................... 6
Failure code [A000N1] (or VHMS_LED display: “n2” o “01”) (Engine: Overrun) .................... 8
Failure code [AA1ANX] (Air cleaner: Clogging) ....................................................................... 10
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............. 12
Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 14
Failure code [B@BAZG] (Engine oil pressure: Low error)....................................................... 16
Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 17
Failure code [B@BCNS] (Engine coolant temperature: Overheating)..................................... 18
Failure code [B@BCZK] (Coolant: Low level).......................................................................... 20
Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 22
Failure code [b@CENS] (Torque converter oil: Overheating).................................................. 24
Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 26
Failure code [B@GAZK] (Battery electrolyte: Low level) ......................................................... 28
Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 30
Failure code [CA111] (Abnormality in engine controller).......................................................... 32
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 34
Failure code [CA122] (Charge (boost) pressure sensor high error) ........................................ 36
Failure code [CA123] (Charge (boost) pressure sensor low error).......................................... 38
Failure code [CA131] (Throttle sensor high error) ................................................................... 40
Failure code [CA132] (Throttle sensor low error)..................................................................... 42
Failure code [CA135] (Engine oil pressure sensor high error)................................................. 44
Failure code [CA141] (Engine oil pressure sensor low error) .................................................. 46
Failure code [CA144] (Coolant temperature sensor high error)............................................... 48
Failure code [CA145] (Coolant temperature sensor low error) ................................................ 50
Failure code [CA153] (Charge (boost) temperature sensor high error) ................................... 52
Failure code [CA154] (Charge (boost) temperature sensor low error) .................................... 54
Failure code [CA187] (Sensor power supply 2 low error) ........................................................ 55
Failure code [CA212] (Engine oil temperature sensor high error) ........................................... 56
Failure code [CA213] (Engine oil temperature sensor low error)............................................. 58
Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 60
Failure code [CA222] (Atmospheric pressure sensor low error) .............................................. 62
Failure code [CA227] (Sensor power supply 2 high error)....................................................... 64
Troubleshooting by failure code (Display of code), Part 3 SEN00560-02
Failure code [CA234] (Engine overspeed)............................................................................... 3
Failure code [CA238] (Ne speed sensor power supply error).................................................. 4
Failure code [CA263] (Fuel temperature sensor high error) .................................................... 6
Failure code [CA265] (Fuel temperature sensor low error) ..................................................... 8
Failure code [CA271] (PCV1 Short circuit) .............................................................................. 10
Failure code [CA272] (PCV1 Disconnection)........................................................................... 12
Failure code [CA273] (PCV2 Short circuit) .............................................................................. 14
Failure code [CA274] (PCV2 Disconnection)........................................................................... 16

8 WA600-6
00 Index and foreword SEN00398-14

Failure code [CA322] (Injector #1 open/short error) ................................................................ 18

Failure code [CA323] (Injector #5 open/short error) ................................................................ 20
Failure code [CA324] (Injector #3 open/short error) ................................................................ 22
Failure code [CA325] (Injector #6 open/short error) ................................................................ 24
Failure code [CA331] (Injector #2 open/short error) ................................................................ 26
Failure code [CA332] (Injector #4 open/short error) ................................................................ 28
Failure code [CA342] (Calibration code inconsistency)........................................................... 30
Failure code [CA351] (Injectors drive circuit error) .................................................................. 32
Failure code [CA352] (Sensor power supply 1 low error)........................................................ 34
Failure code [CA386] (Sensor power supply 1 high error) ...................................................... 36
Failure code [CA431] (Idle validation switch error).................................................................. 38
Failure code [CA432] (Idle validation action error) .................................................................. 41
Failure code [CA441] (Battery voltage low error) .................................................................... 41
Failure code [CA442] (Battery voltage high error) ................................................................... 42
Failure code [CA449] Common rail pressure high error 2 ....................................................... 42
Failure code [CA451] (Common rail pressure sensor high error) ............................................ 44
Failure code [CA452] (Common rail pressure sensor low error) ............................................. 46
Failure code [CA553] (Common rail pressure high error 1)..................................................... 47
Failure code [CA559] (Supply pump pressure very low error 1).............................................. 48
Failure code [CA689] (Engine Ne speed sensor error) ........................................................... 52
Failure code [CA731] (Engine Bkup speed sensor phase error) ............................................. 54
Failure code [CA757] (All continuous data lost error) .............................................................. 55
Failure code [CA778] (Engine Bkup speed sensor error)........................................................ 56
Failure code [CA1228] (EGR valve servo error 1) ................................................................... 58
Failure code [CA1625] (EGR valve servo error 2) ................................................................... 59
Failure code [CA1626] (Bypass valve solenoid current high error) ......................................... 60
Failure code [CA1627] (Bypass valve solenoid current low error)........................................... 62
Failure code [CA1628] (Bypass valve servo error 1) ............................................................... 63
Failure code [CA1629] (Bypass valve servo error 2) ............................................................... 64
Failure code [CA1631] (Bypass valve lift sensor high error).................................................... 66
Failure code [CA1632] (Bypass valve lift sensor low error) ..................................................... 68
Failure code [CA1633] (KOMNET datalink timeout error) ....................................................... 69
Troubleshooting by failure code (Display of code), Part 4 SEN00561-03
Failure code [CA2185] (Throttle sensor supply voltage high error) ......................................... 4
Failure code [CA2186] (Throttle sensor power supply low error) ............................................ 6
Failure code [CA2249] (Supply pump pressure very low error 2)............................................ 7
Failure code [CA2271] (EGR valve lift sensor high error) ....................................................... 8
Failure code [CA2272] (EGR valve lift sensor low error) ......................................................... 10
Failure code [CA2351] (EGR valve solenoid operation short circuit) ...................................... 12
Failure code [CA2352] (EGR valve solenoid operation disconnect)........................................ 14
Failure code [CA2555] (Intake heater relay disconnection error) ............................................ 15
Failure code [CA2556] (Intake heater relay short circuit error)................................................ 16
Failure code [D191KA] (AJSS neutral safety relay: Disconnection) ........................................ 18
Failure code [D191KB] (AJSS neutral safety relay: Short circuit)............................................ 20
Failure code [D192KA] (ECSS solenoid: Disconnection) ........................................................ 22
Failure code [D192KB] (ECSS solenoid: Short circuit) ............................................................ 23
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)........................ 24
Failure code [D198KA] (Transmission oil pressure bypass solenoid: Disconnection)............. 25
Failure code [D198KB] (Transmission oil pressure bypass solenoid: Short circuit) ................ 26
Failure code [D198KY] (Transmission oil pressure bypass solenoid:
Short circuit with power supply line) ................................................................................. 27
Failure code [D5ZHKA] (Terminal C signal: Disconnection) .................................................... 28
Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................ 30
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)............................. 32
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or
stopped state)................................................................................................................... 34
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)............................ 36
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).................................. 38

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SEN00398-14 00 Index and foreword

Failure code [DAF5KP] (Machine monitor: Low output voltage) .............................................. 40

Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system))............................. 42
Failure code [DAQ0KK] (Transmission controller: Low source voltage) .................................. 44
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)........................... 46
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input)) .............................................................................................. 48
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals)........................................................................ 50
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system))............................. 52
Failure code [DAQRMA] (Transmission controller CAN communication: Malfunction)............ 54
Troubleshooting by failure code (Display of code), Part 5 SEN00562-03
Failure code [DB2RKR] CAN communication from engine controller:
Defective communication (Abnormality in target component system) .............................. 4
Failure code [DB90KK] Work equipment controller: Low source voltage (input) ..................... 6
Failure code [DB90KT] (Work equipment controller: Abnormality in controller) ...................... 8
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input) ............................................................................................... 10
Failure code [DB95KX] (Work equipment controller power supply output:
Out of input signal range) ................................................................................................. 12
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement of model selection signals)........................................................................ 14
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) .............................. 16
Failure code [DB9RMA] (Work equipment controller CAN communication: Malfunction) ....... 18
Failure code [DB9RMC] (CAN communication with transmission controller:
Defective operation) ......................................................................................................... 20
Failure code [DBB0KK] (or VHMS_LED display: “n9” o “01”) VHMS controller:
Low source voltage (input) ............................................................................................... 22
Failure code [DBB0KQ] (or VHMS_LED display: “nF” o “11”) VHMS controller:
(Disagreement of model selection signals)....................................................................... 24
Failure code [DBB3KK] (or VHMS_LED display: “n9” o “05”) VHMS controller
battery power supply: Low source voltage (input) ............................................................ 26
Failure code [DBB5KP] (or VHMS_LED display: “n9” o “04”) (VHMS controller
5 V power supply output: Low output voltage).................................................................. 28
Failure code [DBB6KP] (or VHMS_LED display: “n9” o “02”) (VHMS controller
24 V power supply output: Low output voltage)................................................................ 30
Failure code [DBB7KP] (or VHMS_LED display: “n9” o “03”) (VHMS controller
12 V power supply output: Low output voltage)................................................................ 32
Failure code [DBBQKR] (or VHMS_LED display: “n8” o “02”) VHMS controller CAN
communication: Defective communication (Abnormality in target component system).... 34
Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time)...... 36
Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time)..... 38
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time)....... 40
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time)....... 42
Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time)................................................................................ 44
Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time)................................................................................ 46
Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time) ... 48
Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch is kept
pressed for long time)....................................................................................................... 50
Failure code [DD1GLD] (Load meter mode selector switch (+/–): Switch is kept
pressed for long time)....................................................................................................... 52
Troubleshooting by failure code (Display of code), Part 6 SEN00569-03
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed
for long time)..................................................................................................................... 4

10 WA600-6
00 Index and foreword SEN00398-14

Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree ........................ 6
Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit) ......... 8
Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit) .... 10
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ........ 12
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept
pressed for long time)....................................................................................................... 16
Failure code [DDDBKA] (Traction adjustment dial: Disconnection)......................................... 18
Failure code [DDDBKB] (Traction adjustment dial: Short circuit) ............................................ 20
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) ............................... 22
Failure code [DDK4KA] (AJSS FNR switch: Disconnection) ................................................... 24
Failure code [DDK4KB] (AJSS FNR switch: Short circuit)....................................................... 26
Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals disagree) .................... 28
Failure code [DDK6KA] (FNR lever switch: Disconnection) .................................................... 32
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 34
Failure code [DDP5KA] (Lock detection pressure switch of steering lock lever: Disconnection) 36
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)..................... 38
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 40
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 42
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 44
Failure code [DF10KA] (Transmission shift lever switch: Disconnection)................................ 46
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 48
Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”) (Atmospheric temperature
sensor: Out of input signal range) .................................................................................... 50
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) ..................... 52
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 54
Troubleshooting by failure code (Display of code), Part 7 SEN00570-03
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 4
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) ........................ 6
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 8
Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection) ................ 10
Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit).................... 11
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal
range) ............................................................................................................................... 12
Failure code [DGT4KA] (or VHMS_LED display: “n3” o “12”) (Exhaust gas temperature
sensor (F): Disconnection) ............................................................................................... 14
Failure code [DGT4KB] (or VHMS_LED display: “n3” o “11”) (Exhaust gas temperature
sensor (F): Short circuit)................................................................................................... 16
Failure code [DGT5KA] (or VHMS_LED display: “n3” o “22”) (Exhaust gas temperature
sensor (R): Disconnection)............................................................................................... 18
Failure code [DGT5KB] (or VHMS_LED display: “n3” o “21”) (Exhaust gas temperature
sensor (R): Short circuit) .................................................................................................. 20
Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) ............ 22
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ................ 24
Failure code [DHE5KB] (or VHMS_LED display: “n3” o “32”) (Blow-by pressure sensor:
Short circuit) ..................................................................................................................... 26
Failure code [DHE5KY] (or VHMS_LED display: “n3” o “31”) (Blow-by pressure sensor:
Short circuit with power supply line) ................................................................................. 28
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal
range) ............................................................................................................................... 30
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal
range) ............................................................................................................................... 32
Failure code [DHT2L6] (Transmission filter clogging sensor: Signal disagrees with
operating state of engine)................................................................................................. 34
Failure code [DHT8KX] (or VHMS_LED display: “n5” o “33”) (Steering oil pressure sensor:
Out of input signal range) ................................................................................................. 36
Failure code [DHTBKA] (Modulation clutch oil pressure sensor: Disconnection) .................... 38
Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short circuit) ....................... 40

WA600-6 11
SEN00398-14 00 Index and foreword

Failure code [DHU2KX] (or VHMS_LED display: “n7” o “11”) (Front brake oil pressure
sensor (F): Out of input signal range)............................................................................... 42
Failure code [DHU3KX] (or VHMS_LED display: “n7” o “12”) (Rear brake oil pressure
sensor (R): Out of input signal range) .............................................................................. 44
Failure code [DK30KA] (AJSS lever angle sensor: Disconnection)......................................... 46
Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with power supply line) ........ 48
Troubleshooting by failure code (Display of code), Part 8 SEN00571-03
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ................. 3
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with
power supply line)............................................................................................................. 6
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .. 10
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) .................. 13
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with
power supply line)............................................................................................................. 16
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 19
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with
power supply line)............................................................................................................. 22
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)... 24
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)................... 27
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with
power supply line)............................................................................................................. 30
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main):
Disconnection).................................................................................................................. 32
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line) ................................................................................. 34
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree) .................................................................................................. 36
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection).................................................................................................................. 40
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with
power supply line)............................................................................................................. 42
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) .............................................. 44
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range).............................. 46
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line).............. 48
Failure code [DKA0L0] (Lift arm angle sensor: Improper position) .......................................... 50
Troubleshooting by failure code (Display of code), Part 9 SEN00572-03
Failure code [DKD0KA] (Frame angle sensor: Disconnection) ................................................. 4
Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line)................. 6
Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit) . 8
Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection) ........... 10
Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals
disagree)............................................................................................................................. 12
Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection) ............. 14
Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree) 16
Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit)................. 18
Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal
range) ................................................................................................................................. 20
Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short circuit)....................... 22
Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short circuit) ...................... 24
Failure code [DV00KB] (Alarm buzzer: Short circuit) ................................................................ 26
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ..................................... 28
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)......................................... 29
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) .... 30
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection).................................... 32
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ....................................... 33
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ... 34
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) .......................................... 36
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit).............................................. 37

12 WA600-6
00 Index and foreword SEN00398-14

Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)......... 38
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) .................................... 40
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ........................................ 41
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).... 42
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)............................................... 44
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) .................................................. 46
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line).............. 48
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)........................ 50
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) ........................... 50
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with
power supply line) .............................................................................................................. 51
Troubleshooting by failure code (Display of code), Part 10 SEN00573-03
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) .................. 4
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...................... 6
Failure code [DWM1KY] (Work equipment neutral lock EPC solenoid: Short circuit with
power supply line) ............................................................................................................ 8
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ................... 10
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ....................... 12
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power
supply line) ....................................................................................................................... 14
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .................... 16
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ........................ 18
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power
supply line) ....................................................................................................................... 20
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) ........................ 22
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ............................ 24
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 26
Failure code [DWNFKA] (Modulation clutch cut-off release solenoid: Disconnection) ............ 28
Failure code [DWNFKB] (Modulation clutch cut-off release solenoid: Short circuit)................ 30
Failure code [DWNFKY] (Modulation clutch cut-off release solenoid: Short circuit with
power source line) ............................................................................................................ 32
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ......................................... 34
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)............................................. 35
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ........ 36
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) ......................................... 37
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) ............................................. 38
Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection) ................................................ 39
Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit).................................................... 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) .......................................... 41
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 42
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ......... 44
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ...................................... 46
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) .......................................... 48
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ...... 50
Troubleshooting by failure code (Display of code), Part 11 SEN00574-03
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) ..................................... 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ......................................... 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ...................................... 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ..... 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ........ 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) ......................................... 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) ........ 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 28

WA600-6 13
SEN00398-14 00 Index and foreword

Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 30
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) ..... 32
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) ........................ 34
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit)............................ 35
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power
supply line) ....................................................................................................................... 36
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ........................ 37
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)............................ 38
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power
supply line) ....................................................................................................................... 39
Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection)..................................... 40
Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit) ........................................ 42
Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with power source line).... 44
Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction) ........................................ 46
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) (Blow-by pressure: High error) 48
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”)
(Exhaust gas temperature (F): Abnormal heat) ................................................................ 50
Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”)
(Exhaust gas temperature (F): Overheat)......................................................................... 52
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat) ................................................................ 54
Failure code [F@BZNS] (or VHMS_LED display “n3” o “71”)
(Exhaust gas temperature (R): Overheat) ........................................................................ 56
Troubleshooting of electrical system (E-mode) SEN00563-03
Before carrying out troubleshooting of electrical system ......................................................... 4
Information in troubleshooting table......................................................................................... 7
E-1 Engine does not start. ....................................................................................................... 8
E-2 Wiper does not operate..................................................................................................... 18
E-3 Windshield washer does not operate ................................................................................ 26
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 32
E-5 Working lamp does not light up or go off........................................................................... 48
E-6 Step lamp does not light up or go off................................................................................. 56
E-7 Turn signal lamp and hazard lamp do not light up or go off .............................................. 58
E-8 Brake lamp does not light or it keeps lighting up............................................................... 68
E-9 Backup lamp does not light or it keeps lighting up. ........................................................... 72
E-10 Backup buzzer does not sound or it keeps sounding...................................................... 76
E-11 Horn does not sound or it keeps sounding. ..................................................................... 80
E-12 Alarm buzzer does not sound or it keeps sounding ........................................................ 84
E-13 Air conditioner does not operate or stop ......................................................................... 86
E-14 Electric priming pump does not operate or does not stop automatically......................... 88
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00564-02
Method of using troubleshooting chart..................................................................................... 4
Table of failure modes and causes .......................................................................................... 6
H-1 Machine does not start...................................................................................................... 10
H-2 Torque converter lockup is not switched (engine stalls).................................................... 12
H-3 Torque converter lockup is not turned on.......................................................................... 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted ...................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear ............................................... 16
H-6 Time lag is large at the times of starting and shifting gear................................................ 18
H-7 Torque converter oil temperature is high........................................................................... 20
H-8 Steering does not turn [machine with steering wheel]....................................................... 21
H-9 Steering does not turn [machine with AJSS]..................................................................... 22
H-10 Turning, response of steering is poor [machine with steering wheel] ............................. 23
H-11 Turning, response of AJSS is poor [machine with AJSS]................................................ 24
H-12 Steering is heavy [machine with steering wheel] ............................................................ 25
H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel].. 26
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]................ 27

14 WA600-6
00 Index and foreword SEN00398-14

H-15 Wheel brake does not work or does not work well ......................................................... 28
H-16 Wheel brake is not released or it drags .......................................................................... 29
H-17 Parking brake does not work or does not work well ....................................................... 30
H-18 Parking brake is not released or it drags (including emergency release system)........... 31
H-19 Lift arm does not rise ...................................................................................................... 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33
H-21 When rising, lift arm comes to move slowly at specific height ........................................ 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats).............................................. 34
H-23 Hydraulic drifts of lift arm occur often.............................................................................. 34
H-24 Lift arm wobbles during operation................................................................................... 34
H-25 Bucket does not tilt back................................................................................................. 35
H-26 Bucket speed is low or tilting back force is insufficient ................................................... 36
H-27 Bucket comes to operate slowly in the midst of tilting-back............................................ 37
H-28 Bucket cylinder cannot hold down bucket....................................................................... 37
H-29 Hydraulic drifts of bucket occur often.............................................................................. 37
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”)....... 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls............ 38
H-32 Large shocks are made when work equipment starts and stops .................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .............. 38
H-34 ECSS does not operate, and pitching bouncing occurs ................................................. 39
H-35 Fan speed is abnormal (Fan sound and vibration are abnormally large
or engine overheats) ........................................................................................................ 40
Troubleshooting of engine (S-mode) SEN00565-02
Method of using troubleshooting chart .................................................................................... 3
S-1 Engine does not start easily. ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operation .......................................................................................... 13
S-5 Engine does not rotate smoothly (Hunting occurs) ........................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 16
S-8 Oil is consumed much (or exhaust gas color is blue) ....................................................... 18
S-9 Engine oil becomes contaminated quickly ........................................................................ 19
S-10 Fuel consumption is excessive ....................................................................................... 20
S-11 Coolant contains oil (blows back or reduces).................................................................. 21
S-12 Oil pressure drops........................................................................................................... 22
S-13 Oil level rises (Water, fuel in oil)...................................................................................... 24
S-14 Coolant temperature rises too high (Overheating) .......................................................... 26
S-15 Abnormal noise is made ................................................................................................. 27
S-16 Vibration is excessive ..................................................................................................... 28
S-17 Air cannot be bled from fuel circuit.................................................................................. 30

50 Disassembly and assembly

General information on disassembly and assembly SEN01156-03
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 11
Engine and cooling system, Part 1 SEN01157-02
Removal and installation of engine assembly ......................................................................... 2
Removal and installation of radiator assembly ........................................................................ 6
Removal and installation of air aftercooler............................................................................... 11
Removal and installation of cooling fan and fan motor assembly............................................ 12
Removal and installation of damper assembly ........................................................................ 14
Disassembly and assembly of damper assembly.................................................................... 16
Removal and installation of fuel tank assembly....................................................................... 20
Removal and installation of engine hood assembly ................................................................ 22

WA600-6 15
SEN00398-14 00 Index and foreword

Removal and installation of bulkhead assembly...................................................................... 24

Engine and cooling system, Part 2 SEN01158-03
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 8
Removal and installation of fuel injector assembly .................................................................. 24
Removal and installation of engine front seal .......................................................................... 28
Removal and installation of engine rear seal........................................................................... 31
Power train, Part 1 SEN01160-02
Removal and installation of parking brake assembly............................................................... 2
Removal and installation of torque converter and transmission assembly .............................. 4
Power train, Part 2 SEN01162-02
Disassembly and assembly of torque converter assembly...................................................... 2
Disassembly and assembly of transmission assembly............................................................ 29
Disassembly and assembly of transfer assembly.................................................................... 56
Disassembly and assembly of parking brake assembly .......................................................... 71
Power train, Part 3 SEN01164-03
Removal and installation of front axle assembly...................................................................... 2
Removal and installation of rear axle assembly ...................................................................... 4
Removal and installation of center support assembly ............................................................. 6
Disassembly and assembly of center support assembly ......................................................... 8
Disassembly and assembly of differential assembly ............................................................... 12
Power train, Part 4 SEN01165-02
Removal and installation of final drive carrier assembly .......................................................... 2
Disassembly and assembly of final drive carrier assembly ..................................................... 4
Removal and installation of front final drive brake assembly ................................................... 5
Disassembly and assembly of final drive assembly................................................................. 7
Brake system SEN01167-02
Disassembly and assembly of brake assembly ....................................................................... 2
Removal and installation of brake valve assembly .................................................................. 10
Disassembly and assembly of accumulator and charge valve assembly ................................ 11
Disassembly and assembly of slack adjustor assembly .......................................................... 14
Undercarriage and frame SEN01169-02
Removal and installation of center hinge pin ........................................................................... 2
Removal and installation of counterweight assembly .............................................................. 9
Hydraulic system SEN01171-02
Removal and installation of hydraulic tank assembly .............................................................. 2
Removal and installation of hydraulic pump assembly ............................................................ 4
Removal and installation of control valve assembly ................................................................ 8
Disassembly and assembly of control valve assembly............................................................ 10
Removal and installation of steering valve assembly .............................................................. 15
Removal and installation of ECSS accumulator assembly ...................................................... 16
Disassembly and assembly of hydraulic cylinder assembly .................................................... 17
Work equipment SEN01174-02
Removal and installation of work equipment assembly ........................................................... 2
Cab and its attachments SEN01175-02
Removal and installation of operator's cab assembly.............................................................. 2
Removal and installation of operator's cab glass (stuck glass) ............................................... 6
Removal and installation of floor frame assembly ................................................................... 14
Disassembly and assembly of operator’s seat assembly ........................................................ 17
Removal and installation of air conditioner unit assembly ....................................................... 50
Electrical system SEN01177-03
Removal and installation of engine controller assembly .......................................................... 2
Removal and installation of transmission controller assembly ................................................ 4
Removal and installation of loader controller assembly........................................................... 5
Removal and installation of VHMS controller assembly .......................................................... 6
Removal and installation of monitor assembly ........................................................................ 7

16 WA600-6
00 Index and foreword SEN00398-14

90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00412-03
Power train hydraulic circuit diagram....................................................................................... 2
Brake hydraulic circuit diagram ............................................................................................... 3
Work equipment hydraulic circuit diagram
Steering wheel specification ............................................................................................. 5
Steering wheel specification with ECSS........................................................................... 7
AJSS (Advanced Joystick Steering System) specification ............................................... 9
AJSS (Advanced Joystick Steering System) specification with ECSS ............................. 11
Electrical diagrams and drawings SEN00413-04
Air conditioner electrical circuit diagram .................................................................................. 3
Steering wheel specification
Electrical circuit diagram (1/10) ............................................................................................... 5
Electrical circuit diagram (2/10) ............................................................................................... 7
Electrical circuit diagram (3/10) ............................................................................................... 9
Electrical circuit diagram (4/10) ............................................................................................... 11
Electrical circuit diagram (5/10) ............................................................................................... 13
Electrical circuit diagram (6/10) ............................................................................................... 15
Electrical circuit diagram (7/10) ............................................................................................... 17
Electrical circuit diagram (8/10) ............................................................................................... 19
Electrical circuit diagram (9/10) ............................................................................................... 21
Electrical circuit diagram (10/10) ............................................................................................. 23
AJSS (Advanced Joystick Steering System) specification
Electrical circuit diagram (1/10) ............................................................................................... 25
Electrical circuit diagram (2/10) ............................................................................................... 27
Electrical circuit diagram (3/10) ............................................................................................... 29
Electrical circuit diagram (4/10) ............................................................................................... 31
Electrical circuit diagram (5/10) ............................................................................................... 33
Electrical circuit diagram (6/10) ............................................................................................... 35
Electrical circuit diagram (7/10) ............................................................................................... 37
Electrical circuit diagram (8/10) ............................................................................................... 39
Electrical circuit diagram (9/10) ............................................................................................... 41
Electrical circuit diagram (10/10) ............................................................................................. 43
Connector arrangement diagram............................................................................................. 45

WA600-6 17
SEN00398-14

WA600-6 Wheel loader

Form No. SEN00398-14

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

18
 SEN00415-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

WA600-6 1
SEN00415-03 00 Index and foreword

Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.

2 WA600-6
00 Index and foreword SEN00415-03

2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.

WA600-6 3
SEN00415-03 00 Index and foreword

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 WA600-6
00 Index and foreword SEN00415-03

q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

WA600-6 5
SEN00415-03 00 Index and foreword

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.

6 WA600-6
00 Index and foreword SEN00415-03

How to read the shop manual 1

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

1. Composition of shop manual

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

00. Index and foreword

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

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

10. Structure, function and maintenance standard

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

20. Standard value table

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

30. Testing and adjusting

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

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

50. Disassembly and assembly

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

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

2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

WA600-6 7
SEN00415-03 00 Index and foreword

3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.

q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)

q Revisions
Revised brochures are shown in the shop manual composition table.

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

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.

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

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

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

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

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

8 WA600-6
00 Index and foreword SEN00415-03

Explanation of terms for maintenance standard 1

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

1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example:
Standard size Tolerance
–0.022
120
–0.126

a The tolerance may be indicated in the text

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

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

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

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

WA600-6 9
SEN00415-03 00 Index and foreword

2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4. Repair limit and allowable value or allow-

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

10 WA600-6
00 Index and foreword SEN00415-03

Handling of electric equipment and hydraulic component 1

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

Points to remember when handling electric

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

2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.

2) Defective crimping or soldering of connec-

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

WA600-6 11
SEN00415-03 00 Index and foreword

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.

4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5) Oil or dirt stuck to connector

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

12 WA600-6
00 Index and foreword SEN00415-03

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. 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 connec-
tors apart.
a Never pull with one hand.

2] When removing from clips

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

q When removing a connector from a

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

3] Action to take after removing connec-

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

WA600-6 13
SEN00415-03 00 Index and foreword

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

14 WA600-6
00 Index and foreword SEN00415-03

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

WA600-6 15
SEN00415-03 00 Index and foreword

4) Drying wiring harness

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

16 WA600-6
00 Index and foreword SEN00415-03

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

5. Points to remember when troubleshooting

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

WA600-6 17
SEN00415-03 00 Index and foreword

Points to remember when handling hydraulic equipment

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

1. Be careful of the operating environment.

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

2. Disassembly and maintenance work in the

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

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

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

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

18 WA600-6
00 Index and foreword SEN00415-03

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.

WA600-6 19
SEN00415-03 00 Index and foreword

Handling of connectors newly used for engines 1

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

Disconnect connector (1) according to the fol-

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

20 WA600-6
00 Index and foreword SEN00415-03

3. Push lock type

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

Disconnect connector (3) according to the fol-

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

q 114 engine

q 107, 114 engines

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

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

(4) in the direction of the arrow.

q 107 engine

a If the lock is on the underside, use

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

WA600-6 21
SEN00415-03 00 Index and foreword

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

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

2) Connect the connector according to the

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

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

22 WA600-6
00 Index and foreword SEN00415-03

How to read electric wire code 1

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

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

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

Indicates size of wire by nominal No.

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

Indicates type of wire by symbol.

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

1. Type, symbol, and material

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

(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene

WA600-6 23
SEN00415-03 00 Index and foreword

2. Dimensions

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

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

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

“f” of nominal No. denotes flexible”.

24 WA600-6
00 Index and foreword SEN00415-03

3. Color codes table

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

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

4. Types of circuits and color codes

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

WA600-6 25
SEN00415-03 00 Index and foreword

Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]

1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234

2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
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

26 WA600-6
00 Index and foreword SEN00415-03

2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q 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.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

WA600-6 27
SEN00415-03 00 Index and foreword

4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.

28 WA600-6
00 Index and foreword SEN00415-03

Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k 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.

Type 1

1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.

2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

WA600-6 29
SEN00415-03 00 Index and foreword

Type 2

1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)

2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)

30 WA600-6
00 Index and foreword SEN00415-03

Type 3

1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)

2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)

WA600-6 31
SEN00415-03 00 Index and foreword

Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.

a The following table applies to the bolts in Fig. A.

Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370

a The following table applies to the bolts in Fig. B.

Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2

a Fig. A a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)

32 WA600-6
00 Index and foreword SEN00415-03

2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torques for O-ring boss piping joints

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

Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}

4. Table of tightening torques for O-ring boss plugs

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

Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

WA600-6 33
SEN00415-03 00 Index and foreword

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.

Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).

Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.

Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —

34 WA600-6
00 Index and foreword SEN00415-03

8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.

Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.

Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

WA600-6 35
SEN00415-03 00 Index and foreword

Conversion table 1
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.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

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

Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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

36 WA600-6
00 Index and foreword SEN00415-03

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

WA600-6 37
SEN00415-03 00 Index and foreword

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

38 WA600-6
00 Index and foreword SEN00415-03

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

WA600-6 39
SEN00415-03 00 Index and foreword

Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

40 WA600-6
00 Index and foreword SEN00415-03

WA600-6 41
SEN00415-03

WA600-6 Wheel loader

Form No. SEN00415-03

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 11-08 (01)

42
 SEN00400-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification dimension drawing .......................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ....................................................................................................................................... 10
Table of fuel, coolant and lubricants ................................................................................................... 12

WA600-6 1
SEN00400-02 01 Specification

Specification and technical data 1

Specification dimension drawing 1
3,850 mm with lift arm

2 WA600-6
01 Specification SEN00400-02

Specifications 1
3,850 mm with lift arm
Machine model name WA600-6
Serial number 60001 and up 60001 and up
Standard For EU
Operating weight kg 52,900 53,130
Weight

Distribution
Front wheel kg 26,485 26,550
Rear wheel kg 26,335 26,500
3
Bucket capacity (Heaped) m 7.0 7.0
Rated load kN{kg} 123.56 {12,600} 123.56 {12,600}
Data inside the parentheses
P-mode E-mode P-mode E-mode
represents a value when locked up
Travel speed F1 km/h 6.7 6.6 6.7 6.6
Travel speed F2 km/h 11.7 (12.4) 11.5 (12.1) 11.7 (12.4) 11.5 (12.1)
Travel speed F3 km/h 20.3 (21.7) 19.4 (20.9) 20.3 (21.7) 19.4 (20.9)
Travel speed F4 km/h 33.8 (37.7) 31.5 (35.5) 33.8 (37.7) 31.5 (35.5)
Performance

Travel speed R1 km/h 7.3 7.3 7.3 7.3

Travel speed R2 km/h 12.8 (13.5) 12.5 (12.8) 12.8 (13.5) 12.5 (12.8)
Travel speed R3 km/h 22.0 (23.7) 21.1 (22.5) 22.0 (23.7) 21.1 (22.5)
Travel speed R4 km/h 37.0 (41.0) 34.0 (38.4) 37.0 (41.0) 34.0 (38.4)
Max. drawbar pull, forward kN{kg} 429.53{43,800} 357.94{36,500} 429.53{43,800} 357.94{36,500}
Max. drawbar pull, reverse kN{kg} 387.36{39,500} 354.02{36,100} 387.36{39,500} 354.02{36,100}
Gradeability deg. 25 25
Min. turning radius
Center of outside tire mm 7,075 7,075
Outside of chassis (with teeth) mm 8,440 8,440
Overall length (with teeth) mm 11,870 11,870
Overall width (chassis) mm 3,540 3,540
Bucket width (outside width of
mm 3,910 3,910
protector)
Overall height (ROPS cab top) mm 4,460 4,460
Overall height with bucket lifted up to
mm 7,775 7,775
maximum height
Dimensions

Wheelbase mm 4,500 4,500

Tread mm 2,650 2,650
Minimum ground clearance mm 525 525
Max. hinge pin height of bucket mm 5,665 5,665
Dumping clearance (Teeth end/Edge tip) mm 3,730 / 4,005 3,730 / 4,005
Dumping reach (Teeth end/Edge tip) mm 1,885 / 1,690 1,885 / 1,690
Bucket tilt-forward angle deg. 45 45
Bucket tilt-back angle
deg. 50 50
(Operating posture)
Digging depth, 10° (Teeth end/Edge tip) mm 530 / 415 530 / 415

WA600-6 3
SEN00400-02 01 Specification

Machine model name WA600-6 WA600-6

Serial number 60001 and up 60001 and up
Standard for EU
Name SAA6D170E-5
4-cycle, water-cooled, direct injection type with
Type
turbocharger, aftercooler and water-cooled EGR
Number of cylinders – Bore × Stroke mm 6 – 170 x 170
Total piston displacement l {cc} 23.15 {23,150}
P-mode E-mode P-mode E-mode
kW/rpm
Flywheel horsepower 393 {527}/ 382 {513}/ 393 {527}/ 382 {513}/
{HP/rpm}
Engine

1,800 1,700 1,800 1,700

Nm/rpm
Max. torque 2,594/1,000 {264.5/1,000}
{kgm/rpm}
g/kWh
Rated fuel consumption 227 {169} (In P-mode only)
{g/HPh}
High idle speed rpm 2,000
Low idle speed rpm 800
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 90 A
Battery 12 V, 200 Ah × 2 pcs
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Planetary type, multiple disc type, and forward-reverse
Power train

Transmission
4 stages
Reduction gear unit Spiral bevel gear type and splash lubrication type
Differential system Straight bevel gear type
Final drive Single-stage planetary gear and splash lubrication type
Drive method Front and rear wheel drive
Front axle Fixed frame, full floating type
Wheel and axle

Rear axle Center pin supporting, full floating type

Tire 36/65-33-36PR(L-4)
Wheel rim 28.00 x 33WTB
kPa
Tire inflation pressure Front wheel: 525 {5.4} and rear wheel: 525 {5.4}
{kg/cm2}
Independent front and rear wheel brake system of closed
Foot brake multiple wet disc type
Brake

Fully hydraulic type

Drive shaft braking system of wet disc type
Parking brake
Hydraulically released spring-driven brake

4 WA600-6
01 Specification SEN00400-02

Machine model name WA600-6

Serial number 60001 and up 60001 and up
Steering system Standard for EU
Steering
system

Type Articulated steering

Structure Fully hydraulic power steering
478 (Variable displacement type piston pump
l/min
Hydraulic pump delivery

Work equipment pump

HPV125+125)
Steering pump l/min 163 (Variable displacement type piston pump HPV125)
Fan pump l/min 57 (Variable displacement type piston pump LPV45)
Torque converter and
l/min 294 (Gear pump SAL(4)160)
transmission pump
Cooling pump l/min 182 (Gear pump SAL(3)100)
EPC and brake pump l/min 58 (Gear pump SAL(2)32)
Hydraulic system

Control valve

Set pressure for work equipment MPa {kg/cm2} 3-spool type (with HI valve) 34.3 {350}

Set pressure for steering system MPa {kg/cm2} Spool valve type 34.3 {350}

Number of lift arm cylinders –

mm Double-acting piston type, 2 – 200 x 1,067
Bore x Stroke
Cylinder

Number of bucket cylinders –

mm Double-acting piston type, 1 – 225 x 776
Bore x Stroke
Number of steering cylinders –
mm Double-acting piston type, 2 – 115 x 510
Bore x Stroke
Motor
Fan motor Fixed displacement piston type LMF55
equipment

Work equipment
Work

Type of link Single link

Shape of bucket cutting edge Spade nose with teeth

WA600-6 5
SEN00400-02 01 Specification

3,990 mm with lift arm

6 WA600-6
01 Specification SEN00400-02

3,990 mm with lift arm

Machine model name WA600-6
Serial number 60001 and up 60001 and up
Standard For EU
Operating weight kg 52,700 52,930
Weight

Distribution
Front wheel kg 26,640 26,705
Rear wheel kg 25,980 26,145
3
Bucket capacity (Heaped) m 6.4 6.4
Rated load kN{kg} 114.54 {11,680} 114.54 {11,680}
Data inside the parentheses
P-mode E-mode P-mode E-mode
represents a value when locked up
Travel speed F1 km/h 6.7 6.6 6.7 6.6
Travel speed F2 km/h 11.7 (12.4) 11.5 (12.1) 11.7 (12.4) 11.5 (12.1)
Travel speed F3 km/h 20.3 (21.7) 19.4 (20.9) 20.3 (21.7) 19.4 (20.9)
Travel speed F4 km/h 33.8 (37.7) 31.5 (35.5) 33.8 (37.7) 31.5 (35.5)
Performance

Travel speed R1 km/h 7.3 7.3 7.3 7.3

Travel speed R2 km/h 12.8 (13.5) 12.5 (12.8) 12.8 (13.5) 12.5 (12.8)
Travel speed R3 km/h 22.0 (23.7) 21.1 (22.5) 22.0 (23.7) 21.1 (22.5)
Travel speed R4 km/h 37.0 (41.0) 34.0 (38.4) 37.0 (41.0) 34.0 (38.4)
Max. drawbar pull, forward kN{kg} 429.53{43,800} 357.94{36,500} 429.53{43,800} 357.94{36,500}
Max. drawbar pull, reverse kN{kg} 387.36{39,500} 354.02{36,100} 387.36{39,500} 354.02{36,100}
Gradeability deg. 25 25
Min. turning radius
Center of outside tire mm 7,075 7,075
Outside of chassis (with teeth) mm 8,500 8,500
Overall length (with teeth) mm 11,985 11,985
Overall width (chassis) mm 3,540 3,540
Bucket width (outside width of
mm 3,910 3,910
protector)
Overall height (ROPS cab top) mm 4,460 4,460
Overall height with bucket lifted up to
mm 7,925 7,925
maximum height
Dimensions

Wheelbase mm 4,500 4,500

Tread mm 2,650 2,650
Minimum ground clearance mm 525 525
Max. hinge pin height of bucket mm 5,885 5,885
Dumping clearance (Teeth end/Edge tip) mm 3,995 / 4,270 3,995 / 4,270
Dumping reach (Teeth end/Edge tip) mm 1,800 / 1,610 1,800 / 1,610
Bucket tilt-forward angle deg. 45 45
Bucket tilt-back angle
deg. 50 50
(Operating posture)
Digging depth, 10° (Teeth end/Edge tip) mm 515 / 400 515 / 400

WA600-6 7
SEN00400-02 01 Specification

Machine model name WA600-6 WA600-6

Serial number 60001 and up 60001 and up
Standard for EU
Name SAA6D170E-5
4-cycle, water-cooled, direct injection type with
Type
turbocharger, aftercooler and water-cooled EGR
Number of cylinders – Bore × Stroke mm 6 – 170 x 170
Total piston displacement l {cc} 23.15 {23,150}
P-mode E-mode P-mode E-mode
kW/rpm
Flywheel horsepower 393 {527}/ 382 {513}/ 393 {527}/ 382 {513}/
{HP/rpm}
Engine

1,800 1,700 1,800 1,700

Nm/rpm
Max. torque 2,594/1,000 {264.5/1,000}
{kgm/rpm}
g/kWh
Rated fuel consumption 227 {169} (In P-mode only)
{g/HPh}
High idle speed rpm 2,000
Low idle speed rpm 800
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 90 A
Battery 12 V, 200 Ah × 2 pcs
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Planetary type, multiple disc type, and forward-reverse
Power train

Transmission
4 stages
Reduction gear unit Spiral bevel gear type and splash lubrication type
Differential system Straight bevel gear type
Final drive Single-stage planetary gear and splash lubrication type
Drive method Front and rear wheel drive
Front axle Fixed frame, full floating type
Wheel and axle

Rear axle Center pin supporting, full floating type

Tire 36/65-33-36PR(L-4)
Wheel rim 28.00 x 33WTB
kPa
Tire inflation pressure Front wheel: 525 {5.4} and rear wheel: 525 {5.4}
{kg/cm2}
Independent front and rear wheel brake system of closed
Foot brake multiple wet disc type
Brake

Fully hydraulic type

Drive shaft braking system of wet disc type
Parking brake
Hydraulically released spring-driven brake

8 WA600-6
01 Specification SEN00400-02

Machine model name WA600-6

Serial number 60001 and up 60001 and up
Steering system Standard for EU
Steering
system

Type Articulated steering

Structure Fully hydraulic power steering
478 (Variable displacement type piston pump
l/min
Hydraulic pump delivery

Work equipment pump

HPV125+125)
Steering pump l/min 163 (Variable displacement type piston pump HPV125)
Fan pump l/min 57 (Variable displacement type piston pump LPV45)
Torque converter and
l/min 294 (Gear pump SAL(4)160)
transmission pump
Cooling pump l/min 182 (Gear pump SAL(3)100)
EPC and brake pump l/min 58 (Gear pump SAL(2)32)
Hydraulic system

Control valve

Set pressure for work equipment MPa {kg/cm2} 3-spool type (with HI valve) 34.3 {350}

Set pressure for steering system MPa {kg/cm2} Spool valve type 34.3 {350}

Number of lift arm cylinders –

mm Double-acting piston type, 2 – 200 x 1,067
Bore x Stroke
Cylinder

Number of bucket cylinders –

mm Double-acting piston type, 1 – 225 x 776
Bore x Stroke
Number of steering cylinders –
mm Double-acting piston type, 2 – 115 x 510
Bore x Stroke
Motor
Fan motor Fixed displacement piston type LMF55
equipment

Work equipment
Work

Type of link Single link

Shape of bucket cutting edge Spade nose with teeth

WA600-6 9
SEN00400-02 01 Specification

Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name WA600-6
Serial number 60001 and up
Engine (Dry weight) 3,098
Radiator (Dry weight) 433
Torque converter (Dry weight) 486
Transmission (Dry weight) 1,290
Upper drive shaft 29.6
Center drive shaft 60.5
Front drive shaft 65
Rear drive shaft 62.8
Center support 46.4
Front axle 3,635
Rear axle 3,532
Front differential 551
Rear differential 586
Planetary carrier assembly (1 unit) 191
Wheel hub (1 piece) 182.5
Axle pivot (Front) 136.2
Axle pivot (Rear) 190
Wheel (1 piece) 409
Tire (Standard: 35/65-33-36PR L-4) (1 piece) 1,085
Steering valve 66
Steering cylinder (1 unit) 97.8
Hydraulic tank (Dry weight) 492
Work equipment pump 180
Steering pump 103
Fan pump 25
Torque converter, transmission + Cooling + Brake, EPC 48.3
Oil cooler 59.5
Torque converter oil cooler 75
Fan motor 25
Fan 62

10 WA600-6
01 Specification SEN00400-02

Unit: kg
Machine model name WA600-6
Serial number 60001 and up
Work equipment valve 120
Lift cylinder (1 piece) 517
Bucket cylinder 515
Engine hood (top hood, front/rear) 33.4 / 42.4
Engine hood (a side hood) 50.5
Radiator guard 354
Front frame 4,310
Rear frame 4,333
Bucket link (including bushing) 298
Bell crank (including bushing) 1,275
3,850 mm lift arm (including bushing) 3,754
3,990 mm lift arm (including bushing) 3,905
Bucket (with teeth) 5,115
Counterweight 2,780
Fuel tank 426
Battery (1 piece) 64
Cab 1,095
Air conditioner unit 9.8
Operator's seat 50.2
Floor frame 116.3

WA600-6 11
SEN00400-02 01 Specification

Table of fuel, coolant and lubricants 1

a For details of the notes (e.g.,Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Man-
ual.

Refill points Engine oil Transmission Hydraulic oil Cooling

Front axle Rear axle Pins Fuel tank
Capacity pan case system system

Specified capacity l 97 120 592 155 155 — 718 182

Refill capacity l 86 83 443 155 155 — — 147

12 WA600-6
SEN00400-02

WA600-6 Wheel loader

Form No. SEN00400-02

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

14
 SEN00402-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Engine mount and transmission mount................................................................................................ 2
Damper ................................................................................................................................................ 4
Cooling system..................................................................................................................................... 6
Cooling fan pump ............................................................................................................................... 10
Cooling fan motor............................................................................................................................... 18

WA600-6 1
SEN00402-01 10 Structure, function and maintenance standard

Engine and cooling system 1

Engine mount and transmission mount 1

Unit: mm
No. Check item Criteria Remedy
Clearance between stopper and
1 Min. 1 Adjust
support

2 WA600-6
10 Structure, function and maintenance standard SEN00402-01

Unit: mm
No. Check item Criteria Remedy
Standard shim thickness of 1.2 (Parallelism of center support coupling and
2 Adjust
mount transmission coupling is 0.1 mm)

WA600-6 3
SEN00402-01 10 Structure, function and maintenance standard

Damper 1

1. Breather Function
2. Flywheel (shaft side) q The damper reduces torsional vibration due to
3. Breather torque fluctuation and protects vibration in the
4. Cover drive system after the engine from torsional
5. Outer body vibration.
6. Inner body
7. Rubber cushion (large) Operation
8. Rubber cushion (small) q Power from the engine is transmitted to outer
9. Shaft body (5) via the flywheel. Rubber cushions (7)
and (8) absorb torsional vibration of the
engine, and the power is transmitted to the
upper drive shaft between the torque converter
through shaft (9) via inner body (6).

4 WA600-6
10 Structure, function and maintenance standard SEN00402-01

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bearing size Shaft Hole clearance limit
10
and shaft +0.015 –0.000 –0.035 –
85 0.005
+0.003 –0.020 –0.003
Replace
Clearance between bearing –0.000 –0.008 –0.033 –
11 150 0.018
and housing –0.018 –0.033 –0.010
Clearance between inner body –0.012 +0.110 0.042 –
12 85
and shaft –0.034 +0.030 0.144
Standard size Tolerance Repair limit
Wear of oil seal contact surface Finish with
13 –0.000
of shaft 100 –0.18 grinder or replace
–0.087
after chrome-
Wear of oil seal contact surface –0.000 plating repair
14 120 –0.18
of sleeve –0.087
15 Backlash at spline section 0.068 – 0.262 Replace

WA600-6 5
SEN00402-01 10 Structure, function and maintenance standard

Cooling system 1

6 WA600-6
10 Structure, function and maintenance standard SEN00402-01

WA600-6 7
SEN00402-01 10 Structure, function and maintenance standard

1. Radiator upper tank

2. Coolant level sensor
3. Radiator core
4. Radiator lower tank
5. Brake oil cooler (if equipped)
6. Brake oil cooler (if equipped)
7. Air conditioner condenser
8. Aftercooler
9. Torque converter oil cooler
10. Coolant sub-tank
11. Hydraulic oil cooler
12. Cooling fan motor
13. Cooling fan

A: Aftercooler outlet port

B: Aftercooler inlet port
C: Coolant inlet port
D: Hydraulic oil cooler inlet port
E: Hydraulic oil cooler outlet port
F: Coolant port

Specifications
Torque converter Brake oil cooler
Radiator Oil cooler Aftercooler
oil cooler (if equipped)
Triangle and
Type of core GF68-5 PTO-OL straight, 15-hole PTO-LS CF40-1
pipe type
*1) 100 × 558 × 150 × 620 × 25
Fin pitch (mm) 4.0/2P 4.0/2P 4.0/2P
20 stages stages
Total heat dissipation
59.04 2.1512 53.64 4.065 2.90
surface (m2)
Cross sectional area
156.96 — — — —
of flow (m2)
Pressure valve
70 ± 15
cracking pressure — — — —
{0.7 ± 0.15}
(kPa{kg/cm2})
Vacuum valve
0–5
cracking pressure — — — —
{0 – 0.05}
(kPa{kg/cm2})
*1): Size of element

8 WA600-6
SEN00402-01 10 Structure, function and maintenance standard

Cooling fan pump 1

Type: LPV45

P1 : Pump discharge port

PAEPC : EPC output pressure pickup plug
PEPC : EPC valve basic pressure input port
PS : Pump suction port
TO : Drain port

1. Servo valve
2. Air bleeder

10 WA600-6
10 Structure, function and maintenance standard SEN00402-01

1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston

WA600-6 11
SEN00402-01 10 Structure, function and maintenance standard

Function q Cylinder block (7) seals the pressurized oil to

q The pump converts the engine rotation trans- valve plate (8) and carries out relative rotation.
mitted to its shaft to oil pressure and delivers q This surface is designed so that the oil pres-
pressurized oil corresponding to the load. sure balance is maintained at a suitable level.
q It is possible to change the discharge amount q The oil inside each cylinder chamber of cylin-
by changing the swash plate angle. der block (7) is suctioned and discharged
through valve plate (8).
Structure
q Cylinder block (7) is supported to shaft by
spline (11).
q Shaft (1) is supported with front and rear bear-
ings (12).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).

12 WA600-6
10 Structure, function and maintenance standard SEN00402-01

Operation of pump q With the condition of center line (X) of rocker

q Cylinder block (7) rotates together with shaft cam (4) has swash plate angle (a) to axial
(1), and shoe (5) slides on flat surface (A). direction of cylinder block (7), flat surface (A)
q At this time, rocker cam (4) slants around ball functions as cam against shoe (5).
(13). As a result, angle (a) between center line q In this way, piston (6) slides on the inside of
(X) of rocker cam (4) and the axis of cylinder cylinder block (7), so a difference between vol-
block (7) changes. umes (E) and (F) is created inside cylinder
q Angle (a) is called the swash plate angle. block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.

WA600-6 13
SEN00402-01 10 Structure, function and maintenance standard

q As center line (X) of rocker cam (4) matches Control of delivery

the axial direction of cylinder block (7) (swash q If the swash plate angle (a) becomes larger,
plate angle (a) = 0), the difference between the difference between volumes (E) and (F)
volumes (E) and (F) inside cylinder block (7) be c o me s la r g er a nd pu m p d el i v er y ( Q )
becomes 0. increases.
q Suction and discharge of pressurized oil is not q Swash plate angle (a) is changed with servo
carried out in this state. Namely pumping piston (10).
action is not performed. (Actually, however, the q Servo piston (10) reciprocates straight accord-
swash plate angle is not set to 0) ing to the signal pressure of the servo valve.
q This straight motion is transmitted to rocker
cam (4).
q Rocker cam (4) supported with ball (13) slides
around ball (13).

q Swash plate angle (a) is in proportion to the

pump delivery.

14 WA600-6
10 Structure, function and maintenance standard SEN00402-01

Servo valve

P : EPC valve basic pressure

PE : Control piston pressure
PH : Pump discharge pressure
T : Drain port

1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring

WA600-6 15
SEN00402-01 10 Structure, function and maintenance standard

Function q Then, the land of the servo piston pressure

q The servo valve controls the current input to passage is connected to the pump discharge
the EPC valve and pump delivery (Q) so that passage by the notch of spool (5) and the dis-
they will be related as shown in the diagram. charge pressure is led to the servo piston.
q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
q The output pressure of the EPC valve flows in smaller the EPC output pressure, the greater
the piston chamber to push piston (6). the swash plate angle.
q Piston (6) pushes spool (5) until it is balanced
with the spring.

16 WA600-6
SEN00402-01 10 Structure, function and maintenance standard

Cooling fan motor 1

Type: LMF55

P : From fan pump

T : From cooler to tank
TC : To tank

Specifications
Type : LMF55
Capacity : 55.0 cc/rev
Rated speed : 980 rpm
Rated flow : 53.9 l/min
Check valve cracking pressure : 78.5 kPa {0.8 kg/cm2}

18 WA600-6
10 Structure, function and maintenance standard SEN00402-01

1. Output shaft 8. Center spring

2. Case 9. Check valve spring
3. Thrust plate 10. Check valve
4. Piston assembly 11. Pilot valve
5. Cylinder block 12. Spool for reversible valve
6. Valve plate 13. Spring for reversible valve
7. End cover 14. Safety valve

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
9 Check valve spring length load load deformed,
diameter
replace spring
13.7 N 11.0 N
16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}

WA600-6 19
SEN00402-01 10 Structure, function and maintenance standard

1. Hydraulic motor unit

Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.

Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
q This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and gener-
ates force (F1).
q Force F1 (F1 kg = P kg/cm2 x xD2/4 cm2)
q This force is applied to thrust plate (2).
q Since thrust plate (2) is fixed to a certain angle
(“a” degrees) to output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque [T =
F3 x ri] against the (Y - Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s(F3 x ri)] rotates
cylinder block (5) through the piston.
q This cylinder block (5) is coupled to output
shaft (1) with the spline.
q Output shaft (1) rotates and torque is transmit-
ted.

20 WA600-6
10 Structure, function and maintenance standard SEN00402-01

2. Suction valve

Function (2) When stopping

q When the fan pump stops rotating, hydraulic oil q When the engine stops, the fan pump input
does not flow into the motor. revolution becomes 0 rpm.
q Since the motor is revolved by the force of q Hydraulic oil from the pump is not supplied to
inertia, the pressure rises on the outlet side of port (P).
the motor. q As the hydraulic oil does not flow to (MA) side
q When the oil stops flowing in from inlet port (P), of the motor, the motor speed decreases grad-
suction valve (1) sucks in the oil on the outlet ually to stop.
side and supplies it to port (MA) where there is q If the motor shaft is revolved by the force of
not sufficient oil. inertia while the oil flow to port (P) decreases,
q Cavitation is prevented from being generated the oil in port (T) on the outlet side is sent by
accordingly. suction valve (1) to (MA) side.
q Cavitation is prevented from being generated
Operation accordingly.

(1) When starting

q When the hydraulic oil from the pump is sup-
plied to port (P) and the pressure on (MA) side
rises.
q When starting torque is generated in the motor,
the motor starts revolution.
q The oil on outlet (MB) side of the motor returns
through port (T) to the tank.

WA600-6 21
SEN00402-01 10 Structure, function and maintenance standard

3. Operation of reversible valve

(1) When solenoid valve is de-energized (2) When solenoid valve is energized
q When solenoid valve (1) is “de-energized”, q When solenoid valve (1) is “energized”, selec-
hydraulic oil from the pump is cut off by selec- tor valve (2) switches.
tor valve (2). q Hydraulic oil from the pump flows through port
q Port (C) is connected to the tank circuit. (C) into spool chamber (D).
q Accordingly, spool (3) is pressed by spring (4) q Hydraulic oil in chamber (D) compresses
to the right. spring (4).
q As a result, motor port (MA) opens and the q Spool (3) moves to the left.
hydraulic oil flows into the motor to revolve it in q As a result, motor port (MB) opens and the
normal direction (clockwise). hydraulic oil flows into the motor to revolve it in
reverse (counterclockwise).

22 WA600-6
10 Structure, function and maintenance standard SEN00402-01

4. Safety valve

Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.

Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q Accordingly, abnormally high pressure is pre-
vented from being generated in port (P).

WA600-6 23
SEN00402-01

WA600-6 Wheel loader

Form No. SEN00402-01

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

24
 SEN00403-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Power train ........................................................................................................................................... 2
Power train system diagram................................................................................................................. 3
Torque converter and transmission piping diagram ............................................................................. 4
Torque converter .................................................................................................................................. 6
Modulation clutch ............................................................................................................................... 15
Torque converter regulator valve........................................................................................................ 16
Transmission ...................................................................................................................................... 18
Transfer .............................................................................................................................................. 38
Transmission control valve................................................................................................................. 40
ECMV................................................................................................................................................. 43
Main relief valve and torque converter relief valve............................................................................. 50
Lubrication relief valve ....................................................................................................................... 52

WA600-6 1
SEN00403-02 10 Structure, function and maintenance standard

Power train, Part 1 1

Power train 1

1. Center drive shaft Outline

2. Transfer (output) q Power from engine (8) is transmitted through
3. Transmission the flywheel of engine to damper (7). The
4. Torque converter damper output shaft is connected to modula-
5. Transfer (input) tion clutch (9) via upper drive shaft (6). The
6. Upper drive shaft output of the modulation clutch is connected to
7. Damper pump of torque converter (4). The turbine of
8. Engine the torque converter is connected to input shaft
9. Modulation clutch of transmission (3).
10. Rear axle q The transmission has 6 hydraulic clutches to
11. Rear drive shaft set itself to 4 forward gear speeds and 4
12. Center support reverse gear speeds, which is operated
13. Front drive shaft through selection of one of them using an elec-
14. Front axle trically controlled switch.
q The output shaft of the transmission is con-
nected to gear of transfer (2) and the power is
transmitted to the output shaft. The power
from the transfer output shaft is transmitted
through center drive shaft (1), center support
(12), front drive shaft (13) and rear drive shaft
(11) to front axle (14) and rear axle (10), and
then transmitted through the wheels to the
tires.

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10 Structure, function and maintenance standard SEN00403-02

Power train system diagram 1

15. Front differential 23. Hydraulic cooling pump

16. Front brake 24. Power train pump
17. Front final drive 25. Work equipment pump
18. Front tire 26. Steering pump
19. Emergency steering pump (Only machine with 27. Fan pump
emergency steering system) 28. Rear differential
20. Parking brake 29. Rear brake
21. Brake cooling pump (if equipped) 30. Rear final drive
22. Brake and EPC pump 31. Rear tire

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SEN00403-02 10 Structure, function and maintenance standard

Torque converter and transmission piping diagram 1

1. Transmission
2. Power train, hydraulic cooling, brake and EPC pump
3. Transfer (input)
4. Torque converter
5. Transfer (output)
6. Transmission oil level gauge
7. Torque converter oil cooler
8. Torque converter oil filter

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SEN00403-02 10 Structure, function and maintenance standard

Torque converter 1
(Input transfer, PTO, modulation clutch, and torque converter)

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10 Structure, function and maintenance standard SEN00403-02

A: Modulation clutch oil pressure pickup port Specifications

B: From transmission control valve
C: From brake valve (Left)
D: To torque converter regulator valve
E: From lockup clutch ECMV
F: From main relief valve
G: From oil cooler
H: To transfer case

1. Steering, cooling fan pump mounting port

2. Work equipment pump mounting port
3. Modulation clutch output shaft speed sensor
4. Torque converter
5. Input transfer and PTO
6. Modulation clutch
7. Power train, hydraulic oil cooling, brake and Type 3-element, 1-stage, 2-phase
EPC pump mounting port 2.113 (T3/T1)
8. Brake cooling pump (If equipped) mounting Stall torque ratio
2.654 (T3/T2)
port

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SEN00403-02 10 Structure, function and maintenance standard

1. Modulation clutch output shaft 11. Stator shaft

2. Modulation clutch piston 12. Transmission input shaft
3. Modulation clutch outer drum 13. Free wheel
4. Modulation clutch gear (Number of teeth: 43) 14. Race
5. Torque converter input shaft 15. Boss
6. Lockup clutch housing 16. Lockup clutch disc
7. Turbine 17. Lockup clutch plate
8. Drive case 18. Lockup clutch piston
9. Stator 19. Modulation clutch disc
10. Pump 20. Modulation clutch plate

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10 Structure, function and maintenance standard SEN00403-02

1. Coupling
2. PTO gear (Number of teeth: 51)
3. Drive gear (Number of teeth: 54)
4. Input shaft
5. PTO gear (Number of teeth: 51)

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SEN00403-02 10 Structure, function and maintenance standard

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Inside diameter of cover seal
1 +0.050 Repair by hard
ring contact surface 60 60.5
+0.000 chromium-plat-
Inside diameter of retainer seal +0.040 ing or replace
2 140 140.5
ring contact surface +0.000
Backlash between drive gear
3 and modulation clutch inner 0.198 – 0.506
drum
Thickness of modulation clutch
2.8 ±0.08 2.3
disc
Thickness of modulation clutch
4 2.6 ±0.05 2.3
plate
Replace
Total assembly thickness of
40.4 ±0.25 37.1
modulation clutch
Thickness of lockup clutch disc 5.0 ±0.1 4.5
Thickness of lockup clutch
5.0 ±0.1 4.5
5 plate
Total assembly thickness of
15.0 ±0.17 13.9
lockup clutch

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10 Structure, function and maintenance standard SEN00403-02

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit Repair by hard
Outside diameter of coupling oil
1 –0.000 chromium-plat-
seal contact surface 95 94.8
–0.087 ing or replace
Backlash between drive gear
2 0.198 – 0.506
and PTO gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.012
3 130
of input shaft bearing diameter –0.020 –0.052
Inside +0.039 –0.000
75
diameter +0.020 –0.015
Outside –0.000 +0.026
Tolerance for fitness diameter 140
–0.018 –0.014 Replace
4 of PTO gear bearing
(rear) Inside +0.030 –0.000
80
diameter +0.011 –0.015
Outside –0.000 –0.010
Tolerance for fitness diameter 100
–0.015 –0.045
5 of PTO gear bearing
(front) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Standard clearance Clearance limit
Clearance between cage and
6 1.05 – 1.70
case —
(Standard shim thickness: 1.2)

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SEN00403-02 10 Structure, function and maintenance standard

Power transmitting route

When lockup clutch is “disengaged”

Drive case (11) is disconnected from boss (15) and turbine (14) and lockup torque converter works as an
ordinary torque converter.

The power from engine o (from left bottom)

O O
Damper Outer drum (7)
O O
Universal joint Output shaft (8)
O O
Coupling (1) Input shaft (9)
O O
Input shaft (2) Clutch housing (10), drive case (11) and pump (13)
O rotate together
Drive gear (3) O
O Oil is used as medium
Clutch gear (5) O
O Turbine (14) and boss (15)
Modulation clutch (6) O
O Transmission input shaft (16)
(To right top) o

q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3)
and PTO gear (4) and then used as the pump driving power.

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When lockup clutch is “engaged”

Drive case (11) is connected to boss (15) and turbine (14) and lockup torque converter is locked up.

The power from engine o (from left bottom)

O O
Damper Outer drum (7)
O O
Universal joint Output shaft (8)
O O
Coupling (1) Input shaft (9)
O O
Input shaft (2) Clutch housing (10), drive case (11) and pump (13)
O rotate together
Drive gear (3) O
O Lockup clutch (12)
Clutch gear (5) O
O Boss (15)
Modulation clutch (6) O
O Transmission input shaft (16)
(To right top) o

q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3)
and PTO gear (4) and then used as the pump driving power.

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SEN00403-02 10 Structure, function and maintenance standard

Oil flow

q The oil flows through the main relief valve and

its pressure is regulated by the torque con-
verter relief valve, and then it flows to the
pump (4) through inlet port (A) and the oil pas-
sage of housing (1), stator shaft (2) and guide
(3).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6), and
then returned to pump (4). Part of this oil is
sent to the oil cooler through stator (6), oil pas-
sage of stator shaft (2) and outlet port (B).

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10 Structure, function and maintenance standard SEN00403-02

Modulation clutch 1
Outline
q The modulation clutch is installed between the
input transfer and torque converter.
q Regulating the clutch oil pressure by use of
ECMV allows adjusting the clutch connection.
q Sliding the clutch allows reducing the power to
be transmitted to the torque converter.

When clutch is “engaged” (fixed)

q The oil sent from the modulation clutch ECMV
flows to piston (3) through port (A) of cover (1)
and oil passage of output shaft (2). The oil
reached there works as back pressure to drive
piston (3) in the right direction.
q Rise in the clutch oil pressure increases press-
ing force of piston (3), closely contacting disc
(4) and plate (5) each other and as the result
uniting clutch gear (6) and outer drum (7) to
transmit the power.
In this case, the power from clutch gear (6) is
directly transmitted to outer drum (7).

Clutch is in “slip” (partially disengaged)

q As the low clutch oil pressure signal from the
controller is received, the modulation clutch
ECMV reduces the clutch oil pressure.
q As the clutch oil pressure goes low, pressing
force of piston (3) is weakened, causing slip-
page of disc (4) and plate (5). As the result,
speed of outer drum (7) becomes slower than
clutch gear (6).
Thus, the power to be transmitted to outer
drum (7) is reduced.
q Magnitude of the power to be transmitted is
determined by the ratio between the clutch slip
ratio and torque converter's speed.
Slip ratio (%) = (1 – Output shaft speed/Input
shaft speed) x 100

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SEN00403-02 10 Structure, function and maintenance standard

Torque converter regulator valve 1

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.050 +0.025 0.050 –
32 0.111
–0.066 +0.000 0.091
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
2 Valve spring length load load
328 N 312 N
126.6 94.5 122.8
{33.5 kg} {31.8 kg}

3. Torque converter outlet port oil pressure pickup Outline

port q This valve is provided at the torque converter
4. Spool outlet circuit in order to secure an optimum
5. Valve body performance of the torque converter by adjust-
ing its set oil pressure.
A: From torque converter Set pressure:
B: To oil cooler 0.57 ± 0.05 MPa {5.8 ± 0.5 kg/cm2}
C: Drain

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10 Structure, function and maintenance standard SEN00403-02

Operation

q The oil from the torque converter is conducted

to chamber (D) through port (A) and orifice (a).
q When the oil pressure force generated in
chamber (D) is smaller than the tension of
spring (1), spool (2) is pressed leftward, clos-
ing port (A) and port (B).

q If the oil pressure force generated in chamber

(D) becomes larger than the tension of spring
(1), spool (2) is pressed rightward, opening
port (A) and port (B).

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SEN00403-02 10 Structure, function and maintenance standard

Transmission 1
(Transmission, transfer and parking brake)

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10 Structure, function and maintenance standard SEN00403-02

A: From torque converter 1. Transmission control valve

B: To torque converter 2. Lubrication relief valve
C: To lockup clutch 3. Drain valve
D: From power train pump 4. Drain plug
E: From oil cooler 5. Transfer
F: From parking brake emergency release valve 6. Parking brake
G: From lockup clutch ECMV 7. Transmission
H: From main relief valve 8. Torque converter drain tube mounting port
J: From R clutch ECMV 9. Transmission lubrication temperature sensor
K: From F clutch ECMV 10. Speed sensor
L: From 4th clutch ECMV 11. Emergency steering pump mounting port
M: From 2nd clutch ECMV 12. Oil filler tube mounting port
N: From 3rd clutch ECMV 13. Torque converter regulator valve
P: From 1st clutch ECMV 14. Parking brake oil pressure pickup port
R: From torque converter relief valve 15. Strainer

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SEN00403-02 10 Structure, function and maintenance standard

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10 Structure, function and maintenance standard SEN00403-02

1. Transmission input shaft Outline

2. R ring gear (Hub) q The transmission employed consists of the
3. Tie bolt united planetary gear mechanism and disc
4. Clutch disc clutch that provides “4 forward gear speeds
5. Clutch plate and 4 reverse gear speeds”.
6. R planetary pinion (Number of teeth: 28) q The transmission selects a single rotating
7. R clutch housing direction and a single speed by fixing the plan-
8. R ring gear (Number of inside teeth: 86) etary gear mechanism and 2 of 6 disc clutches
9. F ring gear (Number of inside teeth: 90) by use of ECMV.
10. F planetary pinion (Number of teeth: 24) q The transmission transmits the power being
11. F clutch housing transmitted to the transmission input shaft to
12. 4th planetary pinion (Number of teeth: 24) the output shaft after selecting a single speed
13. 4th clutch housing from the 1st to 4th speeds both in the forward
14. 2nd hub and reverse travel. In this case, the gear speed
15. 2nd clutch housing change is done by F and R clutches plus com-
16. 2nd clutch piston housing binations of 4 speed clutches.
17. 3rd clutch housing
18. 3rd ring gear (Number of inside teeth: 90)
19. 3rd planetary pinion (Number of teeth: 20) Number of plates and discs used
20. 1st clutch housing
Clutch No. Number of plates Number of discs
21. 1st ring gear (Number of inside teeth: 90)
22. 1st planetary pinion (Number of teeth: 20) R clutch 5+1 6
23. Transfer input gear (Number of teeth: 46) F clutch 5+1 6
24. Transmission output shaft 4th clutch 3+1 3
25. 1st sun gear (Number of teeth: 50)
2nd clutch 7 8
26. 1st carrier
27. 1st clutch piston 3rd clutch 3+1 3
28. 3rd sun gear (Number of teeth: 50) 1st clutch 3+1 3
29. 1st piston return spring
30. 3rd carrier
31. 3rd clutch piston Combinations of clutches at respective gear
32. 3rd piston return spring speeds and reduction ratio
33. 2nd clutch piston
34. 2nd piston return spring Gear speed Clutch used Reduction ratio
35. 4th ring gear (Number of inside teeth: 90) Forward 1st F x 1st 5.622
36. 4th clutch piston Forward 2nd F x 2nd 3.143
37. 4th sun gear (Number of teeth: 42)
Forward 3rd F x 3rd 1.765
38. 4th piston return spring
39. F clutch piston Forward 4th F x 4th 1.000
40. F and 4th carrier Neutral — —
41. F sun gear (Number of teeth: 42) Reverse 1st R x 1st 5.128
42. F piston return spring
Reverse 2nd R x 2nd 2.866
43. R clutch piston
44. R carrier Reverse 3rd R x 3rd 1.610
45. R piston return spring Reverse 4th R x 4th 0.912
46. Washer spring
47. R sun gear (Number of teeth: 30)
48. Housing

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SEN00403-02 10 Structure, function and maintenance standard

1. Transfer idler gear (Number of teeth: 41)

2. Transfer output gear (Number of teeth: 42)
3. Output shaft
4. Front coupling
5. Rear coupling
6. Parking brake

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10 Structure, function and maintenance standard SEN00403-02

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SEN00403-02 10 Structure, function and maintenance standard

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
1 R clutch spring (12 springs) length load load
78.5 N 66.7 N
68 61.0 63.9
{8.0 kg} {6.8 kg}
72.9 N 61.8 N
2 F clutch spring (12 springs) 68 61.5 63.9
{7.4 kg} {6.3 kg}
85.3 N 72.6 N
3 4th clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
1,627 N 1,380 N
4 2nd clutch spring (5 springs) 6 4.9 5.64
{166 kg} {141 kg}
85.3 N 72.6 N
5 3rd clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
85.3 N 72.6 N
6 1st clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
Total assembled thickness of 6 Standard size Tolerance Repair limit
7
discs and 6 plates for R clutch 53.4 ±0.35 50.2
Total assembled thickness of 6
8 53.4 ±0.35 50.2
discs and 6 plates for F clutch
Total assembled thickness of 3
9 30.8 ±0.26 28.4
discs and 4 plates for 4th clutch
Total assembled thickness of 8
10 discs and 7 plates for 2nd 62.4 ±0.39 58.1
clutch
Replace
Total assembled thickness of 3
11 30.8 ±0.26 28.4
discs and 4 plates for 3rd clutch
Total assembled thickness of 3
12 30.8 ±0.26 28.4
discs and 4 plates for 1st clutch
F, R 5.4 ±0.1 4.9
Thickness of 4th, 3rd,
13 5.4 ±0.1 4.6
clutch disc 1st
2nd 5.0 ±0.1 4.5
F, R, 4th, 3.2 ±0.1 2.9
Thickness of 3rd, 1st
14 5.0 ±0.1 4.5
clutch plate
2nd 3.2 ±0.1 2.9
–0.01
Wear of input shaft Width 2.56 2.30
15 –0.03
seal ring
Thickness 1.7 ±0.1 1.55
–0.01
Wear of input shaft Width 3.0 2.70
16 –0.03
seal ring
Thickness 2.5 ±0.1 2.35
–0.01
Wear of input shaft Width 3.0 2.70
17 –0.03
seal ring
Thickness 3.3 ±0.1 3.15
–0.01
Wear of input shaft Width 3.0 2.70
18 –0.03
seal ring
Thickness 1.9 ±0.1 1.75

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10 Structure, function and maintenance standard SEN00403-02

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Wear of R spacer –0.01
19 Width 4.5 4.05
seal ring –0.03
Thickness 6.0 ±0.15 5.85
–0.01
Wear of housing Width 4.0 3.60
20 –0.04
seal ring
Thickness 5.0 ±0.15 4.85
Wear of 4th spacer –0.01
21 Width 4.0 3.60
housing seal ring –0.03
Wear of seal ring
21 of 4th spacer Thickness 5.1 ±0.12 4.95
housing
Wear of 2nd clutch –0.01
Width 5.0 4.50
22 piston housing –0.03
seal ring Thickness 6.0 ±0.15 5.85
–0.01
Wear of output Width 3.0 2.70
23 –0.03
shaft seal ring
Thickness 1.9 ±0.1 1.75
Backlash between R 0.13 – 0.31
24 sun gear and F, 4th, Replace
planetary pinion 0.14 – 0.35
3rd, 1st
Backlash between R 0.15 – 0.38
25 planetary pinion F, 4th,
and ring gear 0.15 – 0.39
3rd, 1st
Backlash between input gear
26 0.190 – 0.486
and idler gear
Tolerance
Standard size
Tolerance for Shaft Hole
fitness of input Outside –0.000 –0.014
27 200
gear bearing diameter –0.030 –0.060
(Rear)
Inside +0.045 –0.000
110
diameter +0.023 –0.020
Tolerance for Outside –0.000 –0.022
190
fitness of input diameter –0.030 –0.051
28
gear bearing Inside +0.045 –0.000
(Front) 105
diameter +0.023 –0.020
Standard clearance Clearance limit
Clearance between cage and
29 0.85 – 1.70
case —
(Standard shim thickness: 1.1)

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SEN00403-02 10 Structure, function and maintenance standard

26 WA600-6
10 Structure, function and maintenance standard SEN00403-02

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Outside diameter of coupling oil
1 –0.000 Repair by hard
seal contact surface (Rear) 105 104.8
–0.087 chromium-plat-
Outside diameter of coupling oil –0.000 ing or replace
2 125 124.8
seal contact surface (Front) –0.087
Backlash between idler gear
3 0.190 – 0.486
and output gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.014
4 200
of idler gear bearing diameter –0.030 –0.060
Inside +0.045 –0.000
110
diameter +0.023 –0.020
Outside –0.000 –0.014
Tolerance for fitness 190
diameter –0.030 –0.060
5 of output shaft
Inside +0.059 –0.000 Replace
bearing (Rear) 105
diameter +0.037 –0.020
Outside –0.000 –0.022
Tolerance for fitness 190
diameter –0.030 –0.051
6 of output gear
bearing (Front) Inside +0.059 –0.000
105
diameter +0.037 –0.015
Standard clearance Clearance limit
Clearance between cage and
7 0.63 – 1.37
case —
(Standard shim thickness: 1.0)
Clearance between cover and 0.38 – 1.23
8 —
cage (Standard shim thickness: 0.5)

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SEN00403-02 10 Structure, function and maintenance standard

Disc clutch

Structure Operation
When clutch is “engaged” (fixed)

q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through oil the passage
return spring (6) and washer spring (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.

When clutch is “disengaged” (released)

q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q Plate (3) and disc (4) are released from the
frictional force and ring gear (1), as the result,
is also released.
q Washer spring (8) is installed between plate
(3). This spring quickens return of piston (2) as
the clutch is disengaged by providing smooth
separation of plate (3) and disc (4). At the
same time, it is used for preventing the drag-
ging.

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SEN00403-02 10 Structure, function and maintenance standard

Power transmitting route

Forward 1st gear speed

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10 Structure, function and maintenance standard SEN00403-02

F ring gear (4) of F clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.

The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23)
O
2nd clutch piston housing (13)
O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd ring gear (21) 3rd sun gear (22)
O
1st sun gear (15)
O
1st planetary pinion (16)
O
1st carrier (18)
O
Output shaft (24)

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SEN00403-02 10 Structure, function and maintenance standard

Forward 2nd gear speed

F ring gear (4) of F clutch and 2nd hub (19) of 2nd clutch are fixed hydraulically.

The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23)
O
2nd hub (19)
O
Output shaft (24)

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Forward 3rd gear speed

F ring gear (4) of F clutch and 3rd ring gear (21) of 3rd clutch are fixed hydraulically.
The power from torque converter
O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23)
O
2nd clutch piston housing (13)
O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd sun gear (22)
O
Output shaft (24)

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SEN00403-02 10 Structure, function and maintenance standard

Forward 4th gear speed

F ring gear (4) of F clutch and 4th ring gear (12) of 4th clutch are fixed hydraulically.

The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th sun gear (23)
O
Output shaft (24)

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Reverse 1st gear speed

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10 Structure, function and maintenance standard SEN00403-02

R ring gear (7) of R clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.

The power from torque converter

O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) =
R ring gear (9) rotation direction is opposite to
input shaft (1))
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23)
O
2nd clutch piston housing (13)
O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd ring gear (21) 3rd sun gear (22)
O
1st sun gear (15)
O
1st planetary pinion (16)
O
1st carrier (18)
O
Output shaft (24)

WA600-6 37
SEN00403-02 10 Structure, function and maintenance standard

Transfer 1

Outline
q The transfer is installed in the output side of
the transmission and fixed to the transmission
case with the bolt.

Operation

Power transmitting route

Transmission output shaft (1)

O
Transfer input gear (2)
O
Transfer idler gear (3)
O
Transfer output gear (4)
O
Output shaft (5)
O
Center drive shaft
O
Front drive shaft Rear drive shaft
O O
Front axle Rear axle

38 WA600-6
SEN00403-02 10 Structure, function and maintenance standard

Transmission control valve 1

Serial No.: 60001 – (Transmission No. 100090)

A: R clutch oil pressure pickup port 1. R clutch ECMV

B: F clutch oil pressure pickup port 2. F clutch ECMV
C: 4th clutch oil pressure pickup port 3. 4th clutch ECMV
D: 2nd clutch oil pressure pickup port 4. 2nd clutch ECMV
E: 3rd clutch oil pressure pickup port 5. 3rd clutch ECMV
F: 1st clutch oil pressure pickup port 6. 1st clutch ECMV
G: Lockup clutch oil pressure pickup port 7. Lockup clutch ECMV
H: Modulation clutch oil pressure pickup port 8. Modulation clutch ECMV
J: From power train pump 9. Parking brake solenoid valve
K: Main relief oil pressure pickup port 10. Last chance filter
L: Torque converter relief pressure pickup port 11. Main relief valve and torque converter relief
M: To input transfer lubrication valve
N: To parking brake emergency release valve 12. Check valve
(Pilot pressure)
P: To parking brake emergency release valve
(To parking brake piston)

40 WA600-6
10 Structure, function and maintenance standard SEN00403-02

Serial No.: (Transmission No. 100091) and up

A: R clutch oil pressure pickup port 1. R clutch ECMV

B: F clutch oil pressure pickup port 2. F clutch ECMV
C: 4th clutch oil pressure pickup port 3. 4th clutch ECMV
D: 2nd clutch oil pressure pickup port 4. 2nd clutch ECMV
E: 3rd clutch oil pressure pickup port 5. 3rd clutch ECMV
F: 1st clutch oil pressure pickup port 6. 1st clutch ECMV
G: Lockup clutch oil pressure pickup port 7. Lockup clutch ECMV
H: Modulation clutch oil pressure pickup port 8. Modulation clutch ECMV
J: From power train pump 9. Parking brake solenoid valve
K: Main relief oil pressure pickup port 10. Last chance filter
L: Torque converter relief pressure pickup port 11. Main relief valve and torque converter relief
M: To input transfer lubrication valve
N: To parking brake emergency release valve 12. Check valve
(Pilot pressure)
P: To parking brake emergency release valve
(To parking brake piston)

WA600-6 41
SEN00403-02 10 Structure, function and maintenance standard

Operation table of ECMV Outline

q The oil from the pump flows to the transmis-
ECMV sion control valve via the oil filter and then oil
F R 1st 2nd 3rd 4th L/U M/C
Gear speed flow is divided into the main relief circuit and
F1 Q Q Q clutch actuation circuit.
q The pressure of the oil sent to the clutch actua-
F2 Q Q Q Q
tion circuit is regulated by the main relief valve,
F3 Q Q Q Q and then used to actuate the clutch and park-
F4 Q Q Q Q ing brake through the last chance filter. The oil
R1 Q Q Q relieved from the main relief valve is supplied
to the torque converter.
R2 Q Q Q Q
q When the transmission gear is shifted, the
R3 Q Q Q Q ECMV increases the clutch oil pressure
R4 Q Q Q Q smoothly according to the command current
L/U: lockup clutch ECMV from the transmission controller to reduce the
M/C: modulation clutch ECMV gear shifting shocks. The ECMV also keeps
the clutch pressure constant during travel.
q If the F, R, or 1st to 4th ECMV is selected, the
regulated oil pressure is supplied to the
selected clutch to set the transmission in the
desired gear speed.
q In the 2nd, 3rd and 4th speed travel, the lockup
clutch ECMV operates at a speed higher than
the speed being specified from the transmis-
sion controller.
q The modulation clutch ECMV operates at every
gear speed.

42 WA600-6
10 Structure, function and maintenance standard SEN00403-02

ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve

For F, R, 1st, 2nd, 3rd, and 4th clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

A: To clutch
*1:
P: From pump
T: Drain Clutch used Printing on name plate
Dr: Drain F, R, 1st, 2nd, 3rd, 4th D*******
P1: Clutch oil pressure pickup port

1. Fill switch connector

2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)

WA600-6 43
SEN00403-02 10 Structure, function and maintenance standard

Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – Propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.

Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid

Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “ON” by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.

a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).

44 WA600-6
10 Structure, function and maintenance standard SEN00403-02

Operation of ECMV Before shifting gear (when draining)

q ECMV is controlled with the command current (Range A in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.

q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned “OFF”.
Range A: Before shifting gear (When draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling

a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).

WA600-6 45
SEN00403-02 10 Structure, function and maintenance standard

During filling (Range B in chart) Pressure regulation (Range C in chart)

q If a current is given to proportional solenoid (1) q If a current flows in proportional solenoid (1),
while there is no oil in the clutch, a hydraulic the solenoid generates thrust in proportion to
force balanced with the solenoid force is the current. This thrust of the solenoid is bal-
applied to chamber (B) and it pushes pressure anced with the sum of the thrust generated by
control valve (3) to the left. This conducts oil the oil pressure in clutch port and the tension
through pump port (P) and orifice (a) of flow of pressure control valve spring (2), and then
rate pickup valve (4) to start filling the oil to the the pressure is settled.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward.
As the clutch chamber is filled up with oil and
oil flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON” fill switch (5).

46 WA600-6
10 Structure, function and maintenance standard SEN00403-02

ECMV for lockup and modulation clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.

A: To clutch
*1:
P: From pump
T: Drain Clutch used Printing on name plate
Dr: Drain Lockup, modulation K*******
P1: Clutch oil pressure pickup port

1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)

WA600-6 47
SEN00403-02 10 Structure, function and maintenance standard

Outline ECMV for modulation clutch

ECMV for lockup clutch q This valve is used for regulating the clutch oil
q This valve is used to switch the clutch in order pressure to the set pressure.
to regulate the clutch oil pressure to the set It controls oil pressure by employing the pro-
pressure. portional solenoid for adjusting slip ratio of the
Since the modulation waveform is used for the clutch.
pressure application characteristics to the Responding to the command current from the
clutch, ECMV is capable of connecting the controller, the valve controls oil pressure by
lockup clutch smoothly, thereby reducing applying the thrust generated on the propor-
shocks resulting from gear shift. Above also tional solenoid to the pressure control valve
prevents generation of peak torque in the spool.
power train. These arrangements make the In order to control the oil pressure, this valve
machine comfortable to operator and enhance changes levels of the thrust applied to the
durability of the power train. pressure control valve by controlling the com-
mand current.
When changing from torque converter travel to
direct travel Oil pressure control of modulation clutch

At gear shift (in direct travel)

48 WA600-6
10 Structure, function and maintenance standard SEN00403-02

Operation
When clutch is “disengaged” (released) When clutch is “engaged” (fixed)

q While no current is flowing in to proportional q As current is conducted to proportional sole-

solenoid (1), pressure control valve (3) drains noid (1), the oil pressure being balanced with
the oil from clutch port (A) through drain port the solenoid force is applied to chamber (B),
(T). pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q As the clutch is filled with oil, the solenoid
thrust is balanced with the sum of the thrust
generated from oil pressure of the clutch port
and the tension of the pressure control valve
spring (2), and then the pressure is settled.

WA600-6 49
SEN00403-02 10 Structure, function and maintenance standard

Main relief valve and torque converter relief valve 1

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between torque con-
–0.035 +0.013 0.035 –
2 verter relief valve and valve 22 0.078
–0.045 +0.000 0.058
body
Standard size Repair limit
Replace
Installed Installed Installed
Main relief valve spring Free length Free length
3 length load load
(Outside)
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
365.5 N 347 N
4 Main relief valve spring (Inside) 108 78.3 104.8
{37.3 kg} {35.4 kg}
Torque converter relief valve 162.5 N 154 N
5 50 41.5 48.5
spring {16.5 kg} {15.7 kg}

6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief pressure pickup port
(Serial No.: 60001 – (Transmission No. 100090))

50 WA600-6
10 Structure, function and maintenance standard SEN00403-02

Outline Operation of main relief valve

Torque converter relief valve

q The torque converter relief valve constantly
regulates the torque converter inlet circuit
pressure below the set pressure to protect the
torque converter from abnormally high pres-
sure.
Set pressure: 1.02 MPa {10.4 kg/cm2}
(Cracking pressure)

Main relief valve

q The main relief valve regulates the pressure in
the transmission and parking brake hydraulic
circuits to the set pressure. q The oil from the hydraulic pump flows to cham-
Set pressure: 3.58 MPa {36.5 kg/cm2} ber (F) through the filter, port (C) of the relief
(At rated engine speed) valve and orifice (a) of main relief valve (1).

Operation

Operation of torque converter relief valve

q As the oil pressure in the circuit goes beyond

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
q The oil relieved through the main relief valve opening ports (C) and (E).
flows through port (E) into the torque con- Above operation conducts the oil from port (E)
verter. It also flows through orifice (b) of torque to the torque converter.
converter relief valve (3) into chamber (G).
q As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained to the
oil tank through port (A).

WA600-6 51
SEN00403-02 10 Structure, function and maintenance standard

Lubrication relief valve 1

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 +0.000 0.058
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
2 Valve spring length load load
97.4 N 92.6 N
59.7 37 57.9
{9.94 kg} {9.44 kg}

3. Valve body Function

4. Spool q The lubrication relief valve is installed to the
transmission valve and used for maintaining
A: From oil cooler the pressure of the lubrication circuit below the
B: Drain set pressure.
C: Lubrication pressure pickup port Set pressure: 0.26 MPa {2.7 kg/cm2}
(Cracking pressure)

52 WA600-6
SEN00403-02

WA600-6 Wheel loader

Form No. SEN00403-02

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

54
 SEN02455-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Torque converter oil cooler................................................................................................................... 2
Torque converter oil filter...................................................................................................................... 3
Drive shaft ............................................................................................................................................ 5
Center support ..................................................................................................................................... 8
Axle .................................................................................................................................................... 10
Differential .......................................................................................................................................... 14
Limited slip differential........................................................................................................................ 23
Final drive........................................................................................................................................... 28

WA600-6 1
SEN02455-01 10 Structure, function and maintenance standard

Power train, Part 2 1

Torque converter oil cooler 1

1. Torque converter oil cooler Outline

Oil from the torque converter is heated by power
A: Inlet port transmitting energy. This torque converter oil cooler
B: Outlet port enters the torque converter oil cooler through inlet
C: Coolant inlet port (A) to be cooled by engine coolant. Then it
D: Coolant outlet flows into the transmission lubrication system
through outlet port (B).

2 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Torque converter oil filter 1

1. Relief valve
2. Element
3. Drain plug

A: Outlet port
B: Inlet port

WA600-6 3
SEN02455-01 10 Structure, function and maintenance standard

Specifications
q Filtering area: 8,900 cm2 x 3
q Relief pressure: 0.29 – 0.34 MPa
{3 – 3.5 kg/cm2}
(Bypass pressure)

Operation
q Oil from the torque converter charge pump
enters filter inlet port (A). It passes from out-
side to inside of element (2), and flows to outlet
port (B).

q When element (2) is clogged with foreign mat-

ters, or when low oil temperature has caused
pressure at inlet port (A) to increase, oil from
inlet port (A) opens relief valve (1) to flow to
outlet port (B) directly, preventing the pump
and element (2) from being damaged.

4 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Drive shaft 1

1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center drive shaft

k Precautions for tightening torque of spider a The specified torque for the new bolt is
mounting bolts lower than that for the old bolt. Accord-
1. There are 2 types (new and old types) of the ingly, if the new bolt is tightened to the
spider mounting bolts which have the same torque for the old bolt, it may be broken
part No. during operation and the machine may not
a Different tightening torques are specified able to travel.
for the new bolt and old bolt.
3. For the above reason, when "retightening",
2. Since the new and old bolts cannot be distin- "removing" or "installing", be sure to replace
guished from each other by appearances, the the existing bolts with new bolts and tighten
existing spider mounting bolts cannot be them to the torque specified for them.
reused.

WA600-6 5
SEN02455-01 10 Structure, function and maintenance standard

a A new part No. is set for the new bolt. For

the new part No., see the parts book.

3 *Spider mounting bolts (A, C, E):

215 – 255 Nm {21.9 – 26 kgm}
3 Shaft mounting bolts (B, D, F):
245 – 309 Nm {25 – 31.5 kgm}
3 *Spider mounting bolts (G):
107 – 127 Nm {10.9 – 13 kgm}
3 Shaft mounting bolts (H):
98 – 123 Nm {10 – 12.5 kgm}
*: Bolts of new tightening torque (New bolt val-
ues).

Upper drive shaft

Front drive shaft

6 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Center drive shaft

Rear drive shaft

Outline
q Power from the engine is transmitted from the q When the machine is articulated or when it
damper through upper drive shaft (5), torque receives traveling impacts or working impacts,
converter, transmission and transfer to rear the distances between the engine, transmis-
axle through rear drive shaft (4), and also to sion and the front and rear axles change. The
front axle from center drive shaft (3) through drive shafts absorb the fluctuation of the angle
center support (2) and front drive shaft (1). and length with the universal joints and slip
q The drive shafts have the following purpose joints so that the power will be transmitted
besides simple power transmission. without damaging the parts even when the
positions of the components change.

WA600-6 7
SEN02455-01 10 Structure, function and maintenance standard

Center support 1

1. Front coupling Outline

2. Case q The center support is installed between the
3. Breather center drive shaft and the front drive shaft
4. Rear coupling mounted on the front frame.
q With the articulating frame, this part is con-
stantly twisting from side to side, so there is lia-
ble to be large stress on the drive shaft.
Therefore, the center support is used to trans-
mit the power smoothly, to reduce the stress
on the drive shafts, and in this way improve the
durability of the drive shafts.

8 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between case and size Shaft Hole clearance limit
5
bearing –0.000 –0.036 –0.018 –
130 –0.015
–0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 –0.032 – Replace
6 75 –0.029
shaft and bearing +0.032 –0.015 –0.066
Clearance between case and –0.000 –0.036 –0.018 –
7 140 –0.015
bearing –0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 –0.032 –
8 80 –0.029
shaft and bearing +0.032 –0.015 –0.066
Standard size Tolerance Repair limit
9 Wear of oil seal contact surface Finish with
–0.000
95 –0.18 grinder after
–0.087
chrome-plating
–0.000 repair or replace
10 Wear of oil seal contact surface 105 –0.18
–0.087
Max. 0.22
11 End play of coupling shaft Adjust
(Free rotational torque: Not exceeding 3.9 Nm{0.4 kgm})

WA600-6 9
SEN02455-01 10 Structure, function and maintenance standard

Axle 1
Front axle

1. Front axle 8. Oil filler plug

2. Front differential 9. Level plug (front axle)
3. Final drive 10. Level plug (final drive)
4. Front brake 11. Slack adjuster
5. Drain plug (differential)
6. Drain plug (front brake)
7. Drain plug (final drive)

10 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Front axle
(with forcible brake cooling system)

1. Front axle 8. Drain plug (front brake)

2. Front differential 9. Drain plug (final drive)
3. Final drive 10. Oil filler plug
4. Front brake 11. Level plug (front axle)
5. Block 12. Level plug (final drive)
6. Strainer 13. Slack adjuster
7. Drain plug (differential)

WA600-6 11
SEN02455-01 10 Structure, function and maintenance standard

Rear axle

1. Rear axle 7. Drain plug (final drive)

2. Rear differential 8. Oil filler plug
3. Final drive 9. Level plug (rear axle)
4. Rear brake 10. Level plug (final drive)
5. Drain plug (differential) 11. Slack adjuster
6. Drain plug (rear brake)

12 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Rear axle
(with forcible brake cooling system)

1. Rear axle 8. Drain plug (rear brake)

2. Rear differential 9. Drain plug (final drive)
3. Final drive 10. Oil filler plug
4. Rear brake 11. Level plug (rear axle)
5. Block 12. Level plug (final drive)
6. Stainer 13. Slack adjuster
7. Drain plug (differential)

WA600-6 13
SEN02455-01 10 Structure, function and maintenance standard

Differential 1
Front differential

1. Pinion (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 42)

14 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Front differential
(with forcible brake cooling system)

1. Pinion (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 42)

WA600-6 15
SEN02455-01 10 Structure, function and maintenance standard

Rear differential

1. Pinion (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 42)

16 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Rear differential
(with forcible brake cooling system)

1. Pinion (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 42)

WA600-6 17
SEN02455-01 10 Structure, function and maintenance standard

a This diagram shows the front differential mechanism.

18 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance in side bearing outer size clearance limit
Shaft Hole
1 race of differential gear
assembly –0.000 +0.013 0.028 –
225 —
–0.015 –0.016 –0.016
Clearance in side bearing inner
+0.090 –0.000 0.065 –
2 race of differential gear 150 —
+0.065 –0.025 –0.115
assembly
Clearance between differential –0.018 +0.057 0.018 –
3 360 —
carrier and gauge –0.075 –0.000 –0.132
Clearance in outer race of +0.025 +0.020 0.020 –
4 250.825 —
pinion shaft bearing +0.000 –0.027 –0.052
Clearance in inner race of +0.069 +0.025 0.022 –
5 101.6 —
pinion shaft bearing +0.047 –0.000 –0.069
Clearance in outer race of –0.000 +0.033 –0.003 –
6 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of +0.035 –0.000 –0.013 –
7 100 —
pinion shaft bearing +0.013 –0.020 –0.055 Replace
8 End play of pinion gear 0.290
9 Backlash of differential gear 0.25 – 0.33
Standard Tolerance Standard Clearance
Clearance between spider and size Shaft Hole clearance limit
10
differential pinion bushing –0.13 +0.03 0.021 –
46 —
–0.18 –0.02 –0.11
Clearance between spider and –0.13 +0.03
11 52 0.21 – 0.11 —
differential pinion bushing –0.18 –0.02
12 Backlash of bevel gear 0.41 – 0.56
Free rotational torque of bevel
13 6.28 – 18.74 (0.64 – 1.91 kgm)
gear
14 Bevel gear preload 9.81 – 19.61 kN (1,000 – 2,000 kg)
15 Rear runout of bevel gear 0.1
Clearance between bolt and
16 0.08 – 0.13
cap

WA600-6 19
SEN02455-01 10 Structure, function and maintenance standard

a This diagram shows the front differential mechanism.

20 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Unit: mm
No Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of side gear washer
4.0 ±0.05 3.5
2 Thickness of pinion gear washer 3 ±0.08 2.8 Replace
–0.00
3 Wear of oil seal contact surface 110 2.8
–0.08
(1) Press the end of the bolt against the rear of the cap.
(2) In state indicated in (1), turn back the bolt by 20 to 30°.
(3) In the position cited in (2), tighten the nut to fix it in
4 Tightening torque of mounting nut Retighten
place.
Tightening torque of fixed nut:
343 – 441 Nm {35 – 45 kgm}: After adjusting clearance

WA600-6 21
SEN02455-01 10 Structure, function and maintenance standard

Outline While machine is turning

q The power from the engine is transmitted q While the machine is turning, the right and left
through the torque converter, transmission, wheels rotate at different speeds. Accordingly,
and drive shafts to the front and rear axles. pinion gears (4) and side gears (3) in the differ-
q In each axle, the direction of the power is ential assembly rotate and transmit the power
changed by 90° and the rotation speed is of carrier (6) to axle shafts (2), depending on
reduced by bevel pinion (1) and bevel gear (5). the difference in rotation speed between the
Then, the power is transmitted through differ- right and left wheels.
ential mechanism to axle shafts (2).
q The power of the axle shaft is further reduced
in speed by the final drive of the planetary gear
type, and then transmitted to the wheels.

While machine is traveling straight

q While the machine is traveling straight, the
right and left wheels rotate at the same speed.
Accordingly, pinion gears (4) in the differential
assembly do not rotate and the power of car-
rier (6) is transmitted through pinion gears (4)
and side gears (3) to right and left axle shafts
(2) evenly.

22 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Limited slip differential 1

(if equipped)

1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Shaft
7. Side gear
8. Shaft
9. Case
10. Pinion
11. Bevel gear

WA600-6 23
SEN02455-01 10 Structure, function and maintenance standard

a This diagram shows the front differential mechanism.

24 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance in side bearing outer size clearance limit
Shaft Hole
1 race of differential gear
assembly –0.000 +0.013 0.028 –
225 —
–0.015 –0.016 –0.016
Clearance in side bearing inner
+0.090 –0.000 0.065 –
2 race of differential gear 150 —
+0.065 –0.025 –0.115
assembly
Clearance between differential –0.018 +0.057 0.018 –
3 360 —
carrier and gauge –0.075 –0.000 –0.132
Clearance in outer race of +0.025 +0.020 0.020 –
4 250.825 —
pinion shaft bearing –0.000 –0.027 –0.052
Clearance in inner race of +0.069 +0.025 0.022 –
5 101.6 —
pinion shaft bearing +0.047 –0.000 –0.069
Clearance in outer race of –0.000 +0.033 –0.003 –
6 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of +0.035 –0.000 –0.013 –
7 100 —
pinion shaft bearing +0.013 –0.020 –0.055
8 End play of pinion gear 0 – 0.290
9 Backlash of differential gear 0.25 – 0.33
Replace
10 Backlash of bevel gear 0.41 – 0.56
Free rotational torque of bevel
11 6.28 – 18.74
gear
12 Rear runout of bevel gear 0.1
Clearance between stop bolt
13 0.08 – 0.13
and cap
Standard size Tolerance Repair limit
14 Thickness of plate 3.4
±0.02 3.3
3.5
15 Thickness of disc 3.2 ±0.07 3.1
Clearance between disc and
16 0.2 – 0.8
plate (end play)
Standard size Tolerance Repair limit
3.75
17 Thickness of washer
4.0 ±0.05 3.55
4.25
–0.000
18 Wear of oil seal contact surface 110 —
–0.087
(1) Press the end of the bolt against the rear of the cap.
(2) In state indicated in (1), turn back the bolt by 20 to 30°.
Tightening torque of mounting
19 (3) In the position cited in (2), tighten the nut to fix it in place. Retighten
nut
Tightening torque of fixed nut:
343 – 441 Nm {35 – 45 kgm}: After adjusting clearance

WA600-6 25
SEN02455-01 10 Structure, function and maintenance standard

Operation of limited slip differential While machine is traveling straight

The power from the transmission is transmitted 1. When drive forces of right and left wheels
through bevel gear (11), case (9), pressure rings are balanced
(4), shaft (8), pinion (10) to side gears (7), and then [When the road conditions (coefficients of friction)
distributed to the right and left shafts (6). Brake under both wheels and the wheel loads are even
mechanism consisting of disc (2) and plate (3) is and the center of load is at the center of the bucket]
installed to back side of each side gear (7). It gen- The power from the transmission is distributed
erates braking torque in proportion to the torque evenly by the differential gears to the right and left.
transmitted from pressure rings (4) to shaft (8). Under this condition, the slip limits of the right and
Since the brake torque restricts the rotation of side left wheels are the same. Accordingly, when the
gears (7) and case (9), right and left side gears (7) power from the transmission exceeds the slip limits,
cannot rotate freely, thus the operation of the differ- both wheels slip and the differential does not work.
ential is restricted. No load is applied to the brake on the back side of
each side gear.
Mechanism of generation of braking torque by
right and left side gears (7)
Shaft (8) is supported on the cam surfaces made
on the surfaces of pressure rings (4) which are fac-
ing each other. The power (= torque) transmitted
from pressure rings (4) to shaft (8) is transmitted on
the cam surfaces. Force (Fa) to separate both pres-
sure rings (4) is generated by inclination of the cam
surfaces in proportion to the transmitted torque.
Separating load (Fa) acts on the brake on the back
side of each side gear (7) to generate braking
torque.

26 WA600-6
10 Structure, function and maintenance standard SEN02455-01

2. When drive forces of right and left wheels Difference of wheel drive force in each type of dif-
are unbalanced ferential when either wheel slips
[When the road conditions (coefficients of friction)
Wheel drive force
under both wheels and the wheel loads are uneven
(Drive force of slipping wheel is 1)
and either wheel slips more easily]
Example 1: When either wheel is on soft ground in Slipping Locked Total
wheel wheel (Ratio)
digging work
Example 2: When either wheel is on snow and the Limited slip differential 3.64
1 2.64
other one is on asphalt in snow remov- (if equipped) (1.82)
ing work Ordinary differential 1 1 2 (1)
Example 3: When the right and left wheel loads are
unbalanced in travel on a slope On a road where either wheel slips easily, the drive
force of the limited-slip differential is 1.82 times as
The power from the transmission is distributed large as that of the ordinary differential.
evenly by the differential gears to the right and left.
If the distributed drive force limits the wheel slip
limit on the slipping side, the excess of the drive
force is transmitted through the brake on the back
side of the side gear and the case to the brake on
the opposite side (locked side) and given to the
locked wheel.
Only when the excessive drive force exceeds the
braking force, the differential starts working.

While machine is turning

The differential gears in the limited slip differential
operate similarly to those in the ordinary differential.
Accordingly, a difference in rotation speed between
the outer and inner tires necessary for turning is
generated smoothly.

WA600-6 27
SEN02455-01 10 Structure, function and maintenance standard

Final drive 1

1. Axel shaft
2. Sun gear (Number of teeth: 18)
3. Ring gear (Number of teeth: 81)
4. Planetary carrier
5. Planetary gear (Number of teeth: 30)
6. Wheel

28 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Unit: mm
No Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing +0.015 –0.000 –0.020 –
60 —
+0.002 –0.015 –0.030
Clearance between ring gear +0.066 +0.025 –0.009 –
2 266.7 —
hub and bearing +0.034 –0.000 –0.066
Thickness of ring gear mount- Standard size Tolerance Repair limit
3 Replace
ing retainer 22 ±0.1 21.6
Backlash of planetary gear and
4 0.19
sun gear
Backlash of planetary gear and
5 0.20
ring gear
Standard shim thickness of
6 2.3
wheel hub

WA600-6 29
SEN02455-01 10 Structure, function and maintenance standard

Unit: mm
No Check item Criteria Remedy
62.8±4.9 Nm {6.4±0.5 kgm}
Tightening torque of 1st time
7 (Preload 7,845 – 27,459 N {800 – 2,800 kg}) Retighten
mounting bolt
2nd time 279±29.4 Nm {28.5±3.0 kgm}
Standard Tolerance Standard Clearance
Clearance between wheel hub size Shaft Hole clearance limit
8
and bearing +0.051 –0.042 –0.042 –
355.6 —
–0.000 –0.078 –0.129
Replace
Clearance between tube and –0.015 +0.130 0.174 –
9 215.9 —
bearing –0.044 +0.015 0.030
Clearance between wheel hub +0.025 –0.037 –0.037 –
10 285.75 —
and bearing –0.000 –0.069 –0.094

30 WA600-6
10 Structure, function and maintenance standard SEN02455-01

Outline
q Final drive is reduced by the planetary gear
unit in order to gain increased force, and then
drive force is transmitted to the tires.

Operation
q Power transmitted from the differential mecha-
nism to sun gear (2) through axle shaft (1) is
transmitted to planetary gear (5). The plane-
tary gear rotates inside fixed ring gear (3) to
transmit reduced rotation to planetary carrier
(4) and the power is transmitted to wheel (6)
mounted onto the planetary carrier.

WA600-6 31
SEN02455-01

WA600-6 Wheel loader

Form No. SEN02455-01

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)

32
 SEN00404-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Steering system
Steering system .............................................................................................................................................. 4
Steering piping diagram ....................................................................................................................... 4
Steering column ................................................................................................................................... 6
Joystick steering lever linkage ............................................................................................................. 7
Joystick EPC valve............................................................................................................................... 8
Lock valve ............................................................................................................................................ 9
Steering valve..................................................................................................................................... 10
Rotary valve ....................................................................................................................................... 13
Steering control valve......................................................................................................................... 16
Two-way restrictor valve..................................................................................................................... 32
Stop valve........................................................................................................................................... 33
Steering pump .................................................................................................................................... 34
Steering cylinder................................................................................................................................. 48

WA600-6 1
SEN00404-03 10 Structure, function and maintenance standard

Emergency steering piping diagram................................................................................................... 50

Diverter valve ..................................................................................................................................... 51
Emergency steering pump ................................................................................................................. 59

2 WA600-6
10 Structure, function and maintenance standard SEN00404-03

WA600-6 3
SEN00404-03 10 Structure, function and maintenance standard

Steering system 1
Steering piping diagram 1
(Steering wheel specification)

1. Steering cylinder (right) 6. Stop valve (left)

2. Stop valve (right) 7. Steering cylinder (left)
3. Hydraulic tank 8. Accumulator charge valve
4. Steering and fan pump 9. Steering valve (Orbit-roll valve)
5. Steering control valve

4 WA600-6
10 Structure, function and maintenance standard SEN00404-03

AJSS (Advanced Joystick Steering System) specification

1. Steering cylinder (right) a See the “Work equipment hydraulic circuit dia-
2. Hydraulic tank gram”; the steering hydraulic circuit diagram is
3. Steering and fan pump included in the diagram of the work equipment
4. Steering control valve circuit.
5. Steering cylinder (left)
6. EPC valve
7. Accumulator charge valve
8. Rotary valve

WA600-6 5
SEN00404-03 10 Structure, function and maintenance standard

Steering column 1
(Steering wheel specification)

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

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering size clearance limit
Shaft Hole
5 shaft and steering column bear- Replace
ing –0.08 +0.15 –0.05 –
19 0.4
–0.08 –0.05 0.23

6 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Joystick steering lever linkage 1

AJSS (Advanced Joystick Steering System) specification

1. Joystick (steering lever)

2. Potentiometer (lever operating angle)
3. Upper joint
4. Universal joint
5. Lower joint
6. Rotary valve
7. Potentiometer (frame angle)
8. Rod (follow up link)
9. Bracket
10. Steering lock lever
11. Rod
12. Lock valve (steering)
13. Front frame

WA600-6 7
SEN00404-03 10 Structure, function and maintenance standard

Joystick EPC valve 1

AJSS (Advanced Joystick Steering System) specification

1. Minimum pressure assurance pressure reduc- Function

ing valve q EPC valve controls oil supply to the rotary
2. Proportional solenoid valve valve by means of a proportional solenoid
valve controlled by command current from the
machine controller.
C: To rotary valve q Also, the minimum pressure assurance pres-
D: To hydraulic tank sure reducing valve ensures supply of mini-
P1: From EPC pump mum pressure to the rotary valve even if the
P2: From diverter valve proportional solenoid valve fails due to failure
of the controller system.

8 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Lock valve 1
AJSS (Advanced Joystick Steering System)
specification

1. Lever
2. End cap
3. Ball
4. Seat
5. Body

Outline
q The lock valve is installed between the EPC
valve and rotary valve. When the steering lock
lever is set in the “LOCK” position, the lock
valve, interlocked with the steering lock lever,
operates to shut off the oil in the EPC circuit
and disables steering operation.

WA600-6 9
SEN00404-03 10 Structure, function and maintenance standard

Steering valve 1
(Steering wheel specification)

1. Neutral position spring L: To steering cylinder

2. Valve body (To Pb port of steering valve)
3. Check valve P: From PPC pump
4. Spool R: To steering cylinder
5. Sleeve (To Pa port of steering valve)
6. Gear rim T: To hydraulic tank
7. Gear
8. Cover
9. Drive shaft
10. Center pin

10 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Outline Structure
q The steering unit is directly connected to the q Spool (4) is interconnected with the drive shaft
shaft of the steering wheel. The oil from the of the steering wheel and is connected to
PPC pump passes through the steering control sleeve (5) by neutral position spring (1) and
valve, and is switched to the left and right center pin (10) (when the steering wheel is at
steering cylinders to determine the direction of neutral, it does not contact the spool).
travel of the machine. q The top of drive shaft (9) is meshed with center
q The steering unit can be broadly divided into pin (10) and forms one unit with sleeve (5).
the following: spool (4) and sleeve (5), which The bottom is meshed with the spline of gear
have a rotor type direction selection function, (7) of the gear set.
and the gear set (combination of gear (7) and q Valve body (2) has four ports. These are con-
gear rim (6)), which acts as a hydraulic motor nected respectively to the pump circuit, tank
when the steering is operated. circuit, and pilot circuit of the steering demand
valve.
In addition, the port at the pump end and the
port at the tank end are connected by check
valve (3) inside the housing. If there is any fail-
ure in the PPC pump, oil is sucked in directly
from the tank end by the check valve.

WA600-6 11
SEN00404-03 10 Structure, function and maintenance standard

Operation
When turning

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

At neutral

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

12 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Rotary valve 1
AJSS (Advanced Joystick Steering System) specification

1. Neutral position spring T: To hydraulic tank

2. Valve body L: To Pb port of steering control valve
3. Check valve R: To Pa port of steering control valve
4. Spool P: From EPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body

WA600-6 13
SEN00404-03 10 Structure, function and maintenance standard

Outline
q With a steering lever connected on the top, the Structure
rotary valve switches the flow of oil supplied q Spool (4) connects to sleeve (5) through center
from the EPC pump through the EPC valve to pin (10) (which is out of contact with the spool
move the spool of the steering demand valve. when the steering lever is in “neutral“) and
This movement of the spool operates the neutral position spring (1).
steering cylinder to steer the machine. q The top and the bottom of drive shaft (9) are
q On the other hand, the link installed on the engaged with center pin (10) and combined
front frame is connected to the underside of with sleeve (5) and feedback sleeve (7) in one
the rotary valve, which feeds back the steering body.
angle of the machine. q Feedback spool (6) is connected to feedback
This mechanism ensures that the position of sleeve (7) through center pin (10) (which is not
the steering lever always matches the steering in contact with the spool while the steering
position of the machine. wheel is in “neutral“) and loose spring (8).
q Valve body (2) has 4 ports, which are con-
nected to the pump circuit, tank circuit and the
pilot circuit of the steering demand valve
respectively.

14 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Operation
When turning

q When the steering lever is operated, spool (4) overcomes neutral position spring (1) and turns slightly in
relation to sleeve (5). Because of this rotation, the ports of spool (4) and sleeve (5) overlap, so a pas-
sage is formed for the oil to flow, and the oil flows to the steering control valve to steer the machine.

At neutral

q When application of the operating effort on the steering lever is stopped, the return force of neutral posi-
tion spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and
the oil stops flowing.
q When the steering lever is held at a certain angle and the machine is steered to the angle equivalent to
the operating angle of the steering lever (since sleeve (5) turns according to the steering angle of the
machine), spool (4) and sleeve (5) are also returned to the neutral position, and the oil stops flowing.

WA600-6 15
SEN00404-03 10 Structure, function and maintenance standard

Steering control valve 1

(Steering wheel specification)

1. Relief valve A: To steering cylinder

2. Flow control spool B: To steering cylinder
3. Main relief valve P: From steering pump
4. Steering spool Pa: From stop valve
5. Overload relief valve Pb: From stop valve
Pr: To PB port of steering pump
T: To hydraulic tank
Ts: To PLS port of steering pump
Tp: To hydraulic tank

16 WA600-6
10 Structure, function and maintenance standard SEN00404-03

AJSS (Advanced Joystick Steering System) specification

1. Relief valve A: To steering cylinder

2. Flow control spool B: To steering cylinder
3. Main relief valve P: From steering pump
4. Steering spool Pa: From rotary valve
5. Overload relief valve Pb: From rotary valve
Pr: To PB port of steering pump
T: To hydraulic tank
Ts: To PLS port of steering pump
Tp: To hydraulic tank

WA600-6 17
SEN00404-03 10 Structure, function and maintenance standard

(Steering wheel specification) AJSS (Advanced Joystick Steering System)

specification

18 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Steering spool return spring Free length Free length
1 length load load
(Steering wheel specifications)
94.1 N 74.3 N
41.8 37 —
{9.6 kg} {7.6 kg}
Steering spool return spring 94.1 N 74.3 N
1 39.8 35 —
(AJSS specification) {9.6 kg} {7.6 kg}
8.8 N 7.0 N Replace
2 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
372.7 N 297.6 N
3 Flow control valve return spring 85.1 83 —
{38 kg} {30.4 kg}
182.4 N 145.1 N
4 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
8.8 N 7.0 N
5 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}

WA600-6 19
SEN00404-03 10 Structure, function and maintenance standard

Operation of flow amplifier

When spool is at neutral
(When Orbit-roll valve is not in operation)

q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve, steering spool (1) is kept at
neutral by right and left return springs (2).

When spool is in operation

(When oil flows in port (Pa))

q The pressure in port (Pa) rises and steering spool (1) compresses left return spring (2) and moves to the
left.
q The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port
(Pb).
q Since port (Pb) is connected through the Orbit-roll valve to the drain circuit, the oil in port (Pb) is drained.
q Since the pressure generated in port (Pa) is in proportion to the flow rate of the oil, steering spool (1)
moves to a position where the oil pressure reduced by orifice (a) is balanced with the repulsive force of
return spring (2).

20 WA600-6
10 Structure, function and maintenance standard SEN00404-03

When spool is returned

(When steering wheel is stopped)

q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is driven back to neutral by left return spring (2).

WA600-6 21
SEN00404-03 10 Structure, function and maintenance standard

Operation of flow control spool

When steering spool is at neutral position

q The oil from the steering pump flows in port q If the oil pressure in port (Pr) rises above the
(P). set pressure, the swash plate angle of the
q Since notch (e) is closed, the oil pressure in steering pump is reduced to reduce the deliv-
port (P) is increased and then led through ori- ery.
fice (a) to pressure receiving chamber (X) to q If the oil pressure in port (P) keeps rising after
move flow control spool (1) to the left. the delivery of the pump is minimized, flow
q The oil in pressure receiving chamber (Y) is control spool (1) moves to the left further.
drained from port (T1) through orifice (b), notch q If the oil pressure in pressure receiving cham-
(f) and port (T). ber (X) rises above the set pressure, notch (d)
q If the oil pressure in pressure receiving cham- opens and the oil in port (P) is drained through
ber (X) rises above the set pressure, flow con- notch (d) and port (T).
trol spool (1) moves to the left to open notch
(c).
q The oil in port (P) flows through notch (c) and
port (Pr) to the LS valve of the steering pump.
q Port (Pr) is connected through orifice (j) to port
(Tp) and (Ts).
q The oil pressure in port (Pr) is set between the
pump pressure and drain pressure of port (Tp)
because of the passing resistance of notch (c)
and orifice (j).

22 WA600-6
10 Structure, function and maintenance standard SEN00404-03

When steering spool operates

q If steering spool (2) operates, notch (f) closes q The excessive oil from the steering pump is
and pressure receiving chamber (Y) and port drained through notch (d) and port (T).
(T) are disconnected and notch (e) opens. q The oil returning from the steering cylinder is
q The oil pressure in pressure receiving chamber drained through orifice (g) and port (T1).
(Y) rises and flow control spool (1) moves to q Even after flow control spool (1) moves to the
the right and the open area of notch (d) right to close notch (d), it moves further to the
reduces. right, as long as the pressure before notch (e)
q The oil before notch (e) is led to pressure is below the set pressure.
receiving chamber (X) and the oil after notch q Since the open area of notch (c) reduces, the
(e) is led to pressure receiving chamber (Y). oil flow into port (Pr) is reduced and the oil
q If the oil pressure in pressure receiving cham- pressure in port (Pr) lowers.
ber (Y) rises higher than that in port (A), the oil q If the oil pressure in port (Pr) lowers, the LS
flowing from orifice (h) pushes and opens load valve of the steering pump increases the deliv-
check valve (3) to the left. ery of the pump to keep the oil pressure in port
q Since the oil from notch (e) flows through port (Pr) to the set pressure.
(A) to the steering cylinder, a pressure differ- q Flow control spool (1) is held at a position
ence is made between before and after notch where the pressure in port (P) is balanced with
(e). the pressure in port (Pr), thus the delivery of
q Since flow control spool (1) works to keep the the pump is kept constant.
differential pressure between before and after q If the open rate of notch (e) changes, the steer-
notch (e) to the set pressure, the oil is dis- ing pump delivery changes according to it to
charged to the steering cylinder according to keep the oil pressure in port (Pr) constant.
the open rate of notch (e).

WA600-6 23
SEN00404-03 10 Structure, function and maintenance standard

Operation of steering valve

At neutral

q Since the steering wheel is not operated,

steering spool (1) does not move.
q The oil from the steering pump flows in port
(P).
q If the oil pressure in port (P) rises, flow control
spool (2) moves to the left and the oil from the
steering pump is drained through notch (a) and
port (T).

24 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Turning left

q If the steering wheel is turned to the left, the

output pressure from the Orbit-roll valve enters
port (Pa) and steering spool (1) is pushed to
the right.
q The oil from the steering pump flows in port
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (3) is pushed to the left and
opened, conducting oil to the head side of the
left steering cylinder and to the bottom side of
the right steering cylinder to turn the machine
to the left.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(4) and port (T).

WA600-6 25
SEN00404-03 10 Structure, function and maintenance standard

Turning right

q If the steering wheel is turned to the right, the

output pressure from the Orbit-roll valve enters
port (Pb) and steering spool (1) is pushed to
the left.
q The oil from the steering pump flows in port
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (4) is pushed to the right and
opened, conducting the oil flows to the head
side of the right steering cylinder and to the
bottom side of the left steering cylinder to turn
the machine to the right.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(3) and port (T).

26 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Main relief valve

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

Function
q The main relief valve is installed to the steering
valve. It maintains the oil pressure in the steer-
ing circuit to the set pressure during the steer-
ing operation.

WA600-6 27
SEN00404-03 10 Structure, function and maintenance standard

Operation of main relief valve

q If the oil pressure in the steering circuit rises to

the level being set with adjustment screw (1)
and spring (2), pilot poppet (3) opens and the
oil is drained through port (T).
q Pressure balance between receiving chambers
(X) and (Y) is lost and flow control spool (4)
moves to the left.
q As flow control spool (4) operates, the oil from
the steering pump is drained and the pressure
in the steering circuit is kept below the set
pressure.

28 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Overload relief valve Operation

Operation as relief valve

q Port (A) and port (B) are connected to the cyl-

inder circuit and drain circuit, respectively.
q The oil flows through the hole of poppet (1) to
the inside of relief valve poppet (2).
q Check valve poppet (3) and relief valve poppet
(2) are seated securely by the area difference
between diameters (d1) and (d2).

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

Function
q The overload relief valve is installed to the q If the oil pressure in port (A) rises above the
steering valve. It protects the cylinder circuit set pressure of the relief valve, pilot poppet (4)
from abnormally high pressure that can be is pushed and opened to the right.
generated if an impact is applied to the cylinder q The oil flows through pilot poppet (4) and hole
while the steering valve is in neutral. to port (B).
q If abnormally high pressure is generated on
the cylinder side, the overload relief valve
works as a safety valve to prevent breakage of
the cylinder and hydraulic piping.
q If negative pressure is generated on the cylin-
der side, the overload relief valve works as a
suction valve to prevent occurrence of vacuum
in the circuit.

WA600-6 29
SEN00404-03 10 Structure, function and maintenance standard

Operation as suction valve

q As pilot poppet (4) opens, the oil pressure

inside of poppet (1) lowers. q If negative pressure is generated in port (A), it
q Poppet (1) moves to the right to seat pilot pop- acts on the area difference between diameters
pet (4). (d3) and (d4) and pushes and opens check
valve poppet (3) to the right.
q The oil flows through port (B) to port (A) to pre-
vent occurrence of vacuum.

q The oil pressure of inside of relief valve poppet

(2) becomes lower than the oil pressure in port
(A).
q The oil pushes and opens relief valve poppet
(2) to the right and flows through port (A) to
port (B), thus the circuit is protected from
abnormally high pressure.

30 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Relief valve

1. Plug
2. Spring
3. Valve
4. Valve seat

Function
q The relief valve is installed to the steering
valve. If the oil pressure in port (Pr) rises
above the set pressure, the relief valve
relieves the oil to protect the LS circuit of the
steering pump from abnormally high pressure.

WA600-6 31
SEN00404-03 10 Structure, function and maintenance standard

Two-way restrictor valve 1

Operation
q When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and
between poppet (1) and the poppet seat.

1. Two-way restrictor valve

2. Steering control valve

Function
q To reduce the shock caused by the inertia of q When the oil is flowing to arrow i, the oil flows
the machine when the steering is operated, an only from orifice (a) inside poppet (1), so the
orifice is installed in the oil line of the return cir- flow is controlled.
cuit from the cylinder. This applies pressure to
the returning oil, and regulates the movement
of the cylinder piston.

1. Poppet
2. Spring
3. Body

32 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Stop valve 1
(Steering wheel specification)

1. Boot A: From steering valve (Orbit-roll valve)

2. Wiper B: To steering control valve
3. Seal DR: Drain
4. Poppet
5. Spring
6. Spool
7. Spring

WA600-6 33
SEN00404-03 10 Structure, function and maintenance standard

Steering pump 1
Type: HPV125

34 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Outline
q The pump unit is composed of the variable-
capacity swash plate-type piston pump, CO
valve, and LS valve.

PA : Pump discharge port

PB : Pump discharge pressure input port
PC : Pump discharge pressure pick-up port
PD1 : Case drain port
PD2 : Drain plug
PEN : Control pressure pick-up port
PLS : Load pressure input port
PLSC : Load pressure pick-up port
POP : External pilot pressure input port
POPC : External pilot pressure pick-up port
PS : Pump suction port

1. Main pump
2. LS valve
3. CO valve

WA600-6 35
SEN00404-03 10 Structure, function and maintenance standard

1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. CO valve

36 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside each cylinder chamber of cylin-
q Cylinder block (7) is supported to shaft (1) by der block (7) is suctioned and discharged
spline (12). through valve plate (8).
q Shaft (1) is supported by bearings (13) and
(14).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.

WA600-6 37
SEN00404-03 10 Structure, function and maintenance standard

Operation of pump
q Cylinder block (7) rotates together with shaft q Suction and discharge of pressurized oil is not
(1), and shoe (5) slides on flat surface (A). carried out in this state. Namely pumping
q When this happens, rocker cam (4) moves action is not performed. (Actually, however, the
along cylindrical surface (B), so angle (a) swash plate angle is not set to 0)
between center line (X) of rocker cam (4) and
th e axia l d ir ection of cylinde r bloc k ( 7)
changes.
q Angle (a) is called the swash plate angle.

q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.

q As center line (X) of rocker cam (4) matches

the axial direction of cylinder block (7) (swash
plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7)
becomes 0.

38 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) reciprocates straight accord-
ing to the signal pressure of CO and LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).

WA600-6 39
SEN00404-03 10 Structure, function and maintenance standard

1. LS valve

PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Seat
PPL : Load pressure input port 6. Sleeve
PSIG : Drain port 7. Plug
8. Locknut

Function
q The LS (load sensing) valve detects the load
and controls the discharge amount.
q This valve controls the main pump discharge
(Q) with the steering pump signal pressure
(PR).

40 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Operation

1) When the control valve is situated at neutral

q LS valve is a 3-way selector valve, and signal q According to the difference in the areas on
pressure (PR) from the steering valve is led to servo piston (12), the pressure moves in to the
port (H) of sleeve (8). direction of minimizing the swash plate angle.
q Position of spool (6) is determined by the size
of force of spring (4) and the force of signal
pressure (PR) from the steering valve.
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is in neutral when starting
engine, steering valve signal pressure (PR)
reads 1.4 MPa {14 kg/cm2}.
q Spool (6) stops at a position where the open-
ings from port (D) to port (C) and from port (D)
to port (E) are approximately equal.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
q Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.

WA600-6 41
SEN00404-03 10 Structure, function and maintenance standard

2) Action for the direction of maximizing the pump delivery

q If signal pressure (PR) from the steering pump

becomes smaller, spool (6) is pressed to the
left by the force of spring (4).
q As a result of the movement of spool (6), ports
(D) and (E) are connected, then to CO valve.
q CO valve is connected to the drain port, and
the pressure between circuits (D) and (K)
becomes equal to drain pressure (PT). (Opera-
tion of CO valve to be described later on)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the dis-
charge amount larger.

42 WA600-6
10 Structure, function and maintenance standard SEN00404-03

3) Action for the direction of minimizing the pump delivery

q If steering pump signal pressure (PR)

becomes larger, spool (6) is pressed to the
right by the force of signal pressure (PR).
q As a result of the movement of spool (6), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (12) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (12) moves in the direction to minimize
the swash plate angle.

WA600-6 43
SEN00404-03 10 Structure, function and maintenance standard

4) When servo piston is balanced

q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q Combined force of LS valve steering pump sig-
nal pressure (PR) and spring (4) is balanced
and servo piston (12) stops where it is when a
relation of (A0) x (PP) = (A1) x (PEN) is estab-
lished.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.

44 WA600-6
10 Structure, function and maintenance standard SEN00404-03

2. CO valve

PA : Pump port 1. Plug

PDP : Drain port 2. Servo piston assembly
PPL : CO control output port 3. Ball
4. Spool
5. Spring
6. Retainer
7. Cover
8. Spring

Function
q When the pump pressure in the hydraulic cir-
cuit reaches the maximum level, CO (Cut Off)
valve minimizes the pump swash plate angle
and protects the circuit by suppressing the rise
of pressure.
q The minimum pump swash plate angle given
reduces the pump suction torque to improve
fuel economy.

WA600-6 45
SEN00404-03 10 Structure, function and maintenance standard

1) When the actuator load is small and pump discharge pressure (PP) is low

q Spool (3) is positioned closer to the left, and

ports (C) and (D) are connected through inter-
nal passage of spool (3).
q Port (C) of CO valve is connected to port (E) of
LS valve.
q Pump pressure (PP) is present in port (B) and
on the smaller diameter side of servo piston
(9). Port (E) of LS valve has the pressure equal
to that of drain pressure (PT).
q When ports (E) and (G) of LS valve are con-
nected, the pressure on the larger diameter
side of the piston becomes equal to drain pres-
sure (PT), and servo piston (9) moves to the
left.
q The swash plate angle of the pump becomes
larger and the pump discharge increases.

46 WA600-6
10 Structure, function and maintenance standard SEN00404-03

2) When the actuator load is large, and pump discharge pressure (PP) reaches the maximum pressure

q When load is large and pump discharge pres- q As the servo piston moves to the direction to
sure (PP) is high, the force pressing spool (3) minimize the pump swash plate angle, the
to the right becomes larger, and spool (3) pump discharge is reduced accordingly.
moves to the position as shown in the diagram
above.
q Port (C) of CO valve is connected to port (E) of
LS valve.
q Pump pressure (PP) is present in port (B) and
on the smaller diameter side of servo piston
(9).
q Pressure flowing from port (C) to LS valve
becomes main pump pressure (PP) from port
(B).
q When ports (E) and (G) of LS valve are con-
nected, main pump pressure (PP) enters the
larger diameter side of servo piston (9).
q While main pump pressure (PP) is present in
the smaller diameter side of the piston, servo
piston (9) is pressed to the right by its area dif-
ference between the larger and the smaller
diameter sides.

WA600-6 47
SEN00404-03 10 Structure, function and maintenance standard

Steering cylinder 1
Installation of steering cylinder

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering size clearance limit
Shaft Hole
1 cylinder rod and bushing of
frame joint and mounting pin +0.036 +0.207 0.156 –
85 0.7
+0.090 +0.120 0.297
Clearance between steering
+0.036 +0.207 0.156 –
2 cylinder bottom and bushing of 85 0.7
+0.090 +0.120 0.297
frame joint and mounting pin Replace
Standard clearance
Width of bushing Width of hinge
Steering cylinder and front (clearance of a + b)
3
frame joint Max. 0.5 (after
101 ± 2 106 ± 1.5
shim is adjusted)
Steering cylinder and rear Max. 0.5 (after
4 96 ± 1.2 101.5 ± 1
frame joint shim is adjusted)

48 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston rod size Shaft Hole clearance limit Replace pin and
1
and bushing -0.030 +0.279 0.095 – bushing
75 0.655
-0.076 +0.065 0.355
Tightening torque of cylinder
2 270 ± 39.0 Nm {27.5 ± 4.0 kgm}
head
Tightening torque of cylinder
3 294 ± 29.4 Nm {30 ± 3.0 kgm} Retighten
piston
Tightening torque of cylinder
4 58.9 – 73.6 Nm {6–7.5 kgm}
piston lock screw

WA600-6 49
SEN00404-03 10 Structure, function and maintenance standard

Emergency steering piping diagram 1

(Only machine with emergency steering system)

1. Hydraulic tank
2. Steering and fan pump
3. Diverter valve
4. Emergency steering relief valve
5. Check valve
6. Transmission
7. Emergency pump

50 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Diverter valve 1
(Emergency steering) (Only machine with emergency steering system)

1. Check valve A: From emergency pump

2. Check valve B: From emergency pump
3. Check valve D: To hydraulic tank
4. Check valve L: Sensor mounting port
5. Spool P: From steering pump
6. Valve body S: From hydraulic tank
T: To steering control valve

WA600-6 51
SEN00404-03 10 Structure, function and maintenance standard

Function
q In a case where steering is disabled due to
engine stop or pump seizure during machine
traveling, this function enables operation of the
steering wheel, utilizing rotations of the tires
through the transmission to operate the emer-
gency pump.

52 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between body and size Shaft Hole clearance limit
1
spool –0.013 +0.015 0.020 –
40 —
–0.015 +0.007 0.030
Standard size Repair limit
Installed Installed Installed
Free length Free length Replace
2 Spool return spring length load load
216.7 N 205.9 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.6 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}

WA600-6 53
SEN00404-03 10 Structure, function and maintenance standard

(Steering wheel specification)

Operation
q If the pump and engine are normal

q If the steering pump and engine are operating

normally, the steering pump is operated by the
engine, and oil can be sent to the steering
valve, which enables steering.
The emergency pump is operated by the exter-
nal travel force and pushes check valve (2)
open through port (A) of diverter valve (1) and
supplies the oil to port (B).
Spool (3) is pressed to the left as pressure oil
is flowing from the steering pump toward port
(D).
For that reason, oil at port (B) flows to port (C)
to be drained to the hydraulic tank.

54 WA600-6
10 Structure, function and maintenance standard SEN00404-03

q If the machine is running and the pump or engine has failed

q In a case where the machine is running and

the pump or engine has failed, rotations from
the tires operate the emergency pump through
the transmission.
No pressure oil appears at port (D) because
the steering pump is not operating. For that
reason, spool (3) is pressed by spring (4) to
the right.
Oil from the emergency pump goes through
port (A) and port (B), and then flows to the
rotary valve and the steering valve, enabling
steering.
a The emergency pump is enabled for normal
and reverse rotations.

WA600-6 55
SEN00404-03 10 Structure, function and maintenance standard

AJSS (Advanced Joystick Steering System) specification

Operation
q If the pump and engine are normal

q If the steering pump and engine are operating

normally, the steering pump is operated by the
engine, and oil can be sent to the steering
valve, which enables steering.
The emergency pump is operated by the exter-
nal travel force and pushes check valve (2)
open through port (A) of diverter valve (1) and
supplies the oil to port (B).
Spool (3) is pressed to the left as pressure oil
is flowing from the steering pump toward port
(D).
For that reason, oil at port (B) flows to port (C)
to be drained to the hydraulic tank.

56 WA600-6
10 Structure, function and maintenance standard SEN00404-03

q If the machine is running and the pump or engine has failed

q In a case where the machine is running and

the pump or engine has failed, rotations from
the tires operate the emergency pump through
the transmission.
No pressure oil appears at port (D) because
the steering pump is not operating. For that
reason, spool (3) is pressed by spring (4) to
the right.
Oil from the emergency pump goes through
port (A) and port (B), and then flows to the
rotary valve and the steering valve, enabling
steering.
a The emergency pump is enabled for normal
and reverse rotations.

WA600-6 57
SEN00404-03 10 Structure, function and maintenance standard

Emergency steering relief valve

(Only machine with emergency steering sys- q When the pressure inside ports (A) and (B)
tem) reaches the pressure set by the poppet spring
(set pressure), pilot poppet (3) opens and the
hydraulic pressure at port (B) escapes from
port (D) to port (C). This lowers the pressure at
port (B).

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw q When the pressure at port (B) drops, the orifice
Set pressure: 20.6 MPa {210 kg/cm2} of main valve (1) generates a difference in
pressure between port (A) and port (B). Main
Function valve (1) is opened by the pressure at port (A)
Compared to the steering control valve relief pres- and the oil at port (A) is relieved.
sure of 34.3 MPa {350 kg/cm2}, the rated pressure
of the emergency steering pump and diverter valve
are both 20.6 MPa {210 kg/cm2}. Therefore, to pro-
tect the emergency steering pump and diverter
valve, there is a relief valve in the piping from the
diverter valve to the steering valve. When the emer-
gency steering is being operated, and the hydraulic
pressure generated by the steering exceeds 20.6
MPa {210 kg/cm2}, the relief valve is actuated.

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

58 WA600-6
10 Structure, function and maintenance standard SEN00404-03

Emergency steering pump 1

(Only machine with emergency steering system)
SAM(3)100

Unit: mm
No. Check item Criteria Remedy
Standard
Clearance between body and Type Tolerance
1 clearance
spool
SAM(3)-100 0.10 – 0.15 0.19
Clearance between inside
2 diameters of plain bearing and SAM(3)-100 0.020 – 0.043 0.075 Replace
gear shaft
Type Standard size Tolerance Repair limit
3 Driven depth of pin –0.5
SAM(3)-100 14
–0.5
4 Rotation torque of spline shaft 6.86 – 11.8 Nm{0.7 – 1.2 kgm}
Discharge Standard Allowable
Speed pressure
Type discharge discharge
Discharge oil: EO10-CD (rpm) (MPa —
— {kg/cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
20.6
SAM(3)-100 2,500 214 189
{210}

WA600-6 59
SEN00404-03

WA600-6 Wheel loader

Form No. SEN00404-03

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10

60
 SEN00405-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Brake system
Brake system .................................................................................................................................................. 2
Brake piping diagram ........................................................................................................................... 2
Brake.................................................................................................................................................... 4
Brake valve .......................................................................................................................................... 8
Accumulator charge valve.................................................................................................................. 16
EPC relief valve.................................................................................................................................. 22
Accumulator (for brake)...................................................................................................................... 24
Slack adjuster..................................................................................................................................... 26
Parking brake ..................................................................................................................................... 30
Parking brake solenoid valve ............................................................................................................. 32
Emergency parking brake release valve ............................................................................................ 34
Brake cooling pump ........................................................................................................................... 35

WA600-6 1
SEN00405-01 10 Structure, function and maintenance standard

Brake system 1
Brake piping diagram 1

1. Front brake (right) 8. Rear brake (left)

2. Slack adjuster (front) 9. Front brake (left)
3. Hydraulic tank 10. Accumulator charge valve
4. Brake EPC pump 11. Accumulator
5. Transmission control valve 12. Brake valve (right)
6. Rear brake (right) 13. Brake valve (left)
7. Slack adjuster (rear)

2 WA600-6
10 Structure, function and maintenance standard SEN00405-01

WA600-6 3
SEN00405-01 10 Structure, function and maintenance standard

Brake 1

1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc

4 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
9 Return spring length load load
725 N 689 N
104.8 91.5 102.7
{73.9 kg} {70.2 kg}
Standard size Tolerance Repair limit
10 Thickness of plate
2.4 — 2.15
11 Thickness of disc 5.1 — 4.6
Assembled thickness of plate
12 84.9 — 79.4
discs
–0.155 Replace
13 Wear of seal contact surface 430 —
–0.155
Wear of piston seal contact sur- +0.097
14 420 —
face +0.097
Wear of piston seal contact sur- +0.097
15 465 —
face +0.097
Strain of plate and disc contact Standard strain Repair limit
16
surface Max. 0.5 0.7
Backlash of outer gear and
17 0.24 – 0.72
plate
18 Backlash of inner gear and disc 0.19 – 0.62

WA600-6 5
SEN00405-01 10 Structure, function and maintenance standard

Function
q All the 4 wheels are equipped with a main
brake, which is a wet-type multi-disc brake.

q When the brake pedal is pressed down, pres-

sure oil from the slack adjuster moves brake
piston (4) in the direction shown by an arrow
mark to press disc (8) to contact plate (7). This
generates friction force between the disc and
the plate. While the wheel is rotating with the
disc, this friction causes the machine to slow
down and stop.

q When the brake pedal is released, back pres-

sure on brake piston (4) is released and force
of return spring (2) moves the piston in the
direction shown by an arrow mark to release
the brake.

6 WA600-6
SEN00405-01 10 Structure, function and maintenance standard

Brake valve 1
Brake valve (Left)

1. Brake pedals
2. Rod
3. Spool
4. Cylinder

A: To pilot port
P1: From accumulator charge valve
PA: From transmission modulation clutch ECMV
T1: Drain port
T2: To transmission tank

8 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bevel size Shaft Hole clearance limit
5
mounting hole and pin –0.01 +0.022 0.112 –
φ10 0.25
–0.09 +0.022 0.01
Clearance between roller and –0.01 +0.022 0.112 –
6 φ10 0.25
pin –0.09 +0.022 0.01
Standard size Tolerance Repair limit
7 Outside diameter of roller
25.5 ±0.1 25.1
Standard size Repair limit
Installed Installed Installed
Free length Free length Replace
8 Control spring length load load
72 N
27.7 26.5 26.7 —
{7.4 kg}
60.4 N
9 Control spring 42.4 39 41.4 —
{6.2 kg}
19.6 N
10 Control spring 50.4 49.5 49.4 —
{2.0 kg}
57.9 N
11 Return spring 56.9 52.4 51 —
{5.9 kg}
24.5 N
12 Return spring 35.3 17.2 32 —
{2.5 kg}

WA600-6 9
SEN00405-01 10 Structure, function and maintenance standard

Brake valve (right)

1. Brake pedals A: To rear brake

2. Rod B: To front brake
3. Piton and pilot PA: From accumulator charge valve
4. Spool PB: From accumulator charge valve
5. Cylinder, upper PP: From pilot port
6. Spool T: Drain port
7. Cylinder, lower

10 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bevel size Shaft Hole clearance limit
8
mounting hole and pin –0.025 –0.1 0.025 –
φ10 0.25
–0.075 –0.1 0.175
Clearance between roller and –0.025 +0.1 0.025 –
9 φ10 0.25
pin –0.075 +0.1 0.175
Standard size Tolerance Repair limit
10 Outside diameter of roller –0.5
30 29.2
–0.5
Standard size Repair limit
Installed Installed Installed Replace
Free length Free length
11 Control spring length load load
7.66 N
34 3.0 33 —
{0.781 kg}
0N
12 Control spring 46 46 45 —
{0 kg}
60.8 N
13 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
14 Return spring 31.5 19.5 28 —
{1.7 kg}
17.7 N
15 Return spring 17 16.5 16 —
{1.8 kg}

WA600-6 11
SEN00405-01 10 Structure, function and maintenance standard

Outline
q There are 2 brake valves installed in parallel to
front lower part of the operator's seat. They are
operated by pressing the pedal.
q If the right pedal is pressed, the oil is supplied
to the brake cylinder to operate the brake.
q If the left pedal is pressed, the oil is supplied to
the right pedal and the brake is operated simi-
larly to when the right pedal is pressed.
q If the left brake pedal is pressed down, the
modulation clutch pressure is reduced to
reduce the drive force of the tires according to
the pressing angle of the pedal.

Operation
When brake is applied (right brake valve)
Upper section
q If pedal (1) is pressed, the pressing effort is
transmitted through rod (2) and spring (4) to
spool (3). If spool (3) lowers, drain port (a) is
closed and the oil from the pump and accumu-
lator flows through port (A) to port (C) to oper-
ate the rear brake cylinder.

Lower section
q If pedal (1) is pressed, the pressing effort is
transmitted through rod (2) and spring (4) to
spool (3). When spool (3) lowers, the force is
transmitted through plunger (6) to cause spool
(5) to go down. As a result, drain port (b) is
closed and the oil from the pump and accumu-
lator flows through port (B) to port (D) to oper-
ate the front brake cylinder.

12 WA600-6
10 Structure, function and maintenance standard SEN00405-01

When brake is applied (left brake valve)

q If pedal (7) is stepped down, the stepping force
pushes spool (10) down through rod (8) and
spring (9) to close drain port (c). The oil from
the pump and accumulator flows through port
(E) to port (F).
q Since port (F) of the left brake valve is con-
nected to port (PP) of the right brake valve by
the hose, the oil flowing to port (F) flows further
to pilot port (PP) of the right brake valve.
q The oil flowing to pilot port (PP) flows further
through orifice (d) to port (G) and pushes pilot
piston (11) down. It then pushes down spool
(3) through spring and performs the same
operation as that caused by stepping down the
right brake valve.
q When rod (8) is pushed down, the notch of rod
(8) opens to cause oil for the modulation clutch
to flow from port (L) to port (M), and then is
drained. This lowers pressure of the modula-
tion clutch, and drive force transmitted from the
engine to the tires continuously lowers accord-
ing to the stepping angle of the pedal.

WA600-6 13
SEN00405-01 10 Structure, function and maintenance standard

Operation of brake when upper valve has trouble Lower section

(right brake valve) q At the same time when spool (3) in the upper
q Even if the oil leaks from the piping on the section goes upward and port (A) is discon-
upper side, if pedal (1) is pressed, spool (5) is nected from port (C), the front brake cylinder is
moved mechanically and the brake on the also filled with oil and the oil pressure rises
lower side operates normally. between port (B) and port (D). Then, oil enter-
The upper side brake does not operate. ing port (J) through orifice (f) of spool (5)
pushes up spool (5) as much as the amount of
Operation of brake when lower valve has trouble movement of spool (3) to disconnect the port
(right brake valve) (B) from port (D). Also, as drain port (b)
remains closed and the oil entering the brake
q Even if the oil leaks from the piping on the
cylinder is retrained there to maintain the brake
lower side, the brake on the upper side oper-
in operation.
ates normally.
q The pressure in the upper section is balanced
with the pedal pressing force and the pressure
in the lower section is balanced with the pres-
sure in the upper section. When spools (3) and
(5) move in full stroke, the line is fully open
between ports (A) and (C) and ports (B) and
(D). Thus, the pressure in the upper and lower
sections and the oil pressure in the right and
left brake cylinders become the same as the oil
pressure from the pump.
Therefore, until the piston moves in full stroke,
the effect of the brake can be adjusted by the
degree of stepping on the pedal.

Balancing operation
Upper section
q When the rear brake cylinder is filled with oil
and the oil pressure rises between port (A) and
port (C), oil entering port (H) from orifice (e) of
spool (3) resists spring (4) and pushes up
spool (3) to disconnect port (A) from port (C).
At this time, drain port (a) remains closed and
the oil entering the brake cylinder is retrained
there to maintain the brake in operation.

14 WA600-6
10 Structure, function and maintenance standard SEN00405-01

When brake is released (right brake valve)

Upper section
q When pedal (1) is released and the stepping
force is removed from the upper section of the
spool, back pressure from the brake cylinder
and the spool return spring raise spool (3) to
release drain port (a). Oil from the brake cylin-
der flows to the hydraulic tank return circuit to
release the rear brake.

Lower section
q When the pedal is released, spool (3) of the
upper section moves upward and at the same
time, back pressure from the brake cylinder
and the spool return spring move spool (5) to
release drain port (b). Then, oil from the brake
cylinder flows to the tank return circuit to
release the front brake.

WA600-6 15
SEN00405-01 10 Structure, function and maintenance standard

Accumulator charge valve 1

A1: To steering valve (steering wheel specification)

A1: To EPC valve (AJSS specification)
A2: To work equipment valve
ACC1: To right brake valve port PB
To left brake valve port P1
ACC2: To right brake valve port PA
P1: From pump
PP1: To right brake valve port PB
To left brake valve port P1
T: Drain

16 WA600-6
10 Structure, function and maintenance standard SEN00405-01

1. Valve body Function

2. Main relief valve (R3) q The accumulator charge valve keeps the oil
3. Relief valve (R1) pressure from the pump to the set pressure
4. PPC relief valve (R2) and stores it in the accumulator.
(steering wheel specification) q If the oil pressure rises above the set pressure,
4. EPC relief valve (R2) (AJSS specification) the oil from the pump is led to the drain circuit
5. Relief valve (H1) to reduce the load on the pump.

WA600-6 17
SEN00405-01 10 Structure, function and maintenance standard

(Steering wheel specification)

Operation 2. When oil is supplied to accumulator
1. When oil is not supplied to accumulator 1) Cut-in state
(cut-out state) q If the pressure at port (B) drops below the
q Since the pressure at port (B) is higher set pressure of relief valve (R1), piston (2)
than the set pressure of relief valve (R1), is returned downward by the tension of
piston (2) is forced to move upward by the spring (8). This causes valve seat (9) to
hydraulic pressure of port (B). As this closely contact poppet (1) to disconnect
move opens poppet (1), port (C) and port port (C) from port (T).
(T) are shorted. q The right-hand side spring chamber of
q As the rightmost spring chamber of spool spool (6) also gets shuttered off from port
(6) leads to port (C) of relief valve (R1), (T) to increase pressure, leading to pres-
tank pressure prevails. sure at port (P) to rise as well.
q Oil from the pump enters port (P) and q When pressure at port (P) exceeds the
pushes spool (6) to the right with a low pressure at port (B) (accumulator pres-
pressure equivalent to the load of spring sure), oil supply to the accumulator starts.
(5) and then flows from port (A) to the This timing is determined by the area size
EPC valve and the work equipment valve. of orifice (7) and pressure differential
At the same time, it flows to the tank before and after (equivalent to the load of
through orifices (7), (4) and (3). spring (5)). A fixed amount of oil is sup-
plied regardless of the engine speed, and
the remaining amount flows to port (A).

18 WA600-6
10 Structure, function and maintenance standard SEN00405-01

2) When pressure reaches cut-out pressure 3. Safety relief valve (R3)

q When pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure for rises above the set pressure for relief
relief valve (R1), poppet (1) leaves valve valve (R3), the oil from the pump resists
seat (9) to generate a flow of oil, creating spring (10) and pushes ball (11) upward to
relief operation. cause oil to flow into the tank circuit, thus
q The relief operation creates vertical pres- protecting the circuit by defining the maxi-
sure differential for piston (2). Thus, piston mum pressure for the brake circuit.
(2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
q As the rightmost spring chamber of spool
(6) leads to port (C) of relief valve (R1),
tank pressure prevails.
q Since the pressure at port (P) also drops
to the level equivalent to the load of spring
(5), oil supply to port (B) is stopped as
well.

WA600-6 19
SEN00405-01 10 Structure, function and maintenance standard

AJSS (Advanced Joystick Steering System) 2. When oil is supplied to accumulator

specification 1) Cut-in state
Operation q If the pressure at port (B) drops below the
set pressure of relief valve (R1), piston (2)
1. When oil is not supplied to accumulator
is returned downward by the tension of
(cut-out state)
spring (8). This causes valve seat (9) to
q Since the pressure at port (B) is higher
closely contact poppet (1) to disconnect
than the set pressure of relief valve (R1),
port (C) from port (T).
piston (2) is forced to move upward by the
q The right-hand side spring chamber of
hydraulic pressure of port (B). As this
spool (6) also gets shuttered off from port
move opens poppet (1), port (C) and port
(T) to increase pressure, leading to pres-
(T) are shorted.
sure at port (P) to rise as well.
q As the rightmost spring chamber of spool
q When pressure at port (P) exceeds the
(6) leads to port (C) of relief valve (R1),
pressure at port (B) (accumulator pres-
tank pressure prevails.
sure), oil supply to the accumulator starts.
q Oil from the pump enters port (P) and
This timing is determined by the area size
pushes spool (6) to the right with a low
of orifice (7) and pressure differential
pressure equivalent to the load of spring
before and after (equivalent to the load of
(5) and then flows from port (A) to the
spring (5)). A fixed amount of oil is sup-
EPC valve and the work equipment valve.
plied regardless of the engine speed, and
At the same time, it flows to the tank
the remaining amount flows to port (A).
through orifices (7), (4) and (3).

20 WA600-6
10 Structure, function and maintenance standard SEN00405-01

2) When pressure reaches cut-out pressure 3. Safety relief valve (R3)

q When pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure for rises above the set pressure for relief
relief valve (R1), poppet (1) leaves valve valve (R3), the oil from the pump resists
seat (9) to generate a flow of oil, creating spring (10) and pushes ball (11) upward to
relief operation. cause oil to flow into the tank circuit, thus
q The relief operation creates vertical pres- protecting the circuit by defining the maxi-
sure differential for piston (2). Thus, piston mum pressure for the brake circuit.
(2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
q As the rightmost spring chamber of spool
(6) leads to port (C) of relief valve (R1),
tank pressure prevails.
q Since the pressure at port (P) also drops
to the level equivalent to the load of spring
(5), oil supply to port (B) is stopped as
well.

WA600-6 21
SEN00405-01 10 Structure, function and maintenance standard

EPC relief valve 1

1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw

Function
q The EPC relief valves are located between the
EPC brake pump and the EPC valve and
between work equipment units. When the EPC
valve is not operating, or when any abnormal
pressure has occurred in the EPC circuit, oil
from the pump is relieved from this valve in
order to protect the pump and the circuit from
damage.
a For the steering wheel specification model,
read “EPC” as “PPC”.

22 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Operation
q The relief valve is installed on the charge q When pressure at port (B) drops, the orifice of
valve. Port (A) is connected to the pump cir- main valve (1) functions so as to allow pres-
cuit, and port (C), to the drain circuit. sure differential to occur at ports (A) and (B),
Oil runs through the orifice of main valve (1) causing main valve (1) to open due to pressure
and fills port (B). from port (A) and oil in port (A) is drained to
Pilot poppet (4) is seated on the valve seat (3). port (C) for relief.
q When pressure at ports (A) and (B) reaches
the set pressure, pilot poppet (4) opens and oil
pressure at port (B) is carried from port (D) to
port (C), causing pressure at port (B) to drop.

WA600-6 23
SEN00405-01 10 Structure, function and maintenance standard

Accumulator (for brake) 1

1. Valve
2. Top cover
3. Cylinder
4. Piston

Function Specifications
q The accumulator is installed between the Gas used: Nitrogen gas
charge valve and brake valve. The space Amount of gas: 6,000 cc
between cylinder (3) and free piston (4) is filled Charge pressure:
with nitrogen gas. The nitrogen gas absorbs 3.4 ± 0.15 MPa {35 ± 1.5 kg/cm2} (at 50°C)
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine stops by utilizing
its compressibility.

24 WA600-6
SEN00405-01 10 Structure, function and maintenance standard

Slack adjuster 1

1. Cylinder Function
2. Check valve q The slack adjuster is installed on the brake oil
3. Piston line leading to the brake piston from the brake
4. Spring valve, and functions to keep the time lag during
5. Bleeder brake operation at a fixed level.

A: Inlet port
B: Outlet port

26 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between body and size Shaft Hole clearance limit
6
piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Standard size Repair limit Replace
Installed Installed Installed
Free length Free length
7 Slack adjuster spring length load load
49 N
198 90 181 —
{5.0 kg}

WA600-6 27
SEN00405-01 10 Structure, function and maintenance standard

Operation
1. When the brake pedal is pressed down
q Before the brake is pressed down, piston (4) is
restored as much as the amount of stroke (S)
(a full stroke). When the brake pedal is
pressed down, oil discharged from the brake
valve branches into right and left cylinders (2)
from port (P) of the slack adjuster to move pis-
ton (4) as much as the amount of stroke (S) to
the right and the left.

2. When the brake pedal is released

q When the brake is released, return spring (8)
of the brake restores piston (4) as much as the
amount of oil of stroke (S) and the brake
returns to its released state. In other words,
return stroke (T) of brake piston (7) depends
on the amount of oil of stroke (S) and the brak-
ing time lag stays the same regardless of the
amount of wear of the brake disc.
q This move causes brake piston (7) to move as
much as stroke (S). At this time, the relation-
ship between brake piston (7) and the disc is
simply that the clearance is reduced to zero,
and no braking force is generated.

q As the brake valve is kept pressed down fur-

ther, oil pressure from the brake valve exceeds
the specified to open check valve (3) and port
(C) is imposed pressure to function as braking
force.
Thus, the time lag when the brake is in opera-
tion is maintained the same.

28 WA600-6
SEN00405-01 10 Structure, function and maintenance standard

Parking brake 1

1. Output shaft Outline

2. Spring (outside) q The parking brake is a wet-type multi-disc
3. Spring (inside) brake, which is operated mechanically with the
4. Piston spring and stops output shaft (1).
5. Parking brake oil port q The tension of springs (2) and (3) presses disc
6. Plate (7) against plate (6) with piston (4) to stop out-
7. Disc put shaft (1).
8. Wave spring q When releasing, the oil pressure from parking
brake oil port (5) operates piston (4) to release
the pressing force being applied to disc (7) and
plate (6).

30 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed Installed
Free length Free length
9 Parking brake spring (outside) length load load
1,266 N 1,203 N
94 72.6 91.2
{129.2 kg {122.7 kg}
662 N 630 N
10 Parking brake spring (inside) 94 72.6 91.2
{67.6 kg} {64.2 kg}
Standard size Tolerance Repair limit Replace
Thick-
11 Plate 4.0 ±0.05 3.9
ness
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
Load of wave spring 626.4 N ±176.5 N 533 N
13
(testing height: 3.2 mm) {63.9 kg} {±18 kg} {54.3 kg}

WA600-6 31
SEN00405-01 10 Structure, function and maintenance standard

Parking brake solenoid valve 1

1. Movable core
2. Coil
3. Push pin
4. Spring
5. Spool
6. Block
7. Check valve

32 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Operation

When parking brake is applied (when solenoid When parking brake is released (when solenoid
is de-energized) is energized)

q If the parking brake switch is turned “ON”, the q If the parking brake switch is turned “OFF”, the
solenoid is turned “OFF”. As the result, spool solenoid is turned “ON” and spool (1) is moved
(1) is pushed back in the left direction by the rightward. Accordingly, the pressurized oil from
tension of spring (2). Accordingly, pump port the pump flows to the parking brake through
(P) is disconnected from parking brake port port (P), inside of spool (1) and port (A). At the
(A), stopping flow of the pressurized oil from same time, port (T) is closed and the oil is not
the pump to the parking brake. drained. As a result, the spring in the parking
q At the same time, the oil from the parking brake is pushed back by the oil pressure and
brake is drained through ports (A) and (T). As the parking brake is released.
a result, the disc in the parking brake is
pressed by the spring and the parking brake is
applied.

WA600-6 33
SEN00405-01 10 Structure, function and maintenance standard

Emergency parking brake release valve 1

Operation
q When parking brake emergency release switch
(1) is turned to “ON”, solenoid valve (2) starts
operating. and oil pressure from accumulator
(3) enters port (P) . Then pilot press ur e
switches the circuit, and the pressure moves to
the parking brake from port (A) to release the
parking brake.

1. Valve
2. Solenoid valve

A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake (accumulator circuit)

Function
q The emergency release solenoid valve is
installed between the transmission and trans-
mission control. It operates solenoid of the
parking brake release switch installed at the
operator's seat when oil pressure is not avail-
able from the transmission pump due to engine
failure, etc. in order to supply accumulator
charge pressure in the brake circuit to the
parking brake cylinder.

34 WA600-6
10 Structure, function and maintenance standard SEN00405-01

Brake cooling pump 1

SAL(1)22+22
(If equipped)

Unit: mm
No. Check item Criteria Remedy
Type Tolerance Repair limit
Clearance between body
1 SAL(1)-22
and spool 0.10 – 0.15 0.19
SAL(1)-22
Clearance between inside SAL(1)-22
2 diameters of plain bearing 0.06 – 0.119 0.20 Replace
and gear shaft SAL(1)-22
Type Standard size Tolerance Repair limit
3 Driven depth of pin SAL(1)-22 0
10 —
SAL(1)-22 –0.5
Rotation torque of spline
4 3.9 – 9.8 Nm {0.4 – 1.0 kgm}
shaft
Discharge Standard Allowable
Speed
Type pressure discharge discharge —
Discharge oil: EO10-CD (rpm)
— (MPa {kg/cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
SAL(1)-22
3,500 20.6 {210} 73.1 67.5
SAL(1)-22

WA600-6 35
SEN00405-01

WA600-6 Wheel loader

Form No. SEN00405-01

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

36
 SEN00406-00

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Axle mount ........................................................................................................................................... 2
Center hinge pin................................................................................................................................... 7

WA600-6 1
SEN00406-00 10 Structure, function and maintenance standard

Undercarriage and frame 1

Axle mount 1

2 WA600-6
10 Structure, function and maintenance standard SEN00406-00

1. Front axle Front axle

2. Rear axle q Front axle (1) is directly fixed to front frame (4)
3. Rear frame with axle mount bolt (5) as it is directly sub-
4. Front frame jected to the working force.
5. Axle mount bolt
Rear axle
q Rear axle (2) has swaying structure at the cen-
ter of rear axle to enable each tire to make
contact with the ground during travel on a soft
ground.

WA600-6 3
SEN00406-00 10 Structure, function and maintenance standard

4 WA600-6
10 Structure, function and maintenance standard SEN00406-00

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between shaft and size clearance limit
Shaft Hole
1 hole on front support side
(before press fitting bushing) –0.062 +0.381 0.128 –
350 1.0
–0.151 +0.066 0.582
Clearance between shaft and
+2.5 +0.089 –0.911 –
2 hole on front support side 360 —
+1.0 –0.000 –2.5
(before press fitting bushing)
Clearance between shaft and
–0.056 +0.381 0.117 –
3 hole on rear support side 310 1.0
–0.137 +0.061 0.518
(before press fitting bushing)
Replace
Clearance between shaft and
+2.5 +0.089 –0.911 –
4 hole on rear support side 320 —
+1.0 –0.000 –2.5
(before press fitting bushing)
Standard size Tolerance Repair limit
5 Thickness of thrust plate –0.25
27.6 —
–0.39
+0.3
6 Thickness of thrust washer 5 1.3
–0.1
7 Thickness of rear bushing 4.9 ±0.1 —
8 Thickness of front bushing 4.9 ±0.1 —

WA600-6 5
10 Structure, function and maintenance standard SEN00406-00

Center hinge pin 1

1. Front axle Outline

2. Front frame q Front frame (2) and rear frame (3) are coupled
3. Rear frame with each other by the bearing with center
4. Rear axle hinge pins (5) and (6).The steering cylinders
5. Upper hinge pin connect the left and right front frame and rear
6. Lower hinge pin frame. They adjust the bending angle of the
frame, or the turning radius of the machine.

WA600-6 7
SEN00406-00 10 Structure, function and maintenance standard

8 WA600-6
10 Structure, function and maintenance standard SEN00406-00

Unit: mm
No. Item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper size Shaft Hole clearance limit
7
hinge pin and rear frame –0.25 –0.15
140 0 – 0.15 —
–0.30 –0.25
Clearance between upper –0.101 –0.00 0.051 –
8 108 1.0
hinge pin and spacer (small) –0.152 –0.05 0.152
Clearance between upper –0.051 +0.025 0.051 –
9 107.95 1.0
hinge pin and bearing –0.102 –0.000 0.127
Clearance between upper –0.101 –0.00 0.051 –
10 108 1.0
hinge pin and bushing –0.152 –0.05 0.152
Clearance between rear frame –0.250 –0.150
11 140 0.05 – 0.15 —
and bushing –0.300 –0.200
Clearance between front frame –0.000 –0.077 –0.127 –
12 160 —
and lower hinge bearing –0.025 –0.127 –0.052
Clearance between lower hinge –0.076 +0.025 0.056 – Replace
13 100 —
pin and bushing –0.127 –0.020 0.152
Clearance between lower hinge –0.076 –0.000 0.056 –
14 100 1.0
pin and bearing –0.127 –0.020 0.127
Clearance between front frame +0.025 –0.051 –0.127 –
15 212.725 —
and upper hinge bearing –0.000 –0.102 –0.051
Clearance between lower hinge +0.013 +0.076
16 147 0 – 0.088 —
rear frame and bushing –0.012 +0.013
Clearance in seal fitting part of +0.28 +0.025 –0.310 –
17 117.45 —
lower hinge +0.18 –0.030 –0.155
Clearance in seal fitting part of +0.26 +0.063 –0.260 –
18 180 —
upper hinge pin +0.16 –0.000 –0.097
Standard size Tolerance Repair limit
19 Height of upper hinge bushing
43.9 ±0.1 —
20 Height of upper hinge bushing 89.8 ±0.1 —
Standard thickness of shim
21 between upper hinge and 2.4
retainer
Standard thickness of shim
22 between upper hinge and 2.2
retainer
Standard thickness of shim
23 between lower hinge and 1.0
retainer Adjustment

Tightening torque of upper 68.8 Nm {7 kgm} (When shim is adjusted)

24
hinge retainer mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)
Tightening torque of upper 279±29.4 Nm {28.5 ± 3 kgm} (When shim is adjusted)
25
hinge retainer mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)
Tightening torque of lower 34.3 Nm {3.5 kgm} (When shim is adjusted)
26
hinge pin mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)

WA600-6 9
SEN00406-00

WA600-6 Wheel loader

Form No. SEN00406-00

© 2005 KOMATSU
All Rights Reserved
Printed in Japan 11-05 (01)

10
 SEN00407-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Hydraulic piping diagram...................................................................................................................... 2
Work equipment control lever linkage .................................................................................................. 4
Hydraulic tank ...................................................................................................................................... 6
Work equipment hydraulic pump.......................................................................................................... 8

WA600-6 1
SEN00407-01 10 Structure, function and maintenance standard

Hydraulic system, Part 1 1

Hydraulic piping diagram 1

1. Hydraulic tank 10. EPC valve

2. Triple pump 11. Accumulator
(Power train + Hydraulic oil cooling + Brake and 12. Charge valve
EPC pump) (Built-in EPC relief valve)
3. Tandem pump 13. Oil cooler
(Work equipment + Work equipment pump)
4. Tandem pump
(Steering + Cooling fan pump)
5. Bucket cylinder
6. Steering control valve
7. Steering cylinder
8. Work equipment valve
9. Lift cylinder

2 WA600-6
10 Structure, function and maintenance standard SEN00407-01

WA600-6 3
SEN00407-01 10 Structure, function and maintenance standard

Work equipment control lever linkage 1

1. Lift arm control lever

2. Bucket control lever
3. Hold switch
4. Subtotal switch (Load meter specifications)
5. Work equipment lock lever
6. R.H. console forward-reverse slide lever
7. Armrest adjustment lever
8. Kickdown switch
9. Cancel switch (Load meter specifications)
10. Armrest
11. Work equipment EPC valve

4 WA600-6
SEN00407-01 10 Structure, function and maintenance standard

Hydraulic tank 1

1. Filter bypass valve A: Emergency steering suction port

2. Oil filter B: Emergency steering return port
3. Hydraulic tank C: Hydraulic oil cooler and steering return port
4. Oil level sight gauge D: EPC pump suction port
5. Breather E: Steering drain port
6. Oil filler point F: Pump case drain port
7. Strainer G: Main return port
H: Brake drain port

6 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Operation of oil filter bypass valve Breather

q In the case the filters are clogged
Bypass valve (1) opens, and oil returns to the
tank bypassing the filters.
Bypass valve set pressure:
0.15 MPa {1.5 kg/cm2}
q In the case the return circuit turns negative
pressure
Whole valve (2) is held up to serve as the
check valve.
Check valve set pressure:
2.36 MPa {24 kg/cm2}

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

Function
q Prevention of negative pressure in tank
Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated. At this time, poppet (3) is opened
by the differential pressure between the tank
pressure and the atmosphere pressure to pre-
vent generation of the negative pressure.
q Prevention of pressure rise in tank
If the pressure rises to above a specified level
while the circuit is in operation by an increase
or decrease of oil level and the temperature
rise, sleeve (4) is tripped to relieve pressure in
the hydraulic tank.

WA600-6 7
SEN00407-01 10 Structure, function and maintenance standard

Work equipment hydraulic pump 1

Type: HPV125+125

8 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.

ISIG : PC mode selector current

PAF : Front pump discharge port
PAR : Rear pump discharge port
PBF : Pump pressure input port
PBR : Pump pressure input port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Front control pressure pick-up port
PENR : Rear control pressure pick-up port
PEPC : EPC basic pressure port
PEPB : EPC basic pressure pick-up port
PFC : Front pump discharge pressure pick-up
port
PLSF : Front load pressure input port
PLSFC : Front load pressure pick-up port
PLSR : Rear load pressure input port
PLSRC : Rear load pressure pick-up port
PM : PC mode selector pressure pick-up port
PRC : Rear pump discharge pressure pick-up
port
PS : Pump suction port

1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. PC-EPC valve

WA600-6 9
SEN00407-01 10 Structure, function and maintenance standard

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve

10 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside each cylinder chamber of cylin-
q Cylinder block (7) is supported to shaft (1) by der block (7) is suctioned and discharged
spline (14). through valve plate (8).
q Shaft (1) is supported by front and rear bear-
ings (15).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.

WA600-6 11
SEN00407-01 10 Structure, function and maintenance standard

Operation of pump q As center line (X) of rocker cam (4) matches

q Cylinder block (7) rotates together with shaft the axial direction of cylinder block (7) (swash
(1), and shoe (5) slides on flat surface (A). plate angle (a) = 0), the difference between
q When this happens, rocker cam (4) moves volumes (E) and (F) inside cylinder block (7)
along cylindrical surface (B), so angle (a) becomes 0.
between center line (X) of rocker cam (4) and q Suction and discharge of pressurized oil is not
the ax ial di rec tio n of cy li nder b loc k (7) carried out in this state. Namely pumping
changes. action is not performed. (Actually, however, the
q Angle (a) is called the swash plate angle. swash plate angle is not set to 0)

q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston sucks and discharges the oil by
the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.

12 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Control of pump delivery

q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).

WA600-6 13
SEN00407-01 10 Structure, function and maintenance standard

1. LS valve

PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Seat
PPL : Control pressure input port 6. Sleeve
PSIG : Drain port 7. Plug
8. Locknut

Function
q The LS (load sensing) valve detects the load
and controls the discharge amount.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS) [= PP
– PLS], called the LS differential pressure (the
difference between main pump pressure (PP)
and control valve outlet port pressure (PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.

14 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Operation

1) When the control valve is situated at neutral

q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is present in port (J) on
pressure (PLS)(LS pressure) from the inlet port the small diameter side of the piston.
of the control valve brought to spring chamber q According to the difference in the areas on
(B), and pump dischar ge pressure (PP) servo piston (12), the pressure moves in to the
brought to port (H) of sleeve (8). direction of minimizing the swash plate angle.
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit through the control
valve spool)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).

WA600-6 15
SEN00407-01 10 Structure, function and maintenance standard

2) Action for the direction of maximizing the pump delivery

q When the difference between the main pump

pressure (PP) and LS pressure (PLS), in other
wo r ds , L S d iff er e nti a l p re s s ur e ( dP L S)
becomes smaller (for example, when the area
of opening of the control valve becomes larger
and pump pressure (PP) drops), spool (6) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the
delivery larger.

16 WA600-6
10 Structure, function and maintenance standard SEN00407-01

3) Action for the direction of minimizing the pump delivery

q If LS differential pressure (dPLS) becomes

larger (for example, when the area of control
valve opening becomes smaller and the pump
pressure (PP) increases), spool (6) is pressed
to the right by the force of pump pressure (PP).
q As a result of the movement of spool (6), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (12) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (12) moves in the direction to minimize
the swash plate angle.

WA600-6 17
SEN00407-01 10 Structure, function and maintenance standard

4) When servo piston is balanced

q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) x (PP) = (A1) x (PEN), servo piston
(12) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.

18 WA600-6
10 Structure, function and maintenance standard SEN00407-01

2. PC valve

PA : Pump port 1. Plug

PA2 : Pump pressure pilot port 2. Servo piston assembly
PDP : Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL : Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring

Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) and (PP2) (other pump
pressure) are high.
q If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump delivery.
q And if the pump discharge pressure goes low,
it increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and pump delivery (Q) will
become as shown below if the relation is repre-
sented as the parameter of the current value
(X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.

WA600-6 19
SEN00407-01 10 Structure, function and maintenance standard

Operation

1) When the actuator load is small and pump pressure (PP1) and (PP2) are low

Action of PC-EPC valve solenoid (1) a Other pump pressure denotes the pressure of
q Command current (X) is being sent to PC-EPC the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump
q This command current acts on PC-EPC valve pressure is that of the rear pump.
to output the signal pressure in order to modify And for the rear pump pressure, the other
the force pushing piston (2). pump pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined force pressing spool (3) becomes bal-
anced between a set force of spring (4) and
pump pressure (PP1) (self pressure) and
(PP2) (other pump pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.

20 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connecting between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (B) and the nected.
small diameter end of servo piston (9), and q The pressure on port (C) rises and the pres-
other pump pressure (PP2) enters port (A). sure on the large diameter end of the piston
q When pump pressures (PP1) and (PP2) are also rises. Thus, the leftward move of servo
small, spool (3) will be positioned in the left piston (9) is stopped.
side. q Stop position of servo piston (9) (= pump
q Ports (C) and (D) are connected, and the pres- delivery) is determined by a position where
sure entering the LS valve becomes drain press force generated by pressure (PP1) and
pressure (PT). (PP2) on spool (3) and other press force by
PC-EPC valve solenoid are balanced with the
force of spring (4).

WA600-6 21
SEN00407-01 10 Structure, function and maintenance standard

2) When the actuator load is large, and the pump discharge pressure is high

Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end this flow, to make the pump delivery the minimum.
level of this pressure becomes approximately q When servo piston (9) moves to the right,
half of main pump pressure (PP2). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.

22 WA600-6
10 Structure, function and maintenance standard SEN00407-01

q The relationship between the average pump

pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.

q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to spool
(3), so the relationship between the average
pump pressure (PP1 + PP2)/2 and pump deliv-
ery (Q) moves from (A) to (B) as command
current (X) is increased.

WA600-6 23
SEN00407-01 10 Structure, function and maintenance standard

3. PC-EPC valve

C : To PC valve
P : From pilot pump
T : To tank

1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

24 WA600-6
10 Structure, function and maintenance standard SEN00407-01

Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (coil is de-energized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-energized.
sure in proportion to the signal current and q Spool (5) is pushed to the left by spring (4).
outputs it to the PC valve. q Port (P) is closed and the oil from the pilot
pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.

WA600-6 25
SEN00407-01 10 Structure, function and maintenance standard

2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q Hydraulic oil from port (P) flows to port (C) with
sion force of plunger (7). maximum flow rate. As the result, the circuit
q Spool (5) is pushed to the left, and port (P) is pressure between the EPC and PC valves
shut off from port (C). becomes maximum.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be in balance
with pressure of port (C) + spring load of spring
(4).
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.

26 WA600-6
SEN00407-01

WA600-6 Wheel loader

Form No. SEN00407-01

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

28
 SEN02456-00

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Hydraulic system, Part 2
Hydraulic system, Part 2 ................................................................................................................................. 2
Control valve ........................................................................................................................................ 2
CLSS.................................................................................................................................................. 16
Each function and operation of each valve ........................................................................................ 21
Accumulator (for PPC circuit)............................................................................................................. 36
Triple pump ........................................................................................................................................ 37

WA600-6 1
SEN02456-00 10 Structure, function and maintenance standard

Hydraulic system, Part 2 1

Control valve 1
Outline

As for outside views and sectional views, only the 4-spool valve (with ECSS control valve) is shown.

A1 : To bucket cylinder head

A2 : To lift arm cylinder bottom
A3 : To lift arm cylinder bottom
ACC : To ECSS accumulator
B1 : To bucket cylinder bottom
B2 : To lift arm cylinder head
B3 : To bucket cylinder bottom
CP : Pressure sensor installation port
CR : Pressure pick-up port
P1 : From front work equipment hydraulic pump
P2 : From rear work equipment hydraulic pump
PA1 : From bucket dump controller
PA2 : From lift arm raise controller
PACC : From ECSS controller
PB1 : From bucket tilt controller
PB2 : From lift arm lower controller
PLS : To work equipment hydraulic pump LS port
PP : From pilot pump
PPS : To work equipment hydraulic pump
T : To tank
TS : To tank

1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Lift arm Hi and bucket Hi valves
5. Cover 1
6. Cover 2
7. Lift arm suction valve
8. Accumulator charge valve

2 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Outside view

WA600-6 3
SEN02456-00 10 Structure, function and maintenance standard

Sectional view
(1/6)

4 WA600-6
10 Structure, function and maintenance standard SEN02456-00

1. Load check valve (Bucket head)

2. Load check valve (Lift arm bottom)
3. Load check valve (Lift arm Hi) and (Lift arm bottom)
4. Load check valve (Bucket Hi) and (Bucket bottom)
5. Pressure compensation valve (Lift arm head)
6. Load check valve (Bucket bottom)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
7 Check valve spring length load load deformed,
diameter
replace spring
29.4 N 23.5 N
38.9 x 11.5 30.0 —
{3.0 kg} {2.4 kg}

WA600-6 5
SEN02456-00 10 Structure, function and maintenance standard

(2/6)

6 WA600-6
10 Structure, function and maintenance standard SEN02456-00

1. Spool (Boom Hi)

2. Spool (Bucket Hi)
3. Spool (ECSS control)
4. Spool (Lift arm)
5. Spool (Bucket)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
6 Spool return spring length load load
diameter
393 N 315 N
54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
417 N 333 N
7 Spool return spring 54.2 x 34.8 51.2 —
{42.5 kg} {34.0 kg}
If damaged or
351 N 280 N
8 Spool return spring 58.1 x 33.0 51.5 — deformed,
{35.8 kg} {28.6 kg}
replace spring
351 N 280 N
9 Spool return spring 51.6 x 33.0 45.0 —
{35.8 kg} {28.6 kg}
251 N 201 N
10 Spool return spring 54.9 x 24.2 52.0 —
{25.6 kg} {20.5 kg}
263 N 210 N
11 Spool return spring 66.9 x 36.1 63.5 —
{26.8 kg} {21.4 kg}
274 N 219 N
12 Spool return spring 53.2 x 22.3 33.0 —
{27.9 kg} {22.3 kg}

WA600-6 7
SEN02456-00 10 Structure, function and maintenance standard

(3/6)

8 WA600-6
10 Structure, function and maintenance standard SEN02456-00

1. Safety-suction valve (Bucket head)

2. Suction valve (Bucket Hi) and (Bucket bottom)
3. Suction valve (Lift arm head)
4. Safety-suction valve (Bucket bottom)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
x Outside Free length
5 Suction valve spring length load load deformed,
diameter
replace spring
5.5 N 4.4 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}

WA600-6 9
SEN02456-00 10 Structure, function and maintenance standard

(4/6)

1. Unload valve Bucket valve

2. EPC valve (Tilt)
3. Load check valve (Dump)
4. Load check valve (Tilt)
5. EPC valve (Dump)
6. Safety-suction valve (Tilt)
7. Spool
8. Safety-suction valve (Dump)

10 WA600-6
SEN02456-00 10 Structure, function and maintenance standard

(5/6)

12 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Lift arm valve

1. EPC valve (Lower and float)
2. Load check valve (Lift)
3. LS shuttle valve
4. Pressure compensation valve (Lower)
5. EPC valve (Raise)
6. Suction valve (Lower and float)
7. Suction valve (Lower and float)
8. Spool

ECSS valve
9. Spool
10. EPC valve
11. Accumulator charge valve

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
12 Check valve spring length load load
diameter
If damaged or
5.9 N 4.72 N
41.5 x 8.5 31.5 — deformed,
{0.6 kg} {0.48 kg}
replace spring
19.6 N 15.7 N
13 Valve spring 19.2 x 7.2 16.1 —
{2.0 kg} {1.6 kg}
3.04 N 2.43 N
14 Suction valve spring 62.5 x 20.0 39.0 —
{0.31 kg} {0.25 kg}

WA600-6 13
SEN02456-00 10 Structure, function and maintenance standard

(6/6)

14 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Lift arm Hi and bucket Hi valves

1. Load check valve (Lift arm Hi)
2. Spool (Lift arm Hi)
3. Load check valve (Bucket Hi)
4. Spool (Bucket Hi)
5. Suction valve (Bucket Hi)
6. Unload valve
7. Main relief valve
8. LS bypass plug

WA600-6 15
SEN02456-00 10 Structure, function and maintenance standard

CLSS 1
Outline of CLSS 1

Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features: piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control

16 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Basic principle q The pump swash plate angle shifts toward the
maximum position if LS differential pressure
1. Pump swash plate angle control (dPLS) is lower than the set pressure of the LS
q The pump swash plate angle (pump delivery) valve (when the actuator load pressure is
is so controlled that the LS differential pressure high).
(dPLS), which is the differential pressure q If it becomes higher than the set pressure
between the pump discharge pressure (PPS) (when the actuator load pressure is low), the
and LS pressure (PLS) (the actuator load pres- pump swash plate angle shifts toward the mini-
sure) at the control valve outlet, will be con- mum position.
stant.
q [LS differential pressure (dPLS) = Pump dis- LS differential pressure (dPLS) and pump
charge pressure (PPS) – LS pressure (PLS)] swash plate angle

a For details of functions, see the “Hydraulic

pump” paragraph.

WA600-6 17
SEN02456-00 10 Structure, function and maintenance standard

2. Pressure compensation control

q The valve (pressure compensation valve) to q This prevents the bucket from becoming inop-
balance the load is installed to the lift arm head erable because of excessive oil flow to the lift
outlet side of the control valve. arm head due to the lowering of lift arm under
q When actuators are operated simultaneously, its own weight and compound operation of the
the pressure difference (dP) between the bucket.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.

18 WA600-6
10 Structure, function and maintenance standard SEN02456-00

WA600-6 19
SEN02456-00 10 Structure, function and maintenance standard

1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Lift arm Hi valve
5. Bucket Hi valve
6. Bucket spool
7. Lift arm spool
8. ECSS spool
9. Lift arm spool
10. Bucket spool
11. Pressure compensation valve
12. Suction valve
13. Load check valve
14. Accumulator charge valve
15. Main relief valve
Set pressure: 34.3 ± 0.5 MPa {350 ± 5 kg/cm2}
16. Unload valve
Cracking pressure: 1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
17. Safety-suction valve
Set pressure: 36.2 ± 0.5 MPa {370 ± 5 kg/cm2}

20 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Each function and operation of each valve 1

Pressure compensation valve 1
(Installed on the cylinder head side of the lift arm valve)

1) When a high load is applied to the lift arm

1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve

Function q Shuttle valve (3) of the pressure compensation

q High load pressure is generated during inde- valve moves to the right.
pendent operation of the lift arm and com- q Actuator circuit pressure (B) and spring cham-
pound operation with the bucket. ber (C) is connected.
q When the lift arm load pressure becomes q Accordingly, piston (4) is pressed by spring (5)
higher than the bucket, the pressure compen- to the left.
sation valve operates as a load check valve to q Also valve (2) is pressed by piston (4) to the
prevent reverse oil flow in the circuit. left and pump outlet circuit (A) is closed. This
prevents reverse flow of oil from actuator cir-
Operation cuit (B) to pump outlet circuit (A).
q Actuator circuit pressure (B) becomes higher
than pump discharge pressure (PPS) and LS
pressure (PLS).

WA600-6 21
SEN02456-00 10 Structure, function and maintenance standard

2) Compound operation (Lift arm lower + bucket tilt)

Function q Outlet pressure (A) (spool meter-in down-

q If the load pressure is lower than the bucket stream pressure) becomes equal to the bucket
and the flow rate starts increasing during com- outlet pressure.
pound operation, the pressure compensation q Pump pressure (PPS) (spool meter-in
valve compensates the pressure. upstream pressure) becomes equal for all
q On the bucket side, the load pressure is higher actuators.
and the flow rate starts to decrease. q Pump pressure (PPS) and outlet pressure (A)
becomes equal for all spools.
Operation q Pump flow rate is distributed in proportion to
q If the load pressure on the bucket side rises the opening area of respective spools.
during compound operation, the flow rate of
actuator circuit pressure (B) starts to increase.
q As LS pressure (PLS) rises on the bucket side,
shuttle valve (3) of the pressure compensation
valve is pressed to the left.
q Hydraulic oil flows through the internal pas-
sage of piston (4) to spring chamber (C).
q Piston (4) and valve (2) are pressed to the left
and the outlet side of pump circuit (PPS) is cut
off.

22 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Shuttle valve in the pressure compensation valve

1. If holding pressure of port (B) > LS pressure in spring chamber (C)

1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston

Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).

WA600-6 23
SEN02456-00 10 Structure, function and maintenance standard

Area ratio of pressure compensation valve

Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.

24 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Supply of LS pressure
(LS shuttle valve)

1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve

Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Inlet pore (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).

WA600-6 25
SEN02456-00 10 Structure, function and maintenance standard

LS bypass plug 1

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit

Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass plug (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool
(2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.

26 WA600-6
SEN02456-00 10 Structure, function and maintenance standard

ECSS control valve 1

Function
q The controller automatically turns on and off
the accumulator charged with high-pressure
gas according to the travel condition.
q The ECSS control valve gives elasticity to the
vertical movement of the work equipment and
reduces rocking of the machine body during
high-speed travel to improve the operator com-
fort and prevent spillage of material for higher
working efficiency.

28 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Operation Accumulator pressure relief valve

q If the travel speed exceeds 5 km/h, the signal q If the pressure in accumulator (ACC) needs to
is sent to solenoid valve (2) and the pressure is be relieved, loosen plug (3) and nut (4) to open
applied to (a). circuits (PR) and (TS).
q Spool (1) moves to the right.
q As spool (1) moves, the line from (PR) to accu-
mulator (ACC) is closed and the lines from
(A2) to accumulator (ACC) and from (B2) to (T)
are opened. As a result, the ECSS is turned
ON.
q While the travel speed is below 4 km/h, the sig-
nal is not sent to solenoid valve (2) and spool
(1) is in neutral. At this time, the line from (PR)
to accumulator (ACC) is opened and accumu-
lator (ACC) is charged.
q If accumulator (ACC) is charged up to the set
pressure, check valve (5) is closed and the
pressure in accumulator (ACC) does not rise
any more.

WA600-6 29
SEN02456-00 10 Structure, function and maintenance standard

Accumulator charge valve 1

CR : Pressure pickup port

P : From main pump
PP : To the accumulator through ECSS spool
TS1 : To tank
TS2 : To tank
TS3 : To tank

1. Screw
2. Poppet (Safety valve)
3. Spring (Safety valve)
4. Spring (Main pressure reducing valve)
5. Pressure reducing valve spool
6. Poppet (Check valve)
7. Spring (Check valve)

30 WA600-6
10 Structure, function and maintenance standard SEN02456-00

WA600-6 31
SEN02456-00 10 Structure, function and maintenance standard

1. When valve is in neutral and (P) is low

Function
q The discharge pressure of the hydraulic pump
is reduced and the oil is supplied to the ECSS
accumulator.

Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P1) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P1) to port (PR) is closed.
q Poppet (6) is moved to the right by pressure
(P1) and the line from (P1) to (PR) is opened.
If (P1) < (PR), poppet (6) is pressed to the left
by spring (7) and the line from (P1) to (PR) is
closed.

32 WA600-6
10 Structure, function and maintenance standard SEN02456-00

2. When load pressure (P) is high

Operation
q If pressure (P) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P1), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(P1).

WA600-6 33
SEN02456-00 10 Structure, function and maintenance standard

Explanation of operation of Hi valve

34 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Operation
1. When lift arm is raised
Pilot pressure (EPC valve output) is applied to
Lo valve (PA2).
Since this pressure is also applied to Hi valve
spring chamber in parallel, lift arm Hi valve
moves to right and oil from pump flows through
port (P) to port (A).

2. When lift arm is lowered

Pilot pressure (EPC valve output) is applied to
Lo valve (PB2).
Since this pressure is also applied to chamber
on opposite side of Hi valve spring chamber in
parallel, lift arm Hi valve moves to left and
(meter-out) oil flows through port (A3) to port
(T).
When pilot pressure is applied to Lo valve
(PB2), bucket Hi valve is also pressurized.
Since bucket Hi valve has a hole at center of
its spool and chambers on right and left cham-
bers of spool are connected, however, pres-
sure is applied to both of those chambers
simultaneously, thus spool does not move.

3. When bucket is tilted

Pilot pressure (EPC valve output) is applied to
Lo valve (PB1).
Bucket Hi valve has piston, unlike lift arm Hi
valve.
Piston chamber is pressurized and spool
moves to right, thus oil from pump flows
through port (P) to port (B3).
Lo valve Hi valve
Raise Q Q
Lift arm
Lower Q Q
Tilt Q Q
Bucket
Dump Q —

WA600-6 35
SEN02456-00 10 Structure, function and maintenance standard

Accumulator (for PPC circuit) 1

Operation
q After engine is stopped, chamber (A) in the
bladder is compressed by oil pressure in
chamber (B).
q When work equipment EPC solenoid is tripped
by operating the work equipment EPC lever,
pressure inside nitrogen gas chamber (A)
expands the bladder, and the oil in chamber
(B) operates the work equipment valve as the
pilot pressure.

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications
Type of gas : Nitrogen gas
Amount of gas : 500 cc
Max. operating pressure : 3.92 MPa {40 kg/cm2}
Min. operating pressure : 0 MPa {0 kg/cm2}

Function
q Accumulator is installed between the charge
valve and work equipment valve. In the case
the engine is stopped with the lift arm lifted up,
compressed nitrogen gas pressure in the accu-
mulator feeds the pilot oil pressure to the work
equipment valve for operation. Thus the lift
arm and bucket are enabled to descend under
own weight.

36 WA600-6
10 Structure, function and maintenance standard SEN02456-00

Triple pump 1
Power train, Hydraulic oil cooling, brake and EPC pump
SAL(4)160+(3)100+(2)32

Unit: mm
No. Check item Criteria Remedy
Type Tolerance Repair limit
Clearance between body SAL(4)-160 0.11 – 0.16 0.20
1
and spool SAL(3)-100
0.10 – 0.15 0.19
SAL(2)-32
SAL(4)-160 0.06 – 0.14
Clearance between inside
2 diameters of plain bearing SAL(3)-100 0.06 – 0.149 0.20 Replace
and gear shaft
SAL(2)-32 0.06 – 0.125
Type Standard size Tolerance Repair limit
SAL(4)-160 21
3 Driven depth of pin 0
SAL(3)-100 14 —
–0.5
SAL(2)-32 12
Rotation torque of spline
4 19.6 – 33.3 Nm {2.0 – 3.4 kgm}
shaft
Discharge Standard Allowable
Speed
Type pressure discharge discharge
(rpm) —
(MPa {kg/cm2}) (l/min) (l/min)
Discharge oil: EO10-CD
—
Oil temperature: 45 – 55°C SAL(4)-160 20.6 {210} 328.3 303.3
SAL(3)-100 2,200 30 {2.9} 210 183.5
SAL(2)-32 20.6 {210} 62.7 56.0

WA600-6 37
SEN02456-00

WA600-6 Wheel loader

Form No. SEN02456-00

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

38
 SEN00408-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment linkage....................................................................................................................... 2
Bucket .................................................................................................................................................. 6
Bucket positioner and boom kick-out ................................................................................................. 10
Work equipment lubrication.................................................................................................................11
Work equipment cylinder.................................................................................................................... 13

WA600-6 1
 SEN00408-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Work equipment
Work equipment .............................................................................................................................................. 2
Work equipment linkage....................................................................................................................... 2
Bucket .................................................................................................................................................. 6
KMAX (ABR tooth type) ..................................................................................................................... 10
Work equipment lubrication................................................................................................................ 12
Work equipment cylinder.................................................................................................................... 14

WA600-6 1
SEN00408-03 10 Structure, function and maintenance standard

Work equipment 1
Work equipment linkage 1

1. Bucket 8. Bucket hinge pin

2. Bell crank 9. Bell crank pin
3. Bucket cylinder 10. Cord ring
4. Lift arm cylinder
5. Lift arm
6. Bucket link
7. Bucket hinge pin

2 WA600-6
10 Structure, function and maintenance standard SEN00408-03

WA600-6 3
SEN00408-03 10 Structure, function and maintenance standard

4 WA600-6
10 Structure, function and maintenance standard SEN00408-03

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing size clearance limit
Shaft Hole
1 and pin at each end of bucket
link –0.043 +0.215 0.158 –
140 1.0
–0.106 +0.115 0.321
Clearance between bushing
–0.043 +0.215 0.158 –
2 and pin connecting lift arm and 140 1.0
–0.106 +0.115 0.321
bucket
Clearance between bushing
–0.043 +0.215 0.158 –
3 and pin connecting lift arm and 160 1.0
–0.106 +0.115 0.321
frame
Clearance between bushing
–0.043 +0.215 0.158 –
4 and pin connecting bucket cyl- 160 1.0
–0.106 +0.115 0.321 Replace
inder bottom and frame
Clearance between bushing
–0.043 +0.215 0.158 –
5 and pin connecting bucket cyl- 160 1.0
–0.106 +0.115 0.321
inder rod and bell crank
Clearance between bushing
–0.043 +0.215 0.158 –
6 and pin connecting bell crank 180 1.0
–0.106 +0.115 0.321
and lift arm
Clearance between bushing
–0.043 +0.215 0.158 –
7 and pin connecting lift cylinder 140 1.0
–0.106 +0.115 0.321
bottom and frame
Clearance between bushing
–0.043 +0.215 0.158 –
8 and pin connecting lift cylinder 140 1.0
–0.106 +0.115 0.321
rod and lift arm
Standard
Connecting part of bucket cylin- Boss to boss width Width of hinge (a+b) Insert shims to
9 clearance both sides so that
der and frame
clearance will be
163 ± 0.8 160±1.2 1.0 – 5.0
below 1.5 mm on
Connecting part of lift arm and each side.
10 214 ± 1.5 210(+1/–2) 1.5 – 7.5
frame
Connecting part of lift arm and
11 243(+1.5/0) 240(+1/–2) 2.0 – 6.5
bucket
—
Connecting part of bucket link
12 243(+1.5/0) 240(+1/–2) 2.0 – 6.5
and bucket
Connecting part of bell crank
13 243 ± 2 240(+1/–2) 0 – 7.0
and bucket link
Connecting part of lift cylinder
14 174 ± 1.5 170±1.2 1.3 – 6.7 Insert shims to
and frame
both sides so that
Connecting part of bell crank
15 396 ± 0.5 393±0.5 2.0 – 4.0 clearance will be
and lift arm
below 1.5 mm on
Connecting part of bucket cylin- each side.
16 163 ± 2 160±1.2 0.2 – 6.2
der and bell crank
Connecting part of lift arm and
17 174 ± 1.5 170(+1/–2) 2.5 ± 7.5
lift cylinder

WA600-6 5
SEN00408-03 10 Structure, function and maintenance standard

Bucket 1

1. Bucket
2. Tip tooth
3. Pin
4. Wear plate

6 WA600-6
10 Structure, function and maintenance standard SEN00408-03

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Wear of bucket tooth, tip type Replace
35 0
Tightening torque of bucket
2 745 ± 108 Nm {76 ± 11 kgm} Retighten
wear plate mounting bolt

WA600-6 7
SEN00408-03 10 Structure, function and maintenance standard

Bucket (KMAX tooth type)

1. Bucket
2. Tip tooth
3. Pin
4. Wear plate
5. Segment tooth
6. Bolt
7. Nut
8. Washer

8 WA600-6
10 Structure, function and maintenance standard SEN00408-03

KMAX (RP1 tooth type)

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Wear of bucket tooth Replace
61 38
2 Wear of segment tooth 59 21 Replace
Tightening torque of mounting
3 745 ± 108 Nm {75.9 ± 11.0 kgm} Retighten
bolt of bucket wear plate
Tightening torque of mounting
4 1,880 ± 280 Nm {191.7 ± 28.5 kgm} Retighten
bolt of segment
5 Torque for unlocking pin shaft 19.5 ± 8.5 Nm {1.9 ± 0.87 kgm} Below 11 Nm {1.1 kgm} Replace

a 1: Locked state (Flange of pin shaft is oriented up)

a 2: Unlocked state (Flange of pin shaft is oriented sideways)
a 3: Measurement direction of unlocking torque

WA600-6 9
SEN00408-03 10 Structure, function and maintenance standard

KMAX (ABR tooth type)

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Wear of bucket tooth Replace
97 38
2 Wear of segment tooth 90 41 Replace
Tightening torque of mounting
3 745 ± 108 Nm {75.9 ± 11.0 kgm} Retighten
bolt of bucket wear plate
Tightening torque of mounting
4 1,880 ± 280 Nm {191.7 ± 28.5 kgm} Retighten
bolt of segment
5 Torque for unlocking pin shaft 19.5 ± 8.5 Nm {1.9 ± 0.87 kgm} Below 11 Nm {1.1 kgm} Replace

a 1: Locked state (Flange of pin shaft is oriented up)

a 2: Unlocked state (Flange of pin shaft is oriented sideways)
a 3: Measurement direction of unlocking torque

10 WA600-6
10 Structure, function and maintenance standard SEN00408-03

Bucket positioner and boom kick-out 1

Unit: mm
No. Check item Criteria Remedy
Clearance of bucket positioner
1 3–5
switch
Adjust
Clearance in lift arm position
2 0.5 – 1
detector sensor

WA600-6 11
SEN00408-03 10 Structure, function and maintenance standard

Work equipment lubrication 1

1. Bell crank A: Center hinge, upper side

2. Lift arm B: Lift arm cylinder, left side
3. Bucket cylinder C: Lift arm cylinder, right side
4. Front frame D: Lift arm pin, right side
5. Lift cylinder E: Bucket cylinder, bottom side
6. Rear frame F: Lift arm pin, left side
G: Steering cylinder head, left side
H: Steering cylinder head, right side
J: Center support

12 WA600-6
10 Structure, function and maintenance standard SEN00408-03

K: Rear axle, rear side

L: Rear axle, top side
M: Rear axle, front side

WA600-6 13
10 Structure, function and maintenance standard SEN00408-03

WA600-6 15
SEN00408-03

WA600-6 Wheel loader

Form No. SEN00408-03

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

16
SEN00408-03 10 Structure, function and maintenance standard

Work equipment cylinder 1

Lift cylinder

Buket cylinder

Unit: mm
No. Check item Criteria Remedy
cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between
1 piston rod and bush- –0.043 +0.256 0.082– Replace bushing
Lift 140 0.662
ing –0.106 +0.039 0.362
–0.043 +0.256 0.082–
Bucket 140 0.662
–0.106 +0.039 0.362
Tightening torque of Lift 1.27 ± 0.20 kNm {130 ± 20 kgm}
2
cylinder head Bucket 1.67 ± 0.25 kNm {170 ± 25 kgm}
Tightening torque of Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}
3 Retighten
cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Lift 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
4 cylinder piston lock
screw Bucket 58.9 – 73.6 Nm {6.0 – 7.5 kgm}

14 WA600-6
SEN00408-02 10 Structure, function and maintenance standard

Work equipment 1
Work equipment linkage 1

1. Bucket 8. Bucket hinge pin

2. Bell crank 9. Bell crank pin
3. Bucket cylinder 10. Cord ring
4. Lift arm cylinder
5. Lift arm
6. Bucket link
7. Bucket hinge pin

2 WA600-6
10 Structure, function and maintenance standard SEN00408-02

WA600-6 3
SEN00408-02 10 Structure, function and maintenance standard

4 WA600-6
10 Structure, function and maintenance standard SEN00408-02

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing size clearance limit
Shaft Hole
1 and pin at each end of bucket
link –0.043 +0.215 0.158 –
140 1.0
–0.106 +0.115 0.321
Clearance between bushing
–0.043 +0.215 0.158 –
2 and pin connecting lift arm and 140 1.0
–0.106 +0.115 0.321
bucket
Clearance between bushing
–0.043 +0.215 0.158 –
3 and pin connecting lift arm and 160 1.0
–0.106 +0.115 0.321
frame
Clearance between bushing
–0.043 +0.215 0.158 –
4 and pin connecting bucket cyl- 160 1.0
–0.106 +0.115 0.321 Replace
inder bottom and frame
Clearance between bushing
–0.043 +0.215 0.158 –
5 and pin connecting bucket cyl- 160 1.0
–0.106 +0.115 0.321
inder rod and bell crank
Clearance between bushing
–0.043 +0.215 0.158 –
6 and pin connecting bell crank 180 1.0
–0.106 +0.115 0.321
and lift arm
Clearance between bushing
–0.043 +0.215 0.158 –
7 and pin connecting lift cylinder 140 1.0
–0.106 +0.115 0.321
bottom and frame
Clearance between bushing
–0.043 +0.215 0.158 –
8 and pin connecting lift cylinder 140 1.0
–0.106 +0.115 0.321
rod and lift arm
Standard
Connecting part of bucket cylin- Boss to boss width Width of hinge (a+b) Insert shims to
9 clearance both sides so that
der and frame
clearance will be
163 ± 0.8 160±1.2 1.0 – 5.0
below 1.5 mm on
Connecting part of lift arm and each side.
10 214 ± 1.5 210(+1/–2) 1.5 – 7.5
frame
Connecting part of lift arm and
11 243(+1.5/0) 240(+1/–2) 2.0 – 6.5
bucket
—
Connecting part of bucket link
12 243(+1.5/0) 240(+1/–2) 2.0 – 6.5
and bucket
Connecting part of bell crank
13 243 ± 2 240(+1/–2) 0 – 7.0
and bucket link
Connecting part of lift cylinder
14 174 ± 1.5 170±1.2 1.3 – 6.7 Insert shims to
and frame
both sides so that
Connecting part of bell crank
15 396 ± 0.5 393±0.5 2.0 – 4.0 clearance will be
and lift arm
below 1.5 mm on
Connecting part of bucket cylin- each side.
16 163 ± 2 160±1.2 0.2 – 6.2
der and bell crank
Connecting part of lift arm and
17 174 ± 1.5 170(+1/–2) 2.5 ± 7.5
lift cylinder

WA600-6 5
SEN00408-02 10 Structure, function and maintenance standard

Bucket 1

1. Bucket
2. Tip tooth
3. Pin
4. Wear plate

6 WA600-6
10 Structure, function and maintenance standard SEN00408-02

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Wear of bucket tooth, tip type Replace
35 0
Tightening torque of bucket
2 745 ± 108 Nm {76 ± 11 kgm} Retighten
wear plate mounting bolt

WA600-6 7
SEN00408-02 10 Structure, function and maintenance standard

Bucket (KMAX tooth type)

1. Bucket
2. Tip tooth
3. Pin
4. Wear plate
5. Segment tooth
6. Bolt
7. Nut
8. Washer

8 WA600-6
10 Structure, function and maintenance standard SEN00408-02

Unit: mm
No. Item Criteria Remedy
Standard dimension Repair limit
1 Wear of bucket tooth Replace
61 38
2 Wear of segment tooth 59 21 Replace
Tightening torque of mounting
3 745 ± 108 Nm {75.9 ± 11.0 kgm} Retighten
bolt of bucket wear plate
Tightening torque of mounting
4 1,880 ± 280 Nm {191.7 ± 28.5 kgm} Retighten
bolt of segment
5 Torque for unlocking pin shaft 19.5 ± 8.5 Nm {1.9 ± 0.87 kgm} Below 11 Nm {1.1 kgm} Replace

a 1: Locked state (Flange of pin shaft is oriented up)

a 2: Unlocked state (Flange of pin shaft is oriented sideways)
a 3: Measurement direction of unlocking torque

WA600-6 9
SEN00408-02 10 Structure, function and maintenance standard

Bucket positioner and boom kick-out 1

Unit: mm
No. Check item Criteria Remedy
Clearance of bucket positioner
1 3–5
switch
Adjust
Clearance in lift arm position
2 0.5 – 1
detector sensor

10 WA600-6
10 Structure, function and maintenance standard SEN00408-02

Work equipment lubrication 1

1. Bell crank A: Center hinge, upper side

2. Lift arm B: Lift arm cylinder, left side
3. Bucket cylinder C: Lift arm cylinder, right side
4. Front frame D: Lift arm pin, right side
5. Lift cylinder E: Bucket cylinder, bottom side
6. Rear frame F: Lift arm pin, left side
G: Steering cylinder head, left side
H: Steering cylinder head, right side
J: Center support

WA600-6 11
SEN00408-02 10 Structure, function and maintenance standard

K: Rear axle, rear side

L: Rear axle, top side
M: Rear axle, front side

12 WA600-6
10 Structure, function and maintenance standard SEN00408-02

Work equipment cylinder 1

Lift cylinder

Buket cylinder

Unit: mm
No. Check item Criteria Remedy
cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between
1 piston rod and bush- –0.043 +0.256 0.082– Replace bushing
Lift 140 0.662
ing –0.106 +0.039 0.362
–0.043 +0.256 0.082–
Bucket 140 0.662
–0.106 +0.039 0.362
Tightening torque of Lift 1.27 ± 0.20 kNm {130 ± 20 kgm}
2
cylinder head Bucket 1.67 ± 0.25 kNm {170 ± 25 kgm}
Tightening torque of Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}
3 Retighten
cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Lift 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
4 cylinder piston lock
screw Bucket 58.9 – 73.6 Nm {6.0 – 7.5 kgm}

WA600-6 13
SEN00408-02

WA600-6 Wheel loader

Form No. SEN00408-02

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10

14
 SEN00409-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
ROPS cab ............................................................................................................................................ 2
Air conditioner ...................................................................................................................................... 4

WA600-6 1
SEN00409-01 10 Structure, function and maintenance standard

Cab and its attachments 1

ROPS cab 1

1. Front glass 3. Door

2. Front wiper 4. Rear wiper

2 WA600-6
10 Structure, function and maintenance standard SEN00409-01

WA600-6 3
SEN00409-01 10 Structure, function and maintenance standard

Air conditioner 1
Air conditioner piping

1. Air outlet duct

2. Defroster window
3. Air outlet duct
4. Air conditioner unit
5. Dry receiver
6. Compressor
7. Air conditioner condenser
8. Hot water take-out port
9. Hot water return port

4 WA600-6
10 Structure, function and maintenance standard SEN00409-01

Air conditioner condenser

A: Refrigerant gas inlet port

B: Refrigerant gas outlet port

WA600-6 5
SEN00409-01 10 Structure, function and maintenance standard

Air conditioner compressor

1. Refrigerant gas outlet port

2. Refrigerant gas inlet port
3. Clutch

Specifications
Type : Piston pump type
Specified refrigerant : R134a

6 WA600-6
10 Structure, function and maintenance standard SEN00409-01

Air conditioner dry receiver

1. Body
2. Dryer

WA600-6 7
SEN00409-01

WA600-6 Wheel loader

Form No. SEN00409-01

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

8
 SEN01009-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Electrical system, Part 1
Electrical system, Part 1 ................................................................................................................................. 2
Machine monitor system ...................................................................................................................... 2
Machine monitor................................................................................................................................... 8

WA600-6 1
SEN01009-02 10 Structure, function and maintenance standard

Electrical system, Part 1 1

Machine monitor system 1
Outline
q In the machine monitor system, each monitor 4. In addition to the above, the following can be
on the network monitors and controls the vehi- displayed, set, and adjusted by using the char-
cle condition with the sensors installed to vari- acter display and the machine monitor mode
ous parts of the vehicle, and then sends the selector switch which is the operation switch of
result as network information to the machine the character display.
monitor, which displays the information to
notify the operator of the vehicle condition. 1) Load meter (If equipped)
q Loaded/no loaded calibration
q The machine monitor displays the information q Reset of calibration
in the normal mode or service mode. q Display/non-display of load meter
q Printer output format (printer (if equip-
q The normal mode is used to display the infor- ped))
mation to the operator normally. The major 2) Display of odometer
items displayed in this mode are as follows. 3) Reset of filter oil replacement time
4) Input of telephone number
1. Items always displayed 5) Selection of language
q Meters (Speedometer or engine tachome- 6) Adjustment of brightness of the night light-
ter) ing for the machine monitor
q Gauges (Engine coolant temperature 7) Adjustment of time of clock (Load meter (if
gauge, torque converter oil temperature equipped))
gauge, hydraulic oil temperature gauge, 8) Selection of travel speed and engine
and fuel level gauge) speed display
q Pilot indicators 9) Function to display/non-display of travel
q Service meter speed and engine speed on the character
display
The following is displayed according to setting
condition of optional device.
q Load meter calculated weight
q Hours
q Display of travel speed/engine speed on
the character display

2. Items displayed when abnormality is detected

q Caution lamps
q Action code (While an action code is dis-
played, if the monitor panel mode selector
switch (>) is pressed and released, the
failure code (6 digits) is displayed.))

3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(Maintenance monitoring function)

2 WA600-6
10 Structure, function and maintenance standard SEN01009-02

q The service mode function is used for the ease 10. Function of selecting optional device
of troubleshooting for the controllers on the Information of the controller to be used and
network (including the machine monitor itself). optional device are selected.
The major functions used in the service mode
are as follows. 11. Input of machine serial number (No.)
Enter the machine serial number to specify the
1. Display of electrical system failure history machine.
The electrical system failures of each controller
saved in the machine monitor are displayed. 12. Model selection function
The information of those failures is deleted Enter the information of applicable model.
with this function, too.
13. Initialize
2. Display of mechanical system failure history This function is used to set the machine moni-
The mechanical system failures of each con- tor to the state set when delivered.
troller saved in the machine monitor are dis-
played.

3. Real-time monitor
The input and output values recognized by
each controller on the network are displayed in
real time.

4. Reduced-cylinder mode
This function is used to stop fuel injection by
cylinder and specify the cylinder having defec-
tive fuel by shutting off fuel injected from the
fuel injector.

5. No injection cranking
This function is used when lubricating the
engine with the engine stopped when restart-
ing it after a long time of non-operation.

6. Adjustment function
The installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
are corrected and adjusted, and control char-
acteristic data is changed upon request of the
user.

7. Maintenance monitor
The filter and oil replacement period is
changed and its function is stopped.

8. Operating information display function

Fuel consumption per operating hours is dis-
played.

9. Manual snap shot (if equipped)

The direction to take in the snap shot data is
given to the VHMS.

WA600-6 3
SEN01009-02 10 Structure, function and maintenance standard

Machine monitor electrical circuit diagram (AJSS specification)

4 WA600-6
10 Structure, function and maintenance standard SEN01009-02

WA600-6 5
SEN01009-02 10 Structure, function and maintenance standard

Machine monitor electrical circuit diagram (Steering wheel specification)

6 WA600-6
10 Structure, function and maintenance standard SEN01009-02

WA600-6 7
SEN01009-02 10 Structure, function and maintenance standard

Machine monitor 1

1. Torque converter oil temperature gauge 26. Maintenance caution lamp

2. Torque converter oil temperature caution lamp 27. Battery electrolyte level caution lamp
3. Engine coolant temperature gauge 28. Battery charge circuit caution lamp
4. Engine coolant temperature caution lamp 29. Steering oil pressure caution lamp
5. Speedometer or engine tachometer (If equipped)
6. Display of the unit of speedometer or engine 30. Emergency steering pilot lamp (If equipped)
tachometer 31. Output mode pilot lamp (Power mode)
7. Turn signal pilot lamp (Left) 32. Preheater pilot lamp
8. Head lamp high beam pilot lamp 33. Semi auto digging pilot lamp (If equipped)
9. Turn signal pilot lamp (Right) 34. Auto-grease pilot lamp (If equipped)
10. Hydraulic oil temperature gauge 35. Joystick operation pilot lamp
11. Hydraulic oil temperature caution lamp 36. Directional selector pilot lamp (Not used)
12. Fuel level gauge 37. ECSS pilot lamp (If equipped)
13. Fuel level caution lamp 38. Economy operation indicator lamp
14. Central warning lamp 39. Shift position pilot lamp (Forward/reverse)
15. Brake oil pressure caution lamp 40. Shift position pilot lamp (Gear speed)
16. Engine oil pressure caution lamp 41. Shift indicator
17. Fuel filter coolant level caution lamp (Not used) 42. Auto-shift pilot lamp
18. Engine oil level caution lamp 43. Lockup pilot lamp
19. Radiator coolant level caution lamp 44. Shift hold pilot lamp
20. Parking brake pilot lamp 45. Display of bucket loading (If equipped)
21. Air cleaner clogging caution lamp 46. Addition mode: Total loading display/Reduction
22. Transmission oil filter clogging caution lamp mode: Display of level (If equipped)
23. Brake oil temperature caution lamp 47. Working object display (If equipped)
24. Modulation clutch temperature caution lamp 48. Addition/reduction mode display (If equipped)
25. Cooling fan reverse rotation pilot lamp 49. Character display

8 WA600-6
10 Structure, function and maintenance standard SEN01009-02

1. Load meter display selector switch (if equipped)

q Total mass display
2. Load meter mode selector switch (if equipped)
q Material selection
q Addition/reduction selection
3. Character display mode selector switch
4. Character display item selector switch

WA600-6 9
SEN01009-02 10 Structure, function and maintenance standard

List of items displayed on monitor

During starting the engine, the monitor checks if:
1. Starting motor switch ON has been recorded.
2. Charge level is min. the specified value or more.
3. Engine speed is the specified value (500 rpm) or more
At least two items above are satisfied, or CAN communication error (transmission controller:
DAQRKR) or (engine controller: DB2RKR) and charge level are the specified values or more.
Q: Lighting
w: Flashing (1.6 sec., 50% duty)
A: Intermittent (Period: 240 msec., “ON“: 80 msec., “OFF“: 160 msec.)
E: As per separate setting condition
Operating condition: Engine operating
Operating state
condition included, error detection time
(Starting switch ON)

Signal detection controller

counted (As indicated at right)
Detec-
tion time Engine: Stopped Engine is running

Display color
Category

(SEC)

Display of message

Display of message
No. Item Device Remarks

Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Detection

Reset
Central warning lamp

Lights when error (E03, E02)

occurs on each controller and at

Red
When error is made E E E E E E E E E
the same time displays mes-
sage.
14 Central warning lamp LED
Other than above, see “Oper-
ating condition – Central
— — — — — — — —
warning lamp” column of rele-
vant items.
For night Back light:

White
Back

Back light
light

— lighting of When small lamp is turned — — — — — — Monitor

(various back lights)
LED ON
Indicates “0” if error is made
Switchable to speedmeter
in communication other than
The first digit is fixed at 0.
Engine speed Fixed LCD when engine speed is — — — — — — — Engine
Number of display digits (4-dig-
selected or tilt positioner set
its): 0 – 3990
angle is displayed.
Other than when engine Switchable to tachometer
speed is not selected and tilt Trans- Number of display digits (4-dig-
Speedometer Fixed LCD — — — — — — —
positioner set angle is dis- mission its): 0 – 99 (middle 2 out of 4
played digits are used.)
Switching between speedome-
ter/tachometer
Displayed just 3 seconds when
instruction is given from work
When tilt positioner set angle
equipment controller.
is displayed.
Work Number of display digits is 1-
Gauges and meters

Tilt positioner set position

Fixed LCD — — — — — — — equip- digit (–5 to 5) (middle 2 out of 4-
display Lamp does not light up when
ment digits are used, unit is not dis-
error is made in communica-
played).
5 tion.
Operation completion sound
(short beep) and cancel sound
(long beep sound) are given
simultaneously.
Alarm is issued when infor-
mation of “Overrun preven-
Overrun prevention
Remarks

Remarks

tion (in lockup release o

(when lockup release o Trans-
Fixed LCD torque converter mode) alarm w Q w Q —
w

torque converter mode) mission

notice” is obtained from
alarm notice
transmission controller, and is
kept at least 3 minutes.
Note)
Alarm is issued when infor-
mation of “Overrun preven-
Overrun prevention
Remarks

Remarks

tion (in lockup release o

(in lockup release o Trans-
Fixed LCD torque converter mode) alarm w Q w Q —
w

torque converter mode) mission

detecting” is obtained from
alarm
transmission controller, and is
continued at least 3 minutes.
When engine speed is
— — — r/min — — r/min — —
selected
When speed [km/H] is
— — — km/h — — km/h — — Monitor
selected
Unit

6 Unit display LCD When speed [MPH] is

— — — MPH — — MPH — —
selected
Work
When tilt positioner set angle
— — — — — — — equip-
is displayed
ment

Note)
Central
Main part
warning Buzzer Message
(*1)
lamp
Overrun notice Q w w (flashing) —
Overrun Q w w (flashing) Overrun prevention
(*1) When the engine speed is displayed on the center LCD, the display flashes.
When the travel speed is displayed, it is switched to the engine speed and
the display flashes.

10 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Operating condition: Engine operating

Operating state
condition included, error detection time
(Starting switch ON)
counted (As indicated at right)

Signal detection controller

Detec-
Engine: Engine is run-
tion time

Display color
Stopped ning
Category

(SEC)
No. Item Device Remarks

Display of message

Display of message
Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Detection

Reset
Torque converter
Pointer:
1 oil temperature — — — — — — — — —
Movement MAX position: 135°C
gauge Red zone start point: 120°C

DGT1KX B@CENS (b@CENS)

DGT1KX B@CENS (b@CENS)

Level: 110°C
Alarm: Min. 120°C and [No 1/4 of full scale: 80°C

Red
abnormality is detected 10 1 — Q — — Q — (See figures
Min. position 50°C
(DGT1KX is not generated)] below.)
When sensor is grounded: Max.
Monitor of gauge
Torque converter
Indicator: Alarm: Min. 130°C and [No When sensor is disconnected or
2 oil temperature

Red
LED abnormality is detected 10 1 w Q Q w Q Q hot shorted: Min. of gauge
caution lamp
(DGT1KX is not generated)]

When abnormality is

Red
20 5 — — — — — — b@CENS does not display character message.
detected

Engine coolant Pointer:

3 — — — — — — — — —
temperature gauge Movement
Alarm: Min. 102°C and [No
abnormality is detected

Red
3 — Q — — — Q — —
(CA144 and CA145 are not
generated)]
Operation of gauges and meters

MAX position: 135°C

CA145 CA144 B@BCNS

CA145 CA144 B@BCNS

Engine (See figures Level: 85°C

Red
Engine coolant
Indicator: Alarm: Min. 105°C w Q Q w Q Q monitor below.) 1/4 of full scale: 65°C
4 temperature cau- Min. position: 50°C
LED
tion lamp
When abnormality is
— — — — — —
detected

When abnormality is
— — — — — —
detected
Hydraulic oil tem- Pointer: Max. position: 125°C
10 — — — — — — — — —
perature gauge Movement Red zone start point: 100°C
Level: 85°C (green graduations
DGH2KX B@HANS

DGH2KX B@HANS

Alarm: Min. 100°C and [No only)

Red

abnormality is detected 10 1 w Q Q w Q Q 1/4 of full scale: 65°C

(DGH2KX is not generated)] (See figures
Hydraulic oil tem- Monitor (green graduations only)
Indicator: below.)
11 perature caution Min. position: 50°C
LED When sensor is grounded: Max.
lamp
When abnormality is of gauge
20 5 — — — — — — —
detected When sensor is disconnected or
hot shorted: Min. of gauge
Pointer: MAX position: 100%: 10z
12 Fuel level gauge — — — — — — —
Movement 3/4 of full scale: 75%:
Level: 50%: 32z
1/4 of full scale: 25%: 49.5z
Red zone start point:
(See figures See specified LED lighting per-
Monitor
Fuel level caution Indicator: below.) cent or resistance.
Red

13 Min. 61.3 z 10 1 — Q — — Q — Min. position: 0%: 85z

lamp LED
When sensor is disconnected or
hot shorted: Gauge EMPTY
When sensor is grounded:
Gauge FULL

WA600-6 11
SEN01009-02 10 Structure, function and maintenance standard

Operating condition: Engine operating condition

Operating state
included, error detection time counted (As indi-
(Starting switch ON)

Signal detection controller

cated at right)
Detec-
Engine: Engine is
tion time

Display color
(SEC) Stopped running
Category

Device

Display of message

Display of message
No. Item Remarks

Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Detection
Reset
[When F is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
[When R is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
When F is selected 0 0 — Q — — Q — Green
When N is selected 0 0 — Q — — Q — Green Monitor
39 Shift position When R is selected 0 0 — Q — — Q — Green Trans-
LED
40 pilot lamp
When 4th gear speed is selected 0 0 — Q — — Q — Green mission
When 3rd gear speed is selected 0 0 — Q — — Q — Green
When 2nd gear speed is selected 0 0 — Q — — Q — Green
Q Q
Actual gear speed

When 1st gear speed is selected 0 0 — — — — Green

If error is made in communication, display
— — — — — — —
is held until key is turned OFF.
Displayed on right of [Gear speed display].
Upper line: F, N, R
Interlocked with shift valve. In neutral, how-
9-segment Lower line: 1, 2, 3, 4 Trans-
41 Shift indicator 0 0 — — — — — — — ever, gear speed is not displayed.
LCD If error is made in communication, display mission
Displayed on left of [FNR display].
is held until key is turned OFF.
N when F or R solenoid vale is OFF.
When auto-shift is selected 0 0 — Q — — Q — Green
Auto-shift
42 LED If error is made in communication, display
pilot lamp — — — — — — Green
is held until key is turned OFF.
When auto-shift and shift hold is selected 0 0 — Q — — Q — Green
Shift hold
44 LED If error is made in communication, display
pilot lamp — — — — — — —
is held until key is turned OFF.
When lockup functions 0 0 — — — — Q — Green
Lockup pilot
43 LED If error is made in communication, display
lamp — — — — — — —
is held until key is turned OFF.
Functions when key is OFF to provide haz-
7 Turn signal When turn signal switch is input
LED 0 0 — Q — — Q — Green Monitor ard function interlocking with turn signal
9 pilot lamp (including when key is OFF)
switch.
Head lamp
When high beam is functioning: Head
8 high beam LED 0 0 — Q — — Q — Blue Monitor
lamp ON and High beam ON
pilot lamp
Normal oil pressure (CLOSED) — — — — — — —
2G43ZG 2G42ZG

Below specified value (F) (OPEN)

(detection time is continued) and in 45 5 1 — Q — w Q Q Red Front
seconds after engine is started
Below specified value (R) (OPEN)
(detection time is continued) and in 45
5 1 — Q — w Q Q Red Rear
seconds after engine is started
(No detection time)
Below specified pressure (F) (OPEN)
Brake (detection time is continued) and 45 sec-
accumulator onds after engine is started
15 LED Monitor
oil pressure (No detection time) 1 1 — Q — w Q Q Red Front
caution lamp * When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
Below specified pressure (R) (OPEN)
(detection time is continued) and 45 sec-
onds after engine is started
Others

(No detection time) 1 1 — Q — w Q Q Red Rear

* When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
At normal operation — — — — — — — —
Engine oil
B@BAZG

B@BAZG

16 pressure cau- LED Engine oil pressure reduction error is Engine

tion lamp w Q Q w Q Q Red
received

Normal oil level (CLOSED) — — — — — — —

If alarm is detected when key is turned ON,
Engine oil
B@BAZK

Low oil level (OPEN) continues 2 sec- first information is kept until engine oil
18 level caution LED onds. Monitor
lamp 2 1 — Q — — — — Red reaches normal oil level even if engine is
For 300 seconds after engine is stopped, started.
however, no error is detected.
Normal coolant level (CLOSED) — — — — — — —
Radiator
B@BCZK

B@BCZK

19 coolant level LED Monitor

caution lamp Low coolant level (OPEN) 30 1 — Q — — Q — Red

When parking brake is applied (OPEN) — Q — — Q — Red

When parking brake is not applied
Parking — — — — — — —
(CLOSED)
20 brake pilot LED Monitor
lamp Other than when parking brake is applied
and gear shift lever is at “N” position, and 0 0 A Q Q Red
during starting engine

12 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Operating condition: Engine operating condition

Operating state
included, error detection time counted (As indi-
(Starting switch ON)

Signal detection controller

cated at right)
Detec-
Engine: Engine is
tion time

Display color
(SEC) Stopped running
Category

Device

Display of message

Display of message
No. Item Remarks

Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Detection
Reset
Normal (CLOSED) — — — — — — —
Air cleaner

AA1ANX
21 clogging cau- LED Monitor
tion lamp Sensor detects clogging (OPEN) 2 1 — — — — Q — Red

Normal (CLOSED) — — — — — — —

15BONX
Clogging (OPEN) and torque converter
Transmis- 2 1 — — — — Q — Red
oil temperature > 50°C If abnormality is detected while engine is
sion oil filter
22 LED Monitor stopped, alarm is continued even after
clogging cau-

DHT2L6
engine is started.

OFF
tion lamp When abnormality is detected 3 — — — — — — —

— — — — — — Red
Other than below — — — — — — — — —
Temperature increase (Min. 120°C)
5 5 — Q — — — Q — — Red
(notice alarm)
Temperature increase (1 or 2 below)
1. Oil temperature is above 130°C for 5
seconds.

B@C7NS

B@C7NS
2. When travel speed is above 35 km/h
while brake oil temperature, 125°C and 5 5 w Q Q w Q Q Red
Brake oil above, is detected continuously for 5 sec-
23 temperature LED onds. It is released when oil temperature, Monitor
caution lamp 125°C and below, is detected continu-
ously for 5 seconds.
DGR2KX DGR2KA

When abnormality is detected — — — — — — DGR2KX DGR2KA —

When abnormality is detected — — — — — — —

Other than following — — — — — — — — —

Modulated Temperature rise (Forecast alarm) 0 0 — Q — — — Q — — Red
clutch tem-
15W0NT

15W0NT

24 LED
Others

perature
caution lamp Temperature rise 0 0 w Q Q w Q Q Red

Cooling fan forward drive 0 0 — — — — — — — —

As indicated at right

As indicated at right

Cooling fan reverse rotation state is dis-

Cooling fan
played.
reverse rota- Trans-
25 LED Cooling fan reverse rotation 0 0 — Q — — Q — Orange While fan is reversed, message is dis-
tion pilot mission
played on character display.
lamp
COOLING FAN REVERSE ROTATION

Fan switch and solenoid disagree. 0 0 — w — — — w — — Orange

Simultaneously displays contents on mes-
Ordinary — — — — — — —
Maintenance sage display.
26 LED Monitor
caution lamp 30 h or less before maintenance or main-
— Q — E — Q — E Red
tenance time
Normal — — — — — — —
B@GAZK

B@GAZK

Battery elec-
27 trolyte level LED Sensors: Less than 2 V 10 1 — Q — — — Red Monitor
caution lamp

Option is not applied — — — — — — If abnormality is detected while engine is

Normal voltage (hysteresis on the right stopped, alarm is continued even after
— — — — — — —
figure) engine is started.
Insufficient alternator voltage See figures on alternator terminal R volt-
AB00MA

Battery age.
(Hysteresis on the right figure), no start-
charge cir- 30 1 — — — w Q Q Red
28 LED ing motor C signal input, and during run- Monitor
cuit caution ning of engine
lamp
AB00L6

When abnormality is detected 3 1 w Q Q — — — Red

Not in operation — — — — — — — — — —
Steering oil In operation (CN3-3 = OPEN) — — Q — — Q — Red Implemented only when “Emergency steer-
DDE5MA

DDE5MA

29 pressure cau- LED Monitor ing enabled” is specified on optional setting

tion lamp When abnormality is detected — — — — — — — on monitor panel.

WA600-6 13
SEN01009-02 10 Structure, function and maintenance standard

Operating condition: Engine operating condition

Operating state
included, error detection time counted (As indi-
(Starting switch ON)

Signal detection controller

cated at right)
Detec-
Engine: Engine is
tion time

Display color
(SEC) Stopped running
Category

Device

Display of message

Display of message
No. Item Remarks

Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Detection
Reset
Normal operation
Emergency [Operation of divider
1 1 — Q — — Q — Green
30 steering pilot LED (= Below S/T pressure CN3-3=OPEN)] Monitor
lamp and [Travel speed, min. 1 km/h]
Holds in position — — — — — —
Output mode Power mode = P 0 0 — Q — — Q — Green
pilot lamp Trans-
31 LED Selection of power mode is displayed.
(power Power mode = Other than P — — — — — — — — mission
mode)
Preheating Other than below — — — — — — —
32 LED Engine
pilot lamp In preheating (with signal) 0 0 — Q — — Q — Red
Semi auto When auto digging switch is OFF — — — — — — — Work
33 digging pilot LED When auto digging switch is ON 0 0 — Q — — Q — Green equip-
lamp When error is made in communication — — — — — — — ment
Not in operation and not installed — — — — — — —
Operation 1 1 — Q — — Q — Green Status: Port A: Port B: Panel display
w 2 Hz w 1 Hz

w 2 Hz w 1 Hz
Operation: 0 V: 24 V: Lighting
Auto grease Empty tank 3 1 — — — — Green Monitor Abnormality: 0 V: 0 V: Flashing, 2 Hz
34 LED
pilot lamp
Empty tank: 24 V: 0 V: Flashing, 1 Hz
Others

Abnormality: 24 V: 24 V: OFF
Abnormal 3 1 — — — — Green

Option is not applied — — — — — — — — —

Operation of wheel steering system — — — — — — — — Monitor — When steering wheel option is selected
Operation of AJSS system only when joy- Trans- CAN input signal from transmission con-
0 0 — Q — — — Q — — Green
stick optional setting is made. mission troller
AJSS Work
AJSS lever neutral lock (Output from CAN input signal from work equipment
35 operation LED 0 0 A w Q — A w Q — Green equip-
pilot lamp work equipment controller) controller
ment
Operation of FR prohibition function dur-
Trans- CAN input signal from transmission con-
ing locking of AJSS steering only when 0 0 A w Q — A w Q — Green
mission troller
AJSS optional setting is made.
When error is made in communication — — — — — — —
Not operated — — — — — — —
ECSS pilot Trans-
37 LED Operating 0 0 — Q — — Q — Green
lamp mission
When error is made in communication — — — — — — —
Economy Economy mode 0 0 — Q — — Q — Green
operation Trans-
38 LED
indicator Other than above 0 0 — — — — — — — mission
lamp
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.

14 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Character display function

Using the character display function, you can change the display and settings on the machine monitor.
For usage of functions for the operator, see the Operation and Maintenance Manual.
The operator can operate the part “Operator disclosure function” below.

(*1) Once you pass on the ID input screen, you can directly move to the function selection screen without
displaying this screen until the starting switch is turned OFF.

WA600-6 15
SEN01009-02 10 Structure, function and maintenance standard

Operator mode self-check function

Self-check (0th layer) Select “Displayed” for “10. Engine speed or travel
The self-check function operates 3 seconds after speed display on character display and normal
the key is turned ON. screen” in the optional setting. Then, when the
After the key ON, it automatically starts and ends travel speed is displayed on the LCD at the center
the self-check function operation. of the monitor, the engine speed is displayed on the
After 3 seconds, you are brought to the 2nd layer character display.
automatically. when the engine speed is displayed on the LCD,
In self-check mode, the mode switch is disabled. the travel speed is displayed on the character dis-
play.
For machines of SI specification, the travel speed
unit is km/h and for ones of non-SI specification,
the service optional setting is conformed to.

Normal screen (1st layer)

After the self-check, the following screen is auto-
matically displayed.
Press the U switch to move to the 2nd layer.

* The clock is displayed only for the load meter.

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Failure code display screen (1st layer)

q Pressing the > switch while the alarm screen is

displayed changes to the failure code display
screen.
q Pressing the > switch again displays the ser-
vice meter for 10 seconds, and automatically
returns to the alarm screen.
q If you do not perform any switch input for 30
seconds with the failure code display screen
displayed or a new error occurs, you are
returned to the alarm screen.
q When multiple errors occur, every pressing of
the > switch displays items in descending
order of priority. Items of the same priority is
displayed in reverse chronological order of
occurrence.

q Example of failure code display screen (When

DLT3KA, DW7BKA and DKA0L0 occur simul-
taneously))
The upper column displays failure code (6-digits) so
that the ECM CODE and space are sandwiched.
The lower column displays the message 2.

For information on the failure code (6-digits), ECM

CODE, and message 2, see the message list.

The example shows the failure code of WA600-6.

In 10 seconds, you are automatically brought to the

alarm screen.

WA600-6 17
SEN01009-02 10 Structure, function and maintenance standard

Operator disclosure function

Function opened to the operator (2nd layer and lower)

q If any switch operation is not done at least 60 seconds on the 2nd layer or lower, you are brought to the
1st layer automatically.
q Optional items are not displayed if not selected.
q The language selected by the language selection function is displayed.
q For operation after selecting each menu, see the corresponding menu item.
(Select each menu using the U switch.)

Function opened to the operator (2nd layer and lower)

(*1) This display is not available when the load meter function was turned off through OPT selection of Ser-
vice Mode.
(*2) This menu is not available when the function to display the travel speed or rpm on the character display
is turned OFF through the option selection of service mode.

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10 Structure, function and maintenance standard SEN01009-02

Outline of service mode

The service mode function is used for the ease of troubleshooting for the controllers on the network (includ-
ing the machine monitor itself).
When making initial settings and optional settings for the sensors, enter the service mode of the machine
monitor.

Operating method of machine monitor

1. Entering the service mode
1) Operating method
1] Turn the starting switch of the machine ON.
2] When the normal service meter screen or alarm screen is on the character display of the
machine monitor, press the machine monitor mode selector switches 1 (t) and 2 (<) simulta-
neously for 5 seconds. Then, the INPUT ID screen is displayed.

Machine monitor mode display selector switch 1 2) How to input ID

and 2 1] Press the < or > switch. Then, the
value at the cursor position increases
or decreases at the cursor position.
Select a desired value using the U
switch.
2] Completing operations equivalent to 4
digits (1) brings you to the ELECTRIC
FAULT screen.
a If you input an incorrect value,
press t switch to return the cur-
sor to the highest-order digit, and
re-enter values from there.
a If you press the t switch while
the cursor is at the highest-order
digit, the normal service meter
INPUT ID screen
screen or alarm screen is
returned.
a If any switch operation is done at
least 60 seconds during the ID
input, the normal service meter
screen or alarm screen is
returned.

ID to enter the service mode is

“6491”.
Remarks: If the starting switch is
turned OFF in the service mode, the
normal service meter screen or alarm
screen is returned at the next starting
switch ON.

WA600-6 19
SEN01009-02 10 Structure, function and maintenance standard

2. Service mode menu

a The service mode menu shows a different

screen by operating the < or >switch. Select a
target operation menu screen with the switch.
a If you press the U when the following screen
(selection screen) is displayed, the menu
screen/operation screen of each function
appears.
a If you press the t when the following screen
(selection screen) is displayed, the normal ser-
vice meter screen or alarm screen is returned
at the next starting switch ON.

Operation menu screen (character display)

1) ELECTRIC FAULT screen 2) MACHINE FAULT screen

[ ] field displays number of the failure history [ ] field displays number of the failure history
currently recorded (up to 20 cases). currently recorded (up to 20 cases).
Outline Outline
This function is used to check the electrical system This function is used to check the mechanical sys-
failure history of each controller saved in the tem failure history of each controller saved in the
machine monitor. For the failure codes displayed in machine monitor. For the failure codes displayed in
the electrical system failure history, see “Trouble- the mechanical system failure history, see “Trouble-
shooting”. After each failure is repaired and the nor- shooting”.
mal operation is confirmed, delete the failure
history.

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10 Structure, function and maintenance standard SEN01009-02

3) REAL-TIME MONITOR screen 5) NO INJECTION screen

Outline Outline
This function is used to check the input and output This function is used when lubricating the engine
signals, etc. recognized by each controller on the with the engine stopped when restarting it after a
network. long time of non-operation.
For the starting method of engine using this func-
4) CYLINDER CUT-OUT screen tion, see “Testing and adjusting: No injection crank-
ing operation of engine”.

6) TUNING screen

Outline
This function is used to stop fuel injection by cylin-
der and specify the cylinder having defective com-
bustion by shutting off fuel injected from the fuel Outline
injector. The installation errors and manufacturing disper-
For the method of checking using this function, see sion of the sensors, solenoid valves, etc. are cor-
“Testing and adjusting: Operating engine in reduce rected and adjusted, and control characteristic data
cylinder mode”. is changed upon request of the user. Use this func-
tion if you have changed or added sensors, valves
or controllers. For adjustment using this function,
see “Testing and adjusting: Adjustment performed
on the monitor”.

WA600-6 21
SEN01009-02 10 Structure, function and maintenance standard

7) MAINTENANCE MONITOR screen 9) MANUAL SNAP SHOT screen

Outline Outline
This function is explained in “Operation and Mainte- The direction to take in the snap shot data is given
nance Manual, Operation, Character display, Dis- to the VHMS.
play of replacement periods of filters and oils”. The This function is used only when the VHMS is
set replacement periods of a filter and oil are installed.
changed and their functions are stopped. For inspection with this function, see “Testing and
adjusting volume, Inspection with VHMS”.
8) OPERATION INFO screen
10) OPTIONAL SELECT screen

Outline
Fuel consumption per operating hours is displayed. Outline
With this function, you can display installation of an
optional device and change the setting of that
device. Use this function after any optional device
is installed or removed. For the method of setting
and changing this function, see “Testing and adjust-
ing: Adjustment performed on the monitor”.

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10 Structure, function and maintenance standard SEN01009-02

11) Machine serial No. input function screen

Outline
The machine serial No. is displayed and set.
This screen is used for machine management etc.

12) MACHINE screen

a The lower column displays the currently

selected model.

Outline
This function is used to display or select the
machine model.

13) INITIALIZE screen

Outline
This function is used only in the factory. Do not use
it.

WA600-6 23
SEN01009-02 10 Structure, function and maintenance standard

Function of displaying electrical system failure history

1) Display of electrical system failure history and selection of clearing entirely the electrical system failure
history
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
Pressing the t switch changes the screen to the “Electrical system failure history selected” screen.
Pressing the U switch changes the screen to the “Electrical system failure history individual cleared” screen
or the “Electrical system failure history all cleared” screen.

2) Selection of electrical system failure history (1st layer)

Pressing the < switch changes the screen to the “Select initialization” screen.
Pressing the > switch changes the screen to the “Select display of mechanical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.

24 WA600-6
10 Structure, function and maintenance standard SEN01009-02

3) Display of electrical system failure history and the electrical system failure history all clear selected (2nd
layer)
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
Pressing the t switch changes the screen to the “Display electrical system failure history” screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
q If there is only 1 history, the current screen does not change to the “Electrical system failure history all
clear” screen (Only the “Electrical system failure history individual clear” screen is displayed).
q If the number of the histories exceeds 20, they are deleted in order from the oldest one.

4) Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
Select “YES” or “NO” with the < or > switch.
The cursor “_” blinks on the selected item. If “YES” is selected and the t switch is pressed, clearing is exe-
cuted. If “NO” is selected and the t switch is pressed, clearing is cancelled and the display changes as
shown below.
q If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history”
screen of the corresponding failure.
(Returns to the screen before the “Electrical system failure history individual clear” (Electrical system
failure history all clear) screen).)
q If clearing is executed (YES), the current screen returns to the “Display electrical system failure history”
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the “Select electrical system fail-
ure history” screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. At this time, the operation cancel peep (for 1 sec) is
heard.
If any failure history is cleared, the operation acceptance peeps (“ON” for 0.1 sec, “OFF” for 0.1 sec, “ON” for
0.1 sec) are heard.
When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.

WA600-6 25
SEN01009-02 10 Structure, function and maintenance standard

Function of displaying mechanical system failure history

1) Display of mechanical system failure history

The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
q The mechanical system fault histories cannot be deleted.

2) Selection of mechanical system failure history (1st layer)

Pressing the > switch changes the screen to the “Select real-time monitor” screen.
Pressing the < switch changes the screen to the “Select display of electrical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Mechanical system failure history selected” screen.

26 WA600-6
10 Structure, function and maintenance standard SEN01009-02

3) Display of mechanical system failure history (2nd layer)

The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the older ones to the newer ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.

WA600-6 27
SEN01009-02 10 Structure, function and maintenance standard

Function of real-time monitor

The real-time monitor function displays the information saved in the controllers mounted on the machine in
real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It
has 2 display modes of the normal display mode and the 2-item display mode for displaying 2 data simulta-
neously.

Operating procedure
1. Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
inputting screen.

2. Input the ID with the < and > switches, and then press the U switch to enter the screen for the service
mode.
3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch.

28 WA600-6
10 Structure, function and maintenance standard SEN01009-02

4. Press the U switch, and the “Monitor panel information display select screen”.
Each time the < switch or > switch is pressed, the screens to select the following information or function
are displayed in order; the transmission controller information, engine controller information, VHMS con-
troller information, work equipment controller information and 2-item display function.

WA600-6 29
SEN01009-02 10 Structure, function and maintenance standard

5. Press the U switch while a selection screen is 2] Select a desired digit and press the
displayed, and the screen to select the “1 item U switch.
display” function or “2 item display” function is The cursor moves to the 2nd position.
displayed. Select the digits for the all positions in
1) 1 item display screen the same manner as the previous
The screen to select display of the infor- steps.
mation of the monitor panel, transmission 3] Input a value at the lowest-order digit
controller, engine controller, VHMS con- and press the U switch to move to
troller or work equipment controller or the the screen to select the display of 2nd
“2 item display” function are displayed. item.
q If you press the t switch during the
processing, the screen returns to the
“Select 2 items display information”
screen.

***: tem name

%%%%% : Data and unit (Unit: SI unit)
$$$$ : ID number

q Items displayed on the “Display 1 item” q In display of 2 items mode, input the
screen change in order by pressing < and ID of necessary information and
> switches, displaying information held by press the U switch to display 2 items
the controller. simultaneously.
2) 2 item display function q The ID displayed is the same as the
If the “2 item display function” is selected, ID number displayed on the “Display
2 items are displayed simultaneously. 1 item” screen.

1] How to input ID
“00000” is displayed during screen
transition.
Input a value between 0 and 9 at the
cursor (_) position.
First, the cursor appears at the high-
est-order digit. Each time the > or <
switch is pressed, the digit changes
by 1 between 0 and 9.

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10 Structure, function and maintenance standard SEN01009-02

WA600-6 31
SEN01009-02 10 Structure, function and maintenance standard

List of display contents of the real-time monitor

The state of the controller input and output signals can be checked using the real-time monitor function of the
monitor.
The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the machine monitor:
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Monitor software part Part No. of software is dis-
1 20200 VERSION Depends on the software part number
No. played
Application version number is
2 Application version 20221 VERSION (APP) Depends on application version number
displayed
Data version number is dis-
3 Data version 20222 VERSION (DATA) Depends on data version
played
Li: 800 ± 25 rpm
Hi: 2000 ± 50 rpm (P-mode)
4 Engine Speed 01001 ENG SPEED Engine speed is displayed 1900 ± 50 rpm (E-mode)
T/C stall: 1800 ± 100 rpm (P-mode)
1730 ± 100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h ± 5% (P-mode, T/C)
F2/R2: 11.7/12.8 km/h ± 5% (P-mode, T/C)
5 Travel speed 40000 SPEED Travel speed is displayed
F3/R3: 20.3/22.0 km/h ± 5% (P-mode, T/C)
F4/R4: 33.8/37.0 km/h ± 5%(P-mode, T/C)
6 Fuel level 04202 FUEL SENSOR Fuel level is displayed 0 – 100%
Gauge FULL (100%,10 z): 0.32 V When sensor is disconnected or hot
Gauge 1/2 (50%, 32 z): 0.88 V shorted: gauge EMPTY
7 Fuel level 04207 FUEL SENSOR Fuel level is displayed
Caution (61.3 z): 1.45 V When sensor is grounded: gauge
Gauge EMPTY (0%, 85 z): 1.81 V FULL
Coolant temperature, max. 100°C
Engine coolant temper- Coolant temperature is dis-
8 04103 COOLANT TEMP Depends on machine status (°C) Data is obtained from engine con-
ature played
troller.
Torque converter oil Torque converter oil tempera-
9 40100 TC OIL TEMP Depends on machine status (°C) Overheat: 120°C
temperature ture is displayed
When sensor is disconnected or hot
Torque converter oil Torque converter oil tempera- Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
10 40101 TC OIL TEMP
temperature ture is displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Hydraulic oil tempera- Hydraulic oil temperature is Hydraulic tank oil temperature: Max.
11 04401 HYD TEMP Depends on machine status (°C)
ture displayed 100°C
When sensor is disconnected or hot
Hydraulic oil tempera- Hydraulic oil temperature is Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
12 04404 HYD TEMP
ture displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Brake oil temperature is dis-
13 Brake oil temperature 30202 R BRAKE OIL Depends on machine status (°C)
played
Brake oil temperature is dis- (120°C): 1.62 V
14 Brake oil temperature 30205 R BRAKE OIL
played (80°C) : 2.91 V
15 Charge level 04302 ALTERNATOR R Charge level is displayed Depends on machine status (0.0 – 30 V)
Small lamp voltage is dis-
16 Small lamp voltage 40200 SMALL LAMP Depends on machine status (0.0 – 30 V)
played
Battery electrolyte level Battery electrolyte level is
17 40300 BATTERY A Min. 2 V Only when optional setting is made
A displayed
Battery electrolyte level
18 40301 BATTERY B — — Not used.
B
Standard lift arm
Lift arm top: 46.8 ± 2.0deg
Calculation results of lift arm Lift arm bottom: –42.3 ± 3.0deg
19 Lift arm angle 06001 BOOM ANG
angle is displayed Hi lift arm
Lift arm top: 49.3 ± 2.0deg
Lift arm bottom: –40.5 ± 3.0deg
Standard lift arm
Lift arm top: 3.80 ± 0.3 V
Input voltage value to lift arm
Lift arm bottom: 1.33 ± 0.5 V
20 Lift arm angle 06003 BOOM ANG angle sensor potentiometer is
Hi lift arm
displayed
Lift arm top: 3.87 ± 0.3 V
Lift arm bottom: 1.38 ± 0.5 V
(When arm is placed horizontally at
Lift arm bottom pres- BOOM BTM Lift arm bottom pressure is
21 40400 Depends on status rated loading and Hi lift arm opera-
sure PRESS displayed
tion lever at FULL): Approx. 18 MPa
(0MPa) : 0.5V
Lift arm bottom pres- BOOM BTM Lift arm bottom pressure is (10MPa): 1.3V
22 40402
sure PRESS displayed (20MPa): 2.1V
(50MPa): 4.5V
Only when optional setting is made
in load meter
BOOM HEAD Lift arm head pressure is dis-
23 Lift arm head pressure 40500 Depends on status (When arm is placed horizontally at
PRESS played
rated loading and Hi lift arm opera-
tion lever at FULL): Approx. 0.5 MPa
(0MPa) : 0.5V
BOOM HEAD Lift arm head pressure is dis- (10MPa): 1.3V Only when optional setting is made
24 Lift arm head pressure 40501
PRESS played (20MPa): 2.1V in load meter
(50MPa): 4.5V
Lift arm differential pressure
corresponding to no load
25 Calibration pressure 40600 CAL PRESS — Not used.
around level position at load
meter calibration

32 WA600-6
10 Structure, function and maintenance standard SEN01009-02

No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Load meter calculated weight Only when optional setting is made
26 Classified weight 40800 MES LOAD Load weight [t]
is displayed in load meter
27 Position of rotary switch 30802 SW1, SW2, SW3 — — Not used.
28 Position of DIP switch 30904 SW5-1, SW5-2 — — Not used.
29 Position of DIP switch 30905 SW5-3, SW5-4 — — Not used.
30 Position of DIP switch 30906 SW6-1, SW6-2 — — Not used.
31 Position of DIP switch 30907 SW6-3. SW6-4 — — Not used.
D-IN-0: Head lamp
10000000 (Head lamp = on) D-IN-1: Not used
00000000 (Not used) D-IN-2: Starting motor C
00100000 (Starting motor C = on) D-IN-3: Not used
00000000 (Not used) D-IN-4: Auto grease A
The state of input signal is 00001000 (Auto grease: Empty) (Only when optional setting is made
32 Input signal D_IN_0-7 40900 D-IN--0------7
displayed 00000100 (Auto grease: Operation) in auto grease)
00000000 (Auto grease: Abnormal) D-IN-5: Auto grease B
00001100 (Auto grease: Abnormal) (Only when optional setting is made
00000000 (Not used) in auto grease)
00000000 (Not used) D-IN-6: Not used
D-IN-7: Not used
D-IN-8: Not used
D-IN-9: Not used
00000000 (Not used) D-IN-10: Load meter material selec-
00000000 (Not used) tor SW input
00100000 (Load meter material selector SW = (Only when optional setting is made
on) in load meter)
The state of input signal is 00010000 (Load meter addition/reduction selec- D-IN-11: Load meter addition/reduc-
33 Input signal D_IN_8-15 40901 D-IN- 8-----15
displayed tor SW = on) tion selector SW input
00001000 (Right winker on) (Only when optional setting is made
00000100 (Left winker on) in load meter)
00000010 (Monitor mode SW (U) = on) D-IN-12: Winker right
00000001 (Monitor mode SW (t) = on) D-IN-13: Winker left
D-IN-14: Monitor mode SW (U)
D-IN-15: Monitor mode SW (t)
10000000 (Front brake oil pressure SW = on = D-IN-16: Brake oil pressure (Front)
low level) D-IN-17: Brake oil pressure (Rear)
01000000 (Rear brake oil pressure SW = on = D-IN-18: Not used
low level) D-IN-19: Not used
00000000 (Not used) D-IN-20: Air cleaner clogging
Input signal D_IN_16- The state of input signal is 00000000 (Not used) D-IN-21: Not used
34 40902 D-IN-16-----23
23 displayed 00001000 (Air cleaner clogging SW = on) D-IN-22: Parking brake emergency
00000000 (Not used) release SW
00000010 (Parking brake emergency release SW D-IN-23: Load meter total weight
= on) display SW
00000001 (Load meter total weight display SW = (Only when optional setting is made
on) in load meter)
D-IN-24: T/M filter clogging
10000000 (T/M filter clogging SW = on)
(Only when optional setting is made)
00000000 (Not used)
D-IN-25: Not used
00100000 (Parking brake = on)
D-IN-26: Parking brake
00010000 (Coolant level SW = on = low level)
Input signal D_IN_24- The state of input signal is D-IN-27: Coolant level
35 40903 D-IN-24-----31 00000000 (Not used)
31 displayed D-IN-28: Not used
00000100 (Engine oil level SW = on = low level)
D-IN-29: Engine oil level
00000010 (Emergency steering operation SW =
D-IN-30: Emergency steering opera-
on)
tion (Low S/T pressure)
00000000 (Not used)
D-IN-31: Not used
D-IN-32: Subtotal SW
(Only when optional setting is made
10000000 (Subtotal SW = on) in auto grease)
01000000 (Cancel SW = on) D-IN-33: Cancel SW
00100000 (High beam = on) (Only when optional setting is made
Input signal D_IN_32- The state of input signal is 00000000 (Not used) in auto grease)
36 40904 D-IN-32-----39
39 displayed 00001000 (SW for servicing = on) D-IN-34: High beam
00000100 (Monitor mode SW (>) = on) D-IN-35: Not used
00000010 (Monitor mode SW (<) = on) D-IN-36: SW for servicing
00000000 (Not used) D-IN-37: Monitor mode SW (>)
D-IN-38: Monitor mode SW (<)
D-IN-39: Not used
1000 (Buzzer = on) D-OUT-0: Buzzer
Output signal The state of output signal is 0000 (Not used) D-OUT-1: Not used
37 40952 D-OUT-0--3
D_OUT_0-3 displayed 0000 (Not used) D-OUT-2: Not used
0000 (Not used) D-OUT-3: Not used

WA600-6 33
SEN01009-02 10 Structure, function and maintenance standard

The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the VHMS.
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
–30 – +100°C, depending on ambient tem-
1 Ambient temperature 37501 AIR TEMP Ambient temperature
perature
0.0 – 20.0 kPa
2 Blow-by pressure 42801 BLOWBY PRESS Blow-by pressure
See Pm-clinic check sheet.
Engine oil tempera- 0 – 180°C, depending on engine oil tempera-
3 42703 ENG OIL TEMP Engine oil temperature
ture ture
Check after machine is warmed up.
Exhaust temperature EXHAUST TEMP
4 42610 Exhaust temperature (F) 200 – 950°C
(F) F
See Pm-clinic check sheet.
Check after machine is warmed up.
Exhaust temperature EXHAUST TEMP
5 42611 Exhaust temperature (R) 200 – 950°C
(R) R
See Pm-clinic check sheet.
0.00 – 50.00 MPa
6 Brake oil pressure (F) 92800 BRAKE PRESS F Brake oil pressure (F)
See Pm-clinic check sheet.
BRAKE PRESS 0.00 – 50.00 MPa
7 Brake oil pressure (R) 92801 Brake oil pressure (R)
R See Pm-clinic check sheet.
8 Brake signal 92900 BRAKE SIG Brake signal Brake operation = ON
0.00 – 50.00 MPa
9 Steering oil pressure 93000 S/T OIL PRESS Steering oil pressure
See Pm-clinic check sheet.
10 Start signal 93100 START SIG Start signal Starting switch ON = ON
00000000 (Unused) D-IN-0: Unused
01000000 (Download switch under cab D-IN-1: Download switch under
ON = on) cab
00000000 (Unused) D-IN-2: Unused
11 Input signal D_IN_0-7 40944 D-IN--0------7 Input signal state 00000000 (Unused) D-IN-3: Unused
00000000 (Unused) D-IN-4: Unused
00000000 (Unused) D-IN-5: Unused
00000000 (ORBCOMM connection = on) D-IN-6: ORBCOMM connection
00000000 (Brake operation = on) D-IN-7: Brake operation signal
0000 (Unused) D_OUT_0: Unused
Output signal 0000 (Unused) D_OUT_1: Unused
12 40948 D-OUT--0--3 Output signal state
D_OUT_0-3 0010 (During VHMS operation = on) D_OUT_2: VHMS operation
0000 (Unused) D_OUT_3: Unused
0000 (Kept at 0) SEL-0: Kept at 0
0000 (Kept at 0) SEL-1: Kept at 0
13 SEL signal 0-3 00248 D-SEL-0--3 SEL signal state
0010 (Kept at 1) SEL-2: Kept at 1
0000 (Kept at 0) SEL-3: Kept at 0

34 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Engine reduced-cylinder function

1. Using the < and > switches, display “Reduced
cylinder mode selection (CYLINDER CUT-
OUT)” screen, and then press the U switch.

2. Operating method of reduced-cylinder function

Every pressing the > switch moves the cursor to the right (select a cylinder to issue the reduced-cylinder
command).
Every pressing the < switch moves the cursor to the left (select a cylinder to issue the reduced-cylinder com-
mand).
Press the U switch to issue the monitor reduced-cylinder command. Every pressing this switch repeats out-
put/release of the command.
Press the t switch to return to the “Reduced cylinder mode selection (CYLINDER CUT-OUT)” screen and
the reduced-cylinder commands from the monitor are all released.

Operation example: When the 3rd cylinder stop command is issued

WA600-6 35
SEN01009-02 10 Structure, function and maintenance standard

No injection cranking

For the starting method of engine using this function, see “Testing and adjusting: No injection cranking oper-
ation of engine”.
This section describes only the operating method.

36 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Adjustment function
For adjustment using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.
This section describes its outline only.

01: Reset of transmission initial learning

See “Testing and adjusting: Setting of trans-
mission initial learning”.
See “Testing and adjusting: Reset of initial
learning”.
See “Testing and adjusting: Setting of trans-
mission initial learning”.
02: ECMV compensation
See “Testing and adjusting: Adjustment of
transmission ECMV current”.
04: Adjustment of transmission shift point
See “Testing and adjusting: Adjusting a shift
point”.
05: Lift arm angle adjustment of work equipment
controller
See “Testing and adjusting: Adjustment of lift
arm angle sensor (Raise) (for EPC lever)”.
06: Adjustment of lift arm raise lever position
before detent and variations in the dead zone
of EPC
See “Testing and adjusting: Adjusting variation
correcting calibration of lift arm raise lever
before detent”.
See “Testing and adjusting: Adjusting lift arm
raise EPC starting current”.
07: Adjustment of lift arm lower (float) lever and
variations in the dead zone of EPC
See “Testing and adjusting: Adjusting variation
correcting calibration of lift arm lower (float)
EPC lever”.
See “Testing and adjusting: Adjusting lift arm
lower EPC starting current”.
08: Adjustment of bucket tilt lever position before
detent and variations in the dead zone
See “Testing and adjusting: Adjusting variation
correcting calibration of bucket tilt lever posi-
tion before detent”.
See “Testing and adjusting: Adjusting bucket
tilt EPC starting current”.
09: Adjustment of bucket dump EPC starting cur-
rent
See “Testing and adjusting: Adjustment of
bucket dump EPC starting current”.
10: Adjustment of 3-spool valve EPC cylinder
extraction lever and variations in the dead
zone of EPC
a This item shall not be operated.

WA600-6 37
SEN01009-02 10 Structure, function and maintenance standard

11: Adjustment of 3-spool valve EPC cylinder

retraction lever and variations in the dead zone
of EPC
a This item shall not be operated.

12: Adjustment of AJSS neutral position (AJSS

specification)
See “Testing and adjusting: Adjustment of
AJSS neutral position”.

13: Adjustment of AJSS EPC output current (AJSS

specification)
See “Testing and adjusting: Adjustment of
AJSS EPC output current”.

14: Modification of lift arm (boom) lever pattern

See “Testing and adjusting: Modification of lift
arm (boom) lever pattern”.

15: Modification of bucket lever pattern

See “Testing and adjusting: Modification of
bucket lever pattern”.

16: Adjustment of lift arm (boom) raise/lower stop

modulation
See “Testing and adjusting: Adjustment of lift
arm (boom) raise/lower stop modulation”.

17: Adjustment of pump cut-off pressure in lift arm

(boom) raise
See “Testing and adjusting: Adjustment of
pump cut-off pressure in lift arm (boom) raise”

18: Adjustment of lift arm (boom) angle sensor

(raise) (For load meter)
See “Testing and adjusting: Adjustment of lift
arm (boom) angle sensor (raise) (For load
meter)”.

19: Adjustment of lift arm (boom) angle sensor

(lower) (For load meter)
See “Testing and adjusting: Adjustment of lift
arm (boom) angle sensor (lower) (For load
meter)”.

21: Modification of AJSS oil pressure command

table pattern
See “Testing and adjusting: Modification of
AJSS oil pressure command table pattern”.

22: Adjustment of maximum speed limit

See “Testing and adjusting: Adjustment of
maximum speed limit”.

38 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Maintenance monitoring function

1. Selection of display of maintenance monitor function (1st layer)
For the destination you can go to using <, >, and t switches, see “Function 1 for the service person: 2nd
layer transition diagram”.

Pressing the U switch changes the screen to the “Item NO. 1 is displayed” screen.

WA600-6 39
SEN01009-02 10 Structure, function and maintenance standard

2. “Select maintenance item” screen

(1) Using the > switch, display items in ascending order of numbers.
a When the last item is selected, the screen is changed to the “Default value is set” screen.
(2) Using the < switch, display items in descending order of numbers.
a When the last item is selected, the screen is changed to the “All item timer stop/all item valid selector” screen.

a. Change of maintenance interval time

How to input interval
(1) Input a value between 0 and 9 at the cursor
position.
(2) The cursor is positioned at the highest-order
digit. Pressing the > or < switch increases or
decreases the value between 0 and 9.
(3) Input a desired value and press the U switch.
(4) The cursor moves to the 2nd position. Select
the digits for the all positions by performing
steps (2) and (3) above.
(5) After selecting the digit for the lowest position,
press the U switch.
a If the input interval time is acceptable, the
screen changes to the check screen.
a If the input interval time is not acceptable, the
time does not change.
(6) Return the cursor to the highest-order digit.
a The lower limit of set value is 50h.
(7) When you have entered a wrong value to a
position succeeding to the highest-order digit,
move to the highest-order digit using t switch
and repeat the procedure from the first.
a In this case, values that had been entered
remain as they are until modified.
(8) When the cursor is at the highest-order digit,
move to the higher layer using t switch.
q Select YES or NO with the < or > switch.
q The cursor (_) is blinking at the selected item. If
you have selected “YES”, press the t switch to
execute the change. If you have selected “NO”,
press it to return to the “Select maintenance
item” screen without executing the change.
a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When an interval time is changed, the remain-
ing timer time is changed as shown below.
(Interval time being set – Elapsed time from
the last replacement)

40 WA600-6
10 Structure, function and maintenance standard SEN01009-02

b. Selection between enabling or disabling timer 3. Setting of a default value

by item

q Select YES or NO with the < or > switch.

q When “Timer by item” is enabled at present, q The cursor (_) blinks on the selected item. If
“ON o OFF” is displayed at the lower column. “YES” is selected with the t switch, the
q When “Timer by item” is disabled at present, change is executed. If “NO” is selected, the
“OFF o ON” is displayed at the lower column. change is cancelled and the “Select mainte-
a By default, it is “ON” and the timer function is nance item” screen is returned.
enabled. a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When you disable “Timer by item”, “OFF” is
displayed at the upper column. q If the default value is executed, all the currently
q When you enable “Timer by item”, “ON” is dis- changed interval times are returned to the
played at the upper column. default values. It is executed on every item
independent of whether or not the function is
q Select YES or NO with the < or > switch. enabled for a specific item.
q The cursor (_) blinks on the selected item. If
“YES” is selected with the t switch, the q Timer remaining time shall be Default value –
change is executed. If “NO” is selected, the Elapsed time since the last replacement.
change is cancelled and the “Select mainte- a The reset frequency is not incremented and
nance item” screen is returned. remains the same as before the resetting.
a By default, the cursor is set to NO (cancel) to a Set enable for enable or disable of individual
prevent resetting error. items.

q Specify disabling the timer or releasing the dis-

abling by maintenance item.

q If you cancel the timer disabled, interval time

before having been disabled is used as the set
value.

q The timer remaining time is reset.

a The reset frequency is not incremented and
remains the same as before the resetting.

WA600-6 41
SEN01009-02 10 Structure, function and maintenance standard

4. Selection between timer stop for all items and enable by item

*1 Press the U switch to go to the “ALL ITEMS OFF” screen.

*2 When “ALL ITEMS OFF” is selected
*3 When ALL ITEMS OFF is executed:
The timer function for all items is stopped and the “Select maintenance monitor” screen is restored.
Setting for individual items is also disabled.
When ALL ITEMS OFF is canceled:
The operation is cancelled and the MAINTENANCE MONITOR screen is restored.
*4 When “ALL ITEMS ON” is selected
*5 Select YES or NO with the < or > switch.
The cursor (_) is blinking at the selected item.
a By default, the cursor is set to NO (cancel) to prevent resetting error.
*6 When ALL ITEMS ON is executed:
Interval time being set for all items is disabled independent of whether or not it is enabled or dis-
abled for a specific item.
The timer remaining time is reset.
The reset frequency is not incremented and remains the same as before the resetting.
The “Select maintenance monitor” screen is restored. Setting for individual items is also enabled.
When ALL ITEMS OFF is canceled:
The operation is canceled and the “Select maintenance monitor” screen is restored.

42 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Operating information display function

Outline
q The value of fuel consumption is obtained by adding the target injection amount sent from the engine
controller.
q It is not measured but calculated fuel consumption. Use it as a rough standard.

*1 The upper column displays fuel consumption The lower column displays the travel distance
[L/km or L/mile] per 1 km (or 1 mile) from the [km or mile] from the last resetting.
last resetting. The unit km or mile shall be selected depend-
It is calculated from the fuel consumption and ing on that used on the odometer.
travel distance above. The counting is stopped at 9999999.9, the
The unit km or mile shall be selected depend- upper limit.
ing on that used on the odometer.
The counting is stopped at 99999.9, the upper *3 The upper column displays the cumulative fuel
limit. consumption [L] from the last resetting.
The lower column displays the average fuel The counting is stopped at 9999999.9, the
consumption [L/h] from the last resetting. upper limit.
The counting is stopped at 99999.9, the upper The lower column displays the elapsed time [h]
limit. from the last resetting.
The counting is stopped at 9999999.9, the
*2 The upper column displays the cumulative fuel upper limit.
consumption [L] from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.

WA600-6 43
SEN01009-02 10 Structure, function and maintenance standard

*4 Calculation of (*4) is executed when the load 8) If t switch is pressed before finishing
meter is installed. (The screen is not available entering, the cursor moves to the sign
when the load meter is not installed.) position. In this case, the value remains
The upper column displays the loaded volume unchanged. Using the t switch, return to
[ton] from the last resetting. the previous screen.
The counting is stopped at 199999999.9, the 9) If the value confirmed for the lowest-order
upper limit. digit is outside the range from –50.0 to
Short ton or metric ton depends on optional +50.0, the cursor moves to the sign posi-
setting. tion with the value unchanged as with
The lower column displays the loading fre- when the t switch is pressed.
quency from the last resetting.
The counting is stopped at 65000, the upper Processing on the monitor panel:
limit. q Default value: 0.0%
(*1 – *4) q This setting allows correcting the cumulative
Calculation is done only for the duration in fuel consumption (L) in the range of –50.0 to
which the engine is run. +50.0%.

*5 Using the U switch, clear data of (*1), (*2),

(*3), and (*4) to return to the previous screen.
Using the t switch, return to the previous
screen without resetting.
Note: Other than the reset operation above,
you can reset data by initializing the monitor
panel or specifying optional setting to OFF.

Acquisition of fuel consumption (L)

q The monitor panel calculates the cumulative
fuel consumption (L) based on the momentary
fuel consumption (L/h) from the engine control-
ler.

*6 Setting gain correction

1) When the screen appears, the current set
value is displayed and the cursor is placed
on the sign (+/–).
2) When the cursor is placed on the sign,
every pressing the > or < switch displays
“+” io “–” in order.
3) Press the U switch to confirm the sign.
o Cursor moves to the highest-order digit.
4) First, the cursor appears at the highest-
order digit. Each time the > or < switch is
pressed, the value at the digit increases or
decreases between 0 and 9. (The highest-
order digit is between 0 and 2.)
5) Input a desired value and press the U
switch to confirm the entry.
6) The cursor moves to the lowest-order
digit. Select a value in the same manner
as step 4).
7) Input a value at the lowest-order digit and
press the U switch. (The screen returns
to the previous one when the entry is con-
firmed.)

44 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Snap shot function

For this function, see the section of “Testing and adjusting: Manual snapshot function”.

WA600-6 45
SEN01009-02 10 Structure, function and maintenance standard

Function of selecting optional device

For setting using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.

Input of machine serial number (No.)

For setting using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.

Model selection function

For setting using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.

46 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Load meter function 2. Weight calculation

a Machine equipped with load meter The load meter calculates weight (W) by
detecting the lift arm operating pressure (P) by
1. Outline the pressure sensor (A) installed at the lift arm
q The load meter displays the remaining amount cylinder bottom and pressure sensor (B)
of total or target loaded volume by classifying installed at its head and calculating the center
working objects into five types and measuring of gravity by the lift arm angle sensor (C).
the bucket-loaded volume.
q It is provided with the functions to switch
between reduction mode and addition mode,
and between working objects, and the function
to display and clear total loaded volume. To
operate these functions, use the load meter
mode selector switch and monitor panel mode
selector switch.
q It is also equipped with calibration mode, cali-
bration clear mode, and load meter calculation
stop mode. To operate these modes, use the
monitor panel mode selector switch.
q Installing a printer (if equipped) allows printing
of measured data. Weight calculation is done based on the differ-
q For usage of the functions, see Operation and ential pressure (C) between the reference
Maintenance Manual. value (A) where the lift arm pressure with no
load is saved (corrected by calibration) and the
calculated lift arm pressure (B) with load.
In addition, to improve its precision, the detec-
tion function calculates weight during lift arm
raise operation.

WA600-6 47
SEN01009-02 10 Structure, function and maintenance standard

Operation of tires and work equipment gener-

ates spring effect on the machine, however,
the measured lift arm pressure (D) is provided
with the characteristic shown in the figure
below.

The value (D) measured by lift arm raise oper-

ation is calculated based on the value obtained
as the calculated value (B) according to the fol-
lowing calculation criteria.

q For 0.5 seconds after lift arm raise operation

start (E), the lift arm state changes from the
static state to operating state and the pressure
largely fluctuates and is not stable. Therefore,
it is not used for calculation of the calculated
value (B).
q The spring effect of the machine is generated
at interval of approx. 1 second. Therefore, the
calculated value (B) is obtained based on the
mean every 1 second during the period
between the lift arm raise operation start and
the operation end.

48 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Determination of lift arm raise operation start

The load meter determines that the lift arm starts moving and starts weight calculation when all the following
conditions are satisfied.
The lift arm angle is between –10 and –30°.
Condition 1
(The range between the horizontal position and position immediately before it contacts the ground)
The lift arm angle changes at least 0.1° for 0.1 second.
Condition 2
(The lift arm starts moving with min. specified speed in raising direction.)

Determination of lift arm raise operation stop

The load meter determines that the lift arm stops moving and ends weight calculation when one of the follow-
ing conditions is satisfied.
The lift arm angle changes to under 0.5° for 0.5 second.
Condition 1
(The lift arm speed in raise direction is reduced below the specified speed.)
The lift arm angle changes to lowering direction.
Condition 2
(When the lift arm is lowered, weight calculation finishes.)
The lift arm angle changes to above +20°.
Condition 3
(At a high position, weight calculation stops.)
The lift arm raise speed suddenly changed.
Condition 4
(The current angular velocity is decreased 70% or more of the previous one.)
Condition 5 Weight calculation was performed 7 times.

Display of calculated weight

The average of calculated weight values are displayed.
Number of Calculation time
Weight calculation and display method
calculations (sec)
Displays weight based on a single calculation result.
Only 1 time 1.5 – 2.5 In this case, however, the weight display blinks to inform the operator that the preci-
sion is unstable due to short calculation time.
2 times 2.5 – 3.5 Displays weight based on the mean value of 2 calculation results.
Min. 3 times 3.5 – 0.0 Displays weight based on the mean value of latest 3 calculation results.

WA600-6 49
SEN01009-02 10 Structure, function and maintenance standard

3. Reduction/addition mode

Monitor display in addition mode Monitor display in reduction mode

This is the mode to display the bucket-loaded vol- This is the mode to display the bucket-loaded vol-
ume every time. ume every time based on the pre-set target weight.
Use this mode for grasping the work rate. Use this mode for constant loading work.

q When addition mode is selected, “TOTAL q When reduction mode is selected, “REMAIN-
LOADED” is displayed at the display of addi- ING TARGET” is displayed at the display of
tion mode (1), which indicates the value reduction mode (1), which indicates the value
obtained by adding the value at the display of obtained by reducing the value at the display of
calculated bucket-loaded volume (3) to the calculated bucket-loaded volume (3) from the
value at the total loaded volume (2). value specified at the display of total loaded
q Weight calculation can be displayed by cumu- volume (2).
lating up to any 5 working objects indepen- q Weight calculation can be displayed by cumu-
dently. lating up to any 5 working objects indepen-
Working objects can be selected from types A dently.
to E at the working object display (4) in mode Working objects can be selected from types A
selection. to E at the working object display (4) in mode
q The display of total loaded volume (2) indi- selection.
cates up to 9,999 t unless data is cleared by
the load meter subtotal switch. a For the display and calculation method when
The display indicates a value to one decimal the value at the display of bucket-loaded vol-
place (in 100 kg) in the case of max. 999.9 t. ume (3) exceeds the value at the display of
When it exceeds 1000 t, the decimal point dis- remaining volume (2), see Operation and
play disappears and switches to the display in Maintenance Manual “Handling the load
1 t. meter”.
a For details of the display of remaining volume,
a For details of the display of total loaded vol- see “Display of total loaded volume and dis-
ume, see “Display of total loaded volume and play of remaining volume”.
display of remaining volume”.

50 WA600-6
10 Structure, function and maintenance standard SEN01009-02

Display of total loaded volume and display of Load meter subtotal switch
remaining volume
Display of
Actual total loaded
total loaded Remarks
weight (t)
volume
– –99.5 –99.9 Display of decimal point
Display of decimal point
–99.4 – –0.1 –**.* (the second decimal
place is rounded off.)
Display of decimal point
0 – 999.4 ***.* (the second decimal
place is rounded off.)
Display of integer
999.5 – 9999.4 **** (the second decimal
place is rounded off.)
q To clear the display of total loaded volume (in
9999.5 – 9999 Display of integer
addition mode) or display of remaining volume
Unit of calculated weight (in reduction mode), continuously press the
q Calculated weight values are all displayed in SI switch (1) at least 2 seconds.
(metric ton).
If “MPH” has been selected for speed display Specifications Operation after operating switch
in monitor setting, however, it can be switched Printer not Clears the display of total loaded volume (dis-
to short ton (US ton) in service mode optional installed play of remaining volume).
setting. Printer Outputs saved subtotal data on the printer.
If you switch it to short ton, weight display is installed After the output, the subtotal data is cleared.
also output in short ton (US ton) on the printer.

k In countries where SI unit is adopted, the Subtotal data

speed display unit and weight display unit q The following data when calculated weight is
must not be changed to non-SI unit. confirmed is saved as a set.
q Type of working object
q Weight of loading in one bucket
Load meter cancel switch q Total number of loading
q Total loaded volume

Memory capacity: Min. 500 times of loading

q When the switch (1) is pressed during the hold-

ing time of calculated weight (15 seconds after
completion of calculation), the value at the dis-
play of bucket-loaded volume is canceled, and
the calculated weight is abandoned.)
In this case, the display of total loaded volume
(display of remaining volume) newly added
(reduced) is also canceled, and the previous
display value is returned.

WA600-6 51
SEN01009-02 10 Structure, function and maintenance standard

4. Auto subtotal function 5. Cumulative data display function

1) When the printer (if equipped) is connected. Display of data
The 501st weight calculation is executed, q Total loaded volume and total number of load-
and after 15 minutes, data is stored in ing in addition mode or reduction mode are dis-
RAM and up to the 500th data is printed played.
out on the printer at the same time. q Press the load meter mode selector switch to
After the output on the printer, the subtotal display “TOTAL DATA” on the character dis-
data is cleared. play.
The character display displays “LOAD
DATA FULL” and “CLEAR DATA” after
saving the 500th data, and continues
measurement.

2) When the printer (if equipped) is not con-

nected
The 501st weigh calculation is executed,
and after 15 minutes, data is stored in
RAM and up to the 500th weight data by
bucket is abandoned to secure store data
area.
The character display displays “LOAD a The lower column ( - h) dis-
DATA FULL” and “CLEAR DATA” after plays cumulative hours according to the hour
saving the 500th data, and continues meter criteria.
measurement. Example) In the case of display of 12300-
12450h, the cumulative data of 150 hours
Display on character display after 500th data is between 12300 and 12450 hours is displayed
stored in the character display.

q Press the monitor panel mode selector switch

2 (>) or (<) to select “By the item (A) to (E)” or
“All ON” at working object display (1).
In the former case, cumulative weight by type
(2) and the number of loading (3) are dis-
played.
In the latter case, total loaded volume (2) of all
objects from (A) to (E) and the total number of
loading (3) are displayed.

52 WA600-6
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Reset of data
q Cumulative data by the item (A) to (E) or of all objects are reset.
q Display “TOTAL DATA” on the character display. Press the load meter selector switch (A/B) to specify
either “By the item (A) to (E) or “All ON” at the working object display. Press the load meter mode selec-
tor switch (A/B) at least 4 seconds.

6. Printer output (if equipped)

a This function works only when the printer specified in optional setting is installed.

The output format of load meter can be selected from 3 types (A, B, C) of output mode.
The output format of each mode is as follows.

a For selection of output mode and output method, see Operation and Maintenance Manual “Han-
dling the load meter”.
A-mode B-mode C-mode
(Total printer output) (Subtotal printer output) (Operation record printer output)
• Model, serial number • Model, serial number • Model, serial number
• Date and time of printing • Date and time of printing • Date and time of starting record, service
• Subtotal loading data • Loading data meter
(Type/number of loading/loaded mass) (Loaded mass) • Date and time of ending record (printing),
• Total loading data • Subtotal loading data service meter
(Total number of loading/Total loaded (Type/number of loading/loaded mass) • Subtotal loading data
mass) • Total loading data (Type/number of loading/loaded mass)
(Total number of loading/Total loaded • Total loading data
mass) (Total number of loading/Total loaded
mass)
• Maintenance time
(Maintenance item/remaining time)

WA600-6 53
SEN01009-02 10 Structure, function and maintenance standard

7. Calibration 2) Load calibration

q No load calibration and load calibration q This function compensates the reference
are provided: the former measures the pressure with the bucket loaded. It makes
pressure with the bucket empty and the compensation (B) of the error between the
latter measures the pressure with known actual pressure and the reference value
weight loaded. (A) in the vicinity of the position where
q The lift arm is raised with the bucket full load calibration is executed (C) as shown
tilting. In this condition, the lift arm working in the figure below.
pressure with no load (0 kg) or known
weight loaded is saved.
q If the center of gravity of load is deviated
from the factory-set position due to modifi-
cation of the lift arm or bucket, no load or
load calibration must be executed to oper-
ate the machine with high precision.
a The saved calibration data is not cleared
even after the battery has been removed
for a long time.

1) No load calibration
q This function cancels the individual differ-
ence of weight inherent to the machine,
a For the calibration method, see “Operation
e.g. the weight of working equipment. It
and Maintenance Manual”, “Operation of
makes compensation (B) by offsetting the
load meter”.
error between the actual weight and the
reference value (A) as shown below.
8. Calculation stop
The calculation function of the load meter is
stopped.
During the calculation stop, the display of load
meter disappears, and speed display or engine
speed display appears. No data is added to the
total data in this mode.
To restart calculation, select the addition mode
or reduction mode.
a For the calculation stop method, see
“Operation and Maintenance Manual:
Handling the load meter”.

Function of troubleshooting
The machine monitors the input and output signals
constantly for troubleshooting for the system.
If any abnormality is detected by self-diagnosis, the
information on it is transmitted through the network
to the machine monitor. When abnormality occurs,
it can be confirmed on the machine monitor (display
of failure history).

54 WA600-6
10 Structure, function and maintenance standard SEN01009-02

WA600-6 55
SEN01009-02 10 Structure, function and maintenance standard

Rear side of machine monitor

1. Spare rotary switch (SW1)

2. Spare rotary switch (SW1)
3. Spare rotary switch (SW3)
4. Spare DIP switch (SW5-1)
5. Spare DIP switch (SW5-2)
6. Spare DIP switch (SW5-3)
7. Spare DIP switch (SW5-4)
8. Spare DIP switch (SW6-1)
9. Spare DIP switch (SW6-2)
10. Spare DIP switch (SW6-3)
11. Spare DIP switch (SW6-4)

Do not change settings of spare rotary switches and spare DIP switches.

56 WA600-6
10 Structure, function and maintenance standard SEN01009-02

WA600-6 57
SEN01009-02 10 Structure, function and maintenance standard

Signal table by connector

CN1 (070-20-pole) [CN-C01]

Pin No. Specifications I/O Group Form of use Signal name WA600-6 Remarks
1 — — — — —
Power supply of Power supply
2 I — — —
small lamp (+24 V)
Power supply of Power supply
3 I — — —
small lamp (+24 V)
Unswitched power Power supply Unswitched power Unswitched power
4 I —
supply (+24 V) (+24 V) supply (+24 V) supply (+24 V)
Unswitched power Power supply Unswitched power Unswitched power
5 I —
supply (+24 V) (+24 V) supply (+24 V) supply (+24 V)
SW power supply Power supply SW power supply SW power supply
6 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
7 I —
(+24 V) (+24 V) (+24 V) (+24 V)
8 — — — — — —
9 GND I — GND GND GND
10 GND I — GND GND GND
D_OUT_3
11 O A D/O sink (Spare) —
(+24 V, sink 200 mA)
D_OUT_2 (Automatic preheater
12 O A D/O sink —
(+24 V, sink 200 mA) relay)
D_OUT_1 (HST solenoid cutout
13 O A D/O sink —
(+24 V, sink 200 mA) relay)
D_OUT_0
14 O A D/O sink Buzzer (Monitor) Buzzer (Monitor)
(+24 V, sink 200 mA)
Sensor power supply Sensor power Lift arm pressure sen-
15 O — —
output (+24 V) supply sor power supply
Lift arm pressure and
Sensor power supply Sensor power Lift arm angle sensor
16 O — angle sensor power For load meter
output (+5 V) supply power supply
supply
17 GND I — GND GND GND
18 GND I — GND GND GND
19 GND I — GND GND GND
20 GND I — GND GND GND

58 WA600-6
10 Structure, function and maintenance standard SEN01009-02

CN2 (070-18-pole + 12-pole) [CN-C02, CN-C03]

Form of
Pin No. Specifications I/O Group Signal name WA600-6 Remarks
use
CN2A
D_IN_0
1 I B D/I+24V Headlamp Headlamp
(+24 V, 5 mA)
2 D_IN_2 (24 V, 5 mA) I B D/I+24V Starting motor C Starting motor C
Auto grease A
3 D_IN_4 (24 V, 5 mA) I B D/I+24V Auto grease A If equipped
(If equipped)
4 D_IN_6 (24 V, 5 mA) I B D/I+24V (Direction F) —
5 D_IN_8 (24 V, 5 mA) I B D/I+24V (Direction R) —
Load meter material
6 D_IN_10 (24 V, 5 mA) I B D/I+24V (Spare)
selector switch input
D_IN_12
7 I C D/I+24V Winker right Winker right
(NSW 24 V, 5 mA)
D_IN_14 Monitor mode switch 1 Switch for monitor
8 I C D/I+24V U switch input
(NSW 24 V, 5 mA) U input operation
9 GND O — — SIGNAL GND SIGNAL GND
10 D_IN_1 (24 V, 5 mA) I B D/I+24V Starting motor ACC Starting motor ACC
11 D_IN_3 (24 V, 5 mA) I B D/I+24V Preheat operation —
Auto grease B
12 D_IN_5 (24 V, 5 mA) I B D/I+24V Auto grease B If equipped
(If equipped)
13 D_IN_7 (24 V, 5 mA) I B D/I+24V (Direction N) —
14 D_IN_9 (24 V, 5 mA) I B D/I+24V (Spare) —
Load meter addition/
15 D_IN_11 (24 V, 5 mA) I B D/I+24V (Spare) reduction selector switch
input
D_IN_13
16 I C D/I+24V Winker left Winker left
(NSW 24 V, 5 mA)
D_IN_15 Monitor mode switch 1 t Switch for monitor
17 I C D/I+24V t switch input
(NSW 24 V, 5 mA) input operation
18 A_IN_0 (0 – 30 V) I H A/I Alternator R Alternator R
CN2B
D_IN_16 Brake oil pressure Brake oil pressure
19 I D D/IGND
(24 V/GND, 5 mA) (Front) (Front)
D_IN_18 Brake oil level
20 I D D/IGND —
(24 V/GND, 5 mA) (Front)
D_IN_20
21 I D D/IGND Air cleaner clogging 1 Clogging of air cleaner
(24 V/GND, 5 mA)
Parking brake
D_IN_22
22 I D D/IGND (Spare) emergency release
(24 V/GND, 5 mA)
switch signal
D_IN_24 Transmission filter Transmission filter
23 I E D/IGND
(24 V/GND, 5 mA) clogging clogging
24 GND O — GND Sensor GND Sensor GND
D_IN_17 Brake oil pressure Brake oil pressure
25 I D D/IGND
(24 V/GND, 5 mA) (Rear) (Rear)
D_IN_19 Brake oil level
26 I D D/IGND —
(24 V/GND, 5 mA) (Rear)
D_IN_21
27 I D D/IGND Air cleaner clogging 2 —
(24 V/GND, 5 mA)
D_IN_23 Load meter total weight
28 I D D/IGND (Spare)
(24 V/GND, 5 mA) display switch input
D_IN_25 (Seat belt fastening
29 I E D/IGND —
(24 V/GND, 5 mA) warning)
30 A_IN_0 (0 – 30 V) I H A/I Small lamp switch Small lamp switch

WA600-6 59
SEN01009-02 10 Structure, function and maintenance standard

CN3 (070-18-pole + 12-pole) [CN-C04, CN-C05]

Form of
Pin No. Specifications I/O Group Signal name WA600-6 Remarks
use
CN3A
D_IN_26
1 I E D/IGND Parking brake Parking brake
(24 V/GND, 5 mA)
D_IN_28
2 I E D/IGND Engine oil pressure —
(24 V/GND, 5 mA)
D_IN_30 Normal emergency Normal emergency
3 I E D/IGND
(24 V/GND, 5 mA) steering steering
D_IN_32
4 I F D/IGND Subtotal switch Subtotal switch For load meter
(24 V/GND, 5 mA)
D_IN_34
5 I F D/IGND High beam switch High beam switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/IGND Service function 2 Service function 2
(24 V/GND, 5 mA)
D_IN_38 Monitor mode switch 2 < Switch for monitor
7 I G D/IGND < switch input
(24 V/GND, 5 mA) switch input operation
8 P_IN_0(0.5Vp-p) I M P/I (Spare) —
9 GND O — GND GND GND
D_IN_27
10 I E D/IGND Engine coolant level Engine coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/IGND Engine oil level Engine oil level
(24 V/GND, 5 mA)
12 N.C. I E D/IGND N.C. N.C.
D_IN_33
13 I F D/IGND Cancel switch Cancel switch For load meter
(24 V/GND, 5 mA)
D_IN_35
14 I F D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_37 Monitor mode switch 2 >
15 I G D/IGND > switch input
(24 V/GND, 5 mA) input
D_IN_39
16 I G D/IGND Low steering oil pressure Spare
(24 V/GND, 5 mA)
17 P_IN_1(5Vp-p) I M P/I (Spare) —
18 N.C. — — N.C. N.C.
CN3B
A_IN_2
19 I J A/I Fuel level sensor Fuel level sensor
(High-resistance input)
A_IN_4 Torque converter oil Torque converter oil
20 I J A/I
(High-resistance input) temperature sensor temperature sensor
Engine coolant
A_IN_6 temperature sensor
21 I K A/I —
(High-resistance input) (For automatic
preheater)
Lift arm pressure sensor Lift arm pressure sensor
22 A_IN_8 (0 – 5 V) I L A/I For load meter
(Rod) (Head)
Battery electrolyte level Battery electrolyte level
23 A_IN_10 (0 – 14 V) — — If equipped
A (If equipped)
24 GND O — GND SIGNAL GND GND
A_IN_3 Hydraulic oil temperature Hydraulic oil temperature
25 I J A/I
(High-resistance input) sensor sensor
A_IN_5 Engine coolant tempera- Brake oil temperature
26 I J A/I
(High-resistance input) ture sensor sensor
Lift arm pressure sensor Lift arm pressure sensor
27 A_IN_7 (0 – 5 V) I L A/I For load meter
(Bottom) (Bottom)
28 A_IN_9 (0 – 5 V) I L A/I Lift arm angle sensor Lift arm angle sensor
29 GND O — GND SIGNAL GND GND
Battery electrolyte level
30 A_IN_11 (0 – 14 V) — — —
B

60 WA600-6
10 Structure, function and maintenance standard SEN01009-02

CN4 (070 12-pole) [CN-C06]

Form of
Pin No. Specifications I/O Group Signal name WA600-6 Remarks
use
Monitor – transmission
1 S_NET(+) I/O N S-NET work equipment —
controller
Monitor – transmission
2 S_NET(+) I/O N S-NET work equipment —
controller
Cummins engine con-
troller, VSM controller Communication
3 CAN+ I/O P
communication (CAN (+))
(CAN (+))
4 S_NET(–) O N S-NET S_NET GND —
5 S_NET(–) O N S-NET S_NET GND —
6 GND O — GND S_NET shield GND
7 GND O — GND CAN shield CAN: twisted only
Cummins engine con-
Communication
8 CAN- I/O P troller communication
(CAN (–))
(CAN (–))
9 (NC)
10 (NC)
11 (NC)
12 (NC)

CN5 (070-14-pole) [CN-C07]

Form of
Pin No. Specifications I/O Group Signal name WA600-6 Remarks
use
1 (NC) — — —
RS232C serial
2 RS232C_1_RTS I/O Q —
communication
RS232C serial
3 RS232C_1_RD I Q RD —
communication
4 (NC) I R RD N.C. N.C.
5 (NC) I/O R N.C. N.C.
For load meter
BUSY input for load Printer BUSY
6 — — (Spare for medium
meter printer (if equipped)
and large models)
7 (NC) — — —
RS232C serial
8 RS232C_1_CTS I/O Q —
communication
RS232C serial Printer and personal
9 RS232C_1_TX O Q TX
communication computer TX
RS232C serial
10 RS232C_1_SG O Q —
communication
11 (NC) O R N.C. N.C.
12 (NC) O R TX N.C. N.C.
13 (NC) I/O R N.C. N.C.
14 (NC) — — N.C. N.C.

WA600-6 61
SEN01009-02 10 Structure, function and maintenance standard

CN6 (040 8-pole)

Form of
Pin No. Specifications I/O Group Signal name WA600-6 Remarks
use
1 RS232C_0_TXD O S — —
2 (NC) — — N.C. N.C.
3 RS232C_0_TXD O S — —
4 (NC) — — N.C. N.C.
5 RS232C_0_RXD I S — —
6 (NC) — — N.C. N.C.
7 RS232C_0_RXD I S — —
8 GND O — GND —

Setting switches (On circuit board)

Switch Form of
Specifications I/O Group Signal name WA600-6 Remarks
No. use
1 16 Posi rotary switch 1 I — Selection of model (Spare)
Selection of
2 16 Posi rotary switch 2 I — (Spare)
specification
Selection of
3 16 Posi rotary switch 3 I — (Spare)
specification
4 2 Posi DIP switch 1 I — Selection of options (Spare)
5 2 Posi DIP switch 2 I — Selection of options (Spare)
6 2 Posi DIP switch 3 I — Selection of options (Spare)
7 2 Posi DIP switch 4 I — Selection of options (Spare)
8 2 Posi DIP switch 5 I — Selection of options (Spare)
9 2 Posi DIP switch 6 I — Selection of options (Spare)
10 2 Posi DIP switch 7 I — Selection of options (Spare)
11 2 Posi DIP switch 8 I — Selection of options (Spare)

62 WA600-6
10 Structure, function and maintenance standard SEN01009-02

WA600-6 63
SEN01009-02

WA600-6 Wheel loader

Form No. SEN01009-02

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10

64
 SEN00410-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Electrical system, Part 2
Electrical system, Part 2 ................................................................................................................................. 2
Work equipment control system ........................................................................................................... 2
Transmission controller system.......................................................................................................... 38

WA600-6 1
SEN00410-02 10 Structure, function and maintenance standard

Electrical system, Part 2 1

Work equipment control system 1
Work equipment controller

2 WA600-6
10 Structure, function and maintenance standard SEN00410-02

WA600-6 3
SEN00410-02 10 Structure, function and maintenance standard

1. Work equipment control

1) Work equipment control input and output

4 WA600-6
10 Structure, function and maintenance standard SEN00410-02

2) Work equipment control lever operation

Function
q The work equipment controller operates the work equipment by detecting the operating stroke
of raise/lower, tilt/dump from the signals of the work equipment lever potentiometer, and oper-
ating the main spool by operating each EPC valve attached to the main valve with current con-
trol.

WA600-6 5
SEN00410-02 10 Structure, function and maintenance standard

q The work equipment control lever is equipped with detent notches, and it is adjusted so that it
will operate at the maximum speed before each detent. The range beyond lower detent is the
“lift arm float” operation position, where the lift arm operates by external forces.

6 WA600-6
10 Structure, function and maintenance standard SEN00410-02

3) Work equipment neutral lock

Function
q When the work equipment lock lever is operated to the lock position, the lock switch becomes
OPEN, and the controller stops the operation of the work equipment by turning ON the work
equipment neutral lock valve, cutting EPC pilot basic pressure.
a While the work equipment is locked, the detent does not operate, and the lever is not held at
the detent position.

q The safety function, in which the work equipment is continued to be locked until the work
equipment control lever is temporarily returned to the neutral position, even if the work equip-
ment is unlocked, is incorporated.

Operation table
Operation by Operation
Input of controller Work equipment control Output of controller
man of machine
Work Work equipment Work equipment lever Work equipment Oil
equipment lever lever switch potentiometer neutral lock valve pressure
Lock OFF ON
— Cut
(LOCK) (OPEN) (24V)
Free to Lock OFF Work equipment control ON
Cut
(unlocking) (OPEN) lever being operated (24V)
After releasing, lever neutral
Lock to Free OFF OFF
of all work equipment Operating
(unlocking) (OPEN) (OPEN)
detected once
Free ON OFF
— Operating
(FREE) (CLOSE) (OPEN)

WA600-6 7
SEN00410-02 10 Structure, function and maintenance standard

4) Neutral position and work equipment speed

Function
q The work equipment control lever has neutral play of 5% in the lever stroke, and it is adjusted
so that the work equipment will start working from the position beyond the play.
q It also has a function to change the work equipment speed for the lever stroke through setting
of the controllers.
q The lift arm has five changeable tables, and the bucket has three.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: changing the lift arm table or changing the bucket table.”

8 WA600-6
10 Structure, function and maintenance standard SEN00410-02

5) Tilt priority control

Function
q Because CLSS is employed in this machine, although the bucket and the lift arm can be oper-
ated simultaneously, it has a function that prevents the lift arm from rising when the tilt operat-
ing stroke is large, for more efficient digging.
q It is realized by limiting the maximum speed of lift arm raise (table below) for the tilt speed.
a This function does not work in dump operation, which enables the simultaneous operation.
Bucket tilt speed 0% 20% 40% 60% 70% 100%
Maximum speed of lift arm raise 100% 80% 30% 0% 0% 0%

6) Lift arm raise/lower stop modulation

Function
q The work equipment controller operates modulation, when the lift arm stop operation is performed
more suddenly than a certain speed by the operator, for easing stop shock of lift arm raise/lower.
q The operation of this stop modulation function can be changed through setting.
a For the method to change and precautions, refer to “Testing and adjusting: changing the lift
arm raise/lower stop modulation”.

Case A: Modulation rate is 0%

When lever command flow rate > modulation command flow rate
q The output is controlled according to the lever command flow rate.

Case B: Modulation rate is 200%

When lever command flow rate < modulation command flow rate
q The output is controlled according to the modulation command flow rate.

a: Modulation rate is 100% (When machine is delivered)

b: Modulation starting point: 30% of flow rate command.

WA600-6 9
SEN00410-02 10 Structure, function and maintenance standard

7) Speed reduction function in raising cargo lift arm

Function
q When the lift arm is raised with load, the pump delivery is cut off.
q Lift arm above horizontal (Lift arm angle sensor signal)
q Bucket tilt end (Tilt end proximity switch signal)
q Lift arm bottom pressure minimum 20 MPa {204 kg/cm2} (Signal by network communica-
tion from the monitor)
Only when the above conditions are simultaneously satisfied, the lift arm raise maximum speed
will be limited to 70%.
q When the lift arm raise maximum speed is changed between 70% and 100%, modulation is
equipped for reducing shocks, controlling so that the speed will not change suddenly.
q This function can change the condition value of the lift arm bottom pressure through controller
setting. By changing the set value of the lift arm bottom pressure, matching of the lift arm rising
speed and travel speed can be changed.
a For the method to change and procedure, refer to “Testing and adjusting: adjustment of pump
cut-off pressure in lift arm is raised.”

8) Adjusting range before lever detent position and work equipment starting current

Function
q The work equipment controller has an adjusting function for correction dispersion.
q The range before the detent position is adjusted so that the lever potentiometer voltage at the
detent position will be saved, ensuring control before and after the detent. When it is not
adjusted, such phenomena as “the positioner does not operate normally before and after the
detent,” or “the lever position of lift arm float is not normal” may occur.
q When the work equipment starting current is not adjusted, such phenomena as “the neutral
dead zone is large” or “dashing/stopping shock of the work equipment becomes large” may
occur.
a For the adjusting procedure, refer to “Testing and adjusting: Adjustment of lift arm raise lever
position before detent and variations in the dead zone of EPC, Adjustment of lift arm lower
(float) lever and variations in the dead zone of EPC, and Adjustment of bucket tilt lever position
before detent and variations in the dead zone”.

10 WA600-6
10 Structure, function and maintenance standard SEN00410-02

q Adjusting the starting current means to make the controller recognize the current at which the
work equipment starts moving, or the current at which the work equipment valve spool is
“opened”.
q When the starting current is adjusted, the spool is opened and closed once and the EPC cur-
rent output at this time is used as the starting current to make the effect of the spool operation
hysteresis constant.

q The range before lever detent is a range where the lever operating effort before the notch
changes suddenly.

WA600-6 11
SEN00410-02 10 Structure, function and maintenance standard

2. Remote positioner
1) Bucket positioner

Function
q This is a function that the bucket will gently stop at any set position, when the tilt lever is set to
the detent position with the bucket level or lower.

1] Setting stop position

q The stop position of the bucket will change when the positioner is operated through the
operation of the bucket positioner position set switch.
Condition for setting Bucket lever stroke: neutral and travel speed below 5 km/h
(1) When setting it upward from the current stop position, press the bucket posi-
tioner + position set switch position (upward). (Use the downward switch to
change it downward)
(2) +1 for the currently set (saved) position is saved, the setting completion
buzzer sounds (pip, pip), and the monitor displays the value for 3 seconds.
Setting method
(Set position will be maintained when the key is turned off.)
* When the switch is operated exceeding ±5 of the set range, the monitor dis-
plays the same value, and the setting cancel buzzer (pip) sounds.
(3) For further change, release the switch once, and then press it again. (when *,
the same as (2))

12 WA600-6
10 Structure, function and maintenance standard SEN00410-02

2] Operation of tilt detent solenoid

q If the bucket horizontal proximity switch is operated when the bucket lever is at the tilt
detent position, the detent will be reset after the delay time, and the bucket will stop gently.

Delay time:
The bucket horizontal proximity switch is set at the position where the bucket is “downward (–5).”
The flow rate to the tilt cylinder is calculated from the pump delivery, and, when the necessary
oil level for the set position is reached, the detent will be reset and it will stop gently.

3] Tilt stop (gentle)

q After the tilt detent is reset, if the bucket lever is maintained in the tilt detent position, the
tilting operation is not stopped gently.
q When the tilting operation is stopped, if the bucket lever is operated, the faster of the tar-
get speed with the tilt lever operation and the target speed with the stop function is
selected and output.
q If the bucket lever is operated in the direction of dump to a certain degree during the stop
control operation, the stop control operation is stopped and the dump signal is output.

WA600-6 13
SEN00410-02 10 Structure, function and maintenance standard

3. Lift arm remote positioner

Function
a) Raise kick-out (when raise set switch lamp is on)
Set the lift arm lever to “raise detent,” reset the lift arm raise detent when the lift arm rises before the
set position, and perform stop (gentle) control.
When the lift arm is at other positions than the “raise detent,” it is raised with operation by the oper-
ator.
When raise is not selected, only raise detent will operate.
When the detent is turned on, the remote positioner will not operate, and only the kick-out function
(stop at the top position of the lift arm) will operate.

b) Lower lift arm stop (when lower set switch lamp is on)
Set the lift arm lever to the “float detent,” start decreasing the speed when the lift arm is 10° before
the set position, and reset the float detent when it is 4° before the set position, and perform stop
(gentle) control.
If the lift arm lever is kept as it is, the lift arm starts lowering again.
When lower is not selected, only float detent will operate.
When the detent is turned on with the lift arm angle level or lower, the remote positioner will not
operate, and only the float detent function (it will not stop automatically) will operate.

a The remote positioner of lower will not function as positioner, and will not stop, when the detent is
turned on with the lift arm angle level or lower, in order to distinguish it from float operation in grad-
ing operation.

14 WA600-6
10 Structure, function and maintenance standard SEN00410-02

1] Setting stop position

q The stop position of the lift arm will change when the positioner is operated through the
operation of the remote positioner position raise/lower set switch.

Setting and resetting raise stop position

Condition for setting Lift arm lever stroke: neutral
(1) Raise the lift arm to a desired set position.
(2) Press the remote positioner raise position set switch (less than a second).
(3) If the position where the switch is pressed is within the set range, save the
lift arm angle, the setting completion buzzer sounds (pip, pip), and the
switch indicator lights up.
Method of setting
raise stop (4) If it is out of the range (lift arm angle less than 0°), and in sensor errors, it
will not be set again.
(The buzzer will not sound, the set position will not be changed.)
(5) When the set switch is operated less than a second, the set position is
always changed.
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner raise position set switch for a second
or longer.
(2) If it is within the set range when the switch is pressed, the position is set
temporarily. If it is proceed for a second or longer in (3) above, the setting
Method of resetting
cancel buzzer (pip) sounds when a second elapses, raise selection is
raise stop
reset, and the switch indicator goes off.
*After the setting is reset, the whole lift arm angle will be available.
(3) Remote positioner raise stop control is not performed. Only boom kick-out
control will be performed.

Setting and resetting lower stop position

Condition for setting Lift arm lever stroke: neutral
(1) Lower the lift arm to a desired set position.
(2) Press the remote positioner lower position set switch (less than a second).
(3) If the position where the switch is pressed is within the set range, save the
lift arm angle, the setting completion buzzer sounds (pip, pip), and the
switch indicator lights up.
Method of setting
lower stop (4) If it is out of the range (other than lift arm angle of –37° to 0°), and in sensor
errors, it will not be set again.
(The buzzer will not sound, the set position will not be changed.)
(5) When the set switch is operated less than a second, the set position is
always changed.
(The set position is maintained when the key is turned off.)
(1) Press and hold the remote positioner lower position set switch for a second
or longer.
(2) If it is within the set range when the switch is pressed, the position is set
temporarily. If it is proceed for a second or longer in (3) above, the setting
Method of resetting
cancel buzzer (pip) sounds when a second elapses, lower selection is
lower stop
reset, and the switch indicator goes off.
*After the setting is reset, the whole lift arm angle will be available.
(3) Remote positioner lower stop control is not performed.
Only float detent control will be performed.

Settable range of remote positioner stop position

[Raise, lower stop position settable range]
Stop position “Raise” “Lower”
Min. 0° 0 to –37°
0°: Lift arm is level.

WA600-6 15
SEN00410-02 10 Structure, function and maintenance standard

2] Operation of lift arm raise detent solenoid

q When the lift arm raise lever is operated more than a certain point, the raise detent sole-
noid is turned ON. When the former exceeds the notch, the latter is maintained.
q When the remote positioner operates, the detent is turned OFF in the range of the set stop
angle from –2° to +1°.
q When the lift arm raise detent becomes automatically off due to the operation of the stop
(gentle) function, the lift arm raise/lower detent stays off during a second after it is turned
off.

3] Lift arm raise stop (gentle)

q In the lift arm raise stop (gentle), the speed is decreased according to the stop angle in the
range of the set stop angle from –9° to –2° by lift arm angle feedback.
q After the lift arm raise detent is reset, if the lift arm lever is maintained in the raise detent
position, the lift arm raising operation is not stopped (gently) but accelerated so that the
raising speed will reach the maximum when the lift arm is 10° above the stop position.
q Therefore, when operation exceeding the target stop angle is performed while the detent
is maintained with the lift arm raise remote positioner operated, the speed of the lift arm
raise temporarily decreases and then increases.

16 WA600-6
10 Structure, function and maintenance standard SEN00410-02

4] Boom kick-out
q When the lift arm raise detent is set, when the stop position of the remote positioner is not
set or above the stop position, the lift arm slowly stops before the stroke end as kick-out
operation, reducing stop shock due to stroke end.
q When the kick-out operates, the detent is turned OFF in the range of the set stop angle
from –2° to +2.5°.

5] Operation of lift arm lower detent solenoid

q When the lift arm lower lever is operated more than a certain point, the lower detent sole-
noid is turned ON. When the former exceeds the notch, the latter is maintained.
q When the remote positioner operates, the detent is turned OFF in the range of the set stop
angle from –2° to +1°.
q When the lift arm angle is less than –37°, the detent turns on for grading operation, regard-
less of operation of the remote positioner.
q When the lift arm lower detent becomes automatically off due to the operation of the stop
(gentle) function, the lift arm raise/lower detent stays off during a second after it is turned
off.

WA600-6 17
SEN00410-02 10 Structure, function and maintenance standard

4. Semiautomatic digging

Function
Control of semiautomatic digging
q Semiautomatic digging is a function, in which digging operation can easily be performed only with
the kick-down switch and lift arm raise operation, improving the working efficiency of less experi-
enced operators, and the two modes of LOOSE mode/ROCK mode are separately used due to the
characteristics of work objects.

q Select the bucket automatic operation pattern appropriate for work cycle/load
Mode selection No. Object Mode
1 Gravel/sand LOOSE mode
Quarry/
2 ROCK mode
blasted rock

18 WA600-6
10 Structure, function and maintenance standard SEN00410-02

1) Conditions for starting semiautomatic digging

Semiautomatic digging is ready with (1) to (4) below.
(1) The semiautomatic digging switch is either in “ROCK” or “LOOSE” mode.
(2) In forward (with F signal)
Condition 1 (3) Lift arm angle less than –30° (almost to the ground)
(4) Operate the kick-down switch.
* Even when working in 1st, semiautomatic digging will not start without operating
the kick-down switch.
Semiautomatic digging (automatic tilting) will start when the following conditions (1)
and (2) are satisfied.
Condition 2
(1) Perform lift arm raise operation after condition 1 is satisfied.
(2) Travel speed km/h <3.5 × ENG rpm/1,800>

2) Conditions for finishing semiautomatic digging

Automatic tilting is finished when any of the following conditions is satisfied.
(1) Forward finished (F signal: ON o OFF)
Conditions
(2) Lift arm angle level or higher
(3) Detect tilt end (becomes full tilt)

3) Tilt operation of digging mode

1] Operation of LOOSE mode

q Tilt operation will start 0.5 seconds after the conditions for starting semiautomatic digging
are satisfied.
q The speed is increased so that it becomes 100% 10 seconds after starting tilt, the maxi-
mum speed depends on engine speed.

WA600-6 19
SEN00410-02 10 Structure, function and maintenance standard

2] Operation of ROCK mode

q Tilt operation will start 0.6 seconds after the conditions for starting semiautomatic digging
are satisfied.
q Tilt repeats operation/stop, with different tilt time/cycle for each cycle, and the number of
tilts changes until loading is finished in accordance with loading object.
q The maximum speed depends on engine speed.

20 WA600-6
10 Structure, function and maintenance standard SEN00410-02

5. Pump swash plate control

Function
In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary
function when engine speed is low” are included, and based on calculation results of each function, data
with less pump delivery (larger pump EPC current) will be selected.

1) Horsepower loss decrease function in pump relief

q Horsepower loss is decreased by controlling pump delivery in relief, changing the command
value of the pump swash plate, when the work equipment pump is relieved.
q Output to pump EPC is changed with input signal of the loader pump pressure sensor.

WA600-6 21
SEN00410-02 10 Structure, function and maintenance standard

q The work equipment controller operates pump EPC in 200 mA until loader pump pressure reaches 32
MPa, and when it becomes 33 MPa or higher, the controller operates pump EPC in 700 mA.
q In this control, the delivery (pump EPC current) is changed over a second from 700 mA to 200 mA in
order to prevent sudden operation due to rapid increase of flow rate, when the delivery changes in
increasing direction (current decreasing direction).

Pump pressure Current value (A) Pump flow rate

32.4 MPa 0.2 100%
33.3 MPa 0.7 C 30%

22 WA600-6
10 Structure, function and maintenance standard SEN00410-02

2) Pickup auxiliary function when engine speed is low

q When the engine speed is low and torque is low, acceleration of the engine in work equipment
operation is aided by limiting the pump delivery.

q The work equipment controller operates pump EPC in 0.9 A until engine speed reaches 500
rpm, and when it becomes 950 rpm or higher, the controller operates pump EPC in 0.2 A.
Engine speed Current value (A) Pump flow rate
500 rpm 0.9 MIN
700 rpm 0.569 C 40%
950 rpm 0.2 100%

WA600-6 23
SEN00410-02 10 Structure, function and maintenance standard

6. AJSS control

Function
AJSS is a turn control system with a joystick, which senses articulation angle and faithfully bends the
machine in accordance with the tilting angle of AJSS lever, by adopting pilot oil pressure method with
feedback mechanism.

1) AJSS system
q In AJSS, when the joystick steering lever and the frame are connected with link through the
rotary valve, and deviation occurs between the operating angle of the lever and the machine
frame turning angle, the pilot oil pressure is applied to the steering valve from the rotary valve,
and the machine turns in the direction of lever operation until the operating angle of the lever
and the machine frame turning angle match and the rotary valve closes.
q Even if the EPC valve malfunctions, the operator can steer the machine with the function of the
pressure compensation valve of AJSS. In addition, even if the engine stops, the operator can
steer the machine with the operation of the diverter valve as long as the transmission is rotat-
ing (the machine is traveling).

24 WA600-6
10 Structure, function and maintenance standard SEN00410-02

WA600-6 25
SEN00410-02 10 Structure, function and maintenance standard

2) AJSS neutral interlock

q In AJSS, since there is a possibility that the machine operates and turns immediately after the
engine is started, if the joystick steering lever is in a position other than neutral (there is devia-
tion between the operating angle of the lever and the machine frame angle), the engine start
signal is cut, and starting the engine is prohibited by turning the neutral safety relay on.
q If the steering lock lever is locked, and the joystick steering lever is in a position other than neu-
tral while the engine is operating, there is a possibility that the machine turns immediately after
the lever is unlocked, the caution buzzer is sounded in order to call attention of the operator.
q Since the machine does not turn with the steering locked, operation of FR is prohibited with the
transmission controller. Therefore, if the forward-reverse switch of the joystick steering knob is
set to a position other than neutral while the steering is locked, because there is a possibility
that forward-reverse operation occurs immediately after unlocked, the caution buzzer is
sounded in order to call attention of the operator.
Conditions Reference Neutral safety control
Steering pilot Reference
Joystick Steering Engine start
Engine pressure Machine state Transmission
steering lever lock lever neutral safety
NET signal neutral safety
Neutral The key is on,
Without pressure
position Locked the engine is
(switch = OPEN)
deviation stopped
angle less Without pressure
than 6° Unlocked
(switch = OPEN)
Stopped
(below Starting the
500 rpm) Operation engine is not pos-
Without pressure
position Locked sible when the
(switch = OPEN)
deviation joystick steering
angle more lever is operated
than 6° Without pressure
Unlocked
(switch = OPEN)
Transmission
Neutral shift is not possi-
Without pressure
position Locked Lever locked ble when the
(switch = OPEN)
deviation steering is locked
angle less (N maintenance).
Operat- than 6° With pressure Normally
Unlocked
ing (500 (switch = CLOSE) operating
rpm or Transmission
above) Operation The lever is shift is not possi-
Without pressure The caution
position Locked operated while it ble when the
(switch = OPEN) buzzer sounds
deviation is locked steering is locked
angle more (N maintenance)
than 6° With pressure Normally
Unlocked
(switch = CLOSE) operating

26 WA600-6
10 Structure, function and maintenance standard SEN00410-02

3) Speed-sensing steering
q In AJSS, the steering characteristics is changed in accordance with travel speed, by controlling
the pilot basic pressure of the rotary valve with EPC.
q When travel speed is 7 km/h or less, it is controlled to turn speedily when the lever operating
stroke is large, prioritizing V shape work efficiency.
q When travel speed is higher, the turning speed is reduced from the neutral range of lever oper-
ating stroke, limiting sudden turning operation in rapid lever operation.
q It has three changeable tables.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: Modification of AJSS oil pressure command table pattern”.

AJSS characteristics

4) Adjusting neutral position of AJSS

q AJSS recognizes opening of the rotary valve made by lever operation with the frame angle
sensor and lever angel sensor.
q Adjust the neutral position of AJSS to cancel the installation error of the sensors when the
machine travels straight and the rotary valve is set in neutral.
a For adjustment method, see “Testing and adjusting: Adjustment of AJSS neutral position”.

WA600-6 27
SEN00410-02 10 Structure, function and maintenance standard

7. AJSS turn signal control

q In AJSS, since the turn signal can not be reset automatically, the turn signal automatic reset opera-
tion is performed using the frame angle input in the controller.
q This control is operated only in AJSS. (In machines with steering, automatic reset is performed with
the mechanism of the conventional turn signal switch installed in the steering.)

1) Machine circuit

2) Operating and stopping turn signal

The operation and stop conditions of the right turn signal are shown below. (Same for the left turn
signal)
Operation: When the right turn signal switch is pressed while the right turn signal is stopped, the
turn signal flashes because the right turn signal relay operates. The flash operation is
performed with the flasher unit.
Stop: Perform the following operation while the right turn signal is operating in order to stop
the right turn signal.
Press the right turn signal switch again.
Press the left turn signal switch. In this case, the left turn signal will start flashing at the
same time.
After the turn signal lights up, when the machine turns right for 10° or more and then the
machine is set in the straight travel position (8° or less), the right turn signal will stop.
(Automatic stop)
After the turn signal lights up, when the machine turns left for 10° or more, the right turn
signal will stop. (Automatic stop)

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10 Structure, function and maintenance standard SEN00410-02

8. Real-time monitor
1) List of display contents of the real-time monitor
In WA600-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the work equipment controller:
Display of item Display contents in
No. Item ID No. Contents of display data Remarks
name normal operation
Software part Part No. of software is Depends on the soft-
1 20202 VERSION
number displayed ware number
Application Application version Depends on application
2 20225 VERSION APP
Version number is displayed version number
VERSION Data version number is Depends on data ver-
3 Data Version 20226
DATA displayed sion number
When work equipment
Converted value pres- is in neutral
Loader pump
4 94700 PUMP PRESS sure of loader pump oil : 2.0 ± 2.0 MPa
pressure
pressure is displayed Work equipment relief
: 34.0 ± 2.0 MPa
When work equipment
Input voltage value of is in neutral
Loader pump
5 94701 PUMP PRESS loader pump oil pres- : 0.70 ± 0.2V
pressure
sure is displayed Work equipment relief
: 3.22 ± 0.2V
Li (800 rpm)
: 421 ± 30 mA
Hi (above 950 rpm)
Loader pump
Loader pump EPC : 200 ± 10 mA
EPC current
6 94500 PUMP EPC DIR output command cur- Work equipment relief
value
rent value is displayed : 700 ± 10 mA
(command)
Engine stop
(below 500 rpm)
: 900 ± 10 mA
When work equipment
is in neutral:
Results of pump deliv-
264CC/R
7 Pump delivery 94600 PUMP FLOW ery calculation are dis-
Work equipment in
played
relief:
45 ± 10 CC/R
Standard lift arm
Lift arm top
: 46.8 ± 2.0 deg
Lift arm bottom
Calculation results of lift : –42.3 ± 5.0 deg
8 Lift arm angle 06002 BOOM ANG
arm angle is displayed Hi-lift lift arm
Lift arm top
: 49.3 ± 2.0 deg
Lift arm bottom
: –40.5 ± 5.0 deg
Standard lift arm
Lift arm top:
3.80 ± 0.3 V
Input voltage value to lift Lift arm bottom:
arm angle sensor 1.33 ± 0.5 V
9 Lift arm angle 06005 BOOM ANG
potentiometer is dis- Hi-lift lift arm
played Lift arm top:
3.87 ± 0.3 V
Lift arm bottom:
1.38 ± 0.5 V

WA600-6 29
SEN00410-02 10 Structure, function and maintenance standard

Display of item Display contents in

No. Item ID No. Contents of display data Remarks
name normal operation
When machine is travel-
ing straight
Operation angle con-
: 0.0 ± 1.0 deg
verted value of AJSS
10 Frame angle 94400 FRAME ANGLE When fully turned right
frame potentiometer is
: 39.0 ± 4.0 deg
displayed
When fully turned left
: –39.0 ± 4.0 deg
Number of lift Number of lift arm lever Display in accordance
11 arm lever 42100 BOOM LVR operations is displayed with the number of lever
operations in the unit of thousand operations
Neutral
2.50 V ± 0.100 V
Raise (before detent)
3.89 V ± 0.25 V
Lever potenti- Input voltage value to lift
Raise (detent position)
12 ometer voltage 42000 BOOM POT1 arm lever potentiome-
4.11 V ± 0.25 V
lift arm 1 ter 1 is displayed
Lower (before detent)
1.11 V ± 0.25 V
Float (detent position)
0.89 V ± 0.25 V
Neutral
2.50 V ± 0.100 V
Raise (before detent)
1.11 V ± 0.25 V
Lever potenti- Input voltage value to lift
Raise (detent position)
13 ometer voltage 42001 BOOM POT2 arm lever potentiome-
0.89 V ± 0.25 V
lift arm 2 ter 2 is displayed
Lower (before detent)
3.89 V ± 0.25 V
Float (detent position)
4.11 V ± 0.25 V
Number of Number of bucket lever Display in accordance
14 bucket lever 42101 BUCKET LVR operations is displayed with the number of lever
operations in the unit of thousand operations
Neutral
2.50 V ± 0.100 V
Tilt (before detent)
Lever potenti- Input voltage value to
3.89 V ± 0.25 V
15 ometer voltage 42002 BUCKET POT1 bucket lever potentiom-
Tilt (detent position)
bucket 1 eter 1 is displayed
4.11 V ± 0.25 V
Full dump
0.89 V ± 0.25 V
Neutral
2.50 V ± 0.100 V
Tilt (before detent)
Lever potenti- Input voltage value to
1.11 V ± 0.25 V
16 ometer voltage 42003 BUCKET POT2 bucket lever potentiom-
Tilt (detent position)
bucket 2 eter 2 is displayed
0.89 V ± 0.25 V
Full dump
4.11 V ± 0.25V
Neutral
Lift arm raise EPC output command
RAISE EPC 0 ± 10 mA
17 EPC current 41900 current value to lift arm
DIR Max.
(command) raise is displayed
896 ± 10 mA
Neutral
±10 mA
Lift arm lower EPC output command
LOWER EPC Before detent
18 EPC current 41901 current value to lift arm
DIR : 640 ± 10 mA
(command) lower is displayed
Float position
: 1,000 ± 10 mA

30 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Display of item Display contents in

No. Item ID No. Contents of display data Remarks
name normal operation
Neutral
Bucket tilt EPC output command
0 ± 10 mA
19 EPC current 41902 TILT EPC DIR current value to bucket
Max.
(command) tilt is displayed
930 ± 10 mA
Neutral
Bucket dump EPC output command
DUMP EPC 0 ± 10 mA
20 EPC current 41903 current value to bucket
DIR Max.
(command) dump is displayed
848 ± 10 mA
Lever in neutral
: 384 ± 10 mA
Lever operated fully to
J/S EPC cur- EPC output command Check when
the right
21 rent (com- 41908 AJSS EPC DIR current value to AJSS is AJSS is
595 ± 10 mA
mand) displayed locked
Lever operated fully to
the left
595 ± 10 mA
J/S right EPC EPC output command
J/S EPC DIR In WA600-6, there is no
22 current (com- 41904 current value to J/S
RH corresponding functions
mand) right is displayed
J/S left EPC EPC output command
J/S EPC DIR In WA600-6, there is no
23 current (com- 41905 current value to J/S left
LH corresponding functions
mand) is displayed
Lever potenti- Input voltage value to
In WA600-6, there is no
24 ometer voltage 42004 J/S POTI1 J/S lever potentiometer
corresponding functions
J/S1 1 is displayed
Lever potenti- Input voltage value to
In WA600-6, there is no
25 ometer voltage 42005 J/S POTI2 J/S lever potentiometer
corresponding functions
J/S2 2 is displayed
3rd valve 1 Neutral
EPC output command
ECMV current 0 ± 10 mA
26 41906 3RD EPC1 DIR current value to 3rd
value (com- Max.
valve 1 is displayed
mand) 960 ± 10 mA
3rd valve 2
EPC output command
ECMV current Neutral 0 ± 10 mA
27 41907 3RD EPC2 DIR current value to 3rd
value (com- Max. 960 ± 10 mA
valve 2 is displayed
mand)
Number of 3rd Number of 3rd lever Display in accordance
28 lever opera- 42102 3RD LVR operations is displayed with the number of lever
tions in the unit of thousand operations
Lever potenti- Input voltage value to Neutral 2.50 V ± 0.10 V
29 ometer voltage 42006 3RD POT1 3rd valve lever potenti- Retract: 4.11 V ± 0.25 V
3rd valve 1 ometer 1 is displayed Extract: 0.89 V ± 0.25 V
Lever potenti- Input voltage value to Neutral 2.50 V ± 0.10 V
30 ometer voltage 42007 3RD POT2 3rd valve lever potenti- Retract: 0.89 V ± 0.20 V
3rd valve 2 ometer 2 is displayed Extract: 4.11 V ± 0.20 V
When machine is travel-
ing straight
Neutral
Check when
Operation angle con- : 0.0 ± 0.5 deg
AJSS lever the engine is
verted value of AJSS Turn the lever fully to
31 operation 94300 AJSS LEVER stopped, or
lever potentiometer is the right
angle AJSS is
displayed : 20.0 ± 3.0 deg
locked
Turn the lever fully to
the left
: –20.0 ± 3.0 deg

WA600-6 31
SEN00410-02 10 Structure, function and maintenance standard

Display of item Display contents in

No. Item ID No. Contents of display data Remarks
name normal operation
When machine is travel-
ing straight
Neutral
Check when
: 2.5 ± 0.3 V
AJSS lever Input voltage value of the engine is
Turn the lever fully to
32 potentiometer 94301 AJSS LEVER AJSS lever potentiome- stopped, or
the right
voltage ter is displayed AJSS is
: 3.33 ± 0.5 V
locked
Turn the lever fully to
the left
: 1.67 ± 0.5 V
When machine is travel-
ing straight
AJSS frame Input voltage value of : 2.5 ± 0.3 V
33 potentiometer 94401 FRAME ANGLE AJSS frame potentiom- When fully turned right
voltage eter is displayed : 0.96 ± 0.5 V
When fully turned left
: 4.04 ± 0.5 V
When machine is travel-
ing straight
Neutral
AJSS S/T Deviation angle value of Check when
S/T DEFLEC- : 0.0 ± 0.5 deg
34 deviation 94800 AJSS frame and lever is AJSS is
TION Lever fully to the right
angle displayed locked
: 20.0 ± 2.0 deg
Lever fully to the left
: –20.0 ± 2.0 deg
During digging opera-
The state of digging
35 Digging flag 94900 WORK FLAG tion: ON
judgment is displayed
Other than above: OFF
D-IN-0
00000000 D-IN-0 : Semi auto
(Semi auto SW = OFF) : Semi auto ROCK ROCK mode
The state of
Input signal 10000000 mode SW SW
36 40910 input signal is
D_IN_0 – 7 (Semi auto SW = ON) D-IN-1 D-IN-1
displayed
01000000 : Semi auto LOOSE : Semi auto
(Semi auto SW = ON) mode SW LOOSE
mode SW
11000000
(Dump)
10000000
(Bucket level)
00000000
Input signal The state of input signal (Full tilt)
37 40911 D-IN--8-----15
D_IN_8 – 15 is displayed 10100000
(Bucket raise set SW =
ON)
10010000
(Bucket lower set SW =
ON)
D-IN-16
1000000
: Work equip-
(Work position)
ment N lock
Input signal The state of input signal 00000000
38 40912 D-IN-16-----23 SW
D_IN_16 – 23 is displayed (Lock position)
D-IN-17
01000000
: Starter termi-
(Starter operation)
nal C signal

32 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Display of item Display contents in

No. Item ID No. Contents of display data Remarks
name normal operation
D-IN-28
: Lift arm posi-
0000000
tioner raise
00001000
set SW
(Lift arm raise set
D-IN-29
SW = ON)
: Lift arm posi-
00000100
Input signal The state of input signal tioner lower
39 40913 D-IN-24-----31 (Lift arm lower set
D_IN_24 – 31 is displayed set SW
SW = ON)
D-IN-30
00000010
: Right winker
(Right winker SW = ON)
SW
00000001
D-IN-31
(Left winker SW = ON)
: Left winker
SW
Input signal
D_IN_32 – 39 There is no used items
(Work equip- The state of input signal in this data
40 40961 D-IN-32-----39
ment controller is displayed 00000000 is constantly
does not have displayed
33 – 39)
D-OUT-0
10000000
: Work equip-
(Lock position)
ment N lock
00000000
SOL
(Unlock neutral)
D-OUT-1
ON/OFF output state of 01000000
ON/OFF out- : Lift arm raise
SOL_OUT0 to 7 (Raise detent SOL =
41 put 40952 D-OUT--0------7 detent SOL
'0' is displayed when ON)
D_OUT0--7 D-OUT-2
setting current output 00100000
: Lift arm float
(Float detent SOL =
detent SOL
ON)
D-OUT-3
00010000
: Bucket tilt
(Tilt detent SOL=ON)
detent SOL
ON/OFF output state of
SOL_OUT8 to 13 and
ON/OFF out- There is no used items
ON/OFF output state of
42 put 40953 D-OUT-8-----15 in this data
SIG_OUT0 and 1
D_OUT8--15 Constantly 00000000
'0' is displayed when
setting current output
D-OUT-16
: Operate
winker right
10000000 D-OUT-17
(Operate winker right) : Operate
01000000 winker left
(Operate winker left) D-OUT-18
SIG_OUT2 to 3 00001000 : Light up lift
ON/OFF out- HSW_OUT0 to 1 (Operate safety relay) arm posi-
43 put 40954 D-OUT-16----23 ON/OFF output state of 00010000 tioner raise
D_OUT16--23 BATT_RY_OUT is dis- (Display lift arm posi- set indicator
played tioner lower = ON) D-OUT-19
00110000 : Light up lift
(Display lift arm posi- arm posi-
tioner raise/lower = tioner lower
ONon) indicator
D-OUT-20
: Operate
safety relay

WA600-6 33
SEN00410-02 10 Structure, function and maintenance standard

9. Diagnosis
1) Function of troubleshooting
The work equipment controller monitors the input and output signals constantly for troubleshooting
for the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor. When abnormality occurs, it can be confirmed on the machine moni-
tor/VHMS.

34 WA600-6
SEN00410-02 10 Structure, function and maintenance standard

10. Pin assignment

36 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Input and output signals

DEUTSCH-24P [CN-L05]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Bucket lever potentio B Input 13 Boom lever potentio B Input
2 Loader pump press. sensor Input 14 Third EPC lever B Input
3 AJSS frame potentio Input 15 NC Input
4 GND_SIG_D 16 NC Output
5 NC Input 17 Semiauto loading loose mode SW. Input
6 NC Input 18 NC Input
7 Bucket lever potentio A Input 19 Boom lever potentio A Input
8 Boom angle sensor Input 20 Third EPC lever A Input
9 AJSS lever potentio Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 NC Input 23 Semiauto loading rock mode SW. Input
12 NC Input 24 NC Input

DEUTSCH-40P(1) [CN-L06]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC Output 21 NC Input/Output
2 Winker SW. right Input 22 COMM_CAN_L_O Input/Output
3 Remote positioner leveling set SW. Input 23 NC Input/Output
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starter switch(IGN-C) Input
6 NC Input 26 NC Input
7 NC Input 27 NC Input
8 Winker relay left Output 28 NC Input
9 NC Output 29 NC
10 NC Input 30 NC Input
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input/Output
13 Remote positioner lifting set SW. Input 33 NC Input/Output
14 NC Output 34 NC
15 NC Input 35 Lever prohibiting equipment SW. Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input
18 Winker relay right Output 38 Winker SW. left Input
19 NC Output 39 NC
20 Third EPC lever A Input 40 NC Input

DEUTSCH-40P(2) [CN-L07]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Boom lifting EPC Output 26 AJSS EPC Output
7 Work neutral lock solenoid Output 27 Magnetic detent of boom lever float Output
8 Remote positioner lifting lndicator Output 28 NC Output
9 NC Input 29 NC Input
10 Bucket cylinder tilt end SW. Input 30 Bucket positioner up set SW. Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Boom lowering EPC Output 36 Loader pump EPC Output
17 Magnetic detent of boom lever lift Output 37 Magnetic detent of bucket lever tilt Output
18 Remote positioner lowering indicator Output 38 NC Output
19 NC Input 39 NC Input
20 Bucket cylinder horizon SW. Input 40 Bucket positioner down set SW. Input

WA600-6 37
SEN00410-02 10 Structure, function and maintenance standard

Transmission controller system 1

1. Electrical circuit diagram
Transmission controller electrical circuit diagram (steering wheel specification)
Lockup

38 WA600-6
10 Structure, function and maintenance standard SEN00410-02

WA600-6 39
SEN00410-02 10 Structure, function and maintenance standard

Transmission controller electrical circuit diagram (AJSS specification)

Lockup

40 WA600-6
10 Structure, function and maintenance standard SEN00410-02

WA600-6 41
SEN00410-02 10 Structure, function and maintenance standard

2. Transmission controller gear shifting control

1) Electronic modulation function
To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the
modulation control is applied. The clutch oil pressure is controlled properly for the condition of the
hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, and
gear shifting pattern and according to the transmission modulation data table saved in the transmis-
sion controller memory so that the transmission will be set in any gear speed (including the lockup
clutch) smoothly.
The modulation control is also performed for the clutch on the side to be turned off in order to
reduce lowering of the torque.
If an abnormal time lag is made in gear shifting, the learning function corrects the trigger operation
time automatically.

2) Display of gearshift
The transmission controller displays the state of input signal related to gearshift by sending to the
machine monitor via network.

1] Directional indicators
The directional indicators of the machine monitor display the signal input state of the directional
lever, which is input to the transmission controller. Therefore, when the lever is in neutral posi-
tion, and there is no input signal to the transmission controller, the directional indicators totally
go out, and if two signals are input due to a problem, the two indicators may light up at the
same time.
If the directional lever is in “R” state, the backup lamp relay will be operated, and the back lamp
and back buzzer will be operated.

2] Gear speed indicators

The gear speed indicators of the machine monitor display the signal input state of the gear
speed lever, which is input to the transmission controller. Therefore, when the lever is in neutral
position, and there is no input signal to the transmission controller, the gear speed indicators
totally go out, and if two signals are input due to a problem, an indicator different from the lever
position may light up, because priority is given to higher gear speed.

3] Display of actual gear speed

The actual gear speed display of the machine monitor shows the state of the gear speed and
travel direction, which is output from the transmission controller. When the directional lever is in
“N,” it will be “N” display, and when the directional lever is in “F” or “R,” it will be “F” or “R” +
gear speed display. While the parking brake is operating, this will always be “N” display, but
when the clutch is turned off due to operation of the transmission cut-off brake, there will be no
“N” display.

42 WA600-6
10 Structure, function and maintenance standard SEN00410-02

3) Automatic gear shifting function

In this function, auto shift, in which gear speed is automatically decided depending on travel speed,
and manual shift, in which the speed is decided as the gear speed of the gearshift lever, are
included. In auto shift, the auto shift indicator of the machine monitor lights up, and shifting up/down
and ON/OFF of the lockup clutch are changed with the engine power mode and selected shift
mode.
There are two modes, H/L, in auto shift, whose gearshift points are different depending on the
engine power mode.
In auto shift, shifting up/down are controlled in accordance with the directional lever, gearshift lever,
travel speed, accelerator pedal opening ratio, and data saved in the memory of the transmission
controller according to the engine speed. For the gearshift point of each mode, refer to “3. Auto-shift
points table.”

1] Gearshift lever in the 1st to 4th (when steering option is selected)

The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is
limited.
In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed.
Accordingly, if the gearshift lever is in 4th, the gear is shifted up and down between the 2nd
gear speed and 4th gear speeds, and the vehicle starts in the 1st gear speed only when the
kick-down function is used.

2] AJSS
Refer to the section of AJSS.

3] Directional lever in “N” position

The gear speed of transmission gearshift in neutral position is changed in accordance with
travel speed, but display will always be “N”.

4) Shift hold function

q The shift hold function will hold the current gear speed when the hold switch is pressed if the
auto-shift mode is selected, and will not shift up even when the travel speed is increased. Even
if the travel speed is decreased, the gear will not be shifted down.
q While the shift hold function is operating, the shift hold indicator of the machine monitor lights
up. When the shift hold switch is pressed again, the hold will be released, and the indicator will
go out.
q The hold will be released automatically also by the directional lever, gearshift lever, and kick-
down switch operation.
ON/OFF state of lockup will not be held.

5) Kickdown function
1] Kickdown in manual shift operation
q The kickdown switch operates only in the forward 2nd gear speed (F2), and the transmis-
sion is set in the forward 1st gear speed (F1). Operation of the kickdown switch is ignored
in any gear speed other than (F2).
q After the actual gear speed becomes (F1) due to kickdown switch operation, the kickdown
function will be released and the transmission will be set in the gear speed of the lever,
when the directional lever is operated to a position other than forward, or the gearshift
lever is operated to a position other than the 2nd gear speed.

WA600-6 43
SEN00410-02 10 Structure, function and maintenance standard

2] Kickdown in auto-shift operation

q The kickdown function will work regardless of the lever position, if the directional lever is in
a position other than N and the gearshift lever is in a position other than the 1st gear
speed.
q The gear speed selected by the operation of the kickdown switch depends on the travel
speed as shown in the following table.
q After the transmission gear is shifted because of the kickdown switch operation, ordinary
gear shift will be performed in accordance with the auto-shift points table, after the time
due to the no-shift time is passed or when the directional lever is operated.
<Reference>
Gear speed before Output shaft speed [rpm] Gear speed No-shift
Travel speed
shifting when kickdown switch = ON after shifting time
conversion
2nd In all range 1st 5 sec
Below 860 12.5 km/h 1st 5 sec
3rd
Above 860 12.5 km/h 2nd 4 sec
Below 860 12.5 km/h 1st 5 sec
4th
Above 860 12.5 km/h 3rd 4 sec
2nd (lockup) In all range 2nd *1
3rd (lockup) In all range 3rd *1
4th (lockup) In all range 4th *1

*1: When lockup is released due to kickdown switch operation, lockup will not be ON again
until the following conditions are satisfied.
q Perform temporary operation to turn the torque converter lockup switch OFFoON.
q The travel speed changes from lockup ON speed or less to lockup ON speed or more
as in the “3. Auto-shift points table.”

6) Torque converter lockup control function

q ON/OFF operation of the lockup is performed automatically due to ON operation of the torque
converter lockup switch.
q When the lockup clutch is ON, the lockup indicator of the machine monitor lights up.
q Even when the manual shift is selected, if the torque converter lockup switch is ON, ON/OFF of
the lockup is performed automatically by the transmission controller.
q The operation gear speed of lockup is shown in the following table.
Lockup operation gear speed (Lockup operates: Q)
Travel mode
F1 F2 F3 F4 R1 R2 R3 R4
MANUAL Q Q Q Q Q Q
Auto H Q Q Q Q Q Q
Auto L Q Q Q Q Q Q

1] Lockup rotation
For ON/OFF of lockup, refer to “3. Auto-shift points table.”

2] Lockup protection function

q Lockup ON only operates when the moving direction of the machine and the position of
the directional lever match.
Determination of moving direction of the machine
q The machine is thought to be stopping when the transmission controller is started (key
on), or the transmission output shaft speed is below 260 rpm.
q While the machine is thought to be stopping and the transmission output shaft speed
becomes 260 rpm or more, if the directional lever is in “F” position, it is thought to be mov-
ing forward, and if it is in “R” position, it is thought to be moving backward.
Q The travel speed is approximately 4 km/h when the transmission output shaft speed is
260 rpm.

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10 Structure, function and maintenance standard SEN00410-02

7) Hunting prevention function

q The transmission controller prevents hunting by detecting hunting, which occurs between 2nd
and 3rd when auto shift is selected, with the controller.
q If gearshifts of 2nd to 3rd to 2nd to 3rd are performed within 5 seconds from the previous gear-
shift, hunting is thought to have occurred, and the gear speed is selected from 2nd or 3rd,
whose operation time is longer. When hunting prevention function operates, the shift point in
hunting prevention stated in “3. Auto-shift points table” will be selected for the next automatic
gear shifting operation.
q The operation of hunting prevention function ends when the next gear shift operation (including
FR, kickdown operation, etc.) is performed, and the gear will be set to the ordinary shift point of
the auto shift.
q When ON/OFF of 2nd lockup occurs consecutively within 5 seconds, the lock up will be turned
off, and the speed will be changed to lockup ON travel speed when the hunting prevention
function operates.
q The hunting prevention function operates when hunting occurs even in the manual shift.

8) Changing shift points

q The transmission controller has a function to adjust the gearshift points of L mode in auto shift.
q If hunting occurs due to the conditions in a job site, travel speed when shifted up/down can be
changed by adjusting the gearshift points.
a For the changing procedure, refer to “Testing and adjusting: Transmission gearshift point
adjustment.”

9) 4th gear speed derating function

q The transmission controller has a function to limit the operation of the 4th gear speed by
changing the optional setting.
a For the changing procedure, refer to “Optional setting : Prohibition of 4th gear speed.”

10) Transmission initial learning and ECMV current adjustment

q The transmission controller has an adjusting function to correct dispersion between the trans-
mission unit and ECMV solenoid.
q The initial learning function is used to adjust the fill time by changing the trigger operation time.
The ECMV current adjustment function is used to adjust the modulation wave form. Dispersion
of each device is eliminated and the normal condition is obtained by adjusting both of these
items.
q If the adjustment is not performed, a gear shifting shock or a time lag may be made.
a For adjusting procedure, refer to “Testing and adjusting: Setting of transmission initial learning/
Adjustment of transmission ECMV current”.

WA600-6 45
SEN00410-02 10 Structure, function and maintenance standard

3. Auto-shift points table

q The relationship among transmission output shaft speed, engine mode, shift switch, and gear shift-
ing operation are shown below.
Engine mode and shift switch
Power mode Economy mode
Shift switch Shift switch Shift switch Shift switch
H L H L
F1oF2 373 373 373 373
F2oF2 (lockup) 516 – 650 516 – 650 500 – 650 500 – 650
F2oF2 (lockup)
616 – 700 616 – 700 600 – 700 600 – 700
when hunting is prevented
F2oF3 435 – 825 435 – 825 387 – 785 387 – 785
F2oF3
485 – 833 485 – 833 437 – 790 437 – 790
when hunting is prevented
F3oF3 (lockup) 987 903 903 903
Gear
shifting F3oF4 784 – 1,431 784 – 1,431 784 – 1,355 784 – 1,355
operation F4oF4 (lockup) 1,743 1,607 1,607 1,607
F4 (lockup) oF4 1,498 1,498 1,498 1,498
F4oF3 688 – 1,375 688 – 1,375 688 – 1,320 688 – 1,320
F3 (lockup) oF3 805 – 849 721 – 849 721 – 849 721 – 849
F3oF2 333 – 791 333 – 791 319 – 738 319 – 738
F3oF2
283 – 691 233 – 691 269 – 638 219 – 638
when hunting is prevented
F2 (lockup) oF2 445 – 477 445 – 477 430 430

a The transmission output shaft speed of 1 rpm corresponds to 0.0145 km/h.

a The shifting down point of F4oF2 and F3oF2 will be 69 rpm, when the accelerator is idle.

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10 Structure, function and maintenance standard SEN00410-02

4. Transmission protection function

1) Protection function when changing FR
In order to protect the transmission, the controller limits changing F-R operation with the directional
lever during high-speed travel.

1] All range of auto modes (speed position switch at a position other than 1st gear speed) and
manual mode (2nd, 3rd, and 4th)

In auto-shift mode
Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range)
Range II: F-R is changed, transmission is set in 2nd gear speed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to 2nd gear speed with reduction of the travel
speed.

In manual-shift mode
Range I: Only F-R is changed. (Ordinary range)
Range II: F-R is changed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to the speed position with reduction of the travel
speed.

a Two seconds immediately after the F-R changing operation, shifting up/down and kick-
down switch operation will not be accepted, and if shifting up/down operation is performed
with the lever operation, gear shift will be performed in two seconds.
In auto-shift, shifting up will not be performed until 2nd gear speed is obtained by speed
reduction.

Transmission output shaft speed

before gear shift (rpm)
A B C
928 963 1,100
Remarks
(Travel speed 13 km/h 14 km/h 16 km/h
conversion)

WA600-6 47
SEN00410-02 10 Structure, function and maintenance standard

2) Engine overrun prevention function

1] Shift-down prohibit function (Engine overrun prevention function 1)
q In order to protect the engine and pump, the controller performs shift-down protection, in which
operations are not accepted while shifting down, and the alarm is turned ON while it is operating.
q The operation conditions of the shift-down protection is shown below, and the alarm goes ON until
the gear shift position of the shift lever and the actual output gear shift match. Therefore, even when
the travel speed does not decrease, performing the shift-up operation will stop the alarm.
Protect P condition (A or (B and C)) Condition for resetting protect (D and (E or F))
Condition A Condition B Condition C Condition D Condition E Condition F
Target gear
Transmission Transmission Transmission Transmission
speed to shift Engine output Engine output
output shaft output shaft output shaft output shaft
down speed speed
speed speed speed speed
To 3rd gear Min. Min. Below Below
— —
speed 1,721 rpm 1,721 rpm 1,549 rpm 1,549 rpm
To 2nd gear Min. Min. Below Below Below
Min. 895 rpm
speed 1,102 rpm 1,620 rpm 964 rpm 861 rpm 1,440 rpm
To 1st gear Below Below
Min. 895 rpm Min. 895 rpm — —
speed 861 rpm 861 rpm

q The shift-down protection is valid also in kickdown operation in auto-shift. If the machine is
traveling in travel speed above the protect condition when kickdown operation is performed,
the kickdown operation is not accepted, and the alarm goes ON for three seconds.

2] Lockup reset function (Engine overrun prevention function 2)

q When the transmission output shaft speed becomes equivalent to the engine speed of 2,525 rpm
or above, the lockup is released automatically for preventing engine over run, and the alarm goes
off. For five seconds after it is released temporarily, the lockup stays OFF, but if after five seconds
pass and the transmission output shaft speed becomes equivalent to the engine speed of below
2,375 rpm, lockup will be on again.

Lockup OFF travel speed by function of engine overrun prevention (reference)

Lockup operation OFF value (equivalent to engine speed of 2,525 rpm)
WA600-6
Actual gear speed
Output shaft speed (rpm) Reference travel speed (km/h)
F2 1,094 15.9
F3 1,949 28.3
F4 3,439 50.0
R2 1,200 17.4
R3 2,137 31.1
R4 3,770 54.8

3] Forced shift-up function (Engine overrun prevention function 3)

q When traveling in T/C, if the engine speed becomes 2,525 rpm or more, transmission is shifted
up and the alarm goes ON. After shifting up, it will not be shifted down for three seconds.
q After three seconds pass, when the engine speed becomes below 2,375 rpm, the alarm stops
and the shift control becomes the ordinary control.
q When traveling in 4th gear speed, shift-up is not performed, and only the alarm goes ON.

4] Overrun pre-alarm function

q When the engine speed becomes 2,425 rpm or more, the function to warn operation of overrun
prevention action warning operates.
q The alarm is released when the engine speed becomes below 2,325 rpm.

5] Neutralizer function
q When the parking brake switch is ON (while the parking brake switch is operating), transmis-
sion output is maintained in neutral regardless of the state of the gearshift lever, for parking
brake dragging prevention function.
q Therefore, while the key is on, transmission is always in neutral regardless of the state of the lever.

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10 Structure, function and maintenance standard SEN00410-02

5. Engine control

1) Engine torque curve switching function

q The transmission controller selects engine power mode from signal input of engine power
mode changing switch, and while it sends torque curve information used in the engine control-
ler, it also sends engine power mode information of power/economy to the monitor panel.

2) Maximum travel speed limit

q For lower fuel consumption in load and carry, the maximum travel speed is limited by setting
the maximum travel speed (select from three levels), and setting the upper limit to throttle
value in F4 lockup state.
Throttle value
Setting information
upper limit
(1) (Default) 90%
(2) 100%
(3) 80%

3) RPM set
q For improving the working efficiency, the engine speed is maintained at an arbitrary speed.
q The engine speed is set with pressing the accelerator pedal, and RMP set idle up/down switch.
q When the right brake is pressed, RPM set is temporarily released.
q For lower fuel consumption, in a setting with auto deceleration function, if the transmission
neutral continues for four seconds or the work equipment neutral state lasts for four seconds or
longer, if the RPM set SET/ACCEL SW and RPM set RESUME/DECEL SW are not operated,
and if the travel speed is 5 km/h or less, the RPM set function is temporarily released, and
transmission follows the signal of the accelerator pedal.
q In the state where the RPM set is temporarily released, if the transmission is set to a position
other than neutral, or the work equipment is in a state other than N, the throttle control state will
be resumed automatically.
Compo- RPM set RPM set SET/ RPM set RESUME/ Right brake pedal RPM set
nent list function switch ACCEL switch DECEL switch operation switch indicator lamp
Switch
Alternate 3-position Momentary proximity
composi- Momentary seesaw switch In-switch LED
switch switch
tion
Brake operated (GND)
Switch ON(24V) ON(GND) Performed through
Brake not operated
theory OFF(OPEN) OFF(OPEN) electrical circuit
(OPEN)
Resume function
When this switch is
While the RPM set
pressed upward, Function to set
function is released
“RPM set auto decel- throttle stroke
with the right brake
eration function is Save the throttle When the right brake
pedal operation Lights up when the
disabled.” stroke when it is ON pedal is pressed, the
(release), press this RPM set function
When this switch is (lock accelerator RPM set function is
switch and the RPM switch is ON
pressed downward, opening ratio) temporarily released.
set function is
“RPM set auto decel- Controls with input
resumed.
eration function is signal edge
Controls with input
Function enabled.” signal edge
Acceleration function Deceleration function
When the switch is When the switch is
pressed and held for pressed and held for
When this switch is
0.5 seconds, the 0.5 seconds, the
pressed in the mid-
throttle stroke set throttle stroke set
dle, the RPM set
value rises in accor- value lowers in
function is OFF.
dance with the time accordance with the
the switch is time the switch is
pressed. pressed.

WA600-6 49
SEN00410-02 10 Structure, function and maintenance standard

q For description of the RPM set function, a sample time chart is shown below.

q RPM set ON-OFF switch

Used to turn the RPM set system ON and OFF.
q RPM set idle-up/down selector switch
Used to keep the engine speed at any level.

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10 Structure, function and maintenance standard SEN00410-02

6. Modulation clutch
1) Modulation clutch control
q The modulation clutch is a function in which drive force from the engine to the tires is continu-
ously limited in accordance with the brake pedal when the left brake pedal is pressed.

1] Modulation clutch system hydraulic circuit diagram

2] Resume control in releasing left brake pedal

q The transmission controller controls so that sudden change of drive force will not occur in
engagement.

WA600-6 51
SEN00410-02 10 Structure, function and maintenance standard

3] Modulation clutch invalid control in traveling

q When the left brake is used while traveling, since the engagement of the modulation clutch
is released and the effect of engine brake is not obtained, the following control is added so
that the effect of engine brake is obtained in operation of the left brake.

q Modulation clutch invalid control condition

Torque converter lockup = ON
Or
Throttle opening ratio is 30% or less in gear speed of F2, F3, F4, R2, R3, and R4

q Modulation clutch invalid control finish condition

Torque converter lockup = OFF
And
Throttle opening ratio is 30% or more, or in gear speed of F1, R1, and N
Throttle opening
Gear Speed Torque converter lockup Modulation clutch invalid control state
ratio
— — ON
F2
F3
F4 Start invalid control
Max. 30% —
R2
R3
R4
— Min. 30%
F1
OFF End invalid control
R1 —
N

4] Brake load reduction control

q When the machine is decelerated from high speed travel with the accelerator pedal and
brake pedal pressed (in dump approach operation etc.), the brake load is reduced by low-
ering the modulation clutch oil pressure and reducing the transmissibility of the modulation
clutch.
q Condition for starting brake load reduction control
The throttle opening ratio is 70% or above and the output shaft speed is 1,032 rpm (Refer-
ence travel speed: 15 km/h) or above and the brake signal is turned ON.
q Condition for stopping brake load reduction control
The throttle opening ratio is 50% or below or the output shaft speed is below 688 rpm (Ref-
erence travel speed: 10 km/h) or the brake signal is turned OFF.
Throttle Output shaft Brake load Torque Modulation clutch oil
Brake signal
opening ratio speed reduction control converter lockup pressure command value
70% 1,032 rpm ON o OFF Normal control command
ON Started
or above or above OFF o OFF value o 0.2 MPa
50% Below OFF o 0.2 MPa o Normal control
OFF Stopped
or below 688 rpm Normal control command value

5] Modulation clutch control when transmission gear is shifted

q Transmissibility of the modulation clutch is controlled at the times of starting and changing
directions for improved gear shifting and reducing clutch heat load.

6] Modulation clutch control at the time of starting the engine

q For reduced load of the travel system and improved engine start, the modulation clutch is
completely disengaged when the engine is started.
q When the engine speed is 500 rpm or higher, it will be connected directly with the modula-
tion clutch for performing ordinary control.

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10 Structure, function and maintenance standard SEN00410-02

7] Setting modulation clutch drive force

q The slippage ratio of the modulation clutch in F1 can be adjusted with a dial.
Settable range (slippage ratio)
80% – 0%

Input: Dial input voltage V 4.00 3.63 3.25 2.88 2.50 2.13 1.75 1.38 1.00
Dial set recognition % 20 30 40 50 60 70 80 90 100
Target transmissibility % 20 30 40 50 60 70 80 90 100
Target modulation
Output: MPa 0.3 0.35 0.45 0.5 0.6 0.8 1 1.5 2.5
clutch oil pressure
Current value mA 212 222 240 248 264 302 333 408 552

q Image of speed, traction power, and transmissibility

8] Modulation clutch emergency operation switch

q Since the modulation clutch is engaged with command, and disengaged without com-
mand, when the transmission controller fails and cannot issue commands, the vehicle
cannot be moved.
q In order to address such trouble, a circuit to directly connect the modulation clutch with
modulation clutch emergency operation switch is equipped.
When the solenoid valve fails, the plate for emergency escape of ECMV is used to
address the problem.

WA600-6 53
SEN00410-02 10 Structure, function and maintenance standard

7. ECSS

1) ECSS function
q It is a system in which the controller automatically turns on and off the accumulator charged
with high-pressure gas according to the travel condition, and the lift arm operation condition,
improving operator comfort and working efficiency by preventing spillage of material by absorb-
ing the vertical movement of the work equipment, when the vehicle travels at high speed.

ECSS system of WA600-6

1] ECSS system circuit

2] Operation of ECSS
q The operating condition of ECSS is as follows.
Since the ECSS is optional equipment, control will not be performed unless the option of
ECSS is enabled in the optional setting of the machine monitor. For the setting procedure
of options, refer to “Testing and adjusting: Special functions of machine monitor (EMMS),
Select optional equipment.”
Output shaft
ECSS switch Gear Speed ECSS output
speed
OFF All 0 to MAX OFF
1st 0 to MAX OFF
ON Condition A OFF
2nd to 4th
Condition B ON

q The transmission output shaft speed of 206

rpm corresponds to approximately 3 km/h.
q The transmission output shaft speed of 344
rpm corresponds to approximately 5 km/h.

54 WA600-6
10 Structure, function and maintenance standard SEN00410-02

3] Operation of solenoid in ECSS ON/OFF

q Modulation control is performed for the ECSS solenoid with EPC output in switching ON/
OFF, reducing the lowering of the lift arm and occurrence of switching shocks.
q The constant current when the ECSS solenoid is ON is 800 mA.

8. Economy lamp
1) Control of economy lamp
q The transmission controller lights up the economy lamp indicator of the machine monitor when
operating in low fuel consumption, in order to prompt low fuel consumption operation to the
operator.

1] Lighting condition of economy lamp

q When the engine power mode is the economy mode, and the accelerator pedal opening
ratio is 80% or less, the economy lamp is lighted.
Accelerator Power Economy
opening ratio mode mode
Min. 80% OFF OFF
Max. 80% OFF Lighting

2] Turning off economy lamp

q The economy lamp can be constantly kept off with the optional setting of the monitor.
a For the setting procedure, refer to “Testing and adjusting: Special functions of machine
monitor (EMMS), Select optional equipment.”

WA600-6 55
SEN00410-02 10 Structure, function and maintenance standard

9. Cooling fan control

1) Control of fan
q The cooling fan is driven hydraulically and by controlling the swash plate of the main pressure
pump, the horsepower loss and noise are reduced while the temperature is low.

q The information of the engine speed and engine coolant temperature sensed by the engine
controller, and hydraulic oil temperature, and torque converter oil temperature sensed by the
machine monitor is sent through the network to the transmission controller, and then current
control is performed for the swash plate angle of the fan pump so that the fan speed will be
matched to the temperature and engine speed.

56 WA600-6
10 Structure, function and maintenance standard SEN00410-02

2) Fan speed in accordance with temperature

q As for the fan speed, the target fan speed is determined based on the data with highest tem-
perature among coolant temperature, hydraulic oil temperature, and torque converter oil tem-
perature.

q Basic control of fan speed

a. Target speed when air conditioner operates b. Minimum inclination: 850 mA c. Median value: 677 mA

3) Protection function
q For preventing overrun of the motor of the fan pump, the minimum swash plate is used for the
fan pump when the engine speed is 2,650 rpm or higher.
q When the engine speed or respective temperature data cannot be recognized by the transmis-
sion controller due to such cause as failure of network communication, the fan pump EPC cur-
rent is set to 677 mA, which is equivalent to that of the fixed pump.

4) Control for starting engine

In fan control, a different control from the ordinary control with temperature when starting the
engine.
q When stopping the engine (key switch 1-stage on)
When the engine is stopped, the fan pump EPC current of 677 mA is output, for it is the same
as a state where the engine speed cannot be recognized.
q While cranking
While cranking to start the engine, in order to improve engine start, the minimum swash plate is
used for the fan pump by setting the fan EPC current to 850 mA, reducing the torque neces-
sary for starting the engine.

WA600-6 57
SEN00410-02 10 Structure, function and maintenance standard

5) Fan reverse rotation function

q In the hydraulic fan, for cleaning the radiator core, when the fan reverse rotation switch is oper-
ated, the hydraulic fan motor reverse solenoid operates to reverse the fan.

1] Standard specification fan manual reverse rotation function

q It is a function to reverse the fan rotation arbitrarily by the operator. By pressing the fan
manual reverse switch, the turning direction of the fan is changed.

q Changing from forward to reverse, and reverse to forward is performed when the following
conditions are satisfied.
q The fan manual reverse switch is pressed
q The engine speed is 500 rpm or lower.

q The fan reverse indicator flashes when the state of the fan manual reverse switch and the
rotation direction of the fan do not match. While the fan is rotating in reverse direction, the
fan reverse indicator lights up.
Reverse SOL Forward/reverse
Reverse SOL Fan pump Monitor indicator
output before selector switch Engine speed
output EPC output lighting logic
switch operation operation
From OFF to
OFF ON MIN speed From OFF to lighting
ON
From ON to
OFF OFF Ordinary From flashing to OFF
OFF Below 500
From OFF to rpm
ON ON MIN speed From flashing to ON
ON
From ON to
ON OFF Ordinary From flashing to OFF
OFF
From OFF to
OFF OFF Ordinary From OFF to flashing
ON
From ON to
OFF OFF Ordinary From flashing to OFF
OFF
Min. 500 rpm
From OFF to
ON ON As per 3] From flashing to ON
ON
From ON to
ON ON As per 3] From lighting to flashing
OFF

2] Optional specification of fan automatic reverse function

q Not used.

3] Fan speed in reverse

q While it is operating in reverse, cleaning of the radiator core is facilitated by increasing air
flow by turning the fan at the maximum speed without outputting fan pump EPC current
(output 0 mA).
q When the hydraulic oil temperature is below 30°C, however, the fan EPC current is set to
850 mA and the fan speed is minimized to protect the hydraulic circuit.

58 WA600-6
10 Structure, function and maintenance standard SEN00410-02

10. Low temperature bypass control (if equipped)

Low temperature bypass control
q In order to prevent transmission filter peak pressure in extremely low temperature, travel can
optionally prohibited for 30 seconds by bypassing the torque converter charger pump circuit imme-
diately after the engine is started.

1) Operation of low temperature bypass solenoid

The bypass solenoid operates when all the following conditions are satisfied.
(1) Torque converter inlet oil temperature < –20°C
Conditions
(2) Cold district option is enabled
(3) When starting the engine (with C terminal signal and engine speed of 500 rpm or lower)

2) Finishing operation of low temperature bypass solenoid

q Elapsing time after the start of operation is 30 seconds or longer, or cold district option is dis-
abled.

WA600-6 59
SEN00410-02 10 Structure, function and maintenance standard

11. AJSS
1) AJSS control
q Equipment allowing turning of the vehicle (steering operation), forward and reverse movement
and shifting up/shifting down, with the AJSS lever located on the left console.
q Since turning of the vehicle is performed by the work equipment controller, refer to the section
of work equipment controller, for turning operation of AJSS.

2) AJSS shifting up/shifting down switch

q The AJSS shifting up/shifting down switch performs shifting up/shifting down in accordance
with the buttons in the manual shift mode.
a However, when shifting down during high-speed travel, the shift-down protection function oper-
ates and shifting down will be performed after the travel speed has decreased.
q When the shift mode is the auto shift mode (both H and L), the maximum gear speed (gear
shifting range) used in the automatic gear shifting operation is limited.
q In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed.
Accordingly, if the shift range is 4, the gear is shifted up and down between the 2nd gear speed
and 4th gear speed, and the vehicle starts in the 1st gear speed only when the kick-down func-
tion is used.

1] Function of shifting up/shifting down switch

q When the shifting up/shifting down switches are operated at the same time, shift down is
effective.
q After pressing a switch once, the next shifting up/shifting down switch operation is not
accepted for 0.2 seconds.

3) Neutralizer function
q While the parking brake is operating, or the steering lever is locked, neutral is maintained
regardless of the shift lever position.
q Also, while the parking brake is operating, the AJSS indicator and buzzer operate as shown
below.
Shift
Steering
switch Indicator Buzzer
lock
position
ON Arbitrary Lighting None
Sounding
OFF F or R Flashing
(pip, pip)
OFF N OFF None

60 WA600-6
10 Structure, function and maintenance standard SEN00410-02

12. Real-time monitor

1) List of display contents of the real-time monitor
In WA600-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the transmission controller:
Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
Software part Output mass production Depends on the software
1 20201 VERSION
number software part number part number
Output software version
Software appli- Depends on the software
2 20223 VERSION (APP) (software logic part ver-
cation version version
sion)
Software appli- Output software version
Depends on the software
3 cation data ver- 20224 VERSION (DATA) (software data part ver-
version
sion sion)
Output engine mode for 0: power mode
4 Engine mode 41600 ENGINE MODE
controlling engine output 2: economy mode
X1 [mA]
(0 – 1000[mA])
When engine speed is
below 500 rpm
= 677 mA
ECMV output Output to FAN EPC out-
While cranking (C terminal
5 command value 41400 FAN EPC DIR put command current
operation)
(FAN pump) value
= 850 mA
Switching fan reverse
= 850 mA
Fan operating in reverse
= 0 mA
Fan reverse FAN REVERSE Output fan reverse SW 1:ON(CLOSE)
6 93400
switch input SW input state 0:OFF
Torque converter
Output T/C inlet oil tem- *1 [°C] Option for low tem-
7 inlet oil tempera- 41501 T/C IN OIL TEMP
perature (–30 – 100 [°C]) perature detection
ture
*0.01 [V]
(0.00 – 5.00 [°C])
Torque converter 4.72V = 0°C
Output T/C inlet oil tem-
8 inlet oil tempera- 41502 T/C IN OIL TEMP 4.33V = 30°C
perature
ture 3.55V = 60°C
2.20V = 100°C
1.61V = 120°C
Torque converter
Output T/C input shaft x 1 [min-1]
9 input shaft 93500 T/C SPEED:IN
speed (0 – 32,767 [min-1])
speed
Torque converter Output T/C output shaft
T/C x 1 [Nm]
10 output shaft 93501 torque calculated value
TORQUE:OUT (0 – 400,000)
torque (T2)
Transmission
Not used by this
11 input shaft 31200 T/M SPEED IN — 0
machine
speed
x 1 [min-1]
(0 – 32,767 [min-1])
Transmission
Output output shaft speed 0 km/h = 0 rpm
12 output shaft 31400 T/M SPEED:OUT
[PLS_AC_IN_2] 10 km/h = 788 rpm
speed
20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm
x 1 [min-1]
(0 – 32,767 [min-1])
Transmission
T/M Output output shaft speed 0 km/h = 0 rpm
13 output shaft 31404
SPEED:OUT2 [PLS_AC_IN_0] 10 km/h = 788 rpm
speed
20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm

WA600-6 61
SEN00410-02 10 Structure, function and maintenance standard

Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
Transmission
Not used by this
14 cut-off operation 41203 T/M CUT SET — 0
machine
setting
Transmission
Not used by this
15 cut-off (left 41201 T/M CUT OFF P — 0
machine
brake) pressure
Transmission
Not used by this
16 cut-off (left 41202 T/M CUT OFF P — 0
machine
brake) pressure
Torque converter TC SPEED Output torque converter x 1 [%]
17 93700
speed ratio RATIO speed ratio (0 – 100 [%])
Transmission oil Output oil temperature
x 1 [°C]
18 temperature 93600 T/M OIL TEMP value of transmission oil
(0 – 150 [°C])
input temperature (A_IN_1)
x 1 [mV]
(0.00 – 5.00 [V])
Input voltage of Output input voltage 4.72 V = 0°C
19 transmission oil 93601 T/M OIL TEMP value of transmission oil 4.33 V = 30°C
temperature temperature (A_IN_1) 3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
Output oil pressure con-
MOD/C oil pres- x 1 [MPa]
20 92400 MOD/C PRESS version value of MOD/C
sure input (0.00 – 5.00 [MPa])
oil pressure input (A_IN7)
MOD/C oil pres- Output voltage value of
x 1 [mV]
21 sure input volt- 92401 MOD/C PRESS MOD/C oil pressure input
(0.00 – 5.00 [V])
age (A_IN7)
Overheat notice ON
when the value is 2.2
or more (lamp on)
Overheat warning
operates and records
when it is 2.9 or more
Output the value of calcu-
MOD/C heat x 1 [100J/cm2] (lamp on, buzzer
22 92500 MOD/C Q lated heat release value
release value (0.0 – 25.5 [100J/cm2]) operates, action
(Q) of MOD/C
code displays, and
error is recorded)
Overheat warning/
notice OFF when it is
1.8 or less (lamp off),
resumed from error
Output the value of calcu-
MOD/C heat x 1 [0.1kW/cm2]
23 92501 MOD/C q lated heat ratio value (q)
ratio (0.00 – 2.55[0.1kW/cm2])
of MOD/C
RPM set switch
Output the state of input 0: RPM set switch OFF
24 (pressed 95500 THROT LOCK A
signal 1: RPM set switch ON
upward)
RPM set switch
0: RPM set auto decelera-
(pressed down-
Output the state of input tion switch OFF
25 ward) (RPM set 95501 THROT LOCK B
signal 1: RPM set auto decelera-
auto decelera-
tion switch ON
tion switch)
Output throttle
Output throttle correction x 1 [%]
26 correction com- 95400 THROTTLE MOD
command output amount (–100 – 100 [%])
mand
Output throttle
Output throttle upper limit x 0.1 [%]
27 stroke upper 44200 THROT LIMIT UP
command output amount (0.0 – 100.0 [%])
limit value
Output throttle
Output throttle lower limit x 0.1 [%]
28 stroke lower limit 44201 THROT LIMIT LO
command output amount (0.0 – 100.0 [%])
value

62 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
Depends on accelerator
pedal operation
Accelerator pedal = 0
Depends on accelerator
Accelerator pedal partial
Acceleration THROTTLE opening ratio; output
29 93801 pressing (opened side) = 1
mode MODE acceleration mode on
Accelerator pedal partial
control
pressing (pressed side) = 2
Accelerator pedal pressing
=3
Traction setting Output set value of trac- x 1 [%]
30 94000 TRACTION DIAL
input value tion dial (0 – 100 [%])
Traction setting Output voltage value of Output voltage value of
31 94001 TRACTION DIAL
input voltage traction dial setting input traction dial setting input
0: Lockup changing switch
Lockup chang-
Output the state of input OFF
32 ing switch input 95000 LOCK UP SW
signal 1: Lockup changing switch
signal
ON
ECMV output ECMV output to 1st clutch
x 1 [mA]
33 command value 31602 ECMV 1 DIR Output command current
(0 – 1000 [mA])
(1st) value
ECMV output to 2nd
ECMV output
clutch x 1 [mA]
34 command value 31603 ECMV 2 DIR
Output command current (0 – 1000 [mA])
(2nd)
value
ECMV output to 3rd
ECMV output
clutch x 1 [mA]
35 command value 31604 ECMV 3 DIR
Output command current (0 – 1000 [mA])
(3rd)
value
ECMV output to 4th
ECMV output
clutch x 1 [mA]
36 command value 31605 ECMV 4 DIR
Output command current (0 – 1000 [mA])
(4th)
value
ECMV output to FWD
ECMV output
clutch x 1 [mA]
37 command value 31608 ECMV F DIR
Output command current (0 – 1000 [mA])
(FWD)
value
ECMV output to L/U
ECMV output
clutch x 1 [mA]
38 command value 31609 ECMV LU DIR
Output command current (0 – 1000 [mA])
(L/U)
value
ECMV output to MOD/C
ECMV output
ECMV MOD/C clutch x 1 [mA]
39 command value 31640
DIR Output command current (0 – 1000 [mA])
(MOD/C)
value
ECMV output to REV
ECMV output
clutch x 1 [mA]
40 command value 31606 ECMV R DIR
Output command current (0 – 1000 [mA])
(REV)
value
ECMV output Output to ECSS valve
x 1 [mA]
41 command value 93300 ECSS V DIR Output command current
(0 – 1000 [mA])
(ECSS) value
Output fill time value of
Fill time value x 0.01 [sec]
42 41802 FILL TIME 1 1st clutch
(1st) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
Output fill time value of
Fill time value x 0.01 [sec]
43 41803 FILL TIME 2 2nd clutch
(2nd) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
Output fill time value of
Fill time value x 0.01 [sec]
44 41804 FILL TIME 3 3rd clutch
(3rd) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
Output fill time value of
Fill time value x 0.01 [sec]
45 41805 FILL TIME 4 4th clutch
(4th) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)

WA600-6 63
SEN00410-02 10 Structure, function and maintenance standard

Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
Output fill time value of
Fill time value x 0.01 [sec]
46 41808 FILL TIME F FWD clutch
(FWD) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
Output fill time value of
Fill time value x 0.01 [sec]
47 41806 FILL TIME R REV clutch
(REV) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
000*****
: Changing engine mode
SW OFF
100*****
D-IN0
: Changing engine mode
: Engine mode selec-
SW ON
tion SW
*000****
D-IN3
: Stopping air compressor
: Operating air com-
*001****
pressor
: Operating air compressor
D-IN4
Input signal Output the state of input *00*00**
48 40905 D-IN--0------7 : Shift mode L
D_IN_0 – 7 signal : Manual shift mode
D-IN5
*00*10**
: Shift mode H
: Shift mode L
D-IN6
*00*11**
: MOD/C direct con-
: Shift mode H
nection signal
*00***0*
D-IN7
: MOD/C opened
: C terminal signal
*00***1*
: MOD/C directly connected
*00****1
: Cranking
000*0***
: Kickdown SW = OFF
001*0***
: Kickdown SW = ON
00*00***
: Shift hold SW = OFF
D-IN10
00*10***
: Kickdown SW
: Shift hold SW = ON
D-IN11
00**00**
: Shift hold SW
: RPM set SW = OFF
D-IN13
00**01**
: RPM set SW
Input signal Output the state of input : RPM set SW = ON
49 40906 D-IN--8-----15 D-IN14
D_IN_8 – 15 signal 00**0*0*
: RPM set resume
: RPM set resume SW =
SW
OFF
D-IN15
00**0*1*
: RPM set release
: RPM set resume SW =
right brake pedal
ON
SW
00**0**0
: RPM set release right
brake pedal SW = OFF
00**0**1
: RPM set release right
brake pedal SW = ON

64 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
01******
D-IN16
: AJSS shift-up SW = OFF
: AJSS shift-up (nor-
(AJSS specification)
mally open) (AJSS
10******
specification)
: AJSS shift-up SW = ON
shift range 1st (steer-
(AJSS specification)
ing specification)
**01****
D-IN17
: AJSS shift-down SW =
: AJSS shift-up (nor-
OFF (AJSS specification)
mally closed) (AJSS
**10****
specification)
: AJSS shift-down SW=ON
shift range 2nd
(AJSS specification)
(steering specifica-
1000****
tion)
: shift lever 1st
D-IN18
(steering specification)
: AJSS shift-down
0100****
(normally open)
Input signal Output the state of input : shift lever 2nd
50 40907 D-IN-16-----23 (AJSS specification)
D_IN_16 – 23 signal (steering specification)
shift range 3rd (steer-
0010****
ing specification)
: shift lever 3rd
D-IN19
(steering specification)
: AJSS shift-down
0001****
(normally closed)
: shift lever 4th
(AJSS specification)
(steering specification)
shift range 4th (steer-
****100*
ing specification)
: direction lever F
D-IN20
****010*
: direction lever F
: direction lever N
D-IN21
****001*
: direction lever N
: direction lever R
D-IN22
*******0
: direction lever R
: parking brake release
D-IN23
*******1
: parking brake signal
: parking brake operation
D-IN25
0101000* : fill SW F
: F1 traveling D-IN26
0010100* : fill SW R
: R2 traveling D-IN27
0000010* : fill SW 1st
: 3rd neutral D-IN28
0100001* : fill SW 2nd
Input signal Output the state of input
51 40908 D-IN-24-----31 : F4 traveling D-IN29
D_IN_24 – 31 signal
0******0 : fill SW 3rd
: Steering lock lever pres- D-IN30
sure SW = OFF or steer- : fill SW 4th
ing specification D-IN31
0******1 : Steering lever lock
: Steering lock lever pres- pressure SW (con-
sure SW = ON stantly 0 in steering
specification)
Input signal 00000000
D_IN_32 – 39 : when foot brake is
(Transmission Output the state of input released D-IN32
52 40942 D-IN-32-----39
controller does signal 10000000 : brake pressure SW
not have 33 – : when foot brake is
39) pressed

WA600-6 65
SEN00410-02 10 Structure, function and maintenance standard

Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
000***00
: modulation clutch invalid
solenoid OFF
100***00
: modulation clutch invalid D-OUT0
solenoid ON : modulation clutch
*000**00 invalid solenoid
: fan reverse solenoid OFF D-OUT3
ON/OFF output state of *001**00 : fan reverse solenoid
Output signal SOL_OUT0 to 7 : fan reverse solenoid ON D-OUT4
53 40949 D-OUT 0 – 7
D_OUT_0 – 7 '0' is displayed when set- *00*0*00 : fan neutral solenoid
ting current output : fan neutral solenoid OFF (optional)
*00*1*00 D-OUT5
: fan neutral solenoid ON : low temperature
*00**000 bypass solenoid (if
: low temperature bypass equipped)
solenoid OFF
*00**100
: low temperature bypass
solenoid ON
ON/OFF output state of
SOL_OUT8 to 11B,
Output signal Not used by this
54 40950 D-OUT 8 – 15 SIG_OUT0 to 1 00000000
D_OUT_8 – 15 machine
'0' is displayed when set-
ting current output
ON/OFF output state of
SIG_OUT2 to 3,
Output signal HSW_OUT0 to 1, Not used by this
55 40951 D-OUT 16 – 23 00000000
D_OUT_16 – 23 BATT_RY_OUT machine
'0' is displayed when set-
ting current output
16-bit data is dis-
Output initial learning flag 111111
played
Initial learning state of trigger time of (all clutches learned)
56 94100 TRIG FR1234 in the order of F, R, 1,
flag each clutch 000000
2, 3, and 4 on the
[F,R,1,2,3,4] (all clutches to be learned)
monitor

66 WA600-6
10 Structure, function and maintenance standard SEN00410-02

13. Diagnosis
1) Function of troubleshooting
The transmission controller monitors the input and output signals constantly for troubleshooting for
the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor.
When abnormality occurs, it can be confirmed on the machine monitor.

WA600-6 67
SEN00410-02 10 Structure, function and maintenance standard

14. Pin assignment

68 WA600-6
10 Structure, function and maintenance standard SEN00410-02

Input and output signals

DEUTSCH-24P [CN-L02]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 T/C lock up SW. Input 13 Throttle with auto decel Input
2 Fan reverse SW. Input 14 T/C inlet oil temp. sensor Input
3 Traction dial Input 15 NC Input
4 GND_SIG_D 16 PWR_OUT_SENS Output
5 A/C compressor signal Input 17 NC Input
6 Starter switch(IGN-C) Input 18 Shift mode signal H Input
7 E.C.S.S. SW. Input 19 Throttle lock without auto decel Input
8 MOD/C oil pressure Input 20 Memory reset Input
9 T/M oil temp. sensor Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 NC Input 23 Engine mode SW. Input
12 MOD/C direct signal Input 24 Shift mode signal L Input

DEUTSCH-40P(1) [CN-L03]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC Output 21 NC Input/Output
2 ECMV fill SW.:4th Input 22 COMM_CAN_L_O Input/Output
3 ECMV fill SW.:3rd Input 23 NC Input/Output
4 232C_RxD Input 24 PWR_CTR_EXT Input
5 AJSS shift down(NC)or shift lever:4th Input 25 AJSS shift up(NC)or shift lever:2nd Input
6 Parking brake signal Input 26 Direction lever:N Input
7 ECMV fill SW.:1st Input 27 ECMV fill SW.:F Input
8 NC Output 28 Brake pressure SW. Input
9 NC Output 29 GND_SIG_P
10 NC Input 30 MOD/C speed sensor Input
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input/Output
13 ECMV fill SW.:2nd Input 33 NC Input/Output
14 232_TxD Output 34 232C_GND
15 AJSS shift down(NO)or shift lever:3rd Input 35 AJSS shift up(NO)or shift lever:1st Input
16 Direction lever:R Input 36 Direction lever:F Input
17 ECMV fill SW.:R Input 37 NC Input
18 NC Output 38 S/T lever lock pressure SW. Input
19 NC Output 39 GND_SIG_P
20 Speed sensor(1) Input 40 Speed sensor(2) Input

DEUTSCH-40P(2) [CN-L04]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 TM power hold relay Output 24 KEY switch signal Input
5 ECMV:F. clutch Output 25 ECMV:1st clutch Output
6 ECMV:2nd clutch Output 26 ECMV:4th clutch Output
7 MOD/C cut off SOL. Output 27 Fan pump EPC Output
8 NC Output 28 Fan pump neutral solenoid Output
9 NC Input 29 RESUME/DECEL SW. Input
10 NC Input 30 Kick down SW. Input
11 PWR_IN_BATT Input 31 GND_PWR
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 ECMV:R. clutch Output 35 ECMV:lock up clutch Output
16 ECMV:3rd clutch Output 36 ECMV:modulation clutch Output
17 E.C.S.S. solenoid Output 37 Fan pump reverse solenoid Output
18 NC Output 38 T/M bypass solenoid Output
19 SET/ACCEL SW. Input 39 Right brake SW. Input
20 NC Input 40 Shift hold SW. Input

WA600-6 69
SEN00410-02

WA600-6 Wheel loader

Form No. SEN00410-02

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 11-06 (01)

70
 SEN00411-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

10 Structure, function and

maintenance standard 1
Electrical system, Part 3
Electrical system, Part 3 ................................................................................................................................. 2
Electric transmission control ................................................................................................................ 2
Engine starting/stopping circuit ............................................................................................................ 4
Parking brake circuit............................................................................................................................. 7
Sensor.................................................................................................................................................11
VHMS controller related ..................................................................................................................... 33
Work equipment electric lever ............................................................................................................ 37

WA600-6 1
SEN00411-03 10 Structure, function and maintenance standard

Electrical system, Part 3 1

Electric transmission control 1
Combination switch
(Steering wheel specification)

q The directional lever has 3 positions and the gearshift lever switch has 4 positions.The detent mecha-
nism is not installed to each switch but installed to the body of the combination switch. Each switch is
positioned with 2 pins and fixed to the body with 3 screws. If each lever is set in a desired position, the
switch connected by the shaft operates to supply the current to only the circuit of the desired position.
No. Type Operation
1 Directional lever switch Selects the travel direction and neutral.
2 Gearshift lever switch Selects a gear speed.
3 Gearshift lever stopper Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4 Turn signal Turn signal for L.H. and R.H. turns
Returns the turn signal lever automatically to neutral when the steering wheel is
5 Self-cancel
returned after turning to the right or left.
6 Lamp switch Selects the clearance lamp, headlamp, parking lamp, etc.
7 Dimmer switch Selects main beam and low beam.
8 Hazard switch Flashes turn signals to the left and right simultaneously.
9 Hazard pilot lamp Flashes while the hazard lamp flashes.

2 WA600-6
10 Structure, function and maintenance standard SEN00411-03

q Shaft (2) of directional and gearshift lever (1) of

the combination switch is made one with mag-
net (3). As lever (1) moves, magnet (3) moves,
too.
q Control switch (5) having Hall IC's (4) in it is
installed under magnet (3). Hall IC (4) are
arranged on the board for each position.
q When the directional lever is set in the “F” posi-
tion, magnet (3) comes to directly above Hall
IC (4) of the “F” position of the control switch.
Magnet (3) magnetizes Hall IC (4) through the
clearance and case (6).
q Hall IC (4) is in the magnetism sensor circuit
and it detects the magnetism of magnet (3)
and sends the signal of the “F” position of the
directional lever to the current amplifier circuit.
The current amplifier circuit outputs the signal
to operate the transmission valve.

WA600-6 3
SEN00411-03 10 Structure, function and maintenance standard

Engine starting/stopping circuit 1

Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q The engine can not be started while the
directional lever is not in N (Neutral).
q When the AJSS lever is in a position other
than neutral, the engine can not be
started.

4 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Operation 5. When starting switch is turned to “Start” position

1. When starting switch is turned to “ON” position q If the starting switch is turned to the “Start”
q If the starting switch is turned to the “ON” position, terminals B and C of the starting
position, terminals B and BR of the start- switch are closed and the current flows
ing switch are closed and the current flows from the neutral safety relay through the
from the battery through the starting AJSS neutral safety relay to the starting
switch and battery relay coil to the ground motor, and the engine starts rotating.
and the contacts of the battery relay are When the engine starts rotating, fuel injec-
closed. As a result, the power is supplied tion starts to each cylinder with the rota-
to each circuit of the vehicle. tion signal from the engine rotation sensor
Also, the operation signal is provided from connected to the engine controller, and
the terminal ACC of the starting switch then the engine starts.
into the engine controller, and the engine 6. Engine stopped
is ready to start. q If the starting switch is set in the “OFF”
2. Neutral safety circuit position, the current of terminal ACC of
q When the directional lever is set in the “N” the starting switch is cut out and the ACC
position, current flows from the N contact signal to the engine controller is cut out
of the directional switch to the coil of the accordingly, and the engine controller
neutral safety relay, and by conducting the stops fuel injection.
three terminals of the neutral safety relay q When fuel injection stops, the engine
with the five terminals, the engine slows down the rotation and stops. When
becomes ready to be started. the alternator stops generating electricity,
3. AJSS neutral safety circuit voltage supply from R terminal stops, and
q When the engine is started in a condition the current from BR terminal of the start-
other than steering neutral condition, in ing switch is cut out, the contact of the bat-
which the lever angle of AJSS and the tery relay opens, and the power supply
machine frame angle are the same, the provided to various parts of the machine is
machine can begin turning immediately cut out.
after it is started, which can be a cause of
danger. Therefore, if the deviation of the
lever angle and the frame angle, sensed
by the work equipment controller, is 6° or
more, starting the engine is prohibited by
energizing the AJSS neutral safety relay
coil by the work equipment controller, and
opening the three and six terminals of the
relay.
4. Neutral maintaining circuit
q The neutral safety relay may not be main-
tained due to voltage decrease of neutral
signal from the directional lever because
of voltage decrease in starting the engine.
In order to prevent this, the “neutral main-
taining relay” is installed to maintain neu-
tral safety relay as long as the signal from
the C terminal of the starting switch, in
case starting the engine is initiated in neu-
tral state.

WA600-6 5
SEN00411-03 10 Structure, function and maintenance standard

7. When the option “battery disconnect switch” is

equipped
q When the battery disconnect switch is
equipped and the switch is OFF (the con-
tact is opened), the starting switch B termi-
nal, respective controllers, and other
constant power supplies are all cut out,
and the state is the same as when the bat-
tery is not connected.
q The battery disconnect switch is usually
used for substitution to take off the minus
terminal of the battery, when the machine
is stored for a long time (a month or
longer), when the electrical system is
repaired, or when electrical welding is per- Position OFF (cut)
formed. Position ON (connected)
When the battery disconnect switch is turned
off, all the electrical system of the machine will
be inoperative.
q The clock of the monitor/radio and recep-
tion preset memory of radio will be lost,
and need to be set again when using
them.
q Such functions as room lamp, step lamp,
and hazard lamp cannot be used either.
q Since VHMS is saving data with battery
power immediately after the starting
switch is turned off, when turning the bat-
tery disconnect switch off, ensure that the
VHMS operation indicators in the rear
frame left component box and at the side
of the battery disconnect switch have
gone out. If it is turned off before the indi-
cator goes out, a cycle of VHMS data,
from the time the starting switch is turned
on to the time when it is turned off, will be
lost. (Information necessary to set the
machine will not be lost)
q Immediately after the fan is operated in
reverse, power is supplied to the fan
reverse solenoid for a while after the start-
ing switch is turned “OFF” in order to pro-
tect the oil pressure motor.
q When turning the battery disconnect 8. Start auxiliary connector
switch off, ensure that the fan rotating in q This machine is optionally equipped with a
reverse has stopped. start auxiliary connector in compliance
with SAE J1283.
k Important q For usage and precautions of the start
Do not turn off the battery disconnect switch auxiliary connector, refer to Operation
while the engine is rotating and immediately Manual.
after the engine has stopped.
If the battery disconnect switch is turned off
while the alternator is generating electricity, the
generated current has nowhere to go, leading
to overvoltage of the electrical system of the
machine, which may cause serious damage to
the electrical system such as electric devices
or controllers.

6 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Parking brake circuit 1

Operation

1. When starting switch is turned “OFF”

q If the starting switch is turned “OFF,” the con-

tacts of the battery relay open, and no current
flows to the parking brake circuit. While the
starting switch is “OFF,” the current does not
flow into parking brake solenoid valve and the
parking brake is kept applied, regardless of the
position of the parking brake switch, whether it
is “ON (applied)” or “OFF (released).”

WA600-6 7
SEN00411-03 10 Structure, function and maintenance standard

2. When starting switch is turned “ON”

2-1. When parking brake switch is turned “ON (actuate)” before starting switch is turned “ON”

q Since parking brake selector switch is ON, the

current flows from the battery relay through a
contact of parking brake changing switch,
three contacts, parking brake safety relay coil
and to the chassis ground, thus closing three
terminals and five terminals of parking brake
safety relay. The current from the battery relay
keeps flowing into the coil of parking brake
relay to hold its contacts until the battery relay
contacts open and the current does not flow
into the parking brake circuit any more.
q At this time, the current does not flow into park-
ing brake solenoid and the parking brake is
kept applied.
q This signal is input to transmission controller to
keep the transmission in neutral and prevent
the parking brake from dragging while the
parking brake is applied.
q After that, if the parking brake switch is turned
“OFF (released),” the current flows through
battery relay, parking brake safety relay, three
contacts of parking brake selector switch, two
contacts, emergency brake switch, and parking
brake solenoid, to the chassis ground, and the
parking brake is released.

8 WA600-6
10 Structure, function and maintenance standard SEN00411-03

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

q While the starting switch is “OFF,” the current

does not flow into parking brake safety relay
and its contacts are open. Even if the starting
switch is turned ON at this time, the current
does not flow into parking brake solenoid.
Accordingly, the parking brake will not be
released automatically.

WA600-6 9
SEN00411-03 10 Structure, function and maintenance standard

3. When main brake oil pressure lowers (emergency brake is applied)

q If the main brake oil pressure lowers, the con-

tacts of the emergency brake switch installed
to the accumulator open. As a result, the cur-
rent flowing into parking brake solenoid valve
is stopped and the oil in the parking brake cyl-
inder is drained and the parking brake is
applied.
In this case, however, unlike the case where
th e park in g b ra ke sw it ch is tu rn ed “ ON
(applied)”, the transmission is not set in neutral
since the parking brake release signal is flow-
ing into the transmission controller.
By the above operation, when the emergency
brake is applied, the braking distance can be
reduced by using the engine as a brake. Also,
even if the emergency brake is applied, the
vehicle can be moved.

10 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Sensor 1
Modulation clutch rotation sensor
Output shaft rotation sensor 1
Output shaft rotation sensor 2

1. Magnet 3. Harness
2. Locknut 4. Connector

Function
q Modulation clutch rotation sensor is installed
between torque converter and modulation
clutch. Output shaft rotation sensors 1 and 2
are both installed in the output gear section at
the bottom of the transmission main unit.
Those sensors emit pulse signals according to
the gear rotation signal, which are then trans-
mitted to the transmission controller.
q Signals are converted from pulse to the num-
ber of rotation (rpm) in the transmission con-
troller, transmitted to the machine monitor over
the network. The rpm is then converted into
travel speed in the machine monitor for display.

WA600-6 11
SEN00411-03 10 Structure, function and maintenance standard

Modulation clutch pressure sensor

1. Sensor
2. Lead wire
3. Connector

Function
q Installed to the modulation clutch, this sensor
detects pressure of the clutch to be used for
calculating thermal load to the clutch.

12 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Transmission oil temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
Axle oil temperature sensor

1. Thermistor
2. Plug
3. Harness
4. Connector

Function
q Transmission oil temperature sensor detects
the internal temperature of transmission case.
The temperature data is used by transmission
controller to select the temperature table of
electronic modulation so as to control modula-
tion best matched to the oil temperature.
q Data from torque converter oil temperature
sensor and hydraulic oil temperature sensor is
detected by the machine monitor and indicated
to the gauges. At the same time, the data is
transmitted to the transmission controller via
network and used as the cooling fan control
data.
q Axle oil temperature sensor detects the inter-
nal oil temperature of rear axle with the moni-
tor, and outputs a caution signal when the
temperature rises to a high level.

WA600-6 13
SEN00411-03 10 Structure, function and maintenance standard

Kick-down hold switch

1. Switch A (White wiring harness)

2. Spring
3. Harness
4. Switch B (Yellow wiring harness)

Function
q These switches are installed to the knob of the
lift arm control lever. Switch A (1) works as the
kick-down switch and switch B (4) works as the
hold switch.
q These switches are installed to the knob of the
lift arm control lever when load meter (if
equipped) is installed. Switch A works as the
cancel switch and switch B works as the subto-
tal switch.
q Both of switch A (1) and switch B (4) are of
momentary type, that is, their contacts are
closed only while they are pressed.

14 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Driving force adjust dial

Function
q As the dial is turned, engagement ratio of 1st speed modulation clutch changes.

AJSS steering lock switch

Function
q When AJSS steering lock lever is operated,
steering pilot pressure circuit is cut off, lower-
ing the pilot pressure and opening the switch
accordingly.
q When the steering lock lever is OFF, the pilot
pressure is lowered while the engine is not run-
ning. As the result, AJSS does not operate
same as when the steering lock lever is ON.

WA600-6 15
SEN00411-03 10 Structure, function and maintenance standard

AJSS knob

1. Horn switch: horn sounding switch Function

2. Shift down switch: Selects a gear speed.(shift q Directional switch is held at a selected posi-
down) tion. Transmission controller shifts gear
3. Shift up switch: Selects a gear speed.(shift up) according to the signal from the directional
4. Directional switch: Selects the travel direction switch.
and neutral. q Shift-up and -down switches select circuit only
while the switch is being depressed, and the
transmission controller uses this signal for gear
shifting operation accordingly.
q Horn switch operates the relay and sounds the
horn while it is being depressed.

16 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Lift arm angle sensor (if equipped)

1. Oil seal 4. Brush

2. Case 5. Shaft
3. Resistor assembly 6. Connector

Function
q The lift arm angle sensor is installed to the
front frame. When the lift arm angle changes,
the shaft receives the sliding resistance
through the link installed to the lift arm and the
lift arm angle is detected from that sliding resis-
tance.
The angle sensor is installed to a machine
installed with a load meter or electric work
equipment lever.

WA600-6 17
SEN00411-03 10 Structure, function and maintenance standard

AJSS lever angle sensor

AJSS frame angle sensor

1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element

Function
q Lever angle sensor is installed to AJSS lever in
the L.H. console, and frame angle sensor is to
the follow-up linkage of the machine rear
frame. Data from these sensors are converted
to the lever angle and swing angle respectively
inside the work equipment controller.

18 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Loader pump pressure sensor

Lift arm bottom pressure sensor
Lift arm head pressure sensor (load meter (if equipped))
Steering pressure sensor (VHMS (if equipped))
Rear brake pressure sensor (VHMS (if equipped))
Front brake pressure sensor (VHMS (if equipped))

1. Sensor
2. Connector

Function Operation
q Installed to the inlet port circuit for the control q When oil pressure led from the pressure input
valve, these sensors convert pump discharge port applies pressure to the diaphragm of oil
pressure to voltage and transmit to the gover- pressure sensor, the diaphragm is deformed
nor pump controller. from deflection.
q Gauge layer is installed to the opposite of the
diaphragm. Deflection of the diaphragm is con-
verted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.
q After amplifying the voltage, the amplifier
transmits the voltage to the governor controller.
q Relational expression of pressure P (MPa {kg/
cm2}) and output voltage (V)

V = 0.08 {0.008} × P + 0.5

WA600-6 19
SEN00411-03 10 Structure, function and maintenance standard

Fuel level sensor

1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body

Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level.
The float moves the variable resistor through
the arm. The voltage signal is sent to the
machine monitor to indicate the fuel level.
Also, when the machine monitor indicator
reaches a specified position, caution lamp is lit.

20 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Parking brake pressure switch

1. Case 3. Connector
2. Tube

Function
q When the parking brake is released, oil pres-
sure is fed to the brake piston. The oil pressure
operates the pressure switch to turn out the
parking brake pilot lamp on the machine moni-
tor.

WA600-6 21
SEN00411-03 10 Structure, function and maintenance standard

Air cleaner clogging sensor

1. Indicator 3. Adapter
2. Spring

Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.

22 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Transmission clogging sensor

1. Body Function
2. Tube q The clogging sensor is installed to the filter
3. Connector section. If the filter is clogged and the pressure
difference between the lower and higher sides
A: Take-out port on low pressure side reaches a specified level, the switch turns
B: Take-out port on high pressure side OFF, and the maintenance caution lamp lights
up. At the same time, a message appears to
the character display to warn on abnormal situ-
ation.

Operating pressure: 275 kPa {2.8 kg/cm2}

Principle of switching: Differential pressure slid-

ing piston type

WA600-6 23
SEN00411-03 10 Structure, function and maintenance standard

Engine oil level sensor

1. Connector 3. Float
2. Bracket 4. Switch

Function
q The engine oil level sensor is installed to the
side of the oil pan. If the oil level lowers below
the specified level, the float lowers and the
switch is turned “OFF”.

24 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Steering oil pressure sensor switch

1. Body 3. Tube
2. Shaft 4. Connector

Function
q The steering oil pressure sensor switch detects
operation of diverter valve spool, which is
tripped to operate when the steering oil pres-
sure drops.
q If the steering oil pressure drops and the spool
operates, the switch piston is turned OFF and
the circuit opens.

WA600-6 25
SEN00411-03 10 Structure, function and maintenance standard

Radiator coolant level sensor

1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector

Function
q The coolant level sensor is installed to the radi-
ator upper tank. If the coolant level lowers
below the specified level, the float lowers and
the switch is turned “OFF”.

26 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Brake accumulator pressure switch (Rear and front)

1. Case 3. Connector
2. Tube

Function
q If the brake accumulator oil pressure lowers,
the contact becomes OPEN, and the caution
lamp lights up on the machine monitor to warn
of abnormality.

WA600-6 27
SEN00411-03 10 Structure, function and maintenance standard

Battery electrolyte level sensor

1. Body 4. Packing
2. Connector 5. Pin
3. Filter

Function
q The battery electrolyte level sensor is installed
to the battery. If the battery electrolyte level
lowers below the specified level, the sensor tip
is exposed to air and a signal of voltage
change is generated. The signal is sent to the
machine monitor to warn of abnormal situation.

28 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Atmospheric temperature sensor

Specifications
1. Power consumption: Max. 0.5 mW
2. Withstand pressure: 0.98 MPa {10 kg/cm2}
3. Temperature detection range (ambient): –30°C
to 120°C
4. Temperature conservation range: –50°C to
140°C
5. Performance table

Detected
tempera-
–20 –10 0 10 20 50
ture
(°C)
Resis-
tance 30.32 18.58 11.74 7.623 5.077 1.712
(kz)

a: Sensor heat sensitizing portion mount diame-

ter 16 × 1.5

Function
This sensor inputs the atmospheric temperature to
the VHMS controller as a variation of the thermistor
resistance.

WA600-6 29
SEN00411-03 10 Structure, function and maintenance standard

Exhaust temperature sensor and amplifier

Specifications
1. Rated output: DC 24 V
2. Temperature detection range:
100 to 1000°C
300 to 800°C (guaranteed accuracy ±10°C)
3. Output voltage characteristics: as per perfor-
mance table below
4. Range of operating temperature: –40 to 110°C
5. Current consumption: Max. 30 mA

a: Sensor heat sensitizing portion mount diame-

ter R1/8
b: Amplifier
c: Connector (power supply side)
c: Connector (sensor side)

Output voltage characteristics

(ambient temperature: 20°C)…Reference value
Detected
tempera-
50 100 400 700 800
ture
(°C)
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)

Function
A thermocouple type temperature sensor installed
to the inlet port of turbocharger. It outputs the
exhaust temperature data to the VHMS controller.

30 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Blow-by pressure sensor

Specifications
1. Supply voltage: DC 5 V
2. Output voltage: 0.5 V (when engine stops) and
up
3. Size: Mount (portion “a”) R1/4
Outside diameter of pressure-receiving
seat φ37
Cable length 1,110 mm

Function
Converts the internal pressure of engine crankcase
into voltage and inputs the data to the VHMS con-
troller as a blow-by pressure value.

WA600-6 31
SEN00411-03 10 Structure, function and maintenance standard

Communication (ORBCOMM) controller and antenna

Controller

Specifications
1. Operating power supply voltage: DC 12 V to
DC 30 V
2. Size: W306 × D152 × H52 (mm)

Installed position
Installed to under the auxiliary seat.

Connector section
CN1A(ORB-A): AMP070-14
CN1B(ORB-B): SMP070-10
CN2: Communication antenna cable connector

Antenna

Specifications
1. Type: helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: M-P type
4. Length: 165±20 mm

a: Communication antenna mount

Installed position
Installed on top of a pole erected on the front R.H.
side of the machine body.

Function
Transmits data collected and stored by the VHMS
controller to the computer center via communica-
tions satellites.

32 WA600-6
10 Structure, function and maintenance standard SEN00411-03

VHMS controller related 1

a For details of basic precautions, outlines, see
“Testing and adjusting”.

VHMS controller
a For details of basic precautions, outlines,
method of sending and receving data, and the
procedure for the initial setup, see “Testing and
adjusting”.

Specification
1. Voltage of power supply: DC20V – DC30V
2. Size (mm): W272 × D169 × H72

Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine
controller. It also gives commands for transmitting
the accumulated data through the communications
satellite.

WA600-6 33
SEN00411-03 10 Structure, function and maintenance standard

Accelerator pedal sensor

1. Pedal 2. Connector

Function

Accelerator signal
q Accelerator pedal installed to the floor is pro-
vided with accelerator sensor for the engine
controller. When the accelerator pedal is
stepped on, the potentiometer shaft inside the
accelerator sensor starts rotation and resis-
tance value changes accordingly. Potentiome-
ter is applied with a constant level of voltage
from the engine controller. Voltage signal is
transmitted to the engine controller according
to the depressed angle of accelerator pedal. In
addition, the depressed angle is transmitted to
each controller over the network as the accel-
erator pedal opening data.

Idle validation signal

q The idle validation switch is installed to the
same case with the accelerator pedal sensor.
While the accelerator pedal is released, signal
2 is connected to the ground. When the accel-
erator pedal is pressed, signal 3 is connected
to the ground. The engine controller judges by
these signals whether the accelerator pedal is
released or pressed.

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Stop lamp pressure switch

1. Case 3. Connector
2. Tube

Function
q When the foot brake is stepped on and the brake operating pressure is generated, the pressure switch
contact is closed, the relay is operated and stop lamp lights up.

Emergency brake pressure switch (rear)

Emergency brake pressure switch (front)

1. Case 3. Connector
2. Tube

Function
q When the brake accumulator pressure lowers, the switch contact opens. Circuit between the parking
brake switch and parking brake solenoid is cut off, and the parking brake is tripped to operate.

WA600-6 35
SEN00411-03 10 Structure, function and maintenance standard

Resistor for directly coupling modulation clutch

Function
q Resistor for allowing appropriate current to
flow to the ECMV solenoid for modulation
clutch when the modulation clutch direct-cou-
pling switch is turned ON.
q No current flows when the modulation clutch
direct-coupling switch is turned OFF.

Resistance: 30 z

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10 Structure, function and maintenance standard SEN00411-03

Work equipment electric lever 1

WA600-6 37
SEN00411-03 10 Structure, function and maintenance standard

1. Lever 11. Seat

2. Rod 12. Ball
3. Centering spring 13. Detent spring
4. Metering spring 14. Rod
5. Nut 15. Body
6. Rod 16. Solenoid
7. Detent spring 17. Bushing
8. Retainer 18. Body
9. Lever 19. Retainer
10. Potentiometer 20. Rod

38 WA600-6
10 Structure, function and maintenance standard SEN00411-03

Function
q When lever (1) is operated, rod (20) moves up
and down and rotates potentiometer (10)
according to the operating distance of the
lever.
q The operating angle (stroke) of the control
lever is sensed with the potentiometer and out-
put as a signal voltage to the controller.
q A potentiometer is installed, and it outputs 2
signal voltages which are opposite to each
other as shown in “Lever stroke – voltage”
characteristics.

Operation

When work equipment control lever is operated

q Rod (20) is pushed up by spring (4) according
to the operating distance of lever (1).
q Lever (9) and rod (14) installed to the rotary
shaft of potentiometer (10) are connected to
each other.
q Potentiometer (10) outputs voltage according
to the vertical stroke of the rod.

When work equipment is operated to “lift arm

lower” (Similar to “lift arm raise” or “bucket
tilt”)
q If rod (2) on the “lift arm lower” side is pushed
down by lever (1), ball (12) touches projection When “lift arm lower” operation of work equip-
(a) of rod (14) in the middle of the stroke ment control lever is reset
(before electric detent operation starts).
q Lever (1) is returned from the “lift arm lower”
q If rods (2) and (14) are pushed in further, ball
position by pushing down rod (20) with a force
(12) pushes up retainer (8) supported on
larger than the attractive force of the solenoid.
detent spring (7) and escapes out to go over
The “lift arm lower” state also can be reset and
projection (a) of rod (14).
lever (1) can be returned to the neutral position
q At this time, rod (20) on the opposite side is
by turning off the current in solenoid.
pushed up by spring (4).
q If rod (20) is pushed up while the current is
flowing in solenoid (16), nut (5) is attracted by
bushing (17).
q Accordingly, rod (20) is kept pushed up and the
“lift arm lower” state is kept even if the lever is
released.

WA600-6 39
SEN00411-03

WA600-6 Wheel loader

Form No. SEN00411-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

40
 SEN00552-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

20 Standard value table 1

Standard service value table
Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3

WA600-6 1
SEN00552-03 20 Standard value table

Standard service value table for engine 1

Machine model WA600-6

Engine SAA6D170E-5
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (E-mode) 1,900 ± 50 1,900 ± 50
High idle (P-mode) 2,000 ± 50 2,000 ± 50
• Engine coolant Low idle (E-mode) 800 ± 25 800 ± 25
Engine speed temperature: Within rpm
operating range Low idle (P-mode) 800 ± 25 800 ± 25
Rated speed (E-mode) 1,700 1,700
Rated speed (P-mode) 1,800 1,800
• All revolution ranges
Exhaust temperature °C Max. 680 700
• Atmospheric temperature: 20°C
Intake air pressure kPa Min. 126.6 113.3
(Boost pressure) • At rated output (P-mode) (mmHg) {Min. 950} {850}
At sudden acceleration Max. 4.0 5.0
• Engine coolant tem-
Exhaust gas color perature: Within oper- At rated output Bosch Max. 1.5 2.5
(P-mode) index
ating range
At high idle (P-mode) Max. 1.0 2.0
Intake valve 0.32 —
Valve clearance • Normal temperature mm
Exhaust valve 0.62 —
Compression Engine oil temperature: 40 – 60°C MPa Min. 2.94 2.1
pressure Engine speed: 210 – 250 rpm {kg/cm2} {Min. 30} {21}
• At rated output (P-mode) kPa Max. 3.43 9.41
Blow-by pressure
• Engine coolant temperature: Min. 70°C (mmH2O) {Max. 350} {960}
At rated output Min. 0.39 0.24
• Engine oil tempera- (P-mode) {Min. 4.0} {2.4}
Oil pressure ture: Min. 80°C MPa
{kg/cm2} Min. 0.1 0.08
• SAE30 oil At low idle
{Min. 1.0} {0.8}
MPa Min. 1.18
EGR valve and • At low idle {kg/cm2} {Min. 12} —
bypass valve drive oil
pressure • At high idle MPa Min. 1.43 —
{kg/cm2} {Min. 14.6}
Oil temperature • All engine speed ranges (Inside oil pan) °C 90 – 110 120
Belt tension for alter- Deflection made by finger pressure of about
nator and air condi- mm Auto-tensioner Auto-tensioner
98 N {10 kg}
tioner compressor

2 WA600-6
20 Standard value table SEN00552-03

Standard service value table for chassis 1

*: The value shows the value before the detent.
Machine model WA600-6
Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

N o FORWARD, • Engine stopped 10.5 ± 1.0 10.5 ± 1.0

Transmission

REVERSE • Measure at end of switch {1.1 ± 0.1} {1.1 ± 0.1}

switch (*1)

Operating 7.0 ± 1.1 7.0 ± 1.1

Upshift N {kg}
effort • Engine stopped {0.7 ± 0.1} {0.7 ± 0.1}
• Measure at center of lever knob 7.0 ± 1.1 7.0 ± 1.1
Downshift
{0.7 ± 0.1} {0.7 ± 0.1}
Operating N o FORWARD, 5.9 (+4.9/–2.9) Max. 16.7
Directional
lever (*2)

N {kg}
effort REVERSE • Engine stopped {0.6 (+0.5/–0.3)} {Max. 1.7}
N o FORWARD, • Measure at center of lever knob
Stroke mm 35 ± 10 35 ± 10
REVERSE
5.9 (+4.9/–2.9) Max. 16.7
1st o 2nd
{0.6 (+0.5/–0.3)} {Max. 1.7}
Gearshift lever (*2)

Operating 5.9 (+4.9/–2.9) Max. 16.7

2nd o 3rd N {kg}
effort {0.6 (+0.5/–0.3)} {Max. 1.7}
• Engine stopped 5.9 (+4.9/–2.9) Max. 16.7
3rd o 4th • Measure at center of lever knob {0.6 (+0.5/–0.3)} {Max. 1.7}
1st o 2nd 35 ± 10 35 ± 20
Stroke 2nd o 3rd mm 35 ± 10 35 ± 20
3rd o 4th 35 ± 10 35 ± 20
Max. 23.5 Max. 35.3
HOLD o RAISE (*)
{Max. 2.4} {Max. 3.6}
Max. 19.6 Max. 29.4
RAISE o HOLD
{Max. 2.0} {Max. 3.0}
Max. 15.7 Max. 23.5
HOLD o LOWER (*)
Lift arm {Max. 1.6} {Max. 2.4}
LOWER o HOLD
Operating effort

— —
• Engine speed: Low idle Max. 23.5 Max. 35.3
LOWER o FLOAT
Work equipment control lever

• Hydraulic oil temperature: N {kg} {Max. 2.4} {Max. 3.6}

45 – 55°C Max. 19.6 Max. 29.4
FLOAT o HOLD
{Max. 2.0} {Max. 3.0}
Max. 16.7 Max. 25.5
HOLD o DUMP
{Max. 2.0} {Max. 2.6}
Max. 23.5 Max. 35.3
Bucket HOLD o TILT (*)
{Max. 2.4} {Max. 3.6}
Max. 19.6 Max. 29.4
TILT o HOLD
{Max. 2.0} {Max. 3.0}
HOLD io RAISE
37 ± 10 37 ± 15
(*)
Lift arm HOLD io LOWER • Engine speed: Low idle
37 ± 10 37 ± 15
Stroke

(*)
• Hydraulic oil temperature: mm
HOLD io FLOAT 45 – 55°C 45 ± 10 45 ± 15
HOLD o DUMP 45 ± 10 45 ± 15
Bucket
HOLD o TILT (*) 37 ± 10 37 ± 15

(*1): AJSS specification

(*2): Steering wheel specification

WA600-6 3
SEN00552-03 20 Standard value table

Machine model WA600-6

Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

• Engine stopped
Play mm Max. 40 50 – 100
• Machine facing straight to front
• Flat, level, straight, dry, and paved
road 10.0 ± 3 Max. 19.6
Steering wheel

Operating effort N {kg}

• Engine speed: Low idle {1.0 ± 0.3} {Max. 2.0}
(Bucket empty)
• Engine speed: High idle
Turns (Not including play) Turns 3.9 ± 0.3 Max 4.5
• Left lock – right lock

Low idle • Engine started Max. 7.2 Max. 8.0

Operating • Hydraulic oil temperature:
sec.
time High idle 45 – 55°C
• Left lock – right lock Max. 4.2 Max. 5.0
(P-mode)
Serial No.:
53.9 – 73.6 Max. 107.9
60001 –
• Engine started {5.5 – 7.5} {11.0}
60130
Operating effort • Measure at 150 mm N {kg}
from fulcrum of pedal. Serial No.:
37.5 ± 7.5 Max. 56.4
60131
{3.83 ± 0.8} {Max. 5.75}
and up
Accelerator pedal

Serial No.:
60001 – 57 —
60130
Neutral (a1) aFor measuring pos-
ture, see Fig. A at end Serial No.:
of this section 60131 45 ± 2 —
Operating • Engine speed: Low and up
deg.
angle idle Serial No.:
• Hydraulic oil tempera- 60001 – 40 —
ture: Within operating 60130
Max. (a2) range
Serial No.:
60131 17 ± 2 —
and up
Left brake pedal Right brake pedal

294 ± 29.4 Max. 421.4

Operating effort aFor measuring posture, see Fig. B N {kg} {30 ± 3} {Max. 43}
at end of this section
Operating Neutral (a1) 45 —
• Engine speed: Low idle
angle Max. (a2) • Hydraulic oil temperature: Within 15(+1/0) —
deg.
operating range
Play 5 ± 0.5 —
274 ± 30 Max. 393
Operating effort aFor measuring posture, see Fig. B N {kg} {27.9 ± 3.1} {Max. 40}
at end of this section
Operating Neutral (a1) • Engine speed: Low idle 55 —
angle Max. (a2) • Hydraulic oil temperature: Within deg. 18.5 ± 0.5 —
operating range
Play 1.5(+0.5/–0.8) —
A Max. 2.5 —
Fitting of wheel lock ring aFor measuring posture, see Fig. C
B at end of this section Max. 4.0 —
Tire

mm
Clearance of wheel lock • Tire inflation pressure: Specified
C pressure 2 – 15 —
ring

4 WA600-6
20 Standard value table SEN00552-03

Machine model WA600-6

Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

• Engine coolant temper- P-mode 1,800 ± 100 1,800 ± 200

Torque converter stall ature: Within operating
E-mode 1,730 ± 100 1,730 ± 200
Engine speed

range
• Torque converter oil P-mode 1,940 ± 100 1,940 ± 200
Hydraulic stall
temperature: Within E-mode rpm 1,830 ± 100 1,830 ± 200
operating range
• Hydraulic oil tempera- P-mode 1,680 ± 100 1,680 ± 300
Torque converter stall + hydrau-
lic stall ture: Within operating
E-mode 1,590 ± 100 1,590 ± 300
range
• Engine stopped
Play deg. Max. 8 Max. 10
• Machine facing straight to front
• Flat, level, straight, dry, and paved 13.7 ± 4.9
Operating effort N {kg} 23.5 {2.4}
road {1.4 ± 0.5}
AJSS lever

• Engine speed: High idle

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

Low idle • Engine started Max. 6.6 Max. 7.6

Operating • Hydraulic oil temperature: Within
sec.
time High idle operating range
• Left lock – right lock Max. 3.5 Max. 4.5
(P-mode)
Min. 3.09 Min. 3.09
Low idle • Torque converter oil temperature:
Main relief {Min. 31.5} {Min. 31.5}
Within operating range
pressure 3.65 ± 0.2 3.65 ± 0.2
High idle • Working mode: P-mode
{37.2 ± 2.0} {37.2 ± 2.0}
Torque converter inlet port oil 0.94 ± 0.2 0.94 ± 0.2
pressure {9.6 ± 2.0} {9.6 ± 2.0}
Torque converter outlet port oil • Torque converter oil temperature: 0.57 ± 0.1 0.57 ± 0.1
pressure Within operating range {5.8 ± 1.0} {5.8 ± 1.0}
• Working mode: P-mode
Transmission, torque converter

2.48 ± 0.2 2.48 ± 0.2

Modulation clutch oil pressure • Engine speed: High idle {25.3 ± 2.0} {25.3 ± 2.0}
0.12 ± 0.06 0.12 ± 0.06
Lubrication oil pressure
{1.2 ± 0.6} {1.2 ± 0.6}
MPa 2.68 ± 0.2 2.68 ± 0.2
F clutch
{kg/cm2} {27.3 ± 2} {27.3 ± 2}
3.12 ± 0.2 3.12 ± 0.2
R clutch
{31.8 ± 2.0} {31.8 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
1st clutch
• Torque converter oil temperature: {31.3 ± 2.0} {31.3 ± 2.0}
ECMV output Within operating range
2.09 ± 0.2 2.09 ± 0.2
(clutch) oil 2nd clutch • Working mode: P-mode
{21.3 ± 2.0} {21.3 ± 2.0}
pressure • Engine speed: High idle
• Manual switch: ON 3.07 ± 0.2 3.07 ± 0.2
3rd clutch
{31.3 ± 2.0} {31.3 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
4th clutch
{31.3 ± 2.0} {31.3 ± 2.0}
1.84 ± 0.2 1.84 ± 0.2
Lockup clutch
{18.8 ± 2.0} {18.8 ± 2.0}

WA600-6 5
SEN00552-03 20 Standard value table

Machine model WA600-6

Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

• Hydraulic oil temperature: 45 – 55°C 33.3 ± 0.98 33.3 ± 0.98

Steering relief pressure
• Engine speed: High idle (P-mode) {340 ± 10} {340 (+10/–20)}
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idle (P-mode) 2.45 ± 0.1 2.45 ± 0.2
AJSS EPC pressure
• Operating AJSS fuly {25 ± 1} {25 ± 2}
Steering

• Frame lock bar: Lock position MPa

{kg/cm2}
• Hydraulic oil temperature: 45 – 55°C
Min. 0.49 Min. 0.49
Pilot circuit pressure • Engine speed: High idle (P-mode)
{Min. 5} {Min. 5}
• Steering wheel or AJSS operation
• Hydraulic oil temperature: 45 – 55°C 1.18 – 1.47 0.98 – 1.67
Steering control oil pressure
• Engine speed: High idle (P-mode) {12 – 15} {10 – 17}
• Point where
brake oil pres- 5.88 (+0.49/0) 5.88 (+0.98/–0.49)
Charge cut-in pressure • Engine speed: sure warning {60 (+5/0)} {60 (+10/–5)}
Accumulator

Low idle lamp goes out

• Hydraulic oil MPa
temperature: • Point where oil {kg/cm2}
Within operat- pressure is
9.8 (+0.98/0) 9.8 (+1.47/–0.49)
Charge cut-out pressure ing range going up and
{100 (+10/0)} {100 (+15/–5)}
then starts to go
down

1st 6.7 ± 0.3 6.7 ± 0.3

11.7 ± 0.6 11.7 ± 0.6

2nd
P-mode (12.4 ± 0.6) (12.4 ± 0.6)
• ( ): at lockup 20.3 ± 1.0 20.3 ± 1.0
3rd
(21.7 ± 1.1) (21.7 ± 1.1)
33.8 ± 1.7 33.8 ± 1.7
4th
FOR- (33.7 ± 1.7) (33.7 ± 1.7)
WARD
1st 6.6 ± 0.3 6.6 ± 0.3

11.5 ± 0.6 11.5 ± 0.6

2nd
E-mode (12.1 ± 0.6) (12.1 ± 0.6)
• ( ): at lockup 19.4 ± 1.0 19.4 ± 1.0
Power train

3rd
(20.9 ± 1.0) (20.9 ± 1.0)
Travel speed
km/h 31.5 ± 1.6 31.5 ± 1.6
(Bucket empty) 4th
(31.7 ± 1.6) (31.7 ± 1.6)

1st 7.3 ± 0.4 7.3 ± 0.4

12.8 ± 0.6 12.8 ± 0.6

2nd
P-mode (13.5 ± 0.7) (13.5 ± 0.7)
• ( ): at lockup 22.0 ± 1.1 22.0 ± 1.1
3rd
(23.7 ± 1.2) (23.7 ± 1.2)
REVERSE 37.0 ± 1.9 37.0 ± 1.9
4th
(41.0 ± 2.1) (41.0 ± 2.1)
1st 7.3 ± 0.4 7.3 ± 0.4
E-mode 2nd 12.5 ± 0.6 12.5 ± 0.6
• ( ): at lockup 3rd 21.1 ± 1.1 21.1 ± 1.1
4th 34.0 ± 1.7 34.0 ± 1.7

6 WA600-6
20 Standard value table SEN00552-03

Machine model WA600-6

Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

• Hydraulic oil temperature: Within 4.9 (+0.69/0) 4.9 (+0.88/–0.2)

Brake oil pressure
operating range {50 (+7/0)} {50 (+9/–2)}
• Engine stopped MPa
2
• Keep brake pedal depressed at 4.9 {kg/cm } Max. 0.49 Max. 0.49
Drop in brake pressure 2
MPa {50 kg/cm } and measure {Max. 5} {Max. 5}
drop in oil pressure after 5 min.
Wheel brake

• Tire inflation pressure: Specified

pressure
• Flat, level, straight, dry, and paved
road
• Speed when applying brake: 20 km/h,
Performance m Max. 5 Max. 5
braking delay: Within 0.1 sec.
• Brake pedal operating effort:
Specified operating effort
29.4 ± 2.94 N {30 ± 3 kg}
• Measure braking distance
Disc wear • Measure with disc wear indicator mm 0 Max. 5.5
Min. 2.45 Min. 2.45
Parking brake inlet pressure
{Min. 25.0} {Min. 25.0}
• Torque converter oil temperature:
MPa Min. 3.09 Min. 3.09
Parking brake pilot pressure Within operating range
{kg/cm2} {Min. 31.5} {Min. 31.5}
• Engine speed: Low idle
Parking brake

Parking brake solenoid valve Min. 2.45 Min. 2.45

output pressure {Min. 25.0} {Min. 25.0}
• Tire inflation pressure: Specified
pressure
Performance • Flat paved road with 1/5 (11° 20') — Holds in position Holds in position
grade. Dry, paved road surface
• Machine at operating condition
Disc thickness mm 3.2 ± 0.08 Min. 2.97
Work equipment

EPC valve basic pressure • Hydraulic oil temperature: 45 – 55°C 4.02 (+0.2/0) 4.02 (+0.2/–0.2)
(Orbit-roll input pressure) • Engine speed: High idle (P-mode) {41 (+2/0)} {41 (+2/–2)}
EPC

Lift arm RAISE, • Hydraulic oil temperature: Within MPa

EPC valve {kg/cm2}
FLOAT; Bucket operating range 3.72 (+0.2/0) 3.72 (+0.2/–0.2)
output pres-
DUMP, TILT, • Engine speed: High idle (P-mode) {38 (+2/0)} {38 (+2/–2)}
sure
Lift arm LOWER • Control lever operated fully
• Hydraulic oil temperature: Within
33.3 (1.47 ± 0.49) 33.3 ± 1.47
Work equipment relief pressure operating range
{340 (+15/–5)} {340 ± 15}
Work equipment

• Engine speed: High idle

• Hydraulic oil temperature: 45 – 55°C
MPa 3.14 ± 0.29 3.14 ± 0.59
Unload pressure • Engine speed: High idle (P-mode)
{kg/cm2} {32 ± 3} {32 ± 6}
• Work equipment control lever: Neutral
• Hydraulic oil temperature: 45 – 55°C
1.67 ± 0.2 1.67 ± 0.39
LS differential pressure • Engine speed: High idle (P-mode)
{17 ± 2} {17 ± 4}
• Lift arm lever: at half stroke

WA600-6 7
SEN00552-03 20 Standard value table

Machine model WA600-6

Category

Standard value for Service limit

Item Measurement conditions Unit
new machine value

• Hydraulic oil tempera- P-mode 8.6 ± 0.5 Max. 10.5

Lift arm RAISE ture: Within operating
range E-mode 9.1 ± 0.5 Max. 11.1
• Engine speed: High idle
Work equipment speed

• Apply no load P-mode 4.1 ± 0.5 Max. 5.3

aFor measuring posture,
Lift arm LOWER
see Figs. F and G at end
of this section E-mode 4.2 ± 0.5 Max. 5.4
sec.
• Hydraulic oil tempera- P-mode 3.0 ± 0.3 Max. 4.0
Bucket full stroke ture: Within operating
range E-mode 3.2 ± 0.3 Max. 4.2
Work equipment

Bucket • Engine speed: High idle

tilt back • Apply no load P-mode 2.0 ± 0.3 Max. 2.9
Moving bucket aFor measuring posture,
from level position see Figs.H and J at end
E-mode 2.1 ± 0.3 Max. 3.0
of this section
• Hydraulic oil temperature: Within
Retraction of lift arm cylinder operating range
Hydraulic drift

Max. 40 Max. 40
rod • Stop engine and leave for 5 minutes,
then measure for 15 minutes.
mm
aApply no load to bucket and set lift
Retraction of bucket cylin- arm and bucket in level position.
Max. 20 Max. 20
der rod aFor measuring posture, see Fig.K at
end of this section
Proximity
switch

Clearance of bucket posi-

mm 3–5 —
tioner proximity switch

• Engine speed: High idle (P-mode)

• Engine coolant temperature: Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 95°C 980 ± 50 980 ± 100
• Torque converter oil temperature:
Min. 105°C
• Engine speed: High idle rpm
• Engine coolant temperature: Max.
75°C
Hydraulic drive fan

Min. fan speed 200 ± 30 200 ± 50

• Hydraulic oil temperature: Max. 75°C
• Torque converter oil temperature:
Max. 85°C
• Engine speed: High idle (P-mode)
• Engine coolant temperature: Min. 95°C
19.6 ± 2.5 19.6 ± 2.5
Fan drive pressure • Hydraulic oil temperature: Min. 95°C
{200 ± 25} {200 ± 25}
• Torque converter oil temperature:
Min. 105°C MPa
2
• Engine speed: High idle (P-mode) {kg/cm }
• Engine coolant temperature: Min. 95°C
Fan reverse solenoid output 25 ± 2.5 25 ± 2.5
• Hydraulic oil temperature: Min. 95°C
pressure {255 ± 25} {255 ± 25}
• Torque converter oil temperature:
Min. 105°C

8 WA600-6
20 Standard value table SEN00552-03

WA600-6 9
SEN00552-03 20 Standard value table

Machine posture and procedure for performance measurement

a Fig. A a Fig. D

a Fig. B a Fig. E

a Fig. C a Fig. F

10 WA600-6
20 Standard value table SEN00552-03

a Fig. G a Fig. K

a Fig. H

a Fig. J

WA600-6 11
SEN00552-03

WA600-6 Wheel loader

Form No. SEN00552-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)

12
 SEN00553-05

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 9
Measuring engine speed............................................................................................................................... 10
Measuring exhaust gas color ........................................................................................................................ 12
Measuring exhaust temperature ................................................................................................................... 13
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressures .................................................................................................................... 17
Measuring blow-by pressure......................................................................................................................... 20
Measuring engine oil pressure...................................................................................................................... 21
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 22
Measuring intake air (boost) pressure .......................................................................................................... 24
Handling fuel system equipment................................................................................................................... 25
Releasing residual pressure in fuel system .................................................................................................. 25
Testing fuel pressures ................................................................................................................................... 26
Testing return rate and leakage .................................................................................................................... 27
Bleeding air from fuel circuit.......................................................................................................................... 30

WA600-6 1
SEN00553-05 30 Testing and adjusting

Testing leakage in fuel system ...................................................................................................................... 32

Handling reduced cylinder mode operation................................................................................................... 33
Handling no-injection cranking operation ...................................................................................................... 33
Handling controller voltage circuit ................................................................................................................. 34
Replacing and adjusting alternator and air conditioner compressor belt tension.......................................... 35
Adjusting modulation clutch speed sensor and speed sensor ...................................................................... 36
Measuring directional lever and gear shift lever (Steering wheel specification) ............................................ 38
Testing and adjusting power train oil pressure .............................................................................................. 39
Flushing procedure for torque converter and transmission hydraulic circuit ................................................. 53
Method of moving machine when transmission valve is broken ................................................................... 55
Adjusting steering stop valve ........................................................................................................................ 57

2 WA600-6
30 Testing and adjusting SEN00553-05

Tools for testing, adjusting, and troubleshooting 1

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially
C Clearance gauge 1
clearance available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
795-611-1220 Adapter 1
Measuring compression 2
D 6261-71-6150 Gasket 1
pressures
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Measuring blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}

Measuring engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 × 1.5 mm
3
6215-81-9720 O-ring 1
F
795T-690-1110 Block 1
4 01435-00835 Bolt 2
Testing drive oil pres-
07000-E2012 O-ring 3
sure of EGR valve and
bypass valve Pressure gauge: 2.5, 6, 40, 60 MPa
5 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
6 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring intake air
G 1 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring fuel 795-471-1450 Adapter 1
H
pressures 2
07005-00812 Seal washer 1
3 799-101-5160 Nipple 1
4 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 Ø 5 mm × 2 – 3 m
available
Testing fuel return rate Commercially
J 4 Hose 1 Ø 15 mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available

WA600-6 3
SEN00553-05 30 Testing and adjusting

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
Measuring directional
K 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
lever
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
L
power train oil pressure
799-101-5220 Nipple 1 Size: M10 × 1.25
2
07002-11023 O-ring 1 Pressure gauge: 1 MPa {10 kg/cm2}
Method of moving
machine when trans- M 794-423-1190 Plug 1 M20 × 1.5
mission valve is broken
Measuring operating
N 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort of AJSS lever
Testing and adjusting
P 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing and adjusting 799-101-5220 Nipple 1 Size: M10 × 1.25
Q
steering oil pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
4 799-401-3200 Adapter 1 Size 03
1 799-205-2200 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic drive 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
R
fan
799-101-5220 Nipple 1 Size: M10 × 1.25
3 07002-11023 O-ring 1
799-401-3500 Adapter 1 Size 06
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Bleeding air from 799-101-5220 Nipple 1 Size: M10 × 1.25
S
hydraulic drive fan circuit 2
07002-11023 O-ring 1
3 799-401-3500 Adapter 1 Size 06
4 790-261-1130 Coupling 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester
accumulator charge T 1 {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

4 WA600-6
30 Testing and adjusting SEN00553-05

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol

792-610-1701 Gas charge tool 1 Serial numbers: 60001-60634

2
792-610-1702 Gas charge tool 1 Serial numbers: 60635 and up

792-610-1310 Nipple (For Russia) GOST

Testing of accumulator
nitrogen gas pressure
792-610-1320 Nipple (For USA) CCA No. 351
and procedure for T
charging accumlator
with nitrogen gas 792-610-1330 Nipple (For USA) ASA B-571-1965
3 1
DIN 477-1963
792-610-1350 Nipple (For Germany) NEN 3268-1966
SIS-SMS 2235/2238

792-610-1360 Nipple (For Uk) BS341 Part 1-1962

1 793-520-1821 Nipple 1
Testing wheel brake oil 2 793-520-1810 Joint 1
U
pressure 3 385-10178481 Bleeder screw 1
4 793-520-1831 Case assembly 1 M20 × 1.5 (R1/8)
Measuring wear of Commercially
V Slide calipers 1
wheel brake disc available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing parking brake
W
oil pressure 799-101-5220 Nipple 1 Size: M10 × 1.25
2
07002-11023 O-ring
3 799-401-3100 Adapter 1 Size 02
Testing wear of parking Commercially
X Slide calipers 1
brake disc available
Measuring and adjust- 1 79A-264-0021 Push-pull scale 1
ing work equipment Y Commercially
control lever 2 Scale 1
available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
work equipment oil Z
799-101-5220 Nipple Size: M10 × 1.25
pressure 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge 1
1 426-06-32171 Wiring harness 1
Moving machine when
ZA 2 08086-10000 Starting switch 1
removing operator cab
3 421-06-36142 Parking brake switch 1
1 799-608-3101 Service kit 1
2 799-608-3211 • Diskette 1
3 799-608-3220 • Harness 1
VHMS controller initial
ZB Commercially Note type personal com-
setting procedure 4 1 OS: Windows 98/2000/Me/XP/Vista
available puter
Commercially RS232C-USB conversion
5 1
available cable

WA600-6 5
SEN00553-05 30 Testing and adjusting

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
799-601-4101
or T-adapter assembly 1
799-601-4200
For coolant temperature sensor
795-799-5530 • Socket 1 For fuel temperature sensor
For oil temperature sensor
795-799-5540 • Socket 1 For boost temperature sensor
Troubleshooting for
799-601-4130 • T-adapter 1 For Ne sensor
controllers, sensors,
ZC 799-601-4150 • T-adapter 1 For oil pressure sensor
actuators and wiring
harnesses 799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
For common rail pressure sensor
799-601-9420 • T-adapter 1 (included in 799-601-9000 and
799-601-9200, too)
799-601-9430 • Socket 1 For supply pump PCV
799-601-4100
or
799-601-4200
or T-adapter assembly 1
799-601-9000
or
799-601-9200
For engine controller 60P
799-601-4220 • DRC26 adapter 1
(Only 799-601-4100)
For DTM 2P (Does not included
799-601-9010 • DTM adapter
799-601-4100 and 799-601-4200)
Troubleshooting for
controllers, sensors, 799-601-9020 • DT adapter 1 For DT 2P
ZD
actuators and wiring For DT 3P (Does not included
799-601-9030 • DT adapter 1
harnesses 799-601-4100 and 799-601-4200)
799-601-9040 • DT adapter 1 For DT 4P
For DT 6P (Does not included
799-601-9050 • DT adapter 1
799-601-4100 and 799-601-4200)
For DT 8P (Does not included
799-601-9070 • DT adapter (Black) 1
799-601-4100 and 799-601-4200)
799-601-9110 • DT adapter (Gray) 1
799-601-9120 • DT adapter (Black) 1 For DT 12P (Does not included
799-601-9130 • DT adapter (Green) 1 799-601-4100 and 799-601-4200)
799-601-9140 • DT adapter 1

6 WA600-6
30 Testing and adjusting SEN00553-05

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
799-601-4101 T-adapter assembly 1
799-601-4211 • DRC26 adapter 1 For engine controller 50P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7020 • X adapter 1 For X 2P
799-601-7030 • X adapter 1 For X 3P
For SWP 6P (Does not included
799-601-7050 • SWP adapter 1
799-601-8000)
For SWP 14P (Does not included
799-601-7070 • SWP adapter 1
799-601-7000 and 799-601-7100)
For M 1P (Does not included
799-601-7080 • M adapter 1
799-601-7000 and 799-601-7100)
799-601-7090 • M adapter 1 For M 2P
799-601-7110 • M adapter 1 For M 3P
799-601-7120 • M adapter 1 For M 4P
799-601-7130 • M adapter 1 For M 6P
Troubleshooting for
799-601-7150 • S adapter 1 For S 10P
controllers, sensors,
ZD For S 12P
actuators and wiring 799-601-7160 • S adapter (Blue) 1
harnesses (Does not included 799-601-8000)
799-601-7170 • S adapter (Blue) 1 For S 16P
799-601-7210 • AMP040 adapter 1 For AMP040 16P
799-601-7220 • AMP040 adapter 1 For AMP040 20P
799-601-7330 • S adapter (White) 1 For S 16P (Only 799-601-8000)
799-601-7500 T-adapter assembly 1
799-601-7520 • AMP070 adapter 1 For machine monitor 12P
For machine monitor 14P
799-601-7530 • AMP070 adapter 1
For VHMS controller 14P
For machine monitor 18P
799-601-7540 • AMP070 adapter 1
For VHMS controller 18P
For machine monitor 20P
799-601-7550 • AMP070 adapter 1
For VHMS controller 20P
799-601-9100 T-adapter assembly 1
For HD30 31P
799-601-9290 • HD30 adapter 1
(included in 799-601-9000, too)
799-601-9300 T-adapter assembly 1
For transmission controller 40P
799-601-9350 • DRC26 adapter 1
For work equipment controller 40P
For transmission controller 40P
799-601-9360 • DRC26 adapter 1
For work equipment controller 24P
Measuring coolant and
— 799-101-1502 Digital thermometer 1
oil temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort and pressing —
force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}

WA600-6 7
SEN00553-05 30 Testing and adjusting

Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Tester 1
resistance available

8 WA600-6
30 Testing and adjusting SEN00553-05

Sketches of special tools 1

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.

F4 Block

WA600-6 9
SEN00553-05 30 Testing and adjusting

Measuring engine speed 1 2. Measuring torque converter stall speed

1) Referring to “Special function of machine
k Put chocks under the tires. monitor”, select the real time monitoring
k When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01002: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.40100: TC OIL TEMP
Within operating range (Torque converter oil temperature)
q Torque converter oil temperature:
Within operating range

1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Select and display “ENG SPEED” from the
engine controller monitoring items.
a Monitoring item: ENG SPEED
Code No. 01002: ENG SPEED
(Engine speed)

3) Start the engine.

4) Press the left brake pedal securely.
5) Set the transmission auto shift and man-
ual shift selector switch in the MANUAL
position.
6) While keeping the directional lever or for-
ward-reverse switch at the N (Neutral)
position, set the gearshift lever or gear
shift switch to the 4th position.
7) Release the parking brake.
8) While pressing the brake pedal, set the
directional lever or switch to the F (for-
ward) or R (reverse) position.
k Keep pressing the brake pedal
3) Start the engine, set it in the measuring
condition, and measure the engine speed. securely.
9) While running the engine at high idle,
press the accelerator pedal gradually.
When the torque converter stalls, mea-
sure the engine speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
a Measure the torque converter stall
speed when the power mode and
economy mode are turned on.

10 WA600-6
30 Testing and adjusting SEN00553-05

3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to “Special function of machine hydraulic stall (full stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing torque converter stall speed”.
2) Select the two-item simultaneous monitor- 2) Start the engine.
ing (2 ITEMS) and then enter the following 3) Press the left brake pedal securely.
code numbers directly. 4) Set the transmission auto shift and man-
a Monitoring items ual shift selector switch in the MANUAL
[1] Code No.01001: ENG SPEED position.
(Engine speed) 5) While keeping the directional lever at N
[2] Code No. 04401: HYD TEMP (Neutral) position, set the gearshift lever in
(hydraulic oil temperature) the 4th position.
6) Release the parking brake.
7) While pressing the brake pedal, set the
directional lever to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal
securely.
8) While running the engine at high idle, stall
the torque converter and relieve the lift
arm cylinder or bucket cylinder on the
extraction side simultaneously and mea-
sure the engine speed at this time.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
3) Run the engine at high idle. a Measure the full stall speed when the
4) Relieve the lift arm cylinder or bucket cyl- power mode and economy mode are
inder on the extraction side and measure turned on.
the engine speed.
a Measure the hydraulic stall speed
when the power mode and economy
mode are turned on.

WA600-6 11
SEN00553-05 30 Testing and adjusting

Measuring exhaust gas color 1

a Measuring instruments for exhaust gas color
Symbol Part No. Part Name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

k When installing and removing the measuring

instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol- 2) Connect the probe hose, receptacle of the
lowing condition. accelerator switch, and air hose to smoke
q Engine coolant temperature: Within oper- meter A2.
ating range a Keep the pressure of the supplied
compressed air at 1.5 MPa {15 kg/
1. Measuring with handy smoke checker A1 cm2} or below.
1) Stick a sheet of filter paper to smoke 3) Connect the power cable to a 100 V AC
checker A1. receptacle.
2) Insert the exhaust gas intake pipe in the a Confirm that the smoke meter power
muffler (exhaust pipe). switch is in the OFF position, before con-
3) Start the engine and heighten the engine necting the power cable to an outlet.
coolant temperature to the operating range. 4) Loosen the cap nut of the suction pump
4) Accelerate the engine suddenly or run it at and fit the filter paper.
high idle and operate the handle of smoke a Fit the filter paper securely so that the
checker A1 so that the filter paper will exhaust gas will not leak.
absorb the exhaust gas. 5) Turn on the power switch of smoke meter A2.

6) Start the engine and keep it running until

5) Take out the filtering paper and compare it the engine coolant temperature rises to
with the attached scale for judgement. the operating range.
6) Remove the measurement tool after the 7) Accelerate the engine suddenly or run it at
measurement, and make sure that the high idle and press the accelerator pedal
machine is back to normal condition. of smoke meter A2 and collect the
exhaust gas into the filter paper.
2. Measuring with smoke meter A2 8) Put the polluted filtering paper on non-pol-
1) Insert the probe of smoke meter A2 in the luted filtering paper (more than 10 sheets)
outlet of the muffler (exhaust pipe) and fix in the filtering paper holder, and read the
it to the exhaust pipe with a clip. indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.

12 WA600-6
30 Testing and adjusting SEN00553-05

Measuring exhaust temperature 1

a Measuring instrument for exhaust temperature
Symbol Part No. Part Name
B 799-101-1502 Digital thermometer

k Install and remove the measuring instru-

ment after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature:
Within operating range
q Torque converter oil temperature:
4. Procedure for periodic measurement done in
Within operating range
preventive maintenance
1. Open the left side cover.
a To prevent the torque converter from over-
heating, increase the exhaust temperature
2. Remove exhaust temperature pickup plug (1)
once through full-stall operation (torque
(R1/8) at the bottom of exhaust manifold.
converter stall + hydraulic stall), and then
a You may measure at either front or rear
measure the exhaust temperature while
plug.
only the torque converter is stalled.
1) Start the engine and heighten the coolant
temperature to the operating range.
2) Press the left brake pedal securely.
3) Set the transmission auto shift and man-
ual shift selector switch in the MANUAL
position.
4) While keeping the directional lever at N
(Neutral) position, set the gearshift lever to
the 4th position.
5) Release the parking brake.
6) While pressing the brake pedal, set the
directional lever or switch to the F (for-
ward) or R (reverse) position.
k Keep pressing the brake pedal
securely.
3. Install sensor [1] of digital thermometer B and
7) Press the accelerator pedal gradually to
connect them to meter [2].
the high idle. While running the engine at
a Take care that the wiring harness of the
high idle, stall the torque converter and
digital thermometer will not touch a hot
relieve the lift arm cylinder or bucket cylin-
part during measurement.
der on the extraction side simultaneously.
(full stall)
a Increase the exhaust temperature to
about 650°C (the state of (a) in the
figure).
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.

WA600-6 13
SEN00553-05 30 Testing and adjusting

8) As the exhaust temperature reached

about 650°C, release the hydraulic relief
and then decrease the exhaust tempera-
ture by stalling torque converter alone.
(the state of (b) in the figure)
a The exhaust temperature starts low-
ering from the level of the full-stall
operation. Measure the exhaust tem-
perature as it stabilized. (the state of
(c) in the figure)
a If the exhaust temperature rises in
stead of going down, set a higher full
stall temperature than the current one
(650°C).

5. Procedure for measuring the maximum exhaust

temperature
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the thermometer
(in which the maximum value can be
saved).
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
a Corrected value [°C] = Measured value +
2 × (20 – Outside air temperature)

6. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
3 Exhaust temperature pickup plug:
2.9 – 5.9 Nm {0.3 – 0.6 kgm}

14 WA600-6
30 Testing and adjusting SEN00553-05

Adjusting valve clearance 1

a Adjusting tool for valve clearance
Symbol Part No. Part name
Commercially
C Clearance gauge
available

1. Remove covers (1) and (2) and bracket (3) and

then remove 6 cylinder covers (4). For details,
see Disassembly and assembly, “Removal and
installation of cylinder head assembly”.

2. Remove inspection hole plug (a) from the left

side of the timing gear case.
4. When the No. 1 cylinder is at the compression
3. Rotate crankshaft forward to align cut (b) of top dead center, adjust the valve clearances
supply pump drive gear to the center of the marked with q in the valve arrangement draw-
inspection hole. ing.
a Crank the crankshaft using the cranking a When adjusting the position, loosen lock-
device provided in the rear left side of the nut (8) of adjustment screw (7) and then
engine. adjust the clearance by inserting clear-
a The left side in above figure indicates the ance gauge C between crosshead (6) and
compression to dead center of No. 1 cylin- rocker arm (5) until the cylinder becomes
der and right side is the compression to slightly movable.
dead center position of No. 6 cylinder.
a The compression top dead center allows
moving the rocker arm manually by the
valve clearance. When the locker arm is
not movable, the current position is not the
compression top dead center. In this case,
rotate the crankshaft one more turn.

WA600-6 15
SEN00553-05 30 Testing and adjusting

5. Rotate the crankshaft forward by a single turn

to adjust the valve clearance indicated with Q
in the valve arrangement drawing.
a Adjustment procedure is the same as
above.

a Valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm

6. While fixing adjustment screw (7), tighten lock-

nut (8).
3 Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.

7. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
{No.1, 3, 4, 5 and 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 – 73.5 Nm {6 – 7.5 kgm}
3 Inspection hole plug:
58.8 – 78.4 Nm {6.0 – 8.0 kgm}

16 WA600-6
30 Testing and adjusting SEN00553-05

Testing compression pressures 1

a Testing tools for compression pressure
Symbol Part No. Part name
1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
D 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover

k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
a Pull out the injector by driving the weight
caught in a rotating part.
of tool D3 up and down while the pin (indi-
a Measure the compression pressure after the
cated with the arrow) at the tip of tool D3 is
engine is warmed up (Engine oil temperature:
being inserted to hole (a) of adapter (9).
40 – 60°C).

1. Remove covers (1) and (2) and bracket (3) and

then remove cylinder head cover (4) to be
check compression pressures. For details, see
Disassembly and assembly, “Removal and
installation of cylinder head assembly”.

2. Adjust the valve clearance of the cylinder to be

check. For details, see “Adjusting valve clear-
ance”.

3. Disconnect fuel high-pressure tube (5) and

injector harness (6).
a When removing the injector harness,
remove the injector side terminal and
rocker housing side mounting bolt first.
a Loosen two terminal nuts alternately.

4. Remove bolt (7) and then remove injector (8)

along with adapter (9).

WA600-6 17
SEN00553-05 30 Testing and adjusting

5. Install adapter D2 to the mounting hole on the 8. After finishing testing, remove the testing tools
injector and compression gauge D1. and return the removed parts.
a Fit the gasket to the injector end without a Install the injector and fuel high-pressure
fail tube according to the following procedure.
a Fix the adapter using the holder for injec- 1) Install gasket (10) and O-rings (11) and
tor and adapter. (12).
3 Holder mounting bolt: a Take care not to install O-ring (11) to
58.8 – 73.5 Nm {6.0 – 7.5 kgm} slot (b).
a Apply a little amount of engine oil to the 2) Set adapter (9) to injector (8) and then
connecting parts of the adapter and gauge push them into the cylinder head with
so that air will not leak easily. hands.
2 O-ring: Engine oil

6. Set the mode to the no injection cranking oper-

ation. For details, see “Special functions of 3) Install holder (7) and then tighten bolt (13)
machine monitor”. and washer (14) temporarily.
k If the engine is not set in the no-injec- 2 Spherical part of washer: Engine oil
tion cranking mode, it will start and will 4) Install the fuel high-pressure tube and
be dangerous. Accordingly, be sure to then tighten sleeve nut (5).
set the engine in this mode. 5) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7. Rotate the engine with the starting motor and 6) Tighten sleeve nut (5) permanently.
measure the compression pressure. 3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm}
a Read the pressure gauge pointer when it
is stabilized.

18 WA600-6
30 Testing and adjusting SEN00553-05

a Install the injector wiring harness accord-

ing to the following procedure.
1) Assemble injector harness (6) through
inside of the rocker arm housing, and then
fix the connector side with plate (15).

2)Set spacer (16) and fix with bolt (17).

3)Tighten nut (18) on the injector side alter-
nately.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

3 Cylinder head cover mounting bolt:

{No.1, 3, 4, 5 and 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 – 73.5 Nm {6 – 7.5 kgm}

WA600-6 19
SEN00553-05 30 Testing and adjusting

Measuring blow-by pressure 1 8. Press the accelerator pedal gradually to the

high idle. While running the engine at high idle,
a Blow-by pressure measurement tools stall the torque converter and measure the
Symbol Part No. Part Name blow-by pressure.
a Do not keep stalling the torque converter
E 799-201-1504 Blow-by checker
for more than 20 seconds. Take care that
a Measure the blow-by pressure under the fol- the torque converter oil temperature will
lowing condition. not exceed 120°C.
q Engine coolant temperature: a Normally, the blow-by pressure should be
Within operating range measured while the engine is operated at
q Hydraulic oil temperature: the rated output. In the field, however, an
Within operating range approximate value can be obtained by
q Torque converter oil temperature: stalling the torque converter.
Within operating range a If it is impossible to run the engine at the
rated output or stall the torque converter,
1. Stop the engine. Install nozzle [1] and hose [2] measure while the engine is running at
of blow-by checker E to blow-by hose (1) and high idle. The value obtained in this case
connect them to gauge [3]. is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.

2. Start the engine and increase the engine cool-

ant temperature to the operating range.

3. Press the left brake pedal securely.

4. Set the transmission auto shift and manual

shift selector switch in the MANUAL position.

5. While keeping the directional lever or forward-

9. Remove the measurement tool after the mea-
reverse switch at the N (Neutral) position, set
surement, and make sure that the machine is
the gearshift lever or gear shift switch to the
back to normal condition.
4th position.

6. Release the parking brake.

7. While pressing the brake pedal, set the direc-

tional lever or switch to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal securely.

20 WA600-6
30 Testing and adjusting SEN00553-05

Measuring engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part Name 5. While running the engine at low idle and high
idle, measure the oil pressure.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Hydraulic tester
799-101-5230 Nipple (14 × 1.5 mm)
3
6215-81-9720 O-ring

a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature:
Within operating range

1. Open the right side cover.

2. Remove engine oil pressure pickup plug (1)

(14 × 1.5 mm) on the engine oil filter bracket.
6. Remove the measurement tool after the mea-
surement, and make sure that the machine is
back to normal condition.
3 Oil pressure pickup plug:
45 – 49 Nm {4.6 – 5 kgm}

3. Install nipple F3 (14 × 1.5 mm) and then con-

nect hydraulic tester F2 (1 MPa {10 kg/cm2}).

WA600-6 21
SEN00553-05 30 Testing and adjusting

Testing EGR valve and bypass 4. Install EGR valve drive oil supply tube (1) to
valve drive oil pressure 1 the top of tool F4 and tighten flange mounting
bolts (2) on the EGR valve side.
a Testing instruments for EGR valve and bypass 3 Flange mounting bolt (2):
valve drive oil pressure 27 – 34 Nm {2.8 – 3.5 kgm}

Symbol Part No. Part name

795T-690-1110 Block
4 01435-00835 Bolt
F 07000-E2012 O-ring
5 799-101-5002 Hydraulic tester
6 790-261-1204 Digital hydraulic tester

1. Open the right side cover.

2. Remove flange mounting bolts (2) of EGR

valve drive oil supply tube (1) on the EGR
valve side and clamp mounting bolts (3).
5. Install the nipple (component part of F5) to
measuring hole (a) (size: PT 1/8) of took F4
and connect hydraulic tester F5.
Reference: Since the maximum oil pressure to
be measured will be about 3 MPa {30 kg/cm2},
select a proper pressure gauge in the kit.

3. Install tool F4 to the EGR valve oil supply area.

3 Mounting bolt (4) (component part of
F4): 27 – 34 Nm {2.8 – 3.5 kgm}

22 WA600-6
30 Testing and adjusting SEN00553-05

6. Run the engine and measure the oil pressure

at low idle and high idle.

7. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
a Replace the flange O-ring on the EGR
valve side with new one.

3 Flange mounting bolt (2):

27 – 34 Nm {2.8 – 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 – 73.5 Nm {6 – 7.5 kgm}

WA600-6 23
SEN00553-05 30 Testing and adjusting

Measuring intake air (boost) 4. Start the engine.

pressure 1
5. Press the left brake pedal securely.
a Measuring instruments for intake air (boost)
pressure 6. Set the transmission auto shift and manual
Symbol Part No. Part Name shift selector switch in the MANUAL position.
G 799-201-2202 Boost gauge kit
7. While keeping the directional lever or forward-
reverse switch at the N (Neutral) position, set
k When installing and removing the measur-
the gearshift lever or gear shift switch to the
ing instruments, take care not to touch a
4th position.
hot part of the engine.
a Measure the intake air pressure (boost pres-
8. Release the parking brake.
sure) under the following condition.
q Engine coolant temperature:
9. While pressing the brake pedal, set the direc-
Within operating range
tional lever to the F (forward) or R (reverse)
q Hydraulic oil temperature:
position.
k Keep pressing the brake pedal securely.
Within operating range
q Torque converter oil temperature:
Within operating range
10. Press the accelerator pedal gradually to the
high idle. While running the engine at high idle,
1. Open the right side cover.
stall the torque converter and measure the
intake air pressure (boost pressure).
2. Remove exhaust temperature pickup plug (1)
a Do not keep stalling the torque converter
(R1/8) in the rear side of the air intake mani-
for more than 20 seconds. Take care that
fold.
the torque converter oil temperature will
not exceed 120°C.

3. Install nipple [1] in boost gauge kit G and con-

nect pressure gauge [2].
11. Remove the measurement tool after the mea-
surement, and make sure that the machine is
back to normal condition.

24 WA600-6
30 Testing and adjusting SEN00553-05

Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.

WA600-6 25
SEN00553-05 30 Testing and adjusting

Testing fuel pressures 1 5. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester
1 Engine speed Fuel pressure
790-261-1204 Digital hydraulic tester
Min. 0.15 MPa
795-471-1450 Adapter High idle
H 2 {Min. 1.5 kg/cm2}
07005-00812 Seal washer
3 799-101-5160 Nipple
4 799-401-2320 Hydraulic tester

a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.

1. Open the right side cover.

2. Remove plug (1).

6. After finishing testing, remove the testing tools
and return the removed parts.
3 Plug (1): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

3. Install adapter H2.

4. Install nipple H3 to adapter H2 and connect

them to hydraulic tester H4.

26 WA600-6
30 Testing and adjusting SEN00553-05

Testing return rate and leakage 1

a Testing tools for leakage from pressure limiter 1. Preparation work

and return rate from injector 1) Remove tube (3) between common rail (1)
and block (2).
Symbol Part No. Part name 2) Insert spacer J1 to block (2) side and
1 6167-11-6640 Spacer tighten the currently removed joint bolt
again.
2 6206-71-1770 Joint
a Connect the return pipe to the fuel
Commercially tank again, too.
3 Hose (ø5 mm × (2 to 3 m))
available a Be sure to provide a gasket to both
J 4
Commercially
Hose (ø15 mm × (2 to 3 m))
ends of the spacer.
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available

a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.

WA600-6 27
SEN00553-05 30 Testing and adjusting

2. Testing leakage of fuel

1) Route inspection hose J3 in such that it
may be free from slack and then insert its
end to the oil pan (saucer).
2) Set the mode that allows confirming the
engine speed with the real time monitoring
function. For details, see “Special func-
tions of machine monitor”.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After making sure the engine speed is sta-
bilized, measure leakage volume per
minute using measuring cylinder J5.
a You may test for 20 seconds and
3) Insert joint J2 to common rail (1) side and
judge by multiplying the result by 3.
tighten the currently removed joint bolt
a If the leakage of fuel is in the following
again.
range, it is normal.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect inspection hose J3 to the tip of Measurement Leakage volume
joint J2. condition (cc/min)
a Bind the connecting part of the test At stall or relief Max. 10
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage of fuel.

5) After finishing testing, stop the engine.

28 WA600-6
30 Testing and adjusting SEN00553-05

3. Testing return rate of fuel

5) After finishing testing, stop the engine.

1) Remove the hose at spill outlet (4) and
connect inspection hose J4 in stead. Then 4. Work after finishing testing
insert the hose end to the oil pan (saucer). After finishing all testing, remove the testing
2) Set the mode that allows confirming the tools and return the removed parts.
engine speed with the real time monitoring
function. For details, see “Special func-
tions of machine monitor”.
3) Run the engine at the rated output.
4) After making sure the engine speed is sta-
bilized, measure leakage volume per
minute using measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) of fuel is in the
following range, it is normal.

Rated output speed Limit of return rate (spill)

(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200

WA600-6 29
SEN00553-05 30 Testing and adjusting

Bleeding air from fuel circuit 1 5. Shift switch (3) for the electric priming pump in
the engine room to ON position.
a Bleed air according to this procedure in the fol- a Lamp (4) will start flashing and operation
lowing cases. of the electric priming pump will be
q When the fuel filter was replaced started.
q When fuel ran out (Serial No. 60001 – 60149)
q When starting the engine for the first time
after replacing the fuel piping or supply
pump
a When the fuel filter is replaced, don't feed fuel to
the filters, including both the main and pre-filter.
k Pressure is constantly applied to the fuel
circuit as long as operation of the electric
priming pump is continued. Loosening the
air bleeding plug from this state might
allow fuel to burst out. Thus, don't try to
loosen the plug while the pump is in opera-
tion.

1. Set the starting switch to OFF position.

2. Open the right side cover. (Serial No. 60150 and up)

3. Open air bleeding valve (1).

4. Remove cover (2). (Serial No. 60001 – 60149)

30 WA600-6
30 Testing and adjusting SEN00553-05

a The built-in timer of this switch automati- 10. Start the engine with the starting motor.
cally starts or stops operation of the elec- a The air in the high-pressure circuit is bled
tric priming pump. (See the figure below) automatically if the engine is cranked.
a Operation of the electric priming pump is a If the engine does not start, inappropriate
stopped as long as flashing of the lamp is bleeding air in the low-pressure circuit
continued. It is not an error. may be suspected. In this case, perform
a Shifting the switch to “OFF” while the lamp the followings:
is flashing turns off the lamp and stops the 1) Shift the electric priming pump switch to
electric priming pump. ON position.
2) Start the engine while the electric priming
pump is operating.
a If the engine does not start, repeat
this.
3) After the engine starts, let the engine run
for more than 5 minutes to bleed air com-
pletely from the fuel circuit.

6. As the specified duration (about 6.5 minutes) is

expired, lamp (4) automatically goes off, stop-
ping the electric priming pump.
a When the fuel filter alone was replaced,
above completes bleeding air.

7. When fuel is not provided in the fuel circuit

such as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump
was done, set switch (2) to “ON” again after
the electric priming pump is automatically
stopped.

8. Bleeding air, in this case, completes as lamp

(4) went off.

9. Close air bleeding valve (1).

WA600-6 31
SEN00553-05 30 Testing and adjusting

Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.

1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.

4. Run the engine at low idle.

5. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.

6. Run the engine at high idle.

7. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.

8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.

32 WA600-6
30 Testing and adjusting SEN00553-05

Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor. For
details, see “Special functions of machine
2. When a cylinder is selected for the reduced monitor”.
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system

3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
set from the service mode of the machine
monitor.
For details, see “Special functions of
machine monitor”.

WA600-6 33
SEN00553-05 30 Testing and adjusting

Handling controller voltage

circuit 1
1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.

2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.

34 WA600-6
30 Testing and adjusting SEN00553-05

Replacing and adjusting

alternator and air conditioner
compressor belt tension 1
a The auto-tensioner is provided for the alterna-
tor and air conditioner compressor belt. Thus,
testing and adjustment of the belt is usually not
necessary.
a Following describes the auto-tensioner adjust-
ment procedure to be employed for the belt
replacement.

1. Open the right side cover.

2. Remove cover (1).

6. Tighten locknut (2).

7. Install cover (1).

3. Loosen locknut (2), tighten push bolt (3) fully

and then push in tension pulley (4).

4. Replace belt (5).

5. After replacing the belt, loosen push bolt (3)

until its threaded portion protrudes 90 mm.

WA600-6 35
SEN00553-05 30 Testing and adjusting

Adjusting modulation clutch speed sensor and speed sensor 1

1. Modulation clutch output shaft speed sensor

1) Loosen locknut (2) of modulation clutch
output shaft speed sensor (1).
2) Screw in speed sensor (1) until its tip
lightly contacts against the plate (3).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
Gasket sealant (LG-5)

3) Return speed sensor (1) by 3/4 – 1 turn.

4) Fix speed sensor (1) with locknut (2).

3 Locknut:
49.6 – 68.6 Nm {5 – 7 kgm}

36 WA600-6
30 Testing and adjusting SEN00553-05

2. Speed sensor
1) Loosen locknut (6) of speed sensors (4)
and (5).
2) Screw in speed sensors (4) and (5) until
their tip lightly contacts against the gear
tooth (7).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
Gasket sealant (LG-5)

3) Return speed sensors (4) and (5) by 1/2 – 1

turn.

4) Fix speed sensors (4) and (5) with locknut

(6).
3 Locknut: 49.6 – 68.6 Nm {5 – 7 kgm}

WA600-6 37
SEN00553-05 30 Testing and adjusting

Measuring directional Stroke of directional lever (1) and gear shift

lever and gear shift lever lever (2)
(Steering wheel specification) 1 1. Stop the engine.

Measuring instrument 2. Make mark (a) at the center of the control lever
Symbol Part No. Part Name knob. Move the knob in the operating direction
K 79A-264-0021 Push-pull scale and measure its stroke.
a Figure shows the work of directional lever.
k Put chocks under the tires securely.

Operating effort of directional lever (1) and gear

shift lever (2)
1. Stop the engine.

2. Install tool K or a spring balance to a point 10

mm from the control lever end and pull it in the
operating direction to measure the operating
effort at that time.
a Measure the operating effort at each gear
speed.
a Figure shows the work of directional lever.

38 WA600-6
30 Testing and adjusting SEN00553-05

Testing and adjusting power train oil pressure 1

(*1): For transmission Serial No. up to 100090

(*2): For transmission Serial No. 100091 and up

WA600-6 39
SEN00553-05 30 Testing and adjusting

Oil pressure measuring point and measuring 1. Remove rear frame left side cover (13) and
gauge right side cover (14).
a Applicable only to the machine equipped
Measuring with the rear frame side covers
No. Measured oil pressure gauge
MPa {kg/cm2}
1 Main relief pressure 6 {60}
2 Torque converter inlet pressure 2.5 {25}
3 Torque converter outlet pressure 1 {10}
4 Modulation clutch oil pressure 6 {60}
5 Lockup clutch pressure 6 {60}
6 Transmission F clutch pressure 6 {60}
7 Transmission R clutch pressure 6 {60}
8 Transmission 1st clutch pressure 6 {60}
9 Transmission 2nd clutch pressure 6 {60}
10 Transmission 3rd clutch pressure 6 {60}
11 Transmission 4th clutch pressure 6 {60}
12 Lubrication pressure 1 {10}

a Testing and adjusting instruments for power

train oil pressure

Symbol Part No. Part Name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

k Put chocks under the tires.

a Measure the power train oil pressure under the
following condition.
q Engine coolant temperature:
Within operating range
q Torque converter oil temperature:
Within operating range

40 WA600-6
30 Testing and adjusting SEN00553-05

Measurement 5) After finishing measurement, remove the

1. Measuring transmission main relief pressure measuring instruments and return the
1) Remove transmission main relief pressure removed parts.
pickup plug (1) (10 × 1.25 mm).

2) Connect nipple L2 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Start the engine and keep the directional

lever or switch at the N (Neutral) position.
4) While running the engine at low idle and
high idle, measure the transmission main
relief pressure.

WA600-6 41
SEN00553-05 30 Testing and adjusting

2. Measuring torque converter inlet pressure 5) After finishing measurement, remove the
1) Remove torque converter inlet pressure measuring instruments and return the
pickup plug (2) (10 × 1.25 mm). removed parts.

(*1): For transmission Serial No. up to 100090

(*2): For transmission Serial No. 100091 and up

2) Connect nipple L2 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester L1.
a Use the oil pressure gauge of 2.5 MPa
{25 kg/cm2}.

3) Start the engine and keep the directional

lever or switch at the N (Neutral) position.
4) While running the engine at high idle,
measure torque converter relief pressure
(inlet pressure).

42 WA600-6
30 Testing and adjusting SEN00553-05

3. Measuring torque converter outlet pressure 5) Remove the measurement tool after the
1) Remove torque converter outlet pressure measurement, and make sure that the
pickup plug (3). machine is back to normal condition.

2) Connect nipple L2 and oil pressure gauge

[1] in hydraulic tester L1.
a Use the oil pressure gauge of 1 MPa
{10 kg/cm2}.

3) Start the engine and keep the directional

lever or switch at the N (Neutral) position.
4) While running the engine at high idle,
measure torque converter outlet pressure.

WA600-6 43
SEN00553-05 30 Testing and adjusting

4. Measuring modulation clutch pressure

1) Remove modulation clutch pickup plug (4).

9) Remove the measurement tool after the

measurement, and make sure that the
2) Connect nipple L2 and oil pressure gauge
machine is back to normal condition.
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever at N
(Neutral) position, set the gearshift lever in
the 4th position.
7) While pressing the right brake pedal, set
the directional lever or switch to the F (for-
ward) or R (reverse) position.
k Keep pressing the right brake
pedal securely.
8) While running the engine at high idle,
measure the modulation clutch pressure.

44 WA600-6
30 Testing and adjusting SEN00553-05

5. Measuring lockup clutch pressure

k This measurement is done in the travel-
ing condition. Reasonable care, there-
fore, must be pai d to saf ety of
surrounding area.
1) Remove lockup clutch pressure pickup
plug (5).

9) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.

2) Connect nipple L2 and oil pressure gauge

[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Turn the torque converter lockup switch

ON.
4) Set the transmission auto shift and man-
ual shift selector switch in the AUTO posi-
tion.
5) Start the engine and turn the parking
brake switch OFF.
6) Set the gear shift lever or gear shift switch
to 2nd position.
7) Start traveling while setting the directional
lever or switch to the F (forward) or R
(reverse) position.
8) Measure the lockup clutch oil pressure as
the lockup pilot lamp came on while travel-
ing is continued with the engine at high
idle.

WA600-6 45
SEN00553-05 30 Testing and adjusting

6. Measuring F (forward) clutch pressure

1) Remove F (forward) clutch oil pressure
pickup plug (6).

9) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever to the 4th position.
7) While pressing the right brake pedal, set
the directional lever or switch to F (for-
ward).
k Keep pressing the right brake
pedal securely.
8) While running the engine at high idle,
measure the F clutch oil pressure.

46 WA600-6
30 Testing and adjusting SEN00553-05

7. Measuring R (reverse) clutch pressure

1) Remove R (reverse) clutch oil pressure
pickup plug (7).

9) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 4th position.
7) While pressing the right brake pedal, set
the directional lever or switch to R
(reverse).
k Keep pressing the right brake
pedal securely.
8) While running the engine at high idle,
measure the R clutch oil pressure.

WA600-6 47
SEN00553-05 30 Testing and adjusting

8. Measuring 1st clutch pressure

1) Remove 1st clutch oil pressure pickup
plug (8).

8) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 1st position.
k Keep pressing the right brake
pedal securely.
7) While running the engine at high idle,
measure the 1st clutch oil pressure.

48 WA600-6
30 Testing and adjusting SEN00553-05

9. Measuring 2nd clutch pressure

1) Remove 2nd clutch oil pressure pickup
plug (9).

8) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 2nd position.
k Keep pressing the right brake
pedal securely.
7) While running the engine at high idle,
measure the 2nd clutch oil pressure.

WA600-6 49
SEN00553-05 30 Testing and adjusting

10. Measuring 3rd clutch pressure

1) Remove 3rd clutch oil pressure pickup
plug (10).

8) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 3rd position.
k Keep pressing the right brake
pedal securely.
7) While running the engine at high idle,
measure the 3rd clutch oil pressure.

50 WA600-6
30 Testing and adjusting SEN00553-05

11. Measuring 4th clutch pressure

1) Remove 4th clutch oil pressure pickup
plug (11).

8) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge
[1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

3) Set the transmission auto shift and man-

ual shift selector switch in the MANUAL
position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 4th position.
k Keep pressing the right brake
pedal securely.
7) While running the engine at high idle,
measure the 4th clutch oil pressure.

WA600-6 51
SEN00553-05 30 Testing and adjusting

12. Measuring lubrication pressure Adjustment

1) Remove lubrication pressure pickup plug Adjusting transmission main relief valve
k Stop the engine before starting adjustment
(12).
of the transmission main relief valve.
a If the transmission main relief pressure is out
of the specified range, adjust it according to
the following procedure.
1. Remove plug (14) from transmission and
torque converter relief valve plug (13).

2) Connect nipple L2 and oil pressure gauge

[1] in hydraulic tester L1.
a Use the oil pressure gauge of 1 MPa
{10 kg/cm2}.

2. Remove inner spring (16) and outer spring

(15).

3. Adjust the torque converter relief pressure by

changing the number of shims (17).
a Standard shim thickness:
3.5 mm (0.5 × 7 pieces)
a Quantity of adjustment per shim:
0.039 MPa {0.39 kg/cm2}

3) Start the engine and keep the directional

lever or switch at the N (Neutral) position.
4) While running the engine at high idle,
measure the lubrication pressure.

52 WA600-6
30 Testing and adjusting SEN00553-05

Flushing procedure for torque 3) Loosen hexagonal portion (a) of 3 trans-

converter and transmission mission oil filter cases (3) to remove trans-
mission oil filter cases (3).
hydraulic circuit 1 a After removing the transmission oil fil-
a Metal chips and dirt in the torque converter and ter case, clean inside of the case as
transmission hydraulic circuit shorten the lives well as removed parts other than the
of the torque converter and transmission and filter.
can cause internal breakage. Accordingly, 4) Remove 3 filter elements (4) and replace
flush the hydraulic circuit to remove the metal them with 3 flushing elements (561-15-
chips and dirt. 55670).
5) Install 3 transmission oil filter cases (3).
1. Flush the hydraulic circuit in the following
cases. 3 Hexagonal portion (a) of transmis-
1) When metal chips are circulated in the sion oil filter case:
hydraulic circuit because of damage of the 58.8 – 78.5 Nm {6 – 8 kgm}
torque converter, transmission, or another 3 Drain plug:
hydraulic device. 49 – 58.8 Nm {5 – 6 kgm}
2) When the torque converter or transmis-
sion is overhauled or repaired.

2. Install the element for flushing.

1) Open bottom cover (2) provided in accu-
mulator installation position (1) on the left
side of the machine body.

3. Fill the transmission case with oil.

a Add oil through oil filler (5) to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil
level again.
5 Transmission case: 83 l (Refill capacity)
2) Remove 3 transmission oil filter cases (3)
and drain plug (4) to drain oil.
a Before draining oil, prepare an oil
pan.

WA600-6 53
SEN00553-05 30 Testing and adjusting

4. Flush the hydraulic circuit according to the fol- 3) Remove filter element (8) and replace it
lowing procedure. with a new element (561-15-55670).
1) Start the engine and run it at low idle with- 4) Install transmission last chance filter case
out operating the gearshift lever or direc- (7).
tional lever for about 20 minutes. a Replace the current O-ring with a new
a Increase the engine speed to about one, coat it with a small amount of oil
1,500 rpm sometimes. and then install it.
a If the engine coolant temperature 3 Hexagonal portion (b) of transmis-
gauge does not rise to the operating sion last chance filter case:
range because of low atmospheric 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
temperature, continue the warm-up
operation further.
2) Operate or drive the machine for at least
20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st – 4th, including mod-
ulation clutch and lockup clutch).
3) Run the engine at low idle for about 20
minute, similarly to 4-1).

5. Replace the filter element.

1) Replace filter erement (4) used for flush-
ing with new element (714-07-28712) in
the same procedure as 2.
k If the element used for flushing is
used for long hours, it is clogged
quickly. Accordingly, be sure to
replace it with new one.
a Replace the current O-ring with a new
one, coat it with a small amount of oil
and then install it.
2) Add oil and check the oil level again.

6. Replace the transmission last chance filter.

1) Remove cover (6) on the right side of the
rear frame.

2) Loosen hexagonal portion (a) of the trans-

mission last chance filter case (7) to
remove the cases.
a After removing the transmission oil fil-
ter case, clean inside of the case as
well as removed parts other than the
filter.

54 WA600-6
30 Testing and adjusting SEN00553-05

Method of moving machine when transmission valve is broken 1

a Locations of ECMV assemblies and connector Nos.

a Device for moving machine when transmission k When working while the oil temperature is
valve is broken still high, take care not to burn your body.
Symbol Part No. Part Name
1. Remove cover (1) on the left side of the rear
M 794-423-1190 Plug frame.
a Remove mud and dirt from around the
a Even if you cannot move the machine because ECMV.
of breakage of a transmission valve part (elec-
trical system, solenoid valve, spool, etc.), you
can move it by installing plugs M.
k Installation of plugs M to the ECMV is a
means to move the machine from a danger-
ous job site to a safe place where you can
repair it when you cannot move it at any
gear speed because of breakage of the
transmission control valve. Accordingly,
use this method only when the transmis-
sion control valve is broken. Install plugs M
only in an emergency where the broken
machine cannot be towed and there is no
means to move it.
k When moving the machine by this method,
observe the procedure and take care of 2. Disconnect all the connectors from each
safety. ECMV. (14 places)
k Lower the work equipment to the ground
fully, apply the parking brake, and put
chocks under the tires to prevent the
machine from moving.
k When working, stop the engine.

WA600-6 55
SEN00553-05 30 Testing and adjusting

3. Remove 3 solenoids (2) from the modulated k After moving the machine, stop the
clutch ECMV, 2nd ECMV, and F or R ECMV engine, apply the parking brake, and
and install plugs M. put chocks under the tires.
q For forward travel:
F solenoid and 2nd solenoid 6. After moving the machine, remove the devices
q For reverse travel: and return the removed parts.
R solenoid and 2nd solenoid
a If a wrong solenoid is removed, the trans-
mission may be broken. Take care.
a Install each plug with its projection side
toward the ECMV. Check that the O-ring is
fitted to the mating face.
a Take care that mud or dirt will not enter the
removed solenoids and valves.

4. Press the right brake pedal securely.

5. Start the engine, release the parking brake,

and then release the right brake pedal gradu-
ally to start and move the machine.
a If the parking brake cannot be released
because of a trouble in the electrical sys-
tem, see “Method of releasing parking
brake manually”.
k Remove the chocks.
k If the engine is started, the transmis-
sion is engaged and the machine starts
immediately. Accordingly, when start-
ing the engine, check the moving direc-
tion of the machine and secure safety
around the machine thoroughly and
keep pressing the brake pedal.

56 WA600-6
30 Testing and adjusting SEN00553-05

Adjusting steering stop valve 1 5. Tighten locknut (2) by rotating stopper bolt (1)
in the loosening direction 8 – 8.5 turns (c
Preparation dimension: 14.0 – 14.9 mm).
Before adjusting the stopper bolt, operate the steer- a Adjust both the right and left side accord-
ing and check that the frame stoppers contact at ing to above 1 – 5 methods.
each steering end.
a If the frame stoppers are damaged or lost,
repair them so that the frames will contact
against them on each side.

Adjusting
1. Loosen locknut (2) and then tighten stopper
bolt (1) to minimum length (d) so that it may not
contact against steering stop valve (3) during
the steering operation.

2. Run the engine at low idle and then bring front

frame (4) and rear frame (5) into contact each
other by turning the steering wheel slowly.
k Use care in this operation so that your
body or arm may not be caught
between the front and rear frames.
3. Stop the engine and then loosen stop bolt (1)
until it touches the contact surface of steering
stop valve (3).
4. Run the engine at low idle and return the steer-
ing wheel slowly until the clearance between
the tip of steering stop valve (3) and head (b)
of stopper bolt (1) becomes about 20 to 30
mm.

WA600-6 57
SEN00553-05

WA600-6 Wheel loader

Form No. SEN00553-05

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

58
 SEN00554-04

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

30 Testing and adjusting 1

Testing and adjusting, Part 2
Measuring operating effort of AJSS lever (AJSS specification) ...................................................................... 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) ...................... 4
Testing and adjusting steering stopper bolt (AJSS specification) ................................................................... 6
Testing and adjusting steering wheel (Steering wheel specification) .............................................................. 8
Testing steering oil pressure ......................................................................................................................... 10
Bleeding air from steering cylinder circuit ..................................................................................................... 14
Testing hydraulic drive fan ............................................................................................................................ 15
Bleeding air from hydraulic drive fan circuit .................................................................................................. 18
Measuring brake pedal ................................................................................................................................. 20
Measuring brake performance ...................................................................................................................... 21
Testing and adjusting accumulator charge pressure..................................................................................... 22
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas . 24
Testing wheel brake oil pressure................................................................................................................... 30
Measuring wear of wheel brake disc............................................................................................................. 32
Bleeding air from wheel brake circuit ............................................................................................................ 33
Releasing residual pressure in brake accumulator circuit............................................................................. 34

WA600-6 1
SEN00554-04 30 Testing and adjusting

Testing parking brake performance............................................................................................................... 35

Measuring parking brake oil pressure ........................................................................................................... 36
Testing wear of parking brake disc................................................................................................................ 39
Method of releasing parking brake manually ................................................................................................ 40
Measuring and adjusting work equipment control lever ................................................................................ 41
Measuring work equipment oil pressure ....................................................................................................... 42
Bleeding air from work equipment circuit ...................................................................................................... 47
Releasing residual pressure in work equipment circuit ................................................................................. 48
Moving machine for removing operator cab.................................................................................................. 50
Testing and adjusting bucket positioner ........................................................................................................ 52
Testing and adjusting lift arm position detecting lever................................................................................... 54
Checking proximity switch operation indication lamp.................................................................................... 55
Preparations for work on troubleshooting of electric system......................................................................... 56
Procedure for testing diodes ......................................................................................................................... 60

2 WA600-6
30 Testing and adjusting SEN00554-04

Measuring operating effort of AJSS lever (AJSS specification) 1

a Measuring instruments for AJSS lever operat-

ing effort

Symbol Part No. Part Name

N 79A-264-0021 Push-pull scale

a Measure the operating effort of AJSS lever

under the following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature: Within operating range
q Engine speed: Low idle

1. Install and fix push-pull scale N at operating

point (a) of AJSS lever (1).

2. Measure operating effort of AJSS lever (1) by

pulling the lever in the right and left using
push-pull scale N.
a Operate the work equipment control lever
at the ordinary operating speed and mea-
sure the minimum necessary effort to
operate the AJSS lever.

WA600-6 3
SEN00554-04 30 Testing and adjusting

Testing and adjusting AJSS lever angle sensor and frame angle sensor
(AJSS specification) 1

4 WA600-6
30 Testing and adjusting SEN00554-04

Adjusting
Adjust according to Special functions of machine
monitor (EMMS), 7-11 Adjustment of AJSS neutral
position.

WA600-6 5
SEN00554-04 30 Testing and adjusting

Testing and adjusting steering stopper bolt (AJSS specification) 1

6 WA600-6
30 Testing and adjusting SEN00554-04

Testing Adjusting
1. Start the engine and set steering lock lever (1) a If clearance (a) is not normal, adjust it accord-
to Free position. ing to the following procedure.

2. Move AJSS lever (2) to the right or left stroke 1. Set steering lock lever to free position and
end with the engine running at low idle. Main- return the steering to the center position.
tain the steering at that position.
k Operate the steering slowly. Use care 2. Set steering lock lever (1) to lock position.
in this operation so that your body or
arm may not be caught between the 3. Adjust protrusion dimension (b) nonconforming
front and rear frames. side adjustment bolt (5).
a Protrusion dimension (b):
3. Set steering lock lever (1) to lock position. Increasing its length increases clearance (a)
Decreasing it decreases clearance (a)
4. Make sure that clearance (a) between front a Standard protrusion dimension (b) (Refer-
frame (3) and rear frame (4) is normal. ence): 15 mm
a Clearance (a): 20 – 30 mm 3 Locknut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
a Check the left steering and right steering
separately. a After the adjustment, check clearance (a)
again using the above testing procedure.

WA600-6 7
SEN00554-04 30 Testing and adjusting

Testing and adjusting steering

wheel (Steering wheel
specification) 1
a Testing and adjusting device for steering wheel
Symbol Part No. Part name
P 79A-264-0021 Push-pull scale

Measuring play of steering wheel

a Measure the play of the steering wheel under

the following condition.
q Engine: Stopped
q Position of machine: Straight travel condition

Measuring method
1. Move the steering wheel to the right and left 2 – 3
times and check that the steering mechanism is
in neutral, and then make mark (A) on the
machine monitor frame.

2. Turn the steering wheel to the right and make

mark (B) at a position where the operating
effort becomes heavy.

3. Turn the steering wheel to the left and make

mark (C) at a position where the operating
effort becomes heavy. Then, measure the
straight distance between marks (B) and (C).

8 WA600-6
30 Testing and adjusting SEN00554-04

Measuring operating effort of steering wheel Measuring operating time of steering wheel

a Measure the operating effort of the steering a Measure the operating time of the steering
wheel under the following condition. wheel under the following condition.
q Road: Flat, level, paved, and dry road q Road: Flat, level, paved, and dry road
q Engine coolant temperature: q Engine coolant temperature:
Within operating range Within operating range
q Hydraulic oil temperature: q Hydraulic oil temperature:
Within operating range Within operating range
q Tire inflation pressure: Specified pressure q Tire inflation pressure: Specified pressure
q Engine: Low idle (No load on bucket) q Engine speed: Low idle and high idle

Measuring method Measuring method

1. Install push-pull scale P to the steering wheel 1. Start the engine.
knob. a After starting the engine, raise the bucket
a Install push-pull scale P to the center. about 400 mm and release the frame lock
lever.
2. Start the engine.
a After starting the engine, raise the bucket 2. Turn the steering wheel to the right or left
about 400 mm and release the frame lock stroke end.
lever.
3. Turn the steering wheel to the right or left
3. Pull push-pull scale P in the tangential direc- stroke end and measure the full-stroke time.
tion and read it while the steering wheel is a Do not turn the steering wheel forcibly but
moving smoothly. turn it at the speed of 60 revolutions per
a The operating effort is not the value indi- minute.
cated when the steering wheel starts mov- a While running the engine at low idle and
ing. high idle, measure the time to turn the
steering wheel to the right and left respec-
tively.

WA600-6 9
SEN00554-04 30 Testing and adjusting

Testing steering oil pressure 1 1. Steering relief pressure

1) Connect oil pressure gauge [1] of hydrau-
a Measuring instruments for steering oil pressure lic tester Q1 to steering circuit oil pressure
Symbol Part No. Part Name pickup nipple (2) on the right steering cyl-
inder head side.
799-101-5002 Hydraulic tester
1 a Use the oil pressure gauge of 40 MPa
790-261-1203 Digital hydraulic tester {400 kg/cm2}.
799-101-5220 Nipple (10 × 1.25)
Q 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (Size 03)

a Measure the steering oil pressure under the

following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature:
Within operating range

Measuring
k Loosen the oil filler cap of the hydraulic 2) Run the engine at high idle and turn the
tank to release the internal pressure of the steering wheel to the right. When the
hydraulic tank, then operate the steering steering relief valve operates, measure
wheel 2 – 3 times to release the residual the oil pressure.
pressure from the piping. a When the gauge was connected to
k Apply frame lock lever (1). steering circuit pickup plug (3) at the
bottom of the right side steering cylin-
der, measure the pressure by turning
the steering wheel to the left.

3) After finishing measurement, remove the

measuring instruments and return the
removed parts.

10 WA600-6
30 Testing and adjusting SEN00554-04

2. Steering pilot circuit pressure 3) Connect nipple Q2 (10 × 1.25 mm) and oil
1) Remove cover (4) at the accumulator pressure gauge [1] of hydraulic tester Q1.
installation position situated on the left a Use the oil pressure gauge of 6 MPa
side of the machine. {60 kg/cm2}.

2) Remove the steering control circuit pres-

4) While running the engine at high idle,
sure pickup plug (10 × 1.25 mm) (6) or (7)
measure the oil pressure as the steering
of steering valve assembly (5).
wheel is turned.
q (6) Plug: Turn the steering wheel right
(or shift AJSS lever to right)
q (7) Plug: Turn the steering wheel left
(or shift AJSS lever to left)

5) After finishing measurement, remove the

measuring instruments and return the
removed parts.

WA600-6 11
SEN00554-04 30 Testing and adjusting

3. Measuring AJSS EPC solenoid valve output 5) Lock the steering lock lever.
pressure (only for AJSS specification) 6) Start the engine and then measure AJSS
1) Lift and remove step (16). EPC solenoid valve output pressure when
4 Step assembly: 130 kg the engine is set to high idle with AJSS
lever being set at neutral.

2) Disconnect solenoid output pressure hose

(18) from AJSS EPC solenoid valve (17). 7) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.

3) Connect adapter Q4 and solenoid output

pressure hose (18).
4) Connect nipple [2] and oil pressure gauge
[1] in hydraulic tester Q1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

12 WA600-6
30 Testing and adjusting SEN00554-04

Adjusting 2. Steering LS differential pressure

k When adjusting the oil pressure, be sure to 1) If the steering LS differential pressure is
stop the engine. abnormal, adjust LS valve (14) of steering
1. Steering relief pressure pump assembly (13) according to the fol-
1) If the steering relief pressure is abnormal, lowing procedure.
adjust steering relief valve (10) of steering
valve assembly (5) according to the fol-
lowing procedure.

2) Loosen locknut (14) and turn adjustment

screw (15) to adjust the pressure.
a Adjustment screw:
q Turned to the right, the LS differ-
2) Loosen locknut (11) and turn adjustment ential pressure lowers.
screw (12) to adjust the pressure. q Turned to the left, the LS differ-
a Adjustment screw: ential pressure rises.
q Turned to the right, the pressure a Quantity of adjustment per turn of
rises. adjustment screw:
q Turned to the left, the pressure Per turn: 1.3 MPa {13.3 kg/cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
lowers.
a Quantity of adjustment per turn of
adjustment screw:
Per turn: 17.9 MPa {183 kg/cm2}
3 Locknut:
27 – 31 Nm {2.8 – 3.2 kgm}

3. AJSS EPC solenoid valve output pressure

Adjustment of AJSS EPC solenoid valve out-
put pressure is done by adjusting AJSS EPC
output current. For details, see “Special func-
tions of machine monitor”, 7-12 AJSS EPC
output current adjustment (AJSS specifica-
tion).

WA600-6 13
SEN00554-04 30 Testing and adjusting

Bleeding air from steering

cylinder circuit 1
a Before starting the operation, make sure the
specified level of hydraulic oil is provided.
a If the steering valve or the steering cylinder
was removed and installed, bleed air from the
steering circuit according to the following pro-
cedure.

1. Run the engine at idle for about 5 minutes.

2. While running the engine at low idle, steer the

machine to the right and left 4 – 5 times.
a Stop the piston rod about 100 mm before
each stroke end and take care not to
relieve the circuit.

3. While running the engine at high idle, perform

the operation of 2.

4. While running the engine at low idle, move the

piston rod to the stroke end and relieve the cir-
cuit.

14 WA600-6
30 Testing and adjusting SEN00554-04

Testing hydraulic drive fan 1 Tachometer kit R1

a Testing tools for hydraulic drive fan

Symbol Part No. Part Name
1 799-205-1100 Tachometer kit
799-101-5002 Hydraulic tester
2
790-261-1204 Digital hydraulic tester
R
799-101-5220 Nipple (M10 × 1.25)
3
07002-11023 O-ring
4 799-401-3500 Adapter (Size 06)

k Set the bucket bottom horizontally and

lower it to the ground, and then put chocks
under the tires.
k When removing the oil pressure pickup 2) While running the engine at high idle and
plug and disconnecting the hose, loosen low idle, measure the fan speed.
the oil filler cap of the hydraulic tank to 3) After finishing measurement, remove the
release the internal pressure of the tank. measuring instruments and return the
a Measurement condition removed parts.
q Engine coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
q Torque converter oil temperature: Min. 105°C

1. Measuring fan speed

1) Set probe [2] to stand [1] of tachometer kit
R1 and stick reflection tape [3] to the fan.

WA600-6 15
SEN00554-04 30 Testing and adjusting

2. Measuring fan drive oil pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
2) Remove fan net (2) at the center.

7) After finishing measurement, remove the

3) Disconnect P port hose (4) of fan motor measuring instruments and return the
(3). removed parts.

4) Connect adapter R4 and hose (4).

5) Connect nipple R3 (10 × 1.25 mm) and oil
pressure gauge [1] in hydraulic tester R2.
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.

16 WA600-6
30 Testing and adjusting SEN00554-04

3. Measuring fan reverse solenoid output 5) Turn the cooling fan reverse switch ON.
pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan reverse solenoid drive oil
2) Remove fan net (2) at the center. pressure.
a Measure the fan forward and reverse
drive oil pressures. When the fan is
reversed, check that the solenoid
operates and the specified oil pres-
sure is applied.

3) Remove fan reverse solenoid output pres-

sure pickup plug (10 × 1.25 mm) (5) from
fan motor (3).

7) After finishing measurement, remove the

measuring instruments and return the
removed parts.

4) Connect nipple R3 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester R2.
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.

WA600-6 17
SEN00554-04 30 Testing and adjusting

Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit 1 bleeder (3), tighten air bleeder (3).
3 Air bleeder:
a Testing tools for bleeding air from hydraulic drive 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
fan circuit 4) Start the engine and run it at low idle for 5
Symbol Part No. Part Name minutes minimum.
799-101-5002 Hydraulic tester
1 2. Bleeding air from fan motor circuit
790-261-1204 Digital hydraulic tester 1) Open radiator grille (4).
799-101-5220 Nipple (10 × 1.25) 2) Remove fan net (5) at the center.
S 2
07002-11023 O-ring
3 799-401-3500 Adapter (Size 06)
4 790-261-1130 Coupling

a Before starting the operation, make sure the

specified level of hydraulic oil is provided.

1. Bleeding air from fan pump

1) Open pump top cover (1).

3) Disconnect P port hose (7) of fan motor

(6).

2) Stop the engine and then loosen air

bleeder (3) of fan pump (2) to connect air
bleeding hose [1].

18 WA600-6
30 Testing and adjusting SEN00554-04

4) Connect adapter S3 and hose (7).

5) Connect nipple S2 (10 × 1.25 mm) and
hose [1] in hydraulic tester S1 and also
connect air bleeder coupling S4 to the out-
let end of hose.
a Put the outlet end of the hose in an oil
receiver.

6) Run the engine. When the oil flows out of

the outlet end of the hose, stop the
engine.
7) After finishing bleeding air, remove the
tools and return the removed parts.

WA600-6 19
SEN00554-04 30 Testing and adjusting

Measuring brake pedal 1

a Measurement condition
q Engine coolant temperature:
Within operating range
q Engine speed: Low idle

Measuring pressing angle of pedal

1. Install push gauge [1] to the foot of the mea-
surer.
a Set the push gauge in a position 150 mm
from the fulcrum of the pedal.

2. While running the engine at low idle, measure

pedal pressing angle (a1).

3. Apply angle gauge [2] to the brake pedal and

measure pressing angle (a2) from pressing
angle a1 to pressing angle (a3) (a2 = a1 – a3).
q (a2): Pressing angle at pressing effort of
321 ± 32.1 N {32.8 ± 3.3 kg}

20 WA600-6
30 Testing and adjusting SEN00554-04

Measuring brake performance 1

a Measure the brake performance under the fol- Measuring method

lowing condition. 1. Start the engine and drive the machine.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h 2. Set the gear shift lever or gear shift switch to
q Tire inflation pressure: Specified pressure 4th position for run up.
q Tire size: 35/65-33-36PR
q Brake pedal pressing force: Specified press- 3. When the travel speed becomes the braking
ing force initial speed of 20 km/h, press the left brake
294 ± 29.4 N {30 ± 3 kg} pedal with the specified force.
q Pressing time lag: 0.1 second a Decide the approach course and braking
point in advance and apply the brake at
that braking point.

4. Measure the distance from the braking point to

the stop point.
a Perform the above measurement 3 times
and obtain the average.

WA600-6 21
SEN00554-04 30 Testing and adjusting

Testing and adjusting

accumulator charge pressure 1
a Testing and adjusting instruments for accumu-
lator charge pressure
Symbol Part No. Part Name
799-101-5002 Hydraulic tester
T 1
790-261-1204 Digital hydraulic tester

a Measure the accumulator charge pressure

under the following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature: Within operating range
k Put chocks under the tires securely.
k While the engine is stopped, press the
brake pedal at least 100 times to release the
pressure from the accumulator circuit.

Measuring
1. Remove cover (1) at the accumulator installa-
tion position situated on the left side of the
machine.

2. After removing cover (1), insert your hand

through the opening and connect oil pressure
gauge [1] of hydraulic tester T1 to accumulator
charge valve measuring nipple [2].
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.
3. Measure the accumulator charge cut-in pres-
sure.
While running the engine at low idle, when the
brake oil pressure caution lamp on the monitor
panel goes off, measure the oil pressure.
a Cut-in pressure:5.88 (+0.49/0) MPa
{60 (+5/0) kg/cm2}

4. Measure the accumulator charge cut-out pres-

sure.
After the accumulator charge cut-in operation,
the rising oil pressure gauge lowers suddenly.
Measure the oil pressure at this time.

22 WA600-6
30 Testing and adjusting SEN00554-04

a Cut-out pressure:9.8 (+0.98/0) MPa

{100 (+10/0) kg/cm2}

a Adjustment screw:
q Turned to the right, the pressure rises.
q Turned to the left, the pressure lowers.
5. Remove the measurement tool after the mea-
a Quantity of adjustment per turn of adjust-
surement, and make sure that the machine is
ment screw: 5.59 MPa {57 kg/cm2}
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
back to normal condition.
a After finishing measurement, check the
Adjusting
accumulator charge cut-in and cut-out
a If the accumulator charge cut-out pressure is pressures again according to the above
adjusted, the cut-in pressure changes accord- measurement procedure.
ing to the valve area ratio.

1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3) and turn
adjustment screw (5) to adjust the pressure.

WA600-6 23
SEN00554-04 30 Testing and adjusting

Testing of accumulator nitrogen

gas pressure and procedure for
charging accumulator with
nitrogen gas 1
a Testing instrument
Symbol Part No. Part name Remarks
792-610-1701 Serial No. 60001-60634
T2 Gas charge tool
792-610-1702 Serial No. 60635-
Nipple
792-610-1310 (For Russia) GOST

792-610-1320 Nipple CGA No. 351

(For USA)

T3 792-610-1330
Nipple
ASA B-571-1965 Testing of accumulator nitrogen gas pressure
(For USA)
a The nitrogen gas pressure in the accumulator
DIN 477-1963
792-610-1350 Nipple NEN 3268-1966 disconnected from the machine can be mea-
(For Germany)
SIS-SMS 2235/2238 sured according to the following procedure, too.
792-610-1360 Nipple (For UK) BS 341 Part 1-1962 1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the
k Put on proper personal protection items brake circuit to zero.
(goggles, leather gloves and protective a Generally, if the brake pedal is depressed
clothes) so that the leaking nitrogen gas 30 times, the reaction force to the brake
will not touch your skin or clothes and work pedal is lost and the oil pressure is low-
on the windward side as long as possible. ered to zero.
k When handling nitrogen gas in a room or
another place which is not ventilated well, 2. Remove cap (2) and (3) from accumulator (1).
ventilate the work place forcibly and observe (Serial No. 60001-60634)
the Oxygen Deficiency Prevention Rules of
the Labor Safety and Sanitation Law.
k Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accu-
mulator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
3. Remove plug (11) from accumulator (10).
(Serial No. 60635 and up)
Precaution when connecting the gas charging
tool T2
a The threaded portion of the adapter (5) of the
gas charging tool T2 is coated with sealant. If
the adapter is removed unnecessarily, gas
may leak. Never remove it.
a The threaded portion height (B) of valve (8)
may be shorter than the depth (A) of packing
(6) from the end of adapter (5) of gas charging
tool T2 and gas may leak through the threaded
portion of valve (8).
When connecting the gas charging tool T2, fit
the attached O-ring (7) (part number: 07000-
11009) to valve (8), and confirm that gas does
not leak.

24 WA600-6
30 Testing and adjusting SEN00554-04

4. Connect gas charge tool T2 to valve of accu-

mulator according to the following procedure.
1) Turn handle (a) of gas charge tool T2 to
the left until it stops.
q Nitrogen gas cylinder (c) must be
connected even when you measure
only the gas pressure.
q Close the valve of nitrogen gas cylin-
der (c) and handle (b).
q For connection of nitrogen gas cylin-
der (c) and gas charge tool T2, see
"Procedure for charging accumulator
with nitrogen gas".
2) Fit the attached O-ring (7) (part number:
07000-11009) to valve (8).
(Serial No. 60001-60634)

3) Install extension (13) of gas charge tool

T2 to valve (12). (Serial No. 60635 and
up)

4) Connect gas charge tool T2 to valve (8) of

accumulator (1).
(Serial No. 60001-60634)
5) Connect gas charge tool T2 to extension
(13). (Serial No. 60635 and up)

WA600-6 25
SEN00554-04 30 Testing and adjusting

5. Turn handle (a) of gas charge tool T2 to the 6. If the gas pressure is too high or too low, adjust
right slowly and read the gauge. it referring to "Procedure for charging accumu-
a Since the indicated value varies with the lator with nitrogen gas".
ambient temperature, charge the gas a Each time the pressure is measured, some
pressure referring to the following chart. nitrogen gas is discharged and the pres-
(The unit of each value in the formula is sure lowers. Add nitrogen gas by the loss.
°C.)
Indicated gas pressure = 7. Remove gas charge tool T2 from accumulator
Standard gas pressure x ((273 + t)/ (1) and return the removed parts. See "Proce-
(273 + 20)) dure for charging accumulator with nitrogen
t = Gas temperature at time of charge gas".
(°C)
Reference: t may be assumed to be Procedure for charging accumulator with nitro-
ambient temperature. gen gas
a The accumulator disconnected from the machine
Charging accumulator with nitrogen gas can be charged with nitrogen gas according to
chart the following procedure, too.
1. Stop the engine and depress the brake pedal
Ambient Charging nitrogen gas
temperature repeatedly to lower the oil pressure in the
MPa kg/cm2 Remarks
°C brake circuit to zero.
15 4.34 44.2 a Generally, if the brake pedal is depressed
16 4.35 44.4 30 times, the reaction force to the brake
17 4.37 44.5 pedal is lost and the oil pressure is low-
18 4.38 44.7
ered to zero.
19 4.40 44.8
Standard gas
20 4.41 45.0 2. Remove cap (2) and (3) from accumulator (1).
pressure
21 4.43 45.2 (Serial No. 60001-60634)
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8 3. Remove plug (11) from accumulator (10).
39 4.70 47.9 (Serial No. 60635 and up)
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8

26 WA600-6
30 Testing and adjusting SEN00554-04

4. Connect gas charge tool T2 and nitrogen gas

cylinder (c) to valve of accumulator according
to the following procedure.
1) Turn handle (a) of gas charge tool T2 to
the left until it stops.
2) Turn handle (b) to the left to open.
3) Fit the attached O-ring (7) (part number:
07000-11009) to valve (8).
(Serial No. 60001-60634)

4) Install extension (13) of gas charge tool

T2 to valve (12).
(Serial No. 60635 and up)

5. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}.

6. After nitrogen gas starts flowing out of handle

(b), close handle (b).

7. Turn handle (a) slowly to the right to open

valve (4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged
and gas will leak. Accordingly, operate
5) Connect gas charge tool T2 to valve (8) of handle (a) carefully.
accumulator (1).
(Serial No. 60001-60634) 8. Open the valve of nitrogen gas cylinder (c) fur-
6) Connect gas charge tool T2 to extension ther to charge the accumulator with nitrogen
(13). (Serial No. 60635 and up) gas.
7) Connect gas charge tool T2 and nitrogen
gas cylinder (c). 9. During the work, close the valve of nitrogen
q Use nipple T3 to connect the hose, gas cylinder (c) and check the nitrogen gas
depending on the specification of the pressure in the accumulator.
nitrogen gas cylinder. a Since the indicated value varies with the
ambient temperature, charge the gas
pressure referring to the following chart.
(The unit of each value in the formula is
°C.)

WA600-6 27
SEN00554-04 30 Testing and adjusting

Indicated gas pressure = 11. Remove gas charge tool T2 from valve of
Standard gas pressure x ((273 + t)/ accumulator according to the following proce-
(273 + 20)) dure.
t = Gas temperature at time of charge 1) Turn handle (a) to the left to close the
(°C) valve of the accumulator.
Reference:t may be assumed to be 2) Turn handle (b) to the left to open and dis-
ambient temperature. charge nitrogen gas remaining in gas
Charging accumulator with nitrogen gas charge tool T2 and hoses.
chart
3) Remove gas charge tool T2 from valve (8)
Ambient Charging nitrogen gas of the accumulator.
temperature
°C MPa kg/cm2 Remarks (Serial No. 60001-60634)
15 4.34 44.2 a Remove the O-ring without fail.
16 4.35 44.4 4) Remove gas charge tool T2 and extension
17 4.37 44.5 (13). (Serial No. 60635 and up)
18 4.38 44.7
19 4.40 44.8
Standard gas
20 4.41 45.0
pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8

10. After the accumulator is charged to the stan-

dard pressure, close the valve of nitrogen gas
cylinder (c).
q If the accumulator is charged too much,
turn handle (b) to the left slowly with the
valve of nitrogen gas cylinder (c) closed to
release the nitrogen gas gradually to
adjust pressure.

28 WA600-6
30 Testing and adjusting SEN00554-04

12. Apply soap water to valve (8) or (12) of the 14. Install plug (11) to accumulator (10).
accumulator to check that nitrogen gas is not (Serial No. 60635 and up)
leaking.

15. In a week after charging the accumulator with

nitrogen gas, check that the nitrogen gas pres-
sure has not lowered.
a Check the functions in 5 minutes after
stopping the engine. (If the engine is
stopped for more than 5 minutes, the
brake circuit pressure lowers and the func-
tions cannot be checked accurately.)
1) Stop the machine on a level place and set
the parking brake switch to the "PARK-
ING" position.
2) Start the engine and run it at medium
speed for 1 minute and then stop it.
3) Turn the starting switch to the ON position
13. Install cap (3) and (2) to accumulator (1). and depress the brake pedal repeatedly.
(Serial No. 60001-60634) Count the number of depressing until the
3 Cap(3): 9.8 – 12.7 Nm {1.0 – 1.3 kgm} brake oil pressure caution lamp lights up.
Cap(2): 177 – 245 NM {18–25 kgm} q If number of depressing is less than
5: Accumulator gas pressure may
have lowered.
q If number of depressing is 5 or more:
Accumulator gas pressure is normal.

WA600-6 29
SEN00554-04 30 Testing and adjusting

Testing wheel brake oil pressure 1

a Measuring tools for wheel brake oil pressure
Symbol Part No. Part Name
1 793-520-1821 Nipple
2 793-520-1810 Joint
U
3 385-10178481 Bleeder screw
4 793-520-1831 Gauge assembly

k Even when the brake pedal is not usable

due to troubles on brake-related equip-
ment, highly pressurized oil in the accumu-
lator can burst out. Thus, it is required to
release pressure in the accumulator circuit 2. Drop in wheel brake oil pressure
by pressing the brake pedal 100 times mini- 1) Remove cover (1) and bleeder screw (2).
mum while maintaining the engine at
stopped state.
k Apply the parking brake and put chocks
under the tires securely.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake oil pressure under
the following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature: Within operating range

Measuring
1. Wheel brake oil pressure
1) Remove cover (1) and bleeder screw (2). 2) Install nipple U1, joint U2, bleeder screw
U3 and gauge assembly U4.
3) Connect hose [1] to bleeder screw U3 and
then bleed air from the brake circuit. For
details, see “Bleeding air from wheel brake
circuit”.

2) Install nipple U1, joint U2, bleeder screw

U3 and gauge assembly U4.
3) Connect hose [1] to bleeder screw U3 and
then bleed air from the brake circuit. For
details, see “Bleeding air from wheel brake
circuit”.
4) Start the engine and measure the wheel
brake oil pressure as the left brake pedal
is pressed.

30 WA600-6
30 Testing and adjusting SEN00554-04

4) Start the engine and accumulate pressure

in the accumulator.
5) Stop the engine and press the left brake to
set the oil pressure to 4.9 MPa {50 kg/cm2}.
Maintain this state for 5 minutes and then
measure the pressure drop.
a Use care so that the brake pedal may
not be moved for 5 minutes.
a Remove the measuring instruments
after the measurement and return the
currently removed parts to their origi-
nal position. Then bleed air from the
wheel brake circuit. For details, see
Bleeding air from wheel brake circuit.

WA600-6 31
SEN00554-04 30 Testing and adjusting

Measuring wear of wheel brake

disc 1
Symbol Part No. Part name
Commercially
V Slide calipers
available

k Stop the machine in a level place and put

chocks under the tires.

1. Remove cap (1).

2. Lightly press the brake pedal to the stroke end.

4. After testing, return cap (1).

3 Cap (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
3. While shaft (2) is pushed in, measure projec-
tion (x) (wear volume) from guide (3) using a
slide caliper V.
a Keep pressing the brake pedal during
measurement.
a If the protrusion (x) in the figure is below 0,
replace the disc.
q Wear (y): 5.5 – (x): Max. 5.5 mm

32 WA600-6
30 Testing and adjusting SEN00554-04

Bleeding air from wheel brake

circuit 1
k Stop the machine in a level place and put
chocks under the tires.
a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
following procedure.
a Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).

1. Start the engine to accumulate pressure in the

accumulator and then stop the engine.

2. Connect hose [1] to bleeder screw (1) and

place hose [1] in the oil pan.

3. Press the brake pedal and then loosen bleeder

screw (1) to bleed air.
a Return the brake pedal slowly after tight-
ening bleeder screw (1).
a Use the left brake pedal.

4. Repeat this operation until the oil flowing

through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
screw (1) while the oil is flowing.

5. Bleed air from other brake cylinders, too, using

the same procedure.
a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.
a As accumulated pressure in the accumu-
lator is decreased, start the engine to
accumulate pressure in the accumulator.
Then bleed air using the same procedure
as described above.
a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.

WA600-6 33
SEN00554-04 30 Testing and adjusting

Releasing residual pressure in

brake accumulator circuit 1
k Before disconnecting any of the following
brake accumulator circuits, release resid-
ual pressure in that brake circuits.

q Piping between accumulator charge valve and

brake accumulator
q Piping between accumulator charge valve and
parking brake emergency release valve
q Piping between brake accumulator and brake
valve on both sides

1. Stop the engine.

2. Press the brake pedal at least 100 times to

release the pressure from the brake accumula-
tor circuit.

34 WA600-6
30 Testing and adjusting SEN00554-04

Testing parking brake performance1

a Measurement condition
q Tire inflation pressure: Specified pressure
q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation

Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient with no load in the bucket.

2. Press the brake to stop the machine, set the

directional lever in the N position, and stop the
engine.

3. Turn the parking brake switch ON (to park),

and then release the brake gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Measure the parking brake performance
on an uphill and a downhill.

WA600-6 35
SEN00554-04 30 Testing and adjusting

Measuring parking brake oil 3) Connect nipple W2 and oil pressure

pressure 1 gauge [1] of hydraulic tester W1.
a Use the oil pressure gauge with
a Measuring instruments for parking brake oil capacity 6 MPa {60 kg/cm2}.
pressure
Symbol Part No. Part Name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
W 799-101-5220 Nipple (10 × 1.25)
2
07002-11023 O-ring
3 799-401-3100 Adapter (Size 02)

k Put chocks under the tires.

k Install and remove the measuring instru-
ments after the oil temperature lowers fully.

a Measure the parking brake oil pressure under 4) While running the engine at low idle, mea-
the following condition. sure the parking brake inlet pressure.
k Keep pressing the brake pedal for
q Engine coolant temperature:
Within operating range safety.
q Power train oil temperature: a Measure the oil pressure at turning
Within operating range OFF of the parking brake.
a If the parking brake solenoid valve
1. Parking brake inlet pressure output pressure is normal and parking
1) Remove rear frame left side cover (1). brake inlet pressure is abnormal, fail-
ure on the parking brake emergency
release valve can be suspected.

2) Remove parking brake inlet pressure

pickup plug (10 × 1.25 mm) (2).

5) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.

36 WA600-6
30 Testing and adjusting SEN00554-04

2. Parking brake pilot pressure (Transmis-

sion valve seat pressure)
1) Start the engine and then right-articulate
the steering to be maximum.
2) Disconnect parking brake pilot pressure
hose (3).

6) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.

3. Parking brake solenoid valve output pres-

sure
3) Install adapter W3 and connect parking 1) Remove rear frame right side cover (4).
brake pilot pressure hose (3).
4) Connect nipple [2] and oil pressure gauge
[1] in hydraulic tester W1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.

2) Disconnect parking brake solenoid valve

output pressure hose (5).

5) While running the engine at low idle, mea-

sure the parking brake pilot pressure.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
OFF of the parking brake.

WA600-6 37
SEN00554-04 30 Testing and adjusting

3) Install adapter W3 and connect parking

brake solenoid valve output pressure hose
(5).
4) Connect nipple [2] and oil pressure gauge
[1] in hydraulic tester W1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.

5) While running the engine at low idle, mea-

sure the parking brake solenoid valve out-
put pressure.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
OFF of the parking brake.
a If the parking brake pilot pressure is
normal and parking brake solenoid
valve output pressure is abnormal,
failure on the check valve on the
parking brake solenoid inlet side or
failure on the parking brake solenoid
can be suspected.

6) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.

38 WA600-6
30 Testing and adjusting SEN00554-04

Testing wear of parking brake disc1 4. If allowable depth (a) is above the limit, remove
parking brake disc (4) and measure its thick-
Measuring instruments ness (W), referring to Disassembly and assem-
Symbol Part No. Part Name bly, “Removal and installation of parking brake
Commercially disc assembly”.
X Slide calipers q Service limit thickness (W): Min. 2.97 mm
available
a If the parking brake disc thickness is
below the service limit, replace the disc.
a If the parking brake does not work effectively,
check the parking brake disc for wear accord-
ing to the following procedure.
k Lower the work equipment fully and put
chocks under the tires.
k When checking, stop the engine.

1. Drain the oil from the transmission case.

6 Transmission case: 83 l

2. Remove either of 2 plugs (1).

q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.

3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers X.
q Limit depth (a): Max. 30.5 mm

WA600-6 39
SEN00554-04 30 Testing and adjusting

Method of releasing parking brake 4. After moving to a safe place, restore the
manually 1 machine to the original condition.
2 Mounting bolt (2): Adhesive (LT-2)
a The parking brake is controlled hydraulically. If 3 Mounting bolt (2):
you cannot release the parking brake because of 98 – 123 Nm {10 – 12.5 kgm}
a trouble in the transmission, emergency release 2 Plug (1): Gasket sealant (LG-5)
solenoid valve, etc., you can move the machine
by releasing the parking brake manually. q Refilling with oil (Transmission case)
k Releasing the parking brake manually is a After releasing the parking brake manually, add
means to move the machine from a danger- oil through the oil filler to the specified level.
ous job site to a safe place. Apply this Run the engine to circulate the oil through the
means only in an emergency. system. Then, check the oil level again.
k Lower the work equipment to the ground
and put chocks under the tires to prevent
the machine from moving.
k When applying this means, stop the engine.

1. Drain the oil from the transmission case.

6 Transmission case: 83 l

2. Remove 2 plugs (1). (Right and left)

3. Prepare 2 cage mounting bolts (2) and tighten

them alternately in plug (1) installation position.
a Remove 2 bolts (2) on the diagonal positions.
a Tighten 2 bolts (2) to pull piston (3) and
release the parking brake.
a Tighten the 2 bolts gradually and evenly.
(After they reached the seats, give about
3 +1/4 turns further to them.)

40 WA600-6
30 Testing and adjusting SEN00554-04

Measuring and adjusting work 2. Stroke of work equipment control lever

equipment control lever 1 1) Operate the work equipment control lever
and measure its stroke at each position.
a Measuring and adjusting tools for work equip- a Apply a mark to the lever knob and
ment control lever measure the stroke with scale Y2.
Symbol Part No. Part name a If the stroke is out of the standard
range, check for play of the linkage
1 79A-264-0021 Push-pull scale
and wear of the bushing.
Y Commercially
2 Scale
available

a Measure and test the work equipment control

lever under the following condition.
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature: Within operating range
q Engine speed: Low idle
k Apply the lock bar to the frame.

Measuring
1. Operating effort of work equipment control
lever
1) Install and fix push-pull scale Y1 to the
work equipment control lever.
a Install push-pull scale Y1 to the center
of the knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.

WA600-6 41
SEN00554-04 30 Testing and adjusting

Measuring work equipment oil 2) Connect nipple Z2 and oil pressure gauge
pressure 1 [1] of hydraulic tester Z1.
a Use the oil pressure gauge of 40 MPa
a Measuring instruments for work equipment oil {400 kg/cm2}.
pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Z 799-101-5220 Nipple (10 × 1.25)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge

Measuring
1. Preparation work
1) Lower section (b) to the ground keeping
(a) of bucket 30 – 50 mm off the ground.
2) After stopping the engine, lower bucket
bottom (a) and (b) to the ground operating 3) Start the engine and raise the lift arm up
the work equipment lever. Make sure they about 400 mm. Then measure the oil
are on the ground. pressure when the bucket is tilted back at
a After the bucket is grounded, release high idle.
residual pressure in the piping operating
the work equipment lever 2 – 3 times.

4) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
k After measuring the oil pressure,
2. Measurement of work equipment relief
pressure
release pressure in the circuit and
1) Remove work equipment relief pressure
then remove the oil pressure
pickup plug (10 x 1.25 mm) (1).
gauge and nipple using the same
procedure as 1. Preparations for
work.

42 WA600-6
30 Testing and adjusting SEN00554-04

3. Measuring unload oil pressure 4) Measure the oil pressure when the engine
1) Open pump top cover (2). is run at high idle and all levers are set to
neutral.

2) Remove pump pressure pickup plugs

(M10 × 1.25 mm) (3) and (4) from the work
5) Remove the measurement tool after the
equipment pump.
measurement, and make sure that the
q Pump pressure pickup plug (3): F pump
machine is back to normal condition.
k After measuring the oil pressure,
q Pump pressure pickup plug (4): R pump
release pressure in the circuit and
then remove the oil pressure
gauge and nipple using the same
procedure as 1. Preparations for
work.

4. Measuring LS differential pressure

a Before measuring oil pressure of the LS
control circuit, make sure that the work
equipment relief oil pressure and work
equipment PPC oil pressure are normal.
a LS differential pressure is calculated from
the pump discharge pressure and LS
pressure (actuator negative pressure)
3) Install nipple Z2 and then connect oil pres- being measured at the same time.
sure gauge [1] of hydraulic tester Z1. 1) Open pump top cover (2).
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

WA600-6 43
SEN00554-04 30 Testing and adjusting

2) Remove pump pressure pickup plugs a Use the oil pressure gauge of 40 MPa
(M10 × 1.25) (3) and (4), and LS pressure {400 kg/cm2}.
pickup plugs (M10 × 1.25) (5) and (6) from Since the differential pressure is 2.4
the work equipment pump. MPa {25 kg/cm 2 } at maximum, the
q Pump pressure pickup plug (3): For F same gauge can be used throughout
pump the measurement.
q Pump pressure pickup plug (4): For R
pump
q LS pressure pickup plug (5): For F
pump
q LS pressure pickup plug (6): For R
pump
a Measurement shall be conducted
using the combination of pump pres-
sure pickup plug (3) and LS pressure
pickup plug (5) as well as pump pres-
sure pickup plug (4) and LS pressure
pickup plug (6).

4) Start the engine and raise the lift arm

upward about 400 mm.
5) While running the engine at high idle,
measure the pump pressure and LS pres-
sure (actuator negative pressure) at the
same time under the following conditions.
q When the lift arm lever set to half stroke
a Prevent the lift arm cylinder from turn-
ing to full stroke as long as measure-
ment is continued.
a Calculation of LS differential pressure:
LS differential pressure = Pump dis-
charge pressure – LS pressure

3) Install nipple Z2 and then connect oil pres-

sure gauge [1] of hydraulic tester Z1 or dif-
ferential pressure gauge Z3. 6) Remove the measurement tool after the
a When using the differential pressure measurement, and make sure that the
gauge, connect its high-pressure side machine is back to normal condition.
to the pump pressure side and low- k After measuring the oil pressure,
pressure-side to LS pressure side. release pressure in the circuit and
The differential pressure gauge then remove the oil pressure
requires 12 V power supply. Thus, gauge and nipple using the same
connect a battery. procedure as 1. Preparations for
work.

44 WA600-6
30 Testing and adjusting SEN00554-04

Adjusting
a Adjustment of the unload valve is not available.
1. Adjusting work equipment relief pressure
1) Remove inspection cover (7) on the front
frame.

a After the adjustment, measure the

work equipment relief pressure again
using the procedure for measure-
ment.

2) Loosen locknut (9) of main relief valve (8)

of the work equipment control valve and
turn adjustment screw (10) to adjust the
pressure.
a Adjustment screw:
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
12.55 MPa {128 kg/cm2}
3 Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}

WA600-6 45
SEN00554-04 30 Testing and adjusting

2. Adjusting LS differential pressure

1) Loosen locknut (13) of LS valves (11) and
(12) of the work equipment pump and then
turn adjustment screw (14) to adjust the
pressure.
q LS valve (11): For F pump
q LS valve (12): For R pump
a Adjustment screw:
q Turned to the right, the LS differ-
ential pressure lowers.
q Turned to the left, the LS differ-
ential pressure rises.
a Quantity of adjustment per turn of
adjustment screw:
1.3 MPa {13.3 kg/cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}

a After the adjustment, measure LS dif-

ferential pressure again using the
procedure for measurement.

46 WA600-6
30 Testing and adjusting SEN00554-04

Bleeding air from work equipment 2. Air bleeding from hydraulic cylinder
circuit 1 1) Start the engine and run it at low idle for 5
minutes minimum.
1. Bleeding air from work equipment pump 2) While running the engine at low idle, repeat
(piston pump) raising and lowering of the lift arm 4 – 5
1) Remove pump top cover (1). times.
a Do not operate the piston rod beyond
a position 100 mm in front of the
stroke end to prevent relieving.
3) Implement operation of 2) above with the
engine at high idle. Then operate the pis-
ton rod to the stroke end at low idle to
relieve it.
4) Implement the same operation as 2) and
3) above for the bucket and steering, too.
a When a cylinder is replaced, this
operation should be implemented
before connecting the piston rod.

2) Stop the engine and then loosen air

bleeder (3) of work equipment pump (2) to
connect air bleeding hose [1].

3) As oil free from air started to flow out of air

bleeding hose [1] of work equipment pump
(2), tighten air bleeder.
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.

WA600-6 47
SEN00554-04 30 Testing and adjusting

Releasing residual pressure in 2) Loosen locknut (4) of travel damper pres-

work equipment circuit 1 sure relief plug (3) on work equipment
control valve (2).
1. Releasing residual pressure from the cir- 3) Loosen adjustment plug (5) 1/2 – 1 turn to
cuit between respective hydraulic cylinders release the accumulator pressure.
and control valve
a When disconnecting the pipes between
respective hydraulic cylinders and work
equipment, release the residual pressure
in the circuit according to the following
procedure.
1) Stop the engine.
2) Loosen the oil filler cap gradually to
release the internal pressure of the
hydraulic tank
3) Set the work equipment lock lever to free
position.
4) Turn the starting switch ON.
5) Release residual pressure operating the
work equipment lever.

2. Releasing residual pressure from ECSS

(travel damper) circuit
k When disconnecting the piping of the
travel damper circuit (between the
accumulator for travel damper and
work equipment control valve), release
pressure of the accumulator for the
travel damper according to the follow-
ing procedure.
1) Remove inspection cover (1) on the front
frame.

4) After releasing residual pressure, tighten

plug (5) and locknut (4) securely in this
order.
a Loosen locknut (4) to the maximum
before tightening plug (5). After tight-
ening plug (5), tighten locknut (4).
3 Plug:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Locknut:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}

48 WA600-6
30 Testing and adjusting SEN00554-04

3. Releasing residual pressure in quick cou- 5) After releasing the pressure, tighten plug
pler control system (if equipped) (8) and locknut (9) securely in order.
k When disconnecting the quick coupler a Before tightening plug (8), loosen
control system piping (between the locknut (9) fully. Then, tighten plug (8)
work equipment valve and quick cou- and locknut (9) in order.
pler), release the residual pressure in 3 Plug (8):
the circuit according to the following 19.6 – 27.5 Nm {2.0 – 2.8 kgm}
procedure. 3 Locknut (9):
1) Remove quick coupler piping cover (6) (on 19.6 – 27.5 Nm {2.0 – 2.8 kgm}
the left side).

2) Cover piping block (7) with cloths to pro-

tect it from scattering oil.
3) Loosen locknut (9) of plug (8).
4) Slowly loosen plug (8) by 1/2 – 1 turn to
release the pressure in the circuit.

WA600-6 49
SEN00554-04 30 Testing and adjusting

Moving machine for removing operator cab 1

a Wiring harness ZA1

a Machine moving device for removing oper- 1. Remove the operator cab assembly (1). For
ator cab details, see Disassembly and assembly,
“Removal and installation of operator cab
Symbol Part No. Part Name
assembly”.
1 426-06-32171 Wiring harness
ZA 2 08086-10000 Starting switch
3 421-06-36142 Parking brake switch

a When it is impossible to move a machine into

the maintenance shop without removing the
operator cab or when moving a machine to a
safe place with the operator cab being
removed, using wiring harness ZA1 allows
moving the machine.
a In this case, starting switch ZA2 and parking
brake ZA3 are used in place of the starting
switch and parking brake switch used on the
machine body.
k The harness is prepared only for moving
the machine in to a maintenance shop or
moving it from a work site to a safer place.
It should not be used for any purpose other
than above.
k Lower the work equipment to the ground
fully, apply the parking brake, and put
chocks under the tires so that the machine
will not move.

50 WA600-6
30 Testing and adjusting SEN00554-04

2. Connect B, BR, C and ACC of wiring harness 5. Disconnect axle pedal connector L17.
ZA1 to B, BR, C and ACC terminals of starting
switch ZA2. 6. Connect AXL of wiring harness ZA1 to axle
a Use care so that an improper connection pedal connector L17 (male side).
may not occur.
a Figure shows starting switch ZA2.

7. Connect CL16 of wiring harness ZA1 to con-

nector CL16 (female side) that has been dis-
3. Connect P/B of wiring harness ZA1 to connec- connected as the operator cab has been
tor P/B of parking brake switch ZA3. removed.
a Figure shows parking brake switch ZA3. a Only for steering wheel specification

4. Connect CL12 of wiring harness ZA1 to con- 8. Start the engine and move the machine to a
nector CL12 (male side) that has been discon- maintenance shop or a safe place.
nected as the operator cab has been removed. k Remove the chocks.

9. After removing the machine, restore it to the

original condition.

WA600-6 51
SEN00554-04 30 Testing and adjusting

Testing and adjusting bucket Adjusting

positioner 1 1. Adjusting clearance
1) Adjust switch nut (5) so that clearance (b)
a Engine coolant temperature: between the tip of switch protector (4) and
Within operating range switch (1) and sensing surface (2) may
a Hydraulic oil temperature: Within operating range conform to the standard value. Then fix
them to adjusted positions.
Testing a Standard clearance (b): 0.6 – 1.0 mm
1. Stop the engine and make sure clearance (a) 3 Switch nut:
between bucket-levelness detecting proximity 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
switch (1) and detection bar (3), and between
maximum tilt detecting proximity switch (2) and
detection bar (3) is within the standard value.
a Clearance (a): 3 – 5 mm

2) Using shims and the proximity switch

bracket mounting bolt, adjust clearance
(a) between proximity switch (1) and sens-
ing surface (2) and detection bar (3) to the
standard value. Then fix them to the
adjusted positions.
a Clearance (a): 3 – 5 mm
a Using shims, adjust detection bar (3)
so that clearance (a) may conform to
the standard value along every stroke
of the detection bar.

2. While running the engine at high idle, check

the operating position.
(Calculate the mean repeating above opera-
tion 3 times.)

52 WA600-6
30 Testing and adjusting SEN00554-04

2. Adjusting bucket-levelness detecting prox- 3. Adjusting maximum tilt detecting proxim-

imity switch ity switch
1) Start the engine and raise the bucket. 1) Set height (c) of pin center of the lift arm
2) Activate bucket-levelness detecting prox- end to 1,000 mm from the ground surface.
imity switch (6) while operating the bucket
at engine speed 1,500 rpm.
3) Lower the bucket to the ground.
4) Make sure the bucket angle is set in the
range of 0° – 1° downward to the ground.
Repeat above 3 times and if the angle
does not conform to the above angle,
adjust it according to the following proce-
dure.
5) Loosen 2 mounting bolts of bucket-level-
ness detecting proximity switch bracket
(7) and adjust it by changing the installing
position.
6) Make sure 3 times that the bucket angle is
set in the range of 0° – 1° downward to the
2) Tilt the bucket to the maximum position.
ground.
3) Loosen 2 mounting bolts of maximum tilt
detecting proximity switch bracket (9) and
adjust it by changing installing position.
q Set the distance (d) between the end
of detection bar (3) and the center of
maximum tilt detecting proximity
switch (10) to 50 mm.

WA600-6 53
SEN00554-04 30 Testing and adjusting

Testing and adjusting lift arm

position detecting lever 1
Testing
1. Make sure that clearance (a) between lift arm
angle sensor (1) and detection lever (2) is
within the standard value.
q Clearance (a): 0.5 – 1 mm

Adjusting
a If clearance (a) does not conform to the stan-
dard value, adjust it according to the following
procedure.
1. Loosen bolt (3).

2. Adjust position of detection bar (2) so that

clearance (a) between lift arm angle sensor (1)
and detection lever (2) to the standard value.
Then tighten bolt (3).

54 WA600-6
30 Testing and adjusting SEN00554-04

Checking proximity switch

operation indication lamp 1
Proximity switch operation indication lamp
(red)
The proximity switch is provided with the lamp for
indicating the switch operating status. Use this
lamp for the adjustment.
q A: Operation indication lamp (red)

Relative position of the prox-

Operation indication
Proximity switch imity switch sensing surface Remarks
lamp
and the sensed object
Bucket-levelness
detecting proximity Placed in vicinity ON
switch and maximum tilt Operated as the switch center approaches
detecting proximity Placed apart OFF
switch

WA600-6 55
SEN00554-04 30 Testing and adjusting

Preparations for work on

troubleshooting of electric system1
a When carrying out troubleshooting of an elec-
tric circuit related to the machine monitor,
transmission controller, work equipment con-
troller, engine controller or VHMS controller,
expose the related connectors according to the
following procedure.

1. Machine monitor
1) Pull out switches from the cover (1) and
then disconnect the connectors.
(Steering wheel specification)
q C08 connector: Parking brake switch
q C09 connector: Character display 2) Remove cover (1).
mode selector switch
q C10 connector: Character display
item selector switch
q C11 connector: Load meter mode
selector switch (if equipped)
q C12 connector: Load meter display
selector switch (if equipped)
a Don't try to forcibly disconnect the
connectors inserting your hand
through the bottom of the cover. Such
action can damage the connectors or
switches.

3) Remove 4 bracket mounting bolts (3) of

machine monitor (2) and turn over the
machine.
a Use care in this operation so that the
wiring harness may not be forcibly
pulled.

(AJSS specification)
q C08 connector: Parking brake switch
q C09 connector: Character display
mode selector switch
q C10 connector: Character display
item selector switch
q C11 connector: Load meter mode
selector switch (if equipped)
q C12 connector: Load meter display
selector switch (if equipped)
q C13 connector: Front wiper switch
q C14 connector: Hazard switch
q C15 connector: Lamp switch
q C16 connector: Dimmer switch

56 WA600-6
30 Testing and adjusting SEN00554-04

4) Connect T-adapter used for troubleshoot-

ing to connectors C01, C02, C03, C04,
C05 and C06 of machine monitor (2).

2. Transmission controller
1) Remove tray (4) from the right rear side of
the operator seat.

3. Work equipment controller

1) Remove tray (4) from the right rear side of
the operator seat.

2) Remove rear covers (5) and (6) of the

operator seat.
3) Connect T-adapter used for troubleshoot-
ing to connectors L02, L03 and L04 of
transmission controller (7).
a When it is difficult to remove or install
the connectors, do it after removing
the transmission controller first.
a The connectors are fixed in place with
the screw. Loosen the screw before
disconnecting the connector.
a When the connectors were returned
to the original position, tighten the
screw to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}

WA600-6 57
SEN00554-04 30 Testing and adjusting

2) Remove rear covers (5) and (6) of the 4. Engine controller

operator seat. 1) Open the right side cover.
3) Connect T-adapter used for troubleshoot- 2) Connect T-adapter used for troubleshoot-
ing to connectors L05, L06 and L07 of ing to connectors E18, E19 and ENG of
work equipment controller (8). engine controller (9).
a When it is difficult to remove or install a When it is difficult to remove or install
the connectors, do it after removing the connectors, do it after removing
the work equipment controller first. the work equipment controller first.
a The connectors are fixed in place with a The connectors are fixed in place with
the screw. Loosen the screw before the screw. Loosen the screw before
disconnecting the connector. disconnecting the connector.
a When the connectors were returned a When the connectors were returned
to the original position, tighten the to the original position, tighten the
screw to the specified torque. screw to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm} 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

5. VHMS controller
1) Remove front console cover (10) situated
in the right side of the operator seat.
2) Pull out the VHMS controller fixed to the
back side of cover (10).

58 WA600-6
30 Testing and adjusting SEN00554-04

3) Connect T-adapter used for troubleshoot-

ing to connectors V01, V02, V04, V06 and
V07 of VHMS controller (11).
a When it is difficult to remove or install
the connectors, do it after removing
VHMS controller first.

WA600-6 59
SEN00554-04 30 Testing and adjusting

Procedure for testing diodes 1

a Check an assembled-type diode (8 pins) and
independent diode (2 pins) in the following
manner.
a The conductive directions of the assembled-
type diode are indicated on the surface of the
diode as shown in the following figure.

2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
a The conductive directions of the single diode is (–) to the cathode (N) of diode.
indicated on the surface of the diode as shown 2] Apply the red (+) lead of the tester to
in the following figure. the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ever, wh en the conn ectio n 2 ] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
1. When using digital type circuit tester nal short circuit)
1) Switch the testing mode to diode range q The pointer does not swing with both
and confirm the indicated value. the connections of 1] and 2]: Defec-
a Voltage of the battery inside is dis- tive (Internal breaking of wire)
played with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (-) to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.

60 WA600-6
30 Testing and adjusting SEN00554-04

WA600-6 61
SEN00554-04

WA600-6 Wheel loader

Form No. SEN00554-04

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10

62
 SEN00555-06

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

30 Testing and adjusting 1

Testing and adjusting, Part 3
Machine monitor-based adjustment at replacement, disassembly and assembly, and additional
installation for each sensor and controller .................................................................................................. 2
Special functions of machine monitor (EMMS) ............................................................................................... 5

WA600-6 1
SEN00555-06 30 Testing and adjusting

Machine monitor-based adjustment at replacement, disassembly and

assembly, and additional installation for each sensor and controller 1
1) Setting items that are necessary for replacement and disassembly and assembly as well as addi-
tional installation of sensors and controllers.
a When any of the following devices or parts was replaced, disassembled or assembled, the
machine monitor-based initialization of the sensors and solenoids is required.
a The machine monitor-based adjustment shall be implemented in the ascending order of the
item numbers (starting from (A)).
a Refer to the next page for adjustment items (A – P).

Correspondence chart of device, parts and adjustment item

Devices or optional parts being replaced, disassembled, assembled or added Adjustment item
Machine monitor A, B, C, L, M, (N), P
Transmission main body D, E, F
Transmission controller A, B, D. E, F
Transmission ECMV solenoid D, E, F
Lift arm angle sensor G, L, M, (N)
Work equipment control valve I
Work equipment neutral lock EPC solenoid I
Work equipment electric lever H
Work equipment controller A, B, G, H, I, J
AJSS follow up link J
AJSS frame angle sensor J
AJSS lever angle sensor J
AJSS rotary valve J
Work equipment bucket horizontal proximity switch K
Bucket K, L, M, (N)
Lift arm B, G, K, L, M, (N)
VHMS O
Adding and removing an optional device B

2 WA600-6
30 Testing and adjusting SEN00555-06

Adjustment item chart

Adjustment item Contents of adjustment
A Selection of model
B Selection of an optional device
C Input of serial number
D Adjustment of transmission ECMV current
E Reset of transmission initial learning
F Transmission initial learning
G Adjustment of work equipment controller lift arm angle
H Adjustment of work equipment EPC lever position before detent
I Adjustment of work equipment EPC starting current
J Adjustment of AJSS neutral position
K Adjustment of bucket positioner
L Adjustment of load meter lift arm angle
M No load calibration of load meter
N Loaded calibration of load meter
O Initial setting of VHMS

2) User needs-based adjustment

When user pointed out a trouble or requested solution for a trouble, the following setting change
shall be conducted by the machine monitor.

a Refer to the next page for adjustment items (Q – ZE).

Correspondence chart of remarks or request and adjustment item
Contents of user's remarks or request Adjustment item
Want to change the display unit of the speedometer. Q
Want to use the short ton for the load meter weight display unit. R
Want to turn off display of the economy lamp. S
Want to limit the machine maximum speed. T, U
Want to suppress hunting. V
Want to change the gearshift travel speed in the auto shift. V
Fine control is not available in the lift arm raise/lower operation or the response in this oper-
W
ation is poor.
Fine control is not available in the bucket tilt/dump operation or the shock damp effort is
X
weak.
Large shocks result at stopping the lift arm raise/lower or a substantial overrun occurs at
Y
stopping.
Large shocks result from changeover of AJSS or follow to the lever is slow. Z, ZA
Matching at loading to dump truck is poor. ZB
Travel speed indication is too fast/slow. ZC
Want to turn off the character display-based travel speed/engine speed indication. ZD
Want the power mode to turn on as the starting switch is turned on. (Power mode priority) ZE
Want to decrease fuel consumption during high-speed travel (F4 lockup). U

WA600-6 3
SEN00555-06 30 Testing and adjusting

Adjustment item chart

Adjustment item Contents of adjustment Description No. (*)
Q Optional device selecting: Selection of speed unit 11
R Optional device selecting: Selection of weight unit 11
S Optional device selecting: Selection economy lamp display 11
T Optional device selecting: Selection of no 4th position 11
U Adjustment of sensor: Adjustment of maximum travel speed 7-20
V Adjustment of sensor: Adjustment of L mode shift point 7-3
W Adjustment of sensor: Change of lift arm lever pattern 7-13
X Adjustment of sensor: Change of bucket lever pattern 7-14
Y Adjustment of sensor: Adjustment of lift arm lower stop modulation 7-15
Z Adjustment of sensor: Change of AJSS lever pattern 7-11
ZA Adjustment of sensor: Change of AJSS EPC current 7-12
ZB Adjustment of sensor: Change of pump cut-off pressure 7-16
ZC Optional device selecting: Correction of travel peed (change of tire size) 11
ZD Optional device selecting: Change of travel peed/engine speed display 11
ZE Optional setting and change of power mode priority 11

*: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”

a Change of the display unit of the speed meter as well as the weight is not available when the specifica-
tion is prepared for a country where SI unit is employed.

4 WA600-6
30 Testing and adjusting SEN00555-06

Special functions of machine monitor (EMMS) 1

Normal functions and special functions of machine monitor
The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
3) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
4) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.

Operator mode Service mode

1 Service meter/clock display function (*2) 2 Electrical system fault history display function
2 Load meter function (*1) 3 Mechanical system fault history display function
3 Odometer display function 4 Real-time monitoring function
4 Maintenance monitoring function 5 Engine reduced-cylinder function
5 Telephone number input function 6 No injection cranking function
6 Language selection function 7 Adjustment function
7 Monitor brightness adjustment function ⇔ 8 Maintenance monitoring function
8 Time adjustment function (*2) 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Manual snapshot function
function
Travel speed/engine speed display/non-display
10 11 Optional device selecting function
selecting function (*2)
11 Action code display function 12 Machine serial number input function
12 Failure code display function 13 Model selection function
14 Initialize function

*1: This display is not available when the load meter function is turned off through option selection of service mode.
*2: This display is not available when the travel speed/engine speed display selecting function is turned off through
option selection of service mode.

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SEN00555-06 30 Testing and adjusting

Functions and flow of the service mode

6 WA600-6
30 Testing and adjusting SEN00555-06

WA600-6 7
SEN00555-06 30 Testing and adjusting

8 WA600-6
30 Testing and adjusting SEN00555-06

Operator mode 3. Odometer display function

a Following overviews the operator mode. Press [U] switch from the ordinary service
a See the section "Structure, function and main- meter and clock display screen to display the
tenance standard" or the Operation and main- odometer.
tenance manual for details of the operator The load meter specifications displays the
mode. odometer as [<] switch is pressed succeeding
to display of the load meter function.
1. Service meter/clock display function a For details, see the "Other functions of
Turning on the starting switch displays the ser- machine monitor" of the "Operation" sec-
vice meter in the upper space and the clock in tion in the Operation and maintenance
the lower space. manual.

4. Maintenance monitoring function

1) Filter, oil replacement time display (auto-
2. Load meter function (if equipped)
matic display)
Press [U] switch from the ordinary service
As the filter or oil replacement time draws
meter and clock display screen to display the
close, the machine monitor automatically
load meter function.
displays its information to alert operator's
a For more information, see the section
attention.
Structure, function and maintenance stan-
2) Resetting replacement time (selection
dard, "Load meter function", and Attach-
menu)
ment options, "Using load meter" of the
As maintenance operation for a filter or oil
Operation and maintenance manual.
is completed, the machine monitor allows
resetting the time interval through the
switch operation.

WA600-6 9
SEN00555-06 30 Testing and adjusting

5. Telephone number input function 7. Monitor brightness adjustment function

Telephone numbers are entered through the Brightness of the machine monitor is adjust-
switch operation. And modification or cancella- able in seven levels through the switch opera-
tion of the phone numbers in the machine tion.
monitor is also available through the switch a Adjustment of brightness is available in
operation. two approaches – adjustment of the moni-
a When action code [E03] is displayed, a tor alone and separate adjustment of the
phone number is displayed along with monitor and liquid crystal.
[CALL]. a For details, see the "Other functions of
a For details, see the "Other functions of machine monitor" of the Operation section
machine monitor" of the Operation section in the Operation and maintenance man-
in the Operation and maintenance man- ual.
ual.

6. Language selection function

Switch operation allows selecting a display lan-
guage of the machine monitor.
a Functions of the service mode are con-
stantly displayed in English since they are
exempted from the display selection func-
tion.
a A desired language is selectable from
English, Japanese, German, French, Ital-
ian, Spanish and Swedish.
a For details, see the "Other functions of
machine monitor" of the Operation section
in the Operation and maintenance man- 8. Time adjustment function
ual. The time indicated by the clock of the machine
monitor is adjustable.
a For details, see the "Other functions of
machine monitor" of the Operation section
in the Operation and maintenance man-
ual.

10 WA600-6
30 Testing and adjusting SEN00555-06

9. Travel speed/engine speed display select- 11. Action code display function
ing function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to turn on or off the dis- appropriate actions.
play of the travel speed and engine speed. a The figure below shows an example of the
a For details, see the "Other functions of screen on which action code [E03] and
machine monitor" of the Operation section [CALL + Telephone number] are alter-
in the Operation and maintenance man- nately displayed.
ual. a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.

10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
a For details, see the "Other functions of
machine monitor" of the Operation section
in the Operation and maintenance man-
ual.

WA600-6 11
SEN00555-06 30 Testing and adjusting

a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.

12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- TM: Transmission controller
tem and the mechanical system and are WRK: Work equipment controller
recorded as fault history. (For details, see ENG: Engine controller
"Service mode".) VHMS: VHMS controller
a When two or more failures are involved, C: The system where failure occurred
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 3 seconds,
the action code display screen is automat-
ically displayed.

a For details of a displayed failure code, see

"Failure code list".
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.

12 WA600-6
30 Testing and adjusting SEN00555-06

Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
When using Service mode, carry out the fol- mode).
lowing special operation to switch the screen When the cursor is at a location other
display. than the leftmost position, pressing
1-1. Checking screen display the switch returns the cursor to the
Make sure that the machine monitor is set to leftmost position.
the operator mode and any of "Service meter", If any switch operation is not done for
"Action code" or "Failure code" is displayed on 60 seconds or more from ID input
the screen. screen, the normal screen is automat-
1-2. Displaying ID input initial screen ically turned on.
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.

1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.

1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit,
1-5. Selecting service mode menu
move to the highest-order digit using [t]
a Pressing [<] and [>] switches from the
switch to repeat the procedure from the
menu screen displays Service mode
first. In this case, values that had been
menus endlessly in the following order.
entered remain as they are until modified.
a The menus are displayed in the field indi-
When the cursor is at the highest-order
cated with [*] mark.
digit, it can move to the higher layer using
[1] ELECTRIC FAULT: Electrical system
[t] switch.(*1).
fault history display function
[2] MACHINE FAULT: Mechanical sys-
tem fault history display function

WA600-6 13
SEN00555-06 30 Testing and adjusting

[3] REAL-TIME MONITOR: Real-time 2. Electrical system fault history display func-
monitoring function tion (ELECTRIC FAULT)
[4] CYLINDER CUT-OUT: Engine The machine monitor records the past failures
reduced-cylinder function in the electrical system as the failure codes.
[5] NO INJECTION: No injection crank- The failure codes are displayed from the fol-
ing function lowing operations.
[6] TUNING: Adjustment function 2-1. Selecting the menu
[7] MAINTENANCE MONITOR: Mainte- Select the ELECTRIC FAULT from the menu
nance monitoring function screen of Service mode.
[8] OPERATION INFO: Operating infor- a [**] field displays total number of the fault
mation display function history currently recorded (up to 20
[9] SNAPSHOT: Manual snapshot cases).
[10] OPTIONAL SELECT: Optional device
selecting function
[11] MACHINE No. SET: Machine serial
number input function
[12] MACHINE WA6**: Model selection
function
[13] INITIALIZE: Initialize function (Func-
tion specialized for plant)
1-6. Completion of mode and function
Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the menu screen.
2-2. Displaying fault history
a Note, however, that [t] switch functions
Press [U] button while the menu is selected to
as an execution key on [YES/NO] screen.
display the recorded fault history.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces-
sary).
2) When ending an operation completely:
Turn the starting switch off from the cur-
rent state.

2-3. Displayed fault history

The electric system fault history display func-
tion displays the following information.
A: Record number
B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.

14 WA600-6
30 Testing and adjusting SEN00555-06

a For details of a displayed failure code, see 2-6. Deleting all fault history
"Failure code list" of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.

2) Press [U] switch to display the ALL

CLEAR screen.
3) Select "YES" or "NO" using [<] or [>]
switch.
a The selected cursor will start flashing. If
"YES" is selected and [ t ] sw it ch is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault "NO" is selected and t switch is pressed,
history is on the screen displays another set of deletion is cancelled and the "Mainte-
recorded fault history. nance interval change item" screen is
2-5. Deleting individual fault history restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select "YES" or "NO" using [<] or [>] ure is not deletable.
switch.
a The selected cursor will start flashing. If
"YES" is selected and [ t ] switch is
pressed, the information will be deleted. If
"NO" is selected and [t] switch is
pressed, deletion is cancelled and the
"Maintenance interval change item"
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail-
ure is not deletable.

WA600-6 15
SEN00555-06 30 Testing and adjusting

3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Elapsed time 1 (Service meter at first
history currently recorded. occurrence)
E: Elapsed time 2 (Service meter at last
occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
"Failure code list" of the failure code dis-
play function.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.
3-2. Displaying fault history
Press [U] switch while the menu is selected to
display the recorded fault history.

3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.

16 WA600-6
30 Testing and adjusting SEN00555-06

4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] TRANSMISSION: Transmission con-
(for each controller) troller system
q 2 items simultaneous display [3] BOOM: Work equipment controller
(code input) system
4-1. Selecting the menu [4] ENGINE: Engine controller system
Select REAL-TIME MONITORING from the [5] VHMS: VHMS controller system
menu screen of Service mode. [6] 2 ITEMS: 2 items display

4-2. Displaying sub menu 4-4. Setting the 1 item individual monitoring
Press [U] switch while the menu is selected to 1) Select the target controller system of mon-
display the sub menu initial screen. itoring from the sub menu screen.

2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.

WA600-6 17
SEN00555-06 30 Testing and adjusting

3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.

1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
4) Display data for 1 item individual monitor- a The cursor moves to the 2nd position.
ing 3] Set the value in the same order and
The 1 item individual monitoring screen then press [U] switch.
displays the following information. a When you have entered a wrong
A: Item display value to a position except the highest-
B: Monitoring codes (5 digits) order digit, the cursor can move to the
1: Monitoring data highest-order digit using [ t ] switch
(including the unit used) and repeat the procedure from the
a See the "Monitoring code list" for first. In this case, values that had
details. been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.

18 WA600-6
30 Testing and adjusting SEN00555-06

3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.

4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the "Monitoring code list" for details.

WA600-6 19
SEN00555-06 30 Testing and adjusting

Monitoring code list

MON [Mechanical monitor system]
Monitoring Monitoring items Displayed items Data display range Unit
No.
codes (*1) (*2) (*3) (*4)
1 20200 Monitor ROM part number VERSION Arabic numerals Status display
2 20221 Application version VERSION (APP) Arabic numerals Status display
3 20222 Data version VERSION (DATA) Arabic numerals Status display
4 01001 Engine speed ENG SPEED 0 – 3000 rpm
5 40000 Travel speed SPEED 0 – 50 km/h
6 04202 Fuel level FUEL SENSOR 0 – 100 %
7 04207 Fuel level sensor voltage FUEL SENSOR 0.00 – 5.00 V
8 04103 Engine coolant temperature COOLANT TEMP –40 – 210 °C
9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131 °C
Torque converter oil temperature
10 40101 TC OIL TEMP 0.00 – 5.00 V
sensor voltage
11 04401 Hydraulic oil temperature HYD TEMP 24 – 131 °C
Hydraulic oil temperature sensor
12 04404 HYD TEMP 0.00 – 5.00 V
voltage
13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131 °C
Rear brake oil temperature sensor
14 30205 R BRAKE OIL 0.00 – 5.00 V
voltage
15 04302 Charge level ALTERNATOR R 0.00 – 30.00 V
16 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00 V
Battery electrolyte level A sensor
17 40300 BATTERY A 0.00 – 30.00 V
voltage
Battery electrolyte level B sensor
18 40301 BATTERY B 0.00 – 30.00 V
voltage
19 06001 Lift arm angle BOOM ANG –90 – 90 Degree (°)
20 06003 Lift arm angle sensor voltage BOOM ANG 0.00 – 5.00 V
21 40400 Lift arm bottom pressure BOOM BTM PRESS 0.00 – 50.00 MPa
Lift arm bottom pressure sensor volt-
22 40402 BOOM BTM PRESS 0.00 – 5.00 V
age
23 40500 Lift arm head pressure BOOM HED PRESS 0.00 – 50.00 MPa
Lift arm head pressure sensor volt-
24 40501 BOOM HED PRESS 0.00 – 5.00 V
age
25 40600 Calibration pressure CAL PRESS 0.00 – 50.00 MPa
26 40800 Load meter calculated weight MES LOAD 0.00 – 50.00 ton
27 30802 Rotary switch setting state SW1, SW2, SW3 F, F, F Status display
28 30904 DIP switch setting state SW5-1, SW5-2 ON/OFF, ON/OFF Status display
29 30905 DIP switch setting state SW5-3, SW5-4 ON/OFF, ON/OFF Status display
30 30906 DIP switch setting state SW6-1, SW6-2 ON/OFF, ON/OFF Status display
31 30907 DIP switch setting state SW6-3, SW6-4 ON/OFF, ON/OFF Status display
32 40900 Input signal D_IN_0-7 D-IN--0------7 See attached table Status display
33 40901 Input signal D_IN_8-15 D-IN--8------15 See attached table Status display
34 40902 Input signal D_IN_16-23 D-IN--16------23 See attached table Status display
35 40903 Input signal D_IN_24-31 D-IN--24------31 See attached table Status display
36 40904 Input signal D_IN_32-39 D-IN--32------39 See attached table Status display
37 40952 Output signal D_OUT_0-3 D-OUT--0--3 See attached table Status display

20 WA600-6
30 Testing and adjusting SEN00555-06

*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
a Note that the following monitoring items display information involving two to three systems at a time.
No.27: Rotary switch setting state (displays threes switches at a time)
No.28: DIP switch setting state (displays two switches at a time)
No.29: DIP switch setting state (displays two switches at a time)
No.30: DIP switch setting state (displays two switches at a time)
No.31: DIP switch setting state (displays two switches at a time)

WA600-6 21
SEN00555-06 30 Testing and adjusting

MON [Mechanical monitor system]

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
D-IN-0 Head lamp high beam Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 Starting motor BR Starting switch = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting switch = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A
1 40900 D-IN-4 (Applicable to a machine equipped Tank empty or failed = ON (24 V)/OFF (OPEN)
with optional auto grease)
Auto grease B
D-IN-5 (Applicable to a machine equipped In operation or failed = ON (24 V)/OFF (OPEN)
with optional auto grease)
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
Load meter mode selector switch (A/B)
D-IN-10 (Applicable to a machine equipped Pressing of switch = ON (24 V)/OFF (OPEN)
with optional load meter)
Load meter mode selector switch (+/–)
D-IN-11 (Applicable to a machine equipped Pressing of switch = ON (24 V)/OFF (OPEN)
2 40901 with optional load meter)
Lighting of turn signal right lamp = ON (GND)/
D-IN-12 Turn signal right
OFF (OPEN)
Lighting of turn signal left lamp = ON (GND)/
D-IN-13 Turn signal left
OFF (OPEN)
D-IN-14 U switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —
3 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)
D-IN-21 — —
Parking brake emergency release
D-IN-22 Pressing of switch = ON (24 V)/OFF (OPEN)
switch
D-IN-23 Load meter display selector switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-24 Transmission filter clogging No clogging = ON (GND)/OFF (OPEN)
D-IN-25 — —
D-IN-26 Parking brake Parking brake operation = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)

4 40903 D-IN-28 — —
D-IN-29 Engine oil level Low oil level = ON (GND)/OFF (OPEN)
Operation of emergency steering
Operation of emergency steering = ON (GND)/
D-IN-30 (Applicable to a machine equipped
OFF (OPEN)
with the optional emergency steering)
D-IN-31 — —

22 WA600-6
30 Testing and adjusting SEN00555-06

MON [Mechanical monitor system]

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
Load meter subtotal switch
D-IN-32 (Applicable to a machine equipped Pressing of switch = ON (GND)/OFF (OPEN)
with optional load meter)
Load meter cancel switch
D-IN-33 (Applicable to a machine equipped Pressing of switch = ON (GND)/OFF (OPEN)
with optional load meter)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
5 40904
Working fuel consumption display
D-IN-35 Pressing of switch = ON (GND)/OFF (OPEN)
switch
D-IN-36 Service 2 mode ON = ON(GND)/OFF(OPEN)
D-IN-37 [>] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-39 — —
D-OUT-0 Alarm buzzer Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952
D-OUT-2 — —
D-OUT-3 — —

WA600-6 23
SEN00555-06 30 Testing and adjusting

TM [Transmission controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Transmission controller ROM part num- Status
1 20201 VERSION Arabic numerals
ber display
Status
2 20223 Application version VERSION APP 20223
display
Status
3 20224 Data version VERSION DATA 20224
display
0: Power mode Status
4 41600 Selection of engine mode ENGINE MODE
2: Economy mode display
Fan pump EPC current value (Com-
5 41400 FAN EPC DIR 0 – 1000 mA
mand)
FAN REVERSE 0: OFF Status
6 93400 Fan reverse switch input
SW 1: ON (CLOSE) display
7 41501 Torque converter inlet oil temperature T/C IN OIL TEMP –30 – 100°C °C
Torque converter inlet oil temperature
8 41502 T/C IN OIL TEMP 0.00 – 5.00 V
sensor voltage
9 93500 Torque converter input shaft speed T/C SPEED:IN 0 – 32767 rpm
T/C
10 93501 Torque converter output shaft torque 0 – 400000 Nm
TORQUE:OUT
11 31200 Transmission output shaft speed T/M SPEED IN — rpm Not used
12 31400 Transmission output shaft speed T/M SPEED:OUT 0 – 32767 rpm
T/M
13 31404 Transmission output shaft speed 2 0 – 32767 rpm
SPEED:OUT2
TC SPEED
14 41203 Torque converter speed ratio 0 – 200 %
RATIO
15 41201 Transmission cut-off operation setting T/M CUT SET 0.00 – 50.00 MPa
Transmission cut-off (left brake) pres-
16 41202 T/M CUT OFF P 0.00 – 50.00 MPa
sure
Transmission cut-off (left brake) pres-
17 93700 T/M CUT OFF P 0.00 – 5.00 V
sure sensor voltage
18 93600 Transmission oil temperature T/M OIL TEMP 0 – 150 °C
Transmission oil temperature sensor
19 93601 T/M OIL TEMP 0.00 – 5.00 V
input voltage
20 92400 Modulation clutch oil pressure MOD/C PRESS 0.00 – 50.00 MPa
Modulation clutch oil pressure input volt-
21 92401 MOD/C PRESS 0.00 – 5.00 V
age
22 92500 Modulation clutch calorific value MOD/C Q 0 – 25.5 100J/cm2
0.1
23 92501 Modulation clutch calorific rate MOD/C q 0 – 2.55
kW/cm2
THROTTLE
24 95500 Throttle correction command output –100 – 100 %
MOD
THROT LIMIT
25 95501 Throttle opening upper limit output 0 – 100.0 %
UP
26 95400 Throttle opening lower limit output THROT LIMIT LO 0 – 100.0 %
RPM idle-up/down selector switch 0: OFF Status
27 44200 THROT LOCK A
(idle-up) 1: ON display
RPM idle-up/down selector switch 0: OFF Status
28 44201 THROT LOCK B
(idle-down) 1: ON display

24 WA600-6
30 Testing and adjusting SEN00555-06

TM [Transmission controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
0: Accelerator
pedal open
1: Accelerator
pedal partial
pressing (open
side)
THROTTLE Status
29 93801 Accelerator mode 2: Accelerator
MODE display
pedal partial
pressing (press-
ing side)
3: Accelerator
pedal full press-
ing
30 94000 Traction setting input value TRACTION DIAL 0 – 100 %
31 94001 Traction setting input voltage TRACTION DIAL 0.00 – 5.00 V
0: OFF Status
32 95000 Lockup selector switch input signal LOCK UP SW
1: ON display
33 31602 1st ECMV current value (Command) ECMV 1 DIR 0 – 1000 mA
34 31603 2nd ECMV current value (Command) ECMV 2 DIR 0 – 1000 mA
35 31604 3rd ECMV current value (Command) ECMV 3 DIR 0 – 1000 mA
36 31605 4th ECMV current value (Command) ECMV 4 DIR 0 – 1000 mA
F (forward) ECMV current value
37 31608 ECMV F DIR 0 – 1000 mA
(Command)
Lockup clutch ECMV current value
38 31609 ECMV LU DIR 0 – 10000 mA
(Command)
Modulation clutch ECMV current value ECMV MOD/C
39 31640 0 – 1000 mA
(Command) DIR
R (reverse) ECMV current value
40 31606 ECMV R DIR 0 – 1000 mA
(Command)
ECSS (travel damper) solenoid valve
41 93300 ECSS V DIR 0 – 1000 mA
current value (Command)
0 – 2.55
42 41802 1st fill time FILL TIME 1 (When fill is not sec
provided: 0)
0 – 2.55
43 41803 2nd fill time FILL TIME 2 (When fill is not sec
provided: 0)
0 – 2.55
44 41804 3rd fill time FILL TIME 3 (When fill is not sec
provided: 0)
0 – 2.55
45 41805 4th fill time FILL TIME 4 (When fill is not sec
provided: 0)
0 – 2.55
46 41808 F (forward) fill time FILL TIME F (When fill is not sec
provided: 0)
0 – 2.55
47 41806 R (reverse) fill time FILL TIME R (When fill is not sec
provided: 0)
Status
48 40905 Input signal D_IN_0-7 D-IN--0------7 See attached table
display

WA600-6 25
SEN00555-06 30 Testing and adjusting

TM [Transmission controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
49 40906 Input signal D_IN_8-15 D-IN--8-----15 See attached table
display
Status
50 40907 Input signal D_IN_16-23 D-IN-16-----23 See attached table
display
Status
51 40908 Input signal D_IN_24-31 D-IN-24-----31 See attached table
display
Status
52 40942 Input signal D_IN_32-39 D-IN-32-----39 See attached table
display
Status
53 40949 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
display
Status
54 40950 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table Not used
display
Status
55 40951 Output signal D_OUT_16-23 D-OUT-16----23 See attached table Not used
display
Status
56 94100 Clutch trigger initial learning flag TRIG FR1234 0/1(ON/OFF)
display

*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.

26 WA600-6
30 Testing and adjusting SEN00555-06

TM [Transmission controller system]

Input/
Monitoring
No. Output Displayed items Description of ON/OFF switch
code
signal
Engine mode selector switch (Power
D-IN-0 Engine mode selector switch
mode) = ON (GND)/OFF (OPEN)
D-IN-1 — —
D-IN-2 — —
Air conditioner compressor operation =
D-IN-3 Air conditioner compressor operation
1 40905 ON (GND)/OFF (OPEN)
D-IN-4 Shift mode L Shift mode L = ON (GND)/OFF (OPEN)
D-IN-5 Shift mode H Shift mode H = ON (GND)/OFF (OPEN)
Modulation clutch direct connection sig-
D-IN-6 Modulation clutch direct connection signal
nal present = ON (24 V)/OFF (OPEN)
D-IN-7 C terminal signal Starting switch = ON (24 V)/OFF (OPEN)
D-IN-8 — —
D-IN-9 — —
Pressing of switch = ON (GND)/OFF
D-IN-10 Kick-down switch
(OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-11 Shift hold switch
(OPEN)
2 40906 D-IN-12 — —
Pressing of switch = ON (24 V)/OFF
D-IN-13 RPM set ON/OFF switch
(OPEN)
Pressing of switch = ON (GND)/OFF
D-IN-14 RPM set idle-up/down switch selector switch
(OPEN)
Pressing right brake pedal = ON (GND)/
D-IN-15 Throttle lock release right brake pedal switch
OFF (OPEN)

WA600-6 27
SEN00555-06 30 Testing and adjusting

TM [Transmission controller system]

Input/
Monitoring
No. Output Displayed items Description of ON/OFF switch
code
signal
• Shift-up switch
• Joystick steering shift-up
= ON (24 V)/OFF (OPEN)
(Normally open)
(Joystick steering specification)
D-IN-16 (Joystick steering specification)
• Shift lever 1st
• Shift range 1st
= ON (24 V)/OFF (OPEN)
(Steering wheel specification)
(Steering wheel specification)
• Shift-up switch
• Joy stick steering shift-up
= ON (OPEN)/OFF (24 V)
(Normally closed)
(Joystick steering specification)
D-IN-17 (Joystick steering specification)
• Shift lever 2nd
• Shift range 2nd
=ON (24 V)/OFF (OPEN)
(Steering wheel specification)
(Steering wheel specification)
• Shift-up switch
• Joy stick steering shift-up
= ON (OPEN)/OFF (24 V)
(Normally open)
(Joystick steering specification)
D-IN-18 (Joystick steering specification)
• Shift lever 3rd
• Shift range 3rd
= ON (24 V)/OFF (OPEN)
(Steering wheel specification)
3 40907 (Steering wheel specification)
• Shift-up switch
• Joy stick steering shift-up
= ON (OPEN)/OFF (24 V)
(Normally closed)
(Joystick steering specification)
D-IN-19 (Joystick steering specification)
• Shift lever 4th
• Shift range 4th
= ON (24 V)/OFF (OPEN)
(Steering wheel specification)
(Steering wheel specification)
Directional lever F (forward) or directional
Directional lever F (forward) or directional
D-IN-20 selector switch F (forward) = ON (24 V)/
selector switch F (forward)
OFF (OPEN)
Directional lever N (neutral) or directional
Directional lever N (neutral) or directional
D-IN-21 selector switch N (neutral)
selector switch N (Neutral).
= ON (24 V)/OFF (OPEN)
Directional lever R (reverse) or directional
Directional lever R (reverse) or directional
D-IN-22 selector switch R (reverse) = ON (24 V)/
selector switch R (reverse)
OFF (OPEN)
D-IN-23 Parking brake signal Parking brake = ON (24 V)/OFF (OPEN)
D-IN-24 — —
ECMV fill switch F (forward) = ON (GND)/
D-IN-25 F ECMV fill switch F (forward)
OFF (OPEN)
ECMV fill switch R (reverse)
D-IN-26 F ECMV fill switch R (reverse)
= ON (GND)/OFF (OPEN)
ECMV fill switch 1st
D-IN-27 ECMV fill switch 1st
= ON (GND)/OFF (OPEN)
4 40908 ECMV fill switch 2nd
D-IN-28 ECMV fill switch 2nd
= ON (GND)/OFF (OPEN)
ECMV fill switch 3rd
D-IN-29 ECMV fill switch 3rd
= ON (GND)/OFF (OPEN)
ECMV fill switch 4th
D-IN-30 ECMV fill switch 4th
= ON (GND)/OFF (OPEN)
Steering lever lock detection pressure switch Steering lever lock pressure switch
D-IN-31
(Joystick steering specification) = ON (GND)/OFF (OPEN)

28 WA600-6
30 Testing and adjusting SEN00555-06

TM [Transmission controller system]

Input/
Monitoring
No. Output Displayed items Description of ON/OFF switch
code
signal
Brake pressure switch
D-IN-32 Brake pressure switch
= ON (5V)/OFF (OPEN)
D-IN-33 — —
D-IN-34 — —
5 40942 D-IN-35 — —
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-0 Modulation clutch cut-off release solenoid Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 Fan reverse solenoid Output ON = (24 V)/OFF (OPEN)
6 40949
D-OUT-4 Fan neutral solenoid (option) Output ON = (24 V)/OFF (OPEN)
D-OUT-5 Low temperature bypass solenoid Output ON = (24 V)/OFF (OPEN)
D-OUT-6 — —
D-OUT-7 — —

WA600-6 29
SEN00555-06 30 Testing and adjusting

WRK [Work equipment controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
XXXXRYYY [3rd –
10th digits of part
number are dis-
Work equipment controller software ver- played]
1 20202 VERSION —
sion Example: When the
number is 7831-46-
R110 o
"3146R110"
Status
2 20225 Application version VERSION APP Arabic numerals
display
Status
3 20226 Data version VERSION DATA Arabic numerals
display
4 94700 Loader pump pressure PUMP PRESS 0.00 – 50.00 MPa
5 94701 Loader pump pressure sensor voltage PUMP PRESS 0.00 – 5.00 V
6 94500 Loader pump EPC current (Command) PUMP EPC DIR 0 – 1000 mA
7 94600 Pump delivery flow rate PUMP FLOW 0 – 264 cc/r
Degree
8 06002 Lift arm angle BOOM ANG –180.0 – +180.0
(°)
9 06005 Lift arm angle sensor voltage BOOM ANG 0.00 – 5.00 V
Degree
10 94400 Frame angle FRAME ANGLE –180.0 – +180.0
(°)
0 – 256000
11 42100 Lift arm lever operation frequency BOOM LVR (On thousand-time —
basis)
12 42000 Lever potentiometer voltage lift arm 1 BOOM POT1 0.00 – 5.00 V
13 42001 Lever potentiometer voltage lift arm 2 BOOM POT2 0.00 – 5.00 V
0 – 256000
14 42101 Bucket lever operation frequency BUCKET LVR (In a thousand of —
times)
15 42002 Lever potentiometer voltage bucket 1 BUCKET LVR 0.00 – 5.00 V
16 42003 Lever potentiometer voltage bucket 2 BUCKET POT2 0.00 – 5.00 V
17 41900 Lift arm raise EPC current (Command) RAISE EPC DIR 0 – 1000 mA
LOWER EPC
18 41901 Lift arm lower EPC current (Command) 0 – 1000 mA
DIR
19 41902 Bucket tilt EPC current (Command) TILT EPC DIR 0 – 1000 mA
20 41903 Bucket dump EPC current (Command) DUMP EPC DIR 0 – 1000 mA
21 41908 AJSS EPC current (Command) AJSS EPC DIR 0 – 1000 mA
22 41904 AJSS right EPC current (Command) J/S EPC DIR RH 0 – 1000 1mA
23 41905 AJSS left EPC current (Command) J/S EPC DIR LH 0 – 1000 1mA
24 42004 Lever potentiometer voltage AJSS 1 J/S POT1 0.00 – 5.00 V
25 42005 Lever potentiometer voltage AJSS 2 J/S POT2 0.00 – 5.00 V
3-spool valve 1, ECMV and current
26 41906 3RD EPC1 DIR 0 – 1000 1mA
value (Command)
3-spool valve 2, ECMV and current
27 41907 3RD EPC2 DIR 0 – 1000 1mA
value (Command)
0 – 256000
28 42102 3rd lever operation frequency 3RD LVR (In a thousand of —
times)

30 WA600-6
30 Testing and adjusting SEN00555-06

WRK [Work equipment controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Lever potentiometer voltage 3-spool
29 42006 3RD POT1 0.00 – 5.00 0.01V
valve 1
Lever potentiometer voltage 3-spool
30 42007 3RD POT2 0.00 – 5.00 0.01V
valve 2
Degree
31 94300 AJSS lever operation angle AJSS LEVER –180.0 – +180.0
(°)
32 94301 AJSS lever potentiometer voltage AJSS LEVER 0.00 – 5.00 V
33 94401 AJSS frame potentiometer voltage FRAME ANGLE 0.00 – 5.00 V
S/T DEFLEC- Degree
34 94800 AJSS steering deviation angle –180.0 – +180.0
TION (°)
Status
35 94900 Digging-in-progress flag WORK FLAG ON/OFF
display
Status
36 40910 Input signal D_IN_0-7 D-IN--0------7 See attached table
display
Status
37 40911 Input signal D_IN_8-15 D-IN--8-----15 See attached table
display
Status
38 40912 Input signal D_IN_16-23 D-IN-16-----23 See attached table
display
Status
39 40913 Input signal D_IN_24-31 D-IN-24-----31 See attached table
display
Status
40 40961 Input signal D_IN_32-39 D-IN-32-----39 See attached table Not used
display
Status
41 40952 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
display
Status
42 40953 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table Not used
display
Status
43 40954 Output signal D_OUT_16-23 D-OUT-16----23 See attached table
display

*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.

WA600-6 31
SEN00555-06 30 Testing and adjusting

WRK [Work equipment controller system]

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
Pressing of switch ON = ON (24 V)/OFF
D-IN-0 Semiautomatic digging lock mode switch
(OPEN)
Pressing of switch ON = ON (24 V)/OFF
D-IN-1 Semiautomatic digging loose mode switch
(OPEN)

1 40910 D-IN-2 — —
D-IN-3 — —
D-IN-4 — —
D-IN-5 — —
D-IN-6 — —
D-IN-8 Bucket full stroke proximity switch Bucket dump ON = ON (24 V)/OFF (OPEN)
Bucket horizontal ON = ON (24 V)/OFF
D-IN-9 Bucket tilt horizontal proximity switch
(OPEN)
Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-10
(facing upward) (facing upward) = ON (GND)/OFF (OPEN)
2 40911 Remote positioner bucket angle set switch Remote positioner bucket angle set switch
D-IN-11
(facing downward) (facing upward) = ON (GND)/OFF (OPEN)
D-IN-12 — —
D-IN-13 — —
D-IN-14 — —
D-IN-15 — —
Work equipment neutral lock switch
D-IN-16 Work equipment neutral lock switch (Working position) ON = (24 V)/OFF
(OPEN)
Starting switch START = ON (24 V)/OFF
D-IN-17 Starting motor C terminal signal
(OPEN)
D-IN-18 — —
3 40912
D-IN-19 — —
D-IN-20 — —
D-IN-21 — —
D-IN-22 — —
D-IN-23 — —
D-IN-24 — —
D-IN-25 — —
D-IN-26 — —
D-IN-27 — —
Lift arm positioner raise/lower set switch Lift arm positioner raise/lower switch (raise)
D-IN-28
4 40913 (raise) = ON (GND)/OFF (OPEN)
Lift arm positioner raise/lower set switch Lift arm positioner raise/lower set switch
D-IN-29
(lower) (lower) = ON (GND)/OFF (OPEN)
Turn signal right switch = ON (GND)/OFF
D-IN-30 Turn signal right switch
(OPEN)
Turn signal left switch = ON (GND)/OFF
D-IN-31 Turn signal left switch
(OPEN)

32 WA600-6
30 Testing and adjusting SEN00555-06

WRK [Work equipment controller system]

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
D-OUT-0 Work equipment neutral lock solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 Lift arm raise detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-2 Lift arm float detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-3 Bucket tilt detent solenoid Output ON = ON (24 V)/OFF (OPEN)
5 40952
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-16 Operation of turn signal right Output ON = ON (24 V)/OFF (OPEN)
D-OUT-17 Operation of turn signal left Output ON = ON (24 V)/OFF (OPEN)
D-OUT-18 Remote positioner top indicator ON Output ON = ON (24 V)/OFF (OPEN)
D-OUT-19 Remote positioner bottom indicator ON Output ON = ON (24 V)/OFF (OPEN)
6 40954
D-OUT-20 Safety relay operation Output ON = ON (24 V)/OFF (OPEN)
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —

WA600-6 33
SEN00555-06 30 Testing and adjusting

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
POWER SUP-
2 03200 Battery voltage 0.0 – 480.0 V
PLY
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
COOLANT
4 04104 Engine coolant temperature –40 – 210 °C
TEMP
Engine coolant temperature sensor COOLANT
5 04105 0.00 – 5.00 V
voltage TEMP
6 37200 Oil pressure sensor ENG OIL PRESS –99.9 – 999.9 kPa
7 37201 Oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
8 42700 Engine oil temperature ENG OIL TEMP –40 – 210 °C
9 42702 Engine oil temperature sensor voltage ENG OIL TEMP 0.00 – 5.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
11 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
AMBIENT
12 37400 Atmospheric pressure –99.9 – 999.9 kPa
PRESS
AMBIENT
13 37402 Atmospheric pressure sensor voltage 0.00 – 5.00 V
PRESS
14 18400 Air intake temperature INTAKE TEMP –50 – 200 °C
15 18401 Air intake temperature sensor voltage INTAKE TEMP 0.00 – 5.00 V
16 04204 Fuel temperature FUEL TEMP –40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP –50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
22 17900 EGR valve differential pressure EGR DIF PRESS –99.9 – 999.9 kPa
EGR valve differential pressure sen-
23 17901 EGR DIF PRESS 0.00 – 5.00 V
sor voltage
EGR IN PRESS-
24 18000 EGR valve inlet pressure –99.9 – 999.9 kPa
A
EGR valve inlet pressure sensor volt- EGR IN PRESS-
25 18002 0.00 – 5.00 V
age A
EGR VALVE
26 18100 EGR valve position 0.00 – 99.99 mm
POS
EGR VALVE
27 18101 EGR valve position sensor voltage 0.00 – 5.00 V
POS
OUTPUT
28 18700 Engine output torque –24000 – 24000 Nm
TORQUE
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
FINAL THROT-
30 31706 Final accelerator position 0 – 100 %
TLE
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 l/h
Final injection volume command (in INJECT COM-
32 18600 0 – 1000 mg
weight) MAND
33 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA

34 WA600-6
30 Testing and adjusting SEN00555-06

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
34 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
37 18202 Bypass valve position sensor voltage BPS VALVE POS 0.00 – 5.00 V
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
40 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command PRESS COM-
41 36200 0 – 400 MPa
PFIN MAND
PCV valve close timing (BTDC stan-
42 17201 PCV TIMING –180.0 – 180.0 CA
dard)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Incoming value is dis-
Name of selected model (upper 8 dig- played as is Status
44 00400 MACHINE ID (H)
its) (Upper 8 digits of 16 display
characters)
Incoming value is dis-
Name of selected model (lower 8 dig- played as is Status
45 00401 MACHINE ID (L)
its) (Lower 8 digits of 16 display
characters)
Incoming value is dis-
Status
46 20216 Build version BUILD VER played as is (8 char-
display
acters)
Incoming value is dis-
Status
47 20217 Calibration data version CAL VER played as is (8 char-
display
acters)

*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.

WA600-6 35
SEN00555-06 30 Testing and adjusting

VHMS [VHMS controller system]

Monitoring Monitoring items Displayed items Data display range Unit
No. Remarks
code (*1) (*2) (*3) (*4)
1 37501 Atmospheric temperature ATR TEMP –30 + 100 °C
BLOWBY
2 42801 Blow-by pressure 0.0 – 20.0 kPa
PRESS
3 42703 Engine oil temperature ENG OIL TEMP 0 – 180 °C
EXHAUST TEMP
4 42610 Exhaust gas temperature (F) 200 – 950 °C
F
EXHAUST TEMP
5 42611 Exhaust gas temperature (R) 200 – 950 °C
R
BRAKE PRESS
6 92800 Brake oil pressure (F) 0.00 – 50.00 MPa
F
BRAKE PRESS
7 92801 Brake oil pressure (R) 0.00 – 50.00 MPa
R
Status
8 92900 Brake signal BRAKE SIG ON/OFF
display
9 93000 Steering oil pressure S/T OIL PRESS 0.00 – 50.00 MPa
Status
10 93100 Start signal START SIG ON/OFF
display
Status
11 40944 Input signal D_IN_0-7 D-IN--0------7 See attached table
display
Status
12 40948 Output signal D_OUT_0-3 D-OUT--0--3 See attached table
display
Status
13 90947 SEL signal D_SEL_0-3 D-SEL--0--3 See attached table
display

*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.

36 WA600-6
30 Testing and adjusting SEN00555-06

VHMS [VHMS controller system]

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
D-IN-0
D-IN-1
D-IN-2
D-IN-3
1 40944
D-IN-4
D-IN-5
D-IN-6
D-IN-7
D-SEL-0
D-SEL-1
5 40947
D-SEL-2
D-SEL-3
D-OUT-0
D-OUT-1
6 40958
D-OUT-2
D-OUT-3

WA600-6 37
SEN00555-06 30 Testing and adjusting

5. Engine reduced-cylinder function 3) Selecting a cylinder to be reduced

The engine reduced-cylinder function denotes Using [<] or [>] switch, select a cylinder to
setting the injector of a single cylinder or two or be reduced from No. 1 – No. 6 cylinders
more cylinders to electrically no injection state and then settle the selected cylinder using
and turns on the operation on reduced-cylinder [U] switch.
condition. When any cylinders of the engine a The cylinder to be reduced is selectable
were suspected for abnormal output (combus- while the engine is run.
tion), this approach is used to single out the a Any number of cylinders can be reduced –
failed cylinder. a single unit or two or more units.
1) Selecting the menu q [>] switch: Advances the cursor right-
Display the CYLINDER CUT-OUT screen ward
from the menu screen of Service mode. q [<] switch: Advances the cursor left-
ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen

2) Displaying sub menu

Press [U] switch while the menu is
selected to display the sub menu.

a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.

a The cylinder No. and engine speed are

displayed on the upper line and the final
injection rate command is displayed on
the lower line simultaneously.

38 WA600-6
30 Testing and adjusting SEN00555-06

4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.

a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the func- instruction screen will appear.
tion capable of lubricating the engine through a In such case, stop the engine once and
no injection cranking. When a machine has then do the set up again.
been stored for a long time, this function is
used to lubricate the engine prior to its restart in
order to prevent its wear or damages out of oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.

WA600-6 39
SEN00555-06 30 Testing and adjusting

7. Adjustment function a Adjustment function

The machine monitor implements initial setting
No. Adjustment item
after disassembly or replacement of the trans-
mission, or after replacement or addition of 7-1 Adjustment of transmission ECMV current
sensor and EPC valve or controller. Through 7-2 Setting of transmission initial learning
the initial setting, the machine monitor corrects 7-3 Adjustment of transmission shift point
and adjusts the installation error or manufac-
Adjustment of lift arm angle sensor (Raise)
turing variations of individual parts. 7-4
(for EPC lever)
Adjustment of lift arm raise lever position
7-5 before detent and variations in the dead
zone of EPC
Adjusting variation correcting calibration of
7-5-1
lift arm raise lever before detent
7-5-2 Adjusting lift arm raise EPC starting current
Adjustment of lift arm lower (float) lever and
7-6
variations in the dead zone of EPC
Adjusting variation correcting calibration of
7-6-1
lift arm lower (float) EPC lever
7-6-2 Adjusting lift arm lower EPC starting current
Adjustment of bucket tilt lever position
7-7 before detent and variations in the dead
zone
Adjusting variation correcting calibration of
7-7-1 bucket tilt lever position before detent lever
position before detent
7-7-2 Adjusting bucket tilt EPC starting current
Adjustment of bucket dump EPC starting
7-8
current
Adjustment of 3-spool valve EPC cylinder
7-9 extraction lever and variations in the dead
zone of EPC
Adjustment of 3-spool valve EPC cylinder
7-10 retraction lever and variations in the dead
zone of EPC
Adjustment of AJSS neutral position (AJSS
7-11
specification)
Adjustment of AJSS EPC output current
7-12
(AJSS specification)
7-13 Modification of lift arm lever pattern
7-14 Modification of bucket lever pattern
Adjustment of lift arm raise/lower stop
7-15
modulation
Adjustment of pump cut-off pressure in lift
7-16
arm raise
Adjustment of lift arm angle sensor (raise)
7-17
(For load meter)
Adjustment of lift arm angle sensor (lower)
7-18
(For load meter)
Modification of AJSS oil pressure command
7-19
table pattern
7-20 Adjustment of maximum speed limit

40 WA600-6
30 Testing and adjusting SEN00555-06

7-1. Adjustment of transmission ECMV current 4) Using [<] or [>] switch, move the cursor to
7-1-1. Preparations for transmission ECMV current the T/M OIL TEMP screen.
adjustment q [93600]: ID number of transmission
1) Display the REAL-TIME MONITOR from control oil temperature
the menu screen of Service mode. q [******]: Display of transmission con-
trol oil temperature

2) Press [U] switch to display the sub menu

and then select TRANSMISSION using [<] 7-1-2. Conformation of transmission oil tempera-
or [>] switch. (TRANSMISSION screen) ture control
1) Start the engine, press the brake pedal
fully and then release the parking brake.
2) Set the transmission shift mode to the
Manual, directional lever or directional
selector switch to F (forward) and shift
lever or switch to 4th.
3) Make sure from "7-1-1 Preparations for
transmission ECMV current adjustment"
that the transmission controlled oil tem-
perature is 70 – 80°C.If it is out of the
range, stall the torque converter and
adjust the temperature to 70 – 80°C.
4) Return the directional lever or directional
selector switch to N (neutral) and maintain
it in that position. After 3 minutes, make
3) Press [U] switch to settle the real-time
sure the oil temperature is still in the 70 –
monitoring of the transmission controller.
80°C range.
a As the selection is settled, the application
5) Let the oil pervade in the transmission by
program version of the transmission con-
operating the reverse lever or directional
troller will be displayed.
selector switch, or the gearshift lever or
q [20223] : ID number of display item
switch in the following manner.
q [******]: Display of data
a When executing the operation, the
(Program version)
engine shall be set to low idle, man-
ual switch to ON and lockup switch to
OFF.
a Make sure the machine is normal
(failure is not detected).
a When stalling the torque converter,
use care it may not be overheated.

WA600-6 41
SEN00555-06 30 Testing and adjusting

3) Display the TUNING screen from the

Operating
order
1 2 3 4 menu screen of Service mode.
Gear
N2 F2 F1 F2
speed
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.

Operating
5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.

Operating
9 10 11
order
Gear 4) Hold down [U] switch for 5 seconds mini-
N2 R2 N2
speed mum to display 01: TM TRIGGER screen.
Holding Min. 2 Min. 2 Min. 2
time sec. sec. sec.

7-1-3. Adjustment of transmission ECMV current

a Targets of correction are 6 types – F (forward),
R (reverse), 1st, 2nd, 3rd and 4th. As the
engine is started, correction of all of above
clutches is started automatically.
a Since the learning operation requires the spec-
ified oil temperature, the oil temperature must
be adjusted to 70 – 80°C range.
1) Turn on the starting switch (engine is not
started) and then display T/M OIL TEMP
referencing "7-2-1 Preparations for trans-
5) Using [<] or [>] switch from the sub menu,
mission ECMV current adjustment".
select 02: ECMV TUNING.
2) Make sure the transmission controlled oil
temperature is in the 70 – 80°C range
when the engine is set to low idle, acceler-
ator pedal to OFF, directional lever or
directional selector switch to neutral and
parking brake to ON.

6) Press [U] switch to settle the adjustment

item.

42 WA600-6
30 Testing and adjusting SEN00555-06

7) Using [U] switch, select AUTO from the Operating

automatic correction (AUTO) and manual 13 14 15 16
order
correction (MANUAL) selection screen to IP [IP 2-1] [IP 2-2] [IP 2-3] [IP 2-4]
settle the automatic correction.
ECMV/ 2nd/1st 2nd/2nd 2nd/3rd 2nd/4th
frequency time time time time

Operating
17 18 19 20
order
IP [IP 3-1] [IP 3-2] [IP 3-3] [IP 3-4]
ECMV/ 3rd/1st 3rd/2nd 3rd/3rd 3rd/4th
frequency time time time time

Operating
21 22 23 24
order
IP [IP 4-1] [IP 4-2] [IP 4-3] [IP 4-4]
ECMV/ 4th/1st 4th/2nd 4th/3rd 4th/4th
frequency time time time time

a Selecting ECMV TUNING AUTO displays

IP in the character display, automatically 8) As the correction is normally completed,
starting transmission ECMV current OK is displayed in the character display.
adjustment.

a If the correction is not normally ended, the

Operating
code for abnormal end will be indicated.
1 2 3 4 (Following shows an example of the oper-
order
ation in which the 1st time correction of
IP [IP F-1] [IP F-2] [IP F-3] [IP F-4]
the 3rd position has ended abnormally).
ECMV/ F/1st F/2nd F/3rd F/4th
frequency time time time time

Operating
5 6 7 8
order
IP [IP R-1] [IP R-2] [IP R-3] [IP R-4]
ECMV/ R/1st R/2nd R/3rd R/4th
frequency time time time time

Operating
9 10 11 12
order
IP [IP 1-1] [IP 1-2] [IP 1-3] [IP 1-4]
ECMV/ 1st/1st 1st/2nd 1st/3rd 1st/4th
frequency time time time time

WA600-6 43
SEN00555-06 30 Testing and adjusting

a Codes for abnormal end 7-2. Setting of transmission initial learning

When initializing all the past initial trigger learn-
Reason CODE
ing data stored on the transmission controller,
Deviation from correc- employ the following procedure.
1
tion condition 7-2-1. Reset of initial learning
Absence of fill signal 2 1) Turn on the starting switch. (Engine does
In excess of correc- not start)
3 2) Set the directional lever (directional selec-
tion value
tor switch for AJSS specification) to the
a If abnormal end code "1" (NG1: Deviation neutral.
from correction condition) was displayed, 3) Display the TUNING screen from the
set the condition again referencing "7-1-1 menu screen of Service mode.
Preparations for transmission ECMV cur-
rent adjustment" and repeat the correc-
tion.
a If abnormal end code "2" (NG2: Absence
of fill) was displayed, implement trouble-
shooting of the failure codes 15STLH and
DXHTKA. If the state is normal, repeat the
operation starting from "7-1-1 Prepara-
tions for transmission ECMV current
adjustment" and repeat the correction.
(The value of T depends on the applica-
ble gear speed.)
a If the abnormal end code "3" (NG3: In
excess of correction value) was displayed,
execute the troubleshooting of failure
4) Hold down [U] switch for 5 seconds mini-
code 15STL1. Then after making sure the
mum to display 01: TM TRIGGER screen.
condition is normal, implement "7-1-1
Preparations for transmission ECMV cur-
rent adjustment" again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
ler after 3 seconds.
a When it is required to turn on the starting
switch immediately after the adjustment,
maintain the starting switch, just in case,
at off position for 10 seconds minimum
and then turn it on.

44 WA600-6
30 Testing and adjusting SEN00555-06

5) Press [U] switch to settle the adjustment 7-2-2. Preparations for transmission initial learning
item. As the item is settled, the initial 1) Display the REAL-TIME MONITOR from
learning reset screen appears. the menu screen of Service mode.
a If the initial learning is not done, INITIAL
STATUS will be displayed.

2) Press [U] switch to display the sub menu,

select 2 ITEMS using [<] or [>] switch and
a When the initial learning is completed, then settle the selection using [U] switch.
TUNED will be displayed. (SEL ITEMS 1,2 screen)

1] When TUNED is displayed, press [U] 3) From the SEL ITEMS 1,2 screen, enter ID
switch to display the initial learning number 93600 of the transmission control
reset screen. oil temperature and ID number 94100 for
2] Press [<] or [>] switch from the initial displaying the trigger learning.
learning reset screen to move the cur- a Referring to "4-5. Setting 2 items
sor to YES position and then press simultaneous monitoring".
[t] switch to reset the initial learning.
3] When suspending the reset opera-
tion, select NO from above 2] or press
[t] switch on TUNED screen.

WA600-6 45
SEN00555-06 30 Testing and adjusting

4) Using [U] switch, settle 2 items display of 4) Execute the initial learning by operating
the transmission control oil temperature the directional lever or directional selector
and the trigger learning display. switch, or the gearshift lever or switch in
a Content of the trigger learning is displayed the following manner.
for each of F, R, 1st, 2nd, 3rd and 4th
Operating
clutch in the figure. order
1 2 3 4
q 0: Learning not done yet
1: Learning completed Gear
q N2 F2 F1 F2
speed
Holding Min. 6 Min. 6 Min. 6 Min. 4
time sec. sec. sec. sec.

Operating
5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Holding Min. 4 Min. 4 Min. 4 Min. 4
time sec. sec. sec. sec.

Operating
9 10 11
order
Gear
N2 R2 N2
speed
7-2-3. Implementation of transmission initial learn- Holding Min. 4 Min. 4 Min. 4
ing time sec. sec. sec.
a Before starting the transmission initial learning,
be sure to implement "7-1 Adjustment of trans- a Hold the gearshift lever in each gear
mission ECMV current" and "7-2-1 Reset of ini- speed for more than the specified time.
tial learning". Then start the initial learning a If the gearshift lever is operated before the
according to the following procedure. specified time is reached, the initial learn-
a Implement the gearshift operation using actual ing is not completed (TUNED is not dis-
travel, bench travel or while pressing the wheel played).
brake.
k When actual travel is employed for the 7-2-4. Conformation of completion of transmission
operation, be sure to choose a spacious initial learning
field while paying reasonable care to the 1) Referencing "7-2-2 Preparations for trans-
environment. mission initial learning", make sure 111111
a When executing the operation, the engine shall is marked on ID number 94100, indicating
be set to low idle, manual switch to ON and that the initial learning is completed.
lockup switch to OFF. 2) Press [t] switch to end confirmation of the
1) Start the engine, press the brake pedal initial learning.
fully and then release the parking brake.
2) Set the transmission shift mode to the
Manual, directional lever or directional
selector switch to F (forward) and shift
lever or switch to 4th.
3) Make sure from "7-2-2 Preparations for
transmission initial learning" that the trans-
mission control oil temperature is 70 –
80°C. If it is out of the range, stall the
torque converter and adjust the tempera-
ture to 70 – 80°C. (If the initial learning is
performed while the oil temperature is out
of the specified range, time lags and gear-
shift shocks can result).

46 WA600-6
30 Testing and adjusting SEN00555-06

7-3. Adjustment of transmission shift point 3) Using [<] or [>] switch, select 04: SHIFT
a This function is used for modifying the shift rpm screen from the sub menu.
point when the shift mode switch is at L posi-
tion by adding a correction amount.
a The factory default setting of the correction
amount shall be 0.
a The shift point depends on the engine mode.
When this function is used, however, the same
correction value is applied independent of the
engine mode.
a Some of the shift points being adjusted with
the shift point adjustment function may not
include the following shift patterns.
q The shift point that is used when the hunt-
ing prevention function is turned on.
q The shift down point that is used when the
accelerator is set to idle.
4) Press [U] switch to settle the selection.
a After a shift point adjustment is done, confirma-
a As the selection is settled, 0: ALL CLEAR
tion on the machine must be done.
will be displayed in the lower space.
5) Press [U] switch to settle ALL CLEAR.
7-3-1. Clearing an adjusted shift point
a As all the stored values are cleared,
1) Display the TUNING screen from the
the set value is returned to the default
menu screen of Service mode.
and the screen returns to the shift
point adjustment item.
a If [t] switch is pressed in place of [U]
switch, the stored value is not cleared
and the screen returns to the adjust-
ment items.

7-3-2. Adjusting a shift point

a This operation allows changing a gear
shift travel speed when L auto-shift mode
is selected.
a Gear shift patterns are changed as shown
below.
No. Gear shift pattern to be changed
2) Hold down [U] switch for 5 seconds mini- 0 ALL CLEAR
mum to display 01: TM TRIGGER screen. 1 F2 T/C o F3 T/C
2 F2 L/U o F3 L/U
3 F3 T/C o F4 T/C
4 F3 L/U o F4 L/U
5 F4 L/U o F3 L/U
6 F4 T/C o F3 T/C
7 F3 T/C o F2 T/C
8 F3 L/U ON
9 F3 L/U OFF
10 F4 L/U ON
11 F4 L/U OFF
• T/C: Torque converter travel
• L/U: Lockup travel

WA600-6 47
SEN00555-06 30 Testing and adjusting

<Gear shift pattern change procedure> q Selecting –50 rpm decreases the
a As an example of a gear shift pattern speed by approximately 0.7 km/h.
change, following describes the procedure 4) After selecting a desired setting data,
for changing the gear shift travel speed press [t] switch to end the setup proce-
pattern from F2T/C to F3T/C. (The same dure.
applies to other gear shift patterns, too.)
1) Select 04: SHIFT rpm screen using [U]
switch and then select 01:F2T/C o F3T/C
using [<] or [>] switch.

7-4. Adjustment of lift arm angle sensor (Raise)

(for EPC lever)
Following procedure is employed for adjusting
lift arm angle of the work equipment.
2) Press [U] switch to settle the selection. 1) Display the TUNING screen from the
a As the selection is settled, the Shift menu screen of Service mode.
point adjusting value input screen will
appear.
a This screen displays the currently
entered shift point adjusting value.
a Adjusting value input screen when
Adjusting value = 0

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.

3) Press [<] or [>] switch to select a desired

adjusting value.
a When adjusting a shift point, 50 rpm
of the transmission output shaft
speed is used as a unit.
a Adjusting the transmission output
shaft speed by 50 rpm changes the
travel speed by approximately 0.727
km/h.
q Selecting +50 rpm increases the
speed by approximately 0.7 km/h.

48 WA600-6
30 Testing and adjusting SEN00555-06

3) Using [<] or [>] switch, move the cursor to a Lift arm length by lift arm specification
item of 05: RAISE ANGLE.
Lift arm Voltage
Lift arm position
specification range
A Upper limit position 3.80 ± 0.3 V
(Stroke end of raised
B cylinder) 3.87 ± 0.3 V

a Lift arm length by machine model

Machine model A B
WA600-6 3850 mm 3990 mm
WA500-6 3250 mm 3636 mm

7-5. Adjustment of lift arm raise lever position

before detent and variations in the dead
4) Press [U] switch to settle the selection. zone of EPC
a As the selection is settled, the RAISE 7-5-1. Adjusting variation correcting calibration of
ANGLE screen will be displayed. lift arm raise lever before detent
a This adjustment is needed when the electric
(EPC) work equipment lever or the work equip-
ment controller is disassembled or replaced.
a Before starting the adjustment, lower the lift
arm to the ground and stop the engine.
1) Display the TUNING screen from the
menu screen of Service mode.

5) Press [U] switch while the lift arm being

raised to the upper limit (cylinder stroke
end).
6) 2 times of buzzer beep notify completion
of the setting.
7) 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust- 2) Hold down [U] switch for 5 seconds mini-
ment does not start. mum to display 01: TM TRIGGER screen.
8) Press [t] switch to end the adjustment
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
taking place will be stopped even if it is not
completed.
9) When the adjustment did not end suc-
cessfully, check the lift arm angle sensor
voltage from the real time monitor.
10) Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
the real time monitor may fall within the
following range and then implement the
sensor adjustment again.

WA600-6 49
SEN00555-06 30 Testing and adjusting

3) Using [<] or [>] switch, move the cursor to 7-5-2. Adjusting lift arm raise EPC starting current
item of 06: RAISE EPC. a Start the engine prior to the setup opera-
tion.
1) Display the TUNING screen from the
menu screen of Service mode.

4) Raise the lift arm EPC lever to a position

just before the raise detent position and
maintain the lever at this position.
a Take care so that the raise detent opera- 2) Hold down [U] switch for 5 seconds mini-
tion will not start. mum to display 01: TM TRIGGER screen.
5) Pressing [U] switch turns on reading of
lever voltage and then stores the read
voltage replacing the currently stored
standard value.

3) Using [<] or [>] switch, move the cursor to

item of 06: RAISE EPC.

a The setting is complete as 06: RAISE

EPC screen was restored succeeding to 2
times of buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 06:
RAISE EPC screen will be restored.
a If [t] switch is pressed at this point, cor-
rection of variations in the work equipment
4) Lower the lift arm by dumping the bucket
EPC lever detent position is stopped even
and then lift the front wheel.
if it is not completed.

50 WA600-6
30 Testing and adjusting SEN00555-06

5) Start raising the lift arm gradually while 2) Hold down [U] switch for 5 seconds mini-
s e t t i n g t h e e n g i n e t o h ig h i d l e ( t h e mum to display 01: TM TRIGGER screen.
machine body is lowered).
6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position (front wheel is floated).
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

3) Using [<] or [>] switch, move the cursor to

item of 07: LOWER EPC.

8) The setting is complete as 06: RAISE

EPC screen was restored succeeding to 2
times of buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 06: RAISE EPC screen will be
restored succeeding to 2 times of buzzer
beep.
4) Stop the lift arm EPC lever in a position
7-6. Adjustment of lift arm lower (float) lever
just before the float detent position and
and variations in the dead zone of EPC
maintain the lever at this position.
7-6-1. Adjusting variation correcting calibration of
a Take care so that float detent operation
lift arm lower (float) EPC lever
may not turn on.
a This adjustment is needed when the electric
(EPC) work equipment lever or the work equip-
5) Pressing [U] switch turns on reading of
ment controller is disassembled or replaced.
lever voltage and then stores the read
a Before starting the adjustment, lower the
voltage replacing the currently stored
bucket to the ground and stop the engine.
standard value.
1) Display the TUNING screen from the
menu screen of Service mode.

WA600-6 51
SEN00555-06 30 Testing and adjusting

a The setting is complete as 07: LOWER 3) Using [<] or [>] switch, move the cursor to
EPC screen was restored after 2 times of item of 07: LOWER EPC.
buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 07:
LOWER EPC screen will be restored.
a If [u] switch is pressed at this point, cor-
rection of variations in the work equipment
EPC lever detent position is stopped even
if it is not completed.

7-6-2. Adjusting lift arm lower EPC starting current

4) Set the bucket roughly horizontal without
a Start the engine prior to the setup opera-
applying any load.
tion.
5) Start lowering the lift arm gradually while
1) Display the TUNING screen from the
maintaining the engine at high idle.
menu screen of Service mode.
6) Return the lever through fine operation. As
the lift arm is stopped, maintain the lever
at that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.

8) The setting is complete as 07: LOWER

EPC screen was restored after 2 times of
buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 07: LOWER EPC screen will be
restored after 2 times of buzzer beep.

52 WA600-6
30 Testing and adjusting SEN00555-06

7-7. Adjustment of bucket tilt lever position 3) Stop the bucket EPC tilt lever in a position
before detent and variations in the dead just before the tilt detent notch position
zone and maintain the lever at the position.
7-7-1. Adjusting variation correcting calibration of a Take care so that the tilt detent operation
bucket tilt lever position before detent may not be turned on.
a This adjustment is needed when the electric 4) Pressing [U] switch turns on reading of
(EPC) work equipment lever is used or when lever voltage and then stores the read
the work equipment controller was replaced. voltage replacing the currently stored
a Before starting the adjustment, lower the standard value.
bucket to the ground and stop the engine.

a The setting is complete as 08: TILT EPC

1) Hold down [U] switch for 5 seconds mini- screen was restored after 2 times of
mum to display 01: TM TRIGGER screen. buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 08: TILT
EPC screen will be restored.
a If [t] switch is pressed at this point, cor-
rection of variations in the work equipment
EPC lever detent position is stopped even
if it is not completed.

2) Using [<] or [>] switch, move the cursor to

item of 08: TILT EPC.

WA600-6 53
SEN00555-06 30 Testing and adjusting

7-7-2. Adjusting bucket tilt EPC starting current 6) Return the lever through fine operation. As
a Start the engine prior to the setup opera- the bucket is stopped, maintain the lever
tion. at that position.
1) Display the TUNING screen from the 7) Pressing [U] switch turns on reading of
menu screen of Service mode. the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
8) The setting is complete as 08: TILT EPC
screen was restored after 2 times of
buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 08: TILT EPC screen will be
restored after 2 times of buzzer beep.

7-8. Adjustment of bucket dump EPC starting

current
a Start the engine prior to the setup opera-
tion.
1) Display the TUNING screen from the
menu screen of Service Mode.
3) Using [<] or [>] switch, move the cursor to
item of 08: TILT EPC.

4) Lower the lift arm by dumping the bucket

and then lift the front wheel.
5) Start lowering the bucket gradually while
maintaining the engine at high idle (the
machine body is lowered).

54 WA600-6
30 Testing and adjusting SEN00555-06

2) Hold down [U] switch for 5 seconds mini- 8) The setting is complete as 09: DUMP EPC
mum to display 01: TM TRIGGER screen. screen was restored after 2 times of
buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 09: DUMP EPC screen will be
restored after 2 times of buzzer beep.

7-9. Adjustment of 3-spool valve EPC cylinder

extraction lever and variations in the dead
zone of EPC
a This item shall not be operated.

7-10. Adjustment of 3-spool valve EPC cylinder

retraction lever and variations in the dead
zone of EPC
a This item shall not be operated.
3) Using [<] or [>] switch, move the cursor to
item of 09: DUMP EPC.
7-11. Adjustment of AJSS neutral position
(AJSS specification)
1) Display the TUNING screen from the
menu screen of Service mode.

4) Set the bucket roughly horizontal without

applying any load.
5) Start dumping the bucket gradually while
maintaining the engine at high idle.
2) Hold down [U] switch for 5 seconds mini-
6) Return the lever through fine operation. As
mum to display 01: TM TRIGGER screen.
the bucket is stopped, maintain the lever
at that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

WA600-6 55
SEN00555-06 30 Testing and adjusting

3) Using [<] or [>] switch, move the cursor to a Adjust the frame and lever angle sensor
item of 12: J/S NEUTRAL. mounting position so that the voltage dis-
played on the real-time monitoring may fall
in within the following range and then
implement the sensor adjustment again.

Voltage
Angle sensor Lift arm position
range
Straight travel
Frame angle sensor 2.50 ± 0.3 V
position
Lever angle sensor Neutral state 2.50 ± 0.3 V

7-12. Adjustment of AJSS EPC output current

(AJSS specification)
a If this adjustment is necessary, consult the
4) Set the machine to the straight travel posi- factory before performing it.
tion and also set AJSS lever to neutral.
5) Press [U] switch from this state.
a If AJSS lever is not movable from the cur-
rent neutral position to the straight travel
position, adjust AJSS follow-up link.

6) 2 times of buzzer beep notify completion

of the setting.
a 1 second-long beep indicates that the set
frame and lever angle voltage is not con-
forming to the specified value. In this
case, adjustment does not start.
7) Press [t] switch to end the adjustment
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
underway will be stopped even if it is not
completed.
8) When the adjustment was not success-
fully executed, check the frame and lever
angle sensor voltages from the real time
monitoring.

56 WA600-6
30 Testing and adjusting SEN00555-06

7-13. Modification of lift arm lever pattern

a This function is intended for modifying the fine-controllability and response of the lift arm by changing
the data on EPC output current to the lift arm lever stroke.
a Characteristics of tables 1 – 5 are summarized as shown in the table below. (Factory-set table: 3)

a Table No. and function

Table
Function General
No.
• In the lowering operation, the lift arm is lowered at approximately 70% of the maximum
Fine control
1 speed. (Floating speed remains the same)
priority
• In the raising operation, speed change becomes more drastic as the stroke grows bigger.
• In the lowering operation, the lift arm is lowered at approximately 85% of the maximum
Fine control
2 speed. (Floating speed remains the same)
priority
• In the raising operation, controllability at fewer strokes is enhanced.
• This table allows compatibility between controllability and response in both the raise and
3 Standard
lower operations.
Response
4 • Fewer and faster lever strokes enhance the response.
priority
• Response is further improved because of the lever strokes fewer and faster than that of No. 4.
Response
5 • This table allows a greater speed change at fewer strokes than others. Thus, if reasonable
priority
care is not exercised, substantial shocks can result at stopping.

a Normally, change to tables No. 2 to No. 4 is made. When selecting No. 1 or No. 5 table, therefore, thor-
ough preliminary performance check and operator evaluation are required.
a The maximum lowering speed is not available from the data of Tables No. 1 and No. 2. Thus, when
measuring the lift arm lowering speed, Tables No. 3 – No. 5 must be used.

WA600-6 57
SEN00555-06 30 Testing and adjusting

1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the BOOM
TABLE screen will be displayed.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen. 5) Select a desired table from No. 1 – No. 5
by use of [<] or [>] switch.
6) Press [t] switch to settle the adjustment.

3) Using [<] or [>] switch, move the cursor to

item of 14: BOOM TABLE.

58 WA600-6
30 Testing and adjusting SEN00555-06

7-14. Modification of bucket lever pattern

a This function is intended for modifying the fine controllability, response and shock dump of the bucket by
changing the data on EPC output current to the bucket lever stroke.
a Characteristics of tables 1 – 3 are summarized as shown in the table below. (Factory-set table: 2)

a Table No. and function

Table
Function General
No.
Fine control
1 • In the dump and tilt operation, controllability at fewer strokes is enhanced.
priority
• This table allows compatibility between controllability and response in both the dump and tilt
2 Standard
operations.
• Fewer and faster lever strokes enhance the response.
Response
3 • This table makes it easier to dumping load by swinging the bucket as well as shock dump
priority
and leveling of load at the tilt end.

1) Display the TUNING screen from the

menu screen of Service mode.

WA600-6 59
SEN00555-06 30 Testing and adjusting

2) Hold down [U] switch for 5 seconds mini- 7-15. Adjustment of lift arm raise/lower stop
mum to display 01: TM TRIGGER screen. modulation
a When the lift arm lever is operated for sudden
stop, this function modifies the speed reduction
rate of the stop modulation, which is prepared
for alleviating shocks resulting from stopping,
by applying the stop modulation to EPC output
current.
a The modulation used for an automatic stop
with the remote positioner or due to kickout
does not depend on this data.
a Before starting a modification of the modula-
tion by use of this function, "7-13 Modification
of lift arm lever pattern" and operator's evalua-
tion must be done first.
a The stop modulation function acts the same
way in both the raise and lower directions.
3) Using [<] or [>] switch, move the cursor to
a The data at delivery is set to 100% of the stan-
item of 15: BUCKET TBL.
dard.

Modulation
State Remarks
quantity
The stop modulation
Stopping shocks can
is not activated. The
result if the operator
0% lift arm is stopped
does not pay reason-
without delaying to
able care.
the lever stroke.
It allows compatibility
between delay in
100% —
response at stop and
stopping shocks
The lift arm overruns
It alleviates stopping the target stop posi-
4) Press [U] switch to settle the selection. shocks that can result tion because its stop-
200%
a As the selection is settled, the bucket from operator's sud- ping is delayed even
lever adjustment screen will be displayed. den stop operation. when the lever is set
at neutral.

1) Display the TUNING screen from the

menu screen of Service mode.

5) Select a desired table from No. 1 – No. 3

by use of [<] or [>] switch.
6) Press [t] switch to settle the adjustment.

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30 Testing and adjusting SEN00555-06

2) Hold down [U] switch for 5 seconds mini- 7-16. Adjustment of pump cut-off pressure in
mum to display 01: TM TRIGGER screen. lift arm raise
a This function modifies matching of the travel
speed and work equipment speed at dump
approach and hopper charge by changing the
condition of the lift arm bottom pressure, which
is used as a pump flow rate restricting condi-
tion when lifting given load.
a The following lists the pump flow rate restrict-
ing conditions applicable to load lifting opera-
tion.
If the lift arm is operated under the following
initial conditions, its speed is restricted to
approximately 70% and the remaining torque
is used for the travel.
q Lift arm angle > 0° (Horizontal)
q Bucket tilt end detecting proximity switch
3) Using [<] or [>] switch, move the cursor to
signal
item of 16: LOWER STOP.
= Present (Tilt end detection available)
q Lift arm bottom pressure > 20 MPa {204
kg/cm2}
a Modifying the lift arm bottom pressure changes
the matching as shown in the table.
q The following data shows, when the
machine is loaded, the time required for
the lift arm to reach the lift arm top when
the raise operation was started simulta-
neously with start of the machine and the
travel distance at that time.
q Decreasing the currently set pressure acti-
vates the cut-off earlier, thereby lengthen-
ing the lift arm rising time as well as
extending the travel distance.
4) Press [U] switch to settle the selection.
a As the selection is settled, the LOWER Lift arm bot- F1 F2
STOP screen will appear. Working tom pressure
5) Select a desired table from 0, 100 and 200 mode during rising Distance Time Distance Time
by use of [<] or [>] switch. MPa {kg/cm2} (m) (sec) (m) (sec)
6) Press [t] switch to settle the adjustment. 10 {102} 16.5 11 25.1 11.2
Economy 20 {204} 15.5 10.7 24.7 10.7
25 {255} 15 10.2 24.5 10.6
10 {102} 17.8 10.7 26.7 11.1
Power 20 {204} 16.3 10.3 24.4 10.5
25 {255} 15.3 9.8 24.2 10.2

a The pressure at delivery is 20 MPa {204 kg/cm2}.

a Modifying the set value changes the lift arm ris-
ing time.
a When measuring the lift arm rising time for
troubleshooting purpose, be sure to return the
current setting to (20 MPa {204 kg/cm2}).

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SEN00555-06 30 Testing and adjusting

1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the pump cutoff
pressure adjustment screen will be dis-
played.
5) Select a desired pressure in the range of 10
– 20 – 25 (Unit: MPa) by use of [<] or [>]
switch.
6) Press [t] switch to settle the adjustment.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.

7-17. Adjustment of lift arm angle sensor

(raise) (For load meter)
1) Display the TUNING screen from the
menu screen of Service mode.

3) Using [<] or [>] switch, move the cursor to

item of 17: PUMP CUT.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.

62 WA600-6
30 Testing and adjusting SEN00555-06

3) Using [<] or [>] switch, move the cursor to

Lift arm position Voltage range
item of 18: RAISE ANGLE.
Upper limit position
0.5 – 4.5 V
(Stroke end of raised cylinder)

7-18. Adjustment of lift arm angle sensor (lower)

(For load meter)
1) Display the TUNING screen from the
menu screen of Service mode.

4) Press [U] switch to settle the selection.

a As the selection is settled, the RAISE
ANGLE screen will appear.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.

5) Press [U] switch after raising the lift arm to

the upper limit position (cylinder stroke end).
6) 2 times of buzzer beep notify completion
of the setting.
a 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust-
ment does not start. 3) Using [<] or [>] switch, move the cursor to
7) Press [u] switch to end the adjustment item of 19: LOWER ANGLE.
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
underway will be stopped even if it is not
completed.
8) When the adjustment did not end suc-
cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
the real time monitoring may fall within the
following range and then implement the
sensor adjustment again.

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SEN00555-06 30 Testing and adjusting

4) Press [U] switch to settle the selection. 7-19. Modification of AJSS oil pressure com-
a As the selection is settled, the LOWER mand table pattern
ANGLE screen will appear. a This function modifies stopping shock and
response of AJSS by changing the data on
EPC output current to the AJSS lever stroke.
a The table at delivery is Table No. 2.
a Following summarizes characteristics of
respective tables.
<Table No. 1>
q It offers the fine control priority level. In order to
support the operators who have switched from
CAT J/S specification machine, this mode sets
the maximum swing speed lower than the
default value and alleviates shocks resulting
from sudden steering lever operation without
sacrificing operability of AJSS.
q In this table, difference between the high-
speed travel range and low-speed working
5) Press [U] switch after lowering the lift arm
range is reduced.
to the lower limit position (cylinder stroke
q With the traveling speed at 25 km/h or below
end).
and the lever angle at 17° or above, it assures
6) 2 times of buzzer beep notify completion
the maximum swing speed of approximately
of the setting.
90% of the default (Table No. 2).
a 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
<Table No. 2>
the specified value. In this case, adjust-
q This table offers the default level. It strikes a
ment does not start.
balance between the machine performance
7) Press [t] switch 2 times to end the adjust-
and steering performance.
ment mode.
q It is the table when delivered.
a If [t] switch is pressed while the calibra-
q It assures the maximum swing speed when the
tion is continued, the calibration currently
traveling speed is set to 7 km/h or below and
underway will be stopped even if it is not
the lever angle to 17° or above.
completed.
8) When the adjustment did not end suc-
<Table No. 3>
cessfully, check the lift arm angle sensor
q This table offers the response priority level. It
voltage from the real time monitoring.
decreases the sense of catch-up by turning on
a Adjust the lift arm angle sensor mounting
the maximum swing speed, in the low-speed
position so that the voltage displayed on
working range, before the steering lever
the real time monitoring may fall within the
reaches the stroke end.
following range and then implement the
q It, however, allows greater shocks to result
sensor adjustment again.
from sudden steering lever operation – a con-
tradictory phenomenon.
Lift arm position Voltage range q V shape workload priority mode
Lower limit position q It assures the maximum swing speed when the
0.5 – 4.5 V
(Stroke end of lowered cylinder) traveling speed is set to 15 km/h or below and
the lever angle to 15° or above. This table sets
a swing angle faster than the default (Table No.
2) in the lever angle range of 10 – 17° in order
to alleviate the sense of catch-up.
a The maximum swing speed is not available
from the data of Table No. 1. Thus, Table No. 2
or 3 shall be used for measuring the swing
speed.

64 WA600-6
30 Testing and adjusting SEN00555-06

1) Display the TUNING screen from the 4) Press [U] switch to settle the selection.
menu screen of Service mode. a As the selection is settled, the AJSS TBL
screen will be displayed.

2) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen. 5) Select a desired table from 1, 2 and 3 by
use of [<] or [>] switch.
6) Press [t] switch to settle the adjustment.

7-20. Adjustment of maximum speed limit

a This maximum speed limit adjusting function is
used to enhance fuel consumption in the for-
ward 4th lockup travel.
a First select the maximum travel speed
(selected from three levels). Then set the
upper limit of the throttle opening for F (for-
ward), 4th and L/U (lockup) to limit the maxi-
mum travel speed.
a The throttle opening is limited to 90%, when
delivered.
a Select a restricted throttle opening from 80%,
3) Using [<] or [>] switch, move the cursor to
90% and 100% (no restriction).
item of 21: AJSS TBL.
a The state in which F (forward), 4th and L/U
(lockup) are selected is, in other words, the
state in which F4 gear shift is completed and
L/U is at the holding pressure.
a When gear shift to a speed other than F4 is
started or when L/U is cancelled, the upper
limit value of this control becomes 100% (no
restriction).
a Setting at delivery is 90%.
1) Display the TUNING screen from the
menu screen of Service mode.

WA600-6 65
SEN00555-06 30 Testing and adjusting

2) Hold down [U] switch for 5 seconds mini- 8. Maintenance monitoring function
mum to display 01: TM TRIGGER screen. The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.

3) Using [<] or [>] switch, move the cursor to

item of 22: SPEED LIMIT.

2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
4) Press [U] switch to settle the selection.
cumulative replacement frequencies.
a As the selection is settled, the maximum
3) Using [<] or [>] switch, select the item for
speed limit adjustment screen will be dis-
which the maintenance interval is to be
played.
changed from the following.
5) Select “throttle position (80%, 90%, or
100%)” using [<] or [>] switch and then
press [U] switch to settle the setting
change.

66 WA600-6
30 Testing and adjusting SEN00555-06

List of maintenance items

Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG OIL FILTER 500
Fuel pre-filter 41 FUEL P FILT 500
Transmission oil filter 13 TRANSM FILTER 500
Fuel filter 03 FUEL FILT 500
Transmission oil 12 TRANSM OIL 1000
Corrosion resistor 06 CORR-RESISTER 1000
Hydraulic tank breather element 05 HYD BREATHER 2000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000

4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.

5) Maintenance interval time change proce-

dure
1] This cursor (C) is located at the high-
est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd digit.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.

WA600-6 67
SEN00555-06 30 Testing and adjusting

6) Select "YES" or "NO" using [<] or [>] a When "Timer by item" is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
"YES" is selected and [t] switch is
pressed, the information will be deleted. If
"NO" is selected and [t] switch is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If "Timer by item" is disabled, OFF will be
displayed in the upper column.

8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3)
maintenance Interval time change screen
a If "Timer by item" is enabled, ON will be
displays the "Selection between enabling
displayed in the upper column.
or disabling timer by item" screen.
a When "Timer by item" is enabled, the
order of display is ON o OFF.

68 WA600-6
30 Testing and adjusting SEN00555-06

3) Select "YES" or "NO" using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select "YES" or "NO" using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
"YES" is selected and [ t] switch is "YES" is selected and [t] switch is
pressed, the information will be deleted. If pressed, the change will be enabled If
"NO" is selected and [t] switch is "NO" is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
to prevent resetting error. to prevent resetting error.
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment

8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.

a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
value – Elapsed time since the last
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
2) Using [<] or [>] switch, select the INITIALIZE was executed.
screen. a Set enable for enable or disable of individ-
ual items.

8-4. Selection between timer stop for all items and

enable all items
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.

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SEN00555-06 30 Testing and adjusting

2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.

3) Press [U] switch to display the ALL

ITEMS o OFF screen.

a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select "YES" or "NO" using [<] or [>]
switch.
a The selected cursor will start flashing. If
"YES" is selected and [t] switch is
pressed, the information will be deleted. If
"NO" is selected and [t] switch is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
4) Press [<] or [>] switch when selecting the
ALL ITEMS o ON.

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30 Testing and adjusting SEN00555-06

7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I N T E N A N C E M O N I TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I N T E N A N C E M O N I TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- q Loaded volume and loading frequency
cuted to the set value before disabled (This display is available only when the
independent of whether or not it is load meter is installed.)
enabled or disabled for a specific item. 1) Selecting menu
a The timer remaining time is reset. (The Display the OPERATION INFO screen
reset frequency remains the same as from the menu screen of Service mode.
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I N T E N A N C E M O N I TO R
screen is restored.

2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 4] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.

WA600-6 71
SEN00555-06 30 Testing and adjusting

a The lower column displays the

elapsed time [h] from the last reset-
ting.
q The counting is stopped at 99999.9,
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.

2] Cumulative fuel consumption and travel

distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the travel 4] Loaded volume and loading frequency
distance [km or mile] from the last screen
resetting. a The upper column displays the
q The unit km or mile shall be selected loaded volume [ton] from the last
depending on that used on the odom- resetting.
eter. q Upper limit: Counting is stopped at
q The counting is stopped at 99999.9, 199999999.9 or 999999999.9.
the upper limit. q Short ton or metric ton depends on
a Calculation is done only for the dura- optional setting.
tion in which the engine is run. a The lower column displays the load-
ing frequency from the last resetting.
q Upper limit: Counting starts stopped
at 65000 or 99999999999.
a Calculation is done only for the dura-
tion in which the engine is run and the
optional device is used.

3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.

72 WA600-6
30 Testing and adjusting SEN00555-06

4) Deleting display data 7] Press [U] switch when the intended

a Data on screens 5) – 8) allow deletion. value appeared to specify it as the set
a Select a desired item and then delete it value.
using [U] switch. a The cursor moves to the 2nd digit.
a Use [t] switch when canceling deletion of 8] Set the values up to the lowest digit in
data. the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
5) Setting gain correction
a Gain correction denotes the function of
correcting cumulative fuel consumption.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.

2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.

WA600-6 73
SEN00555-06 30 Testing and adjusting

10. Manual snapshot function 3) Press [U] switch to start the snapshot.
a The manual snapshot function stores 7 min- a The upper column displays the
utes and 30 seconds worth data to be used for elapsed time.
Pm clinic or testing/adjustment to VHMS con- a [–] sign in the leftmost position of the
troller. lower column is replaced with [*] and
a When collecting data at a regular interval for it starts flashing.
Pm clinic, it is required to observe the machine a For every 30 seconds, [–] is replaced
operating procedure specified for the quick with [*] starting with the leftmost one.
Pm. As for the data collection for the testing or When two or more [*] signs are dis-
adjustment purpose, however, no specified played, the rightmost one flashes.
machine operating procedure is stipulated". a Pressing [t] switch while the snap-
a When using the data being stored with the shot is taking place stops the snap-
manual snapshot function, a PC must be con- shot.
nected. For the connecting as well as operat-
ing procedure, refer to VHMS controller initial
setting procedure. (Connection of a PC may be
done before or after the snapshot.)
a For detail of operation of the snapshot function,
see the VHMS controller initial setting proce-
dure, "7 Quick Pm implementation procedure".
1) Display the SNAPSHOT screen from the
menu screen of Service mode.

4) Refer to the VHMS controller initial setting

procedure, "7 Pm clinic implementation
procedure for the machine operation".
a After 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be dis-
played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
2) Pressing [U] switch to turn on the ready q #: Data sampling interval is once
(READY) screen. every 1 second.
a The lower column displays 15 pieces of
[–] sign. 5) As 7 minutes and 30 seconds elapsed
from start of the snapshot, following
screen appears and then the initial screen
is restored in 5 seconds later.
(End of snapshot)

74 WA600-6
30 Testing and adjusting SEN00555-06

11. Optional device selecting function

a When enabling optional setting, turn the starting switch off once after changing the current setting and
then turn on the starting switch again after respective in-vehicle controller power supplies have been
completely turned off (it takes approximately 15 seconds).

a List of installed optional devices and their setting

Display in Item
Item Default Description of selection
English No.
When Hi LIFT SHORT lift arm is installed, the setting
Lift arm model LIFT BOOM 1 STD
applicable to each shall be implemented.
AUTO
Auto grease 2 None When an option is provided, select ADD.
GREASE
Low battery electrolyte sensor BAT LIQUID 3 None When an option is provided, select ADD.
TRANSM
Transmission clogging sensor 4 None When an option is provided, select ADD.
CLOG
Printer PRINTER 5 None When an option is provided, select ADD.
Normally, 0% shall be maintained without modify-
Tire size TIRE SIZE 6 0
ing current setting.
SHORT Factory-setting is done through special operation.
Selecting weight unit 7 None
TON Thus, setting change not available.
SPEED Factory-setting is done through special operation.
Travel speed unit 8 MPH
(UNIT) Thus, setting change not available.
Engine speed or travel speed
RPM/ Normally, ADD shall be maintained without modify-
display on character display and 10 Provided
SPEED ing current setting.
normal screen
LOAD
Load meter 11 None When an option is provided, select ADD.
METER
Emergency steering EMERG S/T 13 Provided When an option is not provided, select NO ADD.
Joystick steering or right FNR This item does not function on WA600-6.
J/S-FNR SW 14 NON
switch or both are absent No change allowed
Normally, ADD shall be maintained without modify-
Selecting ECO lamp display ECO LAMP Provided
ing current setting.
ECSS E.C.S.S. 20 None When an option is provided, select ADD.
AUTO RE This item does not function on WA600-6.
Automatic reversing fan 21 None
FAN No change allowed
Torque converter lockup LOCK UP 22 None Select ADD.
FORBID Normally, ADD shall be maintained without modify-
No 4th 23 None
4TH ing current setting.
THROT
Setting RPM 24 None When an option is provided, select ADD.
LOCK
When an option is provided, select ADD.
P-MODE
Power mode priority 25 None (Setting available: Power mode is introduced as
PRI
starting switch is turned on)
COLD This item does not function.
Very cold region specification 26 None
SPEC No change allowed
When an option is provided, select ADD.
AJSS AJSS STG 30 None This item does not function on WA500-6.
No change allowed
EPC 3-lever EPC 3RD 31 None When an option is provided, select ADD.
When an option is provided, select ADD.
VHMS controller VHMS 40 Provided This item does not function on WA500-6.
No change allowed

WA600-6 75
SEN00555-06 30 Testing and adjusting

1) Display the OPTIONAL SELECT screen 11-2. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of
installed optional devices and their setting,
the option setting/not setting selection
applies to the following items.
a If the options are not selected, the option
non-selection screen is displayed.

2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: LIFT BOOM screen will appear.

a If the options are selected, the option

elected screen is displayed.

4) Using [<] or [>] switch, select a desired

optional device from the list of installed
options and their setting.
5) Modify contents of the option setting using
[U] switch. a [U] switch allows alternately displaying
6) Press [t] switch to return to the OPTIONAL the option non-selection screen and the
SELECT screen. option-selected screen.

11-1. Changing lift arm model option selection

a Pressing [U] switch from the 1: LIFT
BOOM screen interchanges A and B.
a As A and B are interchanged, the sound
(beep) indicating acceptance of the opera-
tion will be generated.
a Select the lift arm length for A and B from
the following.

Machine model A B
WA600-6 3850 mm 3990 mm
WA500-6 3250 mm 3636 mm

76 WA600-6
30 Testing and adjusting SEN00555-06

11-3. Setting tire deflection option 12. Machine serial number input function
a Select the tire deflection option from the list of 1) Display the MACHINE No. SET screen
installed optional devices and their setting. from the menu screen of Service mode.
a Pressing [U] switch sequentially displays
[@@]% in the following order.
a The display progresses from +00 through –10.
Pressing [U] switch at this point returns the
display to +00.

Order No.1 No.2 No.3 No.4 No.5 No.6 No.7

@@ +00 +02 +04 +06 +08 +10 +12

Order No.8 No.9 No.10 No.11 No.12 No.13 No.14

@@ –02 –4 –6 –8 –10 –12 +00

a As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
2) Press [U] switch to display the MACHINE
No. screen.
3) Enter the serial number according to the
following procedure.
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
11-4. Storing option selection the same order as above and then
1) When the option selection was changed, press [U] switch to settle.
turn off the starting switch once to stop the a As the selection is settled, the imme-
controller operation completely.(After turn- diately preceding screen is restored.
ing off the starting switch, wait for 5 sec- a Pressing [t] switch while entry is tak-
onds without doing any switch operation.) ing place will move the cursor the
2) The specified option selection is enabled highest-order digit. In this case,
as the starting switch is turned on. repeat entry from the highest-order
a Whenever an option selection is made, turn digit.
off the starting switch once and then turn it a If [t] switch is pressed while the cur-
on again in approximately 15 seconds. sor is at the highest-order digit, the
immediately preceding screen will be
restored.

WA600-6 77
SEN00555-06 30 Testing and adjusting

13. Model selection function 4) Settle the selected model by use of [U]
When the Service mode is turned on, check switch.
the models registered to the machine monitor. a As the selection is settled, the sound
If the selected model was found in the (beep) indicating acceptance of the opera-
machines installed to the machine monitor, tion will be generated, restoring the
there is no need of changing the model even MACHINE screen.
though the model changing function is avail- a Make sure the model on the MACHINE
able. screen is the target model.

13-1. Implementing the model change 13-2. Storing model change

1) Display the MACHINE screen from the 1) When the model change was done, turn off
menu screen of Service mode. the starting switch once to stop the controller
a If WA600-6 is selected, WA6** will be dis- operation completely. (After turning off the
played on the screen. starting switch, wait for 5 seconds without
a In the case of WA500-6, the display will be doing any switch operation.)
WA5**. 2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.

14. Initialize function

This function is used only in the factory. It is,
therefore, not used for a service purpose.

2) Hold down [U] switch for 5 seconds to

display the model selection screen.

3) Using [<] or [>], replace WA5** with

WA6**.
a Press [t] switch when stopping the model
selection.
a As the operation is stopped, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.

78 WA600-6
30 Testing and adjusting SEN00555-06

WA600-6 79
SEN00555-06

WA600-6 Wheel loader

Form No. SEN00555-06

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

80
 SEN00556-05

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

30 Testing and adjusting 1

Testing and adjusting, Part 4
VHMS controller initial setting procedure........................................................................................................ 2
Precautions for replacing VHMS controller ................................................................................................... 22
Pm-clinic inspection table ............................................................................................................................. 28

WA600-6 1
SEN00556-05 30 Testing and adjusting

VHMS controller initial setting 1. Confirmation of machine information,

procedure 1 engine information, transmission controller
information and controller information
a Equipment used for VHMS controller initial set- a This confirmation procedure is targeted at
ting the entire machine.
Confirm and record the machine informa-
Symbol Part No. Part name tion, engine information, VHMS controller
1 799-608-3101 Service kit information and ORBCOMM terminal
information.
2 799-608-3211 • Diskette
3 799-608-3220 • Harness
No. Information to be confirmed
ZB Note type PC
Commercially 1 Model name
4 (Windows 98/2000/Me/XP/
available 2 Machine serial No.
Vista)
Commercially 3 Current service meter hour
5 RS232C-USB conversion cable
available 4 Engine serial No.
5 Transmission serial No.
a Initial setting of VHMS controller shall be done
according to the following procedure. This 6 VHMS controller serial No.
operation is needed prior to a full-scale opera- 7
ORBCOMM terminal serial No.
tion of a machine being delivered and assem- [Only for machines equipped with ORBCOMM]
bled in the field, or prior to resumption of its
operation after a long time of storage. a VHMS controller (1) and ORBCOMM ter-
a Machine data collected with VHMS controller minal (2) are installed in the right side
are stored and managed on WebCARE data- stand of the operator seat.
base. In order to endure smooth data process-
ing on WebCARE, consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit ZB1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the "Special functions of machine monitor" to
understand their procedure beforehand.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM installation specification, imple-
ment the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOMM
installation specification.
a Check each step of the setting work referenc-
ing the VHMS initial setting work check sheet.
a Information such as models shown in the fig-
ures may not be identical with actual ones.

2 WA600-6
30 Testing and adjusting SEN00556-05

2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) With personal computer ZB4 switched 2) Check the controller for normal operation
ON, connect it to download connector referencing 7-segment LED of VHMS con-
DPC7 by wiring harness ZB3. troller.
a Connect RS232C terminal of the PC. a VHMS controller is fed with switch
a If the personal computer does not power supply. Thus, its operation is
have the connection port for RS232C judged normal if its 7-segment LED
terminal, connect by using RS232C- starts flashing while rotating as the
USB conversion cable ZB5. starting switch is turned on and then if
(To use the USB conversion cable, its the controller starts counting in the
driver must be installed to the per- ascending order.
sonal computer.)

3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
a Download connector DLF is installed one that represents the decimal point to
in the front side of the right stand of check whether or not ORBCOMM control-
operator seat. ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.

WA600-6 3
SEN00556-05 30 Testing and adjusting

4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Operating [VHMS initial setting tool] icon on a This work is done inside the cab (from
the PC, start up the VHMS initial setting tool. PC).
a It is prohibited in the initial setting to mod-
Important ify the data of service meter [SMR].
a Appearance of the setup screen of [Machine Information]
the VHMS setting tool depends its 1) Open [Machine Information] tab.
tool. a [Data clear and Set up] menu displays
a When using Ver.3.5.2.1 or older ver- [Machine Information] tab first.
sion (CD-ROM), the setting proce- 2) Check every data for correctness.
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SER-
VICE OPERAT ION TIPS SEK N-
5052)
2) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826119000
3) Select [Data clear and Set up] from
[Select Function] item.
4) Click [OK] button to proceed to the setup
screen.
3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.

4 WA600-6
30 Testing and adjusting SEN00556-05

4) When [Machine Information] information is [Communication Setting] [ORBCOMM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOMM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
mation, press [OK] button.

5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTORY], employ the following
press [OK] button. procedure.
a ORBCOMM installation specification 1] Select [SHORT FAULT HISTORY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.

WA600-6 5
SEN00556-05 30 Testing and adjusting

9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.

10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.

GCC Code Area Remarks

N. America (*1)
*1: Except U.S. Territories in
1 C.S. Americas
Micronesia and Midway Island
Faroe Islands
Europe (*2)
Middle East
*2: Except Faroe Islands
Asia (*3)
120 *3: Except Japan
Africa (*4)
*4: ’ Globalgram mode’ is required
Oceania
CIS
130 Japan

6 WA600-6
30 Testing and adjusting SEN00556-05

6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.

a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].

2) Select [Set up & All clear] and press [Next]

button.

WA600-6 7
SEN00556-05 30 Testing and adjusting

4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.

9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].

7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.

GCC Code Area Remarks

N. America (*1)
*1: Except U.S. Territories in
1 C.S. Americas
Micronesia and Midway Island
Faroe Islands
Europe (*2)
Middle East
*2: Except Faroe Islands
Asia (*3)
120 *3: Except Japan
Africa (*4)
*4: ’ Globalgram mode’ is required
Oceania
CIS
130 Japan

10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.

8 WA600-6
30 Testing and adjusting SEN00556-05

7. Quick Pm clinic implementation procedure 6) Press the buzzer cancel switch [U] to
a Quick Pm denotes the Pm click done by start the snapshot.
use of the manual snapshot function of the a As the snapshot is started, the upper
machine monitor. column starts displaying the elapsed
a It stores 7 minutes and 30 seconds worth time.
of data to VHMS controller. a [–] in the leftmost position of the lower
k Park the machine in a flat place. column is replaced with [*] for every
30 seconds. When 2 or more [*] signs
1) Start the engine. are displayed, the rightmost one
2) Switch the machine monitor to Service flashes.
menu. a When stopping the snapshot currently
a For the procedure of opening Service taking place, press the buzzer cancel
menu, see "Special functions of switch [t].
machine monitor (EMMS)".
3) Display the manual snapshot function
screen from the menu screen of Service
mode.

7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tem-
perature and torque converter oil tem-
4) Press the buzzer cancel switch [U]. perature are within the operating
5) [READY] will be displayed on the screen, range.
turning on the standby mode. a After 10th [*] is displayed (5 minutes
a The lower column displays 15 pieces elapsed from the start), [#] will be dis-
of [–] sign. played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
q #: Indicates the data sampling interval
is once every 1 second.

WA600-6 9
SEN00556-05 30 Testing and adjusting

a Machine operation for snapshot

Machine operation
No. Start End
Machine status Power mode Work equipment
1 0:00 1:00 Low idle OFF —
2 1:00 1:30 Hi idle OFF —
3 1:30 2:00 Hi idle ON —
4 2:00 2:30 Low idle ON Right steering
5 2:30 3:00 Hi idle ON Right steering
6 3:00 3:30 Low idle ON Left steering
7 3:30 4:00 Hi idle ON Left steering
8 4:00 4:30 Low idle ON Bucket relief
9 4:30 5:00 Hi idle ON Bucket relief
10 5:00 5:30 T/C stall (Note 1) ON —
11 5:30 6:00 Hi idle ON —
12 6:00 6:30 T/C stall (Note 1) ON Bucket relief
13 6:30 7:00 Hi idle ON Foot brake operation (Note 2)
14 7:00 7:30 Low idle ON Foot brake operation (Note 2)
(Note 1): 1) Set the auto-shift and manual selector switch to the manual.
2) Press the brake pedal fully, set the lever to F4 (forward at 4th) and set the engine to high idle.

(Note 2): Repeat pumping of the foot brake 20 times.

10 WA600-6
30 Testing and adjusting SEN00556-05

8) As 7 minutes and 30 seconds elapsed

from start of the snapshot, following
screen appears and then the initial screen
is restored in 5 seconds. (End of snap-
shot)

WA600-6 11
SEN00556-05 30 Testing and adjusting

Important 10) Open the quick Pm data to draw a graph.

Data of quick Pm are recorded only once. a Select time for X-axis and select the
Thus, if another quick PM is repeated, the cur- following for Y-axis.
rent data will be overwritten with the last one. q Engine speed
In order to avoid above trouble, be sure to q Fuel Inject (fuel injection)
download data of every completed quick Pm q Blowby Press (Blow-by pressure)
shall to PC. For the procedure, see 8. Down- q F Exhaust Temp (Exhaust temperature
load of setting data. 1, 2 and 3 cylinders)
q R Exhaust Temp (Exhaust tempera-
9) Read the quick PM data by use of the ture 4, 5 and 6 cylinders)
analysis tool. q Engine Oil Temp (Engine oil tempera-
a For detailed usage of the analysis ture)
tool, see the operation and mainte- q Engine Oil Press (Engine oil pres-
nance manual. sure)
q Coolant Temp (Engine coolant tem-
perature)
q Boost Press (Boost pressure)
q Accelerator Pos (Accelerator angle)
q Ambient Temp (Ambient temperature)
q Loader Pump P (Work equipment oil
pressure)
q ST Pump Press (Steering oil pressure)
q Hyd Oil Temp (Hydraulic oil tempera-
ture)
q Boom Bottom P (Lift arm cylinder bot-
tom pressure)
q Boom Angle (Lift arm angle)
q Frame Angle (Frame angle)
q T/M Out Speed (Transmission output
speed)
q Shift Indicator (Shift position)
q Lock Up Signal (Lockup signal)
q T/C Oil Temp (Torque converter oil
temperature)

12 WA600-6
30 Testing and adjusting SEN00556-05

11) Apply a check mark to the Display graph

value at clicked position.

WA600-6 13
SEN00556-05 30 Testing and adjusting

12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
displayed – Not an actual one)

14 WA600-6
30 Testing and adjusting SEN00556-05

13) Record above values in the Pm clinic inspection sheet.

a Following shows the relation between the data needed for Pm clinic and the measuring condi-
tions.

Transmission modulation pressure

Measurement items

Exhaust gas temperature

Steering pump pressure

Rear brake temperature

Loader pump pressure

Front brake pressure

Engine oil pressure
Blow-by pressure

Boost pressure
Engine speed
E/P
Machine operation
mode
Low idle E-mode Q Q Q
Hi idle E-mode Q Q
Hi idle P-mode Q Q
Right steering + low idle P-mode Q
Right steering + high idle P-mode Q
Left steering + low idle P-mode Q
Left steering + high idle P-mode Q
Bucket relief + low idle P-mode Q
Bucket relief + high idle P-mode Q Q
Torque converter stall (Note 1) P-mode Q Q Q Q
Hi idle P-mode
Torque converter stall + bucket relief P-mode Q Q Q Q
Foot brake operation (Note 2) + high idle P-mode Q Q
Foot brake operation (Note 2) + low idle P-mode Q Q

WA600-6 15
SEN00556-05 30 Testing and adjusting

8. Download of setting data

1) Using harness [1] of service kit ZB1, con-
nect PC ZB4 to download connector DLF
in the cab or download connector VDL on
the ground.

2) When using download connector DLF in

the cab, set the starting switch to ON posi-
tion.
3) When using download connector VDL on
the ground, set switch (4) to ON position.
a Download connector DLF in the cab a The green LED will come on.
is installed in the front side of the right
stand of operator seat.

4) Operating [VHMS analysis tool] on PC,

start up the VHMS analysis tool.
a Download connector VDL on the
ground is provided under cover (3) in
the accumulator installation position,
which is located on the left side of the
machine body.

16 WA600-6
30 Testing and adjusting SEN00556-05

a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and a For the operating procedure, see the
maintenance manual. VHMS analysis tool operation and
maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.

5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual. 2) As check of the setting data is finished,
a After making sure the download is end [VHMS analysis tool].
complete, proceed to the next step.

WA600-6 17
SEN00556-05 30 Testing and adjusting

10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, be sure to turn off the
starting switch.
2) End the OS of PC ZB4 and then turn off
the PC power.

11. Report to Komatsu

As steps 1 – 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support Center in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness [1] of service kit ZB1 Komatsu VHMS/WebCARE Support Center
from download connector DLF.

2-3-6, Akasaka Minato-Ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)

E-mail: [email protected]

4) When the data was download to the

ground, disconnect harness [1] of service
kit ZB1 from download connector VDL

18 WA600-6
30 Testing and adjusting SEN00556-05

[For storage] Date of setting:

DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:

Setup step Check item Result

Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.

Connection between PC and VHMS

2 Is the connection secure? yes no
controller

Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)

Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?

Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no

6 Saving of settings Is LED (7-segment) turned off? yes no

7 Confirmation of VHMS function Is LED operation normal? yes no

Is service mode "SNAPSHOT" turned on and is the

8 Execution of quick Pm yes no
switch hit?

9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no

10 Download Is LED operation normal? yes no

Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no

12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no

WA600-6 19
SEN00556-05 30 Testing and adjusting

[For storage] Date of setting:

DB/branch
ORBCOMM Station Opening Work office name
Check Sheet Data entered by:

Setup step Check item Result

Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.

Connection between PC and VHMS

2 Is the connection secure? yes no
controller

Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)

4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no

Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion

6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no

How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)

20 WA600-6
30 Testing and adjusting SEN00556-05

WA600-6 21
SEN00556-05 30 Testing and adjusting

Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1 or
older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
799-608-3101 Service kit new VHMS controller after the replace-
ment.
1 799-608-3210 • Diskette
2-1. Confirmation and saving of VHMS controller
ZB 799-608-3220 • Wiring harness setting information prior to replacement
Commercially Note type PC 1) Connect the PC and start the VHMS initial
2
available (Windows 98/2000/Me/XP) setting tool.
a See the "VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure" for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE, consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the "VHMS initial setting work check
sheet".
a Information such as models shown in the fig-
ures may not be identical with actual ones.

[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a This work is done inside the cab (from PC).
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to "8.
Download of setting data" in "VHMS con-
troller initial setting procedure".

22 WA600-6
30 Testing and adjusting SEN00556-05

2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
a See the "VHMS controller initial set-
ting procedure" for this operation.
2) Select [Save/Load] and press [OK] button.

5) Reconfirm the information and then press

[OK] button to save the information.

3) Select [Load] from [File] of the menu.

6) Select [Exit] from [File] of the menu to end

the VHMS setting tool.
7) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.

WA600-6 23
SEN00556-05 30 Testing and adjusting

4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.

8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.

5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.

24 WA600-6
30 Testing and adjusting SEN00556-05

9) The confirmation screen will ask whether 3. Confirmation, saving and loading of VHMS
or not the data before the above setup is controller setting information (Ver. 3. 5. 2. 1
to be saved. Press [NO] button. or later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
a See the "VHMS controller initial set-
ting procedure" for this operation.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.

10) The setup result is displayed. Confirm the

contents and press [Close] button.

3) Select [Save current setting before

replacement of VHMS controller] and
press [Next] button.

11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.

WA600-6 25
SEN00556-05 30 Testing and adjusting

4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] but- ment of VHMS controller] and press [Next]
ton. button.

5) Select [Exit] from [File] of the menu to end 4) Currently saved information will be dis-
the VHMS initial setting tool. played. Press [Next] button.
6) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.

3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
a See the "VHMS controller initial set-
ting procedure" for this operation.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
5) Adjust the time and press [Apply] button.

26 WA600-6
30 Testing and adjusting SEN00556-05

6) The confirmation screen will ask whether [Operations needed after replacement of VHMS
or not the data before the above setup is controller]
to be saved. Press [NO] button. a Execute the quick Pm referring "7. Executing
a It is not necessary to save the data quick Pm" in "VHMS controller initial setting
before the setting. procedure".
a Download the data referring "8. Download of
setting data" in "VHMS controller initial setting
procedure".
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-Ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)

E-mail: [email protected]

7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.

WA600-6 27
SEN00556-05 30 Testing and adjusting

Pm-clinic inspection table 1

WA600-6 Serial No. 60001 and up
Machine serial No. #

Engine serial No.

hour inspection SAA6D170E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours

Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m

Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.
a Working mode: P-mode
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
Engine at low idle 775 – 825 775 – 825
Engine at high idle 1,950 – 2,050 1,950 – 2,050
Engine at high idle and torque converter
1,700 – 1,900 1,600 – 2,000
stalled
Engine speed rpm
Engine at high idle and work equipment
1,840 – 2,040 1,740 – 2,140
relieved
Torque converter stalled + Work equipment
1,580 – 1,780 1,380 – 1,980
relieved
Engine

Engine at high idle and torque converter kPa Max. 3.43 9.4
Blow-by pressure
stalled {mmH2O} {Max. 350} {960}
Min. 0.34 0.21
Engine at high idle
Lubricating oil MPa {Min. 3.5} {2.1}
SAE15W-40
pressure {kg/cm2} Min. 0.1 0.08
Engine at low idle
{Min. 1.0} {0.8}
Engine at high idle and torque converter kPa Min. 147 133
Boost pressure
stalled {mmHg} {Min. 1,100} {1,000}
Exhaust Engine at high idle and toque converter stalled
°C Max. 650 700
temperature Outside temperature: 20°C

a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
• Torque converter oil Min. 3.09 Min. 3.09
Low idle
Main relief temperature: Within {Min. 31.5} {Min. 31.5}
pressure operating range 3.65 ± 0.2 3.65 ± 0.2
High idle • Working mode: P-mode {37.2 ± 2.0} {37.2 ± 2.0}
Torque converter inlet port oil 0.94 ± 0.2 0.94 ± 0.2
pressure {9.6 ± 2.0} {9.6 ± 2.0}
• Torque converter oil
Torque converter outlet port oil temperature: Within 0.57 ± 0.1 0.57 ± 0.1
pressure operating range {5.8 ± 1.0} {5.8 ± 1.0}
• Working mode: P-mode 2.48 ± 0.2 2.48 ± 0.2
Modulation clutch oil pressure • Engine speed: {25.3 ± 2.0} {25.3 ± 2.0}
Transmission valve

High idle
0.12 ± 0.06 0.12 ± 0.06
Lubrication oil pressure
{1.2 ± 0.6} {1.2 ± 0.6}
MPa 2.68 ± 0.2 2.68 ± 0.2
F clutch
{kg/cm2} {27.3 ± 2} {27.3 ± 2}
3.12 ± 0.2 3.12 ± 0.2
R clutch
{31.8 ± 2.0} {31.8 ± 2.0}
• Torque converter oil 3.07 ± 0.2 3.07 ± 0.2
1st clutch temperature: {31.3 ± 2.0} {31.3 ± 2.0}
ECMV output Within operating range
2.09 ± 0.2 2.09 ± 0.2
(clutch) oil 2nd clutch • Working mode: P-mode
{21.3 ± 2.0} {31.3 ± 2.0}
pressure • Engine speed:
High idle 3.07 ± 0.2 3.07 ± 0.2
3rd clutch
• Manual switch: ON {31.3 ± 2.0} {31.3 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
4th clutch
{31.3 ± 2.0} {31.3 ± 2.0}
1.84 ± 0.2 1.84 ± 0.2
Lockup clutch
{18.8 ± 2.0} {18.8 ± 2.0}

28 WA600-6
30 Testing and adjusting SEN00556-05

Pm-clinic inspection table

WA600-6 Serial No. 60001 and up
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
Secure frame with frame lock bar.
Steering relief Hydraulic oil temperature: 45 – 55°C 32.32 – 34.28 31.32 – 34.28
Steering

pressure Engine speed at high idle {330 – 350} {320 – 350}

MPa
Hydraulic oil temperature: 45 – 55°C {kg/cm2}
AJSS EPC 2.35 – 2.55 2.25 – 2.65
Engine speed at high idle
pressure {24 – 26} {23 – 27}
Operating AJSS fully
Parking brake inlet Min. 2.45 Min. 2.45
pressure {Min. 25.0} {Min. 25.0}
Parking brake pilot Torque converter oil temperature: Min. 3.09 Min. 3.09
MPa
pressure Within operating range {Min. 31.5} {Min. 31.5}
{kg/cm2}
Engine speed: Low idle
Parking brake sole-
Min. 2.45 Min. 2.45
noid valve output
{Min. 25.0} {Min. 25.0}
pressure
Tire inflation pressure: Specified pressure
Parking brake Test on flat and dry paved slope of 1/5
— Stopped Stopped
performance (11° 20').
Set machine in operating state.
Disc thickness mm 3.2 ± 0.08 Min. 2.97
Measure when
Charge cut-in brake oil pres- 5.88 – 6.37 5.39 – 6.86
pressure Hydraulic oil tempera- sure warning {60 – 65} {55 – 70}
ture: Within operating lamp goes off.
range Measure when
Brake

Engine at low idle MPa

Charge cut-out brake oil pres- 9.8 – 10.78 9.31 – 11.27
{kg/cm2}
pressure sure starts low- {100 – 110} {95 – 115}
ering after rising.
Hydraulic oil temperature: Within operating
4.9 – 5.59 4.7 – 5.78
Brake oil pressure range
{50 – 57} {48 – 59}
Engine at low idle
Engine: Stopped
Lowering of brake kPa Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9
oil pressure 2 {kg/cm2} {Max. 5} {Max. 5}
MPa {50 kg/cm } in 5 minutes.
Tire inflation pressure: Specified pressure
Test on flat, level, straight, and dry paved
road.
Wheel brake Braking initial speed: 20km/h,
m Max. 5 Max. 5
performance Delay in pressing pedal: Max 0.1 sec
Brake pedal pressing force:
Specified force, 294 ± 29.4 Nm {30 ± 3 kg}
Measure braking distance.
Wear of wheel
Measure with disc wear indicator. mm 0 Max. 5.5
brake disc
Work equipment Bucket circuit 3.72 – 3.92 3.52 – 5.92
valve relief pressure relieved {38 – 40} {36 – 40}
MPa
Work equipment {kg/cm2}
Lift arm lever at 1.47 – 1.87 1.28 – 2.06
valve LS differential
half stroke {15 – 19} {13 – 21}
pressure Hydraulic oil tem-
Work equipment

perature: 45 – 55°C Rising time 8.1 – 9.1 Max. 10.5

Lift arm speed Engine at high idle
Lowering time 3.6 – 4.6 Max. 5.3
Bucket full stroke sec
Bucket tilt back 2.7 – 3.3 Max. 4.0
time
speed
Bucket at level time 1.7 – 2.3 Max. 2.9
Hydraulic oil tem- Bucket cylinder Max. 20 Max. 20
Hydraulic drift of perature: Within mm/
work equipment operating range 15 min.
Engine: Stopped Lift cylinder Max. 40 Max. 40

Visual check of Front axle There must not be

Axle

—
differential drain plug Rear axle excessive metal powder.

WA600-6 29
SEN00556-05

WA600-6 Wheel loader

Form No. SEN00556-05

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

30
 SEN03364-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Failure code table and fuse locations
Failure codes list ............................................................................................................................................. 2
Fuse locations............................................................................................................................................... 15

WA600-6 1
SEN03364-01 40 Troubleshooting

Failure codes list 1

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
TORQFLOW Electrical
1500L0 Double meshing TM E03
transmission system
Mechanical
15B0NX Transmission filter Clogging MON E01
system
When command current is Electrical
15SAL1 ECMV F clutch TM E03
OFF, fill signal is ON system
When command current is Electrical
15SALH ECMV F clutch TM E01
ON, fill signal is OFF system
When command current is Electrical
15SBL1 ECMV R clutch TM E03
OFF, fill signal is ON system
When command current is Electrical
15SBLH ECMV R clutch TM E01
ON, fill signal is OFF system
When command current is Electrical
15SEL1 ECMV 1st clutch TM E03
OFF, fill signal is ON system
When command current is Electrical
15SELH ECMV 1st clutch TM E01 Troubleshooting
ON, fill signal is OFF system
by failure code
When command current is Electrical
15SFL1 ECMV 2nd clutch TM E03 (Display of
OFF, fill signal is ON system
code), Part 1
When command current is Electrical SEN00558-02
15SFLH ECMV 2nd clutch TM E01
ON, fill signal is OFF system
When command current is Electrical
15SGL1 ECMV 3rd clutch TM E03
OFF, fill signal is ON system
When command current is Electrical
15SGLH ECMV 3rd clutch TM E01
ON, fill signal is OFF system
When command current is Electrical
15SHL1 ECMV 4th clutch TM E03
OFF, fill signal is ON system
When command current is Electrical
15SHLH ECMV 4th clutch TM E01
ON, fill signal is OFF system
Transmission Mechanical
15W0NT Overheat TM E02
modulation clutch system
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G42ZG Front accumulator Low oil pressure MON E03
system
Mechanical
2G43ZG Rear accumulator Low oil pressure MON E03
system
Electrical
44K0L4 Bucket positioner ON/OFF signals disagree WRK E01
system
VHMS system
A000N1 Engine Overrun VHMS — Troubleshooting
(n201)
by failure code
Mechanical
AA1ANX Air cleaner Clogging MON E01 (Display of
system
code), Part 2
Signal disagrees with Electrical SEN00559-03
AB00L6 Alternator MON E03
operating state of engine system
Mechanical
AB00MA Alternator Malfunction MON E03
system
Mechanical
B@BAZG Engine oil Low oil pressure ENG E03
system

2 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Mechanical
B@BAZK Engine oil Low level MON E01
system
Mechanical
B@BCNS Coolant Overheating ENG E02
system
Mechanical
B@BCZK Coolant Low level MON E01
system
Mechanical
B@C7NS Brake oil Overheating MON E02
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@GAZK Battery electrolyte Low level MON E01
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Abnormality in engine Electrical
CA111 — ENG E03
controller system
Engine Ne or Bkup Electrical
CA115 — ENG E03
speed sensor error system
Charge (boost)
Electrical
CA122 pressure sensor high — ENG E03
system
error Troubleshooting
Charge (boost) by failure code
Electrical (Display of
CA123 pressure sensor low — ENG E03
system code), Part 2
error
SEN00559-03
Throttle sensor high Electrical
CA131 — ENG E03
error system
Throttle sensor low Electrical
CA132 — ENG E03
error system
Oil pressure sensor Electrical
CA135 — ENG E01
high error system
Oil pressure sensor low Electrical
CA141 — ENG E01
error system
Coolant temperature Electrical
CA144 — ENG E01
sensor high error system
Coolant temperature Electrical
CA145 — ENG E01
sensor low error system
Charge (boost)
Electrical
CA153 temperature sensor — ENG E01
system
high error
Charge (boost)
Electrical
CA154 temperature sensor low — ENG E01
system
error
Sensor power supply 2 Electrical
CA187 — ENG E03
low error system
Engine oil pressure
Electrical
CA212 sensor high error — ENG E01
system
(VHMS)

WA600-6 3
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Engine oil pressure
Electrical
CA213 sensor low error — ENG E01
system
(VHMS)
Troubleshooting
Ambient pressure Electrical by failure code
CA221 — ENG E01
sensor high error system (Display of
Ambient pressure Electrical code), Part 2
CA222 — ENG E01 SEN00559-03
sensor low error system
Sensor power supply 2 Electrical
CA227 — ENG E03
voltage high error system
Electrical
CA234 Engine overspeed — ENG E02
system
Ne speed sensor
Electrical
CA238 supply power voltage — ENG E03
system
error
Fuel temperature Electrical
CA263 — ENG E01
sensor high error system
Fuel temperature Electrical
CA265 — ENG E01
sensor low error system
Electrical
CA271 PCV1 short circuit — ENG E03
system
Electrical
CA272 PCV1 disconnection — ENG E03
system
Electrical
CA273 PCV2 short circuit — ENG E03
system
Electrical
CA274 PCV2 disconnection — ENG E03
system
Injector #1 open/short Electrical
CA322 — ENG E03
error system
Troubleshooting
Injector #5 open/short Electrical by failure code
CA323 — ENG E03
error system (Display of
Injector #3 open/short Electrical code), Part 3
CA324 — ENG E03 SEN00560-02
error system
Injector #6 open/short Electrical
CA325 — ENG E03
error system
Injector #2 open/short Electrical
CA331 — ENG E03
error system
Injector #4 open/short Electrical
CA332 — ENG E03
error system
Calibration code Electrical
CA342 — ENG E03
incompatibility system
Injectors drive circuit Electrical
CA351 — ENG E03
error system
Sensor power supply 1 Electrical
CA352 — ENG E03
voltage low error system
Sensor power supply 1 Electrical
CA386 — ENG E03
voltage high error system
Idle validation switch Electrical
CA431 — ENG E01
error system
Idle validation action Electrical
CA432 — ENG E03
error system

4 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Engine oil pressure Electrical
CA435 — ENG E03
switch error system
Battery voltage low Electrical
CA441 — ENG E03
error system
Battery voltage high Electrical
CA442 — ENG E03
error system
Common rail pressure Electrical
CA449 — ENG E03
high error 2 system
Common rail pressure Electrical
CA451 — ENG E03
sensor high error system
Common rail pressure Electrical
CA452 — ENG E03
sensor low error system
Common rail pressure Electrical
CA553 — ENG E03
high error 1 system
Supply pump pressure Electrical
CA559 — ENG E03
very low error 1 system
Engine Ne speed Electrical
CA689 — ENG E03
sensor error system
Engine Bkup speed Electrical
CA731 — ENG E03 Troubleshooting
sensor phase error system
by failure code
All continuous data lost Electrical
CA757 — ENG E03 (Display of
error system
code), Part 3
Engine Bkup speed Electrical SEN00560-02
CA778 — ENG E03
sensor error system
EGR valve servo error Electrical
CA1228 — ENG E03
1 system
EGR valve servo error Electrical
CA1625 — ENG E03
2 system
Bypass valve solenoid Electrical
CA1626 — ENG E03
current high error system
Bypass valve solenoid Electrical
CA1627 — ENG E03
current low error system
Bypass valve servo Electrical
CA1628 — ENG E03
error 1 system
Bypass valve servo Electrical
CA1629 — ENG E03
error 2 system
Bypass valve lift sensor Electrical
CA1631 — ENG E03
high error system
Bypass valve lift sensor Electrical
CA1632 — ENG E03
low error system
KOMNET datalink Electrical
CA1633 — ENG E03
timeout error system
Throttle sensor supply Electrical
CA2185 — ENG E03
voltage high error system
Throttle sensor supply Electrical Troubleshooting
CA2186 — ENG E03 by failure code
voltage low error system
(Display of
Supply pump pressure Electrical code), Part 4
CA2249 — ENG E03
very low error 2 system SEN00561-03
EGR valve position Electrical
CA2271 — ENG E03
sensor high error system

WA600-6 5
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
EGR valve position Electrical
CA2272 — ENG E03
sensor low error system
EGR valve solenoid Electrical
CA2351 — ENG E03
operation short circuit system
EGR valve solenoid Electrical
CA2352 — ENG E03
operation disconnection system
Intake heater relay Electrical
CA2555 — ENG E01
voltage disconnection system
Intake heater relay Electrical
CA2556 — ENG E01
voltage high error system
AJSS neutral safety Electrical
D191KA Disconnection WRK E01
relay system
AJSS neutral safety Electrical
D191KB Short-circuit WRK E01
relay system
Electrical
D192KA ECSS solenoid Disconnection TM E01
system
Electrical
D192KB ECSS solenoid Short circuit TM E01
system
Short circuit with power Electrical
D192KY ECSS solenoid TM E01
supply line system
Transmission oil
Electrical
D198KA pressure bypass Disconnection TM E01
system
solenoid
Transmission oil Troubleshooting
Electrical
D198KB pressure bypass Short circuit TM E01 by failure code
system
solenoid (Display of
Transmission oil code), Part 4
Short circuit with power Electrical SEN00561-03
D198KY pressure bypass TM E01
supply line system
solenoid
Electrical
D5ZHKA Terminal C signal Disconnection TM E01
system
Electrical
D5ZHKB Terminal C signal Short circuit TM E01
system
Disconnection or short Electrical
D5ZHKZ Terminal C signal WRK E01
circuit system
Signal disagrees with
Electrical
D5ZHL6 Terminal C signal engine running or stopped MON E01
system
state
Electrical
DA80L4 Auto grease controller ON/OFF signals disagree MON —
system
Electrical
DAF3KK Machine monitor Low source voltage (input) MON E03
system
Electrical
DAF5KP Machine monitor Low output voltage MON E01
system
Defective communication
Machine monitor CAN Electrical
DAFRKR (Abnormality in target MON E03
communication system
component system)
Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Electrical
DAQ0KT Transmission controller Abnormality in controller TM E01
system

6 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Transmission controller Electrical
DAQ2KK Low source voltage (input) TM E03
load power supply line system
Transmission controller
Disagreement of model Troubleshooting
DAQ9KQ model selection wiring MON E03 —
selection signals by failure code
harness
(Display of
Defective communication code), Part 4
Transmission controller Electrical
DAQRKR (Abnormality in target TM E03 SEN00561-03
CAN communication system
component system)
Transmission controller
DAQRMA Malfunction TM E03 —
CAN communication
Defective communication
Engine controller CAN Electrical
DB2RKR (Abnormality in target TM E03
communication system
component system)
Work equipment Electrical
DB90KK Low source voltage (input) WRK E03
controller system
Work equipment Electrical
DB90KT Abnormality in controller WRK E01
controller system
Work equipment
Electrical
DB92KK controller load power Low source voltage (input) WRK E03
system
supply line
Work equipment
Electrical
DB95KX controller power supply Out of input signal range WRK E03
system
output
Work equipment
controller model Disagreement of model
DB99KQ MON E03 —
selection wiring selection signals
harness
Work equipment Defective communication
Electrical
DB9RKR controller CAN (Abnormality in target TM E03
system
communication component system) Troubleshooting
Work equipment by failure code
DB9RMA controller CAN Malfunction MON E03 — (Display of
communication code), Part 5
SEN00562-03
Transmission controller Electrical
DB9RMC Defective operation WRK E03
CAN communication system
VHMS system
DBB0KK VHMS controller Low source voltage (input) VHMS —
(n901)
Disagreement of model VHMS system
DBB0KQ VHMS controller VHMS —
selection signals (nF11)
VHMS controller battery VHMS system
DBB3KK Low source voltage (input) VHMS —
power supply (n905)
VHMS controller 5 V VHMS system
DBB5KP Low output voltage VHMS —
power supply output (n904)
VHMS controller 24 V VHMS system
DBB6KP Low output voltage VHMS —
power supply output (n902)
VHMS controller 12 V VHMS system
DBB7KP Low output voltage VHMS —
power supply output (n903)
Defective communication
VHMS controller VHMS system
DBBQKR (Abnormality in target VHMS —
KOMNET (n802)
component system)
t switch (Panel switch Switch is kept pressed for Electrical
DD15LD MON E01
1) long time system

WA600-6 7
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
U switch (Panel switch Switch is kept pressed for Electrical
DD16LD MON E01
2) long time system
< switch (Panel switch Switch is kept pressed for Electrical
DD17LD MON E01
3) long time system
> switch (Panel switch Switch is kept pressed for Electrical
DD18LD MON E01
4) long time system
Remote positioner
Switch is kept pressed for Electrical Troubleshooting
DD1ALD raise/lower set switch WRK E01
long time system by failure code
(RAISE)
(Display of
Remote positioner code), Part 5
Switch is kept pressed for Electrical
DD1BLD raise/lower set switch WRK E01 SEN00562-03
long time system
(LOWER)
Load meter subtotal Switch is kept pressed for Electrical
DD1CLD MON E01
switch long time system
Load meter mode Switch is kept pressed for Electrical
DD1FLD MON E01
selector switch (A/B) long time system
Load meter mode Switch is kept pressed for Electrical
DD1GLD MON E01
selector switch (+/–) long time system
Load meter display Switch is kept pressed for Electrical
DD1HLD MON E01
selector switch long time system
RPM set ON/OFF Electrical
DDA7L4 ON/OFF signals disagree TM E01
switch system
RPM set idle-up/down Electrical
DDA8KB Short circuit TM E01
switch (idle-up) system
RPM set idle-up/down Electrical
DDA9KB Short circuit TM E01
switch (idle-down) system
Parking brake switch Electrical
DDB6L4 ON/OFF signals disagree TM E03
(Neutralizer) system
Remote positioner Switch is kept pressed for Electrical
DDD1LD WRK E01
bucket angle set switch long time system
Electrical
DDDBKA Traction adjustment dial Disconnection TM E01
system
Electrical Troubleshooting
DDDBKB Traction adjustment dial Short circuit TM E01
system by failure code
Emergency steering Electrical (Display of
DDE5MA Malfunction MON E01 code), Part 6
drive switch system
SEN00569-03
Electrical
DDK4KA AJSS FNR switch Disconnection TM E03
system
Electrical
DDK4KB AJSS FNR switch Short circuit TM E03
system
AJSS shift-up/down Electrical
DDK5L4 ON/OFF signals disagree TM E01
switch system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short circuit TM E03
system
Lock detection pressure
Electrical
DDP5KA switch of steering lock Disconnection TM E01
system
lever
Shift mode selector Electrical
DDT0L4 ON/OFF signals disagree TM E01
switch system

8 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Switch is kept pressed for Electrical
DDW9LD Kick-down switch TM E01
long time system
Switch is kept pressed for Electrical
DDWLLD Hold switch TM E01
long time system
Load meter cancel Switch is kept pressed for Electrical
DDY0LD MON E01
switch long time system
Transmission shift lever Electrical Troubleshooting
DF10KA Disconnection TM E01 by failure code
switch system
(Display of
Transmission shift lever Electrical code), Part 6
DF10KB Short circuit TM E01
switch system SEN00569-03
Atmospheric VHMS system
DGE5KX Out of input signal range VHMS —
temperature sensor (n401)
Transmission oil Electrical
DGF1KA Disconnection TM E01
temperature sensor system
Transmission oil Electrical
DGF1KB Short circuit TM E01
temperature sensor system
Hydraulic oil Electrical
DGH2KX Out of input signal range MON E01
temperature sensor system
Rear brake oil Electrical
DGR2KA Disconnection MON E01
temperature sensor system
Rear brake oil Electrical
DGR2KX Out of input signal range MON E01
temperature sensor system
Torque converter oil Electrical
DGT1KA Disconnection MON E01
temperature sensor system
Torque converter oil Electrical
DGT1KB Short circuit MON E01
temperature sensor system
Torque converter oil Electrical
DGT1KX Out of input signal range MON E01
temperature sensor system
Exhaust gas VHMS system
DGT4KA Disconnection VHMS —
temperature sensor (F) (n312)
Exhaust gas VHMS system
DGT4KB Short circuit VHMS — Troubleshooting
temperature sensor (F) (n311)
by failure code
Exhaust gas VHMS system
DGT5KA Disconnection VHMS — (Display of
temperature sensor (R) (n322)
code), Part 7
Exhaust gas VHMS system SEN00570-03
DGT5KB Short circuit VHMS —
temperature sensor (R) (n321)
Oil pressure sensor of Electrical
DH21KA Disconnection WRK E01
work equipment pump system
Oil pressure sensor of Electrical
DH21KB Short circuit WRK E01
work equipment pump system
Blow-by pressure VHMS system
DHE5KB Short circuit VHMS —
sensor (n332)
Blow-by pressure Short circuit with power VHMS system
DHE5KY VHMS —
sensor supply line (n331)
Lift arm cylinder bottom Electrical
DHPCKX Out of input signal range MON E01
pressure sensor system
Lift arm cylinder head Electrical
DHPDKX Out of input signal range MON E01
pressure sensor system
Transmission filter Signal disagrees with Electrical
DHT2L6 MON E01
clogging sensor operating state of engine system

WA600-6 9
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Steering oil pressure VHMS system
DHT8KX Out of input signal range VHMS —
sensor (n533)
Modulation clutch Electrical
DHTBKA Disconnection TM E03
pressure sensor system
Modulation clutch Electrical
DHTBKB Short circuit TM E03 Troubleshooting
pressure sensor system
by failure code
Front brake oil pressure VHMS system
DHU2KX Out of input signal range VHMS — (Display of
sensor (F) (n711)
code), Part 7
Rear brake oil pressure VHMS system SEN00570-03
DHU3KX Out of input signal range VHMS —
sensor (R) (n712)
AJSS lever angle Electrical
DK30KA Disconnection WRK E01
sensor system
AJSS lever angle Short circuit with power Electrical
DK30KY WRK E01
sensor supply line system
Lift arm EPC lever Electrical
DK59KA Disconnection WRK E03
potentiometer (Main) system
Lift arm EPC lever
Short circuit with power Electrical
DK59KY potentiometer (Main & WRK E03
supply line system
Sub)
Lift arm EPC lever Electrical
DK59L8 Analog signals disagree WRK E03
potentiometer (Main) system
Lift arm EPC lever Electrical
DK5AKA Disconnection WRK E03
potentiometer (Sub) system
Lift arm EPC lever Short circuit with power Electrical
DK5AKY WRK E03
potentiometer (Sub) supply line system
Bucket EPC lever Electrical
DK5BKA Disconnection WRK E03
potentiometer (Main) system
Bucket EPC lever Short circuit with power Electrical
DK5BKY WRK E03
potentiometer (Main) supply line system
Bucket EPC lever
Electrical
DK5BL8 potentiometer (Main & Analog signals disagree WRK E03
system Troubleshooting
Sub)
by failure code
Bucket EPC lever Electrical (Display of
DK5CKA Disconnection WRK E03
potentiometer (Sub) system code), Part 8
Bucket EPC lever Short circuit with power Electrical SEN00571-03
DK5CKY WRK E03
potentiometer (Sub) supply line system
3rd valve (attachment)
Electrical
DK5DKA lever EPC Disconnection WRK E03
system
potentiometer (Main)
3rd valve (attachment)
Short circuit with power Electrical
DK5DKY lever EPC WRK E03
supply line system
potentiometer (Main)
3rd valve (attachment)
lever EPC Electrical
DK5DL8 Analog signals disagree WRK E03
potentiometer (Main & system
Sub)
3rd valve (attachment)
Electrical
DK5EKA lever EPC Disconnection WRK E03
system
potentiometer (Sub)
3rd valve (attachment)
Short circuit with power Electrical
DK5EKY lever EPC WRK E03
supply line system
potentiometer (Sub)

10 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Electrical
DKA0KA Lift arm angle sensor Disconnection WRK E01
system
Electrical Troubleshooting
DKA0KX Lift arm angle sensor Out of input signal range MON E01 by failure code
system
(Display of
Short circuit with power Electrical code), Part 8
DKA0KY Lift arm angle sensor WRK E01
supply line system SEN00571-03
Electrical
DKA0L0 Lift arm angle sensor Improper positioning WRK E01
system
Electrical
DKD0KA Frame angle sensor Disconnection WRK E01
system
Short circuit with power Electrical
DKD0KY Frame angle sensor WRK E01
supply line system
AJSS lever and frame Disconnection or short Electrical
DKD0KZ WRK E01
angle sensor circuit system
Modulation clutch
Electrical
DLFAKA output shaft speed Disconnection TM E03
system
sensor
Modulation clutch
Electrical
DLFALC output shaft speed Speed signals disagree TM E03
system
sensor
Transmission output Electrical
DLT3KA Disconnection TM E03
shaft speed sensor (2) system
Transmission output Electrical
DLT3LC Speed signals disagree TM E03
shaft speed sensor (2) system
Transmission output Electrical
DLT4KB Short circuit TM E03
shaft speed sensor (1) system
Transmission output Electrical
DLT4KX Out of input signal range TM E03
shaft speed sensor (1) system Troubleshooting
Remote positioner raise by failure code
DUM1KB Short circuit WRK — — (Display of
indicator lamp
code), Part 9
Remote positioner SEN00572-03
DUM2KB Short circuit WRK — —
lower indicator lamp
Electrical
DV00KB Alarm buzzer Short circuit MON E01
system
Lift arm raise EPC Electrical
DW4PKA Disconnection WRK E03
solenoid system
Lift arm raise EPC Electrical
DW4PKB Short circuit WRK E03
solenoid system
Lift arm raise EPC Short circuit with power Electrical
DW4PKY WRK E03
solenoid supply line system
Lift arm lower EPC Electrical
DW4QKA Disconnection WRK E03
solenoid system
Lift arm lower EPC Electrical
DW4QKB Short circuit WRK E03
solenoid system
Lift arm lower EPC Short circuit with power Electrical
DW4QKY WRK E03
solenoid supply line system
Electrical
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03
system
Electrical
DW4RKB Bucket tilt EPC solenoid Short circuit WRK E03
system

WA600-6 11
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Short circuit with power Electrical
DW4RKY Bucket tilt EPC solenoid WRK E03
supply line system
Bucket dump EPC Electrical
DW4SKA Disconnection WRK E03
solenoid system
Bucket dump EPC Electrical
DW4SKB Short circuit WRK E03
solenoid system
Bucket dump EPC Short circuit with power Electrical
DW4SKY WRK E03
solenoid supply line system
Electrical Troubleshooting
DW7BKA Fan reverse solenoid Disconnection TM E01 by failure code
system
(Display of
Electrical code), Part 9
DW7BKB Fan reverse solenoid Short circuit TM E01
system SEN00572-03
Short circuit with power Electrical
DW7BKY Fan reverse solenoid TM E01
supply line system
Hydraulic drive fan Electrical
DW7DKA Disconnection TM E01
neutral solenoid system
Hydraulic drive fan Electrical
DW7DKB Short circuit TM E01
neutral solenoid system
Hydraulic drive fan Short circuit with power Electrical
DW7DKY TM E01
neutral solenoid supply line system
Work equipment neutral Electrical
DWM1KA Disconnection WRK E01
lock EPC solenoid system
Work equipment neutral Electrical
DWM1KB Short circuit WRK E01
lock EPC solenoid system
Work equipment neutral Short circuit with power Electrical
DWM1KY WRK E01
lock EPC solenoid supply line system
Lift arm raise magnet Electrical
DWN6KA Disconnection WRK E01
detent solenoid system
Lift arm raise magnet Electrical
DWN6KB Short circuit WRK E01
detent solenoid system
Lift arm raise magnet Short circuit with power Electrical
DWN6KY WRK E01
detent solenoid supply line system
Lift arm float magnet Electrical
DWN7KA Disconnection WRK E01 Troubleshooting
detent solenoid system
by failure code
Lift arm float magnet Electrical
DWN7KB Short circuit WRK E01 (Display of
detent solenoid system
code), Part 10
Lift arm float magnet Short circuit with power Electrical SEN00573-03
DWN7KY WRK E01
detent solenoid supply line system
Bucket tilt magnet Electrical
DWN8KA Disconnection WRK E01
detent solenoid system
Bucket tilt magnet Electrical
DWN8KB Short circuit WRK E01
detent solenoid system
Bucket tilt magnet Short circuit with power Electrical
DWN8KY WRK E01
detent solenoid supply line system
Modulation clutch cut- Electrical
DWNFKA Disconnection TM E01
off release solenoid system
Modulation clutch cut- Electrical
DWNFKB Short circuit TM E01
off release solenoid system
Modulation clutch cut- Short circuit with power Electrical
DWNFKY TM E03
off release solenoid supply line system

12 WA600-6
40 Troubleshooting SEN03364-01

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
Fan pump EPC Electrical
DX16KA Disconnection TM E01
solenoid system
Fan pump EPC Electrical
DX16KB Short circuit TM E01
solenoid system
Fan pump EPC Short circuit with power Electrical
DX16KY TM E01
solenoid supply line system
Pump PC-EPC Electrical
DXA1KA Disconnection WRK E01
solenoid system
Pump PC-EPC Electrical
DXA1KB Short circuit WRK E01
solenoid system
Electrical
DXF0KA AJSS EPC solenoid Disconnection WRK E01 Troubleshooting
system
by failure code
Electrical
DXF0KB AJSS EPC solenoid Short circuit WRK E01 (Display of
system
code), Part 10
Electrical SEN00573-03
DXH1KA Lockup ECMV solenoid Disconnection TM E01
system
Electrical
DXH1KB Lockup ECMV solenoid Short circuit TM E01
system
Short circuit with power Electrical
DXH1KY Lockup ECMV solenoid TM E03
supply line system
1st clutch ECMV Electrical
DXH4KA Disconnection TM E03
solenoid system
1st clutch ECMV Electrical
DXH4KB Short circuit TM E03
solenoid system
1st clutch ECMV Short circuit with power Electrical
DXH4KY TM E03
solenoid supply line system
2nd clutch ECMV Electrical
DXH5KA Disconnection TM E03
solenoid system
2nd clutch ECMV Electrical
DXH5KB Short circuit TM E03
solenoid system
2nd clutch ECMV Short circuit with power Electrical
DXH5KY TM E03
solenoid supply line system
3rd clutch ECMV Electrical
DXH6KA Disconnection TM E03
solenoid system
3rd clutch ECMV Electrical
DXH6KB Short circuit TM E03
solenoid system
3rd clutch ECMV Short circuit with power Electrical Troubleshooting
DXH6KY TM E03 by failure code
solenoid supply line system
(Display of
R clutch ECMV Electrical code), Part 11
DXH7KA Disconnection TM E03
solenoid system SEN00574-03
R clutch ECMV Electrical
DXH7KB Short circuit TM E03
solenoid system
R clutch ECMV Short circuit with power Electrical
DXH7KY TM E03
solenoid supply line system
Electrical
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH8KB F clutch ECMV solenoid Short circuit TM E03
system
Short circuit with power Electrical
DXH8KY F clutch ECMV solenoid TM E03
supply line system

WA600-6 13
SEN03364-01 40 Troubleshooting

Failure Action Category of Reference

Troubled part Trouble Controller
code code record manual
4th clutch ECMV Electrical
DXHHKA Disconnection TM E03
solenoid system
4th clutch ECMV Electrical
DXHHKB Short circuit TM E03
solenoid system
4th clutch ECMV Short circuit with power Electrical
DXHHKY TM E03
solenoid supply line system
3rd valve extract EPC Electrical
DXHJKA Disconnection WRK E03
solenoid system
3rd valve extract EPC Electrical
DXHJKB Short circuit WRK E03
solenoid system
3rd valve extract EPC Short circuit with power Electrical
DXHJKY WRK E03
solenoid supply line system
3rd valve retract EPC Electrical
DXHKKA Disconnection WRK E03
solenoid system
3rd valve retract EPC Electrical
DXHKKB Short circuit WRK E03
solenoid system
3rd valve retract EPC Short circuit with power Electrical Troubleshooting
DXHKKY WRK E03 by failure code
solenoid supply line system
(Display of
Modulation clutch Electrical code), Part 11
DXHPKA Disconnection TM E03
solenoid system SEN00574-03
Modulation clutch Electrical
DXHPKB Short circuit TM E03
solenoid system
Modulation clutch Short circuit with power Electrical
DXHPKY TM E03
solenoid supply line system
Modulation clutch Electrical
DXHPMA Malfunction TM E01
solenoid system
VHMS system
F@BBZL Blow-by pressure High error VHMS —
(n338)
Exhaust gas VHMS system
F@BYNR Abnormal heat VHMS —
temperature (F) (n362)
Exhaust gas VHMS system
F@BYNS Overheating VHMS —
temperature (F) (n361)
Exhaust gas VHMS system
F@BZNR Abnormal heat VHMS —
temperature (R) (n372)
Exhaust gas VHMS system
F@BZNS Overheating VHMS —
temperature (R) (n371)

a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified. VHMS failure codes, which are available
only in VHMS specifications, are stored only in VHMS controller; therefore, they are not recorded in the
abnormality record.
(The VHMS abnormality record can be downloaded by connecting your PC to the VHMS controller.) The
4-digit VHMS failure code enclosed in ( ) indicates an error code that is displayed with two digits on each
7-segment LED of the VHMS controller.

14 WA600-6
40 Troubleshooting SEN03364-01

Fuse locations 1
Connection table of fuse box and circuit breaker
a This connection table indicates the devices to which the power of the fuse box and circuit breaker is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
circuit breaker to see if the power is supplied normally.

Fuse box A

Type of power supply Fuse No. Capacity of fuse Destination of power

1 10 A Starting switch terminal B circuit
2 10 A Hazard lamp circuit
Constant power supply 3 10 A Stair lamp circuit
Circuit breaker CBF1
(30A) 4 10 A Transmission controller (B) circuit
5 10 A Work equipment controller (B) circuit
6 10 A Machine monitor (B), VHMS controller (B) circuit
Switch power supply
7 5A Engine controller circuit
starting switch ACC
8 10 A Horn circuit
9 20 A Air conditioner circuit
10 10 A Auto grease circuit
Switch power supply 11 20 A Rear glass heater circuit
circuit breaker CBF2
(105A) 12 10 A Radio circuit
13 20 A Air suspension seat, DC-DC converter circuit
14 10 A VHMS controller (A) circuit
15 10 A Spare

Fuse box B

Type of power supply Fuse No. Capacity of fuse Destination of power

1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and blinking lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit

Switch power supply 5 10 A Transmission controller (A) circuit

circuit breaker CBF3 6 10 A Parking brake circuit
(105A) 7 10 A Work equipment controller (A) circuit
8 10 A Machine monitor (A) circuit
9 20 A Wiper and washer circuit
10 10 A Spare
11 20 A Main lamp circuit
Relay circuit power 12 10 A Right clearance lamp circuit
supply of small lamp 13 10 A Left clearance lamp circuit
Relay circuit power 14 10 A Right headlamp circuit
supply of small lamp 15 10 A Left headlamp circuit

WA600-6 15
SEN03364-01 40 Troubleshooting

Circuit breaker

Circuit breaker
Type of power supply Breaker capacity Destination of power
No.
Starting switch circuit, work equipment controller circuit,
Constant power supply CBF1 30 A
machine monitor circuit, VHMS controller circuit
Switch power supply CBF2 105 A Fuse box (A): Circuits 8 – 15
Switch power supply CBF3 105 A Fuse box (B): Circuits 1 – 11
Constant power supply CBF4 20 A Engine controller circuit

Locations and numbers of fuse boxes and circuit breakers

16 WA600-6
40 Troubleshooting SEN03364-01

WA600-6 17
SEN03364-01

WA600-6 Wheel loader

Form No. SEN03364-01

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

18
 SEN00557-01

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Testing before troubleshooting........................................................................................................................ 4
Classification and procedures of troubleshooting ........................................................................................... 5
Information contained in troubleshooting table ............................................................................................... 6
Phenomena looking like troubles and troubleshooting Nos. ........................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 45

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SEN00557-01 40 Troubleshooting

Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.

1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a
problem with the method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will
occur again. To prevent this, always investigate why the problem occurred.

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Sequence of events in troubleshooting 1

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SEN00557-01 40 Troubleshooting

Testing before troubleshooting 1

Item Criteria Remedy

1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean or drain
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Between FULL and
4. Check of coolant level Add coolant
LOW
Lubricating oil 5. Check of air cleaner for clogging No red Clean or replace
and coolant 6. Check of level and type of hydraulic oil Between H and L Add oil
In upper range of site
7. Check of level and type of transmission oil Add oil
gauge
8. Check of engine oil filter for clogging — Replace
9. Check of hydraulic oil filter for clogging — Replace
10. Check of transmission oil filter for clogging — Replace
11. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
12. Check of alternator terminal cables for
Electrical — Retighten or replace
looseness and corrosion
parts
13. Check of starting motor terminal cables for
— Retighten or replace
looseness and corrosion
14. Check of operation of instruments — Repair or replace
15. Check for abnormal noise and smell — Repair
Hydraulic and 16. Check for oil leakage — Repair
mechanical
equipment 17. Bleeding air — Bleed air
18. Check of effect of brake — Repair or adjust
19. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
20. Check of battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal
— Replace
of cover
22. Check for removed wire clamp and drooping
— Repair
wire

Electrical 23. Check wiring for wetting with water

Disconnect and dry
equipment (Check connectors and terminals for wetting —
connectors
with water, in particular)
24. Check of slow-blow fuses and fuses for
— Replace
disconnection and corrosion
25. Check of alternator voltage After several-minute
Repair or replace
(with engine at medium speed or higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay
— Replace
(Starting switch OFF ⇔ ON)

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Classification and procedures of troubleshooting 1

Classification of troubleshooting

Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting for electric system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit

Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.

1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code "flashes" when the trouble corresponding to it is detected. Even if a failure code
"lights up" when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).

2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code "flashes" when the trouble corresponding to it is detected. Even if a failure code
"lights up" when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).

3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting related to that phenomenon in the "E-mode", "H-mode", or "S-mode".

WA600-6 5
SEN00557-01 40 Troubleshooting

Information contained in troubleshooting table 1

Action code Failure code

Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine
controller controller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information

Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good

<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When "male" or "female" is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When "male" and "female" is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.

6 WA600-6
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Related circuit diagram

This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• "Connector No. and pin No." from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.

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SEN00557-01 40 Troubleshooting

Phenomena looking like troubles and troubleshooting Nos. 1

Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily. E-1 S-1
4 Engine does not crank E-1 S-2 a)
Engine cranks but exhaust smoke does not comes
5 Engine does S-2 b)
out
not start.
Exhaust smoke comes out but engine does not start
6 S-2 c)
(Fuel is injected)
7 Engine does not pick up smoothly. S-3
8 Engine stops during operation H-2 S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Engine oil becomes contaminated quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Engine oil pressure drops S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Air cannot be bled from fuel circuit S-17
Phenomena related to power train
22 Machine does not start H-1
23 Torque converter lockup is not switched (engine stalls) H-2
24 Torque converter lockup is not turned on H-3
Travel speed is low, rush force is low, grade-ability is low, and gear
25 H-4
speed does not change
26 Large shocks are made when machine starts and gear is shifted H-5
27 Large time lag is made when machine starts and gear is shifted H-6
28 Torque converter oil temperature is high H-7
Phenomena related to steering
29 Machine cannot be steered [machine with steering wheel] H-8
30 Machine cannot be steered [machine with AJSS] H-9
31 Steering response is low [machine with steering wheel] H-10
32 Steering response is low [machine with AJSS] H-11
33 Steering is heavy [machine with steering wheel] H-12
Steering wheel shakes or makes large shocks
34 H-13
[machine with steering wheel]

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Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
35 Steering wheel shakes or makes large shocks [machine with AJSS] H-14
Phenomena related to brake
36 Wheel brake does not work or braking force is low H-15
37 Wheel brake is not reset or it drags H-16
38 Parking brake does not work or braking force is low H-17
Parking brake cannot be reset or it drags
39 H-18
(including emergency release system)
Phenomena related to work equipment
40 Lift arm does not rise H-19
41 Lift arm speed is low or rising force of lift arm is insufficient H-20
42 When lift arm rises, its speed lowers at specific height H-21
43 Bucket cannot be held with lift arm cylinder (Bucket floats) H-22
44 Hydraulic drift of lift arm is large H-23
45 Lift arm shakes during operation H-24
46 Bucket does not tilt back H-25
47 Bucket speed is low or tilting back force is insufficient H-26
48 Bucket spool lowers during tilt-back operation H-27
49 Bucket cannot be held with bucket cylinder H-28
50 Hydraulic drift of bucket is large H-29
Bucket shakes while machine is traveling with load
51 H-30
(Work equipment valve is in HOLD)
Engine speed lowers remarkably or engine stalls during work
52 H-31
equipment control
53 Large shock is made when work equipment starts and stops H-32
When work equipment circuit is relieved singly, other work equipment
54 H-33
moves
55 ECSS does not operate, and pitching or bouncing occurs H-34
Fan speed is abnormal (Fan sound and vibration are abnormally
56 H-35
large or engine overheats)
Others
57 Wiper does not operate E-2
58 Windshield washer does not operate E-3
Headlamp, clearance lamp, tail lamp, and license plate lamp do not
59 E-4
light up or go off
60 Working lamp does not light up or go off E-5
61 Step lamp does not light up or go off E-6
62 Turn signal lamp and hazard lamp do not light up or go off E-7
63 Brake lamp does not light or it keeps lighting up E-8
64 Backup lamp does not light or it keeps lighting up E-9
65 Backup buzzer does not sound or it keeps sounding E-10
66 Horn does not sound or it keeps sounding E-11
67 Warning buzzer does not sound or it keeps sounding E-12
68 Air conditioner does not operate or stop E-13
Electric priming pump does not operate or does not stop
69 E-14
automatically

WA600-6 9
SEN00557-01 40 Troubleshooting

Connection table for connector pin numbers (Rev. 2007.8)

a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.

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44 WA600-6
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T- branch box and T- branch adapter table 1

(Rev. 2007.8)

a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
799-601-2790 Adapter for ECONO 12 ECONO12P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q

WA600-6 45
SEN00557-01 40 Troubleshooting

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7120 Adapter for M 4 M4P q q q q

799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q

46 WA600-6
40 Troubleshooting SEN00557-01

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,

“*” Shows not T-adapter but socket.

WA600-6 47
SEN00557-01

WA600-6 Wheel loader

Form No. SEN00557-01

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)

48
 SEN00558-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Failure code [1500L0] (TORQFLOW transmission: Double meshing) ............................................................ 3
Failure code [15B0NX] (Transmission filter: Clogged) .................................................................................... 4
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) ........................... 6
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) .......................... 8
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) ......................... 10
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) ........................ 12
Failure code [15SEL1] (ECMV (1): When command current is OFF, fill signal is ON).................................. 14
Failure code [15SELH] (ECMV (1): When command current is ON, fill signal is OFF)................................. 16
Failure code [15SFL1] (ECMV (2): When command current is OFF, fill signal is ON) .................................. 18
Failure code [15SFLH] (ECMV (2): When command current is ON, fill signal is OFF) ................................. 20
Failure code [15SGL1] (ECMV (3): When command current is OFF, fill signal is ON) ................................. 22
Failure code [15SGLH] (ECMV (3): When command current is ON, fill signal is OFF) ................................ 24
Failure code [15SHL1] (ECMV (4): When command current is OFF, fill signal is ON) ................................. 26
Failure code [15SHLH] (ECMV (4): When command current is ON, fill signal is OFF) ................................ 28

WA600-6 1
SEN00558-02 40 Troubleshooting

Failure code [15W0NT] (Transmission modulation clutch: Overheating) ...................................................... 30

Failure code [2F00MA] (Parking brake: Malfunction).................................................................................... 31
Failure code [2G42ZG] (Front accumulator: Low oil pressure) ..................................................................... 34

2 WA600-6
40 Troubleshooting SEN00558-02

Failure code [1500L0] (TORQFLOW transmission: Double meshing) 1

Action code Failure code TORQFLOW transmission: Double meshing

Trouble
E03 1500L0 (Transmission controller system)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and warning buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission may be broken.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1] and [15SHL1].
state

WA600-6 3
SEN00558-02 40 Troubleshooting

Failure code [15B0NX] (Transmission filter: Clogged) 1

Action code Failure code Transmission filter: Clogged

Trouble
E01 15B0NX (Machine monitor system)
Contents of • Transmission filter clogging sensor circuit is OPEN. (When torque converter oil temperature is above
trouble 50°C)
Action of • Turns the transmission filter clogging caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission filter clogging caution lamp lights on.
appears on
• The transmission may be broken.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the
Related
monitoring function (Code: 40903, D-IN-24).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Transmission filter clogging The transmission filter may be clogged. Check it directly.
a Prepare with starting switch OFF, then start engine and carry out
Defective transmission troubleshooting.
clogging sensor B09 (male) Transmission oil filter Resistance
2
(Internal disconnection or
short circuit) Normal Max. 1 z
Between (1) and (2)
Clogging Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
Possible causes harness Wiring harness between C03 (female) (5) –
3 Resistance Max. 1 z
and standard (Disconnection or defective B09 (female) (1)
value in normal contact of connector) Wiring harness between B09 (male) (2) –
state Resistance Max. 1 z
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with and carry out troubleshooting
4
24V circuit) in wiring harness Wiring harness between C03 (female) (5) –
Voltage Max. 1 V
B09 (female) (1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective machine monitor C03 (female) Transmission oil filter Resistance
Between (5) and Normal Max. 1 z
chassis ground Clogging Min. 1 Mz

4 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission clogging sensor

WA600-6 5
SEN00558-02 40 Troubleshooting

Failure code [15SAL1] (ECMV F clutch: When command current is OFF,

fill signal is ON) 1

Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller system)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until directional lever or directional
selector switch is set to N (Neutral).
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective F ECMV fill switch
1 Directional lever or
(Internal short circuit) F.SW (male) Resistance
directional switch
Between (1) and F (Forward) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L03 (female) (27) –
Resistance Min. 1 Mz
F.SW (female) (1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
3 Directional lever or
controller L03 Voltage
directional switch
Between (27) and F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V

6 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission F clutch

WA600-6 7
SEN00558-02 40 Troubleshooting

Failure code [15SALH] (ECMV F clutch: When command current is ON,

fill signal is OFF) 1

Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller system)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-25).
• Method of reproducing failure code: Start engine, and set directional lever or switch to F.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective F ECMV fill switch
1 Directional lever or
(Internal disconnection) F.SW (male) Resistance
directional switch
Between (1) and F (Forward) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L03 (female) (27) –
contact of connector) Resistance Max. 1 z
F.SW (female) (1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
3 Directional lever or
controller L03 Voltage
directional switch
Between (27) and F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V

8 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission F clutch

WA600-6 9
SEN00558-02 40 Troubleshooting

Failure code [15SBL1] (ECMV R clutch: When command current is OFF,

fill signal is ON) 1

Action code Failure code ECMV R clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until directional selector switch is set
to N (Neutral).
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective R ECMV fill switch
1 Directional lever or
(Internal short circuit) R.SW (male) Resistance
directional switch
Between (1) and R (Reverse) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Wiring harness between L03 (female) (17) –
Resistance Min. 1 Mz
R.SW (female) (1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
3 Directional lever or
controller L03 Voltage
directional switch
Between (17) and R (Reverse) Max. 1 V
chassis ground Other than above 8 – 10 V

10 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission R clutch

WA600-6 11
SEN00558-02 40 Troubleshooting

Failure code [15SBLH] (ECMV R clutch: When command current is ON,

fill signal is OFF) 1

Action code Failure code ECMV R clutch: When command current is OFF, fill signal is ON
Trouble
E01 15SBLH (Transmission controller system)
Contents of
• When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the R ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-26).
• Method of reproducing failure code: Start engine, and set directional lever or switch to R.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective R ECMV fill switch
1 Directional lever or
(Internal short circuit) R.SW (male) Resistance
directional switch
Between (1) and R (Reverse) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L03 (female) (17) –
contact of connector) Resistance Max. 1 z
R.SW (female) (1)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective transmission
3 Directional lever or
controller L03 Voltage
directional switch
Between (17) and R (Reverse) Max. 1 V
chassis ground Other than above 8 – 10 V

12 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission R clutch

WA600-6 13
SEN00558-02 40 Troubleshooting

Failure code [15SEL1] (ECMV (1): When command current is OFF, fill
signal is ON) 1

Action code Failure code ECMV (1): When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
selector switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring
function (Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 1st ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
switch (Internal short circuit) 1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
Possible causes 2 harness
and standard (Contact with ground circuit) Wiring harness between L03 (female) (7) –
Resistance Min. 1 Mz
value in normal 1.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (7) and 1st (1st speed) Max. 1 V
chassis ground Other than above 8 – 10 V

14 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 1st clutch

WA600-6 15
SEN00558-02 40 Troubleshooting

Failure code [15SELH] (ECMV (1): When command current is ON, fill
signal is OFF) 1

Action code Failure code ECMV (1): When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller system)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine does not travel at 1st.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring
function (Code: 31602, ECMV 1 DIR).
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
Related 40908, D-IN-27).
information • Method of reproducing failure code: Start engine, and set the manual/auto shift selector switch in the
MANUAL position, then set the directional lever or directional selector switch to the F (forward) or R
(reverse), and 1st shift lever position.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 1st ECMV fill
• Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
disconnection) 1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 2
and standard (Disconnection or defective Wiring harness between L03 (female) (7) –
contact of connector) Resistance Max. 1 z
value in normal 1.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (7) and 1st (1st speed) Max. 1 V
chassis ground Other than above 8 – 10 V

16 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 1st clutch

WA600-6 17
SEN00558-02 40 Troubleshooting

Failure code [15SFL1] (ECMV (2): When command current is OFF, fill
signal is ON) 1

Action code Failure code ECMV (2): When command current is OFF, fill signal is ON
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Turns the centralized warning lamp and alarm buzzer ON.
• Judges that the 2nd ECMV fill switch signal is turned ON.
Action of
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
controller
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
selector switch is set to N (Neutral).
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring
function (Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-28).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 2nd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
switch (Internal short circuit) 2.SW (male) Shift lever Resistance
Between (1) and 2nd (2nd speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
Possible causes 2 harness
and standard (Contact with ground circuit) Wiring harness between L03 (female) (13) –
Resistance Min. 1 Mz
value in normal 2.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (13) and 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

18 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 2nd clutch

WA600-6 19
SEN00558-02 40 Troubleshooting

Failure code [15SFLH] (ECMV (2): When command current is ON, fill
signal is OFF) 1

Action code Failure code ECMV (2): When command current is ON, fill signal is OFF
Trouble
E01 15SFLH (Transmission controller system)
Contents of
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine does not travel at 2nd.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring
function (Code: 31603, ECMV 2 DIR).
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
Related 40908, D-IN-28).
information • Method of reproducing failure code: Start engine, and set the manual/auto shift selector switch in the
MANUAL position, then set the directional lever or directional selector switch to the F (forward) or R
(reverse), and 2nd shift lever position.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 2nd ECMV fill
• Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
disconnection) 2.SW (male) Shift lever Resistance
Between (1) and 2nd (2nd speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 2
and standard (Disconnection or defective Wiring harness between L03 (female) (13) –
contact of connector) Resistance Max. 1 z
value in normal 2.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (13) and 2nd (2nd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

20 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 2nd clutch

WA600-6 21
SEN00558-02 40 Troubleshooting

Failure code [15SGL1] (ECMV (3): When command current is OFF, fill
signal is ON) 1

Action code Failure code ECMV (3): When command current is OFF, fill signal is ON
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until directional selector switch is set
to N (Neutral).
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring
function (Code: 31604, ECMV 3 DIR).
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 3rd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
switch (Internal short circuit) 3.SW (male) Shift lever Resistance
Between (1) and 3rd (3rd speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
Possible causes 2 harness
and standard (Contact with ground circuit) Wiring harness between L03 (female) (3) –
Resistance Min. 1 Mz
value in normal 1.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (3) and 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

22 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 3rd clutch

WA600-6 23
SEN00558-02 40 Troubleshooting

Failure code [15SGLH] (ECMV (3): When command current is ON, fill
signal is OFF) 1

Action code Failure code ECMV (3): When command current is ON, fill signal is OFF
Trouble
E01 15SGLH (Transmission controller system)
Contents of
• When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine does not travel at 3rd.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring
function (Code: 31604, ECMV 3 DIR).
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
Related 40908, D-IN-29).
information • Method of reproducing failure code: Turn starting switch ON, and set the manual/auto shift selector
switch in the MANUAL position, then set the directional lever or directional selector switch to the F
(forward) or R (reverse), and 3rd shift lever position.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 3rd ECMV fill
• Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
disconnection) 3.SW (male) Shift lever Resistance
Between (1) and 3rd (3rd speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 2
and standard (Disconnection or defective Wiring harness between L03 (female) (3) –
contact of connector) Resistance Max. 1 z
value in normal 3.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (3) and 3rd (3rd speed) Max. 1 V
chassis ground Other than above 8 – 10 V

24 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 3rd clutch

WA600-6 25
SEN00558-02 40 Troubleshooting

Failure code [15SHL1] (ECMV (4): When command current is OFF, fill
signal is ON) 1

Action code Failure code ECMV (4): When command current is OFF, fill signal is ON
Trouble
E03 15SHL1 (Transmission controller system)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until directional selector switch is set
to N (Neutral).
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring
function (Code: 31605, ECMV 4 DIR).
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-30).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 4th ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
switch (Internal short circuit) 4.SW (male) Shift lever Resistance
Between (1) and 4th (4th speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
Possible causes 2 harness
and standard (Contact with ground circuit) Wiring harness between L03 (female) (2) –
Resistance Min. 1 Mz
value in normal 4.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (2) and 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V

26 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 4th clutch

WA600-6 27
SEN00558-02 40 Troubleshooting

Failure code [15SHLH] (ECMV (4): When command current is ON, fill
signal is OFF) 1

Action code Failure code ECMV (4): When command current is ON, fill signal is OFF
Trouble
E01 15SHLH (Transmission controller system)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
• The machine may not travel at 4th.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring
function (Code: 31605, ECMV 4).
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
Related 40908, D-IN-30).
information • Method of reproducing failure code: Turn starting switch ON, and set the manual/auto shift selector
switch in the MANUAL position, then set the directional lever or directional selector switch to the F
(forward) or R (reverse), and 4th shift lever position.
• This error code may be displayed just after the transmission oil is replaced.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
Defective 4th ECMV fill
• Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
disconnection) 4.SW (male) Shift lever Resistance
Between (1) and 4th (4th speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 2
and standard (Disconnection or defective Wiring harness between L03 (female) (2) –
contact of connector) Resistance Max. 1 z
value in normal 4.SW (female) (1)
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission position.
3
controller • Set the directional lever or directional selector switch to the F
(forward) or R (reverse) position.
L03 Shift lever Voltage
Between (2) and 4th (4th speed) Max. 1 V
chassis ground Other than above 8 – 10 V

28 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to transmission 4th clutch

WA600-6 29
SEN00558-02 40 Troubleshooting

Failure code [15W0NT] (Transmission modulation clutch: Overheating)1

Action code Failure code Transmission modulation clutch: Overheating

Trouble
E02 15W0NT (Transmission controller system)
Contents of
• The calorific value of the modulation clutch is higher than the set value. (Overheating)
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The state (calorific value) of the modulation clutch can be checked with the monitoring function
(Code: 92500, MOD/C Q).
Related
• The state (heat rate) of the modulation clutch can be checked with the monitoring function (Code:
information
92501, MOD/C q).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Transmission controller may be defective
1 Transmission controller
and standard (Since trouble is in system, troubleshooting cannot be carried out.)
value in normal Cause may be wrong operation such as continuous use of
state 2 Overload modulation clutch.
Explain correct operating method to operator.

30 WA600-6
40 Troubleshooting SEN00558-02

Failure code [2F00MA] (Parking brake: Malfunction) 1

Action code Failure code Parking brake: Malfunction

Trouble
E03 2F00MA (Machine monitor system)
Contents of • While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN.
trouble (The neutralizer does not work.)
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The parking brake drags (is kept operated).
machine
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring
function (Code: 40903, D-IN-26).
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
• This error may be displayed because of engine stall operation or the emergency brake is applied
during travel.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective parking brake
1 indicator switch PB.SW (male) Parking brake Resistance
(Internal disconnection) Released Max. 1 z
Between (1) and (2)
Operates Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C08 (male) Parking brake switch Resistance
Defective parking brake ON Min. 1 Mz
2 switch (Internal Between (3) and (4)
OFF Max. 1 z
disconnection)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Possible causes Between (3) and (6) Normal Min. 1 Mz
and standard
a Prepare with starting switch OFF, then carry out troubleshooting
value in normal
without turning starting switch ON.
state
Defective parking brake PB.PS (male) Resistance
3 solenoid (Internal
disconnection) Between (1) and (2) 10 – 40 z
Between (1), (2) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
B06 (male), B07
Parking brake Resistance
(male)
Defective emergency brake Normal brake
4 pressure switch (Internal pressure
disconnection) Max. 1 z
Min. 4.9 MPa
Between (1) and (2) {50 kg/cm2}
Low brake pressure
Min. 3.14 MPa Min. 1 Mz
{32 kg/cm2}

WA600-6 31
SEN00558-02 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C04 (female) (1) –
Resistance Max. 1 z
PB.SW (female) (1)
Wiring harness between C08 (female) (3) –
Resistance Max. 1 z
Disconnection in wiring B06 (female) (1)
harness Wiring harness between B06 (female) (2) –
5 Resistance Max. 1 z
(Disconnection or defective B07 (female) (1)
Possible causes contact) Wiring harness between B07 (female) (2) –
and standard Resistance Max. 1 z
PB.PS (female) (1)
value in normal
Wiring harness between C08 (female) (3) –
state Resistance Max. 1 z
L03 (female) (6)
Wiring harness between PB.SW (female) (2)
Resistance Max. 1 z
– chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Parking brake oil
6 Defective machine monitor C04 Voltage
pressure
Between (1) and Released Max. 1 V
chassis ground Operates 20 – 30 V

32 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to parking brake

WA600-6 33
SEN00558-02 40 Troubleshooting

Failure code [2G42ZG] (Front accumulator: Low oil pressure) 1

Action code Failure code Front brake accumulator: Low oil pressure
Trouble
E03 2G42ZG (Machine monitor system)
Contents of
• 45 seconds after the engine is started, the front brake accumulator pressure sensor circuit is OPEN.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that • The front brake accumulator oil pressure lowers.
appears on • The brake may not work.
machine • The parking brake may keep working.
• The input state (ON/OFF) from the front brake oil pressure sensor can be checked with the
Related
monitoring function (Code: 40902, D-IN-16).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

The front brake accumulator Check the front brake accumulator oil pressure.
1
oil pressure lowers. (See Testing and adjusting.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Front brake
B05 (male) accumulator oil Resistance
pressure
Defective front brake oil
2 pressure sensor (Internal Normal brake
pressure
disconnection) Max. 1 z
Min. 5.88 MPa
Between (1) and (2) {60 kg/cm2}
Low brake pressure
Max. 3.92 MPa Min. 1 Mz
Possible causes {40 kg/cm2}
and standard
value in normal Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between C03 (female) (1) –
contact) Resistance Max. 1 z
B05 (female) (1)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Front brake
C03 (female) accumulator oil Resistance
pressure

4 Defective machine monitor Normal brake

pressure
Max. 1 z
Min. 5.88 MPa
Between (1) and {60 kg/cm2}
chassis ground
Low brake pressure
Max. 3.92 MPa Min. 1 Mz
{40 kg/cm2}

34 WA600-6
40 Troubleshooting SEN00558-02

Circuit diagram related to front brake accumulator

WA600-6 35
SEN00558-02

WA600-6 Wheel loader

Form No. SEN00558-02

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)

36
 SEN00559-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
Failure code [2G43ZG] (Rear accumulator: Low oil pressure) ....................................................................... 4
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ........................................................... 6
Failure code [A000N1] (or VHMS_LED display: “n2” o “01”) (Engine: Overrun) ........................................... 8
Failure code [AA1ANX] (Air cleaner: Clogging) ............................................................................................ 10
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) ................................... 12
Failure code [AB00MA] (Alternator: Malfunction).......................................................................................... 14
Failure code [B@BAZG] (Engine oil pressure: Low error) ............................................................................ 16
Failure code [B@BAZK] (Engine oil: Low level)............................................................................................ 17
Failure code [B@BCNS] (Engine coolant temperature: Overheating) .......................................................... 18
Failure code [B@BCZK] (Coolant: Low level)............................................................................................... 20
Failure code [B@C7NS] (Brake oil: Overheating)......................................................................................... 22
Failure code [b@CENS] (Torque converter oil: Overheating) ....................................................................... 24
Failure code [B@CENS] (Torque converter oil: Overheating)....................................................................... 26
Failure code [B@GAZK] (Battery electrolyte: Low level) .............................................................................. 28

WA600-6 1
SEN00559-03 40 Troubleshooting

Failure code [B@HANS] (Hydraulic oil: Overheating)................................................................................... 30

Failure code [CA111] (Abnormality in engine controller) ............................................................................... 32
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .................................................................... 34
Failure code [CA122] (Charge (boost) pressure sensor high error).............................................................. 36
Failure code [CA123] (Charge (boost) pressure sensor low error) ............................................................... 38
Failure code [CA131] (Throttle sensor high error)......................................................................................... 40
Failure code [CA132] (Throttle sensor low error) .......................................................................................... 42
Failure code [CA135] (Engine oil pressure sensor high error) ...................................................................... 44
Failure code [CA141] (Engine oil pressure sensor low error) ....................................................................... 46
Failure code [CA144] (Coolant temperature sensor high error) .................................................................... 48
Failure code [CA145] (Coolant temperature sensor low error) ..................................................................... 50
Failure code [CA153] (Charge (boost) temperature sensor high error) ........................................................ 52
Failure code [CA154] (Charge (boost) temperature sensor low error).......................................................... 54
Failure code [CA187] (Sensor power supply 2 low error) ............................................................................. 55
Failure code [CA212] (Engine oil temperature sensor high error)................................................................. 56
Failure code [CA213] (Engine oil temperature sensor low error) .................................................................. 58
Failure code [CA221] (Atmospheric pressure sensor high error).................................................................. 60
Failure code [CA222] (Atmospheric pressure sensor low error) ................................................................... 62
Failure code [CA227] (Sensor power supply 2 high error) ............................................................................ 64

2 WA600-6
40 Troubleshooting SEN00559-03

WA600-6 3
SEN00559-03 40 Troubleshooting

Failure code [2G43ZG] (Rear accumulator: Low oil pressure) 1

Action code Failure code Rear accumulator: Low oil pressure

Trouble
E03 2G43ZG (Machine monitor system)
Contents of
• 45 seconds after the engine is started, the rear brake accumulator pressure sensor circuit is OPEN.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that • Low rear brake accumulator oil pressure
appears on • The brake may not work.
machine • The parking brake may keep working.
• The input state (ON/OFF) from the rear brake oil pressure sensor can be checked with the monitor-
Related
ing function (Code: 40902, D-IN-17).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Low rear brake accumulator Check the rear brake accumulator oil pressure.
1
oil pressure (See Testing and adjusting.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake accumu-
B04 (male) Resistance
lator oil pressure
Defective rear brake oil pres- Normal brake
2 sure sensor pressure
(Internal disconnection) Max. 1 z
Min. 5.88 MPa
Between (1) and (2) {Min. 60 kg/cm2}
Low brake pressure
Max. 3.92 MPa Min. 1 Mz
Possible causes {Max. 40 kg/cm2}
and standard
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between C03 (female) (7) – Resis-
contact) Max. 1 z
B04 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake accumu-
C03 (female) Resistance
lator oil pressure
Normal brake
4 Defective machine monitor pressure
Max. 1 z
Wiring harness Min. 5.88 MPa
between (7) – chassis {Min. 60 kg/cm2}
ground Low brake pressure
Max. 3.92 MPa Min. 1 Mz
{Max. 40 kg/cm2}

4 WA600-6
40 Troubleshooting SEN00559-03

Circuit diagram related to rear brake accumulator

WA600-6 5
SEN00559-03 40 Troubleshooting

Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 1

Action code Failure code Bucket positioner: ON/OFF signals disagree

Trouble
E01 44K0L4 (Work equipment controller system)
• The signals input from the bucket proximity switch are combined impossibly.
• After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, full stroke
Contents of signal ON was detected for one second.
trouble • After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, bucket
level-over signal OFF was detected for one second.
• If cause of failure disappears, system resets itself.
Action of
• Judged to be below bucket level.
controller
Problem that
appears on • Bucket leveler does not function
machine
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with
the monitoring function (Code: 40911, D-IN-8). (STD)
Related
• The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the
information
monitoring function (Code: 40911, D-IN-9).
• Method of reproducing failure code: Tilt and dump bucket slowly many times.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective bucket cylinder
level proximity switch F11 Position of bucket Voltage
1
(Internal disconnection or Between (A) and (C) Normal 20 – 30 V
short circuit) Below horizontal Max. 1 V
Between (B) and (C)
Above horizontal 8 – 10 V
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective bucket cylinder full F12 Position of bucket Voltage
stroke proximity switch
2 Between (A) and (C) Normal 20 – 30 V
(Internal disconnection or
short circuit) Tilt full stroke 8 – 10 V
Between (B) and (C) Other than tilt full
Max. 1 V
Possible causes stroke
and standard a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har-
value in normal without turning starting switch ON.
ness
state 3
(Disconnection or defective Wiring harness between F12 (female) (B) – Resis-
contact of connector) Max. 1 z
L07 (female) (10) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
4 ness
(Contact with ground circuit) Wiring harness between F11 (female) (B) – Resis-
Min. 1 Mz
L07 (female) (20) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L07 Position of bucket Voltage
Defective work equipment Between (20) and Below horizontal Max. 1 V
5
controller chassis ground Above horizontal 8 – 10 V
Tilt full stroke 8 – 10 V
Between (10) and
chassis ground Other than tilt full
Max. 1 V
stroke

6 WA600-6
40 Troubleshooting SEN00559-03

Circuit diagram related to bucket proximity switch

WA600-6 7
SEN00559-03 40 Troubleshooting

Failure code [A000N1] (or VHMS_LED display: “n2” o “01”) (Engine:

Overrun) 1

Action code Failure code Engine: Overrun

Trouble
— A000N1 (VHMS controller system)
Contents of
• Engine speed exceeded 2,624 rpm.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The monitor panel does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n2” o “01”.
Related
• VHMS controller inputs engine speed signal with CAN communication from engine controller.
information
• If failure code [CA212] (engine speed sensor high error (VHMS)) is displayed, carry out trouble-
shooting for it first.
• Method of reproducing failure code: Start engine and travel.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Engine speed increased due to shift-down during travel.
and standard 1 Defective operating travel
• Instruct the operator on how to travel the machine properly.
value in normal
state If the above is normal, VHMS controller may be defective.
2 Defective VHMS controller
(Since trouble is in system, troubleshooting cannot be carried out.)

8 WA600-6
40 Troubleshooting SEN00559-03

WA600-6 9
SEN00559-03 40 Troubleshooting

Failure code [AA1ANX] (Air cleaner: Clogging) 1

Action code Failure code Air cleaner: Clogging

Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• The air cleaner clogging sensor circuit is OPEN.
trouble
Action of • Turns the air cleaner clogging caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
appears on
black.
machine
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-20).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Clogged air cleaner The air cleaner may be clogged. Check it directly.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Failure code
E15 (female) Dust indicator
Defective dust indicator “AA1ANX”
2
(Internal disconnection) Normal (Air cleaner is
Turned ON
normal)
Short (1) with (2)
Defective (Air cleaner
Turned OFF
is clogged)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L107 (male) Resistance
Defective dust indicator relay
Between (1) and (2) 200 – 400 z
(L107)
3 a Prepare with starting switch OFF, then start engine and carry out
(Internal disconnection or
short circuit) troubleshooting.
Possible causes When dust indicator relay (L107) is replaced with a relay of the
and standard same type (5-pin type), if the condition becomes normal, the
value in normal exchange relay is defective.
state
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L107 (female) (2) Resis-
4 Max. 1 z
(Disconnection or defective – E15 (female) (1) tance
contact of connector) Wiring harness between E15 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
5 ness
(Contact with ground circuit) Wiring harness between L107 (female) (2) Resis-
Min. 1 Mz
– E15 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
C03 Dust indicator Voltage
6 Defective machine monitor Normal (Air cleaner is
20 – 30 V
Between (3) and normal)
chassis ground Defective (Air cleaner
Max. 1 V
is clogged)

10 WA600-6
40 Troubleshooting SEN00559-03

Circuit diagram related to dust indicator

WA600-6 11
SEN00559-03 40 Troubleshooting

Failure code [AB00L6] (Alternator: Signal disagrees with operating state

of engine) 1

Action code Failure code Alternator: Signal disagrees with operation and stop of engine
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The engine does not start.
appears on
• After the starting switch is simply turned ON, the service meter advances.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective alternator Alternator Engine Voltage
1
(Internal defect) Between terminal R Start
27.5 – 29.5 V
(E03) and chassis (Throttle: Above 1/2)
ground Stopped Max. 1 V
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting
value in normal Hot short in wiring harness
2 Wiring harness between alternator terminal
state (Contact with 24 V circuit)
R (E03) – C02 (female) (18), – R21 (female) Voltage Max. 1 V
(3), – circuit branch
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
C02 Engine Voltage
3 Defective machine monitor
Start
Between (18) and 27.5 – 29.5 V
(Throttle: Above 1/2)
chassis ground
Stopped Max. 1 V

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Circuit diagram related to alternator

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Failure code [AB00MA] (Alternator: Malfunction) 1

Action code Failure code Alternator: Malfunction

Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that • Deteriorated battery
appears on • The engine does not start.
machine • The service meter does not advance.
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Deteriorated battery The battery may be deteriorated. Check it directly.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective alternator Alternator Engine Voltage
2
(Internal defect) Between terminal R Start
27.5 – 29.5 V
(E03) and chassis (Throttle: Above 1/2)
ground Stopped Max. 1 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
Possible causes 3
(Disconnection or defective Wiring harness between alternator terminal Resis-
and standard
contact of connector) Max. 1 z
value in normal R (E03) – C02 (female) (18) tance
state a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
4 ness Wiring harness between alternator terminal
(Contact with ground circuit) R (E03) – C02 (female) (18), – R21 (female) Resis-
Min. 1 Mz
tance
(3), – circuit branch
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
C02 Engine Voltage
5 Defective machine monitor
Start
Between (18) and 27.5 – 29.5 V
(Throttle: Above 1/2)
chassis ground
Stopped Max. 1 V

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Circuit diagram related to alternator

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Failure code [B@BAZG] (Engine oil pressure: Low error) 1

Action code Failure code

Trouble Engine oil pressure: Low error
E03 B@BAZG
Contents of
• When engine was running, engine oil pressure became lower than operating range.
trouble
Action of
• Limits output for travel (Limits injection rate and engine speed)
controller
Problem that
• Engine output drops.
appears on
• If the engine is operated continuously, it may become out of order.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Since engine oil pressure may become excessively low, check it
1 Low engine oil pressure
and standard and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine oil pressure sensor
state Defective engine oil pressure
2 system may be defective.
sensor system
Carry out troubleshooting for failure codes [CA135] and [CA141].

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Failure code [B@BAZK] (Engine oil: Low level) 1

Action code Failure code Engine oil: Low level

Trouble
E01 B@BAZK (Machine monitor system)
Contents of
• The engine oil level sensor circuit is OPEN.
trouble
Action of • Turns the engine oil level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine oil level is low (The engine may be broken).
machine
• The input state (ON/OFF) from the engine oil level sensor can be checked with the monitoring func-
Related
tion (Code: 40903, D-IN-29).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 Low engine oil level The engine oil level may be low. Check it directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective engine oil level
2 sensor E14 (male) Engine oil level Resistance
(Internal disconnection) Between (1) and Normal Max. 1 z
chassis ground Insufficient (Low) Min. 1 Mz
Possible causes
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
3
state (Disconnection or defective Wiring harness between C04 (female) (11) – Resis-
contact) Max. 1 z
E14 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C04 (female) Engine oil level Resistance
4 Defective machine monitor
Wiring harness Normal Max. 1 z
between (11) –
chassis ground Insufficient (Low) Min. 1 Mz

Circuit diagram related to engine oil level sensor

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Failure code [B@BCNS] (Engine coolant temperature: Overheating) 1

Action code Failure code

Trouble Engine coolant temperature: Overheating
E02 B@BCNS
Contents of
• When engine was running, coolant temperature exceeded operating range.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine output drops.
appears on
• If the engine is operated continuously, it may become out of order.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Overheating of engine Since engine coolant temperature may become overheat, check it
1
and standard coolant temperature and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine coolant temperature
state Defective engine coolant
2 sensor system may be defective.
temperature sensor system
Carry out troubleshooting for failure codes [CA144] and [CA145].

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Failure code [B@BCZK] (Coolant: Low level) 1

Action code Failure code Coolant: Low level

Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN.
trouble
Action of • Turns the coolant level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The coolant level is low. The engine overheats (The engine may be broken).
machine
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-27).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 Low coolant level The coolant level may be low. Check it directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective coolant level sen- G05 (male) Sub-tank Resistance
2 sor Below low level
(Internal disconnection) Min. 1 Mz
(Abnormal)
Between (1) and (2)
Above low level
Max. 1 z
Possible causes (Normal)
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
state 3
(Disconnection or defective Wiring harness between C04 (female) (10) – Resis-
contact) Max. 1 z
G05 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C04 (female) Sub-tank Resistance
4 Defective machine monitor Below low level
Wiring harness Min. 1 Mz
(Abnormal)
between (10) –
Above low level
chassis ground Max. 1 z
(Normal)

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Circuit diagram related to coolant level sensor

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Failure code [B@C7NS] (Brake oil: Overheating) 1

Action code Failure code Brake oil: Overheating

Trouble
E02 B@C7NS (Machine monitor system)
• Brake oil temperature was above 130°C for 5 seconds.
Contents of
• When travel speed was above 35 km/h, brake oil temperature, 125°C and above, was detected con-
trouble
tinuously for 5 seconds.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• Brake oil temperature caution lamp lights up
appears on
• The brake may be damaged.
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202, R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205, R BRAKE OIL).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Brake may overheat because brake was operated improperly during
1 Defective brake operation travel.
• Instruct the operator on how to travel the machine properly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil tem- Rear brake oil
R17 (male) Resistance
2 perature sensor temperature
Possible causes
and standard (Internal defect) 25°C
35 – 50 kz
value in normal Between (1) and (2) (Normal temperature)
state 100°C 3.1 – 4.5 kz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Rear brake oil
C05 (female) Resistance
3 Defective machine monitor temperature
Wiring harness 25°C
35 – 50 kz
between (8) – chassis (Normal temperature)
ground 100°C 3.1 – 4.5 kz

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Circuit diagram related to rear brake oil temperature sensor

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Failure code [b@CENS] (Torque converter oil: Overheating) 1

Action code Failure code Torque converter oil: Overheating

Trouble
E02 b@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 120°C.
trouble
Action of • If cause of failure disappears, system resets itself. (120°C and below was detected continuously for 1
controller seconds.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100, TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101, TC OIL TEMP).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
R13 (male) Resistance
2 oil temperature sensor temperature
(Internal defect) 25°C
35 – 50 kz
Possible causes Between (1) and (2) (Normal temperature)
and standard 100°C 3.1 – 4.5 kz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between C05 (female) (2) – Resis-
Min. 1 Mz
R13 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
C05 (female) Resistance
4 Defective machine monitor temperature
25°C
Between (2) and 35 – 50 kz
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kz

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Circuit diagram related to torque converter oil temperature sensor

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Failure code [B@CENS] (Torque converter oil: Overheating) 1

Action code Failure code Torque converter oil: Overheating

Trouble
E02 B@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 130°C.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• If cause of failure disappears, system resets itself. (130°C and blow was detected continuously for 1
controller
second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100, TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101, TC OIL TEMP).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
R13 (male) Resistance
2 oil temperature sensor temperature
(Internal defect) 25°C
35 – 50 kz
Possible causes Between (1) and (2) (Normal temperature)
and standard 100°C 3.1 – 4.5 kz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between C05 (female) (2) – Resis-
Min. 1 Mz
R13 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
C05 (female) Resistance
4 Defective machine monitor temperature
25°C
Between (2) and 35 – 50 kz
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kz

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Circuit diagram related to torque converter oil temperature sensor

WA600-6 27
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Failure code [B@GAZK] (Battery electrolyte: Low level) 1

Action code Failure code Battery electrolyte: Low level

Trouble
E01 B@GAZK (Machine monitor system)
Contents of
• The electrolyte level sensor (if equipped) circuit is CLOSE.
trouble
Action of • Turns the electrolyte level caution lamp ON.
controller • If cause of failure disappears, system resets itself.
Problem that • Turns the electrolyte level caution lamp ON.
appears on • The electrolyte level is low
machine • Engine may not start easily.
• The input state (voltage) from the electrolyte level sensor can be checked with the monitoring func-
Related
tion (Code: 40300, BATTERY A).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 The electrolyte level is low The electrolyte level may be low. Check it directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective electrolyte level Battery electrolyte
D05 (male) Resistance
2 sensor level
(Internal disconnection) Normal Max. 1 z
Between (1) and
chassis ground Insufficient level
Min. 1 Mz
Possible causes (Low level)
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
state 3
(Disconnection or defective Wiring harness between C05 (female) (5) – Resis-
contact) Max. 1 z
D05 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Battery electrolyte
C05 (female) Resistance
4 Defective machine monitor level
Wiring harness Normal Max. 1 z
between (5) – chassis Insufficient level
ground Min. 1 Mz
(low level)

Circuit diagram related to battery electrolyte level sensor

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Failure code [B@HANS] (Hydraulic oil: Overheating) 1

Action code Failure code Hydraulic oil: Overheating

Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 100°C.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The hydraulic oil overheat warning is turned ON (If the machine is used as it is, the pump and cylin-
appears on
der seals may be broken).
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

1 Overheating of hydraulic oil The hydraulic oil may be overheating.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective hydraulic oil tem- Hydraulic oil
HD.T (male) Resistance
2 perature sensor temperature
(Internal defect) 25°C
35 – 50 kz
Between (1) and (2) (Normal temperature)
Possible causes 100°C 3.1 – 4.5 kz
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 3 ness
(Contact with ground circuit) Wiring harness between C05 (female) (7) – Resis-
Min. 1 Mz
HD.T (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hydraulic oil
C05 (female) Resistance
4 Defective machine monitor temperature
Wiring harness 25°C
35 – 50 kz
between (7) and (Normal temperature)
chassis ground 100°C 3.1 – 4.5 kz

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Circuit diagram related to hydraulic oil temperature sensor

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Failure code [CA111] (Abnormality in engine controller) 1

Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
• Internal defect occurred in controller.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Circuit breaker (CBF4) may be defective. Check it directly. (If the cir-
Defective circuit breaker
1 cuit breaker is shut down, the circuit probably has a grounding fault,
(CBF4)
etc.)
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between E19 (female) (4) – Resis-
2 Max. 1 z
(Disconnection or defective battery (+) tance
Possible causes
contact of connector) Wiring harness between E19 (female) (1) – Resis-
and standard Max. 1 z
value in normal chassis ground tance
state a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between E19 (female) (4) – Resis-
Min. 1 Mz
battery (+) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
4 Defective engine controller
E19 Voltage
Between (4) and (1) 20 – 30 V

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Circuit diagram related to engine controller power supply

WA600-6 33
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Failure code [CA115] (Engine Ne or Bkup speed sensor error) 1

Action code Failure code Engine Ne or Bkup speed sensor error

Trouble
E03 CA115 (Engine controller system)
Contents of
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• The engine does not start. (if engine has been stopped.)
appears on
• Engine stops. (if engine has been running.)
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Ne speed sensor may be installed defectively. Check it directly.
Defective installation of Ne
Possible causes 3 (Defective installation of sensor itself, internal defect of flywheel,
speed sensor
and standard etc.)
value in normal Bkup speed sensor may be installed defectively. Check it directly.
state Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply
speed sensor
pump, etc.)
Defective sensor connection Ne and Bkup speed sensors may be connected defectively
5
(Improper connection) (improper connection). Check them directly.
If causes 1 – 5 are not the cause of the trouble, the engine control-
6 Defective engine controller ler may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)

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Failure code [CA122] (Charge (boost) pressure sensor high error) 1

Action code Failure code Charge (boost) pressure sensor high error
Trouble
E03 CA122 (Engine controller system)
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally high.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine does not accelerate smoothly.
appears on
• Black smoke increases during operation.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply sys-
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 tem of charge pressure sen-
bleshooting for it first.
sor (boost pressure sensor)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
sensor
2 Between (1) and (3) Power supply 4.75 – 5.25V
(boost pressure sensor)
(Internal defect) Charge pressure sensor voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring harness
and controller for another cause of trouble before judgment.
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal Max. 1 z
state ness – PIM (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (47) Resis-
contact of connector) Max. 1 z
– PIM (female) (3) tance
Wiring harness between ENG (female) (44) Resis-
Max. 1 z
– PIM (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) Resis-
Grounding fault in wiring har- – PIM (female) (1) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
– PIM (female) (3) and chassis ground tance
Wiring harness between ENG (female) (44) Resis-
Min. 1 Mz
– PIM (female) (2) and chassis ground tance

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– PIM (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – PIM (female) (3)
5 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – PIM (female) (1) and between ENG Resis-
Min. 1 Mz
Possible causes tance
(female) (44) – PIM (female) (2)
and standard
Wiring harness between ENG (female) (47)
value in normal Resis-
– PIM (female) (3) and between ENG Min. 1 Mz
state tance
(female) (44) – PIM (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
ENG Voltage
6 Defective engine controller Between
Power supply 4.75 – 5.25V
(37) and (47)
Between
Signal 0.3 – 4.7 V
(44) and (47)

Circuit diagram related to charge pressure sensor (boost pressure sensor)

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Failure code [CA123] (Charge (boost) pressure sensor low error) 1

Action code Failure code Charge (boost) pressure sensor low error
Trouble
E03 CA123 (Engine controller system)
Contents of
• Charge pressure sensor (boost pressure sensor) circuit is abnormally low.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine does not accelerate smoothly.
appears on
• Black smoke increases during operation.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state

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Failure code [CA131] (Throttle sensor high error) 1

Action code Failure code Throttle sensor high error

Trouble
E03 CA131 (Engine controller system)
Contents of
• Throttle sensor circuit is abnormally high.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor If failure code [CA2185] or [CA2186] is also indicated, carry out
1
power supply system troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L17 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25V
(Power supply)
Defective accelerator pedal (9 ± 2% of power
2 When released
(Internal defect) supply)
Between (2) and (3)
(73 ± 2% of power
When pressed
supply)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
Possible causes too, for another cause of trouble, and then judge.
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring har- Wiring harness between E18 (female) (22) – Resis-
Max. 1 z
ness L17 (female) (1) tance
3
(Disconnection or defective Wiring harness between E18 (female) (9) – Resis-
contact of connector) Max. 1 z
L17 (female) (2) tance
Wiring harness between E18 (female) (23) – Resis-
Max. 1 z
L17 (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (22) – Resis-
Grounding fault in wiring har- L17 (female) (1) Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between E18 (female) (9) – Resis-
Min. 1 Mz
L17 (female) (2) tance
Wiring harness between E18 (female) (23) – Resis-
Min. 1 Mz
L17 (female) (3) tance

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Possible causes E18 Accelerator pedal Voltage
and standard Between All range
value in normal 4.75 – 5.25V
5 Defective engine controller (22) and (23) (Power supply)
state
(9 ± 2% of power
When released
supply)
Between (9) and (23)
(73 ± 2% of power
When pressed
supply)

Circuit diagram related to throttle sensor

(Serial No.: 60001 – 60130)

(Serial No.: 60131 and up)

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Failure code [CA132] (Throttle sensor low error) 1

Action code Failure code Throttle sensor low error

Trouble
E03 CA132 (Engine controller system)
Contents of
• Throttle sensor circuit is abnormally low.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA131].
state

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Failure code [CA135] (Engine oil pressure sensor high error) 1

Action code Failure code Engine oil pressure sensor high error
Trouble
E01 CA135 (Engine controller system)
Contents of
• Engine oil pressure sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply sys-
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 tem of engine oil pressure
bleshooting for it first.
sensor
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective engine oil pressure
2 Between (1) and (2) Power supply 4.75 – 5.25V
sensor (Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal Max. 1 z
state ness – POIL (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (47) Resis-
contact of connector) Max. 1 z
– POIL (female) (2) tance
Wiring harness between ENG (female) (13) Resis-
Max. 1 z
– POIL (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) Resis-
Grounding fault in wiring har- – POIL (female) (1) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
– POIL (female) (2) and chassis ground tance
Wiring harness between ENG (female) (13) Resis-
Min. 1 Mz
– POIL (female) (3) and chassis ground tance

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– POIL (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
5 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – POIL (female) (1) and between ENG Resis-
Min. 1 Mz
Possible causes tance
(female) (13) – POIL (female) (3)
and standard
Wiring harness between ENG (female) (47)
value in normal Resis-
– POIL (female) (2) and between ENG Min. 1 Mz
state tance
(female) (13) – POIL (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
ENG Voltage
6 Defective engine controller Between
Power supply 4.75 – 5.25V
(37) and (47)
Between
Signal 0.3 – 4.7 V
(13) and (47)

Circuit diagram related to engine oil pressure sensor

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Failure code [CA141] (Engine oil pressure sensor low error) 1

Action code Failure code Engine oil pressure sensor low error
Trouble
E01 CA141 (Engine controller system)
Contents of
• Engine oil pressure sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
function (Code: 37201).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA135].
state

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Failure code [CA144] (Coolant temperature sensor high error) 1

Action code Failure code Coolant temperature sensor high error

Trouble
E01 CA144 (Engine controller system)
Contents of
• Coolant sensor circuit is abnormally high.
trouble
Action of
• Sets coolant temperature to fixed value (90°C), and continues operation.
controller
Problem that
appears on • Starting performance of engine lowers during low temperature.
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitor-
ing function (Code: 04104).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
TWTR (male) Coolant temperature Resistance

Defective coolant tempera- 0°C 30 – 37 kz

1
ture sensor (Internal defect) 25°C 9.3 – 10.7 kz
Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (15) Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective – TWTR (female) (A) tance
and standard contact of connector) Wiring harness between ENG (female) (38) Resis-
value in normal Max. 1 z
state – TWTR (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between ENG (female) (15) Resis-
Min. 1 Mz
– TWTR (female) (A) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Coolant temperature Resistance
0°C 30 – 37 kz
4 Defective engine controller
25°C 9.3 – 10.7 kz
Between
50°C 3.2 – 3.8 kz
(15) and (38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z

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Circuit diagram related to coolant temperature sensor

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Failure code [CA145] (Coolant temperature sensor low error) 1

Action code Failure code Coolant temperature sensor low error

Trouble
E01 CA145 (Engine controller system)
Contents of
• Coolant sensor circuit is abnormally low.
trouble
Action of
• Sets coolant temperature to fixed value (90°C), and continues operation.
controller
Problem that
appears on • Starting performance of engine lowers during low temperature.
machine
• The input state (temperature) from the coolant temperature sensor can be checked with the monitor-
ing function (Code: 04104).
Related
• The input state (voltage) from the coolant temperature sensor can be checked with the monitoring
information
function (Code: 04105).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA144].
state

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Failure code [CA153] (Charge (boost) temperature sensor high error) 1

Action code Failure code Charge (boost) temperature sensor high error
Trouble
E01 CA153 (Engine controller system)
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally high.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
TIM (male) Air boost temperature Resistance
Defective charge tempera- 0°C 29 – 36 kz
ture sensor
1 25°C 9 – 11 kz
(boost temperature sensor) Between (A) and (B)
(Internal defect) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (A) and
In all range Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes
ness Wiring harness between ENG (female) (23) Resis-
and standard 2 Max. 1 z
(Disconnection or defective – TIM (female) (A) tance
value in normal
contact of connector) Wiring harness between ENG (female) (47) Resis-
state Max. 1 z
– TIM (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between ENG (female) (23) Resis-
Min. 1 Mz
– TIM (female) (A) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Air boost temperature Resistance
4 Defective engine controller 0°C 29 – 36 kz
Between 25°C 9 – 11 kz
(23) and (47) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z

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Circuit diagram related to charge temperature sensor (boost temperature sensor)

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Failure code [CA154] (Charge (boost) temperature sensor low error) 1

Action code Failure code Charge (boost) temperature sensor low error
Trouble
E01 CA154 (Engine controller system)
Contents of
• Charge temperature sensor (boost temperature sensor) circuit is abnormally low.
trouble
Action of
• Sets charge temperature (boost temperature) to fixed value (70°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA153].
state

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Failure code [CA187] (Sensor power supply 2 low error) 1

Action code Failure code Sensor power supply 2 low error

Trouble
E03 CA187 (Engine controller system)
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Bkup speed sensor: Operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and
Action of continues operation.
controller • Charge pressure sensor sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}), and continues
operation.
• EGR valve lift sensor limits output and closes EGR and bypass valves.
• Bypass valve lift sensor limits output and closes EGR and bypass valves.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA227].
state

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Failure code [CA212] (Engine oil temperature sensor high error) 1

Action code Failure code Engine oil temperature sensor high error
Trouble
E01 CA212 (Engine controller system)
Contents of
• Engine oil temperature sensor circuit is abnormally high.
trouble
Action of
• Sets engine oil temperature to fixed value (100°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (temperature) from the engine oil temperature sensor can be checked with the moni-
toring function (Code: 42700).
Related
• The input state (voltage) from the engine oil temperature sensor can be checked with the monitoring
information
function (Code: 42702).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
TOIL (male) Oil temperature Resistance

Defective engine oil temper- 0°C 30 – 37 kz

1
ature sensor (Internal defect) 25°C 9.3 – 10.7 kz
Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (17) Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective – TOIL (female) (A) tance
and standard contact of connector) Wiring harness between ENG (female) (47) Resis-
value in normal Max. 1 z
state – TOIL (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between ENG (female) (17) Resis-
Min. 1 Mz
– TOIL (female) (A) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Oil temperature Resistance
0°C 30 – 37 kz
4 Defective engine controller
25°C 9.3 – 10.7 kz
Between
50°C 3.2 – 3.8 kz
(17) and (47)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z

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Circuit diagram related to engine oil temperature sensor

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Failure code [CA213] (Engine oil temperature sensor low error) 1

Action code Failure code Engine oil temperature sensor low error
Trouble
E01 CA213 (Engine controller system)
Contents of
• Engine oil temperature sensor circuit is abnormally low.
trouble
Action of
• Sets engine oil temperature to fixed value (100°C), and continues operation.
controller
Problem that
appears on
machine
• The input state (oil temperature) from the engine oil temperature sensor can be checked with the
monitoring function (Code: 42700).
Related
• The input state (voltage) from the engine oil temperature sensor can be checked with the monitoring
information
function (Code: 42702).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA212].
state

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Failure code [CA221] (Atmospheric pressure sensor high error) 1

Action code Failure code Atmospheric pressure sensor high error

Trouble
E01 CA221 (Engine controller system)
Contents of
• Atmospheric pressure sensor circuit is abnormally high.
trouble
Action of
• Sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and continues operation.
controller
Problem that
appears on • Engine output drops.
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective power supply sys-
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 tem of atmospheric pressure
bleshooting for it first.
sensor
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
PAMB Voltage
Defective atmospheric pres- Between (1) and (3) Power supply 4.75 – 5.25V
2
sure sensor (Internal defect) Between (2) and (3) Signal 0.3 – 4.7 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between ENG (female) (37) Resis-
Disconnection in wiring har- Max. 1 z
state – PAMB (female) (1) tance
ness
3
(Disconnection or defective Wiring harness between ENG (female) (38) Resis-
contact of connector) Max. 1 z
– PAMB (female) (3) tance
Wiring harness between ENG (female) (3) – Resis-
Max. 1 z
PAMB (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) Resis-
Grounding fault in wiring har- – PAMB (female) (1) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between ENG (female) (38) Resis-
Min. 1 Mz
– PAMB (female) (3) and chassis ground tance
Wiring harness between ENG (female) (3) – Resis-
Min. 1 Mz
PAMB (female) (2) and chassis ground tance

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– PAMB (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – PAMB (female) (3)
5 ness Wiring harness between ENG (female) (37)
Possible causes (with another wiring harness) – PAMB (female) (1) and between ENG Resis-
Min. 1 Mz
and standard tance
(female) (3) – PAMB (female) (2)
value in normal
Wiring harness between ENG (female) (38)
state Resis-
– PAMB (female) (3) and between ENG Min. 1 Mz
tance
(female) (3) – PAMB (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between (37) and (38) 4.75 – 5.25V
Between (3) and (38) 0.3 – 4.7 V

Circuit diagram related to atmospheric pressure sensor

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Failure code [CA222] (Atmospheric pressure sensor low error) 1

Action code Failure code Atmospheric pressure sensor low error

Trouble
E01 CA222 (Engine controller system)
Contents of
• Atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
• Sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and continues operation.
controller
Problem that
appears on • Engine output drops.
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA221].
state

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Failure code [CA227] (Sensor power supply 2 high error) 1

Action code Failure code Sensor power supply 2 high error

Trouble
E03 CA227 (Engine controller system)
Contents of
• Sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (50.99 kPa {0.52 kg/cm2}), and
Action of
continues operation.
controller
• Charge pressure sensor (boost pressure sensor) sets charge pressure (boost pressure) to fixed
value (400 kPa {4.1 kg/cm2}), and continues operation.
• EGR and bypass valve position sensors limit output and close EGR and bypass valves.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Related system defects If another code is displayed, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Bkup speed sensor
G connector
system
Oil pressure sensor POIL connector
Disconnect device Charge pressure
Defective sensor suggested on the sensor
2 PIM connector
(Internal defect) right. At this time, if (Boost pressure
failure code is not sensor)
indicated, the device Atmospheric
is defective. PAMB connector
pressure sensor
Possible causes EGR valve lift sensor SEGR connector
and standard Bypass valve position
value in normal SBP connector
sensor
state
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (37) Resis-
3 Max. 1 z
(Disconnection or defective – each sensor (female) (Terminal of 5 V) tance
contact of connector) Wiring harness between ENG (female) (47) Resis-
Max. 1 z
– each sensor (female) (Terminal of GND) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Grounding fault in wiring har- Resis-
– each sensor (female) (Terminal of 5 V) and Min. 1 Mz
4 ness tance
chassis ground
(Contact with ground circuit)
Wiring harness between ENG (female) (47)
Resis-
– each sensor (female) (Terminal of GND) Min. 1 Mz
tance
and chassis ground

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring har-
5 ness Wiring harness between ENG (female) (37)
Possible causes
and standard (with another wiring harness) – each sensor (female) (Terminal of 5 V) and Resis-
Min. 1 Mz
between ENG (female) (47) – each sensor tance
value in normal (female) (Terminal of GND)
state
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
6 Defective engine controller
ENG Voltage
Between (37) and (47) 4.75 – 5.25V

Circuit diagram related to sensor power supply 2 (5 V)

WA600-6 65
SEN00559-03

WA600-6 Wheel loader

Form No. SEN00559-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

66
 SEN00560-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Failure code [CA234] (Engine overspeed)...................................................................................................... 3
Failure code [CA238] (Ne speed sensor power supply error) ......................................................................... 4
Failure code [CA263] (Fuel temperature sensor high error) ........................................................................... 6
Failure code [CA265] (Fuel temperature sensor low error)............................................................................. 8
Failure code [CA271] (PCV1 Short circuit) ................................................................................................... 10
Failure code [CA272] (PCV1 Disconnection)................................................................................................ 12
Failure code [CA273] (PCV2 Short circuit) ................................................................................................... 14
Failure code [CA274] (PCV2 Disconnection)................................................................................................ 16
Failure code [CA322] (Injector #1 open/short error) ..................................................................................... 18
Failure code [CA323] (Injector #5 open/short error) ..................................................................................... 20
Failure code [CA324] (Injector #3 open/short error) ..................................................................................... 22
Failure code [CA325] (Injector #6 open/short error) ..................................................................................... 24
Failure code [CA331] (Injector #2 open/short error) ..................................................................................... 26
Failure code [CA332] (Injector #4 open/short error) ..................................................................................... 28

WA600-6 1
SEN00560-02 40 Troubleshooting

Failure code [CA342] (Calibration code inconsistency) ................................................................................ 30

Failure code [CA351] (Injectors drive circuit error)........................................................................................ 32
Failure code [CA352] (Sensor power supply 1 low error) ............................................................................. 34
Failure code [CA386] (Sensor power supply 1 high error) ............................................................................ 36
Failure code [CA431] (Idle validation switch error) ....................................................................................... 38
Failure code [CA432] (Idle validation action error)........................................................................................ 41
Failure code [CA441] (Battery voltage low error) .......................................................................................... 41
Failure code [CA442] (Battery voltage high error)......................................................................................... 42
Failure code [CA449] Common rail pressure high error 2............................................................................. 42
Failure code [CA451] (Common rail pressure sensor high error) ................................................................. 44
Failure code [CA452] (Common rail pressure sensor low error)................................................................... 46
Failure code [CA553] (Common rail pressure high error 1) .......................................................................... 47
Failure code [CA559] (Supply pump pressure very low error 1) ................................................................... 48
Failure code [CA689] (Engine Ne speed sensor error) ................................................................................. 52
Failure code [CA731] (Engine Bkup speed sensor phase error)................................................................... 54
Failure code [CA757] (All continuous data lost error) ................................................................................... 55
Failure code [CA778] (Engine Bkup speed sensor error) ............................................................................. 56
Failure code [CA1228] (EGR valve servo error 1) ........................................................................................ 58
Failure code [CA1625] (EGR valve servo error 2) ........................................................................................ 59
Failure code [CA1626] (Bypass valve solenoid current high error) ............................................................... 60
Failure code [CA1627] (Bypass valve solenoid current low error) ................................................................ 62
Failure code [CA1628] (Bypass valve servo error 1) .................................................................................... 63
Failure code [CA1629] (Bypass valve servo error 2) .................................................................................... 64
Failure code [CA1631] (Bypass valve lift sensor high error) ......................................................................... 66
Failure code [CA1632] (Bypass valve lift sensor low error)........................................................................... 68
Failure code [CA1633] (KOMNET datalink timeout error) ............................................................................. 69

2 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA234] (Engine overspeed) 1

Action code Failure code Engine overspeed

Trouble
E02 CA234 (Engine controller system)
Contents of
• Engine speed exceeded operating range.
trouble
Action of • Reduce fuel injection rate until engine speed lowers in operating range.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine speed changes.
machine
Related • Engine speed can be checked by monitoring function (Code: 01002).
information • Method of reproducing failure code: Start engine and keep running at high idle.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Possible causes
and standard The method of using the installed machine may be improper, so
2 Usage is improper
value in normal instruct the operator on how to use the machine properly.
state If causes 1 and 2 are not the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)

WA600-6 3
SEN00560-02 40 Troubleshooting

Failure code [CA238] (Ne speed sensor power supply error) 1

Action code Failure code Ne speed sensor power supply error

Trouble
E03 CA238 (Engine controller system)
Contents of
• Error occurred in Ne speed sensor power supply (5 V) circuit.
trouble
• Controls with signal from Bkup speed sensor.
Action of
• Limits output and continues operation.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Engine output drops.
appears on • Engine stops during operation (when Bkup speed sensor is also defective)
machine • Engine cannot start during stop (when Bkup speed sensor is also defective)
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnect device
Defective Ne speed sensor suggested on the
1
(Internal defect) right. At this time, if
Ne speed sensor NE connector
failure code is not
indicated, the device
is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (16) Resis-
2 Max. 1 z
(Disconnection or defective – NE (female) (1) tance
contact of connector) Wiring harness between ENG (female) (48) Resis-
Possible causes Max. 1 z
– NE (female) (2) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (16) Resis-
3 ness Min. 1 Mz
– NE (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (48) Resis-
Min. 1 Mz
– NE (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between ENG (female) (16)
(with another wiring harness) – NE (female) (1) and between ENG Resis-
Min. 1 Mz
tance
(female) (48) – NE (female) (2)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective engine controller
ENG Voltage
Between (16) and (48) 4.75 – 5.25 V

4 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to Ne speed sensor power supply

WA600-6 5
SEN00560-02 40 Troubleshooting

Failure code [CA263] (Fuel temperature sensor high error) 1

Action code Failure code Fuel temperature sensor high error

Trouble
E01 CA263 (Engine controller system)
Contents of
• Fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Sets fuel temperature to fixed value (90°C), and continues operation.
controller
Problem that • Usually fuel injection rate is corrected by fuel temperature signal, but fuel injection rate for substitute
appears on water temperature sensor signal. (If fuel temperature sensor and water temperature sensor are mal-
machine function condition, fix the water temperature signal (95°C) and to continue engine operation.)
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
TFUEL (male) Fuel temperature Resistance

Defective fuel temperature 0°C 30 – 37 kz

1
sensor (Internal defect) 25°C 9.3 – 10.7 kz
Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (30) Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective – TFUEL (female) (A) tance
and standard contact of connector) Wiring harness between ENG (female) (47) Resis-
value in normal Max. 1 z
state – TFUEL (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (30) Resis-
3 ness Min. 1 Mz
– TFUEL (female) (A) and chassis ground tance
(Contact with ground circuit)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Fuel temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
4 Defective engine controller Between
50°C 3.2 – 3.8 kz
(30) and (47)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z

6 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to fuel temperature sensor

WA600-6 7
SEN00560-02 40 Troubleshooting

Failure code [CA265] (Fuel temperature sensor low error) 1

Action code Failure code Fuel temperature sensor low error

Trouble
E01 CA265 (Engine controller system)
Contents of
• Fuel temperature sensor circuit is abnormally low.
trouble
Action of • Injection rate by fuel temperature sensor is compensated with coolant temperature sensor (If coolant
controller temperature sensor is abnormal, the controller sets to fixed value (95°C) and continues operation.)
Problem that
appears on
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA263].
state

8 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 9
SEN00560-02 40 Troubleshooting

Failure code [CA271] (PCV1 Short circuit) 1

Action code Failure code PCV1 short circuit

Trouble
E03 CA271 (Engine controller system)
Contents of
• Short circuit was detected in supply pump PCV1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related
• While engine is running, pulse voltage of about 24 V is applied to PCV1 (1) (if normal) and it cannot
information
be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (4) – Resis-
2 ness Min. 1 Mz
PCV1 (female) (1) tance
Possible causes (Contact with ground circuit)
Wiring harness between ENG (female) (5) – Resis-
and standard Min. 1 Mz
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between ENG (female) (4) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5) –
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (4) and (5) 2.3 – 5.3 z
Between (4), (5) and
Min. 1 Mz
chassis ground

10 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to supply pump PCV1

WA600-6 11
SEN00560-02 40 Troubleshooting

Failure code [CA272] (PCV1 Disconnection) 1

Action code Failure code PCV1 disconnection

Trouble
E03 CA272 (Engine controller system)
Contents of
• Disconnection was detected in supply pump PCV1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related
• While engine is running, pulse voltage of about 24 V is applied to PCV1 (1) (if normal) and it cannot
information
be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective supply pump PCV1 (male) Resistance
1 PCV1
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (4) – Resis-
2 Max. 1 z
(Disconnection or defective PCV1 (female) (1) tance
Possible causes contact of connector) Wiring harness between ENG (female) (5) – Resis-
and standard Max. 1 z
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (4) – Resis-
3 ness Min. 1 Mz
PCV1 (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (5) – Resis-
Min. 1 Mz
PCV1 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (4) and (5) 2.3 – 5.3 z
Between (4), (5) and
Min. 1 Mz
chassis ground

12 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to supply pump PCV1

WA600-6 13
SEN00560-02 40 Troubleshooting

Failure code [CA273] (PCV2 Short circuit) 1

Action code Failure code PCV2 short circuit

Trouble
E03 CA273 (Engine controller system)
Contents of
• Short circuit was detected in supply pump PCV2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related
• While engine is running, pulse voltage of about 24 V is applied to PCV2 (1) (if normal) and it cannot
information
be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective supply pump PCV2 (male) Resistance
1
PCV2 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (9) – Resis-
2 ness Min. 1 Mz
PCV2 (female) (1) tance
Possible causes (Contact with ground circuit)
Wiring harness between ENG (female) (10) Resis-
and standard Min. 1 Mz
– PCV2 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between ENG (female) (9) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV2 (female) (1) and chassis ground
Wiring harness between ENG (female) (10)
Voltage Max. 1 V
– PCV2 (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (9) and (10) 2.3 – 5.3 z
Between (9), (10) and
Min. 1 Mz
chassis ground

14 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to supply pump PCV2

WA600-6 15
SEN00560-02 40 Troubleshooting

Failure code [CA274] (PCV2 Disconnection) 1

Action code Failure code PCV2 disconnection

Trouble
E03 CA274 (Engine controller system)
Contents of
• Disconnection was detected in supply pump PCV2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related
• While engine is running, pulse voltage of about 24 V is applied to PCV2 (1) (if normal) and it cannot
information
be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective supply pump without turning starting switch ON.
1 PCV2
PCV2 (male) Resistance
(Internal disconnection)
Between (1) and (2) 2.3 – 5.3 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (9) – Resis-
2 Max. 1 z
(Disconnection or defective PCV2 (female) (1) tance
contact of connector) Wiring harness between ENG (female) (10) Resis-
Possible causes Max. 1 z
– PCV2 (female) (2) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (9) – Resis-
3 ness Min. 1 Mz
PCV2 (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (10) Resis-
Min. 1 Mz
– PCV2 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
4 Defective engine controller
Between (9) and (10) 2.3 – 5.3 z
Between (9), (10) and
Min. 1 Mz
chassis ground

Circuit diagram related to supply pump PCV2

16 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 17
SEN00560-02 40 Troubleshooting

Failure code [CA322] (Injector #1 open/short error) 1

Action code Failure code Injector #1 system disconnection or short circuit

Trouble
E03 CA322 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #1 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #1 INJ (male) Resistance
1
(Internal defect) Between (1) and (12) 0.4 – 1.1 z
Between (1), (12) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (45) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (1) tance
contact of connector) Wiring harness between ENG (female) (53) Resis-
Possible causes Max. 1 z
– INJ (female) (12) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (45) Resis-
3 ness Min. 1 Mz
– INJ (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (53) Resis-
Min. 1 Mz
– INJ (female) (12) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (45) and (53) 0.4 – 1.1 z
Between (45), (53) and
Min. 1 Mz
chassis ground

18 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #1

WA600-6 19
SEN00560-02 40 Troubleshooting

Failure code [CA323] (Injector #5 open/short error) 1

Action code Failure code Injector #5 system disconnection or short circuit

Trouble
E03 CA323 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #5 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #5 INJ (male) Resistance
1
(Internal defect) Between (5) and (8) 0.4 – 1.1 z
Between (5), (8) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (46) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (5) tance
contact of connector) Wiring harness between ENG (female) (60) Resis-
Possible causes Max. 1 z
– INJ (female) (8) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (46) Resis-
3 ness Min. 1 Mz
– INJ (female) (5) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (60) Resis-
Min. 1 Mz
– INJ (female) (8) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (46) and (60) 0.4 – 1.1 z
Between (46), (60) and
Min. 1 Mz
chassis ground

20 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #5

WA600-6 21
SEN00560-02 40 Troubleshooting

Failure code [CA324] (Injector #3 open/short error) 1

Action code Failure code Injector #3 system disconnection or short circuit

Trouble
E03 CA324 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #3 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable.
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #3 INJ (male) Resistance
1
(Internal defect) Between (3) and (10) 0.4 – 1.1 z
Between (3), (10) – chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (55) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (3) tance
contact of connector) Wiring harness between ENG (female) (52) Resis-
Possible causes Max. 1 z
– INJ (female) (10) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (55) Resis-
3 ness Min. 1 Mz
– INJ (female) (3) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (52) Resis-
Min. 1 Mz
– INJ (female) (10) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (55) and (52) 0.4 – 1.1 z
Between (55), (52) and
Min. 1 Mz
chassis ground

22 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #3

WA600-6 23
SEN00560-02 40 Troubleshooting

Failure code [CA325] (Injector #6 open/short error) 1

Action code Failure code Injector #6 system disconnection or short circuit

Trouble
E03 CA325 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #6 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable.
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #6 INJ (male) Resistance
1
(Internal defect) Between (6) and (7) 0.4 – 1.1 z
Between (6), (7) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (57) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (6) tance
contact of connector) Wiring harness between ENG (female) (59) Resis-
Possible causes Max. 1 z
– INJ (female) (7) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (57) Resis-
3 ness Min. 1 Mz
– INJ (female) (6) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (59) Resis-
Min. 1 Mz
– INJ (female) (7) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (57) and (59) 0.4 – 1.1 z
Between (57), (59) and
Min. 1 Mz
chassis ground

24 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #6

WA600-6 25
SEN00560-02 40 Troubleshooting

Failure code [CA331] (Injector #2 open/short error) 1

Action code Failure code Injector #2 system disconnection or short circuit

Trouble
E03 CA331 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #2 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable.
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #2 INJ (male) Resistance
1
(Internal defect) Between (2) and (11) 0.4 – 1.1 z
Between (2), (11) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (54) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (2) tance
contact of connector) Wiring harness between ENG (female) (51) Resis-
Possible causes Max. 1 z
– INJ (female) (11) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (54) Resis-
3 ness Min. 1 Mz
– INJ (female) (2) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (51) Resis-
Min. 1 Mz
– INJ (female) (11) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (54) and (51) 0.4 – 1.1 z
Between (54), (51) and
Min. 1 Mz
chassis ground

26 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #2

WA600-6 27
SEN00560-02 40 Troubleshooting

Failure code [CA332] (Injector #4 open/short error) 1

Action code Failure code Injector #4 system disconnection or short circuit

Trouble
E03 CA332 (Engine controller system)
Contents of
• Disconnection or short circuit was detected in injector #4 circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Engine output drops.
appears on
• Speed does not become stable.
machine
• Method of reproducing failure code: Start engine.
Related
• While engine is running, pulse voltage of about 65 V is applied to injector (+) side (if normal) and it
information
cannot be measured with circuit tester.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective injector #4 INJ (male) Resistance
1
(Internal defect) Between (4) and (9) 0.4 – 1.1 z
Between (4), (9) and chassis
Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (56) Resis-
2 Max. 1 z
(Disconnection or defective – INJ (female) (4) tance
contact of connector) Wiring harness between ENG (female) (58) Resis-
Possible causes Max. 1 z
– INJ (female) (9) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between ENG (female) (56) Resis-
3 ness Min. 1 Mz
– INJ (female) (4) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (58) Resis-
Min. 1 Mz
– INJ (female) (9) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ENG (female) Resistance
5 Defective engine controller
Between (56) and (58) 0.4 – 1.1 z
Between (56), (58) and
Min. 1 Mz
chassis ground

28 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to injector #4

WA600-6 29
SEN00560-02 40 Troubleshooting

Failure code [CA342] (Calibration code inconsistency) 1

Action code Failure code Engine controller data inconsistency

Trouble
E03 CA342 (Engine controller system)
Contents of
• Data inconsistency occurred in engine controller.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA111].
state

30 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 31
SEN00560-02 40 Troubleshooting

Failure code [CA351] (Injectors drive circuit error) 1

Action code Failure code Injector drive circuit error

Trouble
E03 CA351 (Engine controller system)
Contents of
• Error was detected in injector drive circuit.
trouble
Action of • Limits output for travel (Limits common rail pressure)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Check the failure code (injector system error code) that is displayed
1 Defect in related system at the same time. If another code is displayed, carry out trouble-
shooting for it.
Defective circuit breaker Circuit breaker (CBF4) may be defective. Check it directly.
2
(CBF4) If circuit breaker is shut down, circuit probably has ground fault.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between E19 (female) (4) – Resis-
3 Max. 1 z
(Disconnection or defective battery (+) tance
Possible causes
contact of connector) Wiring harness between E19 (female) (1) – Resis-
and standard Max. 1 z
value in normal chassis ground tance
state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between E19 (female) (4) – Resis-
4 ness Min. 1 Mz
battery (+) tance
(Contact with ground circuit)
Wiring harness between E19 (female) (1) – Resis-
Min. 1 Mz
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective engine controller
E19 Voltage
Between (4) and (1) 20 – 30 V

32 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to engine controller power supply

WA600-6 33
SEN00560-02 40 Troubleshooting

Failure code [CA352] (Sensor power supply 1 low error) 1

Action code Failure code Sensor power supply 1 low error

Trouble
E03 CA352 (Engine controller system)
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA386].
state

34 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 35
SEN00560-02 40 Troubleshooting

Failure code [CA386] (Sensor power supply 1 high error) 1

Action code Failure code Sensor power supply 1 high error

Trouble
E03 CA386 (Engine controller system)
Contents of
• Sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Disconnect device
Defective sensor Common rail
2 suggested on the PFUEL
(Internal defect) pressure sensor
right. At this time, if
failure code is not
indicated, the device Ne speed sensor NE connector
is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (33) Resis-
Max. 1 z
Disconnection in wiring har- – PFUEL (female) (1) tance
ness Wiring harness between ENG (female) (16) Resis-
3 Max. 1 z
(Disconnection or defective and NE (female) (1) – chassis ground tance
contact of connector) Wiring harness between ENG (female) (47) Resis-
Possible causes Max. 1 z
– PFUEL (female) (3) tance
and standard
Wiring harness between ENG (female) (48) Resis-
value in normal Max. 1 z
– NE (female) (2) tance
state
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (33) Resis-
Min. 1 Mz
– PFUEL (female) (1) and chassis ground tance
Grounding fault in wiring har-
Wiring harness between ENG (female) (16) Resis-
4 ness Min. 1 Mz
– NE (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
– PFUEL (female) (3) and chassis ground tance
Wiring harness between ENG (female) (48) Resis-
Min. 1 Mz
– NE (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring har- Wiring harness between ENG (female) (33)
Resis-
5 ness – PFUEL (female) (1) and between ENG Min. 1 Mz
tance
(with another wiring harness) (female) (47) – each sensor (female)
Wiring harness between ENG (female) (16) Resis-
Min. 1 Mz
– NE (female) (1) tance

36 WA600-6
40 Troubleshooting SEN00560-02

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting
value in normal 6 Defective engine controller ENG Voltage
state
Between (16) – (48) and
4.75 – 5.25 V
(33) – (47)

Circuit diagram related to sensor power supply 1 (5 V)

WA600-6 37
SEN00560-02 40 Troubleshooting

Failure code [CA431] (Idle validation switch error) 1

Action code Failure code Idle validation switch error

Trouble
E01 CA431 (Engine controller system)
Contents of
• Error was detected in idle validation switch circuit.
trouble
Action of
• Operates at position of throttle of throttle sensor.
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: 18300).
Related
• The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring func-
information
tion (Code: 18301).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L17 Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1 See Fig. 1 on the next
1
(Internal defect) Between (6) and (4) Signal 2 page
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then turn starting switch ON
Defective power supply of and carry out troubleshooting
2
idle validation switch 4.5 –
Between C30 (1) and (2) Voltage
5.5 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (32) – Resis-
Max. 1 z
L17 (female) (4) tance
Disconnection in wiring har- Wiring harness between E18 (female) (11) – Resis-
Max. 1 z
ness L17 (female) (5) tance
Possible causes 3
(Disconnection or defective Wiring harness between E18 (female) (1) – Resis-
and standard contact of connector) Max. 1 z
L17 (female) (6) tance
value in normal
state Wiring harness between L04 (female) (34) – Resis-
Max. 1 z
C30 (female) (1) tance
Wiring harness between L02 (female) (4) – Resis-
Max. 1 z
C30 (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between E18 (female) (32) – Resis-
Grounding fault in wiring har- L17 (female) (4) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between E18 (female) (11) – Resis-
Min. 1 Mz
L17 (female) (5) and chassis ground tance
Wiring harness between E18 (female) (1) – Resis-
Min. 1 Mz
L17 (female) (6) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between E18 (female) (32) –
Voltage Max. 1 V
Hot short in wiring harness L17 (female) (4) and chassis ground
5
(Contact with 24 V circuit) Wiring harness between E18 (female) (11) –
Voltage Max. 1 V
L17 (female) (5) and chassis ground
Wiring harness between E18 (female) (1) –
Voltage Max. 1 V
L17 (female) (6) and chassis ground

38 WA600-6
40 Troubleshooting SEN00560-02

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard
E18 Signal name Voltage
value in normal 6 Defective engine controller
state Between
Signal 1
(11) and (32) See Fig. 1 below
Between (1) and (32) Signal 2

Circuit diagram related to throttle sensor

(Serial No.: 60001 – 60130)

(Serial No.: 60131 and up)

WA600-6 39
SEN00560-02 40 Troubleshooting

Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Operating range: Operating range of accelerator
pedal

40 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA432] (Idle validation action error) 1

Action code Failure code Idle validation action error

Trouble
E03 CA432 (Engine controller system)
Contents of
• Action error was detected in idle validation switch circuit.
trouble
Action of • Operates at position of throttle of accelerator pedal (throttle sensor).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: 18300).
Related
• The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring func-
information
tion (Code: 18301).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA431].
state

Failure code [CA441] (Battery voltage low error) 1

Action code Failure code Battery voltage low error

Trouble
E03 CA441 (Engine controller system)
Contents of
• Low voltage was detected in battery voltage circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA111].
state

WA600-6 41
SEN00560-02 40 Troubleshooting

Failure code [CA442] (Battery voltage high error) 1

Action code Failure code Battery voltage high error

Trouble
E03 CA442 (Engine controller system)
Contents of
• High voltage was detected in battery voltage circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA111].
state

Failure code [CA449] Common rail pressure high error 2 1

Action code Failure code Common rail pressure high error 2

Trouble
E03 CA449 (Engine controller system)
Contents of
• There is high pressure error (level 2) in common rail pressure sensor circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA553].
state

42 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 43
SEN00560-02 40 Troubleshooting

Failure code [CA451] (Common rail pressure sensor high error) 1

Action code Failure code Common rail pressure sensor high error
Trouble
E03 CA451 (Engine controller system)
Contents of
• Common rail pressure sensor circuit is abnormally high.
trouble
Action of • Limits output for travel (Limits common rail pressure)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402).
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective common rail pres- If failure code [CA352] or [CA386] is also indicated, carry out trou-
1
sure sensor power system bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
PFUEL Voltage
Defective common rail pres- Between (1) and (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal defect) Between (2) and (3) Signal 0.25 – 4.6 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
without turning starting switch ON.
and standard
Disconnection in wiring har- Wiring harness between ENG (female) (33) Resis-
value in normal Max. 1 z
ness – PFUEL (female) (1) and chassis ground tance
state
3 (Disconnection in wiring or
Wiring harness between ENG (female) (25) Resis-
defective contact in connec- Max. 1 z
tor) – PFUEL (female) (2) and chassis ground tance
Wiring harness between ENG (female) (47) Resis-
Max. 1 z
– PFUEL (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (33) Resis-
Min. 1 Mz
ness – PFUEL (female) (1) tance
4
(Short circuit with GND cir- Wiring harness between ENG (female) (25) Resis-
cuit) Min. 1 Mz
– PFUEL (female) (2) tance
Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
– PFUEL (female) (3) tance

44 WA600-6
40 Troubleshooting SEN00560-02

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (33)
Resis-
– PFUEL (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (25) – PFUEL (female) (2)
5 ness Wiring harness between ENG (female) (33)
Possible causes (with another wiring harness) – PFUEL (female) (1) and between ENG Resis-
Min. 1 Mz
and standard tance
(female) (47) – PFUEL (female) (3)
value in normal
Wiring harness between ENG (female) (25)
state Resis-
– PFUEL (female) (2) and between ENG Min. 1 Mz
tance
(female) (47) – PFUEL (female) (3)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
Between (33) and (47) 4.75 – 5.25 V
Between (25) and (47) 0.25 – 4.6 V

Circuit diagram related to common rail pressure sensor

WA600-6 45
SEN00560-02 40 Troubleshooting

Failure code [CA452] (Common rail pressure sensor low error) 1

Action code Failure code Common rail pressure sensor low error
Trouble
E03 CA452 (Engine controller system)
Contents of
• Common rail pressure sensor circuit is abnormally low.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402).
• Method of reproducing failure code: Turn the starting switch ON.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA451].
state

46 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA553] (Common rail pressure high error 1) 1

Action code Failure code Common rail pressure high error 1

Trouble
E03 CA553 (Engine controller system)
Contents of • Excessively high pressure is detected in the common rail pressure sensor circuit (Excessively high
trouble pressure, which is far beyond the specified pressure, is indicated for over 10 sec).
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly. (Viscosity is high)
Defective electrical system of Electrical system of common rail pressure sensor may be defective.
3
Possible causes common rail pressure sensor Carry out troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal Mechanical system of common rail pressure sensor may be defec-
4 of common rail pressure sen-
state tive. Check it directly.
sor
Spring damage, seat wear, or ball stuck of overflow valve is sus-
5 Defective overflow valve
pected. Check it directly.
6 Clogged overflow pipe Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.

WA600-6 47
SEN00560-02 40 Troubleshooting

Failure code [CA559] (Supply pump pressure very low error 1) 1

Action code Failure code Supply pump no-pressure feed error 1

Trouble
E03 CA559 (Engine controller system)
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of • Limits common rail pressure.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
Related
the monitoring function (Code: 36400).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check
of pressure in fuel low pressure circuit, see Testing and adjusting,
Defect in low pressure cir- “Testing fuel pressure”.
3
cuit parts
Pressure in fuel low-pressure Min. 0.15 MPa
circuit {Min. 1.5 kg/cm2}
4 Clogged fuel filter, strainer a For more information on troubleshooting, see Note 2.
Electrical system of supply pump PCV may be defective. Carry out
Defective electrical system of
5 troubleshooting for failure code [CA271], [CA272], [CA273], or
supply pump PCV
[CA274].
Defective common rail pres- Mechanical system of common rail pressure sensor may be defec-
6
Possible causes sure sensor tive. Check whether wiring harness is damaged.
and standard a For check of leakage through pressure limiter, see Testing and
value in normal adjusting, “Testing fuel return rate and leakage”.
state 7 Defective pressure limiter
Max. 10 cc/min
Leakage through pressure limiter
(at full stall or relief)
a For check of limited return rate (spill) from injector, see Testing
and adjusting, “Testing fuel return rate and leakage”.
Speed at rated operation Limited return (spill) rate
(stall load) from injector

8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not the cause of the trouble, supply pump may
9 Defective supply pump
be defective.

<Using check sheet>

While carrying out troubleshooting above, record troubleshooting contents on the “Check sheet for no-pres-
sure feed” attached separately.

48 WA600-6
40 Troubleshooting SEN00560-02

Note 1: When low-pressure circuit is defective, check the following:

q Fuel level
q Clogged fuel tank breather
q Water separator/Prefilter filled with water
q Clogged fuel filter
q Clogged screen in water separator
q Stuck or worn feed pump, clogged filter
q Leaked or clogged low-pressure fuel pipe
q Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
q Fuel in oil pan (fuel leakage in head cover)

Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.

WA600-6 49
SEN00560-02 40 Troubleshooting

Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name

A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather

B. Check with machine monitor (Abnormality record, monitoring, cylinder cutout operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 800 ± 25
01002 Engine speed High idle rpm 2,000 ± 50
Full stall (P-mode) rpm 1,680 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 147
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 1,100}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Standard value Measured
Function Cutout cylinder Check conditions Unit Good Bad
(Reference value) value
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
Cylinder 3 Low idle rpm — — —
cut-out
Cylinder 4 Low idle rpm — — —
function
Cylinder 5 Low idle rpm — — —
Cylinder 6 Low idle rpm — — —

Standard value Measured

C. Checking fuel circuit pressure Check conditions Unit Good Bad
(Reference value) value
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}

D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

Standard value Measured

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
(Reference value) value
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
1,600 rpm
Rating or equivalent
cc/min 1,020
1,700 rpm
Rating or equivalent
12 Return rate from injector cc/min 1,080 Return rate:
1,800 rpm
Rating or equivalent
cc/min 1,140
1,900 rpm
Rating or equivalent
cc/min 1,200
2,000 rpm

50 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 51
SEN00560-02 40 Troubleshooting

Failure code [CA689] (Engine Ne speed sensor error) 1

Action code Failure code Engine Ne speed sensor error

Trouble
E03 CA689 (Engine controller system)
Contents of
• Error was detected in engine Ne speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Bkup speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If failure code [CA238] is displayed, carry out troubleshooting for it
1
ply system first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between ENGINE (female) Resis-
ness Max. 1 z
(16) – NE (female) (1) tance
2 (Disconnection in wiring or
Wiring harness between ENGINE (female) Resis-
defective contact in connec- Max. 1 z
tor) (48) – NE (female) (2) tance
Wiring harness between ENGINE (female) Resis-
Max. 1 z
(27) – NE (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (16) Resis-
Min. 1 Mz
ness – NE (female) (1) and chassis ground tance
3
(Short circuit with GND cir- Wiring harness between ENG (female) (48) Resis-
cuit) Min. 1 Mz
– NE (female) (2) and chassis ground tance
Possible causes Wiring harness between ENG (female) (27) Resis-
Min. 1 Mz
and standard – NE (female) (3) and chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Wiring harness between ENG (female) (16)
Resis-
– NE (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
4 ness Wiring harness between ENG (female) (16)
(with another wiring harness) – NE (female) (1) and between ENG Resis-
Min. 1 Mz
tance
(female) (27) – NE (female) (3)
Wiring harness between ENG (female) (48)
Resis-
– NE (female) (2) and between ENG Min. 1 Mz
tance
(female) (27) – NE (female) (3)
Defective installation of sen- Installation of Ne speed sensor may be defective (wrong clearance)
5 sor or defective speed sens- and speed sensing part (flywheel) may be defective. Check them
ing part directly.
If causes 1 – 5 are not the cause of the trouble, engine Ne speed
Defective engine Ne speed
6 sensor may be defective. (Since trouble is in system, troubleshoot-
sensor
ing cannot be carried out.)
If causes 1 – 6 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)

52 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to engine Ne speed sensor

WA600-6 53
SEN00560-02 40 Troubleshooting

Failure code [CA731] (Engine Bkup speed sensor phase error) 1

Action code Failure code Engine Bkup speed sensor phase error
Trouble
E03 CA731 (Engine controller system)
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of • Controls the engine with signal from engine Ne speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
• Method of reproducing failure code: Start engine.
Related
• Bkup speed sensor is changed together with the fuel supply pump (For details, see “Removal and
information
installation of fuel supply pump” in Disassembly and assembly).

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].

54 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA757] (All continuous data lost error) 1

Action code Failure code All continuous data lost error

Trouble
E03 CA757 (Engine controller system)
Contents of
• All data in engine controller are lost.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA111].
state

WA600-6 55
SEN00560-02 40 Troubleshooting

Failure code [CA778] (Engine Bkup speed sensor error) 1

Action code Failure code Engine Bkup speed sensor error

Trouble
E03 CA778 (Engine controller system)
Contents of
• Error was detected in engine Bkup speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Ne speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
ness Max. 1 z
– G (female) (1) tance
2 (Disconnection in wiring or
Wiring harness between ENG (female) (47) Resis-
defective contact in connec- Max. 1 z
tor) – G (female) (2) tance
Wiring harness between ENG (female) (26) Resis-
Max. 1 z
– G (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (37) Resis-
Min. 1 Mz
ness – G (female) (1) and chassis ground tance
3
(Short circuit with GND cir- Wiring harness between ENG (female) (47) Resis-
cuit) Min. 1 Mz
– G (female) (2) and chassis ground tance
Possible causes Wiring harness between ENG (female) (26) Resis-
Min. 1 Mz
and standard – G (female) (3) and chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– G (female) (1) and between ENG (female) Min. 1 Mz
tance
Short circuit in wiring har- (47) – G (female) (2)
4 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – G (female) (1) and between ENG (female) Resis-
Min. 1 Mz
tance
(26) – G (female) (3)
Wiring harness between ENG (female) (47)
Resis-
– G (female) (2) and between ENG (female) Min. 1 Mz
tance
(26) – G (female) (3)
Defective installation of sen- Installation of Bkup speed sensor may be defective (wrong clear-
5 sor or defective speed sens- ance) and speed sensing part (in supply pump) may be defective.
ing part Check them directly.
If causes 1 – 5 are not the cause of the trouble, engine Bkup speed
Defective engine Bkup
6 sensor may be defective. (Since trouble is in system, troubleshoot-
speed sensor
ing cannot be carried out.)
If causes 1 – 6 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)

56 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to engine Bkup speed sensor

WA600-6 57
SEN00560-02 40 Troubleshooting

Failure code [CA1228] (EGR valve servo error 1) 1

Action code Failure code EGR valve servo error 1

Trouble
E03 CA1228 (Engine controller system)
Contents of
• There is servo error (level 1) of EGR valve.
trouble
Action of • Performs open control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
a For measurement of EGR valve drive pressure, see Testing and
adjusting, “Measuring EGR valve and bypass valve drive oil pres-
sure”.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Possible causes Engine Engine oil pressure
and standard Defective engine oil pressure
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
value in normal system (main circuit)
state High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is not normal, carry out troubleshooting (S-
mode) for mechanical system. (S-12 Oil pressure lowers.)
Defective EGR valve oil Oil pump or relief valve for EGR valve circuit may be defective.
4
pump Check it directly.
Defective EGR valve oil [ ]Oil pressure supply piping for EGR valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
If causes 1 – 7 are not the cause of the trouble, engine controller
8 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)

58 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA1625] (EGR valve servo error 2) 1

Action code Failure code EGR valve servo error 2

Trouble
E03 CA1625 (Engine controller system)
Contents of
• There is servo error (level 2) of EGR valve.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA1228].
state

WA600-6 59
SEN00560-02 40 Troubleshooting

Failure code [CA1626] (Bypass valve solenoid current high error) 1

Action code Failure code Bypass valve solenoid current high error
Trouble
E03 CA1626 (Engine controller system)
Contents of
• High current was detected in drive circuit of bypass valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective bypass valve sole- without turning starting switch ON.
1
noid (Internal defect) BP (male) Resistance
Between (1) and (2) 10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness
Wiring harness between ENG (female) (31) Resis-
2 (Disconnection in wiring or Max. 1 z
– BP (female) (1) tance
defective contact in connec-
tor) Wiring harness between ENG (female) (11) – Resis-
Max. 1 z
BP (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Ground fault in wiring har-
value in normal ness Wiring harness between ENG (female) (31) Resis-
3 Min. 1 Mz
state (Short circuit with GND cir- – BP (female) (1) and chassis ground tance
cuit) Wiring harness between ENG (female) (11) – Resis-
Min. 1 Mz
BP (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short in wiring harness Wiring harness between ENG (female) (31)
4 Voltage Max. 1 V
(Contact with 24 V circuit) – BP (female) (1) and chassis ground
Wiring harness between ENG (female) (11) –
Voltage Max. 1 V
BP (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
ENG (female) Resistance
Between (31) and (11) 10 – 21 z

60 WA600-6
40 Troubleshooting SEN00560-02

Circuit diagram related to bypass valve solenoid & lift sensor

WA600-6 61
SEN00560-02 40 Troubleshooting

Failure code [CA1627] (Bypass valve solenoid current low error) 1

Action code Failure code Bypass valve solenoid drive circuit disconnection error
Trouble
E03 CA1627 (Engine controller system)
Contents of
• Disconnection error was detected in drive circuit of bypass valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA1626].
state

62 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA1628] (Bypass valve servo error 1) 1

Action code Failure code Bypass valve servo error 1

Trouble
E03 CA1628 (Engine controller system)
Contents of
• There is servo error (level 1) of bypass valve.
trouble
Action of • Performs open control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
a For measurement of bypass valve drive pressure, see Testing
and adjusting, “Measuring EGR valve and bypass valve drive oil
pressure”.
Improper bypass valve drive Engine speed Bypass valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Possible causes Engine Engine oil pressure
and standard Defective engine oil pressure
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
value in normal system (main circuit)
state High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is not normal, carry out troubleshooting (S-
mode) for mechanical system. (S-12 Oil pressure drops)
Defective bypass valve oil Oil pump or relief valve for bypass valve circuit may be defective.
4
pump Check it directly.
Defective bypass valve oil Oil pressure supply piping for bypass valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective bypass valve oil Oil pressure return piping for bypass valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective bypass valve Bypass valve may be damaged mechanically. Check it directly.
If causes 1 – 7 are not the cause of the trouble, engine controller
8 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)

WA600-6 63
SEN00560-02 40 Troubleshooting

Failure code [CA1629] (Bypass valve servo error 2) 1

Action code Failure code Bypass valve servo error 2

Trouble
E03 CA1629 (Engine controller system)
Contents of
• There is servo error (level 2) of bypass valve.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA1628].
state

64 WA600-6
40 Troubleshooting SEN00560-02

WA600-6 65
SEN00560-02 40 Troubleshooting

Failure code [CA1631] (Bypass valve lift sensor high error) 1

Action code Failure code Bypass valve lift sensor high error
Trouble
E03 CA1631 (Engine controller system)
Contents of
• Bypass valve lift sensor circuit is abnormally high.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SBP Voltage
Defective bypass valve lift
2 Between (1) and (2) Voltage 4.75 – 5.25 V
sensor (Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal ness Max. 1 z
– SBP (female) (1) tance
state 3 (Disconnection in wiring or
Wiring harness between ENG (female) (38) Resis-
defective contact in connec- Max. 1 z
tor) – SBP (female) (2) tance
Wiring harness between ENG (female) (29) Resis-
Max. 1 z
– SBP (female) (3), (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring har- Wiring harness between ENG (female) (37) Resis-
Min. 1 Mz
ness – SBP (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between ENG (female) (38) Resis-
cuit) Min. 1 Mz
– SBP (female) (2) and chassis ground tance
Wiring harness between ENG (female) (29) Resis-
Min. 1 Mz
– SBP (female) (3), (4) and chassis ground tance

66 WA600-6
40 Troubleshooting SEN00560-02

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– SBP (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – SBP (female) (2)
Possible causes 5 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – SBP (female) (1) and between ENG Resis-
and standard Min. 1 Mz
tance
value in normal (female) (29) – SBP (female) (3), (4)
state Between wiring harness of ENG (female)
Resis-
(38) – SBP (female) (2) and between ENG Min. 1 Mz
tance
(female) (29) – SBP (female) (3), (4)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (38) 4.75 – 5.25 V

Circuit diagram related to bypass valve solenoid & lift sensor

WA600-6 67
SEN00560-02 40 Troubleshooting

Failure code [CA1632] (Bypass valve lift sensor low error) 1

Action code Failure code Bypass valve lift sensor low error
Trouble
E03 CA1632 (Engine controller system)
Contents of
• Bypass valve lift sensor circuit is abnormally low.
trouble
• Limits output and continues operation.
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).
• Method of reproducing failure code: Start engine

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA1631].
state

68 WA600-6
40 Troubleshooting SEN00560-02

Failure code [CA1633] (KOMNET datalink timeout error) 1

Action code Failure code KOMNET datalink timeout error

Trouble
E03 CA1633 (Engine controller system)
Contents of
• There is error in KOMNET communication circuit with applicable machine.
trouble
Action of • Operates in default mode or holds the state set when error occurred.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on
machine
Related
• Method of reproducing failure code: Start engine.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Carry out troubleshooting for failure code [DB2RKR].
state

WA600-6 69
SEN00560-02

WA600-6 Wheel loader

Form No. SEN00560-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

70
 SEN00561-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 4
Failure code [CA2185] (Throttle sensor supply voltage high error) ................................................................ 4
Failure code [CA2186] (Throttle sensor power supply low error).................................................................... 6
Failure code [CA2249] (Supply pump pressure very low error 2) ................................................................... 7
Failure code [CA2271] (EGR valve lift sensor high error) ............................................................................... 8
Failure code [CA2272] (EGR valve lift sensor low error) .............................................................................. 10
Failure code [CA2351] (EGR valve solenoid operation short circuit) ............................................................ 12
Failure code [CA2352] (EGR valve solenoid operation disconnect) ............................................................. 14
Failure code [CA2555] (Intake heater relay disconnection error) ................................................................. 15
Failure code [CA2556] (Intake heater relay short circuit error) ..................................................................... 16
Failure code [D191KA] (AJSS neutral safety relay: Disconnection) ............................................................. 18
Failure code [D191KB] (AJSS neutral safety relay: Short circuit) ................................................................. 20
Failure code [D192KA] (ECSS solenoid: Disconnection).............................................................................. 22
Failure code [D192KB] (ECSS solenoid: Short circuit) ................................................................................. 23
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) ............................................. 24

WA600-6 1
SEN00561-03 40 Troubleshooting

Failure code [D198KA] (Transmission oil pressure bypass solenoid: Disconnection) .................................. 25
Failure code [D198KB] (Transmission oil pressure bypass solenoid: Short circuit) ...................................... 26
Failure code [D198KY] (Transmission oil pressure bypass solenoid: Short circuit with power supply line).. 27
Failure code [D5ZHKA] (Terminal C signal: Disconnection).......................................................................... 28
Failure code [D5ZHKB] (Terminal C signal: Short circuit) ............................................................................. 30
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) .................................................. 32
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) .......... 34
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) ................................................. 36
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) ....................................................... 38
Failure code [DAF5KP] (Machine monitor: Low output voltage) ................................................................... 40
Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system)) ..................................................... 42
Failure code [DAQ0KK] (Transmission controller: Low source voltage) ....................................................... 44
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) ................................................ 46
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))........ 48
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals) ................................................................................................ 50
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system)) ..................................................... 52
Failure code [DAQRMA] (Transmission controller CAN communication: Malfunction) ................................. 54

2 WA600-6
40 Troubleshooting SEN00561-03

WA600-6 3
SEN00561-03 40 Troubleshooting

Failure code [CA2185] (Throttle sensor supply voltage high error) 1

Action code Failure code Throttle sensor supply voltage high error
Trouble
E03 CA2185 (Engine controller system)
Contents of
• Voltage of throttle sensor power supply (5V) circuit is high.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The engine does not reach full throttle.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Disconnect device
Defective accelerator pedal suggested on the
1
(Internal defect) right. At this time, if
Accelerator pedal L17 connector
failure code is not
indicated, the device
is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between E18 (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective L17 (female) (1) tance
contact of connector) Wiring harness between E18 (female) (23) – Resis-
Possible causes Max. 1 z
L17 (female) (3) tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between E18 (female) (22) – Resis-
3 ness Min. 1 Mz
L17 (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between E18 (female) (23) – Resis-
Min. 1 Mz
L17 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between E18 (female) (22) –
(with another wiring harness) L17 (female) (1) and E18 (female) (23) – L17 Resis-
Min. 1 Mz
tance
(female) (3)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective engine controller
E18 Voltage
Between (22) and (23) 4.75 – 5.25 V

4 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to throttle sensor

(Serial No.: 60001 – 60130)

(Serial No.: 60131 and up)

WA600-6 5
SEN00561-03 40 Troubleshooting

Failure code [CA2186] (Throttle sensor power supply low error) 1

Action code Failure code Throttle sensor power supply low error
Trouble
E03 CA2186 (Engine controller system)
Contents of
• Voltage of throttle sensor power supply (5V) circuit is low.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine does not reach full throttle.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA2185].
state

6 WA600-6
40 Troubleshooting SEN00561-03

Failure code [CA2249] (Supply pump pressure very low error 2) 1

Action code Failure code Supply pump pressure very low error 2
Trouble
E03 CA2249 (Engine controller system)
Contents of
• There is no-pressure feed error (level 2) in supply pump.
trouble
Action of • Limits common rail pressure.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402).
• Method of reproducing failure code: Start engine.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA559].
state

WA600-6 7
SEN00561-03 40 Troubleshooting

Failure code [CA2271] (EGR valve lift sensor high error) 1

Action code Failure code EGR valve lift sensor high error
Trouble
E03 CA2271 (Engine controller system)
Contents of
• EGR valve lift sensor circuit is abnormally high.
trouble
• Limits output and continues operation.
Action of
• Closes EGR valve.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101).
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power sup- If failure code [CA187] or [CA227] is also indicated, carry out trou-
1
ply system bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
SEGR Voltage
Defective EGR valve lift sen-
2 Between (1) and (2) Power supply 4.75 – 5.25 V
sor (Internal defect)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
value in normal Max. 1 z
ness – SEGR (female) (1) tance
state 3
(Disconnection or defective Wiring harness between ENG (female) (47) Resis-
contact of connector) Max. 1 z
– SEGR (female) (2) tance
Wiring harness between ENG (female) (19) Resis-
Max. 1 z
– SEGR (female) (3), (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37) Resis-
Grounding fault in wiring har- – SEGR (female) (1) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
– SEGR (female) (2) and chassis ground tance
Wiring harness between ENG (female) (19) Resis-
Min. 1 Mz
– SEGR (female) (3), (4) and chassis ground tance

8 WA600-6
40 Troubleshooting SEN00561-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between ENG (female) (37)
Resis-
– SEGR (female) (1) and ENG (female) (47) Min. 1 Mz
tance
Short circuit in wiring har- – SEGR (female) (2)
Possible causes 5 ness Wiring harness between ENG (female) (37)
(with another wiring harness) – SEGR (female) (1) and ENG (female) (19) Resis-
and standard Min. 1 Mz
tance
value in normal – SEGR (female) (3), (4)
state Wiring harness between ENG (female) (47)
Resis-
– SEGR (female) (2) and ENG (female) (19) Min. 1 Mz
tance
– SEGR (female) (3), (4)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
6 Defective engine controller
ENG Voltage
Between (37) and (47) 4.75 – 5.25 V

Circuit diagram related to EGR valve solenoid & lift sensor

WA600-6 9
SEN00561-03 40 Troubleshooting

Failure code [CA2272] (EGR valve lift sensor low error) 1

Action code Failure code EGR valve lift sensor low error
Trouble
E03 CA2272 (Engine controller system)
Contents of
• EGR valve lift sensor circuit is abnormally low.
trouble
• Limits output and continues operation.
Action of
• Closes EGR valve.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101).
• Method of reproducing failure code: Start engine.

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA2271].
state

10 WA600-6
40 Troubleshooting SEN00561-03

WA600-6 11
SEN00561-03 40 Troubleshooting

Failure code [CA2351] (EGR valve solenoid operation short circuit) 1

Action code Failure code EGR valve solenoid operation short circuit error
Trouble
E03 CA2351 (Engine controller system)
Contents of
• High current was detected in drive circuit of EGR valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR valve.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective EGR valve sole- without turning starting switch ON.
1
noid (Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (22) Resis-
2 Max. 1 z
(Disconnection or defective – EGR (female) (1) tance
contact of connector) Wiring harness between ENG (female) (11) – Resis-
Max. 1 z
EGR (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Grounding fault in wiring har-
value in normal Wiring harness between ENG (female) (22) Resis-
3 ness Min. 1 Mz
state – EGR (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between ENG (female) (11) – Resis-
Min. 1 Mz
EGR (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between ENG (female) (22)
4 Voltage Max. 1 V
(Contact with 24 V circuit) – EGR (female) (1) and chassis ground
Wiring harness between ENG (female) (11) –
Voltage Max. 1 V
EGR (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
ENG (female) Resistance
Between (22) and (11) 10 – 21z

12 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to EGR valve solenoid & lift sensor

WA600-6 13
SEN00561-03 40 Troubleshooting

Failure code [CA2352] (EGR valve solenoid operation disconnect) 1

Action code Failure code EGR valve solenoid operation disconnection error
Trouble
E03 CA2352 (Engine controller system)
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
• Limits output and continues operation.
Action of
• Closes EGR valve.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code [CA2351].
state

14 WA600-6
40 Troubleshooting SEN00561-03

Failure code [CA2555] (Intake heater relay disconnection error) 1

Action code Failure code Intake heater relay disconnection error

Trouble
E01 CA2555 (Engine controller system)
Contents of
• Disconnection error was detected in intake air heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out trouble shooting for failure code CA2556].
state

WA600-6 15
SEN00561-03 40 Troubleshooting

Failure code [CA2556] (Intake heater relay short circuit error) 1

Action code Failure code Intake heater relay short circuit error
Trouble
E01 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in intake heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Heater relay drive conditions vary depending on applicable machine.
information • Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective intake heater relay without turning starting switch ON.
1
(Internal defect) L106 (male) Resistance
Between (1) and (2) 200 – 400 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between E18 (female) (40) – Resis-
2 Max. 1 z
(Disconnection or defective L106 (female) (1) tance
contact of connector) Wiring harness between E18 (female) (42) – Resis-
Possible causes Max. 1 z
and standard L106 (female) (2) tance
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between E18 (female) (40) – Resis-
3 ness Min. 1 Mz
L106 (female) (1) and chassis ground tance
(Contact with ground circuit)
Wiring harness between E18 (female) (42) – Resis-
Min. 1 Mz
L106 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
4 Defective engine controller E18 Heater relay Voltage
Between Operating condition 20 – 30 V
(40) and (42) Stop condition Max. 1 V

16 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to intake heater relay

WA600-6 17
SEN00561-03 40 Troubleshooting

Failure code [D191KA] (AJSS neutral safety relay: Disconnection) 1

Action code Failure code AJSS neutral safety relay: Disconnection

Trouble
E01 D191KA (Work equipment controller system)
Contents of • Since the AJSS neutral safety relay output system is disconnected, signals are not output to the neu-
trouble tral safety relay.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • While operating AJSS lever, engine can be started (Steering moves immediately after engine start.).
machine
• Applicable only to AJSS specification machines (if equipped)
Related
• Method of reproducing failure code: While engine is stopped, operate AJSS lever.
information
• If the AJSS neutral position is not adjusted (initialized), the neutral safety relay does not operate.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective AJSS neutral without turning starting switch ON.
1 safety relay (L104)
L104 (male) Resistance
(Internal disconnection)
Between (1) and (2) 200 – 400 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (4) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective L104 (female) (1) tance
contact of connector) Wiring harness between L104 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Defective work equipment and operate AJSS lever.
3
controller L07 Voltage
Between (4) and chassis ground 20 – 30 V

18 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to AJSS neutral safety relay

WA600-6 19
SEN00561-03 40 Troubleshooting

Failure code [D191KB] (AJSS neutral safety relay: Short circuit) 1

Action code Failure code AJSS neutral safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of
• Abnormal current flowed because of ground fault in AJSS neutral safety relay output system.
trouble
Action of • Turns the output to the AJSS neutral safety relay OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • While operating AJSS lever, engine can be started (Steering moves immediately after engine starts.).
machine
• Applicable only to AJSS specification machines (if equipped)
Related • Method of reproducing failure code: While engine is stopped, operate AJSS lever.
information • If the AJSS neutral position is not adjusted (initialized), the neutral safety relay does not operate.
• While error is detected, controller does not output voltage.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective AJSS neutral L104 (male) Resistance
1 safety relay (L104)
(Internal short circuit) Between (1) and (2) 200 – 400 z
Between (1), (2) and
Possible causes Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L07 (female) (4) – Resis-
Min. 1 Mz
L104 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Defective work equipment and operate AJSS lever.
3
controller L07 Voltage
Between (4) and chassis ground 20 – 30 V

20 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to AJSS neutral safety relay

WA600-6 21
SEN00561-03 40 Troubleshooting

Failure code [D192KA] (ECSS solenoid: Disconnection) 1

Action code Failure code ECSS solenoid: Disconnection

Trouble
E01 D192KA (Transmission controller system)
Contents of • Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is
trouble turned ON.
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
Related 93300 ECSS V DIR).
information • Applicable only to ECSS specification machines (if equipped)
• Method of reproducing failure code: Turn the starting switch and ECSS switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective ECSS solenoid without turning starting switch ON.
1
(Internal disconnection) F24 (male) Resistance
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L04 (female) (17) – Resis-
value in normal 2 Max. 1 z
(Disconnection or defective F24 (female) (1) tance
state contact of connector) Wiring harness between F24 (female) (2) – Resis-
Max. 1 z
L04 (female) (13) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con-
3 L04 (female) Resistance
troller
Wiring harness between
5 – 15 z
(17) and (13)

Circuit diagram related to ECSS solenoid

22 WA600-6
40 Troubleshooting SEN00561-03

Failure code [D192KB] (ECSS solenoid: Short circuit) 1

Action code Failure code ECSS solenoid: Short circuit

Trouble
E01 D192KB (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the chassis ground, abnormal current flowed when
trouble ECCS solenoid output is ON
Action of • Turns the output to the ECSS solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
93300 ECSS V DIR).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and ECSS switch ON and drive in a gear
speed other than 1st.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ECSS solenoid F24 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness Wiring harness between L04 (female) (17) –
state (Contact with ground circuit) F24 (female) (1) wiring harness and chassis Resis-
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (17) and (13) 5 – 15 z
Between (17), (13) and
Min. 1 Mz
chassis ground

Circuit diagram related to ECSS solenoid

WA600-6 23
SEN00561-03 40 Troubleshooting

Failure code [D192KY] (ECSS solenoid: Short circuit with power supply
line) 1

Action code Failure code ECSS solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller system)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied
trouble when ECSS solenoid output was turned OFF.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The ECSS keeps operating.
machine
• The output state (current) to the ECSS solenoid can be checked with the monitoring function (Code:
Related 93300 ECSS V DIR).
information • Applicable only to ECSS specification machines (if equipped)
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective ECSS solenoid F24 (male) Resistance
1
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and chassis
Min. 1 Mz
ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (17) –
Voltage Max. 1 V
F24 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (17) and (13) 5 – 15 z
Between (17), (13) and
Min. 1 Mz
chassis ground

Circuit diagram related to ECSS solenoid

24 WA600-6
40 Troubleshooting SEN00561-03

Failure code [D198KA] (Transmission oil pressure bypass solenoid:

Disconnection) 1

Action code Failure code Transmission oil pressure bypass solenoid: Disconnection
Trouble
E01 D198KA (Transmission controller system)
Contents of
• Transmission oil pressure bypass solenoid trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• Transmission oil pressure bypass solenoid is not set in WA600-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.

WA600-6 25
SEN00561-03 40 Troubleshooting

Failure code [D198KB] (Transmission oil pressure bypass solenoid:

Short circuit) 1

Action code Failure code Transmission oil pressure bypass solenoid: Short circuit
Trouble
E01 D198KB (Transmission controller system)
Contents of
• Transmission oil pressure bypass solenoid trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• Transmission oil pressure bypass solenoid is not set in WA600-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.

26 WA600-6
40 Troubleshooting SEN00561-03

Failure code [D198KY] (Transmission oil pressure bypass solenoid:

Short circuit with power supply line) 1

Action code Failure code Transmission oil pressure bypass solenoid: Short circuit with power
Trouble
E01 D198KY line (Transmission controller system)
Contents of
• Transmission oil pressure bypass solenoid trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• Transmission oil pressure bypass solenoid is not set in WA600-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.

WA600-6 27
SEN00561-03 40 Troubleshooting

Failure code [D5ZHKA] (Terminal C signal: Disconnection) 1

Action code Failure code Terminal C signal: Disconnection

Trouble
E01 D5ZHKA (Transmission controller system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.).
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related
with the monitoring function (Code: 40905, D-IN-7) (Transmission controller system).
information
• Method of reproducing failure code: Set the starting switch to START position

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.1 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch CL12 Starting switch Resistance
2
(Internal disconnection)
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
ness L103 (female) (5) tance
3
(Disconnection or defective Wiring harness between L103 (female) (3) Resis-
contact of connector) Max. 1 z
and L104 (female) (6) tance
Possible causes Wiring harness between L104 (female) (3) – Resis-
and standard Max. 1 z
L02(female) (6) tance
value in normal
a Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Wiring harness between CL12 (female) (3) –
Resis-
L103 (female) (5) and CL12 (female) (3) – Min. 1 Mz
tance
Grounding fault in wiring har- circuit branch end point and chassis ground
4 ness Wiring harness between L103 (female) (3) –
(Contact with ground circuit) L104 (female) (6) and L103 (female) (3) – Resis-
Min. 1 Mz
tance
circuit branch end point and chassis ground
Wiring harness between L104 (female) (3) –
Resis-
L02 (female) (6) and 104 (female) (3) – cir- Min. 1 Mz
tance
cuit branch end point and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective transmission con- L02 Starting switch Voltage
5
troller
Between (6) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

28 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to engine starting system

WA600-6 29
SEN00561-03 40 Troubleshooting

Failure code [D5ZHKB] (Terminal C signal: Short circuit) 1

Action code Failure code Terminal C signal: Short circuit

Trouble
E01 D5ZHKB (Transmission controller system)
Contents of • Terminal C system is shorted with the power source (Engine speed is above 500 rpm and starting
trouble switch terminal C signal has been input.).
Action of • Engine start assistance is not working.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related
with the monitoring function (Code: 40905, D-IN-7) (Transmission controller system).
information
• Method of reproducing failure code: Start engine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch CL12 Starting switch Resistance
1
(Internal disconnection)
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
after engine start and during engine operation
Wiring harness between CL12 (female) (3) –
Possible causes L103 (female) (5) and CL12 (female) (3) – Voltage Max. 1 V
and standard circuit branch end point and chassis ground
value in normal Hot short in wiring harness
2 Wiring harness between L103 (female) (3) –
state (Contact with 24 V circuit)
L104 (female) (6) and L103 (female) (3) – Voltage Max. 1 V
circuit branch end point and chassis ground
Wiring harness between L104 (female) (3) –
L02 (female) (6) and L104 (female) (3) – cir- Voltage Max. 1 V
cuit branch end point and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective transmission con- L02 Starting switch Voltage
3
troller
Between (6) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

30 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to engine starting system

WA600-6 31
SEN00561-03 40 Troubleshooting

Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short

circuit) 1

Action code Failure code Terminal C signal: Disconnection or short circuit

Trouble
E01 D5ZHKZ (Work equipment controller system)
Contents of • Terminal C system is disconnected (Engine speed is above 500 rpm and no starting switch terminal
trouble C signal has been input.)
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Engine starts when work equipment control lever is not at Neutral
machine
• The input state (ON/OFF) from starting switch terminal C to work equipment controller can be
Related
checked with the monitoring function (Code: 40912, D-IN-17) (Work equipment controller system).
information
• Method of reproducing failure code: Set the starting switch to START position

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.1 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch CL12 Starting switch Resistance
2
(Internal disconnection)
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between CL12 (female) (3) – Resis-
3 Max. 1 z
(Disconnection or defective L103 (female) (5) tance
Possible causes contact of connector) Wiring harness between L103 (female) (3) – Resis-
and standard Max. 1 z
value in normal L06 (female) (25) tance
state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CL12 (female) (3) –
Grounding fault in wiring har- Resis-
L103 (female) (5) and CL12 (female) (3) – Min. 1 Mz
4 ness tance
circuit branch end point and chassis ground
(Contact with ground circuit)
Wiring harness between L103 (female) (3) –
Resis-
L06 (female) (25) and L103 (female) (3) – Min. 1 Mz
tance
circuit branch end point and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective work equipment L06 Starting switch Voltage
5
controller
Between (25) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

32 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to engine starting system

WA600-6 33
SEN00561-03 40 Troubleshooting

Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine
running or stopped state) 1

Action code Failure code Terminal C signal: Signal disagrees with operation and stop of
Trouble
E01 D5ZHL6 engine (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.)
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) from starting switch terminal C to machine monitor can be checked with
Related
the monitoring function (Code: 40900, D-IN-2) (Machine monitor system).
information
• Method of reproducing failure code: Set the starting switch to START position

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.1 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
1
box A (See cause 4.)
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch CL12 Starting switch Resistance
2
(Internal disconnection)
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
ness L103 (female) (5) tance
3
(Disconnection or defective Wiring harness between L103 (female) (3) – Resis-
contact of connector) Max. 1 z
L104 (female) (6) tance
Possible causes Wiring harness between L104 (female) (3) – Resis-
and standard Max. 1 z
C02 (female) (2) tance
value in normal
a Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Wiring harness between CL12 (female) (3) –
Resis-
L103 (female) (5) and CL12 (female) (3) – Min. 1 Mz
tance
Grounding fault in wiring har- circuit branch end point and chassis ground
4 ness Wiring harness between L103 (female) (3) –
(Contact with ground circuit) L104 (female) (6) and L103 (female) (3) – Resis-
Min. 1 Mz
tance
circuit branch end point and chassis ground
Wiring harness between L104 (female) (3) –
Resis-
C02 (female) (2) and L104 (female) (3) – cir- Min. 1 Mz
tance
cuit branch end point and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
5 Defective machine monitor C02 Starting switch Voltage
Between (2) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V

34 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to engine starting system

WA600-6 35
SEN00561-03 40 Troubleshooting

Failure code [DA80L4] (Auto grease controller: ON/OFF signals

disagree) 1

Action code Failure code Auto grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• Both auto grease sensor input circuits A and B are in the same state (OPEN or CLOSE).
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Auto grease does not work.
machine
• The input state (ON/OFF) from the auto grease controller can be checked with the monitoring func-
Related tion (Code: 40900, D-IN-4, D-IN-5).
information • Applicable only to machines equipped with auto grease function (if equipped)
• Method of reproducing failure code: Turn the starting switch and auto grease start button ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between C02 (female) (3) – Resis-
1 Max. 1 z
(Disconnection or defective R38 (female) (2) tance
contact of connector) Wiring harness between C02 (female) (12) – Resis-
Max. 1 z
R38 (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between C02 (female) (3) Resis-
2 ness Min. 1 Mz
and R38 (female) (2) and chassis ground tance
(Contact with ground circuit)
Wiring harness between C02 (female) (12) – Resis-
Min. 1 Mz
R38 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard
Hot short in wiring harness Wiring harness between C02 (female) (3)
value in normal 3 Voltage Max. 1 V
(Contact with 24 V circuit) and R38 (female) (2) and chassis ground
state
Wiring harness between C02 (female) (12)
Voltage Max. 1 V
and R38 (female) (3) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Auto grease start
R38 Voltage
button ON

Defective auto grease con- In operation Max. 1 V

Between (2) and
troller chassis ground Not in operation
4 20 – 30 V
(Internal disconnection or (with empty tank)
short circuit) In operation 20 – 30 V
Between (3) and
chassis ground Not in operation
Max. 1 V
(with empty tank)
a If the above troubleshooting results are normal, refer to and carry
out troubleshootings for auto grease system.

36 WA600-6
40 Troubleshooting SEN00561-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Auto grease start
C02 Voltage
button ON
Possible causes In operation Max. 1 V
and standard Between (3) and
value in normal chassis ground Not in operation
5 Defective machine monitor 20 – 30 V
state (with empty tank)
In operation 20 – 30 V
Between (12) and
chassis ground Not in operation
Max. 1 V
(with empty tank)
a If the above troubleshooting results are normal, refer to and carry
out troubleshootings for auto grease system.

Circuit diagram related to auto grease

WA600-6 37
SEN00561-03 40 Troubleshooting

Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 1

Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of
trouble the UNSW power supply (power supply for memory) is below 17 V.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
• The service meter reading is abnormal, the odometer does not advance and fault history data is not
appears on
saved.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Shut down of circuit breaker If the circuit breaker is shut down, the circuit probably has a ground-
1
(CBF1) ing fault, etc. (See cause 4.)
Defective fuse No.6 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
2
box A (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR2
Disconnection in wiring har- Resis-
D13 – battery relay BTR1 D11 – circuit Max. 1 z
ness tance
3 breaker CBF1 R01
(Disconnection or defective
Wiring harness between circuit breaker Resis-
contact) Max. 1 z
CBF1 R02 – fuse No.6 of fuse box A tance
Wiring harness between fuse No.6 of fuse Resis-
Max. 1 z
box A – C01 (female) (4) (5) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR2
Possible causes Resis-
D13 – battery relay BTR1 D11 – circuit Max. 1 z
and standard tance
breaker CBF1 R01 and chassis ground
value in normal Grounding fault in wiring har-
state 4 ness Wiring harness between circuit breaker
Resis-
(Contact with ground circuit) CBF1 R02 – fuse No.6 of fuse box A and Max. 1 z
tance
chassis ground
Wiring harness between fuse No.6 of fuse
box A – C01 (female) (4), (5) and fuse No.6 Resis-
Max. 1 z
of fuse box A – circuit branch end point and tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between battery relay BTR2
D14 – circuit breaker CBF3 R06 and chassis Voltage Max. 1 V
ground
Hot short in wiring harness Wiring harness between circuit breaker
5
(Contact with 24 V circuit) CBF3 R05 – fuse No.8 of fuse box B and Voltage Max. 1 V
chassis ground
Wiring harness between fuse No.8 of fuse
box B – C01 (female) (6), (7) and fuse No.8
Voltage Max. 1 V
of fuse box B – circuit branch end point and
chassis ground

38 WA600-6
40 Troubleshooting SEN00561-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard C01 Voltage
value in normal 6 Defective machine monitor Between (4), (5) and (9), (10),
state 20 – 30 V
(17), (18), (19), (20)
Between (6), (7) and (9), (10),
20 – 30 V
(17), (18), (19), (20)

Circuit diagram related to machine monitor power supply

WA600-6 39
SEN00561-03 40 Troubleshooting

Failure code [DAF5KP] (Machine monitor: Low output voltage) 1

Action code Failure code Machine monitor: Low output voltage

Trouble
E01 DAF5KP (Machine monitor system)
Contents of • When the voltage of the SW power supply (power supply for operation) is above 17 V, the voltage of
trouble the sensor is below 5 V.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that
appears on • Machine monitor does not display load.
machine
Related • Applicable only to machines equipped with load meter (if equipped)
information • Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (C) and (A) 5 kz ± 20%
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm angle sen- a Prepare with starting switch OFF, then turn starting switch ON
1
sor (Internal short circuit) and carry out troubleshooting
F13 Lift arm cylinder Voltage
Between (C) and (A) Constant 4.85 – 5.15 V
Constant 0.83 – 4.1 V
Between (B) and (A) At max. length 3.50 – 4.1 V
At min. length 0.83 – 1.88 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes F14 (male) Resistance
and standard Between (A), (B), (C) and
value in normal Min. 1 Mz
chassis ground
state
Defective lift arm bottom a Prepare with starting switch OFF, then turn starting switch ON
2 pressure sensor and carry out troubleshooting
(Internal short circuit) Lift arm bottom
F14 (male) Voltage
pressure
Between (C) and (B) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F15 (male) Resistance
Defective lift arm rod pres- Between (A), (B), (C) and
Min. 1 Mz
3 sure sensor chassis ground
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
F15 (male) Lift arm rod pressure Voltage
Between (C) and (B) Constant 4.85 – 5.15 V

40 WA600-6
40 Troubleshooting SEN00561-03

Cause Standard value in normal state/Remarks on troubleshooting

Defective lift arm rod pres- Constant 0.50 – 4.50 V

3 sure sensor Between (C) and (A) When released 0.50 – 0.90 V
(Internal short circuit) When relieved 3.02 – 3.42 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C01 (female) (16) Resis-
Min. 1 Mz
and JF1 (female) (1) tance
Possible causes Grounding fault in wiring har-
and standard Wiring harness between JF1 (female) (2) – Resis-
4 ness Min. 1 Mz
value in normal F13 (female) (A) tance
(Contact with ground circuit)
state Wiring harness between JF1 (female) (3) – Resis-
Min. 1 Mz
F14 (female) (B) tance
Wiring harness between JF1 (female) (4) – Resis-
Min. 1 Mz
F15 (female) (B) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective machine monitor C01 Lift arm cylinder Voltage
Between (16) and
Constant 4.85 – 5.15 V
chassis ground

Circuit diagram related to machine monitor sensor

WA600-6 41
SEN00561-03 40 Troubleshooting

Failure code [DAFRKR] (CAN communication with machine monitor:

Defective communication (Abnormality in target component system)) 1

Action code Failure code CAN communication with machine monitor:

Trouble Defective communication (Abnormality in target component system)
E03 DAFRKR (Machine monitor system)
Contents of • Communication via CAN signal line between the machine monitor and transmission controller is
trouble defective.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
1
(Disconnection or defective Wiring harness between C06 (female) (3), Resis-
contact of connector) Max. 1 z
(8) – L03 (female) (22), (32) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
2 ness Wiring harness between C06 (female) (3),
(Contact with ground circuit) (8) – L03 (female) (22), (32) and chassis Resis-
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Possible causes Hot short in wiring harness
3 Wiring harness between C06 (female) (3),
and standard (Contact with 24 V circuit)
(8) – L03 (female) (22), (32) and chassis Voltage Max. 1 V
value in normal ground
state
a Prepare with starting switch OFF, then carry out troubleshooting
Contact of wiring harness without turning starting switch ON.
4
(Between CANH – CANL) C06 (female) Resistance
Between (3) – (8) Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 Resis-
5 Defective terminal resistor Between (A) – (B) 120 ± 12 z
(male) tance
E21 Resis-
Between (A) – (B) 120 ± 12 z
(male) tance
If causes 1 – 5 are not detected, machine monitor may be defective.
6 Defective machine monitor
(Since trouble is in system, troubleshooting cannot be carried out.)

42 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to CAN communication

WA600-6 43
SEN00561-03 40 Troubleshooting

Failure code [DAQ0KK] (Transmission controller: Low source voltage) 1

Action code Failure code Transmission controller: Low source voltage

Trouble
E03 DAQ0KK (Transmission controller system)
• Voltage of UNSW power supply (battery direct power supply) of the transmission controller is low.
Contents of
• Voltage of UNSW power supply (battery direct power supply) is below 18 V and engine speed is
trouble
below 500 rpm.
• Cannot sense the input signals normally.
Action of
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
controller
selector switch is set to N (Neutral).
Problem that
appears on • The machine cannot operate normally.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Shut down of circuit breaker If the circuit breaker is shut down, the circuit probably has a ground-
1
(CBF1) ing fault, etc. (See cause 4.)
Defective fuse No.4 of fuse If the fuse is broken, the circuit probably has a grounding fault, etc.
2
box A (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR2
Resis-
Disconnection in wiring har- D13 – battery relay BTR1 D11 – circuit Max. 1 z
tance
ness breaker CBF1 R01
3
(Disconnection or defective Wiring harness between circuit breaker Resis-
contact of connector) Max. 1 z
CBF1 R02 – fuse No.4 of fuse box A tance
Wiring harness between fuse No.4 of fuse
Resis-
box A – L04 (female) (1), (11), – circuit Max. 1 z
Possible causes tance
branch end point
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Wiring harness between battery relay BTR2
Resis-
D13 – battery relay BTR1 D11 – circuit Min. 1 Mz
tance
Grounding fault in wiring har- breaker CBF1 R01 and chassis ground
4 ness Wiring harness between circuit breaker
(Contact with ground circuit) CBF1 R02 – fuse No.4 of fuse box A and Resis-
Min. 1 Mz
tance
chassis ground
Wiring harness between fuse No.4 of fuse
Resis-
box A – L04 (female) (1), (11), – circuit Min. 1 Mz
tance
branch end point and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con-
5 L04 Voltage
troller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)

44 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to transmission controller power supply

WA600-6 45
SEN00561-03 40 Troubleshooting

Failure code [DAQ0KT] (Transmission controller: Abnormality in

controller) 1

Action code Failure code Transmission controller: Abnormality in controller

Trouble
E01 DAQ0KT (Transmission controller system)
Contents of
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
trouble
• Sets the internal adjustment values to the default values.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The gear shifting feeling of the transmission may become bad.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective transmission con- Since trouble is in system, troubleshooting cannot be carried out.
1
state troller (Replace controller.)

46 WA600-6
40 Troubleshooting SEN00561-03

WA600-6 47
SEN00561-03 40 Troubleshooting

Failure code [DAQ2KK] (Transmission controller load power supply

line: Low source voltage (input)) 1

Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble
E03 DAQ2KK (input) (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input is turned OFF, UNSW power supply (battery direct power sup-
trouble
ply) is above 20 V and solenoid power supply is below 18 V
• Turns the centralized warning lamp and alarm buzzer ON.
• Strain itself not to display failure codes that may be false detected due to low 24 V solenoid source
Action of
voltage
controller
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
selector switch is set to N (Neutral).
Problem that
appears on • Transmission is stuck in Neutral.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L117 (male) Resistance
Defective fan motor relay
Between (1) and (2) 200 – 400 z
(L117)
1 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection or
short circuit) and carry out troubleshooting
When fan motor relay (L117) is replaced with a relay of the same
type (5-pin type), if the condition becomes normal, the fan motor
relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes ness Wiring harness between L04 (female) (2), Resis-
2 Max. 1 z
and standard (Disconnection or defective (12), (22) – L117 (female) (5) tance
value in normal contact of connector) Wiring harness between L117(female) (3) – Resis-
state Max. 1 z
fuse No.4 of fuse box A tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har- Wiring harness between L04 (female) (2),
Resis-
3 ness (12), (22) – L117 (female) (5) and chassis Min. 1 Mz
tance
(Contact with ground circuit) ground
Wiring harness between L117(female) (3) – Resis-
Min. 1 Mz
fuse No.4 of fuse box A and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con-
4 L04 Voltage
troller
Between (2), (12), (22) and (21),
20 – 30 V
(31), (32), (33)

48 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to transmission controller power supply

WA600-6 49
SEN00561-03 40 Troubleshooting

Failure code [DAQ9KQ] (Transmission controller model selection:

Disagreement of model selection signals) 1

Action code Failure code Transmission controller model selection: Disagreement of model
Trouble
E03 DAQ9KQ selection signals (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
failure code is still used.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Strain itself not to display failure codes which may be false detected.
• If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shifting shocks may be made.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Improper machine monitor Set the controller model of the machine monitor (See Testing and
1
state model selection adjusting.)

50 WA600-6
40 Troubleshooting SEN00561-03

WA600-6 51
SEN00561-03 40 Troubleshooting

Failure code [DAQRKR] (CAN communication with transmission

controller: Defective communication (Abnormality in target component
system)) 1

Action code Failure code CAN communication with transmission controller:

Trouble Defective communication (Abnormality in target component system)
E03 DAQRKR (Transmission controller system)
Contents of • Communication via CAN signal line between the machine monitor and transmission controller is
trouble defective.
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L03 (female) (22) – Resis-
1 Max. 1 z
(Disconnection or defective C06 (female) (8) tance
contact of connector) Wiring harness between L03 (female) (32) – Resis-
Max. 1 z
C06 (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L03 (female) (22) – Resis-
2 ness Min. 1 Mz
C06 (female) (8) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L03 (female) (32) – Resis-
Min. 1 Mz
C06 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard Hot short in wiring harness Wiring harness between L03 (female) (22) –
3 Voltage Max. 1 V
value in normal (Contact with 24 V circuit) C06 (female) (8) and chassis ground
state Wiring harness between L03 (female) (32) –
Voltage Max. 1 V
C06 (female) (3) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Contact of wiring harness without turning starting switch ON.
4
(Between CANH – CANL) C06 (female) Resistance
Between (3) – (8) Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 Resis-
5 Defective terminal resistor Between (A) – (B) 120 ± 12 z
(male) tance
E21 Resis-
Between (A) – (B) 120 ± 12 z
(male) tance
If causes 1 – 5 are not detected, transmission controller may be
Defective transmission con-
6 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)

52 WA600-6
40 Troubleshooting SEN00561-03

Circuit diagram related to CAN communication

WA600-6 53
SEN00561-03 40 Troubleshooting

Failure code [DAQRMA] (Transmission controller CAN communication:

Malfunction) 1

Action code Failure code Transmission controller CAN communication (optional setting): Mal-
Trouble
E03 DAQRMA function (Transmission controller system)
Contents of
• Options set by machine monitor are different from those recognized by transmission controller.
trouble
• The transmission controller takes setting of options which the transmission controller recognizes
Action of
itself.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Wrong setting of options Set options correctly.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L03 (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective C06 (female) (8) tance
contact of connector) Wiring harness between L03 (female) (32) – Resis-
Max. 1 z
C06 (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L03 (female) (22) – Resis-
Possible causes 3 ness Min. 1 Mz
C06 (female) (8) and chassis ground tance
and standard (Contact with ground circuit)
value in normal Wiring harness between L03 (female) (32) – Resis-
Min. 1 Mz
state C06 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L03 (female) (22) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) C06 (female) (8) and chassis ground
Wiring harness between L03 (female) (32) –
Voltage Max. 1 V
C06 (female) (3) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con-
5 L03 Voltage
troller
Between (22), (32) and
4–8V
chassis ground

54 WA600-6
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Circuit diagram related to CAN communication

WA600-6 55
SEN00561-03

WA600-6 Wheel loader

Form No. SEN00561-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

56
 SEN00562-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1

Troubleshooting by failure code

(Display of code), Part 5
Failure code [DB2RKR] CAN communication from engine controller:
Defective communication (Abnormality in target component system) ........................................................ 4
Failure code [DB90KK] Work equipment controller: Low source voltage (input) ............................................ 6
Failure code [DB90KT] (Work equipment controller: Abnormality in controller).............................................. 8
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input)........................................................................................................................ 10
Failure code [DB95KX] (Work equipment controller power supply output: Out of input signal range).......... 12
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement of model selection signals) ................................................................................................ 14
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) ...................................................... 16
Failure code [DB9RMA] (Work equipment controller CAN communication: Malfunction)............................. 18
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation) .............. 20

WA600-6 1
SEN00562-03 40 Troubleshooting

Failure code [DBB0KK] (or VHMS_LED display: “n9” o “01”) VHMS controller:
Low source voltage (input) ........................................................................................................................ 22
Failure code [DBB0KQ] (or VHMS_LED display: “nF” o “11”) VHMS controller:
(Disagreement of model selection signals) ............................................................................................... 24
Failure code [DBB3KK] (or VHMS_LED display: “n9” o “05”) VHMS controller battery
power supply: Low source voltage (input)................................................................................................. 26
Failure code [DBB5KP] (or VHMS_LED display: “n9” o “04”) (VHMS controller 5 V
power supply output: Low output voltage)................................................................................................. 28
Failure code [DBB6KP] (or VHMS_LED display: “n9” o “02”) (VHMS controller 24 V
power supply output: Low output voltage)................................................................................................. 30
Failure code [DBB7KP] (or VHMS_LED display: “n9” o “03”) (VHMS controller 12 V
power supply output: Low output voltage)................................................................................................. 32
Failure code [DBBQKR] (or VHMS_LED display: “n8” o “02”) VHMS controller CAN
communication: Defective communication (Abnormality in target component system) ............................... 34
Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept pressed for long time) ........................... 36
Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept pressed for long time) .......................... 38
Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept pressed for long time) ............................ 40
Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept pressed for long time) ............................ 42
Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time) ........................................................................................................ 44
Failure code [DD1BLD] (Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time) ........................................................................................................ 46
Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept pressed for long time) ........................ 48
Failure code [DD1FLD] (Load meter mode selector switch (A/B):
Switch is kept pressed for long time) ........................................................................................................ 50
Failure code [DD1GLD] (Load meter mode selector switch (+/–):
Switch is kept pressed for long time) ........................................................................................................ 52

2 WA600-6
40 Troubleshooting SEN00562-03

WA600-6 3
SEN00562-03 40 Troubleshooting

Failure code [DB2RKR] CAN communication from engine controller:

Defective communication (Abnormality in target component system) 1

Action code Failure code CAN communication from engine controller:

Trouble Defective communication (Abnormality in target component system)
E03 DB2RKR (Transmission controller system)
Contents of • Communication via CAN signal line between the transmission controller and engine controller is
trouble defective.
• Does not update CAN communication information from engine controller.
• Keeps engine speed at 2,100 rpm.
Action of • Holds recognized position of accelerator at 80%.
controller • Does not sense modulation clutch slip.
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • The monitor does not display normally
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between E18 (female) (47) – Resis-
1 Max. 1 z
(Disconnection or defective L03 (female) (22) tance
contact of connector) Wiring harness between E18 (female) (46) – Resis-
Max. 1 z
L03 (female) (32) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between E18 (female) (47) – Resis-
2 ness Min. 1 Mz
L03 (female) (22) and chassis ground tance
(Contact with ground circuit)
Wiring harness between E18 (female) (46) – Resis-
Min. 1 Mz
L03 (female) (32) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard
Hot short in wiring harness Wiring harness between E18 (female) (47) –
value in normal 3 Voltage Max. 1 V
(Contact with 24 V circuit) L03 (female) (22) and chassis ground
state
Wiring harness between E18 (female) (46) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Contact of wiring harness without turning starting switch ON.
4
(Between CAN H – CAN L) C06 (female) Resistance
Between (3) – (8) Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 Resis-
5 Defective terminal resistor Between (A) – (B) 120 ± 12 z
(male) tance
E21 Resis-
Between (A) – (B) 120 ± 12 z
(male) tance
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

4 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to CAN communication

WA600-6 5
SEN00562-03 40 Troubleshooting

Failure code [DB90KK] Work equipment controller: Low source voltage

(input) 1

Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of UNSW power supply (battery direct power supply) is 18 V or less.
• Does not display failure codes other than this code if voltage of UNSW power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of • Even if cause of failure disappears, system does not reset itself until AJSS lever and work equipment
controller control lever are set to N (Neutral).
• Turns the centralized warning lamp and alarm buzzer ON.
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Shut down of circuit breaker If the circuit breaker is shut down, the circuit probably has a ground-
1
(CBF1) ing fault, etc. (See cause 4.)
Defective fuse No.5 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
2
box A (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between battery relay BTR2
Disconnection in wiring har- Resis-
D13 – battery relay BTR1 D11 – circuit Max. 1 z
ness tance
3 breaker CBF1 R01
(Disconnection or defective
Wiring harness between circuit breaker Resis-
contact of connector) Max. 1 z
CBF1 R02 – fuse No.5 of fuse box A tance
Wiring harness between fuse No.5 of fuse Resis-
Max. 1 z
Possible causes box A – L07 (female) (1), (11) tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state
Wiring harness between battery relay BTR2
Resis-
D13 – battery relay BTR1 D11 – circuit Min. 1 Mz
tance
Grounding fault in wiring har- breaker CBF1 R02 and chassis ground
4 ness Wiring harness between circuit breaker
(Contact with ground circuit) CBF1 R02 – fuse No.5 of fuse box A and Resis-
Min. 1 Mz
tance
chassis ground
Wiring harness between fuse No.5 of fuse
Resis-
box A – L07 (female) (1), (11) and chassis Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment
5 L07 Voltage
controller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)

6 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to work equipment controller power supply

WA600-6 7
SEN00562-03 40 Troubleshooting

Failure code [DB90KT] (Work equipment controller: Abnormality in

controller) 1

Action code Failure code Work equipment controller system: Abnormality in controller
Trouble
E01 DB90KT (Work equipment controller system)
Contents of • The information in the ROM (non-volatile memory) of the work equipment controller system is abnor-
trouble mal.
• Sets the internal adjustment values to the default values.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The machine may false detect errors.
appears on
• Performance degrades since the machine is controlled with improper data.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective work equipment Since trouble is in system, troubleshooting cannot be carried out.
1
state controller (Replace controller.)

8 WA600-6
40 Troubleshooting SEN00562-03

WA600-6 9
SEN00562-03 40 Troubleshooting

Failure code [DB92KK] Work equipment controller load power supply

line: Low source voltage (input) 1

Action code Failure code Work equipment controller load power supply line: Low source volt-
Trouble
E03 DB92KK age (input) (Work equipment controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input turned OFF, UNSW power supply (battery direct power sup-
trouble
ply) above 20 V and solenoid power supply below 18 V
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until AJSS lever and work equipment
control lever are set to N (Neutral).
Problem that
appears on • Work equipment does not move.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between battery relay BTR2 Resis-
Max. 1 z
ness D15 – circuit breaker CBF3 R06 tance
1
(Disconnection in wiring har- Wiring harness between circuit breaker Resis-
ness and defective contact) Max. 1 z
CBF3 R05 – fuse No.7 of fuse box B tance
Wiring harness between fuse No.7 of fuse Resis-
Max. 1 z
box B – L07 (female) (2), (12), (22) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between battery relay BTR2 Resis-
state Grounding fault in wiring har- D15 – circuit breaker CBF3 R06 Min. 1 Mz
tance
2 ness
(Contact with ground circuit) Wiring harness between circuit breaker Resis-
Min. 1 Mz
CBF3 R05 – fuse No.7 of fuse box B tance
Wiring harness between fuse No.7 of fuse Resis-
Min. 1 Mz
box B – L07 (female) (2), (12), (22) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment
3 L07 Voltage
controller
Between (2), (12), (22) –
20 – 30 V
(21), (31), (32), (33)

10 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to work equipment controller 24 V power supply

WA600-6 11
SEN00562-03 40 Troubleshooting

Failure code [DB95KX] (Work equipment controller power supply

output: Out of input signal range) 1

Action code Failure code Work equipment controller power supply output: Out of input signal
Trouble
E03 DB95KX range (Work equipment controller system)
Contents of
• Nominal voltage output of 5 V sensor power supply system is out of range (Outside 4.7 – 5.3 V)
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The operator cannot operate the work equipment and AJSS (Machine stops entirely).
appears on
• The following potentiometer error is appeared.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective frame angle poten- a Prepare with starting switch OFF, then carry out troubleshooting
tiometer without turning starting switch ON.
1
(Internal disconnection or L12 (male) Resistance
short circuit) Between (B) and (C) 4 – 6 kz

Defective AJSS lever poten- a Prepare with starting switch OFF, then carry out troubleshooting
tiometer without turning starting switch ON.
2
(Internal disconnection or S30 (male) Resistance
short circuit) Between (B) and (C) 4 – 6 kz

Defective 3-spool valve EPC a Prepare with starting switch OFF, then carry out troubleshooting
lever potentiometer without turning starting switch ON.
3
(Internal disconnection or S16 (male) Resistance
short circuit) Between (4) and (1) 2.5 – 3.9 kz
Possible causes
Defective lift arm EPC lever a Prepare with starting switch OFF, then carry out troubleshooting
and standard
potentiometer without turning starting switch ON.
value in normal 4
state (Internal disconnection or S03 (male) Resistance
short circuit) Between (4) and (1) 2.5 – 3.9 kz

Defective bucket EPC lever a Prepare with starting switch OFF, then carry out troubleshooting
potentiometer without turning starting switch ON.
5
(Internal disconnection or S02 (male) Resistance
short circuit) Between (4) and (1) 2.5 – 3.9 kz
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
6 ness
(Contact with ground circuit) Wiring harness between L05 (female) (22) – Resis-
Min. 1 Mz
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Defective work equipment and carry out troubleshooting
7
controller L05 Voltage
Between (22) and (21) 4.85 – 5.15 V

12 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to work equipment controller 5 V power supply

WA600-6 13
SEN00562-03 40 Troubleshooting

Failure code [DB99KQ] (Work equipment controller model selection:

Disagreement of model selection signals) 1

Action code Failure code Work equipment controller model selection: Disagreement of model
Trouble
E03 DB99KQ selection signals (Machine monitor system)
Contents of
• Work equipment controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
failure code is still used.
Action of
• Does not display failure codes which may be false detected.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shifting shocks may be made.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Improper machine monitor Set the controller model of the machine monitor (See Testing and
1
state model selection adjusting.)

14 WA600-6
40 Troubleshooting SEN00562-03

WA600-6 15
SEN00562-03 40 Troubleshooting

Failure code [DB9RKR] CAN communication with work equipment

controller: Defective communication (Abnormality in target component
system) 1

Action code Failure code CAN communication with work equipment controller:
Trouble Defective communication (Abnormality in target component system)
E03 DB9RKR (Transmission controller system)
Contents of • Communication via CAN signal line between the work equipment controller and transmission control-
trouble ler is defective.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of • Uses CAN information that was sent from work equipment controller before the occurrence of the
controller error.
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L06 (female) (22) – Resis-
1 Max. 1 z
(Disconnection or defective L03 (female) (22) tance
contact of connector) Wiring harness between L06 (female) (32) – Resis-
Max. 1 z
L03 (female) (32) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L06 (female) (22) – Resis-
2 ness Min. 1 Mz
L03 (female) (22) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L06 (female) (32) – Resis-
Min. 1 Mz
L03 (female) (32) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard Hot short in wiring harness Wiring harness between L06 (female) (22) –
3 Voltage Max. 1 V
value in normal (Contact with 24 V circuit) L03 (female) (22) and chassis ground
state Wiring harness between L06 (female) (32) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Contact of wiring harness without turning starting switch ON.
4
(Between CAN H – CAN L) C06 (female) Resistance
Between (3) – (8) Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 Resis-
5 Defective terminal resistor Between (A) – (B) 120 ± 12 z
(male) tance
E21 Resis-
Between (A) – (B) 120 ± 12 z
(male) tance
If causes 1 – 5 are not detected, work equipment controller may be
Defective work equipment
6 defective. (Since trouble is in system, troubleshooting cannot be
controller
carried out.)

16 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to CAN communication

WA600-6 17
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Failure code [DB9RMA] (Work equipment controller CAN

communication: Malfunction) 1

Action code Failure code Work equipment controller CAN communication (optional setting):
Trouble
E03 DB9RMA Malfunction (Machine monitor system)
Contents of
• Options set by machine monitor are different from those recognized by work equipment controller.
trouble
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• The work equipment controller takes setting of options which the work equipment controller recog-
controller
nizes itself.
Problem that
appears on —
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Wrong setting of options Set options correctly.
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L06 (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective C06 (female) (8) tance
contact of connector) Wiring harness between L06 (female) (32) – Resis-
Max. 1 z
C06 (female) (3) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L06 (female) (22) – Resis-
Possible causes 3 ness Min. 1 Mz
C06 (female) (8) and chassis ground tance
and standard (Contact with ground circuit)
value in normal Wiring harness between L06 (female) (32) – Resis-
Min. 1 Mz
state C06 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L06 (female) (22) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) C06 (female) (8) and chassis ground
Wiring harness between L06 (female) (32) –
Voltage Max. 1 V
C06 (female) (3) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment
5 L06 Voltage
controller
Between (22), (32) and
4–8V
chassis ground

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Circuit diagram related to CAN communication

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Failure code [DB9RMC] (CAN communication with transmission

controller: Defective operation) 1

Action code Failure code CAN communication with transmission controller: Defective opera-
Trouble
E03 DB9RMC tion (Work equipment controller system)
• Communication via CAN signal line between the work equipment controller and transmission control-
ler is defective.
Contents of
• The travel speed signal cannot be transmitted from transmission controller.
trouble
• The engine start prohibition signal cannot be transmitted from transmission controller.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Action of
• Judges that the travel speed is at 0 km/h.
controller
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Problem that • The operator may not use semiautomatic digging occasionally or cannot use it entirely.
appears on • The engine can start when the AJSS lever is not in neutral
machine • Swing speed increases because AJSS cannot sense travel speed properly.
Related
• Method of reproducing failure code: Turn the starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L06 (female) (22) – Resis-
1 Max. 1 z
(Disconnection or defective L03 (female) (22) tance
contact of connector) Wiring harness between L06 (female) (32) – Resis-
Max. 1 z
L03 (female) (32) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L06 (female) (22) – Resis-
2 ness Min. 1 Mz
L03 (female) (22) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L06 (female) (32) – Resis-
Min. 1 Mz
L03 (female) (32) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard Hot short in wiring harness Wiring harness between L06 (female) (22) –
3 Voltage Max. 1 V
value in normal (Contact with 24 V circuit) L03 (female) (22) and chassis ground
state Wiring harness between L06 (female) (32) –
Voltage Max. 1 V
L03 (female) (32) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Contact of wiring harness without turning starting switch ON.
4
(Between CAN H – CAN L) C06 (female) Resistance
Between (3) – (8) Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CAN1 Resis-
5 Defective terminal resistor Between (A) – (B) 120 ± 12 z
(male) tance
E21 Resis-
Between (A) – (B) 120 ± 12 z
(male) tance
If causes 1 – 5 are not detected, transmission controller may be
Defective transmission
6 defective. (Since trouble is in system, troubleshooting cannot be
controller
carried out.)

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Circuit diagram related to CAN communication

WA600-6 21
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Failure code [DBB0KK] (or VHMS_LED display: “n9” o “01”)

VHMS controller: Low source voltage (input) 1

Action code Failure code VHMS controller: Low source voltage (input)
Trouble
— DBB0KK (VHMS controller system)
Contents of
• Voltage of VHMS controller switch fell to below 19.5 V while the engine speed is above 500 rpm)
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n9” o “01”.
information • If failure code [DAF3KK] (Machine monitor: Low source voltage (input)) is displayed, carry out trou-
bleshooting for it first.
• Method of reproducing failure code: Start engine and raise the engine speed above 500 rpm

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.14 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
box A (See cause 3.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har-
Wiring harness between fuse No.14 of fuse Resis-
ness Max. 1 z
2 box A – V01 (female) (8), (9) tance
(Disconnection or defective
contact) Wiring harness between V01 (female) (11),
Resis-
Possible causes (12), (19), (20), V02 (female) (12), V04 Max. 1 z
tance
and standard (female) (9) and chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between fuse No.14 of fuse
(Contact with ground circuit) box A – V01 (female) (8), (9) and chassis Resis-
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then carry out troubleshooting
after starting engine and raising the engine speed above 500 rpm
4 Defective VHMS controller V01 Voltage
Between (8), (9) and (11), (12),
20 – 30 V
(19), (20) or chassis ground

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Circuit diagram related to VHMS controller power supply

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Failure code [DBB0KQ] (or VHMS_LED display: “nF” o “11”)

(VHMS controller: Disagreement of model selection signals) 1

Action code Failure code VHMS controller: Disagreement of model selection signals
Trouble
— DBB0KQ (VHMS controller system)
Contents of
• Improperly connected connectors were detected.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The system may not work properly.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “nF” o “11”.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Improperly connected con-
Check connection between V02 and V04 connectors, and V03 and
and standard 1 nectors in VHMS controller
V05 connectors for abnormality.
value in normal (when the system is normal)
state If the above is normal, VHMS controller may be defective.
2 Defective VHMS controller
(Since trouble is in system, troubleshooting cannot be carried out.)

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Failure code [DBB3KK] (or VHMS_LED display: “n9” o “05”)

VHMS controller battery power supply: Low source voltage (input) 1

Action code Failure code VHMS controller: Low source voltage (input)
Trouble
— DBB3KK (VHMS controller system)
Contents of
• Constant voltage of VHMS controller fell to below 10 V.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “n9” o “05”.
• Method of reproducing failure code: Keep the starting switch turned OFF

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.6 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
box A (See cause 3.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har-
Wiring harness between fuse No.6 of fuse Resis-
ness Max. 1 z
2 box A – V01 (female) (6), (7) tance
(Disconnection or defective
contact) Wiring harness between V01 (female) (11),
Resis-
Possible causes (12), (19), (20), V02 (female) (12), V04 Max. 1 z
tance
and standard (female) (9) and chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between fuse No.6 of fuse
(Contact with ground circuit) box A – V01 (female) (6), (7) and chassis Resis-
Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
4 Defective VHMS controller V01 Voltage
Between (6), (7) and (11), (12),
20 – 30 V
(19), (20) or chassis ground

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Circuit diagram related to VHMS controller power supply

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Failure code [DBB5KP] (or VHMS_LED display: “n9” o “04”)

(VHMS controller 5 V power supply output: Low output voltage) 1

Action code Failure code VHMS controller 5 V power supply output: Low output voltage
Trouble
— DBB5KP (VHMS controller system)
Contents of
• VHMS controller 5 V sensor power supply is shorted with the chassis ground.
trouble
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “n9” o “04”.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
1 ness Wiring harness between V01 (female) (5) –
Possible causes (Contact with ground circuit) V13 (female) (B), – V14 (female) (B), – V23 Resis-
Min. 1 Mz
and standard (female) (B), – V25 (female) (B) and chassis tance
value in normal ground
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
2 Defective VHMS controller V01 Voltage
Between (5) and (11), (12), (19),
4.5 – 5.5 V
(20) or chassis ground

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Circuit diagram related to VHMS controller 5 V sensor power supply

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Failure code [DBB6KP] (or VHMS_LED display: “n9” o “02”)

(VHMS controller 24 V power supply output: Low output voltage) 1

Action code Failure code VHMS controller 24 V power supply output: Low output voltage
Trouble
— DBB6KP (VHMS controller system)
Contents of
• VHMS controller 24 V sensor and indicator lamp power supply is shorted with the chassis ground.
trouble
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “n9” o “02”.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
1 ness Wiring harness between V01 (female) (2) –
Possible causes (Contact with ground circuit) V21 (female) (1), – V29 (female) (1), – V30 Resis-
Min. 1 Mz
and standard tance
(female) (1) and chassis ground
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
2 Defective VHMS controller V01 Voltage
Between (2) and (11), (12), (19),
20 – 30 V
(20) or chassis ground

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Circuit diagram related to VHMS controller 24 V sensor power supply

WA600-6 31
SEN00562-03 40 Troubleshooting

Failure code [DBB7KP] (or VHMS_LED display: “n9” o “03”)

(VHMS controller 12 V power supply output: Low output voltage) 1

Action code Failure code VHMS controller 12 V power supply output: Low output voltage
Trouble
— DBB7KP (VHMS controller system)
Contents of
• VHMS controller 12 V indicator lamp power supply is shorted with the chassis ground.
trouble
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on —
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related downloading data stored in the VHMS controller).
information • The LED of the VHMS controller displays “n9” o “03”.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
1 ness
Possible causes (Contact with ground circuit) Wiring harness between V01 (female) (3) – Resis-
Min. 1 Mz
and standard V15 (female) (1) and chassis ground tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting
2 Defective VHMS controller V01 Voltage
Between (3) and (11), (12), (19),
11.5 – 12.5 V
(20) or chassis ground

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Circuit diagram related to VHMS controller 12 V sensor power supply

WA600-6 33
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Failure code [DBBQKR] (or VHMS_LED display: “n8” o “02”)

VHMS controller CAN communication: Defective communication
(Abnormality in target component system) 1

Action code Failure code VHMS controller CAN communication: Defective communication
Trouble (Abnormality in target component system)
— DBBQKR (VHMS controller system)
Contents of
• CAN communication information from each controller cannot be received.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The system may not work properly.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n8” o “02”.
information • If failure code [CA1633], [DAFRKR], [DAQRMA], [DB2RKR], [DB9RKR], [DB9RMA] or [DB9RMC]
is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between V06 (female) (12) –
Resis-
ness C06 (female) (8), – E18 (female) (47), – L03 Max. 1 z
1 tance
(Disconnection or defective (female) (22), – L06 (female) (22)
contact of connector) Wiring harness between V06 (female) (4) –
Resis-
C06 (female) (3), – E18 (female) (46), – L03 Max. 1 z
tance
(female) (32), – L06 (female) (32)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between V06 (female) (12) –
Possible causes C06 (female) (8), – E18 (female) (47), – L03 Resis-
Grounding fault in wiring har- Min. 1 Mz
and standard (female) (22), – L06 (female) (22) and chas- tance
2 ness
value in normal sis ground
(Contact with ground circuit)
state Wiring harness between V06 (female) (4) –
C06 (female) (3), – E18 (female) (46), – L03 Resis-
Min. 1 Mz
(female) (32), – L06 (female) (32) and chas- tance
sis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between V06 (female) (12) –
C06 (female) (8), – E18 (female) (47), – L03
Voltage Max. 1 V
Hot short in wiring harness (female) (22), – L06 (female) (22) and chas-
3
(Contact with 24 V circuit) sis ground
Wiring harness between V06 (female) (4) –
C06 (female) (3), – E18 (female) (46), – L03
Voltage Max. 1 V
(female) (32), – L06 (female) (32) and chas-
sis ground

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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
E21 (male) Resistance
Defective CAN end point Between (A) and (B) 110 – 140 z
4
Possible causes resistance a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal CAN1 (male) Resistance
state
Between (A) and (B) 110 – 140 z
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
5 Defective VHMS controller V06 Voltage
Between (4), (12) and
4–8V
chassis ground

Circuit diagram related to VHMS controller CAN communication

WA600-6 35
SEN00562-03 40 Troubleshooting

Failure code [DD15LD] (t switch (Panel switch 1): Switch is kept

pressed for long time) 1

Action code Failure code t switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept CLOSED
trouble for more than continuous 1 minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor (cannot enter the service mode).
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1) can
Related be checked with the monitoring function (Code: 40901 D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective t switch (Panel t switch
1 switch 1) (Internal short cir- C09 (male) Resistance
(Panel switch 1)
cuit)
ON Max. 1 z
Between (4) and (5)
Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between C02 (female) (17) –
Voltage Max. 1 V
C09 (female) (4) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
t switch
3 Defective machine monitor C02 Voltage
(Panel switch 1)
Between (17) and ON 20 – 30 V
chassis ground Other than above Max. 1 V

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Circuit diagram related to t switch and U switch

WA600-6 37
SEN00562-03 40 Troubleshooting

Failure code [DD16LD] (U switch (Panel switch 2): Switch is kept

pressed for long time) 1

Action code Failure code U switch (Panel switch 2): Switch is kept pressed for long time
Trouble
E01 DD16LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
Related can be checked with the monitoring function (Code: 40901 D-IN-14).
information • The operator may not be able to use the monitoring function because of the U switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective U switch (Panel U switch
1 switch 2) (Internal short cir- C09 (male) Resistance
(Panel switch 2)
cuit)
ON Max. 1 z
Between (5) and (6)
Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between C02 (female) (8) –
Voltage Max. 1 V
C09 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
U switch
3 Defective machine monitor C02 Voltage
(Panel switch 2)
Between (8) and ON 20 – 30 V
chassis ground Other than above Max. 1 V

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Circuit diagram related to t switch and U switch

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Failure code [DD17LD] (< switch (Panel switch 3): Switch is kept
pressed for long time) 1

Action code Failure code < switch (Panel switch 3): Switch is kept pressed for long time
Trouble
E01 DD17LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept
trouble “CLOSED” for more than continuous 1 minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
Related be checked with the monitoring function (Code: 40904 D-IN-38).
information • The operator may not be able to use the monitoring function because of the < switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective < switch (Panel < switch
1 switch 3) (Internal short cir- C10 (female) Resistance
(Panel switch 3)
cuit)
ON Max. 1 z
Between (4) and (5)
Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between C10 (female) (4) – Resis-
Min. 1 Mz
C04 (female) (7) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
< switch
3 Defective monitor panel C04 (female) Voltage
(Panel switch 3)
Between (7) and ON Max. 1 V
chassis ground Other than above 20 – 30 V

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Circuit diagram related to > switch and < switch

WA600-6 41
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Failure code [DD18LD] (> switch (Panel switch 4): Switch is kept
pressed for long time) 1

Action code Failure code > switch (Panel switch 4): Switch is kept pressed for long time
Trouble
E01 DD18LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept
trouble “CLOSED” for more than continuous 1 minute.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
Related be checked with the monitoring function (Code: 40904 D-IN-37).
information • The operator may not be able to use the monitoring function because of the > switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective > switch (Panel > switch
1 switch 4) (Internal short cir- C10 (female) Resistance
(Panel switch 3)
cuit)
ON Max. 1 z
Between (5) and (6)
Other than above Min. 1 Mz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between C10 (female) (6) – Resis-
Min. 1 Mz
C04 (female) (15) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
> switch
3 Defective monitor panel C04 (female) Voltage
(Panel switch 3)
Between (15) and ON Max. 1 V
chassis ground Other than above 20 – 30 V

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Circuit diagram related to > switch and < switch

WA600-6 43
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Failure code [DD1ALD] (Remote positioner raise/lower set switch (raise):

Switch is kept pressed for long time) 1

Action code Failure code Remote positioner raise/lower set switch (raise): Switch is kept
Trouble
E01 DD1ALD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system has a grounding fault, operator
trouble cannot set raising.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
• The remote positioner raise stop function does not work.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked
Related
with the monitoring function (Code: 40913 D-IN-28).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch (raise)
Raise Max. 1 z
(Internal short circuit) Between (5) and (6)
Other than above Min. 1 Mz
Between (5), (6) and
Possible causes Constant Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L06 (female) (13) – Resis-
Min. 1 Mz
S14 (female) (6) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment Remote positioner
3 L06 (male) Voltage
controller raise/lower set switch
Between (13) and Raise Max. 1 V
chassis ground Other than above 7 – 10 V

44 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to remote positioner raise/lower set switch

WA600-6 45
SEN00562-03 40 Troubleshooting

Failure code [DD1BLD] (Remote positioner raise/lower set switch

(lower): Switch is kept pressed for long time) 1

Action code Failure code Remote positioner raise/lower set switch (lower): Switch is kept
Trouble
E01 DD1BLD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system has a grounding fault, operator
trouble cannot set lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The operator cannot set the lift arm lower set position.
appears on
• The remote positioner raise stop function does not work.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked
Related
with the monitoring function (Code: 40913 D-IN-29).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch
Lower Max. 1 z
(Internal short circuit) Between (4) and (5)
Other than above Min. 1 Mz
Between (4), (5) and
Possible causes Constant Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L06 (female) (3) – Resis-
Min. 1 Mz
S14 (female) (4) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment Remote positioner
3 L06 (male) Voltage
controller raise/lower set switch
Between (3) and Lower Max. 1 V
chassis ground Other than above 7 – 10 V

46 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to remote positioner raise/lower set switch

WA600-6 47
SEN00562-03 40 Troubleshooting

Failure code [DD1CLD] (Load meter subtotal switch: Switch is kept

pressed for long time) 1

Action code Failure code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • The load meter subtotal switch may not operate because of grounding fault in load meter subtotal
trouble switch system.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The total amount of load cannot be set to 0 on the screen.
machine
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904 D-IN-32).
information • Applicable only to machines equipped with load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter subtotal
S08 (male) Resistance
Defective load meter subtotal switch
1
switch (Internal short circuit) ON Max. 1 z
Between (3) and (4)
OFF Min. 1 Mz
Between (3), (4) and
Possible causes Constant Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between C04 (female) (4) – Resis-
Min. 1 Mz
S08 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Load meter subtotal
3 Defective machine monitor C04 (male) Voltage
switch
Between (4) and ON Max. 1 V
chassis ground OFF 20 – 30 V

48 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to load meter cancel switch & subtotal switch

WA600-6 49
SEN00562-03 40 Troubleshooting

Failure code [DD1FLD] (Load meter mode selector switch (A/B): Switch
is kept pressed for long time) 1

Action code Failure code Load meter mode selector switch (A/B): Switch is kept pressed for
Trouble
E01 DD1FLD long time (Machine monitor system)

Contents of • The input circuit of the load meter mode selector switch (A/B) is kept “CLOSED” for more than con-
trouble tinuous 1 minute
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The working object cannot be changed.
machine
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901 D-IN-10).
information • Applicable only to machines equipped with load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter mode
Defective load meter mode C11 (male) Resistance
selector switch (A/B)
1 selector switch (A/B)
ON Max. 1 z
(Internal short circuit) Between (5) and (6)
OFF Min. 1 Mz
Between (5), (6) and
Possible causes Constant Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short in wiring harness and carry out troubleshooting
2
(Contact with 24 V circuit) Wiring harness between C02 (female) (6) –
Voltage Max. 1 V
C11 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Load meter mode
3 Defective machine monitor C02 (female) Voltage
selector switch (A/B)
Between (6) and ON 20 – 30 V
chassis ground OFF Max. 1 V

50 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to load meter mode selector switch

WA600-6 51
SEN00562-03 40 Troubleshooting

Failure code [DD1GLD] (Load meter mode selector switch (+/–): Switch
is kept pressed for long time) 1

Action code Failure code Load meter mode selector switch (+/–): Switch is kept pressed for
Trouble
E01 DD1GLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept “CLOSED” for more than contin-
trouble uous 1 minute
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The operator cannot make settings of load meter addition mode.
machine
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901 D-IN-11).
information • Applicable only to machines equipped with load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter mode
Defective load meter mode C11 (male) Resistance
selector switch (+/–)
1 selector switch (+/–)
ON Max. 1 z
(Internal short circuit) Between (4) and (5)
OFF Min. 1 Mz
Between (4), (5) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short in wiring harness and carry out troubleshooting
2
(Contact with 24 V circuit) Wiring harness between C02 (female) (15) –
Voltage Max. 1 V
C11 (female) (4) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Load meter mode
3 Defective machine monitor C02 (female) Voltage
selector switch (+/–)
Between (15) and ON 20 – 30 V
chassis ground OFF Max. 1 V

52 WA600-6
40 Troubleshooting SEN00562-03

Circuit diagram related to load meter mode selector switch

WA600-6 53
SEN00562-03

WA600-6 Wheel loader

Form No. SEN00562-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

54
 SEN00569-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 6
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) .............. 4
Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree ............................................... 6
Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up): Short circuit) ................................ 8
Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down): Short circuit) .......................... 10
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................. 12
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ........................................................................................................ 16
Failure code [DDDBKA] (Traction adjustment dial: Disconnection) .............................................................. 18
Failure code [DDDBKB] (Traction adjustment dial: Short circuit).................................................................. 20
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)..................................................... 22
Failure code [DDK4KA] (AJSS FNR switch: Disconnection) ........................................................................ 24
Failure code [DDK4KB] (AJSS FNR switch: Short circuit) ............................................................................ 26
Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals disagree) ......................................... 28
Failure code [DDK6KA] (FNR lever switch: Disconnection).......................................................................... 32

WA600-6 1
SEN00569-03 40 Troubleshooting

Failure code [DDK6KB] (FNR lever switch: Short circuit) ............................................................................. 34

Failure code [DDP5KA] (Lock detection pressure switch of steering lock lever: Disconnection).................. 36
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) .......................................... 38
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)....................................... 40
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)................................................ 42
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)........................... 44
Failure code [DF10KA] (Transmission shift lever switch: Disconnection) ..................................................... 46
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)......................................................... 48
Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”) (Atmospheric temperature sensor:
Out of input signal range).......................................................................................................................... 50
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnection) ........................................... 52
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)............................................... 54

2 WA600-6
40 Troubleshooting SEN00569-03

WA600-6 3
SEN00569-03 40 Troubleshooting

Failure code [DD1HLD] (Load meter display selector switch: Switch is

kept pressed for long time) 1

Action code Failure code Load meter display selector switch: Switch is kept pressed for long
Trouble time
E01 DD1HLD (Machine monitor system)
Contents of • The load meter display selector switch does not operate because of grounding fault in the load meter
trouble display selector switch system.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Unable to display cumulative data
machine
• The input state (weight) from the load meter display selector switch can be checked with the monitor-
Related ing function (Code: 40800 MES LOAD).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter display
Defective load meter display C12 (male) Resistance
selector switch
1 selector switch (Internal
ON Max. 1 z
short circuit) Between (5) and (6)
OFF Min. 1 Mz
Between (5), (6) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between C03 (female) (10) – Resis-
Min. 1 Mz
C12 (female) (6) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Load meter display
3 Defective machine monitor C03 (male) Voltage
selector switch
Between (10) and ON Max. 1 V
chassis ground OFF 20 – 30 V

4 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to load meter display selector switch

WA600-6 5
SEN00569-03 40 Troubleshooting

Failure code [DDA7L4] (RPM set ON/OFF switch: ON-OFF signals disagree1

Action code Failure code RPM set ON/OFF switch: ON/OFF signals disagree
Trouble
E01 DDA7L4 (Transmission controller system)
Contents of
• RPM set does not function because of a hot short circuit in RPM set ON-OFF switch system.
trouble
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set ON-OFF switch (push up) can be checked with the mon-
itoring function (Code: 44200 THROT LOCK A).
Related
• The input state (ON/OFF) from the RPM set ON-OFF switch (pressed downward) can be checked
information
with the monitoring function (Code: 44201 THROT LOCK B).
• Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set ON/OFF
S12 (male) Resistance
switch

Defective RPM set ON/OFF ON Min. 1 Mz

1 Between (4) and (5)
switch (Internal short circuit) OFF Max. 1 z
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
and carry out troubleshooting
value in normal
state Hot short in wiring harness Wiring harness between L02 (female) (13) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S12 (female) (4) and chassis ground
Wiring harness between L02 (female) (19) –
Voltage Max. 1 V
S12 (female) (6) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
RPM set ON/OFF
L02 Voltage
switch
Defective transmission
3 ON Max. 1 V
controller Between (13) and
chassis ground OFF 20 – 30 V
Between (19) and ON 20 – 30 V
chassis ground OFF Max. 1 V

6 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to RPM set ON/OFF switch

WA600-6 7
SEN00569-03 40 Troubleshooting

Failure code [DDA8KB] (RPM set idle-up/down selector switch (idle-up):

Short circuit) 1

Action code Failure code RPM set idle-up/down selector switch (idle-up): Short circuit
Trouble
E01 DDA8KB (Transmission controller system)
Contents of • Idle-up does not function due to ground fault in RPM set idle-up/down selector switch (idle-up) sys-
trouble tem.
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON-OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-up)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set idle-up/
S13 (male) Resistance
down selector switch
Defective RPM set idle-up/ Idle-up position Min. 1 Mz
1 down selector switch (Inter- Between (4) and (5)
Idle-down position Max. 1 z
nal short circuit)
Idle-up position Max. 1 z
Between (5) and (6)
Idle-down position Min. 1 Mz
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
Possible causes
and standard a Prepare with starting switch OFF, then turn starting switch ON
Grounding fault in wiring har- and carry out troubleshooting
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (19) – Resis-
Min. 1 Mz
S13 (female) (6) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
RPM set idle-up/
L04 Voltage
down selector switch
Defective transmission Idle-up position or
3 Between (29) and 7 – 10 V
controller neutral
chassis ground
Idle-down position Max. 1 V
Idle-up position Max. 1 V
Between (19) and
chassis ground Idle-down position or
7 – 10 V
neutral

8 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to RPM set idle-up/down selector switch

WA600-6 9
SEN00569-03 40 Troubleshooting

Failure code [DDA9KB] (RPM set idle-up/down selector switch (idle-down):

Short circuit) 1

Action code Failure code RPM set idle-up/down selector switch (idle-down): Short circuit
Trouble
E01 DDA9KB (Transmission controller system)
Contents of • Engine speed cannot be set to optional speed due to ground fault in the RPM set idle-up/down selec-
trouble tor switch system.
Action of • Turns RPM set function OFF
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON-OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-down)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
RPM set idle-up/
S13 (male) Resistance
down selector switch
Defective RPM set idle-up/ Idle-up position Min. 1 Mz
1 down selector switch (Inter- Between (4) and (5)
Idle-down position Max. 1 z
nal short circuit)
Idle-up position Max. 1 z
Between (5) and (6)
Idle-down position Min. 1 Mz
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (29) – Resis-
Min. 1 Mz
S13 (female) (4) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
RPM set idle-up/
L04 Voltage
down selector switch
Defective transmission Idle-up position or
3 Between (29) and 7 – 10 V
controller neutral
chassis ground
Idle-down position Max. 1 V
Idle-up position Max. 1 V
Between (19) and
chassis ground Idle-down position or
7 – 10 V
neutral

10 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to RPM set idle-up/down selector switch

WA600-6 11
SEN00569-03 40 Troubleshooting

Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF

signals disagree) 1

Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree)
Trouble
E03 DDB6L4 (Transmission controller system)
(This failure code may be displayed when parking brake emergency release switch is turned ON.)
• Controller outputs a failure signal when all conditions are satisfied.
Contents of
1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble
2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature under 25°C
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The machine cannot travel or parking brake indicator is kept OFF.
machine
• The input state (ON/OFF) from the parking switch can be checked with the monitoring function
(Code: 40903 D-IN-26).
• The input state (ON/OFF) from the parking brake indicator switch can be checked with the monitor-
ing function (Code: 40907 D-IN-23).
Related
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is displayed,
information
carry out troubleshooting for it first.
• If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnor-
mality in target component system) is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch and parking brake switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Parking brake oil
PB.SW (male) Resistance
pressure
Defective parking brake indi-
When parking brake is
1 cator switch
(Internal disconnection)
released, Min. 0.61 Max. 1 z
MPa {Min. 6.2 kg/cm2}
Between (1) and (2)
When parking brake
applied, Max. 0.34 Min. 1 Mz
MPa {Max. 3.5 kg/cm2}
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard C08 (male) Parking brake switch Resistance
value in normal Defective parking brake ON Min. 1 Mz
state 2 switch (Internal disconnec- Between (3) and (4)
OFF Max. 1 z
tion)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (3) and (6) Normal Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between C04 (female) (1) – Resis-
Max. 1 z
ness PB.SW (female) (1) tance
3
(Disconnection or defective Wiring harness between PB.SW (female) (2) Resis-
contact) Max. 1 z
– chassis ground tance
Wiring harness between C08 (female) (3) – Resis-
Max. 1 z
L03 (female) (6) tance

12 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting
value in normal Defective transmission con- L03 Parking brake switch Voltage
4
state troller
Between (6) and ON Max. 1 V
chassis ground OFF 20 – 30 V

WA600-6 13
SEN00569-03 40 Troubleshooting

Circuit diagram related to parking brake switch

14 WA600-6
40 Troubleshooting SEN00569-03

WA600-6 15
SEN00569-03 40 Troubleshooting

Failure code [DDD1LD] (Remote positioner bucket angle set switch:

Switch is kept pressed for long time) 1

Action code Failure code Remote positioner bucket angle set switch: Switch is kept pressed
Trouble for long time
E01 DDD1LD (Work equipment controller system)
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket
Contents of
angle set switch system.
trouble
• Detected continuous operation for 30 seconds and longer.
Action of • Judged that remote positioner bucket angle set switch is turned ON
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Remote positioner raise set signal: Setting is changed to upward by 1° (degree) and the monitor dis-
Problem that plays the changed angle
appears on • Remote positioner lower set signal: Setting is changed to downward by 1° (degree) and the monitor
machine displays the changed angle
• Direction setting cannot be changed to upward or downward.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with
the monitoring function (Code: 40911 D-IN-10, D-IN-11).
Related
• Only for load meter specification (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Remote positioner
S17 (male) bucket angle set Resistance
switch
Defective remote positioner
1 bucket angle set switch Upward ON Max. 1 z
Between (4) and (5)
(Internal short circuit) OFF Min. 1 Mz
Downward ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
without turning starting switch ON.
value in normal Grounding fault in wiring har-
state Wiring harness between L07 (female) (30) – Resis-
2 ness Min. 1 Mz
S17 (female) (6) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L07 (female) (40) – Resis-
Min. 1 Mz
S17 (female) (4) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Remote positioner
L07 (female) bucket angle set Voltage
Defective work equipment switch
3
controller Upward ON Max. 1 V
Between (40) and
chassis ground OFF 7 – 10 V
Between (30) and Downward ON Max. 1 V
chassis ground OFF 7 – 10 V

16 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to remote positioner bucket angle set switch

WA600-6 17
SEN00569-03 40 Troubleshooting

Failure code [DDDBKA] (Traction adjustment dial: Disconnection) 1

Action code Failure code Traction adjustment dial: Disconnection

Trouble
E01 DDDBKA (Transmission controller system)
Contents of • Traction adjustment disabled because of disconnection in the traction adjustment dial system
trouble (Traction adjustment dial signal voltage: Max. 0.3 V)
• For the traction adjustment dial value, use the value immediately before abnormality occurs.
Action of
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
controller
selector switch is set to N (Neutral).
Problem that
appears on • Traction adjustment is disabled
machine
• The input state (%) from the traction adjustment dial can be checked with the monitoring function
(Code: 94000 TRACTION DIAL).
Related
• The input state (Voltage) from the traction adjustment dial can be checked with the monitoring func-
information
tion (Code: 94001 TRACTION DIAL).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
S09 (male) Dial position Voltage
Defective traction adjustment Between (1) and (3) Normal 4.75 – 5.25 V
1
dial (Internal disconnection)
Normal 0.5 – 4.5 V
Between (2) and (3) MAX position 0.5 – 1.0 V
MIN position 4.0 – 4.5 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Wiring harness between L02 (female) (3) – Resis-
Disconnection in wiring har- Max. 1 z
and standard S09 (female) (2) tance
value in normal 2 ness
Wiring harness between L02 (female) (21) – Resis-
state (Internal disconnection) Max. 1 z
S09 (female) (3) tance
Wiring harness between L02 (female) (22) – Resis-
Max. 1 z
S09 (female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L02 Dial position Voltage
Defective transmission con- Between (3) and
3 Normal 4.75 – 5.25 V
troller chassis ground
Normal 0.5 – 4.5 V
Between (22) and
MAX position 0.5 – 1.0 V
chassis ground
MIN position 4.0 – 4.5 V

18 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to traction adjustment dial

WA600-6 19
SEN00569-03 40 Troubleshooting

Failure code [DDDBKB] (Traction adjustment dial: Short circuit) 1

Action code Failure code Traction adjustment dial: Short circuit

Trouble
E01 DDDBKB (Transmission controller system)
Contents of • Traction adjustment disabled because of hot short circuit in the traction adjustment dial system
trouble (Traction adjustment dial signal voltage: Min 4.7 V)
• For the traction adjustment dial value, use the value immediately before abnormality occurs.
Action of
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
controller
selector switch is set to N (Neutral).
Problem that
appears on • Traction adjustment is disabled
machine
• The input state (%) from the traction adjustment dial can be checked with the monitoring function
(Code: 94000 TRACTION DIAL).
Related
• The input state (Voltage) from the traction adjustment dial can be checked with the monitoring func-
information
tion (Code: 94001 TRACTION DIAL).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S09 (male) Dial position Voltage
Defective traction adjustment Between (1) and (3) Normal 4.75 – 5.25 V
1
dial (Internal short circuit)
Normal 0.5 – 4.5 V
Between (2) and (3) MAX position 0.5 – 1.0 V
MIN position 4.0 – 4.5 V
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard Hot short in wiring harness Wiring harness between L02 (female) (3) –
value in normal 2 Voltage Max. 1 V
(Contact with 24 V circuit) S09 (female) (2) and chassis ground
state
Wiring harness between L02 (female) (22) –
Voltage Max. 1 V
S09 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L02 Dial position Voltage
Defective transmission con- Between (3) and
3 Normal 4.75 – 5.25 V
troller chassis ground
Normal 0.5 – 4.5 V
Between (22) and
MAX position 0.5 – 1.0 V
chassis ground
MIN position 4.0 – 4.5 V

20 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to traction adjustment dial

WA600-6 21
SEN00569-03 40 Troubleshooting

Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1

Action code Failure code Emergency steering drive switch: Malfunction

Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine stopped, steering pump pressure detected because of ground fault in the emergency
trouble steering drive switch system.
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The emergency steering operates.
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
function (Code: 40903 D-IN-30).
information
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Relieve the steering circuit

Defective emergency steer- Steering relief oil

T04 (male) Resistance
1 ing drive switch pressure
(Internal defect) Low Min. 1 Mz
Between (1) and (2)
Normal Max. 1 z
Between (1), (2) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between C04 (female) (3) – Resis-
Min. 1 Mz
T04 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Relieve the steering circuit
3 Defective machine monitor Steering relief oil
C04 (female) Voltage
pressure
Between (3) and Low 20 – 30 V
chassis ground Normal Max. 1 V

22 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to emergency steering drive switch

WA600-6 23
SEN00569-03 40 Troubleshooting

Failure code [DDK4KA] (AJSS FNR switch: Disconnection) 1

Action code Failure code AJSS FNR switch: Disconnection

Trouble
E03 DDK4KA (Transmission controller system)
Contents of
• AJSS FNR signal input is disabled because of disconnection in the AJSS FNR input signal system.
trouble
• Sets to neutral
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until AJSS FNR switch is set to N
(Neutral).
Problem that
appears on • The machine does not travel.
machine
• The input signal (ON/OFF) from the AJSS FNR switch can be checked with the monitoring function
Related (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for AJSS specification (if equipped)
• Method of reproducing failure code: Turn the starting switch and AJSS FNR switch ON

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No.5 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S31 (male) AJSS FNR switch Resistance
F (Forward) Max. 1 z
Between (1) and (2)
Defective AJSS FNR switch Other than above Min. 1 Mz
2 (Internal disconnection or N (Neutral) Max. 1 z
short circuit) Between (1) and (3)
Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) and (4)
Other than above Min. 1 Mz
Between (1), (2), (3),
Normal Min. 1 Mz
(4) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard
Wiring harness between L03 (female) (16) – Resis-
value in normal Max. 1 z
state Disconnection in wiring har- S31 (female) (4) tance
ness Wiring harness between L03 (female) (26) – Resis-
3 Max. 1 z
(Disconnection or defective S31 (female) (3) tance
contact of connector) Wiring harness between L03 (female) (36) – Resis-
Max. 1 z
S31 (female) (2) tance
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box B – S31 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03(female) (16) – Resis-
Min. 1 Mz
S31 (female) (4) and chassis ground tance
Grounding fault in wiring har-
Wiring harness between L03(female) (26) – Resis-
4 ness Min. 1 Mz
S31 (female) (3) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L03(female) (36) – Resis-
Min. 1 Mz
S31 (female) (2) and chassis ground tance
Wiring harness between fuse No. 5 of fuse Resis-
Min. 1 Mz
box B – S31 (female) (1) tance

24 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 AJSS FNR switch Voltage
Possible causes
and standard Between (36) and F (Forward) 20 – 30 V
value in normal Defective transmission con- chassis ground Other than above Max. 1 V
5
state troller
Between (26) and N (Neutral) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

Circuit diagram related to AJSS FNR switch

WA600-6 25
SEN00569-03 40 Troubleshooting

Failure code [DDK4KB] (AJSS FNR switch: Short circuit) 1

Action code Failure code AJSS FNR switch: Short circuit

Trouble
E03 DDK4KB (Transmission controller system)
Contents of
• Multiple signal input because of hot short circuit in the AJSS FNR input signal system.
trouble
• Sets to neutral
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until AJSS steering FNR switch is set
to N (Neutral).
Problem that
appears on • The machine does not travel.
machine
• The input signal (ON/OFF) from the AJSS steering FNR switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for AJSS specification (if equipped)
• Method of reproducing failure code: Turn the starting switch and AJSS steering FNR switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S31 (male) AJSS FNR switch Resistance
F (Forward) Max. 1 z
Between (1) and (2)
Defective AJSS FNR switch Other than above Min. 1 Mz
1 (Internal disconnection or N (Neutral) Max. 1 z
short circuit) Between (1) and (3)
Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) and (4)
Other than above Min. 1 Mz
Between (1), (2), (3),
Normal Min. 1 Mz
(4) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L03 (female) (16) –
Possible causes S31 (female) (4)
Voltage Max. 1 V
and standard • Set the AJSS FNR switch to other than R
value in normal (Reverse)
state Hot short in wiring harness Wiring harness between L03 (female) (26) –
2
(Contact with 24 V circuit) S31 (female) (3)
Voltage Max. 1 V
• Set the AJSS FNR switch to other than N
(Neutral)
Wiring harness between L03 (female) (36) –
S31 (female) (2)
Voltage Max. 1 V
• Set the AJSS FNR switch to other than F
(Forward)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 AJSS FNR switch Voltage
Between (36) and F (Forward) 20 – 30 V
Defective transmission con- chassis ground Other than above Max. 1 V
3
troller
Between (26) and N (Neutral) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

26 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to AJSS FNR switch

WA600-6 27
SEN00569-03 40 Troubleshooting

Failure code [DDK5L4] (AJSS shift-up/down switch: ON/OFF signals

disagree) 1

Action code Failure code AJSS shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of
• AJSS shift-up/down switch system has disconnection, ground fault or hot short.
trouble
Action of • Turns the shift-up/down function of AJSS OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear cannot be shift up and down with AJSS.
machine
• The input signal (OFF input) from the AJSS shift-up switch can be checked with the monitoring
function (Code: 40907 D-IN-16).
• The input signal (ON input) from the AJSS shift-up switch can be checked with the monitoring
function (Code: 40907 D-IN-17).
Related
• The input signal (OFF input) from the AJSS shift-down switch can be checked with the monitoring
information
function (Code: 40907 D-IN-18).
• The input signal (ON input) from the AJSS shift-down switch can be checked with the monitoring
function (Code: 40907 D-IN-19).
• Method of reproducing failure code: Turn starting switch and AJSS shift-up/down switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 5 in fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4).
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
AJSS shift-up/down
S31 (male) Resistance
switch
Shift-up ON Min. 1 Mz
Between (1) – (5)
Shift-up OFF Max. 1 z
Defective AJSS shift-up/down Shift-up ON Max. 1 z
2 switch Between (1) – (6)
Shift-up OFF Min. 1 Mz
(Internal short circuit)
Shift-up ON Min. 1 Mz
Between (1) – (7)
Shift-up OFF Max. 1 z
Possible causes
and standard Shift-up ON Max. 1 z
Between (1) – (8)
value in normal Shift-up OFF Min. 1 Mz
state
Between (5), (6), (7),
Normal Min. 1 Mz
(8) – chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 in fuse Resis-
Max. 1 z
box B – S31 (female) (1) tance
Disconnection in wiring Wiring harness between L03 (female) (5) – Resis-
harness Max. 1 z
S31 (female) (5) tance
3 (Disconnection in wiring or
Wiring harness between L03 (female) (15) – Resis-
defective contact in Max. 1 z
connector) S31 (female) (15) tance
Wiring harness between L03 (female) (25) – Resis-
Max. 1 z
S31 (female) (25) tance
Wiring harness between L03 (female) (35) – Resis-
Max. 1 z
S31 (female) (35) tance

28 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 in fuse Resis-
Min. 1 Mz
box B – S31 (female) (1) and chassis ground tance
Wiring harness between L03 (female) (5) – Resis-
Min. 1 Mz
Ground fault in wiring harness S31 (female) (5) and chassis ground tance
4
(Contact with GND circuit) Wiring harness between L03 (female) (15) – Resis-
Min. 1 Mz
S31 (female) (15) and chassis ground tance
Wiring harness between L03 (female) (25) – Resis-
Min. 1 Mz
S31 (female) (25) and chassis ground tance
Wiring harness between L03 (female) (35) – Resis-
Min. 1 Mz
S31 (female) (35) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (5) –
Voltage Max. 1 V
Possible causes S31 (female) (5) and chassis ground
Hot short
and standard Wiring harness between L03 (female) (15) –
5 (Contact with 24V circuit) in Voltage Max. 1 V
value in normal S31 (female) (15) and chassis ground
wiring harness
state Wiring harness between L03 (female) (25) –
Voltage Max. 1 V
S31 (female) (25) and chassis ground
Wiring harness between L03 (female) (35) –
Voltage Max. 1 V
S31 (female) (35) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
AJSS shift-up/down
L03 Voltage
switch
Between (5) – Shift-down ON Max. 1 V
chassis ground Shift-down OFF 20 – 30 V
Defective transmission
6 Shift-down ON 20 – 30 V
controller Between (15) –
chassis ground Shift-down OFF Max. 1 V
Between (25) – Shift-up ON Max. 1 V
chassis ground Shift-up OFF 20 – 30 V
Between (35) – Shift-up ON 20 – 30 V
chassis ground Shift-up OFF Max. 1 V

WA600-6 29
SEN00569-03 40 Troubleshooting

Circuit diagram related to AJSS shift-up/down switch

30 WA600-6
40 Troubleshooting SEN00569-03

WA600-6 31
SEN00569-03 40 Troubleshooting

Failure code [DDK6KA] (FNR lever switch: Disconnection) 1

Action code Failure code FNR lever switch: Disconnection

Trouble
E03 DDK6KA (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is disconnected or in ground fault, all the lever
trouble signals are not input
• Sets to neutral
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that
• The machine does not travel.
appears on
• Shift indicator turns out.
machine
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel specification (STD)
• Method of reproducing failure code: Turn the starting switch and FNR (directional) switch ON

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 5 in fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4).
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L04 FNR (directional) lever Voltage
Between (1) and (10) Normal 20 – 30 V
Defective FNR (directional) N (Neutral) 20 – 30 V
2 lever switch (Internal discon- Between (2) and (10)
Other than above Max. 1 V
nection or short circuit)
F (Forward) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
Possible causes
and standard R (Reverse) 20 – 30 V
Between (4) and (10)
value in normal Other than above Max. 1 V
state
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box B – L04 (female) (1) tance
Disconnection in wiring har- Wiring harness between L03 (female) (16) – Resis-
Max. 1 z
ness L04 (female) (4) and chassis ground tance
3
(Disconnection or defective Wiring harness between L03 (female) (26) – Resis-
contact of connector) Max. 1 z
L04 (female) (2) and chassis ground tance
Wiring harness between L03 (female) (36) – Resis-
Max. 1 z
L04 (female) (3) and chassis ground tance
Wiring harness between chassis ground – Resis-
Max. 1 z
L04 (female) (10) tance

32 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box B – L04 (female) (1) and chassis ground tance
Grounding fault in wiring har-
Wiring harness between L03 (female) (16) – Resis-
4 ness Min. 1 Mz
L04 (female) (4) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L03 (female) (26) – Resis-
Min. 1 Mz
L04 (female) (2) and chassis ground tance
Possible causes
Wiring harness between L03 (female) (36) – Resis-
and standard Min. 1 Mz
L04 (female) (3) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 FNR (directional) lever Voltage
Between (36) and F (Forward) 20 – 30 V
Defective transmission con- chassis ground Other than above Max. 1 V
5
troller
Between (26) and N (Neutral) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

Circuit diagram related to FNR (directional) lever switch

WA600-6 33
SEN00569-03 40 Troubleshooting

Failure code [DDK6KB] (FNR lever switch: Short circuit) 1

Action code Failure code FNR lever switch: Short circuit

Trouble
E03 DDK6KB (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is hot short, all the FNR (directional) lever sig-
trouble nals are not input.
• Sets to neutral
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that • The machine does not travel.
appears on • Multiple shift indicator turns on.
machine • Travel is enabled by using joystick FNR switch after setting the shift to neutral.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel specification (STD)
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L04 FNR (directional) lever Voltage
N (Neutral) 20 – 30 V
Defective FNR (directional) Between (2) and (10)
1 lever switch (Internal short Other than above Max. 1 V
circuit) F (Forward) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
R (Reverse) 20 – 30 V
Between (4) and (10)
Other than above Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (16) –
Possible causes Voltage Max. 1 V
L04 (female) (4)
and standard
value in normal Hot short in wiring harness Wiring harness between L03 (female) (26) –
2 Voltage Max. 1 V
state (Contact with 24 V circuit) L04 (female) (2)
Wiring harness between L03 (female) (36) –
Voltage Max. 1 V
L04 (female) (3)
Wiring harness between L04 (female) (10) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 FNR (directional) lever Voltage
Between (36) and F (Forward) 20 – 30 V
Defective transmission con- chassis ground Other than above Max. 1 V
3
troller
Between (26) and N (Neutral) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (16) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V

34 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to FNR (directional) lever switch

WA600-6 35
SEN00569-03 40 Troubleshooting

Failure code [DDP5KA] (Lock detection pressure switch of steering lock

lever: Disconnection) 1

Action code Failure code Lock detection pressure switch of steering lock lever: Disconnection
Trouble
E01 DDP5KA (Transmission controller system)
Contents of • Steering lock lever lock signal cannot be detected because of disconnection of lock detection pres-
trouble sure switch of steering lock lever.
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If steering lock lever is locked, steering can be operated.
machine
• The input state (ON/OFF) from the lock detection pressure switch of the steering lock lever can be
Related
checked with the monitoring function (Code: 40908 D-IN-31).
information
• Method of reproducing failure code: Turn the starting switch ON and lock the steering lock lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
Defective lock detection troubleshooting.
pressure switch of steering L13 (male) Steering lock lever Resistance
1
lock lever
(Internal disconnection) Lock Min. 1 Mz
Between (1) and (2)
Release Max. 1 z
Possible causes
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard
ness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L03 (female) (38) – Resis-
contact of connector) Max. 1 z
L13 (female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con- L03 Steering lock lever Voltage
3
troller
Between (38) and Lock 8 – 10 V
chassis ground Release Max. 1 V

36 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to lock detection pressure switch of steering lock lever

WA600-6 37
SEN00569-03 40 Troubleshooting

Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals

disagree) 1

Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of • The signals input from the transmission manual/auto shift selector switch are combined in an impos-
trouble sible manner.
Action of • Selects the manual shift mode.
controller • If cause of failure disappears, system resets itself.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode dur-
appears on
ing auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905 D-IN-4, D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S10 (male) Shift mode Resistance
Manual shift Min. 1 Mz
Between (1) and
Auto shift (L) Min. 1 Mz
(2), (3), (4)
Auto shift (H) Min. 1 Mz
Manual shift Min. 1 Mz
Defective transmission man-
1 ual/auto-shift selector switch Between (2) and (3) Auto shift (L) Min. 1 Mz
(Internal defect). Auto shift (H) Max. 1 z
Manual shift Min. 1 Mz
Between (3) and (4) Auto shift (L) Max. 1 z
Auto shift (H) Max. 1 z
Manual shift Min. 1 Mz
Between (2) and (4) Auto shift (L) Min. 1 Mz
Possible causes
and standard Auto shift (H) Max. 1 z
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L02 (female) (18) – Resis-
2 Max. 1 z
(Disconnection or defective S10 (female) (2) tance
contact of connector) Wiring harness between L02 (female) (24) – Resis-
Max. 1 z
S10 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L02 (female) (18) – Resis-
3 ness Min. 1 Mz
S10 (female) (2) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L02 (female) (24) – Resis-
Min. 1 Mz
S10 (female) (4) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L02 (female) (18) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) S10 (female) (2) and chassis ground
Wiring harness between L02 (female) (24) –
Voltage Max. 1 V
S10 (female) (4) and chassis ground

38 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L02 Shift mode Voltage
Possible causes
and standard Manual shift Max. 1 V
Defective transmission con- Between (18) and
value in normal 5 Auto shift (L) Max. 1 V
troller chassis ground
state Auto shift (H) 20 – 30 V
Manual shift Max. 1 V
Between (24) and
Auto shift (L) 20 – 30 V
chassis ground
Auto shift (H) 20 – 30 V

Circuit diagram related to transmission manual/auto shift selector switch.

WA600-6 39
SEN00569-03 40 Troubleshooting

Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for

long time) 1

Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• Since the kick-down switch system is in ground fault, the kick-down is not turned OFF.
trouble
Action of • Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, turn the kick-down ON once.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-10).
information
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S07 (male) Kick-down switch Resistance
Defective kick-down switch
1 ON Max. 1 z
(Internal short circuit) Between (1) and (2)
OFF Min. 1 Mz
Between (1), (2) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L04 (female) (30) – Resis-
Min. 1 Mz
S07 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con- L04 Kick-down switch Voltage
3
troller
Between (30) and ON Max. 1 V
chassis ground OFF 8 – 10 V

40 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to kick-down switch and hold switch

WA600-6 41
SEN00569-03 40 Troubleshooting

Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)1

Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is in ground fault, the hold switch cannot be selected.
trouble
Action of • Holds once when a grounding fault occurs, then do not control holding.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, turn the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-11).
information
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S07 (male) Hold switch Resistance
Defective hold switch
1 ON Max. 1 z
(Internal short circuit) Between (3) and (4)
OFF Min. 1 Mz
Between (3), (4) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L04 (female) (40) – Resis-
Min. 1 Mz
S07 (female) (3) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective transmission con- L04 Hold switch Voltage
3
troller
Between (40) and ON Max. 1 V
chassis ground OFF 8 – 10 V

42 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to kick-down switch and hold switch

WA600-6 43
SEN00569-03 40 Troubleshooting

Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed
for long time) 1

Action code Failure code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is in ground fault and load meter cancel switch does not function.
trouble
Action of • None in particular.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Unable to cancel cumulative data
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904 D-IN-33).
information • Only for load meter specification (if equipped)
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Load meter cancel
S08 (male) Resistance
Defective load meter cancel switch
1
switch (Internal short circuit) ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
Between (1), (2) and
Possible causes Normal Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between C04 (female) (13) – Resis-
Min. 1 Mz
S08 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Load meter cancel
3 Defective machine monitor C04 (male) Voltage
switch
Between (13) and ON Max. 1 V
chassis ground OFF 20 – 30 V

44 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to load meter cancel switch & subtotal switch

WA600-6 45
SEN00569-03 40 Troubleshooting

Failure code [DF10KA] (Transmission shift lever switch: Disconnection) 1

Action code Failure code Transmission shift lever switch: Disconnection

Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or in ground fault, the
trouble signal is not input.
Action of • Fixed to the shift range before the abnormality occurred
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator displays the shift range before the abnormality occurred
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function
Related (Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information • Only for steering wheel specification (STD)
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L04 Shift range Voltage
Between (1) and
Normal 20 – 30 V
chassis ground
Between (5) and 1st (1st speed) 20 – 30 V
Defective transmission shift
chassis ground Other than above Max. 1 V
1 lever switch
(Internal disconnection) Between (6) and 2nd (2nd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (7) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (8) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse Resis-
Possible causes Max. 1 z
box B – L04 (female) (1) tance
and standard
Disconnection in wiring har- Wiring harness between L03 (female) (5) – Resis-
value in normal Max. 1 z
state ness L04 (female) (8) and chassis ground tance
2
(Disconnection or defective Wiring harness between L03 (female) (15) – Resis-
contact of connector) Max. 1 z
L04 (female) (7) and chassis ground tance
Wiring harness between L03 (female) (25) – Resis-
Max. 1 z
L04 (female) (6) and chassis ground tance
Wiring harness between L03 (female) (35) – Resis-
Max. 1 z
L04 (female) (5) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 5 of fuse Resis-
Min. 1 Mz
box B – L04(female) (1) tance
Wiring harness between L03 (female) (5) – Resis-
Grounding fault in wiring har- L04 (female) (8) and chassis ground Min. 1 Mz
tance
3 ness
(Contact with ground circuit) Wiring harness between L03 (female) (15) – Resis-
Min. 1 Mz
L04 (female) (7) and chassis ground tance
Wiring harness between L03 (female) (25) – Resis-
Min. 1 Mz
L04 (female) (6) and chassis ground tance
Wiring harness between L03 (female) (35) – Resis-
Min. 1 Mz
L04 (female) (5) and chassis ground tance

46 WA600-6
40 Troubleshooting SEN00569-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 Shift range Voltage
Between (35) and 1st (1st speed) 20 – 30 V
Possible causes
and standard chassis ground Other than above Max. 1 V
value in normal Defective transmission con- 2nd (2nd speed) 20 – 30 V
4 Between (25) and
state troller
chassis ground Other than above Max. 1 V
Between (15) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (5) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V

Circuit diagram related to transmission shift lever switch

WA600-6 47
SEN00569-03 40 Troubleshooting

Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1

Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmis-
trouble sion shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
controller • If cause of failure disappears, system resets itself.
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator indicates the shift range input to the higher gear speed.
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
information • Only for steering wheel specification (STD)
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L04 Shift range Voltage
Between (5) and 1st (1st speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Defective transmission shift
1 lever switch Between (6) and 2nd (2nd speed) 20 – 30 V
(Internal short circuit) chassis ground Other than above Max. 1 V
Between (7) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (8) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (5) –
Possible causes Voltage Max. 1 V
L04 (female) (8) and chassis ground
and standard
value in normal Hot short in wiring harness Wiring harness between L03 (female) (15) –
2 Voltage Max. 1 V
state (Contact with 24 V circuit) L04 (female) (7) and chassis ground
Wiring harness between L03 (female) (25) –
Voltage Max. 1 V
L04 (female) (6) and chassis ground
Wiring harness between L03 (female) (35) –
Voltage Max. 1 V
L04 (female) (5) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L03 Shift range Voltage
Between (35) and 1st (1st speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Defective transmission con- 2nd (2nd speed) 20 – 30 V
3 Between (25) and
troller
chassis ground Other than above Max. 1 V
Between (15) and 3rd (3rd speed) 20 – 30 V
chassis ground Other than above Max. 1 V
Between (5) and 4th (4th speed) 20 – 30 V
chassis ground Other than above Max. 1 V

48 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to transmission shift lever switch

WA600-6 49
SEN00569-03 40 Troubleshooting

Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”)

(Atmospheric temperature sensor: Out of input signal range) 1

Action code Failure code Atmospheric temperature sensor: Out of input signal range
Trouble
— DGE5KX (VHMS controller system)
Contents of • Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
trouble less.
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the atmospheric temperature.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n4” o “01”.
information • The input state (temperature) from the atmospheric temperature sensor can be checked with the
monitoring function (Code: 37501 ATR TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective atmospheric tem- Atmospheric
perature sensor C58 (male) Resistance
1 temperature
(Internal disconnection or
25°C (Normal temp) 3.6 – 4.7 kz
short circuit)
Between (1) and (2) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between V02 (female) (10) – Resis-
2 Max. 1 z
(Disconnection or defective C58 (female) (2) tance
contact of connector) Wiring harness between C58 (female) (2) – Resis-
Possible causes Max. 1 z
chassis ground tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
state 3 ness
(Contact with ground circuit) Wiring harness between V02 (female) (10) – Resis-
Min. 1 Mz
C58 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between V02 (female) (10) –
Voltage Max. 1 V
C58 (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Atmospheric
V02 (female) Resistance
5 Defective VHMS controller temperature
25°C (Normal temp) 3.6 – 4.7 kz
Between (10) and (12) About 0°C 10.2 – 13.4 kz
About 40°C 2.1 – 2.6 kz

50 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to atmospheric temperature sensor

WA600-6 51
SEN00569-03 40 Troubleshooting

Failure code [DGF1KA] (Transmission oil temperature sensor:

Disconnection) 1

Action code Failure code Transmission oil temperature sensor: Disconnection

Trouble
E01 DGF1KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission oil temperature sensor signal system,
Contents of the transmission oil temperature reading is higher than normal range
trouble (Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15°C) and transmission oil
temperature sensor signal voltage: Min. 3.7 V (55°C))
Action of • Judges that the transmission oil temperature is lower.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shift shocks may be made.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601 T/M OIL TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil
temperature sensor (Internal Transmission oil
1 TM.T (male) Resistance
disconnection or short cir- temperature
cuit) 25°C (Normal temp) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L02 (female) (9) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective TM.T (female) (1) tance
contact of connector) Wiring harness between TM.T (female) (2) Resis-
Max. 1 z
and L02 (female) (21) – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- Transmission oil
3 L02 (female) Resistance
troller temperature
25°C (Normal temp) 35 – 50 kz
Between (9) and (21)
100°C 3.1 – 4.5 kz

52 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to transmission oil temperature sensor

WA600-6 53
SEN00569-03 40 Troubleshooting

Failure code [DGF1KB] (Transmission oil temperature sensor: Short

circuit) 1

Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the transmission oil temperature is higher.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Gear shift shocks may be made.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601 T/M OIL TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil Transmission oil
1 temperature sensor (Internal TM.T (male) Resistance
temperature
short circuit)
25°C (Normal temp) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L02 (female) (9) – Resis-
Min. 1 Mz
TM.T (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- Transmission oil
3 L02 (female) Resistance
troller temperature
25°C (Normal temp) 35 – 50 kz
Between (9) and (21)
100°C 3.1 – 4.5 kz

54 WA600-6
40 Troubleshooting SEN00569-03

Circuit diagram related to transmission oil temperature sensor

WA600-6 55
SEN00569-03

WA600-6 Wheel loader

Form No. SEN00569-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

56
 SEN00570-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 7
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) .................................. 4
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection) ................................................ 6
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ............................... 8
Failure code [DGT1KA] (Torque converter oil temperature sensor: Disconnection) ..................................... 10
Failure code [DGT1KB] (Torque converter oil temperature sensor: Short circuit) ..........................................11
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)..................... 12
Failure code [DGT4KA] (or VHMS_LED display: “n3” o “12”)
(Exhaust gas temperature sensor (F): Disconnection) ............................................................................. 14
Failure code [DGT4KB] (or VHMS_LED display: “n3” o “11”)
(Exhaust gas temperature sensor (F): Short circuit) ................................................................................. 16
Failure code [DGT5KA] (or VHMS_LED display: “n3” o “22”)
(Exhaust gas temperature sensor (R): Disconnection) ............................................................................. 18
Failure code [DGT5KB] (or VHMS_LED display: “n3” o “21”)
(Exhaust gas temperature sensor (R): Short circuit)) ............................................................................... 20

WA600-6 1
SEN00570-03 40 Troubleshooting

Failure code [DH21KA] (Work equipment pump oil pressure sensor: Disconnection) .................................. 22
Failure code [DH21KB] (Work equipment pump oil pressure sensor: Short circuit) ..................................... 24
Failure code [DHE5KB] (or VHMS_LED display: “n3” o “32”)
(Blow-by pressure sensor: Short circuit) ................................................................................................... 26
Failure code [DHE5KY] (or VHMS_LED display: “n3” o “31”)
(Blow-by pressure sensor: Short circuit with power supply line) ............................................................... 28
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).................... 30
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)....................... 32
Failure code [DHT2L6] (Transmission filter clogging sensor:
Signal disagrees with operating state of engine) ...................................................................................... 34
Failure code [DHT8KX] (or VHMS_LED display: “n5” o “33”)
(Steering oil pressure sensor: Out of input signal range) .......................................................................... 36
Failure code [DHTBKA] (Modulation clutch oil pressure sensor: Disconnection) ......................................... 38
Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short circuit) ............................................. 40
Failure code [DHU2KX] (or VHMS_LED display: “n7” o “11”)
(Front brake oil pressure sensor (F): Out of input signal range) ............................................................... 42
Failure code [DHU3KX] (or VHMS_LED display: “n7” o “12”) (Rear brake oil pressure sensor (R):
Out of input signal range).......................................................................................................................... 44
Failure code [DK30KA] (AJSS lever angle sensor: Disconnection) .............................................................. 46
Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with power supply line).............................. 48

2 WA600-6
40 Troubleshooting SEN00570-03

WA600-6 3
SEN00570-03 40 Troubleshooting

Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input

signal range) 1

Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the hydraulic oil temperature is higher
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission oil Hydraulic oil
1 temperature sensor (Internal HD.T (male) Resistance
temperature
short circuit)
25°C (Normal temp) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between C05 (female) (7) – Resis-
Min. 1 Mz
HD.T (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hydraulic oil
3 Defective machine monitor C05 (female) Resistance
temperature
Between (7) and 25°C (Normal temp) 35 – 50 kz
chassis ground 100°C 3.1 – 4.5 kz

4 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to hydraulic oil temperature sensor

WA600-6 5
SEN00570-03 40 Troubleshooting

Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnection)1

Action code Failure code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Machine monitor system)
• Due to disconnection in rear brake oil temperature sensor signal system, the signal level is higher
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the rear brake oil temperature is lower
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil tem- Hydraulic oil
1 perature sensor (Internal dis- R17 (male) Resistance
temperature
connection)
25°C (Normal temp) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring har- without turning starting switch ON.
value in normal ness Wiring harness between C05 (female) (8) – Resis-
state 2 Max. 1 z
(Disconnection or defective R17 (female) (1) tance
contact of connector) Wiring harness between R17 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective machine monitor C05 (female) Oil temperature Resistance
Between (8) and 25°C (Normal temp) 35 – 50 kz
chassis ground 100°C 3.1 – 4.5 kz

6 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to rear brake oil temperature sensor

WA600-6 7
SEN00570-03 40 Troubleshooting

Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input
signal range) 1

Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the rear brake oil temperature is higher
controller • If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective rear brake oil tem- Hydraulic oil
1 perature sensor (Internal R17 (male) Resistance
temperature
short circuit)
Between (1) and 25°C (Normal temp) 35 – 50 kz
chassis ground 100°C 3.1 – 4.5 kz
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between C05 (female) (8) – Resis-
Min. 1 Mz
R17 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective machine monitor C05 (female) Oil temperature Resistance
Between (8) and 25°C (Normal temp) 35 – 50 kz
chassis ground 100°C 3.1 – 4.5 kz

8 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to rear brake oil temperature sensor

WA600-6 9
SEN00570-03 40 Troubleshooting

Failure code [DGT1KA] (Torque converter oil temperature sensor:

Disconnection) 1

Action code Failure code Torque converter oil temperature sensor: Disconnection
Trouble
E01 DGT1KA (Transmission controller system)
Contents of
• Torque converter oil temperature sensor trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• Torque converter oil temperature sensor is not set in WA600-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.

10 WA600-6
40 Troubleshooting SEN00570-03

Failure code [DGT1KB] (Torque converter oil temperature sensor:

Short circuit) 1

Action code Failure code Torque converter oil temperature sensor: Short circuit
Trouble
E01 DGT1KB (Transmission controller system)
Contents of
• Torque converter oil temperature sensor trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• Torque converter oil temperature sensor is not set in WA600-6.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.

WA600-6 11
SEN00570-03 40 Troubleshooting

Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

input signal range) 1

Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in torque converter oil temperature sensor signal system, the signal level is
trouble lower than normal range (torque converter oil temperature voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the torque converter oil temperature is higher
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The torque converter oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective torque converter Torque converter oil
1 oil temperature sensor (Inter- R13 (male) Resistance
temperature
nal short circuit)
25°C (Normal temp) 35 – 50 kz
Between (1) and (2)
100°C 3.1 – 4.5 kz
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state Wiring harness between C05 (female) (2) – Resis-
(Contact with ground circuit) Max. 1 z
R13 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Torque converter oil
3 Defective machine monitor C05 (female) Resistance
temperature
Between (2) and 25°C (Normal temp) 35 – 50 kz
chassis ground 100°C 3.1 – 4.5 kz

12 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to torque converter oil temperature sensor

WA600-6 13
SEN00570-03 40 Troubleshooting

Failure code [DGT4KA] (or VHMS_LED display: “n3” o “12”) (Exhaust

gas temperature sensor (F): Disconnection) 1

Action code Failure code Exhaust gas temperature sensor (F): Disconnection
Trouble
— DGT4KA (VHMS controller system)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 4.9 V
trouble and above.
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n3” o “12”.
information • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
monitoring function (Code: 42610 EXHAUST TEMP F).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
Defective exhaust gas tem- V29 Voltage
temperature
perature sensor on the
1 50 – 100°C 1.0 – 3.5 mV
engine front side (Internal
short circuit) 300 – 400°C 11.2 – 15.6 mV
Between (1) and (2)
500 – 600°C 19.7 – 24.2 mV
700 – 800°C 28.1 – 32.6 mV
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V11 Voltage
Defective exhaust gas tem- temperature
perature sensor amplifier on Between (A) and (C) Normal 20 – 30 V
2
the engine front side
Possible causes 50 – 100°C 1.0 – 1.6 V
(Internal short circuit)
and standard 300 – 400°C 2.1 – 2.7 V
value in normal Between (B) and (C)
500 – 600°C 2.9 – 3.6 V
state
700 – 800°C 3.8 – 4.4 V
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between V11 (female) (B) – Resis-
3 Max. 1 z
(Disconnection or defective V02 (female) (7) tance
contact of connector) Wiring harness between V29 (female) (2) – Resis-
Max. 1 z
V27 (female) (2) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V02 Voltage
temperature
4 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (7) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

14 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to exhaust gas temperature sensor (F)

WA600-6 15
SEN00570-03 40 Troubleshooting

Failure code [DGT4KB] (or VHMS_LED display: “n3” o “11”) (Exhaust

gas temperature sensor (F): Short circuit) 1

Action code Failure code Exhaust gas temperature sensor (F): Short circuit
Trouble
— DGT4KB (VHMS controller system)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 0.3 V or
trouble less.
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “11”.
Related • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
information monitoring function (Code: 42610 EXHAUST TEMP F).
• If failure code [DBB6KP] (VHMS controller 24V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V29 Voltage
temperature
50 – 100°C 1.0 – 3.5 mV
Defective exhaust gas tem-
perature sensor on the 300 – 400°C 11.2 – 15.6 mV
1 Between (1) and (2)
engine front side (Internal 500 – 600°C 19.7 – 24.2 mV
short circuit) 700 – 800°C 28.1 – 32.6 mV
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V29 (male) Resistance
Between (1) and (2) Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Possible causes
Exhaust gas
and standard V11 Voltage
temperature
value in normal
state Between (A) and (C) Normal 20 – 30 V

Defective exhaust gas tem- 50 – 100°C 1.0 – 1.6 V

perature sensor amplifier on 300 – 400°C 2.1 – 2.7 V
2 Between (B) and (C)
the engine front side 500 – 600°C 2.9 – 3.6 V
(Internal short circuit) 700 – 800°C 3.8 – 4.4 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V11 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between F11 (female) (B) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) V02 (female) (7) and chassis ground
Wiring harness between V29 (female) (2) –
Voltage Max. 1 V
V27 (female) (2) and chassis ground

16 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between F11 (female) (B) – Resis-
4 ness Min. 1 Mz
V02 (female) (7) and chassis ground tance
(Contact with ground circuit)
Wiring harness between V29 (female) (2) – Resis-
Possible causes Min. 1 Mz
V27 (female) (2) and chassis ground tance
and standard a Prepare with starting switch OFF, then start engine and carry out
value in normal troubleshooting.
state
Exhaust gas
V02 Voltage
temperature
5 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (7) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

Circuit diagram related to exhaust gas temperature sensor (F)

WA600-6 17
SEN00570-03 40 Troubleshooting

Failure code [DGT5KA] (or VHMS_LED display: “n3” o “22”) (Exhaust

gas temperature sensor (R): Disconnection) 1

Action code Failure code Exhaust gas temperature sensor (R): Disconnection
Trouble
— DGT5KA (VHMS controller system)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 4.9 V
trouble and above.
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n3” o “22”.
information • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
monitoring function (Code: 42611 EXHAUST TEMP R).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
Defective exhaust gas tem- V30 Voltage
temperature
perature sensor on the
1 50 – 100°C 1.0 – 3.5 mV
engine rear side (Internal
short circuit) 300 – 400°C 11.2 – 15.6 mV
Between (1) and (2)
500 – 600°C 19.7 – 24.2 mV
700 – 800°C 28.1 – 32.6 mV
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V12 Voltage
Defective exhaust gas tem- temperature
perature sensor amplifier on Between (A) and (C) Normal 20 – 30 V
2
the engine rear side
Possible causes 50 – 100°C 1.0 – 1.6 V
(Internal short circuit)
and standard 300 – 400°C 2.1 – 2.7 V
value in normal Between (B) and (C)
500 – 600°C 2.9 – 3.6 V
state
700 – 800°C 3.8 – 4.4 V
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between V12 (female) (B) – Resis-
3 Max. 1 z
(Disconnection or defective V02 (female) (5) tance
contact of connector) Wiring harness between V30 (female) (2) – Resis-
Max. 1 z
V28 (female) (2) tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V02 Voltage
temperature
4 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (5) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

18 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to exhaust gas temperature sensor (R)

WA600-6 19
SEN00570-03 40 Troubleshooting

Failure code [DGT5KB] (or VHMS_LED display: “n3” o “21”) (Exhaust

gas temperature sensor (R): Short circuit) 1

Action code Failure code Exhaust gas temperature sensor (R): Short circuit
Trouble
— DGT5KB (VHMS controller system)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 0.3 V or
trouble less.
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “21”.
Related • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
information monitoring function (Code: 42611 EXHAUST TEMP R).
• If failure code [DBB6KP] (VHMS controller 24V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Exhaust gas
V30 Voltage
temperature
50 – 100°C 1.0 – 3.5 mV
Defective exhaust gas tem-
perature sensor on the 300 – 400°C 11.2 – 15.6 mV
1 Between (1) and (2)
engine rear side (Internal 500 – 600°C 19.7 – 24.2 mV
short circuit) 700 – 800°C 28.1 – 32.6 mV
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V30 (male) Resistance
Between (1) and (2) Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Possible causes
Exhaust gas
and standard V12 Voltage
temperature
value in normal
state Between (A) and (C) Normal 20 – 30 V

Defective exhaust gas tem- 50 – 100°C 1.0 – 1.6 V

perature sensor amplifier on 300 – 400°C 2.1 – 2.7 V
2 Between (B) and (C)
the engine rear side 500 – 600°C 2.9 – 3.6 V
(Internal short circuit) 700 – 800°C 3.8 – 4.4 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V12 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between V12 (female) (B) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) V02 (female) (5) and chassis ground
Wiring harness between V30 (female) (2) –
Voltage Max. 1 V
V28 (female) (2) and chassis ground

20 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between V12 (female) (B) – Resis-
4 ness Min. 1 Mz
V02 (female) (5) tance
(Contact with ground circuit)
Wiring harness between V30 (female) (2) – Resis-
Possible causes Min. 1 Mz
V28 (female) (2) tance
and standard a Prepare with starting switch OFF, then start engine and carry out
value in normal troubleshooting.
state
Exhaust gas
V02 Voltage
temperature
5 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (5) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

Circuit diagram related to exhaust gas temperature sensor (R)

WA600-6 21
SEN00570-03 40 Troubleshooting

Failure code [DH21KA] (Work equipment pump oil pressure sensor:

Disconnection) 1

Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Trouble
E01 DH21KA (Work equipment controller system)
• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the signal
Contents of
voltage is lower than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that work equipment pump oil pressure reads 0
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F16 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective work equipment a Prepare with starting switch OFF, then start engine, tilt the bucket
pump oil pressure sensor and carry out troubleshooting.
1
(Internal disconnection or
F16 Work equipment Voltage
short circuit)
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
When bucket tilt
3.02 – 3.42 V
relieved
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Disconnection in wiring har- Wiring harness between L05 (female) (2) – Resis-
Max. 1 z
and standard ness F16 (female) (C) tance
value in normal 2
(Disconnection or defective Wiring harness between L05 (female) (21) – Resis-
state contact of connector) Max. 1 z
F16 (female) (A) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
F16 (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (2) – Resis-
3 ness Min. 1 Mz
F16 (female) (C) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L05 (female) (22) – Resis-
Min. 1 Mz
F16 (female) (B) and chassis ground tance
a Prepare with starting switch OFF, then start engine, tilt the bucket
and carry out troubleshooting.
L05 Work equipment Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
4 Work equipment controller
Normal 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (2) and (21)
When bucket tilt
3.02 – 3.42 V
relieved

22 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to work equipment pump oil pressure sensor

WA600-6 23
SEN00570-03 40 Troubleshooting

Failure code [DH21KB] (Work equipment pump oil pressure sensor:

Short circuit) 1

Action code Failure code Work equipment pump oil pressure sensor: Short circuit
Trouble
E01 DH21KB (Work equipment controller system)
• Due to hot short circuit in the work equipment pump oil pressure sensor signal system, the signal
Contents of
voltage is higher than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that work equipment pump oil pressure is higher
controller • If cause of failure disappears, system resets itself.
Problem that
• Remote positioner inaccuracy of stopping
appears on
• Cut-off function does not work when work equipment system is relieved.
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with the
information
monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve bucket tilt

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F16 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground

Defective work equipment a Prepare with starting switch OFF, then start engine, tilt the bucket
1 pump oil pressure sensor and carry out troubleshooting.
(Internal short circuit) F16 Bucket Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (C) and (A)
Possible causes When bucket tilt
3.02 – 3.42 V
and standard relieved
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (2) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) F16 (female) (C) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
F16 (female) (B) and chassis ground
a Prepare with starting switch OFF, then start engine, tilt the bucket
and carry out troubleshooting.
L05 Bucket Voltage
Defective work equipment Between (22) and (21) Normal 4.85 – 5.15 V
3
controller Normal 0.50 – 4.50 V
Neutral 0.50 – 0.90 V
Between (2) and (21)
When bucket tilt
3.02 – 3.42 V
relieved

24 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to work equipment pump oil pressure sensor

WA600-6 25
SEN00570-03 40 Troubleshooting

Failure code [DHE5KB] (or VHMS_LED display: “n3” o “32”) (Blow-by

pressure sensor: Short circuit) 1

Action code Failure code Blow-by pressure sensor: Short circuit

Trouble
— DHE5KB (VHMS controller system)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 0.1 V or less.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “32”.
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is displayed,
carry out troubleshooting for it first.
• Method of reproducing failure code: Start engine and performs troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
V25 Engine speed Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Defective blow-by pressure Normal 0.50 – 4.50 V
sensor Between (C) and (A)
1 High idle 0.50 – 0.90 V
(Internal disconnection or
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V25 Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Disconnection in wiring har- Wiring harness between V01 (female) (5) – Resis-
Max. 1 z
and standard ness V25 (female) (B) tance
value in normal 2
(Disconnection or defective Wiring harness between V25 (female) (C) – Resis-
state contact of connector) Max. 1 z
V02 (female) (18) tance
Wiring harness between V25 (female) (A) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between V01 (female) (5) – Resis-
3 ness Min. 1 Mz
V25 (female) (B) and chassis ground tance
(Contact with ground circuit)
Wiring harness between V25 (female) (C) – Resis-
Min. 1 Mz
V02 (female) (18) and chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
V02 Engine speed Voltage
4 Defective VHMS controller
Normal 4.85 – 5.15 V
Between (18) and (12) Normal 0.50 – 4.50 V
High idle 0.50 – 0.90 V

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40 Troubleshooting SEN00570-03

Circuit diagram related to blow-by pressure sensor

WA600-6 27
SEN00570-03 40 Troubleshooting

Failure code [DHE5KY] (or VHMS_LED display: “n3” o “31”) (Blow-by

pressure sensor: Short circuit with power supply line) 1

Action code Failure code Blow-by pressure sensor: Short circuit with power supply line
Trouble
— DHE5KY (VHMS controller system)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 4.7 V and above.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
Related • The LED of the VHMS controller displays “n3” o “31”.
information • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
• Method of reproducing failure code: Start engine and performs troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
V25 Engine speed Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Defective blow-by pressure Normal 0.50 – 4.50 V
Between (C) and (A)
1 sensor High idle 0.50 – 0.90 V
(Internal short circuit)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V25 Resistance
Possible causes Between (A), (B), (C) and
Min. 1 Mz
and standard chassis ground
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting
Hot short in wiring harness Wiring harness between V01 (female) (5) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) V25 (female) (B) and chassis ground
Wiring harness between V25 (female) (C) –
Voltage Max. 1 V
V02 (female) (18) and chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
V02 Engine speed Voltage
3 Defective VHMS controller
Normal 4.85 – 5.15 V
Between (18) and (12) Normal 0.50 – 4.50 V
High idle 0.50 – 4.50 V

28 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to blow-by pressure sensor

WA600-6 29
SEN00570-03 40 Troubleshooting

Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out
of input signal range) 1

Action code Failure code Lift arm cylinder bottom pressure sensor: Out of input signal range
Trouble
E01 DHPCKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift
arm cylinder bottom pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder bottom pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bot-
tom pressure sensor voltage is lower than normal range
(Lift arm cylinder bottom pressure sensor signal voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with
the monitoring function (Code: 40400 BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402 BOOM BTM PRESS).
• Applicable only to machines equipped with load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F14 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm cylinder
bottom pressure sensor a Prepare with starting switch OFF, then start engine, raise the lift
1 arm and carry out troubleshooting.
(Internal disconnection or
short circuit) F14 Lift arm Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Possible causes Lift arm bottom relief 3.02 – 3.42 V
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Disconnection in wiring har- Wiring harness between C01 (female) (16) – Resis-
Max. 1 z
ness F14 (female) (B) tance
2
(Disconnection in wiring har- Wiring harness between C05 (female) (9) – Resis-
ness and defective contact) F14 (female) (C) Max. 1 z
tance
Wiring harness between F14 (female) (A) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C01 (female) (16) –
Grounding fault in wiring har- Resis-
F14 (female) (B), – circuit branch end and Min. 1 Mz
3 ness tance
chassis ground
(Contact with ground circuit)
Wiring harness between C05 (female) (9) –
Resis-
F14 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground

30 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between C01 (female) (16) –
Hot short in wiring harness F14 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Wiring harness between C05 (female) (9) –
Possible causes F14 (female) (C), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
C01 and C05 Lift arm Voltage
Between C01 (16)
5 Defective machine monitor Normal 4.85 – 5.15 V
and chassis ground
Normal 0.50 – 4.50 V
Between C05 (9) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm bottom relief 3.02 – 3.42 V

Circuit diagram related to lift arm cylinder bottom pressure sensor

WA600-6 31
SEN00570-03 40 Troubleshooting

Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
input signal range) 1

Action code Failure code Lift arm cylinder head pressure sensor: Out of input signal range
Trouble
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift
arm cylinder head pressure sensor voltage is lower than normal range
Contents of (Lift arm cylinder head pressure sensor signal voltage: Less than 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500 BOOM HEAD PRESS).
Related • The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501 BOOM HEAD PRESS).
• Applicable only to machines equipped with load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F15 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm head pres-
sure sensor a Prepare with starting switch OFF, then start engine, lower the lift
1 arm and carry out troubleshooting.
(Internal disconnection or
short circuit) F15 (male) Lift arm Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Between (C) and (A) Neutral 0.50 – 0.90 V
Possible causes Lift arm head relief 3.02 – 3.42 V
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Disconnection in wiring har- Wiring harness between C01 (female) (16) – Resis-
Max. 1 z
ness F15 (female) (B) tance
2
(Disconnection in wiring har- Wiring harness between C05 (female) (4) – Resis-
ness and defective contact) F15 (female) (C) Max. 1 z
tance
Wiring harness between F15 (female) (A) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C01 (female) (16) –
Grounding fault in wiring har- Resis-
F15 (female) (B), – circuit branch end and Min. 1 Mz
3 ness tance
chassis ground
(Contact with ground circuit)
Wiring harness between C05 (female) (4) –
Resis-
F15 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground

32 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between C01 (female) (16) –
Hot short in wiring harness F15 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24 V circuit) chassis ground
Wiring harness between C05 (female) (4) –
Possible causes F15 (female) (C), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
C01 and C05 Lift arm Voltage
Between C01 (16)
5 Defective machine monitor Normal 4.85 – 5.15 V
and chassis ground
Normal 0.50 – 4.50 V
Between C05 (4) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm head relief 3.02 – 3.42 V

Circuit diagram related to lift arm cylinder bottom pressure sensor

WA600-6 33
SEN00570-03 40 Troubleshooting

Failure code [DHT2L6] (Transmission filter clogging sensor: Signal

disagrees with operating state of engine) 1

Action code Failure code Transmission filter clogging sensor: Signal disagrees with operating
Trouble
E01 DHT2L6 state of engine (Machine monitor system)
Contents of • Due to abnormal transmission clogging sensor signal, transmission clogging sensor signal voltage
trouble does not agree with the engine operation or stopping in normal condition.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The transmission filter clogging caution lamp does not light up.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the mon-
Related
itoring function (Code: 40903 D-IN-24).
information
• Method of reproducing failure code: Start engine and drive the machine in high idle

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
Defective transmission clog- troubleshooting.
ging sensor B09 (male) Transmission filter Resistance
1
(Internal disconnection or
short circuit) Normal Max. 1 z
Between (1) and (2)
Clogging Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between C03 (female) (5) – Resis-
2 Max. 1 z
(Disconnection or defective B09 (female) (1) tance
contact of connector) Wiring harness between B09 (male) (2) – Resis-
Max. 1 z
Possible causes chassis ground tance
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 3 ness
(Contact with ground circuit) Wiring harness between C03 (female) (5) – Resis-
Min. 1 Mz
B09 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between C03 (female) (5) –
Voltage Max. 1 V
B09 (female) (1) and chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Transmission filter
5 Defective machine monitor C03 (female) Resistance
inlet pressure
Between (5) and Normal Max. 1 z
chassis ground Clogging Min. 1 Mz

34 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to transmission clogging sensor

WA600-6 35
SEN00570-03 40 Troubleshooting

Failure code [DHT8KX] (or VHMS_LED display: “n5” o “33”) (Steering

oil pressure sensor: Out of input signal range) 1

Action code Failure code Steering oil pressure sensor: Out of input signal range
Trouble
— DHT8KX (VHMS controller system)
Contents of
• Input signal voltage from the steering oil pressure sensor reads 4.9 V and above or less than 0.3 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the steering oil pressure
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n5” o “33”
Related • The input state (oil pressure) from the steering oil pressure sensor can be checked with the monitor-
information ing function (Code: 93000 S/T OIL PRESS).
• If failure code [DBB5KP] (VHMS controller 5 V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V23 (male) Steering operation Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Defective steering oil pres-
Between (C) and (A) Neutral 0.50 – 0.90 V
1 sure sensor (Internal discon-
nection or short circuit) When relieved 3.2 – 3.4 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V23 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes
ness Wiring harness between V02 (female) (16) – Resis-
and standard 2 Max. 1 z
value in normal (Disconnection or defective V23 (female) (C) tance
state contact of connector) Wiring harness between V23 (female) (A) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between V02 (female) (16) – Resis-
Min. 1 Mz
V23 (female) (C) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between V02 (female) (16) –
Voltage Max. 1 V
V23 (female) (C) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V02 (female) Steering operation Voltage
5 Defective VHMS controller
Normal 0.50 – 4.50 V
Between (16) and (12) Neutral 0.50 – 0.90 V
When relieved 3.2 – 3.4 V

36 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to steering oil pressure sensor

WA600-6 37
SEN00570-03 40 Troubleshooting

Failure code [DHTBKA] (Modulation clutch oil pressure sensor:

Disconnection) 1

Action code Failure code Modulation clutch oil pressure sensor: Disconnection
Trouble
E03 DHTBKA (Transmission controller system)
• Due to disconnection or ground fault in modulation clutch oil pressure sensor system, modulation
Contents of
clutch oil pressure signal voltage is lower than normal range (Modulation clutch oil pressure sensor
trouble
signal voltage: Max. 0.3 V).
• Uses modulation clutch oil pressure signal value output immediately before abnormality occurs.
Action of • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
controller • Even if cause of failure disappears, system does not reset itself until directional selector switch is set
to N (Neutral).
Problem that
appears on • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
machine
• The input state (pressure) from the modulation clutch oil pressure sensor can be checked with the
monitoring function (Code: 92400 MOD/C PRESS).
Related
• The input state (voltage) from the modulation clutch oil pressure sensor can be checked with the
information
monitoring function (Code: 92401 MOD/C PRESS).
• Method of reproducing failure code: Start engine and drive the machine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
T03 (male) Resistance

Defective modulation clutch Between (A), (B), (C) and

Min. 1 Mz
oil pressure sensor chassis ground
1
(Internal disconnection or a Prepare with starting switch OFF, then carry out troubleshooting
short circuit) without turning starting switch ON.
T03 Voltage
Between (B) and (A) 0.9 – 1.2 V
Between (C) and (A) 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L02 (female) (8) – Resis-
Max. 1 z
Possible causes ness T03 (female) (C) tance
2
and standard (Disconnection or defective Wiring harness between L02 (female) (16) – Resis-
value in normal contact of connector) Max. 1 z
T03 (female) (B) tance
state
Wiring harness between L02 (female) (21) – Resis-
Max. 1 z
T03 (female) (A) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L02 (female) (8) – Resis-
3 ness Max. 1 z
T03 (female) (C) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L02 (female) (16) – Resis-
Max. 1 z
T03 (female) (B) and chassis ground tance
a Prepare with starting switch OFF, then start engine, travel and
carry out troubleshooting.
Modulation clutch oil
Defective transmission con- L02 Voltage
4 pressure
troller
Between (16) and (21) Normal 4.75 – 5.25 V
0 MPa {0 kg/cm²} 1V
Between (8) and (21)
4.9 MPa {50 kg/cm²} 5V

38 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to modulation clutch oil pressure sensor

WA600-6 39
SEN00570-03 40 Troubleshooting

Failure code [DHTBKB] (Modulation clutch oil pressure sensor: Short

circuit) 1

Action code Failure code Modulation clutch oil pressure sensor: Short circuit
Trouble
E03 DHTBKB (Transmission controller system)
Contents of • Due to hot short circuit in the modulation clutch oil pressure sensor system, the modulation clutch oil
trouble pressure sensor detect pressure is higher than normal range
• Uses modulation clutch oil pressure signal value output immediately before abnormality occurs.
• Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until directional selector switch is set
to N (Neutral).
Problem that
appears on • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
machine
• The input state (pressure) from the modulation clutch oil pressure sensor can be checked with the
monitoring function (Code: 92400 MOD/C PRESS).
Related
• The input state (voltage) from the modulation clutch oil pressure sensor can be checked with the
information
monitoring function (Code: 92401 MOD/C PRESS).
• Method of reproducing failure code: Start engine and drive the machine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
T03 (male) Resistance
Between (A), (B), (C) and
Defective modulation clutch Min. 1 Mz
chassis ground
1 oil pressure sensor (Internal
a Prepare with starting switch OFF, then turn starting switch ON
short circuit)
and carry out troubleshooting
T03 Voltage
Between (B) and (A) 0.9 – 1.2 V
Possible causes Between (C) and (A) 20 – 30 V
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting
state
Hot short in wiring harness Wiring harness between L02 (female) (8) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) T03 (female) (C) and chassis ground
Wiring harness between L02 (female) (16) –
Voltage Max. 1 V
T03 (female) (B) and chassis ground
a Prepare with starting switch OFF, then start engine, travel and
carry out troubleshooting.
Modulation clutch oil
Defective transmission con- L02 Voltage
3 pressure
troller
Between (16) and (21) Normal 20 – 30 V
0 MPa {0 kg/cm²} 1V
Between (8) and (21)
4.9 MPa {50 kg/cm²} 5V

40 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to modulation clutch oil pressure sensor

WA600-6 41
SEN00570-03 40 Troubleshooting

Failure code [DHU2KX] (or VHMS_LED display: “n7” o “11”) (Front

brake oil pressure sensor (F): Out of input signal range) 1

Action code Failure code Front brake oil pressure sensor: Out of input signal range
Trouble
— DHU2KX (VHMS controller system)
Contents of
• Input signal voltage from the front brake oil pressure sensor reads 4.9 V and above or less than 0.3 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the brake signal
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n7” o “11”.
Related • The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
information function (Code: 92900 BRAKE SIG).
• If failure code [DBB5KP] (VHMS controller 5 V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
V14 (male) Wheel brake Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Defective front brake oil
pressure sensor (Internal When front brake
Between (C) and (A)
1 accumulator 0.50 – 0.90 V
disconnection or short cir-
cuit) oil pressure reads 0
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V14 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes ness Wiring harness between V02 (female) (8) – Resis-
2 Max. 1 z
and standard (Disconnection or defective V14 (female) (C) tance
value in normal contact of connector) Wiring harness between V14 (female) (A) – Resis-
state Min. 1 Mz
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
Wiring harness between V02 (female) (8) – Resis-
(Contact with ground circuit) Min. 1 Mz
V14 (female) (C) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between V02 (female) (8) –
Voltage Max. 1 V
V14 (female) (C) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
V02 (female) Wheel brake Voltage
Normal 4.85 – 5.15 V
5 Defective VHMS controller
Normal 0.50 – 4.50 V
Between (8) and (12) When front brake
accumulator 0.50 – 0.90 V
pressure reads 0

42 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to the front brake oil pressure sensor

WA600-6 43
SEN00570-03 40 Troubleshooting

Failure code [DHU3KX] (or VHMS_LED display: “n7” o “12”) (Rear

brake oil pressure sensor (R): Out of input signal range) 1

Action code Failure code Rear brake oil pressure sensor: Out of input signal range
Trouble
— DHU3KX (VHMS controller system)
Contents of
• Input signal voltage from the rear brake oil pressure sensor reads 4.9 V and above or less than 0.3 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Monitoring function fails to monitor the brake signal
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n7” o “12”.
Related • The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
information function (Code: 92900 BRAKE SIG).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is displayed,
carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
V13 (male) Wheel brake Voltage
Between (B) and (A) Normal 4.85 – 5.15 V
Normal 0.50 – 4.50 V
Defective rear brake oil pres- When rear brake
Between (C) and (A)
1 sure sensor (Internal discon- accumulator 0.50 – 0.90 V
nection or short circuit) pressure reads 0
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
V13 (male) Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes ness Wiring harness between V02 (female) (6) – Resis-
2 Max. 1 z
and standard (Disconnection or defective V13 (female) (C) tance
value in normal contact of connector) Wiring harness between V13 (female) (A) – Resis-
state Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
3 ness
Wiring harness between V02 (female) (6) – Resis-
(Contact with ground circuit) Min. 1 Mz
V13 (female) (C) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between V02 (female) (6) –
Voltage Max. 1 V
V13 (female) (C) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
V02 (female) Wheel brake Voltage
Normal 4.85 – 5.15 V
5 Defective VHMS controller
Normal 0.50 – 4.50 V
Between (6) and (12) When rear brake
accumulator 0.50 – 0.90 V
pressure reads 0

44 WA600-6
40 Troubleshooting SEN00570-03

Circuit diagram related to the rear brake oil pressure sensor

WA600-6 45
SEN00570-03 40 Troubleshooting

Failure code [DK30KA] (AJSS lever angle sensor: Disconnection) 1

Action code Failure code AJSS lever angle sensor: Disconnection

Trouble
E01 DK30KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in AJSS lever angle sensor system, AJSS lever angle signal
trouble voltage is lower than normal range (AJSS angle sensor signal voltage: Max. 0.3 V).
• Judges that AJSS is operated to the left
Action of • Stops the steering neutral safety function
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}
• If cause of failure disappears, system resets itself.
Problem that • The engine does not start.
appears on • Steering fine control is disabled (the machine jounces when performing steering operation).
machine • Disabled to swing at full speed
• The input state (voltage) from the AJSS lever angle sensor can be checked with the monitoring func-
tion (Code: 94300 AJSS LEVER, 94301 AJSS LEVER).
Related
• Method of reproducing failure code: Turn the starting switch ON and operate AJSS
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S30 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective AJSS angle sensor and carry out troubleshooting (steering lock).
1 (Internal disconnection or
S30 AJSS lever Voltage
short circuit)
Between (B) and (C) Normal 4.85 – 5.15 V
Normal 0.30 – 4.70 V
Lever in neutral 2.20 – 2.80 V
Possible causes Between (A) and (C) Full steering to right
2.83 – 3.83 V
and standard (straight travel state)
value in normal Full steering to left
state 1.17 – 2.17 V
(straight travel state)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (9) – Resis-
Max. 1 z
ness S30 (female) (4) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) Max. 1 z
S30 (female) (C) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S30 (female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (9) – Resis-
3 ness Min. 1 Mz
S30 (female) (A) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L05 (female) (22) – Resis-
Min. 1 Mz
S30 (female) (B), – circuit branch end tance

46 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L05 AJSS lever Voltage
Possible causes Between (22) and (9) Normal 4.85 – 5.15 V
and standard
value in normal Defective work equipment Normal 0.30 – 4.70 V
4
state controller Lever in neutral 2.20 – 2.80 V

Between (21) and (9) Full steering to right

2.83 – 3.83 V
(straight travel state)
Full steering to left
1.17 – 2.17 V
(straight travel state)

Circuit diagram related to AJSS lever angle sensor

WA600-6 47
SEN00570-03 40 Troubleshooting

Failure code [DK30KY] (AJSS lever angle sensor: Short circuit with
power supply line) 1

Action code Failure code AJSS lever angle sensor: Short circuit with power supply line
Trouble
E01 DK30KY (Work equipment controller system)
• Due to hot short circuit in the AJSS lever angle sensor system, the AJSS lever angle signal voltage is
Contents of
higher than normal range
trouble
(AJSS lever angle sensor signal voltage: Min. 4.7 V)
• Judges that AJSS lever is operated to the right
Action of • Stops the AJSS neutral safety function
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}
• If cause of failure disappears, system resets itself.
Problem that • Once the engine stops, the engine does not start.
appears on • Steering fine control is disabled (the machine jounces when performing steering operation).
machine • Disabled to swing at full speed
• The input state (voltage) from the AJSS lever angle sensor can be checked with the monitoring func-
tion (Code: 94300 AJSS LEVER, 94301 AJSS LEVER).
Related
• Method of reproducing failure code: Turn the starting switch ON and operate AJSS lever
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S30 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective AJSS angle sensor and carry out troubleshooting (steering lock).
1
(Internal short circuit) S30 AJSS lever Voltage
Possible causes
Between (B) and (C) Normal 4.85 – 5.15 V
and standard
value in normal Normal 0.30 – 4.70 V
state Lever in neutral 2.20 – 2.80 V

Between (A) and (C) Full steering to right

2.83 – 3.83 V
(straight travel state)
Full steering to left
1.17 – 2.17 V
(straight travel state)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (9) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S30 (female) (4) and chassis ground
Wiring harness between L05 (female) (22) –
Voltage Max. 1 V
S30 (female) (B), – circuit branch end

48 WA600-6
40 Troubleshooting SEN00570-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (steering lock).
L05 AJSS lever Voltage
Possible causes Between (22) and (9) Normal 4.85 – 5.15 V
and standard
value in normal Defective work equipment Normal 0.30 – 4.70 V
3
state controller
Lever in neutral 2.20 – 2.80 V

Between (21) and (9) Full steering to right

2.83 – 3.83 V
(straight travel state)
Full steering to left
1.17 – 2.17 V
(straight travel state)

Circuit diagram related to AJSS lever angle sensor

WA600-6 49
SEN00570-03

WA600-6 Wheel loader

Form No. SEN00570-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

50
 SEN00571-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine Model Serial number

WA600-6 60001 and up

40 Troubleshooting 1

Troubleshooting by failure code

(Display of code), Part 8
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ........................................ 3
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)........ 6
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ....................... 10
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ....................................... 13
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)....... 16
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....................................... 19
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) ...... 22
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ........................ 24
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ........................................ 27
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) ....... 30
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection) ....... 32
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main):
Short circuit with power supply line).......................................................................................................... 34

WA600-6 1
SEN00571-03 40 Troubleshooting

Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main):
Analog signals disagree)........................................................................................................................... 36
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub):
Disconnection) .......................................................................................................................................... 40
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):
Short circuit with power supply line).......................................................................................................... 42
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).................................................................... 44
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) ................................................... 46
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ................................... 48
Failure code [DKA0L0] (Lift arm angle sensor: Improper position) ............................................................... 50

2 WA600-6
40 Troubleshooting SEN00571-03

Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)

Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer system, the signal
Contents of
voltage is lower than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective lift arm EPC lever and carry out troubleshooting
potentiometer S03 Lift arm EPC lever Voltage
1
(Internal disconnection or Between (4) and (1) Normal 4.85 – 5.15 V
short circuit) Lever in neutral 2.40 – 2.60 V
Raise operation
3.64 – 4.14 V
(Before detent)
Possible causes Raise operation
Between (3) and (1) 3.86 – 4.36 V
and standard (Detent position)
value in normal Lower operation
0.86 – 1.36 V
state (Before detent)
Float operation 0.64 – 1.14 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (19) – Resis-
Max. 1 z
ness S03 (female) (3) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
Max. 1 z
ness and defective contact) S03 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S03 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (19) – Resis-
3 ness Min. 1 Mz
S03 (female) (3) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S03 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance

WA600-6 3
SEN00571-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Lift arm EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Possible causes
Lever in neutral 2.40 – 2.60 V
and standard
value in normal Defective work equipment Raise operation
4 3.64 – 4.14 V
state controller (Before detent)
Raise operation
Between (19) and (21) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V

4 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to lift arm EPC lever potentiometer

WA600-6 5
SEN00571-03 40 Troubleshooting

Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
circuit with power supply line) 1

Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with the power
Trouble supply line
E03 DK59KY (Work equipment controller system)
• Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
Defective lift arm EPC lever S03 Lift arm EPC lever Voltage
1 potentiometer
(Internal short circuit) Between (4) and (1) Normal 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Raise operation
3.64 – 4.14 V
state (Before detent)
Raise operation
Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
(Before detent)
Float operation 0.64 – 1.14 V
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (19) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S03 (female) (3) and chassis ground
Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

6 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Lift arm EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Possible causes
Lever in neutral 2.40 – 2.60 V
and standard
value in normal Defective work equipment Raise operation
3 3.64 – 4.14 V
state controller Between (19) and (21) (Before detent)
Raise operation
3.86 – 4.36 V
(Detent position)
Lower operation
0.86 – 1.36 V
Between (19) and (21) (Before detent)
Float operation 0.64 – 1.14 V

WA600-6 7
SEN00571-03 40 Troubleshooting

Circuit diagram related to lift arm EPC lever potentiometer

8 WA600-6
40 Troubleshooting SEN00571-03

WA600-6 9
SEN00571-03 40 Troubleshooting

Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog
signals disagree) 1

Action code Failure code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift arm EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Cannot recognize the lift arm EPC lever position correctly.
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5 %, as
the regular potentiometer.
Action of • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
controller trality ±5 %.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
• Work equipment moves with the lever set to neutral.
Problem that
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on
neutral.
machine
• If both Main and Sub potentiometers are abnormal, lift arm does not move.
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
S03 Lift arm EPC lever Voltage
Between (4) and (1) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Possible causes
and standard Defective lift arm EPC lever Raise operation
3.64 – 4.14 V
value in normal potentiometer (Before detent)
1
state (Internal disconnection or Raise operation
short circuit) Between (3) and (1) 3.86 – 4.36 V
(Detent position)
Float operation 0.64 – 1.14 V
Lower operation
0.86 – 1.36 V
(Before detent)
Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

10 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (13) – Resis-
Max. 1 z
Disconnection in wiring har- S03 (female) (2) tance
ness Wiring harness between L05 (female) (19) – Resis-
2 Max. 1 z
(Disconnection in wiring har- S03 (female) (3) tance
ness and defective contact) Wiring harness between L05 (female) (21) – Resis-
Max. 1 z
S03 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S03 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (13) – Resis-
Grounding fault in wiring har- S03 (female) (2) and chassis ground Min. 1 Mz
tance
3 ness
(Contact with ground circuit) Wiring harness between L05 (female) (19) – Resis-
Min. 1 Mz
S03 (female) (3) and chassis ground tance
Between L05 (female) (22) – S03 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L05 (female) (13) –
Voltage Max. 1 V
Hot short in wiring harness S03 (female) (2) and chassis ground
Possible causes 4
(Contact with 24 V circuit) Wiring harness between L05 (female) (19) –
and standard Voltage Max. 1 V
value in normal S03 (female) (3) and chassis ground
state Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Lift arm EPC lever Voltage
Between (22) and
Normal 4.85 – 5.15 V
(21)
Lever in neutral 2.40 – 2.60 V
Raise operation
3.64 – 4.14 V
(Before detent)
Raise operation
Between (19) and (21) 3.86 – 4.36 V
(Detent position)
Defective work equipment
5 Float operation 0.64 – 1.14 V
controller
Lower operation
0.86 – 1.36 V
(Before detent)
Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Raise operation
Between (13) and (21) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

WA600-6 11
SEN00571-03 40 Troubleshooting

Circuit diagram related to lift arm EPC lever potentiometer

12 WA600-6
40 Troubleshooting SEN00571-03

Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub):

Disconnection) 1

Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective lift arm EPC lever and carry out troubleshooting (work equipment lock)
potentiometer S03 (male) Lift arm EPC lever Voltage
1
(Internal disconnection or Between (4) and (1) Normal 4.85 – 5.15 V
short circuit) Lever in neutral 2.40 – 2.60 V
Raise operation
0.86 – 1.36 V
(Before detent)
Possible causes Raise operation
Between (2) and (1) 0.64 – 1.14 V
and standard (Detent position)
value in normal Lower operation
3.64 – 4.14 V
state (Before detent)
Float operation 3.86 – 4.36 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (13) – Resis-
Max. 1 z
ness S03 (female) (2) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) S03 (female) (1) Max. 1 z
tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S03 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (13) – Resis-
3 ness Min. 1 Mz
S03 (female) (2) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S03 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance

WA600-6 13
SEN00571-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Lift arm EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Possible causes
Lever in neutral 2.40 – 2.60 V
and standard
value in normal Defective work equipment Raise operation
4 0.86 – 1.36 V
state controller (Before detent)
Raise operation
Between (13) and (21) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V

14 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to lift arm EPC lever potentiometer

WA600-6 15
SEN00571-03 40 Troubleshooting

Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
circuit with power supply line) 1

Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with the power
Trouble supply line
E03 DK5AKY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S03 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
Defective lift arm EPC lever S03 (male) Lift arm EPC lever Voltage
1 potentiometer
(Internal short circuit) Between (4) and (1) Normal 4.85 – 5.15 V
Possible causes
and standard Lever in neutral 2.40 – 2.60 V
value in normal Raise operation
0.86 – 1.36 V
state (Before detent)
Raise operation
Between (2) and (1) 0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
(Before detent)
Float operation 3.86 – 4.36 V
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (13) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S03 (female) (2) and chassis ground
Between L05 (female) (22) – S03 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

16 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Lift arm EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Possible causes
Lever in neutral 2.40 – 2.60 V
and standard
value in normal Defective work equipment Raise operation
3 0.86 – 1.36 V
state controller Between (13) and (21) (Before detent)
Raise operation
0.64 – 1.14 V
(Detent position)
Lower operation
3.64 – 4.14 V
Between (13) and (21) (Before detent)
Float operation 3.86 – 4.36 V

WA600-6 17
SEN00571-03 40 Troubleshooting

Circuit diagram related to lift arm EPC lever potentiometer

18 WA600-6
40 Troubleshooting SEN00571-03

Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main):

Disconnection) 1

Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• Judges that the bucket EPC lever was fully operated in the dumping direction.
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground

Defective bucket EPC lever a Prepare with starting switch OFF, then turn starting switch ON
potentiometer and carry out troubleshooting (work equipment lock)
1
(Internal disconnection or S02 Bucket EPC lever Voltage
short circuit) Between (4) and (1) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Possible causes Between (3) and (1)
and standard Tilt operation
3.86 – 4.36 V
value in normal (Detent position)
state Full dump operation 0.69 – 1.14 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (7) – Resis-
Max. 1 z
ness S02 (female) (3) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) Max. 1 z
S02 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S02 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (7) – Resis-
3 ness Min. 1 Mz
S02 (female) (3) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S02 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance

WA600-6 19
SEN00571-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Bucket EPC lever Voltage
Possible causes Between (22) and (21) Normal 4.85 – 5.15 V
and standard
value in normal Defective work equipment Lever in neutral 2.40 – 2.60 V
4
state controller Between (7) and (21) Tilt operation
3.64 – 4.14 V
(Before detent)
Tilt operation
3.86 – 4.36 V
Between (7) and (21) (Detent position)
Full dump operation 0.64 – 1.14 V

20 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to bucket EPC lever potentiometer

WA600-6 21
SEN00571-03 40 Troubleshooting

Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short

circuit with power supply line) 1

Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with the power
Trouble supply line
E03 DK5BKY (Work equipment controller system)
• Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• Judges that the bucket EPC lever was fully operated in the tilting direction.
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective bucket EPC lever and carry out troubleshooting (work equipment lock)
1 potentiometer (Internal short
S02 Bucket EPC lever Voltage
circuit)
Between (4) and (1) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
Possible causes 3.86 – 4.36 V
(Detent position)
and standard
value in normal Full dump operation 0.64 – 1.14 V
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (7) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Bucket EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Defective work equipment Lever in neutral 2.40 – 2.60 V
3
controller Tilt operation
3.64 – 4.14 V
(Before detent)
Between (7) and (21)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V

22 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to bucket EPC lever potentiometer

WA600-6 23
SEN00571-03 40 Troubleshooting

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog

signals disagree) 1

Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
• Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Contents of
(Bucket EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Bucket EPC
trouble
lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Cannot recognize the bucket EPC lever position correctly.
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5 %, as
the regular potentiometer.
Action of • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
controller trality ±5 %.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
• Work equipment moves with the lever set to neutral.
Problem that
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on
neutral.
machine
• If both Main and Sub potentiometers are abnormal, bucket does not move.
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
S02 Bucket EPC lever Voltage
Possible causes Between (4) and (1) Normal 4.85 – 5.15 V
and standard Defective bucket EPC lever
value in normal potentiometer Lever in neutral 2.40 – 2.60 V
1
state (Internal disconnection or Tilt operation
short circuit) 3.64 – 4.14 V
(Before detent)
Between (3) and (1)
Tilt operation
3.86 – 4.36 V
(Detent position)
Full dump operation 0.64 – 1.14 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

24 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring har- S02 (female) (2) tance
ness Wiring harness between L05 (female) (7) – Resis-
2 Max. 1 z
(Disconnection in wiring har- S02 (female) (3) tance
ness and defective contact) Wiring harness between L05 (female) (21) – Resis-
Max. 1 z
S02 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S02 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (1) – Resis-
Grounding fault in wiring har- S02 (female) (2) and chassis ground Min. 1 Mz
tance
3 ness
(Contact with ground circuit) Wiring harness between L05 (female) (7) – Resis-
Min. 1 Mz
S02 (female) (3) and chassis ground tance
Between L05 (female) (22) – S02 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes and carry out troubleshooting
and standard Wiring harness between L05 (female) (1) –
value in normal Voltage Max. 1 V
Hot short in wiring harness S02 (female) (2) and chassis ground
state 4
(Contact with 24 V circuit) Wiring harness between L05 (female) (7) –
Voltage Max. 1 V
S02 (female) (3) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Bucket EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
3.64 – 4.14 V
(Before detent)
Between (7) and (21)
Defective work equipment Tilt operation
5 3.86 – 4.36 V
controller (Detent position)
Full dump operation 0.64 – 1.14 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.61 – 1.14 V
(Detent position)
Full dump operation 3.96 – 4.36 V

WA600-6 25
SEN00571-03 40 Troubleshooting

Circuit diagram related to bucket EPC lever potentiometer

26 WA600-6
40 Troubleshooting SEN00571-03

Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub):

Disconnection) 1

Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Max. 0.3 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground

Defective bucket EPC lever a Prepare with starting switch OFF, then turn starting switch ON
potentiometer and carry out troubleshooting (work equipment lock)
1
(Internal disconnection or S02 Bucket EPC lever Voltage
short circuit) Between (4) and (1) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Possible causes Between (2) and (1)
and standard Tilt operation
0.64 – 1.14 V
value in normal (Detent position)
state Full dump operation 3.96 – 4.36 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (1) – Resis-
Max. 1 z
ness S02 (female) (2) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) Max. 1 z
S02 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S02 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (1) – Resis-
3 ness Min. 1 Mz
S02 (female) (2) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S02 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance

WA600-6 27
SEN00571-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Bucket EPC lever Voltage
Possible causes Between (22) and (21) Normal 4.85 – 5.15 V
and standard
value in normal Defective work equipment Lever in neutral 2.40 – 2.60 V
4
state controller Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

28 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to bucket EPC lever potentiometer

WA600-6 29
SEN00571-03 40 Troubleshooting

Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short

circuit with power supply line) 1

Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with the power
Trouble supply line
E03 DK5CKY (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal volt-
trouble
age: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S02 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective bucket EPC lever and carry out troubleshooting (work equipment lock)
1 potentiometer (Internal short
S02 Bucket EPC lever Voltage
circuit)
Between (4) and (1) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Tilt operation
0.86 – 1.36 V
(Before detent)
Between (2) and (1)
Tilt operation
Possible causes 0.64 – 1.14 V
(Detent position)
and standard
value in normal Full dump operation 3.86 – 4.36 V
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (1) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S02 (female) (2) and chassis ground
Between L05 (female) (22) – S02 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
L05 Bucket EPC lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Defective work equipment Lever in neutral 2.40 – 2.60 V
3
controller Tilt operation
0.86 – 1.36 V
(Before detent)
Between (1) and (21)
Tilt operation
0.64 – 1.14 V
(Detent position)
Full dump operation 3.86 – 4.36 V

30 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to bucket EPC lever potentiometer

WA600-6 31
SEN00571-03 40 Troubleshooting

Failure code [DK5DKA] (3-spool valve (attachment) EPC lever

potentiometer (Main): Disconnection) 1

Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Discon-
Trouble nection
E03 DK5DKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool (attachment) EPC lever potentiometer (Main),
Contents of
the signal voltage is lower than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• Judges that the 3-spool valve (attachment) EPC lever was fully operated in the retracting direction.
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
Action of in control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
checked with the monitoring function (Code: 42006 3rd POT1).
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
Related checked with the monitoring function (Code: 42007 3rd POT2).
information • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective 3-spool valve and carry out troubleshooting (work equipment lock)
(attachment) EPC lever
1 3-spool valve
potentiometer (Internal dis-
connection or short circuit) S16 (male) (attachment) EPC Voltage
Possible causes lever
and standard Between (4) and (1) Normal 4.85 – 5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (20) – Resis-
Max. 1 z
ness S16 (female) (3) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) Max. 1 z
S16 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S16 (female) (4) tance

32 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (20) – Resis-
3 ness Min. 1 Mz
S16 (female) (3) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S16 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting (work equipment lock)
value in normal 3-spool valve
state L05 (attachment) EPC Voltage
lever
Defective work equipment Between (22) and (21) Normal 4.85 – 5.15 V
4
controller
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (20) and (21) operation
Full retraction
0.64 – 1.14 V
operation

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer

WA600-6 33
SEN00571-03 40 Troubleshooting

Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer

(Main): Short circuit with power supply line) 1

Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Short
Trouble circuit with power supply line
E03 DK5DKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool (attachment) EPC lever potentiometer (Main) system, the sig-
Contents of
nal voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Main) signal voltage: Max. 4.7 V).
• Judges that the 3-spool valve (attachment) EPC lever was fully operated in the extending direction.
• If the 3-spool valve (attachment) EPC lever potentiometer (Sub) is normal, the Sub potentiometer is
Action of in control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
checked with the monitoring function (Code: 42006 3rd POT1).
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
Related checked with the monitoring function (Code: 42007 3rd POT2).
information • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective 3-spool valve and carry out troubleshooting (work equipment lock)
(attachment) EPC lever
1 3-spool valve
potentiometer (Internal short
Possible causes circuit) S16 (male) (attachment) EPC Voltage
and standard lever
value in normal Between (4) and (1) Normal 4.85 – 5.15 V
state
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hot short in wiring harness Wiring harness between L05 (female) (20) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S16 (female) (3) and chassis ground
Between L05 (female) (22) – S16 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

34 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
3-spool valve
Possible causes L05 (attachment) EPC Voltage
and standard lever
value in normal Defective work equipment Between (22) and (21) Normal 4.85 – 5.15 V
3
state controller
Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (20) and (21) operation
Full retraction
0.64 – 1.14 V
operation

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer

WA600-6 35
SEN00571-03 40 Troubleshooting

Failure code [DK5DL8] (3-spool valve (attachment) EPC lever

potentiometer (Main): Analog signals disagree) 1

Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Main): Analog
Trouble signals disagree
E03 DK5DL8 (Work equipment controller system)
• The 3-spool valve (attachment) EPC lever potentiometer (Main & Sub) input signals disagree with each
Contents of other.
trouble (3-spool valve (attachment) EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or
(3-spool valve (attachment) EPC lever potentiometer signal voltage (both Main and Sub): Min. 5.3 V)
• Cannot recognize the 3-spool valve (attachment) EPC lever position correctly.
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ± 5 %, as
the regular potentiometer.
Action of • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
controller trality ± 5 %.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
• Work equipment moves with the lever set to neutral.
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, 3-spool valve (attachment) cylinder does not
move.
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
checked with the monitoring function (Code: 42006 3rd POT1).
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
Related checked with the monitoring function (Code: 42007 3rd POT2).
information • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
3-spool valve
Possible causes S16 (male) (attachment) EPC Voltage
and standard Defective 3-spool valve
(attachment) EPC lever lever
value in normal 1
state potentiometer (Internal dis- Between (4) and (1) Normal 4.85 – 5.15 V
connection or short circuit) Lever in neutral 2.40 – 2.60 V
Full extension
3.86 – 4.36 V
Between (3) and (1) operation
Full retraction
0.64 – 1.14 V
operation
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (2) and (1) operation
Full retraction
3.86 – 4.36 V
operation

36 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (14) – Resis-
Max. 1 z
Disconnection in wiring har- S16 (female) (2) tance
ness Wiring harness between L05 (female) (20) – Resis-
2 Max. 1 z
(Disconnection in wiring har- S16 (female) (3) tance
ness and defective contact) Wiring harness between L05 (female) (21) – Resis-
Max. 1 z
S16 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S16 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (female) (14) – Resis-
Grounding fault in wiring har- S16 (female) (2) and chassis ground Min. 1 Mz
tance
3 ness
(Contact with ground circuit) Wiring harness between L05 (female) (20) – Resis-
Min. 1 Mz
S16 (female) (3) and chassis ground tance
Between L05 (female) (22) – S16 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting
value in normal Wiring harness between L05 (female) (14) –
Voltage Max. 1 V
state Hot short in wiring harness S16 (female) (2) and chassis ground
4
(Contact with 24 V circuit) Wiring harness between L05 (female) (20) –
Voltage Max. 1 V
S16 (female) (3) and chassis ground
Between L05 (female) (22) – S16 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
3-spool valve
L05 Voltage
(attachment) EPC lever
Between (22) and (21) Normal 4.85 – 5.15 V
Lever in neutral 2.40 – 2.60 V
Full extension
Defective work equipment 3.86 – 4.36 V
5 Between (20) and (21) operation
controller
Full retraction
0.64 – 1.14 V
operation
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (14) and (21) operation
Full retraction
3.86 – 4.36 V
operation

WA600-6 37
SEN00571-03 40 Troubleshooting

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer

38 WA600-6
40 Troubleshooting SEN00571-03

WA600-6 39
SEN00571-03 40 Troubleshooting

Failure code [DK5EKA] (3-spool valve (attachment) EPC lever

potentiometer (Sub): Disconnection) 1

Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Discon-
Trouble nection
E03 DK5EKA (Work equipment controller system)
• Due to disconnection or grounding fault in the 3-spool valve (attachment) EPC lever potentiometer
Contents of
(Sub), the signal voltage is lower than normal range (3-spool valve (attachment) EPC lever potenti-
trouble
ometer (Sub) signal voltage: Max. 0.3 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
Action of is in control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on —
machine
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
checked with the monitoring function (Code: 42006 3rd POT1).
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
Related checked with the monitoring function (Code: 42007 3rd POT2).
information • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective 3-spool valve and carry out troubleshooting (work equipment lock)
(attachment) EPC lever
1 3-spool valve
potentiometer (Internal dis-
connection or short circuit) S16 (attachment) EPC Voltage
Possible causes lever
and standard Between (4) and (1) Normal 4.85 – 5.15 V
value in normal Lever in neutral 2.40 – 2.60 V
state
Full extension
0.64 – 1.14 V
Between (2) and (1) operation
Full retraction
3.86 – 4.36 V
operation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between L05 (female) (14) – Resis-
Max. 1 z
ness S16 (female) (2) tance
2
(Disconnection in wiring har- Wiring harness between L05 (female) (21) – Resis-
ness and defective contact) Max. 1 z
S16 (female) (1) tance
Wiring harness between L05 (female) (22) – Resis-
Max. 1 z
S16 (female) (4) tance

40 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring har-
Wiring harness between L05 (female) (14) – Resis-
3 ness Min. 1 Mz
S16 (female) (2) and chassis ground tance
(Contact with ground circuit)
Between L05 (female) (22) – S16 (female) Resis-
Min. 1 Mz
(4), – circuit branch end and chassis ground tance
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting (work equipment lock)
value in normal 3-spool valve
state L05 (attachment) EPC Voltage
lever
Defective work equipment Between (22) and (21) Normal 4.85 – 5.15 V
4
controller
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (14) and (21) operation
Full retraction
3.86 – 4.36 V
operation

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer

WA600-6 41
SEN00571-03 40 Troubleshooting

Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub):

Short circuit with power supply line) 1

Action code Failure code 3-spool valve (attachment) EPC lever potentiometer (Sub): Short
Trouble circuit with power supply line
E03 DK5EKY (Work equipment controller system)
• Due to hot short circuit in the 3-spool (attachment) EPC lever potentiometer (Sub) system, the signal
Contents of
voltage is higher than normal range
trouble
(3-spool valve (attachment) EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the 3-spool valve (attachment) EPC lever potentiometer (Main) is normal, the Main potentiometer
is in control.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until 3-spool valve (attachment) EPC
lever is set to N (Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Main) can be
checked with the monitoring function (Code: 42006 3RD POT1).
• The input state (voltage) from the 3-spool valve (attachment) EPC lever potentiometer (Sub) can be
Related checked with the monitoring function (Code: 42007 3RD POT2).
information • Method of reproducing failure code: Turn the starting switch ON and operate 3-spool valve (attach-
ment) lever
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S16 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Defective 3-spool valve and carry out troubleshooting (work equipment lock)
(attachment) EPC lever
1 3-spool valve
potentiometer (Internal short
Possible causes circuit) S16 (attachment) EPC Voltage
and standard lever
value in normal Between (4) and (1) Normal 4.85 – 5.15 V
state
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (2) and (1) operation
Full retraction
3.86 – 4.36 V
operation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L05 (female) (14) –
2 Voltage Max. 1 V
(Contact with 24 V circuit) S16 (female) (2) and chassis ground
Between L05 (female) (22) – S16 (female)
Voltage Max. 1 V
(4), – circuit branch end and chassis ground

42 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting (work equipment lock)
3-spool valve
Possible causes L05 (attachment) EPC Voltage
and standard lever
value in normal Defective work equipment Between (22) and (21) Normal 4.85 – 5.15 V
3
state controller
Lever in neutral 2.40 – 2.60 V
Full extension
0.64 – 1.14 V
Between (14) and (21) operation
Full retraction
3.86 – 4.36 V
operation

Circuit diagram related to 3-spool valve (attachment) EPC lever potentiometer

WA600-6 43
SEN00571-03 40 Troubleshooting

Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1

Action code Failure code Lift arm angle sensor: Disconnection

Trouble
E01 DKA0KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in lift arm angle sensor system, the signal voltage is lower than
trouble normal range (Lift arm angle sensor signal: Max. 0.3 V).
• Judges that lift arm is at the lowest position.
• Resets the remote positioner function.
• Resets semi auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF.
• If cause of failure disappears, system resets itself.
Problem that • Remote positioner malfunction (operation does not stop)
appears on • Faulty semi-auto digging operation (operation does not start)
machine • No PC control while the lift arm is rising
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
(Code: 06005 BOOM ANG).
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
Defective lift arm angle sen- chassis ground
sor a Prepare with starting switch OFF, then start engine and carry out
1
(Internal disconnection or troubleshooting.
short circuit)
Possible causes F13 Lift arm position Voltage
and standard Between (C) and (A) Normal 4.85 – 5.15 V
value in normal Normal 1.00 – 4.00 V
state
Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between F13 (female) (A) – Resis-
Max. 1 z
ness chassis ground tance
2
(Disconnection in wiring har- Wiring harness between F13 (female) (B) – Resis-
ness and defective contact) Max. 1 z
L05 (female) (8) tance
Wiring harness between F13 (female) (C) – Resis-
Max. 1 z
C01 (female) (16) tance

44 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F13 (female) (B) –
Grounding fault in wiring har- Resis-
L05 (female) (8) or C05 (female) (10) and Min. 1 Mz
3 ness tance
chassis ground
(Contact with ground circuit)
Possible causes Wiring harness between F13 (female) (C) –
and standard Resis-
C01 (female) (16), – circuit branch end and Min. 1 Mz
value in normal tance
chassis ground
state
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.

Defective work equipment L05 Lift arm position Voltage

4
controller Normal 0.83 – 4.17 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

Circuit diagram related to lift arm angle sensor

WA600-6 45
SEN00571-03 40 Troubleshooting

Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1

Action code Failure code Lift arm angle sensor: Out of input signal range
Trouble
E01 DKA0KX (Machine monitor system)
• Due to disconnection or ground fault in lift arm angle sensor system, the signal voltage is not input
Contents of (Lift arm angle sensor signal voltage: Max. 1 V).
trouble • Due to hot short circuit in lift arm angle sensor system, the signal voltage is higher than normal level
(Lift arm angle sensor signal voltage: Min. 4 V).
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
(Code: 06005 BOOM ANG).
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
Defective lift arm angle sen- chassis ground
sor a Prepare with starting switch OFF, then start engine and carry out
1
(Internal disconnection or troubleshooting.
short circuit)
F13 Lift arm position Voltage
Between (C) and (A) Normal 4.85 – 5.15 V
Normal 1.00 – 4.00 V
Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Possible causes
Lower stroke end 1.00 – 1.88 V
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring har- Wiring harness between F13 (female) (A) – Resis-
Max. 1 z
ness chassis ground tance
2
(Disconnection in wiring har- Wiring harness between F13 (female) (B) – Resis-
ness and defective contact) Max. 1 z
L05 (female) (8) or C05 (female) (10) tance
Wiring harness between F13 (female) (C) – Resis-
Max. 1 z
C01 (female) (16) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F13 (female) (B) –
Grounding fault in wiring har- Resis-
L05 (female) (8) or C05 (female) (10) and Min. 1 Mz
3 ness tance
chassis ground
(Contact with ground circuit)
Wiring harness between F13 (female) (C) –
Resis-
C01 (female) (16), – circuit branch end and Min. 1 Mz
tance
chassis ground

46 WA600-6
40 Troubleshooting SEN00571-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between F13 (female) (B) –
4 Voltage Max. 1 V
(Contact with 24 V circuit) L05 (female) (8) or C05 (female) (10)
Possible causes Wiring harness between F13 (female) (C) –
and standard Voltage Max. 1 V
C01 (female) (16), – circuit branch end
value in normal
a Prepare with starting switch OFF, then start engine and carry out
state
troubleshooting.
C05 Lift arm position Voltage
5 Defective machine monitor
Normal 0.83 – 4.17 V
Between (10) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

Circuit diagram related to lift arm angle sensor

WA600-6 47
SEN00571-03 40 Troubleshooting

Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power
supply line) 1

Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
• Due to disconnection or hot short in lift arm angle sensor system, the signal voltage is higher than
Contents of
normal range
trouble
(Lift arm angle sensor signal: Min. 4.7 V).
• Judges that lift arm is at the highest position.
• Resets the remote positioner function.
• Resets semi auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF.
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neutral).
Problem that • Remote positioner malfunction
appears on • Faulty semi-auto digging operation
machine • No PC control while the lift arm is rising
• The input state (angle) from the boom angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
Related
• The input state (voltage) from the boom angle sensor can be checked with the monitoring function
information
(Code: 06005 BOOM ANG).
• Method of reproducing failure code: Turn the starting switch ON

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm angle sen- a Prepare with starting switch OFF, then start engine and carry out
1
sor (Internal short circuit) troubleshooting.
F13 Lift arm position Voltage
Between (C) and (A) Normal 4.85 – 5.15 V
Normal 1.00 – 4.00 V
Possible causes Between (B) and (A) Raise stroke end 3.50 – 4.00 V
and standard Lower stroke end 1.00 – 1.88 V
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between F13 (female) (B) –
Hot short in wiring harness L05 (female) (8) or C05 (female) (10) and Voltage Max. 1 V
2
(Contact with 24 V circuit) chassis ground
Wiring harness between F13 (female) (C) –
C01 (female) (16), – circuit branch end and Voltage Max. 1 V
chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.

Defective work equipment L05 Lift arm position Voltage

3
controller Normal 0.83 – 4.17 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

48 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to lift arm angle sensor

WA600-6 49
SEN00571-03 40 Troubleshooting

Failure code [DKA0L0] (Lift arm angle sensor: Improper position) 1

Action code Failure code Lift arm angle sensor: Improper position
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly.
trouble (Lift arm angle upper limit +5° and above or lift arm angle lower limit +5° or above)
• Resets the remote positioner function.
• Resets semi auto digging function.
• No PC control while the lift arm is rising.
Action of
• When the remote positioner lower setting is ON, turns OFF the lift arm float detent, and when the
controller
remote positioner lower setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm raise detent OFF
• If cause of failure disappears, system resets itself.
Problem that • Remote positioner malfunction (operation does not stop)
appears on • Faulty semi-auto digging operation (operation does not start)
machine • Faulty PC control operation when boom rises
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002 BOOM ANG).
Related • The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
information (Code: 06005 BOOM ANG).
• Method of reproducing failure code: Start engine and set the lift arm to raise or lower stroke end
• This error may be displayed when boom angle sensor is initialized wrongly.

Cause Standard value in normal state/Remarks on troubleshooting

Defective lift arm angle sen- a Adjustment of lift arm angle sensor may be defective. Check it
1
sor adjustment directly (see “Testing and adjusting“).
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
F13 (male) Resistance
Between (A) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
Defective lift arm angle sen- a Prepare with starting switch OFF, then start engine and carry out
2
Possible causes sor (Internal short circuit) troubleshooting.
and standard
value in normal F13 Lift arm position Voltage
state Between (C) and (A) Normal 4.85 – 5.15 V
Normal 1.00 – 4.00 V
Between (B) and (A) Raise stroke end 3.50 – 4.00 V
Lower stroke end 1.00 – 1.88 V
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.

Defective work equipment L05 Lift arm position Voltage

3
controller Normal 0.83 – 4.17 V
Between (8) and
Raise stroke end 3.50 – 4.00 V
chassis ground
Lower stroke end 1.00 – 1.88 V

50 WA600-6
40 Troubleshooting SEN00571-03

Circuit diagram related to lift arm angle sensor

WA600-6 51
SEN00571-03

WA600-6 Wheel loader

Form No. SEN00571-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

52
 SEN00572-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 9
Failure code [DKD0KA] (Frame angle sensor: Disconnection)....................................................................... 4
Failure code [DKD0KY] (Frame angle sensor: Short circuit with power supply line) ...................................... 6
Failure code [DKD0KZ] (AJSS lever and frame angle sensor: Disconnection or short circuit) ....................... 8
Failure code [DLFAKA] (Modulation clutch output shaft speed sensor: Disconnection) ............................... 10
Failure code [DLFALC] (Modulation clutch output shaft speed sensor: Speed signals disagree)................. 12
Failure code [DLT3KA] (Transmission output shaft speed sensor (2): Disconnection) ................................. 14
Failure code [DLT3LC] (Transmission output shaft speed sensor (2): Speed signals disagree) .................. 16
Failure code [DLT4KB] (Transmission output shaft speed sensor (1): Short circuit)..................................... 18
Failure code [DLT4KX] (Transmission output shaft speed sensor (1): Out of input signal range) ................ 20
Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short circuit) .......................................... 22
Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short circuit).......................................... 24
Failure code [DV00KB] (Alarm buzzer: Short circuit) .................................................................................... 26
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ........................................................ 28
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ............................................................ 29

WA600-6 1
SEN00572-03 40 Troubleshooting

Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ........................ 30
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ....................................................... 32
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ........................................................... 33
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ....................... 34
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).............................................................. 36
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ................................................................. 37
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ............................. 38
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) ........................................................ 40
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ............................................................ 41
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)........................ 42
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)................................................................... 44
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ...................................................................... 46
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .................................. 48
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)............................................ 50
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) ............................................... 50
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) ........... 51

2 WA600-6
40 Troubleshooting SEN00572-03

WA600-6 3
SEN00572-03 40 Troubleshooting

Failure code [DKD0KA] (Frame angle sensor: Disconnection) 1

Action code Failure code Frame angle sensor: Disconnection

Trouble
E01 DKD0KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in frame angle sensor system, the frame angle sensor signal
trouble voltage is outside the lower limit (frame angle sensor signal: Max. 0.3 V).
• Stops the AJSS neutral safety function.
Action of
• Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
controller
• If cause of failure disappears, system resets itself.
• The engine can be started while AJSS lever is operated (The machine turns just after engine is
Problem that
started).
appears on
• Steering fine control is not possible (the machine jounces when performing steering operation).
machine
• The winker cannot be automatically reset.
• The input state (angle) from the frame angle sensor can be checked with the monitoring function
(Code: 94400 FRAME ANGLE).
Related • AJSS (if equipped) specification only
information • Method of reproducing failure code: Turn the starting switch ON.
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L12 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground

Defective frame angle sensor a Prepare with starting switch OFF, then start engine and carry out
1 (Internal disconnection or troubleshooting.
short circuit) L12 Frame Voltage
Between (B) and (C) Normal 4.85 – 5.15 V
Normal 0.46 – 4.54 V
While machine is
2.20 – 2.80 V
Between (A) and (C) traveling straight
Possible causes
and standard Full steering to right 0.46 – 1.46 V
value in normal Full steering to left 3.54 – 4.54 V
state
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L05 (3) – L12 Resis-
Disconnection in wiring harness (female) (A) Max. 1 z
tance
2 (Disconnection in wiring har-
ness and defective contact) Wiring harness between L05 (21) – L12 Resis-
Max. 1 z
(female) (C) tance
Wiring harness between L05 (22) – F12 Resis-
Max. 1 z
(female) (B) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between L05 (3) – L12 Resis-
Min. 1 Mz
3 harness (female) (A) and chassis ground tance
(Contact with ground circuit) Wiring harness between L05 (22) – L12
Resis-
(female) (B), – circuit branch and chassis Min. 1 Mz
tance
ground

4 WA600-6
40 Troubleshooting SEN00572-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L05 Frame position Voltage
Possible causes
and standard Between (22) and (21) Normal 4.85 – 5.15 V
value in normal Defective work equipment
4 Normal 0.46 – 4.54 V
state controller
While machine is
2.20 – 2.80 V
Between (3) and (21) traveling straight
Full steering to right 0.46 – 1.46 V
Full steering to left 3.54 – 4.54 V

Circuit diagram related to frame angle sensor

WA600-6 5
SEN00572-03 40 Troubleshooting

Failure code [DKD0KY] (Frame angle sensor: Short circuit with power
supply line) 1

Action code Failure code Frame angle sensor: Short circuit with power supply line
Trouble
E01 DKD0KY (Work equipment controller system)
Contents of • Due to hot short circuit in frame angle sensor system, the frame angle sensor signal voltage is out-
trouble side the higher limit (frame angle sensor signal: Max. 4.7 V).
• Stops the AJSS neutral safety function.
Action of
• Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
controller
• If cause of failure disappears, system resets itself.
• The engine can be started while AJSS lever is operated (The machine turns just after engine is
Problem that
started).
appears on
• Steering fine control is not possible (the machine jounces when performing steering operation).
machine
• The winker cannot be automatically reset.
• The input state (angle) from the frame angle sensor can be checked with the monitoring function
(Code: 94400 FRAME ANGLE).
Related • AJSS (if equipped) specification only
information • Method of reproducing failure code: Turn the starting switch ON.
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L12 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then start engine and carry out
Defective frame angle sensor troubleshooting.
1
(Internal short circuit)
L12 Frame Voltage
Possible causes
Between (B) and (C) Normal 4.85 – 5.15 V
and standard
value in normal Normal 0.46 – 4.54 V
state While machine is
2.20 – 2.80 V
Between (A) and (C) traveling straight
Full steering to right 0.46 – 1.46 V
Full steering to left 3.54 – 4.54 V
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L05 (3) – L12
Hot short in wiring harness Voltage Max. 1 V
2 (female) (A) and chassis ground
(Contact with 24 V circuit)
Wiring harness between L05 (22) – L12
(female) (B), – circuit branch and chassis Voltage Max. 1 V
ground

6 WA600-6
40 Troubleshooting SEN00572-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L05 Frame position Voltage
Possible causes
and standard Between (22) and (21) Normal 4.85 – 5.15 V
value in normal Defective work equipment
3 Normal 0.46 – 4.54 V
state controller
While machine is
2.20 – 2.80 V
Between (3) and (21) traveling straight
Full steering to right 0.46 – 1.46 V
Full steering to left 3.54 – 4.54 V

Circuit diagram related to frame angle sensor

WA600-6 7
SEN00572-03 40 Troubleshooting

Failure code [DKD0KZ] (AJSS lever and frame angle sensor:

Disconnection or short circuit) 1

Action code Failure code AJSS angle sensor & frame angle sensor: Disconnection or short circuit)
Trouble
E01 DKD0KZ (Work equipment controller system)
Contents of • Due to displacement of the AJSS lever angle sensor and frame angle sensor, the AJSS lever posi-
trouble tion cannot be detected normally (steering deviation angle: Min. +25°).
• Cannot recognize the ADJSS lever position correctly.
Action of • Stops the AJSS neutral safety function.
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
• If cause of failure disappears, system resets itself.
• The engine can start even when the AJSS lever is not in neutral (the machine turns immediately after
Problem that the engine starts).
appears on • The engine cannot start when the AJSS lever is in neutral.
machine • Steering speed is different according to the steering direction, to the right or to the left.
• The winker cannot be automatically reset.
• The input state (angle) from the AJSS lever angle sensor can be checked with the monitoring func-
tion (Code: 94300 AJSS LEVER, Code: 94301 AJSS LEVER).
• The input state (angle) from the frame angle sensor can be checked with the monitoring function
(Code: 94400 FRAME ANGLE, Code: 94401 FRAME ANGLE).
Related • The steering deviation angle can be checked with the monitoring function (Code: 94800 STEERING
information DEFLECTION).
• AJSS (if equipped) specification only
• Method of reproducing failure code: Turn the starting switch ON.
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective frame angle sensor a The frame angle sensor adjustment may be defective. Check it
1
adjustment directly. (See Testing and adjusting.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L12 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and chassis ground Min. 1 Mz
Defective frame angle sensor a Prepare with starting switch OFF, then start engine and carry out
2 (Internal disconnection or troubleshooting.
short circuit) L12 Frame Voltage
Between (B) and (C) Normal 4.85 – 5.15 V
Normal 0.46 – 4.54 V
Lever in neutral 0.46 – 4.54 V
Possible causes Between (A) and (C)
Full steering to right 0.46 – 1.46 V
and standard
value in normal Full steering to left 3.54 – 4.54 V
state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S30 (male) Resistance
Between (B) and (C) 5 kz ± 20 %
Between (A), (B), (C) and chassis ground Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON
Defective AJSS angle sensor and carry out troubleshooting (steering lock)
3 (Internal disconnection or S30 AJSS lever Voltage
short circuit) Between (B) and (C) Normal 4.85 – 5.15 V
Normal 0.30 – 4.70 V
Lever in neutral 2.20 – 2.80 V
Between (A) and (C) Full steering to right
2.83 – 3.83 V
(straight travel)
Full steering to left
1.17 – 2.17 V
(straight travel)

8 WA600-6
40 Troubleshooting SEN00572-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L05 Frame Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Normal 0.46 – 4.54 V
When lever is in
2.20 – 2.80 V
Between (3) and (21) neutral
Full steering to right 0.46 – 1.46 V
Possible causes
Full steering to left 3.54 – 4.54 V
and standard
value in normal 4
Defective work equipment a Prepare with starting switch OFF, then turn starting switch ON
state controller and carry out troubleshooting (steering lock)
L05 AJSS lever Voltage
Between (22) and (21) Normal 4.85 – 5.15 V
Normal 0.30 – 4.70 V
When lever is in
2.20 – 2.80 V
neutral
Between (9) and (21) Full steering to right
2.83 – 3.83 V
(straight travel)
Full steering to left
1.17 – 2.17 V
(straight travel)

Circuit diagram related to AJSS lever angle sensor and frame angle sensor

WA600-6 9
SEN00572-03 40 Troubleshooting

Failure code [DLFAKA] (Modulation clutch output shaft speed sensor:

Disconnection) 1

Action code Failure code Modulation clutch output shaft speed sensor: Disconnection
Trouble
E03 DLFAKA (Transmission controller system)
• Due to disconnection or hot short circuit in the modulation clutch output shaft speed sensor system,
Contents of the modulation clutch output shaft speed sensor signal voltage is outside the higher limit.
trouble (Modulation clutch output shaft speed sensor signal voltage: Min. 1.5 V)
• Signal from the modulation clutch output shaft speed sensor is 0 rpm.
• Uses modulation clutch output immediately before abnormality occurs.
• Stops modulation clutch control with the directional lever or directional selector switch in N (Neutral),
Action of
and directly connect the modulation clutch.
controller
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• The modulation clutch is directly connected once the directional lever or directional selector switch is
appears on
placed in N (Neutral).
machine
Related
• Method of reproducing failure code: Engine started + Travel
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective modulation clutch
a The modulation clutch output shaft speed sensor adjustment may
1 output shaft speed sensor
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch
output shaft speed sensor MOD OUT (male) Resistance
2
(Internal disconnection or Between (1) and (2) 500 – 1,000 z
short circuit)
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L03 (female) (29) – Resis-
3 Max. 1 z
value in normal (Disconnection in wiring har- MOD OUT (female) (2) tance
state ness and defective contact) Wiring harness between L03 (female) (30) – Resis-
Max. 1 z
MOD OUT (female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between L03 (female) (30) –
Voltage Max. 1 V
MOD OUT (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 (female) Resistance
5
troller Between (29) and (30) 500 – 1,000 z
Between (29), (30) and
Min. 1 Mz
chassis ground

10 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to modulation clutch output shaft speed sensor

WA600-6 11
SEN00572-03 40 Troubleshooting

Failure code [DLFALC] (Modulation clutch output shaft speed sensor:

Speed signals disagree) 1

Action code Failure code Modulation clutch output shaft speed sensor: Speed signals dis-
Trouble agree
E03 DLFALC (Transmission controller system)
• Due to ground fault in the modulation clutch output shaft speed sensor, the modulation clutch output
shaft speed sensor signal voltage is outside the lower limit.
• This failure code appears under the following conditions.
Contents of
1) Engine speed: Min. 700 rpm
trouble
2) Modulation clutch pressure: Min. 2 MPa {19.6 kg/cm2}
3) Modulation clutch speed: 0 rpm
4) Modulation clutch speed sensor signal line: Disconnection is not detected
• Uses modulation clutch output immediately before abnormality occurs.
• Stops modulation clutch control with the directional lever or directional selector switch in N (Neutral),
Action of
and directly connect the modulation clutch.
controller
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• The modulation clutch is directly connected once the directional lever or directional selector switch is
appears on
placed in N (Neutral).
machine
Related
• Method of reproducing failure code: Engine started + Travel
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective modulation clutch
a The modulation clutch output shaft speed sensor adjustment may
1 output shaft speed sensor
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch MOD OUT (male) Resistance
2 output shaft speed sensor
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
Possible causes Between (1), (2) and
Min. 1 Mz
and standard chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between L03 (female) (30) – Resis-
Min. 1 Mz
MOD OUT (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 (female) Resistance
4
troller Between (29) and (30) 500 – 1,000 z
Between (29), (30) and
Min. 1 Mz
chassis ground

12 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to modulation clutch output shaft speed sensor

WA600-6 13
SEN00572-03 40 Troubleshooting

Failure code [DLT3KA] (Transmission output shaft speed sensor (2):

Disconnection) 1

Action code Failure code Transmission output shaft speed sensor (2): Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor (2), the trans-
Contents of mission output shaft speed sensor (2) signal voltage is outside the higher limit.
trouble (Transmission output shaft speed sensor (2) signal: Min. 1.5 V)
• Signal from the transmission output shaft speed sensor is 0 rpm.
• When the transmission output shaft speed sensor (1) is normal: Performs control by the transmission
output shaft speed sensor (1).
• When abnormality (DLT4KB, DLT4KX) detection conditions excluding the detection time of the trans-
mission output shaft speed sensor (1) are detected:
Action of
1) In the auto-shift mode, change the shift mode to the manual mode.
controller
2) In the auto-shift mode, change the mode for transmitting signal to the machine monitor to the man-
ual mode.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
• The input state (speed) from the transmission output shaft speed sensor (1) can be checked with the
monitoring function (Code: 31400 T/M SPEED OUT).
Related
• The input state (speed) from the transmission output shaft speed sensor (2) can be checked with the
information
monitoring function (Code: 31404 T/M SPEED OUT2).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission out-
a The transmission output shaft speed sensor (2) adjustment may
1 put shaft speed sensor (2)
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission out-
put shaft speed sensor (2) REV OUT2 (male) Resistance
2
(Internal disconnection or Between (1) and (2) 500 – 1,000 z
short circuit)
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L03 (female) (39) – Resis-
3 Max. 1 z
value in normal (Disconnection in wiring har- REV OUT2 (female) (2) tance
state ness and defective contact) Wiring harness between L03 (female) (40) – Resis-
Max. 1 z
REV OUT2 (female) (1) tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between L03 (female) (40) –
Voltage Max. 1 V
REV OUT2 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 Resistance
5
troller Between (39) and (40) 500 – 1,000 z
Between (39), (40) and
Min. 1 Mz
chassis ground

14 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to transmission output shaft speed sensor (2)

WA600-6 15
SEN00572-03 40 Troubleshooting

Failure code [DLT3LC] (Transmission output shaft speed sensor (2):

Speed signals disagree) 1

Action code Failure code Transmission output shaft speed sensor (2): Speed signals disagree
Trouble
E03 DLT3LC (Transmission controller system)
• Due to ground fault in the transmission output shaft speed sensor (2), the transmission output shaft
speed sensor (2) signal voltage is outside the lower limit.
Contents of • This failure code appears under the following conditions.
trouble 1) Transmission output shaft speed sensor (1): Min. 200 rpm
2) Transmission output shaft speed sensor (2): 0 rpm
3) Transmission clutch speed sensor (2) signal line: Disconnection is not detected.
• When the transmission output shaft speed sensor (1) is normal: Performs control by the transmission
output shaft speed sensor (1).
• When abnormality (DLT4KB, DLT4KX) detection conditions excluding the detection time of the trans-
mission output shaft speed sensor (1) are detected:
Action of
1) In the auto-shift mode, change the shift mode to the manual mode.
controller
2) In the auto-shift mode, change the mode for transmitting signal to the machine monitor to the man-
ual mode.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
• The input state (speed) from the transmission output shaft speed sensor (1) can be checked with the
monitoring function (Code: 31400 T/M SPEED OUT).
Related
• The input state (speed) from the transmission output shaft speed sensor (2) can be checked with the
information
monitoring function (Code: 31404 T/M SPEED OUT2).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission out-
a The transmission output shaft speed sensor (2) adjustment may
1 put shaft speed sensor (2)
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission out- REV OUT2 (male) Resistance
2 put shaft speed sensor (2)
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
Possible causes Between (1), (2) and
Min. 1 Mz
and standard chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between L03 (female) (40) – Resis-
Min. 1 Mz
REV OUT2 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 Resistance
4
troller Between (39) and (40) 500 – 1,000 z
Between (39), (40) and
Min. 1 Mz
chassis ground

16 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to transmission output shaft speed sensor (2)

WA600-6 17
SEN00572-03 40 Troubleshooting

Failure code [DLT4KB] (Transmission output shaft speed sensor (1):

Short circuit) 1

Action code Failure code Transmission output shaft speed sensor (1): Short circuit
Trouble
E03 DLT4KB (Transmission controller system)
• Due to ground fault in the transmission output shaft speed sensor (1), the transmission output shaft
speed sensor (1) signal voltage is outside the lower limit.
Contents of • This failure code appears under the following conditions.
trouble 1) Transmission output shaft speed sensor (1): Min. 200 rpm
2) Transmission output shaft speed sensor (2): 0 rpm
3) Transmission clutch speed sensor (2) signal line: Disconnection is not detected.
• When the transmission output shaft speed sensor (2) is normal: Performs control by the transmission
output shaft speed sensor (2).
• When abnormality (DLT3KA, DLT3LC) detection conditions excluding the detection time of the trans-
mission output shaft speed sensor (2) are detected:
Action of
1) In the auto-shift mode, change the shift mode to the manual mode.
controller
2) In the auto-shift mode, change the mode for transmitting signal to the machine monitor to the man-
ual mode.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
• The input state (speed) from the transmission output shaft speed sensor (1) can be checked with the
monitoring function (Code: 31400 T/M SPEED OUT).
Related
• The input state (speed) from the transmission output shaft speed sensor (2) can be checked with the
information
monitoring function (Code: 31404 T/M SPEED OUT2).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission out-
a The transmission output shaft speed sensor (1) adjustment may
1 put shaft speed sensor (1)
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission out- REV OUT1 (male) Resistance
2 put shaft speed sensor (1)
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
Possible causes Between (1), (2) and
Min. 1 Mz
and standard chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between L03 (female) (20) – Resis-
Min. 1 Mz
REV OUT1 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 Resistance
4
troller Between (20) and (29) 500 – 1,000 z
Between (20), (29) and
Min. 1 Mz
chassis ground

18 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to transmission output shaft speed sensor (1)

WA600-6 19
SEN00572-03 40 Troubleshooting

Failure code [DLT4KX] (Transmission output shaft speed sensor (1):

Out of input signal range) 1

Action code Failure code Transmission output shaft speed sensor (1): Out of input signal
Trouble range
E03 DLT4KX (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor (1), the trans-
Contents of mission output shaft speed sensor (1) signal voltage is outside the higher limit.
trouble (Transmission output shaft speed sensor (1) signal: Min. 1.5 V)
• Signal from the transmission output shaft speed sensor is 0 rpm.
• When the transmission output shaft speed sensor (2) is normal: Performs control by the transmission
output shaft speed sensor (2).
• When abnormality (DLT3KA, DLT3LC) detection conditions excluding the detection time of the trans-
mission output shaft speed sensor (2) are detected:
Action of
1) In the auto-shift mode, change the shift mode to the manual mode.
controller
2) In the auto-shift mode, change the mode for transmitting signal to the machine monitor to the man-
ual mode.
• If cause of failure disappears, system resets itself.
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
• The input state (speed) from the transmission output shaft speed sensor (1) can be checked with the
monitoring function (Code: 31400 T/M SPEED OUT).
Related
• The input state (speed) from the transmission output shaft speed sensor (2) can be checked with the
information
monitoring function (Code: 31404 T/M SPEED OUT2).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

Defective transmission out-
a The transmission output shaft speed sensor (1) adjustment may
1 put shaft speed sensor (1)
be defective. Check it directly (see Testing and adjusting).
adjustment
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission out-
put shaft speed sensor (1) REV OUT1 (male) Resistance
2
(Internal disconnection or Between (1) and (2) 500 – 1,000 z
short circuit)
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L03 (female) (20) – Resis-
3 Max. 1 z
value in normal (Disconnection in wiring har- REV OUT1 (female) (1) tance
state ness and defective contact) Wiring harness between L03 (female) (29) – Resis-
Max. 1 z
REV OUT1 (female) (2) tance
a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness and carry out troubleshooting
4
(Contact with 24 V circuit) Wiring harness between L03 (female) (20) –
Voltage Max. 1 V
REV OUT1 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L03 Resistance
5
troller Between (20) and (29) 500 – 1,000 z
Between (20), (29) and
Min. 1 Mz
chassis ground

20 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to transmission output shaft speed sensor (1)

WA600-6 21
SEN00572-03 40 Troubleshooting

Failure code [DUM1KB] (Remote positioner raise indicator lamp: Short

circuit) 1

Action code Failure code Remote positioner raise indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise indicator lamp system is shorted with the chassis ground, the sig-
trouble nal is not output to the indicator lamp.
Action of • Turns off the remote positioner raise indicator output.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The remote positioner raise indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise lamp can be checked with the monitoring
Related
function (Code: 40954 D-OUT-18).
information
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (See inspection procedure for
Defective remote positioner diode)
raise indicator lamp (light- S14 (male) Resistance
1
emitting diode)
(Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Between (1), (2) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L07 (female) (8) – Resis-
Min. 1 Mz
S14 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment Remote positioner
3 L07 Voltage
controller raise
Between (8) and When used 20 – 30 V
chassis ground When not used Max. 1 V

22 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to remote positioner raise/lower indicator lamp

WA600-6 23
SEN00572-03 40 Troubleshooting

Failure code [DUM2KB] (Remote positioner lower indicator lamp: Short

circuit) 1

Action code Failure code Remote positioner lower indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower indicator lamp system is shorted with the chassis ground, the sig-
trouble nal is not output to the indicator lamp.
Action of • Turns off the remote positioner lower indicator output.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The remote positioner lower indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower lamp can be checked with the monitoring
Related
function (Code: 40954 D-OUT-19).
information
• Method of reproducing failure code: Engine started + lift arm lower

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (See inspection procedure for
Defective remote positioner diode)
lower indicator lamp (light- S14 (male) Resistance
1
emitting diode)
(Internal short circuit) Between (2) and (3) Min. 1 Mz (No continuity)
Between (2), (3) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L07 (female) (18) – Resis-
Min. 1 Mz
S14 (female) (3) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment Remote positioner
3 L07 Voltage
controller raise
Between (18) and When used 20 – 30 V
chassis ground When not used Max. 1 V

24 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to remote positioner raise/lower indicator lamp

WA600-6 25
SEN00572-03 40 Troubleshooting

Failure code [DV00KB] (Alarm buzzer: Short circuit) 1

Action code Failure code Alarm buzzer: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power supply line.
trouble
Action of • Stops alarm buzzer output.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function
Related
(Code: 40952, D-OUT-0).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L20 (female) Starting switch Voltage
Between (1) and
ON 20 – 30 V
chassis ground
Defective alarm buzzer
1 For 2 sec after ON
(Internal short circuit) 20 – 30 V
(Alarm buzzer sounds)

Between (1) and (2) For 3 sec from 2 sec

after ON
Max. 1 V
(Alarm buzzer does
Possible causes not sound)
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short in wiring harness and carry out troubleshooting
state 2
(Contact with 24 V circuit) Wiring harness between C01 (female) (14) –
Voltage Max. 1 V
L20 (female) (2) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C01 Starting switch Voltage
ON 20 – 30 V
3 Defective machine monitor For 2 sec after ON
Max. 1 V
(Alarm buzzer sounds)
Between (14) and
chassis ground For 3 sec from 2 sec
after ON
20 – 30 V
(Alarm buzzer does
not sound)

26 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to alarm buzzer

WA600-6 27
SEN00572-03 40 Troubleshooting

Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1

Action code Failure code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm raise EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
Related
tion (Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm raise EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
F07 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (6) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F07 (female) (1) tance
ness and defective contact) Wiring harness between L07 (female) (3) – Resis-
Max. 1 z
F07 (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (6) and (3) 5 – 15 z

Circuit diagram related to lift arm raise EPC solenoid

28 WA600-6
40 Troubleshooting SEN00572-03

Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1

Action code Failure code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm raise EPC solenoid output was ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • Lift arm does not rise
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
Related
tion (Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise EPC F07 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (6) – Resis-
Min. 1 Mz
F07 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (6) and (3) 5 – 15 z
Between (6), (3) and
Min. 1 Mz
chassis ground

Circuit diagram related to lift arm raise EPC solenoid

WA600-6 29
SEN00572-03 40 Troubleshooting

Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
power supply line) 1

Action code Failure code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm raise EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
• When work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm raise EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
tion (Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise EPC F07 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (6) –
Voltage Max. 1 V
F07 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (6) and (3) 5 – 15 z
Between (6), (3) and
Min. 1 Mz
chassis ground

30 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to lift arm raise EPC solenoid

WA600-6 31
SEN00572-03 40 Troubleshooting

Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1

Action code Failure code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm lower EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
Related
function (Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm lower EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
F08 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (16) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F08 (female) (1) tance
ness and defective contact) Wiring harness between L07 (female) (3) – Resis-
Max. 1 z
F08 (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (16) and (3) 5 – 15 z

Circuit diagram related to lift arm lower EPC solenoid

32 WA600-6
40 Troubleshooting SEN00572-03

Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1

Action code Failure code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the lift arm lower EPC solenoid output was ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float magnet detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
Related
function (Code: 41901 LOWER EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm lower

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm lower EPC F08 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (16) – Resis-
Min. 1 Mz
F08 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (16) and (3) 5 – 15 z
Between (16), (3) and
Min. 1 Mz
chassis ground

Circuit diagram related to lift arm lower EPC solenoid

WA600-6 33
SEN00572-03 40 Troubleshooting

Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
power supply line) 1

Action code Failure code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the lift arm lower EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
• When work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
tion (Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm lower EPC F08 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (16) –
Voltage Max. 1 V
F08 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (16) and (3) 5 – 15 z
Between (16), (3) and
Min. 1 Mz
chassis ground

34 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to lift arm lower EPC solenoid

WA600-6 35
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Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1

Action code Failure code Bucket tilt EPC solenoid: Disconnection

Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid output signal output signal system is disconnected, no current
trouble flows when the bucket tilt EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Bucket does not tilt.
machine
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
Related
(Code: 41902 TILT EPC DIR).
information
• Method of reproducing failure code: Engine started + bucket tilt

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket tilt EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
F09 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (5) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F09 (female) (1) tance
ness and defective contact) Wiring harness between L07 (female) (13) – Resis-
Max. 1 z
F09 (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (5) and (13) 5 – 15 z

Circuit diagram related to bucket tilt EPC solenoid

36 WA600-6
40 Troubleshooting SEN00572-03

Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1

Action code Failure code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the chassis ground, abnormal cur-
trouble rent flowed when the bucket tilt EPC solenoid output was ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
• Bucket does not tilt.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
Related
(Code: 41902 TILT EPC DIR).
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt EPC F09 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (5) – Resis-
Min. 1 Mz
F09 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (5) and (13) 5 – 15 z
Between (5), (13) and
Min. 1 Mz
chassis ground

Circuit diagram related to bucket tilt EPC solenoid

WA600-6 37
SEN00572-03 40 Troubleshooting

Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
power supply line) 1

Action code Failure code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system was shorted with the power source, abnormal volt-
trouble age was applied when the bucket tilt EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
tion (Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt EPC F09 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (5) –
Voltage Max. 1 V
F09 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (5) and (13) 5 – 15 z
Between (5), (13) and
Min. 1 Mz
chassis ground

38 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to bucket tilt EPC solenoid

WA600-6 39
SEN00572-03 40 Troubleshooting

Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1

Action code Failure code Bucket dump EPC solenoid: Disconnection

Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when
trouble the bucket dump EPC solenoid output is ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Bucket does not dump.
machine
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
Related
function (Code: 41903 DUMP EPC DIR).
information
• Method of reproducing failure code: Engine started + bucket dump

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket dump EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
F10 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (15) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F10 (female) (1) tance
ness and defective contact) Wiring harness between L07 (female) (13) – Resis-
Max. 1 z
F10 (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (15) and (13) 5 – 15 z

Circuit diagram related to bucket dump EPC solenoid

40 WA600-6
40 Troubleshooting SEN00572-03

Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1

Action code Failure code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the bucket dump EPC solenoid output was ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• If cause of failure disappears, system resets itself.
Problem that
• Bucket does not dump.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
Related
function (Code: 41903 DUMP EPC DIR).
information
• Method of reproducing failure code: Start engine and dump the bucket.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket dump EPC F10 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (15) – Resis-
Min. 1 Mz
F10 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (15) and (13) 5 – 15 z
Between (15), (13) and
Min. 1 Mz
chassis ground

Circuit diagram related to bucket dump EPC solenoid

WA600-6 41
SEN00572-03 40 Troubleshooting

Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
power supply line) 1

Action code Failure code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the bucket dump EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• If cause of failure disappears, system resets itself.
Problem that
• When work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
• The output state (current) to the lift arm raise EPC solenoid can be checked with the monitoring func-
tion (Code: 41900 RAISE EPC DIR).
• The output state (current) to the lift arm lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
• The output state (current) to the bucket tilt EPC solenoid can be checked with the monitoring function
(Code: 41902 TILT EPC DIR).
Related
• The output state (current) to the bucket dump EPC solenoid can be checked with the monitoring
information
function (Code: 41903 DUMP EPC DIR).
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket dump EPC F10 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (15) –
Voltage Max. 1 V
F10 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (15) and (13) 5 – 15 z
Between (15), (13) and
Min. 1 Mz
chassis ground

42 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to bucket dump EPC solenoid

WA600-6 43
SEN00572-03 40 Troubleshooting

Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1

Action code Failure code Fan reverse solenoid: Disconnection

Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse sole-
trouble noid output is ON.
Action of • Disables the automatic fan reverse function (if equipped).
controller • If cause of failure disappears, system resets itself.
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function
appears on
(if equipped) specification.
machine
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective fan reverse sole- without turning starting switch ON.
1 noid
G07 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L04 (female) (37) – Resis-
value in normal 2 Max. 1 z
(Disconnection or defective G07 (female) (1) tance
state contact of connector) Wiring harness between G07 (female) (2) Resis-
Max. 1 z
and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con-
3 L04 (female) Resistance
troller
Between (37) and
35 – 45 z
chassis ground

44 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to fan reverse solenoid

WA600-6 45
SEN00572-03 40 Troubleshooting

Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1

Action code Failure code Fan reverse solenoid: Short circuit

Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system was short circuited, abnormal current flowed when the fan
trouble reverse solenoid output was ON.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (if equipped).
controller
• If cause of failure disappears, system resets itself.
Problem that • The fan cannot turn in reverse by operating the fan reverse switch.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function
machine (if equipped) specification.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse sole- G07 (male) Resistance
1 noid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L04 (female) (37) – Resis-
Min. 1 Mz
G07 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con-
3 L04 (female) Resistance
troller
Between (37) and
35 – 45 z
chassis ground

46 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to fan reverse solenoid

WA600-6 47
SEN00572-03 40 Troubleshooting

Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power
supply line) 1

Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan reverse switch output was OFF.
Action of • Disables the automatic fan reverse function (if equipped).
controller • If cause of failure disappears, system resets itself.
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function
appears on
(if equipped) specification.
machine
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan reverse sole- G07 (male) Resistance
1 noid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short in wiring harness and carry out troubleshooting
state 2
(Contact with 24 V circuit) Wiring harness between L04 (female) (37) –
Voltage Max. 1 V
G07 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con-
3 L04 (female) Resistance
troller
Between (37) and
35 – 45 z
chassis ground

48 WA600-6
40 Troubleshooting SEN00572-03

Circuit diagram related to fan reverse solenoid

WA600-6 49
SEN00572-03 40 Troubleshooting

Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid:

Disconnection) 1

Action code Failure code Hydraulic drive fan neutral solenoid: Disconnection
Trouble
E01 DW7DKA (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA600-6.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Optional setting may be improper.
value in normal 1 Referring to “11. Optional device selecting function” in “Special functions of machine monitor
state (EMMS)” in “Testing and adjusting”, check that AUTO RE FAN is set to “NO ADD”.

Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short

circuit) 1

Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit
Trouble
E01 DW7DKB (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA600-6.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Optional setting may be improper.
value in normal 1 Referring to “11. Optional device selecting function” in “Special functions of machine monitor
state (EMMS)” in “Testing and adjusting”, check that AUTO RE FAN is set to “NO ADD”.

50 WA600-6
40 Troubleshooting SEN00572-03

Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short

circuit with power supply line) 1

Action code Failure code Hydraulic drive fan neutral solenoid: Short circuit with power supply
Trouble line
E01 DW7DKY (Transmission controller system)
Contents of
• A hydraulic drive fan neutral solenoid error was detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on —
machine
Related
• The hydraulic drive fan neutral solenoid is not set in WA600-6.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Optional setting may be improper.
value in normal 1 Referring to “11. Optional device selecting function” in “Special functions of machine monitor
state (EMMS)” in “Testing and adjusting”, check that AUTO RE FAN is set to “NO ADD”.

WA600-6 51
SEN00572-03

WA600-6 Wheel loader

Form No. SEN00572-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

52
 SEN00573-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 10
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection).......................................... 4
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ............................................. 6
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) ......... 8
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)......................................... 10
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ............................................ 12
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) ........ 14
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).......................................... 16
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ............................................. 18
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) ......... 20
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection).............................................. 22
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ................................................. 24
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) .................... 26
Failure code [DWNFKA] (Modulation clutch cut-off release solenoid: Disconnection).................................. 28
Failure code [DWNFKB] (Modulation clutch cut-off release solenoid: Short circuit) ..................................... 30

WA600-6 1
SEN00573-03 40 Troubleshooting

Failure code [DWNFKY] (Modulation clutch cut-off release solenoid:

Short circuit with power source line) ......................................................................................................... 32
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)............................................................... 34
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) .................................................................. 35
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) .............................. 36
Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection)............................................................... 37
Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) .................................................................. 38
Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection)...................................................................... 39
Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit) ......................................................................... 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)................................................................ 41
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ................................................................... 42
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ............................... 44
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ............................................................ 46
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)................................................................ 48
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ........................... 50

2 WA600-6
40 Troubleshooting SEN00573-03

WA600-6 3
SEN00573-03 40 Troubleshooting

Failure code [DWM1KA] (Work equipment neutral lock solenoid:

Disconnection) 1

Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to the work equipment EPC solenoid according to an input signal from the
Action of
work equipment lock lever.
controller
• If cause of failure disappears, system resets itself.
Problem that
• Each work equipment EPC solenoid lock normally works according to an input signal from the work
appears on
equipment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
1 neutral lock solenoid
B02 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (7) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- B02 (female) (1) tance
ness and defective contact) Wiring harness between B02 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 z

4 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to work equipment neutral lock solenoid

WA600-6 5
SEN00573-03 40 Troubleshooting

Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short

circuit) 1

Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the chassis ground, abnor-
trouble mal current flowed when the work equipment neutral lock solenoid output was ON.
• Stops outputting the signal to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the work
controller equipment lock lever.
• If cause of failure disappears, system resets itself.
Problem that • Each work equipment solenoid EPC lock normally works according to an input signal from the work
appears on equipment lock lever.
machine • The wiring harness or controller may be burnt out.
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment
1 neutral lock solenoid B02 (male) Resistance
(Internal short circuit) Between (1) and (2) 35 – 45 z
Possible causes Between (1), (2) – chassis ground Min. 1 Mz
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
Wiring harness between L07 (female) (7) – Resis-
(Contact with ground circuit) Max. 1 z
B02 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 z

6 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to work equipment neutral lock solenoid

WA600-6 7
SEN00573-03 40 Troubleshooting

Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short

circuit with power supply line) 1

Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble ply line
E01 DWM1KY (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the power source, abnor-
trouble mal voltage was applied when the work equipment neutral lock solenoid output was OFF.
• Do not stop output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment EPC solenoid according to an input signal from the
controller work equipment lock lever.
• If cause of failure disappears, system resets itself.
Problem that
appears on • All work equipment do not move.
machine
• The output state (ON/OFF) to the work equipment neutral lock EPC solenoid can be checked with
the monitoring function (Code: 40952, D-OUT-0).
Related • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
information lever to the LOCK position
• The work equipment can be operated by disconnecting the work equipment neutral lock solenoid
connector (Disconnection in wiring harness).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment B02 (male) Resistance
1 neutral lock solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Possible causes Min. 1 Mz
chassis ground
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short in wiring harness and carry out troubleshooting
2
(Contact with 24 V circuit) Wiring harness between L07 (female) (7) –
Voltage Max. 1 V
B02 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (7) and chassis ground 35 – 45 z

8 WA600-6
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Circuit diagram related to work equipment neutral lock solenoid

WA600-6 9
SEN00573-03 40 Troubleshooting

Failure code [DWN6KA] (Lift arm raise magnet detent solenoid:

Disconnection) 1

Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at raise detent position.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-1).
information
• Method of reproducing failure code: Engine start + lift arm raise detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm raise mag- without turning starting switch ON.
1 net detent solenoid
S05 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes
ness Wiring harness between L07 (female) (17) – Resis-
and standard 2 Max. 1 z
(Disconnection or defective S05 (female) (1) tance
value in normal
contact) Wiring harness between S05 (female) (2) – Resis-
state Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

10 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lift arm magnet detent solenoid

WA600-6 11
SEN00573-03 40 Troubleshooting

Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short
circuit) 1

Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner raise does not function.
appears on
• The lift arm is not held at raise detent position.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise mag- S05 (male) Resistance
1 net detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (17) – Resis-
Min. 1 Mz
S05 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

12 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lift arm magnet detent solenoid

WA600-6 13
SEN00573-03 40 Troubleshooting

Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
circuit with power supply line) 1

Action code Failure code Lift arm raise magnet detent solenoid: Short circuit with power sup-
Trouble ply line
E01 DWN6KY (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system was shorted with the power source,
trouble abnormal voltage was applied when the lift arm raise magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• If cause of failure disappears, system resets itself.
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-1).
information
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm raise mag- S05 (male) Resistance
1 net detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (17) –
Voltage Max. 1 V
S05 (female) (1) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation

14 WA600-6
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Circuit diagram related to lift arm magnet detent solenoid

WA600-6 15
SEN00573-03 40 Troubleshooting

Failure code [DWN7KA] (Lift arm float magnet detent solenoid:

Disconnection) 1

Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
E01 DWN7KA (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-2).
information
• Method of reproducing failure code: Engine started + lift arm float detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm float mag- without turning starting switch ON.
1 net detent solenoid
S06 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L07 (female) (27) – Resis-
2 Max. 1 z
value in normal (Disconnection or defective S06 (female) (1) tance
state contact) Wiring harness between S06 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

16 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lift arm magnet detent solenoid

WA600-6 17
SEN00573-03 40 Troubleshooting

Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short
circuit) 1

Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
E01 DWN7KB (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• If cause of failure disappears, system resets itself.
Problem that
• The lift arm remote positioner lower does not function.
appears on
• The lift arm is not held at float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-2).
information
• Method of reproducing failure code: Engine started + lift arm float detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm float mag- S06 (male) Resistance
1 net detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L07 (female) (27) – Resis-
Min. 1 Mz
S06 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

18 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lift arm magnet detent solenoid

WA600-6 19
SEN00573-03 40 Troubleshooting

Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
circuit with power supply line) 1

Action code Failure code Lift arm float magnet detent solenoid: Short circuit with power sup-
Trouble ply line
E01 DWN7KY (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system was shorted with the power
trouble source, abnormal voltage was applied when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• If cause of failure disappears, system resets itself.
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-2).
information
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lift arm float mag- S06 (male) Resistance
1 net detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
Possible causes chassis ground
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short in wiring harness and carry out troubleshooting
state 2
(Contact with 24 V circuit) Wiring harness between L07 (female) (27) –
Voltage Max. 1 V
S06 (female) (1) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Lift arm lever Voltage
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V

20 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lift arm magnet detent solenoid

WA600-6 21
SEN00573-03 40 Troubleshooting

Failure code [DWN8KA] (Bucket tilt magnet detent solenoid:

Disconnection) 1

Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
E01 DWN8KA (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the tilt detent position.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective bucket tilt magnet without turning starting switch ON.
1 detent solenoid
S04 (male) Resistance
(Internal disconnection)
Between (1) and (2) 35 – 45 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
Possible causes
ness Wiring harness between L07 (female) (37) – Resis-
and standard 2 Max. 1 z
(Disconnection or defective S04 (female) (1) tance
value in normal
contact) Wiring harness between S04 (female) (2) – Resis-
state Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

22 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to bucket magnet detent solenoid

WA600-6 23
SEN00573-03 40 Troubleshooting

Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)1

Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
E01 DWN8KB (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the bucket tilt magnet detent solenoid output was ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
Problem that
• Bucket leveler does not work.
appears on
• The bucket is not held at the tilt detent position.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (37) – Resis-
Min. 1 Mz
S04 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

24 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to bucket magnet detent solenoid

WA600-6 25
SEN00573-03 40 Troubleshooting

Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted

with the power source) 1

Action code Failure code Bucket tilt magnet detent solenoid: Short circuit with power supply line
Trouble
E01 DWN8KY (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system was shorted with the power
trouble source, abnormal voltage was applied when the bucket tilt magnet detent solenoid output was ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
controller • If cause of failure disappears, system resets itself.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective bucket tilt magnet S04 (male) Resistance
1 detent solenoid
(Internal short circuit) Between (1) and (2) 35 – 45 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (37) –
Voltage Max. 1 V
S04 (female) (1) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 Bucket lever Voltage
3
controller Neutral Max. 1 V
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation

26 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to bucket magnet detent solenoid

WA600-6 27
SEN00573-03 40 Troubleshooting

Failure code [DWNFKA] (Modulation clutch cut-off release solenoid:

Disconnection) 1

Action code Failure code Modulation clutch cut-off release solenoid: Disconnection
Trouble
E01 DWNFKA (Transmission controller system)
Contents of • Since the modulation clutch cut-off release solenoid power supply system is disconnected, no cur-
trouble rent flows when the modulation clutch cut-off release solenoid is ON.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
• The cut-off release function cannot be used.
appears on
• The engine is not used as brake when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with the
Related
monitoring function (Code: 40949, D-OUT-0).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective modulation clutch without turning starting switch ON.
1 cut-off release solenoid
T02 (male) Resistance
(Internal disconnection)
Between (1) and (2) 30 – 40 z
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness between L04 (female) (7) – Resis-
Possible causes 2 Max. 1 z
(Disconnection or defective T02 (female) (1) tance
and standard
contact) Wiring harness between T02 (female) (2) – Resis-
value in normal Max. 1 z
state chassis ground tance
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Directional lever or
Defective transmission con- L04 directional selector Voltage
3 switch
troller
N position Max. 1 V
Between (7) and
chassis ground F or R
20 – 30 V
(when travelling)

28 WA600-6
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Circuit diagram related to modulation clutch cut-off release solenoid

WA600-6 29
SEN00573-03 40 Troubleshooting

Failure code [DWNFKB] (Modulation clutch cut-off release solenoid:

Short circuit) 1

Action code Failure code Modulation clutch cut-off release solenoid: Short circuit
Trouble
E01 DWNFKB (Transmission controller system)
Contents of • Since the modulation clutch cut-off release solenoid power supply system was shorted with the chas-
trouble sis ground, abnormal current flowed when the modulation clutch cut-off release solenoid was ON.
Action of • Turns the output to the modulation clutch cut-off release solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The cut-off release function cannot be used.
appears on
• The engine is not used as brake when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with the
Related
monitoring function (Code: 40949, D-OUT-0).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch T02 (male) Resistance
1 cut-off release solenoid
(Internal short circuit) Between (1) and (2) 30 – 40 z
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring har- without turning starting switch ON.
2 ness
(Contact with ground circuit) Wiring harness between L04 (female) (7) – Resis-
Min. 1 Mz
T02 (female) (1) and chassis ground tance
Possible causes
a Prepare with starting switch OFF, then start engine and carry out
and standard
troubleshooting.
value in normal
state Directional lever or
Defective transmission con- L04 directional selector Voltage
3 switch
troller
N position Max. 1 V
Between (7) and
chassis ground F or R
20 – 30 V
(when travelling)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON (See inspection procedure for
diode).
4 Defective diode (HD4) HD4 (male) Resistance
Between (1) – (2) Min. 1 Mz (No continuity)
Between (3) – (2) Min. 1 Mz (No continuity)

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Circuit diagram related to modulation clutch cut-off release solenoid

WA600-6 31
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Failure code [DWNFKY] (Modulation clutch cut-off release solenoid:

Short circuit with power source line) 1

Action code Failure code Modulation clutch cut-off release solenoid: Short circuit with power
Trouble supply line
E03 DWNFKY (Transmission controller system)
• Since the modulation clutch cut-off release solenoid power supply system was shorted with the
Contents of
power source, abnormal voltage was applied when the modulation clutch cut-off release solenoid
trouble
output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the directional lever or directional selector switch
Action of to N (Neutral).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
• The cut-off function cannot be used.
appears on
• The modulation clutch cannot be cut off when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with the
Related
monitoring function (Code: 40949, D-OUT-0).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch T02 (male) Resistance
1 cut-off release solenoid
(Internal short circuit) Between (1) and (2) 30 – 40 z
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
Possible causes
Hot short in wiring harness and carry out troubleshooting
and standard 2
value in normal (Contact with 24 V circuit) Wiring harness between L04 (female) (7) –
Voltage Max. 1 V
state T02 (female) (1) and chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Directional selector
Defective transmission con- L04 switch or directional Voltage
3 lever
troller
N position Max. 1 V
Between (7) and
chassis ground F or R
20 – 30 V
(when travelling)

32 WA600-6
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Circuit diagram related to modulation clutch cut-off release solenoid

WA600-6 33
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Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1

Action code Failure code Fan pump EPC solenoid: Disconnection

Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid output is ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective fan pump EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
R12 (male) Resistance
tion)
Between (1) and (2) 5 – 10 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (23) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective R12 (female) (2) tance
contact of connector) Wiring harness between L04 (female) (27) – Resis-
Max. 1 z
R12 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (27) and (23) 5 – 10 z

Circuit diagram related to fan pump EPC solenoid

34 WA600-6
40 Troubleshooting SEN00573-03

Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1

Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the fan pump EPC solenoid output was ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump EPC R12 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 10 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (27) Resis-
Min. 1 Mz
and R12 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (23) and (27) 5 – 10 z
Between (23) (27) and
Min. 1 Mz
chassis ground

Circuit diagram related to fan pump EPC solenoid

WA600-6 35
SEN00573-03 40 Troubleshooting

Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
power supply line) 1

Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan pump EPC solenoid output was OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • The fan speed is set to the minimum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400 FAN EPC DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fan pump EPC R12 (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 10 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (27)
Voltage Max. 1 V
and R12 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (23) and (27) 5 – 10 z
Between (23), (27) and
Min. 1 Mz
chassis ground

Circuit diagram related to fan pump EPC solenoid

36 WA600-6
40 Troubleshooting SEN00573-03

Failure code [DXA1KA] (Pump PC-EPC solenoid: Disconnection) 1

Action code Failure code Pump PC-EPC solenoid: Disconnection

Trouble
E01 DXA1KA (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader
trouble pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the loader pump PC-EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Fuel consumption may become poor when engine speed is low.
appears on • Engine acceleration performance is deteriorated.
machine • The lift arm may increase speed suddenly.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective loader pump PC- without turning starting switch ON.
1 EPC solenoid (Internal dis-
T02 (male) Resistance
connection)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (23) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective T01 (female) (2) tance
contact of connector) Wiring harness between L07 (female) (36) – Resis-
Max. 1 z
T01 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (23) and (36) 5 – 15 z

Circuit diagram related to loader pump PC-EPC solenoid

WA600-6 37
SEN00573-03 40 Troubleshooting

Failure code [DXA1KB] (Pump PC-EPC solenoid: Short circuit) 1

Action code Failure code Pump PC-EPC solenoid: Short circuit

Trouble
E01 DXA1KB (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when the loader pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the loader pump PC-EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• Fuel consumption may become poor when engine speed is low.
Problem that
• Engine acceleration performance is deteriorated.
appears on
• The lift arm may increase speed suddenly.
machine
• The wiring harness or controller may be burnt out.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective loader pump PC- T01 (male) Resistance
1 EPC solenoid (Internal short
circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (36) – Resis-
Min. 1 Mz
T01 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (23) and (36) 5 – 15 z
Between (23), (36) and
Min. 1 Mz
chassis ground

Circuit diagram related to loader pump PC-EPC solenoid

38 WA600-6
40 Troubleshooting SEN00573-03

Failure code [DXF0KA] (AJSS EPC solenoid: Disconnection) 1

Action code Failure code AJSS EPC solenoid: Disconnection

Trouble
E01 DXF0KA (Work equipment controller system)
Contents of • Since the AJSS EPC solenoid system is disconnected, no current flows when the AJSS EPC sole-
trouble noid output is ON.
Action of • Stops outputting the signal to the AJSS EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Steering according to AJSS operation becomes less effective.
machine
• The output state (current) to the AJSS EPC solenoid can be checked with the monitoring function
(Code: 40908 AJSS EPC DIR).
Related
• Method of reproducing failure code: Engine started
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO”
AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective AJSS EPC sole- without turning starting switch ON.
1 noid
B01 (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (23) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective B01 (female) (2) tance
contact of connector) Wiring harness between L07 (female) (26) – Resis-
Max. 1 z
B01 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (23) and (26) 5 – 15 z

Circuit diagram related to AJSS EPC solenoid

WA600-6 39
SEN00573-03 40 Troubleshooting

Failure code [DXF0KB] (AJSS EPC solenoid: Short circuit) 1

Action code Failure code AJSS EPC solenoid: Short circuit

Trouble
E01 DXF0KB (Work equipment controller system)
Contents of • Since the AJSS EPC solenoid system was shorted with the chassis ground, abnormal current flowed
trouble when the AJSS EPC solenoid output was ON.
Action of • Stops outputting the signal to the AJSS EPC solenoid.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Steering according to AJSS operation becomes less effective.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the AJSS EPC solenoid can be checked with the monitoring function
(Code: 40908 AJSS EPC DIR).
Related
• Method of reproducing failure code: Start engine
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective AJSS EPC sole- B01 (male) Resistance
1 noid
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (26) – Resis-
Min. 1 Mz
B01 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective work equipment L07 (female) Resistance
3
controller Between (23) and (26) 5 – 15 z
Between (23), (26) and
Min. 1 Mz
chassis ground

Circuit diagram related to AJSS EPC solenoid

40 WA600-6
40 Troubleshooting SEN00573-03

Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1

Action code Failure code Lockup ECMV solenoid: Disconnection

Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Torque converter lockup is not turned on
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine, turn the torque convertor lockup switch ON, and
drive the machine.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective lockup ECMV without turning starting switch ON.
1 solenoid
LC.PS (male) Resistance
(Internal disconnection)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (23) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective LC.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (35) – Resis-
Max. 1 z
LC.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (23) and (35) 5 – 15 z

Circuit diagram related to lockup ECMV solenoid

WA600-6 41
SEN00573-03 40 Troubleshooting

Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1

Action code Failure code Lockup ECMV solenoid: Short circuit

Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Torque converter lockup is not turned on.
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (35) – Resis-
Max. 1 z
LC.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (23) and (35) 5 – 15 z
Between (23), (35) and
Min. 1 Mz
chassis ground

Circuit diagram related to lockup ECMV solenoid

42 WA600-6
40 Troubleshooting SEN00573-03

WA600-6 43
SEN00573-03 40 Troubleshooting

Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with

power supply line) 1

Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the directional lever or directional selector switch
Action of to N (Neutral).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
• Keeps neutral until the directional lever or directional selector switch is moved to N (Neutral).
appears on
• The lockup function is kept ON.
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related
(Code: 31609 ECMV LU DIR)
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective lockup ECMV LC.PS (male) Resistance
1 solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (35) –
Voltage Max. 1 V
LC.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (23) and (35) 5 – 15 z
Between (23), (35) and
Min. 1 Mz
chassis ground

44 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to lockup ECMV solenoid

WA600-6 45
SEN00573-03 40 Troubleshooting

Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1

Action code Failure code 1st clutch ECMV solenoid: Disconnection

Trouble
E03 DXH4KA (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st.)
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective 1st clutch ECMV without turning starting switch ON.
1 solenoid (Internal disconnec-
1.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (3) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective 1.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (25) – Resis-
Max. 1 z
1.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (25) and (3) 5 – 15 z

46 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to 1st clutch ECMV solenoid

WA600-6 47
SEN00573-03 40 Troubleshooting

Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1

Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
E03 DXH4KB (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 1st clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (25) – Resis-
Min. 1 Mz
1.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (25) and (3) 5 – 15 z
Between (25), (3) and
Min. 1 Mz
chassis ground

48 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to 1st clutch ECMV solenoid

WA600-6 49
SEN00573-03 40 Troubleshooting

Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with
power supply line) 1

Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH4KY (Transmission controller system)
Contents of • When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 1st clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related infor-
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
mation
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (25) –
Voltage Max. 1 V
1.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (25) and (3) 5 – 15 z
Between (25), (3) and
Min. 1 Mz
chassis ground

50 WA600-6
40 Troubleshooting SEN00573-03

Circuit diagram related to 1st clutch ECMV solenoid

WA600-6 51
SEN00573-03

WA600-6 Wheel loader

Form No. SEN00573-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

52
 SEN00574-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 11
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)............................................................. 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ................................................................ 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) ............................ 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ........................................................... 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) ............................................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ........................... 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) .............................................................. 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit).................................................................. 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ............................. 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) .............................................................. 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) .................................................................. 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) .............................. 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) ........................................................... 28
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)............................................................... 30

WA600-6 1
SEN00574-03 40 Troubleshooting

Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)........................... 32
Failure code [DXHJKA] (3-spool valve extract EPC solenoid: Disconnection) ............................................. 34
Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short circuit) ................................................. 35
Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short circuit with power supply line)............. 36
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) ............................................. 37
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) ................................................. 38
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line)............. 39
Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection) .......................................................... 40
Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit).............................................................. 42
Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with power source line) ......................... 44
Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction).............................................................. 46
Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) (Blow-by pressure: High error) .................... 48
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”)
(Exhaust gas temperature (F): Abnormal heat)......................................................................................... 50
Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”)
(Exhaust gas temperature (F): Overheat) ................................................................................................. 52
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat)......................................................................................... 54
Failure code [F@BZNS] (or VHMS_LED display “n3” o “71”)
(Exhaust gas temperature (R): Overheat)................................................................................................. 56

2 WA600-6
40 Troubleshooting SEN00574-03

WA600-6 3
SEN00574-03 40 Troubleshooting

Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1

Action code Failure code 2nd clutch ECMV solenoid: Disconnection

Trouble
E03 DXH5KA (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31603, ECMV 2 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective 2nd clutch ECMV without turning starting switch ON.
1 solenoid (Internal disconnec-
2.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (6) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective 2.PS (female) (1) tance
contact of connector) Wiring harness between L04 (female) (13) – Resis-
Max. 1 z
2.PS (female) (2) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (6) and (13) 5 – 15 z

4 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 2nd clutch ECMV solenoid

WA600-6 5
SEN00574-03 40 Troubleshooting

Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1

Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH5KB (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 2nd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31603, ECMV 2 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (6) – Resis-
Min. 1 Mz
2.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (6) and (13) 5 – 15 z
Between (6), (13) and
Min. 1 Mz
chassis ground

6 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 2nd clutch ECMV solenoid

WA600-6 7
SEN00574-03 40 Troubleshooting

Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
power supply line) 1

Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH5KY (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31603, ECMV 2 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (6) –
Voltage Max. 1 V
2.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (6) and (13) 5 – 15 z
Between (6), (13) and
Min. 1 Mz
chassis ground

8 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 2nd clutch ECMV solenoid

WA600-6 9
SEN00574-03 40 Troubleshooting

Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1

Action code Failure code 3rd clutch ECMV solenoid: Disconnection

Trouble
E03 DXH6KA (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31604, ECMV 3 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective 3rd clutch ECMV without turning starting switch ON.
1 solenoid (Internal disconnec-
3.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (13) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective 3.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (16) – Resis-
Max. 1 z
3.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (16) and (13) 5 – 15 z

10 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 3rd clutch ECMV solenoid

WA600-6 11
SEN00574-03 40 Troubleshooting

Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1

Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
E03 DXH6KB (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 3rd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31604, ECMV 3 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (16) – Resis-
Min. 1 Mz
3.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (16) and (13) 5 – 15 z
Between (16), (13) and
Min. 1 Mz
chassis ground

12 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 3rd clutch ECMV solenoid

WA600-6 13
SEN00574-03 40 Troubleshooting

Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
power supply line) 1

Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH6KY (Transmission controller system)
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 3rd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to Neutral.
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31604, ECMV 3 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (16) –
Voltage Max. 1 V
3.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (16) and (13) 5 – 15 z
Between (16), (13) and
Min. 1 Mz
chassis ground

14 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 3rd clutch ECMV solenoid

WA600-6 15
SEN00574-03 40 Troubleshooting

Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1

Action code Failure code R clutch ECMV solenoid: Disconnection

Trouble
E03 DXH7KA (Transmission controller system)
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional selector switch to R (Reverse).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective R (Reverse) clutch without turning starting switch ON.
1 ECMV solenoid (Internal dis-
R.PS (male) Resistance
connection)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (3) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective R.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (15) – Resis-
Max. 1 z
R.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (15) and (3) 5 – 15 z

16 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to R (Reverse) clutch ECMV solenoid

WA600-6 17
SEN00574-03 40 Troubleshooting

Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1

Action code Failure code R clutch ECMV solenoid: Short circuit

Trouble
E03 DXH7KB (Transmission controller system)
Contents of • When the R (Reverse) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when R (Reverse) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional selector switch to R (Reverse).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid (Internal
short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (15) – Resis-
Min. 1 Mz
R.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (15) and (3) 5 – 15 z
Between (15), (3) and
Min. 1 Mz
chassis ground

18 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to R (Reverse) clutch ECMV solenoid

WA600-6 19
SEN00574-03 40 Troubleshooting

Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with

power supply line) 1

Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH7KY (Transmission controller system)
Contents of • Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the R (Reverse) ECMV solenoid output was OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The machine can travel only in R (Reverse).
machine
• The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring func-
Related tion (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional switch to R (Reverse).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid (Internal
short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Hot short in wiring harness without turning starting switch ON.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (15) –
Voltage Max. 1 V
R.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (15) and (3) 5 – 15 z
Between (15), (3) and
Min. 1 Mz
chassis ground

20 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to R (Reverse) clutch ECMV solenoid

WA600-6 21
SEN00574-03 40 Troubleshooting

Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1

Action code Failure code F clutch ECMV solenoid: Disconnection

Trouble
E03 DXH8KA (Transmission controller system)
Contents of • When the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
Related tion (Code: 31608, ECMV F DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional switch to F (Forward).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective F (Forward) clutch without turning starting switch ON.
1 ECMV solenoid (Internal dis-
F.PS (male) Resistance
connection)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (13) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective F.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (5) – Resis-
Max. 1 z
F.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (5) and (13) 5 – 15 z

22 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to F (Forward) clutch ECMV solenoid

WA600-6 23
SEN00574-03 40 Troubleshooting

Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1

Action code Failure code F clutch ECMV solenoid: Short circuit

Trouble
E03 DXH8KB (Transmission controller system)
Contents of • When the F (Forward) clutch ECMV solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when F (Forward) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F (Forward) clutch ECMV solenoid can be checked with the monitor-
Related ing function (Code: 31608, ECMV F DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional switch to F (Forward).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid (Internal
short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (5) – Resis-
Min. 1 Mz
F.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (5) and (13) 5 – 15 z
Between (5), (13) and
Min. 1 Mz
chassis ground

24 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to F (Forward) clutch ECMV solenoid

WA600-6 25
SEN00574-03 40 Troubleshooting

Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with

power supply line) 1

Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH8KY (Transmission controller system)
Contents of • Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the F (Forward) ECMV solenoid output was OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The machine can travel only F (Forward).
machine
• The output state (current) to the F (Forward) clutch ECMV solenoid can be checked with the monitor-
Related ing function (Code: 31608, ECMV F DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional switch to F (Forward).

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid (Internal
short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Hot short in wiring harness without turning starting switch ON.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (5) –
Voltage Max. 1 V
F.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (5) and (13) 5 – 15 z
Between (5), (13) and
Min. 1 Mz
chassis ground

26 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to F (Forward) clutch ECMV solenoid

WA600-6 27
SEN00574-03 40 Troubleshooting

Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1

Action code Failure code 4th clutch ECMV solenoid: Disconnection

Trouble
E03 DXHHKA (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV
trouble solenoid output is ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective 4th clutch ECMV without turning starting switch ON.
1 solenoid (Internal disconnec-
4.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L04 (female) (3) – Resis-
value in normal 2 Max. 1 z
state (Disconnection or defective 4.PS (female) (2) tance
contact of connector) Wiring harness between L04 (female) (26) – Resis-
Max. 1 z
4.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (26) and (3) 5 – 15 z

28 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to 4th clutch ECMV solenoid

WA600-6 29
SEN00574-03 40 Troubleshooting

Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1

Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 4th clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L04 (female) (26) – Resis-
Min. 1 Mz
4.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (26) and (3) 5 – 15 z
Between (26), (3) and
Min. 1 Mz
chassis ground

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Circuit diagram related to 4th clutch ECMV solenoid

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Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
power supply line) 1

Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 4th clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective 4th clutch ECMV 4.PS (male) Resistance
1 solenoid (Internal short cir-
cuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L04 (female) (26) –
Voltage Max. 1 V
4.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
3
troller Between (26) and (3) 5 – 15 z
Between (26), (3) and
Min. 1 Mz
chassis ground

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Circuit diagram related to 4th clutch ECMV solenoid

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Failure code [DXHJKA] (3-spool valve extract EPC solenoid:

Disconnection) 1

Action code Failure code 3-spool valve extract EPC solenoid: Disconnection
Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) extract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) extract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not extracted.
machine
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (3) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F22 (female) (2) tance
ness and defective contact) Wiring harness between L07 (female) (25) – Resis-
Max. 1 z
F22 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) extract EPC solenoid

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Failure code [DXHJKB] (3-spool valve extract EPC solenoid: Short

circuit) 1

Action code Failure code 3-spool valve extract EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid
trouble
output was ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (25) – Resis-
Min. 1 Mz
F22 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) extract EPC solenoid

WA600-6 35
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Failure code [DXHJKY] (3-spool valve extract EPC solenoid: Short

circuit with power supply line) 1

Action code Failure code 3-spool valve extract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHJKY (Work equipment controller system)
• Since the 3-spool valve (attachment) extract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) extract EPC sole-
trouble
noid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not extracted.
appears on
• The 3-spool valve (attachment) extract EPC solenoid may be burnt out.
machine
• The output state (current) to the 3-spool valve (attachment) extract EPC solenoid can be checked
with the monitoring function (Code: 41906, 3RD EPC1 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started + 3-spool valve (attachment) extract
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) extract EPC without turning starting switch ON.
1
solenoid F22 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (25) –
Voltage Max. 1 V
F22 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (25) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) extract EPC solenoid

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40 Troubleshooting SEN00574-03

Failure code [DXHKKA] (3-spool valve retract EPC solenoid:

Disconnection) 1

Action code Failure code 3-spool valve retract EPC solenoid: Disconnection
Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the 3-spool valve (attachment) retract EPC solenoid output signal system is disconnected, no
trouble current flows when the 3-spool valve (attachment) retract EPC solenoid output is ON.
• Continues outputting.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The 3-spool valve (attachment) cylinder is not retracted.
machine
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F23 (male) Resistance
(Internal disconnection) Between (1) and (2) 5 – 15 z
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (3) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- F23 (female) (2) tance
ness and defective contact) Wiring harness between L07 (female) (35) – Resis-
Max. 1 z
F23 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) retract EPC solenoid

WA600-6 37
SEN00574-03 40 Troubleshooting

Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)1

Action code Failure code 3-spool valve retract EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
chassis ground, abnormal current flowed when the 3-spool valve (attachment) retract EPC solenoid
trouble
output was ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The wiring harness or controller may be burnt out.
machine
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started + 3-spool valve (attachment) retract
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F23 (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (35) – Resis-
Min. 1 Mz
F23 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) retract EPC solenoid

38 WA600-6
40 Troubleshooting SEN00574-03

Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short

circuit with power supply line) 1

Action code Failure code 3-spool valve retract EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHKKY (Work equipment controller system)
• Since the 3-spool valve (attachment) retract EPC solenoid output signal system was shorted with the
Contents of
power source, abnormal voltage was applied when the 3-spool valve (attachment) retract EPC sole-
trouble
noid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/tilt, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The 3-spool valve (attachment) cylinder is not retracted.
appears on
• The 3-spool valve (attachment) retract EPC solenoid may be burnt out.
machine
• The output state (current) to the 3-spool valve (attachment) retract EPC solenoid can be checked
with the monitoring function (Code: 41907, 3RD EPC2 DIR).
Related • 3-spool valve (attachment)-equipped model specification only
information • Method of reproducing failure code: Engine started
• This error is not displayed on a machine which is not equipped with 3-spool valve (attachment). If it is
displayed, select “NO ADD” 3-spool valve option in option setting.

Cause Standard value in normal state/Remarks on troubleshooting

Defective 3-spool valve a Prepare with starting switch OFF, then carry out troubleshooting
(attachment) retract EPC without turning starting switch ON.
1
solenoid F23 (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (35) –
Voltage Max. 1 V
F23 (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective work equipment without turning starting switch ON.
3
controller L07 (female) Resistance
Between (35) and (3) 5 – 15 z

Circuit diagram related to 3-spool valve (attachment) retract EPC solenoid

WA600-6 39
SEN00574-03 40 Troubleshooting

Failure code [DXHPKA] (Modulation clutch solenoid: Disconnection) 1

Action code Failure code Modulation clutch ECMV solenoid: Disconnection

Trouble
E03 DXHPKA (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system is disconnected, no current flows
trouble when the modulation clutch ECMV solenoid output is ON.
• Stops outputting the signal to the modulation clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The machine cannot travel.
appears on
• The machine may be able to travel with modulation direct coupling signal.
machine
• The output state (current) to the modulation clutch ECMV solenoid can be checked with the monitor-
Related
ing function (Code: 31640 ECMV MOD/C DIR).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch MC.PS (male) Resistance
1 ECMV solenoid
(Internal disconnection) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
and standard Disconnection in wiring har-
ness Wiring harness between L07 (female) (23) – Resis-
value in normal 2 Max. 1 z
state (Disconnection in wiring har- MC.PS (female) (2) tance
ness and defective contact) Wiring harness between L07 (female) (36) – Resis-
Max. 1 z
MC.PS (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L07 (female) Resistance
3
troller Between (36) and (23) 5 – 15 z
Between (36), (23) and
Min. 1 Mz
chassis ground

40 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to modulation clutch ECMV solenoid

WA600-6 41
SEN00574-03 40 Troubleshooting

Failure code [DXHPKB] (Modulation clutch solenoid: Short circuit) 1

Action code Failure code Modulation clutch ECMV solenoid: Short circuit
Trouble
E03 DXHPKB (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system was shorted with the chassis
trouble ground, abnormal current flowed when the modulation clutch ECMV solenoid output was ON.
• Stops outputting the signal to the modulation clutch ECMV solenoid.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The machine cannot travel.
appears on
• The machine may be able to travel with modulation direct coupling signal.
machine
• The output state (current) to the modulation clutch ECMV solenoid can be checked with the monitor-
Related
ing function (Code: 31640 ECMV MOD/C DIR).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
Defective modulation clutch without turning starting switch ON.
1 ECMV solenoid
MC.PS (male) Resistance
(Internal short circuit)
Between (1) and (2) 5 – 15 z
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 2 ness
state (Contact with ground circuit) Wiring harness between L07 (female) (36) – Resis-
Min. 1 Mz
MC.PS (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
Defective transmission con- without turning starting switch ON.
3
troller L04 (female) Resistance
Between (36) and (23) 5 – 15 z

Circuit diagram related to modulation clutch ECMV solenoid

42 WA600-6
40 Troubleshooting SEN00574-03

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Failure code [DXHPKY] (Modulation clutch solenoid: Short circuit with

power source line) 1

Action code Failure code Modulation clutch ECMV solenoid: Short circuit with power supply
Trouble line
E03 DXHPKB (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system was shorted with the power
trouble source, abnormal voltage was applied when the modulation clutch ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
appears on • The machine does not travel.
machine
• The output state (current) to the modulation clutch ECMV solenoid can be checked with the monitor-
Related
ing function (Code: 31640 ECMV MOD/C DIR).
information
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch MC.PS (male) Resistance
1 ECMV solenoid
(Internal short circuit) Between (1) and (2) 5 – 15 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Possible causes
a Prepare with starting switch OFF, then turn starting switch ON
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L07 (female) (36) –
Voltage Max. 1 V
MC.PS (female) (1) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L07 (female) Resistance
3
troller Between (36) and (23) 5 – 15 z
Between (36), (23) and
Min. 1 Mz
chassis ground

44 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to modulation clutch ECMV solenoid

WA600-6 45
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Failure code [DXHPMA] (Modulation clutch solenoid: Malfunction) 1

Action code Failure code Modulation clutch ECMV solenoid: Malfunction

Trouble
E01 DXHPMA (Transmission controller system)
Contents of • Difference between the pressure detected by the modulation clutch pressure sensor and pressure
trouble commanded from the modulation clutch ECMV solenoid is 0.3 MPa {3 kg/cm2} or more.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on —
machine
• The output state (current) to the modulation clutch ECMV solenoid can be checked with the monitor-
ing function (Code: 31640 ECMV MOD/C DIR).
• The state (current) of the modulation clutch pressure can be checked with the monitoring function
Related
(Code: 92400, MOD/C PRESS).
information
• The state (voltage) of the modulation clutch pressure can be checked with the monitoring function
(Code: 92401, MOD/C PRESS).
• Method of reproducing failure code: Engine started + Travel

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective modulation clutch
ECMV solenoid MC.PS (male) Resistance
1
(Internal disconnection or Between (1) and (2) 5 – 15 z
short circuit)
Between (1), (2) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective transmission con- L04 (female) Resistance
2
troller Between (36) and (23) 5 – 15 z
Possible causes
Between (36), (23) and
and standard Min. 1 Mz
chassis ground
value in normal
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Set transmission auto/manual shift selector switch to “Manual”.
• Turn parking brake switch OFF.
• Press right brake to prevent machine from moving.
Defective modulated clutch
3 • Engine P mode
pressure sensor
T03 Gear speed Voltage
Between (B) to (A) Any speed 20 – 30 V
2.78 –
Between (C) to (A) F4 or R4 (Engine: High idle)
3.28 V
Emergency modulated clutch
Emergency modulated clutch direct engagement switch may be
4 direct engagement switch
turned ON. Check it directly.
ON

46 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to modulation clutch ECMV solenoid

WA600-6 47
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Failure code [F@BBZL] (or VHMS_LED display: “n3” o “38”) (Blow-by

pressure: High error) 1

Action code Failure code Blow-by pressure: High error

Trouble
— F@BBZL (VHMS controller system)
Contents of
• Blow-by pressure exceeded 9.41 kPa {960 mmH2O}.
trouble
Action of
• None in particular.
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “38”
• The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
Related
function (Code: 42801 BLOWBY PRESS)
information
• If failure code: DHE5KB (Blow-by pressure sensor: Ground fault) or failure code: DHE5KY (Blow-by
pressure sensor: Short circuit with power supply line) is displayed, troubleshooting for it is performed
first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

Check the engine for abnormality. Correct, if any.
1 Blow-by pressure increases
Possible causes Check the breather hose for clogging, bend, or break. If any, repair it.
and standard Defective blow-by pressure
value in normal 2 Check the blow-by pressure sensor for abnormality. Replace, if any.
sensor
state
If the above items 1 and 2 is normal, the VHMS controller may be
3 Defective VHMS controller defective. (Troubleshooting cannot be carried out since the defect is
in the machine monitor.)

48 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to blow-by sensor

WA600-6 49
SEN00574-03 40 Troubleshooting

Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”) (Exhaust

gas temperature (F): Abnormal heat) 1

Action code Failure code Exhaust gas temperature (F): Abnormal heat
Trouble
— F@BYNR (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas tem-
Contents of perature beyond the limit line 2 was detected min. 10 seconds.
trouble (Exhaust gas temperature limit line 2: Straight line between 750°C at rated output speed at minimum
and 800°C at max. torque speed at maximum)
Action of
• None in particular.
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “62”.
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
monitoring function (Code: 42610 EXHAUST TEMP F).
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Ground fault) is displayed, troubleshooting for it is
performed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

Exhaust gas temperature at
the engine front side abnor-
1 Check the engine for abnormality. Correct, if any.
mally rises.
(When the system is normal)
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal Exhaust gas
state V02 Voltage
temperature
2 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (7) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

50 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to exhaust gas temperature sensor (F)

WA600-6 51
SEN00574-03 40 Troubleshooting

Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”) (Exhaust

gas temperature (F): Overheat) 1

Action code Failure code Exhaust gas temperature (F): Overheat

Trouble
— F@BYNS (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas tem-
Contents of perature beyond the limit line 1 was detected min. 1 seconds.
trouble (Exhaust gas temperature limit line 1: Straight line between 700°C at rated output speed at minimum
and 750°C at max. torque speed at maximum)
Action of
• None in particular.
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “61”
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
monitoring function (Code: 42610 EXHAUST TEMP F).
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Ground fault) is displayed, troubleshooting for it is
performed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

Exhaust gas temperature at
the engine front side abnor-
1 Check the engine for abnormality. Correct, if any.
mally rises.
(When the system is normal)
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal Exhaust gas
state V02 Voltage
temperature
2 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (7) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

52 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to exhaust gas temperature sensor (F)

WA600-6 53
SEN00574-03 40 Troubleshooting

Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”) (Exhaust

gas temperature (R): abnormal heat) 1

Action code Failure code Exhaust gas temperature (R): Abnormal heat
Trouble
— F@BZNR (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Contents of perature beyond the limit line 2 was detected min. 10 seconds.
trouble (Exhaust gas temperature limit line 2: Straight line between 750°C at rated output speed at minimum
and 800°C at max. torque speed at maximum)
Action of
• None in particular.
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “72”.
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
monitoring function (Code: 42611 EXHAUST TEMP R).
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Ground fault) is displayed, troubleshooting for it is
performed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

Exhaust gas temperature at
the engine rear side
1 Check the engine for abnormality. Correct, if any.
increases abnormally. (When
the system is normal)
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal Exhaust gas
state V02 Voltage
temperature
2 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (5) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

54 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to exhaust gas temperature sensor (R)

WA600-6 55
SEN00574-03 40 Troubleshooting

Failure code [F@BZNS] (or VHMS_LED display “n3” o “71”) (Exhaust

gas temperature (R): Overheat) 1

Action code Failure code Exhaust gas temperature (R): Overheat

Trouble
— F@BZNS (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Contents of perature beyond the limit line 1 was detected min. 1 second.
trouble (Exhaust gas temperature limit line 1: Straight line between 700°C at rated output speed at minimum
and 750°C at max. torque speed at maximum)
Action of
• None in particular.
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n3” o “71”.
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
monitoring function (Code: 42611 EXHAUST TEMP R).
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Ground fault) is displayed, troubleshooting for it is
performed first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

Exhaust gas temperature at
the engine rear side
1 Check the engine for abnormality. Correct, if any.
increases abnormally. (When
the system is normal)
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal Exhaust gas
state V02 Voltage
temperature
2 Defective VHMS controller 50 – 100°C 1.0 – 1.6 V
300 – 400°C 2.1 – 2.7 V
Between (5) and (12)
500 – 600°C 2.9 – 3.6 V
700 – 800°C 3.8 – 4.4 V

56 WA600-6
40 Troubleshooting SEN00574-03

Circuit diagram related to exhaust gas temperature sensor (R)

WA600-6 57
SEN00574-03

WA600-6 Wheel loader

Form No. SEN00574-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

58
 SEN00563-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 4
Information in troubleshooting table................................................................................................................ 7
E-1 Engine does not start. .............................................................................................................................. 8
E-2 Wiper does not operate .......................................................................................................................... 18
E-3 Windshield washer does not operate ..................................................................................................... 26
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off................................... 32
E-5 Working lamp does not light up or go off. ............................................................................................... 48
E-6 Step lamp does not light up or go off ...................................................................................................... 56
E-7 Turn signal lamp and hazard lamp do not light up or go off ................................................................... 58
E-8 Brake lamp does not light or it keeps lighting up.................................................................................... 68
E-9 Backup lamp does not light or it keeps lighting up. ................................................................................ 72
E-10 Backup buzzer does not sound or it keeps sounding. .......................................................................... 76
E-11 Horn does not sound or it keeps sounding. .......................................................................................... 80
E-12 Alarm buzzer does not sound or it keeps sounding ............................................................................. 84

WA600-6 1
SEN00563-03 40 Troubleshooting

E-13 Air conditioner does not operate or stop............................................................................................... 86

E-14 Electric priming pump does not operate or does not stop automatically .............................................. 88

2 WA600-6
40 Troubleshooting SEN00563-03

WA600-6 3
SEN00563-03 40 Troubleshooting

Before carrying out troubleshooting of electrical system 1

Connection table of fuse box and circuit breaker
a This connection table shows the devices to which each power supply of the fuse box and circuit breaker
supplies power (A switch power supply is a device which supplies power while the starting switch is in
the ON position and a constant power supply is a device which supplies power while the starting switch
is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
circuit breaker to see if the power is supplied normally.

Fuse box A

Type of power supply Fuse No. Capacity of fuse Destination of power

1 10A Starting switch terminal B circuit
2 10A Hazard lamp circuit
Constant power supply 3 10A Step lamp circuit
Circuit breaker CBF1
(30A) 4 10A Transmission controller (B) circuit
5 10A Work equipment controller (B) circuit
6 10A Machine monitor (B), VHMS controller (B) circuit
Switch power supply
7 5A Engine controller circuit
Starting switch ACC
8 10A Horn circuit
9 20A Air conditioner circuit
10 10A Auto grease circuit
Switch power supply 11 20A Rear glass heater circuit
Circuit breaker CBF2
(105A) 12 10A Radio circuit
13 20A Air suspension seat, DC-DC converter circuit
14 10A VHMS controller (A) circuit
15 10A Spare

4 WA600-6
40 Troubleshooting SEN00563-03

Fuse box B

Type of power supply Fuse No. Capacity of fuse Destination of power

1 10A Turn signal lamp circuit
2 10A Back-up lamp and blinking lamp circuit
3 20A Front working lamp circuit
4 20A Rear working lamp circuit

Switch power supply 5 10A Transmission controller (A) circuit

Circuit breaker CBF3 6 10A Parking brake circuit
(105A) 7 10A Work equipment controller (A) circuit
8 10A Machine monitor (A) circuit
9 20A Wiper and washer circuit
10 10A Spare
11 20A Main lamp circuit
Relay circuit power 12 10A Right clearance lamp
supply of small lamp 13 10A Left clearance lamp
Lighting switch circuit 14 10A Right headlamp
power supply 15 10A Left headlamp

Circuit breaker

Circuit breaker Capacity of

Type of power supply Destination of power
No. breaker
Starting switch circuit, work equipment controller circuit,
Constant power supply CBF1 30A
machine monitor circuit, VHMS controller circuit
Switch power supply CBF2 105A Fuse box (A): Circuits 8 – 15
Switch power supply CBF3 105A Fuse box (B): Circuits 1 – 11
Constant power supply CBF4 20A Engine controller circuit

WA600-6 5
SEN00563-03 40 Troubleshooting

Locations of fuse boxes and circuit breakers, and fuse Nos.

6 WA600-6
40 Troubleshooting SEN00563-03

Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.

Trouble Problem that appears on machine

Related
Information related to detected trouble or troubleshooting
information

Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit
comes into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
junction
For troubleshooting, insert or connect T-junction adapter
3 shown below unless especially specified.
• When “male” or “female” is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
junction adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-junction
adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.

Related circuit diagram

This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging
point: indicate the ends of branch or source of merging
within the parts of the same wiring harness
• Arrow (⇔): Roughly indicates mounting place on machine.

WA600-6 7
SEN00563-03 40 Troubleshooting

E-1 Engine does not start. 1

Contents of
• Engine does not start. (Steering wheel specification)
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box A is normal.
Related (If it is broken, check the related wiring harness for grounding fault.)
information • The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function
(Code: 40906, D-IN-15).
• If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK6KA] is displayed, carry out troubleshooting
for it first.

Cause Standard value in normal state/Remarks on troubleshooting

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective fuse No. 5 in fuse If fuse is broken, circuit probably has ground fault etc.
2
box B (See cause 11.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
3 Defective battery Battery relay Switch position Voltage
Between terminals OFF 20 – 30 V
B and E ON Max. 1 V
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch START and carry out trouble-
shooting
Starting motor Voltage
Possible
causes and Between terminals
Power supply input 20 – 30 V
standard value Defective starting motor B and E
4
in normal state (Internal defect) Between terminals
Battery input Max. 1 V
R and E
Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
a Prepare with starting switch OFF, then turn starting switch ON
Defective alternator and carry out troubleshooting
5
(Internal short circuit) Wiring harness between alternator terminal
Voltage Max. 1 V
R and chassis ground
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and carry out troubleshooting in each case.
Defective starting switch Starting switch Position of switch Resistance
6
(Internal disconnection)
Between terminals OFF Min. 1 Mz
B (C51) and C (C53) START Max. 1 z

8 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
L04 FNR (Direction) lever Voltage
Between (1) and (10) Any position 20 – 30 V
Defective FNR (directional)
lever switch N (Neutral) 20 – 30 V
7 Between (2) and (10)
(Internal disconnection or Other than above Max. 1 V
short circuit) F (Forward) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
R (Reverse) 20 – 30 V
Between (4) and (10)
Other than above Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R21 (male) Diode range Continuity
Measure at (1) in
Between (1) and (2) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R22 (male) Diode range Continuity
Measure at (3) in
Between (3) and (2) Secured
diode range.
Measure at (1) in
Between (1) and (2) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and
standard value R23 (male) Diode range Continuity
Defective diode (R21, R22,
in normal state Measure at (2) in
8 R23, R24, R25 or R26) Between (2) and (1) Secured
diode range.
(Internal disconnection)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R24 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R25 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R26 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L103 (male) Resistance
Defective neutral safety relay Between (1) and (2) 200 – 400 z
9 (L103)
a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral safety relay (L103) is replaced with a relay of the
same type, if the condition becomes normal, the neutral safety relay
is defective.

WA600-6 9
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L104 (male) Resistance
Defective AJSS neutral safety Between (1) and (2) 200 – 400 z
10 relay (L104) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When AJSS neutral safety relay (L104) is replaced with a relay of
the same type, if the condition becomes normal, the AJSS neutral
safety relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L112 (male) Resistance
Defective neutral holding relay Between (1) and (2) 200 – 400 z
11 (L112) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral holding relay (L112) is replaced with a relay of the
same type, if the condition becomes normal, the neutral holding
relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between starting motor termi- Resis-
Max. 1 z
nal B – starting motor terminal B tance
Possible
causes and Wiring harness between D12 – starting Resis-
Max. 1 z
standard value motor terminal B tance
in normal state Wiring harness between starting motor termi- Resis-
Max. 1 z
nal E – chassis ground tance
Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
L103 (female) (5), – L112 (female) (1) tance
Wiring harness between L103 (female) (3) – Resis-
Max. 1 z
L104 (female) (6), – L112 (female) (3) tance
Wiring harness between L104 (female) (3) –
Resis-
Disconnection in wiring har- R23 (female) (2), – R24 (female) (2), – R25 Max. 1 z
tance
ness (female) (2), – R26 (female) (2)
12
(Disconnection or defective Wiring harness between R23 (female) (1) or Resis-
contact of connector) Max. 1 z
R24 (female) (1) – E01 (female) (1) tance
Wiring harness between R25 (female) (1) or Resis-
Max. 1 z
R26 (female) (1) – E02 (female) (1) tance
Wiring harness between L112 (female) (5) – Resis-
Max. 1 z
R22 (female) (3) tance
Wiring harness between R22 (female) (2) – Resis-
Max. 1 z
L103 (female) (1) tance
Wiring harness between L07 (female) (4) – Resis-
Max. 1 z
L104 (female) (1) tance
Wiring harness between L103 (female) (2),
Resis-
L104 (female) (2) or L112 (female) (2) – Max. 1 z
tance
chassis ground
Wiring harness between L04 (female) (3) – Resis-
Max. 1 z
R22 (female) (1) tance

10 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between starting motor termi-
Resis-
nal B – starting motor terminal B and chassis Min. 1 Mz
tance
ground
Wiring harness between D12 – starting Resis-
Min. 1 Mz
motor terminal B and chassis ground tance
Wiring harness between CL12 (female) (3) –
Resis-
L103 (female) (5), – L112 (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between L103 (female) (3) –
Resis-
L104 (female) (6), – L112 (female) (3) and Min. 1 Mz
tance
chassis ground
Grounding fault in wiring har- Wiring harness between L104 (female) (3) –
13 ness R23 (female) (2), – R24 (female) (2), – R25 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (2), – R26 (female) (2), – circuit tance
branch end and chassis ground
Wiring harness between R23 (female) (1) or
Resis-
R24 (female) (1) – E01 (female) (1) and Min. 1 Mz
Possible tance
chassis ground
causes and
Wiring harness between R25 (female) (1) or
standard value Resis-
in normal state R26 (female) (1) – E02 (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between L112 (female) (5) Resis-
Min. 1 Mz
and R22 (female) (3) and chassis ground tance
Wiring harness between R22 (female) (2) Resis-
Min. 1 Mz
and L103 (female) (1) and chassis ground tance
Wiring harness between L07 (female) (4) – Resis-
Min. 1 Mz
L104 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
14 Wiring harness between alternator terminal
(Contact with 24 V circuit)
R – E01 (female) (2), – E02 (female) (2), – Voltage Max. 1 V
circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 AJSS Voltage
15
controller
Between (4) – Neutral Max. 1 V
chassis ground Other than above 20 – 30 V
Defective engine controller As the engine controller power supply can be detective, carry out
16
power supply troubleshooting for “Failure code CA111”.

WA600-6 11
SEN00563-03 40 Troubleshooting

Contents of
• Engine does not start. (AJSS specification)
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box A is normal.
Related (If it is broken, check the related wiring harness for grounding fault.)
information • The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function
(Code: 40906, D-IN-15).
• If failure code [DDK4KA], [D5ZHKA], [D5ZHKB], [D5ZHKZ] is displayed, carry out troubleshooting
for it first.

Cause Standard value in normal state/Remarks on troubleshooting

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective fuse No. 5 in fuse If fuse is broken, circuit probably has ground fault etc.
2
box B (See cause 11.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
3 Defective battery Battery relay Switch position Voltage
Between terminals OFF 20 – 30 V
B and E ON Max. 1 V
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch START and carry out trouble-
shooting
Starting motor Voltage
Possible
causes and Between terminals
Power supply input 20 – 30 V
standard value Defective starting motor B and E
4
in normal state (Internal defect) Between terminals
Battery input Max. 1 V
R and E
Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
a Prepare with starting switch OFF, then turn starting switch ON
Defective alternator and carry out troubleshooting
5
(Internal short circuit) Wiring harness between alternator terminal
Voltage Max. 1 V
R and chassis ground
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and carry out troubleshooting in each case.
Defective starting switch Starting switch Position of switch Resistance
6
(Internal disconnection)
Between terminals OFF Min. 1 Mz
B (C51) and C (C53) START Max. 1 z

12 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S31 (male) AJSS FNR switch Resistance
F (Forward) Max. 1 z
Between (1) and (2)
Defective AJSS FNR switch Other than above Min. 1 M z
7 (Internal disconnection or N (Neutral) Max. 1 z
short circuit) Between (1) and (3)
Other than above Min. 1 M z
R (Reverse) Max. 1 z
Between (1) and (4)
Other than above Min. 1 M z
Between (1), (2), (3),
Any position Min. 1 M z
(4) – chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R21 (male) Diode range Continuity
Measure at (1) in
Between (1) and (2) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R22 (male) Diode range Continuity
Measure at (3) in
Between (3) and (2) Secured
diode range.
Measure at (1) in
Between (1) and (2) Secured
diode range.
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value R23 (male) Diode range Continuity
in normal state Defective diode (R21, R22,
Measure at (2) in
8 R23, R24, R25 or R26) Between (2) and (1) Secured
diode range.
(Internal disconnection)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R24 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R25 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
R26 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Secured
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L103 (male) Resistance
Defective neutral safety relay Between (1) and (2) 200 – 400 z
9 (L103) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral safety relay (L103) is replaced with a relay of the
same type, if the condition becomes normal, the neutral safety relay
is defective.

WA600-6 13
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L104 (male) Resistance
Defective AJSS neutral safety Between (1) and (2) 200 – 400 z
10 relay (L104) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When AJSS neutral safety relay (L104) is replaced with a relay of
the same type, if the condition becomes normal, the AJSS neutral
safety relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L112 (male) Resistance
Defective neutral holding relay Between (1) and (2) 200 – 400 z
11 (L112) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral holding relay (L112) is replaced with a relay of the
same type, if the condition becomes normal, the neutral holding
relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between starting motor termi- Resis-
Max. 1 z
nal B – starting motor terminal B tance
Possible
causes and Wiring harness between D12 – starting Resis-
Max. 1 z
standard value motor terminal B tance
in normal state Wiring harness between starting motor termi- Resis-
Max. 1 z
nal E – chassis ground tance
Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
L103 (female) (5), – L112 (female) (1) tance
Wiring harness between L103 (female) (3) – Resis-
Max. 1 z
L104 (female) (6), – L112 (female) (3) tance
Wiring harness between L104 (female) (3) –
Resis-
Disconnection in wiring har- R23 (female) (2), – R24 (female) (2), – R25 Max. 1 z
tance
ness (female) (2), – R26 (female) (2)
12
(Disconnection or defective Wiring harness between R23 (female) (1) or Resis-
contact of connector) Max. 1 z
R24 (female) (1) – E01 (female) (1) tance
Wiring harness between R25 (female) (1) or Resis-
Max. 1 z
R26 (female) (1) – E02 (female) (1) tance
Wiring harness between L112 (female) (5) – Resis-
Max. 1 z
R22 (female) (3) tance
Wiring harness between R22 (female) (2) – Resis-
Max. 1 z
L103 (female) (1) tance
Wiring harness between L07 (female) (4) – Resis-
Max. 1 z
L104 (female) (1) tance
Wiring harness between L103 (female) (2),
Resis-
L104 (female) (2) or L112 (female) (2) – Max. 1 z
tance
chassis ground
Wiring harness between S31 (female) (3) – Resis-
Max. 1 z
R22 (female) (1) tance

14 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between starting motor termi-
Resis-
nal B – starting motor terminal B and chassis Min. 1 Mz
tance
ground
Wiring harness between D12 – starting Resis-
Min. 1 Mz
motor terminal B and chassis ground tance
Wiring harness between CL12 (female) (3) –
Resis-
L103 (female) (5), – L112 (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between L103 (female) (3) –
Resis-
L104 (female) (6), – L112 (female) (3) and Min. 1 Mz
tance
chassis ground
Grounding fault in wiring har- Wiring harness between L104 (female) (3) –
13 ness R23 (female) (2), – R24 (female) (2), – R25 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (2), – R26 (female) (2), – circuit tance
branch end and chassis ground
Wiring harness between R23 (female) (1) or
Resis-
R24 (female) (1) – E01 (female) (1) and Min. 1 Mz
Possible tance
chassis ground
causes and
standard value Wiring harness between R25 (female) (1) or
Resis-
in normal state R26 (female) (1) – E02 (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between L112 (female) (5) Resis-
Min. 1 Mz
and R22 (female) (3) and chassis ground tance
Wiring harness between R22 (female) (2) Resis-
Min. 1 Mz
and L103 (female) (1) and chassis ground tance
Wiring harness between L07 (female) (4) – Resis-
Min. 1 Mz
L104 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
14 Wiring harness between alternator terminal
(Contact with 24 V circuit)
R – E01 (female) (2), – E02 (female) (2), – Voltage Max. 1 V
circuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective work equipment L07 AJSS Voltage
15
controller
Between (4) – Neutral Max. 1 V
chassis ground Other than above 20 – 30 V
Defective engine controller As the engine controller power supply can be detective, carry out
16
power supply troubleshooting for “Failure code CA111”.

WA600-6 15
SEN00563-03 40 Troubleshooting

Circuit diagram related to engine starting system

16 WA600-6
40 Troubleshooting SEN00563-03

WA600-6 17
SEN00563-03 40 Troubleshooting

E-2 Wiper does not operate 1

Contents of
(1) Front wiper does not operate. (Steering wheel specification)
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 9 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 6.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C27 Wiper switch Voltage
Between (2) and
Lo 20 – 30 V
chassis ground
Defective front wiper motor Between (1) and
2 Hi 20 – 30 V
(Internal defect) chassis ground
Between (6) and
Normal 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C27 (5) and chassis ground until wiper motor
stops.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
LW21 (female) Wiper switch Voltage
Possible Between (3) and
Normal 20 – 30 V
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
(Internal defect) chassis ground
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat (20 – 30 V)
set in INT, voltage is
chassis ground ↔0V
output intermittently.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C13 Voltage
Between (5) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective front wiper switch
4 LW21 (female) Wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (1) and (5) INT and OFF Max. 1 z
Other than above Min. 1 Mz

18 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LW21 (female) (2) – Resis-
Max. 1 z
L21 (female) (4) tance
Wiring harness between LW21 (female) (3) – Resis-
Max. 1 z
L21 (female) (5) tance
Wiring harness between LW21 (female) (4) – Resis-
Max. 1 z
Disconnection in wiring C27 (female) (1) tance
harness Wiring harness between LW21 (female) (5) – Resis-
5 Max. 1 z
(Disconnection or defective L21 (female) (2) tance
contact of connector) Wiring harness between LW21 (female) (7) – Resis-
Max. 1 z
fuse No. 9 of fuse box B, – circuit branch end tance
Wiring harness between LW21 (female) (6) – Resis-
Max. 1 z
BL2 (female) (1) tance
Wiring harness between C27 (female) (3) – Resis-
Possible Max. 1 z
chassis ground tance
causes and
standard value Wiring harness between L21 (female) (1) – Resis-
Max. 1 z
in normal state chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LW21 (female) (2) – Resis-
Min. 1 Mz
L21 (female) (4) and chassis ground tance
Wiring harness between LW21 (female) (3) – Resis-
Min. 1 Mz
L21 (female) (5) and chassis ground tance
Wiring harness between LW21 (female) (4) – Resis-
Grounding fault in wiring Min. 1 Mz
C27 (female) (1) and chassis ground tance
6 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (5) –
Resis-
L21 (female) (2), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between LW21 (female) (7) –
Resis-
fuse No. 9 of fuse box B, – circuit branch end Min. 1 Mz
tance
and chassis ground
Wiring harness between LW21 (female) (6) – Resis-
Min. 1 Mz
BL2 (female) (1) and chassis ground tance

WA600-6 19
SEN00563-03 40 Troubleshooting

Contents of
(2) Rear wiper does not operate. (Steering wheel specification)
trouble
Related
• Since the rear wiper switch, or wiring harness is defective, the rear wiper does not operate.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C40 Wiper switch Voltage
Between (2) and
ON 20 – 30 V
Defective rear wiper motor chassis ground
1
(Internal defect) Between (1) and
Normal 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C40 (1) and chassis ground until wiper motor
stops.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
LW21 Voltage
Between (7) and chassis ground 20 – 30 V
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
LW21 Wiper switch Resistance
Possible
Between (7) and (9) ON Max. 1 z
causes and
standard value Between (8) and (9) OFF Max. 1 z
in normal state Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LW21 (female) (7) – Resis-
Max. 1 z
Disconnection in wiring C40 (female) (1) tance
harness Wiring harness between LW21 (female) (8) – Resis-
3 Max. 1 z
(Disconnection or defective C40 (female) (3) tance
contact of connector) Wiring harness between LW21 (female) (9) – Resis-
Max. 1 z
C40 (female) (2) tance
Wiring harness between CN40 (female) (4) Resis-
Max. 1 z
and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between LW21 (female) (8) – Resis-
Grounding fault in wiring Min. 1 Mz
C40 (female) (3) tance
4 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (9) – Resis-
Min. 1 Mz
C40 (female) (2) tance
Wiring harness between LW21 (female) (7) – Resis-
Min. 1 Mz
C40 (female) (1), – circuit branch end tance

20 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to wiper (Steering wheel specification)

WA600-6 21
SEN00563-03 40 Troubleshooting

Contents of
(3) Front wiper does not operate. (AJSS specification)
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 9 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 6.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C27 Wiper switch Voltage
Between (2) and
Lo 20 – 30 V
chassis ground
Defective front wiper motor Between (1) and
2 Hi 20 – 30 V
(Internal defect) chassis ground
Between (6) and
Normal 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C27 (5) and chassis ground until wiper motor
stops.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L21 Wiper switch Voltage
Possible Between (3) and
Normal 20 – 30 V
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
(Internal defect) chassis ground
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V
set in INT, voltage is
chassis ground ↔0V
output intermittently.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C13 Voltage
Between (5) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective front wiper switch
4 C13 Wiper switch Resistance
(Internal defect)
Between (5) and (2) Lo Max. 1 z
Between (5) and (3) Hi Max. 1 z
Between (5) and (6) INT Max. 1 z
Between (1) and (2) INT and OFF Max. 1 z
Other than above Min. 1 Mz

22 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C13 (female) (2) – Resis-
Max. 1 z
C27 (female) (3) tance
Wiring harness between C13 (female) (3) – Resis-
Max. 1 z
C27 (female) (3) tance
Disconnection in wiring Wiring harness between C13 (female) (4) – Resis-
Max. 1 z
harness BL1 (female) (1) tance
5
(Disconnection or defective Wiring harness between C13 (female) (5) – Resis-
contact of connector) Max. 1 z
fuse No. 9 of fuse box B, – circuit branch end tance
Wiring harness between C13 (female) (6) – Resis-
Max. 1 z
L21 (female) (4) tance
Wiring harness between C27 (female) (3) – Resis-
Possible Max. 1 z
chassis ground tance
causes and
standard value Wiring harness between L21 (female) (1) – Resis-
Max. 1 z
in normal state chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C13 (female) (2) – Resis-
Min. 1 Mz
C27 (female) (3) and chassis ground tance
Wiring harness between C13 (female) (3) – Resis-
Min. 1 Mz
C27 (female) (3) and chassis ground tance
Grounding fault in wiring
6 harness Wiring harness between C13 (female) (4) –
Resis-
(Contact with ground circuit) BL1 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between C13 (female) (5) –
Resis-
fuse No. 9 of fuse box B, – circuit branch end Min. 1 Mz
tance
and chassis ground
Wiring harness between C13 (female) (6) – Resis-
Min. 1 Mz
L21 (female) (4) and chassis ground tance

WA600-6 23
SEN00563-03 40 Troubleshooting

Contents of
(4) Rear wiper does not operate. (AJSS specification)
trouble
Related
• Since the rear wiper switch, or wiring harness is defective, the rear wiper does not operate.
information

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C40 Wiper switch Voltage
Between (2) and
ON 20 – 30 V
Defective rear wiper motor chassis ground
1
(Internal defect) Between (4) and
Normal 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C40 (1) and chassis ground until wiper motor
stops.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C28 Voltage
Between (3) and chassis ground 20 – 30 V
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
C28 Wiper switch Resistance
Possible
Between (2) and (3) ON Max. 1 z
causes and
standard value Between (1) and (2) OFF Max. 1 z
in normal state Other than above Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C28 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring C40 (female) (3) tance
harness Wiring harness between C28 (female) (2) – Resis-
3 Max. 1 z
(Disconnection or defective C40 (female) (2) tance
contact of connector) Wiring harness between C28 (female) (3) – Resis-
Max. 1 z
C40 (female) (1) tance
Wiring harness between C40 (female) (4) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C28 (female) (1) – Resis-
Grounding fault in wiring Min. 1 Mz
C40 (female) (3) tance
4 harness
(Contact with ground circuit) Wiring harness between C28 (female) (2) – Resis-
Min. 1 Mz
C40 (female) (2) tance
Wiring harness between C28 (female) (3) – Resis-
Min. 1 Mz
C40 (female) (1), – circuit branch end tance

24 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to wiper (AJSS specification)

WA600-6 25
SEN00563-03 40 Troubleshooting

E-3 Windshield washer does not operate 1

Contents of
(1) Windshield washer does not operate. (Steering wheel specification)
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
Defective front washer motor and carry out troubleshooting
1
(Internal defect) BL1 Voltage
Between (1) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON
Defective rear washer motor and carry out troubleshooting
2
(Internal defect) BL3 Voltage
Between (1) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
Defective diode without turning starting switch ON (See test procedure for diode).
3
(HD1, HD2, HD3) HD1, HD2, HD3 (male) Resistance
Between (1) and (2) Min. 1 Mz (continuity is broken)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
LW21 Voltage
Between (7) and chassis ground 20 – 30 V
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Defective front wiper switch without turning starting switch ON.
standard value 4
(Internal defect) Washer switch of
in normal state LW21 (male) Resistance
front wiper switch
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Between (7), (6) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
LW21 Voltage
Between (7) and
20 – 30 V
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective rear wiper switch without turning starting switch ON.
5
(Internal defect)
Washer switch of rear
LW21 (male) Resistance
wiper switch
ON Max. 1 z
Between (7) and (10)
OFF Min. 1 Mz
Between (7), (10) and
Normal Min. 1 Mz
chassis ground

26 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Washer switch of rear
Defective rear wiper switch LW21 (male) Resistance
5 wiper switch
(Internal defect)
Between (7) and (10) ON Max. 1 z
Between (7), (10) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Washer switch of
L21 (male) Voltage
front wiper switch
Defective wiper timer (relay) Between (3) and
6 Normal 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
Possible chassis ground
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Wiring harness between LW21 (female) (6) – Resis-
Max. 1 z
Disconnection in wiring BL1 (female) (1), – L21 (female) (2) tance
harness Wiring harness between LW21 (female) (7) – Resis-
7 Max. 1 z
(Disconnection or defective fuse No. 9 of fuse box B tance
contact of connector) Wiring harness between LW21 (female) (10) Resis-
Max. 1 z
– BL3 (female) (1) tance
Wiring harness between BL1 (female) (2), Resis-
Max. 1 z
BL3 (female) (2) – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wring harness between LW21 (female) (6) –
Resis-
BL1 (female) (1), – L21 (female) (2), – circuit Min. 1 Mz
Grounding fault in wiring tance
branch end and chassis ground
8 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (7) – Resis-
Min. 1 Mz
fuse No. 9 of fuse box B, – circuit branch end tance
Wiring harness between LW21 (female) (10)
Resis-
– BL3 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground

WA600-6 27
SEN00563-03 40 Troubleshooting

Circuit diagram related to windshield washer (Steering wheel specification)

28 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(2) Windshield washer does not operate. (AJSS specification)
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
Defective front washer motor and carry out troubleshooting
1
(Internal defect) BL1 Voltage
Between (1) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then turn starting switch ON
Defective rear washer motor and carry out troubleshooting
2
(Internal defect) BL3 Voltage
Between (1) and chassis ground 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
Defective diode without turning starting switch ON (See test procedure for diode).
3
(HD1, HD2, HD3) HD1, HD2, HD3 (male) Resistance
Between (1) and (2) Min. 1 Mz (continuity is broken)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C13 Voltage
Between (5) and chassis ground 20 – 30 V
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Defective front wiper switch without turning starting switch ON.
standard value 4
(Internal defect) Washer switch of
in normal state C13 (male) Resistance
front wiper switch
ON Max. 1 z
Between (5) and (4)
OFF Min. 1 Mz
Between (5), (4) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C28 Voltage
Between (3), (5) and
20 – 30 V
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Defective rear wiper switch without turning starting switch ON.
5
(Internal defect)
Washer switch of rear
C28 (male) Resistance
wiper switch
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (5), (6) and
Normal Min. 1 Mz
chassis ground

WA600-6 29
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Washer switch of rear
Defective rear wiper switch C28 (male) Resistance
5 wiper switch
(Internal defect)
Between (3) and (2) ON Max. 1 z
Between (3), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Washer switch of
L21 (male) Voltage
front wiper switch
Defective wiper timer (relay) Between (3) and
6 Normal 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and
Wiring harness between C13 (female) (4) – Resis-
standard value Max. 1 z
in normal state BL1 (female) (1), – L21 (female) (2) tance
Disconnection in wiring Wiring harness between C13 (female) (5),
Resis-
harness C28 (female) (3), (5) or C47 (female) (3), (5) Max. 1 z
7 tance
(Disconnection or defective – fuse No. 9 of fuse box B
contact of connector) Wiring harness between C28 (female) (6) – Resis-
Max. 1 z
BL3 (female) (1) tance
Wiring harness between BL1 (female) (2),
Resis-
BL3 (female) (2) or BL5 (female) (2) – chas- Max. 1 z
tance
sis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wring harness between C13 (female) (4) –
Resis-
BL1 (female) (1), – L21 (female) (2), – circuit Min. 1 Mz
tance
branch end and chassis ground
Grounding fault in wiring
8 harness Wiring harness between C13 (female) (5),
(Contact with ground circuit) C28 (female) (3), (5) or C47 (female) (3), (5) Resis-
Min. 1 Mz
– fuse No. 9 of fuse box B, – circuit branch tance
end and chassis ground
Wiring harness between C28 (female) (6) –
Resis-
BL3 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground

30 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to windshield washer (AJSS specification)

WA600-6 31
SEN00563-03 40 Troubleshooting

E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1

Contents of (1) None of headlamp, clearance lamp, tail lamp, and license lamp does not light up.
trouble (Steering wheel specification)
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• Input state (Voltage) from lamp switch (small lamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40200 SMALL LAMP).
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 11 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L02 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
2 (Internal disconnection or
short circuit) OFF Min. 1 Mz
Possible Between (1) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (1), (2), (5)
Normal Min. 1 Mz
and chassis ground
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
contact of connector) Max. 1 z
box B – L02 (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
4 harness Wiring harness between fuse No. 11 of fuse
(Contact with ground circuit) Resis-
box B – L02 (female) (1), – circuit branch Min. 1 Mz
tance
end and chassis ground

32 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(2) Either of headlamp low and high beams does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the lamp switch and dimmer switch (low and high beams) is
defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
Related and go off normally.
information • Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 14 or If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
No. 15 of fuse box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L02 (male) Headlamp switch Resistance
Defective lamp switch OFF Min. 1 Mz
2 (Internal disconnection or
short circuit) Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Between (1), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch L02 (male) Dimmer switch Resistance

3 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (3) and (6)
High Max. 1 z
Between (3), (6) and
Normal Min. 1 Mz
Possible chassis ground
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Wiring harness between L02 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring fuse No. 11 of fuse box B tance
harness Wiring harness between fuse No. 15 of fuse Resis-
4 Max. 1 z
(Disconnection or defective box B – left HEAD (female) (2) tance
contact of connector) Wiring harness between fuse No. 14 of fuse Resis-
Max. 1 z
box B – right HEAD (female) (2) tance
Wiring harness between relay L118 (female) Resis-
Max. 1 z
(3) – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L02 (female) (1) –
Resis-
fuse No. 11 of fuse box B and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between fuse No. 15 of fuse
(Contact with ground circuit) Resis-
box B – left HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
Wiring harness between fuse No. 14 of fuse
Resis-
box B – right HEAD (female) (2) and chassis Min. 1 Mz
tance
ground

WA600-6 33
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
• Headlamp switch is OFF
Wiring harness between L02 (female) (1) –
Possible
fuse No. 11 of fuse box B and chassis Voltage Max. 1 V
causes and
Hot short in wiring harness ground
standard value 6
in normal state (Contact with 24 V circuit) Wiring harness between fuse No. 15 of fuse
box B – left HEAD (female) (2) and chassis Voltage Max. 1 V
ground
Wiring harness between fuse No. 14 of fuse
box B – right HEAD (female) (2) and chassis Voltage Max. 1 V
ground

34 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(3) Headlamp low beam does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch L02 (male) Dimmer switch Resistance

2 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (3) and (6)
High Max. 1 z
Between (3), (6) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible
causes and L118 (male) Resistance
standard value Between (1) and (2) 200 – 400 z
3 Defective dimmer relay (L118)
in normal state
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When dimmer relay (L118) is replaced with a relay of the same type,
if the condition becomes normal, the dimmer relay is defective.
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Disconnection or defective Wiring harness between L118 (female) (6) – Resis-
contact of connector) Max. 1 z
HEAD (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
5 harness Wiring harness between L118 (female) (6) –
(Contact with ground circuit) Resis-
HEAD (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground

WA600-6 35
SEN00563-03 40 Troubleshooting

Contents of
(4) Headlamp high beam does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch L02 (male) Dimmer switch Resistance

2 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (3) and (6)
High Max. 1 z
Between (3), (6) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 z
3 Defective dimmer relay (L118)
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting
standard value When dimmer relay (L118) is replaced with a relay of the same type,
in normal state if the condition becomes normal, the dimmer relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L02 (female) (6) – Resis-
Max. 1 z
harness L118 (female) (1) tance
4
(Disconnection or defective Wiring harness between L118 (female) (2) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between HEAD (3) and L118 Resis-
Max. 1 z
(female) (5) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between L02 (female) (6) – Resis-
Min. 1 Mz
5 harness L118 (female) (1) tance
(Contact with ground circuit) Wiring harness between L118 (female) (5) –
Resis-
HEAD (3), – circuit branch end and chassis Min. 1 Mz
tance
ground

36 WA600-6
40 Troubleshooting SEN00563-03

Contents of (5) Clearance lamp does not light up or go off. (Steering wheel specification)
trouble (6) Tail lamp does not light up or go off. (Steering wheel specification)
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
Related • Carry out the following troubleshooting when the headlamp and turn signal lights up.
information • The input state (voltage) from the headlamp switch (small lamp) can be checked with the monitoring
function (Code: 40200, SMALL LAMP).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 12 or No. If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
13 of fuse box B (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L02 (male) Headlamp switch Resistance
Defective headlamp switch OFF Min. 1 Mz
3 (Internal disconnection or
short circuit) Between (1) and (5) SMALL Max. 1 z
HEAD Max. 1 z
Between (1), (5) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L115 (male) Resistance
Between (1) and (2) 200 – 400 z
Defective small lamp relay
4 a Prepare with starting switch OFF, then turn starting switch ON
(L115)
and carry out troubleshooting
When small lamp relay (L115) is replaced with a relay of the same
Possible
type, if the condition becomes normal, the small lamp relay is defec-
causes and
tive.
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L02 (female) (2) – Resis-
Max. 1 z
L115 (female) (1) tance
Wiring harness between L115 (female) (2) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between L115 (female) (3) – Resis-
Max. 1 z
fuse No. 14 or No. 15 of fuse box B tance
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between fuse No. 12 of fuse
5 Resis-
(Disconnection or defective box B – right COMBI (female) (1), – G01 Max. 1 z
contact of connector) tance
(female) (4)
Wiring harness between fuse No. 13 of fuse
Resis-
box B – left COMBI (female) (1), – G02 Max. 1 z
tance
(female) (4)
Wiring harness between COMBI (female) (2) Resis-
Max. 1 z
– chassis ground tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance

WA600-6 37
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L02 (female) (2) – Resis-
Min. 1 Mz
L115 (female) (1) and chassis ground tance
Wiring harness between L115 (female) (3) –
Resis-
fuse No. 14 or No. 15 of fuse box B and Min. 1 Mz
Grounding fault in wiring tance
chassis ground
harness
6
(Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact of connector) without turning starting switch ON.
Wiring harness between fuse No. 12 of fuse
Resis-
box B – right COMBI (female) (1), – G01 Min. 1 Mz
tance
(female) (4) and chassis ground
Wiring harness between fuse No. 13 of fuse
Resis-
Possible box B – left COMBI (female) (1), – G02 Min. 1 Mz
tance
causes and (female) (4) and chassis ground
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
• Headlamp switch is OFF
Wiring harness between L02 (female) (2) –
Voltage Max. 1 V
L115 (female) (1) and chassis ground
Between L115 (female) (3) – fuse No. 14 or
No. 15 of fuse box B wiring harness and Voltage Max. 1 V
Hot short in wiring harness chassis ground and chassis ground
7
(Contact with 24 V circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between fuse No. 12 of fuse
box B – right COMBI (female) (1), – G01 Voltage Max. 1 V
(female) (4) and chassis ground
Wiring harness between fuse No. 13 of fuse
box B – left COMBI (female) (1), – G02 Voltage Max. 1 V
(female) (4) and chassis ground

38 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to headlamp, clearance lamp and tail lamp (Steering wheel specification)

WA600-6 39
SEN00563-03 40 Troubleshooting

Contents of (7) None of headlamp, clearance lamp, tail lamp, and license lamp does not light up.
trouble (AJSS specification)
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• Input state (Voltage) from lamp switch (small lamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40200 SMALL LAMP).
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 11 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C15 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (4) and (3)
SMALL or HEAD Max. 1 z
2 (Internal disconnection or
short circuit) OFF Min. 1 Mz
Possible Between (4) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
contact of connector) Max. 1 z
box B – C15 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
4 harness Wiring harness between fuse No. 11 of fuse
(Contact with ground circuit) Resis-
box B – C15 (female) (4), – circuit branch Min. 1 Mz
tance
end and chassis ground

40 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(8) Either of headlamp low and high beams does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the lamp switch and dimmer switch (low and high beams) is
defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
Related and go off normally.
information • Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 14 or If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
No. 15 of fuse box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C15 (male) Headlamp switch Resistance
Defective lamp switch OFF Min. 1 Mz
2 (Internal disconnection or
short circuit) Between (4) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Between (4), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch C16 (male) Dimmer switch Resistance

3 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (4) and (2)
High Max. 1 z
Between (4), (2) and
Normal Min. 1 Mz
Possible chassis ground
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Wiring harness between C15 (female) (4) – Resis-
Max. 1 z
Disconnection in wiring fuse No. 11 of fuse box B tance
harness Wiring harness between fuse No. 15 of fuse Resis-
4 Max. 1 z
(Disconnection or defective box B – left HEAD (female) (2) tance
contact of connector) Wiring harness between fuse No. 14 of fuse Resis-
Max. 1 z
box B – right HEAD (female) (2) tance
Wiring harness between relay L118 (female) Resis-
Max. 1 z
(3) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C15 (female) (4) –
Resis-
fuse No. 11 of fuse box B and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between fuse No. 15 of fuse
(Contact with ground circuit) Resis-
box B – left HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
Wiring harness between fuse No. 14 of fuse
Resis-
box B – right HEAD (female) (2) and chassis Min. 1 Mz
tance
ground

WA600-6 41
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
• Headlamp switch is OFF
Wiring harness between C15 (female) (4) –
Possible
fuse No. 11 of fuse box B and chassis Voltage Max. 1 V
causes and
Hot short in wiring harness ground
standard value 6
in normal state (Contact with 24 V circuit) Wiring harness between fuse No. 15 of fuse
box B – left HEAD (female) (2) and chassis Voltage Max. 1 V
ground
Wiring harness between fuse No. 14 of fuse
box B – right HEAD (female) (2) and chassis Voltage Max. 1 V
ground

42 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(9) Headlamp low beam does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch C16 (male) Dimmer switch Resistance

2 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (4) and (2)
High Max. 1 z
Between (4), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible
causes and L118 (male) Resistance
standard value Between (1) and (2) 200 – 400 z
3 Defective dimmer relay (L118)
in normal state
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When dimmer relay (L118) is replaced with a relay of the same type,
if the condition becomes normal, the dimmer relay is defective.
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Disconnection or defective Wiring harness between L118 (female) (6) – Resis-
contact of connector) Max. 1 z
HEAD (female) (1) tance
a Prepare with starting switch OFF, then carry out troubleshooting
Grounding fault in wiring without turning starting switch ON.
5 harness Wiring harness between L118 (female) (6) –
(Contact with ground circuit) Resis-
HEAD (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground

WA600-6 43
SEN00563-03 40 Troubleshooting

Contents of
(10) Headlamp high beam does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40900 D-IN-0).
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-
itoring function (Code: 40904 D-IN-34).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective dimmer switch C16 (male) Dimmer switch Resistance

2 (Internal disconnection or Low Min. 1 Mz
short circuit) Between (4) and (2)
High Max. 1 z
Between (4), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L118 (male) Resistance
Between (1) and (2) 200 – 400 z
3 Defective dimmer relay (L118)
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting
standard value When dimmer relay (L118) is replaced with a relay of the same type,
in normal state if the condition becomes normal, the dimmer relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between C16 (female) (2) – Resis-
Max. 1 z
harness L118 (female) (1) tance
4
(Disconnection or defective Wiring harness between L118 (female) (2) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between HEAD (3) and L118 Resis-
Max. 1 z
(female) (5) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between C16 (female) (2) – Resis-
Min. 1 Mz
5 harness L118 (female) (1) tance
(Contact with ground circuit) Wiring harness between L118 (female) (5) –
Resis-
HEAD (3), – circuit branch end and chassis Min. 1 Mz
tance
ground

44 WA600-6
40 Troubleshooting SEN00563-03

Contents of (11) Clearance lamp does not light up or go off. (AJSS specification)
trouble (12) Tail lamp does not light up or go off. (AJSS specification)
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
Related • Carry out the following troubleshooting when the headlamp and turn signal light up.
information • The input state (voltage) from the headlamp switch (small lamp) can be checked with the monitoring
function (Code: 40200, SMALL LAMP).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 12 or No. If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
13 of fuse box B (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C15 (male) Headlamp switch Resistance
Defective headlamp switch OFF Min. 1 Mz
3 (Internal disconnection or
short circuit) Between (4) and (3) SMALL Max. 1 z
HEAD Max. 1 z
Between (4), (3) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L115 (male) Resistance
Between (1) and (2) 200 – 400 z
Defective small lamp relay
4 a Prepare with starting switch OFF, then turn starting switch ON
(L115)
and carry out troubleshooting
When small lamp relay (L115) is replaced with a relay of the same
Possible
type, if the condition becomes normal, the small lamp relay is defec-
causes and
tive.
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C15 (female) (3) – Resis-
Max. 1 z
L115 (female) (1) tance
Wiring harness between L115 (female) (2) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between L115 (female) (3) – Resis-
Max. 1 z
fuse No. 14 or No. 15 of fuse box B tance
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between fuse No. 12 of fuse
5 Resis-
(Disconnection or defective box B – right COMBI (female) (1), – G01 Max. 1 z
contact of connector) tance
(female) (4)
Wiring harness between fuse No. 13 of fuse
Resis-
box B – left COMBI (female) (1), – G02 Max. 1 z
tance
(female) (4)
Wiring harness between COMBI (female) (2) Resis-
Max. 1 z
– chassis ground tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance

WA600-6 45
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C15 (female) (3) – Resis-
Min. 1 Mz
L115 (female) (1) and chassis ground tance
Wiring harness between L115 (female) (3) –
Resis-
fuse No. 14 or No. 15 of fuse box B and Min. 1 Mz
Grounding fault in wiring tance
chassis ground
harness
6
(Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact of connector) without turning starting switch ON.
Wiring harness between fuse No. 12 of fuse
Resis-
box B – right COMBI (female) (1), – G01 Min. 1 Mz
tance
(female) (4) and chassis ground
Wiring harness between fuse No. 13 of fuse
Resis-
Possible box B – left COMBI (female) (1), – G02 Min. 1 Mz
tance
causes and (female) (4) and chassis ground
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
• Headlamp switch is OFF
Wiring harness between C15 (female) (3) –
Voltage Max. 1 V
L115 (female) (1) and chassis ground
Between L115 (female) (3) – fuse No. 14 or
No. 15 of fuse box B wiring harness and Voltage Max. 1 V
Hot short in wiring harness chassis ground
7
(Contact with 24 V circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between fuse No. 12 of fuse
box B – right COMBI (female) (1), – G01 Voltage Max. 1 V
(female) (4) and chassis ground
Wiring harness between fuse No. 13 of fuse
box B – left COMBI (female) (1), – G02 Voltage Max. 1 V
(female) (4) and chassis ground

46 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to headlamp, clearance lamp and tail lamp (AJSS specification)

WA600-6 47
SEN00563-03 40 Troubleshooting

E-5 Working lamp does not light up or go off. 1

Contents of
(1) Either of front working lamp and rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related ground.
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C33 (male) Working lamp switch Resistance
OFF Min. 1 Mz
REAR Max. 1 z
Between (1) and (2)
FRONT (& SIDE) Min. 1 Mz
ALL Min. 1 Mz
OFF Min. 1 Mz
Defective working lamp switch
REAR Min. 1 Mz
1 (Internal disconnection or Between (1) and (3)
short circuit) FRONT (& SIDE) Max. 1 z
Possible
causes and ALL Max. 1 z
standard value OFF Min. 1 Mz
in normal state
REAR Min. 1 Mz
Between (1) and (4)
FRONT (& SIDE) Min. 1 Mz
ALL Max. 1 z
Between (1), (2), (3),
(4) and chassis Normal Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between L02 (female) (5) – Resis-
2 Max. 1 z
(Disconnection or defective C33 (Steering wheel specification) tance
contact of connector) Wiring harness between C15 (female) (3) – Resis-
Max. 1 z
C33 (female) (1) (AJSS specification) tance

Contents of
(2) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
information
lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
Possible Defective fuse No. 3 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
causes and 2
box B (See cause 6.)
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Defective front working lamp without turning starting switch ON.
3
relay (L109) L109 (male) Resistance
Between (5) and (6) 200 – 400 z

48 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective front working lamp
3 When front working lamp relay (L109) is replaced with a relay of the
relay (L109)
same type, if the condition becomes normal, the front working lamp
relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C33 (male) Working lamp switch Resistance

Defective working lamp switch OFF Min. 1 Mz

4 (Internal disconnection or REAR Min. 1 Mz
short circuit) Between (1) and (3)
FRONT (& SIDE) Max. 1 z
ALL Max. 1 z
Between (1), (3) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C33 (female) (3) – Resis-
Max. 1 z
L109 (female) (5) tance
Wiring harness between L109 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Possible Wiring harness between L109 (female) (1) – Resis-
Max. 1 z
causes and C41 (female) (1), – C42 (female) (1) tance
Disconnection in wiring
standard value harness Wiring harness between C41 (female) (2), Resis-
in normal state 5 Max. 1 z
(Disconnection or defective C42 (female) (2) – chassis ground tance
contact of connector) Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
box B – L109 (female) (2) tance
Wiring harness between L109 (female) (3) – Resis-
Max. 1 z
FW01 (female) (1), – FW02 (female) (1) tance
Wiring harness between FW01 (female) (2), Resis-
Max. 1 z
FW02 (female) (2) – chassis ground tance
Wiring harness between fuse No. 4 of fuse Resis-
Max. 1 z
box B – L109 (female) (4) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C33 (female) (3) –
Resis-
L109 (female) (5), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between L109 (female) (1) –
Grounding fault in wiring Resis-
C41 (female) (1), – C42 (female) (1) and Min. 1 Mz
6 harness tance
chassis ground
(Contact with ground circuit)
Wiring harness between fuse No. 3 of fuse
Resis-
box B – L109 (female) (2), – circuit branch Min. 1 Mz
tance
end and chassis ground
Wiring harness between L109 (female) (3) –
Resis-
FW01 (female) (1), – FW02 (female) (1), – Min. 1 Mz
tance
circuit branch end and chassis ground

WA600-6 49
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Possible
causes and Wiring harness between L109 (female) (1) –
standard value Hot short in wiring harness C41 (female) (1), – C42 (female) (1) and Voltage Max. 1 V
7
in normal state (Contact with 24 V circuit) chassis ground
Wiring harness between L109 (female) (3) –
FW01 (female) (1), – FW02 (female) (1), – Voltage Max. 1 V
circuit branch end and chassis ground

50 WA600-6
40 Troubleshooting SEN00563-03

Contents of
(3) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
information
lamp first.

Cause Standard value in normal state/Remarks on troubleshooting

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
Defective fuse No. 4 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L110 (male) Resistance
Between (5) and (6) 200 – 400 z
Defective rear working lamp
3 a Prepare with starting switch OFF, then turn starting switch ON
relay (L110)
and carry out troubleshooting
When rear working lamp relay (L110) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible C33 (male) Working lamp switch Resistance
causes and
Defective working lamp switch OFF Min. 1 Mz
standard value
in normal state 4 (Internal disconnection or REAR Max. 1 z
short circuit) Between (1) and (2)
FRONT (& SIDE) Min. 1 Mz
ALL Min. 1 Mz
Between (1), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C33 (female) (2) – Resis-
Max. 1 z
L110 (female) (5) tance
Disconnection in wiring Wiring harness between L110 (female) (6) – Resis-
Max. 1 z
harness chassis ground tance
5
(Disconnection or defective Wiring harness between L110 (female) (1) – Resis-
contact of connector) Max. 1 z
G03 (female) (1), – G04 (female) (1) tance
Wiring harness between G03 (female) (2) or Resis-
Max. 1 z
G04 (female) (2) – chassis ground tance
Wiring harness between fuse No. 4 of fuse Resis-
Max. 1 z
box B – L110 (female) (2) tance

WA600-6 51
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between C33 (female) (2) –
Resis-
L110 (female) (5), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between L110 (female) (1) –
Resis-
Grounding fault in wiring G03 (female) (1), – G04 (female) (1), – cir- Min. 1 Mz
tance
6 harness cuit branch end and chassis ground
Possible (Contact with ground circuit) Wiring harness between fuse No. 4 of fuse
causes and box B – L110 (female) (2), – circuit branch
standard value end and chassis ground
in normal state • If one of above conditions is applicable, Resis-
Min. 1 Mz
ADD front working lamp (if equipped) is tance
also in failure.
For machines equipped with, ADD front
working lamp also does not light up.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
7 Wiring harness between L110 (female) (1) –
(Contact with 24 V circuit) Resis-
G03 (female) (1), – G04 (female) (1), – cir- Max. 1 z
tance
cuit branch end and chassis ground

52 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to working lamp (Steering wheel specification)

WA600-6 53
SEN00563-03 40 Troubleshooting

Circuit diagram related to working lamp (AJSS specification)

54 WA600-6
40 Troubleshooting SEN00563-03

WA600-6 55
SEN00563-03 40 Troubleshooting

E-6 Step lamp does not light up or go off 1

Contents of
Step lamp does not light up or go off
trouble
• The switch, lamp, or wiring harness of the step lamp or tail lamp system is defective.
Related
• The step lamp switch is installed in 2 places: upper left section from the operator's seat and the step
information
section. Both switches can be used to turn on/off the step lamp.

Cause Standard value in normal state/Remarks on troubleshooting

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 3 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box A (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
C19 (male) Step lamp switch Resistance
Defective step lamp switch Up or Down Min. 1 Mz
(at upper left section from Between (3) and (4)
Down or Up Max. 1 z
3 operator's seat)
(Internal disconnection or Up or Down Max. 1 z
Between (5) and (6)
short circuit) Down or Up Min. 1 Mz
Between (3), (4), (5),
(6) and chassis Normal Min. 1 Mz
ground
a Prepare with starting switch OFF, then carry out troubleshooting
Possible without turning starting switch ON.
causes and D09 (male) Step lamp switch Resistance
standard value Defective step lamp switch Up or Down Min. 1 Mz
in normal state (at step section) Between (A) and (B)
4 Down or Up Max. 1 z
(Internal disconnection or
short circuit) Up or Down Max. 1 z
Between (A) and (C)
Down or Up Min. 1 Mz
Between (A), (B), (C)
Normal Min. 1 Mz
and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
box A – D09 (female) (A) tance
Disconnection in wiring Wiring harness between D09 (female) (B) – Resis-
Max. 1 z
harness C19 (female) (3) tance
5
(Disconnection or defective Wiring harness between D09 (female) (C) – Resis-
contact of connector) Max. 1 z
C19 (female) (6) tance
Wiring harness between C19 (female) (4), Resis-
Max. 1 z
(5) – C45 (female) (1) tance
Wiring harness between C45 (female) (2) – Resis-
Max. 1 z
chassis ground tance

56 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 3 of fuse Resis-
Min. 1 Mz
Grounding fault in wiring box A – D09 (female) (A) and chassis ground tance
harness Wiring harness between D09 (female) (B) – Resis-
6 Min. 1 Mz
(Disconnection or defective C19 (female) (3) and chassis ground tance
Possible contact of connector) Wiring harness between D09 (female) (C) – Resis-
causes and Min. 1 Mz
C19 (female) (6) and chassis ground tance
standard value
Wiring harness between C19 (female) (4), Resis-
in normal state Min. 1 Mz
(5) – C45 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Hot short in wiring harness Max. 1 V

7 Wiring harness between C19 (female) (4),
(Contact with 24 V circuit) (After
(5) – C45 (female) (1)
Voltage switched
• Switch over the switch and measure the
over: 20 –
voltage again
30 V)

Circuit diagram related to step lamp

WA600-6 57
SEN00563-03 40 Troubleshooting

E-7 Turn signal lamp and hazard lamp do not light up or go off 1

Contents of (1) Either of turn signal lamp and hazard lamp does not light up or go off. (Steering wheel specification)
trouble (STD)
Related
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 1 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B and No.2 of fuse box A (See causes 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L113 (male) Resistance
Between (5) and (6) 200 – 400 z
2 Defective hazard relay (L113)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When hazard relay (L113) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat 20 to 30 V ↔ 0 V.
3 (Internal disconnection or
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L19 (male) Resistance
Between (3) or (4) and
Min. 1 Mz
chassis ground
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Turn signal lamp and
L03 (male) Resistance
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Neutral
Between (2) and (3) Turn signal lever:
Max. 1 z
Right
Hazard lamp switch:
Max. 1 z
ON
Defective turn signal lamp and
hazard lamp switches Turn signal lever: Left Max. 1 z
4
(Internal disconnection or Turn signal lever:
short circuit) Min. 1 Mz
Neutral
Between (2) and (4) Turn signal lever:
Min. 1 Mz
Right
Hazard lamp switch:
Max. 1 z
ON
Hazard lamp switch:
Max. 1 z
ON
Between (1) – (5)
Hazard lamp switch:
Min. 1 Mz
OFF
Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground

58 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L113 (female) (3) Resis-
Max. 1 z
and L19 (female) (3) tance
Disconnection in wiring Resis-
Between L113 (female) (6) – fuse B (1) Max. 1 z
harness tance
5
(Disconnection or defective Wiring harness between L113 (female) (5) – Resis-
contact of connector) Max. 1 z
fuse A (2) tance
Wiring harness between L19 (female) (4) – Resis-
Max. 1 z
L03 (female) (2) tance
Possible
Wiring harness between L19 (female) (1) – Resis-
causes and Max. 1 z
chassis ground tance
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L113 (female) (3) – Resis-
6 harness Min. 1 Mz
L19 (female) (3) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L19 (female) (4) – Resis-
Min. 1 Mz
L03 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L113 (female) (3) –
7 Voltage Max. 1 V
(Contact with 24 V circuit) L19 (female) (3) and chassis ground
Wiring harness between L19 (female) (4) –
Voltage Max. 1 V
L03 (female) (2) and chassis ground

Contents of
(2) Either of turn signal lamp and hazard lamp does not light up or go off. (AJSS specification)
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 1 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B and No.2 of fuse box A (See causes 4.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat (20 – 30 V) ↔ 0 V.
2 (Internal disconnection or
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Possible
without turning starting switch ON.
causes and
standard value L19 (male) Resistance
in normal state Between (3) or (4) and
Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between L113 (female) (3) – Resis-
Max. 1 z
harness L19 (female) (3) tance
3
(Disconnection or defective Wiring harness between L19 (female) (1) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between L19 (female) (4) – Resis-
Max. 1 z
circuit branch end point tance

WA600-6 59
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L113 (female) (3) – Resis-
4 harness Min. 1 Mz
L19 (female) (3) and chassis ground tance
Possible (Contact with ground circuit)
Wiring harness between L19 (female) (4) – Resis-
causes and Min. 1 Mz
circuit branch end point and chassis ground tance
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness Wiring harness between L113 (female) (3) –
5 Voltage Max. 1 V
(Contact with 24 V circuit) L19 (female) (3) and chassis ground
Wiring harness between L19 (female) (4) –
Voltage Max. 1 V
circuit branch end point and chassis ground

Contents of
(3) Turn signal lamp does not light up or go off (Steering wheel specification)
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
information

Cause Standard value in normal state/Remarks on troubleshooting

If a specific turn signal lamp does not light up, its bulb may be
1 Broken bulb
broken or may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Turn signal lamp and
L03 (male) Resistance
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Between (2) and (3) Neutral
Defective turn signal lamp and
hazard lamp switches Turn signal lever:
2 Max. 1 z
(Internal disconnection or Right
short circuit)
Turn signal lever: Left Max. 1 z
Turn signal lever:
Possible Min. 1 Mz
Between (2) and (4) Neutral
causes and
standard value Turn signal lever:
Min. 1 Mz
in normal state Right
Between (2), (3), (4)
Normal Max. 1 z
and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (3) – Resis-
Max. 1 z
G01 (female) (1), – right COMBI (female) (3) tance
Disconnection in wiring Wiring harness between L03 (female) (4) – Resis-
Max. 1 z
harness G02 (female) (1), – left COMBI (female) (3) tance
3
(Disconnection or defective Wiring harness between G01 (female) (6) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between right and left Resis-
Max. 1 z
COMBI (female) (2) – chassis ground tance

60 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L03 (female) (3) –
Grounding fault in wiring Resis-
G01 (female) (1), – right COMBI (female) (3), Min. 1 Mz
4 harness tance
– circuit branch end and chassis ground
(Contact with ground circuit)
Wiring harness between L03 (female) (4) –
Possible Resis-
G02 (female) (1), – left COMBI (female) (3), Min. 1 Mz
causes and tance
– circuit branch end and chassis ground
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L03 (female) (3) –
Hot short in wiring harness G01 (female) (1), – right COMBI (female) (3), Voltage Max. 1 V
5
(Contact with 24 V circuit) – circuit branch end and chassis ground
Wiring harness between L03 (female) (4) –
G02 (female) (1), – left COMBI (female) (3), Voltage Max. 1 V
– circuit branch end and chassis ground

Contents of
(4) Turn signal lamp does not light up or go off (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• The input state from the turn signal switch to the controller can be checked with the monitoring func-
Related
tion (Code: 40913 D-IN30, D-IN31).
information
• The output state from the controller to the winker relay can be checked with the monitoring function
(Code: 40954 D-0UT16, D-OUT17).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S22 (male) Turn signal lever Resistance
Neutral Min. 1 Mz
Defective turn signal lever Between (5) and (4) Right Min. 1 Mz
switch
2 Left Max. 1 z
(Internal disconnection or
short circuit) Neutral Min. 1 Mz
Possible
causes and Between (5) and (6) Right Max. 1 z
standard value Left Min. 1 Mz
in normal state
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L121 (male) Resistance
Between (1) and (2) 200 – 400 z
Defective turn signal lamp
3
relay (right) (L121) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When turn signal lamp relay (right) (L121) is replaced with a relay of
the same type, if the condition becomes normal, the turn signal lamp
relay (right) is defective.

WA600-6 61
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Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L122 (male) Resistance
Between (1) and (2) 200 – 400 z
Defective turn signal lamp
4
relay (left) (L122) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When turn signal lamp relay (left) (L122) is replaced with a relay of
the same type, if the condition becomes normal, the turn signal lamp
relay (left) is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between S22 (female) (4) – Resis-
Min. 1 Mz
L06 (female) (38) tance
Wiring harness between S22 (female) (6) – Resis-
Min. 1 Mz
L06 (female) (2) tance
Resis-
Between S22 (female) (5) – chassis ground Min. 1 Mz
tance
Wiring harness between L121 (female) (1) or Resis-
Max. 1 z
L122 (female) (1) – fuse No. 1 of fuse box B tance
Wiring harness between L121 (female) (2) – Resis-
Max. 1 z
L06 (female) (18) tance
Disconnection in wiring
harness Wiring harness between L122 (female) (2) – Resis-
5 Max. 1 z
(Disconnection or defective L06 (female) (8) tance
contact of connector)
Wiring harness between L121 (female) (3) – Resis-
Max. 1 z
G01 (female) (1), – right COMBI (female) (3) tance
Possible
causes and Wiring harness between L122 (female) (3) – Resis-
Max. 1 z
standard value G02 (female) (1), – left COMBI (female) (3) tance
in normal state Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between right COMBI Resis-
Max. 1 z
(female) (2) – chassis ground tance
Wiring harness between left COMBI (female) Resis-
Max. 1 z
(2) – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between S22 (female) (4) – L06 (female) (38) Resis-
Min. 1 Mz
and chassis ground tance
Between S22 (female) (6) – L06 (female) (2) Resis-
Min. 1 Mz
and chassis ground tance
Wiring harness between L121 (female) (1) or
Resis-
L122 (female) (1) – fuse No. 1 of fuse box B Min. 1 Mz
tance
Grounding fault in wiring and chassis ground
6 harness Wiring harness between L121 (female) (2) – Resis-
(Contact with ground circuit) Min. 1 Mz
L06 (female) (18) and chassis ground tance
Wiring harness between L122 (female) (2) – Resis-
Min. 1 Mz
L06 (female) (8) and chassis ground tance
Wiring harness between L121 (female) (3) –
Resis-
G01 (female) (1), – right COMBI (female) (3), Min. 1 Mz
tance
– circuit branch end and chassis ground
Wiring harness between L122 (female) (3) –
Resis-
G02 (female) (1), – left COMBI (female) (3), Min. 1 Mz
tance
– circuit branch end and chassis ground

62 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L121 (female) (3) –
Hot short in wiring harness G01 (female) (1), – right COMBI (female) (3), Voltage Max. 1 V
7
(Contact with 24 V circuit) – circuit branch end and chassis ground
Wiring harness between L122 (female) (3) –
G02 (female) (1), – left COMBI (female) (3), Voltage Max. 1 V
– circuit branch end and chassis ground
Possible
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting.
in normal state Press turn signal switch R Voltage Max. 1 V
L06 (2)
Release turn signal switch R Voltage 8 – 10 V
Press turn signal switch L Voltage Max. 1 V
Defective work equipment L06 (38)
8
controller Release turn signal switch L Voltage 8 – 10 V
Press turn signal switch R Voltage Max. 1 V
L06 (18)
Press turn signal switch R again Voltage 20 – 30 V
Press turn signal switch L Voltage Max. 1 V
L06 (8)
Press turn signal switch L again Voltage 20 – 30 V

Contents of
(5) Hazard lamp does not light up or go off (Steering wheel specification)
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse in fuse box A
1 If fuse is broken, circuit probably has ground fault.
(2)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Resis-
Disconnection in wiring Between fuse box B (2) – L113 (female) (5) Max. 1 z
tance
harness
Resis-
2 (Disconnection in wiring or Between fuse box B (2) – L113 (female) (1) Max. 1 z
tance
defective contact in
connector) Resis-
Between L113 (female) (2) – L03 (female) (1) Max. 1 z
tance
Possible
causes and Resis-
Between L03 (female) (5) – chassis ground Max. 1 z
standard value tance
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring harness without turning starting switch ON.
3
(Contact with GND circuit) Wiring harness between L113 (female) (2) – Resis-
Min. 1 Mz
L03 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective hazard lamp switch L03 (male) Hazard lamp switch Resistance
4 (Internal disconnection or Between (2) and ON Max. 1 z
short circuit) (3), (4) OFF Min. 1 Mz
Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground

WA600-6 63
SEN00563-03 40 Troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible L113 (male) Resistance
causes and Between (1) – (2) 200 – 400 z
standard value Defective hazard lamp relay
5 a Prepare with starting switch OFF, then turn starting switch ON
in normal state (L113)
and carry out troubleshooting.
Replace hazard lamp relay (L113) with another relay of same type.
If condition becomes normal at this time, hazard lamp relay is defec-
tive.

Contents of
(6) Hazard lamp does not light up or go off (AJSS specification)
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse in fuse box A
1 If fuse is broken, circuit probably has ground fault.
(2)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Resis-
harness Between fuse box A (2) – CN14 (female) (2) Max. 1 z
tance
2 (Disconnection in wiring or
Between C14 (female) (4) – L113 (female) Resis-
defective contact in Max. 1 z
connector) (1) tance
Between C14 (female) (4) – L114 (female) Resis-
Max. 1 z
(5) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harness Between C14 (female) (4) – L113 (female) Resis-
3 Min. 1 Mz
(Contact with GND circuit) (1) and chassis ground tance
Possible Between C14 (female) (4) – L114 (female) Resis-
causes and Min. 1 Mz
(5) and chassis ground tance
standard value
a Prepare with starting switch OFF, then carry out troubleshooting
in normal state
without turning starting switch ON.

Defective hazard lamp switch C14 (male) Hazard lamp switch Resistance
4 (Internal disconnection or ON Max. 1 z
short circuit) Between (2) and (4)
OFF Min. 1 Mz
Between (2), (4) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L113 (male) Resistance
Between (1) – (2) 200 – 400 z
Defective hazard lamp relay
5 a Prepare with starting switch OFF, then turn starting switch ON
(L113)
and carry out troubleshooting.
Replace hazard lamp relay (L113) with another relay of same type.
If condition becomes normal at this time, hazard lamp relay is defec-
tive.

64 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible L114 (male) Resistance
causes and Between (1) – (2) 200 – 400 z
standard value Defective turn signal lamp
6 a Prepare with starting switch OFF, then turn starting switch ON
in normal state relay (L114)
and carry out troubleshooting.
Replace turn signal lamp relay (L114) with another relay of same
type. If condition becomes normal at this time, turn signal lamp relay
is defective.

WA600-6 65
SEN00563-03 40 Troubleshooting

Circuit diagram related to turn signal lamp and hazard lamp (Steering wheel specification)

66 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to turn signal lamp and hazard lamp (AJSS specification)

WA600-6 67
SEN00563-03 40 Troubleshooting

E-8 Brake lamp does not light or it keeps lighting up. 1

Contents of
Brake lamp does not light or it keeps lighting up.
trouble
• The lamp or wiring harness of the brake lamp system is abnormal.
Related
• The input state of brake lamp switch signal to the controller can be checked with the monitoring
information
function (Code: 40942 D-IN-32).

Cause Standard value in normal state/Remarks on troubleshooting

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
Defective fuse No. 2 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L102 (male) Resistance
Defective brake lamp relay
Between (1) and (2) 200 – 400 z
(L102)
3 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection or
short circuit) and carry out troubleshooting
When brake lamp relay (L102) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Possible L16 (male) Brake pedal Resistance
causes and Defective brake lamp switch
standard value 4 (Internal disconnection or Pressed Max. 1 z
short circuit) Between (1) and (2)
in normal state Released Min. 1 Mz
Between (1), (2) and
Normal Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse Resis-
Max. 1 z
box B – L102 (female) (2), – L16 (female) (1) tance
Wiring harness between L16 (female) (2) – Resis-
Max. 1 z
Disconnection in wiring L102 (female) (5) tance
harness Wiring harness between L102 (female) (6) – Resis-
5 Max. 1 z
(Disconnection or defective chassis ground tance
contact of connector) Wiring harness between L102 (female) (1) – Resis-
Max. 1 z
G01 (female) (5), – G02 (female) (5) tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance

68 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resis-
box B – L102 (female) (2), – L16 (female) (1) Min. 1 Mz
Grounding fault in wiring tance
and chassis ground
6 harness
(Contact with ground circuit) Wiring harness between L16 (female) (2) – Resis-
Min. 1 Mz
Possible L102 (female) (5) and chassis ground tance
causes and Wiring harness between L102 (female) (1) –
standard value Resis-
G01 (female) (5), – G02 (female) (5), – cir- Min. 1 Mz
in normal state tance
cuit branch end and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness between L16 (female) (2) –
Hot short in wiring harness Voltage Max. 1 V
7 L102 (female) (5) and chassis ground
(Contact with 24 V circuit)
Wiring harness between L102 (female) (1) –
G01 (female) (5), – G02 (female) (5), – cir- Voltage Max. 1 V
cuit branch end and chassis ground

WA600-6 69
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Circuit diagram related to brake lamp

70 WA600-6
40 Troubleshooting SEN00563-03

WA600-6 71
SEN00563-03 40 Troubleshooting

E-9 Backup lamp does not light or it keeps lighting up. 1

Contents of
Backup lamp does not light or it keeps lighting up. (Steering wheel specification)
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
information (If disconnection or short circuit occurs, failure code D160KA or D160KB is displayed.)

Cause Standard value in normal state/Remarks on troubleshooting

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
Defective fuse No. 2 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L101 (male) Resistance
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse Resis-
Max. 1 z
box B – L101 (female) (2) tance
Wiring harness between L101 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring G01 (female) (2), – G02 (female) (2) tance
Possible harness Wiring harness between L101 (female) (5) – Resis-
causes and 4 Max. 1 z
(Disconnection or defective L04 (female) (4) tance
standard value contact of connector) Wiring harness between L101 (female) (6) – Resis-
in normal state Max. 1 z
chassis ground tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resis-
box B – L101 (female) (2) and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between L101 (female) (1) –
(Contact with ground circuit) Resis-
G01 (female) (2), – G02 (female) (2), – cir- Min. 1 Mz
tance
cuit branch end and chassis ground
Wiring harness between L101 (female) (5) –
Resis-
L04 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
6 Wiring harness between L101 (female) (1) –
(Contact with 24 V circuit)
G01 (female) (2), – G02 (female) (2), – cir- Voltage Max. 1 V
cuit branch end and chassis ground

72 WA600-6
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Circuit diagram related to backup lamp relay (Steering wheel specification)

WA600-6 73
SEN00563-03 40 Troubleshooting

Contents of
Backup lamp does not light or it keeps lighting up. (AJSS specification)
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
information (If disconnection or short circuit occurs, failure code D160KA or D160KB is displayed.)

Cause Standard value in normal state/Remarks on troubleshooting

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
Defective fuse No. 2 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L101 (male) Resistance
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse Resis-
Max. 1 z
box B – L101 (female) (2) tance
Wiring harness between L101 (female) (1) – Resis-
Max. 1 z
Disconnection in wiring G01 (female) (2), – G02 (female) (2) tance
Possible harness Wiring harness between L101 (female) (5) Resis-
causes and 4 Max. 1 z
(Disconnection or defective and S31 (female) (4) tance
standard value contact of connector) Wiring harness between L101 (female) (6) – Resis-
in normal state Max. 1 z
chassis ground tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G02 (female) (6) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resis-
box B – L101 (female) (2) and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between L101 (female) (1) –
(Contact with ground circuit) Resis-
G01 (female) (2), – G02 (female) (2), – cir- Min. 1 Mz
tance
cuit branch end and chassis ground
Wiring harness between L101 (female) (5) –
Resis-
S31 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
6 Wiring harness between L101 (female) (1) –
(Contact with 24 V circuit)
G01 (female) (2), – G02 (female) (2), – cir- Voltage Max. 1 V
cuit branch end and chassis ground

74 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to backup lamp relay (AJSS specification)

WA600-6 75
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E-10 Backup buzzer does not sound or it keeps sounding. 1

Contents of
Backup buzzer does not sound or it keeps sounding (Steering wheel specification)
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
information (If disconnection or short circuit occurs, failure code D160KA or D160KB is displayed.)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective backup buzzer
1 (Internal disconnection or G06 Gear shift lever Voltage
short circuit) R Max. 1 V
Between (1) and (2)
Other than R 20 – 30 V
Defective fuse No. 2 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L101 (male) Resistance
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse Resis-
Max. 1 z
Possible box B – L101 (female) (2) tance
causes and Disconnection in wiring Wiring harness between L101 (female) (1) – Resis-
standard value Max. 1 z
harness G06 (female) (1) tance
in normal state 4
(Disconnection or defective Wiring harness between L101 (female) (5) – Resis-
contact of connector) Max. 1 z
L04 (female) (4) tance
Wiring harness between L101 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G06 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resis-
box B – L101 (female) (2) and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between L101 (female) (1) –
(Contact with ground circuit) Resis-
G06 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between L101 (female) (5) –
Resis-
L04 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
6 Wiring harness between L101 (female) (1) –
(Contact with 24 V circuit)
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground

76 WA600-6
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Circuit diagram related to backup buzzer (Steering wheel specification)

WA600-6 77
SEN00563-03 40 Troubleshooting

Contents of
Backup buzzer does not sound or it keeps sounding (AJSS specification)
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
information (If disconnection or short circuit occurs, failure code D160KA or D160KB is displayed.)

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Defective backup buzzer
1 (Internal disconnection or G06 Gear shift lever Voltage
short circuit) R Max. 1 V
Between (1) and (2)
Other than R 20 – 30 V
Defective fuse No. 2 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
box B (See cause 5.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L101 (male) Resistance
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse Resis-
Max. 1 z
Possible box B – L101 (female) (2) tance
causes and Wiring harness between L101 (female) (1) – Resis-
Disconnection in wiring Max. 1 z
standard value harness G06 (female) (1) tance
in normal state 4
(Disconnection or defective Wiring harness between L101 (female) (5) – Resis-
contact of connector) Max. 1 z
S31 (female) (4) tance
Wiring harness between L101 (female) (6) – Resis-
Max. 1 z
chassis ground tance
Wiring harness between G06 (female) (2) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 2 of fuse
Resis-
box B – L101 (female) (2) and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
5 harness Wiring harness between L101 (female) (1) –
(Contact with ground circuit) Resis-
G06 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between L101 (female) (5) –
Resis-
S31 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Hot short in wiring harness
6 Wiring harness between L101 (female) (1) –
(Contact with 24 V circuit)
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground

78 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to backup buzzer (AJSS specification)

WA600-6 79
SEN00563-03 40 Troubleshooting

E-11 Horn does not sound or it keeps sounding. 1

Contents of
Horn does not sound or it keeps sounding (Steering wheel specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 8 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box A (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L116 (male) Resistance
Defective horn relay (L116)
Between (1) and (2) 200 – 400 z
2 (Internal disconnection or
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective horn switch
3 (Internal disconnection or L05 (male) Horn switch Resistance
short circuit) Between (1) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON
Possible
and carry out troubleshooting. (Disconnect connector and mea-
causes and
sure on female side)
standard value
in normal state Defective horn F03, F04 Horn switch Voltage
4 (Internal disconnection or ON Max. 1 V
Between
short circuit)
F03 (1) and (2) OFF 20 – 30 V
Between ON Max. 1 V
F04 (1) and (2) OFF 20 – 30 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 8 of fuse
Resis-
box A – L116 (female) (1), – F03 (female) Max. 1 z
tance
(2), – F04 (female) (2)
Disconnection in wiring Wiring harness between L116 (female) (2) – Resis-
harness Max. 1 z
5 L05 (female) (1) tance
(Disconnection or defective
Wiring harness between L116 (female) (3) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between L116 (female) (5) – Resis-
Max. 1 z
F03 (female) (1), – F04 (female) (1) tance
Wiring harness between horn switch – chas- Resis-
Max. 1 z
sis ground tance

80 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 8 of fuse
Possible box A – L116 (female) (1), – F03 (female) Resis-
Min. 1 Mz
causes and Grounding fault in wiring (2), – F04 (female) (2), – circuit branch end tance
standard value 6 harness and chassis ground
in normal state (Contact with ground circuit) Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
L05 (male) (1) and chassis ground tance
Wiring harness between F03 (female) (1),
Resis-
F04 (female) (1) – L116 (female) (5) and Min. 1 Mz
tance
chassis ground

Circuit diagram related to horn (Steering wheel specification)

WA600-6 81
SEN00563-03 40 Troubleshooting

Contents of
Horn does not sound or it keeps sounding (AJSS specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 8 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box A (See cause 6.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L116 (male) Resistance
Defective horn relay (L116)
Between (1) and (2) 200 – 400 z
2 (Internal disconnection or
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

Defective AJSS horn switch S31 (male) Horn switch Resistance

3 (Internal disconnection or ON Max. 1 z
short circuit) Between (9) and (10)
OFF Min. 1 Mz
Between (9) or (10)
Normal Min. 1 Mz
and chassis ground
Possible
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting. (Disconnect connector and mea-
in normal state sure on female side)
Defective horn F03, F04 (female) Horn switch Voltage
4 (Internal disconnection or ON 20 – 30 V
Between F03
short circuit)
(female) (1) and (2) OFF Max. 1 V
Between F04 ON 20 – 30 V
(female) (1) and (2) OFF Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 8 of fuse
Resis-
box A – L116 (female) (1), – F03 (female) Max. 1 z
tance
(2), – F04 (female) (2)
Disconnection in wiring Wiring harness between L116 (female) (2) – Resis-
harness Max. 1 z
5 S31 (female) (9) tance
(Disconnection or defective
Wiring harness between L116 (female) (3) – Resis-
contact of connector) Max. 1 z
chassis ground tance
Wiring harness between L116 (female) (5) – Resis-
Max. 1 z
F03 (female) (1), – F04 (female) (1) tance
Wiring harness between S31 (female) (10) – Resis-
Max. 1 z
chassis ground. tance

82 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between fuse No. 8 of fuse
Possible box A – L116 (female) (1), – F03 (female) Resis-
Min. 1 Mz
causes and Grounding fault in wiring (2), – F04 (female) (2), – circuit branch end tance
standard value 6 harness and chassis ground
in normal state (Contact with ground circuit) Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
S31 (male) (9) and chassis ground tance
Wiring harness between F03 (female) (1),
Resis-
F04 (female) (1) – L116 (female) (5) and Min. 1 Mz
tance
chassis ground

Circuit diagram related to horn (AJSS specification)

WA600-6 83
SEN00563-03 40 Troubleshooting

E-12 Alarm buzzer does not sound or it keeps sounding 1

Contents of
• Alarm buzzer does not sound or it keeps sounding
trouble
• The alarm buzzer output circuit is disconnected or shorted with the chassis ground.
Related • The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
information 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 8 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box B (See cause 4.)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
• Check 2 seconds after starting switch is turned ON.
Defective alarm buzzer
2 L20 (female) Alarm buzzer Normal/Defective
(Internal short circuit)
Sounds Buzzer is normal
Ground (2)
Does not sound. Buzzer is defective
a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between fuse No. 8 of fuse Resis-
3 Max. 1 z
(Disconnection or defective box B – L20 (female) (1) tance
Possible contact of connector) Wiring harness between L20 (female) (2) – Resis-
causes and Max. 1 z
C01 (female) (14) tance
standard value
a Prepare with starting switch OFF, then carry out troubleshooting
in normal state
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between fuse No. 8 of fuse Resis-
4 harness Min. 1 Mz
box B – L20 (female) (1), – circuit branch end tance
(Contact with ground circuit)
Wiring harness between L20 (female) (2) – Resis-
Min. 1 Mz
C01 (female) (14) tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
C01 Starting switch Voltage
For 2 sec after ON
5 Defective machine monitor (Alarm buzzer does 20 – 30 V
Between (14) and not sound)
chassis ground For 2 – 3 sec after ON
(Alarm buzzer Max. 1 V
sounds)

84 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to alarm buzzer

WA600-6 85
SEN00563-03 40 Troubleshooting

E-13 Air conditioner does not operate or stop 1

Contents of
Air conditioner does not operate or stop.
trouble
Related • The following is troubleshooting for only the section between the air conditioner and operator's cab.
information For troubleshooting for the air conditioner unit, see the Shop Manual for the air conditioner.

Cause Standard value in normal state/Remarks on troubleshooting

Defective fuse No. 9 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box A (See cause 2.)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
• When fuse No. 9 of fuse box A is broken
Wiring harness between fuse No. 9 of fuse
Grounding fault in wiring Resis- Min. 1
box A – A05 (female) (4), – A08 (female) (2),
2 harness tance Mz
– A11 (female) (4)
(Contact with ground circuit)
• If fuse No. 9 of fuse box A is broken while the above trouble-
shooting result is normal, blower main relay, magnet clutch relay,
blower motor or fuse (5A) in air conditioner unit and its connecting
wiring harness are defective.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
Wiring harness Starting switch Voltage
Disconnection or grounding between A02
ON 20 – 30 V
fault in air conditioner control (female) (3) – A01
Possible
panel power supply or ground (female) (19) OFF Max. 1 V
causes and
3 wire harness
standard value a Prepare with starting switch OFF, then carry out troubleshooting
(Disconnection or defective
in normal state without turning starting switch ON.
contact of connector or
contact with ground circuit) Wiring harness between A02 (female) (3) – Resis-
Max. 1 z
A01 (female) (19) tance
Wiring harness between A01 (female) (19) – Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
Relay Starting switch Voltage
Wiring harness ON 20 – 30 V
Disconnection or grounding between A05
fault in relay wiring harness (female) (1) and
4 (Disconnection or defective chassis ground OFF Max. 1 V
contact of connector or Wiring harness
contact with ground circuit) ON 20 – 30 V
between A08
(female) (1) and
chassis ground OFF Max. 1 V

If the above troubleshooting result is normal, each relay and its con-
necting wiring harness are defective.

86 WA600-6
40 Troubleshooting SEN00563-03

Circuit diagram related to air conditioner

WA600-6 87
SEN00563-03 40 Troubleshooting

E-14 Electric priming pump does not operate or does not stop
automatically 1

Contents of
Electric priming pump does not operate or does not stop automatically
trouble
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker CBF4 is turned OFF, circuit probably has ground
2
CBF4 fault. (Check cause No. 5)
Disconnection in wiring har- a Prepare with battery ground cable disconnected, then connect it
ness (Power supply system) and carry out troubleshooting (since power supply is unswitched).
3
(Disconnection in wiring or
defective contact in connector) Between EP3 (1) – (2) Voltage 20 – 30 V

a Prepare with battery ground cable disconnected, then connect

battery and turn electric priming pump ON and carry out trouble-
shooting.
Disconnection in wiring
harness (Drive power supply • Lamp blinks but stops in about 5 seconds.
system) Between EP2 (1) – (2) Voltage 20 – 30 V
4
(Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out
defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Between EP3 (female) (2) and chassis Resis-
Max. 1 z
ground tance
a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible
unswitched).
causes and
standard value Wiring harness between EP3 (female) (1) –
Resis-
in normal state circuit breaker CBF4 (R15) and chassis Min. 1 Mz
tance
Ground fault in wiring harness ground
5
(Contact with GND circuit) Wiring harness between EP3 (female) (3) – Resis-
Min. 1 Mz
EP2 (female) (1) and chassis ground tance
Wiring harness between EP3 (female) (4) – Resis-
Min. 1 Mz
EP2 (female) (2) and chassis ground tance
Resis-
Between EP2 (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
Defective electric priming Between EP3 (3) – (4) Voltage 20 – 30 V
pump switch • Lamp blinks but output voltage is improper.
6
(Malfunction or automatic stop • Results of troubleshooting steps 1 – 4 are normal and lamp does
failure) not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective.
(Turn toggle switch OFF to stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 a If pump is overloaded, power supply is turned OFF automatically
pump
to protect circuit (Priming switch is reset automatically).

88 WA600-6
40 Troubleshooting SEN00563-03

Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible unswitched).
causes and Resis-
Between EP2 (male) (1) – (2) 1–3z
standard value 8 Trouble in electric priming tance
in normal state pump
Resis-
Between EP2 (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EP2 (male) (2) – pump body Min. 1 Mz
tance

Circuit diagram related to electric priming pump

WA600-6 89
SEN00563-03

WA600-6 Wheel loader

Form No. SEN00563-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

90
 SEN00564-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 4
Table of failure modes and causes ................................................................................................................. 6
H-1 Machine does not start........................................................................................................................... 10
H-2 Torque converter lockup is not switched (engine stalls) ......................................................................... 12
H-3 Torque converter lockup is not turned on ............................................................................................... 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted............................................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear .................................................................... 16
H-6 Time lag is large at the times of starting and shifting gear ..................................................................... 18
H-7 Torque converter oil temperature is high................................................................................................ 20
H-8 Steering does not turn [machine with steering wheel]............................................................................ 21
H-9 Steering does not turn [machine with AJSS] .......................................................................................... 22
H-10 Turning, response of steering is poor [machine with steering wheel]................................................... 23
H-11 Turning, response of AJSS is poor [machine with AJSS]..................................................................... 24

WA600-6 1
SEN00564-02 40 Troubleshooting

H-12 Steering is heavy [machine with steering wheel].................................................................................. 25

H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel] ....................... 26
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS] ..................................... 27
H-15 Wheel brake does not work or does not work well ............................................................................... 28
H-16 Wheel brake is not released or it drags................................................................................................ 29
H-17 Parking brake does not work or does not work well ............................................................................. 30
H-18 Parking brake is not released or it drags (including emergency release system) ................................ 31
H-19 Lift arm does not rise............................................................................................................................ 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient................................................................. 33
H-21 When rising, lift arm comes to move slowly at specific height.............................................................. 34
H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) ................................................................... 34
H-23 Hydraulic drifts of lift arm occur often ................................................................................................... 34
H-24 Lift arm wobbles during operation ........................................................................................................ 34
H-25 Bucket does not tilt back ...................................................................................................................... 35
H-26 Bucket speed is low or tilting back force is insufficient ......................................................................... 36
H-27 Bucket comes to operate slowly in the midst of tilting-back ................................................................. 37
H-28 Bucket cylinder cannot hold down bucket ............................................................................................ 37
H-29 Hydraulic drifts of bucket occur often ................................................................................................... 37
H-30 Bucket wobbles during travel with cargo (Work equipment valve is set to “HOLD”) ............................ 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls ................................. 38
H-32 Large shocks are made when work equipment starts and stops.......................................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .................................... 38
H-34 ECSS does not operate, and pitching bouncing occurs ....................................................................... 39
H-35 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats) ............ 40

2 WA600-6
40 Troubleshooting SEN00564-02

WA600-6 3
SEN00564-02 40 Troubleshooting

Method of using troubleshooting chart 1

This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.

Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable troubleshooting, put a check against the item.
cause.Keeping the content of the questions in a When carrying out the troubleshooting,
mind, read the matrix and proceed with Step 2 check the easier items first. It is not neces-
and Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
No. Remedy
Ask the operator and check the following points. Diagnosis
q Did the problem suddenly start? Steering does not turn in both directions (left
1
o Related equipment broken and right)
q Was the steering wheel heavy before? Steering turns only in one direction (left or
2
o Wear of related parts, defective seal right)
Steering is heavy when turned in both direc-
3 tions (left and right)
Step 2. Checks before troubleshooting
q Before measuring the oil pressure or starting 4 Steering wheel is heavy in one direction (left
or right)
the troubleshooting, confirm the checks before
5 Work equipment moves
starting items, check for leakage of oil, or for
loose bolts. This will prevent wasting time
when troubleshooting. The items given under 2. Find the matching cause in the Cause column.
“Checks before troubleshooting” are checks If a problem is found, the Q marks on the same
that are particularly important to make about line as the troubleshooting are the causes. (In
the condition of the machine before starting the Diagnosis item 2 in the same diagram below
actual troubleshooting. the cause is c or e.)
When there is one Q mark:
Example: Checks before starting troubleshooting Carry out troubleshooting for the other items
marked with Q in the same Cause column to
q Is oil level and type of oil in hydraulic tank cor-
check if the problem occurs, then make
rect?
repairs.
q Is there any oil leakage from steering valve or
When there are two or more Q marks:
demand valve?
Go to Step 3 to narrow down the cause.
q Is steering linkage adjusted properly?

4 WA600-6
40 Troubleshooting SEN00564-02

3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the cause column. taken the action given in the remedy line.
In the same way as in Step 2, if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
b or e.)

5. Narrow down the causes.

Of the causes found in Step 2 and Step 4,
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1 and Step 3.
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are c or e, and the causes in
Diagnosis item 5 are b or e, so Cause e is
the common cause.)

WA600-6 5
SEN00564-02 40 Troubleshooting

Table of failure modes and causes 1

Clogging of torque converter charging pump strainer

Part that can cause failures

Clogging or air intake on torque converter charging

Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Defective torque converter charging pump

Defect of transmission controller system

Defective operation of relevant ECMV
Internal breakage of torque converter

Wear or seizure of relevant clutch

Internal breakage of transmission
Clogging of last chance filter
Defective regulator valve
pump suction side
Defective engine
Defective PTO
Failure mode
Machine does not start Q Q Q Q Q Q Q Q Q Q Q
Torque converter lockup is not switched (engine stalls) Q Q
Q Q Q Q Q
Power train

Torque converter lockup is not turned on

Travel speed is slow, thrusting force is weal, uphill traveling power is Q Q Q Q Q Q Q Q Q Q Q Q
weak, and gear is not shifted
Shocks are large at the times of starting and shifting gear Q Q Q Q Q Q Q
Time lag is large at the times of starting and shifting gear Q Q Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q Q
Steering does not turn [machine with steering wheel] Q
Steering does not turn [machine with AJSS] Q
Turning, response of steering is poor [machine with steering wheel] Q
Steering

Turning, response of steering is poor [machine with AJSS] Q

Steering is heavy [machine with steering wheel]
When machine turns, it shakes or makes large shocks [machine with
steering wheel]
When machine turns, it shakes or makes large shocks [machine with AJSS]
Wheel brake does not work or does not work well Q
Wheel brake is not released or it drags
Brake

Parking brake does not work or does not work well

Parking brake is not released or it drags (including emergency release
system)
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient
When rising, lift arm comes to move slowly at specific height
Lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drifts of lift arm occur often
Lift arm wobbles during operation
Bucket does not tilt back Q
Work equipment

Bucket speed is low or tilting back force is insufficient

Bucket comes to operate slowly in the midst of tilting-back
Bucket cylinder cannot hold down bucket
Hydraulic drifts of bucket occur often
Bucket wobbles during travel with cargo (Work equipment valve is set to
“HOLD”)
Engine speed lowers remarkably or engine stalls during work equipment
Q
control
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment
moves
ECSS does not operate, and pitching housing occurs
Fan speed is abnormal (Fan sound and vibration are abnormally large or
engine overheats)

6 WA600-6
 Defective clutch piston
Defective seal of relevant clutch piston

Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft

WA600-6
Q
Q Q Q
Clogging of transmission breather
Defective operation of transmission oil

Q
Q
temperature sensor

Q
Defective transmission output shaft speed sensor
40 Troubleshooting

Defective seal of work equipment and steering

Q
Q
system hydraulic pump shaft
Clogging or air intake on steering pump suction side

Q Q
Q Q
Defective steering pump

Q Q
Defective steering pump servo
Defective Orbit-roll

Q Q
Defective steering stop valve
Defective steering main relief valve
Defective demand spool

Q
Defective steering spool of steering valve
Defective safety-suction valve

Q Q Q Q Q
Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of AJSS EPC solenoid valve line filter
Defective AJSS EPC solenoid valve

Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective operation of rotary valve

Q
Defective steering wheel or steering shaft
Defective seal of brake piston

Q
Defective operation of brake piston
Internal breakage of wheel brake

Q Q Q Q
Wear of wheel brake disc

Q
Seized wheel brake disc plate

Q
Q
Q
Q Q Defective brake pump
Q Q
Q Q
Q Q

Clogging or air intake on brake pump suction side

Air in wheel brake circuit
Defective brake valve

Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

H-11

H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
Q H-16
Q Q Q Q H-15
H-14
H-13
H-12
H-10

7
SEN00564-02
SEN00564-02 40 Troubleshooting

Part that can cause failures

Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve
Defective operation of check valve (between last
Gas leakage from accumulator, defective seal of
Defective operation of wheel brake emergency

Defective harness of parking brake switch line

Defective operation of parking brake piston
chance filter and parking brake solenoid)

Defective seal of parking brake piston

Defective accumulator charge valve

Seized parking brake disc plate

Defective parking brake spring

Wear of parking brake disc

Defective slack adjuster
Defective axle oil
switch

piston
Failure mode
Machine does not start Q Q Q Q
Torque converter lockup is not switched (engine stalls)
Power train

Torque converter lockup is not turned on

Travel speed is slow, thrusting force is weal, uphill traveling power is
weak, and gear is not shifted Q

Shocks are large at the times of starting and shifting gear Q

Time lag is large at the times of starting and shifting gear
Torque converter oil temperature is high
Steering does not turn [machine with steering wheel] Q
Steering does not turn [machine with AJSS] Q
Turning, response of steering is poor [machine with steering wheel] Q
Steering

Turning, response of steering is poor [machine with AJSS] Q

Steering is heavy [machine with steering wheel] Q
When machine turns, it shakes or makes large shocks [machine with Q
steering wheel]
When machine turns, it shakes or makes large shocks [machine with Q
AJSS]
Wheel brake does not work or does not work well Q Q Q Q
Wheel brake is not released or it drags Q
Brake

Parking brake does not work or does not work well Q Q Q Q Q

Parking brake is not released or it drags (including emergency release
Q Q Q Q Q
system)
Lift arm does not rise
Lift arm speed is low or rising force of lift arm is insufficient
When rising, lift arm comes to move slowly at specific height
Lift arm cylinder cannot hold down bucket (Bucket floats)
Hydraulic drifts of lift arm occur often
Lift arm wobbles during operation
Bucket does not tilt back
Work equipment

Bucket speed is low or tilting back force is insufficient

Bucket comes to operate slowly in the midst of tilting-back
Bucket cylinder cannot hold down bucket
Hydraulic drifts of bucket occur often
Bucket wobbles during travel with cargo (Work equipment valve is set
to “HOLD”)
Engine speed lowers remarkably or engine stalls during work equip-
ment control
Large shocks are made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment
moves
ECSS does not operate, and pitching housing occurs Q
Fan speed is abnormal (Fan sound and vibration are abnormally large or
engine overheats)

8 WA600-6
 Clogging or air intake on work equipment pump

Q
Q
Q
Q
Q
Q
Q
Q
Q
suction side

Q
Defective work equipment controller

WA600-6
Defective work equipment pump

Q Q
Defective work equipment pump servo

Q
Q
Defective work equipment valve body
Defective work equipment main relief valve
40 Troubleshooting

Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve

Q Q Q Q Q Q
Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Defective lift arm spool of work equipment valve

Q Q
Q Q
Q
Q
Q
Q
Q
Defective bucket spool of work equipment valve
Defective lift arm load check valve of work

Q
Q
Q
Q
Q
Q
equipment valve

Defective safety-suction valve on bucket head side

Q
Q
of work equipment valve

Defective safety-suction valve on bucket bottom

Q
Q
Q
Q
Q
side of work equipment valve

Q
Q
Q
Defective lift arm cylinder

Q
Defective bucket cylinder

Q
Q
Q
Q
Q
Defective seal of lift arm cylinder piston

Q
Q
Q
Q
Q
Q
Defective seal of bucket cylinder piston

Q
Defective stroke of lift arm EPC lever

Q
Defective stroke of bucket EPC lever
Defect in electrical system of lift arm or bucket EPC

Q
lever

Clearance error of pin or bush of working

Q
equipment linkage

Q
Defective ECSS solenoid valve

Q
Q
Q
Q
Q
Q
Q
Defective ECSS charge valve
Malfunction of fan pump EPC solenoid valve
Defect in fan pump
Defect in fan motor

Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1

Q Q Q H-35
H-11

H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10

9
SEN00564-02
SEN00564-02 40 Troubleshooting

H-1 Machine does not start 1

Ask the operator about the following: Cause

Parking brake emergency

q Has the machine come not to start sud-
denly?

Torque converter
Torque converter

Main relief valve

charging pump

Parking brake
o Seizure of clutch, breakage of parts

Transmission

release valve
Check valve
ECMV
Did the machine cause any abnormal
noise at the time and where?

Checks before troubleshooting

q Does the machine monitor function nor-
mally? a b c d e f g h i j k l m n o p q

Defective operation of spool of parking brake emergency release valve

q Has the machine monitor displayed any
failure code of the electrical system?

Defective operation of check valve (between last chance filter and

q Are the transmission oil level and the oil
type appropriate?
q Did you smell deteriorated or burnt trans-
mission oil?

Defective operation of parking brake solenoid valve

Defective operation of torque converter relief valve
q Have the transmission filter and strainer
been clogged?
q Can you find any damage or oil leak from

The relevant clutch piston seal is defective

The parking brake piston seal is defective

The relevant clutch shaft seal is defective
the appearance?

Defective operation of relevant ECMV

Set pressure drop of main relief valve
Internal breakage of torque converter
Clogging or air intake on suction side

q Has the drive shaft been broken?

Wear or seizure of relevant clutch

Internal breakage of transmission
q Have the wheel brake and the parking
The charging pump is defective

brake been locked?

Clogging of last chance filter

parking brake solenoid)

The PTO is defective
Clogging of strainer

No. Remedy E E E x E E E x E x E E x x
Diagnosis x C x x x x * x * * x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The machine does not start at specific gear speeds Q Q Q Q Q
When the transmission oil temperature is low, the
3 charging pump or the transmission filter causes any Q Q
abnormal noise (s)
When the transmission oil temperature rises, the
4 Q Q Q Q
machine comes not to start
Metal (Aluminum, copper, iron, etc.) powders are
5 Q Q Q
adhered to the transmission filter or the strainer
The speed is higher at all gear
6 When the stall speed of speeds Q Q Q Q Q Q Q Q
the torque converter is
The speed is higher at spe-
7 measured Q Q Q Q Q
cific gear speeds
The oil pressure is low at all
8 Q Q Q Q Q Q Q
gear speeds
When the ECMV out- The oil pressure is low at spe-
9 Q Q Q Q
put (Clutch) oil pres- cific gear speeds
sure is measured
The oil pressure does not
10 become stable as the gauge Q Q
fluctuates

11 When the torque converter relief (Inlet) oil pressure is Q Q Q Q Q Q

measured, the oil pressure is low.

*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”

10 WA600-6
40 Troubleshooting SEN00564-02

* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the para-
graph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and dust
around the ECMV completely and clean it, and then tighten the
mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the man- Transmission ECMV
ual mode: a b c d e f g h i j k l
Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N

Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode

Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q

Defective operation of 2nd clutch ECMV (Fill switch)

F1

Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear speed

F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When the gear speed is N in the manual mode, the clutch of the
gear speed (Marked with Q), to which the gear shift lever is set, is
ON.
q Even if the gear shift lever is used when the gear speed is N, the
clutch position cannot be changed.

No. Remedy Failure x x x x x x x x x x x x

Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV

WA600-6 11
SEN00564-02 40 Troubleshooting

H-2 Torque converter lockup is not switched (engine stalls) 1

Checks before troubleshooting Cause

q Is the oil level of transmission case appropriate? a b

Defective operation of lockup clutch ECMV

Wear or seizure of lockup clutch disc
Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0 Q
2 Lockup cannot be turned off even when the lockup oil pressure is 0 Q

12 WA600-6
40 Troubleshooting SEN00564-02

H-3 Torque converter lockup is not turned on 1

Ask the operator about the following: Cause

q Has the lockup come not to turn on suddenly? a b c d e f g
o Seizure or breakage inside torque converter

Drop of transmission main relief valve set pressure

q
q Did any abnormal noise occur at the time? o Breakage of parts

Defective operation of lockup clutch ECMV

Checks before troubleshooting

Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc
q Is the oil level of transmission case appropriate?

Defective seal of lockup clutch shaft

q Is there any external oil leakage?

Clogging of last chance filter

Crack on lockup clutch case
Check of abnormality
q Main relief oil pressure
q Lockup oil pressure
q Travel speed

Remedy
No. Diagnosis Transmission E x x x x C x
controller self-diagnosis code x

1 Main relief oil pressure is low Q

2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q

WA600-6 13
SEN00564-02 40 Troubleshooting

H-4 Travel speed is slow, thrusting force is weak, uphill traveling power
is weak, and gear is not shifted 1
Ask the operator about the following:

Torque converter
Torque converter

Torque converter

Main relief valve

Regulator valve
charging pump

Parking brake
Transmission
q Has the abnormality occurred suddenly?

oil cooler
o Breakage of related equipment

Others
ECMV
Did any abnormal noise occur at the time and
where?
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j k l m n o p q r s
Check of abnormality
q Execute digging and measure traveling speeds on a

Defective seal of work equipment and steering system hydraulic

Breakage of oil cooler and piping (After torque converter outlet)
Clogging of oil cooler and piping (After torque converter outlet)
level ground and on a slope to check whether the
abnormality actually occurs or is a matter of opera-
tor's sense

pump shaft (Mixing of hydraulic oil in transmission case)

Defective operation of torque converter relief valve
Checks before troubleshooting
q Is any failure code of the electrical system displayed
on the machine monitor?
q Are the transmission oil level and the oil type appro- Clogging or air intake on pump suction side
priate?

Defective seal of relevant clutch piston

Defective operation of relevant ECMV

Defective seal of parking brake piston

Drop of main relief valve set pressure
Defective operation of regulator valve

Defective seal of relevant clutch shaft

Internal breakage of torque converter
q Haven't the transmission filter and strainer been
clogged?

Internal breakage of transmission

The charging pump is defective

Oil leak inside torque converter

q Is any external oil leak found on the mating faces of

Clogging of last chance filter

piping and valves around the torque converter and
the transmission?
q Isn't the wheel brake or the parking brake being

Clogging of breather
Clogging of strainer

Note Engine degradation

dragged?
q Are the tire air pressure and the tread shape appro-
priate?
q Is the operating method correct?
NOTE: When the inspection result was “Engine degra-
dation,” proceed to Troubleshooting of engine
(S-mode).

No. Diagnosis Remedy C E x E E x E E E E x E x C E

x x x x x x x x * x * x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q

3 When the transmission oil temperature is low, the charging Q Q

pump or the transmission filter causes any abnormal noise

4 The torque converter oil temperature is heated abnormally Q Q Q Q Q Q Q Q Q Q Q Q

high
5 The transmission oil level rises and falls Q Q Q Q Q Q

6 Metal (Aluminum, copper, iron, etc.) powders are adhered Q Q Q

to the transmission filter or the strainer

7 The engine low idle and high idle speeds are measured to Q Q Q
be abnormal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q

10 The oil pressure drops as Q Q Q Q

the oil temperature rises
The oil pressure is low at
11 all gear speeds Q Q Q Q Q Q Q Q Q
When the ECMV output
(Clutch) oil pressure is mea- The oil pressure is low at
12 sured specific gear speeds Q Q Q Q

The oil pressure does not

13 become stable as the Q Q
gauge fluctuates
When the torque converter relief (Inlet) oil pressure is
14 measured, the oil pressure is low. (No. 11 – 13 are nor- Q Q Q
mal.)
When the oil pressure at the torque converter outlet is
15 measured, the oil pressure is low. (No. 14 is normal.) Q

*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”

14 WA600-6
40 Troubleshooting SEN00564-02

* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and
dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the Transmission ECMV
manual mode: a b c d e f g h i j k l

Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N

Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode

Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q

Defective operation of 2nd clutch ECMV (Fill switch)

F1

Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear speed

F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position cannot be changed.

No. Remedy Failure x x x x x x x x x x x x

Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is dis-
(2) connected. When the failure code is 15SFLH, the failure code comes not to be 15SFLH Q
displayed when the ECMV is replaced with any one other than the 2nd clutch
ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV

WA600-6 15
SEN00564-02 40 Troubleshooting

H-5 Shocks are large at the times of starting and shifting gear 1

Ask the operator about the following: Cause

Did shocks become large suddenly?

Torque converter
q

Main relief valve

charging pump

Parking brake
Transmission
o Breakage of related equipment

Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Did shocks become large gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j k l
Checks before troubleshooting

Defective return (Release) of relevant clutch piston

q Did any of the following abnormal phenomena occur at the same

Defective transmission oil temperature sensor

time: The traveling speed is slow, the braking is weak, the uphill

Clogging or air intake on pump suction side

travelling power is weak, the gear is not shifted. o Execute H-3

Defective operation of relevant ECMV a

Defect of transmission controller system
Defective operation of main relief valve

Defective seal of relevant clutch piston

Defective seal of parking brake piston

Defective seal of relevant clutch shaft
Checks before troubleshooting

The charging pump is defective

q Is any failure code of the electrical system displayed on the

Clogging of last chance filter

machine monitor?
q Are the transmission oil level and the oil type appropriate?
q Haven't the transmission filter and strainer been clogged?

Clogging of strainer
q Is any external oil leak found on the mating faces of pipings and
valves around the torque converter and the transmission?
q Isn't the engine speed high at the time of low idling?
q Isn't play of each drive shaft large?

No. Remedy C E x E x x x
Diagnosis x x x * ** * * **
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 The oil pressure is low at all gear speeds Q Q Q Q Q Q
When the ECMV output
4 (Clutch) oil pressure is mea- The oil pressure is low at specific gear speeds Q Q Q
sured
5 The oil pressure is high at all gear speeds Q

a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
* : See “Troubleshooting by failure code (Display of code).”
**

16 WA600-6
40 Troubleshooting SEN00564-02

* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and
dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the Transmission ECMV
manual mode: a b c d e f g h i j k l

Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N

Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode

Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q

Defective operation of 2nd clutch ECMV (Fill switch)

F1

Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear speed

F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position cannot be changed.

No. Remedy Failure x x x x x x x x x x x x

Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is dis-
(2) connected. When the failure code is 15SFLH, the failure code comes not to be 15SFLH Q
displayed when the ECMV is replaced with any one other than the 2nd clutch
ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV

WA600-6 17
SEN00564-02 40 Troubleshooting

H-6 Time lag is large at the times of starting and shifting gear 1

Ask the operator about the following: Cause

Did the time lag become large suddenly?

Torque converter
q

Main relief valve

charging pump

Parking brake
Transmission
o Breakage of related equipment

Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Has the time lag become large gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j
Check of abnormality

Defective operation of transmission oil temperature sensor

q Did any of the following abnormal phenomena occur at the same time:
The traveling speed is slow, the braking is weak, the uphill travelling
power is weak, the gear is not shifted. o Execute H-4

Clogging or air intake on pump suction side

Checks before troubleshooting
Is any failure code of the electrical system displayed on the machine

Defective seal of relevant clutch piston

q

Defective operation of relevant ECMV

Defective seal of parking brake piston

Drop of main relief valve set pressure

Defective seal of relevant clutch shaft

monitor?
q Are the transmission oil level and the oil type appropriate?

The charging pump is defective

Haven't the transmission filter and strainer been clogged?

Clogging of last chance filter

q
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?

Clogging of strainer

No. Remedy C E x E x x x
Diagnosis x x x * * **
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the charging
3 pump or the transmission filter Q Q

4 The torque converter oil temperature is heated abnormally high Q Q Q Q

5 When the ECMV output (Clutch) oil The oil pressure is low at all gear speeds Q Q Q Q Q
6 pressure is measured The oil pressure is low at specific gear speeds Q Q Q

a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
**: See “Troubleshooting by failure code (Display of code).”

18 WA600-6
40 Troubleshooting SEN00564-02

* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and
dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the Transmission ECMV
manual mode: a b c d e f g h i j k l

Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N

Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q

Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode

Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q

Defective operation of 2nd clutch ECMV (Fill switch)

F1

Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear speed

F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position cannot be changed.

No. Remedy Failure x x x x x x x x x x x x

Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is dis-
(2) connected. When the failure code is 15SFLH, the failure code comes not to be 15SFLH Q
displayed when the ECMV is replaced with any one other than the 2nd clutch
ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV

WA600-6 19
SEN00564-02 40 Troubleshooting

H-7 Torque converter oil temperature is high 1

Ask the operator about the following: Cause

Torque converter
Does the oil temperature rise when the torque converter stalls

Torque converter

Torque converter
q

Main relief valve

charging pump

Transmission
and does the temperature fall at the time of no load?

oil cooler

Others
o Selection of improper gear speed
Did any abnormal noise occur at the time and where?
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method a b c d e f g h i j k l

Defective seal of work equipment and steering system hydraulic

Breakage of oil cooler and piping (After torque converter outlet)
Check of abnormality

Clogging of oil cooler and piping (After torque converter outlet)

q Measure the torque converter oil temperature to find if the oil

pump shaft (Mixing of hydraulic oil in transmission case)

temperature is really high.
o The torque converter oil temperature gauge is defective

Checks before troubleshooting

Clogging or air intake on pump suction side

q Are the coolant level in the radiator and the belt tension appropri-
ate?

Drop of main relief valve set pressure

Internal breakage of torque converter
q Are the oil level in the transmission and the oil type appropriate?

Internal breakage of transmission

The charging pump is defective

Oil leak inside torque converter

q Haven't the transmission filter and strainer been clogged?
NOTE: When the inspection result was “Engine degradation,” pro-
ceed to Troubleshooting of engine (S-mode).

Clogging of breather

Note Engine degradation

Clogging of strainer

Remedy C E E E E E E C E
No. Diagnosis x x x x x x x x x x x

1 When the transmission oil temperature is low, the charging pump or the transmis- Q Q
sion filter causes any abnormal noise

2 Traveling speed, braking force and uphill travelling power do not occur at all gear Q Q Q Q Q Q Q Q Q Q Q
speeds
Traveling speed, braking force and uphill travelling power do not occur at specific
3 Q
gear speeds
4 The transmission oil level rises and falls Q Q Q

5 Metal powders (Aluminum, copper, iron, etc.) are adhered to the transmission filter Q Q Q
and the strainer
6 The engine low idle and high idle speeds are measured to be abnormal Q Q Q
7 When the stall speed of the torque converter is measured, the speed is high Q Q Q Q Q Q Q Q Q
8 The oil pressure drops as the oil temperature rises Q
When the ECMV
9 output (Clutch) oil The oil pressure is low at all gear speeds Q Q Q Q Q
10 pressure is The oil pressure is low at specific gear speeds Q
measured
11 The oil pressure does not become stable as the gauge vibrates Q Q

12 When
the torque converter relief (Inlet) oil pressure is measured, the oil pressure is
Q Q Q
low. (No. 9 – 11 are normal.)

13 When
the oil pressure at the torque converter outlet is measured, the oil pressure is
Q
low. (No. 12 is normal.)

20 WA600-6
40 Troubleshooting SEN00564-02

H-8 Steering does not turn [machine with steering wheel] 1

Ask the operator about the following: Cause

Did the problem suddenly start? o Breakage of related equipment

Hydraulic cylinder
q

Hydraulic pump

Steering valve
Charge valve

Stop valve
Did the machine cause any abnormal noise at the time and where?

Orbit-roll
Checks before troubleshooting
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken? a b c d e f g h i j k
q Is the steering stop valve properly adjusted?

Defect in steering cylinder (defective piston seal)

q Has the lock bar been removed from the frame?

Clogging or air intake on pump suction side

Defective actuation of demand spool

Defective actuation of steering spool
Defective accumulator charge valve

Defective safety-suction valve

Defective steering pump
Defective brake pump

Defective stop valve

Defective Orbit-roll
Defective PTO
No. Diagnosis Remedy E E E E E E E E E x x
x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q Q
3 Steering is heavy when turned in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low, or there is no pressure in both directions (left
9 Q Q Q Q Q Q Q Q Q
When steering relief and right)
pressure is measured Oil pressure is low, or there is no pressure in one direction (left or
10 Q Q
right)

11 When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no Q Q Q Q Q
oil pressure
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q

a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is left in the steering, check the operation of the work equipment also.

WA600-6 21
SEN00564-02 40 Troubleshooting

H-9 Steering does not turn [machine with AJSS] 1

Ask the operator about the following: Cause

Hydraulic cylinder
q Did the problem suddenly start?

Hydraulic pump

solenoid valve

Steering valve
Charge valve

Rotary valve
o Breakage of related equipment

AJSS EPC
Did the machine cause any abnormal noise at the time and where?

Checks before troubleshooting

q Is oil level in hydraulic tank correct? Is the type of oil correct? a b c d e f g h i j k l
q Is the steering shaft broken?

Defect in steering cylinder (defective piston seal)

q Has the lock bar been removed from the frame?

Clogging or air intake on pump suction side

q Is the AJSS followup link properly adjusted?

Defective actuation of demand spool

Defective actuation of steering spool
Defective AJSS EPC solenoid valve
Defective accumulator charge valve

Defective actuation of rotary valve

Defective safety-suction valve

Defective steering pump
Defective brake pump

Clogged line filter

Defective PTO
No. Diagnosis Remedy E E E E E C x E E E x x
x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q
3 AJSS is heavy when turned in both directions (left and right) Q Q Q
4 AJSS is heavy in one direction (left or right)
5 Work equipment moves Q Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low, or there is no pressure in both
9 Q Q Q Q Q Q Q Q Q Q Q
When steering relief pressure is directions (left and right)
measured Oil pressure is low, or there is no pressure in one
10 Q
direction (left or right)

11 When AJSS EPC solenoid valve output pressure is measured, oil pressure is found to Q Q Q Q Q Q Q
be low or there is no oil pressure
12 When AJSS EPC solenoid valve Oil pressure is low Q Q Q Q
13 basic pressure is measured There is no oil pressure Q Q Q

22 WA600-6
40 Troubleshooting SEN00564-02

H-10 Turning, response of steering is poor [machine with steering wheel]1

Ask the operator about the following: Cause

Hydraulic cylinder
q Did the problem suddenly start?

Hydraulic pump

Steering valve
Charge valve
o Breakage of related equipment

Stop valve
Orbit-roll
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m

Defect in steering cylinder (defective piston seal)

Checks before troubleshooting

Clogging or air intake on pump suction side

q Is oil level in hydraulic tank correct? Is the type of oil correct?

Defective actuation of demand spool

Defective accumulator charge valve
Defective steering pump servo

Defective safety-suction valve

Defective main relief valve
Defective steering pump

Defective steering spool

Defective brake pump

Defective stop valve

Defective Orbit-roll
Defective PTO
No. Diagnosis Remedy E E E E E E E E E E E x E
x x x x x x x x x x x
1 Turning, response of steering wheel is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering wheel is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low, or there is no pressure in both directions Q Q Q Q Q Q Q
9 Q Q Q
When steering relief (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one direction
10 Q Q
(left or right)

11 When Orbit-roll output pressure is measured, oil pressure is found to be low or Q Q Q Q Q

there is no oil pressure

12 When Orbit-roll basic pressure is measured, oil pressure is found to be low or there Q Q Q Q
is no pressure
13 When steering pump servo assembly is replaced, oil pressure is found to be normal Q

a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is left in the steering, check the operation of the work equipment also.

WA600-6 23
SEN00564-02 40 Troubleshooting

H-11 Turning, response of AJSS is poor [machine with AJSS] 1

Ask the operator about the following: Cause

Hydraulic cylinder
q Did the problem suddenly start?

Steering pump

solenoid valve

Steering valve
Charge valve

Rotary valve
o Breakage of related equipment

AJSS EPC
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m n

Defect in steering cylinder (defective piston seal)

Checks before troubleshooting

Clogging or air intake on pump suction side

q Is oil level in hydraulic tank correct? Is the type of oil correct?

Defective actuation of demand spool

Defective actuation of steering spool

Defective AJSS EPC solenoid valve
Defective accumulator charge valve
Defective steering pump servo

Defective safety-suction valve

Defective main relief valve
Defective steering pump
Defective brake pump

Defective rotary valve

Clogged line filter
Defective PTO

No. Diagnosis Remedy E E E E E E C x E E E E x E

x x x x x x x x x x x
1 Turning, response of steering wheel is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering wheel is poor in one direction (left or right) Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q
4 Work equipment moves Q Q Q Q Q Q Q Q Q Q
5 Work equipment does not move Q Q Q Q
6 Abnormal noise comes from around PTO Q
7 Abnormal noise comes from around hydraulic tank Q Q

8 Oil pressure is low, or there is no pressure in both Q Q Q Q Q Q Q Q Q Q Q Q

When steering relief directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one
9 direction (left or right) Q

10 When
AJSS EPC solenoid valve output pressure is measured, oil pressure is
Q Q Q Q Q Q Q
found to be low or there is no oil pressure
When steering pump servo assembly is replaced, oil pressure is found to be
11 normal Q

a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is left in the steering, check the operation of the work equipment also.

24 WA600-6
40 Troubleshooting SEN00564-02

H-12 Steering is heavy [machine with steering wheel] 1

Check of abnormality Cause

Is the steering difficult to turn? o See H-8

Hydraulic pump

Steering valve
Charge valve

Stop valve
Orbit-roll

Others
Measure the operating effort and turning speed, and check the “Standard value table” to
see if they are abnormal.

Ask the operator about the following: a b c d e f

Did the problem suddenly start? o Breakage of related equipment broken

Defective actuation of steering wheel or steering shaft

q
q Was there previously any symptom that may lead to heavy steering?
o Wear of related equipment, defective seal

Checks before troubleshooting

Defective actuation of steering spool

Defective accumulator charge valve
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the tire inflation pressure correct?

Defective brake pump

Defective stop valve

Defective Orbit-roll
Remedy E E E E E E
No. Diagnosis x x x x x x
1 Steering is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy in one direction (left or right) Q
3 Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
4 When steering relief Oil pressure is low, or there is no pressure in both directions (left and right) Q Q Q Q
5 pressure is measured Oil pressure is low, or there is no pressure in one direction (left or right) Q
6 When Orbit-roll output pressure is measured, oil pressure is found to be low Q Q Q Q
7 When Orbit-roll basic Oil pressure is low Q Q
8 pressure is measured There is no oil pressure Q

WA600-6 25
SEN00564-02 40 Troubleshooting

H-13 When machine turns, it shakes or makes large shocks [machine

with steering wheel] 1

Check of abnormality Cause

Is the steering difficult to turn? o See H-8

Hydraulic pump
q

Steering valve
Charge valve

Stop valve
Orbit-roll

Cylinder
q Is there any abnormal noise from around the steering equipment

Checks before troubleshooting

q Is the steering wheel play correct?
a b c d e f g h i
q Is there any abnormality in the connection between the steering shaft and

Defect in steering cylinder (defective piston seal)

the Orbit-roll?
q Is the tire inflation pressure correct?

Defective actuation of demand spool

Defective actuation of steering spool

Defective accumulator charge valve

Defective safety-suction valve

Defective main relief valve
Defective brake pump

Defective stop valve

Defective Orbit-roll
No. Diagnosis Remedy E E E E E E E E E
x x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in both directions (left and right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Machine jerks or there is excessive shock when steering is operated to end of its stroke Q
5 Work equipment also jerks Q Q
6 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q
7 pressure is measured Oil pressure is unstable in one direction (left or right) Q Q
8 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q
9 pressure is measured Oil pressure is unstable in one direction (left or right) Q
10 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q

26 WA600-6
40 Troubleshooting SEN00564-02

H-14 When machine turns, it shakes or makes large shocks [machine

with AJSS] 1

Check of abnormality Cause

Is the steering difficult to turn? o See H-9

AJSS EPC solenoid valve

q
q Is there any abnormal noise from around the steering equipment

Hydraulic pump

Steering valve
Charge valve

Rotary valve

Cylinder
Checks before troubleshooting
q Is the AJSS play correct?
q Is the AJSS followup link properly adjusted?
q Is the tire inflation pressure correct?
a b c d e f g h i

Defect in steering cylinder (defective piston seal)

Defective actuation of EPC solenoid valve

Defective actuation of demand spool

Defective actuation of steering spool

Defective accumulator charge valve

Defective actuation of rotary valve

Defective safety-suction valve

Defective main relief valve
Defective brake pump
No. Diagnosis Remedy E E x E E E E E E
x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one directions (left or right) Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Work equipment also jerks Q Q
5 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q Q
6 pressure is measured Oil pressure is unstable in one direction (left or right) Q
7 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q Q
8 pressure is measured Oil pressure is unstable in one direction (left or right)
9 When AJSS EPC solenoid valve basic pressure is measured, oil pressure is found to be unstable Q Q

WA600-6 27
SEN00564-02 40 Troubleshooting

H-15 Wheel brake does not work or does not work well 1

Check of abnormality Cause

Slack adjuster
Charge valve
q Test the effectiveness of the brake referring to “Measuring

Wheel brake
Accumulator
Brake pump

Brake valve

Others
brake performance” in “Testing and adjusting” to check
whether the abnormality actually occurs or is a matter of oper-
ator's sense
a b c d e f g h i j k l m n
Ask the operator about the following:

Gas leakage from accumulator, defective seal of piston

q Has the brake come not to work suddenly?
o Breakage of brake
Did any abnormal noise occur at the time and where?
q Has the brake come not to work gradually?
o Wear of related equipment, defective seal

Defective accumulator charge valve

Defective operation of brake piston

The brake piston seal is defective
Checks before troubleshooting
q Is oil level and type of oil in hydraulic tank correct?

Defective right brake valve

Internal breakage of brake

Defective left brake valve
Air intake on suction side
q Is the play of brake pedal appropriate?

Defective slack adjuster

Defective brake pump
q Isn't the oil leaked from brake piping or tube deformed?

Wear of brake disc

q Are the tire air pressure and the tread state appropriate?

Air in brake circuit

Improper axle oil
Defective PTO

No. Remedy E E E E x E E E E E E E E x
Diagnosis x x x x x x x x x x
1 The brake does not work only when the left brake pedal is stepped on Q
2 When the left brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q Q Q Q
3 When the right brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q Q Q
4 When the left brake pedal is stepped on, a strong resistance is felt Q
5 When the right brake pedal is stepped on, a strong resistance is felt Q
6 To get the specified braking force, an extremely strong leg-power is required Q Q Q Q Q
7 When the brake works, an abnormal noise occurs from the brake Q Q Q
8 Work equipment and steering wheel does not move Q Q
9 Work equipment and steering wheel move slowly Q Q Q
10 Abnormal noise comes from around PTO Q
11 Abnormal noise comes from around hydraulic tank or brake pump Q Q
12 Much metal powders are mixed in the oil when it is drained from the axle case Q
13 When the accumulator charge pressure is measured, the oil pressure is low. Q Q Q
14 The brake does not work immediately when the engine is stopped Q
15 The brake works after some time lag Q Q
16 When brake pressure is measured, the oil pressure is low Q
17 When brake piston pressure effect is measured, the pressure effect is large Q Q
18 When wear of brake disc is measured, the amount of wear is large Q Q
19 Air is discharged when the air is bled from the brake system Q

28 WA600-6
40 Troubleshooting SEN00564-02

H-16 Wheel brake is not released or it drags 1

Ask the operator about the following: Cause

Was the brake locked suddenly? o Breakage of related equipment

Slack adjuster
q

Wheel brake
Brake valve
Did the machine cause any abnormal noise at the time and where?

Checks before troubleshooting

q Has the brake pedal returned completely? a b c d e
q Isn't the parking brake turned ON?

Defective operation of slack adjuster

Defective operation of brake piston
Defective right brake valve

Seizure of brake disc plate

Defective left brake valve
No. Remedy E E E E x
Diagnosis x x x x
1 The machine does not travel at all Q Q
2 The machine travels a little Q Q Q
When residual pressure in the brake accumulator circuit is released using only the left brake pedal, the brake is
3 released Q

When residual pressure in the brake accumulator circuit is released using only the right brake pedal, the brake is
4 Q
released
5 When air bleeder at wheel is opened, oil leaks out and the brake is released Q
6 When air bleeder is opened, large amount of oil flows out Q Q
7 When wear of brake disc is measured and the brake pedal is released, the piston returns Q
8 When wear of brake disc is measured and the brake pedal is released, the piston does not return Q Q

WA600-6 29
SEN00564-02 40 Troubleshooting

H-17 Parking brake does not work or does not work well 1

Ask the operator about the following: Cause

Has the brake come not to work suddenly? o Breakage of related equipment

Parking brake
q

Solenoid
Did the machine cause any abnormal noise at the time and where?

Valve
q Has the brake come not to work gradually?
o Wear of related equipment, defective seal
a b c d e
Checks before troubleshooting

Defective parking brake emergency release valve

q Isn't the parking brake emergency release switch turned ON?
q Hasn't the mechanical release of parking brake performed?

Defective operation of parking brake piston

Defective parking brake solenoid valve

Defective parking brake spring

Wear of parking brake disc

No. Remedy x E x E x
Diagnosis x x
1 The parking brake is not applied even if the engine stops Q Q Q
2 When wear of parking brake disc is checked, the disc thickness is lower than Standard value Q
3 When the parking brake inlet pres- With the parking brake switch ON, there is no oil pressure (Normal) Q Q
4 sure is measured With the parking brake switch ON, there is a oil pressure Q Q Q
5 When the parking brake solenoid With the parking brake switch ON, there is no oil pressure (Normal) Q Q
6 valve output pressure is measured With the parking brake switch ON, there is a oil pressure Q

30 WA600-6
40 Troubleshooting SEN00564-02

H-18 Parking brake is not released or it drags (including emergency

release system) 1

Check of abnormality Cause

Parking brake
q Is there any abnormality in the power train system?

Solenoid
o See H-1, H-4, H-5 and H-6 (Power train hydraulic system)

Wheel
Valve
a b c d e

Defective operation of wheel brake emergency brake switch

Defective parking brake emergency release valve

Seizure of parking brake disc and plate

Defective parking brake solenoid valve

Defective seal of parking brake piston

No. Remedy x E E x
Diagnosis x x

1 The parking brake is released when the emergency release switch is turned ON Q Q
(The parking brake switch does not release the brake)

2 The parking brake is released, when “Method of releasing parking brake manually”is executed Q Q Q
(The parking brake switch and emergency release switch does not release the brake)
3 When the parking brake inlet pressure is measured Oil pressure is normal Q Q
4 (While operating the parking switch) Oil pressure is low Q Q
5 When the parking brake output pressure is measured Oil pressure is normal Q Q
6 (While operating the emergency release switch) Oil pressure is low Q Q
7 When the parking brake solenoid valve output pressure is measured, the oil pressure is low Q

8 When the wheel brake piping oil pressure is measured, the oil pressure is lower than the emergency brake Q
working pressure (3.6 ± 0.49 MPa {37 ± 5 kg/cm2})

a If any abnormality is left in releasing of the parking brake, check the operation of the power train also,
because the power train main relief pressure is used as the parking brake release pressure. (The emer-
gency release circuit uses the wheel brake circuit oil pressure.)

WA600-6 31
SEN00564-02 40 Troubleshooting

H-19 Lift arm does not rise 1

Ask the operator about the following: Cause

equipment pump

Work equipment
q Did the lift arm stop suddenly?

Bypass valve
Tank – Work
o Seizure or breakage of each component

Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered?
o Wear of parts and fatigue of springs a b c d e f g h i j

Defective operation of lift arm load check valve

Internal breakage of valve body (lift arm spool)
Checks before troubleshooting

Clogging or air intake on pump suction side

q Is the oil level in the hydraulic tank proper?

Defective operation of main relief valve

Defective work equipment pump servo
q Is the stroke of the lift arm control lever proper?

Damaged lift arm cylinder piston seal

Defective operation of unload valve
q Is the engine speed proper?

Defective work equipment pump

q Has the machine monitor displayed any failure code?

Defective operation of spool

o See Troubleshooting by failure code (Display of code)

Defective PTO
No. Diagnosis Remedy C E E E E E E x x x
E x x x x x x
1 Bucket does not move and lift arm does not rise Q Q Q Q Q
2 Lift arm can raise chassis but does not rise Q Q
3 Bucket moves but lift arm does not rise Q Q
4 Lift arm can rise when not loaded but cannot when loaded Q Q Q Q Q
5 Work equipment pump is making abnormal sound Q Q
6 Hydraulic drift of lift arm cylinder is large Q Q Q Q
7 When lift arm and bucket are operated simultaneously, lift arm does not rise Q
8 When work equipment pump and servo assembly is replaced, lift arm rises normally Q

32 WA600-6
40 Troubleshooting SEN00564-02

H-20 Lift arm speed is low or rising force of lift arm is insufficient 1

Checks before troubleshooting Cause

equipment pump

Work equipment
q Is the stroke of the lift arm control lever proper?

Tank – Work
q Is the engine speed proper?

Cylinder
valve
Check of abnormality
q The troubles of the rising force and rising speed are strongly related to each
other. The rising speed lowers first. Measure the lift arm rising speed while it a b c d e f g h i
is loaded and check abnormality with the “Standard values table.”

Defective operation and defective adjustment of main relief valve

Internal wear or breakage of valve body (lift arm spool)

Defective operation of lift arm load check valve
Clogging or air intake on pump suction side

Defective operation of ECSS charge valve

Defective work equipment pump servo

Damaged lift arm cylinder piston seal

Defective operation of unload valve
Defective work equipment pump
A C
No. Remedy C E E E E E E x x
Diagnosis E x x x x x x

1 Tilting force and speed of bucket are abnormal and rising speed of lift arm is low Q Q Q Q Q Q
2 Tilting force and speed of bucket are normal and rising speed of lift arm is low Q Q Q
3 After oil temperature rises, rising speed lowers more in step 1 Q
4 Work equipment pump is making abnormal sound Q Q
5 Hydraulic drift of cylinder is large Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q
7 When work equipment pump and servo assembly is replaced, lift arm moves normally Q

WA600-6 33
SEN00564-02 40 Troubleshooting

H-21 When rising, lift arm comes to move slowly at specific height 1
Checks before troubleshooting
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-20 Lift arm speed is low or rising force of lift
arm is insufficient”

H-22 Lift arm cylinder cannot hold down bucket (Bucket floats) 1
See “H-20 Lift arm speed is low or rising force of lift arm is insufficient.”

Checks before troubleshooting

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
q Oil leak from lift arm cylinder piston seal

H-23 Hydraulic drifts of lift arm occur often 1

Ask the operator about the following:
q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
Checks before troubleshooting
q Is the lift arm spool at the neutral position? o The spool detent is defective
Check of abnormality
q Check the hydraulic drift of the lift arm with the “Standard values table.”
Cause
q Oil leakage in lift arm cylinder
q Imperfect fitting of suction valve on bottom side
q Imperfect fitting of lift arm spool

H-24 Lift arm wobbles during operation 1

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the HOLD position.
Diagnosis and Cause
Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-23 Hydraulic drifts of the lift arm occur
often.”
2. If the lift arm cylinder can lift the machine, see “H-20 Lift arm speed is low or rising force of lift arm is
insufficient.”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke
o The cause is vacuum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder head side is defective

34 WA600-6
40 Troubleshooting SEN00564-02

H-25 Bucket does not tilt back 1

Ask the operator about the following: Cause

equipment pump

Work equipment
q Did the bucket stop suddenly?

Tank – Work
o Seizure or breakage of each component

Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
a b c d e f g h i j
Checks before troubleshooting

Defective operation of bucket bottom suction valve (Suction safety valve)

Defective operation of bucket bottom safety valve (Suction safety valve)
q Is the oil level in the hydraulic tank proper?
q Is the stroke of the bucket control lever proper?
q Is the engine speed proper?
q Has the machine monitor displayed any failure code?
o See Troubleshooting by failure code (Display of code)

Internal breakage of valve body (lift arm spool)

Clogging or air intake on pump suction side

Defective operation of main relief valve

Defective work equipment pump servo

Damaged bucket cylinder piston seal

Defective operation of unload valve
Defective work equipment pump
Defective PTO

C
No. Remedy C E E E E E E E x x
Diagnosis E x x x x x x x

1 Lift arm does not move and bucket does not tilt back Q Q Q Q Q
2 Bucket can raise chassis but does not tilt back Q Q
3 Lift arm moves but bucket does not tilt back Q Q
4 Bucket can tilt back when not loaded but cannot when used for digging or scooping Q Q Q Q Q Q
5 Work equipment pump is making abnormal sound Q Q
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
7 When lift arm and bucket are operated simultaneously, bucket does not tilt back Q
8 When work equipment pump and servo assembly is replaced, bucket moves normally Q

WA600-6 35
SEN00564-02 40 Troubleshooting

H-26 Bucket speed is low or tilting back force is insufficient 1

Checks before troubleshooting Cause

equipment pump

Work equipment
q Is the stroke of the bucket control lever proper?

Tank – Work
q Is the engine speed proper?

Cylinder
valve
q Is the work equipment linkage bushing normal (Is abnormal sound
made)?

Check of abnormality a b c e f g h i j k
q Check by actual operation that the tilting back force is insufficient.

Defective operation of bucket bottom suction valve (Suction safety valve)

Defective operation of bucket bottom safety valve (Suction safety valve)
q Measure the operating speed of the bucket and check it with the “Stan-
dard value table.”

Defective operation and defective adjustment of main relief valve

Internal wear or breakage of valve body (bucket spool)

Clogging or air intake on pump suction side

Defective operation of ECSS charge valve

Defective work equipment pump servo

Damaged bucket cylinder piston seal

Defective operation of unload valve
Defective work equipment pump

A C
No. Remedy C E E E E E E E x x
Diagnosis E x x x x x x x

Rising force and speed of lift arm are abnormal and tilting back force and speed of bucket are Q Q Q Q Q Q
1
low
Rising force and speed of lift arm are normal and tilting back force and speed of bucket are
2 Q Q Q Q
low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
4 Work equipment pump is making abnormal sound Q Q
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q Q Q
7 When work equipment pump and servo assembly is replaced, bucket moves normally Q

36 WA600-6
40 Troubleshooting SEN00564-02

H-27 Bucket comes to operate slowly in the midst of tilting-back 1

Checks before troubleshooting
q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see “H-26 Bucket speed is low or tilt-back
force is insufficient.”

H-28 Bucket cylinder cannot hold down bucket 1

See “H-26. The bucket moves slowly or the tilting-back force is insufficient.”
Checks before troubleshooting
q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of safety valve (with suction valve) on the bucket cylinder head side of work equipment
valve
q Oil leak from bucket cylinder piston seal

H-29 Hydraulic drifts of bucket occur often 1

Ask the operator about the following:
q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
Checks before troubleshooting
q Is the bucket spool at the neutral position? o The spool detent is defective
Check of abnormality
q Refer to the “Standard value table” and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool

H-30 Bucket wobbles during travel with cargo (Work equipment valve is
set to “HOLD”) 1
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder head side. For other abnor-
mal phenomena, refer to diagnoses for relevant abnormal phenomena.

WA600-6 37
SEN00564-02 40 Troubleshooting

H-31 During operation of machine, engine speed lowers remarkably or

engine stalls 1
Checks before troubleshooting
Is the working equipment main relief pressure normal?
Cause
q Defective work equipment pump servo
q Defective working equipment pump unit
q Defective working equipment pump servo EPC input voltage
q Defective engine system

H-32 Large shocks are made when work equipment starts and stops 1
Cause
q Defective operation of control valve spool
q Defective working equipment electric lever system
o See Troubleshooting by failure code (Display of code)

H-33 When work equipment circuit is relieved singly, other work

equipment moves 1
Cause
q Pressure is not released properly from main spool of moving equipment o Replace main spool

38 WA600-6
40 Troubleshooting SEN00564-02

H-34 ECSS does not operate, and pitching bouncing occurs 1

Ask the operator about the following: Cause

Did pitching bouncing occur suddenly? o Breakage of related equipment

Solenoid valve
q

Accumulator
Controller
Did any abnormal noise occur at the time and where?

Sensor
q Has pitching bouncing occurred gradually? o Wear of related equipment, defective seal

Checks before troubleshooting

a b c d
q Is the state of ECSS switch proper?

Defective transmission output shaft speed sensor

Defective operation of work equipment controller
Gas leakage from accumulator, defective seal
Defective ECSS solenoid valve
No. Diagnosis Remedy x x x A
x
1 The ECSS actuation speed (5 km/h) largely fluctuates Q Q
2 The ECSS does not operate under no load Q Q
3 When the ECSS operates under load, the lift arm lowers the maximum distance (30 cm or more) Q
4 The ECSS does not operate at all Q Q Q Q

WA600-6 39
SEN00564-02 40 Troubleshooting

H-35 Fan speed is abnormal (Fan sound and vibration are abnormally
large or engine overheats) 1

1. Measure the fan speed and check that it is abnormal. Cause

Malfunction of fan pump EPC solenoid valve

2. Check that the fan is not deformed or worn unevenly.

3. Measurement conditions
q Engine: P mode
q Coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
q Torque converter oil temperature: Min. 105°C

Defect in fan motor

Defect in fan pump
Remedy
No. x x x
Diagnosis
1 Fan pump EPC output current is abnormal Q
2 Fan drive circuit pressure is abnormal Q Q

*: Fan pump EPC output current: 586.5 ± 20 mA (When all control levers are in neutral)

40 WA600-6
40 Troubleshooting SEN00564-02

WA600-6 41
SEN00564-02

WA600-6 Wheel loader

Form No. SEN00564-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

42
 SEN00565-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Engine does not start easily...................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operation................................................................................................................ 13
S-5 Engine does not rotate smoothly (Hunting occurs) ................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................. 16
S-8 Oil is consumed much (or exhaust gas color is blue) ............................................................................. 18
S-9 Engine oil becomes contaminated quickly ............................................................................................. 19
S-10 Fuel consumption is excessive............................................................................................................. 20
S-11 Coolant contains oil (blows back or reduces) ....................................................................................... 21
S-12 Oil pressure drops ................................................................................................................................ 22
S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 24
S-14 Coolant temperature rises too high (Overheating) ............................................................................... 26
S-15 Abnormal noise is made ....................................................................................................................... 27

WA600-6 1
SEN00565-02 40 Troubleshooting

S-16 Vibration is excessive ........................................................................................................................... 28

S-17 Air cannot be bled from fuel circuit ....................................................................................................... 30

2 WA600-6
40 Troubleshooting SEN00565-02

Method of using troubleshooting chart 1

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 fail-
ure 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 right corresponds to the items
were answers can be obtained from the user or
operator.
A is the basic content. B is the items that can be
obtained from the user or operator depending on
their level.

Check items:
Simple items checked by the serviceman to deter-
mine the causes. C in the chart to the right corre-
sponds to them.

Causes:
The contents to be determined after asking ques-
tions and checking items.
The serviceman determines causes of high proba-
bility from A, B, and C.

Troubleshooting:
The content for ultimately verifying whether the
determined causes are truly the defective factors
by using troubleshooting tools or making direct
checking starting with probable causes of higher
order.

This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E: A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.

WA600-6 3
SEN00565-02 40 Troubleshooting

<Example of troubleshooting> Exhaust smoke is black

Let us assume that the questions and item check were conducted when a defect of black exhaust gas is
detected. Now suppose that three symptoms have causal relationship with this problem: namely, [Exhaust
gas gradually became black], [Power was lost gradually], and [Dust indicator turned red].

4 WA600-6
40 Troubleshooting SEN00565-02

If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes.

Procedure for determining the causes from these relationship and leading to the troubleshooting will be
explained in step 1 to 3 in the following diagram.

WA600-6 5
SEN00565-02 40 Troubleshooting

S-1 Engine does not start easily. 1

General causes for poor startability include the follow- Cause
ing

Clogged air breather hole in fuel tank cap

q Electrical system is not normal

Defective contact of valve, valve seat

Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping
q Fuel level is low

Clogging of feed pump gauze filter

Defective intake air heater system

Defective or deteriorated battery

Defective alternator (generator)
q Air intake is in short

(coolant mixing in the exhaust)

Defective alternator (regulator)

Clogged air cleaner element

Wear of piston ring, cylinder

q Wrong fuel selection
q Coolant mixing in the exhaust pipe
a Common rail type fuel injection system (CRI) rec-

Cracked EGR cooler

ognizes the fuel injection timing electrically. There-

Clogged fuel filter

Defective injector
fore, there are cases where the engine does not
start before the crankshaft makes two revolutions
maximum after starting operation. This is not an
abnormal state, however.
Confirm recent repair history
Degree of use
Operated for long period E E E E E
of machine
Gradually became worse Q Q w w Q Q
Ease of starting
Starts when warm w w
Questions

Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation & Maintenance
Manual w w w Q Q

Engine oil must be added more frequently w

Preheat monitor does not indicate normal operation during preheating or at
w
low temperature
Charge level monitor indicates abnormal charging during operation w w
Dust indicator lamp is red w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w Q
No response or heavy resistance felt when operating priming pump w Q Q
Starting motor cranks engine slowly Q w
When engine is and air breathing plug is removed from fuel filter, fuel fails to w w
cranked with be discharged
starting motor, When spill hose is separated from injector, spill flow drops w
Check items

When exhaust manifold is touched immediately after starting engine, temper-

ature of some cylinders is low w

Engine does not pick up smoothly, and combustion is irregular Q Q w

There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w

Inspect air cleaner directly q

Removing EGR cooler outlet gas piping causes coolant containing antifreeze
q
to flow out (*1)
When compression pressure is measured, the oil pressure is low. q q
Air is discharged when air is bled from fuel system q
Troubleshooting

Inspect fuel filter directly q

Inspect fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*2)” q
Speed of some cylinders does not change when operated in reduced cylin-
q
der mode
Intake air heater mount does not warm up during preheating operation q
Is voltage 26 – 30V between alternator terminal B and terminal E Yes q
with engine at low idle? No q
Specific gravity of electrolyte and voltage of battery are low q
Replace

Replace
Replace

Replace

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean

Clean

Clean

Remedy
For *1 and *2, see the next page

6 WA600-6
40 Troubleshooting SEN00565-02

*1: EGR cooler inlet gas piping

Loosen 4 mount bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if
colorless and transparent.

*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

WA600-6 7
SEN00565-02 40 Troubleshooting

S-2 Engine does not start 1

a) Engine does not crank Cause

Cracked EGR cooler (coolant mixing in the exhaust)

General causes why engine does not turn

Defective starting motor (Safety relay section)

q Seizure inside engine:
See the troubleshooting for “S-4 Engine stops during opera-

Defective starting motor (Motor section)

tions”.

Defective battery terminal connection

q Electrical system is not normal

Defective wiring of starting circuit

Defective or deteriorated battery
q Defective power train:

Damaged flywheel ring gear

Carry out troubleshooting in H-mode.

Defective starting switch

Defective battery relay
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E

Condition of horn when starting Does not sound. Q Q w
switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items

Speed of rotation is low Q w

When starting switch is set to Makes grating noise w w
START, the starting pinion
comes out, but Soon disengages pinion again w
Makes rattling noise and does not turn w Q Q w

Removing EGR cooler outlet gas piping causes coolant containing antifreeze to flow out(*1) q
q

Carry out troubleshooting

Inspect flywheel ring gear directly
Specific gravity of electrolyte and voltage of battery are low q
Troubleshooting

There is no voltage (20 – 30V) between battery relay terminal

in E-mode
q
B and terminal E
Turn the starting switch OFF, When terminal B and terminal C of starting switch are con- q
connect the cord, then turn nected, engine starts
starting switch ON and carry When the safety relay outlet terminal B and terminal C are
out troubleshooting q
connected, engine starts
When the safety relay outlet terminal B and terminal C are q
connected, engine does not start
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Remedy

For *1, see the next page

8 WA600-6
40 Troubleshooting SEN00565-02

*1: EGR cooler inlet gas piping

Loosen 4 mount bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if
colorless and transparent.

WA600-6 9
SEN00565-02 40 Troubleshooting

b) Engine turns but no exhaust smoke comes out Cause

Defective operation of overflow valve (not closing)

General causes why engine turns but no exhaust smoke
comes out

Clogged air breather hole in fuel tank cap

Seizure or abnormal wear of feed pump

Wrong connection of supply pump PCV

q Fuel is not being supplied

Stuck or seized supply pump plunger

q Supply of fuel extremely small

Leakage, clogging, air in fuel piping

Defective operation of flow damper

q Improper selection of fuel (particularly in winter)

Clogged feed pump gauze filter

Broken supply pump shaft, key

Defective supply pump PCV

Insufficient fuel in tank

Defective fuel injector

Improper fuel used

Clogged fuel filter

Confirm recent repair history E
Questions

Degree of use of machine Operated for long period E E E

Exhaust smoke suddenly stops coming out (when starting again) w Q w w w E E
Replacement of filters not carried out according to Operation & Maintenance
Manual w w E Q

Fuel tank is found to be empty w

Clogged air breather hole in fuel tank cap w
Rust and water are detected when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, no fuel is inside the fuel filter w w
Check items

Leakage from fuel piping w

and the air breathing plug is removed from the fuel Q Q w Q
When engine is cranked filter, fuel fails to discharge
with starting motor, When spill hose is separated from injector, spill
Q w w w w Q
flow drops

Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Troubleshooting

Inspect the fuel feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q q q
Carry out troubleshoot by “PCV1 Error (:2) or PCV2 Error (*3)” q
Inspect overflow valve directly q
Engine can start when operated in reduced cylinder mode q q
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Correct
Correct

Correct
Clean
Add

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA271], and Code [CA272]
*3: Troubleshooting by failure code (Display of code), Code [CA273], and Code [CA274]

10 WA600-6
40 Troubleshooting SEN00565-02

c) Exhaust smoke comes out but engine does not start Cause

Defective coolant temperature sensor or defective wiring harness

(Fuel is being injected)

General causes why exhaust smoke comes out but engine

does not start
q Rotating force in short due to defective electrical system
q Supply of fuel small

Wear of valve system (valve, rocker lever, etc.)

q Small air intake

Clogged air breather hole in fuel tank cap

Clogged injection nozzle, defective spray

q Improper selection of fuel

Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping

Defective intake air heater system

Defective or deteriorated battery
Clogged feed pump gauze filter
Worn piston ring, cylinder liner
Clogged air cleaner element

Improper fuel used

Clogged fuel filter

Check recent repair history
Degree of machine operation Machine operated for long period E E E E
Suddenly failed to start w w Q
Questions

Non-specified fuel is being used Q Q

Replacement of filters not carried out according to Operation & Maintenance Manual w w w
Engine oil replenishment increasing w
Preheat monitor not indicating normal operation during preheating or at low temper-
w
ature
Dust indicator turned red w
Clogged air breather hole in fuel tank cap Q
Rust and water are detected when fuel tank is drained w w
When removed, no fuel is inside the fuel filter w
Leakage from fuel piping w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Check items

Fuel fails to discharge, when bleeding air plug of the

Q w w
When engine is cranked with fuel filter is removed
starting motor, Spill flow drops, when spill hose is separated from w
injector
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w

Inspect air cleaner directly q

Inspect valve system directly q
When compression pressure is measured, the oil pressure is low. q
Troubleshooting

Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Inspect the fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Testing a single unit injector indicates defective spraying q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge indication is not normal q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Replace
Replace
Correct
Clean

Clean

Clean

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

WA600-6 11
SEN00565-02 40 Troubleshooting

S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Cause
q Insufficient intake of air

Clogged air breather hole in fuel tank cap

Clogged injection nozzle, defective spray

Defective contact of valve and valve seat

Seizure and interference of turbocharger

q Insufficient supply of fuel

Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping

Defective operation of flow damper

q Fuel injection condition not normal

Clogged feed pump gauze filter

q Improper selection of fuel

Worn piston ring, cylinder liner

Clogged air cleaner element
q Controller in derate control mode

(excessive injector leakage)

Improper valve clearance
(Controlling injection capacity (output) due to an error
in the electrical system)
q EGR valve is stuck in open state

Clogged fuel filter

Stuck EGR valve
(Shortage of air intake due to excessive EGR gas)

Confirm recent repair history

Degree of use of machine Operated for long period E E E E E E
Questions

Engine pick-up suddenly became poor Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation & w w w
Maintenance Manual
Engine oil must be added more frequently w
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Rust and water are detected when fuel tank is drained w w
Leakage from fuel piping w
No response or heavy resistance felt when operating priming pump w Q Q
When exhaust manifold is touched immediately after starting engine, tempera-
Q w
ture of some cylinders is low
Blue under light load w
Color of exhaust gas
w Q w w
Check items

Black
Abnormal noise is heard from around cylinder head w
Abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w

Inspect air cleaner directly q

Carry out troubleshoot by “EGR Valve Servo Error (*1)” in E-mode. q
When compression pressure is measured, the oil pressure is low. q q
Troubleshooting

Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Inspect the fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*2)” q
Speed of some cylinders does not change when operated in reduced cylinder
q q
mode
Replace
Replace

Replace
Replace

Replace

Replace

Replace

Replace
Correct
Adjust
Clean

Clean

Clean

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

12 WA600-6
40 Troubleshooting SEN00565-02

S-4 Engine stops during operation 1

General causes why engine stops during operations Cause
q Seizure inside engine

Broken auxiliary equipment (pump, compressor, etc.)

Breakage of valve system (valve, rocker lever, etc.)

Defective power supply wiring for engine controller

q Insufficient supply of fuel
q Overheating
q Defective power train:

Clogged air breather hole in fuel tank cap

Broken, seized piston or connecting rod
Carry out troubleshooting in H-mode.

Stuck or seized supply pump plunger

Broken, seized crankshaft metal

Leakage, clogging in fuel piping

Clogged feed pump gauze filter

Broken supply pump shaft, key

Defective starting switch wiring

Broken, seized feed pump
Broken, seized gear train
Insufficient fuel in tank

Defective power train

Clogged fuel filter
Confirm recent repair history
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine
w w w w Q w Q w w
stopped suddenly
Questions

Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters not carried out according to Operation & Mainte-
nance Manual w w

Fuel level monitor indicates low fuel level w

Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w
Rust and water are detected when fuel tank is drained w w
Metal particles are found when oil pan is drained w w w
Check items

Does not turn at all w w

When engine is cranked Turns in opposite direction w
manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when loaded on the machine side w

Inspect valve system directly q

Carry out troubleshooting in H-mode

Inspect piston and connecting rod directly. q

Inspect crankshaft metal directly q
Troubleshooting

Inspect gear train directly q

Inspect fuel filter directly q
Inspect fuel feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q
Engine rotates when auxiliary equipment (pump, compressor) is removed q
Check power supply wiring for engine controller q
Check starting switch wiring q
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Correct
Clean

Clean
Add

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]

WA600-6 13
SEN00565-02 40 Troubleshooting

S-5 Engine does not rotate smoothly (Hunting occurs) 1

General causes why engine does not rotate smoothly Cause
q Mixing of air in the fuel system

Defective operation of flow damper (excessive injector leakage)

q Rotation sensor is not normal

Defective Bkup speed sensor or defective wiring harness

(abnormality where it fails to make error indication)

Defective Ne speed sensor or defective wiring harness

q EGR valve is not normal
q Bypass valve is not normal

Clogged air breather hole in fuel tank cap

Clogged fuel injector, defective injection

Defective operation of bypass valve

Leakage, clogging, air in fuel piping

Defective operation of EGR valve
Low idle speed setting is too low

Clogged feed pump gauze filter

Insufficient fuel in tank

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Questions

Occurs at a certain speed range Q Q Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slope w Q Q
Replacement of filters not carried out according to Operation & Maintenance Manual w w
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap w
Check
item

Rust and water are detected when fuel tank is drained Q Q

Leakage from fuel pipe w

Carry out troubleshoot by “EGR Valve Servo Error (*1)” q

Carry out troubleshoot by “Bypass Valve Servo Error (*2)” q
Troubleshooting

Air is discharged when the air is bled from the fuel system q
Inspect the fuel feed pump gauze filter directly q
Inspect the fuel filter directly q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*3)” q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*4)” q
Correct or replace
Correct or replace
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Correct
Clean
Add

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA1628], and Code [CA1629]
*3: Troubleshooting by failure code (Display of code), Code [CA689]
*4: Troubleshooting by failure code (Display of code), Code [CA778]

14 WA600-6
40 Troubleshooting SEN00565-02

S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Insufficient intake of air

Defective fuel temperature sensor or defective wiring harness

q

Defective charge pressure sensor or defective wiring harness

q Insufficient supply of fuel

Defective mounting of charge pressure sensor (air leak)

q Fuel injection condition not normal
q Improper selection of fuel
q Overheating

Defective drive of injector (signal or solenoid)

See the troubleshooting for “S-14 Coolant Tem-

Clogged air breather hole in fuel tank cap

Defective contact of valve and valve seat

Clogged fuel injector, defective injection

Seizure or interference of turbocharger
perature Too High (Overheat)”

Stuck or seized supply pump plunger

q Controller in derate control mode

Leakage, clogging in fuel piping

Clogged feed pump gauze filter

Air leakage from air intake pipe

Worn piston ring, cylinder liner

(Controlling injection capacity (output) due to an

Clogged air cleaner element

error in the electrical system)

Improper valve clearance

Clogged fuel filter

Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Questions

Suddenly Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation & Maintenance Manual w
Engine oil must be added more frequently Q Q Q
Dust indicator is red w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w
Output reduces after a break w
Black w w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
w
Check items

Interfering noise is heard from around turbocharger

Abnormal noise is heard from around cylinder head w
High idle speed of engine is low Q
High idle speed under no load is normal, but speed suddenly drops when load is
w w Q
applied
Engine does not pick up smoothly, and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w

Inspect air cleaner directly q

Inspect intake air piping directly q
When boost pressure is measured, the oil pressure is low q q q
When compression pressure is measured, the oil pressure is low q q
Troubleshooting

Inspect valve clearance directly q

Inspect fuel filter directly q
Inspect fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Check the mount of boost pressure sensor directly q
Carry out troubleshoot by “Chg Air Press Sensor Error (*2)” q
Carry out troubleshoot by “Fuel Temp Press Sensor Error (*3)” q
Replace
Replace

Replace

Replace

Replace
Replace
Replace

Replace
Replace
Correct

Correct

Correct
Adjust
Clean

Clean

Clean

Remedy
For *1, *2 and *3, see the next page

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA122], and Code [CA123]
*3: Troubleshooting by failure code (Display of code), Code [CA263], and Code [CA265]

WA600-6 15
SEN00565-02 40 Troubleshooting

S-7 Exhaust smoke is black (Incomplete combustion) 1

General causes why exhaust smoke is black Cause
q Insufficient intake of air

Air leakage between turbocharger and cylinder head

Clogged fuel spill piping (on the cylinder head side)

Defective coolant temperature sensor or defective

q Insufficient supply of fuel
q Fuel injection condition not normal
q Improper selection of fuel

Defective contact of valve or valve seat

q Overheating

Seizure or interference of turbocharger

Stuck or seized supply pump plunger

See the troubleshooting for “S-14 Coolant Tem-
perature Too High (Overheat)”

Worn piston ring, cylinder liner

q Controller in derate control mode

Clogged air cleaner element

Improper injection pressure

Abnormal wear of injector
(Controlling injection capacity (output) due to an

Improper valve clearance

Crushed, clogged muffler

Improper injection timing

Clogged, seized injector
error in the electrical system)
q EGR valve is stuck in open state

Stuck EGR valve

(Shortage of air intake due to excessive EGR gas)

wiring harness
Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Suddenly became black w Q Q Q
Questions

Color of exhaust gas Gradually became black w Q Q Q

Blue under light load w
Non-specified fuel is being used Q Q
Engine oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Dust indicator is red w
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operated in low-temperature mode during normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temper- w
ature of some cylinders is low
Abnormal noise is heard from around turbocharger w
Check items

Abnormal noise is heard from around cylinder head w

Torque converter stall or high pump relief speed (excessive fuel injection) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly, and combustion is irregular Q Q Q Q Q Q w
Blow-by gas is excessive w w
Spill flow is excessive when spill hose is separated from injector w

Inspect air cleaner directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshoot by “EGR Valve Servo Error (*1)” q
Troubleshooting

When compression pressure is measured, the oil pressure is low. q q

Inspect valve clearance directly q
When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by “Rail Press Very Low Error (*2)” q q
Speed of some cylinders does not change when operated in reduced cylin-
der mode q

Inspect fuel spill piping (on the cylinder head side) directly q
Carry out troubleshoot by “Coolant Temp Sensor Error (*3)” q
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace

Replace
Replace

Replace
Correct

Correct
Adjust
Clean

Remedy

For *1, *2 and *3, see the next page

16 WA600-6
40 Troubleshooting SEN00565-02

*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*3: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]

WA600-6 17
SEN00565-02 40 Troubleshooting

S-8 Oil is consumed much (or exhaust gas color is blue) 1

General causes why oil consumption is excessive Cause
q Abnormal oil combustion

Turbocharger

Oil leakage from EGR valve and bypass valve stem

q Extended operation for long hours in low or high

Worn or damaged valve (stem, guide, and seal)

idle (continuous no load operation for 20 minutes
and longer inhibited)

Leakage from oil pan, cylinder head, etc.

q Oil leakage to outside
q Wear of lubricating system

Clogged breather or breather hose

Dust sucked in from intake system

Worn, damaged rear seal surface

Worn piston ring, cylinder liner

Leakage from oil drain plug

Wear of seal at blower end
Worn seal at turbine end

Leakage from oil cooler

Leakage from oil piping

Leakage from oil filter
Broken piston ring

Broken oil cooler

Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E E E

Oil consumption suddenly increased w Q
Engine oil must be added more frequently Q w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Q w
Check items

Inside of turbocharger exhaust outlet pipe is contaminated with oil

There is oil in the coolant w
Color of exhaust gas blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w

When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is contaminated abnormally q
Excessive play of turbocharger shaft q q
Troubleshooting

When EGR valve and bypass valve are removed, exhaust port is contami-
q
nated with oil
Inspect breather, breather hose directly q
When compression pressure is measured, the oil pressure is low. q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Correct

Correct
Correct
Correct
Correct
Clean

Remedy

18 WA600-6
40 Troubleshooting SEN00565-02

S-9 Engine oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas due to internal wear

Clogged lubricating drain tube of turbocharger

q Clogging of lubrication route

Defective seal at turbocharger turbine end

q Improper fuel is being used
q Improper oil is being used

Clogged breather, breather hose

q Operated under excessive load

Worn piston ring, cylinder liner

Defective oil filter safety valve

Worn valve, valve guide

Exhaust smoke is black

Worn EGR valve guide

Clogged oil cooler

Clogged oil filter
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E E

Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates clogging when the oil temperature rises w Q
Metal particles are found when oil is drained in oil filter Q Q
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check item

Color of exhaust gas

Black w
Excessive Q Q w
Amount of blow-by gas
None w

Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is contaminated with oil q
Troubleshooting

When compression pressure is measured, the oil pressure is low. q q

(See S-7)
Inspect breather, breather tube directly q
Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Clean

Clean
—
Remedy

WA600-6 19
SEN00565-02 40 Troubleshooting

S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause
q Leakage of fuel

Defective coolant temperature sensor or defective wiring harness

q Fuel injection condition (fuel pressure and injection timing) not normal
q Excessive fuel injection

Fuel leakage from fuel filter, piping, etc.

Defective common rail fuel pressure

Leakage of fuel inside head cover

Defective supply pump plunger

Defective feed pump oil seal

Defective injector operation

Defective injector spray
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E

More than for other machines of same model Q Q Q
Condition of fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing, smelling of diesel oil w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
low w w
Check items

Low idle speed is too high Q

Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q
Color of exhaust gas
White Q

Remove head cover and inspect directly q

Troubleshooting

Inspect feed pump oil seal directly q

Carry out troubleshoot by “Rail Press Very Low Error (*1)” q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by “Coolant Temp Sensor Error (*2)” q
Replace
Replace
Replace
Replace
Replace
Correct
Correct

Correct

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]

20 WA600-6
40 Troubleshooting SEN00565-02

S-11 Coolant contains oil (blows back or reduces) 1

General causes why oil in coolant Cause
q Internal leakage of lubricating system

Hole drilled by damages or pitching of cylinder liner O-ring

q Internal leakage of cooling system

Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block

Broken oil cooler core, O-ring

Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Excessive air bubbles inside radiator, coolant spurts back w w
Check
item

Hydraulic oil or power train oil is milky w

When hydraulic oil or power train oil is drained, water is discharged w

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

shooting

q q
Trouble-

Inspect cylinder block, liner directly Carry out trou-

bleshooting in
Inspect cylinder liner directly. q H-mode
Pressure-tightness test of cylinder head shows there is leakage q
Replace
Replace
Replace
Replace
Replace

—
Remedy

WA600-6 21
SEN00565-02 40 Troubleshooting

S-12 Oil pressure drops 1

General causes why oil pressure drops Cause
q Leakage, clogging, wear of lubrication system

Defective hydraulic sensor or defective wiring harness

q Hydraulic control is not normal
q Selection of oil by the temperature etc. specified in the

Leakage, crushing or clogging of hydraulic pipe

Operation and Maintenace Manual is not observed.

Defective oil level sensor or wiring harness

Clogging or breakage of pipe inside oil pan
q Oil deteriorated by overheating

Leakage from EGR hydraulic piping

Clogged strainer inside oil pan

Defective oil pump relief valve

Defective EGR oil pump

Wear of metal journal
Lack of oil in oil pan

Defective oil pump

Clogged oil filter

Water, fuel in oil
Confirm recent repair history
Degree of use of
Questions

Operated for long period E E E E

machine
Oil pressure monitor indicates low pressure level Q w
Non-specified fuel is being used Q Q
Replacement of filters not carried out according to Operation & Maintenance Manual w
Indicates a drop of hydraulic pressure during low idle w Q Q
Indicates a drop of oil pressure during low and high idle Q w w w Q Q Q
Oil pressure monitor
Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level w w
Oil pan oil level is in short w
Leakage or crushing with external hydraulic pipe w w
Check items

Oil is cloudy white or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil is drained from oil filter w Q Q
See S-13

Metal particles are detected in oil filter q

Troubleshooting

Inspect oil pan strainer, pipe directly q q

Oil pump rotation is heavy, there is play q
Oil pump relief valve, spring is fatigued or damaged q
Inspect oil filter directly q
Relief valve of EGR oil pump is damaged or has oil leak q
Inspect EGR hydraulic piping directly q
Carry out troubleshoot by “Eng Oil Press Sensor Error (*1)” q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Add
—

Remedy

*1: Troubleshooting by failure code (Display of code), Code [CA135], and Code [CA141]

22 WA600-6
40 Troubleshooting SEN00565-02

WA600-6 23
SEN00565-02 40 Troubleshooting

S-13 Oil level rises (Water, fuel in oil) 1

General causes why oil level rises Cause
q Coolant mixing in the oil (oil turns cloudy)

Clogging of water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells diluted diesel fuel)
a If oil mixes with the coolant, carry out troubleshooting by S-11

Defective seal of auxiliary equipment (pump or compressor)

Hole drilled by damages or pitching of cylinder liner O-ring
Coolant contains oil

Cracked EGR cooler (mixing of coolant)

Broken cylinder head, head gasket
Leakage of fuel inside head cover

Worn, damaged rear seal surface

Internal cracks in cylinder block

Broken oil cooler core, O-ring

Defect inside supply pump

Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E E

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in the coolant Q Q Q w
Engine oil smells of diesel fuel w w
Oil is milky Q Q
After starting engine, drops of water come from muffler Q Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bubbles appear
or water spurts back w Q
Check items

Exhaust gas is white Q

Clogged water pump drain hole (breather hole) w
Water comes out when water pump drain hole (breather hole) is cleaned w
Damper oil is decreasing w
Hydraulic tank oil level is decreasing on applicable machine side w

Removing EGR cooler inlet gas piping causes coolant containing antifreeze to flow out (*1) q
When compression pressure is measured, the oil pressure is low q
Troubleshooting

Remove head cover and inspect directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of cylinder head shows there is leakage q
Remove water pump and inspect directly q
Remove supply pump and inspect directly q
Inspect the seal of auxiliary machine directly q
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct

Remedy

For *1, see the next page

24 WA600-6
40 Troubleshooting SEN00565-02

*1: EGR cooler inlet gas piping

Loosen 4 mounting bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if
colorless and transparent.

WA600-6 25
SEN00565-02 40 Troubleshooting

S-14 Coolant temperature rises too high (Overheating) 1

General causes why coolant temperature becomes too Cause
high

Drop in performance of fan pump, fan motor

q Lack of cooling air (deformation, damages of fan)

Defective radiator cap (pressure valve)

q Drop in heat dissipation efficiency

Water leakage to outside EGR cooler

Defective coolant temperature gauge

Hole drilled by damages or pitching
Broken cylinder head, head gasket

Rise of power train oil temperature

q Defect in the coolant circulation system

Defective operation of thermostat

q Power train oil temperature is rising:

Clogged, crushed radiator fins

Carry out troubleshoot in H-mode

Deformed or damaged fan

Clogged, broken oil cooler
of cylinder liner O-ring

Clogged radiator core

Broken water pump
Lack of coolant
Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Questions

Suddenly increased Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge Does not go down from red
range w

Radiator coolant level monitor indicates low level Q w

Engine oil level has risen, oil is cloudy white w Q
Fan speed is low w w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, coolant spurts back w
When light bulb is held behind radiator, no light passes through w
Check items

Radiator shroud and inside of underguard on applicable machine side are

clogged with dirt or mud w w

Coolant leakage from cracks in the radiator hose or loose clamps w

Coolant flows out from radiator overflow hose w
Power train oil temperature gauge on applicable machine side enters red w
range faster than engine coolant temperature gauge

Inspect coolant leakage from EGR cooler directly q Carry out troubleshooting in H-mode
When compression pressure is measured, the oil pressure is low. q Carry out troubleshooting in H-mode
Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting

Temperature difference between top and bottom radiator tanks is excessive q

When function test is carried out on thermostat, it does not open even at
q
cracking temperature
Temperature difference between top and bottom radiator tanks is slight q
Inspect radiator core directly q
When function test is carried out on the radiator cap, cracking pressure is low q
Inspect fan directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace

Replace

Replace

Replace
Replace

Replace
Replace
Replace
Correct
Correct
Add

—
—

Remedy

26 WA600-6
40 Troubleshooting SEN00565-02

S-15 Abnormal noise is made 1

General causes why abnormal noise is made Cause
q Abnormality due to defective parts

Air leakage between turbocharger and cylinder head

Defect inside muffler (dividing board out of position)

Breakage of valve system (valve, rocker lever, etc.)
q Abnormal combustion
q Air sucked in from intake system

Cracks or gas leakage from EGR gas piping

Excessive wear of piston ring, cylinder liner

a Judge if noise is from inside or outside before proceeding
with troubleshooting

Seizure or interference of turbocharger

a When engine is not fully warmed up, engine noise rises

Missing, seized gear train bushing

slightly because of operation in the low temperature mode.
This is not abnormal, however.

Improper gear train backlash

Deformed or damaged fan

a When engine is accelerated, it enters acceleration mode,

Improper valve clearance

Dirt caught in the injector

Clogged, seized injector
where engine noise remains slightly higher for about 5
seconds maximum. This is not abnormal, however.

Confirm recent repair history

Degree of use of machine Operated for long period E
Questions

Gradually increased Q Q Q
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
Engine oil must be added more frequently w
Metal particles are found when oil is drained in oil filter Q w w
Leakage of air between turbocharger and cylinder head w
Abnormal noise is heard from around turbocharger w
Abnormal noise is heard from around EGR gas piping w
Abnormal noise is heard from around cylinder head w w
Abnormal noise is heard from around muffler w
Check items

When exhaust manifold is touched immediately after starting engine, temperature of w Q

some cylinders is low
Blue under light load w
Color of exhaust gas
Black Q w Q
Engine pickup is poor and combustion is abnormal w
Abnormal noise is loud when accelerating engine Q Q Q Q
Blow-by gas is excessive w w

When turbocharger is rotated by hand, it is found to be heavy q

Inspect EGR gas piping directly q
Inspect valve system directly q
Troubleshooting

When muffler is removed, abnormal noise disappears q

Inspect valve clearance directly q
When compression pressure is measured, the oil pressure is low. q
Inspect gear train directly q q
Inspect fan directly q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Abnormal noise is emitted only when starting engine q
Replace
Replace
Replace

Replace

Replace
Replace
Replace

Replace
Correct

Correct

Correct
Adjust

Remedy

WA600-6 27
SEN00565-02 40 Troubleshooting

S-16 Vibration is excessive 1

General causes why vibration is excessive Cause
q Defective parts (abnormal wear, breakage, etc.)

Broken part inside upper drive shaft or damper

Loose engine mounting bolts, broken cushion
Stuck valve system (valve, rocker lever, etc.)
q Alignment with applicable machine side is not normal

Wear of front support spigot joint portion

q Abnormal combustion

Worn main metal, connecting rod metal

a If there is abnormal noise together with the vibration, carry out trouble-
shooting also for “S-15 Abnormal noise is made”.

Improper gear train backlash

Worn camshaft bushing
Confirm recent repair history
Questions

Degree of use of machine Operated for long period E E E E

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Non-specified fuel is being used Q Q
Metal particles are found when oil is drained in oil filter w w
Metal particles are found when oil pan is drained w w
Q Q
Check items

Oil pressure is low at low idle

Vibration occurs at mid-range speed Q Q
Vibration follows engine speed Q Q Q Q
Exhaust smoke color is black w

Inspect valve system directly q

Troubleshooting

Inspect main metal, connecting rod metal directly q

Inspect gear train directly q
Inspect camshaft bushing directly q
Inspect engine mount bolt, cushion directly. q
Inspect front support spigot directly q
Inspect inside of upper drive shaft or damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy

28 WA600-6
40 Troubleshooting SEN00565-02

WA600-6 29
SEN00565-02 40 Troubleshooting

S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.

Defective wiring harness of electric priming pump

Improper setting of air bleeding valve (Closed)
q Fuel is not supplied or is supplied very little.

Malfunction of electric priming pump switch

q Fuel valve or air bleeding valve is not set properly.

Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.

Improper setting of fuel valve (Closed)

Malfunction of electric priming pump

q Fuel return piping is clogged.

Clogged fuel tank cap breather hole

Clogged water separator screen

Clogged air bleeding piping

Low battery charge level

Clogged fuel filter
Low fuel level
Confirm recent repair history
Questions

Degree of use of
Operated for long period E E
machine
Non-specified fuel is being used Q Q
Fuel tank is empty w
Fuel tank cap breather hole is clogged w
Fuel is leaking from fuel piping w
Check items

Switch lamp does not blink w w Q

When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
Q Q Q Q w w w Q Q
of hose soon

Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting

Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-14) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace

Replace
Charge
Correct
Correct
Correct
Correct
Correct

Clean
Add

Remedy

30 WA600-6
40 Troubleshooting SEN00565-02

Note 1: Check of air bleeding piping for clogging

q Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
q Remove air bleeding pipings (2), (3) and blow compressed air against its both ends to check for clog-
ging.

WA600-6 31
SEN00565-02

WA600-6 Wheel loader

Form No. SEN00565-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

32
 SEN01156-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools ...............................................................................................................................11

WA600-6 1
SEN01156-03 50 Disassembly and assembly

How to read this manual 1

(Rev. 2009.1)

1. Removal and installation of assemblies

Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained

4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque

5 : Amount of oil or coolant to be replenished

Sketches of special tools

q Various special tools are illustrated for the local
manufacture.

2 WA600-6
50 Disassembly and assembly SEN01156-03

2. Disassembly and assembly of assemblies

Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.

WA600-6 3
SEN01156-03 50 Disassembly and assembly

Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.

Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive

Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant

LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.

4 WA600-6
50 Disassembly and assembly SEN01156-03

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant

LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum

• Used to lubricate linkages, bearings, etc.

lubricant
disulfide

• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
compound
prevention
Seizure

pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease

LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)

WA600-6 5
SEN01156-03 50 Disassembly and assembly

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease

• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)

Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer

PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive

• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass

facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material

SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)

6 WA600-6
50 Disassembly and assembly SEN01156-03

Special tools list 1

a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”)

New•Remodel
Essentiality

Illustration
Quantity
Sym-
Work item Part number Part name Nature of work, remarks
bol

795-799-5410 Adapter t 1 Removal and installation

Removal of fuel injector 1
795-799-5420 Remover t 1 of fuel injector assembly
and cylinder head
assembly Removal and installation
2 795T-675-1110 Socket q 1 N Q
of high-pressure pipings
Engine rear seal and Removal of engine front
3 795-931-1100 Seal puller assembly q 1
front seal and rear seals
795T-621-1180 Push tool t 1 Q Press fitting of oil seal
795T-621-1171 Push tool t 1 N Q Press fitting of dust seal
Engine front seal 4
A 795-902-1460 Bolt t 3 Press fitting of oil seal
01582-02218 Nut t 3 and dust seal
795T-621-1161 Push tool t 1 R Q
795T-621-1190 Push tool t 1 N Q Press fitting of engine
Engine rear seal 5
01050-32235 Bolt t 5 rear seal
01050-32245 Bolt t 5
Assembly of damper 6 793-612-1120 Push tool t 1 Press fitting of bearing
assembly 7 793T-612-1310 Push tool q 1 N Q Press fitting of oil seal
Cylinder head assembly 8 790-331-1120 Wrench (angle) q 1 Angle tightening of bolt
Removal and installation
C 792-900-1350 Wrench t 1
of turbine shaft nut
Disassembly and Removal and installation
assembly of torque D 793-613-1210 Wrench t 1
of stator shaft nut
converter assembly
793-615-1110 Wrench t 1 Measurement of rotation
E
01306-10616 Bolt t 1 torque of input shaft
Disassembly and
Operation check of clutch
assembly of transmission F 799-301-1500 Oil leak tester t 1
piston
and transfer assembly
Measurement of rotation
Disassembly and 1 793-615-1130 Spline wrench t 1 torque of intermediate
assembly of transfer G shaft
assembly Measurement of rotation
2 796-730-2300 Wrench assembly t 1
torque of input shaft

WA600-6 7
SEN01156-03 50 Disassembly and assembly

New•Remodel
Essentiality

Illustration
Quantity
Sym-
Work item Part number Part name Nature of work, remarks
bol

790-501-5200 Unit repair stand t 1

1
790-901-4110 Bracket t 1
2 793T-622-1810 Plate t 1 N Q
Bearing preload adjust-
3 792-103-0901 Wrench t 1
ment
Press fitting of differen-
4 793T-622-1180 Push tool t 1 Q
tial case bearing
Press fitting of pinion
5 793T-622-1840 Push tool t 1 N Q shaft main bearing inner
race
790-201-2460 Plate t 1 Press fitting of main bear-
6
790-201-2690 Plate t 1 ing outer race
Disassembly and
assembly of differential 790-101-5621 Plate t 1
Press fitting of sub-bear-
assembly 7 790-101-5421 Grip t 1
H ing outer race
01010-81240 Bolt t 1
Press fitting of sub-bear-
8 790-201-2860 Spacer t 1
ing inner race
792-525-1000 Micrometer t 1 Bearing preload adjust-
9
792-525-1220 Adapter t 1 ment
Press fitting of differen-
10 793T-622-1820 Push tool t 1 N Q
tial cage oil seal
Press fitting of differen-
793T-622-1830 Push tool t 1 N Q
tial cage dust seal
11
790-101-5221 Grip t 1
01010-81240 Bolt t 1
Removal and installation
Centering of transmission
of center support assem- 12 793T-620-1410 Centering tool t 1 N Q
bly
– center support
Removal and installation
1 793T-622-1910 Fixture t 3 N Q
of wheel hub
792-520-2110 Installer t 1 Installation of floating
Disassembly and assem- 2
bly of rear brake assem- J 792-530-1600 Push tool t 1 seal
bly 792T-422-1220 Plate t 1 Q
3 790-101-5421 Grip t 1 Press fitting of oil seal
01010-81240 Bolt t 1

8 WA600-6
50 Disassembly and assembly SEN01156-03

New•Remodel
Essentiality

Illustration
Quantity
Sym-
Work item Part number Part name Nature of work, remarks
bol

790-101-2300 Push tool t 1

790-101-2310 • Block 1
790-101-2320 • Screw 1
790-101-2330 • Nut 2
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4 Installation of lower cen-
1
790-101-2410 • Joint 2 ter hinge bearing
02215-11622 • Nut 2
793-520-2640 Push tool t 1
790-438-1030 Guide t 1
790-438-1050 Bar t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
Installation of center
K 790-101-2300 Push tool t 1
hinge bearing
790-101-2310 • Block 1
790-101-2330 • Nut 1
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4
790-101-2410 • Joint 2
Installation of upper cen-
2 02215-11622 • Nut 2
ter hinge bearing
790-438-1050 Bar t 2
01580-12016 Nut t 2
790-438-1010 Push tool t 1
790-438-1020 Guide t 1
790-438-1040 Screw t 1
790-101-2102 Puller t 1
790-101-1102 Pump t 1
Removal and installation
Steering valve assembly 1 793T-664-1110 Bracket t 1 N Q of steering valve assem-
bly
796-946-1310 Guide
2 t 1
T (For 723-46-40100)
796-946-1320 Guide Replacement of pres-
Control valve assembly 3 t 1 sure compensation valve
(For 723-46-40100) seal
796-946-1330 Sleeve
4 t 1
(For 723-46-40100)

WA600-6 9
SEN01156-03 50 Disassembly and assembly

New•Remodel
Essentiality

Illustration
Quantity
Sym-
Work item Part number Part name Nature of work, remarks
bol

790-502-1003 Cylinder repair stand q 1 Disassembly and assem-

1 bly of hydraulic cylinder
790-101-1102 Pump q 1 assembly
790-102-4300 Wrench assembly t 1 Removal and installation
2
790-102-4310 Pin t 2 of piston assembly
3 790-720-1000 Expander q 1
796-720-1690 Ring (For lift arm) q 1
07281-02169 Clamp q 1
796-720-1720 Ring (For bucket) q 1
Installation of piston ring
4 07281-02429 Clamp q 1
Ring
796-720-1660 q 1
(For steering)
Hydraulic cylinder 07281-01159 Clamp q 1
U
assembly 790-201-1702 Push tool kit t 1
• Push tool
790-201-1881 1
(For lift arm and bucket)
5 • Push tool Press fitting of bushing
790-201-1821 1
(For steering)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 Press fitting of dust seal
• Plate
790-201-1690 1
(For lift arm and bucket)
790-201-1630 • Plate (For steering) 1
Operator cab glass 1 793-498-1210 Lifter (Suction cup) t 2 Installation of operator
X
(stuck glass) 2 20Y-54-13180 Stopper rubber t 2 cab glass (stuck glass)

10 WA600-6
50 Disassembly and assembly SEN01156-03

Sketches of special tools 1

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

A2 socket

A4 Push tool (For oil seal)

WA600-6 11
SEN01156-03 50 Disassembly and assembly

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

A4 push tool (For dust seal)

A5 push tool (For both standard and sleeved seal)

12 WA600-6
50 Disassembly and assembly SEN01156-03

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

A5 push tool (For sleeved seal)

A7 push tool (For oil seal)

WA600-6 13
SEN01156-03 50 Disassembly and assembly

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

H2 plate

H4 push tool

14 WA600-6
50 Disassembly and assembly SEN01156-03

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

H5 push tool

H10 push tool

WA600-6 15
SEN01156-03 50 Disassembly and assembly

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

H11 push tool

H12 centering tool

16 WA600-6
50 Disassembly and assembly SEN01156-03

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

J1 fixture

J3 plate

WA600-6 17
SEN01156-03 50 Disassembly and assembly

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

T1 bracket

18 WA600-6
50 Disassembly and assembly SEN01156-03

WA600-6 19
SEN01156-03

WA600-6 Wheel loader

Form No. SEN01156-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

20
 SEN01157-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Engine and cooling system, Part 1
Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 6
Removal and installation of air aftercooler .....................................................................................................11
Removal and installation of cooling fan and fan motor assembly ................................................................. 12
Removal and installation of damper assembly ............................................................................................. 14
Disassembly and assembly of damper assembly ......................................................................................... 16
Removal and installation of fuel tank assembly ............................................................................................ 20
Removal and installation of engine hood assembly ...................................................................................... 22
Removal and installation of bulkhead assembly ........................................................................................... 24

WA600-6 1
SEN01157-02 50 Disassembly and assembly

Removal and installation of 3. Remove air hose (2). [*1]

engine assembly 1 4. Remove komaclone hose and tube assembly
(3). [*2]
Removal 5. Disconnect dust indicator hoses (4).
6. Remove air cleaner (5). [*3]
k Stop the machine on level ground and set 7. Disconnect connector E15 (6).
the frame lock bar. 8. Disconnect wiring harness (7).
k Lower the work equipment to the ground 9. Remove air cleaner bracket (8).
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove the radiator assembly, referring to

“Removal and installation of radiator assembly”.

q Overall view of machine right side

2. Open the bulkhead cover to remove cover (1)

of the air cleaner.

10. Remove bracket and heat insulation cover (9)

assembly.

2 WA600-6
50 Disassembly and assembly SEN01157-02

11. Disconnect drive shaft (10). [*4] 16. Disconnect fuel supply hose (16).
a Remove the bottom mounting bolt as
shown below.
1) Pull pin (11) out of a location near the
engine mount, which is situated in the
front right side, and then push in forcing
screw (B).
2) Turn forcing screw (B) for deburring and
then remove the bottom mounting bolt of
the drive shaft.

17. Disconnect connector EP1 (17) and EP2 (18).

18. Disconnect clamps (19) and (20).
19. Disconnect 2 fuel hoses (21).

12. Remove cover (12).

13. Disconnect connector E16 (13).
14. Loosen the adjustment bolt of air conditioner
compressor (14) and then remove air condi-
tioner compressor belt (15). [*5]
15. Remove air conditioner compressor (14).
a Don't disconnect the air conditioner hose.

q Left side
20. Disconnect torque converter cooler (TC) cool-
ant tubes (22) and (23).
a Connection: O-ring
21. Disconnect coolant tube (24).
a Replacement of gasket (G)
22. Disconnect heater hose (25).

WA600-6 3
SEN01157-02 50 Disassembly and assembly

23. Disconnect starting motor terminal (26). a Front right side and left side lifting hooks
24. Disconnect connector ER1 (27). are provided in the bottom.
25. Disconnect connector ER2 (28).
26. Disconnect connector ER3 (29).
27. Disconnect wiring harness (30).
28. Disconnect grounding wire ER06 (31).
29. Disconnect engine grounding wire (32).
30. Remove engine mount bolts (33) and (34). [*6]

31. Lift and remove engine assembly (35), using T-

shaped lifting tool [1].
a F: Rear side lifting hook
4 Engine assembly: 3,200 kg

4 WA600-6
50 Disassembly and assembly SEN01157-02

Installation

q Carry out installation in the reverse order to

removal.

[*1]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2]
3 Komaclone tube assembly hose clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

[*3]
3 Air cleaner band:
12.7 – 17.6 Nm {1.3 – 1.8 kgm}

[*4]
3 Drive shaft assembly mounting bolt:
107 – 127 Nm {10.9 – 13.0 kgm}

[*5]
a Adjust the air conditioner compressor belt ten-
sion, referring to “Adjusting air conditioner
compressor belt tension” in Testing and adjust-
ing.

[*6]
3 Engine mount bolt:
824 – 1030 Nm (84 – 105 kgm)
Target: 927 Nm (94.5 kgm)

q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to increase
coolant temperature and then confirm the cool-
ant level again.
5 Coolant: 160 l

WA600-6 5
SEN01157-02 50 Disassembly and assembly

Removal and installation of 7. Disconnect connector G05 (5) and disconnect

radiator assembly 1 the clip of the wiring harness.

Removal
k Park the machine on flat ground and set the
safety bar to the frame.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.

1. Remove cover (1).

8. Disconnect right and left chains (6).

9. Disconnect hoses (7) and (8).
10. Remove reservoir tank (9).

2. Drain the engine coolant.

6 Coolant: 160 l

3. Remove the engine hood and covers, referring 11. Disconnect hose (10).
to “Removal and installation of engine hood 12. Remove covers (11) and (12).
assembly”. a Take care in this operation not to damage
the aftercooler core.
4. Remove cover (2).
5. Disconnect cover (3).
6. Disconnect 2 hoses (4) from the reservoir tank.

6 WA600-6
50 Disassembly and assembly SEN01157-02

13. Remove right and left side bars (13). 17. Disconnect fan drain hose (19), fan inlet hose
14. Remove cover and frame assembly (14). (20) and fan outlet hose (21).
a Take care in this operation not to damage 18. Remove clamp (22).
the aftercooler core.

19. Disconnect connectors G06 (23) and GR1 (24)

15. Disconnect air conditioner hose clamps (15) situated in the rear left side of the radiator.
from radiator guard (16). 20. Disconnect clamp (30).
a BB: Back buzzer

16. Open radiator grille (17) and remove 3 fan

guards (18). 21. Remove 3 mounting bolts of left side and then
open fan motor and support assembly (25).[*1]

WA600-6 7
SEN01157-02 50 Disassembly and assembly

22. Fix fan motor and support assembly (25) in the 25. Lift and float the radiator guard and fan assem-
manner shown below. bly (28).
1) Remove pin (51) from the hinged portion a (B): The mounting bolt position in the rear
of fan motor and support assembly (25). side of the radiator.
4
2) Remove lock pin (52) and then fix the
Radiator guard and fan assembly:
assembly to the bracket (BKT) using lock
pin (52). 650 kg
26. Disconnect sponge (29).

23. Remove right and left mounting bolts (26).

a Leave a counter mark (M) to the position.
24. Remove the cover of section (A) and remove
right and left mounting bolts (27).
a The mounting bolt is provided in the rear
side of the radiator, too.

8 WA600-6
50 Disassembly and assembly SEN01157-02

27. Lift radiator guard and fan assembly (28) 34. Disconnect connectors (36) from the radiator
slowly. outlet.
28. Take out radiator guard and fan assembly (28) a Replacement of gasket (G)
while avoiding contact against tube (C) of the a When disconnecting the outlet at the con-
aftercooler. nection with radiator hose (38) (it takes
more than an hour)
1) Loosen right and left side clamps (37) and
then push radiator hose (38) all the way in
the radiator. [*5]
a Hose (38) is disconnected later (as
the radiator assembly is lifted up).

35. Disconnect air conditioner condenser assem-

bly (40) directing bracket (39) outward.
a Remove the air conditioner hose clamp
prior to the above operation.
36. Lift radiator assembly (41) temporarily and
remove right and left side mounting bolts (42).
[*6]
37. Disconnect hose (38) (noted in the foregoing)
29. Disconnect aeration hose (30). while the radiator assembly being lifted up.
30. Loosen radiator hose clamps (31) and (32). [*2]
31. Loosen air hose clamp (33). [*3]
32. Disconnect air tube (34).
33. Remove air hose (35). [*4]

WA600-6 9
SEN01157-02 50 Disassembly and assembly

38. Float radiator assembly (41). Installation

4
q Carry out installation in the reverse order to
Radiator assembly: 450 kg
removal.
39. Disconnect radiator hose (43).
40. Take out radiator assembly (41). [*1]
a AC: Aftercooler 3 Fan motor and support assembly mounting
a Take care in this operation not to damage bolt:
the core. 245 – 309 Nm {25 – 31.5 kgm}
a Make sure that clearance (a) between the
shroud and fan is uniform (Standard clearance:
6 mm). When not uniform, loosen mounting
bolts (12) to adjust the clearance.
3 Mounting bolt (12):
490 – 608 Nm {50 – 62 kgm}

[*2]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*4]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*5]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*6]
3 Radiator assembly (28) mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}

q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to increase
coolant temperature and then confirm the cool-
ant level again.
5 Coolant: 160 l

10 WA600-6
50 Disassembly and assembly SEN01157-02

Removal and installation of air 6. Push up fender (6).

a Fender: If equipped
aftercooler 1
7. Open doors (7) and (8).
Removal
k Park the machine on flat ground and set the
safety bar to the frame.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.

1. Remove cover (1).

8. Remove bar (9).

9. Remove mounting bolt (10).
10. Slowly take out air aftercooler assembly (5)
through the side face while using care not to
damage air conditioner hose (H).
a Take care in this operation not to damage
the core.
a Take care in this operation not to damage
the radiator guard (G).

2. Disconnect reservoir tank hose (2).

3. Disconnect air hose (3). [*1]
4. Remove air tube and bracket assembly (4). [*2]
5. Lift air aftercooler assembly (5) temporarily.
4 Air aftercooler assembly: 45 kg

Installation
q Carry out installation in the reverse order to
removal.

[*1], [*2]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

WA600-6 11
SEN01157-02 50 Disassembly and assembly

Removal and installation of cooling 6. Remove lock plate (9). [*2]

fan and fan motor assembly 1 7. Remove fan mounting nut (10) to remove cool-
ing fan (11). [*3]
Removal
k Stop the machine on level ground and set
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.

1. Open grille (1) to take out fan guard (2).

8. Remove 4 mounting bolts to remove fan motor

assembly (7) (noted in the foregoing).

2. Disconnect connector G07 (3).

a Disconnect the wiring harness clamp.
3. Disconnect IN port hose (4), Dr port hose (5)
and OUT port hose (6) from fan motor assem-
bly (7).
a Prepare an oil pan and a detent plug since
the above operation allows oil to flow out.
4. Disconnect the top and bottom fan guards from
radiator guard.
5. Remove 3 mounting bolts of left side and then
open fan motor and support assembly (8). [*1]
a Fix it using the lock pin.

12 WA600-6
50 Disassembly and assembly SEN01157-02

Installation
q Carry out installation in the reverse order to
removal.

[*1]
3 Fan motor and support assembly (8) mount-
ing bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Make sure that clearance (a) between the
shroud and fan is uniform (Standard clearance:
6 mm). When not uniform, loosen mounting
bolts (12) to adjust the clearance.
3 Mounting bolt (12):
490 – 608 Nm {50 – 62 kgm}

[*2]
a It is not allowed to turn the hole alignment side
on lock plate (9) to the loosening side.

[*3]
3 Mounting nut:
441 – 539 Nm {45.0 – 55.0 kgm}

q Refilling with oil (Hydraulic oil tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

WA600-6 13
SEN01157-02 50 Disassembly and assembly

Removal and installation of

damper assembly 1
Removal
k Stop the machine on level ground and set
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove the engine hood and covers, referring

to “Removal and installation of engine hood 10. Remove bracket (10) and heat insulation cover
assembly”. (9) assembly.
2. Open the bulkhead cover to remove cover (1) 11. Remove bracket (10).
of the air cleaner.

12. Referencing “Removal and installation of

3. Remove air hose (2). [*1] hydraulic pump assembly”:
4. Remove komaclone hose and tube assembly 1) Remove steering and fan pump assembly
(3). [*2] (11) and work equipment hydraulic pump
5. Disconnect dust indicator hoses (4). assembly (12).
6. Remove air cleaner (5). [*3] 2) Remove drive shaft (13). [*4]
4
7. Disconnect connector E15 (6).
Drive shaft: 30 kg
8. Disconnect wiring harness (7).
9. Remove air cleaner bracket (8).

14 WA600-6
50 Disassembly and assembly SEN01157-02

13. Lift and remove flywheel assembly (14). [*5] Installation

4 Flywheel assembly: 45 kg
q Carry out installation in the reverse order to
14. Lift and remove damper cover and shaft removal.
assembly (15). [*6]
4
[*1]
3
Damper cover and shaft assembly: 70 kg
Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2]
3 Komaclone tube assembly hose clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

[*3]
3 Air cleaner band:
12.7 – 17.6 Nm {1.3 – 1.8 kgm}

[*4]
3 Drive shaft assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

15. Lift and remove damper body assembly (16) [*5]

from the flywheel (FW). [*7] 3 Flywheel mounting bolt:
4 Damper body assembly: 80 kg 98 – 123 Nm {10 – 12.5 kgm}

[*6]
2 Mating face: Gasket sealant (LG-1)
3 Damper cover and shaft assembly (15)
mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Remove plug (17) situated at the bottom of the
machine and plug (18) situated on the side
face, and then fill ENS grease through plug
hole (17) until the grease level comes to the
bottom of plug (18).
2 ENS grease:
427-12-11871 (GREASE) (250 ± 30 cc)
2. Install plugs (17) and (18).
3 Plug: 5.9 – 11.8 Nm {0.6 – 1.2 kgm}

[*7]
3 Damper body assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}

WA600-6 15
SEN01157-02 50 Disassembly and assembly

Disassembly and assembly of 4. Invert cover (7) to remove oil seal (8).
damper assembly 1
Special tools

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
6 793-612-1120 Push tool t 1
A
7 793T-612-1310 Push tool q 1 N Q

a ENS grease:
427-12-11871 (GREASE) (contained in 2-kg
can) should be used. 5. Using push tool [11], remove bearing (9),
a Before using ENS grease, make sure other spacer (10) and bearing (11) from cover (7).
greases are completely cleaned off. It is pro-
hibited to mix ENS grease with other greases.

Disassembly

Damper cover and shaft assembly (1)

1. Remove oil seal (2) from damper cover and
shaft assembly (1).
2. Remove snap rings (3) and (4).

3. Using blocks [1] and push tool [2], remove shaft

(6) from damper cover and shaft assembly (1).
a Cover the floor with wood chips so that the
shaft may not be damaged should it fall off.

16 WA600-6
50 Disassembly and assembly SEN01157-02

Damper body assembly Assembly

6. Remove the flange mounting bolt and then
remove flange (13), 4 small rubbers (14), 4 Damper body assembly
large rubbers (15), inner body assembly (16), a See the figure to the left.
outer body (17) and flange (19), in this order. 1. Set outer body (17) to flange (19) aligning the
a Don't remove spacer (12) and plug (18) mounting bolt hole.
from inner body (16). They must be handled 2 Mating face: Gasket sealant (LG-1)
as integral part of inner body assembly. 2. Set inner body assembly (16) aligning the lever
tip of inner body assembly (16) to the mark (M)
on outer body (17).
a The mark (M) is provided at 4 points on
the circumference on the both sides of the
outer body.
3. Assemble 4 small rubbers (14) and 4 large rub-
bers (15) to the positions indicated on the fig-
ure.
2 Before assembling the rubbers, apply
the entire face of the rubbers, outer
periphery of inner body and inner
periphery of outer body with ENS
grease (G2-U-S).
2 After assembling the rubbers, fill each
of 4 clearances (P) between the rub-
bers and inner body with 100 cc of
ENS grease.
4. Install flange (13).
2 Mating face: Gasket sealant (LG-1)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2 Fill the top face (shaft insertion por-
tion) of spacer (18) with 30 cc of ENS
grease.

q View from cover (13).

WA600-6 17
SEN01157-02 50 Disassembly and assembly

Damper cover and shaft assembly 11. In the same way, press fit bearing (11) to
5. Install plug (20), 3 plugs (21) and breather (22) damper cover (7).
to the damper cover (7). a When press fitting bearing (11), make sure
that inner diameter of spacer (10) and
bearing (11) is aligned.

6. Set tool A7 on the press bench and then set

damper cover (7) on tool A7.
a Use care in this operation not to incline the 12. Invert damper cover (7).
damper cover.
13. Using tool A7, press fit oil seal (8) to cover (7).
a Overall length: 125 mm
2 Seal lip surface: ENS grease
a Seal driven depth: (a) = 5 ± 0.5 mm
2 Space between bearing and oil seal
(indicated as T): ENS grease (20 ml)

7. Apply adhesive to the outer periphery of bear-

ing (9).
2 Outer periphery of bearing:
Locktite No. 648
8. Using push tools A6 and A7, press fit bearing
(9) to damper cover (7).
a Overall length: 150 mm
2 Ball of bearing (9):
To be filled with ENS grease
9. Using push tools A6 and A7, press fit bearing
(9) to damper cover (7).
a Using the clearance gauge, make sure the
clearance is within the standard value.
Clearance (b): 0 – 0.6 mm
10. Install spacer (10) aligning it to the bearing
inner diameter.

18 WA600-6
50 Disassembly and assembly SEN01157-02

14. Press fit shaft (6) from the top of cover (7) set-
ting push tool A6 at the bottom.
2 Inner periphery of bearing:
Locktite No. 648
2 Spline of shaft: Molybdenum disul-
fide-based desiccating and lubricating
agent (LM-P)
Sumico Lubricant Low Coll Dry
Spray or equivalent
a Leave the spline as is for 2 to 3 minutes
after applying the above agent.
a Before press fitting, remove foreign sub-
stances deposited on the outside of the
shaft and inside of the bearing.

15. Invert the damper cover and shaft assembly

and install snap rings (3) and (4).
2 Ball of bearing (11):
To be filled with ENS grease
2 Space between bearing and oil seal
(indicated as U): ENS grease (60 ml)
16. Set the damper cover and shaft assembly on
the block [8].
17. Using push tools [4], [9] and [10], press fit oil
seal (2).
a Oil seal driven depth:
± 0.5 mm from the damper cover end face
2 Oil seal lip surface: ENS grease

WA600-6 19
SEN01157-02 50 Disassembly and assembly

Removal and installation of fuel 6. Open right and left covers (8) as well as cover
tank assembly 1 (9).

Removal
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.

1. Drain fuel from the tank.

6 Fuel tank: 133 l (When filled up)
7. Remove right and left oil cooler (OC) mounting
bolts (10).
2. Disconnect wiring connector R16 (1) situated a Don't disconnect the oil hose and coolant
in the front side of the fuel tank. hose from the oil cooler (OC).
3. Disconnect clamp (2).

8. Disconnect clamp (11) of the blow-by hose

4. Disconnect fuel supply hose (3) and fuel return
(BH).
hoses (4) and (5) in the upper right of the fuel tank.
9. Disconnect clamps (12) and (13) of the muffler
a Before disconnecting, attach them a tag or
drain hose (MD).
equivalent to make the later position iden-
tification easier.
5. Disconnect hose clamp (7).

20 WA600-6
50 Disassembly and assembly SEN01157-02

10. Disconnect radiator drain (15). Installation

q Carry out installation in the reverse order to
removal.

[*1]
3 Fuel tank mounting bolt
1,520 – 1,910 Nm {155 – 195 kgm}
Target: 1,720 Nm {175 kgm}

[*2]
a Adjust the shim so that the clearance on the
fuel tank mounting surface may become 0.5
mm or less.

11. Disconnect engine drain (16). q Refilling with oil (Hydraulic oil tank)
12. Disconnect bracket (17). Fill oil from the oil filler.
13. Remove oil filler port (18).
14. Lift fuel tank (19) temporarily.
15. Remove 6 right and left mounting bolts (20). [*1]
a Shims are provided for 6 right and left
mounting bolts (20). Confirm their num-
bers and positions. [*2]
16. Lift and remove fuel tank (13).
4 Fuel tank assembly: 430 kg (Fuel not
included)

WA600-6 21
SEN01157-02 50 Disassembly and assembly

Removal and installation of 4. Remove step (6) on the right side of the
engine hood assembly 1 machine body and then install it on boss (A) of
the left side.
Removal a Use it as the step when removing covers
k Stop the machine on level ground and set (7) and (8).
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.

1. Remove pre-cleaner (1) and muffler (2).

2. Remove hoods (3) and (4).
a A tapped hole for lifting is provided in the
four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg

5. Remove covers (7) and (8).

a Hook (F) is provided at the top of the rear
side of cover (7). The pin (P) situated at
the bottom of the side hood (SH) protect
cover (7) from falling off as the mounting
bolt is removed.

3. Remove cover (5).

22 WA600-6
50 Disassembly and assembly SEN01157-02

6. Push up fender (10). Installation

a Fender (10): If equipped q Carry out installation in the reverse order to
7. Remove engine right side door (11). removal.
4 Engine right side door: 45 kg
8. Remove cover (12).
a Just like cover (7), cover (12) is also pro-
tected from falling off as the bolt is
removed.

9. Disconnect air conditioner hose clamps (13)

from right side hood (14).

10. Remove stay (15).

11. Lift and remove side hood (16).
4 Side hood (one side): 55 kg
a Remove the right side, too.

WA600-6 23
SEN01157-02 50 Disassembly and assembly

Removal and installation of 3. Push up fender (5).

4. Lift and remove handrail and step assembly (6).
bulkhead assembly 1 5. Remove cover (7).
Removal a Hook (F) is provided at the top of the rear
k Stop the machine on level ground and set side of cover (7). The pin (P) situated at
the frame lock bar. the bottom of the side hood (SH) protects
k Lower the work equipment to the ground com- cover (7) from falling off as the mounting
pletely and stop the engine. Apply the parking bolt is removed.
brake and put the blocks under the wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.

k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.

1. Remove pre-cleaner (1) and muffler (2).

2. Remove hoods (3) and (4).
a A tapped hole for lifting is provided in the
four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg

6. Remove cover (8).

7. Remove step (9).

24 WA600-6
50 Disassembly and assembly SEN01157-02

8. Remove cover (10). 15. Open the engine right side door.
16. Disconnect air conditioner hose (16). [*1]
a The hose with larger diameter

9. Remove clamp (11).

10. Lift and remove handrail and step assembly
(12). 17. Disconnect air conditioner hose clamps (17)
11. Remove handrail mounting bolt (13). from right side hood (18).
12. Lift and remove handrail and ladder assembly 18. Lift and remove right side hood (18).
(14). a Remove the left side, too.
4
13. Remove step (40) on the right side of the
Side hood (one side): 55 kg
machine body and then install it on boss (A) of
the left side. a Haul in air conditioner hose (16) on the
a Use it as the step when removing cover engine side to the cab side.
(15).
14. Remove cover (15).
a Just like cover (7), cover (15) is also pro-
tected from falling off as the bolt is
removed.

WA600-6 25
SEN01157-02 50 Disassembly and assembly

19. Disconnect air conditioner hose clamps (19).

20. Disconnect air conditioner hose (20).
21. Disconnect receiver dryer and bracket assem-
bly (21) from the bulkhead assembly.
22. Disconnect clamps (22) and (23).
23. Disconnect washer tank (24).
a Disconnect connectors BL1 and BL3 from
the back.
a Haul in air conditioner hose (20) from the
engine side.
24. Remove air cleaner cover (25).
25. Disconnect hose clamps (26).
26. Disconnect dust indicator hose (27).
27. Remove right and left brackets (34).

Installation
q Carry out installation in the reverse order to
removal
[*1]
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Before tightening, make sure O-ring (70) is
provided in the air conditioner hose piping con-
nection.
a Check that there is no defect or deterioration
on the O-ring.
28. Disconnect clamps (28). a When connecting the refrigerant piping, coat
the O-ring with compressor oil for refrigerant
(R134a) (Denso: ND-OIL8, Zexel: ZXL100PG
(PAG 46 or equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}

29. Lift and remove bulkhead assembly (33). [*2]

4 Bulkhead assembly: 220 kg

[*2]
3 Bulkhead assembly mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}

q Filling of air conditioning gas

Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 850 ± 50 g

26 WA600-6
50 Disassembly and assembly SEN01157-02

WA600-6 27
SEN01157-02

WA600-6 Wheel loader

Form No. SEN01157-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

28
 SEN01158-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Engine and cooling system, Part 2
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of cylinder head assembly ...................................................................................... 8
Removal and installation of fuel injector assembly ....................................................................................... 24
Removal and installation of engine front seal ............................................................................................... 28
Removal and installation of engine rear seal ................................................................................................ 31

WA600-6 1
SEN01158-03 50 Disassembly and assembly

Removal and installation of fuel

supply pump assembly 1
Removal
k Stop the machine on level ground and set
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) from
the battery before starting with the work.

a The work of aligning No.1 or No.6 cylinder

compression top dead center is not necessary.
a The special tool for pulling the gear out is not
necessary.

1. Remove pre-cleaner (1) and muffler (2).

2. Remove hoods (3) and (4).
a A tapped hole for lifting is provided in the
four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg

6. Remove stay (8).

a FSP: Fuel supply pump

3. Push up fender (5).

4. Remove door (6).
5. Remove cover (7).
a Hook (F) is provided at the top of the rear
side of cover (7). The pin (P) situated at
the bottom of the side hood (SH) protect
cover (7) from falling off as the mounting
bolt is removed.

2 WA600-6
50 Disassembly and assembly SEN01158-03

7. Remove wiring harness cover (9).

a Use care so that the washer may not fall
off.
8. Disconnect the clamp of breather tube (10)
and the fixing bolt (10-1).
9. Disconnect the breather hose (10-2) from Y
side, too.
10. Remove mounting bolt (11) and then lift
breather tube assembly (12) slightly.
11. Remove wiring harness cover (13).
a Use care so that the washer may not fall
off.
a Care must be exercised in removing cover
(13). Removing cover (13) forcibly without
slightly lifting breather tube assembly (12) 12. Remove bracket (14).
may generate cracks in (B) portion since a 5 mounting bolts
breather (12) is made of plastics. 13. Disconnect connector PFUEL (15).
a An O-ring is installed in breather (12)
installation position.

14. Disconnect clamps (16).

15. Remove high-pressure piping cover (17).
· Y View · Z View

WA600-6 3
SEN01158-03 50 Disassembly and assembly

16. Disconnect connectors INJ (18) and G (19). 24. Disconnect tube (31). [*2]
17. Disconnect connectors PCV1 (20) and PCV2 a Prepare an oil pan since oil flows out dur-
(21). ing this operation.
25. Remove 3 clamps (32).
26. Disconnect bracket (33) and remove tube (34).
[*3]
27. Remove tube (35). [*4]
28. Disconnect clamps (36).

18. Remove clamps (22) to (24).

19. Remove covers (25) and (26).
20. Remove high-pressure piping (27).
a Before removing the tube, clean adjacent
sections thoroughly so that foreign sub-
stances may not enter the supply pump
and common rail.
21. Remove bracket (28).

29. Remove tube (37).

30. Remove bracket (38).
31. Remove fuel supply pump assembly (39).
22. Remove tube (29). [*1]
23. Disconnect connector G (30).

4 WA600-6
50 Disassembly and assembly SEN01158-03

32. Remove the followings from fuel supply pump Installation

assembly (39). 1. Install the followings to fuel supply pump
1) Oil tube (40) assembly (39).
2) Plate (41) 1) Key (47)
3) Overflow pipe adapter (42) 2) Coupling (46)
3) Washer (45)
4) Nut (44)
3 Nut (44):
176 – 196 Nm {18 – 20 kgm}

4) Nut (44)
5) Washer (45)
6) Coupling (46)
7) Key (47)
5) Plate (41)
6) Oil tube (40)
a Exchange gaskets (GA) and (G10).
q GA: Accessory gaskets of the
supply pump.
q G10: Part number is 07005-
01012.
7) Overflow valve (43)
3 Plate (41) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Oil tube (40) joint bolt:
Top: 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Bottom: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Overflow valve (43):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}

WA600-6 5
SEN01158-03 50 Disassembly and assembly

2. Assemble the fuel supply pump assembly by

aligning (A) and (AA) at the position where a
spline tooth is missing.

High-pressure piping
k When handing the high-pressure pipe
and clamp, pay attention the following.
q It is strictly prohibited to bend the
high-pressure piping to use it again or
using it in other locations.
q Install the specified clamp securely in
the specified position with the speci-
fied torque.
q Don't apply lubricant and the like to
the high-pressure piping sleeve nut
and the threaded portion of the mat-
ing side.
a Axial force in the tightening
can be excessive, potentially
damaging the high-pressure
piping.
3. Install fuel supply pump assembly (39). k Before installing the high-pressure pip-
3 Fuel supply pump mounting bolt: ing, check it for the following defects. If
59 – 74 Nm {6 – 7.5 kgm} there is any of these defects, it can
3 Bracket (38) mounting bolt: c a u s e f u e l l e a k a g e . A c c o r d i n g l y,
59 – 74 Nm {6.0 – 7.5 kgm} replace the high-pressure piping.
4. Install oil tube (37). q Check the taper seal of the connect-
3 Oil tube (37) joint bolt: ing part (Part (a): Part of 2 mm from
9.8 – 12.7 Nm {1.0 – 1.3 kgm} the end) for visible lengthwise slit (b)
a Exchange 4 gaskets (G). and dent (c).
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.

6 WA600-6
50 Disassembly and assembly SEN01158-03

5. Tighten high-pressure piping (27) temporarily. k Make sure that a clearance of 10 mm mini-
6. Tighten clamps (22) to (24) temporarily. mum is provided between the high-pres-
7. Tighten high-pressure piping (27) permanently. sure piping and adjacent wiring harness. If
3 High-pressure piping sleeve nut: not, secure the clearance by adjusting the
39.2 – 44.1 Nm {4.0 – 4.5 kgm} wiring harness position.
8. Tighten clamps (22) to (24) permanently.
3 Clamping bolt: q Bleeding air
9.8 ± 1.0 Nm {1 ± 0.1 kgm} Bleed air from the fuel system, referring to
9. Tighten bracket (28) permanently. “Bleeding air from fuel system” in Testing and
10. Install covers (25) and (26). adjusting.

q Carry out the succeeding installation in the

reverse order of removal.

[*1]
3 Tube (29)
Joint bolt (Overflow valve):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve nut (Fuel block side):
24 – 27 Nm {2.4 – 2.7 kgm}

[*2]
3 Tube (31)
Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (31) sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}

[*3]
3 Tube (34) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*4]
3 Tube (35) joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (35) sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}

WA600-6 7
SEN01158-03 50 Disassembly and assembly

Removal and installation of 4. Remove air hose (2). [*1]

cylinder head assembly 1 5. Remove komaclone hose and tube assembly
(3). [*2]
Special tools 6. Disconnect dust indicator hoses (4).
7. Remove air cleaner (5). [*3]

New/Remodel
8. Disconnect connector E15 (6).
Sym- 9. Disconnect wiring harness (7).

Necessity
Part No. Part name
bol

Sketch
10. Remove air cleaner bracket (8).

Q'ty
795-799-5410 Adapter t 1
1
795-799-5420 Remover t 1
A
2 795T-675-1110 Socket q 1 N Q
8 790-331-1120 Wrench (angle) q 1

Removal

k Stop the machine on level ground and set

the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Drain the engine coolant.

6 Coolant: 160 l

2. Remove the engine hood and covers, referring

to “Removal and installation of engine hood
assembly”.
11. Remove bracket and heat insulation cover (9)
3. Open the bulkhead cover to remove cover (1) assembly.
of the air cleaner. 12. Disconnect muffler drain tube (10).

8 WA600-6
50 Disassembly and assembly SEN01158-03

13. Remove flange (11). 15. Disconnect fuel hose (13).

16. Disconnect tubes (14) and (15). [*4]
17. Remove filter assembly (16).

14. Lift and remove muffler (12).

4 Muffler assembly: 100 kg
18. Remove fuel tube clamps (17).
19. Remove fuel tube (18). [*5]
20. Disconnect fuel tube (19).
21. Disconnect connector TOIL (20).
a Pull out connector by driving lock (L)
upward.
22. Disconnect connector POIL (21) in the follow-
ing manner.
1) When disconnecting connector POIL (21),
slide lock (L1) rightward.
2) Pull out connector POIL (21) while push-
ing lock (L2).
23. Remove tube assembly (22).

q Overall view of right side

WA600-6 9
SEN01158-03 50 Disassembly and assembly

24. Lift and remove filter assembly (23). 27. Remove turbocharger coolant tube assembly
(26). [*7]
28. Remove turbocharger lubrication tubes (27)
and (28).
29. Remove turbocharger coolant tube (29).
30. Disconnect exhaust tube (30).

25. Disconnect wiring harness (24).

26. Lift and remove air tube and bracket assembly

(25). [*6]

31. Disconnect connectors V30 (31-1) and V29

(31-2).
a Push the lock when disconnecting them.

10 WA600-6
50 Disassembly and assembly SEN01158-03

32. Lift and remove turbocharger and exhaust 37. Disconnect 6 injector connectors (38).
manifold assembly (32). [*8] 38. Disconnect connector CN6 (39).
4
39. Remove wiring harness bracket (40).
Turbocharger and exhaust manifold
assembly: 120 kg

40. Disconnect high-pressure piping clamps (41)

to (43).
33. Remove breather and tube assembly (33). 41. Remove tubes (44) to (46). [*9]
34. Remove wiring harness covers (34) and (35). 42. Remove brackets (47) and (48).

35. Disconnect connector (36). 43. Disconnect high-pressure piping clamps (49)
36. Remove high-pressure piping cover (37). and (50).
44. Remove fuel tube (51). [*10]

WA600-6 11
SEN01158-03 50 Disassembly and assembly

45. Remove clamp (52). 54. Disconnect connectors PCV1 (60) and PCV2
46. Remove covers (53) and (54). (61).
47. Loosen clamps (55) and (56). 55. Disconnect wiring harness clamp (62).
48. Remove high-pressure piping tube assembly (57). 56. Remove tubes (63) to (65). [*11]
49. Disconnect connector (58). 57. Remove fuel supply pump assembly (66).
50. Disconnect fuel hose (120). a Do not loosen overflow valve (ofv).
51. Disconnect connector PIM (121). a Do not remove oil tube (t) and plate (p).

52. Disconnect wiring harness clamp (59) from

rear side of the fuel supply pump. 58. Disconnect clamps (67).
53. Disconnect the connector from the bottom of 59. Disconnect tube (68). [*12]
clamp (59).

12 WA600-6
50 Disassembly and assembly SEN01158-03

60. Disconnect sleeve (69). 64. Disconnect sleeve nut (75) on the high-pres-
61. Remove high-pressure piping (70). sure piping injector side.
a Tool A2 allows implementing this work
from the side face rather than from the
top.

62. Remove bracket (71).

63. Remove 4 mounting bolts (73) from the radia-
tor side of intake manifold assembly (72).
a Tool A2

WA600-6 13
SEN01158-03 50 Disassembly and assembly

65. Remove high-pressure piping (74). 71. Lift and remove air intake manifold assembly
66. Lift air intake manifold assembly (72) tempo- (72).
4
rarily.
Air intake manifold assembly: 110 kg
a Using eyebolt [1] and lifting tool [2], lift the
assembly temporarily on to the mounting
bolt hole of bracket (71) (noted in the fore-
going).
67. Remove the mounting bolts of air intake mani-
fold assembly (72).
68. Install guide bolts [3].
a Use the filter mounting bolt as the guide
bolt.
a The convexed tube bites into the inner
face of the connector. Thus, care must be
exercised in using the guide bolt to avoid
damaging the tube. (See the following
section)
69. Remove all mounting bolts of air intake mani-
fold assembly (72). 72. Remove bracket (77).
73. Remove turbocharger lubrication tube (78) and
coolant tube (79).
74. Remove air vent tube (80).

70. Remove connector (76).

a Take care a convexed tube bites into the
inner face of the connector (indicated as
A).

14 WA600-6
50 Disassembly and assembly SEN01158-03

75. Remove cylinder head cover (81). 84. Using tool A1, remove fuel injector assembly
a Check that you can move the rocker arm (92).
of the No.1 or No.6 cylinder with the fin- a Remove the assembly by hitching tip of
gers by the distance of the valve clear- tool A1 on hole (H) of the fuel injector.
ance. a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pliers.

76. Remove terminal mounting nuts (82).

a Loosen the nuts alternately. 85. Lift and remove cylinder head assembly (93).
4
77. Remove wiring harness assembly mounting
Cylinder head assembly: 50 kg
bolts (83) and spacer (84).
78. Loosen locknut (85) and then loosen adjust- 86. Remove the cylinder head gasket.
ment screw (86).
79. Remove rocker arm and shaft assembly (87).

80. Remove plush rod (88).

81. Remove crosshead assembly (89).
82. Remove rocker housing (90).
83. Remove fuel injector holder (91).

WA600-6 15
SEN01158-03 50 Disassembly and assembly

Installation

Cylinder head assembly

1. Install the cylinder head gasket.

2. Lift and install cylinder head assembly (93).
4 Cylinder head assembly: 50 kg
a Check the punch mark on the mounting
bolt head. If 5 marks are punched, replace
it with a new one without using it.
a Tighten the mounting bolts in the following
order.
2 Cylinder head assembly mounting bolt: a After tightening the main bolt, apply a
Molybdenum disulfide grease (LM-P) punch mark (a) on its head (this mark shall
3 Cylinder head mounting bolts (1 – 7): not be applied to a new bolt).
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time: 90 – 120° retightening
a For retightening, use tool A8 (see Special
tool list). When not using tool A8, apply a
marking to the cylinder head and bolt with
a felt pen and then retighten the bolt by
90° – 120° (target is 120°).
3 Cylinder head assembly mounting bolts
(8 and 9):
93.2 – 103 kgm {9.5 – 10.5 kgm}

16 WA600-6
50 Disassembly and assembly SEN01158-03

Fuel injector
a Make sure that inside of the injector hole is
free from dusts.
2 O-ring: Engine oil (EO30-DH)
3. Assemble gasket (94) and O-rings (95) and
(96) to fuel injector (92).
a Use care not to install O-ring (95) in
groove (A) at the center.
4. Insert fuel injector (92) to adapter (97) and
injector holder (91).
5. Attach spherical washer (100) to bolt (99) and
then tighten injector holder (91) temporarily.
2 Spherical washer: Engine oil (EO30-
DH)

a Tightening of injector holder (91) is done

permanently after installing the intake
manifold and tightening the high-pressure
piping temporarily.

6. Install push rod (88).

a Check that the push rod end is securely
placed in the cam follower socket.

7. Apply gasket sealant and then install rocker

housing (90).
2 Rocker housing: Gasket sealant (LG-7)
a Diameter of the gasket sealant line shall
be 2 to 3 mm and it should be applied
along the housing groove as shown below.
a Do not forget to install O-ring (OR).
3 Rocker housing mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}

8. Install crosshead (89).

WA600-6 17
SEN01158-03 50 Disassembly and assembly

9. Adjust the crosshead in the following procedure. a After tightening the locknut, check the
1) Loosen locknut (102) and then loosen valve clearance again.
adjustment screw (103) to a position
where it does not contact with valve stem
(104).
2) Maintain the contact with valve stem (105)
on the push rod side by pressing the con-
tact surface against the rocker arm using
a finger.
3) Tighten adjustment screw (103) to confirm
the position where adjustment screw (103)
is contacted against valve stem (104).
4) Drive in adjustment screw (103) further by
20 – 30° from the contacting position
against valve stem (104).
5) Tighten locknut (102) while suppressing
move of adjustment screw (103). Injector wiring harness
3 Locknut: 11. Install spacer (84).
53.0 – 64.7 Nm {5.4 – 6.6 kgm} a When installing the spacer, direct its slit
(B) toward the upside.

Rocker arm assembly

10. Install rocker arm assembly (87).
12. Install terminal mounting nut (82) and wiring
a Insert respective rocker arm at a position
harness fixing bolt (83).
where the riveted side of the shaft faces
a Tighten the terminal mounting nuts alter-
the front side of the engine.
nately.
3 Terminal mounting nut:
a When installing, direct the wider seat of
the shaft to the rocker arm housing.
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
a Make sure that the ball of adjustment
screw (86) is securely fitted to the push
rod socket.
a When tightening the mounting bolt, make
sure adjustment screw (86) is not pushing
the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30-DH)
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
a Adjust valve clearance, referring to “Test-
ing and adjusting valve clearance” in Test-
ing and adjusting.
3 Locknut (85):
57.8 – 77.4 Nm {5.9 – 7.9 kgm}

18 WA600-6
50 Disassembly and assembly SEN01158-03

Air intake manifold assembly k Before installing the high-pressure pip-

13. Place connector (76) on air lifted intake mani- ing, check it for the following defects. If
fold assembly (72) being lifted. there is any of these defects, it can
c a u s e f u e l l e a k a g e . A c c o r d i n g l y,
4 Air intake manifold and diffuser assembly: replace the high-pressure piping.
140 kg q Check the taper seal of the connect-
a Pay attention to biting of the tube into (A) ing part (Part (a): Part of 2 mm from
portion. the end) for visible lengthwise slit (b)
and dent (c).
q Check part (d) (end of the taper seal:
Part at 2 mm from the end) for
stepped-type wear (fatigue) which
your nail can feel.

14. Install air intake manifold assembly (72).

a Tighten the mounting bolts in the order
indicated in the figure (clockwise starting
at the center).

High-pressure piping
k When handing the high-pressure pipe
and clamp, pay attention the following.
q It is strictly prohibited to bend the
high-pressure piping to use it again or
using it in other locations.
q Install the specified clamp securely in
the specified position with the speci-
fied torque.
q Don't apply lubricant and the like to
the high-pressure piping sleeve nut
and the threaded portion of the mat-
ing side.
a Axial force in the tightening
can be excessive, potentially
damaging the high-pressure
piping.

WA600-6 19
SEN01158-03 50 Disassembly and assembly

15. Install O-ring (106) to high-pressure piping 20. Install cylinder head cover (81).
sleeve (101). a A different tightening torque is employed
2 O-ring: Engine oil (EO30-DH) for No. 2 cylinder mounting bolt alone.
16. Tighten sleeve nut (75) temporarily aligning it 3 Cylinder head cover mounting bolt:
connector (98) of the injector. No.1, 3, 4, 5 and 6 cylinders:
a When it is difficult to hitch sleeve nut to the 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
threaded portion, turn the spanner while No. 2 cylinder:
pushing sleeve nut (75) end toward the 58.8 – 73.5 Nm {6 – 7.5 kgm}
injector by use of a short bar and the like. 21. Install air vent tube (80).
17. Tighten the common rail side sleeve nut (69) 3 Air bleeding tube joint bolt (Cylinder
temporarily, too. head side):
18. Tighten injector holder (91) permanently. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Injector holder mounting bolt: 22. Install turbocharger coolant tube (79) and lubri-
58.9 – 73.5 Nm {6.0 – 7.5 kgm} cation tube (78).
19. Tighten high-pressure piping sleeve nuts (69) 23. Install bracket (77).
and (75) permanently using the spanner type
torque wrench.
3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm}
a After finishing the work, check that O-
ring (106) is not projected from the
end of the sleeve nut (75).

20 WA600-6
50 Disassembly and assembly SEN01158-03

High-pressure piping clamp Fuel supply pump

24. Install the clamp on the high-pressure pipe in a If overflow valve (ofv) was loosened or oil tube
the following procedure. (t) and plate (p) were removed, restore them,
1) Manually tighten 17 high-pressure piping referring to “Installation of fuel supply pump
clamps (107) temporarily in the position assembly”.
indicated in the figure.
2) Manually tighten common rail slide clamp
bracket (108) and clamp (52) temporarily
and then tighten clamp (52).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket
(108) to the specified torque.
4) Tighten high-pressure piping clamp (107).
3 High-pressure piping side clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5) Install cover (53) on the common rail side
sleeve nut.
a When installing it, direct the slit down-
ward. 25. Install the fuel supply pump assembly by align-
ing (A) and (AA) at the position where a spline
tooth is missing.

WA600-6 21
SEN01158-03 50 Disassembly and assembly

3 Fuel supply pump (66) mounting bolt: [*1]

59 – 74 Nm {6 – 7.5 kgm} 3 Air hose clamp:
3 Bottom bracket (111) mounting bolt: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
59 – 74 Nm {6 – 7.5 kgm}
[*2]
3 Komaclone tube assembly hose clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}

[*3]
3 Air cleaner band:
12.7 – 17.6 Nm {1.3 – 1.8 kgm}

[*4]
3 Tube (15) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Tube (14) joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (14) sleeve nut:
High-pressure piping 84 – 132 Nm {8.5 – 13.5 kgm}
k Handle the high-pressure piping and
clamp in the same way as the piping [*5]
between the fuel injector and common 3 Tube (18) joint bolt:
rail (noted in the foregoing) is handled. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
26. Tighten high-pressure piping (57) temporarily. 3 Tube (18) (Supply pump side):
27. Tighten clamps (55), (56) and (109) temporarily. 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
28. Tighten bracket (110) temporarily.
29. Tighten high-pressure piping (57) permanently. [*6]
3 High-pressure piping sleeve nut: 3 Air hose clamp:
39.2 – 44.1 Nm {4.0 – 4.5 kgm} 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
30. Tighten clamps (55), (56) and (109) permanently.
3 Clamping bolt: [*7]
9.8 ± 1.0 Nm {1 ± 0.1 kgm} 3 Coolant tube assembly (26) joint bolt:
31. Tighten bracket (110) permanently. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
32. Install cover (54).
[*8]
Exhaust manifold assembly
1. When the exhaust manifold assembly was dis-
assembled, apply connection (A) (2 locations)
with the adhesive (heat resistant sealing
agent) before assembling it.
2 Exhaust manifold connection:
Liquid adhesive (Holtz MH 705)

q Carry out the succeeding installation in the

reverse order of removal.

22 WA600-6
50 Disassembly and assembly SEN01158-03

a Tighten the mounting bolts in the following [*11]

order. a Exchange 4 gaskets.
2 Exhaust manifold mounting bolt: 3 Oil tube (63) joint bolt (Supply pump side):
Seizure prevention compound (LC-G) 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(NEVER-SEEZ [Bostik, Inc] or equivalent) 3 Oil tube (63) joint bolt (Block side):
3 Exhaust manifold mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
1st time: 39.2 – 58.8 Nm {4.0 – 6.0 kgm} 3 Tube (65) joint bolt (Supply pump side):
2nd time: 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
98.1 – 122.6 Nm {10 – 12.5 kgm} Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
3 Tubes (64):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

[*12]
3 Tube (68) joint bolt (Corrosion resistor side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
Reference
q Bleeding air
Installation of turbocharger assembly Bleed air from the fuel system, referring to
1. Lift and install turbocharger assembly (112). “Bleeding air from fuel system” in Testing and
4 Turbocharger assembly: 55 kg adjusting.

2 Turbocharger mounting bolt and nut:

Seizure prevention compound (LC-G)
(NEVER-SEEZ [Bostik, Inc] or equivalent)
3 Turbocharger mounting bolt and nut:
78.5 – 88.3 Nm {8.0 – 9.0 kgm}

[*9]
3 Oil tube (44) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tubes (45) and (46) sleeve nut:
54 – 93 Nm {5.5 – 9.5 kgm}
3 Tube (46) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*10]
3 Tube (51) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

WA600-6 23
SEN01158-03 50 Disassembly and assembly

Removal and installation of fuel q Overall view of right side

injector assembly 1
Special tools

New/Remodel
Necessity

Sketch
Sym-

Q'ty
Part No. Part name
bol

795-799-5410 Adapter t 1 N
1
A 795-799-5420 Remover t 1 N
2 795T-675-1110 Socket q 1 N Q

3. Disconnect high-pressure piping clamps (1) to

Removal
k
(3).
Stop the machine on level ground and set
4. Remove tubes (4) and (5). [*1]
the frame lock bar.
k
5. Remove bracket (6).
Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove the engine hood and covers, referring

to “Removal and installation of engine hood
assembly.”

2. Remove the filter, air tube, injector wiring har-

ness brackets, referring to “Removal and
installation of cylinder head assembly.”
q Overall view of top surface
6. Disconnect high-pressure piping clamps (7)
and (8).
a A clamp is provided on the fuel supply
pump side.

24 WA600-6
50 Disassembly and assembly SEN01158-03

7. Remove clamp (9). q Tool A2

8. Remove cover (10).

12. Remove terminal mounting nuts (15).

9. Disconnect 6 sleeves (11) and (12). a Loosen the nuts alternately.
10. Remove high-pressure pipings (13). 13. Remove wiring harness assembly mounting
11. Remove cylinder head cover (14). bolts (16) and spacer (17).
14. Remove fuel injector holder (21).

15. Using tool A1, remove fuel injector assembly

(22).
a Remove the assembly by hitching tip of
tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pliers.
a The figure shows the removed rocker arm
and shaft assembly.

a When tool A2 is not available, disconnect

sleeve (12) through the top.

WA600-6 25
SEN01158-03 50 Disassembly and assembly

Installation 5. Install terminal mounting nut (15) and wiring

harness fixing bolt (16).
Fuel injector a Tighten the terminal mounting nuts alter-
a Check that the inside of the injector sleeve is nately.
free from dirt. 3 Terminal mounting nut:

2 O-ring: Engine oil (EO30-DH) 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

1. Assemble gasket (24) and O-rings (25) and
(26) to fuel injector (22).
a Use care not to install O-ring (25) in
groove (A) at the center.
2. Insert fuel injector (22) to adapter (27) and
injector holder (21).
3. Attach spherical washer (30) to bolt (29) and
then tighten injector holder (31) temporarily.
2 Spherical washer: Engine oil (EO30-DH)
a Tightening of injector holder (21) perma-
nently after tightening the high-pressure
piping temporarily.

High-pressure piping
k When handing the high-pressure pipe and
clamp, pay attention the following.
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it
in other locations.
q Install the specified clamp securely in the
specified position with the specified torque.
q Don't apply lubricant and the like to the
high-pressure piping sleeve nut and the
threaded portion of the mating side.
a Axial force in the tightening can be
excessive, potentially damaging
the high-pressure piping.
k Before installing the high-pressure piping,
Injector wiring harness
check it for the following defects. If there is
4. Install spacer (17). any of these defects, it can cause fuel leak-
a When installing the spacer, direct its slit age. Accordingly, replace the high-pressure
(B) toward the upside. piping.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.

26 WA600-6
50 Disassembly and assembly SEN01158-03

6. Install O-ring (32) to sleeve (31) of high-pres- High-pressure piping clamp

sure piping (13). 12. Install the clamp on the high-pressure pipe in
2 O-ring: Engine oil (EO30-DH) the following procedure.
7. Tighten sleeve nut (12) temporarily aligning it 1) Manually tighten 17 high-pressure piping
connector (28) of the injector. clamps (33) temporarily in the position
a When it is difficult to hitch sleeve nut (12) indicated in the figure.
to the threaded portion, turn the spanner 2) Manually tighten common rail slide clamp
while pushing sleeve nut (12) end toward bracket (34) and clamp (9) temporarily
the injector using a short bar and the like. and then tighten clamp (9).
8. Tighten the common rail side sleeve nut (11) 3 Common rail side clamp bolt:
temporarily, too. 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
9. Tighten injector holder (21) permanently. 3) Tighten common rail side clamp bracket
3 Injector holder mounting bolt: (34) to the specified torque.
59 – 74 Nm {6.0 – 7.5 kgm} 4) Tighten high-pressure piping clamp (33).
10. Tighten high-pressure piping sleeve nuts (11) 3 High-pressure piping side clamp bolt:
and (12) permanently using the spanner type 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
torque wrench. 5) Install covers (10) on the common rail side
3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm} sleeve nut.
a After finishing the work, check that O-ring a When installing it, direct the slit down-
(32) is not projected from the end of the ward.
sleeve nut (12).
11. Install cylinder head cover (14).
a A different tightening torque is employed
for No. 2 cylinder mounting bolt alone.
3 Cylinder head cover mounting bolt:
No.1, 3, 4, 5 and 6 cylinders:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
No. 2 cylinder:
58.8 – 73.5 Nm {6 – 7.5 kgm}

q Carry out the succeeding installation in the

reverse order of removal.

[*1]
3 Tube (4) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tube (5) sleeve nut:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

a Reference the precautions in “Removal and

installation of cylinder head” for the installation.

k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.

q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.

WA600-6 27
SEN01158-03 50 Disassembly and assembly

Removal and installation of 4. Disconnect hose clamps (3).

engine front seal 1 5. Remove bar (4).
6. Remove 3 covers (5).
Special tools

New/Remodel
Sym-

Necessity
Part No. Part name
bol

Sketch
Q'ty
3 795-931-1100 Seal puller assembly t 1
Push tool
795T-621-1180 t 1 Q
(For oil seal)
A Push tool
4 795T-621-1171 t 1 N Q
(For dust seal)
795-902-1460 Bolt t 3
01582-02218 Nut t 3
7. Lift pulley and damper assembly (6) tempo-
rarily.
8. Lift and remove pulley and damper assembly
Removal (6). [*1]
k Stop the machine on level ground and set
4 Pulley and damper assembly (6): 50 kg
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.

1. Remove muffler (1).

2. Remove cover (2-1).
3. Sling hood (2-2) to remove.
4 Hood (2-2): 45 kg
a A tapped hole for lifting is provided in the
four corners of the hood (2-2).

9. Remove dust seal (7).

10. Remove front seal (8) in the following proce-
dure.

28 WA600-6
50 Disassembly and assembly SEN01158-03

1) Replace the tip of tool A3 with the hook Installation

type one.
2) Hitch the hook to the hoop of front seal 1. Clean, degrease and then dry the contact sur-
(8). face between the front cover and front seal.
3) Remove the seal using impacts of the 2. Using a clean cloth, remove foreign matter
slide hammer (SH). deposited the crankshaft flange.
q Tool A3 a Clean foreign matter deposited on the seal
lip surface (surface around the crank
shaft) and then degrease and dry the sur-
face.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.

3. Install front oil seal (8) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
a CS: Crankshaft
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
1) Install the oil seal directing its side
stamped with IN toward the inside of the
engine.
a The OUT stamped side is directed
toward the outside of the engine.

WA600-6 29
SEN01158-03 50 Disassembly and assembly

2) Using tool A4, press fit oil seal (8) to the

front case in such that dimension (a) in the
figure is met.
a Oil seal press fitting dimension (a):
18.5 mm (when measured from the front
cover end face)

3) Using tool A4 (for dust seal), press fit dust

seal (7) to the front case in such that
dimension (b) in the figure is met.
a Dust seal press fitting dimension (b):
2 mm (Projection out of the front
cover end face)

q Carry out the succeeding installation in the

reverse order of removal.
[*1]
3 Pulley and damper mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6 Nm {23 – 27 kgm}
3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}

30 WA600-6
50 Disassembly and assembly SEN01158-03

Removal and installation of 3. Remove rear seal (2).

engine rear seal 1 a Take care in the removal not to damage
the seal installation position on the fly-
Special tools wheel housing and the seal contact sur-
face on the crankshaft.

New/Remodel
a Before removing, slightly drive the seal in
Sym-

Necessity
Part No. Part name once to free it from fixation.
bol

Sketch
a When rear seal (2) is fixed too hard to the

Q'ty
flywheel housing (FWH), remove the fol-
Seal puller lowing procedure.
3 795-931-1100 q 1 a The left one in the following figure is
assembly
the standard seal and the right one is
795T-621-1161 Push tool t 1 R Q
A the sleeved seal.
795T-621-1190 Push tool t 1 N Q 1) Replace the tip of tool A3 with the drill
5
01050-32235 Bolt t 5 type one.
01050-32245 Bolt t 5 2) Drill several holes about 3 mm in
diameter into rear seal (2).
3) Set tool A3 to the drilled hole. (Tip:
Drill type)
4) Remove rear seal with impact of slide
Removal hammer (SH).
a When the sleeve is attached, cut sleeve
k Stop the machine on level ground and set (5) using a gad and hammer to remove it.
the frame lock bar. a Take care not to damage crankshaft (4).
k Lower the work equipment to the ground a Remove all the chips.
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove the damper assembly, referring to

“Removal and installation of damper assembly.”

2. Lift and remove flywheel (1). [*1]

4 Flywheel assembly: 40 kg

q Tool A3

WA600-6 31
SEN01158-03 50 Disassembly and assembly

Installation q Procedure for installing standard seal

a Don't apply gear or oil to the seal lip surface.
a Check the Teflon seal (Laydown lip seal) by 1) Contact larger inner diameter side (b) of
checking the wear of the shaft and replace it plastic inside cylinder (3) of rear seal (2)
with the “Standard seal” or “Sleeved seal”. against the end face of crank shaft (4).
a When wear on the shaft is not serious and only a Take care not to mistake the direction
makes it look lustrous (depth of wear is 10 mm of the plastic inside cylinder.
or less when checked with finger cushion) and
no scratch is recognized, assemble the stan-
dard seal (A). When the above is not applica-
ble, assemble sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling
the assembly guide.
a (5): Shows the sleeve.
a Don't remove assembly guide (3) from rear
seal (2) until the assembly is complete.
a Handle rear seal (2) and sleeve (5) as an inte-
gral part. Don't try to separate them.

2) Applying equal force to both hands, push

in the hoop of rear seal (2).
3) After pushing in rear seal (2), remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.

a Clean, degrease and then dry the contact sur-

face between the rear seal and flywheel hous-
ing.
a Clean foreign matter deposited on the seal lip
surface (surface around the crank shaft) and
then degrease and dry the surface.
a Check the crankshaft end face corner and lip
siding surface for scratches due to the hous-
ing, burrs or rusts.

32 WA600-6
50 Disassembly and assembly SEN01158-03

4) Tighten the bolts evenly to press fit rear a Tighten tool A5 (for standard seal)
seal (2) until the end of tool A5 reaches first until it reaches the bolt (45 mm)
the end of crankshaft (4). and then tighten the bolt (35 mm).
a Oil seal press fitting dimension (when a Rear seal driving depth (a): 20 mm
measured from the shaft end face) from end of crankshaft.
(a): 20 mm a After press fitting the seal, remove the
a After press fitting the rear seal, red sealant layer from its periphery.
remove the red sealant layer from its
periphery.

q Carry out the succeeding installation in the

q Procedure for installing sleeved seal reverse order of removal.
a When installing the rear seal, do not apply oil [*1]
or grease to the shaft and sleeve inside cylin- Flywheel assembly
der surface (C). a Check the punch mark on the mounting bolt
1) Set sleeve and rear seal assembly (6) to head. If 5 marks are punched, replace it with a
tool A5 (for sleeved seal) new one without using it.
2 Sleeve inside cylinder surface (C): a In order to prevent the flywheel from rotating,
Gasket sealant (LG-7) fix the space between the flywheel and fly-
2) Set sleeve (5) of the rear seal to the end of wheel housing using the bolt hole.
crankshaft (4) and tighten the 5 bolts (45 a Tighten the mounting bolts in the following
mm) evenly to press fit sleeve and rear order.
seal assembly (6) until the end of tool A5 2 Flywheel assembly mounting bolt:
reaches the end of crankshaft (4). Engine oil (EO30-DH)
3 Flywheel assembly mounting bolt:
1st time : 196.1 ± 19.6 Nm {20 ± 2 kgm}
2nd time : 460.9 ± 19.6 Nm {47 ± 2 kgm}
3rd time : 90 – 120° retightening
a After tightening the bolt, make a punch mark
(a) on its head. (When a new bolt is used, do
not make a punch mark on its head.)

3) Remove tool A5 (for sleeved seal) and

install tool A5 (for standard seal).
4) Tighten the 5 bolts evenly to press fit
sleeve and rear seal assembly (6) until the
end of tool A5 (for standard seal) reaches
the end of crankshaft (4).

WA600-6 33
SEN01158-03 50 Disassembly and assembly

q Measure radial runout or facial runout of the

flywheel using dial gauge [1].
a Standard radial and facial runout:
Measuring
Tolerance (mm)
items
Radial
0.13
runout
Facial 0.0005 × Diameter of
runout measuring point

a When the measured value is out of the

standard, determine the cause by disas-
sembling the flywheel again.

34 WA600-6
50 Disassembly and assembly SEN01158-03

WA600-6 35
SEN01158-03

WA600-6 Wheel loader

Form No. SEN01158-03

© 2011 KOMATSU
All Rights Reserved
Printed in Japan 03-11

36
 SEN01160-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Power train, Part 1
Removal and installation of parking brake assembly ...................................................................................... 2
Removal and installation of torque converter and transmission assembly ..................................................... 4

WA600-6 1
SEN01160-02 50 Disassembly and assembly

Removal and installation of

parking brake assembly 1
Removal
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Set the frame lock bar.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove the drain plug to drain oil from the

transmission case.
6 Transmission case: Approx. 83 l

q Rear side
2. Remove rear drive shaft (1). [*1]
4 Rear drive shaft: 65 kg

3. Disconnect hose (2).

4. Remove plug (3) and then screw in the pre-
pared parking brake release bolt (B) (M12 ×
1.75, L = 70 mm minimum) until it is uniformly
stopped.
5. Remove 12 mounting bolt (4). [*1]
6. Remove 4 mounting bolt (5).
7. Remove top and bottom plugs (6) and then
remove parking brake assembly (7), using the
forcing screw.
4 Parking brake assembly:120 kg

2 WA600-6
50 Disassembly and assembly SEN01160-02

Installation
q Installation is done in the reverse order of
removal.

[*1]
3 Mounting bolt:
215 – 255 Nm {21.9 – 26.0 kgm}

q Refilling with oil

Tighten the drain plug and then feed power line
oil (TO30) from the oil filler.
5 Transmission case: Approx. 83 l

q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air from vari-
ous parts”.

WA600-6 3
SEN01160-02 50 Disassembly and assembly

Removal and installation of 6. Remove guard (40).

torque converter and 7. Remove upper drive shaft (2). [*2]
a (D) shows damper.
transmission assembly 1
4 Upper drive shaft: 30 kg
Removal
k Lower the work equipment to the ground 8. Remove guard (41).
completely and stop the engine. Apply the
parking brake and put the blocks under the a T/M: Transmission
wheels.
k Set the frame lock bar.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: approx. 443 l

2. Remove the floor frame assembly, referring to

“Removal and installation of floor frame
assembly.“

3. Remove the work equipment pump assembly,

steering and fan pump assembly, referring to
“Removal and installation of hydraulic pump
assembly.”

4. Remove the drain plug to drain oil from the

transmission case.
6 Transmission case: Approx. 83 l

q Drive shaft
5. Remove rear drive shaft (1). [*1]
4 Rear drive shaft: 65 kg
9. Remove guard (3).
10. Remove center drive shaft (4). [*3]
4 Center drive shaft: 65 kg

4 WA600-6
50 Disassembly and assembly SEN01160-02

q Rear side 16. Disconnect hoses (12) and (13).

11. Remove tube, bracket and hose assembly (6).
12. Remove hose (7).

q Right side
17. Disconnect hoses (14) and (15).
13. Remove right and left transmission side covers 18. Disconnect connector (16).
(8). 19. Disconnect bracket (17).

q Left side q Top side

14. Disconnect torque converter cooler hoses (9) 20. Disconnect 3 hoses (18).
and (10).
15. Disconnect clamp (11).

WA600-6 5
SEN01160-02 50 Disassembly and assembly

21. Disconnect hoses (19) and (20) from the check

valve (CV).
a DV: Diverter valve

25. Disconnect 2 tubes (29) from the hydraulic

tank.
26. Remove tube assembly (30).
22. Remove 2 blowout hoses (21) from the steer-
ing valve (SV).

q Front side
27. Disconnect parking brake hose (31).
23. Remove right and left brackets (23). 28. Disconnect clamps (32).
24. Disconnect the hoses and tubes from the
hydraulic tank.
(24): 2 oil cooler hoses
(25): Oil cooler return hose
(26) Top: Steering drain tube
(26) Bottom: Pump drain hose
(27): Oil cooler and steering return tube
(28): 2 emergency steering return hoses
and suction tube

6 WA600-6
50 Disassembly and assembly SEN01160-02

29. Disconnect filler tube (33). q Bottom right and left sides
a Fasten filler tube (33) to the emergency 33. Remove mounting bolt (37). [*5]
steering hose by use of a string. 34. Remove right and left brackets (38). [*6]
a Above is needed since the opposite side
bracket interferes with the suction tube as
the assembly is lifted.

q Top side
30. Disconnect clamp (34).
31. Remove mounting bolt (35). [*4]
a Check the number of the shims in
35. Lift and remove torque converter and transmis-
advance.
sion assembly (36).
4 Torque converter and transmission
assembly: 2,000 kg
a Incline the torque converter side approx.
30° when lifting.

32. Lift air torque converter and transmission

assembly (36) temporarily.

WA600-6 7
SEN01160-02 50 Disassembly and assembly

Installation
q Installation is done in the reverse order of
removal.

[*1]
3 Rear drive shaft mounting bolt:
215 – 255 Nm {21.9 – 26.0 kgm}
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}

[*2]
3 Mounting bolt of drive shaft between dampers:
107 – 127 Nm {10.9 – 13.0 kgm}

[*3]
3 Center drive shaft mounting bolt:
215 – 255 Nm {21.9 – 26.0 kgm}

[*4]
3 Top side mounting bolt:
157 – 196 Nm {16.0 – 20.0 kgm}

[*5], [*6]
3 Mounting bolt at bottom right and left side:
245 – 309 Nm {25.0 – 31.5 kgm}

q Refilling with oil

Tighten the drain plug and then feed power line
oil (TO30) from the oil filler.
5 Transmission case: Approx. 83 l

q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: approx. 443 l

q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air of various
parts.”

8 WA600-6
50 Disassembly and assembly SEN01160-02

WA600-6 9
SEN01160-02

WA600-6 Wheel loader

Form No. SEN01160-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

10
 SEN01162-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly 1

Power train, Part 2

Disassembly and assembly of torque converter assembly ............................................................................. 2
Disassembly and assembly of transmission assembly ................................................................................. 29
Disassembly and assembly of transfer assembly ......................................................................................... 56
Disassembly and assembly of parking brake assembly ............................................................................... 71

WA600-6 1
SEN01162-02 50 Disassembly and assembly

Disassembly and assembly of 5) Remove torque converter PTO lubrication

torque converter assembly 1
tube (1c).

Special tools

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
C 792-900-1350 Wrench t 1
D 793-613-1210 Wrench t 1
793-615-1110 Wrench t 1
E
01306-10616 Bolt t 1

6) Using sling [1], sling torque converter and

Disassembly
PTO assembly (2).
1. Preparation work
7) Remove 16 mounting bolts (3).
1) Set the transmission and torque converter
a Do not remove 2 sub-assembly bolts
assembly on the block vertically.
(25).
4 Transmission and torque converter
assembly: 1,800 kg
2) Remove oil tube (1) between the torque
converter and transfer.
3) Remove modulated clutch lubrication
hose (1a).

4) Disconnect torque converter speed sensor

wiring harness (1b).

2 WA600-6
50 Disassembly and assembly SEN01162-02

8) Using forcing screws [2] (M12, P = 1.75 2. Seal cage

mm), disconnect torque converter and Remove mounting bolts (6) and seal cage (7).
PTO assembly (2) from transmission
assembly (4).
9) Remove torque converter and PTO
assembly (2) from transmission assembly
(4).

3. Modulated clutch assembly

1) 1) Remove 7 mounting bolts (8).
2) Using forcing screws [4] (M12, P = 1.75
mm), disconnect modulated clutch assem-
4 Torque converter and PTO assem- bly (9) from torque converter and PTO
bly: 490 kg assembly (2).
10) Remove modulated clutch speed sensor
(5).

3) Using sling [5] (M10, P = 1.5 mm), remove

modulated clutch assembly (9).

WA600-6 3
SEN01162-02 50 Disassembly and assembly

4) Disassemble modulated clutch assembly 5] Remove seal ring (15) from piston
according to the following procedure. (14) and remove seal ring (17) from
1] Remove snap ring (10). clutch outer drum shaft (16).
2] Remove plate (11).

6] Reverse the case and remove snap

3] Remove 7 discs (12) and 8 plates ring (18).
(13) alternately.

7] Support case (19) and push out

4] Using eyebolts (M12, P = 1.75 mm), clutch outer drum shaft (16) with push
remove piston (14). tool [6] (Outside diameter: 60 mm).

4 WA600-6
50 Disassembly and assembly SEN01162-02

8] Remove seal rings (21) from clutch 3) Using sling [7], remove torque converter
outer drum shaft (16). case (23).

9] Remove bearing (22) from cover (19).

10] Remove 2 dowel pins (20). 5. Coupling and drive gear
1) Remove coupling (24).
2) Remove 6 mounting bolts (25).
3) Using forcing screws [8] (M12, P = 1.75
mm), remove cage (26).

4. Torque converter case

1) Remove 6 mounting bolts (24) from the
inside of torque converter case (23).
2) Remove 2 sub-assembly bolts (25).
4) Remove shim (27).
a Check the quantity and thickness of
the shim.

WA600-6 5
SEN01162-02 50 Disassembly and assembly

5) Remove oil seal (28) from cage (26). 11) Remove outer race (36) from torque con-
6) Remove outer race (29) from cage (26) verter case (35)

7) Remove 16 mounting bolts (30).

a Before removing shaft (31), remove 6. PTO gear
gear (34) from it. (Forcing screws: a Since the right and left cages and gears of
M10, P = 1.5 mm) PTO A (Right side) and PTO B (Left side)
8) Remove input shaft (31). are different, keep the removed parts sep-
9) Remove bearings (32) and (33) from input arately.
shaft (31). a The covers of the PTO A and PTO B are
u s e d f o r t r a n s p o r ta t i o n o f t h e u n i t .
Accordingly, they are not installed to the
actual machine.

10) Remove gear (34).

a Move the gear aside to remove.

1) PTO gear A (Right side)

1] Reverse the torque converter case.
2] Remove lubrication tube (43).
3] Remove 8 mounting bolts (44).

6 WA600-6
50 Disassembly and assembly SEN01162-02

4] Using forcing screws [10] (M12, P = 9] Remove bearing (48) from gear (47).
1.75 mm), remove cage (45).
5] Remove outer race (46) from cage
(45).

10] Remove 2 mounting bolts (39) and 4

mounting bolts (39a).
11] Using forcing screws [9] (M12, P =
6] Reverse the torque converter case. 1.75 mm), remove cage (40).
7] Remove snap ring (41) and plate a Covers (39b) and (39c) are used
(41a). for transportation of the unit.
A c c o r d i n g l y, t h e y a r e n o t
installed to the actual machine.

8] Using push tool [9] (Outside diameter:

80 mm), remove gear (47).
a Take care not to drop the gear. 12] Remove snap ring (41) from cage
(40) and remove bearing (42).

WA600-6 7
SEN01162-02 50 Disassembly and assembly

2) PTO gear B (Left side) 8. Modulated clutch gear

Remove PTO gear B similarly to PTO gear 1) Using forcing screws [12] (M10, P = 1.5
A (Right side). mm), remove modulated clutch gear (53).
2) Remove upper bearing (54a) from modu-
<Steps 7 – 17 are disassembly procedures for lated clutch gear (53).
the torque converter>
7. Locknut
1) Straighten the locking part of lock plate
(50a) and remove 2 lock bolts (49) and
stopper plate (50).
2) Remove side pin (51) from locknut (52).

3) Remove outer races (55a) and (55b) from

modulated clutch gear (53).

9. Cage
1) Remove cage (56).
2) Remove outer race (57) from cage (56).
3) Using tool C, remove locknut (52).

8 WA600-6
50 Disassembly and assembly SEN01162-02

10. Torque converter assembly 3) Remove bearings (54b) and (60) from
1) Set the torque converter assembly on the torque converter input shaft (59).
blocks. 4) Remove 2 dowel pins (61).
2) Remove 30 mounting bolts (76).
3) Using eyebolts [16] (M10, P = 1.5 mm),
remove turbine shaft assembly (82) from
stator shaft assembly (93).

12. Lockup clutch housing

1) Remove snap ring (62) and plate (63).

4) Using eyebolts [16] (M10, P = 1.5 mm),

set turbine shaft assembly (82) to tool
[16a] (Height: 124 mm).

2) Remove 30 mounting bolts (64).

3) Using forcing screws [14] (M10, P = 1.5
mm), remove lockup clutch housing (65).

11. Torque converter input shaft

1) Remove 16 mounting bolts (58).
2) Using forcing screws [13] (M10, P = 1.5
mm), remove torque converter input shaft
(59).

WA600-6 9
SEN01162-02 50 Disassembly and assembly

4) Remove bearing (66) from lockup clutch 2) Remove seal rings (70) from piston (69).
housing (65).

5) Remove seal rings (68) from lockup clutch 14. Discs and plate
housing (65). Remove 2 discs (71) and 1 plate (72).

13. Piston 15. Turbine

1) Using eyebolts (M6, P = 1 mm), remove 1) Using tool [16a] (M10, P = 1.5 mm), sup-
piston (69). port turbine shaft assembly (82).
2) Using eyebolts [16] (M10, P = 1.5 mm),
remove drive case (77).

10 WA600-6
50 Disassembly and assembly SEN01162-02

3) Remove 23 mounting bolts (80) 5) Remove bushing (88), ball (89) and free-
4) Remove turbine (82) from boss (81). wheel (90) from race (87).
a Check the arrow of the turbine rota- a Take care not to lose the ball.
tion direction at part (G).

17. Pump
16. Stator 1) Using tool D, remove locknut (91).
1) Remove stator assembly (84) from pump a Note that locknut (91) has left-handed
(83). threads.
a Check that the side having a shoulder
at stator part (F) is on the input side.

2) Remove 14 mounting bolts (74).

3) Remove stator shaft assembly (93) from
2) Remove upper snap ring (85a). housing (73).
3) Remove race (87) from stator (86).
4) Remove lower snap ring (85b).

WA600-6 11
SEN01162-02 50 Disassembly and assembly

4) Support retainer (97) and push out stator Assembly

shaft (93) with push tool [17].
5) Remove inner race (94a). <Steps 1 – 12 are assembly procedures for the
6) Remove inner race (94b) from stator shaft torque converter>
(93). a After installing each bearing, drop about 6 cc
7) Remove seal ring (95). of transmission oil (TO10 or TO30) onto it and
rotate it about 10 turns.
a When installing a bearing by expansion fit,
drop about 6 cc of transmission oil (TO10 or
TO30) onto it and rotate it about 10 turns
before cooling it in dry ice.

1. Pump
1) Install bearing (98) to guide (100).
a Match the product Nos. (C) and
match symbols “A” (D) of the inner
race (A) and outer race (B) of the
bearing and use those races as an
assembly.
8) Remove 12 mounting bolts (96) from 2) Install pump (99) and retainer (97).
pump (99). a Check the arrow of rotation direction
9) Remove retainer (97). of the pump.
10) Remove bearing (98) from guide (100). Direction of arrow: Counterclockwise
when seen from input side
3) Install 12 mounting bolts (96).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}

12 WA600-6
50 Disassembly and assembly SEN01162-02

4) Install seal ring (95) to stator shaft (93). 9) Install locknut (91) and tighten it with tool
5) Using push tool [17a] (Inside diameter: 91 D.
mm), install inner race (94b). a Note that locknut (91) has left-handed
2 Seal ring: Grease (G2-LI) threads.
2 Locknut: Adhesive (LT-2)
3 Locknut:
441 – 490 Nm {45 – 50 kgm}

6) Install stator shaft (93) to housing (73) and

tighten 14 mounting bolts (74).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm} 2. Stator
1) Install freewheel (90), ball (89) and bush-
ing (88) to race (87).
a When installing, take care of the ball.

7) Install pump assembly (92) to shaft (93).

8) Using push tool [17b] (Inside diameter: 91
mm), press fit inner race (94a).

WA600-6 13
SEN01162-02 50 Disassembly and assembly

a When installing the freewheel, direct 5) Install stator assembly (84) to pump
arrow (b) of the free rotation direction assembly (83).
indicated on the front side of the cage a Apply transmission oil (TO10 or
toward the output (pump) side. TO30) to bushing (88) shown in the
a Do not remove sprag (d). above figure.
a When inserting, take care that drag a Check that the side having a shoulder
clip (c) on the periphery of the one- at stator part (F) is on the input side.
way clutch will not be hitched in the a Check the rotation direction from the
ball groove of the outer race. input side. (Take care that the rota-
a When inserting, do not use a hammer tion direction is opposite to the normal
etc. but use your hands. rotation direction.)
Clockwise direction: Locked
Counterclockwise direction: Free

2) Install lower snap ring (85b) to stator (86).

a Check the arrow of rotation direction
of the stator (E).
Direction of arrow: Counterclockwise 3. Piston
when seen from input side Install seal rings (70) to piston (69).
3) Install race (87). a Set pressure receiving side (e) of the seal
4) Install upper snap ring (85a). ring in the direction of the arrow shown
below.
2 Seal ring: Grease (G2-LI)

14 WA600-6
50 Disassembly and assembly SEN01162-02

4. Lockup clutch housing 5. Turbine

1) Using push tool [18] (Outside diameter: 1) Install boss (81) to turbine (82).
139 mm), press fit bearing (66) to lockup a Check the arrow of rotation direction
clutch housing (65). of the turbine at (G).
2) Install 2 dowel pins (61). Direction of arrow: Counterclockwise
when seen from input side
2) Install 23 mounting bolts (80).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}

3) Install seal ring (68) to lockup clutch hous-

ing (65).
a Set pressure receiving side (f) of the
seal ring in the direction of the arrow
shown below.
2 Seal ring: Grease (G2-LI) 3) Support turbine (82) with tool [16a]
(Height: 124 mm).
4) Using eyebolts [16] (M10, P = 1.5 mm),
set drive case (77).

4) Using eyebolts (M6, P = 1 mm), install pis-

ton (69) to housing (65).
a Set the dowel pin (67) to the hole on
the piston side.

WA600-6 15
SEN01162-02 50 Disassembly and assembly

6. Discs and plate 4) Tighten 30 mounting bolts (64) into lockup

1) Install 2 discs (71) and 1 plate (72) alter- clutch housing (65).
nately. 2 Mounting bolt: Adhesive (LT-2)
a Apply transmission oil (TO30) to the 3 Mounting bolt:
discs. 59 – 74 Nm {6.0 – 7.5 kgm}

2) Using eyebolts [19] (M12, P = 1.75 mm),

install lockup clutch housing (65). 7. Torque converter input shaft
a Take care that the piston will not 1) Install plate (63) and snap ring (62).
come off.
3) Using push tool [20] (Inside diameter: 81
mm), press fit the inner race of bearing
(66).

2) Drive 2 dowel pins (6) into lockup clutch

housing (65).

16 WA600-6
50 Disassembly and assembly SEN01162-02

3) Using push tool [30] (Inside diameter: 66 8. Cage

mm), press fit bearing (60) to torque con- 1) Using push tool [21] (Outside diameter:
verter input shaft (59). 149 mm), press fit outer race (57) to cage
(56).

4) Using push tool [31] (Inside diameter: 76

mm), press fit bearing (54b) to torque con- 2) Install cage (56).
verter input shaft (59).

5) Using eyebolts [13] (M10, P = 1.5 mm), 9. Torque converter assembly

install torque converter input shaft (59). 1) Set stator shaft assembly (93) on the
6) Tighten 16 mounting bolts (58). blocks.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}

WA600-6 17
SEN01162-02 50 Disassembly and assembly

2) Using eyebolts [16] (M10, P = 1.5 mm), 2) Install upper bearing (54a) to modulated
install turbine shaft assembly (82) to stator clutch gear (53).
shaft assembly (93). a Press fit the bearing until the clear-
3) Tighten 30 mounting bolts (76). ance is eliminated.
2 Mounting bolt: Adhesive (LT-2) 3) Using eyebolts [12] (M10, P = 1.5 mm),
3 Mounting bolt: install modulated clutch gear (53).
49 – 59 Nm {5 – 6 kgm}

11. Locknut
10. Modulated clutch gear 1) Install locknut (52).
1) Using push tool [22] (Outside diameter: a Install the locknut and adjust the pre-
114 mm), press fit outer races (55a) and load after assembling the case.
(55b) to modulated clutch gear (53).
a Press fit the outer races until the
clearance is eliminated.

2) Using tool C, tighten locknut (52).

18 WA600-6
50 Disassembly and assembly SEN01162-02

3) Adjustment of preload on modulated 12. Drive gear

clutch gear bearing 1) Using push tool [23] (Outside diameter:
Adjust the bearing according to the follow- 129 mm), press fit outer race (36) to
ing procedure. torque converter case (35).
a After installing the bearing, drop 6 cc
of transmission oil (TO30) onto it and
revolve it about 10 turns.
1] Tighten locknut (52) to 98 – 123 Nm
{10.0 – 12.5 kgm}.
2] Rotate modulated clutch gear (53) 20
turns and check the tightening torque
of 98 – 123 Nm {10.0 – 12.5 kgm} for
locknut (52) again.
3] If the tightening torque has changed,
repeat 1] and 2] above.
4] If the tightening torque has not
changed, loosen locknut (52).
5] Tighten locknut (52) to 39 – 49 Nm
{4 – 5 kgm} and rotate modulated 2) Set gear (34) to the case.
clutch gear (53) 20 turns. a Move the gear aside to install.
6] Loosen locknut (52) until the phase of
the 8 side pin holes of locknut (52) is
matched to that of the 5 side pin holes
of torque converter input shaft (59).
a The loosening angle must be in
the range of 0 – 9°, however.
7] When the holes are matched by the
above operation, insert side pin (51)
from the side and install stopper plate
(50) and lock plate (50a).
8] Check that modulated clutch gear
(53) has not play.
9] Under this condition, measure the
rotation torque of torque converter
input shaft (59).
Rotation torque: Must be in range of
0.98 – 2.94 Nm {0.1 – 0.3 kgm}.
a When measuring the rotation
torque, fix modulated clutch gear
(53) so that it will not be turned
by dragging.
10] Tighten 2 lock bolts (49).
11] Bend part (g) of lock plate (50a) to
lock the bolt securely.
a Use a new lock plate.

WA600-6 19
SEN01162-02 50 Disassembly and assembly

3) Using push tool [32] (Inside diameter: 76 7) Press fit oil seal (28) to cage (26).
mm), press fit bearings (32) and (33) to 2 Oil seal: Grease (G2-LI)
input shaft (31). a Fill 40 – 60% of the space between
4) Install input shaft (31) to gear (34). the main lip and dust lip with grease.
5) Tighten 16 mounting bolts (30). 2 Oil seal press fitting face:
a Since the gear and shaft are press fit- Gasket sealant (LG-5)
ted to each other, tighten all the bolts a Apply the gasket sealant thinly to the
gradually. inside of the housing hole and wipe
2 Mounting bolt: Adhesive (LT-2) off the projected part.
3 Mounting bolt: 245.0 – 309.0 Nm
{25.0 – 31.5 kgm}

6) Using push tool [24] (Outside diameter:

129 mm), press fit outer race (29) to cage
(26).

20 WA600-6
50 Disassembly and assembly SEN01162-02

8) Adjustment of preload on input shaft (31)

bearing
Adjust the bearing according to the follow-
ing procedure.
a After installing the bearing, drop 6 cc
of transmission oil (TO30) onto it and
revolve it about 10 turns.
1] Fit the O-ring and install cage (26)
without setting shim (27).
2 O-ring: Grease (G2-LI)
2] Tighten mounting bolts (25) to 4.80 ±
0.98 Nm {0.5 ± 0.1 kgm}.
3] Rotate input shaft (31) 20 turns and
check the tightening torque of 4.80 ±
0.98 Nm {0.5 ± 0.1 kgm} for mount-
ing bolts (25) again.
4] If the tightening torque has changed,
repeat 2] and 3] above.
5] If the tightening torque has not
changed, measure clearance (h)
between the case and cage (27) at 3
places (j) and obtain the average.
a Check that the dispersion of
clearance (h) is 0.15 mm or less.
a If the dispersion of clearance (h)
is larger than 0.15 mm, check the
bearing for improper installation
and then take remedies to
reduce the dispersion to 0.15
mm or less.
6] Loosen the bolts to set input shaft
(31) free and measure rotation torque
(A) of input shaft (31) with tool E.
7] Install shim (27) increased by the
clearance obtained in the above
steps.
Shim thickness (k): Average clear-
ance + (Increased shim: 0.15 – 0.35
mm)
Standard clearance: 1.05 – 1.70 mm
Standard shim thickness: 1.2 mm
8] Tighten mounting bolts (25) to 98.0 –
122.5 Nm {10.0 – 12.5 kgm}.
9] Check that input shaft (31) has no
play.
10] Under this condition, measure rota-
tion torque (B) of input shaft (31) with
tool E.
Rotation torque (B – A): Must be in
range of 0.98 – 1.96 Nm {0.1 – 0.2
kgm}.

WA600-6 21
SEN01162-02 50 Disassembly and assembly

13. PTO gear A (Right side) 4) Using push tool [25] (Outside diameter: 99
1) Install bearing (42) to cage (40) and install mm), press fit outer race (46) to cage (45).
snap ring (41). 5) Using push tool [26] (Inside diameter: 56
mm), press fit bearing (48) to gear (47).

2) Fit the O-ring and install cage (40) by

using forcing screws [9] (M12, P = 1.75 6) Reverse the torque converter case.
mm). 7) Set gear (47) to the case and press fit it
2 O-ring: Grease (G2-LI) with push tool [11] (Outside diameter: 55
3) Tighten 4 mounting bolts (39a) and 2 mm).
mounting bolts (39). 8) After press fitting gear (47), install snap
a Covers (39b) and (39c) are used for ring (41a).
transportation of the unit. Accord-
ingly, they are not installed to the
actual machine.

9) Using eyebolts [28] (M12, P = 1.75 mm),

install cage (45).

22 WA600-6
50 Disassembly and assembly SEN01162-02

10) Tighten 8 mounting bolts (44). 16. Torque converter case

11) Install lubrication tube (43). 1) Using sling [7], install torque converter
3 Joint bolt: case (23).
19.6 – 29.4 Nm {2.0 – 3.0 kgm}

2) Tighten 2 sub-assembly bolts (25).

3) Tighten 6 mounting bolts (24) on the
14. PTO gear B (Left side) inside of torque converter case (23).
Install the PTO gear B (Left side) similarly to a Since the case and cage are press fit-
PTO gear A (Right side). ted to each other, tighten all the bolts
gradually.
15. Coupling 2 Mounting bolt: Adhesive (LT-2)
Install coupling (24).

WA600-6 23
SEN01162-02 50 Disassembly and assembly

17. Modulated clutch assembly 5] Install seal ring (15) to piston (14).
1) Assemble the modulated clutch assembly 2 Seal ring: Grease (G2-LI)
according to the following procedure. a Set groove (k) of the seal ring as
1] Using push tool (Outside diameter: shown below.
114 mm), install bearing (22) to cover
(19).
2] Install 2 dowel pins (20).

6] Install seal ring (17) to clutch outer

drum shaft (16).
2 Seal ring: Grease (G2-LI)
3] Using push tool [29] (Inside diameter: a Set groove (m) of the seal ring as
76 mm), press fit cover (19) to clutch shown below.
outer drum shaft (20).
a Press the inner race.

7] Using eyebolts (M12, P = 1.75 mm),

install piston (14).
4] Install snap ring (18).

24 WA600-6
50 Disassembly and assembly SEN01162-02

8] Install 8 plates (13) and 7 discs (12) 3) Install 2 dowel pins (102) to the case.
alternately. a Drive in each dowel pins to the hole
a Soak the disc in clean transmis- end of the case.
sion oil for at least 2 minutes. 4) Install O-ring (103) to the case.
2 O-ring: Grease (G2-LI)

9] Install plate (11).

10] Install snap ring (10). 5) Using sling [5] (M10, P = 1.5 mm), install
a Using a bar which can be modulated clutch assembly (9).
inserted in the internal tooth a To check that the disc of the modu-
space, adjust the internal teeth of lated clutch assembly is not caught,
the disc. check that there is not clearance
between the cover and case before
tightening the cover mounting bolts.

2) Remove the plug and tighten 2 disc bolts

(101) (M12, P = 1.75 mm, 01024-81270).
3 Disc bolt:
Max. 49 Nm {Max. 5 kgm}
a By this work, piston (14) is pressed to
prevent the disc from moving.

WA600-6 25
SEN01162-02 50 Disassembly and assembly

6) Tighten 7 mounting bolts (8). 19. Related work

a Remove 2 disc bolts (101) (01024- 1) Install modulated clutch speed sensor (5).
81270) installed in the above step 2 Between cover and threaded part
and install the plug. of sensor: Gasket sealant (LG-5)
2 Plug (when reused):
Gasket sealant (LG-5)

2) Procedure for adjusting modulated clutch

speed sensor
1] Tighten modulated clutch speed sen-
18. Seal cage sor (5a) until it touches the plate of
1) Install seal ring (21). clutch outer drum shaft (16) and then
2 Seal ring: Grease (G2-LI) return it 3/4 – 1 turn.
2] Tighten locknut (5b).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}

2) Fit the O-ring and install seal cage (7).

3) Tighten mounting bolts (6).

26 WA600-6
50 Disassembly and assembly SEN01162-02

3) Using sling [1], install torque converter 4) Using sling [1], sling torque converter and
and PTO assembly (2) to transmission PTO assembly (2), and tighten 16 mount-
assembly (4). ing bolts (3).
4 Torque converter and PTO assem- a The 2 sub-assembly bolts (25) do not
bly: 490 kg need to be tightened since they have
2
not been removed.
Transmission input shaft seal ring:
Grease (G2-LI)
a Project each seal ring evenly from the
shaft.
a If 2 seal rings (104) and 2 seal rings
(105) are pushed in forcibly, they may
be broken. Take care.

5) Set the transmission and torque converter

assembly on the block horizontally.
4 Transmission and torque converter
assembly: 1,800 kg
6) Install torque converter PTO lubrication
tube (1c).

7) Install torque converter speed sensor wir-

ing harness (1b).

WA600-6 27
SEN01162-02 50 Disassembly and assembly

8) Install modulated clutch lubrication hose

(1a).
9) Install oil tube (1) between the torque con-
verter and transfer.

28 WA600-6
50 Disassembly and assembly SEN01162-02

Disassembly and assembly of

transmission assembly 1

Special tool

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
F 799-301-1500 Oil leak tester t 1

Disassembly
1. Preparation work
1) Disconnect the torque converter assembly
from the transmission assembly. For
details, see “Disassembly and assembly
of torque converter assembly”.
2) Remove transmission wiring harness (1).

7) Remove 3 torque converter regulator

mounting bolts (4) and torque converter
regulator valve (5).

3) Install eyebolts (M10, P = 1.5 mm) to part

(a) and sling the transmission control
valve assembly.
4) Remove 11 transmission control valve
assembly mounting bolts (2).
5) Lift off transmission control valve assem-
bly (3).
a Remove the O-ring, too.
4 Transmission control valve assem-
bly: 65 kg
6) Remove 4 lubrication valve mounting bolts
(2a) and lubrication valve assembly (2b).

WA600-6 29
SEN01162-02 50 Disassembly and assembly

8) Using eyebolts [1] (M16, P = 2.0 mm), 3) Using sling [3] (M12, P = 1.75 mm), sling
remove 6 sleeves (6). transmission case (9).

9) Remove lubrication tube (7). 4) Remove 14 case mounting bolts (10).

5) Using 2 forcing screws [4] (M12, P = 1.75
mm), disconnect transmission case (9).

2. Transmission case
1) Using sling [2] (M12, P = 1.75 mm), sling 6) Using sling [5] (M12, P = 1.75 mm),
transmission and transfer assembly (8). remove transmission case (9).
2) Set transmission and transfer assembly 4 Transmission case: 160 kg
(8) on the block with the transfer case
down.
4 Transmission and transfer assem-
bly: 1,250 kg

30 WA600-6
50 Disassembly and assembly SEN01162-02

3. Check of operating condition of piston 5. Input shaft and No. 1 carrier assembly
Using tool F, check the operating condition of 1) Install 2 eyebolts [6] (M16, P = 2.5 mm).
the piston before disassembling. a Stop tightening eyebolts [6] before
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2} they reach the housing.
2) Using bar [7], remove input shaft and car-
Piston (from above) Stroke (mm) rier assembly (12).
No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7

3) Disassemble the input shaft and carrier

assembly according to the following pro-
cedure.
1] Remove snap ring (13).
2] While supporting the housing, push
out shaft (14).

4. Tie bolts
Remove 20 tie bolts (11).
a When only the transfer assembly needs to
be disassembled, leave 2 tie bolts (11a),
and the transmission assembly can be
removed from the transfer case.
a Since 2 (11a) of the 20 tie bolts are short,
make marks on them.
a Do not use an impact wrench to loosen
the tie bolts, since it can damage the
cushion sleeve.

3] Remove snap ring (15).

4] While supporting the housing, push
out carrier assembly (16) with push
tool [8] (Outside diameter: 129 mm).

WA600-6 31
SEN01162-02 50 Disassembly and assembly

5] Remove snap ring (17) from the 11] Remove shaft (25), ball (26), 2 thrust
housing and remove bearing (18). washers (27), bearing (28) and plane-
6] Remove seal ring (gold) (19) from the tary gear (29) from carrier (16).
bearing. a Take care not to lose the ball.

7] Remove snap ring (20) from carrier

assembly (16) and remove ring gear 6. Springs
(21). Remove 12 springs (30) and 36 springs (31).
a Springs (31) are installed between the
plates.

8] Remove snap ring (22) from carrier

assembly (16) and remove bearing
(23).
9] Remove spacer (24) from carrier 7. Discs and plates
assembly (16). Remove 6 discs (32), 5 plates (33) and piston
10] Remove seal ring (gold) (24a) from plate (34).
spacer (24).

32 WA600-6
50 Disassembly and assembly SEN01162-02

8. No. 1 piston housing 9. Springs

1) Using eyebolts [9] (M18, P = 2.5 mm), Remove 12 springs (41) and 36 springs (42).
remove piston housing (35). a Springs (42) are installed between the
plates.

2) Using eyebolts [10] (M10, P = 1.5 mm),

remove piston (36) from housing (35).
10. Discs and plates
Remove 6 discs (43), 5 plates (44) and piston
plate (45).

3) Remove piston (38) and seal rings (39)

and (40) from housing (37).

11. No. 2 piston housing

Using eyebolts [11] (M18, P = 2.5 mm), remove
piston housing (46).
a Remove ring gear and carrier assembly
(47), too.

WA600-6 33
SEN01162-02 50 Disassembly and assembly

12. No. 1 ring gear and No. 2 carrier assembly 4] Remove bearing (55) from carrier
1) Using eyebolts [12] (M10, P = 1.5 mm), assembly (47).
remove ring gear and carrier assembly
(47) from No. 2 piston housing (46).

5] Remove spacer (145) from carrier

(47).
2) Remove piston (49) and seal rings (50) 6] Remove 2 seal rings (gold) (146) from
and (51) from housing (48). spacer (145).
7] Remove sun gear (147).
8] Remove bearing (148) from sun gear
(147).
9] Remove sun gear (149).

3) Disassemble the ring gear and carrier

assembly according to the following pro-
cedure.
1] Reverse ring gear and carrier assem-
bly (47). 10] Reverse ring gear and carrier assem-
2] Remove ring gear (53). bly (47).
3] Remove snap ring (52) and ring gear 11] Remove snap ring (56) which is fixing
(54). the planetary gear shaft.

34 WA600-6
50 Disassembly and assembly SEN01162-02

12] Remove shaft (58), plug (59), ball 15. No. 3 piston housing
(60), thrust washer (61), bearing (62) 1) Using eyebolts [13] (M18, P = 2.5 mm),
and planetary gear (63) from carrier remove No. 3 piston housing (70).
(57).
a Take care not to lose the ball.

2) Remove piston (71) and seal rings (72)

and (73) from housing (70).

13. Springs
1) Remove 12 springs (64) and 18 springs
(65).
a Springs (65) are installed between the
plates.
2) Remove guide pin (66).

3) Remove cushion sleeve (70a) from No. 3

piston housing (70).
a Check slit position (A).

14. Discs and plates

Remove 3 plates (67), 3 discs (68) and piston
plate (69).

WA600-6 35
SEN01162-02 50 Disassembly and assembly

16. No. 4 clutch (Revolution clutch) 4] Using push tool [16] (Outside diame-
1) Using eyebolts [14] (M18, P = 2.5 mm), ter: 5 mm), drive roll pin (79) into the
remove revolution clutch assembly (74) inside of carrier (78).
and No. 4 housing (75) together. 5] Remove shaft (80), plug (81), thrust
washer (82), bearing (83) and plane-
tary gear (84) from carrier (78).
a Take care not to lose the roll pin.

2) Disassemble the No. 6 carrier assembly

according to the following procedure.
1] Reverse the revolution clutch assem-
bly. 3) Disassemble the No. 5 carrier assembly
2] Remove snap ring (76). and ring gear according to the following
procedure.
1] Using bar [17], remove No. 5 ring
gear (85) from revolution clutch
assembly (74).

3] Using bar [15], remove No. 6 carrier

assembly (77) from revolution clutch
assembly (74).

36 WA600-6
50 Disassembly and assembly SEN01162-02

2] Using push tool [19] (Outside diame- 4) Disassemble the revolution clutch assem-
ter: 5 mm), drive roll pin (92) into car- bly according to the following procedure.
rier (91). 1] Remove snap ring (98) and then
3] Remove shaft (93), plug (94), thrust remove revolution clutch (99) from
washer (95), bearing (96) and plane- housing (75) with bar [20].
tary gear (97) from carrier (91).
a Take care not to lose the roll pin.

2] Remove bolts (101) and housing

(102) from ring gear (116).
4] Remove snap ring (86) and remove
sun gear (87) and bearing (88) from
No. 5 ring gear (85).
5] Remove snap ring (87a) of sun gear
(87) and then remove bearing (88).

3] Remove 8 discs (103), 8 wave springs

(104) and 7 plates (105) from ring
gear (116).

WA600-6 37
SEN01162-02 50 Disassembly and assembly

4] Remove inner gear (106) from ring 10] Remove snap ring (154).
gear (116). 11] Using puller [22], remove housing
5] Remove bearing (107) from inner (111) from shaft (110).
gear (106).

12] Using puller [18], remove shaft (110)

6] Using press fitting tool [21] (Inside from No. 5 carrier (91).
diameter: 160 mm), compress the
disc spring and remove snap ring
(108).
a Installed load of disc spring:
240 kg
7] Remove 5 disc springs (109).

13] Remove snap ring (90) from shaft

(110) and remove sun gear (89).

8] Remove piston (151) from housing

(150).
9] Remove seal rings (152) and (153).

38 WA600-6
50 Disassembly and assembly SEN01162-02

14] Remove snap ring (121) and then 19. No. 5 piston housing
remove bearing (123) from housing 1) Using eyebolts [23] (M18, P = 2.5 mm),
(122). remove No. 5 piston housing (129).
2) Using eyebolts [24] (M10, P = 1.5 mm),
remove piston (130) from piston housing
(129).

17. Springs
Remove 12 springs (124) and 18 springs
(125). 3) Remove seal ring (132) from housing
a Springs (125) are installed between the (129) and remove seal ring (131) from pis-
plates. ton (130).

18. Discs and plates

Remove 3 plates (126), 3 discs (127) and pis-
ton plate (128).

WA600-6 39
SEN01162-02 50 Disassembly and assembly

20. Springs 23. No. 6 piston housing

Remove 12 springs (133) and 18 springs 1) Using eyebolts [25] (M18, P = 2.5 mm),
(134). remove No. 6 piston housing (139).
a Springs (134) are installed between the 2) Remove ring gear (140).
plates. 3) Using eyebolts [26] (M10, P = 1.5 mm),
remove piston (141) from piston housing
21. Discs and plates (139).
Remove 3 plates (135), 3 discs (136) and pis-
ton plate (137).

22. Guide pins

Remove 6 guide pins (138).

4) Remove seal ring (143) from housing

(139) and remove seal ring (142) from pis-
ton (141).

40 WA600-6
50 Disassembly and assembly SEN01162-02

Assembly 2) Using eyebolts [26] (M10, P = 1.5 mm),

Precautions for assembly install piston (141) to piston housing (139).
q Apply transmission oil (TO10) to the rotary 3) Using eyebolts [25] (M18, P = 2.5 mm),
parts and sliding parts before installing. install No. 6 piston housing (139).
4) Install ring gear (140).
q Coat each seal ring with grease (G2-LI) and 5) Drive 2 dowel pins (155) into housing
install it evenly. (139).
q Coat the inside and outside fixed surfaces of
each bearing with adhesive (ThreeBond
1373B or equivalent) when installing.
q When installing the discs of each clutch, set
their notches to each other.
q Check that each snap ring is fitted securely to
the groove.

1. Preparation work
Clean all the parts and remove burrs etc.

2. No. 6 piston housing

1) Install seal ring (143) to housing (139) and
install seal ring (142) to piston (141).
2 Seal ring: Grease (G2-LI)

a Set groove (a) of the seal ring against

direction (b) of the pressure.

WA600-6 41
SEN01162-02 50 Disassembly and assembly

3. Guide pins a Set groove (c) of the seal ring against

Install 6 guide pins (138). direction (d) of the pressure.
a Length of guide pin: 125 mm

4. Discs, plates and springs

1) Install piston plate (137).
2) Install 3 discs (136), 18 springs (134) and
3 plates (135) alternately.
3) Install 12 springs (133).

2) Using eyebolts [24] (M10, P = 1.5 mm),

install piston (130) to No. 5 piston housing
(129).
3) Using eyebolts [23] (M18, P = 2.5 mm),
install No. 5 piston housing (129).

4) Drive 2 dowel pins (156) into housing

(129).

5. No. 5 piston housing

1) Install seal ring (132) to housing (129) and
install seal ring (131) to piston (130).
2 Seal ring: Grease (G2-LI)

42 WA600-6
50 Disassembly and assembly SEN01162-02

6. Discs, plates and springs 3] Install No. 6 carrier assembly (77) to

1) Install lower plate (128). shaft (110).
2) Install 3 discs (127), spring (125) and 3 4] Install snap ring (76).
plates (126) alternately.
3) Install springs (124).

5] Install sun gear (87) and bearing (88)

to shaft (110).
6] Using push tool [30] (Inside diameter:
95 mm), press fit bearing (88).

7. No. 6 and No. 5 carriers

1) Assemble the No. 6 carrier assembly 7] Install snap ring (87a).
according to the following procedure. 8] Install No. 5 ring gear (85) to sun gear
1] Install thrust washer (82), bearing (87).
(83), planetary gear (84), plug (81) 9] Install snap ring (86).
and shaft (80) to carrier (78). 10] Install sun gear (89) and snap ring
2] Using push tool [16] (Outside diame- (90).
ter: 5 mm), drive in roll pin (79).

WA600-6 43
SEN01162-02 50 Disassembly and assembly

11] Install seal ring (158) to shaft (110). 3] Fit spacer (159) to No. 4 housing
2 Seal ring: Grease (G2-LI) (122) and tighten 2 mounting bolts
(160).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

2) Install shaft (110) and No. 6 carrier assem-

bly (77) to No. 5 piston housing (129).

4] Set No. 5 carrier (91) to the tool and

install No. 4 housing (122).
5] Using push tool [31] (Inside diameter:
121 mm), press fit bearing (123).

3) Assemble the No. 5 carrier assembly

according to the following procedure.
1] Install thrust washer (95), bearing
(96), planetary gear (97), plug (94)
and shaft (93) to carrier (91).
2] Using push tool [19] (Outside diame-
ter: 5 mm), drive in roll pin (92). 6] Install snap ring (121) to No. 5 carrier
(91).

44 WA600-6
50 Disassembly and assembly SEN01162-02

8. No. 4 housing 4) Install 5 disc springs (109).

1) Install No. 4 housing (122) and No. 5 car- 5) Using press fitting tool [21] (Inside diame-
rier (91) to shaft (110). ter: 160 mm), compress the disc spring
2) Drive in 2 dowel pins (161). and install snap ring (108).
a Installed load of disc spring: 240 kg

9. No. 4 clutch (Revolution clutch) 6) Using push tool [33] (Inside diameter: 106
1) Using push tool [32] (Outside diameter: mm), press fit bearing (107) to inner gear
119 mm), press fit bearing (120) to hous- (106).
ing (102). 7) Install inner gear (106) to ring gear (116).

2) Install seal ring (153) to housing (150) and

install seal ring (152) to piston (151).
2 Seal ring: Grease (G2-LI)
3) Install piston (151) to housing (150).

WA600-6 45
SEN01162-02 50 Disassembly and assembly

8) Install 7 plates (105), 8 wave springs (104) 11) Using eyebolts, install revolution clutch
and 8 discs (103) to ring gear (116). assembly (74) to No. 4 housing (122).
12) Install snap ring (98).

9) Install housing (102) to ring gear (116) and

tighten bolts (101).
2 Mounting bolt: Adhesive (LT-2) 10. Spacer
3 Mounting bolt: 1) Install 2 seal rings (146) to spacer (145).
156.8 – 196.0 Nm {16 – 20 kgm} 2 Seal ring: Grease (G2-LI)

10) Install 2 seal rings (162) to housing (102). 2) Install spacer (145) to shaft (110).
2 Seal ring: Grease (G2-LI)

46 WA600-6
50 Disassembly and assembly SEN01162-02

11. Sun gear a Set groove (e) of the seal ring against
1) Using push tool [34] (Outside diameter: 99 direction (f) of the pressure.
mm), press fit bearing (148) to sun gear
(147).

2) Install piston (71) to piston housing (70).

3) Drive 2 dowel pins (163) into piston hous-
2) Install sun gear (147) to shaft (110). ing (70).

4) Install cushion sleeve (70a) to No. 3 piston

12. No. 3 piston housing housing (70).
1) Install seal ring (73) to housing (70) and a Set slit position (A) as checked when
install seal ring (72) to piston (71). removed.
2 Seal ring: Grease (G2-LI)

WA600-6 47
SEN01162-02 50 Disassembly and assembly

5) Using eyebolts [13] (M18, P = 2.5 mm), 15. No. 1 ring gear and No. 2 and No. 3 carrier
install No. 3 piston housing (70). assembly
1) Assemble the ring gear and carrier
assembly according to the following pro-
cedure.
1] Install thrust washer (61), bearing (62)
and planetary gear (63) to carrier (57).
2] Install plug (59) and ball (60) to shaft
(58) and then install them to carrier
(57).

13. Guide pins

Install 6 guide pins (66).
a Length of guide pin: 225 mm

14. Discs, plates and springs

1) Install piston plate (69).
2) Install 3 discs (68), 18 springs (65) and 3
plates (67) alternately. 3] Install snap ring (56) to fix the plane-
3) Install 12 springs (64). tary gear shaft to ring gear and carrier
assembly (57).

4] Install No. 1 ring gear (54) to carrier

assembly (57).
5] Install snap ring (52).

48 WA600-6
50 Disassembly and assembly SEN01162-02

2) Install sun gear (148) to sun gear (147). a Set groove (g) of the seal ring against
direction (h) of the pressure.

3) Install No. 2 and No. 3 carriers (57) to No.

3 piston housing (70). 3) Using eyebolts (M18, P = 2.5 mm), install
No. 2 piston housing (46) to No. 3 piston
housing (70).
4) Drive 2 dowel pins (164) into piston hous-
ing (70).

16. No. 2 piston housing

1) Install seal ring (51) to housing (48) and
install seal ring (50) to piston (49).
2 Seal ring: Grease (G2-LI)
2) Install piston (49) to housing (48).

WA600-6 49
SEN01162-02 50 Disassembly and assembly

17. Discs, plates and springs 18. Sun gear

1) Install lower plate (45). 1) Using push tool [35] (Inside diameter: 86
2) Install 6 discs (43), springs (42) and 6 mm), press fit bearing (150) to sun gear
plates (44) alternately. (149).
3) Install springs (41).

2) Install sun gear (149) to No. 2 and No. 3

carrier (57).

19. No. 1 carrier assembly and input shaft

1) Assemble the input shaft and carrier
assembly according to the following pro-
cedure.
1] Install thrust washer (27), bearing
(28) and planetary gear (29) to carrier
(16).
2] Install ball (26) to shaft (25) and then
install them to carrier (16).

50 WA600-6
50 Disassembly and assembly SEN01162-02

3] Drive 1 dowel pin (151) to carrier (16). 2] Install snap ring (13) to input shaft
4] Install seal ring (gold) (152) to spacer (14).
(24). 3] Install seal ring (154), 2 seal rings
2 Seal ring: Grease (G2-LI) (155), 2 seal rings (156) and 2 seal
5] Install spacer (24) to carrier (16). ring (157) to the input shaft (14).
6] Install ring gear (21) and snap ring 2 Seal ring: Grease (G2-LI)
(20).

3) Install the input shaft (14) to sun gear

2) Assemble the input shaft according to the (149).
following procedure.
1] Using push tool [27] (Inside diameter:
71 mm), press fit bearing (153) to the
input shaft (14).

4) Install No. 1 carrier (16) to No. 2 and No. 3

carrier (57).

WA600-6 51
SEN01162-02 50 Disassembly and assembly

20. No. 1 piston housing 21. Discs, plates and springs

1) Install seal ring (40) to housing (37) and 1) Install piston plate (34).
install seal ring (39) to piston (38). 2) Install 6 discs (32), springs (31) and 5
2 Seal ring: Grease (G2-LI) plates (33) alternately.
2) Install piston (38) to housing (37). 3) Install spring (30).

a Set groove (j) of the seal ring against

direction (k) of the pressure. 22. Housing
1) Using push tool [27] (Inside diameter: 131
mm), press fit bearing (18) to housing
(12).

3) Using eyebolts (M18, P = 2.5 mm), install

No. 1 piston housing (37) to No. 2 piston
housing (48).
4) Drive in 2 dowel pins (158). 2) Install snap ring (17) to housing (12).
3) Install seal ring (gold) (19) to housing (12).
2 Seal ring: Grease (G2-LI)

52 WA600-6
50 Disassembly and assembly SEN01162-02

4) Install 2 eyebolts [29] (M10, P = 2.5 mm). 23. Tie bolts

a Stop tightening eyebolts [29] before Install 20 tie bolts (11).
they reach the housing. a If only the transfer assembly was disas-
5) Sling and install housing (12). sembled, fix the clutch with 2 tie bolts
2 Spline (a) of input shaft: (11a).
Grease (LM-G) a There are 2 short ones (11a) in the 20 tie
bolts. Check their marks made when
removed.
a Tighten each tie bolt with the fingers until it
reaches the tap hole so that it will not
damage the cushion sleeve.
a Use an impact wrench only after the
threads are engaged perfectly.
3 Mounting bolt:
157 – 177 Nm {16 – 18 kgm}

24. Check of operating condition of piston

Using tool F, check the operating condition of
the piston before disassembling.
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2}

Piston (from above) Stroke (mm)

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7

WA600-6 53
SEN01162-02 50 Disassembly and assembly

25. Transmission case 26. Related work

1) Using sling [5] (M12, P = 1.75 mm), install 1) Sling the transmission and transfer
transmission case (9). assembly and set them on the side.
4 Transmission case: 160 kg 4 Transmission and transfer assem-
bly: 1,250 kg
2) Install lubrication tube (7).
3 Joint bolt:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}

2) Using eyebolts [1] (M16, P = 2.0 mm),

install 6 sleeves (6).

3) Install torque converter regulator valve (5).

3 Mounting bolt (4):
53.9 – 63.7 Nm {5.5 – 6.5 kgm}

3) Install case mounting bolts (10a) and

(10b).
3 Mounting bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}

54 WA600-6
50 Disassembly and assembly SEN01162-02

4) Fit the O-ring, install eyebolts (M10, P = 7) Install the torque converter assembly to
1.5mm) to part (a), and install transmis- the transmission assembly. For details,
sion control valve assembly (3). see “Disassembly and assembly of torque
2 O-ring: Grease (G2-LI) converter assembly”.
3 Mounting bolt (2):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
4 Transmission control valve assem-
bly: 65 kg
5) Install lubrication valve assembly (2b) and
tighten 4 mounting bolts (2a).

6) Install transmission wiring harness (1).

WA600-6 55
SEN01162-02 50 Disassembly and assembly

Disassembly and assembly of

transfer assembly 1

Special tool

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
F 799-301-1500 Oil leak tester t 1
1 793-615-1130 Spline wrench t 1
G
2 796-730-2300 Wrench assembly t 1

Disassembly
1. Preparation work
1) Disconnect the torque converter assembly
from the transmission assembly. For
details, see “Disassembly and assembly
of torque converter assembly”.
2) Remove transmission wiring harness (1).

7) Remove 3 torque converter regulator

mounting bolts (4) and torque converter
regulator valve (5).

3) Install eyebolts (M10, P = 1.5 mm) to part

(a) and sling the transmission control
valve assembly.
4) Remove 11 transmission control valve
assembly mounting bolts (2).
5) Lift off transmission control valve assem-
bly (3).
a Remove the O-ring, too.
4 Transmission control valve assem-
bly: 65 kg
6) Remove 4 lubrication valve mounting bolts
(2a) and lubrication valve assembly (2b).

56 WA600-6
50 Disassembly and assembly SEN01162-02

8) Using eyebolts [1] (M16, P = 2.0 mm), 3) Using sling [3] (M12, P = 1.75 mm), sling
remove 6 sleeves (6). transmission case (9).

9) Remove lubrication tube (7). 4) Remove 14 case mounting bolts (10).

5) Using 2 forcing screws [4] (M12, P = 1.75
mm), disconnect transmission case (9).

2. Transmission case
1) Using sling [2] (M12, P = 1.75 mm), sling 6) Using sling [5] (M12, P = 1.75 mm),
transmission and transfer assembly (8). remove transmission case (9).
2) Set transmission and transfer assembly 4 Transmission case: 160 kg
(8) on the block with the transfer case
down.
4 Transmission and transfer assem-
bly: 1,250 kg

WA600-6 57
SEN01162-02 50 Disassembly and assembly

3. Check of operating condition of piston 5. Remove speed sensors (12).

Using tool F, check the operating condition of
the piston before disassembling.
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2}

Piston (from above) Stroke (mm)

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7

6. Input shaft bearing cage assembly

1) Remove 6 mounting bolts (13).
2) Using forcing screws [6] (M10, P = 1.5
mm), remove bearing cage assembly (14).

4. Tie bolts
1) Remove 18 tie bolts (11).
a Since the transmission assembly is
not disassembled at this time, leave 2
tie bolts (11a) to fix the sub-assembly.
a Do not use an impact wrench to
loosen the tie bolts, since it can dam- 3) Remove outer race (15) from bearing
age the cushion sleeve. cage assembly (14).
2) Install 2 eyebolts (M10, P = 2.5 mm) to the
tie bolt holes and lift off the transmission
assembly.
4 Transmission assembly: 500 kg

58 WA600-6
50 Disassembly and assembly SEN01162-02

7. Input shaft gear assembly 10. Parking brake assembly

1) Using forcing screws [7] (M12, P = 1.75 a For disassembly of the parking brake
mm), remove input shaft gear assembly assembly, see “Disassembly and assem-
(16). bly of parking brake assembly”.
2) Remove bearings (17) and (18) from input 1) Remove 2 plugs (26) and tighten the
shaft gear assembly (16). mounting bolts.
a Tighten the bolts alternately little by
little.
a Tighten the bolts to pull the piston.
2) Remove 12 mounting bolts (27).
a Do not remove 4 hexagon socket
head bolts (sub-assembly bolts) (28).
3) Remove 4 mounting bolts (29).
4) Using forcing screws [9], remove seal
cage (30).

8. Parking brake emergency release valve

1) Reverse the case.
2) Remove mounting bolts (20) and parking
brake emergency release valve (21).
3) Using forcing screws [8] (M10, P = 1.5
mm), remove sleeve (22).

5) Remove oil seal (31) and dust seal (32)

from seal cage (30).

9. Coupling (rear side)

Remove mounting bolt (23), holder (24) and
coupling (25).

WA600-6 59
SEN01162-02 50 Disassembly and assembly

6) Using forcing screws [10] (M12, P = 13. Seal cage

1.75m m), disco nnect parkin g b rake 1) Remove 4 mounting bolts (39).
assembly (33). 2) Remove seal cage (40).
7) Using eyebolts [11], remove parking brake 3) Remove shim (41).
assembly (33). a Check the quantity and thickness of
the inserted shim.
4) Remove oil seal (43) and dust seal (42)
from seal cage (40).

11. Gear cover

1) Remove 3 mounting bolts (34).
2) Move gear cover (35) aside.
14. Input shaft bearing cage
1) Remove 6 mounting bolts (44).
2) Remove seal cage (45).
3) Remove bearings (46a) and (46b) and
spacer (47) from seal cage (45).
a Since the 2 bearings are not inter-
changeable, keep them as a set.

12. Coupling (front side)

Remove mounting bolt (36), holder (37) and
coupling (38).

15. Output shaft gear

1) Using eyebolts [12] (M12, P = 1.75 mm),
take out output shaft gear (48) and output
shaft together.
a Sling output shaft gear (48) around
gear cover (35).

60 WA600-6
50 Disassembly and assembly SEN01162-02

2) Remove gear cover (35).

5) Remove outer race (55) from bearing

3) Remove output shaft (49) from output cage assembly (54).
shaft gear (48).

4) Remove outer race (50). 17. Intermediate shaft gear assembly

1) Using forcing screws [14] (M12, P = 1.75
mm), remove intermediate shaft gear
assembly (56).
2) Remove bearings (57) and (58) from inter-
mediate shaft gear assembly (56).

16. Intermediate shaft bearing cage assembly

1) Remove 2 mounting bolts (51).
2) Remove cover (52).
3) Remove 8 mounting bolts (53).
4) Using forcing screws [13] (M12, P = 1.75
mm), remove bearing cage assembly (54).
a Check the quantity and thickness of
the inserted shim.

WA600-6 61
SEN01162-02 50 Disassembly and assembly

3) Remove outer race (59). Assembly

1. Intermediate shaft gear assembly
1) Outer race (intermediate shaft side)
Using push tool [1] (Outside diameter: 199
mm), press fit outer race (59) to the case.

18. Cover (input shaft side)

1) Remove 6 mounting bolts (60).
2) Using forcing screw [15] (M12, P = 1.75
mm), remove cover (61). 2) Install bearings (57) and (58) to intermedi-
ate shaft gear (56).
3) Apply grease to the roller surfaces of the
bearing, rolling surfaces (d) of the inner
and outer races, inner race flanges, and
roller contact surface (e).
2 Parts (d) and (e) of bearing:
Grease (LM-G)
4) Using forcing screws [14] (M12, P = 1.75
mm), install intermediate shaft gear
assembly (56).

3) Remove outer race (62) from cover (61).

62 WA600-6
50 Disassembly and assembly SEN01162-02

2. Intermediate shaft bearing cage assembly 5] Using tool G1 and a torque wrench,
1) Using push tool [2] (Outside diameter: 199 measure the rotation torque of inter-
mm), press fit outer race (55) to bearing mediate shaft gear (56).
cage (54). Rotation torque:
0.98 – 1.96 Nm {0.1 – 0.2 kgm}
Standard shim thickness: 1 mm
Standard clearance: 0.63 – 1.37 mm
a Check that the gear has no play.
6] Adjust the quantity of the shims to set
the rotation torque in the above
range.
7] After finishing adjustment, tighten the
m o u n t i n g b o l ts t o t h e s p e c i f i e d
torque.
a After installing the bearing, drop
about 6 cc of transmission oil
(TO30) onto it and revolve it
about 10 turns.
2) Fit the O-ring and install intermediate shaft
bearing cage assembly (54) without set-
ting the shim.
2 O-ring: Grease (G2-LI)

3. Cover (input shaft side)

1) Using push tool [3] (Outside diameter: 189
mm), press fit outer race (62) to bearing
cage (61).
3) Adjustment of preload on intermediate
shaft bearing
Adjust the shim of bearing cage (54)
according to the following procedure.
1] Install bearing cage (54) without set-
ting shim (62) and tighten the mount-
ing bolts to 4.9 Nm {0.5 kgm}.
a Use all the mounting bolts.
2] Rotate intermediate shaft gear (56)
20 turns and check the tightening
torque of 4.9 Nm {0.5 kgm} for the
mounting bolts.
3] If the tightening torque has changed,
repeat 1] and 2] above.
4] If the tightening torque has not
changed, set shim (62) (Standard
thickness: 1 mm) and tighten the
m o u n t i n g b o l ts t o t h e s p e c i f i e d
torque.

WA600-6 63
SEN01162-02 50 Disassembly and assembly

2) Fit the O-ring and install cover (61) without 5. Bearing cage assembly (input shaft gear
setting the shim. side)
2 O-ring: Grease (G2-LI) 1) Using push tool [4] (Outside diameter: 199
a Tighten the bolts temporarily at this mm), press fit outer race (15) to bearing
time. cage (14).

2) Using forcing screws [6] (M12, P = 1.75

4. Input shaft gear assembly
mm), install input shaft bearing cage
1) Press fit bearings (17) and (18) to input
assembly (14).
shaft gear (16).
3) Install 6 mounting bolts (13).
2 Mounting bolt: Adhesive (LT-2)
2) Apply grease to the roller surfaces of the
bearing, rolling surfaces (d) of the inner
and outer races, inner race flanges, and
roller contact surface (e).
2 Parts (d) and (e) of bearing:
Grease (LM-G)
3) Using forcing screws [7] (M12, P = 1.75
mm), install input shaft gear (16).

64 WA600-6
50 Disassembly and assembly SEN01162-02

4) Adjustment of preload on input shaft bear- 6. Bearing cage assembly (output shaft side)
ing 1) Using the push tool, press fit outer race
Adjust the shim of bearing cage (61) (46a), spacer (47) and bearing (46b) to
according to the following procedure. bearing cage (45).
a Since the preload on the input shaft 2) Fit the O-ring and install bearing cage
bearing is adjusted without removing assembly (45).
the intermediate shaft bearing, the 2 O-ring: Grease (G2-LI)
rotation torque is roughly doubled. 3) Install 6 mounting bolts (44).
1] Install bearing cage (61) without set-
ting shim (63) and tighten the mount-
ing bolts to 4.9 Nm {0.5 kgm}.
a Use all the mounting bolts.
2] Rotate input shaft gear (16) 20 turns
and check the tightening torque of 4.9
Nm {0.5 kgm} for mounting bolts
(60).
3] If the tightening torque has changed,
repeat 1] and 2] above.
4] If the tightening torque has not
changed, set shim (63) (Standard
thickness: 1.1 mm) and tighten the
m o u n t i n g b o l ts t o t h e s p e c i f i e d
torque.
5] Using tool G2 and a torque wrench,
7. Output shaft gear assembly
measure the rotation torque of inter-
1) Apply grease to spline (f) of output shaft
mediate shaft gear (16).
(49).
2 Spline (f) of shaft: Grease (LM-G)
Rotation torque:
1.96 – 3.92 Nm {0.2 – 0.4 kgm}
Standard shim thickness: 1.1 mm
Standard clearance: 0.85 – 1.70 mm
a Check that the gear has no play.
6] Adjust the quantity of the shims to set
the rotation torque in the above
range.
7] After finishing adjustment, tighten the
m o u n t i n g b o l ts t o t h e s p e c i f i e d
torque.

2) Install output shaft (49) to output shaft

gear (48).

WA600-6 65
SEN01162-02 50 Disassembly and assembly

3) Put gear cover (35) in the case. 3] Tighten mounting bolts (39) to 0.49 –
4) Using sling [12], sling and install output 0.98 Nm {0.05 – 0.10 kgm}.
shaft gear (48). 4] Using the thickness gauge, measure
a Sling output shaft gear (48) around clearance (a) between seal cage (40)
gear cover (35). and mounting face.
Shim thickness (b):
a – (0.05 to 0.10 mm)
5] Install shim (41) of thickness (b)
obtained by the above step and
tighten mounting bolts (39).
Shim thickness: 0.15, 0.2, 0.5 mm
6] After adjusting the shim, tighten
mounting bolts (39) to the specified
torque.

5) Set gear cover (35) and install 3 mounting

bolts (34).
2 Mounting bolt: Adhesive (LT-2)

8. Seal cage assembly (output shaft side)

1) Using the push tool, press fit oil seal (43)
and dust seal (42) to seal cage (40).
2 Oil seal: Grease (G2-LI)
2 Press fitting face of oil seal:
Gasket sealant (LG-5)
2 Dust seal: Grease (G2-LI) 9. Coupling (front side)
2 Mating faces of oil seal and dust 1) Apply grease to spline (g) of the shaft.
seal: Grease (G2-LI) 2 Spline (g) of shaft: Grease (LM-G)

a Apply the gasket sealant thinly to the 2) Fit the O-ring and press fit coupling (38).
inside of the housing hole and wipe 3) Install holder (37) and bolt (36).
off the projected part. 2 O-ring: Grease (G2-LI)

2) Adjust the shim according to the following 2 Mounting bolt: Adhesive (LT-2)

procedure. 3 Mounting bolt:

1] Fit the O-ring and install seal cage 824 – 1,030 Nm {84 – 105 kgm}
(40) without setting the shim.
2 O-ring: Grease (G2-LI)
2] Install the coupling temporarily and
rotate the shaft about 20 turns.

66 WA600-6
50 Disassembly and assembly SEN01162-02

5) Using the push tool, press fit oil seal (31)

10. Parking brake assembly and dust seal (32) to seal cage (30).
a For assembly of the parking brake assem- 2 Oil seal: Grease (G2-LI)
bly, see "Disassembly and assembly of 2 Dust seal: Grease (G2-LI)
parking brake assembly". 2 Press fitting face of oil seal:
1) Apply grease to spline (h) of the shaft. Gasket sealant (LG-5)
2 Spline (h) of shaft: Grease (LM-G) 2 Mating faces of oil seal and dust
seal: Grease (G2-LI)
a Apply the gasket sealant thinly to the
inside of the housing hole and wipe
off the projected part.

2) Using eyebolts [11], install parking brake

assembly (33).

6) Fit the O-ring, install seal cage (30), and

tighten 4 mounting bolts (29).
2 O-ring: Grease (G2-LI)

3) Install 12 mounting bolts (27).

2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98.0 – 123 Nm {10.0 – 12.5 kgm}
4) Remove the bolts which have been clamp-
ing the piston and install 2 plugs (26).

WA600-6 67
SEN01162-02 50 Disassembly and assembly

11. Coupling (rear side) 13. Speed sensor

Fit the O-ring and install coupling (25), holder 1) Install speed sensors (12).
(24) and bolt (23). a Take care that the direction of the
a Set coupling (25) to the position of the sensor wiring harness outlet will not
coupling on the opposite side. be opposite to the mounting direction
2 O-ring: Grease (G2-LI) of the connector.
3 Mounting bolt: 2 Between case and threaded part of
824 – 1,030 Nm {84 – 105 kgm} speed sensor: Adhesive (LG-5)
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}

12. Parking brake emergency release valve

1) Fit the O-ring and install sleeve (22), using 2) Method of adjusting speed sensor
forcing screws [8]. 1] Tighten speed sensor (12a) until it
2 O-ring: Grease (G2-LI) touches gear (12b) and then return it
2) Fit the O-ring, install parking brake emer- by 1/2 – 1 turn.
gency release valve (21) and tighten 2] Tighten locknut (12c).
mounting bolts (20). 3 Locknut:
2 O-ring: Grease (G2-LI) 49.0 – 68.6 Nm {5 – 7 kgm}

68 WA600-6
50 Disassembly and assembly SEN01162-02

14. Tie bolts

1) Install 2 eyebolts (M10, P = 2.5 mm) to the
tie bolt holes and sling and install the
transmission assembly.
4 Transmission assembly: 500 kg
2) Install 20 tie bolts (11).
a Use 2 tie bolts (11a) to fix the trans-
mission as a sub-assembly.
a There are 2 short ones (11a) in the 20
tie bolts. Check their marks made
when removed.
a Tighten each tie bolt with the fingers
until it reaches the tap hole so that it
will not damage the cushion sleeve.
a Use an impact wrench only after the
threads are engaged perfectly. 16. Transmission case
3 Mounting bolt: 1) Using sling [5] (M12, P = 1.75 mm), install
157 – 177 Nm {16 – 18 kgm} transmission case (9).
4 Transmission case: 160 kg

15. Check of operating condition of piston

2) Using eyebolts [1] (M16, P = 2.0 mm),
Using tool F, check the operating condition of
install 6 sleeves (6).
the piston.
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2}

Piston (from above) Stroke (mm)

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7

WA600-6 69
SEN01162-02 50 Disassembly and assembly

3) Install case mounting bolts (10a) and 3) Fit the O-ring, install eyebolts (M10, P =
(10b). 1.5 mm) to part (a), and install transmis-
3 Mounting bolt: sion control valve assembly (3).
53.9 – 122.6 Nm {5.5 – 12.5 kgm} 2 O-ring: Grease (G2-LI)
3 Mounting bolt (2):
44.1 – 55.9 {4.5 – 5.5 kgm}
4 Transmission control valve assem-
bly: 65 kg
4) Install lubrication valve assembly (2b) and
4 mounting bolts (2a).

17. Related work

1) Install lubrication tube (7).

2) Install torque converter regulator valve (5).

3 Mounting bolt (4):
53.9 – 63.7 {5.5 – 6.5 kgm}
5) Install transmission wiring harness (1).
6) Connect the transmission assembly to the
torque converter assembly. For details,
see “Disassembly and assembly of torque
converter assembly”.

70 WA600-6
50 Disassembly and assembly SEN01162-02

Disassembly and assembly of 2) Remove 12 mounting bolts (8).

parking brake assembly 1
a Do not remove 4 hexagon socket
head bolts (sub-assembly bolts) (9).
Disassembly 3) Remove 4 mounting bolts (10).
1. Preparation work 4) Using forcing screws [2], remove seal
Disconnect the torque converter assembly cage (11).
from the transmission assembly. For details,
see “Disassembly and assembly of transmis-
sion assembly”.

2. Parking brake emergency release valve

1) Remove mounting bolts (1) and parking
brake emergency release valve (2).
2) Using forcing screws [1] (M10, P = 1.5
mm), remove sleeve (3).

5) Remove oil seal (12) and dust seal (13)

from seal cage (11).

3. Coupling (rear side)

Remove mounting bolt (4), holder (5) and cou-
pling (6).

6) Using forcing screws [3] (M12, P = 1.75

mm), disconnect parking brake assembly
(14).
7) Using eyebolts [4], remove parking brake
assembly (14).

4. Parking brake assembly

1) Remove 2 plugs (7) and tighten the
mounting bolts.
a Tighten the bolts alternately little by
little.
a Tighten the bolts to pull the piston.

WA600-6 71
SEN01162-02 50 Disassembly and assembly

5. Cover assembly 6. Springs

1) Remove 4 hexagon socket head bolts (15) Remove 18 outer springs (19) and 18 inner
from cover (16). springs (20).
a Since the cover is floated by the
springs, loosen the hexagon socket
head bolts gradually and evenly.

7. Piston
1) Using eyebolts [6] (M12, P = 1.75 mm), lift
2) Using eyebolts [5], lift off cover (16). off piston (22) from housing (21).

3) Remove bearing (17) and dowel pin (18) 2) Remove seal rings (23) and (24) from pis-
from cover (16). ton (22).

72 WA600-6
50 Disassembly and assembly SEN01162-02

8. Spacer assembly 10. Plate

1) Remove spacer (25) from housing (21). 1) Reverse the housing.
2) Remove 4 mounting bolts (28) and plate
(29).

2) Using push tool [7], remove inner race

(26) from spacer (25).

11. Snap ring and end plate

Remove snap ring (30) and end plate (31).

9. Gear
Using eyebolts [8] (M12, P = 1.75 mm),
remove gear (27) from housing (21).
12. Plates, discs and wave springs
Remove 8 plates (32), 7 discs (33) and 7 wave
springs (34) alternately.

WA600-6 73
SEN01162-02 50 Disassembly and assembly

Assembly 3. Springs
1. Cover Install 18 outer springs (19) and 18 inner
Assemble the cover assembly according to the springs (20).
following procedure.
1) Using push tool [1] (Outside diameter: 189
mm), press fit bearing (17) to cover (16).
2) Install 2 dowel pins (18).

4. Piston
1) Install seal rings (23) and (24) to piston
(22).
a Set grooves (a) of the seal rings as
2. Spacer assembly shown below.
1) Using push tool [2] (Inside diameter: 106 2 Seal ring: Grease (G2-LI)

mm), press fit inner race (26) to spacer 2) Install piston (22) to cover (16).
(25).
2) Press fit spacer assembly (25) to cover
assembly (16).

74 WA600-6
50 Disassembly and assembly SEN01162-02

5. Plugs 7. Gear
1) Remove 2 plugs (7). Install gear (27).
2) Fit the washers to 2 parking brake assem-
bly mounting bolts and tighten them into
the plug holes.
a Tighten the bolts alternately little by
little.
a Tighten the bolts to pull the piston.

8. Plates, discs and wave springs

Install 8 plates (33), 7 discs (32) and 7 wave
springs (34) alternately.

6. Housing
1) Fit the O-ring to cover (16) and install
housing (21), using sling [9].
2 O-ring: Grease (G2-LI)

9. Snap ring and end plate

Install end plate (31) and fix it with snap ring
(30).

2) Tighten 4 hexagon socket head bolts (15).

WA600-6 75
SEN01162-02 50 Disassembly and assembly

10. Plate 12. Seal cage

Install plate (29) and tighten mounting bolts 1) Press fit oil seal (12) and dust seal (13) to
(28). seal cage (11).
2 Mounting bolt: Adhesive (LT-2) 2 Oil seal: Grease (G2-LI)
2 Press fitting face of oil seal:
Gasket sealant (LG-5)
2 Dust seal: Grease (G2-LI)
2 Mating faces of oil seal and dust
seal: Grease (G2-LI)
a Apply the gasket sealant thinly to the
inside of the oil seal fitting section of
the cover and wipe off the projected
part.

11. Plugs
1) Reverse the parking brake assembly.
2) Remove the 2 bolts used to install the
springs and install plugs (7).
2 Plug: Adhesive (LT-2)

2) Install seal cage (11) and tighten mounting

bolts (10).

76 WA600-6
50 Disassembly and assembly SEN01162-02

13. Parking brake assembly 14. Coupling (rear side)

1) Apply grease to spline (h) of the shaft. Fit the O-ring and install coupling (6), holder
2 Spline (h) of shaft: Grease (LM-G) (5) and bolt (4).
a Set coupling (6) to the position of the cou-
pling on the opposite side.
2 O-ring: Grease (G2-LI)
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

2) Using eyebolts [4], install parking brake

assembly (14).

15. Parking brake emergency release valve

1) Fit the O-ring and install sleeve (3), using
forcing screws [1].
2 O-ring: Grease (G2-LI)
2) Fit the O-ring, install parking brake emer-
gency release valve (2), and tighten
mounting bolts (1).
2 O-ring: Grease (G2-LI)

3) Install 12 mounting bolts (8).

2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}

16. Related work

Connect the transmission assembly to the
transfer assembly. For details, see “Disassem-
bly and assembly of transmission assembly”.

WA600-6 77
SEN01162-02

WA600-6 Wheel loader

Form No. SEN01162-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

78
 SEN01164-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly

Power train, Part 3
Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Removal and installation of center support assembly..................................................................................... 6
Disassembly and assembly of center support assembly ................................................................................ 8
Disassembly and assembly of differential assembly..................................................................................... 12

WA600-6 1
SEN01164-03 50 Disassembly and assembly

Removal and installation of front 4. Disconnect brake hose (3).

axle assembly 1
Removal
k Park the machine on level ground.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Release the remaining pressure in the
brake accumulator system, referring to
“Releasing remaining pressure in the
hydraulic system” in Testing and adjusting.

1. Remove the bucket assembly, referring to

“Removal and installation of work equipment
assembly”. 5. Remove mounting bolts (4) and disconnect
front drive shaft (5). [*2]
2. Place the lift arm (1) to the support stand [1]. a Lift the drive shaft with rope, etc. to pre-
Operate the work equipment control lever to lift vent falling.
the machine body and set the block [2] to the
front frame. 4 Front drive shaft: 65 kg
a Release the parking brake since the
machine body moves forward.
a Lift the lift arm high enough to allow the
front axle to hang and be withdrawn, lock
the work equipment control lever, apply
parking brake and stop the engine.

k Set the lock bar to the frame and put

the blocks under the rear wheels.

3. Lift and remove tire assembly (2). [*1]

4 Tire assembly: 1,550 kg

2 WA600-6
50 Disassembly and assembly SEN01164-03

6. Lift front axle assembly (6) temporarily and Installation

remove the mounting bolts. [*3] q Carry out installation in the reverse order to
a Don't lift by section (A) as it has floating removal.
seal. To lift, mount plate [1], etc. to the
tapped holes for the wheel hub rim mount- [*1]
ing bolts. 3 Hub nut: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
7. Gently lift and remove front axle assembly (6). 3 Mounting bolt:
4
215 – 255 Nm {21.9 – 26.0 kgm}
Front axle assembly: 3,700 kg
[*3]
3 Mounting bolt:
2,890 – 3,630 Nm {295 – 370 kgm}

q Bleeding air from the brake circuit

Bleed air from the front brake, referring to
“Bleeding air from various system” in Testing
and adjusting.

WA600-6 3
SEN01164-03 50 Disassembly and assembly

Removal and installation of rear 6. Disconnect rear drive shaft (2). [*2]
axle assembly 1 a Lift the drive shaft with rope, etc. to pre-
vent falling.
4
Removal
k
Rear drive shaft assembly: 65 kg
Park the machine on level ground. Set the
the lock bar to the frame and put the blocks
under the wheels. 7. Disconnect front support lubrication tube (3).
k Loosen the filler cap of the hydraulic tank a Disconnect the clamp on the frame.
gradually to release the residual pressure
from the hydraulic tank.
k Release the remaining pressure in the
brake accumulator system, referring to
“Releasing remaining pressure in the
hydraulic system” in Testing and adjusting.

1. Set the rear axle on block [1] to the left and

right.
a To prevent the rear axle from jumping
upward when the tires are removed.

2. Lift the machine body with the work equipment

and set the axle assembly on block [2].
8. Disconnect brake hose (4) from the slack
adjustor. [*3]

3. Hold the work equipment level and lift the

machine body with block [3] and jack (50 ton) [4].
4. Sling tire assembly (1) temporarily and remove
9. Disconnect rear support lubrication tubes (6)
the hub nuts.
and (7).
5. Lift and remove tire assembly (1). [*1]
4 Tire assembly: 1,550 kg 10. Fasten the axle support and rear axle using
chain, etc. and tightening with lever block [7].

4 WA600-6
50 Disassembly and assembly SEN01164-03

11. Lift one side temporarily and set a garage jack Installation
to the other side to remove the support mount- q Carry out installation in the reverse order to
ing bolt. [*4] removal.

12. Gently lower rear axle assembly (9) by holding [*1]

the left and right sides balanced. 3 Hub nut: 824 – 1,030 Nm {84 – 105 kgm}
4 Rear axle assembly: 3,900 kg
[*2]
a Pull out the rear axle assembly from the 3 Mounting bolt:
bottom of the frame, using the crane and 215 – 255 Nm {21.9 – 26.0 kgm}
the garage jack.
[*3]
a Bleed air from the slack adjustor, referring to
“Bleeding air from various systems” in Testing
and adjusting.

[*4]
3 Support mounting bolt:
2,450.0 – 3,038.0 Nm {250.0 – 310.0 kgm}

13. Lift and remove support (10) (front and rear)

from the rear axle.
4 Front support: 140 kg
4 Rear support: 230 kg

WA600-6 5
SEN01164-03 50 Disassembly and assembly

Removal and installation of center 2. Remove front drive shaft (2). [*2]
support assembly 1 4 Front drive shaft: 65 kg
Special tools a When removing the drive shaft, lift the
drive shaft with a rope, etc. to prevent fall-

New/Remodel
ing.

Necessity
Sym-
Part No. Part name

Sketch
bol 3. Disconnect lubrication tube (3).

Q'ty
4. Lift the center support temporarily and remove
H 12 793T-620-1410 Centering tool t 1 N Q
mounting bolts (4). [*3]

Removal
k Park the machine on level ground. Turn the
steering wheel fully to the left, set the work
equipment completely on to the ground and
put the blocks under the wheels.
k Disconnect the cable from the negative (–)
terminal of the battery.

1. Disconnect center drive shaft (1). [*1]

4 Center drive shaft: 65 kg
a When removing the drive shaft, lift the
5. Lift and remove center support assembly (5).
drive shaft with a rope, etc. to prevent fall-
ing. 4 Center support assembly: 47 kg
a Check the number of shims, if any,
between the center support and the frame
for assembling data.

6 WA600-6
50 Disassembly and assembly SEN01164-03

Installation
q Carry out installation in the reverse order to
removal.

[*1]
3 Mounting bolt:
215 – 255 Nm {21.9 – 26.0 kgm}

[*2]
3 Mounting bolt:
215 – 255 Nm {21.9 – 26.0 kgm}

[*3]
a To make the transmission coupling surface and
the center support (CS) coupling surface paral-
lel, mount tool H12 and a dial gauge [1] to the
transmission (T/M). Adjust parallelism and
radial runout by turning the coupling on the
side of center support (CS).
a Install shims to the center support mounting
face for adjustment.
a Tighten the mounting bolts after shim adjust-
ment.
3 Mounting bolt:
490.0 – 608.0 Nm {50.0 – 62 kgm}
a Parallelism: Max. 0.1

WA600-6 7
SEN01164-03 50 Disassembly and assembly

Disassembly and assembly of 3. Shaft

center support assembly 1 1) Set shaft case assembly (6) on the press.
2) Pull out shaft (7) using the press.
Disassembly a Cover the floor with wood chips so
1. Coupling that the shaft may not be damaged
Remove center bolt (1) and then remove should it fall off.
retainer (2), O-ring (3) and coupling (4).
a Make match marks to coupling (4) and the
shaft end surface.

3) Remove spacer (8), bearing (9) and

retainer (5) from the shaft.

2. Retainer
Remove the mounting bolts of retainer (5).
a Remove all mounting bolts by rotating the
shaft.

4. Oil seal
Remove oil seal (10) and O-ring (11) from
retainer (5).

8 WA600-6
50 Disassembly and assembly SEN01164-03

5. Case Assembly
1) Remove oil seal (12) from the case. 1. Bearing outer race
2) Remove bearing (13), bearing outer races Install bearing outer races (14) and (15) to
(14) and (15) from the case. case (16).
a Make sure that there is no clearance
between the outer races and the case
end.

2. Oil seal
Install oil seal (10) to retainer (5).
2 Oil seal lip surface: Grease (G2-LI)
a Driven dimension of oil seal:
(a) = 2 ± 0.5 mm

WA600-6 9
SEN01164-03 50 Disassembly and assembly

3. Bearing
1) Install retainer (5) to the shaft and press fit
bearing (9).
a After installing the bearing, check that
no clearance is present between the
shaft end.
2) Install the spacer.
2 Bearing inner circumference:
Grease (G2-LI)

5. Retainer
Fix retainer (5) to the case.
3 Mounting bolt:
59 – 73.5 Nm {6 – 7.5 kgm}

4. Case
1) Install O-ring (11) to retainer (5).
a Fit the O-ring securely to the groove.

6. Bearing seal
1) Press fitting bearing (13) in the shaft.
2 Bearing (13): Grease (G2-LI)
2) Install oil seal (12) to the case.
a Seal press fit dimension: ±0.5 mm
from the case end
2 Seal lip surface and portion (C) of the case:
Grease (G2-LI)
2) Hold the shaft upright and install the case
(16).
a Apply grease amply to (a) portion of
the retainer and the rolling surfaces
(b) of the bearing.
a Take care that the O-ring is not
engaged.

10 WA600-6
50 Disassembly and assembly SEN01164-03

7. Coupling
Assembly coupling (4) and install O-ring (3)
and retainer (2), and then fix with center sup-
port (1).
a Install coupling (4) by matching to the
match mark.
3 Center bolt:
824 – 1,030 Nm {84 – 105 kgm}

8. Testing
Check that end play is within the specified
range.
a End play: Max. 0.22 mm
a If end play is 0, check that free rotational
torque reads 3.9 Nm {0.4 kgm} maximum
with grease applied to the seal and bear-
ing.

9. Filling grease
Fill grease through tapped hole (d) of the case.
a Fill grease until it comes out of the
breather (17).
2 Inside the case:
Grease (G2-LI) (900 cc)

WA600-6 11
SEN01164-03 50 Disassembly and assembly

Disassembly and assembly of Disassembly

differential assembly 1 1. Differential gear assembly
1) Install tool H2 to tool H1.
Special tools 2) Set differential gear assembly (1) to tool H2.
a Considering the weight of the differ-

New/Remodel
ential gear assembly, maintain the

Necessity
Symbol Part No. Part name balance of the assembly after setting

Sketch
it to tool H1.
4 Differential gear assembly: 560 kg

Q'ty
790-501-5200 Unit repair stand t 1
1
790-901-4110 Bracket t 1
2 793T-622-1810 Plate t 1 N Q
3 792-103-0901 Wrench t 1
4 793T-622-1180 Push tool t 1 Q
5 793T-622-1840 Push tool t 1 N Q
790-201-2460 Plate t 1
6
790-201-2690 Plate t 1
790-101-5621 Plate t 1
H
7 790-101-5421 Grip t 1
01010-81240 Bolt t 1
8 790-201-2860 Spacer t 1 2. Coupling
1) Remove the bolt and remove holder (2).
1 792-525-1000 Micrometer t 1
9
2 792-525-1220 Adapter t 1
10 793T-622-1820 Push tool t 1 N Q
793T-622-1830 Push tool t 1 N Q
11 790-101-5221 Grip t 1
01010-81240 Bolt

2) Remove O-ring and remove coupling (3).

12 WA600-6
50 Disassembly and assembly SEN01164-03

3. Cage assembly 2) Remove 20 bolts and lift and remove sup-

1) Remove 6 bolts and remove cage assem- port bevel pinion assembly (9).
bly (4). 4 Support bevel pinion assembly:
100 kg

2) Remove oil seal (6), dust seal (7) and the

O-ring from cage (5). 3) Remove shim (10).
a Check the number of the shims in
advance.

4. Support bevel pinion assembly

1) Remove retainer (8) from the pinion shaft.
4) Push down support bevel pinion assembly
(9) using a press. Remove bevel pinion
assembly (12) together with bearing (11)
from support assembly.
a Set the blocks, etc, under the bevel
pinion assembly to prevent falling to
the floor.

WA600-6 13
SEN01164-03 50 Disassembly and assembly

5. Disassembly of bevel pinion assembly 7. Differential gear assembly

1) Remove spacer (14) from bevel pinion 1) Invert the bracket of tool H1.
assembly (12).

2) Remove right and left locks (19).

2) Remove bearing (16) from bevel pinion a After removing the lock, mark the lock
shaft (15), using a press. position on the adjustment nut.

6. Disassembly of support assembly 3) Loosen the adjustment nut (20) using tool
Remove bearing outer races (17) and (18) H3 until the nut can be turned manually.
from support assembly (13).

14 WA600-6
50 Disassembly and assembly SEN01164-03

4) Lift differential gear assembly (21) tempo- 8) Lift and remove differential gear assembly
rarily. (21).

5) Remove 4 bearing cap mounting bolts 8. Disassembly of differential gear assembly

(22) each to the left and right. 1) Remove 24 bolts and remove bevel gear
6) Remove left and right bearing caps (23). (25) from case (26).
a Separate the left and right bearing a Make match marks to the bevel gear
cap. and the case before disassembling.
2) Remove bearing (27).

7) Lift off differential gear assembly (21)

slightly to remove the left and right bear- 3) Remove 8 bolts and remove case assem-
ings (24). bly (28) from case (26).
a Care should be taken not to drop the a Make match marks to the case before
bearing when lifting. disassembling.
a Separate the left and right bearings.

WA600-6 15
SEN01164-03 50 Disassembly and assembly

4) Remove washer (29) from the inside of 7) Remove cross shaft pinion gear assembly
case assembly (28). (33) from case (26).
a Make match marks to the cross shaft
and case before disassembling.

5) Remove bearing (30) from case (31).

8) Remove side gear (34) from case (26).

6) Remove side gear (32) from case (26).

9) Remove washer (35) from the inside of

case (26).

16 WA600-6
50 Disassembly and assembly SEN01164-03

10) Remove washer (37), pinion gear (38) and Assembly

bushing (39) from cross shaft (36). 1. Carrier case
1) Install tool H2 to tool H1.
2) Set carrier case (40) to tool H2.

9. Carrier case
1) Remove carrier case (40) from tool H2.
2) Remove tool H2 from tool H1. 2. Assembly of differential gear assembly
1) Use tool H4 to press fit bearing (24) to
case (26).

2) Install washer (35) to the inside of case

(26).

WA600-6 17
SEN01164-03 50 Disassembly and assembly

3) Install side gear (34) to case (26). 6) Install side gear (32) to case (26).

4) Install bushing (39), pinion gear (38) and 7) Use tool H4 to press fit bearing (30) to
washer (37) in this order to cross shaft case (31).
(36).

8) Install washer (29) to the inside of case

assembly (28).
5) Install cross shaft and pinion gear assem-
bly (33) to case (26).
a Match the markings on the cross
shaft and the case.

18 WA600-6
50 Disassembly and assembly SEN01164-03

9) Install case assembly (28) to case (26). 2) Install spacer (14) to bevel pinion assem-
a Match the marking on the case. bly (12).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

4. Assembly of support assembly

1) Use tool H6 to install bearing outer race
10) Install bevel gear (25) to case (26). (18) to support assembly (13).
a Match the markings on the bevel gear 2) Use tool H7 to install bearing outer race
and the case. (17) to support assembly (13).
2 Mounting bolt: a Press fit outer race until it comes in
Liquid adhesive (LT-2) contact with the support.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}

5. Assembly of support and bevel pinion

assembly
1) Install support assembly (13) and bearing
3. Assembly of bevel pinion assembly
(11) to bevel pinion assembly (12).
1) Use tool H5 to press fit bearing (16) to
bevel pinion shaft (15).

WA600-6 19
SEN01164-03 50 Disassembly and assembly

2) Use tool H8 to press fit bearing (11) to 3) Tighten adjustment nut (20) to the carrier
support assembly (13). case temporarily.
3) Install retainer (8) to the pinion shaft after 4) Install left and right bearing caps (23).
press fitting. a Check the markings on the left and
right bearing caps and match them to
the dowel pins.
5) Tighten 4 bearing cap mounting bolts (22)
each to the left and right.
a Tighten the bolts after rotating the
bevel gear 20 to 30 rounds to run in
the bearing.
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

6. Installation of differential gear assembly.

1) Lift differential gear assembly (21) to the
installation position of the carrier case.
a Keep the gear assembly off the car-
rier case.

a Install the left and right locks for the

adjustment nut after completing the
“Pre-load adjustment of bearing”,
“Backlash adjustment” and “Testing
and adjusting of tooth contact.”

7. Preload adjustment of bearing

1) Install tools H9-2 to the threaded portions
2) Install bearing outer races (24) to the left (A) of the right and left cap tops.
and right of the differential gear. a Tighten until play is eliminated.
a Match the left and right bearings by 2) Using tool H9-1, measure dimension (L).
checking the match marks on the left 3) Add 0.38 ± 0.10 mm to measured value
and right inner races. (L) and set the scale of tool H9-1 to the
obtained value.
a The added dimension will be the
deflection of the case made by giving
a preload.

20 WA600-6
50 Disassembly and assembly SEN01164-03

a Precautions in adjusting pre-load

If the deflection should exceed the
standard dimension due to overtight-
ening of the adjustment nut, return
the nut to the position before the
adjustment.
To do this, lightly hit the bearing cap
and bevel gear with a plastic hammer,
etc. while rotating the bevel gear.
Make sure that no clearance exists in
(b) portion and then make adjustment
again.

4) Using tool H3, tighten nut (20).

a Using tool H3, tighten adjustment nut
(20) so that the increase will be 0.38 ±
0.10 mm.

8. Installation of bevel pinion assembly

1) Invert the tool H1.

5) Put push-pull scale [2] to the tip of bevel

gear (25) and measure the starting force.
Starting force:
24.5 – 44.1 N {2.5 – 4.5 kg}
(Reference value)
a If the starting force is out of the above
range, return to step 3 and adjust
again.

WA600-6 21
SEN01164-03 50 Disassembly and assembly

2) Install shim (10). 9. Installation of cage assembly

a Install the shim removed during disas- 1) Use tool H10 press fit dust seal (7) to cage
sembly. (5), using oil seal (6) and tool H11.
a Standard shim thickness: 1.45 mm 2 Oil seal lip surface: Grease (G2-LI)
a Shim margin for adjustment: 0.8 – 2.1 mm 2 Dust seal lip surface: Grease (G2-LI)

2) Install cage assembly (4) with 6 bolts.

3 Mounting bolt:
3) Install O-ring, and then lift and install sup-
port bevel pinion assembly (9).
59 – 74 Nm {6 – 7.5 kgm}

4) Tighten support bevel pinion assembly (9)

10. Installation of coupling
with 20 bolts.
3 Mounting bolt:
1) Install O-ring and coupling (3).
2 Contact surface of the retainer and
490 – 608 Nm {50 – 62 kgm}
coupling: LM-G or LM-P

22 WA600-6
50 Disassembly and assembly SEN01164-03

2) Install holder (2) and tighten bolt. 3) If backlash is off the reference value, shift
a Tighten the bolts gradually after rotat- the bevel gear for adjustment.
ing the bevel gear and bevel pinion a Adjust bevel gear shifting with adjust-
20 to 30 rounds. ment nut (20), using tool H3.
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

4) To keep the pre-load given to bearing (24)

unchanged, turn the nuts on both sides by
the same quantity and in the same direction.
a In the case backlash is in short of the
11. Backlash adjustment reference value
1) Hold the probe of dial gauge [1] to the tip Loosen adjustment nut (20A) on the
of the bevel gear tooth at a right angle. side of the bevel gear and tighten
2) Read the scale when the bevel gear is adjustment nut (20B). (Direction A)
turned in the right direction of rotation with a In the case backlash is in excess of
the bevel pinion fixed. the reference value
a Measure at 3 to 4 points. Loosen adjustment nut (20B) on the
q Backlash reference value: side of the bevel gear and tighten
0.41 – 0.56 mm adjustment nut (20B). (Direction B)

WA600-6 23
SEN01164-03 50 Disassembly and assembly

12. Testing of tooth contact 2) If the bevel pinion is excessively away

Apply thin layer of red lead on the tooth sur- from the bevel gear, the contact mark will
face of the bevel gear. Turn the bevel gear in be as shown in the following figure. Make
the forward and backward directions and correction according to the following pro-
check the contact mark left on the bevel gear. cedure:
a Proper tooth contact q Reduce the number of shims of the
Fifty percent of the total length of a tooth is cage assembly (on the bevel pinion
in contact centering around the pitch line side) and shift it in the direction of (C).
toward the heel with approx. q Adjust the bearing adjustment nut
5 mm of the toe side remaining unmarked and shift the bevel gear in the direc-
or not in contact. tion of (D) away from the bevel pinion.

13. Adjusting of tooth contact 3) If the bevel pinion is excessively close to

1) If proper tooth contact mark was not the bevel gear, the contact mark will be as
obtained upon checking, proceed to a shown in the following figure. Make cor-
tooth adjustment. rection according to the following proce-
a Make adjustment by shifting the bevel dure:
gear and increasing/decreasing the q Increase the number of shims of the
number of shims (shifting of bevel cage assembly (on the bevel pinion
pinion gear) of the cage assembly. side) and shift it in the direction of (E).
a After adjustment, check the backlash q Adjust the bearing adjustment nut
again. and shift the bevel gear in the direc-
a When making adjustment by shifting tion of (F) closer to the bevel pinion.
the bevel gear, don't change pre-load
given the bearing. Accordingly, turn
the respective left and right adjust-
ment nuts by the same quantity
(check with the shifting of the notch)
and in the same direction.
a Shim thickness: 0.05, 0.2, 0.3 and
1.0 mm

24 WA600-6
50 Disassembly and assembly SEN01164-03

4) If the bevel gear is excessively close to 14. Lock

the bevel pinion, the contact mark will be Install lock (19) of adjustment nut (20).
as shown in the following figure. Make 3 Mounting bolt:
correction according to the following pro- 98 – 123 Nm {10 – 12.5 kgm}
cedure:
q Decrease the number of shims of the
cage assembly (on the bevel pinion
side) and shift it in the direction of (C).
q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (D) away from the bevel pinion.

5) If the bevel gear is excessively away from

the bevel pinion, the contact mark will be
as shown in the following figure. Make
correction according to the following pro-
cedure:
q Increase the number of shims of the
cage assembly (on the bevel pinion
side) and shift it in the direction of (E).
q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (F) closer to the bevel pinion.

WA600-6 25
SEN01164-03

WA600-6 Wheel loader

Form No. SEN01164-03

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 02-10 (01)

26
 SEN01165-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Power train, Part 4
Removal and installation of final drive carrier assembly ................................................................................. 2
Disassembly and assembly of final drive carrier assembly............................................................................. 4
Removal and installation of front final drive brake assembly .......................................................................... 5
Disassembly and assembly of final drive assembly........................................................................................ 7

WA600-6 1
SEN01165-02 50 Disassembly and assembly

Removal and installation of final 4. Pull out drive shaft (4).

drive carrier assembly 1 a To make it easier to pull out, attach an
eyebolt, etc. to the end of the drive shaft to
Removal pull it out with.
k Park the machine on level ground. Set the
work equipment completely on to ground
and put the blocks under the wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Lift the machine body with the work equipment,

set a support stand under the axle. Lift the tire
assembly temporarily and remove the hub
mounting bolts.
Operate the crane to remove the tire assembly
(1). [*1]
4 Tire assembly: 1,450 kg

5. Sling and remove the drive shaft (4).

4 Drive shaft: 60 kg

2. Remove drain plug (2) from the cover (3) and

drain oil from the final drive case. [*2]
6 Final drive case: approx. 25 l
6. Remove snap ring (5) and then remove sun
3. Remove 12 bolts and remove cover (3), then gear (6) and spacer (7).
remove the O-ring. [*3]

2 WA600-6
50 Disassembly and assembly SEN01165-02

7. Remove 3 hexagonal socket head bolts and Installation

sling the final drive carrier assembly (8) to q Installation is done in the reverse order of
remove. [*4] removal.
a Hold the assembly parallel to the ring gear
using a bar, etc., remove the carrier [*1]
assembly. 3 Hub mounting bolt:
4 Final drive carrier assembly: 160 kg 824.0 – 1,030.0 Nm {84.0 – 105.0 kgm}

[*2]
3 Oil pressure pickup plug:
127.4 – 176.4 Nm {13 – 18 kgm}
3 Drain plug (2): 58.8 – 78.4 Nm {6 – 8 kgm}

[*3]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}

[*4]
3 Carrier assembly mounting bolt (with hexag-
onal socket head):
98 – 123 Nm {10 – 12.5 kgm}

q Refilling with oil

5 Final drive case (one side):
Approx. 25 l (AXO80)

WA600-6 3
SEN01165-02 50 Disassembly and assembly

Disassembly and assembly of 2. Remove 2 bearings (4) from planetary gear (3).
final drive carrier assembly 1 a Store the bearing, etc. that has developed
a run-in in a separate group of the bear-
Disassembly ings (2 bearings), shaft and a ball to pre-
1. Using the press, pull out the shaft (1) and vent them from being re-assembled with
remove planetary gear (3). other parts.
a When the shaft is pushed out, lock ball (2)
falls for which care should be taken not to
lose it.
a Enter a number to case (5). Care should
be taken not to mix removed parts with
others.

Assembly
1. Install 2 bearings (4) to the planetary gear (3)
and set them to carrier case (5).
a Match the position exactly to the hole on
the case.

2. Align the notch hole for the ball on the side of

carrier case (5) to the ball hole of shaft (1).
Press fit the shaft in until the ball hole makes
contact with the case end.

3. Install ball (2) to the hole and press fit shaft (1).

4 WA600-6
50 Disassembly and assembly SEN01165-02

Removal and installation of front 4. Sling the final drive brake assembly (5) tempo-
final drive brake assembly 1 rarily and remove 28 bolts (6). [*3]
a Don't hook on the floating seal retainer
Removal directly for slinging.
1. Remove the final drive shaft assembly, refer- a When removing the final drive brake
ring to section 1 to 6, “Removal and installation assembly, use chain block on one side to
of final drive carrier assembly.” balance the assembly.
4 Final drive brake assembly: 850 kg
2. Remove 3 bolts and remove the brake tube
cover (1). [*1]

5. Sling and remove the final drive brake assem-

3. Remove the clamp, brake tube (2) and nipple
bly (5).
(3). [*2]
a Carefully remove the piston air bleeder
a Remove the brake tube on the side of the
plug (4) to prevent damages.
slack adjuster too.
a Leave the piston air bleeder plug (4)
6. Remove the piston air bleeder plug (4). [*4]
installed as it is not removable.

WA600-6 5
SEN01165-02 50 Disassembly and assembly

Installation
q Installation is done in the reverse order of
removal.

[*1]
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}

[*2]
3 Clamp mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
3 Nipple (3): 84 – 132 Nm {8.5 – 13.5 kgm}

[*3]
3 Mounting bolt: 824 – 981 Nm {84 – 100 kgm}

[*4]
3 Air bleeder plug (4):
84 – 132 Nm {8.5 – 13.58 kgm}

6 WA600-6
50 Disassembly and assembly SEN01165-02

Disassembly and assembly of 3. Fix the final drive assembly (3) and brake
final drive assembly 1 assembly (4) using jig J1.
a Install the tool at 3 points.
Special tools q Install the jig J1 until the final drive assem-
bly is assembled.

New/remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
J 1 793T-622-1910 Fixture t 3 N Q

Disassembly
1. Set final drive brake assembly (1) on a flat
place with the final drive side on top.

4. Remove 8 mounting bolts, and then retainer

(5) and shim (6).
a Check the thickness and quantity of the
shims in advance.

2. Remove 3 hexagonal socket head bolts and

sling final drive carrier assembly (2) to remove.
4 Final drive carrier assembly: 160 kg

5. Sling the ring gear assembly (7) to remove.

4 Ring gear assembly: 110 kg

WA600-6 7
SEN01165-02 50 Disassembly and assembly

6. Disassembly of carrier assembly

For details on disassembly of carrier assembly
(2), referring to “Disassembly and assembly of
final drive carrier assembly.”

7. Disassembly of ring gear assembly

1) Remove 6 lock plates (8) and then remove
ring gear hub (9) from the ring gear (10).
2) Remove bearing (11) from the ring gear
hub (9).

2. Assembly of final drive carrier assembly (2)

a For details on assembly of carrier assem-
bly (2), referring to “Disassembly and
assembly of final drive carrier assembly.”
3. Insert ring gear assembly (7) and remove tool
J1.

Assembly
a Before assembly, check that every part is
washed clean and not attached with dirt or
damaged.

1. Assembly of ring gear assembly (7)

1) Press fit bearing (11) in to ring gear hub
(9).
a Make sure that there is no clearance
between the hub after press fitting the
bearing. 4. How to adjust wheel bearing
2) Engage ring gear hub (9) to the ring gear 1) Temporarily tighten retainer (5) with 3
(10) and install 6 lock plates (8). mounting bolts with specified torque with-
a When assembling, hold the lock plate out installing shim (6).
with the wider portion to the inside. 3 Temporary tightening torque
a Fully degrease tapped holes. 57.9 – 67.7 Nm {5.9 – 6.9 kgm}
2 Mounting bolt: Adhesive (LT-2) a While rotating wheel hub 5 to 6 times,
3 Mounting bolt: tighten the retainer evenly until a
27 – 34 Nm {2.8 – 3.5 kgm} specified torque is reached.

8 WA600-6
50 Disassembly and assembly SEN01165-02

2) Measure the dimension (a) between the 5) Assemble the calculated shim (6) and
retainer end and the tube end using a retainer (5) and tighten them to a specified
depth gauge [1] or depth micro gauge torque with all of the mounting bolts.
through the measuring hole of retainer (5). 2 Mounting bolt: Adhesive (LT-2)
a Take measurement at 2 locations and 3 Mounting bolt:
calculate the mean. 245 – 289 Nm {25 – 29.5 kgm}
3) Remove the retainer (5) and measure the a While rotating wheel hub 5 to 6 times,
thickness (b) of the retainer. tighten the retainer evenly until a
a Take measurement at 2 locations and specified torque is reached.
calculate the mean.
4) Calculate the thickness (c) of shim (6)
using the following equation:
Thickness of shim (c) (mm) =
(a) – (b) +0.3 (mm)
a Obtain necessary thickness with a
minimum number of shim.
a Thickness of shim:
0.2, 0.3 and 1.0 (mm)

6) Rotate the wheel hub again and check

that the rotation is normal.

5. Install the final drive carrier assembly (2) with 3

bolts with hexagonal socket head.
3 Carrier assembly mounting bolt (with
hexagonal socket head):
98 – 123 Nm {10 – 12.5 kgm}

WA600-6 9
SEN01165-02

WA600-6 Wheel loader

Form No. SEN01165-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

10
 SEN01167-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Brake system
Disassembly and assembly of brake assembly .............................................................................................. 2
Removal and installation of brake valve assembly ....................................................................................... 10
Disassembly and assembly of accumulator and charge valve assembly ......................................................11
Disassembly and assembly of slack adjustor assembly ............................................................................... 14

WA600-6 1
SEN01167-02 50 Disassembly and assembly

Disassembly and assembly of 3. Tube assembly

brake assembly 1 1) Remove 2 hexagonal socket head bolts
and lift off tube assembly (2).
Special tools a Take care not to drop the assembly
since bearing inner race may be

New/Remodel
removed together.
4 Tube assembly: 115 kg

Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
1 793T-622-1910 Fixture t 3 N Q
792-520-2110 Installer t 1
2
792-530-1600 Push tool t 1
J
792T-422-1220 Plate t 1 Q
3 790-101-5421 Grip t 1
01010-81240 Bolt t 1

Disassembly
k Remove internal parts (such as piston,
disc, plate, floating seal, etc.) with care to 2) Remove retainer (3) from tube (4).
prevent them from being damaged by
impact, falling, etc.

1. Remove the final drive brake assembly, refer-

ring to “Removal and installation of final drive
brake assembly.”

a For details on disassembly of final drive

assembly, refer to “Disassembly and
assembly of final drive assembly.”

2. Final drive brake assembly

Install tool J1 to final drive brake assembly (1),
invert to hold the brake assembly side on top.
a After placing the assembly on a flat place, 3) Remove bearing inner race (5).
remove the tool J1.

2 WA600-6
50 Disassembly and assembly SEN01167-02

4. Cylinder assembly 5) Remove seal ring (11) from piston (10).

1) Remove 24 mounting bolts and lift off cyl-
inder assembly (6).

6) Remove seal ring (13) from cylinder (12).

7) Remove 12 mounting bolts, and then
2) Use an eyebolt, bar, etc. to push in spring remove sleeve (14) from cylinder (12).
(8), pull out lower pin (7).
3) Remove spring (8) and guide (9).

5. Plate disc
1) Remove plate (15).
4) Remove piston (10). a Before removing the plate and disc,
provide the plate and outer gear, and
the disc and wheel hub with counter
marks.

WA600-6 3
SEN01167-02 50 Disassembly and assembly

2) Remove disc (16). 2) Remove floating oil seal (19) and oil seal
a Remove disc carefully, avoiding dam- (20) from the outer gear.
ages as it is made of a soft material.

7. Retainer
3) Remove 12 plates and 11 discs alter- 1) Remove floating seal (19) from retainer
nately. (21).
4) Remove plate (17) at the end. 2) Remove 6 mounting bolts and retainer
a Thickness of plate (17) is 10 mm. (21).

8. Wheel hub assembly

6. Outer gear
Remove outer races (23) and (24) from the
1) Remove outer gear (18).
wheel hub (22).
a Take care not to drop the floating seal
on the bottom.

4 WA600-6
50 Disassembly and assembly SEN01167-02

Assembly 2) After installation measure the height (a) at

a Before assembly, check that every part is 4 points on the circumference and check
washed clean and not attached with dirt or that dimensional difference reads within
damaged. 1 mm.
a Before assembly, apply engine oil to the sliding a Apply a thin layer of axle oil (AXO80)
surfaces of each part. to the top end surface (b) of the float-
a Completely remove white powder on the sur- ing seal (19).
face of the O-ring of floating seal using engine
oil, etc.
k Install floating seal carefully as a flaw, how-
ever minor, on the floating seal due to
impact or falling may cause oil leakage.

1. Wheel hub
1) Use tool [1] (outside diameter: 355 mm) to
press fit outer race (24) to wheel hub (22).
2) Use tool [2] (outside diameter: 285 mm) to
press fit outer race (23) to wheel hub (22).

3) Install retainer (21).

3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

2. Retainer
1) Use tool J2 to install floating seal (19) to
retainer (21).
a Fully degrease the contact surface
between floating seal and the hub O-
ring.
a Use tool J2 to evenly tighten O-ring of
the floating seal by avoiding twist.

WA600-6 5
SEN01167-02 50 Disassembly and assembly

3. Outer gear 3) After installation measure the height (a) at

1) Use tool J3 to press fit oil seal (20) to 4 points on the circumference and check
outer gear (18). that dimensional difference reads within
a Press fit oil seal to be flush with the 1 mm.
outer gear case end surface. a Apply a thin layer of axle oil (AXO80)
2 Oil seal lip surface: to the top end surface (b) of the float-
Grease (G2-LI) ing seal (19).

2) Use tool J2 to install floating seal (19) to 4) Install outer gear (18).
outer gear (18). a Take care not to drop the floating seal
a Fully degrease the contact surface on the bottom.
between floating seal and the O-ring a Install the outer gear avoiding oil seal
of outer gear. at the bottom to ride up.
a Use tool J2 to evenly tighten O-ring of
the floating seal by avoiding twist.

6 WA600-6
50 Disassembly and assembly SEN01167-02

4. Plate and disc

1) Install plate (17) first.
a Thickness of plate (17) is 10 mm.
a Plate may be used either on the front
or back side.

5. Cylinder assembly
1) Install sleeve (14) to cylinder (12).
3 Mounting bolt:
58.8 – 78.4 Nm {6 – 8 kgm}
2) Install seal ring (13) to cylinder (12).
2) Install plate (15). 2 Outer circumference of seal ring:
a Install by matching the counter marks Grease (G2-LI)
on the plate and outer gear.
3) Install disc (16).
a Install disc carefully, avoiding dam-
ages as it is made of soft material.
a Install by matching the counter marks
on the disc and wheel hub.
4) Install plate (15) and disc (16) alternately
in this order from the bottom up.
a 12 plates (15) and 11 discs (16)

3) Install seal ring (11) to piston (10).

2 Outer circumference of seal ring:
Grease (G2-LI)

WA600-6 7
SEN01167-02 50 Disassembly and assembly

4) Install piston (10). 7) Install cylinder assembly (6).

3 Mounting bolt:
245 – 289 Nm {25 – 29.5 kgm}

5) Place guide (9) through spring (8) and

install them to piston (7).
6) Use the eyebolt and bar to push in spring 6. Tube assembly
and fix it to the lower side of guide (9) 1) Install bearing inner races (5) to the wheel
through pin (7). hub.

2) Install retainer (3) to the tube (4).

8 WA600-6
50 Disassembly and assembly SEN01167-02

3) Install tube assembly (2).

3 Hexagonal socket head bolt:
98 – 123 Nm {10 – 12.5 kgm}

7. Final drive and brake assembly

1) Install tool J1 to final drive and brake
assembly (1), invert to hold the final drive
assembly side on top.
2) After placing the assembly on a flat place,
remove the tool J1.

a Assemble final drive assembly, refer-

ring to “Disassembly and assembly of
final drive assembly.”

WA600-6 9
SEN01167-02 50 Disassembly and assembly

Removal and installation of brake 4. Disconnect hoses (7) to (11) from the left brake
valve assembly 1 valve.
a Remove each nipple.
Removal
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Set the frame lock bar.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Release the remaining pressure in the
brake accumulator system, referring to
“Releasing remaining pressure in the
hydraulic system” in Testing and adjusting.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove cover (1).

5. Disconnect connector C18 (12) from the right

brake valve.
6. Remove 3 mounting bolts, and remove right
2. Disconnect hoses (2) to (5) from the right brake valve (13).
brake valve. 7. Remove 3 mounting bolts, and remove left
3. Disconnect drain hose (6). brake valve (14).
a Remove each nipple.

a Bottom view

Installation
q Installation is done in the reverse order of
removal.

q After installing brake valves, check the brake

performance.

10 WA600-6
50 Disassembly and assembly SEN01167-02

Disassembly and assembly of

accumulator and charge valve
assembly 1
Disassembly

1. Remove bushing (2) from body (1).

2. Remove filter (3) from bushing (2).
a Remove the ring.

3. Remove plug (4).

4. Remove retainer (5).

5. Remove nut (6).

6. Remove screw (7).
k Remove carefully by holding the mat-
ing faces pressed together by hand as
the inside is tensioned by spring.

7. Remove spring (8) and retainer (9).

8. Remove nut (10).

9. Remove screw (11).
k Remove carefully by holding the mat-
ing faces pressed together by hand as
the inside is tensioned by spring.

10. Remove spring (12) and ball (13).

WA600-6 11
SEN01167-02 50 Disassembly and assembly

11. Remove relief valve (14). Assembly

12. Remove plug (15). 1. Install relief valve (14).

k Remove carefully by holding the mat- 3 Relief valve:
ing faces pressed together by hand as 78.5 – 88.3 Nm {8 – 9 kgm}
the inside is tensioned by spring.
2. Install filter (19) to spool (17).
13. Remove spring (16). a Take care of the mounting direction of the
14. Remove spool (17). filter (angled portion to the back).
15. Remove ring (18) from spool (17). 3. Install ring (18).
16. Remove filter (19). 4. Install spool (17).
5. Install spring (16).
6. Install plug (15).
3 Plug: 53.9 – 68.6 Nm {5.5 – 7 kgm}

12 WA600-6
50 Disassembly and assembly SEN01167-02

7. Install ball (13) and spring (12). 15. Install filter (3) to bushing (2).
8. Install screw (11). a Take care of the mounting direction of the
9. Install nut (10). filter (angled portion to the back).
3 Nut: 9.8 – 11.8 Nm {1 – 1.2 kgm} a Fix with the ring.
16. Install bushing (2) to body (1).
10. Install retainer (9) and spring (8). 3 Bushing:
11. Install screw (7). 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
12. Install nut (6).
3 Nut: 9.8 – 11.8 Nm {1 – 1.2 kgm}

13. Install retainer (5).

14. Install plug (4).
3 Plug: 30.4 – 37.3 Nm {3.1 – 3.8 kgm}

WA600-6 13
SEN01167-02 50 Disassembly and assembly

Disassembly and assembly of

slack adjustor assembly 1
Disassembly

1. Bleeder
Remove bleeder (2) from body (1).

4. Valve
a Don't disassemble valve unless neces-
sary. If disassembled, replace with whole
cylinder assembly.
1) Remove cover (8) from cylinder (4) and
remove plug (9), spring (10), valve (11)
and seat (12).
2. Cylinder a To remove the valve, blow air through
Remove the mounting bolt and disconnect body the oil hole of the cylinder and the
(1) from cylinder (4) together with bracket (3). body.
k Remove carefully by holding the mat- a Cover the cylinder oil port with hand
ing faces pressed together by hand as to prevent the air from being blown
the inside is tensioned by spring. into rapidly.
a Care should be taken not to change
the combination of valve (11) and cyl-
inder (4). To replace, replace by the
valve and cylinder assembly as a set.
(Because of diameter clearance of
0.04 to 0.10 (mm) between the cylin-
der and the valve))
2) Remove O-ring (13) and ring (14) from
valve (11).

3. Piston
1) Remove O-ring (6) from body (1).
2) Remove spring (5) from cylinder (4).
3) Push out piston (7) and remove O-ring.
a Remove the piston gently by pressing
it with a rod of 10 mm diameter from
(B).
a Take care not to damage the
threaded portion with the rod.

14 WA600-6
50 Disassembly and assembly SEN01167-02

Assembly 2. Piston
1) Install O-ring (14) to piston (7).
1. Valve 2) Insert piston (7) to cylinder (4).
1) Install O-ring (13) and ring (14) to valve a Make sure that the piston moves
(11). smoothly.
2) Install seat (12) and valve (11) in this
order, to cylinder (4).
3) Fill area (E) with grease (G2-LI).
2 Area (E): Grease (G2-LI)
4) Install spring (10), plug (9) and cover (8) in
the order.
2 Plug (9) threaded portion:
Cemedine 366
3 Plug (9): 49 – 63 Nm {5 – 6.5 kgm}

3. Cylinder
1) Install O-ring (6) to body (1).
2) Install spring (5) to cylinder (4).
3) Install body (1) and cylinder (4) together
with bracket (3).

4. Bleeder
Install bleeder (2).
3 Bleeder screw: 10 – 20 Nm {1 – 2 kgm}

WA600-6 15
SEN01167-02

WA600-6 Wheel loader

Form No. SEN01167-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

16
 SEN01169-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Undercarriage and frame
Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight assembly ..................................................................................... 9

WA600-6 1
SEN01169-02 50 Disassembly and assembly

Removal and installation of center Removal

hinge pin 1 k Lower the work equipment to the ground
completely and stop the engine. Apply the
Special tools parking brake and put the blocks under the
wheels.
k

New/Remodel
Set the frame lock bar.
k

Necessity
Sym- Loosen the filler cap of the hydraulic tank
Part No. Part name

Sketch
bol gradually to release the residual pressure

Q'ty
from the hydraulic tank.
k Lower the work equipment to the ground
790-101-2300 Push tool t 1
completely. Release the remaining pres-
790-101-2310 • Block 1 sure in the piping, referring to “Releasing
790-101-2320 • Screw 1 remaining pressure” in work equipment
790-101-2330 • Nut 2 cylinder in Testing and adjusting.
k Disconnect the negative terminal (–) of the
790-101-2340 • Washer 1
battery before starting with the work.
790-101-2350 • Leg 2
790-101-2360 • Plate 4 1. Remove the work equipment assembly, refer-
1
790-101-2410 • Joint 2 ring to “Removal and installation of work equip-
ment assembly.”
02215-11622 • Nut 2
793-520-2640 Push tool t 1 2. Remove the floor frame assembly, referring to
790-438-1030 Guide t 1 “Removal and installation of floor frame
790-438-1050 Bar t 2 assembly.”
790-101-2102 Puller (30-ton) t 1
3. Disconnect brake hose (1).
790-101-1102 Pump t 1 4. Disconnect 4 pressure inspection hoses (2).
K 790-101-2300 Push tool t 1 5. Disconnect valve hoses (3) and (4) of the work
790-101-2310 • Block 1 equipment.
6. Disconnect valve drain hose (5) of the work
790-101-2330 • Nut 1
equipment.
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4
790-101-2410 • Joint 2
2 02215-11622 • Nut 2
790-438-1050 Bar t 2
01580-12016 Nut t 2
790-438-1010 Push tool t 1
790-438-1020 Guide t 1
790-438-1040 Screw t 1
790-101-2102 Puller t 1
790-101-1102 Pump t 1

2 WA600-6
50 Disassembly and assembly SEN01169-02

7. Disconnect the left and right grease hoses (6). 12. Use the jacks (50-ton × 2) [3] to the front and
8. Remove pin (7) on the side of the left and right rear frames to adjust height and set block [5].
steering cylinder heads. [*1]
a Check the number and the position of the
shims (8) in advance.
a Contract the rod of steering cylinder (9).

q Lower hinge pin

13. Remove retainer (12).

9. Remove drive shaft guard (10).

10. Remove drive shaft (11). [*2]
4 Drive shaft: 65 kg

14. Use the puller to remove the lower hinge pin

(13).

11. Set blocks [1] and jacks (50-ton × 2) [2] to the

counterweight.

WA600-6 3
SEN01169-02 50 Disassembly and assembly

q Upper hinge pin q Lower side front frame

15. Remove retainer (14). 19. Remove plate (19).
a Check the number of the shims in 20. Remove dust seal (20).
advance. 21. Remove retainer (21).
22. Remove dust seal (22) from retainer (21).
23. Remove bearing (23).

16. Remove the upper hinge pin (15), using the

puller.
q Upper side front frame
17. Remove bushing (16).
24. Remove bushing (24).
18. Remove the frame lock bar, pull front frame
25. Remove retainer (25).
(17) forward and disconnect the frame.
26. Remove dust seal (26) from retainer (25).
a Upper bushing of the upper hinge pin is
27. Remove bearing (27).
caught by the rear frame (18) (part B). Lift
28. Remove dust seal (28).
rear frame (18) slightly and disconnect the
frame.

q Lower side rear frame

29. Remove bushing (29).

4 WA600-6
50 Disassembly and assembly SEN01169-02

Installation 4) Measure the clearance between retainer

(21) and the hinge plate clearance at 4
q Lower side front frame equally divided points on the circumfer-
1. Use push tool K1 and block [1] to press fit ence.
bearing (23) to the front frame. 5) Combine the shims (shim pack) so that
a Don't change the bearing and spacer com- their total thickness will be 0.08 – 018
bination as the bearing clearance has (mm) less than the measured value.
been adjusted. a Standard shim thickness (B): 1 mm
2 Bearing: a Thickness of shim: 0.1, 0.5 mm
Molybdenum disulfide lubricant (LM-P) 6) Install the shim pack and tighten retainer
(21) permanently.
2 Mounting bolt:
Adhesive (Loctite No.262)
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}

2. Install dust seal (22) to retainer (21).

a Install dust seal lip (L1) so as to face out-
side.
2 Dust seal lip surface:
Molybdenum disulfide lubricant (LM-P)
q Upper side front frame
6. Use push tool K2 and press fit bearing (27) to
the front frame.
2 Bearing:
Molybdenum disulfide lubricant (LM-P)

3. Install dust seal (20).

2 Dust seal lip surface:
Molybdenum disulfide lubricant (LM-P)
4. Install plate (19).
5. Install retainer (21) in the following order.
1) Install retainer (21) avoiding one-sided
tightening.
3 Mounting bolt:
34.3 ± 3.4 Nm {3.5 ± 0.4 kgm}
2) Loosen retainer (21) mounting bolt.
3) Install retainer (21) again avoiding one-
sided tightening.
3 Mounting bolt:
34.3 ± 3.4 Nm {3.5 ± 0.4 kgm}

WA600-6 5
SEN01169-02 50 Disassembly and assembly

7. Install dust seal (26) to retainer (25).

a Install the dust seal lip so as to face out-
side.
2 Dust seal lip surface:
Molybdenum disulfide lubricant (LM-P)

q Lower side rear frame

11. Install bushing (29).

8. Install retainer (25) in the following order.

1) Install retainer (25) at every other position
avoiding one-sided tightening.
3 Mounting bolt:
68.6 ± 7 Nm {7 ± 0.8 kgm}
2) Loosen retainer (25) mounting bolt.
3) Install retainer (25) again at every other
position avoiding one-sided tightening.
3 Mounting bolt:
68.6 ± 7 Nm {7 ± 0.8 kgm}
4) Measure clearance (A) between retainer
(25) and the front frame at 4 equally
divided points on the circumference.
5) Combine the shims (shim pack) so that
their total thickness will be 0.08 – 018
(mm) less than the measured value.
a Standard shim thickness (A): 2.2 mm
a Thickness of shim: 0.1, 0.5 mm
6) Install the shim pack and tighten retainer
(25) permanently.
2 Mounting bolt:
Adhesive (Loctite No.262)
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
9. Install bushing (24).
2 (u), (v) face:
Molybdenum disulfide lubricant (LM-P)
10. Install dust seal (28).
2 Dust seal lip surface:
Molybdenum disulfide lubricant (LM-P)

6 WA600-6
50 Disassembly and assembly SEN01169-02

q Lower hinge pin

12. Install retainer (12) to lower hinge pin with 4
bolts (32).
2 Tapped hole side of the mounting bolt
(32): Liquid adhesive (Loctite No. 262)
3 Mounting bolt (32):
455 – 565 Nm {46.5 – 58 kgm}
13. Align the center of front frame (FF) and rear
frame (RF).
14. Install the lower hinge pin by taking care about
the position (*) of mounting bolt (32).
2 Lower hinge pin:
Molybdenum disulfide lubricant (LM-P)
a Degrease the tapered portion (bushing
q Upper hinge pin
contact surface). Don't allow grease and
16. Measure the thickness (t) of retainer (14) at 3
other lubricant to be attached.
hole (H) locations, before installing it.
15. Install retainer (12) with 6 bolts (33) to the fol-
lowing procedure.
2 Tapped hole side of the mounting bolt
(33): Liquid adhesive (Loctite No. 262)
1) Tighten bolts (33) in order of [1] to [6].
3 Mounting bolt (33):
235 – 285 Nm {23.5 – 29.5 kgm}
2) Tighten bolts (33) clockwise in the order of
[3], [5], [2], [4], [6], [1].
a Tighten bolts (33) in repetition until
they become immobile.
3 Mounting bolt (33):
235 – 285 Nm {23.5 – 29.5 kgm}

17. Install upper hinge pin (15) by paying attention

to the bolt hole position (see figure above).
2 Upper hinge pin:
Molybdenum disulfide lubricant (LM-P)
2 (t) face:
Molybdenum disulfide lubricant (LM-P)
18. Install bushing (16) from lower.
2 (w), (x) face:
Molybdenum disulfide lubricant (LM-P)

WA600-6 7
SEN01169-02 50 Disassembly and assembly

19. Install retainer (14) to the upper hinge with

mounting bolts (34).
3 Mounting bolt (34):
610 – 765 Nm {62.5 – 78 kgm}
20. Tighten mounting bolts (35) of retainer (14)
according to the following procedure.
1) Tighten mounting bolts (35) of retainer
(14) with specified torque.
a Take care of the tilting of retainer and
uneven bolt tightening.
a Tighten bolts (35) in repetition until
they all become immobile.
3 Mounting bolt (35):
455 – 565 Nm {46.5 – 58 kgm}
2) Measure distance (L) from the end face of
hole (H) of retainer (14) to rear frame
q Carry out the succeeding installation in the
(RF). (Hole: 3 places)
reverse order of removal.
a Subtract thickness (t) of retainer (14)
[*1]
measured in step 16 from distance (L)
1. Install O-ring (31) and pin (7).
to the rear frame to obtain clearance
a When replacing dust seal (D), install it so
(C).
that lips (L) and (LL) will be facing outside.
2 Dust seal lip: Lubricant (LM-P)
C=L-t
3) Combine the shims (shim pack) so that
a (8): Shim
their total thickness will be 0.08 – 018
Thickness of shim: 0.2, 0.5, 1.5, 3 mm
(mm) less than clearance (C).
a Thickness of shim: 0.3, 0.4, 0.5 mm
4) Remove mounting bolts (34) and (35) of
retainer (14).
2 Tapped hole side of the mounting
bolts (34) and (35):
Liquid adhesive (Loctite No. 262)
5) Assemble the shim pack and install
retainer (14) to the upper hinge pin with
mounting bolts (34).
3 Mounting bolt (34):
610 – 765 Nm {62.5 – 78 kgm}
6) Tighten mounting bolts (35) of retainer
(14) with specified torque.
a Tighten bolts (35) in repetition until
they all become immobile. [*2]
a Take care of the tilting of retainer and 3 Drive shaft mounting bolt:
uneven bolt tightening. 215 – 255 Nm {21.9 – 26.0 kgm}
3 Mounting bolt (35):
455 – 565 Nm {46.5 – 58 kgm}

8 WA600-6
50 Disassembly and assembly SEN01169-02

Removal and installation of

counterweight assembly 1
Removal
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Set the frame lock bar.

1. Lift the counterweight assembly (1) tempo-

rarily.
2. Remove mounting bolts (2) and lift counter-
weight assembly (1) to remove. [*1]
4 Counterweight assembly: 2,320 kg

Installation

q Carry out installation in the reverse order to

removal.

[*1]
3 Counterweight mounting bolt:
2,450 – 3,040 Nm {250 – 310 kgm}

WA600-6 9
SEN01169-02

WA600-6 Wheel loader

Form No. SEN01169-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

10
 SEN01171-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly

Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of hydraulic pump assembly ................................................................................... 4
Removal and installation of control valve assembly ....................................................................................... 8
Disassembly and assembly of control valve assembly ................................................................................. 10
Removal and installation of steering valve assembly ................................................................................... 15
Removal and installation of ECSS accumulator assembly ........................................................................... 16
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 17

WA600-6 1
SEN01171-02 50 Disassembly and assembly

Removal and installation of 5. Disconnect suction tube (5). [*1]

hydraulic tank assembly 1
Removal

k Lower the work equipment to the ground

completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Set the frame lock bar.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Release the remaining pressure in the pip-
ing, referring to “Releasing remaining pres-
sure in work equipment cylinder” in Testing 6. Disconnect hoses and tubes from the top of
and adjusting. the hydraulic tank.
k Disconnect the negative terminal (–) of the q (6) : Steering drain
battery before starting with the work. q (7) : Pump drain
q (8) : EPC suction
1. Drain the oil from the hydraulic tank. q (9) : Main return
6
q (10): Cooler and steering return
Hydraulic tank: approx. 443 l
q (11): Brake drain
2. Raise fender (1). q (12): Emergency steering return
3. Lift and remove the handrail and step assembly (2). q (13): Emergency steering suction
q (3): Hydraulic tank assembly
7. Lift and remove hydraulic tank assembly (3).[*2]
4 Hydraulic tank assembly: 490 kg

4. Remove cover (4).

2 WA600-6
50 Disassembly and assembly SEN01171-02

Installation
q Carry out installation in the reverse order to
removal

[*1]
1. Install suction tube (5) with the drain port (DP)
facing downward.
a Loosen bracket (14) and install suction
tube (5) so that hose (H) will be level (no
step between the left and right side of the
hose (H)).
q (3): Hydraulic tank assembly

[*2]
3 Mounting bolt:
490 – 608 Nm {50 – 62.0 kgm}

q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: approx. 443 l

q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air of various
parts.”

WA600-6 3
SEN01171-02 50 Disassembly and assembly

Removal and installation of Remove power train, hydraulic oil cooler, EPC
hydraulic pump assembly 1 and brake pump assembly by the following pro-
cedure.
Removal
k
1) Remove the floor frame assembly, referring to
Lower the work equipment to the ground
“Removal and installation of floor frame
completely and stop the engine. Apply the
assembly.“
parking brake and put the blocks under the
wheels.
k
2) Remove cover (4).
Set the frame lock bar.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: approx. 443 l

2. Remove covers (51) and (52).

3) Remove suction tube (5).

General view
(1) Power train, hydraulic oil cooler, EPC and
brake pump assembly
(2) :Work equipment hydraulic pump assembly
(3) :Steering fan pump assembly

4 WA600-6
50 Disassembly and assembly SEN01171-02

4) Disconnect hose (7) to the brake component 7) Remove washer tank (60).
box. a Disconnect connectors BL1 and BL3 from
5) Disconnect the hydraulic oil cooler hose (8). the back.
6) Disconnect hose (9) to the charge valve. 8) Remove the air cleaner cover (61).
7) Remove suction hose (10). 9) Disconnect hose clamp (62).
8) Lift and remove the power train, hydraulic 10) Disconnect dust indicator hose (63).
cooler, EPC and brake pump assembly (1). 11) Remove covers (64) to (66).
4
12) Remove frame (67).
Power train, hydraulic oil cooler, EPC
and brake pump assembly: 50 kg

Removal of work equipment hydraulic pump

assembly
1) Disconnect suction tube (11).
Removal of work equipment hydraulic pump
assembly and steering fan pump assembly
1) Remove fender (53).
2) Remove cover (54).
a A hook is provided at the top on the back
of cover (54). A pin located at the bottom
of side hood prevents cover (54) from fall-
ing when the mounting bolt is removed.
Referring to the “Removal and installation
of bulkhead assembly.“

2) Disconnect fan pump injection hose (12).

3) Disconnect air conditioner hose clamp (55).

4) Disconnect air conditioner hose (56).
5) Disconnect receiver drier bracket assembly
(57) from the frame.
6) Disconnect clamps (58) and (59).

WA600-6 5
SEN01171-02 50 Disassembly and assembly

3) Disconnect hose (13). Remove steering fan pump assembly by the fol-
4) Disconnect clamp (14). lowing procedure.
5) Disconnect valve hoses (15) and (16) of the 1) Disconnect EPC basic pressure port hose
work equipment. PEPC (20).
6) Disconnect load pressure input port hose (17). 2) Disconnect drain hose (22).
7) Disconnect pump pressure input port hose 3) Disconnect injection hose (23) to steering
(18). valve.
8) Disconnect return hose (19). 4) Disconnect load pressure input hose PLS (24).
9) Disconnect EPC basic pressure port hose 5) Disconnect load pressure pick-up port hose
PEPC (20). (25).
10) Disconnect connectors DT2 from portion (A). 6) Disconnect pump pressure input port hose (26)
(band color: green).
7) Disconnect EPC basic pressure port hose
PEPC (27).
8) Disconnect fan injection hose (28).
9) Disconnect connector R12 (29).
10) Disconnect suction tubes (30) and (31).
11) Lift and remove the steering fan pump assem-
bly (3). [*2]
4 Steering fan pump assembly: 130 kg

11) Lift and remove work equipment hydraulic

pump assembly (2). [*1]
4 Work equipment hydraulic pump assembly:
180 kg

6 WA600-6
50 Disassembly and assembly SEN01171-02

Installation
q Carry out installation in the reverse order to
removal.

[*1], [*2]
3 Upper side mounting bolt:
456 – 568 Nm {46.5 – 58 kgm}
a Since a long tool cannot enter the lower side,
first tighten with a small torque wrench. Use
wrench [1], bar [2] and hammer [3] for angle
tightening for the second time.
3 Lower side mounting bolt
First time: 33.3 ± 2.9 Nm {3.4 ± 0.3 kgm}
Second time:45 ± 5° retightening

q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: approx. 443 l

q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air of various
parts.”

WA600-6 7
SEN01171-02 50 Disassembly and assembly

Removal and installation of 4. Disconnect EPC valve connectors F24 (4), F07
control valve assembly 1 (5) and F10 (6) from the right side of control
valve assembly.
k Park the machine in a flat place. Apply
parking brake and apply chocks to the tires.
k Set the boom on the stand and check that it
does not descend.
k Set the frame lock bar.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
k Release the remaining pressure in the pip-
ing, referring to section “Releasing remain-
ing pressure in work equipment cylinder”
in “Testing and adjusting.”
k Disconnect the negative terminal (–) of the
battery before starting with the work.
5. Disconnect hydraulic oil pressure sensor con-
Removal nector F16 (7), EPC valve connectors F08 (8)
and F09 (9) from the bottom of control valve
assembly.
6. Disconnect clamp (10).
1. Drain the oil from the hydraulic tank.
6 Hydraulic tank: approx. 443 l

2. Remove cover (1).

7. Disconnect the following hoses from rear side

of the control valve assembly:
q (11): From work equipment hydraulic
pump
q (12): To bucket cylinder bottom
3. Disconnect hose (3) between the work equip- q (13): To lift arm cylinder bottom
ment and hydraulic pump from control valve q (14): To ECSS accumulator
assembly (2). q (15):To lift arm cylinder head
q Left side of (15): To lift arm cylinder bottom
q (16): To bucket cylinder bottom
q Left side of (16): To bucket cylinder head
q (17): Drain port (to hydraulic tank)
q Left side of (17): From work equipment
hydraulic pump

8 WA600-6
50 Disassembly and assembly SEN01171-02

Installation
q Carry out installation in the reverse order to
removal.

q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: approx. 443 l

q Air bleeding
8. Disconnect the following hoses. Bleed the air from the circuit between the valve
q (18): Marked with 2 red lines and the hydraulic cylinder. For details, see
q (19): Marked with 1 white line Testing and adjusting, “Bleeding air of various
q (20): Marked with 2 white lines parts.”

9. Lift control valve assembly (2) temporarily and

remove the mounting bolts.
10. Lift and remove control valve assembly (2).
a Rotate and remove control valve assem-
bly (2) from the hole.
4 Control valve assembly:
120 kg (STD)
140 kg (ECSS)

WA600-6 9
SEN01171-02 50 Disassembly and assembly

Disassembly and assembly of

control valve assembly 1
a This section deals with only precautions to be
followed when reassembling the control valve
assembly.

Special tools

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol
Q'ty

796-946-1310 Guide
2 t 1
(For 723-46-40100)
796-946-1320 Guide
T 3 t 1
(For 723-46-40100)
796-946-1330 Sleeve
4 t 1
(For 723-46-40100)

a The sectional view shows the 4-spool valve (with ECSS control valve).

10 WA600-6
50 Disassembly and assembly SEN01171-02

Procedures for replacing pressure compensa- 3. Set tool T2 to piston (2) and push it in slowly by
tion valve seal hand so that seal (5) may spread out evenly.

a Since there are many types of pressure com- a The seal may be also fitted by pushing it
pensation valve, mark the positions when down to the flat surface of the tool and
removing to correspond to the original. then pushing it in with the tool fitted to the
1. Remove piston (2), plug (3) and spring (4) from piston.
pressure compensation valve (1).

2. Remove piston (2) from seals (5) and (6).

4. Similarly to fitting of seal (5), set tool T3 to pis-

ton (2) from the same direction and push it in
slowly with the hand so that seal (6) will
expand evenly.
a The seal may be also fitted by pushing it
down to the flat surface of the tool and
then pushing it in with the tool fitted to the
piston.

a There are many types of piston.

WA600-6 11
SEN01171-02 50 Disassembly and assembly

5. Keep compensation tool T4 fitted to piston (2) Assembly of control valve assembly
for about one minutes so that seals (5) and (6)
are adapted well. q Coat the sliding surface with engine oil and
a Check that there is no protrusion or cut on then reassemble the control valve assembly.
the seal.
q Section C-C
2 Portion (P): Seal end 242 (20% diluted alco-
hol) or equivalent
a One rotation of adjustment screw changes
pressure by approx. 20.5 MPa {209 kg/cm2}.
a Identical for the left and right

6. Assemble the piston in the sleeve.

a If it is found difficult to install the piston, do
not attempt to push it in forcibly, but set it
to compensation tool T4 again and install
the piston to the sleeve after adapting the
seal.

7. Fit plug (3) and spring (4) to piston (2), then

assemble pressure compensation valve (1).
a After the installation, push the piston by
hand and check that the piston reacts only
with spring force.

12 WA600-6
50 Disassembly and assembly SEN01171-02

q Section AA-AA

a Care required for the order of tightening

After tightening plug (7), tighten nut (8).
(To seal oil with the tapered portion at the tip of
plug (7).)

q Sections K-K, J-J and H-H

aApply one drip (approx. 0.02 g) of Loctite No.

638 to plugs (9), (10) and (11) and tighten
them.
2 Plugs (9), (10) and (11):
Apply one drip (approx. 0.02 g) of Loctite
No. 638

WA600-6 13
SEN01171-02 50 Disassembly and assembly

q Control valve cover block (CB)

a Referring to the sectional view.
2 Mating face of upper and lower control valve
cover block (SE):
SEALEND 242 or equivalent
q Tighten the control valve cover block mounting
bolts according to the order shown in the fig-
ure. (A o D o C o B)
3 Control valve cover block mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}

q Plate (P)
a Referring to the sectional view.
2 Mating face (SE1) of control valve plate (P):
SEALEND 242 or equivalent
q Tighten the plate mounting bolts according to
the order shown in the figure (A o D o C o B)
3 Plate mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}

q Pressure compensation valve

a Install by checking the mark provided
when respective pressure compensation
valves were removed.

q Main relief valve assembly

After installation to the control valve, referring
to “Testing and adjusting of work equipment oil
pressure” in Testing and adjusting.

14 WA600-6
50 Disassembly and assembly SEN01171-02

Removal and installation of 10. Disconnect pilot hose (11) from the back.
steering valve assembly 1 11. Remove U-bolt (12).
12. Disconnect steering pump hose (13) from the
Special tools back.

New/Remodel
Necessity
Sym-
Part No. Part name

Sketch
bol

Q'ty
T 1 793T-664-1110 Bracket t 1 N Q

Removal
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Set the frame lock bar. 13. Using box assembly (20) mounting hole, install
k Loosen the filler cap of the hydraulic tank tool T1.
gradually to release the residual pressure 14. Remove 3 mounting bolts, and remove steer-
from the hydraulic tank. ing valve assembly (14).
k Release the remaining pressure in the pip- 15. Slide steering valve assembly (14) to lift and
ing, referring to “Releasing remaining pres- remove it.
4
sure in work equipment cylinder” in Testing Steering valve assembly: 70 kg
and adjusting.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: approx. 443 l
2. Disconnect clamp (1).
3. Lift and remove the handrail and step assem-
bly (2).
a Disconnect connector of light (L).
4. Lift and remove box assembly (20).

Installation
q Carry out installation in the reverse order to
removal

q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
5 Hydraulic tank: approx. 443 l
5. Disconnect pilot hose (3) from steering valve
assembly (14).
q Air bleeding
6. Disconnect bracket (4).
Bleed the air from the circuit between the valve
7. Disconnect steering cylinder hoses (5) and (6).
and the hydraulic cylinder. For details, see Test-
8. Disconnect drain hose (7).
ing and adjusting, “Bleeding air of various parts.”
9. Disconnect hoses (8) to (10) from (Tp) port.

WA600-6 15
SEN01171-02 50 Disassembly and assembly

Removal and installation of ECSS Installation

accumulator assembly 1 q Carry out installation in the reverse order to
removal
Removal
k Lower the work equipment to the ground q Refilling with oil (hydraulic tank)
completely and stop the engine. Apply the Refill hydraulic oil through the oil filler port to
parking brake and put the blocks under the the specified level. Let the oil circulate in the
wheels. hydraulic system by starting the engine. Then
k Set the frame lock bar. check the oil level again.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure q Air bleeding
from the hydraulic tank. Bleed the air from the circuit between the valve
k Release the remaining pressure in the pip- and the hydraulic cylinder. For details, see
ing, referring to “Releasing remaining pres- Testing and adjusting, “Bleeding air of various
sure in work equipment cylinder” in Testing parts.”
and adjusting.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Remove cover (1).

2. Disconnect fuel hose (2).

3. Remove clamp (3), lift and remove ECSS
accumulator assembly (4).
4 ECSS accumulator assembly: 130 kg

16 WA600-6
50 Disassembly and assembly SEN01171-02

Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Piston rod assembly
1) Remove piping from the cylinder assem-
Special tools bly.
2) Remove the mounting bolts and then dis-

New/Remodel
connect head assembly (1).

Necessity
Sym- 3) Pull out piston rod assembly (2).
Part No. Part name

Sketch
bol a Place a container under the cylinder

Q'ty
to catch the oil.
Cylinder repair
790-502-1003 q 1
1 stand
790-101-1102 Pump q 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
796-720-1690 Ring (For lift arm) q 1
07281-02169 Clamp q 1
Ring
796-720-1720 q 1
(For bucket)
4
07281-02429 Clamp q 1
Ring 4) Disassemble the piston rod assembly as
796-720-1660 q 1
(For steering) follows.
07281-01159 Clamp q 1 1] Set piston rod assembly (2) in tool U1.
U 790-201-1702 Push tool kit t 1
• Push tool
790-201-1881 (For lift arm and 1
bucket)
5
• Push tool
790-201-1821 1
(For steering)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 • Plate 2] Remove stopper screw (3) of piston
790-201-1690 (For lift arm and 1
assembly (4).
bucket)
a Common for the lift arm, arm and
• Plate bucket cylinders
790-201-1630 1
(For steering) Screw size: M12 × pitch 1.75

WA600-6 17
SEN01171-02 50 Disassembly and assembly

a If the caulking of screw (3) is too 2. Disassembly of piston assembly

strong and it cannot be removed, 1) Remove ring (11).
tighten the screw fully, then fit tap (T) 2) Remove wear ring (12).
to the thread and remove the screw. 3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).

3] Using tool U2, remove piston assem-

bly (4). 3. Disassembly of cylinder head assembly
q When not using tool U2, use the 1) Remove O-ring and backup ring (15).
drill holes (H) (φ10: 2 places) and 2) Remove snap ring (16) and then remove
loosen piston assembly. dust seal (17).
4] Remove head assembly (1) from pis- 3) Remove rod packing (18).
ton rod assembly (2). 4) Remove buffer ring (19).
5) Remove busing (20).

18 WA600-6
50 Disassembly and assembly SEN01171-02

Assembly
a Be careful not to damage the packing, dust
seals, and O-rings.
a Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
a Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) before
installing it.
1. Assembly of head assembly
1) Using tool U5, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool U6, install dust seal (17), and
secure with snap ring (16).
5) Install the backup ring and O-ring (15).

3. Piston rod assembly

1) Install head assembly (1) to piston rod
assembly (2).
2) Set piston rod assembly (2) in tool U1.

2. Assembly of piston assembly

1) Using tool U3, expand piston ring (13).
a Set the piston ring on tool U3, and
t ur n th e h an dl e 8 – 1 0 t im e s t o
expand the ring.
2) Set tool U4, and compress piston ring
(13).
3) Install the backup ring and O-ring (14).
4) Assemble wear ring (12).
5) Assemble ring (11).
a Be careful not to open the end gap of
the ring too wide.
2 Ring groove: Grease (G2-LI)

WA600-6 19
SEN01171-02 50 Disassembly and assembly

3) Assemble piston assembly (4) as follows. q When using a new part for either or
both of piston rod assembly (2) and
q When using piston rod assembly (2) piston assembly (4)
and piston assembly (4) again
1] Screw in piston assembly (4) until it
a Wash thoroughly and remove all metal makes contact with the rod end sur-
particles and dirt. face (B). Use tool U2 (noted in the
1] Screw in piston assembly (4) by using foregoing) to tighten it.
tool U2, and tighten piston assembly 3 Piston assembly:
(4) until the position of the screw 294 ± 29.4Nm {30 ± 3.0kgm}
thread hole (H1) which is in piston rod
assembly (2) halfway matches.
a Remove all burrs and flashes on
the threaded portion with a file.

2] Machine one of the holes used to

install screw (3).
a Align a drill horizontal with the V-
groove of the thread of piston rod
2] Tighten screw (3). assembly (2) and piston assem-
2 Screw part female screw side: bly (4), then carry out machining.
Loctite No.262 q Screw machining dimension
3 Screw: (mm)
58.9 – 73.6 Nm {6 – 7.5 kgm}
Prepara-
3] Caulk thread at four places (a) of Prepara-
tion hole Tapping
screw (3) with punch. tion hole Screw size
drill diam- depth
depth
eter
24 *1 20 *1
10.3 12 × 1.75
43 *2 36 *2

*1: Steering cylinder

*2: Bucket cylinder and lift arm cylinder

20 WA600-6
50 Disassembly and assembly SEN01171-02

3] After machining, wash thoroughly to 5) Tighten head assembly (1) with mounting
remove all metal particles and dust. bolts.
4] Tighten screw (3). 3 Mounting bolt:
2 Screw part female screw side:
Cylinder name Tightening torque
Loctite No.262
3 Screw: Steering 270 ± 39 Nm {27.5 ± 4.0 kgm}
58.9 – 73.6Nm {6 – 7.5kgm} 1,670 ± 250 Nm
Bucket
5] Caulk thread at four places (a) of {170 ± 25 kgm}
screw (3) with punch. 1,270 ± 200 Nm
Lift arm
{130 ± 20 kgm}

4) Assemble the cylinder tube to piston rod

assembly (2).
a Align axial center of the cylinder tube, 6) Install piping.
then insert.
a Check that the ring is not broken and
has not come out, then push in fully.

WA600-6 21
SEN01171-02

WA600-6 Wheel loader

Form No. SEN01171-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

22
 SEN01174-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2

WA600-6 1
SEN01174-02 50 Disassembly and assembly

Removal and installation of work 3. Move the machine to backward and disconnect
equipment assembly 1 the bucket.

Removal 4. Disconnect pin lubrication hose (3).

k Park the machine on flat ground and set the 5. Lift bucket cylinder assembly (4) temporarily,
safety bar to the frame. pull out rod pin (5). Then disconnect the cylin-
k Lower the work equipment to the ground com- der rod and bell crank. [*3]
pletely and stop the engine. Apply the parking a Install block between the cylinder bottom
brake and put the blocks under the wheels. and frame.
k Disconnect the negative terminal (–) of the a Check the thickness and number of the
battery before starting with the work. shims in advance.
4 Rod pin: 40 kg
1. Lift the bucket link temporarily, and remove
bucket link pin (1). [*1] 4 Bucket cylinder assembly: 550 kg
4 Bucket link pin: 35 kg

a Fix the bucket link to the bell crank using a

wire.
a Check the thickness and number of the
shims in advance.

6. Install support stands [2] at the end of the lift

arm, and release the remaining pressure in the
hydraulic piping.

2. Remove bucket hinge installing pin (2). [*2]

k Absolutely do not insert fingers into
the pin hole.
a Check the thickness and number of the
shims in advance.
4 Bucket hinge pin: 35 kg

2 WA600-6
50 Disassembly and assembly SEN01174-02

7. Sling lift arm cylinder assembly (7) temporarily

and remove installing pin (6). [*4]
a Check the thickness and number of the
shims in advance.
a When lowering the lift arm cylinder assem-
bly, put the block into the top of the axle.
4 Rod pin: 35 kg
4 Lift arm cylinder assembly (1 piece): 530 kg

13. Lift bucket link assembly (16) temporarily.

14. Remove installing pin (15) and remove bucket
link (16) from bell crank (14). [*7]
a Check the thickness and number of the
shims in advance.
4 Bucket link pin: 35 kg
4 Bucket link: 300 kg

8. Remove cover (8).

9. Disconnect lift arm angle sensor connector
F13 (9).
10. Remove lift arm angle sensor assembly (10). [*5]

15. Lift lift arm assembly (13) temporarily.

16. Remove lift arm installing pin, lift and remove
lift arm assembly (13). [*8]
4 Mounting pin: 45 kg
4
11. Lift bell crank and bucket link assembly (11)
Lift arm assembly: 3,950 kg
temporarily.
12. Remove installing pin (12) and disconnect from
lift arm assembly (13). [*6]
4 Mounting pin: 65 kg
4 Bucket link and bell crank: 1,650 kg

WA600-6 3
SEN01174-02 50 Disassembly and assembly

17. Pull out dust seal (17) and bushing (18) from Installation
lift arm (13). [*9] q Carry out installation in the reverse order to
removal

k Use a bar to mach the pin holes. Absolutely

do not insert fingers.

a Apply specified lubricant to the seal. Take care

not to damage seal when installing the pin.
a Supply grease to each pin until it comes out
through the joint.

[*1]
Installation of bucket link pin
a Apply lubricant to inside the bushing and seal
18. Pull out dust seal (19) and bushing (20) from before installing the pin.
bell crank (14). [*9] 2 Inside bushing and seal:
Molybdenum disulfide lubricant (LM-P or
equivalent) or Hyper white (G2-T)
1. Lift the bucket link, align the hole of installing
pin (1) and install cord ring (23).
a Apply lubricant or grease to the cord ring
groove.
2 Cord ring groove:
Molybdenum disulfide lubricant
(LM-G or equivalent) or Grease
(G2-LI)

2. Insert shims so that clearance (a) is equal on

the left and right.
q Clearance (a) (each left and right):
19. Pull out dust seal (21) and bushing (22) from Max. 1.5 mm
q Shim thickness and type: 1.5 mm
bucket link (16). [*9]
3. Assemble installing pin (1) and tighten bolt (24)
to lock it.
k Absolutely do not insert fingers into
the pin hole.
a Take care not to damage the pin and seal.
a Take care that the cord ring is not
engaged.

4 WA600-6
50 Disassembly and assembly SEN01174-02

a Apply lubricant after installing the pin. [*3]

2 Greasing Installation of bucket cylinder pin (rod side)
Molybdenum disulfide lubricant (LM-G or a Apply lubricant to inside the bushing and seal
equivalent) or Hyper white (G2-T) before installing the pin.
[*2] 2 Inside bushing and seal:
Installation of bucket hinge pin Molybdenum disulfide lubricant (LM-P or
a Apply lubricant to inside the bushing and seal equivalent) or Hyper white (G2-T)
before installing the pin. a Shim not required for clearance (c)
2 Inside bushing and seal: 1. Assemble installing pin (5) and tighten bolt (27)
Molybdenum disulfide lubricant (LM-P or to lock it.
equivalent) or Hyper white (G2-T) k Absolutely do not insert fingers into
1. Operate the control lever, align the hole of the pin hole.
bucket installing pin (2) and install cord ring a Take care not to damage the pin and seal.
(25).
a Apply lubricant or grease to the cord ring
groove.
2 Cord ring groove:
Molybdenum disulfide lubricant (LM-
G or equivalent) or Grease (G2-LI)

2. Install shim to clearance (b).

q Clearance (b) (each left and right):
Max. 1.5 mm
q Shim thickness and type: 1.5 mm

3. Assemble installing pin (2) and tighten bolt (26)

to lock it.
k Absolutely do not insert fingers into
2. Adjust the bucket positioner, referring to sec-
tion “Testing and adjusting bucket positioner” in
the pin hole.
“Testing and adjusting.”
a Take care that the cord ring is not
engaged.
a Take care not to damage the pin and seal.

a Apply lubricant after installing the pin.

2 Greasing
Molybdenum disulfide lubricant (LM-
G or equivalent) or Hyper white (G2-T)

WA600-6 5
SEN01174-02 50 Disassembly and assembly

[*4]
Installation of lift arm cylinder pin (rod side)
a Apply lubricant to inside the bushing and seal
before installing the pin.
2 Inside bushing and seal:
Molybdenum disulfide lubricant (LM-P or
equivalent) or Hyper white (G2-T)
a Shim is not required.
1. Assemble installing pin (6) and tighten bolt (28)
to lock it.
k Absolutely do not insert fingers into
the pin hole.
a Take care not to damage the pin and seal.
a Apply lubricant after installing the pin.
2 Greasing
Molybdenum disulfide lubricant (LM-
G or equivalent) or Hyper white (G2-T)
[*7]
Installation of bucket link pin
a Shim is not required.

1. Align the hole of bucket link installing pin (15)

and install cord ring (30).
a Apply lubricant or grease to the cord ring
groove.
2 Cord ring groove:
a Apply lubricant after installing the pin. Molybdenum disulfide lubricant (LM-
2 Greasing G or equivalent) or Grease (G2-LI)
Molybdenum disulfide lubricant (LM-
G or equivalent) or Hyper white (G2-T) 2. Assemble installing pin (15) and tighten bolt
[*5] (31) to lock it.
a Adjust the lift arm position detecting lever, k Absolutely do not insert fingers into
referring to section “Testing and adjusting lift the pin hole.
arm position detecting lever” in “Testing and a Take care that the cord ring is not engaged.
adjusting.” a Take care not to damage the pin and seal.
a Apply lubricant to inside the bushing and
[*6] seal before installing the pin.
Installation instructions for bell crank center pin 2 Inside bushing and seal:

a Apply lubricant to inside the bushing and seal Molybdenum disulfide lubricant (LM-P
before installing the pin. or equivalent) or Hyper white (G2-T)
2 Inside bushing and seal:
Molybdenum disulfide lubricant (LM-P or
equivalent) or Hyper white (G2-T)
a Shim is not required.
1. Assemble installing pin (12) and tighten bolt
(29) to lock it.
k Absolutely do not insert fingers into
the pin hole.
a Take care not to damage the pin and seal.

6 WA600-6
50 Disassembly and assembly SEN01174-02

[*8] 2. Assemble dust seals (17), (19) and (21).

Installation of lift arm pin (Frame side) a Install dust seal lip so as to face outside.
a Apply lubricant to inside the bushing and seal
before installing the pin.
2 Inside bushing and seal:
Molybdenum disulfide lubricant (LM-P or
equivalent) or Hyper white (G2-T)
1. Install shim to clearance (d).
q Clearance (d) (each left and right):
Max. 1.5 mm
q Shim thickness class: 1.5 mm

2. Assemble installing pin (32) and tighten bolt

(33) to lock it.
k Absolutely do not insert fingers into
the pin hole.
a Take care not to damage the pin and seal.

[*9]
1. Using hydraulic cylinder [3], etc., press fit
bushings (18), (20) and (22) to lift arm (13), bell
crank (14) and bucket link (16) respectively.
q Bushing mounting dimension (e): 12.5 mm

WA600-6 7
SEN01174-02

WA600-6 Wheel loader

Form No. SEN01174-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

8
 SEN01175-02

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Cab and its attachments
Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator's cab glass (stuck glass)....................................................................... 6
Removal and installation of floor frame assembly ........................................................................................ 14
Disassembly and assembly of operator’s seat assembly ............................................................................. 17
Removal and installation of air conditioner unit assembly ............................................................................ 50

WA600-6 1
SEN01175-02 50 Disassembly and assembly

Removal and installation of 7. Remove cover (8) and internal air filter.
operator's cab assembly 1 8. Remove plate (9).
9. Remove 3 mounting bolts (11) and remove
Removal duct (10).
10. Remove 4 mounting bolts, then remove duct
k Disconnect the negative terminal (–) of the (12).
battery before starting with the work.

1. Open cover (1).

2. Remove box (2).
3. Remove covers (3) and (4).
a Place the left console (LC) in front.

11. Remove covers (13) to (15).

4. Disconnect hose (5) from the side of the air

conditioner unit.
5. Remove box (6).
6. Remove mat (7).

12. Remove cover (16).

2 WA600-6
50 Disassembly and assembly SEN01175-02

13. Remove bracket (17). 17. Connector CN17 (22): Disconnect accelerator
microswitch.
18. Connector CN18 (23): Disconnect brake pedal
cancel switch.
a For round handle specification only

14. Remove bracket (18).

15. Remove hose and duct assemblies (19) and
(20).
19. Disconnect connectors CN CL16 (24), CN
CL17 (25) and CN CL18 (26).

16. Disconnect link (21).

a AJSS specification only (excluding round
handle)
20. Remove bracket mounting bolts (27) between
the column and cab.
a For round handle specification only

WA600-6 3
SEN01175-02 50 Disassembly and assembly

21. Remove left and right covers (28). 25. Disconnect connector CN-C58 (37) from the
front right side of the operator's cab.
a For VHMS specification only

26. Disconnect connector CN V34 (38).

a For ORBCOM specification only

22. Remove covers (29) and (30).

27. Disconnect window washer hose (39).

28. Remove the clamp and disconnect window
washer hose (40).
29. Disconnect connectors CN-CL11 (41), CN-
CL12 (42) and CN-CL13 (43).
30. Remove the clamps (44) and (45) to discon-
nect wiring harness (46) and window washer
hose (40).
31. Remove left and right mounting bolts (47) and
(48) from lower. [*2]
23. Remove mounting bolts (31) and (32) from 32. Lift and remove operator's cab assembly (49).
lower, then remove left and right mounting [*3]
4
bolts (33) from top to assemble the operator's
Operator's cab assembly: 1,100 kg
cab and floor frame.
24. Remove left and right mounting bolts (34) from
top, to disassemble the operator's cab and
floor frame. [*1]

When self-driving without the cab during

transportation
Arrange for the following parts:
q Wiring harness:
426-06-31540
q Descriptive plate in English:
426-98-33410

4 WA600-6
50 Disassembly and assembly SEN01175-02

Installation k After installing the floor mat, check if

q Carry out installation in the reverse order to the brake valve boot (B) is crushed.
removal a Also check if the accelerator pedal boot is
crushed.
[*1] q Example of bad boot condition where
3 Operator's cab mounting bolt (34) (2 bolts, the boot (B) is crushed
upper): 883 – 981 Nm {90 – 100 kgm}

[*2]
3 Operator's cab mounting bolt (47) (4 bolts,
front): 883 – 981 Nm {90 – 100 kgm}

3 Operator's cab mounting bolt (48) (8 bolts,

rear): 1,157 – 1,442 Nm {118 – 147 kgm}

[*3]
Replace seal (S) between the operator's cab and
floor frame.
1. Remove greases and dusts from the pasting q Example of good boot condition where
face. the boot (B) is not crushed
2. Attach seal (S) aligning the upper circumfer-
ence of the floor frame.
q (a): R10 – 20 mm
a Have the seal ends (P) closely adhered
mutually without any gap. (Portion A)
q (b): 20 mm

WA600-6 5
SEN01175-02 50 Disassembly and assembly

Removal and installation of operator's cab glass (stuck glass) 1

a Operator's cab window glass is wholly of stuck (1): Right door window glass
glass type. (2): Rear window glass of right door
a In this section, the procedure for replacing the (3): Left door window glass
stuck glasses is explained. (4): Rear window glass of left door
(5): Rear window glass
(6): Seal (both-sided adhesive tape)
(7): Front window glass
(8): Right front side window glass
(9): Left front side window glass
(10): Weather strip

6 WA600-6
50 Disassembly and assembly SEN01175-02

Special tools a If the window glass is broken finely, it may

be removed with a knife [4] and a screw-

New • Remodel
driver.
a Widening the cut with a flat blade screw-

Essentiality

Illustration
Sym-
Part number Part name driver, cut the dam rubber and adhesive

Quantity
bol
with knife [4].

1 793-498-1210 Lifter (Suction cup) t 2 (The figure shows the operator's cab of a
X wheel loader.)
2 20Y-54-13180 Stopper rubber t 2

Removal
a Remove the window glass to be replaced
according to the following procedure.
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).

2. Remove the window glass.

a If a seal cutter is not available, make holes

on the adhesive and dam rubber with a
drill and pass a fine wire (piano wire, etc.)
[2] through the holes. Then, grip the both
ends of the wire with priors [3], etc. (or
hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and dam rubber.
Since the wire may be broken by the fric-
tional heat, apply lubricant to the wire.
(The figure shows the operator's cab of a
wheel loader.)

WA600-6 7
SEN01175-02 50 Disassembly and assembly

Installation Preparation
1. Using a knife and scraper [5], remove the
Processing sequence remaining adhesive and dam rubber from the
metal sheets (glass sticking surfaces) of the
Preparation (cleaning) operator's cab.
a Remove the adhesive and dam rubber to
O a degree that they will not affect adhesion
of the new adhesive. Take care not to
Primer coating scratch the painted surfaces.
q Cab side: SUNSTAR 435-95 (If the painted surfaces are scratched,
q Glass side: SUNSTAR 435-40 adhesion will be lowered.)

O After applying the primer, leave it for at (The figure shows the operator's cab of a
least 5 minutes to dry (proceed to the next wheel loader.)
step within 24 hours).

Apply both-sided adhesive rubber (on the cab

side).

a Only for the front glass and the front side glass
Install weather strip to the window glass.
Inject the following to between the weather strip
and glass:
Silicone sealant (ThreeBond 5211E)

Positioning of window glass 2. Remove oil, dust, and dirt, etc. form the stick-
ing surfaces of cab (8) and window glass (9)
O with white gasoline.
a If the sticking surfaces are not cleaned
Apply adhesive (SUNSTAR Industry sealant Peta- well, the glass may not be stuck perfectly.
Seal 551) (on the cab side) a Clean the all black part on the back side of
the window glass.
O Within 5 minutes a After cleaning the sticking surfaces, leave
them for at lease 5 minutes to dry.
Adhere window glass (The figure shows the operator's cab of a
* Hold the glass pressed for 10 hours minimum. wheel loader.)

O 8 hours minimum (a Only for the front

glass and the front side glass)

Seal between the front glass and front side glass.

Adhesive (SUNSTAR PENGUINE SEAL No. 2505)
* Don't move the glass for 24 hours minimum.

8 WA600-6
50 Disassembly and assembly SEN01175-02

Primer coating 3) Apply primer for coating evenly around

3. Apply primer (10). whole of the circumference for coating on
a The using limit of primer is 4 months after operator's cab (8).
the date of manufacture. Do not use the (a): Min. 25 mm
primer after this limit. 2 Paint primer for the cab:

a Use the primer within 2 hours after SUNSTAR 435-95

unpacking it. a Do not apply the primer more than 2
a Even if the primer is packed again just times.
after it is unpacked, use it within 24 hours (If it is applied more than 2 times, its
after it is unpacked for the first time. performance will be lowered.)
(Discard the primer 24 hours after it is a Never apply the wrong primer.
unpacked.) If the glass primer, etc. is applied by
1) Stir the primers for both of paint and glass mistake, wipe it off with white gaso-
sufficiently before using them. line.
a If the primer has been stored in a a After applying the primer, leave it for
refrigerator, leave it at the room tem- at least 5 minutes to dry. Proceed to
perature for at least half a day before applying both-sided adhesive tape
stirring it. within 24 hours.
(If the primer is unpacked just after (The figure shows the operator's cab on a
taken out of the refrigerator, water will power shovel.)
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.

a (9): Glass

WA600-6 9
SEN01175-02 50 Disassembly and assembly

4) Apply primer for coating glass around Adhere both-sided adhesive tape
whole of the inner circumference for black 4. Stick both-sided adhesive tape (6) along the
coating of window glass (9). inside edge of cab (8).
(a): Min. 25 mm a Do not remove the release tape of dam
2 Glass primer: SUNSTAR 435-40 rubber on the glass sticking side before
a Black coating on glass is for protec- sticking the glass.
tion against optical degradation. a When sticking the dam rubber, do not
a Do not apply the primer more than 2 touch the cleaned surface to the utmost.
times. a Take particular care for preventing the
(If it is applied more than 2 times, its adhesive tape from floating at the corner.
performance will be lowered.) a When sticking both-sided adhesive tape
(6) around the edge completely, don't
allow the both ends of the tape to be over-
lapped when jointed. Or provided a clear-
ance of about 5 mm at the joint (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a (The figure shows the operator's cab
on a power shovel.)

a (8): Cab

a Never apply the wrong primer.

If the paint primer, etc. is applied by
mistake, wipe it off with white gaso-
line.

10 WA600-6
50 Disassembly and assembly SEN01175-02

a (6): Adhesive tape Adhesive coating

a (8): Cab 6. Preparation for applying adhesive
a (a): Range for applying primer (noted q Adhesive:
in the foregoing) SUNSTAR Industry sealant Peta-Seal
a (15): Adhesive (to be described later) 551
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part form the nozzle tip.

1) Set adhesive cartridge (12) to caulking

gun [7].
a An electric caulking gun is more effi-
Positioning of window glass cient.
5. Position the new window glass.
1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then posi-
tion the window glass to be the clearances
evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line (n).
a Apply tape [6] to three locations
including the left and right sides and
the bottom of glass for precise posi-
tioning.
3) Cut the tape between window glass (9)
2) Cut the tip of the adhesive nozzle (14) so
and operator's cab (8) with a knife, etc.
that dimensions (q) and (r) will be as fol-
and then remove the window glass.
lows.
a Do not remove the release tape of the
q Dimension (q): 10 mm
both-sided adhesive tape before the
q Dimension (r): 15 mm
glass is installed.
(The figure shows the operator's cab on a
power shovel.)

3) Remove the release tape of dam rubber

on the glass adhesive side.

WA600-6 11
SEN01175-02 50 Disassembly and assembly

7. Apply adhesive. Installation of window glass

a Apply adhesive (15) to dimensions (s) and 8. Install the window glass.
(t) in the figure to the both-sided adhesive 1) Install window class (9), matching it to the
tape (6) of operator's cab (8). lines of the positioning tapes drawn in step
q Dimension (s): 10 mm 5.
q Dimension (t): 15 mm a Since the window glass cannot be
2 Adhesive: removed and stuck again, stick it with
SUNSTAR Industry sealant Peta-Seal utmost caution.
551 2) After sticking window glass (9), press all
a Apply adhesive (15) higher than dam rub- around of it until it sticks to the dam rubber
ber (6). closely.
a Apply the adhesive evenly with same a Press the corners of the window glass
height level. firmly.
a (a): Range for applying primer (noted in (The figure shows the operator's cab on a
the foregoing) power shovel.)

a Install window glass within 5 minutes after

applying the adhesive.

a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X1.

a Wipe off the projected adhesive.

12 WA600-6
50 Disassembly and assembly SEN01175-02

9. Fix the window glass. 10. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator's cab and window glass.
X2 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
(The figure shows the operator's cab on a a When cleaning the glass, do not give an
power shovel.) impact on it.

a Only for the front glass and the front side

glass
11. Seal section (A) between front glass (7) and
front side glass (8) and (9).
2 Section (A): Adhesive (SUNSTAR PEN-
GUINE SEAL No. 2505)
q (b): 5mm
a Don't move the glass for 24 hours mini-
mum.

2) To adhere the window glass and the both-

sided adhesive tape completely, use styro-
foam [9] and rubber band [10] to fix them
tightly for 10 hours minimum to cure.
(The figure shows the operator's cab on a
power shovel.)

WA600-6 13
SEN01175-02 50 Disassembly and assembly

Removal and installation of floor q AJSS specifications (excluding round han-

frame assembly 1 dle)
4. Disconnect hoses (6) to (9) from the AJSS
Removal valve (lower left side of floor frame).
5. Disconnect clamp (10).
k Lower the work equipment to the ground 6. Disconnect hoses (11) (band color: green) and
completely. Release the remaining pres- (12) (no band).
sure in the piping, referring to “Releasing
remaining pressure in work equipment cyl- q Common specifications
inder” in Testing and adjusting. 7. Disconnect hoses (13) to (15).
k Disconnect the negative terminal (–) of the
battery before starting with the work.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere. q Round handle specification
8. Disconnect hoses (16) to (19).
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.

1. Disconnect clamp (3).

2. Disconnect heater hose (4).
a Confirming their destination.
3. Disconnect air conditioner hose (5). [*1]

14 WA600-6
50 Disassembly and assembly SEN01175-02

9. Disconnect hoses (20) to (23) from the right q AJSS specifications (excluding round han-
brake valve. dle)
10. Disconnect drain hose (24). 13. Disconnect rod (31).
a Disconnect the clamp. a Check and record the installed length.

11. Disconnect clamp (25). 14. Disconnect air conditioner wiring harness con-
12. Disconnect hoses (26) to (30) from the left nector CL13 (32), front frame wiring harness
brake valve. connector FL11 (33) and transmission wiring
harness connector LT1 (34) from the lower
right corner of the floor frame.
a Disconnect the clamp.
15. Disconnect grounding wire (35).
16. Disconnect clamp (36).

WA600-6 15
SEN01175-02 50 Disassembly and assembly

17. Disconnect the following connectors from Installation

lower of the rear floor frame: q Carry out installation in the reverse order to
q From the upper left section: BV2 (37), LR7 removal
(38), LR11 (39) and LR1 (40)
q From lower left section: [*1]
BV1 (41), BL1 (42), LR2 (43), LR3 (44), a Install hoses without twists.
LR4 (45) a Carefully install the air conditioner hose piping,
FL7: For side work lamp (If equipped) preventing dirt, dusts, water content, etc. from
FL6: For side work lamp (If equipped) entering the hoses.
18. Disconnect clamp (46). a Before tightening, make sure O-ring (70) is
19. Disconnect connector BL2 (47). provided in the air conditioner hose piping con-
20. Disconnect bracket (48). nection.
a Amply apply the compressor oil for R134a
(Denso: ND-OIL8 or Zexel: ZXL100PG
(PAG46 or equivalent)) to the O-rings.

21. Remove floor frame assembly (49).

a Lift the floor frame assembly gently while
3
checking for any undisconnected clamp,
hose, harness, etc. Air conditioner gas piping tightening torque

4 Floor frame assembly: 320 kg Screw size Tightening torque

16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

q Filling of air conditioning gas

Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 850 ± 50g

q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.

16 WA600-6
50 Disassembly and assembly SEN01175-02

Disassembly and assembly of 2. Removal and installation of seat pad and

operator’s seat assembly 1 backrest upholstery

[ Manufactured by GRAMMER ]

a Although the machine of the joystick steering

specification is not equipped with the left arm-
rest, its operator's seat assembly are also dis-
assembled and assembled according to the
following procedure.

I. Upper seat

1. Removal and installation of storage box

Removal
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Undo the 4 screws (1), and remove the
backrest upholstery (2).
3) Undo the 5 screws (4), and remove the
seat pad (5).
4) Disconnect the connectors (3) and (6).

Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5
Removal screws (4).
1) Open the storage box (1). 3) Install the backrest upholstery (2), and fix
2) Remove the hook (3). it with the 4 screws (1).
3) Undo the screws (2) and remove the stor- 4) Install the storage box by referring to "1.
age box (1). Removal and installation of storage box".

Installation
1) Set the storage box (1) and fix it with the
screws (2).
2) Install the hook (3).

WA600-6 17
SEN01175-02 50 Disassembly and assembly

3. Removal and installation of mechanical 4. Removal and installation of armrests

lumbar support (If equipped)

Removal Removal
1) Remove the storage box by referring to "1. 1) Remove the cover (1).
Removal and installation of storage box". 2) Unscrew the hexagon nuts (2) and
2) Remove the backrest upholstery by refer- remove the nuts and washers (3).
ring to "2. Removal and installation of seat 3) Remove the armrests (4).
pad and backrest upholstery".
3) Drill off the rivets (1), loosen the spring
steel sheets (2) from the L-bar (3) and Installation
remove them. 1) Set the armrests (4).
4) Unhook the L-bars (3) from the catch ele- 2) Put the washers (3) and tighten hexagon
ment (4). nuts (2).
5) Undo the hexagon socket screw (5) and 3 Hexagon nuts: 25 Nm {2.6 kgm}
remove the adjusting knob (6) with the 3) Install the cover (1).
toothed wheel (7).
6) Drill off the rivet (8), remove the wrap
spring brake element (9) and the catch
element (4).

Installation
1) Install the wrap spring brake element (9)
and the catch element (4), and fix them
with the rivets (8).
2) Install the adjusting knob (6) and the
toothed wheel (7), and tighten the hexa-
gon socket screw (5).
3) Install the catch element (4) to the L-bars
(3) and fix with the rivets (1).
4) Install the 2 spring steel sheets (2) to the
L-bar (3), and fix with the rivets (1).
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
Removal and installation of storage box".

18 WA600-6
50 Disassembly and assembly SEN01175-02

5. Disassembly and assembly of backrest

Removal a Insert the bearing (B/8) into the upper

1) Detach the storage box by referring to "1. hole on the backrest support on the
Removal and installation of storage box". right side (figure B/4).
2) Remove the backrest upholstery by refer- 2) Press the backrest (1) slightly to the left
ring to "2. Removal and installation of seat and install it.
pad and backrest upholstery". a The big cylindrical stamping on the
3) Remove the armrests by referring to "4. backrest adjustment (figure C/2) must
Removal and installation of armrests". (If engage into the big positional bore
equipped) hole on the backrest support on the
4) Disassemble the backrest adjustment by left side (figure C/3).
referring to "6. Disassembly and assembly a The integral catch on the backrest
of backrest adjustment". (figure A/1) must engage into the tor-
5) Unscrew the hexagon nut (5) and remove sion spring (figure A/9).
the washers (6) and (7). 3) Put the washer (10) and tighten the hexa-
6) Remove the hexagon bolt (11) and the gon bolt (11).
washer (10). 4) Put the washers (6) and (7), and tighten
7) Press the backrest (1) slightly to the left the hexagon nut.
and take it off upwards. 3 Hexagon nuts: 25 Nm {2.6 kgm}
8) Remove the bearing (8) and the torsion 5) Assemble the backrest adjustment by
spring (9) from the backrest (1). referring to "6. Disassembly and assembly
of backrest adjustment".
Installation 6) Install the armrests by referring to "4.
1) Install the bearing (8) and the torsion Removal and installation of armrests". (If
spring (9) to the backrest (1). equipped)
a Oil the bearing point (Q) on the back-
rest (1) for the bearing (8) with acid-
free multiple-purpose lubricant.

WA600-6 19
SEN01175-02 50 Disassembly and assembly

7) Install the backrest upholstery by referring 7. Disassembly and assembly of seat angle
to "2. Removal and installation of seat pad and seat depth adjuster
and backrest upholstery".
8) Install the storage box by referring to "1.
Removal and installation of storage box".

6. Disassembly and assembly of backrest

adjustment

Disassembly
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Remove the backrest upholstery by refer-
ring to "2. Removal and installation of seat
pad and backrest upholstery".
3) Remove the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
Disassembly
4) Fold the backrest (1) forwards.
1) Remove the seat pad by referring to "2.
5) Unscrew 3 flat-headed screws (2), remove
Removal and installation of seat pad and
the adaptor plate (3) and the flat-headed
backrest upholstery".
screw (4).
2) Remove the switch by the following proce-
6) Remove the lever (5) and handle (6).
dure. (If equipped)
1] Disconnect the spring (1).
2] Tilt the switch-plate (2) forwards and
Assembly
remove it.
1) Fold the backrest(1) forwards.
3] Drill off the rivet (3) and remove the
2) Install the handle (6) and the lever (5).
seat switch (4).
3) Tighten the 3 flat-headed screws (4),
install the adaptor plate (3) and then
tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4)
must engage into the nut of the adap-
tor plate (3).
3 Flat-headed screw:
12 Nm {1.2 kgm}
4) Install the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
Removal and installation of storage box".

20 WA600-6
50 Disassembly and assembly SEN01175-02

3) Remove the flexible support plate (7) by 1] Turn the lever (14) clockwise until it
the following procedure. snaps-in, install the plate (15).
1] Press the spring plate (5) ("P" posi- 2] Install the spring (13) to hook (a) of
tion) inwards (arrow), operate the the lever (14) and hook (b) of the
lever for seat angle adjustment (6). plate (15).

2] Pull the flexible support plate (7) to 3] Install the cover (9), the levers for
backwards and remove it. seat angle and seat depth adjustment
4) Remove the plate (15) by the following (6), (10), the linkage rod (11) and the
procedure. locking lever (12), then tighten the
1] Drill off the rivet and remove the hexagon socket screws (8).
spring steel sheet (5). 4] Install the spring steel sheet (5) and
2] Unscrew the hexagon socket screws fix it with the rivet.
(8), remove the cover (9), the levers 6) Install the flexible support plate by the fol-
for seat angle and seat depth adjust- lowing procedure.
ment (6), (10), the linkage rod (11) 1] Press the spring plate (5) ("P" posi-
and the locking lever (12). tion) inwards (arrow), operate the
3] Remove the spring (13). lever for seat angle adjustment (6).
4] Turn the lever (14) clockwise until it 2] Swivel the flexible support plate (7)
snaps-in, pull the plate (15) to the upwards and install it.
very front and remove it. 3] Install the end hook of the linkage rod
5) Remove the covers on the right and left (11) to the position (c) of the lever
side by referring to "8. Removal and instal- (10), and the other side of hook of the
lation of covers". linkage rod (11) to the port (d) of the
6) Unscrew the nut (16), remove the lever lever (14).
(14) and the screw (17).
7) Drill off the rivet (18) and remove the
spring steel sheets (19).
8) Drill off the rivet (20) and remove the
locating element (21).

Assembly
1) Install the locating element (21) and fix it
with the rivet (20).
2) Install the spring steel sheets (19) and fix
it with the rivet (18).
3) Set the lever (14) and the screw (17), and
fix with nut (16).
4) Install the covers on the right and left side
by referring to "8. Removal and installation
of covers".
5) Assemble the plate (15) by the following
procedure.

WA600-6 21
SEN01175-02 50 Disassembly and assembly

Removal
1) Remove the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".
2) Remove spring(1) and switch-plate (2). (If
equipped)
3) Remove the flexible support plate by fol-
lowing procedure.
1] Press the spring sheet inwards
(arrow), operate the lever for seat
angle adjustment (3).
2] Pull the flexible support plate (4) to
backwards and remove it.
4) Remove the spring (5).
7) Install the switch (4) by the following pro- 5) Turn the lever (6) clockwise until it snaps-
cedure. (If equipped) in, pull the plate (7) to the very front and
1] Install the seat switch (4) and fix it remove it.
with the rivet (3). 6) Drill off the rivet (8) and remove the wash-
2] Tilt the switch-plate (2) forwards and ers (9).
install it. 7) Unhook the covers (10) by pulling them
3] Install the spring (1). forwards and remove them in an upward
8) Install the seat pad by referring to "2. direction.
Removal and installation of seat pad and
backrest upholstery".
Installation
8. Removal and installation of covers 1) Install the covers (10) of right and left.
2) Install the washers (9) and fix it with the
rivet (8).
3) Turn the lever (6) clockwise until it snaps-
in, then install the plate (7).
4) Remove the spring (5) (see 7. Disassem-
bly and assembly of seat angle and seat
depth adjuster).
5) Install the flexible support plate (4) (see 7.
Disassembly and assembly of seat angle
and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see
7. Disassembly and assembly of seat
angle and seat depth adjuster). (If
equipped)
7) Install the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".

22 WA600-6
50 Disassembly and assembly SEN01175-02

9. Removal and installation of slide rails Installation

1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon
socket screws (8).
a Replace the hexagon socket screws
(8) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the
suspension system.
4) Put the washers (7) and install the seat
top assembly (1) and remove.
5) Put the washers (5) and nuts (6), then
tighten the hexagon socket screws (4).
a Replace the hexagon socket screws
(4) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far for-
ward as possible.
7) Put the nuts (3) and tighten the hexagon
socket screws (2).
a Replace the hexagon socket screws
(2) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far
back as possible.
9) Install the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".
Removal
1) Remove the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".
2) Push the seat top assembly (1) as far
back as possible.
3) Unscrew the hexagon socket screws (2)
and remove the nuts (3).
4) Push the seat top assembly (1) as far for-
ward as possible.
5) Unscrew the hexagon socket screws (4),
remove the washers (5) and nuts (6).
6) Remove the seat top assembly (1) and
remove the washers (7).
7) Disconnect the bellows from the upper
part of the suspension system and lay it
down.
8) Unscrew the hexagon socket screws (8)
and remove the nuts (9).
9) Remove the slide rails (10).

WA600-6 23
SEN01175-02 50 Disassembly and assembly

II. Suspension 2. Removal and installation of front cover

1. Removal and installation of top cover

Removal
1) Remove the upper part of the seat by
Removal referring to "I. Upper seat".
1) Remove the upper part of the seat by 2) Remove the top cover by referring to "1.
referring to "I. Upper seat". Removal and installation of top cover".
2) Pull the connecting cable (3) inwards 3) Bore out 2 rivet heads and drive out blind
through the upper cover (2). rivets (1), remove the front cover (2).
3) Remove the 2 bellows pins (1) and take
the upper cover (2) off.
Installation
1) Install the front cover (2) and fix it with the
Installation 2 rivets (1).
1) Install the connecting cable (3) inwards 2) Install the top cover by referring to "1.
through the upper cover (2). Removal and installation of top cover".
2) Install the upper cover (2) and fix it with 3) Install the upper part of the seat by refer-
the 2 bellows pins (1). ring to "I. Upper seat".
3) Install the upper part of the seat by refer-
ring to "I. Upper seat".

24 WA600-6
50 Disassembly and assembly SEN01175-02

3. Removal and installation of bellows

Installation
Removal 1) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 2) Install the bellows (2).
referring to "I. Upper seat". 3) Fix the bellows (2) with pins (3) to the
2) Remove the bellows (2) from the upper lower part of the suspension (6) in the
part of the suspension (1) by following reverse order of their removal.
procedure. 4) Fix the connecting cable with the cable tie
1] Take bellows pins (4) off on the front. (10). (If equipped)
2] Take bellows pins (3) off on the left 5) Fix the bellows (2) with pins (3) to the
side of the top. upper part of the suspension (1) in the
3] Remove 2 bellows pins (4) on the reverse order of their removal.
back and take 2 bellows pins (3) off 6) Install the upper part of the seat by refer-
the upper part of the suspension sys- ring to "I. Upper seat".
tem (1).
4] Take 3 bellows pins (3) on the right
side off the upper part of the suspen-
sion (1) and pull the bellows (2) over
the handle for vertical shock absorber
adjustment (9).
3) Remove the bellows (2) from the lower
part of the suspension (6) by the following
procedure.
1] Take 3 bellows pins (3) on the front
side off the lower part of the suspen-
sion (6).
2] Release 2 bellows pins (3) on the left
side from the lower part of the sus-
pension (6).
3] Release 4 bellows pins (3) on the
back side from the lower part of the
suspension (6).
4] Remove a cable tie (10) on the right
side from the connecting cable, and
take 2 bellows pins (3) off the lower
part of the suspension (6). (If
equipped)
4) Lift the bellows (2) over the lower part of
the suspension (6) and remove the bel-
lows (2) in a downward direction.
5) Remove the wire insert (5) from the bel-
lows (2).

WA600-6 25
SEN01175-02 50 Disassembly and assembly

4. Removal and installation of Bowden pull

wire and handle for vertical shock absorber
adjustment

Removal 10) Mark the points where the Bowden pull

1) Remove the upper part of the seat by wire (5) is fastened with the swinging
referring to "I. Upper seat". structure (14) with the cable tie (8) and
2) Remove the top cover by referring to "1. take the cable tie (8) off.
Removal and installation of top cover". 11) Pull the fixation (12) off the vertical shock
3) Take the bellows off by referring to "3. absorber (13).
Removal and installation of bellows". 12) Take the Bowden pull wire (5) off the bear-
4) Move the suspension system to the high- ing (9).
est position. 13) Remove the fixation (12) from the fork
k Risk of crushing! Secure the sus- (11).
pension between the swinging 14) Take the Bowden pull wire (5) off the fork
structure and lower part of the (11), remove the fork (11) and compres-
suspension system with suitable sion spring (10).
spacers. 15) Mark the location of the mounting hole for
5) Screw out Torx screw (2). the Bowden pull wire (5) in the upper part
6) Pull the handle for vertical shock absorber of the suspension (4), pull the Bowden pull
adjustment (1) off the upper part of the wire (5) out of the upper part of the sus-
suspension (4). pension (4) and then remove it.
7) Remove the Bowden pull wire (5) from the
handle for vertical shock absorber adjust-
ment (1).
8) Push the Bowden pull wire (5) off the
bearing for Bowden pull wire (6).
9) Bore out the rivet head and drive out the
blind rivet (7), and remove the bearing for
Bowden pull wire (6).

26 WA600-6
50 Disassembly and assembly SEN01175-02

Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper
part of the suspension (4) through the
location of the mounting hole marked
before removing the Bowden pull wire (5).
3) Install the fork (11) and compression
spring (10), and take the Bowden pull wire
(5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bear-
ing (9).
6) Put the fixation (12) to the vertical shock
absorber (13).
7) Install the Bowden pull wire (5) and fix it
with the cable tie (8) at the marked points.
a Install the Bowden pull wire according
to the marking.
8) Install the bearing for Bowden pull wire (6)
and fix it with the rivet (7).
9) Install the Bowden pull wire (5) to the
bearing for Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the han-
dle for vertical shock absorber adjustment
(1).
11) Install the handle for vertical shock
absorber adjustment (1) to the upper part
of the suspension (4).
12) Tighten Torx screw (2).
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to "3.
Removal and installation of bellows".
14) Install the top cover by referring to "1.
Removal and installation of top cover".
15) Install the upper part of the seat by refer-
ring to "I. Upper seat".

WA600-6 27
SEN01175-02 50 Disassembly and assembly

5. Removal and installation of vertical shock Installation

absorber 1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the
suspension system with suitable
spacers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock
absorber (4), make sure the labeling
is on top.
3) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (3).
5) Install the fixation (2) and bearing (1) to
the vertical shock absorber (4).
6) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (6).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (6).
7) Install the circlip (8) to the stud (6).
8) Install the bellows off by referring to "3.
Removal and installation of bellows".
9) Install the top cover by referring to "1.
Removal and installation of top cover".
Removal 10) Install the upper part of the seat by refer-
1) Remove the upper part of the seat by ring to "I. Upper seat".
referring to "I. Upper seat".
2) Remove the top cover by referring to "1.
Removal and installation of top cover".
3) Take the bellows off by referring to "3.
Removal and installation of bellows".
4) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure
(7) and vertical shock absorber (4).
7) Take the fixation (2) and bearing (1) off the
vertical shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging struc-
ture (7) and the vertical shock absorber
(4).
10) Remove the vertical shock absorber (4) in
an upward direction.

28 WA600-6
50 Disassembly and assembly SEN01175-02

6. Removal and installation of compressor

Removal 11) Pull the compressed-air hose (7) off the

1) Remove the upper part of the seat by compressor (3).
referring to "I. Upper seat". a Do not use a screwdriver to lift the
2) Remove the top cover by referring to "1. compressed-air hose (7) off the spike
Removal and installation of top cover". of the compressor (3).
3) Take the bellows off by referring to "3. a Heat the compressed-air hose (7) at
Removal and installation of bellows". the head of compressor (3) (e.g.
4) Move the suspension system to the high- using a hot-air blower) and then, pull
est position. it off in one move.
k Risk of crushing! Secure the sus- 12) Pull out the compressor cable (5) in a
pension between the swinging downward direction and remove compres-
structure and lower part of the sus- sor (3) to the front.
pension system with suitable spac- 13) Remove the support (9) from the lower
ers. part of the suspension (2).
5) Mark the points where the compressor
cable (5) is fastened with the 6 cable ties
(6) and remove the cable ties (6).
6) Disconnect the right-angle plug (10) from
the height level control unit (1).
7) Disconnect the electric connector of the
flat plug (11).
8) Mark the points where the compressed-air
hose (7) is fastened with the cable tie (12)
and remove the cable tie (12).
9) Mark the points where the compressor (3)
is fastened with the 2 cable ties (4) and
remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the
compressor (3) and push it backwards off
the compressed-air hose (7).

WA600-6 29
SEN01175-02 50 Disassembly and assembly

Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Install the support (9) to the lower part of
the suspension (2).
3) Install the compressor (3) to the support
(9).
4) Install the compressed-air hose (7) and fix
it with cable tie (4) at the marked points.
a Loosely apply the cable tie (4) until
the locking head of the cable tie (4) is
located slightly over the front curve of
compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the
pliers to tighten the locking head of
the cable tie (4) to 310 Nm{31.6 kgm}
in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air
hose (7).
6) Install them to the spike of the compressor
(3).
7) Fix the compressor (3) with the cable ties
(4) at marked points.
a Fix the cable tie according to the
marking.
8) Fix the compressed-air hose (7) with cable
tie (12) at the marked points.
9) Connect the electric connector of the flat
plug (11).
10) Connect the right-angle plug (10) to the
height level control unit (1).
11) Install the compressor cable (5) and fix it
with cable tie (6) at the marked points.
a Tie back any excess length of the
compressor cable (5).
12) Install the bellows off by referring to "3.
Removal and installation of bellows".
13) Install the top cover by referring to "1.
Removal and installation of top cover".
14) Install the upper part of the seat by refer-
ring to "I. Upper seat".

30 WA600-6
50 Disassembly and assembly SEN01175-02

7. Removal and installation of height level

controller

Removal 9) Pull the air input hoses (10) and (11) off
1) Remove the upper part of the seat by the pneumatic spring (see "8. Removal
referring to "I. Upper seat". and installation of air hose").
2) Remove the top cover by referring to "1. 10) Mark the place where the cable is fas-
Removal and installation of top cover". tened with the right-angle plugs (13) and
3) Take the bellows off by referring to "3. (14) and the cable tie and then remove the
Removal and installation of bellows". cable tie.
4) Move the suspension system to the high- 11) Mark the place where the Bowden pull
est position. wire (19) is fastened with the cable tie and
k Risk of crushing! Secure the sus- remove the cable tie.
pension between the swinging 12) Unhook the Bowden pull wires (3) and
structure and lower part of the sus- (19) from the height level control (1).
pension system with suitable spac- 13) Mark and then disconnect the right-angle
ers. plugs (13) and (14) from the height level
5) Loosen up the 2 circlips (17) from the stud control unit (1).
(18) and then remove them. 14) Remove the 2 hexagon nuts (4) from the
6) Knock out the stud (18) from the lower thread of the height level control (1).
part of the suspension (15) and then 15) Remove the plate (7), loop of the webbing
remove it. (5) and the edge protection strip (6).
a Firmly hold the webbing (5) and let it 16) Remove the height level control (1) from
carefully roll back to the rewinder on the upper part of the suspension (8).
the height level controller (1). 17) Undo the Torx screw (9) and take the
7) Remove the 2 buffers (16) from the loop of attachment for Bowden pull wire (2) off the
the webbing (5). height level valve (1).
8) Mark the points where the air input hoses a To do this, first release the 2 catchers
(10) and (11) are fastened with 5 cable on the backside of the attachment for
ties (12) and remove the cable ties (12). Bowden pull wire (2) and take the
attachment for Bowden pull wire (2)
off the height level valve (1).

WA600-6 31
SEN01175-02 50 Disassembly and assembly

18) Pull the Bowden pull wire (3) out of the

attachment for Bowden pull wire (2).
19) Remove the height level controller in an
upward direction.

Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the
attachment for Bowden pull wire (2).
4) Install the attachment for Bowden pull wire
(2) to the height level controller (1).
5) Tighten the Torx screw (9) to height level
controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the
upper part of the suspension (8).
7) Install the plate (7), loop of the webbing
(5) and the edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread
of the height level controller (1).
9) Connect the right-angle plugs (13) and
(14) to the height level controller (1) at the
marked point.
10) Install the Bowden pull wires (3) and (19)
to the height level controller (1).
11) Install the Bowden pull wire (19) and fix it
with the cable tie at the marked points.
12) Install the right-angle plugs (13) and (14)
and fix them with the cable tie at the
marked points.
13) Install the air input hoses (10) and (11) to
the pneumatic spring (see "8. Removal
and installation of air hose").
14) Fix the air input hoses (10) and (11) with
the 5 cable ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the
webbing (5).
16) Install the stud (18) to the lower part of the
suspension (15).
17) Install the 2 circlips (17) to the stud (18)
and then remove them.
18) Install the bellows off by referring to "3.
Removal and installation of bellows".
19) Install the top cover by referring to "1.
Removal and installation of top cover".
20) Install the upper part of the seat by refer-
ring to "I. Upper seat".

32 WA600-6
50 Disassembly and assembly SEN01175-02

Adjustment 7) Adjust the output level (2) as follows.

1) Remove the upper part of the seat by Adjust the clearance between valve lever
referring to "I. Upper seat". (6) and cam disc (7) by turning the cross-
2) Remove the top cover by referring to "1. head screw (10).
Removal and installation of top cover". q Specified value: The valve lever (6)
3) Take the bellows off by referring to "3. must seat on the cam disc without
Removal and installation of bellows". pressure (7).
4) Move the suspension system to the high- q Turn the cross-head screw (10) to the
est position. left, the valve lever (6) is moving
k Risk of crushing! Secure the sus- towards the cam disc (7). This
pension between the swinging increases the pressure on the valve
structure and lower part of the sus- tappets (4) at the output valve (2) and
pension system with suitable spac- the air escapes the output valve (2)
ers. earlier.
5) Loosen the self-tapping screw (9) a half q Turn the cross-head screw (10) to the
turn. right, the valve lever (6) is moving
6) Adjust the micro-switch (3) as follows. away from the cam disc (7). This
Adjust the clearance between cam switch decreases the pressure on the valve
(5) and cam disc (7) by turning the cross- tappets (4) at the output valve (2) and
head screw (8). the air escapes the output valve (2)
q Specified clearance (A) = 0.5 mm. later.
q Turn the cross-head screw (8) to the 8) Tighten the self-tapping screw (9) after the
left, the cam switch (5) is moving adjustment has been completed.
towards the cam disc (7). 9) Install the bellows off by referring to "3.
q Turn the cross-head screw (8) to the Removal and installation of bellows".
right, the cam switch (5) is moving 10) Install the top cover by referring to "1.
away from the cam disc (7). Removal and installation of top cover".
q When the cam switch (5) seats on the 11) Install the upper part of the seat by refer-
cam disc (7) under pressure, the com- ring to "I. Upper seat".
pressor (11) turns too early and runs
already during the compression and
expansion of the seat suspension.

WA600-6 33
SEN01175-02 50 Disassembly and assembly

8. Removal and installation of compressed-air

hoses

a Disconnect the hose not more than 1 to 2 7) Pull the compressed-air hose (11) off the
times. Check the hose for damage before con- compressor (5) and remove it. (Refer to
necting it. "6. Removal and installation of compres-
sor")
8) Pull the compressed-air hose with angle
Removal (8) off the pneumatic spring (9) and then
1) Remove the upper part of the seat by off the air tank (10).
referring to "I. Upper seat". a When pulling the hoses out, the
2) Remove the top cover by referring to "1. retaining ring of the quick coupling
Removal and installation of top cover". (13) must first be completely pressed
3) Take the bellows off by referring to "3. back (e.g. using a flat pliers) to avoid
Removal and installation of bellows". marks.
4) Move the suspension system to the high- 9) Mark the points where the compressed-air
est position. hose with angle (8) is fastened with cable
k Risk of crushing! Secure the sus- ties (6), (7) and (12) and then remove the
pension between the swinging cable ties (6), (7) and (12).
structure and lower part of the sus- 10) Remove the air hose with angle (8).
pension system with suitable spac- 11) Mark the points where the air input hoses
ers. (3) and (4) are fastened with the cable ties
5) Mark the points where the compressed-air (2) and (6) and remove the cable ties (2)
hose (11) is fastened with the cable tie and (6).
(12) and remove the cable tie (12). 12) Pull the air input hoses (3) and (4) out of
6) Pull the compressed-air hose (11) off the the pneumatic spring (9).
pneumatic spring (9). 13) Remove the height level controller (1) with
a When pulling the hoses out, the air input hoses (3) and (4).
retaining ring of the quick coupling a To ensure the tightness, the air input
(13) must first be completely pressed hoses (3) and (4) cannot be removed
back (e.g. using a flat pliers) to avoid from the height level control (1).
marks.

34 WA600-6
50 Disassembly and assembly SEN01175-02

Installation a Apply pressure to insert the air hose

a Always replace a damaged (marks) hose with with angle (8) into the pneumatic
a new one. It is possible to cut the damaged spring (9) and air tank (10) up to the
part off (about 12 mm) using special tools (14) blue marking.
only once. After the cut off, the blue marking 6) Fix the compressed air hose with angle (8)
should be (arrow) set back by the length of the with cable ties (6), (7) and (12) at the
cut off piece. marked points.
a Do not fix the cable tie (12) at the
1) Move the suspension system to the high- angle.
est position. 7) Install the compressed-air hose (11) to the
k Risk of crushing! Secure the sus- compressor (5). (Refer to "6. Removal and
pension between the swinging installation of compressor")
structure and lower part of the sus- 8) Install the compressed-air hose (11) to the
pension system with suitable spac- pneumatic spring (9).
ers. 9) Fix the compressed-air hose with the
2) Install the height level controller (1) with cable tie (12) at the marked points.
air input hoses (3) and (4). 10) Install the bellows off by referring to "3.
a Cut the air input hose (3) or (4) off at Removal and installation of bellows".
the leaky area and connect the new 11) Install the top cover by referring to "1.
air input hose (3) or (4) to an appro- Removal and installation of top cover".
priate adapter. Subsequently, cut the 12) Install the upper part of the seat by refer-
excess length off. ring to "I. Upper seat".
3) Install the air input hoses (3) and (4) to the
pneumatic spring (9). Hydrostatic test
4) Fix the air input hoses (3) and (4) with the a After the installation of a compressed-air hose,
cable ties (2) and (6) at the marked points. the hydraulic test of the suspension should be
5) Install the compressed-air hose with angle performed.
(8) to the pneumatic spring (9) and then q Apply 60 kg load to the suspension for 24
off the air tank (10). hours.
a To avoid kinking, always install the q The lowering within this time may not
compressed-air hose with angle (8) exceed 15 mm.
first on the pneumatic spring (9). a The compressed-air hoses are locked after
they have been connected.

WA600-6 35
SEN01175-02 50 Disassembly and assembly

9. Removal and installation of Bowden pull 8) Undo the 3 cross-head screws (7).
wires and handle for height adjustment 9) Take the Bowden pull wires (1) and (6) off
the holder for Bowden pull wire (4), and
then pull them out of the upper part of the
suspension (2).
10) Remove the holder (4) for Bowden pull
wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden
pull wire (4) are wedged into the 2
latching noses (arrow) at the lower
part of the holder for Bowden pull wire
(4). Carefully separate the parts.
a To remove the handle, use a screw-
driver to bend open the handle (5)
between the handle (5) and holder for
Bowden pull wire (4) so that the 2
latching noses are released from the
handle (5).
a Take the handle (5) off the holder for
Bowden pull wire (4).

Installation
1) Install the handle (5) to holder (4), if
removed.
a When the handle (5) is deformed,
replace it.
2) Install the Bowden pull wires (1) and (6) to
the holder for Bowden wire (4).
a Adjust the new Bowden pull wire to
Removal the length of the old one (excess
1) Remove the upper part of the seat by length of the wire).
referring to "I. Upper seat". 3) Install the holder (4) to the upper part of
2) Remove the top cover by referring to "1. the suspension (2) and tighten the 3
Removal and installation of top cover". cross-head screws (7).
3) Take the bellows off by referring to "3. 4) Install the Bowden pull wire (6) to the
Removal and installation of bellows". height level controller. (See "7. Removal
4) Mark the points where the Bowden pull and installation of height level controller".)
wire (1) is fastened with the 2 cable ties 5) Install the Bowden pull wire (1) to the
(3), and then remove the cable ties (3). height level controller (See "7. Removal
5) Mark the points where the Bowden pull and installation of height level controller".)
wire (6) is fastened with the 2 cable ties 6) Fix the Bowden pull wire (6) with the 2
(8), and then remove the cable ties (8). cable ties (8) at the marked points.
6) Take the Bowden pull wire (1) off the a Loosely fix the Bowden pull wire with
height level controller and pull it out of the the cable ties at the marked points
holder for Bowden pull wire (See "7. and make sure it is not distorted.
Removal and installation of height level 7) Fix the Bowden pull wire (1) with the 2
controller".) cable ties (3) at the marked points.
a To release the tension of the Bowden a Loosely fix the Bowden pull wire with
pull wire (1), press the handle for the cable ties at the marked points
height adjustment (5) upwards. and make sure it is not distorted.
7) Take the Bowden pull wire (6) off the 8) Install the bellows off by referring to "3.
height level controller. (See "7. Removal Removal and installation of bellows".
and installation of height level controller") 9) Install the top cover by referring to "1.
a To release the tension of the Bowden Removal and installation of top cover".
pull wire (6), press the handle for 10) Install the upper part of the seat by refer-
height adjustment (5) upwards. ring to "I. Upper seat".

36 WA600-6
50 Disassembly and assembly SEN01175-02

Checking and adjustment 5) Check the clearance between the Bowden

a When checking and adjustment is performed wire lever (10) and holder for Bowden wire
through removal and installation, pass proce- end cap (9).
dures 1) and 2) of "Checking". q Specified value: Distance (A) between
(Checking) 1 and 3.5 mm with the handle for
1) Remove the upper part of the seat by height adjustment (2) in the up posi-
referring to "I. Upper seat". tion.
2) Remove the top cover by referring to "1. q When the specified value exceeds
Removal and installation of top cover". 3.5 mm, the suspension cannot be
3) Operate the handle for height adjustment lifted above the middle position.
(2) several times in both directions and
check the following: (Adjustment)
q Bowden pull wires (1) and (3) for 1) Adjustment of the Bowden pull wire (3):
easy-running. 1] Loosen the counternut (6) and adjust
q Bowden wire lever (10), valve lever the clearance between the Bowden
(14) and valve tappets (13) at the out- wire lever (10) and holder for Bowden
put valve (12) for smoothness of run- wire end cap (9) using the locknut (5).
ning. q Turn the locknut (5) inwards, the
4) Check the neutral position of the handle Bowden pull wire gets longer.
for seat height adjustment (2) and the ten- q Turn the locknut (5) outwards,
sile force of the retracting spring (11) on the Bowden pull wire gets
the height level valve (4): shorter.
q The retracting spring (11) must fix the q Specified value: Clearance (A)
handle for seat height adjustment (2) between 1 and 3.5 mm.
in neutral position. 2] Secure the locknut (5) with the coun-
q The retracting spring (11) must tightly ternut (6) and make sure not to distort
pull the Bowden pull wires (1 and 3) the Bowden pull wire (3).
and keep the Bowden wire lever (10) 3] Operate the handle for seat height
in neutral position. adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.

WA600-6 37
SEN01175-02 50 Disassembly and assembly

2) Adjustment of the Bowden pull wire (1):

1] Loosen the counternut (7) and adjust
the tension of the Bowden pull wire
(1) on the height valve (4) using the
locknut (8).
q Turn the locknut (8) inwards, the
Bowden pull wire gets longer.
q Turn the locknut (8) outwards,
the Bowden pull wire gets
shorter.
q Specified value: The Bowden
wire (8) must be tightened, but
not distorted on the suspension
device on the height level valve
(4).
2] Secure the locknut (8) with the coun-
ternut (7) and make sure not to distort
the Bowden pull wire (1).
3] Operate the handle for seat height
adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.

38 WA600-6
50 Disassembly and assembly SEN01175-02

10. Removal and installation of pneumatic

spring

Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Remove the 2 air input hoses, com- ers.
pressed-air hose and air input hose with 2) Turn the spring system by 180° and place
angle from the pneumatic spring (6) by it onto the upper part (1).
referring to "8. Removal and installation of 3) Slightly compress the pneumatic spring
compressed-air hoses". (6) and install the pneumatic spring (6) to
5) Undo the counter sunk screw (3) from the the swinging structure (5) and lower part
pneu matic sp rin g (6 ) a nd rem ove it of the suspension (2).
together with the washer (4). 4) Tighten the counter sunk screw (7) to the
6) Move the suspension system to the high- pneumatic spring (6).
est position. 3 Counter sunk screw (6):
k Risk of crushing! Secure the sus- 6 Nm {0.61 kgm}
pension between the swinging 5) Turn the spring system by 180° and place
structure and lower part of the sus- it onto the upper part (1).
pension system with suitable spac- 6) Put the washer (4) to the pneumatic spring
ers. (6) and tighten the counter sunk screw (3).
7) Turn the spring system by 180° and place 3 Counter sunk screw (3):
it onto the upper part (1). 6 Nm {0.61 kgm}
8) Undo the counter sunk screw (7) from the
pneumatic spring (6).
9) Slightly compress the pneumatic spring
(6) and remove it from the swinging struc-
ture (5) and lower part of the suspension
(2).

WA600-6 39
SEN01175-02 50 Disassembly and assembly

7) Install the 2 air input hoses, compressed-

air hose and air input hose with angle to
the pneumatic spring (6) by referring to "8.
Removal and installation of compressed-
air hoses".
8) Install the bellows off by referring to "3.
Removal and installation of bellows".
9) Install the top cover by referring to "1.
Removal and installation of top cover".
10) Install the upper part of the seat by refer-
ring to "I. Upper seat".

40 WA600-6
50 Disassembly and assembly SEN01175-02

11. Removal and installation of air tank for

additional air supply

Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Move the suspension system to the high- ers.
est position. 2) Install the clamp (5) to the bracket (6), if
k Risk of crushing! Secure the sus- removed.
pension between the swinging a Replace the clamp with new one, if
structure and lower part of the sus- required.
pension system with suitable spac- 3) Install the air tank (3) to bracket (2) and
ers. clamp (5).
5) Remove the air hose with angle (4) from 4) Install the air hose with angle (4) to the air
the air tank (3) by referring to "8. Removal tank (3) by referring to "8. Removal and
and installation of compressed-air hoses". installation of compressed-air hoses".
6) Remove the air tank (3) from bracket (2) 5) Install the bellows off by referring to "3.
and clamp (5). Removal and installation of bellows".
7) Take the clamp (5) off the bracket (6) in a 6) Install the top cover by referring to "1.
downward direction, if required. Removal and installation of top cover".
a To do this, use a screwdriver to press 7) Install the upper part of the seat by refer-
through the hole (arrow) in the ring to "I. Upper seat".
bracket against the catchers (arrow)
of the clamp (5) and pull the clamp (5)
out in a downward direction.

WA600-6 41
SEN01175-02 50 Disassembly and assembly

12. Removal and installation of cable harness

Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Move the suspension system to the high- ers.
est position. 2) Connect the right-angle plug (6) to the
k Risk of crushing! Secure the sus- height level control unit (1).
pension between the swinging 3) Connect the electric connection (flat plug)
structure and lower part of the sus- of the compressor cable (4) to the cable
pension system with suitable spac- harness of the connector plug (2) and
ers. cable harness of the machine power con-
5) Mark the points where the cable of the nector (3).
machine power connector (3) is fastened 4) Fix the cable harness of the connector
with the cable tie (8) on the upper part of plug (2) and cable harness of the machine
the suspension (7) and remove the cable power connector (3) with the cable ties (5)
tie (8). at the marked points.
6) Mark places where the cable harness of a Run the cable harnesses (2) and (3)
the connector plug (2) and cable harness and fix them with the cable ties (5) so
of the machine power connector (3) are that they are neither squeezed nor
fastened with the cable ties (5) and otherwise damaged.
remove the cable ties (5). 5) Fix the cable of the machine power con-
7) Disconnect the electric connection (flat nector (3) with the cable tie (8) on the
plug) of the compressor cable (4) to the upper part of the suspension (7) at the
cable harness of the connector plug (2) marked points.
and cable harness of the machine power
connector (3).
8) Disconnect the right-angle plug (6) from
the height level control unit (1).

42 WA600-6
50 Disassembly and assembly SEN01175-02

6) Install the bellows off by referring to "3.

Removal and installation of bellows".
7) Install the top cover by referring to "1.
Removal and installation of top cover".
8) Install the upper part of the seat by refer-
ring to "I. Upper seat".

WA600-6 43
SEN01175-02 50 Disassembly and assembly

13. Disassembly and assembly of upper part of

the suspension system

Disassembly 8) Move the suspension system to the high-

1) Remove the upper part of the seat by est position.
referring to "I. Upper seat". k Risk of crushing! Secure the sus-
2) Remove the top cover referring to "1. pension between the swinging
Removal and installation of top cover". structure (7) and lower part of the
3) Take the bellows off by referring to "3. suspension system with suitable
Removal and installation of bellows". spacers.
4) Take the Bowden pull wire and handle off 9) Bore out 2 rivet heads and drive out blind
the upper part of the suspension (1) by rivets (10), remove the stops (9).
referring to "4. Removal and installation of 10) Push the upper part of the suspension (1)
Bowden pull wires and handle for vertical forwards until the cut-outs (arrow) on the
shock absorber". left and right sides at the guiding rails (2)
a The Bowden pull wire does not need are located at the same height with the
to be taken off the vertical shock front rollers (8) of the swinging structure
absorber. (7).
5) Remove the vertical shock absorber from 11) Remove the upper part of the suspension
the upper part of the suspension (1) by (1) on the front side over the rollers (8)
referring to "5. Removal and installation of and the back rollers (6) of the swinging
vertical shock absorber". structure (7).
6) Remove the height level controller from
the upper part of the suspension (1) by
referring to "7. Removal and installation of
height level controller".
a Air input hoses do not need to be
taken off the pneumatic spring.
7) Remove Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".

44 WA600-6
50 Disassembly and assembly SEN01175-02

Assembly
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Push the upper part of the suspension (1)
forwards until the cut-outs (arrow) on the
left and right sides at the guiding rails (2)
are located at the same height with the
front rollers (8) of the swinging structure
(7).
3) Install the upper part of the suspension (1)
on the back rollers (6) and the front rollers
(8) of the swinging structure (7).
a Apply acid-free multi-purpose lubri-
cant to the side surfaces (F) of the 2
guiding rails (2) of the rollers (6).
4) Install the stops (9) and fix with the 2 rivets
(10).
5) Install Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
6) Install the height level controller to the
upper part of the suspension (1) by refer-
ring to "7. Removal and installation of
height level controller".
7) Install the vertical shock absorber to the
upper part of the suspension (1) by refer-
ring to "5. Removal and installation of ver-
tical shock absorber".
8) Install the Bowden pull wire and handle to
the upper part of the suspension (1) by
referring to "4. Removal and installation of
Bowden pull wires and handle for vertical
shock absorber".
9) Install the bellows off by referring to "3.
Removal and installation of bellows".
10) Install the top cover by referring to "1.
Removal and installation of top cover".
11) Install the upper part of the seat by refer-
ring to "I. Upper seat".

WA600-6 45
SEN01175-02 50 Disassembly and assembly

14. Lower part of the suspension system

Removal 8) Unscrew the 2 hexagon nuts (11), remove

1) Remove the upper part of the seat by washers (10) and counter sunk screws
referring to "I. Upper seat". (9).
2) Remove the top cover by referring to "1. 9) Undo the 2 corrugated-head screws (5)
Removal and installation of top cover". and take the U-shaped profiles (6) off the
3) Take the bellows off by referring to "3. guiding rail (8).
Removal and installation of bellows". 10) Push the upper part of suspension (1) with
4) Remove compressor from the lower part the swinging structure (3) backwards until
of the suspension (7) by referring to "6. the 2 fixed bearings (4) on the swinging
Removal and installation of compressor". structure (3) can be taken out through the
a Compressor cable and compressed- cut-outs (arrows) of the guiding rails (8) on
air hose do not need to be removed. the upper part of suspension (1).
a Protect the compressor against 11) Lift the upper part of the suspension (1)
shocks (impacts) by fixing it on the with the swinging structure (3) out and pull
swinging structure with adhesive it out together with the 2 rollers (2) from
tape. the guiding rails (8) by turning sideways.
5) Remove the webbing from the lower part
of the suspension (7) by referring to "7.
Removal and installation of height level Installation
controller". 1) Install the upper part of the suspension (1)
6) Undo the counter sunk screw from the with the swinging structure (3) together
pneumatic spring by referring to "10. with the 2 rollers (2) to the guiding rails
Removal and installation of pneumatic (8).
spring". a Apply acid-free multi-purpose lubri-
7) Remove the 2 cable ties for the vehicle cant to the bearing surface at the side
power connector cable on the lower part (F) of the 2 guiding rails (8) of the roll-
of suspension(7) by referring to "12. ers (2).
Removal and installation of cable har- 2) Install the U-shaped profile (6) to the guid-
ness". ing rail (8) and tighten the 2 corrugated-
head screws (5).

46 WA600-6
50 Disassembly and assembly SEN01175-02

3) Put the counter sunk screws (9) and the

washers (10), and tighten the 2 hexagon
nuts (11).
4) Install the 2 cable ties for the machine
power connector cable on the lower part
of suspension(7) by referring to "12.
Removal and installation of cable har-
ness".
5) Tighten the counter sunk screw to the
pneumatic spring by referring to "10.
Removal and installation of pneumatic
spring".
6) Install the webbing to the lower part of the
suspension (7) by referring to "7. Removal
and installation of height level controller".
7) Install compressor to the lower part of the
suspension (7) by referring to "6. Removal
and installation of compressor".
8) Install the bellows off by referring to "3.
Removal and installation of bellows".
9) Install the top cover by referring to "1.
Removal and installation of top cover".
10) Install the upper part of the seat by refer-
ring to "I. Upper seat".

WA600-6 47
SEN01175-02 50 Disassembly and assembly

15. Swinging structure

Removal 9) Take the Bowden pull wires for height

1) Remove the upper part of the seat by level adjustment off the height level valve
referring to "I. Upper seat". by referring to "9. Removal and installation
2) Remove the top cover by referring to "1. of Bowden pull wire and handle for height
Removal and installation of top cover". adjustment".
3) Take the bellows off by referring to "3. 10) Remove the pneumatic spring by referring
Removal and installation of bellows". to "10. Removal and installation of pneu-
4) Take the Bowden pull wire for vertical matic spring".
shock absorber adjustment off the vertical 11) Remove the air tank for additional air sup-
shock absorber by referring to "4. ply by referring to "11. Removal and instal-
Removal and installation of Bowden pull lation of air tank for additional air supply".
wire and handle for vertival shock 12) Remove the cable harness by referring to
absorber adjustment". "12. Removal and installation of cable har-
5) Take the vertical shock absorber off the ness".
swinging structure by referring to "5. 13) Take the upper part of the suspension off
Removal and installation of vertical shock the swinging structure by referring to "13.
absorber". Removal and installation of upper part of
6) Remove the compressor by referring to "6. the suspension".
Removal and installation of compressor". 14) Take the lower part of the suspension off
7) Take the webbing off the lower part of the the swinging structure by referring to "14.
suspension by referring to "7. Removal Removal and installation of lower part of
and installation of height level controller". the suspension".
8) Remove the cable tie for the air input 15) Take 4 rollers (5), 2 rollers (6), 2 fixed
hoses of the height level control and pull bearings (9) and 4 felt rings (4) off the
the air input hoses off the pneumatic swinging structure (1).
spring by referring to "8. Removal and 16) Pull the tube piece (8) out of the fixed
installation of compressed-air hoses". bearing (9).
17) Remove the 2 buffers (7) from the swing-
ing structure (1).
18) Remove the edge protection strip (2) from
the swinging structure (1).

48 WA600-6
50 Disassembly and assembly SEN01175-02

Installation 12) Install the Bowden pull wires for height

1) Check: maximum clearance (A) or (B) level adjustment to the height level valve
between the rollers (5) and guiding rails of by referring to "9. Removal and installation
the lower part of the suspension (11) or of Bowden pull wire and handle for height
upper part of the suspension (10) over the adjustment".
complete adjustment length. 13) Install the cable tie for the air input hoses
2) Place the washer compensating for clear- of the height level controller and pull the
ance (2) between the roller (5 or 6) and air input hoses to the pneumatic spring by
axle of the swinging structure (1), if neces- referring to "8. Removal and installation of
sary. compressed-air hoses".
a Clearance spacers (with thickness of 14) Install the webbing to the lower part of the
0.2 mm and 0.5 mm) are included in suspension by referring to "7. Removal
the wear parts set. and installation of height level controller".
3) Install the edge protection strip (2) to the 15) Install the compressor by referring to "6.
swinging structure (1). Removal and installation of compressor".
4) Install the 2 buffers (7) to the swinging 16) Install the vertical shock absorber to the
structure (1). swinging structure by referring to "5.
5) Put the tube piece (8) to the fixed bearing Removal and installation of vertical shock
(9). absorber".
6) Install 4 rollers (5), 2 rollers (6), 2 fixed 17) Install the Bowden pull wire for vertical
bearings (9) and 4 felt rings (4) to the shock absorber adjustment to the vertical
swinging structure (1). shock absorber by referring to "4.
7) Install the lower part of the suspension to Removal and installation of Bowden pull
the swinging structure by referring to "14. wire and handle for vertival shock
Removal and installation of lower part of absorber adjustment".
the suspension". 18) Install the bellows off by referring to "3.
8) Install the upper part of the suspension to Removal and installation of bellows".
the swinging structure by referring to "13. 19) Install the top cover by referring to "1.
Removal and installation of upper part of Removal and installation of top cover".
the suspension". 20) Install the upper part of the seat by refer-
9) Install the cable harness by referring to ring to "I. Upper seat".
"12. Removal and installation of cable har-
ness".
10) Install the air tank for additional air supply
by referring to "11. Removal and installa-
tion of air tank for additional air supply".
11) Install the pneumatic spring by referring to
"10. Removal and installation of pneu-
matic spring".

WA600-6 49
SEN01175-02 50 Disassembly and assembly

Removal and installation of air 4. Disconnect hose (5) from the side of the air
conditioner unit assembly 1 conditioner unit.
5. Remove box (6).
Removal 6. Remove mat (7) to the front.

k Park the machine on level ground. Apply

parking brake and put the blocks under the
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in 7. Remove cover (8) and internal air filter.
advance. 8. Remove plate (9).
a Ask professional traders for collecting and fill- 9. Remove 3 mounting bolts (11) and remove
ing operation of refrigerant (R134a). duct (10).
a Never release the refrigerant (R134a) to the
atmosphere.

k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.

1. Open cover (1).

2. Remove box (2).
3. Remove covers (3) and (4).
a Place the left console (LC) in front. 10. Remove duct (12) from the air conditioner unit
assembly (13).

50 WA600-6
50 Disassembly and assembly SEN01175-02

11. Disconnect wiring harness clamp (14). Installation

12. Remove duct (15). q Installation is done in the reverse order of
13. Disconnect connectors A10 (16) and A11 (17). removal.

[*1]
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Before tightening, make sure O-ring (70) is
provided in the air conditioner hose piping con-
nection.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexcel:
ZXL100PG (PAG 46 or equivalent)).
14. Disconnect clamp (18). 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
15. Disconnect clamp (20).
16. Remove mounting bolt (21), then disconnect
air conditioner tube (22). [*1]
17. Disconnect 2 heater hoses (23).
a Confirming their destination.
a Arrange for a container.

[*2]
a Install the air conditioner unit after applying
Cemedine 366E or equivalent to the lower
hatched area (all around the circumference) of
the air conditioner unit.
2 Lower hatched area (all around the circum-
18. Remove air conditioner unit assembly (13). [*2]
ference) of the air conditioner unit:
Cemedine 366E or equivalent

q Filling of air conditioning gas

Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 850 ± 50 g

WA600-6 51
SEN01175-02 50 Disassembly and assembly

k After installing the floor mat, check if the

brake valve boot (B) is crushed.

a Also check if the accelerator pedal boot is

crushed.

q Example of bad boot condition where the

boot (B) is crushed

q Example of good boot condition where the

boot (B) is not crushed

52 WA600-6
50 Disassembly and assembly SEN01175-02

WA600-6 53
SEN01175-02

WA600-6 Wheel loader

Form No. SEN01175-02

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 02-09 (01)

54
 SEN01177-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

50 Disassembly and assembly1

Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 4
Removal and installation of loader controller assembly .................................................................................. 5
Removal and installation of VHMS controller assembly ................................................................................. 6
Removal and installation of monitor assembly................................................................................................ 7

WA600-6 1
SEN01177-03 50 Disassembly and assembly

Removal and installation of 5. Disconnect connector E19 (5), EP18 (6) and
engine controller assembly 1 ENG (7). [*1]
6. Remove engine controller (8).
Removal a Grounding wire (E) is tightened together.
k Park the machine on level ground. Apply
parking brake and put the blocks under the
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

1. Lift fender (1)

2. Open cover (2).

3. Disconnect fuel hose clamp (3).

4. Disconnect connector EP1 (4).

2 WA600-6
50 Disassembly and assembly SEN01177-03

Installation
q Installation is done in the reverse order of
removal.

[*1]
q Check for any sands, dusts, water content, etc.
inside (particularly lower section) the controller
connector. If any, completely remove them with
air blow. (Sands, dust and water causes defec-
tive contact or inundation.)

a Reference

q How to replace O-ring seal for power supply

connector J3P (5)
O-ring seal:
1010-074-0406 (Nihon-Deutsch Ltd.)

1) Use tweezers [1] to catch and hold the

stopper to remove the cover (8).

2) Use tweezers [1] to remove O-ring (9).

WA600-6 3
SEN01177-03 50 Disassembly and assembly

Removal and installation of 4. Remove covers (3) and (4).

transmission controller assembly1 a Place the left console (LC) in front.

Removal

k Park the machine on level ground. Apply

parking brake and put the blocks under the
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
1. Open cover (1).
2. Remove box (2). (Standard specification)
3. Remove cover (14) according to the following
procedure. (Machine with load meter)
1) Remove 2 rear mounting bolts (9) of
printer assembly. 5. Disconnect connectors L02 (5), L03 (6) and
2) Lift up printer assembly (10) a little and L04 (7).
disconnect wiring connectors (11) and 6. Remove transmission controller assembly (8).
(12).

3) Remove 4 cover mounting bolts (13) and

remove printer assembly (10) and cover
Installation
(14) together.
q Carry out installation in the reverse order to
removal

4 WA600-6
50 Disassembly and assembly SEN01177-03

Removal and installation of loader 4. Remove covers (3) and (4).

controller assembly 1 a Place the left console (LC) in front.

Removal

k Park the machine on level ground. Apply

parking brake and put the blocks under the
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
1. Open cover (1).
2. Remove box (2). (Standard specification)
3. Remove cover (14) according to the following
procedure. (Machine with load meter)
1) Remove 2 rear mounting bolts (9) of
printer assembly. 5. Disconnect connectors L05 (5), L06 (6) and
2) Lift up printer assembly (10) a little and L07 (7).
disconnect wiring connectors (11) and 6. Remove loader controller assembly (8).
(12).

3) Remove 4 cover mounting bolts (13) and

remove printer assembly (10) and cover
Installation
(14) together.
q Carry out installation in the reverse order to
removal

WA600-6 5
SEN01177-03 50 Disassembly and assembly

Removal and installation of VHMS 2. Disconnect connectors V01 (2), V02 (3), V04
controller assembly 1 (4) and V06 (5).
a Color of connector on the side of V02 (3)
Removal controller: green
3. Disconnect V07 (6) when ORBCOM controller
k Park the machine on level ground. Apply is installed.
parking brake and put the blocks under the 4. Remove VHMS controller assembly (7).
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.

a Before removing VHMS controller, download

the remaining data of the controller to be
removed and check and record the setting
information, referring to “Precautions for
replacing VHMS controller” in Testing and
adjusting.

1. Remove cover controller assembly (1) from

under the right console.

Installation

q Carry out installation in the reverse order to

removal

a After completing the installation of VHMS con-

troller, reset the installed controller referring to
“Precautions for replacing VHMS controller” in
Testing and adjusting.

a Cover controller assembly has been

removed.

6 WA600-6
50 Disassembly and assembly SEN01177-03

Removal and installation of q AJSS specification

monitor assembly 1 1. Remove floor mat.
2. Remove covers (20) and (21).
Removal

k Park the machine on level ground. Apply

parking brake and put the blocks under the
wheels.
k Set the lock bar to the frame.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
a When replacing the machine monitor assem-
bly, too, record the "service meter reading" and
"odometer reading".

q Round handle specification

1. Pull out switches (1) to (5).
3. Disconnect ducts (22) and (23) of air condi-
tioner hoses.
4. Disconnect connector CN A03 for the air con-
ditioner solar sensor from section (A).
5. Pull out switches (24) to (30). (q Referring to
Section 1, Round handle.)

2. Disconnect connectors from switches (1) to (5)

respectively.
a Confirming their destination.
3. Tilt handle (6).
4. Remove front console (7). [*1]

WA600-6 7
SEN01177-03 50 Disassembly and assembly

6. Disconnect connectors from switches (24) to q Common to Round handle and AJSS speci-
(32) respectively. fications.
9. Remove left and right mounting bolts (8), and
a Confirming their destination. invert monitor assembly (9).
(24): CN C09
(25): CN C10
(26): CN C14
(27): CN C16
(28): CN C12 (if equipped)
(29): CN C11 (if equipped)
(30): CN C08
(31): CN C13
(32): CN C15
a See from the back.

10. Disconnect connectors C01 (10), C06 (11),

C02 (12), C03 (13), C04 (14) and C05 (16).
11. Remove bracket (17).

7. Remove cover (33). [*2]

8. Remove front console (34). [*3]

8 WA600-6
50 Disassembly and assembly SEN01177-03

Installation

q Carry out installation in the reverse order to

removal

a If the machine monitor assembly was replaced,

perform the following settting.
q Reset the radio setting (time, etc.). (Refer-
ring to the “Handling of cassette stereo
player with AM/FM radio” in the operation
and maintenance manual.
q Set the "service meter" and "odometer".

[*1], [*2], [*3]

a Care should be taken for different sections for
mounting.
RW: Rubber washer
S: Spacer
W: Washer

WA600-6 9
SEN01177-03

WA600-6 Wheel loader

Form No. SEN01177-03

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 12-10

10
 SEN00412-03

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 2
Power train hydraulic circuit diagram ................................................................................................... 2
Brake hydraulic circuit diagram ............................................................................................................ 3
Work equipment hydraulic circuit diagram
Steering wheel specification ...................................................................................................... 5
Steering wheel specification with ECSS.................................................................................... 7
AJSS (Advanced Joystick Steering System) specification ........................................................ 9
AJSS (Advanced Joystick Steering System) specification with ECSS .....................................11

WA600-6 1
SEN00412-03 90 Diagrams and drawings

Hydraulic diagrams and drawings 1

Power train hydraulic circuit diagram 1

2 WA600-6
90 Diagrams and drawings SEN00412-03

Brake hydraulic circuit diagram 1

WA600-6 3
SEN00412-03 90 Diagrams and drawings

(Forced brake cooling system attached)

4 WA600-6
90 Diagrams and drawings SEN00412-03

Work equipment hydraulic circuit diagram 1

Steering wheel specification

WA600-6 5
90 Diagrams and drawings SEN00412-03

Steering wheel specification with ECSS

WA600-6 7
90 Diagrams and drawings SEN00412-03

AJSS (Advanced Joystick Steering System) specification

WA600-6 9
90 Diagrams and drawings SEN00412-03

AJSS (Advanced Joystick Steering System) specification with ECSS

WA600-6 11
90 Diagrams and drawings SEN00412-03

WA600-6 13
SEN00412-03

WA600-6 Wheel loader

Form No. SEN00412-03

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 11-08 (01)

14
 SEN00413-04

WHEEL LOADER 1SHOP MANUAL

WA600-6

Machine model Serial number

WA600-6 60001 and up

90 Diagrams and drawings

Electrical diagrams and drawings
Air conditioner electrical circuit diagram ......................................................................................................... 3
Steering wheel specification
Electrical circuit diagram (1/10)....................................................................................................................... 5
Electrical circuit diagram (2/10)....................................................................................................................... 7
Electrical circuit diagram (3/10)....................................................................................................................... 9
Electrical circuit diagram (4/10)......................................................................................................................11
Electrical circuit diagram (5/10)..................................................................................................................... 13
Electrical circuit diagram (6/10)..................................................................................................................... 15
Electrical circuit diagram (7/10)..................................................................................................................... 17
Electrical circuit diagram (8/10)..................................................................................................................... 19
Electrical circuit diagram (9/10)..................................................................................................................... 21
Electrical circuit diagram (10/10)................................................................................................................... 23
AJSS (Advanced Joystick Steering System) specification
Electrical circuit diagram (1/10)..................................................................................................................... 25
Electrical circuit diagram (2/10)..................................................................................................................... 27
Electrical circuit diagram (3/10)..................................................................................................................... 29

WA600-6 1
SEN00413-04 90 Diagrams and drawings

Electrical circuit diagram (4/10)..................................................................................................................... 31

Electrical circuit diagram (5/10)..................................................................................................................... 33
Electrical circuit diagram (6/10)..................................................................................................................... 35
Electrical circuit diagram (7/10)..................................................................................................................... 37
Electrical circuit diagram (8/10)..................................................................................................................... 39
Electrical circuit diagram (9/10)..................................................................................................................... 41
Electrical circuit diagram (10/10)................................................................................................................... 43
Connector arrangement diagram .................................................................................................................. 45

2 WA600-6
90 Diagrams and drawings SEN00413-04

Air conditioner electrical circuit diagram 1

WA600-6 3
 Electrical circuit diagram (1/10)
Electrical circuit diagram (1/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 5
 Electrical circuit diagram (2/10)
Electrical circuit diagram (2/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 7
 Electrical circuit diagram (3/10)
Electrical circuit diagram (3/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 9
 Electrical circuit diagram (4/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 11
 Electrical circuit diagram (5/10)
Electrical circuit diagram (5/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 13
 Electrical circuit diagram (6/10)
Electrical circuit diagram (6/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 15
 Electrical circuit diagram (7/10)
Electrical circuit diagram (7/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 17
 Electrical circuit diagram (8/10)
Electrical circuit diagram (8/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 19
 Electrical circuit diagram (9/10)
Electrical circuit diagram (9/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 21
 Electrical circuit diagram (10/10)
Electrical circuit diagram (10/10) 1 WA600-6
Steering wheel specification

SEN00413-04
WA600-6 23
 Electrical circuit diagram (1/10)
Electrical circuit diagram (1/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 25
 Electrical circuit diagram (2/10)
Electrical circuit diagram (2/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 27
 Electrical circuit diagram (3/10)
Electrical circuit diagram (3/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 29
 Electrical circuit diagram (4/10)
Electrical circuit diagram (4/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 31
 Electrical circuit diagram (5/10)
Electrical circuit diagram (5/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 33
 Electrical circuit diagram (6/10)
Electrical circuit diagram (6/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 35
 Electrical circuit diagram (7/10)
Electrical circuit diagram (7/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 37
 Electrical circuit diagram (8/10)
Electrical circuit diagram (8/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 39
 Electrical circuit diagram (9/10)
Electrical circuit diagram (9/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 41
 Electrical circuit diagram (10/10)
Electrical circuit diagram (10/10) 1 WA600-6
AJSS (Advanced Joystick Steering System) specification

SEN00413-04
WA600-6 43
 Connector arrangement diagram
WA600-6
Connector arrangement diagram WA600-6

Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1.PS DT2 2 1st ECMV solenoid AN-8 D04 Terminal 1 Battery relay (Left) L-9 JE5 — 6 Junction connector K-7 PAMB FRAMATONE 3 Atmospheric pressure sensor AV-3
1.SW DT 2 1st ECMV fill switch AN-8 D05 DT2 2 Battery electrolyte level sensor (for VHMS, if equipped) L-7 JF1 — 6 Junction connector A-2 PB.PS DT2 2 Parking brake solenoid AM-6
2.PS DT2 2 2nd ECMV solenoid AM-9 D06 Terminal 1 Heater relay M-9 JF2 — 6 Junction connector D-1 PB.SW DT2 2 Parking brake indicator switch AL-1
2.SW DT 2 2nd ECMV fill switch AN-8 D07 Terminal 1 Heater relay M-9 JF3 — 6 Junction connector A-5 PCV1 SUMITOMO 2 Supply pump AV-4
3.PS DT2 2 3rd ECMV solenoid AM-9 D08 Terminal 1 Heater relay M-9 JF4 — 6 Junction connector A-3 PCV2 SUMITOMO 2 Supply pump AV-3
3.SW DT 2 3rd ECMV fill switch AN-9 D09 DT2 3 Step lamp switch L-8 JF5 — 6 Junction connector A-5 PFUEL AMP 3 Common rail pressure sensor AT-5
4.PS DT2 2 4th ECMV solenoid AL-9 D10 Terminal 1 GND J-9 JF6 — 6 Junction connector A-5 PIM SUMITOMO 3 Charge pressure (boost pressure) sensor AU-6
4.SW DT 2 4th ECMV fill switch AK-9 D11 Terminal 1 Battery relay (Right) L-8 JF7 — 6 Junction connector A-4 POIL FRAMATONE 3 Engine oil pressure sensor AU-1
A01 AMP040 20 Air conditioner control panel C-8 D12 Terminal 1 Battery relay (Right) L-7 JF8 — 6 Junction connector A-3 R.PS DT2 2 R (Reverse) solenoid AK-8
A02 AMP040 16 Air conditioner control panel C-8 D13 Terminal 1 Battery relay (Left) L-9 JF9 — 6 Junction connector A-5 R.SW DT 2 R (Reverse) fill switch AK-8
A03 YAZAKI 2 Solar radiation sensor E-1 D14 Terminal 1 Battery relay (Left) N-7 JF11 — 6 Junction connector (if equipped) R01 Terminal 1 Circuit breaker CBF1 N-9
A05 SUMITOMO 5 Blower main relay AB-5 D15 Terminal 1 Battery M-7 JF12 — 6 Junction connector (if equipped) R02 Terminal 1 Circuit breaker CBF1 N-9
A08 YAZAKI 4 Magnet clutch relay AB-8 D16 Terminal 1 Battery K-4 JF13 — 6 Junction connector R03 Terminal 1 Circuit breaker CBF2 N-8
A10 YAZAKI 18 Air conditioner unit X-5 D17 Terminal 1 Battery H-9 JF14 — 6 Junction connector (if equipped) R04 Terminal 1 Circuit breaker CBF2 N-8
A11 SUMITOMO 4 Air conditioner unit V-2 D18 Terminal 1 Battery G-9 JR1 — 6 Junction connector (if equipped) AF-6 R05 Terminal 1 Circuit breaker CBF3 N-8
A12 SUMITOMO 2 Coolant Hi/Lo switch W-3 D19 Terminal 1 Disconnection switch (if equipped) H-9 JR2 — 6 Junction connector J-3 R06 Terminal 1 Circuit breaker CBF3 N-8
B01 DT2 2 AJSS EPC solenoid L-4 D20 Terminal 1 Disconnection switch (if equipped) H-9 JR3 — 6 Junction connector AF-5 R07 Terminal 1 Slow-blow fuse SBF1 M-9
B02 DT2 2 EPC cut-off solenoid L-4 DIODE1 DT2 2 Diode AI-5 JR4 — 6 Junction connector K-5 R08 Terminal 1 Slow-blow fuse SBF1 M-9
B03 — 7 Junction connector L-3 DIODE2 DT2 2 Diode AI-5 JT1 DT2(B) 8 Junction connector AI-6 R09 Terminal 1 GND (Rear frame) J-3
B04 DT2 2 Rear brake accumulator low pressure switch L-3 DIODE3 DT2 2 Diode AK-6 JT2 DT2 6 Junction connector AI-5 R10 Terminal 1 GND (Rear frame) K-5
B05 DT2 2 Front brake accumulator low pressure switch N-3 DLF BENDIX 5 Download connector P-7 JT3 DT2 6 Junction connector AI-5 R12 DT2 2 Fan pump EPC solenoid AN-4
B06 DT2 2 Rear emergency brake switch L-2 DR1 DT2 6 Intermediate connector (Step lamp switch) K-6 JT4 DT2 6 Junction connector AK-6 R13 DT2 2 Torque converter oil temperature sensor K-6
B07 DT2 2 Front emergency brake switch L-3 E01 DT2 2 Starting motor AE-9 JV1 — 6 Junction connector N-4 R14 Terminal 1 Circuit breaker CBF4 N-9
B08 DT2 2 Parking brake emergency release solenoid N-4 E02 DT2 2 Starting motor AD-8 JV2 — 6 Junction connector L-4 R15 Terminal 1 Circuit breaker CBF4 N-9
B09 X 2 Transmission oil filter clogging sensor L-2 E03 Terminal 1 Alternator terminal R AD-2 JV3 — 6 Junction connector N-4 R16 DT2 2 Fuel level sensor I-2
B10 Terminal 1 GND (Rear frame) L-3 E04 Terminal 1 Alternator terminal B AF-1 JV4 — 6 Junction connector L-4 R17 DT2 12 Rear brake oil temperature sensor H-2
BL1 DT2(B) 12 Intermediate connector (Brake component box) W-3 E05 Terminal 1 Alternator terminal E AD-3 KOM DT2(Gr) 12 Data download U-9 R21 YAZAKI 3 Diode AB-8
BL1 KES0 2 Front windshield washer G-9 E13 Terminal 1 Heater AD-3 L01 Terminal 1 GND (Floor frame) W-3 R22 YAZAKI 3 Diode AA-8
BL2 DT2 4 Intermediate connector (Windshield washer) X-5 E14 DT2 2 Engine oil level sensor AF-1 L02 DRC26 24 Transmission controller U-9 R23 YAZAKI 2 Diode AA-8
BL3 KES0 2 Rear windshield washer G-9 E15 DT2 2 Dust indicator AG-1 L02 SWP 6 Lighting switch, Dimmer switch (Steering wheel specification) R24 YAZAKI 2 Diode Y-7
BL4 DT2 2 Intermediate connector (Rear windshield washer (if equipped)) I-2 E16 DT2 2 Air conditioner compressor AD-1 L03 DRC26 40 Transmission controller U-9 R25 YAZAKI 2 Diode Y-7
BL5 KES0 2 Rear windshield washer (if equipped) I-2 E17 DT2 2 Diode AH-4 L03 SWP 6 Turn and Hazard switch (Steering wheel specification) R26 YAZAKI 2 Diode Y-6
BP DT-T 2 Not used AR-2 E18 DRC26 50 Engine controller AH-3 L04 DRC26 40 Transmission controller V-8 R28 DT2 2 Diode K-5
BV1 DT2(B) 12 Intermediate connector (VHMS component box) W-3 E19 DTP 4 Engine controller AH-2 L04 SWP 14 Shift switch (Steering wheel specification) R38 DT2 6 Auto grease controller (if equipped)
BV2 DT2(B) 6 Intermediate connector (VHMS controller) X-3 E20 Terminal 1 Starting motor terminal B AD-5 L05 DRC26 24 Work equipment controller V-8 RES DT-T 2 Resistor AU-1
BV3 DT2(B) 6 Intermediate connector (VHMS rear and engine harness) N-5 E21 DT2 3 Resistor AH-2 L05 DT2 2 Steering wheel horn switch (Steering wheel specification) REV OUT1 DT2 2 Speed sensor 1 AI-3
C01 AMP070 20 Machine monitor Q-1 E22 Terminal 1 GND (Engine unit) AG-2 L06 DRC26 40 Work equipment controller V-8 REV OUT2 DT2 2 Speed sensor 2 AI-3
C02 AMP070 18 Machine monitor Q-1 EGR DT-T 2 EGR valve solenoid AR-4 L07 DRC26 40 Work equipment controller V-8 RT1 DT2 12 Intermediate connector G-1
C03 AMP070 12 Machine monitor O-3 EP1 DT2 2 Intermediate connector (for engine harness) AV-1 L08 DT2(Gr) 12 Intermediate connector (VHMS harness) W-8 S01 DT2 2 Lift arm neutral lock switch Q-8
C04 AMP070 18 Machine monitor O-4 EP2 DT2 2 Priminnig pump AU-1 L10 M 6 Intermediate connector (Printer harness) U-9 S02 DT2 4 Lift arm and Bucket EPC lever S-9
C05 AMP070 12 Machine monitor O-4 EP3 DT2 6 Timer AT-1 L11 AMP 2 Air suspension seat V-2 S03 DT2 4 Lift arm and Bucket EPC lever R-8
C06 AMP070 12 Machine monitor Q-1 EP4 Terminal 1 GND AT-1 L12 DT2 3 Frame angle potentiometer (AJSS specification) U-2 S04 DT2 2 Lift arm and Bucket EPC lever S-9
C07 AMP070 14 Machine monitor O-5 ENG DRC 60 Engine controller AV-2 L13 DT2 2 Steering lock switch (AJSS specification) V-2 S05 DT2 2 Lift arm and Bucket EPC lever R-8
C08 SWP 6 Parking brake switch O-5 ER1 DT2(B) 12 Intermediate connector (Engine controller) AH-8 L16 DT2 2 Stop lamp switch S-1 S06 DT2 2 Lift arm and Bucket EPC lever R-8
C09 SWP 6 Monitor mode switch 1 S-1 ER2 DT2(Gr) 12 Intermediate connector (Engine controller) AH-7 L17 DT2(B) 12 Intermediate connector (Steering wheel specification) S07 DT2 4 Lift arm lever kickdown and hold switch R-8
C10 SWP 6 Monitor mode switch 2 R-1 ER3 L 2 Intermediate connector (Heater relay) AF-5 L17 M 4 DC24V/DC12V converter AA-5 S08 DT2 4 Bucket lever switch (Load meter specification) S-9
C11 SWP 6 Load meter mode switch 1 O-5 ER6 Terminal 1 GND (Alternator) AE-5 L17 DT2(B) 6 Accelerator pedal P-1 S09 X 3 Variable traction control Y-7
C12 SWP 6 Load meter mode switch 2 O-4 F.PS DT2 2 F ECMV solenoid AL-6 L18 DT2 6 Intermediate connector (Steering wheel specification) S1 DT2 2 Lift arm and Bucket EPC lever R-8
C13 M 6 Front wiper switch (AJSS specification) R-1 F.SW DT1 2 F ECMV fill switch AM-6 L18 YAZAKI 2 DC12V outlet P-7 S2 DT2 2 Lift arm and Bucket EPC lever R-8
C14 YAZAKI 7 Hazard switch (AJSS specification) R-1 F01 M 6 Intermediate connector (Combination lamp (Right), headlamp) A-4 L19 KES1 4 Flasher unit AB-7 S3 DT2 2 Lift arm and Bucket EPC lever S-9
C15 KES1 4 Lighting mode switch (AJSS specification) O-2 F02 M 6 Intermediate connector (Combination lamp (Left), headlamp) A-2 L20 M 2 Alarm buzzer AB-6 S10 DT2 4 Auto shift switch Y-8
C16 YAZAKI 7 Dimmer switch O-2 F03 AMP 090 2 Horn Lo B-6 L21 S 10 Intermediate connector (Wiper) (Steering wheel specification) S11 SWP 6 Engine power mode switch Z-9
C18 SWP 6 RPM set cancel switch (Right brake pedal) P-1 F04 AMP 090 2 Horn Hi B-6 L21 KES1 6 Interval wiper timer AB-6 S12 SWP 6 RPM set ON/OFF switch Z-8
C19 SWP 6 Step lamp ON/OFF switch B-7 F07 DT2 2 Lift arm raise EPC solenoid A-1 L22 M 2 Resistor AA-4 S13 SWP 6 RPM set ACC/DEC switch Z-9 a AJSS specification a Steering wheel specification
C20 YAZAKI 9 AM/FM radio I-2 F08 DT2 2 Lift arm lower EPC solenoid C-1 Emergency parking release switch S14 SWP 6 Lift arm remote positioner set switch Y-8
L23 SUMITOMO 16 U-9
C21 Terminal 1 GND (Radio) C-8 F09 DT2 2 Bucket tilt EPC solenoid C-1 Modulation clutch direct joint switch S15 SWP 6 Intermediate connector S-9
C22 SWP 6 Hydraulic drive fan reverse switch F-2 F10 DT2 2 Bucket dump EPC solenoid A-1 L25 M 1 Option connector AB-7 S16 DT2 4 3-spool valve (attachment) EPC lever (if equipped)
C23 SWP 6 Auto grease switch (if equipped) E-9 F11 DT2 3 Bucket level positioner proximity switch A-3 L26 M 1 Option connector AB-6 S17 SWP 6 Bucket remote positioner set switch Z-8
C24 SWP 6 Glass heater switch C-8 F12 DT2 3 Bucket tilt detecting proximity switch A-3 L45 D-sub 25 Printer (if equipped) S18 SWP 6 Torque converter lockup switch Z-8
C25 KES1 2 Room lamp E-9 F13 DT2 3 Lift arm angle sensor E-1 L46 HOSHIDEN 4 Printer (if equipped) S19 YAZAKI 2 Cigarette lighter AA-8
C26 M 1 Left door switch (Room lamp) F-9 F14 DT2 3 Lift arm bottom pressure sensor (Load meter specification) C-1 L101 SHINAGAWA 6 Relay No.1 Backup lamp AA-3 S20 SWP 6 ECSS switch Y-8
C27 M 6 Front wiper motor B-7 F15 DT2 3 Lift arm rod pressure sensor (Load meter specification) D-1 L102 SHINAGAWA 6 Relay No.2 Stop lamp AA-3 S21 SWP 6 AUTO DIG switch AA-9
C28 SWP 6 Rear wiper switch (AJSS specification) C-8 F16 DT2 3 Loader pump pressure sensor B-1 L103 SHINAGAWA 5 Relay No.3 Neutral safety AA-3 S22 SWP 6 Turn signal switch (AJSS specification) R-8
C29 M 1 Right door switch (Room lamp) D-9 F20 Terminal 1 GND (Front frame) A-4 L104 SHINAGAWA 5 Relay No.4 AJSS neutral safety AA-2 S30 DT2 3 AJSS lever angle sensor (AJSS specification) X-6
C30 KES1 2 Resistor (AJSS specification) P-1 F21 DT2 4 Intermediate connector A-4 L105 SHINAGAWA 5 Relay No.5 Parking brake safety AA-2 S31 DTM 12 Joystick lever switch (AJSS specification) X-7
C33 SWP 4 Working lamp switch D-8 F22 DT2 2 3rd valve (attachment) EXT EPC solenoid (if equipped) L106 SHINAGAWA 5 Relay No.6 Preheating Z-3 SBP DT-T 4 Not used AR-2
C34 SWP 6 Fog lamp switch (if equipped) D-9 F23 DT2 2 3rd valve (attachment) RET EPC solenoid (if equipped) L107 SHINAGAWA 5 Relay No.7 Dust indicator Z-3 SEGR DT-T 4 EGR valve lift sensor AS-4
C35 SWP 6 Warning lamp (Beacon) switch (if equipped) D-9 F24 DT2 2 ECSS solenoid (if equipped) A-1 L108 SHINAGAWA 6 Relay No.8 S working lamp AA-3 T01 DT2 2 Pump EPC solenoid H-1
C36 M 2 Speaker (Left) F-9 F25 DT2 2 Intermediate connector (Front working lamp (if equipped)) B-1 L109 SHINAGAWA 6 Relay No.9 F working lamp AA-2 T02 DT2 2 Modulation clutch cut-off solenoid F-2
C37 M 2 Speaker (Right) E-9 F26 DT2 2 Intermediate connector (Fog lamp (if equipped)) A-3 L110 SHINAGAWA 6 Relay No.10 R working lamp AA-2 T03 DT2 3 Modulation clutch pressure switch F-1
C38 Terminal 1 Rear glass heater E-9 FF01 M 2 Fog lamp (Right) (if equipped) L111 SHINAGAWA 5 Relay No.11 R glass heater Z-3 T04 DT2 2 Emergency steering drive switch F-2
C39 Terminal 1 Rear glass heater G-9 FF02 M 2 Fog lamp (Left) (if equipped) L112 SHINAGAWA 5 Relay No.12 Start neutral hold Z-3 TFUEL PACKARD 2 Fuel temperature sensor AT-1
C40 M 4 Rear wiper motor H-1 FL6 DT2 2 Side working lamp (if equipped) X-3 L113 SHINAGAWA 5 Relay No.13 Hazard Z-2 TGN Terminal 1 GND (Transmission body) AM-9
C41 M 2 Front working lamp (Left) B-7 FL7 DT2 2 Side working lamp (if equipped) W-3 L114 SHINAGAWA 6 Relay No. 14 Turn signal (AJSS specification) AA-1 TIM PACKARD 2 Charge temperature (boost temperature) sensor AU-6
C42 M 2 Front working lamp (Right) B-7 FL11 DRC12 40 Intermediate connector (Floor frame – Front frame) V-2 L115 SHINAGAWA 5 Relay No.15 Small lamp AA-2 TM.T DT2 2 Transmission oil temperature sensor AI-3
C43 DT2 2 Warning lamp (Beacon) (if equipped) D-9 FW01 M 2 Front working lamp (Right) (if equipped) L116 SHINAGAWA 5 Relay No.16 Horn Z-2 TOIL PACKARD 2 Engine oil temperature sensor AV-2
C45 M 2 Step lamp F-9 FW02 M 2 Front working lamp (Left) (if equipped) L117 SHINAGAWA 5 Relay No.17 Fan motor Z-2 TWTR PACKARD 2 Coolant temperature sensor AT-5
C46 DT2 6 Intermediate connector (Side wiper harness (if equipped)) C-8 G DENSO 3 Backup speed sensor AV-4 L118 SHINAGAWA 5 Relay No.18 Dimmer Z-2 V01 AMP070 20 VHMS controller Q-7
C47 SWP 6 Side wiper switch (if equipped) G01 M 6 Rear combination lamp (Right) I-9 L119 SHINAGAWA 6 Relay No.19 Fog lamp Z-2 V02 AMP070 18 VHMS controller O-6
C48 M 4 Side wiper motor (Left) (if equipped) G02 M 6 Rear combination lamp (Left) K-7 L120 SHINAGAWA 5 Relay No.20 S wiper Z-1 V04 AMP070 18 VHMS controller P-7
C49 M 4 Side wiper motor (Right) (if equipped) G03 M 2 Rear working lamp (Right) I-9 L121 SHINAGAWA 5 Relay No. 21 Right turn (AJSS specification) T-9 V06 AMP070 14 VHMS controller O-6
C50 Terminal 1 GND (Cab) B-7 G04 M 2 Rear working lamp (Left) K-8 L122 SHINAGAWA 5 Relay No. 22 Left turn (AJSS specification) T-1 V07 AMP070 10 VHMS controller O-6
C51 Terminal 1 Starting switch terminal B O-3 G05 DT2 2 Coolant level sensor K-8 L123 SHINAGAWA 6 Relay No.23 AUX (Cab) (if equipped) T-1 V08 AMP070 14 ORBCOM unit W-8
C52 Terminal 1 Starting switch terminal BR O-3 G06 DT2 2 Backup buzzer K-6 L141 SHINAGAWA 5 Printer power source relay (if equipped) V09 AMP070 10 ORBCOM unit X-7
C53 Terminal 1 Starting switch terminal C O-3 G07 DT2 2 Fan reverse solenoid J-9 L142 YAZAKI 2 Diode (if equipped) V10 DT2 4 Intermediate connector T-1
C54 Terminal 1 Starting switch terminal ACC O-3 GR1 DT2(B) 12 Intermediate connector (Radiator guard harness) K-6 L143 YAZAKI 2 Diode (if equipped) V11 DT2 3 Exhaust gas temperature sensor amplifier M-5
C56 KES1 2 Room lamp B-8 HD.T DT2 2 Hydraulic oil temperature sensor AK-7 L144 YAZAKI 2 Diode (if equipped) V12 DT2 3 Exhaust gas temperature sensor amplifier M-5
C57 DT2 2 Intermediate connector (Warning lamp (Beacon) (if equipped)) C-8 HD1 YAZAKI 2 Diode (F washer) Y-6 L145 YAZAKI 2 Diode (if equipped) V13 DT2 3 Rear brake pressure sensor M-1
C58 DT2 2 Outside temperature sensor (if equipped) P-1 HD2 YAZAKI 2 Diode (R washer) Y-5 LC.PS DT2 2 Torque converter lockup solenoid AN-7 V14 DT2 3 Front brake pressure sensor L-2
C90 DT2 6 AUX (Cab) harness (if equipped) E-9 HD3 YAZAKI 2 Diode (S washer) Z-5 LR1 DTHD4 1 Intermediate connector X-5 V15 Plug connector 1 VHMS start indicator (12V) M-1
CAN1 DT2 3 Resistor O-3 HD4 YAZAKI 3 Diode (M/C cut-off lift arm BBC cut-off solenoid) Z-4 LR2 L 2 Intermediate connector X-3 V16 Plug connector 1 VHMS start indicator (12V) N-3
CL11 DRC12 70 Intermediate connector (Floor harness – Cab harness) X-6 HEAD M 3 Headlamp (Right) B-6 LR3 L 2 Intermediate connector X-4 V17 Terminal 1 VHMS starting switch N-2
CL12 DRC12 24 Intermediate connector (Floor harness – Cab harness) X-6 HEAD M 3 Headlamp (Left) A-3 LR4 L 2 Intermediate connector X-5 V18 Terminal 1 VHMS starting switch N-2
CL13 DRC12 24 Intermediate connector (Floor harness – Cab harness) X-6 INJ DT-T 12 Fuel injector AV-4 LR5 DT2 6 Intermediate connector X-5 V19 Terminal 1 VHMS starting switch N-2
Intermediate connector J1939 DT-T 3 — AS-5 LR7 DT2(G) 12 Intermediate connector X-4 V20 Terminal 1 VHMS starting switch N-2
CL14 DT2 2 X-7
(Backup lamp) (Steering wheel specification) JB1 — 6 Junction connector H-2 LR11 DRC18 40 Intermediate connector X-4 V21 DT2(B) 6 Intermediate connector I-9
Intermediate connector JB1 — 14 Junction connector AS-5 LS1 S(L) 12 Intermediate connector Q-8 V22 G 1 VHMS operation indicator (24V) I-9
CL16 DT2(Gr) 12 O-2
(Steering column switch) (Steering wheel specification) JB2 — 19 Junction connector AT-5 LS2 S(W) 16 Intermediate connector Q-7 V23 DT2 3 Steering pressure sensor L-5
Intermediate connector JBB1 — 6 Junction connector L-9 LS3 S(L) 16 Intermediate connector Q-7 V25 DT2 3 Blow-by pressure sensor I-3
CL17 DT2(B) 12 O-2
(Steering column switch) (Steering wheel specification) JBB2 — 6 Junction connector L-8 LS6 DTM 12 Intermediate connector (AJSS specification) V-2 V27 DT2 2 Exhaust gas temperature sensor amplifier G-2
Intermediate connector JE1 — 6 Junction connector AD-7 LS7 DTM 2 Intermediate connector (AJSS specification) U-2 V28 DT2 2 Exhaust gas temperature sensor amplifier F-2
CL18 DT2 6 O-3
(Steering column switch) (Steering wheel specification) JE1 — 6 Junction connector J-9 LT1 HD30 31 Intermediate connector AI-6 V29 DT2 2 Exhaust gas temperature sensor (Right) J-3
COMBI M 3 Front combination lamp (Right) A-6 JE2 — 6 Junction connector AD-7 MC.PS DT2 2 Modulation clutch solenoid AN-6 V30 DT2 2 Exhaust gas temperature sensor (Left) J-3
COMBI M 3 Front combination lamp (Left) E-1 JE2 — 6 Junction connector K-8 MOD OUT DT2 2 Modulation clutch output speed sensor AK-7 V33 Plug connector 1 ORBCOM unit W-7
D01 Terminal 1 Battery relay (Right) L-7 JE3 — 6 Junction connector AD-6 NE FRAMATONE 3 Ne speed sensor AV-3 V34 Plug connector 1 Antenna cable B-6
D02 Terminal 1 Battery relay (Right) L-8 JE3 — 6 Junction connector K-7 P1 DT2 4 Lift arm and Bucket EPC lever R-9 V35 Plug connector 1 Antenna B-7
D03 Terminal 1 Battery relay (Left) M-7 JE4 — 6 Junction connector K-9 P2 DT2 4 Lift arm and Bucket EPC lever S-9 VDL BENDIX 5 Download connector N-3
SEN00413-04
WA600-6 45
90 Diagrams and drawings SEN00413-04

WA600-6 47
SEN00413-04

WA600-6 Wheel loader

Form No. SEN00413-04

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 09-10

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